PG Diploma in Piping Engineering – Topic 06
Types of Plant Designing – Grassroots, Brownfield, Hydrocarbon and Non-Hydrocarbon Projects
Industrial plant designing is one of the most important parts of the engineering world. Every refinery, chemical plant, water treatment plant, power plant, and manufacturing facility needs proper planning, layout design, equipment selection, piping design, safety planning, and construction management.
In this topic, we will understand the four major categories of plant designing:
- Grassroots Project – A completely new plant built from zero.
- Brownfield Project – Expansion or modification of an existing plant.
- Hydrocarbon Projects – Plants dealing with oil, gas, chemicals and refinery products.
- Non-Hydrocarbon Projects – Plants dealing with water, food, paper, oxygen, waste treatment etc.
This explanation is written in very simple language so that students, beginners and fresh engineers can clearly understand how industries plan and design different types of plants.
1. Grassroots Project
A Grassroots Project (also known as a Greenfield project) means designing and constructing a plant completely from scratch on a new or empty land. There is no existing structure, no old equipment, and no previous pipeline network. Everything is designed fresh.
Characteristics of Grassroots Projects
- Completely new land – The project starts with land surveys, soil testing, layout planning and building new foundations.
- New equipment selection – All pumps, compressors, tanks and pipelines are selected fresh without restrictions.
- Flexible layout – Engineers can create the most efficient and safe design because there are no limitations.
- High cost and long duration – These projects require huge investment and more time.
- Modern technology – Latest machines, automation, safety systems and energy-efficient solutions can be implemented.
Examples of Grassroots Projects
- New refinery construction
- New chemical plant on a new site
- New LNG terminal
- New large-scale food processing facility
- New thermal power plant or wind farm
In simple words, Grassroots projects give engineers complete freedom to create the best design from the beginning.
2. Brownfield Project
A Brownfield Project refers to modifying, expanding or upgrading an existing plant that is already in operation. Engineers must work around existing structures, old pipelines, equipment and limited space.
Characteristics of Brownfield Projects
- Existing plant conditions – Many pipelines, cable trays and equipment are already installed.
- Limited space – New design must fit into the available area without disturbing production.
- Shutdown planning – Some modifications can only happen when the plant is temporarily shut down.
- Compatibility – New pipelines and equipment must match old systems.
- Safety complexity – Working inside a running plant requires strict safety measures.
Typical Brownfield Work Includes
- Adding new equipment to increase plant capacity
- Replacing old pipelines with new ones
- Upgrading pumps, compressors or heat exchangers
- Expanding storage tanks or utility systems
- Connecting new units to existing networks
Brownfield projects require highly skilled engineers because designing in restricted spaces is complex and must avoid interference with old systems.
3. Hydrocarbon Projects
Hydrocarbon projects include all plants related to oil, natural gas, petrochemicals and refinery operations. These plants deal with hazardous, flammable and high-pressure fluids, so safety and piping design are extremely important.
Common Hydrocarbon Plants
- Oil Refining – crude oil separation and conversion
- Gas Separation Units
- Ammonia & Urea Production
- Aromatics (Benzene, Toluene, Xylene)
- Benzene & Butadiene Production
- Ethylene & Propylene Production
- Fertilizer Manufacturing
- GTL – Gas to Liquid Conversion
- LNG – Liquefied Natural Gas Plants
- Paint and Polymer Production
- Polyethylene & Polypropylene Manufacturing
- Sulfur Recovery Units
Key Features of Hydrocarbon Projects
- High temperature and high pressure piping systems
- Explosion-proof designs due to flammable chemicals
- Strict international standards such as ASME, API, NFPA
- Complex piping networks with heavy supports and insulation
- Advanced control & instrumentation for safe operations
Hydrocarbon projects form the backbone of the energy and chemical industry. Piping engineers play a major role in making these plants safe and reliable.
4. Non-Hydrocarbon Projects
Non-hydrocarbon projects include all plants that handle non-flammable or less hazardous fluids such as water, air, food products, paper pulp and waste treatment. These projects are very important for public health, manufacturing and daily life.
Examples of Non-Hydrocarbon Plants
- Water Treatment Plants
- Sewage Treatment Plants
- Waste Management and Recycling Plants
- Pulp and Paper Manufacturing
- Air Separation Units (Oxygen, Nitrogen, Argon, Helium)
- Chlorine Production Units
- Food Processing Plants – dairy, juice, soft drink, bakery
- Beer Distillation / Brewery Plants
Features of Non-Hydrocarbon Projects
- Handling of water, sludge, gases and food products
- Smoother piping requirements compared to hydrocarbons
- Hygienic and sanitary piping standards in food industries
- Corrosion-resistant materials like HDPE, SS304, PVC
- Large tanks, basins and reactors for treatment processes
These plants are essential for environmental protection, clean water supply and manufacturing of daily-use items.
Conclusion
Plant designing is a broad field that includes new project development, plant expansion, upgrading old units and designing for different sectors such as hydrocarbons and non-hydrocarbons. Each type of project has its own challenges, design standards, piping requirements and safety considerations.
Understanding Grassroots, Brownfield, Hydrocarbon and Non-Hydrocarbon projects helps piping engineers become industry-ready and capable of working in various domains. These concepts are very important for interviews, real project work and long-term professional growth.
This detailed explanation gives you a strong foundation for understanding how industries plan, design and develop complex engineering plants.