Plant Layout Design Rules (PDF) | What is Piping (2024)

Plant layout design means efficiently placing equipment, piping, instrumentation, and other manufacturing supports and facilities with proper planning during the design stage to create the most effective plant layout. It is directly related to project costs as well. The most efficient plant layout has less overall project cost and the most utilization of all resources.

The main objective of efficient plant layout design is to design and construct the plant in an economic fashion that meets all the process requirements and client specifications while operating in a safe reliable manner. This article provides the basic considerations for the development of plant layout. For more details in any of the listed points, you can refer to any standard piping books.

Principles of Plant Layout

While developing plant layout following 10 principles are kept in mind.

Plant Layout Design rules for Site Selection

  • Location
  • Area Allocation
  • Transport Facilities
  • Manpower availability
  • Industrial Infrastructure
  • Community Infrastructure
  • Availability of Water
  • Availability of Power
  • Effluent Disposal
  • Availability of Industrial Gas
  • Site Size
  • Ecology
  • Pollution

What is Plot Plan & its requirement?

The plot plan is the master plan locating each unit/facility within the plot boundary for a process industry such as

  • Refinery
  • Chemical /Agro Chemical / Petro Chemical / Organic Chemical / Inorganic Chemical
  • Fertilizer
  • Pharmaceutical
  • Metallurgical
  • Power Generation

It is used to locate the unit/facility.

The following main aspects shall be considered during the development of the layout.

  • Process requirement
  • The economy of piping material and cables
  • Erection & Construction requirements
  • Safety requirements.
  • Operation and Maintenance requirements.
  • Grouping of similar equipment for the convenience of maintenance & safety wherever possible.

Data to be collected before starting the process plant layout development

Data from the Civil Department

  • Plane table survey map.
  • Contour survey map.
  • Soil bearing capacity.
  • Nature of Soil
  • Rail/Road Access.

Data required from Electrical Team

  • Location of Electric Supply Point.
  • Supply voltage levels.
  • Fault Levels.
  • Voltage Levels required within the unit.
  • Proposed distribution scheme.

Non Plant Facilities

  • Administrative Block
  • Canteen
  • Workshop
  • R&D, QC Lab, and Pilot Plant
  • GateHouse/Time office
  • Security Arrangements
  • Vehicle Parking
  • Medical Centre
  • Ware House
  • Covered Area
  • Open Area
  • Solid Warehouse
  • Liquid Warehouse
  • Steel / Scrap Yard
  • Fire Station
  • Weigh Bridge
  • Staff Colony

Meteorological Data

  • Minimum, Maximum and Normal Temperature during the year
  • Rainfall
  • Intensity and Direction of the wind (wind rose)
  • Seismic zone
  • Wet and Dry Bulb temperatures
  • Relative humidity
  • Flood level

Process Data

  • Size/Capacity of the processing unit
  • Knowledge of the type of plant
  • The sequence of process flow
  • Hazardous nature of the plant
  • The Overall operating philosophy
  • Fully Automatic
  • Partially Automatic
  • Manual
  • Batch/Continuous
  • Raw material receipt and product dispatch philosophy
  • Storage Philosophy
  • Effluent plant capacity and discharge points, incineration requirements, etc.
  • Type of Hazard
  • No of flares

Data on Utilities

  • Source and/or supply point of raw water
  • Quality of Water available
  • Water Consumption for the process
  • The requirement of different types of utilities such as Steam, Air, Nitrogen, DM water, Firewater, Brine, etc.
  • Capacities and Grouping philosophy.

Statutory Requirements and process plant layout

  • State Industrial Development Corporation (SIDC)
  • Central / State Environmental Pollution Control Boards (PCBs)
  • Factory Inspectorate
  • State Electricity Boards (SEB)
  • Chief Controller of Explosives (CCOE)
  • Static and Mobile Pressure Vessel Rules (SMPV)
  • Tariff Advisory Committee (TAC)
  • National Fire Protection Association (NFPA)
  • Aviation Laws
  • Chief Inspector of Boilers (CIB)
  • Oil Industry Safety Directorate (OISD)
  • Food and Drug Administration (FDA)
  • Ministry of Environment and Forest (MoEF)

Expansion Philosophy during plant layout development

  • Within the unit
  • Additional Units
  • Near future expansion
  • Far future expansion

Considerations during plant layout

  • Normally Construction is permitted on maximum 50% of the plot area with a total built-up area equal to the area of the plot (i.e. F.S.I. = 1 (Depending upon the regulation governing the area and the type of industry))
  • Area reserved for tree plantation shall be 1/3 of the area occupied.
  • Water storage capacity – 24 hr. minimum.
  • Domestic water – 100 liters per person per day
  • Water requirement for Boiler – Steam rating x Working factor
  • Cooling tower – 11/4 % of capacity as drift and blowdown losses
  • Washing – 10-15 liters per day per sq.ft. of the floor area of the plant
  • Gardening – 5 liters per day per sq.ft. of garden area
  • Parking space – 10% of the plot area

Roads & Paving considerations in Plant Layout

  • Roads in the plant shall be planned for effective movement of the trucks, cranes & emergency vehicles, etc. Road width (Blacktop) shall be generally as follows unless specially requested.
  • Main plant road & roads connecting to Plant boundaries, roads for fire fighting access is 6 meters wide (Min)
  • Secondary roads 4 meters wide (Min)
  • The turning radius of the road shall be adequate for the mobile equipment & shall clear of any obstruction. Minimum turning radius to be the same as the length of the vehicle.
  • The finish of the road i.e. graded or blacktop shall be decided in the beginning while developing a plot layout.
  • Paving should be provided around the equipment where spillage is likely occurring. For example Pumps or machinery, below furnace or fire heaters, compressor, etc.
  • Also paving should be provided below Air fin cooler those are located at grade.
  • Area handling acids, alkalis, or toxic material shall be paved and bunded. Proper surface treatment shall be provided to paving to meet the service requirements.

The below sketch (Fig. 1) shows the minimum distance required between the road and the facility. This distance shall be reviewed to the case to case basis for the project.

Elevations Requirement

  • Below data for the elevations should be generally followed.
  • Underside the base plate of Structural steel: Min150 mm. above HP of finished grade/paving.
  • Stair or ladder pads: Min75 mm. above HP of finished grade/paving.
  • Top of Pedestal of Vessel & Tower: Min300 mm. above HP of finished grade/paving.
  • Top of Pump pedestal: Min200 mm. above HP of finished grade/paving.

Insulation & Fire Proofing considerations in plant layout

  • Fireproofing requirements for pipe rack, vessel supports, process structure should be considered as these reduce the clearances with access, pipework, instrument & electrical equipment.
  • Proper insulation thickness should be considered for pipework & equipment clearances.

Equipment Layout and locations

  • Pumps: Locate pumps close to suction source considering NPSH requirement. Pumps & driver axis should be located perpendicular to pipe rack or other equipment to minimize fire exposure in case of pump seal failure.
  • Gas compressor or Expanders: Gas compressors should be located downwind of the fired heaters, flare, or any open flame equipment. They may be grouped together for maintenance & operations (Common EOT / drop-down area, the single sunshade can be made)
  • Plant Air & Instrument air compressors: Plant air & instrument air is vital to service for the plant. These units should be located near the control room & shall be kept in a safe area sufficiently away from HAC of equipment.
  • Heat Exchangers: Heat exchangers are generally placed on grade unless otherwise due to process or technical reasons. (Platform for vertical heat exchangers, Tube bundle removal area, access to mobile crane or monorail with hoist shall be considered)
  • Air cooler: Air cooler located such a way to allow access to mobile lifting equipment. Preferably air cooler is located in the main equipment row in accordance with process requirement.
  • Cooling Towers: Cooling towers shall be located away from the process equipment & downwind of process equipment, substation, main pipe rack.
  • Offsite Tanks: Storage tanks (Grouped and shall be surrounded by dike wall, Primary/secondary roads for adequate firefighting accessibility, Lower elevations than the other occupancies and downwind of flares, furnace heaters). Emergency shutdown valve, pumps, manifold & transfer piping shall be outside dike area.

Considerations for Pipe ways / Pipe racks

  • Pipe ways or pipe racks should be overhead in-process main unit and at grade in off-site.
  • Width is determined based on present need + 10% at outset the job + 15% for the future requirements or as specified by the client.
  • The requirement of expansion bays, anchor bays & bracing shall be checked with stress / structural engineer at the beginning of the pipe rack layout.

Relief valve and Flare systems

  • A closed relief valve system
  • Self-draining
  • No pocket to avoid condensation & backpressure.
  • Flare shall be located upwind process unit & storage.

Clearance at Pig Receiver

  • The area at the end closure of the Receiver shall be kept free to avoid any incident.
  • Provide concrete wall minimum 20 meters away (Fig. 2) from the end closure if the area needs to be utilized for any equipment.

Personal protection Considerations

  • Eyewash and emergency showers shall be provided in an area where operators are subject to hazardous sprays or spills.
  • Breathing air stations in the facilities handling extremely toxic gases/fluids.

Fig. 3 shows a typical plant layout.

What is a Hazard Classification?

  • Hazardous area classification is the risk locating plan for each unit/facility within the plot boundary for the process industry.
  • The Plot plan will be used by indicating the boundaries of the risk area.
  • HAC drawings are generally used by operators while issuing work permits.

HAC Standard

  • HAZARDOUS AREA: An area in which an explosive gas atmosphere is present, or maybe expected to be present, in quantities such as to require special precautions for the construction, installation, and use of apparatus.
  • NON-HAZARDOUS AREA: An area in which an explosive gas atmosphere is not expected to be present, in quantities such as to require special precautions for the construction, installation, and use of apparatus.

Process Requirements

  • Proper interconnection between equipment to achieve intended process parameters.
  • Normally equipment is arranged in the process fluid flow sequence. A requirement like gravity flow (Equipment Drain piping), Thermosyphon system should be considered, Limitation of pressure & temperature (process parameters) to be considered
  • The requirement of upstream and downstream pipe lengths for instruments.
  • Hazardous & Toxic fluid shall be identified. (H2S, Cyanide, Methanol, etc.)
  • Equipment handling hazardous fluids like flare and direct-fired equipment containing open flame shall be located separately.
  • Similarly, equipment handling toxic material shall be located with the restricted access or in accordance with local statutory regulation.

Economic Considerations

  • Equipment shall be located without affecting the process requirement for maximum economy of pipework & supporting steel with consistent standard clearances, construction, and maintenance & safety requirements.
  • Runs of exotic material & large bore piping shall be minimized.
  • Optimum utilization of the structure to be ensured.

Erection & Construction

  • Road access for the erection of pipe support/pipes and equipment.
  • The clear area for the crane to erect equipment on the location from the trucks.
  • The minimum one side of the pipe rack shall be kept clear.

Fig. 4 shows relative locations for area Layout.

Plant Layout Design Rules (PDF) | What is Piping (2024)

FAQs

What is a piping layout? ›

Piping Arrangement Drawings, Sections, and Elevations

The piping arrangement drawing evolves from the foundation location and equipment location drawings. It shows all pieces of mechanical equipment, including vessels in the unit and the pipes connecting them, including manholes, ladders, platforms, cages, and davits.

What are the four types of plant layout? ›

Table of Contents
  • Product or Line Layout:
  • Process or Functional Layout:
  • Fixed Position Layout:
  • Combination Type of Layout:

What is plant layout specification? ›

Plant layout can be defined as a technique of locating machines, processes and plant services within the factory so as to achieve the greatest possible output of high quality at the lowest possible total cost of manufacturing. From: Production Planning and Control, 2019.

What are the types of plant layout? ›

Types of Plant Layout:
  • (a) Product Layout (or Line Layout):
  • (b) Process Layout (or Functional Layout):
  • (c) Combination Layout:
  • (d) Fixed Position Layout:

What is this piping? ›

Within industry, piping is a system of pipes used to convey fluids (liquids and gases) from one location to another. The engineering discipline of piping design studies the efficient transport of fluid.

What are the uses of pipes? ›

Uses
  • Plumbing.
  • Tap water.
  • Irrigation.
  • Pipelines transporting gas or liquid over long distances.
  • Compressed air systems.
  • Casing for concrete pilings used in construction projects.
  • High-temperature or high-pressure manufacturing processes.
  • The petroleum industry: Oil well casing. Oil refinery equipment.

Which is the line layout? ›

The line layout is the definition of the list format for the items to be displayed. Line layout variants consist of a number of fields. These constitute the columns of the list and therefore determine the line layout of a list line. All lines in the list have the same line layout.

What is a functional layout? ›

A factory that has a functional layout is one in which manufacturing operations are grouped together on the basis of the function, technology or equipment used. A factory that uses this approach would install all equipment of a particular type in one area with separate areas assigned each type of equipment.

How do you make a piping layout? ›

Piping Layout Guidelines

Piping for vertical vessels should be located radially around the vessel on the pipe rack side, or should align with adjacent equipment. Leave adequate space for access to platforms, ladders, manways, instruments and drop areas.

What is process plant design? ›

Process Plant Design provides an introduction to the basic principles of plant design and shows how the fundamentals of design can be blended with commercial aspects to produce a final specification; how textbook parameters can be applied to the solution of real problems; and how training in chemical engineering can ...

What is technique of plant location? ›

It may be defined as a technique of locating machines, processes and plant services within the factory so as to achieve the right quantity and quality of output at the lowest possible cost of manufacturing. It involves a judicious arrangement of production facilities so that workflow is direct.

What is a fixed layout? ›

Fixed layout, also known as static layout, is an outline with fixed width, measured in pixels. As the name suggests, the layout is programmed to be fixed. So no matter what the screen size or resolution, the width of the elements will remain the same.

What is a good plant layout? ›

A good plant layout must have facilities such as water, ventilation, retiring room, etc., in the plant. It should also safeguard the health of the workers. A good layout must be flexible enough so as to incorporate any change in the management policies.

What is product or line layout? ›

In manufacturing engineering, a product layout refers to a production system where the work stations and equipment are located along the line of production, as with assembly lines. Usually, work units are moved along line (not necessarily a geometric line, but a set of interconnected work stations) by a conveyor.

What is piping in soil? ›

Soil piping is a naturally occurring, hydraulic process that leads to the development of macropores (large, air-filled voids) in the subsurface that are associated with landslides and collapse subsidence. It is most commonly associated with 'soil', a term that has contextual meanings.

What does piping work mean? ›

plumbing and piping works means installing any liquid, water or sanitary piping, or any associated fittings, including thermal insulation, for the conveyance of liquid, potable. Sample 1.

What is piping describe with suitable example? ›

Piping is the way to combine two or more commands. Explanation. A pipe is two or more commands separated by pipe char '|'. That tells the shell to arrange for the output of the preceding command to be passed as input to the following command. More generally, a pipe is a method of Inter-Process Communication (IPC).

What is pipe and types? ›

Pipes come in several types and sizes. They can be divided into three main categories: metallic pipes, cement pipes and plastic pipes. Metallic pipes include steel pipes, galvanised iron pipes and cast iron pipes. Cement pipes include concrete cement pipes and asbestos cement pipes.

What are pipes and their advantages? ›

Introduction on Advantages and Disadvantages of Various Pipes
Plastic PipeAdvantages
HDPE pipeGood toughness, good fatigue strength, good temperature resistance. light weight, good flexibility and good impact resistance.
PVC/UPVC pipeStrong corrosion resistance, ease of bonding, cheap, hard texture
7 more rows
12 Jun 2017

What are the five properties of pipe? ›

Product properties of pipe materials
  • Abrasion resistance. am ≤ 0,25 mm.
  • Bending tensile strength. 18 N/mm²
  • Biological resistance. assured.
  • Fire resistance. non-inflammable.
  • Chemical resistance pH. 0 to 14.
  • Tightness. 2,4 bar.
  • Compression strength. min. 100 N/mm²
  • Elasticity module. ~ 50.000 N/mm²

What are the three types of layouts? ›

There are mainly three types of layout: 1. Product or Line Layout 2. Process Layout 3. Combination of Product and Line Layouts.

What is layout example? ›

The definition of a layout is an arrangement, plan or design. An example of a layout is a drawing of how a house will be built. (informal) An establishment or property, especially a large residence or estate.

What are the two types of layout design rules? ›

Layout design rules: Contacts rules

metal to p-active (p-diffusion) metal to n-active (n-diffusion)

What is loop layout? ›

The loop store layout takes customers along a single path, past all available products, before arriving at the checkout. This approach maximizes overall product exposure and streamlines customer traffic, but it can also limit browsing opportunities when traffic volume is high.

What is a layout plan? ›

layout plan means a plan of the entire site showing location of plots / building blocks, roads, open spaces, entry / exits, parking, landscaping etc. indicating the activity for all land parcels.

What is plant layout PPT? ›

 Plant Layout is the physical arrangement of equipment and facilities within a plant.  Plant layout is the organization of physical facilities like machinery , equipment & the allocation of space for the various activities of the plant & personnel working in the plant.

What are the 4 major types of facility designs used? ›

There are four main types of facility layouts: process, product, fixed-position, and cellular.

What is a cell layout? ›

What is a Cellular Layout? A cellular layout is the physical organization within a company that improves workflow, efficiency, and production. This structure entails the creation of work cells, which are micro units of 3-12 workers. Each unit contains a certain number of machines and supplies.

What is hybrid layout? ›

Hybrid layouts are layouts that combine all three traditionally layouts considering product characteristics and capacity requirements. In this research, a systematic methodology to design the hybrid layouts is performed.

What is the role of piping layout engineer? ›

Piping Layout Engineer - ASU determine and develop the most suitable, economically and working on technically complex piping layout within proposals, projects execution, as part of a project team, in accordance with design & engineering standards.

What is the importance of properly designing piping systems? ›

An optimum pipe system design is critical to the operation and longevity of the overall infrastructure and requires a multipronged approach. With appropriate maintenance, piping is typically expected to last the age of the building, while other equipment is replaced at the end of its service life.

What is no pocket in piping? ›

"Do not pocket" means that the vapor can condense and perhaps fill the vapor line with liquid if it is not level or sloping toward the next piece of equipment.

What are the types of process design? ›

Three categories of process design can be used to differentiate the types of process design: Analytical, Experimental, and Procedural.
  • Analytical or Attribute Centered Design.
  • Procedural or Operation Centered Design.
  • Experimental Object or Search Centered Design.
26 Sept 2017

What are the 7 factors of influencing plant layout? ›

7 Major Factors Affecting Plant Layout | Industrial Management
  • (1) Policies of management:
  • (2) Plant location:
  • (3) Nature of the product:
  • (4) Volume of production:
  • (5) Availability of floor space:
  • (6) Nature of manufacturing process:
  • (7) Repairs and maintenance of equipment and machines:

What is process design process? ›

In chemical engineering, process design is the choice and sequencing of units for desired physical and/or chemical transformation of materials. Process design is central to chemical engineering, and it can be considered to be the summit of that field, bringing together all of the field's components.

How is factor rating calculated? ›

Factor Rating Method

Assign each location according to the merits of the location for each factor. Calculate the rating for each location by multiplying factor assigned to each location with basic factors considered. Find the sum of product calculated for each factor and select best location having highest total score.

What is factor rating system? ›

Factor Rating

This method involves qualitative and quantitative inputs, and evaluates alternatives based on comparison after establishing a composite value for each alternative. Factor Rating consists of six steps: Determine relevant and important factors. Assign a weight to each factor, with all weights totaling 1.00.

What are the tools and techniques of plant layout? ›

The six tools and techniques used for layout planning/plant layout are as follows: 1. Operation process charts 2. Flow process charts 3. Process flow diagram 4.

What is fluid design? ›

What is fluid web design? In fluid web design, the widths of page elements are set proportional to the width of the screen or browser window. A fluid website expands or contracts based on the width of the current viewport. Fluid design helps make websites more usable across device types with varying screen dimensions.

What is elastic layout? ›

A mixform between the fixed and the fluid layout is the elastic layout. The element-widths are expressed in em, which depends on the font size. Therefore the layout does not change when the Window size changes, but rather when the font size changes.

What is assembly line layout? ›

The assembly line is a type of machine or work center layout that is dictated by the product. In an assembly line environment, the product being manufactured moves continuously through the line from one work center to the next.

What are the basic principles of layout? ›

"Proximity", "alignment", "repetition" and "contrast" are regarded as some of the basic principles of layout design, and are effective techniques for improving visual hierarchy and readability, thus leaving a strong impression on the user.

What is importance of layout? ›

An effective layout not only looks attractive, but also helps the viewer understand the message the design is conveying. In other words, understanding layout is key when it comes to creating user-friendly, engaging designs, particularly in the realms of web design and advertising.

Why is plant layout needed? ›

A good layout should ensure short moves and should always tend towards completion of product. It also includes interdepartmental movements and material handling equipment. This includes the flow pattern reduction of unnecessary handling, space for movement and analysis of handling methods.

What is a product style layout? ›

Product layout is one of the three basic production and manufacturing plant layouts. In this design, the layout of equipment and processes in the workstations are distributed around the needs of the end product. Each station is given a small task to complete in a certain sequence.

Where is product layout used? ›

Product layouts are found in flow shops (repetitive assembly and process or continuous flow industries). Flow shops produce high-volume, highly standardized products that require highly standardized, repetitive processes. In a product layout, resources are arranged sequentially, based on the routing of the products.

What is process and product layout? ›

Meaning. Product Layout is a type of layout design in which the resources needed to produce the product are arranged in one line, as per the sequence of operations. Process Layout refers to the type of layout design wherein the resources having hom*ogeneous processes or functions are combined together. Product.

What is the role of piping layout engineer? ›

Piping Layout Engineer - ASU determine and develop the most suitable, economically and working on technically complex piping layout within proposals, projects execution, as part of a project team, in accordance with design & engineering standards.

What is piping in operating system? ›

In computer programming, especially in UNIX operating systems, a pipe is a technique for passing information from one program process to another. Unlike other forms of interprocess communication (IPC), a pipe is one-way communication only.

What is piping in fashion? ›

Piping is a trim or edging formed by sewing a thin strip of folded fabric — typically bias binding — into a narrow tube and attaching it to the edge of a piece of fabric. It can also include cord to give it extra body. Piping is often used to define or reinforce the style lines of a garment.

What is piping in soil? ›

Soil piping is a naturally occurring, hydraulic process that leads to the development of macropores (large, air-filled voids) in the subsurface that are associated with landslides and collapse subsidence. It is most commonly associated with 'soil', a term that has contextual meanings.

What is the scope of piping? ›

Piping engineering is a niche field, it has its utility mainly in designing of oil and gas refineries, power plants, pharmaceutical plants, metal and mining plants etc.

What is the meaning of piping engineer? ›

Piping engineers are engineering professionals who are responsible for the creation of piping systems that transport materials such as oil, gas, water, and waste from one location to another.

What is the responsibility of piping supervisor? ›

Piping supervisors are in charge of the installation and maintenance of pipelines. A piping supervisor works in the oil and gas industry to manage the installation and maintenance of pipelines.

Is pipe a device? ›

A PIPE is akin to a FIFO device. Both FIFO and PIPE map GT. M devices to UNIX pipes, the conceptual difference being that whereas a FIFO device specifies a named pipe, but does not specify the process on the other end of the pipe, a PIPE device specifies a process to communicate with, but the pipes are unnamed.

What is the purpose of pipe system call? ›

pipe() is a Linux system function. The pipe() system function is used to open file descriptors, which are used to communicate between different Linux processes. In short, the pipe() function is used for inter-process communication in Linux.

What is distribution pipe? ›

Distribution pipe means an open-jointed or perforated pipe used in the dispersion of septic tank or other treatment facility effluent into absorption trenches, seepage trenches, or seepage beds.

What is piping and binding? ›

Binding is used to clean finish edges of a garment part where piping is used mostly for decorative purpose. A good example of piping is t-shirt neck binding and sleeve placket binding in a shirt sleeve, Example of binding: Inner vest armhole and neck finishing using binding.

How do you do piping? ›

How to Make & Sew Piping - YouTube

How do you make a piping design? ›

7 Easy Piping Techniques You Can Master - Topless Baker - YouTube

What is piping and exit gradient? ›

This type of Piping is called backward erosion piping. Generally, backward erosion piping failure occurs when the exit gradient becomes greater than the critical hydraulic gradient. The hydraulic gradient near the exit point of the water is called the exit gradient.

How can we prevent piping? ›

To prevent the possibility of erosion and piping, following approaches are used:
  1. By providing cut off wall at downstream side.
  2. Increasing the flow path by providing impervious blanket.
  3. Use of protective filter.

What is pipe failure? ›

1] A common piping failure is the rupture of the piping wall due to excessive stress.

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