I use tilesets, probably because I started with the LNP. I also make use of DFHack & Therapist (couldn't imagine playing without Therapist at all). As for DFHack, I make extensive use of the clean command, and usually prospect & reveal at the start of a new embark, to see what I'll have to play with, and to avoid aquifers.
As for my fort design, I tend to be a bit more compact, like you do. I'll turn a starting area into my walled-in pasture/farm area, and connect it down to my "real" fort. Then I'll add an outside entryway, with depot access & trap-filled "guest" access. But inside the fort, I tend to go with a grand staircase connecting everything, a 3 level grand dining/meeting/throne room, with apartments on each level. I also like to make one access point to that area, so I can put a mister in, so every dwarf going to the meeting hall or their rooms goes under it. Workshops are on their own level, usually everything on the same level, with an entire storage area above & below them.
But other than goblinite harvesting, magma pumps, water reservoirs, power plants & that kind of thing, everything is fairly close.
Burrows... I usually tend to have only a couple - one covering the entire domain (inside, farms, pastures, mining areas), to keep dwarves from roaming outside. (I also always turn off fishing & hunting.) The second is my "safety" zone, covering most of the inside areas of the fort, a slight downsizing of the previous zone, which is used when invaders come. I've tried to do specialty burrows - one for the farmers, one for the crafters, one for the military, and one for nobles... but I tend to give up on that pretty fast.
I also hardly ever use the caverns, other than breaching them for spores and then walling them off. Best is if I breach into open air, so I have less concern over critters coming out. And I have never yet dug into the circus.
I honestly get bored with forts after about 15 years - once they're established pretty well, with everything dug out, smoothed, engraved, and food/drink supplies going steady. I find I enjoy the initial challenge of getting it all set up more.