PLOT PLAN

Data to be collected before starting of plot plan

Plane table survey map: This document shows the extent of plot with overall area identifying all the existing constraints such as transmission line, structure, pond, place of worship etc. Nearby road, railway lines, drains etc. This will show the geographical north direction. Location of power and water connections is also shown. Contour Survey Map: This will shows the level of plot with respect to mean sea level. Soil Survey: Soil survey is conducted to establish the soil bearing capacity which will required for civil design. Non-Plant Facilities: Administrative Block Canteen Workshop R&D, QC laboratory Gate house /Time office Security Arrangement Vehicle parking Medical Centre Ware House Steel/scrap yard Fire station Weigh bridge Staff colony

Process Data: A lot of process data required before develop plot plan Size/capacity of the process unit to work out the area to accommodate the same. Type of plant whether located indoor or outdoor or extent of enclosure required Sequence of process flow to locate the process unit in proper manner Hazardous natures of plant to keep proper inter unit distance and workout fire water storage volume.

Check List North South Mark Wind Rose or Direction of prevailing wind. Grid Marking Finish ground Level Battery limits of complex (area boundary ) Green Belt/Green verge/Green Area/Gardening(One third of area has been provided for green belt and landscaping ) as per requirements of MOE&F in the earlier report Equipment list and Size (if possible) Coordinates of main roads, process units, utility units, buildings, storage tanks and main pipe rack. Notes Complete Title Box Legend The general plot plan drawing shall give the layout of the whole plant(s). It should be prepared in accordance with one of the following scales: 1:500. 1:1000, 1:2000 Main Gate Material Movement Gate (optional) Watch Tower (Four sides of Plant area, It should arrange in such a way that it will watch whole plant.) Plant Boundary Road /Petrol Road (all around the boundary) (Generally 5m or 6 m wide) Security Check post cum Time office (Near Main Gate)/security office Administrative Building (Near Main gate) Canteen (Near Main Gate) Car parking (Near Main Gate) Workshop and Store or Ware House (sometime both are separate Building) (Ware house should be nearer to the material movement gate to avoid extra traffic of truck in process unit. Workshop should be nearer to TG building for easy maintenance purpose. Chemical House (Nearer to water treatment area) Fabrication Yard/construction yard/laydown Area(After completion of construction it will utilize as a green belt) Equipment shall be arranged to minimize piping runs (particularly, for large sized piping and alloy piping) as far as possible. Clear access ways having minimum width of 600 mm shall be provided for the operators access around equipment. Large capacity storage tanks containing flammable and explosive fluids shall be located in outer areas as far as possible.

Guard pond is located nearer to Effluent treatment Plant (ETP). All the treated effluent store in guard pond for future use in horticulture and dust suppression of coal handling plant.

 Water System
Raw Water Reservoir /Raw Water Storage Tank (Near to source of water supply) Raw Water pump House (Near to Raw Water Storage tank) Fire Water Storage Tank Fire Water Pump House (Near to Fire Water Storage tank) Clarifier water tank, DM Plant, Service Water Tank , potable Water Tank etc are placed nearer to each other. The Placing of each equipment as per flow process of water treatment as per Plant Water System P&ID. Cooling Tower Place as per wind direction. Location of cooling tower depends upon the main plant location. Water tret ment & supply sould be in such place where coal dust cannot contaminate it.....

Points to Note:
Normally Construction is permitted on 50% of the plot area with total built up area equal to area of the plot ((Floor spacing Index(F.S.I)=1)
The Floor Space Index (FSI) or Floor Area Ratio (FAR) is the ratio of the total floor area of buildings on a certain location to the size of the land of that location. As a formula: Floor Area Ratio = (Total covered area on all floors of all buildings on a certain plot)/(Area of the plot)

Area reserved for tree plantation shall be 1/3 of the area occupied. Water storage capacity - 24 hr. minimum. Domestic water - 100 litres per person per day Water requirement for Boiler Steam rating x Working factor Cooling tower - 2% of capacity as drift and blow down losses Washing - 10-15 litres per day per sq.ft. of floor area of the plant Gardening - 5 litres per day per sq.ft. of garden area Height of Boiler Chimney H (in m) = 14 Q 1/3 where Q is the amount of SO2 generated in kg/hr. Inter unit distance based on the type and nature of the process.

Steps To Be Considered While Developing The Plot Plan:

Study the contour map and establish the grade levels/terraces. Establish the N-S and E-W (or X-Y) grids, the plant north in relation to geographical north. Establish the free area along the plot boundary as per the statutory norms. Work out the area requirements for the green belt, vehicle parking etc. as per the norms.

The process blocks shall be located in the sequential order of process flow so that material handling (solid/liquid) is minimum. The blocks shall also be arranged considering prevailing wind direction so that flammable gases do not get carried to sources of ignition Storage tanks shall be grouped according to process classification. Centralised control room shall be located in safe area close to process plant. Process units shall be serviced by peripheral roads for easy approach. Electrical sub-stations shall be placed at the load centre to minimise cabling Receiving station shall be placed near the supply point. Ware houses shall be located close to the material gate to avoid truck traffic within the process area. Flares, Furnaces/Heaters, cooling towers, etc. shall be placed depending on the wind direction. Provision of future expansion shall be considered. Raw water storage shall be placed closer to water source. Fire and raw water tanks shall be located together. Fire stations shall be away from the hazardous area and nearer to main gate. Effluent treatment plant shall be located away from the process and utility area on the downwind direction. Workshop, contractors shed, storage yard, etc. shall be at centralised location serviced by peripheral roads. Two gates are preferred, one for the material entry with weigh bridge and the other one for man entry. Administrative block, laboratories, etc. shall be located closer to the man entry gate. Process unit can be separated within a fencing providing additional gate. Consider recommendation from the statutory authorities for inter unit distances. Residential colony shall be located away from the plant more closer to the city limits. Tank Diameter- Where tank spacing is expressed in terms of tank diameter, the following criteria governs: (a) If tanks are in different services, or different types of tanks are used, the diameter of the tank which requires the greater spacing is used. (b) If tanks are in similar services, the diameter of the largest tank is used Tank Spacing- Is the unobstructed distance between tank shells, or between tank shells and the nearest edge of adjacent equipment, property lines, or buildings. Where the prevailing wind is defined, the administration and service facilities and directly fired equipment, etc., shall not be located windward of process Units and storage tanks, etc. The administration and service area shall be located at a safe place on the site in order to protect personnel from hazards. It shall preferably be located near the main gate alongside the main road of the plant. Flare and burn pit shall be located at the end of the site with sufficient distance to prevent personnel hazard.

Waste water treating Unit shall be located near at the lowest point of the site so as to collect all of effluent streams from the processing Unit. The minimum space between security fence and units boundary shall be 20 m, and between security fence and equipment shall be 30 m. In case of special units such as flammable material storage with vapor release and toxic materials, minimum space shall be at least 60 m from site boundaries adjacent to centers of population (domestic, work or leisure ). Fire water pumps and equipment shall be sufficiently remote from processing, storage and loading areas, where a major fire could occur. Access roads shall be at least 3 m from processing equipment between road edges to prevent vehicle collisions.

Following points to be consider while developing explosive tank farm area. Classification of Petroleum product: Class-A : Liquid which have flash point less than 230C. Class-B : Liquid which have flash point of 230C and above but below 650C Class-C: Liquid which have flash point of 650C and above but below 930C Excluded petroleum : Liquid which have flash point above 93 0C

Layout of Explosive Tank farm area: Petroleum storage tank shall be located in dyke enclosures with roads all around the enclosure. Dyke enclosure should be able to contain the complete contents of the largest tank in the tank farm in case of an emergency. Enclosure capacity shall be calculated after deducting volume of the tank (other than the largest tank) up to the height of enclosure. A free board of 200mm shall be considering in fixing height of the dyke. The height of tank enclosure dyke shall be at least 1m and shall not be more than 2m above . ( as per NFPA-30 page no. 30-23, wall of the dyke area shall be restricted to an average height of 1.8m(6ft) above interior grade)average ground level inside. However, for excluded petroleum it can be 600mm. Tank shall be arranged in two rows so that each tank is approachable from surround road. Tank height shall not be exceed one and half times (1 ) e diameter of the tank or 20m, whichever is less. Minimum distance between tank shell and the inside of the dyke wall shall not be less than one half the height of the tank.

Layout of Gas Storage: Storage vessels are not allowed below ground level. Vessels shall be located in open Vessels are not to be installed above one another.

If vessels are more than one then longitudinal axis are parallel. Vessels installed with their dished end facing each other shall have screen walls in between them.

Layout of Pipe racks and Sleepers

In general, pipe racks for process Units and pipe sleepers for the off-site facilities shall be considered as the principals support of the pipe way. Run pipe lines overhead should be grouped in pipe racks in a systematic manner. Pipe rack runs oriented in the same direction shall be at consistent elevations. Pipe rack runs oriented opposite to these runs shall be at other elevations to accommodate crossing of lines at pipe racks junctions and to accommodate branch line intersections. Single level pipe racks are preferred, if more than one level is required, the distance between levels oriented in the same direction shall be adequate for maintenance but not less than 1.25 meters. Maximum pipe rack widths shall be 10 m. If widths larger than 10 m are required, the pipe rack shall be designed to be of two stages. Actual widths shall be 110% of the required widths or the required widths plus 1m. Allow ample space for routing instrument lines and electrical conduit. Provide 25% additional space for future instrument lines and electrical conduit adjacent to that required.

Provide 20% additional space on the pipe rack for future piping. This space shall be continued and clear on each level for the full length of the rack. The width allocation may be split in two sections but not more than two Allow a continuous clear area of 4 meters high by 4 meters wide below main racks in process Units for maintenance access ways. Pipe racks outside process areas shall have the following minimum overhead refinery/plant clearances: main roadway: 5 meters, access roads: 4.5 meters, railroads: 6.7 meters above top of rail. Except for special cases, minimum width of pipe rack shall be 6 m. The width of pipe rack shall be designed to accommodate all pipes involved plus 20% space for future expansion or modification. Where the pipe rack supports air coolers, the preferred width shall be the width of air coolers. In multi-level pipe racks, pipe carrying corrosive fluids shall be on the lower level, and utility lines should be at the upper floor. Large size or heavy weight pipes shall be located at the lower level and on extreme sides. Width of pipe rack is estimated as W=(fxnxs)+A+B, where f=factor of safety, f=1.5 if pipes are counted from PFD, f=1.2 if pipes are counted from P&ID n=Number of lines in the densest area up to size 450NB s=300mm (estimated average spacing) s=225mm (if lines are smaller than 250NB) A= Additional width for 1. Lines larger than 450NB 2. For instrument cable tray/duct 3. For electrical cable tray B=for future provision =20% of (fxnxs)+A Normally width is limited to 6m, if width workout is more than 6m then arrangement to be done in multi layer.

Head room normally provided as below Clear head room under structure / pipe lines inside operating area =2200mm Head room over rail (from top of rail) =7000mm Clear Head room over crest of road for crane movement=7000mm Clear Head room over crest of road for truck movement=6000mm Clear Head room over crest of road between process unit=4500mm

Layout of Control Room and Electrical Sub-Station

The control room and substation shall be located as close as possible to the plant equipment, maintaining a minimum distance from viewpoint of noise and safety requirements. The control rooms, and substation shall be spaced at least 15 m from the nearest process equipment surface. The control room and substation shall be located with consideration to convenience in daily operation.

The control room shall be positioned so that the operator can command a view of the whole system which is under control. Large buildings, or equipment shall not be placed in front of the control room. The location of the main electrical substation should be as close to the site boundary and the maximum distance possible from the main processing plant this has the effect of reducing high voltage cabling costs.

Control Valve Arrangement:

Fire Fighting Requirements:

Each individual process Unit shall be provided with sufficient open spaces there around that, fire trucks can be run and operated thereat. The width of access way there to, shall be 6 meters minimum

Building Requirements:
Service buildings include offices, control rooms, laboratories, houses, shops, warehouses, garages, cafeterias and hospitals. These structures and areas require protection of personnel from possible fires and explosions of major plant equipment and may require additional spacing from high risk facilities. The service buildings shall be located near the entrance of the plant and be readily accessible to a public road or highway. Spacing at refineries, petrochemicals, chemicals, and gas plants for buildings shall be in accordance with Oil Insurance Association (OIA) recommendation.

Access Requirements:
Access ways within the plant shall be provided for maintenance, emergency case, and for fire fighting from the road around the plant. Piping system shall be laid in such a way to make possible passage of mobile equipment. Operating passageway between equipment or piping and adjacent equipment generally is 1050 mm minimum except when otherwise shown on drawings. Minimum widths of access way shall be as follows: Vehicular access ways within units: 4.0 m Pedestrian access ways and elevated walkway: 1.2 m Stairways and platforms: 0.8 m Footpaths in tanks areas: 0.6 m Maintenance access around equipment: 1m Fire truck access way: 6m

Minimum headroom clearance for access ways shall be as follows: Over railways or main road: 6.8 m Over access roads for heavy trucks: 6 m For passage of truck: 4 m For passage of personnel: 2.1 m Over fork-lift truck access: 2.7 m

Layout of Flare System:

Flare systems are required to dispose of large quantities of flammable gases, especially during an emergency shutdown. Flares are principally of the multi jet ground or elevated type, and as a result will require large sterile areas around them to isolate them from personnel, equipment and property from effects of heat radiation and convection. When locating ground flares care must be taken to insure that the discharge plume does no overheat area or create no go areas within the plant with respect to operating personnel. It can be seen therefore that the flare of either type must be located in a remote location within the overall site facilities upwind and to the side of the process facilities and far enough away from the boundary fence so as not to effect the adjacent community.

Layout of Cooling Tower:

Proper equipment layout is essential to ensure that the cooling tower will operate at its rated capacity. The objective is for the evaporative cooled equipment to be located so that fresh air is allowed to enter the unit freely and unobstructed and to ensure that recirculation is minimized. The first step in achieving this goal is to consider the many factors that may affect the cooling tower installation. During the design of the system, special attention needs to be given to space limitations, surrounding structures, existing units, proximity of neighbors, prevailing winds, piping, and any possible future expansion plans. Once this information is obtained, the guidelines contained in this bulletin can be used to determine the best layout for the equipment. The cooling tower should be located away from fresh air intakes, operable windows, kitchen exhaust, and prevailing winds directed toward public areas. Induced Draft Counterflow Unit Layout: (Single Unit Installations) The first item to consider is the position of the unit with respect to other structures. The top of the cooling tower must be equal to or higher than any adjacent walls, buildings or other structures. When the top of the unit is lower than the surrounding structures (Figure 1), recirculation can be a major problem. If the unit is on the windward side, as shown in Figure 1, the discharge air will be forced against the building and then spread in all directions, including downward, toward the air inlets. When the wind comes from the opposite direction, the resulting negative pressure area created by the wind passing over the building will cause the discharge air to be forced back

into the inlets, as shown in Figure 2.Even if neither of these conditions occurs, the presence of much taller structures can potentially inhibit the dissipation of the hot moist discharge air.

Single or multiple Unit Installation: Induced draft, counter flow design unit may have air inlets located on all four side of the unit. When it is located near a wall or other structure that blocks the fresh air entering into the unit, consideration must be given to the clear distance between the air inlet and that blockage. Therefore it is essential to provide adequate space in front of each air inlet to ensure proper air flow and prevent air recirculation. Space Requirements for Maintenance :
When a unit is located in close proximity to other structures, walls or equipment, there are minimum clearances required for periodic maintenance.Proper access must be provided for: Adjustment and replacement of drive belts Lubrication of motors and bearings Cleaning of water distribution system Access to cold water basin for cleaning Access to the pumps of closed circuit coolers and condensers for maintenance. Water cooling towers are located downwind from all the facilities any sources of ignition, and centres of population. The location of the cooling towers must be such that their plumes do not pollute or create hazards for either the operating company personnel or any adjacent communities. Cooling towers are therefore being located down wind of processing facilities, utility plant, administration buildings etc. and at such a distance not to be effected by flammable, toxic or hazardous material discharges.

Layout of Boiler and Utility Plants :

Boiler and Utility Plants are located, centrally to the main users, which they supply, upwind of any equipment processing flammable or hazardous products, and separated from any hazardous area. The main objective of centralizing the boiler and utility plants is to minimize the interconnecting facilities between the boiler and utility plants and their main users. This has the effect of reducing the installed cost of any interconnecting system Another important factor to be considered when locating the boiler plant is the height of the boiler exhaust stack and its location relative to the prevailing wind, as it is most important that the

products of combustion are dispersed without polluting the local community of any of the on site facilities or buildings. Main plant is generally located highest grade level of the ground. Main plant location is related to switchyard location, chimney location, Coal handling plant location etc. BTG should be at highest elevation (above historic High Flood Level (HFL which u get from Hydrology report or contour maps) Coal Handlg Plant should be in direction where wind blows it opposite to places where water & plant equipment are installed. We dont want dust in our plant (ideally) Switchyard should be placed where wind cannot carry Cooling Tower drops to switchyard. Water & swityard should be opposite.

Layout of STG Building: List of equipment placed at Ground Level: Boiler feed Pump (BFP) Dirty oil tank/transfer pump, clean oil tank/ transfer pump ACW pumps / acw booster pumps ACW plate type heat exchangers Air Compressor / Control panel Air Driers/Air receiver Station Sump or sump pump Condensate Extraction Pump (CEP), CEP strainer H2 and Co2 storage cylinder Cable rack or bus ducts CW piping Condensate Ceaning System Turbine Lube oil cooler HP and LP Dosing Skid

List of equipment placed at 5.0 m floor: Condenser LP Heater HP Heater Turbine Lube Oil Tank Turbine Flask Tank

 HP & LP Flash Tank List of equipment placed at 10.5m floor: HP & LP Heater Main Steam strainer HP and LP Bypass Gland Steam Condenser Cable Gallery

List of equipment placed at 15.5m floor: Turbine Generator Control Room Battery Charger Room

List of equipment placed at different height: Dearator-27m Condenser-5m Turbine and Generator-15m Height of TG Building-30m Size of TG Building- Length per unit 75m + Service Building 27m and Width 60m Height of Bunker bay-58.5m Height of Boiler House-70m Height of Boiler Drum-54m Height of ESP-32m Height of ID fan-6m Height of chimney-275m Air Handling Uni-21m Auxiliary PRDS-21m ACW Tank-27m CBD Tank-27m Bunker operating Floor-34m Potable Water Tank-34m Service Water tank-34m

 Generally a 1000MW fossil fuel fired station requiring a 90-200 acres site. (1Acres=4046.873 m2) The requirement of water in steam cycle is of order of 3 to 4 tonnes/hr/MW and make-up quantity 2-3% of the same. In once through system of circulating water the amount required will be approx.. 20000 m3hr/100MW One 100MW unit will produce about 400 to 450 tonnes of fly ash per day on full load. A turbine shaft rotates at 3000 rpm. And generate AC current of frequency of 50 cycles per sec.