16-QMP-05-3A

DESIGN BASIS

FOR

PLOT PLAN

General Revision (due to change in organization name) &

0 18.01.07 SUBM BLJ MKB
Issued for Implementation
0 12.08.98 Issued for Implementation RA RP RP
Word

Rev. Date Description Prpd. Chkd. Appd.

Standard Number Rev.
DESIGN BASIS
FOR PLOT PLAN
04-DB-001 0
Saipem Triune Engineering Pvt. Ltd.,
New Delhi Sheet 1 of 9
 16-QMP-05-3A

CONTENTS

1.0 SCOPE 3

2.0 CODES AND STANDARDS 3

3.0 DESIGN DATA 3

4.0 CRITERIA FOR LOCATION OF VARIOUS FACILITIES 3

5.0 SAFETY DISTANCE FOR HYDROCARBON STORAGE AND HANDLING 6

6.0 SAFETY DISTANCES FOR PRESSURE STORAGE 7

7.0 SAFETY DISTANCES FOR FILLING STORAGE & TRANSPORTATION OF GAS

CYLINDERS 8

8.0 SAFETY DISTANCES AS PER VASUDEVAN COMMITTEE REPORT FOR LPG

STORAGE AND HANDLING FACILITIES 9

9.0 CO-ORDINATION & APPROVAL OF OVERALL PLOT PLAN & UNIT LAYOUT 9

Standard Number Rev.

Word

DESIGN BASIS
FOR PLOT PLAN 04-DB-001 0
Saipem Triune Engineering Pvt. Ltd.,
New Delhi Sheet 2 of 9
 16-QMP-05-3A

1.0 SCOPE
This specification covers design basis for overall plot plan of various plants and indicates
major parameters for location of different facilities and safe distances as per rules and safe
engineering practices.
The specification also covers the overhead and horizontal clearance provided in units,
requirements of maintenance platforms, access ways and ladders.

The general practices followed for transportation and clearances required from various
statutory bodies are also covered.

2.0 CODES AND STANDARDS

2.1 Petroleum Rules 1976 (For Hydrocarbon Storage under CCE).

2.2 Code of practice for LPG storage installations IS 6044 Part II 1972 Industrial, Commercial
and Domestic Bulk Storage Installation.

2.3 The static and Mobile pressure vessels (unfired) rules – 1981 (For Pressure Storage of gases
under Chief Controller of Explosives).

2.4 Gas Cylinder Rules 1981 (For filling and handling of gas cylinders under CCE).

2.5 Home Ministry Circular (for perimeter walls)

2.6 The Institute of Petroleum Refining safety Code - Part III.

Model Code of safety Practice in Petroleum Industry.

2.7 Standard for storage and handling of LPG at utility gas plants (NFPA 59-1979).

2.8 Report of Committee set up to review safety and operating procedures in LPG filling,

Transporting and distribution (Vasudevan Committee Report).

2.9 D.G.C.A. rules.

2.10 OISD Standard 118 (For Layouts for Oil and Gas Installation)

3.0 DESIGN DATA

To be compiled as per Codes and Standards

4.0 CRITERIA FOR LOCATION OF VARIOUS FACILITIES

4.1 Layout Planning

In sequential order of process flow

Standard Number Rev.
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DESIGN BASIS
FOR PLOT PLAN 04-DB-001 0
Saipem Triune Engineering Pvt. Ltd.,
New Delhi Sheet 3 of 9
 16-QMP-05-3A

4.2 Orientation

To suit wind direction to avoid flow of hydrocarbon gases and flame travel over vital areas /
source of ignition.

4.3 Units

Central location with straight approach from Main gate.

Orientation to suit process flow with minimum piping runs

Location of tall columns & furnaces close to road side for ease of construction

Close to main entry

Locate on high ground to avoid flooding

4.4 Storage Tanks

Arrangement as per CCE rules.

In undulating areas storage tanks shall be located in lower elevations.

Storage tanks shall be grouped according to product classification.

4.5 Utility Block

Close to unit block

4.6 Main Receiving Station

Close to battery limit with minimum overhead power lines over project site.

4.7 H.V. Sub Station

Preferably at load centres of loads upto 10/20 M.W.

One or more numbers shall be provided as per operational needs and limiting distances.

4.8 Low Voltage Sub-station

Generally these shall be located at load centres in such a way that distance between
distribution transformer and farthest motor is limited to 150/200 metres.

4.9 Approach Road to Sub-station and Transformer Bays

To facilitate crane movement for maintenance and erection

Standard Number Rev.

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DESIGN BASIS
FOR PLOT PLAN 04-DB-001 0
Saipem Triune Engineering Pvt. Ltd.,
New Delhi Sheet 4 of 9
 16-QMP-05-3A

4.10 Power Plant

Gas/Oil Based: Central to units and utility block and preferably closest to Main Receiving
Station

Coal Based: Location away from vital facilities to avoid coal dust

4.11 Flare

Upwind of units and at safe distance. Height and distance of flare shall be decided after heat

radiation studies.

4.12 Dispatch Facilities

Truck loading - Close to product movement gate

Rail loading - To suit rail layout & at 100 m distance from storage tanks
(Preferably be located along the periphery of the installation).

4.13 Effluent Plant

Locate minimum one block away from unit area.

Down wind of units and important areas to avoid smell problems.

In lower grade to facilitate gravity flow

Closer to disposal point

4.14 Sulphur Unit & Loading

Close to product movement gate and away from population areas.

Away from hazardous areas

Minimum distance of 50 M shall be kept from building / boundary wall

4.15 Service Corridors

Pipeways to be marked and specified in plot plan.

4.16 Construction Facilities

Sufficient open areas to be left

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DESIGN BASIS
FOR PLOT PLAN 04-DB-001 0
Saipem Triune Engineering Pvt. Ltd.,
New Delhi Sheet 5 of 9
 16-QMP-05-3A

4.17 Fire Station

Close to main entry gate with straight approach to units as far as possible

Fire drill areas - Close to Fire station

Fire water pump - In utility block.

House - min. 60 m from unit battery.

- min. 60 m from petroleum storage tanks.
- Near water source.

4.18 Control Room

Locate distinctly in the process block or in the adjoining block

Location at safe distance in non-hazardous electrical area classification

4.19 Pressure Storage

Max. Vessels in each group shall be six.

Max. capacity in each group shall be 13000 cu.m.

Top surface of the vessels in a group shall be on the same plane.

Longitudinal axies of horizontal vessel (Bullet) shall not point towards other vessel/vital
process equipment / control room.

LPG vessel shall not be located within the same dykes where other flammable liquid
hydrocarbons are located.

4.20 Cooling Towers

Locate away from process area preferably down-stream direction of wind.

4.21 Smoking Booths

Locate upwind of any hydrocarbon source/ facility

5.0 SAFETY DISTANCE FOR HYDROCARBON STORAGE AND HANDLING

5.1 Under Petroleum Rules – 1976

5.1.1 Distance of flare to still, pump house 90 M

any storage tanks and process units

5.1.2 Distance between storage tank and still, 90 M

boiler or furnace
Standard Number Rev.
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DESIGN BASIS
FOR PLOT PLAN 04-DB-001 0
Saipem Triune Engineering Pvt. Ltd.,
New Delhi Sheet 6 of 9
 16-QMP-05-3A

5.1.3 Location of LPG storage or filling 30 M

facilities to hydrocarbon storage and
blending or filling and protected works

5.1.4 Inter distances between storage tanks and Table I and II of Petroleum
other facilities Rules 1976

5.1.5 Height of tank dyke wall for tank farm area Not to exceed 2.0 M and
Min. 1.0 M
5.1.6 Tank storage capacity in one dyke area

i. Fixed roof tanks 60,000 M3

ii. Floating roof tanks 120,000 M3

5.2 Under OISD Standard 118 (July 1995)

5.2.1 For inter distances between blocks/facilities refer Table-1

5.2.2 For equipment spacing within process units, refer Table-2

5.2.3 For interdistances between Tanks/offsite facilities (For small installations), refer Table-3

5.2.4 For inter distances between storage tanks / offsite facilities, refer Table-4

5.2.5 For interdistances between storage tanks, refer Table-5

5.2.6 For distances from boundary fencing, refer Table-6

5.3 Additional Consideration as per Safety Engineering Practice

5.3.1 Approach to units and hydrocarbon storage tanks area shall be from two sides

5.3.2 Distance between control room to process unit equipments.

Minimum 15 M

Preferable 30 M

5.3.3 Distance between centre of main road to process unit battery limit.

To suit area classification

6.0 SAFETY DISTANCES FOR PRESSURE STORAGE

6.1 Under static and mobile pressure vessel (unfired) rules 1981

6.1.1 Distance from pressure storage to buildings 30 M (for above 40 M3 storage )

and adjoining properly line storage

Standard Number Rev.

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DESIGN BASIS
FOR PLOT PLAN 04-DB-001 0
Saipem Triune Engineering Pvt. Ltd.,
New Delhi Sheet 7 of 9
 16-QMP-05-3A

6.1.2 Distance between 2 groups of 6 30 M (not more than 6

pressure vessels each vessels shall be grouped
together)

6.1.3 Distance from loading / unloading 9.0 M

points to adjoining property line,
pressure storage container.

6.2 Under OISD Standard-118 (July 1995)

6.2.1 For interdistances for LPG facilities, refer Table-7

6.2.2 For interdistances between LPG storage vessels and boundary / property line / group of
buildings not associated with LPG plant, refer Table-8

6.3 Additional Consideration as per Safe Engineering Practice

6.3.1 Distance between pressure vessels Minimum ¼ dia of adjacent

Vessels

6.3.2 Distance between LPG pump station 15 M

and storage vessel.

6.3.3 Distance between any process unit 60 M

and LPG storage.

6.3.4 Distance between LPG pressure vessel, 90 M

LPG filling shed and flare or any source
of ignition.

6.3.5 LPG pressure vessels shall be located down

wind side of process units as far as possible.

6.3.6 Area around LPG filling station shall be free

from depressions and low pocket.

6.3.7 In undulating areas, LPG storage shall be

planned in lower elevation areas.

7.0 SAFETY DISTANCES FOR FILLING STORAGE & TRANSPORTATION OF GAS

CYLINDERS

7.1 Under Gas Cylinder Rules 1981

7.1.1 Distance between LPG Cylinder storage 15.0 M (for storage over
and adjacent building and facilities. 30 M3)

7.1.2 Distance between LPG filling station 10.0 M

and adjoining bldgs.

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DESIGN BASIS
FOR PLOT PLAN 04-DB-001 0
Saipem Triune Engineering Pvt. Ltd.,
New Delhi Sheet 8 of 9
 16-QMP-05-3A

7.2 Additional consideration as per Safe Engineering Practices

7.2.1 LPG filling station shall be located down wind of the plant.

7.2.2 LPG filling shed shall be open from all sides for proper ventilation to avoid concentration of
LPG gas on floor.

7.2.3 Flooring inside the LPG filling and storage shed be of non sparking type.

8.0 SAFETY DISTANCES AS PER VASUDEVAN COMMITTEE REPORT FOR LPG

STORAGE AND HANDLING FACILITIES

8.1 Safety zone around facility 30 M minimum

80 M preferable

8.2 Distance between truck loading 15 M

and cylinder stacks.

8.3 No. of exists 2

9.0 CO-ORDINATION & APPROVAL OF OVERALL PLOT PLAN & UNIT LAYOUT

Co-ordination with all Department mainly Project /Process / Mech. / Elect. / Inst. / Piping /
Structural / Pipeline / Construction.

Client approval

CCE approval before issue for construction

Standard Number Rev.

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DESIGN BASIS
FOR PLOT PLAN 04-DB-001 0
Saipem Triune Engineering Pvt. Ltd.,
New Delhi Sheet 9 of 9