General Plot Plan Development Philosophy
General Plot Plan Development Philosophy
General Plot Plan Development Philosophy
• Plot plan is a primary document in design of a plant. It takes lot of experience, knowledge of
international and local standards and regulations as well as Process Flow.
1. Block System
Block layout should be adopted as far as possible. The entire area should be sub-divided into
blocks. If process units are operated in an integrated way, and shutdowns are taken simultaneously
of these units, then they may be considered as single block for inter distances and relative placement
purpose.
2. Process Flow
Plant layout arrangement should follow the general route of raw material to process unit(s) with
tankages interposed as required followed by storage & despatch facilities. Blocks should be arranged
in sequential order of process flow.
3. Flooding
All units and roads should be located on high ground to avoid flooding.
4. Roads
All process units and dyked enclosures of storage tanks shall be planned in separate blocks with
roads all around for access and safety. Primary traffic roads in the installation should be outside
hazardous areas. Roads separating the blocks shall act as firebreaks.
Pedestrian pathways should be provided / marked alongside the primary traffic roads. Alternative
access shall be provided for each facility so that it can be approached for firefighting in the event of
blockage on one route.
Road widths, gradient and turning radii at road junctions shall be designed to facilitate movement of
the largest firefighting vehicle in the event of emergency.
Layout of the facilities shall be made to minimise truck traffic ingress in the plant. Two road
approaches from the highway / major road should be provided, one for employees and other for
product / material movement. Both these approaches should be available for receipt of assistance in
emergency.
Roads should be provided in a symmetric manner to serve all process areas requiring access for the
operation, maintenance and firefighting. These roads should encircle the process blocks/ process
units.
5. Pipe Racks
Main pipe racks / pipe track shall not be routed through process units. Provide overhead clearance for
vehicles over roadways and railroads.
6. Rail
Rail spur shall be located close to the periphery of the plant to minimise road/pipe crossings and
blockage of roads during shunting. Locate Rail loading facilities along the periphery of the installation.
7. Ignition Sources
Presence of ignition source shall always be contemplated beyond the boundary wall of the
installation.
8. Flare Stacks
Located flare stacks upwind of the process units to avoid leaking hydrocarbon vapors reaching flare
stack and getting ignited. Area around flare should be paved.
Located Fired heaters upwind of process unis to avoid hydrocarbon vapors entering in fired heaters.
Cooling towers shall be located downwind side of process units to avoid fog created by them drift into
process units and cause visibility problems as well as corrosion problems. The short side of the tower
shall be located into the prevailing summer wind, to accomplish maximum efficiency.
Control room should be located in a non-hazardous area. Control room should be upwind of process
plants, hydrocarbon storage and handling facilities. Control room shall not be located at lower level
than surrounding plants and tank farms to avoid flooding with process fluids or contaminated rain
water. There shall be no structure that could fall on the control room in case of a blast.
Sulfur handling is a dusty operation. Dust from such operations shall not reach process units. They
should be located downwind side of process units. Minimum separation distance of 50 meters is
recommended between sulfur storage / handling and any facility or boundary wall.
Equipment drawing air (e.g. air compressors, air blower, FD fan etc) should be located away from
Sulfur recovery unit / Sulfur handling facility.
Sulphur recovery unit and sulphur loading area should be located close to product movement gate
and away from process units, hazardous and populated areas.
13. Petrolium Coke Handling
Petroleum coke storage and handling facilities should be located as far as possible away from
process units, air separation plants, populated and hazardous areas.
Group storage tanks according to product classification as per relevant national standard. If the area
is hilly, locate storage tanks at lower elevations.
If a power generation facility supplies steam to a process block also, locate it near that process block.
When external power grid is interconnected with plant’s own power generation facilities, then either
locate the power generation block near the plant boundary or run external power transmission lines
underground. Power transmission lines shall never be run above the plant as well as parking
areas. Horizontal clearance between power transmission lines and plant shall be as per local
electricity rules.
Locate High Tension substations near the major load centers.Locate Low Tension substation in such
a way that distance between distance between distribution transformer and farthest motor is
minimum.
Fire station, firewater storage & firewater pump house shall be located at a safe place away from
hazardous areas. Fire station should be upwind of process units and hydrocarbon storage area with
straight approach to process units / other critical areas.
17. Loading/Unloading
Locate truck loading/unloading facilities close to the product movement gate, and orient in such a way
to provide one way traffic pattern for entrance and exit.
Erection methods shall be studied for all types of equipment / structures. Towers, reactors, fired
equipment etc should be located in such an area so to facilitate erection.
Separate collection system should be provided for different types of waste generated in the process
plant such as oily water, caustic, acid effluents, fecal etc. Effluent Treatment Plant should be located
minimum one block away from process unit area, down wind of process units and important areas
considering odour & emission of volatile organic compound.
ETP Plant should be closer to disposal point by the side of the boundary and at lower grade to
facilitate gravity flow of effluent.
Maintenance requirements for each type of equipment shall be identified and considered.
Smoking booths should not be provided in the hydrocarbon industry. However if required, these shall
be located at minimum distance of 60 meters from any hydrocarbon source.
Locating unit blocks based on their hazard characteristics, wind direction etc. is a critical activity while
developing plot plan. Following rules needs to be adhered to while developing a plot plan.
Input Data Required For Plot Plan Development
All the important input information must be collected from various sources such as Client, Process
Licensor, External Agencies, Government Database etc. so that a proper plot plan can be developed.