Development

of
Plot Plan

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What is Plot Plan & it’s requirement?
 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.

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Basis of 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

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Introduction
The following main aspects shall be
considered during development of the layout.
 Process requirement
 Economy of piping material and cables
 Erection & Construction requirements
 Safety requirements.
 Operation and Maintenance requirements.
 Grouping of similar equipment for
convenience of maintenance & safety
wherever possible.

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Data to be collected before starting
 Civil
 Plane table survey map.
 Contour survey map (at 10M grid).
 Soil Bearing capacity.
 Nature of Soil
 Rail/Road Access.

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Data to be collected before starting
 Electrical
 Location of Electric Supply Point.
 Supply voltage levels.
 Fault Levels.
 Voltage Levels required within the unit.
 Proposed distribution scheme.

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

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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
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Process Data
 Size/Capacity of the process unit
 Knowledge on the type of plant
 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

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Data on Utilities
 Source and/or supply point of raw
water
 Quality of Water available
 Water Consumption for the process
 Requirement of different types of
utilities such as Steam, Air, Nitrogen,
DM water, Fire water, Brine, etc.
 Capacities and Grouping philosophy.

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Statutory Requirements
 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)
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Expansion Philosophy
 Within the unit
 Additional Units
 Near future expansion
 Far future expansion

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Points to Note
 Normally Construction is permitted on maximum 50%
of the plot area with total built up area equal to 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 litres per person per day
 Water requirement for Boiler - Steam rating x Working factor
 Cooling tower - 11/4 % 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
 Parking space - 10% of the plot area
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Points to Note (Cont’d.)
 Roads & Paving
Roads in the plant shall be planned for
effective movement of the trucks, cranes &
emergency vehicles etc. Road width (Black
top) 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)
 Turning radius of the road shall be adequate for
the mobile equipment & shall clear of any
obstruction. Minimum turning radius to be same
as the length of vehicle.
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Points to Note (Cont’d.)
 Roads & Paving (Cont’d.)
 The finish of road i.e. graded or black top shall be
decided in the beginning while developing plot
layout.
 Paving should be provided around the equipments
where spillage is likely occur. For example :
Pumps or machineries, 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 service
requirement.
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The below sketch shows minimum distance required between the
road and the facility. This distance shall be reviewed to case to
case basis for the project.

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Points to Note (Cont’d.)
 Elevations
Below table for the elevations should be
generally followed.
 Under side 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.

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Points to Note (Cont’d.)
 Insulation & Fire Proofing
 Fire proofing requirements for pipe rack,
vessel supports, process structure should
be considered as these reduces the
clearances with access, pipe work,
instrument & electrical equipment.
 Proper insulation thickness should be
considered for pipe work & equipment
clearances.

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Equipment 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, single sunshade can be made)

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Equipment locations (Cont’d.)
 Plant Air & Instrument air compressors
 Plant air & instrument air is vital service for the
plant. These units should be located near the
control room & shall be kept in 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)

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Equipment locations (Cont’d.)
 Air cooler
 Air cooler located such a way to allow the access
to mobile lifting equipment.
 Preferably air cooler is located in a 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.

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Equipment locations (Cont’d.)
 Offsite Tanks
 Storage tanks (Grouped and shall be surrounded by dike
wall, Primary/secondary roads for adequate fire fighting
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.
 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 future requirement or as specified
by client.
 Requirement of expansion bays, anchor bays & bracing shall
be checked with stress / structural engineer at the beginning
of the rack layout.

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Relief valve and Flare systems
 Closed relief valve system
 Self draining
 No pocket to avoid condensation & back
pressure.
 Flare shall be located upwind process unit
& storage.

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Clearance at Pig Receiver
 Area at the end closure of Receiver shall be kept free to avoid
any incident.
 Provide concrete wall minimum 20 meter away from the end
closure if area needs to be utilized for any equipment.

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Personal protection
 Eye wash and emergency showers shall
be provided in area where operators
are subject to hazardous sprays or
spills.
 Breathing air stations in the facilities
handling extremely toxic gases / fluids.

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Fahud E-Station layout

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Process Requirement
 Proper interconnection between equipment to achieve intended
process parameters.
 Normally equipment is arranged in the process fluid flow
sequence. Requirement like gravity flow (Equipment Drain
piping), Thermosyphon system should be considered,
Limitation of pressure & temperature (process parameters) to
be considered
 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.

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Thermosyphon system

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

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Erection & Construction
 Road access for erection of pipe support / pipes and
equipment.
 Clear area for crane to erect equipment on the
location from the trucks.
 Minimum one side of pipe rack shall be kept clear.

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Page - 34
 Prevailing Wind
Flare
.

Effluent Utilities
Treatment .

Storage Process Control Main

Tank Farm Units Room Access

Loading / Ware Admin

Unloading House .

Loading / Security
Unloading Access
Access

Relative Locations of Area Layout

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HAC Representation

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