Professional Documents
Culture Documents
presentation
This article provides the basic considerations for the development of plant layout in a presentation form. For more
details in any of the listed points you can refer to any standard piping books. This presentation will provide an
overview on basic considerations.
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
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
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.
Electrical
Administrative Block
Canteen
Workshop
R&D, QC Lab and Pilot Plant
Gate House/Time office
Security Arrangements
Vehicle Parking
Medical Centre
Ware House
Covered Area
Open Area
Solid Warehouse
Liquid Warehouse
Steel / Scrap Yard
Fire Station
Weigh Bridge
Staff Colony
Meteorological Data
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
Data on Utilities
Statutory Requirements
Expansion Philosophy
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
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.
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 occurring. 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.
The below sketch (Fig. 1) shows minimum distance required between the road and the facility. This distance shall be
reviewed to case to case basis for the project.
Fig. 1: Minimum distance required between the road and the facility
Elevations
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.
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)
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)
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.
Offsite Tanks: Storage tanks (Grouped and shall be surrounded by dike wall, Primary/secondary roads for
adequate firefighting 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 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.
Area at the end closure of Receiver shall be kept free to avoid any incident.
Provide concrete wall minimum 20 meter away (Fig. 2) from the end closure if area needs to be utilized for
any equipment.
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.
Hazardous area classification is the risk locating plan for each unit/facility within the plot boundary for a
process industry.
The Plot plan will be used by indicating boundaries of risk area.
HAC drawings are generally used by operator while issuing work permits.
HAC Standard
HAZARDOUS AREA: An area in which an explosive gas atmosphere is present, or may be expected to be
present, in quantities such as to require special precautions for the construction, installation and use of
apparatus.
NON-HAZARDOUS AREA: An area in which an explosive gas atmosphere is not expected to be present,
in quantities such as to require special precautions for the construction, installation and use of apparatus.
Process Requirement
Economic Considerations
Equipment shall be located without affecting the process requirement for maximum economy of pipe work
& supporting steel with consistent standard clearances, construction, and maintenance & safety
requirements.
Runs of exotic material & large bore piping shall be minimized.
Optimum utilization of the structure to be ensured.