PLANT DESIGN AND LAYOUT

Prepared By :-
- P. B Khambhalia
- Pinal Trivedi
- Ronak Jadav
- Harsh Desai
- Nisarg Panchal
- Sagar Kotadiya

Guided by :-
Shri Pradip Keshwani

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CITING CRITERIA
General Criteria for selection of location of industries are

1. Land availability and its cost. 6. Transport facilities.

2. Raw material availability. 7. Sewage and Drainage.

3. Labour availability. 8. Drinking and process water facilities.

4. Infrastructure availability. 9. Place for solid and liquid waste disposal.

5. Access to market. 10. Interlinking with other plants.

Surrounding population density and distance from the public.

Distance from highway and railway and from transport centres.
Suitability of climate, environment and factors related to ecology, geology, meteorology,
and micro & macro biology.

Government policy advantages like subsidies, incentives and zoning (area reservation eg.
SEZ) if prescribed. Other techno-economic criteria.

FROM THE FOLLOWING DATA SELECT THE MOST ADVANTAGEOUS LOCATION FOR SETTING
A PLANT FOR MAKING TRANSISTOR RADIOS.

Total sales−Total expenses

Rate of return (RoR), %¿ x100
Total investment

RoR for Site X = 27.5%

RoR for Site Y = 42.5%

RoR for Site Z= 7.5 %

Location Y can be selected because of higher rate of return.

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RULES OF ZONING AND TOWN PLANNING SHOULD CONSIDER AS FOLLOWS:
• Location: Highly Explosive, Inflammable or Toxic substance should be located away
from dense population. Increasing distance from public reduces the effect of
explosion, gas release and radiation.

• Climate: Study of prevailing winds is useful to decide location of offices and their air
conditioning air intakes, storage tanks, warehouses, drainage and waste disposal,
direction of exhausted smoke, fumes, dust, gas etc., with respect to surrounding
locality.

• Terrain (land, topography): If bridges over streams, ditches, etc., are necessary they
should be fenced by handrails i.e. high and intermediate rails.

• Nature of Site. It should be large enough for safe layout with sufficient space for all
buildings, roads, parking and storing areas, effluent treatment plant and considering
future expansions. Minimum distances as per fire laws, explosive laws must be
considered.

• Accessibility: Rail, road, river, sea and airport facilities should be ensured. Fast
communications facility should be developed.

• Environment: If air impurities and interaction of emissions or sources of ignition etc.

from adjacent sites are harmful, they should be considered. Noise and vibration due
to neighbouring industries, transport vehicles, running trains, low flying aircraft
should be considered.

• General Provisions: Adequate water supply for drinking, Process and fire fighting,
drainage of rain water, process water, fire water etc., and water /air/ land pollution
problems must be considered.

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ENVIRONMENTAL GUIDELINES
Rule 5 of the Environment (Protection) Rules, 1986, gives following siting criteria to be
considered by the Government while

Prohibiting or restricting the location of industries and the carrying on processes and
operation in different areas

1. Standards for quality of environment laid down for an area.

2. Maximum- allowable limits of pollutants (including noise) for an area.

3. Likely emission from the proposed industry.

4. Topographic and climatic features of an area.

5. Biological diversity of the area to be preserved.

6. Environmentally compatible land use.

7. Adverse environmental impact likely to be caused by the industry (EIA is required).

8. Proximity to a legally protected area.

9. Proximity to human settlements.

10. Any other relevant factor.

To prevent air, water and soil pollution arising out of industrial projects, the Industrial
Licensing procedure requires that the entrepreneurs before setting up the industry should
obtain clearance from Central/ State Air and Water Pollution Control Board.

The Industrial Policy Statement of July 1980, recognised the need for preserving ecological
balance and improving living conditions in the urban centres of the country. On the basis of
this Policy, indiscriminate expansion of the existing industries and setting up of new
industrial undertakings within the' limits of metropolitan cities and the larger towns are
restricted.

Following conditions are also to be fulfilled:

• The State Director of Industries confirms that the site of the project has been
approved from environmental angle by the competent State Authority.

• The entrepreneur commits both to the State Government and Central Government
that he will install the appropriate equipment, implement and the prescribed
measures for the prevention and control of pollution.

• The concerned State Pollution Control Board has certified that the proposal meets
with the environmental requirements and that the equipment installed or proposed
to be installed are adequate and appropriate to the requirement.

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 • The entrepreneur will be required to submit half-yearly progress report on
installation of pollution control devices to the respective State Pollution Control
Boards.

• Depending on the nature and location of the project, the entrepreneur will be
required to submit comprehensive Environmental Impact Assessment Report, and
Environmental Management Plans.

SITING GUIDELINES:
In a selected site, the following factors must be recognised.

1. No forest land shall be converted into non-forest activity for the sustenance of the
industry.

2. No prime agricultural land shall be converted into industrial site.

3. Within the acquired site the industry must locate itself at the lowest location to remain
obscured from general sight.

4. Land acquired shall be sufficiently large to provide space for appropriate treatment of
waste water still left for treatment after maximum possible reuse and recycle. Reclaimed
(treated) wastewater shall be used to raise green belt and to create water body for
aesthetics, recreation and if possible, for aquaculture. The green belt shall be ½ km wide
around the battery limit of the industry. For industry having odour problem it shall be a.
kilometre wide.

5. The green belt between two adjoining large scale industries shall be one kilometre. Green
belt should also be provided within factory premises.

6. Enough space should be provided for storage of solid wastes so that these could be
available for possible reuse.

7. Layout and form of the industry, that may come up in the area must conform to the
landscape of the area without affecting the scenic features of that place.

8. Associated township of the industry must be created at a space having physiographic

barrier between the industry and the township.

9. Each industry is required to maintain three ambient air quality measuring stations within
120-degree angle between stations.

METEOROLOGICAL ASPECTS
• While selecting a site, climatic conditions should also be considered.

• It should not have any adverse effect on industrial processes otherwise more control
measures may be required.

• High or law temperature, more moisture, high or low wind velocity, frequent raining,
cloudy atmosphere, Infrequent changes in weather condition, effect of nearby
seashore, effect of hills and jungles, effect of long time sunrays etc.
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 • Have considerable effect on raw materials, products and processes. Gas leakages
from industry, their concentration and damage distances vary depending on weather
conditions. 

• Global warming and greenhouse effect should be decreased by preventing emissions

of CO2, and O3, depleting substances.

SEPARATION DISTANCES:
• Some of the natural life sustaining systems and some specific land uses are sensitive
to industrial impacts because of the nature and extent of fragility.

• With a view to protecting such industrial sites, the following distances from the areas
shall be maintained:

1. Ecologically and/or otherwise sensitive areas: at least 25 km; depending on the geo-
climatic conditions the requisite distance shall have to be increased by the
appropriate agency.

2. Coastal Areas: at least 6 km from high tide line.

3. Flood Plane of the Riverine Systems: at least ½ km from the flood plane or modified
flood plane affected by dam in the upstream or by flood control systems.

4. Transport/Communication System: at least ½ km from highway and railway.

5. Major Settlements (3, 00,000 population): distance from settlements is difficult to

maintain because of urban sprawl.

Factors to determine separation are

(1) Explosion effect

(2) Radiant heat from a burning material

(3) Ignition of a vapour escape and

(4) Heavy concentration of a toxic gas.

• Normally 15m (50 ft) is suggested for the storage of petroleum products excluding
LPG.

• For LPG a smaller distance is allowable if radiation walls and/ or water drench
systems are provided.

• From an ignition source, for ethylene storage, 90 m is suggested for pressure storage
and 60 m for refrigerated storage. Risk of failure of a pressure storage is higher than
that of refrigerated storage.

• Mecklenburgh (1973) suggested 15 m distance from process units, furnaces, boilers,

effluent plants and loading areas and 30 m from cooling towers, gasholders and flare
stacks to adjacent process units, main roads or site boundary.

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SOME SUGGESTED DISTANCES ARE AS UNDER:

No. Unit Separation Distance (mt)

1 Flammable liquid, low to medium pressures 10-25
2 High flammability, high pressure 35-50
3 Direct fired boilers and furnaces 35-50
4 Blow down stack with flare 40-75
5 Loading facility 35
6 Public roads and railroads 35
7 Cooling towers 35
8 Storage tanks 25-50

SEPARATION DISTANCES FOR MHA UNITS

Separation
Chemical Largest tank size (tonne)
distance (mt)
25-40
300
41-80
LPG at >1.4 bar absolute 400
81-120
OR 500
121-300
Flammable gas or 600
>300
moisture at >Boiling Point 1000
25 or more cylinders or
100
tank up to 5t
LPG, refrigerated, at 1.4 bar absolute 50 or more 1000
Flammable gas or mixture 15 or more 500
Flammable gas or Mixture having BP<0oC,
50 or more 1000
refrigerated or cooled at 1.4 bar absolute.
Liquid or mixture of liquids
10000 or more 250
having Flash Point < 21oC
HF 10 or more 1000
O2 20 or more 1000
SO3 15 or more 1000
Acrylonitrile 20 or more 250
HCN 20 or more 1000
CS2 20 or more 250
Chlorine 10-100 1000
> 100 1500

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Bromine 40 or more 600
H2 2 or more 500
Phosgene 2 or more 1000
Methyl isocynate 15 1000
EO, or -25 500
Propylene oxide (ambient pressure) > 25 1000
Liquid O2 500 or more 500
Ammonium nitrate - bagged in stacks of 300 t 600
600=[(Stack
Loose distance =
Size(t)/300)]^(1/3)

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NEED OF PLANNING & FOLLOW UP
It is basic and most essential requirement for safety engineering approach in design,
planning and construction.

• Proper and efficient utilization of available floor space.

• Transportation of work from one point to another point without any delay.

• Proper utilization of production capacity.

• Reduce material handling costs.

• Utilize labour efficiently.

• Reduce Accidents.

• Provide ease of supervision and control.

• Allow easy maintenance of machines in the plant.

• Improve Productivity.

Safety and comfort of people are achieved by considering ergonomic aspects.

1. Products and product layout

2. Raw materials, processes and their layout

3. Size and type of site and building.

4. Machinery, vessels and equipment required.

5. Assessment of manpower required.

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 6. Relationship between departments.

7. Process flow chart.

8. String and flow diagrams.

9. Templates and scale models.

10. Drawings and plot plans, and

11. Travel chart etc

FOLLOW UP
• As need for planning is important, follow up action according to that planning is
equally important.

• Without follow up no planning can be executed.

• Therefore distinct responsibilities should be assigned to different persons to

implement the follow up actions of every stage or step decided in planning.

• It should be reported to the higher officer, feedback should be received for

correction or addition if any and the work should be completed within a stipulated
time. All points of safety, health, environment and ergonomic factors should be
included from the built-in stage.

• If this follow-up is missed in the initial stage, later follow-up may become continuous
and costly.

PLANT DESIGN AND LAYOUT

• If components of design process in any structure, vessel, equipment etc. are weak or
not properly designed, they may fail.

• A component should-be designed to withstand

- static loads, dynamic loads, internal and external pressure, corrosion & erosion,
loads due to large differences in temperature / pressure, loads due to external
impacts (wind, settlement, earthquakes etc.)

- Proper Factor of Safety and Material of Construction is also important

- These loads may be included in the design process for pressure plant containing
flammable, explosive or toxic substances or liquids above their flash points or boiling
points.

- Components of Control Systems should be properly integrated with necessary safety

devices, trips and alarms, interlocks, pressure reducing valve (PRV), non-return valve
(NRV), excess flow valve (EFV) and automatic process controllers etc.

- Plant or factory premises vary in size and manpower employment. Giant

Petrochemical, Fertilizer Plant

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 - Under the Factories Act, more welfare facilities are required from bigger factories
depending on number of workers arid male-female employment

- Stringent safety provisions are applicable to chemical plants and Major Hazard
(MAH) installations

- Before starting a factory, Permission from local authority and other related
government departments is also required.

- Definition of a 'factory' is given under the Factories Act 1948 and it is the main Act
(together with State Factories Rules) applicable to the layout, design, construction
and working of a factory.

- A plant should be located after considering siting criteria and be constructed by

considering statutory requirements mentioned.

GENERAL PRINCIPALS OF PLANNING AND DESIGN

1. Siting criteria as mentioned.

2. Good transportation facilities.

3. Safe handling and storage facilities.

4. Personal and Welfare facilities.

5. Engineering, utility and safety facilities.

6. Walkway, stairs, platform, ramps etc.

7. Good lighting and ventilation.

8. Elevators and lifting machines

9. Boilers and pressure vessels.

10. Fixed and portable machinery and equipment.

11. Electrical installation.

12. Fire protection.

13. Other provisions for health and safety, viz. effluent disposal, water, first-aid,
emergency power, equipment and emergency planning etc

GENERAL PRINCIPLES OF ANY WORKPLACE DESIGN

1. Plan the ideal, then the practical.

2. Plan the whole, then the detail.

3. Plan the work process and equipment around the system requirements.

4. Plan the workplace layout around the process and equipment.

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 5. Plan the final enclosure around the workplace layout

6. Use trials to evaluate alternatives and to check the final design.

Design aspects should include proper buildings and roads layout, storage & process layouts,
proper heights, lights, depths, spacing and dimensions considering ergonomic requirements,
loads and climatic factors and specific process hazards

IMPORTANT POINTS FOR GOOD PLANNING AND DESIGN

• Sound foundations, Stable construction and loading, Non-congested machinery

layout (safety distance 1 m), No overcrowding.

• Minimum floor area per worker (1 to 2 m 2), Minimum alley width, Safe roadways,
walkways, yards etc., Prescribed ventilation area (15% of floor area).

• Sufficient natural and mechanical ventilation, Sufficient natural and artificial lighting,
Open plant for chemical processes, dykes, Boundaries and blast walls (to withstand 7
kgf/cm2 force),

• safe layout and erection of chemical vessels and equipment,

• ergonomic considerations, segregation of noisy and dusty processes,

• fencing and covering of water-ways, reservoirs, ditches, floor openings, gutters etc.

• separate entrance and exit gates, parking plots, safe layout of control room,
provision of fire prevention and protection systems, safe storage of flammable,
explosive and toxic materials, waste disposal arrangements for solid, liquid and
gaseous wastes, ; effluent treatment plant (ETP), scrubbers, incinerators, flare or
exhaust as per requirement, safe : discharge of smoke, fumes, dusts, gases etc., '
maintenance of separation distances, proper layout of utilities (water, power, steam,
air, oil, inert gas etc.) and ancillary services,

• Safe transportation and security arrangement, hazards identification and removal,

safe pipe work, follow-up of standards, codes and reliability criteria, \ limitation of
inventory, fail-safe design, built-in safety devices etc.

• Selection of these various points depends on Process, Technical & Safety

requirements.

GENERAL PRINCIPLES FOR GOOD LAYOUT

1. Enough work space (2 m2 per 'person) should be provided for workers to work
without restriction.

2. Proper roads, walkways, tracks, alleys, catwalks etc. should be provided for free
passage of men and materials to avoid delay and obstruction.

3. Sufficient doors, windows, ventilators and open space must be provided for good
ventilation and lighting.

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 4. Installation of machinery, floors, stairs, lifting machines, electric wiring etc. must be
done to ensure safety. Allow at least 1 m space around each machine.

5. Keep the handling of materials to the minimum. Use mechanical means to reduce
manual strain.

6. Provide safe means of access to all work places.

7. Provide safe transport facilities for men and materials.

8. Provide adequate emergency exits.

9. Purchase and arrange in orderly manner machines and equipment with built-in
safety.

10. Isolate high noise, vibration, fire, explosion and toxic hazards. Design a work bench,
table, booth, roof, ladder, platform, sheet, support etc. with safety standards to
avoid such hazards.

11. Allow space for future expansion.

12. Provide repair and maintenance workshop, welfare facilities and education and
training facilities.

13. Use appropriate colours, notices, signs, labels, posters etc. for safety.

14. Provide easy locations of fire alarms, firefighting equipment, personal protective
equipment, emergency assembly points, medical centre, safety office etc.

15. Provide and maintain good housekeeping.

FACTORS OF PLANT LAYOUT AND DESIGN FROM SAFETY POINT OF VIEW

1. Safe design and construction using safety standards and good engineering practices.

2. Statutory requirements for plant layout and design.

3. Containment of leakage and accidents.

4. Segregation of different risks.

5. Safe storage, process, utilities and waste disposal design.

6. Safe control room location & design.

7. Emergency control devices.

8. Firefighting and gas leak control facilities. Ample water storage.

9. Auto controls, alarms, trips, interlocks and necessary safety devices.

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10. Railings and guarding at chances of fall, cross over and on moving machinery.

11. Roads of sufficient width and signs.

12. Safe loading, unloading, transport and piping facilities.

13. Security round the clock.

14. Wind direction and speed indicator with recorder to know wind direction and speed.

15. First aid centre and ambulance van.

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15
 STANDARDS AND CODES OF PRACTICE FOR PLANT AND EQUIPMENT

• Various Indian Standards are available for considering safe design and layout of
industrial

• buildings, plants and equipment. They are the good guidelines for all safety people.
Some are mentioned below in Table

N
Title I.S No
o

1 Sectional List of Indian Standards on Safety -

2 Sectional List of Indian Standards on Civil Engineering -

3 Industrial plant layout 8091 8091

4 Code of safe practice for layout of outside facilities in an industrial plant 8089 8089

5 Safety requirements for floor and wall openings, railings and toe boards 4912

6 Structural safety of buildings : Masonry walls 1905

7 Structural safety of buildings : Loading standards 875

8 Structural safety of buildings : Shallow foundation 1904

1042
9 Glossary of terms relating to doors
8

10 Selection of , installation and maintenance of timber doors and windows 4913

11 Steel doors, windows and ventilators 1038

12 Steel windows for industrial buildings 1361

13 Industrial ventilation 3103

14 Industrial lighting 6665

15 Daylighting of factory buildings 6060

16 Steel Tubular scaffolding 4014

17 Fire safety of buildings (General) : Materials and details of construction 1642

18 Fire safety of buildings (General) : Electrical installations. 1646

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 Fire safety of industrial buildings : General storage and warehousing including
19 3594
cold storages.

20 Installation and internal fire hydrants in multi-story buildings 3844

21 Safety code for handling and storage of building materials 7969

22 Fire resistance test of structures 3809

23 Code of practice for noise reduction in industrial buildings 3483

24 Industrial safety belts and harnesses 3521

25 Glossary of terms relating to corrosion of metals 3531

26 Recommended design practice for corrosion prevention of steel structures 9172

27 Code of practice for cathodic protection of steel structures 8062

28 Safety code for scaffolds and ladders 3696

Safety Code for construction, operation and maintenance of river valley 1038
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projects 6

30 Standard colours for building and decorative finishes 1650

Codes of practice are generally followed where no statutory provisions are available or
where missing details are required In that case code of practice should be followed.
Code of Practice for… IS

Architectural and building drawings 962

Day lighting of buildings 2440
Demolition of buildings 4130
Design & construction of floors & roofs 14215
Design & construction of steel chimney 6533
External hydrant system 13039
Fire safety in hotels 13716
Fire safety in iron & steel industry 13694
Galleries and opening in dams 12966
Laying mastic flooring in LPG industries 13074
Manufacture of safety books & shoes 13295

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 Measurement of civil engineering works 3385
Structural safety 13063
Super capacity bucket elevator 12941

Safety Code for…. IS Safety Code for…. IS

Conditions for
Body Protection 8519 8964
woodworking machines
Chemical Laboratory 4209 Data processing equipment 10422
Colours and signs 9457 Devices for gas cylinder 5903
8520,
Concrete framed structures 8989 Equipment, eye, face, ear
8940
Conveyors 7155 Foot & Leg 10667
Electro heat installation 519 Glove, industrial 6994
Footwear for steel plants 10348 Masonry walls 1905
Industrial radiography 2598 Nets, industrial 11057
Working with construction
7293 Structural loading 875
machinery
Handling and storage of
7969 Hand tools 8235
building materials
Hot bituminous construction 5916 Scaffolding, steel 4014
8089,
Layout of industrial plant Relief valves 3233
8091
Plant railways 8218 Shallow foundations 1904
Powered industrial trucks 6305

NATIONAL BUILDING CODE

SP 7 - 1983 is a single code containing various IS on building construction in one volume. It
contains regulations useful to various departments, municipal administrations and public
bodies. It lays down provisions for public safety with regard to structural sufficiency, fire
hazards and health aspects of buildings. Other subjects included are building requirements,
materials, structural design, electrical installations, lighting, ventilation, air conditioning,
lifts, acoustics, plumbing services, gas supply, safety of workers and public during
construction and rules for erection of signs and outdoor display structures.

Following special publications are also relevant

SP 6 ISI Handbook for structural engineers (7 parts).

SP 10 Nomograms for thickness of masonry walls.

SP 16 Design aids for reinforced concrete,

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SP 20 Handbook on masonry design and construction.

SP 21 Summaries of IS for building materials.

SP 22 Codes for earthquake engineering.

SP 23 Handbook on concrete mixes.

SP 24 Code for plain and reinforced concrete.

SP 25 Causes and prevention of cracks in building.

SP 27 Method of measurement of building works.

SP 33 Handbook on timber engineering.

SP 36 IS on soil engineering (2 Parts) for plumbing services engineers.

SP 41 Handbook on functional requirements of buildings.

SP 1650 Standard colours for building and decorative finishes. (Revision of IS:1650)

ERGONOMIC CONSIDERATION FOR PLANT DESIGN AND LAYOUT:

Important ergonomic factors to be considered in plant layout and design include:

1. Free space (80 to 100 cm) around each machine for easy and safe movement.

2. No overcrowding. Breathing space of 14.2 m" per worker (max height 4.2 m).

3. Ventilation opening -15% of the floor area minimum. Window bottom height I meter or
less from the working floor for natural ventilation.

4. A traversing part or materials carried by machinery should not approach within 50 cm

(Sec. 25 of the Factories Act prescribes 45 cm) of any fixed structure which is not part of the.

5. Suitable platforms, safe means of access and lifting appliance suspension points should be

provided to facilitate cleaning and maintenance

6. Height and position of seats, valves, gauges, indicators, displays, meters, knobs, controls,
handles, switches, push buttons, brakes, notices etc. should be suitable to the operators.
Safe manual lifting' methods should be utilised.

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TYPES OF ERGONOMIC DESIGN
No
Type Includes
.
Seat, bench or console (control or comfort) design, positions
Work-space
1 of controls, displays & materials, operator’s body, data and
design
their working models including computer graphics.
Light, ventilation, heat, humidity, noise, vibration etc.
Environmental
2 comfortable to
design
the operator.
Work time or Working hours, intervals, shift schedule and inter-personal
3
situation design aspects of work.
Exchange of information between man and machine or
environment e.g. display gives and control receives
4 Interface design information. Proper design of such displays (pointers, letters,
numbers, figure etc.) and controls (knobs, brakes, switches,
size, shape, position, forces etc.) most convenient to the men
Allocation of function / job between man and machine and
5 System design procedure. New techniques to understand limitations of each
other and to fill the gap by the best design.

All these areas overlap and are interrelated. The main object of such ergonomic design is to
get long term gain with no adverse effects on health and safety and to minimise human
errors, efforts, stress and strain and ultimately risks and accidents.

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THANK YOU

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