Security Level 2

BG-62104

ISSUED APR. 1, ’14

BUSINESS GUIDE

PLOT PLAN SCREENING MEETING

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CONTENTS

1. GENERAL 2

1.1 Intent 2
1.2 Scope 2
1.3 Purpose and Meaning of Plot Plan Screening Meetings 2
1.4 Basic requirements 2
1.5 Related Manuals 2

2. CLASSIFICATION OF MEETING 3

3. PROCEDURE 3

Appendix (1) Execution Procedure of Plot Plan Screening Meeting (P.1/1)

Appendix (2) Plot Plan Screening Meeting (Project) (P.1/6 - 6/6)

History (P.2/2)

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1. GENERAL

1.1 Intent

This manual covers the procedure of screening meetings for Plot Plan at the job design stage.

1.2 Scope

This manual applies to the screening meetings for every job which is required to prepare a Plot Plan.

1.3 Purpose and Meaning of Plot Plan Screening Meetings

A Plot Plan screening meeting is a control measure of the design review process which is conducted to evaluate
the design requirements, to meet these requirements at each issue stage of Plot Plan Design Process and to
identify problems and propose solutions.

The Plot Plan screening meeting is attended by Project Engineering Manager (PEM), and Assigned engineers
(AE) of each discipline including construction and operation.

The following elements of design review outlined below shall be included:

- compliance with the design requirements based on the contract;

- safety and operability study;
- study of client’s requirements;
- maintainability study;
- study of the requirements from the viewpoint of construction method; and
- compliance with the statutory requirements such as safe distance based on the applicable laws and
regulations.

1.4 Basic requirements

(1) Make use of basic information about Plot Plans, which are mentioned in the first part of BG-13201 “Plant
layout(For Chemical Plant)” as a checklist for the project member concerned.

(2) Establish the issue stage of the Plot Plan, according to BG-13202 “Setting of Plot Plan Issue Stage”

(3) Each discipline notes the following point at the meeting.

- To establish plot plan as FEED document

- To freeze material for plot plan
- To minimize the number of ERI

1.5 Related Manuals

BG-13202 “Setting of Plot Plan Issue Stage”

BG-13201 “Plant layout (For Chemical Plant)”

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2. CLASSIFICATION OF MEETING

Plot Plan screening meetings should be classified into the following depending on when they are held in the project
schedule;

(1) Plot Plan screening meeting No.1

(2) Plot Plan screening meeting No.2

(3) Plot Plan screening meeting (AFD(1))

(4) Plot Plan screening meeting (with client and/or licenser)

(1)
Note: AFD, abbreviation for approved for design

3. PROCEDURE

Appendix shows the procedure for Plot Plan screening meetings, under the heading of purpose, time of holding,
organizer, participants, recording, reporting and notes in each meeting respectively.

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Appendix (1) Execution Procedure of Plot Plan Screening Meeting

4. PLOT PLAN SCREENING MEETING

1. PLOT PLAN SCREENING MEETING No.1 2. PLOT PLAN SCREENING MEETING No.2 3. PLOT PLAN SCREENING MEETING(AFD)
(WITH CLIENT/LICENSER)
(1) Purpose (a) To ensure that design requirements for the Plot Plan To evaluate that design requirements do meet the To evaluate that design requirements do meet the To evaluate that design requirements do meet the
meet the requirements of the contract, and to identify requirements of the contract, and to identify technical requirements of the contract, and to identify technical requirements of the contract, with client and/or licenser, and
technical problems and propose solutions. problems and propose solutions, prior to determination of problems and propose solutions, prior to determination of to identify technical problems and propose solutions.
(b) To review the implementation of the design B.L (battery limits on layout, and matching points of layout of all itemized equipment.
requirements from the viewpoint of operability and piping) and layout of main equipment.
maintainability of the plant and economics.
(2) Time of Holding Before issuing PRELIMINARY PLOT PLAN Before issuing AFP (1) PLOT PLAN. Before issuing AFD PLOT PLAN According to the contract with client/licenser.(It should be
held before issuing AFP PLOT PLAN if practicable)
(3) Organizer PEM (2) PEM (2) PEM (2) /DC (3) PM/PEM
(4) Participants LAE/AE (Process Engineer) LAE/AE (Process Engineer) LAE/AE (Process Engineer) LAE/AE (Process Engineer)
LAE/AE (Mechanical Engineer) LAE/AE (Mechanical Engineer) LAE/AE (Mechanical Engineer) LAE/AE (Piping Engineer)
LAE/AE (Piping Engineer) LAE/AE (Piping Engineer) LAE/AE (Piping Engineer) Client and/or licenser
LAE/AE (Electrical Engineer) LAE/AE (Civil Engineer) LAE/AE (Civil Engineer)
LAE/AE (Instrument Engineer) CC (in charge of construction planning) or CM CC (in charge of construction planning)or CM
LAE/AE (Civil Engineer) AE (in charge of operation) LAE/AE (in charge of operation)
CC (in charge of construction planning) or CM
(5) Recording (a) Design data settled and confirmed must be reflected (a) Design data settled and confirmed must be reflected (a) Design data settled and confirmed must be reflected (a) Design data settled and confirmed must be reflected in
in the Plot Plan. in the Plot Plan. in the Plot Plan. the Plot Plan.
(b) Minutes of meeting should be prepared and (b) Minutes of meeting should be prepared and (b) Minutes of meeting must be prepared and submitted (b) Minutes of meeting must be prepared and submitted to
distributed, as necessary. distributed, as necessary. to client and/or licenser. client and/or licenser.
(6) Reporting Superior in charge should report to Gr.M, when Not necessary Not necessary Not necessary
necessary.
(7) Notes (a) Preparation prior to the meeting (a) The Issue stage of the Plot Plan to be approved by the
- The originator of the Plot Plan shall prepare a memorandum summarizing the policy points areas of special interest, and items to be confirmed at the meeting. client should be indicated in the Coordination
- Each AE shall prepare a memorandum listing pending items. He also makes comments on the Plot Plan concerned. Procedure. If possible, AFP is the suitable stage for
client’s approval.
(b) Notations at the meeting (b) PEM should collect comments made by the client as
much as possible before the meeting, and should
- PEM should control the discussion and ensure it is thorough enough. prepare counter measures for these comments in
- Regarding pending items, the date of obtaining each necessary piece of information and person responsible shall be made clear. consultation with relevant AE.
- PEM(or PE) shall check the following items, in particular: (c) In the meeting minutes, the items approved by the
- Confirmation of basic points(bench marks, etc.); client and pending items should be listed clearly.
- Scope stipulated in the contract(comparison with the Plot Plan issued at the stage of proposal); (d) PM should give instructions to each AE concerned as
- Layout requirements stipulated in the contract; to the technical study for pending items.
- Client’s comments on the Plot Plan(measures to be taken and their follow-up) (e) When the client requests modifications of (or the
- Site conditions(climate, ground conditions, environment, etc.); addition to) the Plot Plan after AFP stage, such
- Battery limit conditions(incoming and outgoing of raw materials, utilities, products, wastes, etc.); modifications and/or additions should be dealt with
- Layout of roads, drains, pipe racks, cable routes, buildings, large towers. carefully so as to conform to the “Change order clause”
Are they reasonably arranged and efficient for the equipment transport, storage, assembling, installation, operation and maintenance? of the contract.
- Legal and technical consideration for safety and environmental protection; (f) For a new (inexperienced) process, the meeting with
- Economic efficiency; licenser should be carried out carefully after sufficient
- Is the local currency balance taken into account in deciding the types of civil buildings? pre-study so as to absorb all necessary know-how.
- Are the piping lines and wiring routes minimized(compact design)?
- Are the construction works of the client's scope effectively utilized?
- Is the Plot Plan consistent with the relevant application documents for the authorities?

Notes: (1) AFP, abbreviation for approved for planning

(2) PM calls the meeting, when nobody is appointed to PEM.
(3) In case of outsourcing after FEED (AFP)

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Appendix (2)-1/6
TITLE: PLOT PLAN, SCREENING MEETING (PROJECT)
TIME OF CHECK: Preliminary, AFP,AFD

Pre. AFP AFD CHECK ITEMS AND POINTS A B C REFERENCE & REMARKS

1. Purpose To avoid any influence

The purpose of this CHECK LIST is to implement the by person’s experience
Plot Plan Screening Meeting effectively. As a rule, it will level, check points
be held just before issuing Plot Plan. including technical
contents are given in
2. General “Reference”.
(1) Arrange Plot plan screening meeting at following /p
stage.
<In-house Screening>
( ) (a) No.1 (before preliminary issue) ( )
( ) (b) No.2 (before AFP issue) ( )
( ) (c) No.3 (before AFD issue) ( ) Note(1) Frequency and
( ) ( ) ( ) <Screening with Client / Licensor(1) > ( ) timing of the meeting
(2) Request following Departments to attend the meeting. shall be decided in
<In-house Screening> accordance with the
( ) (a) Plot Plan Screening NO.1 ( ) Contract and project
Assigned Engineer (A/E) of Process, Equipments, state.
Piping, Electrical, Instrument, Civil and
Construction Department
( ) (b) Plot Plan Screening NO.2 ( )
A/E of Process, Equipment, Piping, Civil,
Construction and Operation Department
(In case that HAZOP study is mandatory according
to the contract, presence of safety manager for the Note(2) If required,
Project should be considered.) (2) Electrical and
( ) (c) Plot Plan Screening NO.3 (same as item (b) above) ( ) Instrument A/E are
<Screening meeting with Client and/or Licensor> also involved in the
( ) ( ) ( ) (a) Client / Licensor, Piping A/E and Process A/E ( ) meeting.
(3) Preparatory work
( ) ( ) ( ) (a) Summarize concept, note, issues, etc. by Piping ( )
A/E.
( ) ( ) ( ) (b) Request each A/E to check plot plan using ( )
CHECK LIST and gather comments beforehand
( ) ( ) ( ) (c) Request each A/E to inform pending matter ( )
( ) ( ) ( ) (d) In case that some equipment information is not ( )
fixed, “HOLD” marks are added.
(4) Recording
( ) ( ) ( ) (a) Piping A/E prepares a Minutes of Meeting (MOM) ( )
for each In-house and Client/Licensor meeting. It
contains action items, person in charge and due
date. MOM will be distributed by project team to
both project A/E and/or Client/Licensor.
(5) Important consideration for the meeting
<In-house Screening>
( ) ( ) ( ) (a) Ensure follow-up of meeting results. ( )
<Screening with Client / Licensor>
( ) ( ) ( ) (a) Make sure the timing to obtain approval by the ( )
Client / Licensor. This should be described in the
project coordination procedure.

MEMO

1 WORK NO. : CHECKER REPORT

0 REQ. NO. : A:PE→PEM(PM)

REV. SIGN DATE SIGN DATE SIGN DATE ITEM NO. : B:PEM(PM)→PM
A B C :

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TIME OF CHECK: Preliminary, AFP,AFD

Pre. AFP AFD CHECK ITEMS AND POINTS A B C REFERENCE & REMARKS

( ) ( ) ( ) (b) Absorb Licensor’s know-how through the meeting ( )

especially for the new process.

3. Confirmation at each issue stage (3) Note(3) Refer to BG-

Check following items on the plot plan at each issue stage 13202 “Setting of Plot
whether the result of the check meets main purpose. Plan Issue Stage”. The
(1) Preliminary (PRE) use of this TWC
( ) (a) Requirement of area size (B.L., size limitation) ( ) differs depending on
( ) (b) Consideration of the erection method for big ( ) the Contract (global
towers and large size heavy equipments collaboration, etc.) or
( ) (c) Allocation of main structure, piperack and ( ) government
buildings application.
( ) (d) Required distance between facilities according to ( ) Detail contents of Plot
local law and explosion-proof/non-explosion proof Plan shall be
classification. confirmed beforehand.
( ) (e) Requirement from the Contract ( )
( ) (f) Client / Licensor approval ( ) Note(4) Scope of
(2) Approved For Planning (AFP) Client / Licensor
( ) (a) B.L. condition such as area connection, tie-in point ( ) approval should be
of piping line, drainage, electrical/instrument reasonable to the
facility Contractor based on
( ) (b) Fixed location of major equipments. All itemized ( ) the Contract.
equipment are allocated if required.
( ) (c) Client / Licensor approval (4) ( ) Note(5) In case that
(3) Approved For Design (AFD) early applications are
( ) (a) Fixed location of all itemized equipment ( ) required, some
( ) (b) Column number of piperack and structure ( ) information like road
( ) (c) Application related to local authority (5) ( ) width and its layout
( ) (d) Final approval of the Client ( ) must be decided before
(4) Approved For Construction (AFC) AFD issue.
( ) (a) Execution of construction works and feedback ( )

4. Others
( ) ( ) ( ) (1) Refer to the feedback from similar project. Plot plan ( )
shall be reviewed by the experienced engineer.
( ) ( ) ( ) (2) Confirm with Client about design ( )
condition/requirements on a timely basis to meet
design schedule. Confirmation includes Environment
& safety matter relating to local authority.
( ) ( ) (3) Consider layout/size change of the large size rotating ( )
machines or material handling equipments because
they impact surrounding equipment layout in case that
Vendor is not decided yet.
( ) ( ) ( ) (4) Check any impact to the application drawing for local ( )
authority in case that plot plan is changed after
application.
( ) (5) Confirm benchmark. ( )
( ) ( ) (6) Confirm consistency of foundation anchor point ( )
between the plot plan and civil drawing.

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TITLE: PLOT PLAN, SCREENING MEETING (PROJECT)
TIME OF CHECK: Preliminary, AFP,AFD

[Reference]
Pre. AFP AFD CHECK ITEMS AND POINTS A B C REFERENCE & REMARKS

Detail check points by project team for Plot Plan Screening

Meeting
1. Confirmation of contractual conditions
(1) Scope of works in the Contract(1) (compare between ( ) Note(1) Related local
job conditions and proposal data.) law and special
(2) Requirements by the Client for Plant layout especially ( ) requirement such as
for the requirement based on local laws and standards. OTA, OSHA/NFPA,
(3) Confirmation with the Client about the classification ( ) HAZOP, etc. will be
of the Plant such as high pressure gas Plant, hazardous checked.
material handling plant etc. based on the applicable
local laws.

2. Reflection of site conditions

(1) Weather conditions such as temperature, rainfall, ( )
snowfall, wind speed, wind direction, presence of
earthquake etc.
(2) Location of the Plant against the direction of annual
average wind should be
(a) Downwind of ignition source. ( )
(b) Windward of toxic and flammable substances. ( )
(c) Downwind of public facilities and residential ( )
quarter
(3) Topographic conditions
(a) High/low land, desert, coast, groundwater level, ( )
etc.
(b) Flat, slope or terrace ( )
(c) Partially low land to cause gas accumulation or ( )
flood.
(d) Any difficulty to do construction works such as ( )
pilling work, heavy equipment
transportation/erection etc.
(4) Utilities
(a) Ensure fire water source ( )

3. Overall layout Refer to G-TEG BG-

(1) Requirements of applicable laws and standards. 13201
(a) Distance from the adjacent Plants. ( ) “Plant Layout for
(b) Distance between noise/bad odor source in the ( ) Chemical Plant”
Plant and residential area based on the project
Spec. or local laws.
(c) Safety distance from public buildings and ( )
residential area.
(d) Restriction of Plant height due to the airplane ( )
route, etc.
(e) Consideration of water drops (fog) issue caused by ( )
steam from the plant and cooling tower drops.
(f) Emergency access from/to public road, access way ( )
for ambulance/fire engine.
(g) Requirement for HAZOP study. ( )
(h) Others ( )
(2) Scope of damage insurance and its requirements such ( )
as distance between facilities, fire protection
equipments, etc.
(3) Layout of process plant
(a) In case that process plant is enclosed by roads on ( )
four directions, is it restricted by applicable laws
and regulations?

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TITLE: PLOT PLAN, SCREENING MEETING (PROJECT)
TIME OF CHECK: Preliminary, AFP,AFD

Pre. AFP AFD CHECK ITEMS AND POINTS A B C REFERENCE & REMARKS

(b) Confirm requirement by laws about the distance ( )

from other plant. Base point of the distance should
be confirmed whether it is from the surface of
equipment or outside of the Oil fence.
(c) Ensure sufficient explosion-proof distance between ( )
the process plant and ancillary facilities (office,
utility facilities etc.) so that the process area is
isolated as a special zone.
(d) Take measures for disaster prevention such as fire ( )
water loops, hydrant, water curtains, etc.
(4) Layout of utility facilities (Steam, Water, Electric
power, Air etc.)
(a) Keep sufficient distance from process plant to ( )
prevent trouble from there.
(b) Make sure whether layout of water piping line and ( )
electric power/instrument cables are above or
under ground.
(c) Keep steam & air lines away from the flammable ( )
and high-pressure line.
(d) Keep safety distance between BOILER facility ( )
(ignition source) and equipment handling
flammable lines.
(e) Keep safety distance between substation (ignition ( )
source of spark) and facilities handling the
flammable source.
(f) Allocate WWT facility at downward location of ( )
waster water lines/trenches
(g) Allocate air inlet/emission duct not to be affected ( )
by any wind direction.
(5) Layout of storage tank, warehouse
(a) Allocate close to receiving and shipment facility. ( )
(b) Distance between Storage tank/warehouse and ( )
other unit/facilities should be enough space
because those facilities are the second hazardous
area following the process plant. Further, they
should not be placed at the location higher than
other facilities.
(c) Consider arrangement of low risk facilities such as ( )
water, nitrogen, air etc. between Process plant and
residential area to prevent the spread of noise to
residential area.
(6) Layout of flare stack and burn pit
(a) Keep away from the process plant and tank area ( )
that are the ignition source. (However, delta P for
larger piping diameter and economic efficiency
should be studied.)
(7) Layout of office, laboratory and maintenance shop
(a) Keep away from the process plant and tank area ( )
(b) Keep windward of toxic and flammable substances. ( )
(c) Confirm requirement of analyzer house for online ( )
gascromatgraph.
(8) Layout of road inside the Plant
(a) More than two access routes are required for fire ( )
engine, ambulance and prohibition of traffic.
(b) Endure access route for maintenance works. ( )
(c) Minimize dead end and follow local laws about ( )
length and width of dead end.

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TITLE: PLOT PLAN, SCREENING MEETING (PROJECT)
TIME OF CHECK: Preliminary, AFP,AFD

Pre. AFP AFD CHECK ITEMS AND POINTS A B C REFERENCE & REMARKS

(d) Design criteria (such as road width, space above ( )

the road, underground piping,
crossing/curve/gradient of road) between plants,
plants or facilities according to the applicable laws
and standards (including regional laws).
(e) Reflect heavy rainfall condition to the storm drain ( )
design.
(9) Optimize location of Central Control Room (CCR) and ( )
Main/Sub substation (S/S). In case of larger plant,
number of S/S will be studied considering cable
length. CCR with explosion-proof structure will be
studied so that it can be located in the process plant.
(10) Confirmation of B.L conditions
(a) Confirm with the Client about tie-in point or ( )
carrying-in/out route for raw materials, utilities,
wastes and products.

4. Layout and structure in the process area

Following design concept shall be confirmed considering
construction and operation economics.
(1) Confirm Client’s expectation to the Contractor ( )
especially for Cost plus fee contract.
(2) Minimize plant area within safety and other mandatory ( )
requirement.
(3) Vertical and horizontal dimensions of plant area. (1:1-- ( )
-1.5:1 is recommendable)
(4) Allocate main roads and pipe racks methodically. ( )
(5) Consider process flow and pressure loss. ( )
(6) Minimize piping Bill of Material especially for high- ( )
grade, large bore and high-pressure piping.
(7) Reflect requirement of straight pipe length for large ( )
size flow meter in the main piping route.
(8) Optimize economical layout for large electric ( ) Note(2) It will be paid
equipments (electric panel, motor etc.). Non- special attention if
explosion-proof type is economical if they can be there is H2 atmosphere.
located. (2)
(9) Optimize economical structure/pipe rack design ( )
comparing RC to steel structure (by civil engineer).
(10) Reflect soil condition around heavy equipments and ( )
main rotating machines.
(11) Allocate steps/ladders considering emergency ( )
evacuation. Blind alley due to one access way should
not be designed.
(12) Reflect safety requirement for the layout of eye ( )
washer and hose station.
(13) Is there any unit equipment that can’t be located in ( )
process area in terms of explosion-proof capability?
What are the countermeasures in such cases?
(14) Optimize R curve of cables for cable pit and large- ( )
sized motor.
(15) Optimize routing of underground piping, ( )
underground cable, and trench in order to install them
without any difficulty and wastage.
(16) Follow-up process requirements
(a) Reflect gravity flow requirement to equipment ( )
elevation
(b) Reflect relationship between equipment elevation ( )
and natural circulation lines.

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TITLE: PLOT PLAN, SCREENING MEETING (PROJECT)
TIME OF CHECK: Preliminary, AFP,AFD

Pre. AFP AFD CHECK ITEMS AND POINTS A B C REFERENCE & REMARKS

(c) Reflect requirement for minimum distance from/to ( )

the equipment due to polymerization and
consolidation issue.
(17) Follow-up operational requirement
(a) Operability, maintainability, frequency from/to the ( )
control room.
(b) Sampling points and analyzer house ( )
(18) Necessity to study plant modification for capacity ( )
increase in the future.

5. Construction and maintenance

(1) Confirm the construction procedure
(a) Transportation and installation method for heavy ( )
equipment and heavy crane/Gin pole.
(b) Requirement for pile foundation and soil ( )
improvement.
(c) Field assembling area for construction works. ( )
(d) Construction sequence such as underground works ( )
and equipment transportation route/method.
(e) Impact to adjacent Plants ( )
(f) Area wise plant start-up schedule. ( )
(2) Confirm transportation and maintenance procedure
during operation
(a) Carrying-in/carrying-out way (trucks, railway, ship ( )
etc.) for raw material and products.
(b) Handling of chemical and lubricants ( )
(c) Handling of packing such as Raschig ring, catalyst ( )
(d) Maintenance space and transportation route for ( )
heat exchanger tube, pump, compressor, etc. by the
plan and side view.
(e) Maintainability of safety and control valves at high ( )
elevation.
(f) Maintenance location for large valves whether it is ( )
on the structure/pipe rack or at maintenance shop
after transportation from plant area.
(g) Reflect work permit system in the process area due ( )
to protection of fire source to OSBL area after
commissioning of OSBL facilities.

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