DESIGN BASIS FOR PLOT PLAN

DARSHAN Institute of Engineering & Technology

(Rajkot - Gujarat) (INDIA)
Department of Civil Engineering

DESIGN BASIS
FOR
PLOT PLAN

PROF. HIREN B. VALAMBHIYA (B.E. CIVIL)

Mo. +91909970 2170
E-mail: chhotemistry@gmail.com

DARSHAN INSTITUTE OF ENGINEERING AND TECHNOLOGY

Rajkot-Gujarat (INDIA)

DESIGN BASIS FOR PLOT PLAN

CONTENTS

1.0

SCOPE
3

2.0

CODES AND STANDARDS

3.0

DESIGN DATA

4.0

CRITERIA FOR LOCATION OF VARIOUS FACILITIES 3

5.0

SAFETY DISTANCE FOR HYDROCARBON STORAGE

AND HANDLING

6.0

SAFETY DISTANCES FOR PRESSURE STORAGE

7.0

SAFETY DISTANCES FOR FILLING STORAGE &

TRANSPORTATION OF GAS CYLINDERS

8.0

SAFETY DISTANCES AS PER VASUDEVAN FOR LPG

STORAGE AND HANDLING FACILITIES

9.0

CO-ORDINATION & APPROVAL OF OVERALL PLOT

PLAN & UNIT LAYOUT

PROF. HIREN B. VALAMBHIYA (B.E. CIVIL)

Mo. +91909970 2170
E-mail: chhotemistry@gmail.com

10

DARSHAN INSTITUTE OF ENGINEERING AND TECHNOLOGY

Rajkot-Gujarat (INDIA)

DESIGN BASIS FOR PLOT PLAN

1.0

SCOPE
This specification covers design basis for overall plot plan of various plants and
indicates major parameters for location of different facilities and safe distances as
per rules and safe engineering practices.
The specification also covers the overhead and horizontal clearance provided in
units, requirements of maintenance platforms, access ways and ladders.
The general practices followed for transportation and clearances required from
various statutory bodies are also covered.

2.0

CODES AND STANDARDS

2.1

Petroleum Rules 1976 (For Hydrocarbon Storage under CCE).

2.2

Code of practice for LPG storage installations IS 6044 Part II 1972 Industrial,
Commercial and Domestic Bulk Storage Installation.

2.3

The static and Mobile pressure vessels (unfired) rules 1981 (For Pressure
Storage of gases under Chief Controller of Explosives).

2.4

Gas Cylinder Rules 1981 (For filling and handling of gas cylinders under CCE).

2.5

Home Ministry Circular (for perimeter walls)

2.6

The Institute of Petroleum Refining safety Code - Part III.

Model Code of safety Practice in Petroleum Industry.

2.7

Standard for storage and handling of LPG at utility gas plants (NFPA 59-1979).

2.8

Report of Committee set up to review safety and operating procedures in LPG

filling, Transporting and distribution (Vasudevan Committee Report).

2.9

D.G.C.A. rules.

2.10

OISD Standard 118 ( For Layouts for Oil and Gas Installation)

3.0

DESIGN DATA
To be compiled as per Codes and Standards

4.0

CRITERIA FOR LOCATION OF VARIOUS FACILITIES

PROF. HIREN B. VALAMBHIYA (B.E. CIVIL)

Mo. +91909970 2170
E-mail: chhotemistry@gmail.com

DARSHAN INSTITUTE OF ENGINEERING AND TECHNOLOGY

Rajkot-Gujarat (INDIA)

DESIGN BASIS FOR PLOT PLAN

4.1

Layout Planning
In sequential order of process flow.

4.2

Orientation
To suit wind direction to avoid flow of hydrocarbon gases and flame travel over
vital areas / source of ignition.

4.3

Units
Central location with straight approach from Main gate.
Orientation to suit process flow with minimum piping runs
Location of tall columns & furnaces close to road side for ease of construction
Close to main entry
Locate on high ground to avoid flooding

4.4

Storage Tanks
Arrangement as per CCE rules.
In undulating areas storage tanks shall be located in lower elevations.
Storage tanks shall be grouped according to product classification.

4.5

Utility Block
Close to unit block

4.6

Main Receiving Station

Close to battery limit with minimum overhead power lines over project site.

4.7

H.V. Sub Station

Preferably at load centers of loads up to 10/20 MW.
One or more numbers shall be provided as per operational needs and limiting
distances.

4.8

Low Voltage Sub-station

PROF. HIREN B. VALAMBHIYA (B.E. CIVIL)

Mo. +91909970 2170
E-mail: chhotemistry@gmail.com

DARSHAN INSTITUTE OF ENGINEERING AND TECHNOLOGY

Rajkot-Gujarat (INDIA)

DESIGN BASIS FOR PLOT PLAN

Generally these shall be located at load centers in such a way that distance
between distribution transformer and farthest motor is limited to 150/200 meters.
4.9

Approach Road to Sub-station and Transformer Bays

To facilitate crane movement for maintenance and erection

4.10

Power Plant
Gas/Oil Based: Central to units and utility block and preferably closest to Main
Receiving Station
Coal Based: Location away from vital facilities to avoid coal dust

4.11

Flare
Upwind of units and at safe distance. Height and distance of flare shall be decided
after heat radiation studies.

4.12

Dispatch Facilities
Truck loading -

Close to product movement gate

Rail loading

To suit rail layout & at 100 m distance from storage tanks

(Preferably be located along the periphery of the

installation).
4.13

Effluent Plant
Locate minimum one block away from unit area.
Down wind of units and important areas to avoid smell problems.
In lower grade to facilitate gravity flow
Closer to disposal point

4.14

Sulphur Unit & Loading

Close to product movement gate and away from population areas.
Away from hazardous areas
Minimum distance of 50 M shall be kept from building / boundary wall

PROF. HIREN B. VALAMBHIYA (B.E. CIVIL)

Mo. +91909970 2170
E-mail: chhotemistry@gmail.com

DARSHAN INSTITUTE OF ENGINEERING AND TECHNOLOGY

Rajkot-Gujarat (INDIA)

DESIGN BASIS FOR PLOT PLAN

4.15

Service Corridors
Pipeways to be marked and specified in plot plan.

4.16

Construction Facilities
Sufficient open areas to be left.

4.17

Fire Station
Close to main entry gate with straight approach to units as far as possible
Fire drill areas

Close to Fire station

Fire water pump

House

4.18

In utility block.

min. 60 m from unit battery.

min. 60 m from petroleum storage tanks.
Near water source.

Control Room
Locate distinctly in the process block or in the adjoining block
Location at safe distance in non-hazardous electrical area classification

4.19

Pressure Storage
Max. Vessels in each group shall be six.
Max. capacity in each group shall be 13000 cu.m.
Top surface of the vessels in a group shall be on the same plane.
Longitudinal axies of horizontal vessel (Bullet) shall not point towards other
vessel/vital process equipment / control room.
LPG vessel shall not be located within the same dykes where other flammable
liquid hydrocarbons are located.

4.20

Cooling Towers

PROF. HIREN B. VALAMBHIYA (B.E. CIVIL)

Mo. +91909970 2170
E-mail: chhotemistry@gmail.com

DARSHAN INSTITUTE OF ENGINEERING AND TECHNOLOGY

Rajkot-Gujarat (INDIA)

DESIGN BASIS FOR PLOT PLAN

Locate away from process area preferably down-stream direction of wind.

4.21

Smoking Booths
Locate upwind of any hydrocarbon source/ facility

5.0

SAFETY DISTANCE FOR HYDROCARBON STORAGE AND

HANDLING

5.1

Under Petroleum Rules - 1976

5.1.1

Distance of flare to still, pump house

any storage tanks and process units

5.1.2

Distance between storage tank and still,

boiler or furnace

5.1.3

Location of LPG storage or filling

facilities to hydrocarbon storage and
blending or filling and protected works
Inter distances between storage tanks and
other facilities

5.1.4

5.1.5

Height of tank dyke wall for tank farm area

5.1.6

Tank storage capacity in one dyke area

a. Fixed roof tanks
b. Floating roof tanks

90 M

90 M

30 M

Table I and II of Petroleum

Rules 1976
Not to exceed 2.0 M and
Min. 1.0 M

60,000 M^3
120,000 M^3

5.2

Under OISD Standard 118 (July 1995)

5.2.1

For inter distances between blocks/facilities refer Table-1

5.2.2

For equipment spacing within process units, refer Table-2

5.2.3
For inter distances between Tanks/offsite facilities (For small installations), refer
Table-3
5.2.4

For inter distances between storage tanks / offsite facilities, refer Table-4

5.2.5

For inter distances between storage tanks, refer Table-5

PROF. HIREN B. VALAMBHIYA (B.E. CIVIL)

Mo. +91909970 2170
E-mail: chhotemistry@gmail.com

DARSHAN INSTITUTE OF ENGINEERING AND TECHNOLOGY

Rajkot-Gujarat (INDIA)

DESIGN BASIS FOR PLOT PLAN

5.2.6

For distances from boundary fencing, refer Table-6

5.3

Additional Consideration as per Safety Engineering Practice

5.3.1

Approach to units and hydrocarbon storage tanks area shall be from two sides

5.3.2

Distance between control room to process unit equipments.

Minimum 15 M
Preferable 30 M

5.3.3

Distance between centre of main road to process unit battery limit.

To suit area classification

6.0

SAFETY DISTANCES FOR PRESSURE STORAGE

6.1

Under static and mobile pressure vessel (unfired) rules 1981

6.1.1

Distance from pressure storage to buildings

and adjoining properly line storage

30 M (for above 40 M^3 storage)

6.1.2
Distance between 2 groups of 6
vessels
pressure vessels each

shall be grouped together)

6.1.3

Distance from loading / unloading

points to adjoining property line,
pressure storage container.

9.0 M

6.2

Under OISD Standard-118 (July 1995)

6.2.1

For inter distances for LPG facilities, refer Table-7

6.2.2

For inter distances between LPG storage vessels and boundary / property line /
group of buildings not associated with LPG plant, refer Table-8

6.3

Additional Consideration as per Safe Engineering Practice

6.3.1

Distance between pressure vessels Minimum dia of adjacent Vessels

6.3.2

Distance between LPG pump station

PROF. HIREN B. VALAMBHIYA (B.E. CIVIL)

Mo. +91909970 2170
E-mail: chhotemistry@gmail.com

30 M (not more than 6

15 M

DARSHAN INSTITUTE OF ENGINEERING AND TECHNOLOGY

Rajkot-Gujarat (INDIA)

DESIGN BASIS FOR PLOT PLAN

and storage vessel.

6.3.3

Distance between any process unit

and LPG storage.

60 M

6.3.4

Distance between LPG pressure vessel,

LPG filling shed and flare or any source
of ignition.

90 M

6.3.5

LPG pressure vessels shall be located down

wind side of process units as far as possible.

6.3.6

Area around LPG filling station shall be free

from depressions and low pocket.

6.3.7

In undulating areas, LPG storage shall be

planned in lower elevation areas.

7.0

SAFETY DISTANCES FOR FILLING STORAGE &

TRANSPORTATION OF GAS CYLINDERS

7.1

Under Gas Cylinder Rules 1981

7.1.1

Distance between LPG Cylinder storage

and adjacent building and facilities.

7.1.2

Distance between LPG filling station

and adjoining bldgs.

7.2

Additional consideration as per Safe Engineering Practices

7.2.1
7.2.2

LPG filling station shall be located down wind of the plant.

LPG filling shed shall be open from all sides for proper ventilation to avoid
concentration of LPG gas on floor.

7.2.3

Flooring inside the LPG filling and storage shed be of non sparking type.

8.0

SAFETY DISTANCES AS PER VASUDEVAN COMMITTEE

REPORT FOR LPG STORAGE AND HANDLING FACILITIES

8.1

Safety zone around facility

PROF. HIREN B. VALAMBHIYA (B.E. CIVIL)

Mo. +91909970 2170
E-mail: chhotemistry@gmail.com

15.0 M (for storage over

30 M3)
10.0 M

30 M minimum
DARSHAN INSTITUTE OF ENGINEERING AND TECHNOLOGY
Rajkot-Gujarat (INDIA)

DESIGN BASIS FOR PLOT PLAN

80 M preferable
8.2

Distance between truck loading

and cylinder stacks.

15 M

8.3

No. of exists

9.0

CO-ORDINATION & APPROVAL OF OVERALL PLOT PLAN & UNIT

LAYOUT

Co-ordination with all Departments mainly Project /Process / Mech. / Elect. / Inst.
/ Piping / Structural / Pipeline / Construction.
Client approval.
CCE approval before issue for construction.

PROF. HIREN B. VALAMBHIYA (B.E. CIVIL)

Mo. +91909970 2170
E-mail: chhotemistry@gmail.com

DARSHAN INSTITUTE OF ENGINEERING AND TECHNOLOGY

Rajkot-Gujarat (INDIA)