PIPING ENGINEERING CELL
PLOT PLAN
The selection of a project site is a
major corporate decision considering the
various factors that make the plant
technologically and economically viable.
The industrial policy of the government is a
major factor to be considered. Availability
of the various supporting facilities such as
power, water, effluent disposal, manpower
etc. have also to be taken into consideration
along with the size and nature of the
industry. Once the site selection is done, the
next activity is to develop the plot plan.
Plot plan is the master plan locating
each unit/facility within the plot boundary
for a process plant belonging to industrial
sectors such as the following.
i) Refinery
ii) Chemical / Agro Chemical /
Petro-Chemical/ Organic Chemical /
Inorganic Chemical
iii) Fertilizer
iv) Pharmaceutical
v) Metallurgical
vi) Electric Power Generation
The development of plot plan is a much
involved job. While locating the various
units/facilities within the plot, consideration
shall be given to the operation, maintenance
and safety aspects related to the plant and to
that of the neighbour, fire hazards, location
of power and water supply, expansion
facilities, man-material movements, etc. in a
balanced manner.
Before the activity of development of the
plot plan starts, there are a lot of data,
related to all disciplines of engineering, to
be collected and analysed and/or made use
Plot Plan.doc
T. N. GOPINATH
of. Data to be collected before starting to
evolve a plot plan can be classified as
follows.
1.0 BASIC DATA
1.1 Civil
1.1.1 PLANE TABLE SURVEY MAP
This document shows the extent of
the plot with the overall area identifying all
the existing constraints such as transmission
lines, structures, ponds, place of worship (if
any) etc. The survey covers 20 to 30 metres
beyond the extent of the specified plot to
show the nearby roads, drains, etc. and
broad features of the neighbouring plots.
This will also show the geographical north
direction. The location of power and water
connections are also shown therein.
(Ref. Fig. 1)
1.1.2 CONTOUR SURVEY MAP
Contour survey map shows the levels
of the plot with respect to the Mean Sea
Level (MSL). These levels are taken at 10
metre grid so that the topography of the plot
is well represented. This will establish the
co-ordinates; normally North-South and
East-West or it could be X-Y as well. The
contour map will also show the benchmarks
indicating the MSL to establish the level of
the plot. (Ref. Fig. 2)
1.1.3 SOIL SURVEY
Soil survey is conducted to establish
the load bearing capacity of the soil which
will be required for the civil design. The
nature of the soil is also tested to determine
the expansive nature, corrosion properties
etc.
1.2 Electrical
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The data related to electrical will 1.3.11 Fire Station

constitute the supply voltage levels, the
voltage levels required within the plant and 1.3.12 Weigh Bridge
fault levels to establish the power
distribution system, the location of supply 1.3.13 Staff Colony
point to decide the location of the receiving
station and the requirement of the state 1.4 Meteorological Data
electricity boards.
This data is required to arrive at the
1.3 Non Plant Facilities location of the process area, utility area
and the type of enclosure required for the
Necessary data is required to be building, basic design parameters, the
collected, to arrive at the block size of the drainage details, etc. The data includes:
following facilities, before the work is
started on the development of plot plan. The 1.4.1 Minimum, maximum and normal
user department should be consulted to temperatures during the year
arrive at the requirement and the allocation
should also be proportionate to the available 1.4.2 Rainfall
plot area and the effective process area.
1.4.3 Intensity and direction of the wind
1.3.1 Administrative Block (wind rose)

1.3.2 Canteen 1.4.4 Seismic zone

1.3.3 Workshop 1.4.5 Wet and Dry Bulb temperatures

1.3.4 R & D, QC (Quality Control) 1.4.6 Flood level

Laboratory and Pilot Plant
1.5 Process data
1.3.5 Gate House / Time Office
A lot of data related with the
1.3.6 Security Arrangements working of the process plant is also required
to develop a plot plan. The necessary data
1.3.7 Vehicle Parking includes:

1.3.8 Medical Centre 1.5.1 Size / capacity of the process unit to

work out the area to accommodate
1.3.9 Ware House the same.

i) Covered Area 1.5.2 Knowledge on the type of plant,

ii) Open Area whether it is to be located indoors or
iii) Solid Warehouse outdoors or the extent of enclosure
iv) Liquid Warehouse required.

1.3.10 Steel / Scrap Yard

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1.5.3 Sequence of process flow to locate Nitrogen, DM Water, Soft Water,

the process unit in the proper Cooling Water, Chilled Water,
manner. Brine, etc.
1.6.5 Capacities and the grouping
1.5.4 Hazardous nature of the plant to philosophy based on the nature of
keep proper inter-unit distances and utilities.
to work out the fire water storage
volume. 1.7 Statutory Requirements

1.5.5 The overall operating philosophy of Based on the location, nature and
the plant such as type of the plant, the requirements by the
i) Fully Automatic statutory authorities are well spelt out in any
ii) Partially Automatic country. Knowledge and application of these
iii) Manual are essential to develop the plot plan. These
iv) Batch / Continuous talk about the requirements of the Green
belt, Floor area occupation, (FSI) Floor
1.5.6 Raw material receipt and product Space Index, Width of the roads, Free area
despatch philosophy to be maintained along the plot boundary,
Height and tread of the steps, Floor to floor
1.5.7 Storage Philosophy such as the distances, requirements of distances to be
requirement of above ground and/or maintained between the units, requirements
underground storages, the nature of within the petroleum storages and gas
storage material etc. are required to storages, fire fighting requirements, height
decide on the block size. of chimneys, etc. These requirements are as
per the norms set by various government
1.5.8 Effluent plant capacity and discharge bodies in charge of industrial safety. In
points, incineration requirements, India, where the developers of this course
etc. hail from, a typical set of institutions and
bodies which are involved in granting
1.5.9 Type of hazard to decide fire hydrant permissions for the proposed activity are as
system. follows. This list for other nations will be
similar in spirit behind these permissions,
1.5.10 Number of flares. but different in nomenclature.
The following compilation does
1.6 Data on Utilities indeed have a strong India flavour. In a
course like this which is so popular all over
The following data on utilities are the world, it is a bit unfair. But, if you read
required to be gathered to size and locate the through the various rules and guidelines,
various utilities. you would certainly see through the basic
philosophy and pronounced safety concerns
1.6.1 Source and/or supply point of Raw which set the rules of the game. These are
water not different in different countries. The
1.6.2 Quality of water available differences in the guidelines will only be in
1.6.3 Water consumption for the process detail and not in the philosophy. Try to get
1.6.4 Requirement of different types of to these underlying philosophy and
utilities such as Steam, Air,

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overriding safety concerns in all the Based on the data collected as listed above,
specifics that follow. the following details shall be worked out so
that these can be used for the development
1.7.1 State Industrial Development of a plot plan.
Corporation (SIDC)
2.1 Block dimensions of the following
1.7.2 Central / State Environmental facilities:
Pollution Control Boards (PCBS) 2.1.1 Process plants considering the
1.7.3 Factory Inspectorate expansion philosophy

1.7.4 State Electricity Boards (SEB) 2.1.2 Utilities based on the grouping
philosophy and expansion
1.7.5 Chief Controller of Explosives
requirements
(CCOE)
2.1.3 Electrical receiving station and sub-
1.7.6 Static and Mobile Pressure Vessel station
Rules (SMPV)
2.1.4 Uncovered storage spaces
1.7.7 Tariff Advisory Committee (TAC)
2.1.5 Solid warehouses
1.7.8 Aviation Laws
1.7.9 Chief Inspector of Boilers (CIB) 2.1.6 Non explosive chemical storages/
Explosive chemical storages as per
1.7.10 Oil Industry Safety Directorate classification
(OISD)
2.1.7 Petroleum Storage as per
1.7.11 Food and Drug Administration classification
(FDA) 2.1.8 Fire water storage requirements
1.7.12 Ministry of Environment and Forest
(MoEF) 2.1.9 Acid / Alkali storage

1.8 Expansion Philosophy 2.1.10 Steel and scrap yard

The philosophy of expansion within 2.1.11 Raw material storage and treatment
the unit and additional units should be facilities
considered while developing a plot plan.
The expansion could be segregated as near 2.1.12 Contractor’s shed
future expansion and far future expansion
and both should reflect in the overall plot 2.1.13 Effluent treatment & Incinerator
plan. plants

2.0 DEVELOPMENT OF PLOT PLAN 2.1.14 Flare stacks

2.1.15 Control room

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2.1.16 Administrative buildings, workshop,
canteen, laboratories, pilot plant etc.
2.2 Tentative details of Pipe rack/Sleepers
2.3 Inter unit distances based on the type
and nature of the process.
2.4 Safety distances for the storages
based on the relevant statutory
regulations.
3.0 POINTS TO NOTE
3.1. Normally, Construction is permitted on
a maximum of 50% of the plot area
with total built-up area equal to the
area of the plot (i.e. F.S.I. = 1
(Depending upon the regulation
governing the area and the type of
industry)
3.2. Area reserved for tree plantation shall
be 1/3 of the area occupied.
3.3. Parking space – 10% of the plot area
3.4. Water storage capacity – 24 hr.
minimum.
The following basics can be used to estimate
the water requirement.
3.4.1 Domestic water - 100 litres per person
per day
3.4.2 Water requirement for Boiler - Steam
rating x Working factor
3.4.3 Cooling tower – 1.25 % of capacity as
drift and blow down losses
3.4.4 Washing - 10-15 litres per day per
sq.ft. of floor area of the plant
3.4.5 Gardening - 5 litres per day per sq.ft.
of garden area
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3.5. Height of Boiler Chimney H (in m) =
14 Q 1/3 where Q is the quantity of SO2
generated in kg/hr.
4.0 STEPS TO BE CONSIDERED
WHILE DEVELOPING THE
PLOT PLAN
4.1 Study the contour map and establish
the grade levels/terraces.
4.2 Establish the N-S and E-W (or X-Y)
grids, the plant north in relation to
geographical north.
4.3 Establish the free area along the plot
boundary as per the statutory norms.
4.4 Work out the area requirements for the
green belt, vehicle parking etc. as per
the norms.
4.5 The process blocks shall be located in
the sequential order of process flow so
that material handling (solid/liquid) is
minimum.
4.6 The blocks shall also be arranged
considering prevailing wind direction
so that flammable gases do not get
carried to sources of ignition.
4.7 Storage tanks shall be grouped
according to process classification.
4.8 Centralised control room shall be
located in safe area close to the
process plant.
4.9 Two adjacent process units shall be
located based on annual shut down
philosophy so that hot work shall not
affect the operation.
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4.10 Process unit shall be located on higher
ground away from the unwanted
traffic.
4.11 Process units shall be serviced by
peripheral roads for easy approach.
4.12 Utility block shall be kept at safe area
close to process plants.
4.13 Electrical sub-stations shall be placed
at the load centre to minimise cabling.
4.14 Receiving station shall be placed near
the supply point.
4.15 Ware houses shall be located close to
the material gate to avoid truck traffic
within the process area.
4.16 Flares, Furnaces/Heaters, cooling
towers, etc. shall be placed depending
on the wind direction.
4.17 Provision of future expansion shall be
considered.
4.18 Raw water storage shall be placed
closer to water source. Fire and raw
water tanks shall be located together.
4.19 Fire stations shall be away from the
hazardous area and nearer to main
gate.
4.20 Effluent treatment plant shall be
located away from the process and
utility area on the downwind direction.
4.21 Workshop, contractor’s shed, storage
yard, etc. shall be at centralised
location serviced by peripheral roads.
4.22 Two gates are preferred, one for the
material entry with weigh bridge and
the other one for man entry.
Plot Plan.doc
4.23 Administrative block, laboratories, etc.
shall be located closer to the man entry
gate.
4.24 Process unit can be separated within a
fencing providing additional gate.
4.25 Consider recommendation from the
statutory authorities for inter unit
distances.
4.26 Residential colony shall be located
away from the plant and relatively
closer to the city limits.
5.0 POINTS TO CONSIDER WHILE
DEVELOPING THE EXPLOSIVE
TANK FARM WHICH REQUIRES
CCOE APPROVAL.
5.1 Layout of Liquid Storage
5.1.1 CLASSIFICATION OF
PETROLEUM PRODUCTS
i) Class-A - Liquids, which have flash
point less than 23oC
ii) Class-B - Liquids which have flash
point 23oC and above but
below 65oC
iii) Class-C - Liquids which have flash
point 65oC and above but
below 93oC
iv) Excluded
Petroleum: Liquids, which have flash
point above 93oC
5.1.2 REGULATORY QUANTITY
ABOVE WHICH LICENCE IS
NECESSARY
i) Petroleum Class A - 30 litres
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In case of motor conveyance or stationary
engines, capacity of fuel tank.
ii) Petroleum Class B - 2500 litres
provided it is contained in a receptacle not
exceeding 1000 litres capacity
iii) Petroleum Class C - 45000 litres
5.1.3 LAYOUT CONSIDERATIONS FOR
EXPLOSIVE TANK FARM
i) Petroleum storage tanks shall be
located in dyked enclosures with roads
all around the enclosure.
ii) Dyked enclosure should be able to
contain the complete contents of the
largest tank in the tank farm in case of
an emergency. Enclosure capacity
shall be calculated after deducting the
volume of the tanks (other than the
largest tank) upto the height of
enclosure. A free board of 200 mm
shall be considered in fixing the height
of the dyke.
In case of excluded petroleum, the
capacity of the dyked enclosure could
be based on spill containment and not
containment on tank rupture.
iii) The height of tank enclosure dyke
shall be at least 1 m and shall not be
more than 2 m above average ground
level inside. However, for excluded
petroleum, it can be 600 mm.
iv) Class A and/or Class B petroleum can
be stored in the same dyked enclosure.
When Class C is stored together, all
safety stipulations applicable to Class
A and Class B shall apply.
v) Excluded petroleum shall not be stored
in the same dyke.
Plot Plan.doc
vi) Tanks shall be arranged in two rows so
that each tank is approachable from the
surrounding road.
vii) The tank height shall not exceed one
and a half times the diameter of tank or
20 m, whichever is less.
viii) Minimum distance between the tank
shell and the inside of the dyke wall
shall not be less than one half the
height of the tank. Height is
considered from bottom to the top
curb angle.
ix) It is better that the corner of the bund
should be rounded and not at right
angle as it is difficult to extinguish fire
in a 900 angle corner because of the air
compression effect.
x) There should be a minimum of two
access points on opposite sides of the
bund to allow safe access/escape in all
wind directions.
xi) Distances to be observed around
facilities in an installation shall be as
per the relevant chart furnished in the
Petroleum Rules. (Refer Fig. 3 &
relevant Table in the Petroleum Rules)
5.2 Layout of Gas Storage
5.2.1 Storage Vessels are not allowed
below the ground level. They are to
be installed above the ground level.
5.2.2 Vessels shall be located in open.
5.2.3 Vessels are not to be installed above
one another.
5.2.4 If vessels in the installation are more
than one, the longitudinal axis of
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vessels should be parallel to each guidelines in SMPV, which are

other.
5.2.5 Top surfaces of vessels are required to
be made in one plane.
5.2.6 Vessels installed with their dished
ends facing each other shall have
screen walls in between them.
5.2.7 The distances to be observed between
two vessels in one installation and
distance from building or a group of
buildings or line of adjoining property
are given in Table 1 & Table 2.
5.2.8 The area where vessels, pumping
equipment, loading and unloading
facilities and direct fired vaporizers are
provided shall be enclosed by an
Industrial Type Fence at least 2 m high
along the perimeter of Safety Zone.
5.2.9 The minimum distances to be observed
around installation shall be as per the
reproduced in Table 1 & Table 2.
5.2.10 Notwithstanding anything contained
in the sub rules above, the storage of
LPG can be placed underground or
covered by earth in such a manner and
subject to such conditions as may be
specified by the notifications by the
Central Government.
5.2.11 Above ground vessel for storage of
corrosive flammable or toxic gas in
liquefied state shall be provided with
enclosure wall all around the ground.
The minimum distance between vessel
and enclosure wall shall be the
diameter of the vessel or five meters
whichever is less. Ground shall be
graded to form a slope away from
pumps, compressors or equipments.
The height of the enclosure shall be 30
cm on the upper side and gradually
increasing to 60 cm on the lower side,
at the end of which, a shallow sump
for collection of spilled liquid if any,
shall be provided.

TABLE 1
Minimum Safety distances for flammable, corrosive & toxic gases

S. No. Water capacity of Vessels Minimum distance Minimum distance

( in litres ) from Building or between Pressure
Group of bldgs/line Vessels
of adjoining property

i Not above 2000 5 metres 1 metre

ii Above 2000 but not 10 metres 1 metre

above 10000

iii Above 10000 but not 15 metres 1.5 metres

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above 20000

iv Above 20000 but not 20 metres 2 metres

above 40000

v Above 40000 30 metres 2 metres

TABLE 2
Minimum Safety distances for non-toxic gases

Sl. No. Water Capacity of Vessels Minimum distance MinimumDdistan

( in litres ) from Building or ce between
Group of Bldgs/line Pressure Vessels
of adjoining
Property

i Not above 2000 3 metres 1 metre

ii Above 2000 but not 5 metres 1.5 metre

above 10000

iii Above 10000 but not 10 metres 2 metres

above 20000

iv Above 20000 15 metres Diameter of larger

vessel

Note: The distances specified above may be reduced by the Chief Controller in cases where
he/she is of the opinion that additional safety measures have been provided.

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TABLE - 3
Minimum Clearances to be considered in a Process Unit
(As per OISD guidelines)

1. Process units to flare 90M

2. Storage tanks class A/B 0.5D or 15M for Class

A/B, 6M for Class C

3. Storage tank to vehicle unloading 15M - Class A/B

3M - Class C

4. Vehicle unloading to boundary facing 15M - Class A/B

3M - Class C

5. Storage tank periphery to boundary facing 15M - Class A/B

4.5M - Class C

6. Electrical substation to process units 15M

7. Head room over main refinery roads 7.6M

8. Head room over main service roads 6M

9. Head room over secondary roads 4.5M - for cranes

3.6M - for trucks

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Fig. 1

Fig. 2

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Fig. 3

Fig. 4: EQUIPMENT LAYOUT - EXPLOSIVE TANK FARM

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