SHT. 1 OF 8 PIPING ENGINEERING PREPARATION OF PLOT PLANS SCOPE [y's Procedure detines the mothod to be followed for prepay od lowad for proparation of Plot P Al PREPARATORY WORK REQUIRED PrePeration of Pot Plans AT Oban roman Client and study the contour survey drawing forthe choson pot. itis essential 7310 undawarthe levels inthe Plot correctly, Take help from the Survevor Compare i €eded to understand the contours, * . eagee AB The Architect / Piping Leed Engineer shall ve the she, posstie botore the start of Grainaimotiana me oP to Got coar idea of elevations ofthe Pot and natural nore wo 4 {ains/mutiahs otc existing on/near tho plot ‘9 Qoian bask pot pan prapare by proceed losnaor/.Aeocbeprooees lelpine or Clon # availa 4 Qbiain chonts: specie requirements on locaton of Main Gate, Goods Gato, Admin Building, Guest House otc A9 Decide Statutory Rules / Regulations applicable based or here itis located. Discuss with the Client fo finalise the followed. BL 1S. OF PREPARATION OF TH - Following documents/guidelines shail orm the basis of Plot Plans: 8.1 The contour survey drawing for the plot B2 Meteorological data (wind rose, rainfall etc. for the area where plot is located) B3 Data collected during site visit (t any), B.4 Basic plot pian (it any) from Process Dept / Client / Process Licensor. 8.5 Cliont’s requirements regarding orientation of Main Gate, Admin building etc. (w.r1. Vastu Shasta’, if applicable). BG List of process plants, off included in the plat plan, 8.7 Equipment list for the project. 8.8 P&I diagrams for process plants and offsites / ulities, i available, 8.8 Plot plan (As Bui) for existing facities i the project is located in an existing complex. B.10 Statutory Regulations to be followed B.11 Local regulations lke SIOC (State Industral Development Corporation) rules, Gram Panchayat rules etc A FACILITIES —__ Tho Main Gato, Goods Gate (if any) and the Securty Gate Hous per “Vastu Shastra’ if applicable), 2 Process plants. 3 _Lay-down areas for Large equipment / Columns. 4 5 utities and non-plant buildings (all facilites) to be (to be located as Area / Pathways for Crane Movement. Ulilties like Cooling Towers, Air Compressors, and Air Drying Units, Chilling Plants, AHUs, HVAC units, Boller, Hot Oil Units etc. 6 Raw water / Fire water Systems consisting of Raw Waler / Fire Water Storage with Pump House, Raw Water Treatment / Filtration Plant, DM / DW / Pure Water / WF Plants with their Storage. C7 Offsites ‘ike Liquid and Gas storages, material handing systems, Solid Material Storages (Open or in Silos) C8 — Storages under the purview of chief controller of explosives (CCE) (Liquid Hydrocarbons / Other Flammable Liquid Storage, Pressurised Gas Storage, Drum Storage, Gas Cylinders Storage).co C10 ca C12 C13, ca cas ce ca C18 cag C20 Car C22 C23 C24 C25 C28 C27 C28 C29 C30 C31 C32 PREP! 0.1 D2 D3 SHT. 20F 8 PIPING ENGINEERING PREPARATION OF PLOT PLANS Storago of Toxic / Lethal iquids — Acids, Ammonia et. Solvent /Diesal Drum Unioading & Storage Area, Fire water pump house, Flare (with safety zone around it as per PCB requirements). Infrastructure consisting of — Piperacks Pipe sleepers Roads Underground Piping - OWS, CRWS, Dom. Sewage etc. Underground Cables / Cables in trenches Boundary Wall/ Fence Fire Water Mains ‘Storm Water Drains Domeste Sewage Treatment Plant Erfiuent treatment plant, Sludge Treatment Plant, Incinerators, Sludge dumping area Sludge drying area. Non-Plant Buildings ~ Admin Building, Canteen, Toilets, Warehouse, Laboratories, Health Centre, Fire Oticer's Room, Change Room, Time Otfice, Guest house, Workshop. Facilities for Drivers / Cleaners etc Electrical Faciities — Switch yard/ Two Pole Structure, Sub-station, MCC / PCC rooms, H.T. Switch Gear rooms, D.G. Shed, Captive Power Plant sic Control rooms and rack rooms. Existing H.T. Cables crossing the Plt. Existing nulahs, it any, on the plot. Proposed nullah diversion it any. Green Belt / Gréen Spaces Car Parking, Scooter / Motoreycle / Cycle Parking areas, Tanker /lory parking areas Weigh bridges Liquid Loading / Un-loading areas - By Road Tankers or by Rail Tankers Solids Loading / Un-loading areas ~ By Road Trucks or by Rallway. Wagons. pen Yard for storage of equipment / scrap / construction materials / equipment Railway siding with Unloading / Storage Platforms ‘Area for structural / piping / equipment fabrication Watch Towers along the boundary ofthe Plot Jetty and approach road and Pipe Sleepers to Jety. ‘Area for bore-wols (i required). Any other facility required for the Project. TION OF PI rc Confirm tne List of Facities fo be provided in the Plot. Confirm the “future’ expansion philosophy Decide approximate sizes of al facilities inthe ‘Lis of Facilities’. Follow guidelines below for deciding approximate sizes a) Process Plants — As per Basic Equipment Layouts oven by Process Department /Licensors. if not available, the equipment layouts are needed 10 be prepared to decide area required The process plant area also needs “Laydown areas for Large Equipment Tall Columns. The erection of these equipment needs area ’ pathways for movement of Large Cranes. Decide the pathway /area requirement mn Consultation with the Construction Dept >) Utilities — Decide in consultation with Client whether the utites wil b> located in a shed or outdoor. Sometimes some of them would be locatod in a shed while others are located outdoors. Obtain approximate foot prints (size of area required) of utity units and other Ulilty equipment (as per the List of Facilties) from Mechanical Enginoers (who procure the utlity packages) and decide approximate size of ‘shed ‘outdoor space required to locate all the tity units / equipment. LETT° ® ° 9 » SHT.3 OF 8 PIPING ENGINEERING PREPARATION OF PLOT PLANS Baw Water / Fire Water Storage ___ Capacity of Raw Waler Storage is avaiable in the law Water Storage Tank PDS. Normally the Fire Water ‘Storage is located adjacent to Raw Water Storage such that the incoming raw water flows into Fire Water Storage tank first and then overflows into the Raw Water Storage Tank The capactt of Fire Water Storage Tank depends on type of plant (ordinary medium / high hazard) and number of hydrants required for the fire fighting system. It also depends on Medium Velocity Spray Systems / Sprinkler Systems, required forthe plant To decide the Fire Water Storage Capacity, it is necessary to decide type of plant as per the TAC / LPA rules, decide the tentative route of the Fire Water Mains (ater frst run of the Pit Pian) and decide number of hydrants required and decide Storage Capacity accordingly The Fire Water / Raw Water tanks are normally ROG Construction, located half below the ground and half above ground (approx). Decide space required on above basis. Hazardous (flami Liquid St a — Refineries = — Use 0.18.0 rules to decide layouts of storages — Petrochemical — Use 0.1.8.0 rules to decide layouts of Plants storages (with Client's approval for use of 0.15.0. rules) — Other Plants — Use CCE rules for liquids talling Under CCE purview (Hydrocarbons + some —Nor-hydro carbons). For hazardous (flammable) liquids not falling under CCE purview, the storage may also be designed as per CCE rules (with Clients agreement) to keep them safe. ‘Storage of toxic / lethal liquids - Storage tanks to be located in a dyke with ‘capacity 170% of the largest tank in the dyke (Dyke height 1.8 M max). State Pollution Control Board rules require that these liquids are not allowed to drain to the ground water. Storage of all Acids and Alkalis falls in this category. ‘Pressurised Gas Storages - Mainly Horton Spheres, bullets & mounded bullets — Refineries — Use 0.1.0. rules for preparation of storage layouts. — Petrochemical Plants — Use 0.15.0. rules for preparation of storage layouts — Other Plants — Use SMPV (Static & Mobile Pressure Vessels) rules for the layout Electrical facilities _The space required for each electrical faclty needs to be decided in consultation with Electrical Engineers working on the joD. Indian Electroty Act to be followed when locating other non-electrical facilties ‘agjacento electrical facilities, Piperack & Sleepers _ To decide size of piperacks / sleepers, the route of Tacks / sleepers is needed to be known. Hence the correct size of piperacks and sleepers can be decided onty when fist run ofthe Plot Plan ready Based on the route of Piperacks / Sleepers, prepare the interconnection diagram using the P&! Diagram for the Project (Process & Utilities). Based on this dagram decide the piperack wicth and number of ers (use with & load calculation chart). Take care of {ture expansion requirements. ‘Aso take into account the space required for Elecfical & Instrumental Cable ‘Trays in consutation with Electrical and Instrument Groups.id %) m) n) SHT.40F 8 PIPING ENGINEERING PREPARATION OF PLOT PLANS The pipe sleepers are used only in cases where obstruction to movernent of People and vehicles is not a problem. The elevation of frst tier of sleepers is. kept normally at 500 mm from ground level The elevation of first tor of piperack is kept at 4.5 m for clear passage of fire tenders / foam trucks etc. The elevation of upper ters is decided based on sizes of pipelines. ‘The “first run’ Plot Pian would require revision to accommodate the correct ‘width of piperack and sleepers, Material Handing Systems & Storage of Sol Materials in Sos She area ‘The material handing engineers normally decise the Layout of the conveyors {or transfer of sols from one point to other and also location of the storage such that transter by conveyors is possible They also decide the sizeof the storage silos / sheds / open area required for solids storage based on capacity required as per basic documents. Hence for pian involving transfer of solids & storage of solids, itis essential to involve material handling engineers in preparation of plot plan. ETP (Etiyent Treatment Plant) —_ Space required depends on amount and type of efuents to be treated, This Gata is available in the BEP. I not avaiable, obtain from the Process Dept / Licensor / Cent. The approximate space required can be obtained from the Environmental Department by giving them above data ‘The ETP’ also may have the sludge treatment plant, sludge dumping area / tying area, The space required fo a these facites is based on the experience of Process Engineers / Licensors. Groen Balt / Open Space — Green Belt / Open Space to be maintained in the Plot shall be as por the SIID.C. (State Industral Development Corporation) rules or any other statutory regulations applicable. The Flare — {The fare has a safety zone around it to take care of State Pollution Control Board. requirements of maximum concentration of polstants allowed at ground level. The size of safety zone depends on type and amount of gases Boing bumt and height of the flare. The Environmental Departmant decides the height of flare and size of safety zone based on the type and amount of ‘gases being flared. Railway Yard/Siding __ ‘The space required for @ this faclly can be decided only by agencies approved by indian Raalways. Normally this space requirement / layout of yard 7'siding is decided by the Client by employing such approved agencies. Its worth remembering that this facility requires lots of space. Infrastructure Roads ~ Width to be minimum 4.5 m. 6 m with is commonly used. For Plants located in SIDC area, check SIDC rues for road with. Provide 10 m / 12 m wide roads with coniral dividers only when the foad has dense to & fo trafic, in both crections. _— Cables trenches ~ Obtain size and route from Electrical Engineers i trenches are required. _— Underground Piping ~ Decide space required based on number of Underground services to be accommodated. — Underground Cables - Obtain space requirement from Electrical Engineers Cables are run underground _— _Piperacks / Sleepers ~ Ref to n) above — Storm Water Drains — Obtain max. size of drain from Civil group. ‘delals, prepare. a_skelch indicating how this0) P) 9 n ) uy) SHT. 5 OF 8 PIPING ENGINEERING PREPARATION OF PLOT PLANS infrastructure would be arranged between Road Edge and outer Periphery of facilities located adjacent to the Road. Use this sketch when developing the Plot Plan, Non-Plant Buildings __ Decide size and space requirements for these buildings in close co-ordination with the Client. Client's views and requirements for these faclties change frequently and hence itis always advisable to be liberal in space provision for cities The Canteen size should be suitable for number of people in the General Shift, State Factory rules shal be folowed forthe size. Number of tolets (and their size) in the Plant is decided based on number of Personnel in the General Shift, as per State Factory Rules. Admin Building requires additional space around it for parking for Senior Management Vehicles and garden (beautification) etc. Reserve enough ‘space for this in consultation with Client and the Architects, Control Room / Rack Room Size to be obtained from the Instrument Engineers working on the job. The Control Room Building normally houses some other facies also. (e.g Battery Room, Plant Office, Toilets, HVAC Room etc). Sometimes the Client Fequires offices for the Operators / other personnel, Conference Room in this, building. These should be taken into account when deciding the space requirement for the Control Room Block, H.T. Power Cables running across the Plot __ Normally the State Electricity Authoriies would not agree to relocate these HT. Cables away from the Plot. Hence some space is required to be kept vacant on either side of these H.T. Cables. Vacant space needs to be decided in consultation with the concemed Electrical Authorties. This vacant Space should not be encroached upon by any plant facility except the roads crossing these cables, ‘of Gate House, Fir ‘5 Room / Room, Change Room / Time Office — Decide sizes in consultation with the Client and based on the number of Personnel in the General Shit. Vehicles Parking Areas __ Decide number of / type of vehicles to be parked in consultation with the Client. Decide space required as per this data, For proper parking arrangements and provision of space, obtain help from the Architects Rail Tanker Loading & i — This area involves movement of Rail Tankers & Road Tankers and hence Fequires trafic logistic study to decide the pattern of traffic and arrangement of loading / unloading areas and platforms. A person well versed in trafic logistics is required to prepare the logistics study for smooth movement of Vehicles to & fro the loading / unloading / parking areas, For Rail Tanker loading / unloading operations, an agency approved by Indian Railways is required to prepare the layout of loading / unloading areas and the railway yard / siding, For Road Tankers, it is fest to design the arrangement for once through traffic, no back-ups (to avoid accidents) Road Truck / Tankers Parki ‘When the road Truck / tankers trafic to & fro from the plant is very heavy, the State / SIDC authorities do not permit the Truck / Tankers to be parked on the roads / areas outside the plant boundaries. They are required to be parked inside the plant boundaries,SHT.6OF 8 PIPING ENGINEERING PREPARATION OF PLOT PLANS hs Truck | Tankers parking area is provided based on logistic study of Truck | Tankers movements and number of Truck / Tankers which are needed to be Parked inside, waiting either tor loading or unloading, This area needs proper planning for safe movement of loaded / empty tankers, without need for backing up to avoid accidents ¥) Best Rooms for Tanker Drivers / Cleaners —__ Size to be decided as per number of Road Truck / Tankers which would be Parked in the parking area at any time. This facility along with the tanker Parking area is required to be fenced (with manned Gates) to avoid tanker Givers / cleaners entering and loitering inside the plant area, w) Guest House __ This is a building / area where the Senior Management of the Company and Company guests (some from abroad) stay / visit and hence requires more attention from the Architects. Hence the decision on space provision is best lett to the Architects and the Client It's worth keeping in mind that this facility requires fot of space. x) Solvent Diesel Drum Unioading & Storage — This area normally would fall under CCE purview. Layout would be as per CCE rules. The loading and unloading of filed and empty drums requires Unloading area with proper road access and unloading gantry for unloading drums (without ‘dropping’ from the trucks. y) — Weigh Bridge __ The space required can be obtained from Weigh Bridge suppliers. Approx. ‘space required can be also obiained from Mechanical Enginesrs who procure the Weigh Bridge, 2) Jetty with Approach Road— Jetty is designed by Specialists. Normally the Client appoints a Specialist ‘Agency for Jety design and incorporation in the Plot. D4 Proceed with preparation of Plot Pian as follows. — '@) Decide finished ground level of the Plot based on the maximum flood level and in close co-ordination with Client. I the Plot has large slopes (his & valleys), it may be better to make it a ‘terraced’ plot, i.e. Plot will have diferent levels in different areas. As cutting and filing is costly, “terracect Plot saves a lot of cost for the Client b) Fora ‘terraced plot, the terrace boundaries need spacial attention as these require RCC walls / Stone embankments which require enough vacant space ‘on both sides of these boundaries. The facilties on both sides of these boundaries are located keeping tis requirement in mind. Finalise "Plant North’ (preferably vertically up) w.r.. the magnetic north. Both these directions should be shown on the plot plan. Also add the "wind Rose’ con the plot plan d) Select a suitable scale, for the drawing based on the plot size. Use AO / At size drawing for the Plot Plan. ©) Decide the Plot areas to be used for ‘present and future’ pants and ‘demarcate these areas in the Plot accordingly 1) For the ‘present’ area, add suitable width of “Green Bet’ all around the Plot ‘adjacent to and inside the boundary ofthe area. This should be ciear area and ho pat factty should overiap in this area except the Waich Towers (! any). Follow the S.1.C / State Government rules for Green Bet / Greon areas in the Plot Decide the locations of Main Gate and Goods Gate based on the following — °) 2 1) $.1.D.C / Local / State Govt / Highway Authority Rules 2 Vastu Shasta irvohvod 3) Danaty of Truck Tanker rai anvsaped Oe eed4) d ”) m) ") 9°) °) v 8) SHT. 7 OF 8 PIPING ENGINEERING PREPARATION OF PLOT PLANS 4) Location of H.T. Cables, if running across the Plot. 5) _ Provide min. 2 exits to the Plot to ensure safe evacuation of personnel in case of emergencies / mishaps in the Plant. Locate the “Switchyard / Two Pole’ structure at the point where the power enters the Plot, Follow regulations given below to locate various facities in the Plot — 1) Refineries — _OISD regulations are mandatory. Also use the TAC / LPA rules & State Factory rules as applicable. 2) Betrochemical Plants OSD regulations with Client's approval. Also use the TAC / LPA rules & State Factory rules as applicable. 3) Chemical Plants © —_Ragulations of State Directorate of Health & Safety (Factory Rules) and TAC / LPA Rules. 4) ant — Regulations of State Directorate of Health & Safety (Factory Rules) and TAC / LPA Rules. Process Plants — Locate at safe distance from the boundary fence / wall and from each other / other faciliies. Show all major equipment in case of ‘outdoor plants. Locate Raw Water Storage & Water Treatment Facilities at the point where the Raw Water Supply Pipeline enters the Plot, as far as possible. Locate Fire Water Storage (with pump house) adjacent to Raw Water Storage. To ensure availablity of Fire Water all the time, the Raw Water ‘Supply is first routed to the Fire Water Storage and from there it overtlows to the Raw Water Storage. ‘The Fire Water Storage & Pump House is normally located away from all ‘other facilities to avoid it getting affected in case of fre / mishaps in the Plant. Locate the flammable and pressurised storages away from the Process Plants. Locate the flare stack downwind (w.rt. the predominant wind direction) trom process areas to avoid flare flame transmission to Process Plants. Locate Cooling Towers away from Switch-yard and transformers to avoid water sprays on electrical equipment. {As far as possible treat ‘all process plants together, ‘all utilities together, “all off-sites-logether, all non-plant building together’ as separate groups and Tecate them accordingly in the Plot Plan, These Groups are normally segregated by major roads (6 m wide) running around and between them. ‘The individual plants / storages / uilty areas /tacilties in these ‘Groups’ are separated from each other by minor roads (4.5 M min. wicth) “CCE’ & non-CCE tankages are segregated from each other by means of roads. Long road tankers require higher radius of curvature at the road turing Provide proper radius for road tunings for roads on which long road tankers would ply. Electrical facilities ike Substations / MCC Rooms / PCC Rooms H.T. Switchgear rooms require inputs from Electrical Engineers for proper location wart olher plant facilities and distribution of electrical loads. Obtain their help for locating these faites Locate the Truck / Tanker parking areas such that the truck / tanker traffic is ‘away from the Admin Bldg & Process Plants and also the trafic does not ply through the Plot. tis best to keep this traffic adjacent tothe plant boundary on the opposite side of the Plot w.rt. the area where Process Plants and the ‘Admin, Building is located Provide a separate Goods Gate, it necessary.» u) y w) SHT. 8 OF 8 PIPING ENGINEERING PREPARATION OF PLOT PLANS Locate the Railway siding nearest to the location of existing Railway Tracks / Railway Station. The orientation of the siding / yard inside the Piot should be decided in consultation with the Agency appointed by Client for design of the same. Locate the Process Piants and the storage areas at higher levels ( if the Piot “terraced' ) to facilitate gravity drainage of effluent to the ETP. Locate the ETP at the lowest level to facilitate receipt of effiuent drainage by gravity. Divide the large tank farms with intemal roads (min. 4.5 m wide) such that each tank can be approached by fire water monitor jet or mobile foam jet on all the sides.