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ÿþDevelopment of Plot Plan Basis of Site Selection 1. Location 1.1 Area Allocation 1.2 Transport Facilities 1.3 Manpower availability 5. Industrial Infrastructure 6. Community Infrastructure 7. Availability of Water 8. Availability of Power 9. Effluent Disposal 10. Availability of Industrial Gas 11. Site Size 12. Ecology 13. Pollution Plot plan is master plan locating each unit/facility within the plot boundary for process industry such as& 1. Refinery 2. Chemical /Agro Chemical / Petro Chemical / Organic Chemical / Inorganic Chemical 3. Fertilizer 4. Pharmaceutical 5. Metallurgical 6. Power Generation Data to be collected before starting 1.1 Civil 1.1.1. Plane table survey map. 1.1.2. Contour survey map(at 10M grid). 1.1.3. Soil Bearing capacity. 1.1.4. Nature of Soil 1.1.5. Rail/Road Access. Data to be collected before starting 1.2 Electrical 1.2.1. Location of Electric Supply Point. 1.2.2. Supply voltage levels. 1.2.3. Fault Levels. 1.2.4. Voltage Levels required within the unit. 1.2.5. Proposed distribution scheme. 1.3 Non Plant Facilities nð Administrative Block nð Canteen nð Workshop nð R&D, QC Lab and Pilot Plant nð Gate House/Time office nð Security Arrangements nð Vehicle Parking nð Medical Centre nð Ware House nð Covered Area nð Open Area nð Solid Warehouse nð Liquid Warehouse nð Steel / Scrap Yard nð Fire Station nð Weigh Bridge nð Staff Colony 1.4 Meteorological Data nð Minimum, Maximum and Normal Temperature during the year nð Rainfall nð Intensity and Direction of the wind(wind rose) nð Seismic zone nð Wet and Dry Bulb temperatures nð Flood level 1.5 Process Data nð Size/Capacity of the process unit nð Knowledge on the type of plant nð Sequence of process flow nð Hazardous nature of the plant nð The Overall operating philosophy nð Fully Automatic nð Partially Automatic nð Manual nð Batch/Continuous nð Raw material receipt and product dispatch philosophy nð Storage Philosophy nð Effluent plant capacity and discharge points, incirneration requirements, etc. nð Type of Hazard nð No of flares 1.6 Data on Utilities nð Source and/or supply point of raw water nð Quality of Water available nð Water Consumption for the process nð Requirement of different types of utilities such as Steam, Air, Nitrogen, DM water, Brine, etc. nð Capacities and Grouping philosophy nð Utility grouping philosophy 1.7 Statutory Requirements nð State Industrial Development Corporation(SIDC) nð Central / State Environmental Pollution Control Boards (PCBS) nð Factory Inspectorate nð State Electricity Boards (SEB) nð Chief Controller of Explosives (CCOE) nð Static and Mobile Pressure Vessel Rules (SMPV) nð Tariff Advisory Committee (TAC) nð Aviation Laws nð Chief Inspector of Boilers (CIB) nð Oil Industry Safety Directorate (OISD) nð Food and Drug Administration (FDA) nð Ministry of Environment and Forest (MoEF) 1.8 Expansion Philosophy nð Within the unit nð Additional Units nð Near future expansion nð Far future expansion Points to Note nð Normally Construction is permitted on 50% of the plot area with total built up area equal to area of the plot (i.e. F.S.I. = 1 (Depending upon the regulation governing the area and the type of industry)) nð Area reserved for tree plantation shall be 1/3 of the area occupied. nð Water storage capacity - 24 hr. minimum. nð Domestic water - 100 litres per person per day nð Water requirement for Boiler - Steam rating x Working factor nð Cooling tower - 2% of capacity as drift and blow down losses nð Washing - 10-15 litres per day per sq.ft. of floor area of the plant nð Gardening - 5 litres per day per sq.ft. of garden area Height of Boiler Chimney H (in m) = 14 Q 1/3 where Q is the amount of SO2 generated in kg/hr.Inter unit distance based on the type and nature of the process. Safety distances for the storages based on the relevant statutory regulations. Data to be generated before developing the plot plan 2.1 Block dimensions of: 2.1.1 Process plants considering the expansion philosophy. 2.1.2 Utilities based on the grouping philosophy and expansion requirements. 2.1.3 Electrical receiving station and sub-station. 2.1.4 Uncovered storage spaces. 2.1.5 Solid ware houses. 2.1.6 Non explosive chemical storages Explosive chemical storages as per classification. 2.1.7 Petroleum Product as per classification. 2.1.8 Fire water storage requirements. 2.1.9 Acid / Alkali storage. 2.1.10 Steel and scrap yard. 2.1.11 Raw material storage and treatment facilities. 2.1.12 Contractor s shed. 2.1.13 Effluent treatment & Incinerator plants. 2.1.14 Flare stacks. 2.1.15 Control room. 2.1.16 Administrative buildings, workshop, canteen, laboratories, pilot plant etc. 2.2 Tentative details of pipe rack/sleepers. 2.3 Fire water storage requirements based on the hazard classification. Layout of liquid storage nð Classification of Petroleum Products * Class-A - Liquid which has flash point less than 23 deg cel. * Class-B - Liquid which has flash point 23 deg cel. and above below 65 deg cel. * Class-C -Liquid which has flash point of 65 deg cel. and above but below 93 deg cel. * Excluded Petroleum : Liquid which has flash point above 93 deg cel. Fig.3: Equipment Layout - Explosive Tank farm Regulatory quantity above which License is necessary * Petroleum Class A - 30 litres in case of motor conveyance of stationary engines, capacity of fuel tank. * Petroleum Class B - 2,500 litres provided it is contained in a receptacle not exceeding 1,000 liters capacity. * Petroleum Class C - 45,000 litres Layout consideration for Explosive Tank Form nð Petroleum Storage tanks should be located in dyked enclosures with roads all around the enclosures. nð 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. nð In case of excluded petroleum the capacity of the dyked enclosure could be based on spill containment and not containment on tank rupture. nð 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. ð 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. Excluded petroleum shall not be stored in the same dyke. Tanks shall be arranged in two rows so that each tank is approachable from the surround road. The tank height shall not exceed one and a half times the diameter of tank or 20 M whichever is less. Layout consideration for Explosive Tank Form& nð The tank height shall not exceed one and a half times the diameter of tank or 20 M whichever is less. nð 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. nð It is better that the corner of the bund should be rounded and not at right angle as it is difficult extinguish fire in a 900 angle corner because of the air compression effect. ð There should be a a minimum of two access points on opposite sides of the bund to allow safe access/ escape in all wind directions 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). Layout of Gas Storage nð Storage Vessels are not allowed below ground level.They are to be installed above ground level. nð Vessels shall be located in open. nð Vessels are not to be installed above one another. nð If vessels in the installation are more than one, the longitudinal axis of vessels should be parallel to each other. nð Top surfaces of vessels are required to be made in one plane. nð Vessels installed with their dished ends facing each other shall have screen walls in between them. nð The distances to be observed between two vessels in one installation and distance from building or group of building or line of adjoining property are given in Table 1 & Table 2. ð The area where vessels, pumping equipment, loading and unloading facilities and direct fired vaporisers are provided shall be enclosed by an Industrial Type Fence at least 2 M high along the perimeter of Safety Zone. The minimum distances to be observed around installation shall be as per the guidelines in SMPV which are reproduced in Table 1 and 2. TABLE 1 Minimum Safety distances for flammable, corrosive & toxic gases Sl. No. Water capacity of Vessels Minimum distance Minimum distance ( in litres ) from Building or between Pressure Group of bldgs/line of Vessels adjoining property i Not above 2000 5 metres 1 metre ii Above 2,000 but not 10 metres 1 metre above 10,000 iii Above 10,000 but not 15 metres 1.5 metres above 20,000 iv Above 20,000 but not 20 metres 2 metres above 40,000 v Above 40,000 30 metres 2 metres TABLE 2 Minimum Safety distances for non-toxic gases Sl. No. Water capacity of Vessels Minimum distance Minimum distance from Building or between Pressure Group of bldgs/line Vessels ( in litres ) of adjoining property i Not above 2000 3 metres 1 metre ii Above 2,000 but not 5 metres 1.5 metre above 10,000 iii Above 10,000 but not 10 metres 2 metres above 20,000 iv Above 20,000 15 metres Diameter of larger vessel Note : The distances specified above may be reduced by the Chief Controller in cases where he is of the opinion that additional safety measures have been provided. STEPS TO BE CONSIDERED WHILE DEVELOPING THE PLOT PLAN nð Study the contour map and establish the grade levels/terraces. nð Establish the N-S and E-W (or X-Y) grids, the plant north in relation to geographical north. nð Establish the free area along the plot boundary as per the statutory norms. nð Work out the area requirements for the green belt, vehicle parking etc. as per the norms. nð The process blocks shall be located in the sequential order of process flow so that material handling (solid/liquid) is minimum. ð The blocks shall also be arranged considering prevailing wind direction so that flammable gases do not get carried to sources of ignition. Storage tanks shall be grouped according to process classification. Centralised control room shall be located in safe area close to process plant. STEPS TO BE CONSIDERED WHILE DEVELOPING THE PLOT PLAN nð Two adjacent process units shall be located based on annual shut down philosophy so that hot work shall not affect the operation. nð Process unit shall be located on higher ground away from the unwanted traffic. nð Process units shall be serviced by peripheral roads for easy approach. nð Utility block shall be kept at safe area close to process plants. nð Electrical sub-stations shall be placed at the load centre to minimise cabling nð Receiving station shall be placed near the supply point. nð Ware houses shall be located close to the material gate to avoid truck traffic within the process area. ð Flares, Furnaces/Heaters, cooling towers, etc. shall be placed depending on the wind direction. Provision of future expansion shall be considered. Raw water storage shall be placed closer to water source. Fire and raw water tanks shall be located together. STEPS TO BE CONSIDERED WHILE DEVELOPING THE PLOT PLAN nð Fire stations shall be away from the hazardous area and nearer to main gate. nð Effluent treatment plant shall be located away from the process and utility area on the downwind direction. nð Workshop, contractor s shed, storage yard, etc. shall be at centralised location serviced by peripheral roads. nð Two gates are preferred, one for the material entry with weigh bridge and the other one for man entry. nð Administrative block, laboratories, etc. shall be located closer to the man entry gate. nð Process unit can be separated within a fencing providing additional gate. nð Consider recommendation from the statutory authorities for inter unit distances. nð Residential colony shall be located away from the plant more closer to the city limits. ********

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