Piperack Guide

CONTENTS 1.0 GENERAL A - TERMINOLOGY A.1. A.2.
Structure Foundations
B DEFINITION CRITERIA B.1. B.2. 2.0 Rack Width Number of tiers
MATERIAL SELECTION A MATERIAL USED B SELECTION CRITERIA
3.0
BASIS OF ANALYSIS A PERMANENT LOAD A.1. A.2. A.3. Weight Of Framework Fireproofing Heat Insulation Weight of Piping
B LIVE LOAD B.1. B.2. Liquid Load In Pipe <12 Platform and access load
C EXAMPLES ON THE DETERMINATION FOR THE DISTRIBUTION OF VERTICAL LOAD ON PIPERACK C.1. C.2. Determination of the Average Of Pipes Diameter Load Distribution Between Main Cross Beam And Intermediate Cross Beam.
D CLIMATIC LOAD D.1. D.2. Snow Wind
E SEISMIC LOAD
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F TEMPERATURE LOAD F.1. F.2. Structure Expansion Or Contraction Anchoring Friction Piping Guide
G OTHER LOADS H COMBINATION OF LOADS H.1. Combination of Various Elementary Cases
I CONDITION OF DEFLECTION I.1. I.2. 4.0 Acceptable Vertical Deflection Acceptable Horizontal Displacement On The Portal Frame
STEEL PIPERACK A CONSTRUCTION ARRANGEMENT A.1. A.2. A.3. A.4. A.5. A.6. Intermediate Cross Beam Longitudinal Beam Portal Frame Post-Foundation Connection Longitudinal Stability Particular Case
5.0
CONCRETE PIPERACK A VARIOUS FORMS B METHODS OF EXECUTION B.1. B.2. B.3. B.4. Racks Cast In Place Racks Semi-Prefabricated Racks Completely Prefabricated Choice Of Execution Methods
C STUDIES AND CALCULATIONS C.1. C.2. Studies Calculations
D CONSTRUCTION ARRANGEMENT D.1. D.2. D.3. Reinforcement Fixation of Cooler Accessories
1.0
GENERAL 1. INTRODUCTION This document is a guide on the procedures or working methods in the field of civil. In case of contradiction of this document with the General Protocols, this document superceded the General Protocols. 2. OBJECTIVE This document covers the regulation by service 347 and 357 of TECHNIP for the piperacks in the petroleum, petrochemicals and similar industries. Any deviation from this regulation shall be approved by the Head of Service, however the customer particular rules or requirements have priority over this requirement. 3. REFERENCES This document shall be used with the following documents :A. GE 357.10.1. GE 357.10.2. GE .357.14.1. GE 357.15.1 Objectives and use of the guide of studies. General Rule applicable to the studies. Concrete Foundation And Works General Information. Frame and handling general Information.
TERMINOLOGY Piperacks is a structure made of steel, concrete or mixed supporting :One or more layers of piping. Electrical or instrument cable tray. Air cooler in certain case.
Piperack comprises of two parts :Steel or concrete structure. Concrete foundation.
A piperack composes of various element with the following terminology :A.1. Structure A.1.1. Main Cross Beam The main cross beam is a horizontal beam connected to two posts to form the portal frame and to support the pipes.
A.1.2. Portal Frame The element of piperack forms by two posts and one or more main cross beams. A.1.3. Longitudinal Beam The longitudinal beam is a horizontal beam connecting two portal frame in longitudinal direction. Generally, the members are used to support the lateral forces, intermediate cross beams and post of coolers. Especially to transmit the horizontal force to the bracing bay. A.1.4 Width of Piperack The width of piperack is the distance between the axis of the posts. A.1.5 Piperack Spacing Piperack spacing is the distance between the portal frames. A.1.6 Intermediate cross beam The intermediate cross beam is a horizontal cross members supported by longitudinal beams. They are used to reduce the deflection of small pipes. Their requirement is decided by piping department. The intermediate cross beam shall be steel. A.1.7 Longitudinal stability Longitudinal stability forms by two consecutive portal frame connected by members which restraint the longitudinal forces.
PIPE-RACKS
INTERMEDIATE CROSS BEAM PIPE LAYER LEVEL LONGITUDINAL BEAM
COLUMN PORTAL FRAME MAIN CROSS BEAM
I=
WIDTH OF PIPERACK
L = PORTAL SPACING
LONGITUDINAL STABILITY
A.2.
Foundations A.2.1. Footing Footing is a member rest on good ground, in the case of pile this is called pipe cap. A.2.2. Longitudinal Beam Longitudinal beam is a beam connecting the two consecutive footing in longitudinal direction. Longitudinal beam incorporated with the footing.
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Longitudinal beam rested on the footing.
Longitudinal beam semi-incorporated with the footing.
B.
DEFINITION CRITERIA The piperack is define by two principal criteria, i.e. :Width of piperack and numbers of tiers. B.1. Width Of Piperack (normally it is in multiple of 1.5m) i.e. : 3 meters ; 4.50 meters ; 6 meters ; 7.50 meters ; 9 meters. B.2. Number Of Levels longitudinal beam longitudinal beam longitudinal beam 1 level cross beam 2 level cross beam 3 level cross beam 1 level cross beam 2 level cross beam 3 level cross beam + + + + + + 1 longitudinal beam 1 longitudinal beam 2 longitudinal beam 1 level cooler + 2 1 level cooler + 2 1 level cooler + 3
2.0
MATERIAL SELECTION A. MATERIAL USED The material used for the piperack structure are as follows :- Metal frame - Concrete - Mixed (metal frame concrete) B. SELECTION CRITERIA (If the material is not specified by Client) The selection criteria are :- The cost of finishes work. - The completion date. - Nature of contract The choice of materials used must be made by specialist engineers after detail economic survey in agreement with the project engineer and various factor especially the contract requirement : - Fireproofing. - Planning schedule (duration) - Reduce time for studies (in the case of standard contract of fixed price for studies). For overseas contract : - Cost of transport (distance) - Possibility of material supply locally. - Potential of local labour.
3.0
BASIS OF ANALYSIS This chapter will explains the determination methods for loads on piperacks. The guides are as follows : A - PERMANENT LOAD A.1. A.2. A.3. Weight of framework. Fireproofing heat insulation. Weight of piping.
B - LIVE LOAD B.1. B.2. Liquid load in piping with diameter 12. Platforms and access load.
C - EXAMPLES ON THE DETERMINATION FOR THE DISTRIBUTION OF VERTICAL LOAD ON PIPERACK C.1. C.2. Determination of average diameter for the pipes. Load distribution on main cross beam and intermediate cross beam.
D - CLIMATIC LOAD D.1. D.2. Snow Wind
E - SEISMIC LOAD F - THERMAL LOAD F.1. F.2. Structure expansion - contraction Achoring friction guide of piping.
G - OTHER LOADS H - LOAD COMBINATIONS H.1. Example of various elementary cases.
I - CONDITIONS OF DEFLECTION I.1. I.2. A. A.1. Acceptable vertical deflection. Acceptable horizontal displacement on portal frame.
PERMANENT LOAD Weight of framework The actual weight of the elements constituting the piperacks shall be used especially for concrete piperacks. Estimated values total weight of piperack : (including water and pipe) for average dia. 8 - Pipe-rack 1 level - Pipe-rack 2 levels - Pipe-rack 2 levels + cooler : : : 80 kg/m2 120 kg/m2 180 kg/m2
The weight of platforms and access on the piperack to be included. A.2. Fireproofing and heating insulation. A.2.1. Weight of fireproofing coating : See standard (STE.00.17.40.001) A.2.2. Weight of heat insulator on the lines. (provided by service piping)
A.3.
Weight of pipe The weight of pipes size between 2 to 12 shall be taken as uniform load as set out in the following sections. The empty space between pipes can be used (unless stated otherwise) for pipes with diameter equal to the average pipe size. A.3.1. Dead weight for pipes 2 to 12
NOMINAL DIAMETER
EXTERNAL DIAMETER (mm)
SCHEDULE
DISTANCE BETWEEN PIPES 150mm TO 300mm (WITHOUT INSULATION) 140 175 210 270 325 385 450
DEAD WEIGHT OF PIPES (kg)
Per m 2 3 4 6 8 10 12 1) 2) 60.3 88.9 114.3 168.3 219.1 273.1 323.9 40 40 40 40 30 30 30 5.4 11.3 16.2 28.6 37.2 52.1 67
Per m2 40 70 80 110 120 140 150
The loads for pipes of > 12 shall be calculated separately. Normally the uniform load per m2 for insulated pipes is smaller than the uninsulated pipes due to the space provided between pipes for the insulated pipes.
A.3.2
Reference Diameter of Piping The calculation can be simplified by taking the average diameter of pipes for load calculation. Pipes with diameter more than twice the average diameter of pipes layer shall be considered as follows:Uniform load shall be recalculate without these pipes. These pipes shall be consider as point load
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A.3.3
Piping Load Distribution Coefficient Between Main Cross Beam (M) And Intermediate Cross Beam (I) SMALLER PIPE DIAMETER DISTANCE BETWEEN MAIN CROSS BEAM 4.5m M I 0.9 0.1 6m M 0.8 0.9 0.9 0.9 I 0.2 0.1 0.1 0.1 7.5m M I 0.7 0.8 0.8 0.9 0.8 0.9 0.9 0.3 0.2 0.2 0.1 0.2 0.1 0.1 9m M 0.6 0.6 0.7 0.8 0.7 0.7 0.8 I 0.4 0.4 0.3 0.2 0.3 0.3 0.2 M 0.4 0.4 0.5 0.5 0.5 0.6 0.7 0.7 12m I 0.6
ZONE 0.6B
REFERENCE PIPE DIAMETER
3 - 4 6 8 10 - 12 ZONE A ZONE B Note B. :
< 2 2 <3 3 < 4 4 < 6 > 6 : :
ZONE A
0.5 0.5 0.5 0.4 0.3 0.3
No intermediate cross beam requires Require more than one intermediate cross beam
To be confirmed by piping discipline
When the large pipes can support the smaller pipes, the intermediate cross beam is not necessary.
OPERATING LOAD B.1 Liquid Load For Pipes < 12 The calculation of the liquid loads in the piping be determined from simplified assumptions as follows :Pipes with 0.5 full of water Pipes with 0.75 full of water Pipes with full of water
The choice between the three assumptions will be mentioned on particular rule of the contract :B.1.1 Type of unit (product to be transport) (see service requirement) Customer preference
Case for Pipes Transporting Gas In the traditional case, these lines shall be considered as transporting the liquids. Particular cases : Lines for liquid or vapour All the pipes are for gas transportation
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In these particular case, the operating load will be the load provided by the service piping, however the other possible loads due to operation shall be considered. B.1.2 Liquid phase of the material Present of ice on cold line, etc.
Case for Pipes > 12 The value of the operation load will be the actual values provided by the service piping.
B.1.3 NOMINAL DIAMETER 2 3 4 6 8 10 12 B.2
Operating Load of Piping 12 DISTANCE BETWEEN CENTRE OF PIPES 140 175 210 270 325 385 450 Full Kg/m 1.1 2.4 4.1 9.3 16.5 26 37 Kg/m 10 15 20 35 50 70 85
2
EXTERNAL DIAMETER (mm) 60.3 88.9 114.3 168.3 219.1 273.1 323.9
SCHEDULE
LOAD IN KG Full Kg/m 1.7 3.6 6.2 14 24.8 39.1 55.5 Kg/m 15 25 30 55 75 105 130
2
Full Kg/m 2.2 4.8 8.2 18.6 33 52.1 74 Kg/m2 20 30 40 70 100 140 170
40 40 40 40 30 30 30
Platform And Access Load Load on platform and access shall be considered (value provided on particular rule)
C. C.1
EXAMPLES OF CALCULATION FOR DETERMINATION AND DISTRIBUTION OF VERTICAL LOAD ON PIPERACK Determination Of Reference OF Pipes C.1.1 Maximum Pipes Diameter < 12 of pipes on the support: 72, 63, 84, 26, 18 Pipes are considered full of water
Weight of pipes per m length 7 x (5.4 + 2.2) 6 x (11.3 + 4.8) 8 x (16.2 + 8.2) 2 x (28.6 + 18.6) 1 x (37.2 + 33) = = = = = 53.2 96.6 195.2 94.4 70.2 509.6 kg
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Dead Load
Operating Load
12
Average pipe load (Dead Load + Operating Load)

=2 1.3 kg/m len gth
5 10 24
Reference average pipe diameter is 4 Because 16.2 + 8.2 = 24.4 kg/m > 21.3 kg/m IMPORTANT NOTE : Since the largest pipe size is not more than 2 times the average diameter, the option of average pipe is conservative. When one or more of the pipes obviously deviate from the average diameter, it is better to calculate them separately. C.1.2 For Pipes with Diameter > 12 Point loads shall be considered separately for lines with dia > 12 C.1.3 Particular Case If it is obvious that the average pipes size in some part is different from the other part, the average pipe for each part shall be used. C.2 Load Distribution Between Main Cross Beam And Intermediate Cross Beam (Generated By The Pipes) C.2.1 Pipes Layer with Minimum > 12 Normally pipes with > 12 do not require intermediate supports. Load on main cross beam V = P xL P : Pipe weight per meter length L : Distance between main cross beam
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C.2.2
Pipes Layer with Maximum < 12 a) Reference represent the whole pipes on the rack Example : reference pipe 6
MB
MB
L1 = 7.5m
L2 = 9m
LOAD DISTRIBUTION BETWEEN (IB) AND (MB) AS PER TABLE A.3.3 (PAGE 11)
Vertical load on support is proportional to the width of concerned area.

1 2
= L1 x 0.1 = 7.5 x 0.1 = 0.75 m = L2 x 0.2 = 9 x 0.2 = 1.8 m = =
L1 L 0.9 + 2 0.8 2 2
7.5 9 0.9 + 0.8 = 8.97 m 2 2
For load distribution coefficient refer to A.3.3
For dead load case distribution, load on cross beam will be as follow: Main cross beam Intermediate cross beam Intermediate cross beam = 110 x 6.97 = 797 kg/m = 110 x 0.75 = 82.5 kg/m = 110 x 1.8 = 198 kg/m See Table A.3.1 (Page 10)
Similar calculation shall be done for operating weight. b) Average pipes diameter is not including the whole pipes average 3 +1 line 12 Data L = L = 7.5 m (minimum 1) Pipes dead weight
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MB
IB
IB
Load distribution on the cross beam. 70 x 7.5 x 0.3 = 157 kg/m intermediate cross beam 70 x 7.5 x 0.7 = 367 kg/m main cross beam Point load on the cross beam due to pipe > 12 Not supported on intermediate beam Load supported by main cross beam
67 x 7.5 = 502.5 kg Weight of pipe 12 per m length. Space taken by line 12 = 0.33 m (external diameter) Point load from pipe 12 shall be reduce by the value equivalent to the 3 ref pipe. 502.5 (367 x 0.33) = 381 kg Similar method of calculation shall be performed for operating load. P = 381 kg
367 kg/m
C.2.3
Other cases Similar calculation as above.
C.2.4
Summary Minimum > 12 Point load to be considered for calculation Homogenous pipes Maximum < 12 Nonhomogenous pipes (max > 2 x average ) uniform distributed load + point load uniform distributed load
Other cases
Uniform distributed load + Point load
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D. D.1
CLIMATIC LOAD Snow The effect of snow on the piperacks support and pipes are not considered (unless otherwise stated in the particular regulation)
D.2.
Wind D.2.1. Wind effect General expression form : H = Qh x Ct x Sp Where Qh : wind dynamic pressure at height h. Ct : shape factor Sp : surface area facing the wind. D.2.2. Transversal wind a) Action on the supports Ct = 1.3 shape factor for flat surface (concrete or fireproof frame) Ct = 1.8 shape factor for profile steel frame. For other case see regulation. The effect of shielding of another parallel elements are not considered. b) Wind load on pipe layer H = Qh ( + 0.1 x l) x L apply on each horizontal layer. Where = Diameter of the largest pipe with a minimum of 250 mm. l = Width of pipe layer. L = Length of pipe layer.
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D.2.3. Example of calculation for transverse wind load. Qh = 100 kg/m EL + 5.5 EL + 4.5 HEA 240 Columns Main cross beam TIE BEAM = 1PE140 INTERMEDIATE SUPPORT/ AND COLUMN = HEA 120 7.5m Pipe layer Larger = 400
6m
Note : To simplify the calculation of wind load, the load will be applied : At the piping layer elevation, At the base of column.
However wind load shall be applied at the right location when justified by beam size/or location, mainly for tie beam. Wind load at Elev = 5.5 : H1 Column Longitudinal Beam Intermediate Column Piping : : : : 100 x 1.8 x 0.24 x 2.75 x 2 100 x 1.8 x 0.24 x 7.5 x 2 100 x 1.8 x 0.12 x 1.0 x 2 100 x (0.4 + 0.1 x 6) x 7.5 = = = = 238 648 43 750 1 680 kg
Column surface for calculation of H1 H1 2.75
2.75
H3
H2
Column surface for calculation of H1 and H2.
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Wind load at Elev. 0 : H2 H3 Column : 100 x 1.8 x 0.24 x 2.75 = 119 kg Remark : Wind load distribution on column for pipe rack with two layer of pipes H1 for calculation of H1 H2 for calculation of H2
H3
for calculation of H3 V3
D.2.4. Longitudinal wind load a) Action on the supports Ct = shape factor Sp = Surface area exposed to wind effect ie: All columns All relevant transversal supports of first portal / and last one only.
b) Horizontal wind load to be considered at each piping layer V = Qh x x 1 x L (applied at each piping layer) Where
= Width of piping layer

L Top layer = Length of part considered = Friction drag coefficient depending of piping layer location 0.1
0.05 Bottom layer 0.05 Values of B
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c) Wind load on vertical piping layer Wind parallel to pipe layer. H = Qh x Sp Sp = Exposed surface of pipe layer.
Sp
d) Wind effect for tee-off pipe lines Similar method as transversal wind load. H = Qh ( + 0.1 I) L For isolated pipe line H = Qh x 0.6 x I = diameter of concerned pipe line. I = width of concerned pipe. e) Longitudinal load distribution (steel pipe rack) Load to be applied : 1. At the tie beam level 2. At the base of column
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At the tie beam level H1 = H2 = Load applied at the tie beam level on the first portal. Load applied at the tie beam level on the last portal. AREA FOR H, AREA FOR H2
H1 h
H2
H3
H5 A B
H5 C
H3 D
PIPERACK UNDER
STARTING
CONSIDERATION
STARTING
POINT
L1
L2
H1 =
Wind on transverse support. + Wind on horizontal and vertical surface of pipe layer in zone length L1. + Wind on tee off pipe layer in zone L1. + effect of wind on post and bracings in zone L1 (at concerned height). Wind on transverse support. + Wind on horizontal and vertical surface of pipes layer in zone L2. + Wind on the tee off pipes layer in zone L2. + effect of wind on post and bracing in zone L2 (at concerned height).
H2 =
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POINT
At The Base of Column H3 : H5 : Wind load on column (at concerned height) Wind load on restrain column and on bracing f) Wind load stability post + Wind load on bracing at concerned height
Load Distribution on Foundation Normal Foundation Longitudinal shear load = H3 Foundation of stability bay Longitudinal shearing load = H+
H1 - H2 2 h
Vertical load
= (H1 + H2) x
SEISMIC LOAD Important Note Seismic load shall not be combined with climatic load. If the particular rule require to check for seismic, it will be checked for para paraseismic regulation.
F F.1
THERMAL LOAD STRUCTURE EXPANSION/SHRINKAGE F.1.1 Entirely Steel Load developed due to steel expansion shall be taken into consideration when it will give abnormal effect on the frame (expansion coefficient 11 x 10-6 per C) Metal steel frames expose to air, in France it is acceptable for a variation of temperature 27C which is correspondent to the variation in length of 0.3 mm per meter length. Under this conditions, load due to the expansion of the frame is negligible when the distance between two expansion joints does not exceed 60m. F.1.2 Entirely Concrete The concrete pipe rack with tie beam cast in situ to the column, the problem will be severe as the beam cannot expand freely. In this
21
case the effect of expansion or shrinkage of concrete shall be considered as it will result of several bars of constraint.
22
In practice the distance between the expansion joint shall not exceed the following value : F.1.3 30m for pipe rack cast in place 40m for precast pipe rack
Concrete Portal - With Steel Tie Beams (Similar method as entirely metal).
F.2
ANCHORING - FRICTION - GUIDE OF PIPES Expansion of hot line pipings create force on their support : Friction : movement of lines on their support. Anchorage : Prevent displacement of lines in two directions (anchoring) Prevent displacement of lines in one direction (guide)
Important note : The vertical load combination for calculating the thermal forces are :Dead loads + Operating load : : Pipes dead weight Pipes insulation weight Weight of liquids in pipes
This combination will be considered for operating condition. F.2.1 Consideration of Thermal Forces a) For intermediate support. Anchoring : Friction : Intermediate cross anchored, Fa = 0. beam will not be
The horizontal force due to longitudinal movement of the pipes will be considered as follows :Ff Ff p = : = 0.1 x p Force developed at the intermediate sliding support. Vertical load at the intermediate sliding support (operating condition)
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The force Ff shall be applied on the top flange of the intermediate cross beam with the following assumptions :Only the inertia of the top flange will be taken for determination of the horizontal bending stress. The bending stress in the vertical plane is negligible because of the lateral support provide by the friction lines.
b) On the main cross beam Friction (Ff = friction force) Horizontal force due to pipe movement on the sliding support shall be determined as follows : Ff = Ff = = xpx horizontal force acting on main support and which development deflection on the horizontal member. coefficient of friction between pipes shoes and cross beam. = = = 0.4 (steel on steel) 0.05 to 0.1 (for teflon or similar)
Coefficient depend on the percentage of pipes on the cross beam with temperature more than 150C. 0 41 61 81 % to to to to 40 60 80 100 0.4 0.6 0.8 1
p -
Vertical load acting on main support (operating condition)
Anchor (Fa = anchoring force) The anchoring forces of pipings on the main cross beam shall be provided by piping discipline. In practice, the calculation from piping disciplines is not available during the pipe rack design, therefore the design of pipe rack elements are base on the estimate value. When the calculations from piping disciplines is available, a final checks shall be performed especially for cross beam.
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The anchoring force always act on the top flange of the cross beam, the design of main cross beam is identical to the previous intermediate cross beam.
IMPORTANT NOTE The forces given by piping disciplines are generally large (temperature used for calculation > operating temperature) Therefore, partial safety factor used for load shall be taken as 1.
c) On portal (transversal force) Horizontal piping forces shall be applied at the main transversal support levels. The following factors shall be applied to determine the transversal forces : Pipe rack off-site Ft = Ft = Ft = 0.1 x p : 0.05 x p : 0 : 1st layer 2nd layer other layers Ft Ft
Ft = p =
Transversal horizontal load Vertical load on the support (operating condition)
Site Pipe rack Ft Ft Ft Ft = = = = 0.15 x p 0.1 x p 0.05 x p 0 1st layer (bottom) 2nd layer 3rd layer others layers the previous
After reception the actual forces, assumption shall be verified.
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d) On portal (longitudinal forces) Horizontal anchorage and friction forces developed on the main cross beam shall be applied horizontally at the junction to the column for designing the column itself
e) On stability bay (longitudinal action) The longitudinal force on pipe rack restrain is the sum of various horizontal forces acting between two expansion joint of pipe rack. Anchor Anchoring force to be applied on the pipe rack restrain is the sum of various anchoring forces on the main cross beam. Friction The total friction force applied on the pipe rack restrain is the sum of various forces on the main cross beam. Horizontal force acting on pipe rack restrain depend on :Location of pipe rack restrain. Number of anchor point for the length of the pipe rack concerned.
Examples :FF Case 1 Stability bay located at the end of piperack. FA Case 2 FF FA FF FA
FF RN 0
FF = 0
Stability bay located at the middle of piperack FF FF
Case 3
FF 0
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As shown in the example, it is difficult to generalise a method to determine the total friction force on the piperack. The value of the anchoring force will reach it maximum when the displacement due to temperature effect has stopped. This mean the combination force of anchoring and friction is only happen during early stage. Conclusion : In the operating condition, the anchoring and friction force will not be added for determination of overall forces on the piperack restrain. Horizontal force due to friction shall be : Ff = where xpx = = friction factor (sliding / traverse) (0.05 < < 0.4) coefficient depends on number of lines with temperature more than 150C (refer item F.2.1 (b) ). vertical load acting on the concern member.
p f) Summary -
For intermediate cross beam (longitudinal action) Anchoring : 0 Friction : 0.1 x p = Ff
For main cross beam (longitudinal action) Anchoring : Estimate calculation for piping design + Verification Friction : pxx
Ff
For portal (transversal action) Lateral Anchoring (rack off-site) = Ft = = 0.1 x 0.05 x 0 x p p p 1st layer (bottom) 2nd layer other layer
Lateral Anchoring (Site Rack) = = Ft = = 0.15 0.1 0.05 0 x x x x p p p p 1st layer (bottom) 2nd layer 3rd layer other layer
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For stability bay (longitudinal action) Anchor Friction : sums of all anchoring forces on main support. : Ff = x p x
Never add anchor and friction force. G OTHER LOADS This document provides the necessary guide for calculation and design of elements in the piperacks for supporting the pipes. However, by extension a piperack can support : hoisting and handling equipment cooler boiler
During the progress of the calculation of piperack, the forces due to this equipment shall be considered in the various load cases : Dead loads Live (operating) loads Climatic loads
It is should be noted that the possible dynamic loads by these equipments shall never be combined with climatic loads. H H.1 LOAD COMBINATIONS THE VARIOUS ELEMENTARY CASES Dead loads : Dead weight for : members walkways pipes P insulation fire proofing (operating load only) liquid loads live (passage) loads
Thermal loads structure expansion anchorage load longitudinal friction loads D A F
Service climatic load transverse wind load longitudinal wind load Vt Vl
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Seismic load Ultimate climatic load transverse wind load longitudinal wind load
Wt Wl
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LOAD COMBINATIONS COMBINATION FOR LOAD ON FOUNDATION P + Vt P + Vl P + Wt P + Wl P+S P + G + A + Vt P + G + A + Vl P+G+F P + G + A + Wt P + G + A + Wl P+G+A+S LOAD COMBINATIONS STEEL STRUCTURE 1.33 P + 1.5 Vt 1.33 P + 1.5 Vl P + Wt P + Wl P+S 1.33 P + 1.5 G + A + 1.5 Vt 1.33 P + 1.5 G + A + 1.5 Vl 1.33 P + 1.5 G + 1.5 F P + G + A + Wt P + G + A + Wl P+G+A+S FOR LOAD COMBINATION FOR CONCRETE STRUCTURE P + Vt P + Vl P + Wt P + Wl P+S P + G + A + Vt P + G + A + Vl P + 1.2 G + 1.2 F P + 1.5 G + A + 1.5 Vt P + G + A + Wt P + 1.5 G + A + 1.5 Vl P + G + A + Wl P+G+A+S COMBINATION NO. 1 2 3 4 5 6 7 8 9 10 11
CASE
NORMAL CASE
EXTREME CASE
SEISMIC
SERVICE NORMAL CASE
EXTREME SERVICE CASE SEISMIC
Note : Loading case (D : Structural expansion), any other possible cases shall be added to the combinations.
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J J.1
CONDITIONS OF DEFLECTION ACCEPTABLES VERTICAL DEFLECTION J.1.1 Steel Piperack Main Cross Beam The deflection of these beams due to total Service load shall not exceed 1/400 of the length. Intermediate Cross Beams + Longitudinal Beams The total deflection (intermediate cross beam + tie beam) under total loads in the service case shall not exceed 1/200 of the intermediate cross beam. Note : The deflection given above shall be reduced (information given by piping discipline) when allowable pipe deflection is lower. J.1.2 Concrete Piperack (Where The Intermediate Cross Beam Is Steel) Intermediate Cross Beam The deflection o these beams due to total Service load shall not exceed 1/300 of the length. Others elements Checking of deflection for beam with L/H < 15 normally is not necessary.
J.2
ACCEPTABLE HORIZONTAL DISPLACEMENT ON THE PORTAL FRAME J.2.1 Steel Portal Frame Horizontal displacement due to normal service wind load shall not exceed :J.2.2 1/150 e height of piperack if it is not supporting equipment. 1/200 e height of the piperack if it is supporting equipment (air cooler)
Concrete Portal Frame Due to rigidity of the concrete, a verification of horizontal displacement in piperack is not necessary. (Normal density at reinforcement 150 kg / m of concrete and density of concrete 350 kg / m)
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Note : It should be noted that the uncertainly of the concrete deformation due to development and formation of cracking only give unprecise value of displacement. 4.0 A A.1 STEEL PIPERACK CONSTRUCTION ARRANGEMENT INTERMEDIATE CROSS BEAM Normally the profile of intermediate cross beam is IPE type. When the percentage of hot lines is high, it is better to use the profile HEA type which provide better inertia in the horizontal direction (friction). A.1.1 Arrangement Detail CONNECTION INTERMEDIATE CROSS BEAM 1
POST CONNECTION
LONGITUDINAL BEAM
Connection 1 : This type of connection shall not transmit shearing force to the base of post which produce torsion to the cross beam. Connection 2 : The connection shall be able to ensure the stability of the post due to friction load on the intermediate cross beam. The connection is considered partially restraint the horizontal forces from intermediate cross beam.
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In practice, the connection are shown below :Connection 1 POSSIBLE OVERHANG
POST
Connection 2 GUSSET IF NECESSARY
POSSIBILITY
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A.1.2
Other Provisions Intermediate cross beam and members at the same level
TIE BEAM INTERMEDIATE CROSS BEAM
Intermediate cross beam on longitudinal beams
POSSIBLE OVERHANG INTERMEDIATE CROSS BEAM
TIE BEAM
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A.2
LONGITUDINAL BEAM A.2.1 Member Between Spacing The tie beam profile type IPE is connected to the column by pin joint connection using double cleat. A.2.2 Spacing > 9 m The beams shall be make to form lattice. Height of the lattice 1/15 < h < 1/10 of the spacing
~ 15 H
Elevation For lattice members, they shall be checked for horizontal buckling (lateral restrain). A.2.3 Spacing > 12 m (For low weight pipe layer). The tie beam can be supported by stay wire and braced horizontally.
Stay Wire For example :
35
A.3
PORTAL FRAME
STIFFNER
BRACING
The column are always profile type H to ensure maximum radius of gyration for good buckling strength. Transverse members generally not made from profile type H, but made from profile type IPE. The stability of the tranverse portal frame can be ensured by :Stiffners bracing members
36
A.4
POST FOUNDATION CONNECTION For a continuous piperack, the connection of column to foundation in longitudinal direction to the piperack will be pin-jointed type. However the connection of column to foundation in the axis of portal can be pin-jointed or fixed type. A.4.1 Pin Type. Advantage : no moment transfer small size foundation two bolts of average diameter thin plate without gusset simple connection (see STC.00.18.10.009)
Disadvantages A.4.2 bigger size of the columns and cross beams compared to fixed type connection. significant horizontal displacement (see STC.00.18.10.014)
Fixed type Advantages : -
smaller dimension of the columns and cross beams compared to pin type connection reduce horizontal displacement
Disadvantages : large foundation lot of bolts massive connection thick base plate and stiffners
Synthesis The adopted solution will be selected according to technical data (ground characteristic, etc.) and economic (cost of material, nature of contract) by considering the structure (portal + bolt + foundation).
37
A.5
STABILITY BAY A.5.1 Purpose To ensure longitudinal stability of the piperack members due to various horizontal load. The sections of piperack are separated by methods (oblong holes, corbels) of preventing transmission of horizontal load from one section to another. The length of the section is limited to 60m for the French climate for negligible effect of thermal expansion. A.5.2 Choice of Section The choice of isolation location shall be done according to certain criteria:change in geometric of the piperack (number of levels or width) junction of two perpendicular piperack. As for as possible, the isolation should not be located, between the principal anchoring of the pipe layer so that the horizontal force apply to the cross member of stability is small. INCORRECT POSITION OF ISOLATION
CORRECT POSITION OF THE ISOLATION FOR THE SECTION ANCHORING PRINCIPAL
An isolation shall be checked for connection of piperack with structures except in the case where the structure ensure the stability of the unit.
38
A.5.3
Position of Bracing The distance between two bracing stability does not exceed 60m (for French climate). The position in the medium of the section is most usually used. For piperack with limited bay, the position of stability bracing shall be located at end bay so that the anchoring load do not have to be transmitted from anchoring point at the end of piperack to the stability bracing by tie beam. The choice of the position can also depend on obstruction on the ground (road passage, pumps etc.)
A.5.4
Principle Two general principal are :a) Bracing stability bay Advantages : Less weight of the structure
Negligible displacement at top which is in agreement with the theory for piping calculation (zero displacement) Disadvantages Obstruction on the ground
MAIN BRACING
PRINCIPLE
39
b)
Portal Stability Bay Advantages : No obstruction
Disadvantages : Bigger weight of structure Top portion displacement is significant
STIFFNER
PROFILE COMBINATION
Important Note : Attention with uplift for the calculation of the anchor bolt for the stability bay. In the calculation for this type of stability bay add a horizontal load at the level of cross beam equal to 1/100 of the sum of vertical load acting on this part.
40
A.6
PARTICULAR CASE Strengthening the main cross beam at the anchoring point. Principal Increase the Iy inertial of the main cross beam or provide additional support.
INCREASE Iy
ANCHOR
ADDITIONAL SUPPORT
WELDED
HORIZONTAL BRACING
MAIN CROSS BEAM
MINI ANCHOR LINE
IPE BONDS TO CROSS BEAM PRINCIPLE BY REINFORCEMENT (PROVIDE DRAINAGE)
TO BE PROSCRIBE FOR FIREPROOF CROSS BEAM
41
5.0
CONCRETE PIPERACK A. VARIOUS SHAPES (See Sketch Page 49 to 51) The concrete piperacks are generally comprises of concrete main frame. The frame is connected by concrete or steel tie beams. Their standard width are 3m ; 4.5m ; 6m ; 7.5m ; 9m. They comprise of 1, 2 or 3 stages according to the number of pipe layers to be supported. The cooler also can be supported with or without platform. When the width of the piperack is less than 3m, normally only one column is required at the centre.
42
43
RACK WIDTH L 4500 6000 7500 7500 7500 9000 9000
DISTANCE BETWEEN PORTAL 6000 6000 6000 7500 9000 7500 9000
COLUMN 400 x 400 400 x 400 400 x 400 400 x 400 500 x 400 500 x 400 500 x 400
CROSS BEAM 400 x 300 400 x 300 500 x 300 500 x 300 500 x 300 600 x 300 600 x 300
TIE BEAM 400 x 300 400 x 300 400 x 300 500 x 300 600 x 300 500 x 300 600 x 300
PREDIMENSION PIPE RACK 1 LEVEL VALID FOR PIPES AVERAGE 12"
44
VARIOUS METHODS OF EXECUTION B.1 CAST IN-SITU RACK All the piperack members are casted at place. No prefabricated member is used. B.2 SEMI PREFABRICATION RACK The footings and posts are cast in placed. The horizontal beams (longitudinal beams, cross beams, tie beams) are prefabricated. B.3 PREFABRICATED RACK The footing is cast in place or prefabricated. The columns and beam (longitudinal beam, cross beam, tie beams) are prefabricated. Otherwise, all the members of main frame is prefabricated. B.4 CHOICE OF METHOD OF EXECUTION The choice depend on 3 criteria : size of piperack the size of the work which is the most important consideration site and weather condition for economic
In fact, it is impossible to impose a priority to the Subcontractor due to following reasons : Perhaps the selected Subcontractor does not have necessary material for prefabrication. The local agent of the subcontractor does not want to construct the rack as method prerecognise by TECHNIP. If the subcontractor is requested to follow the TECHNIP prerecognise method, the subcontractor will always try to find ways for change order. Generally, the subcontractor under estimate the priority of the execution of concrete racks, they will wait at the last minute to look at the drawings. However, TECHNIP shall advice the subcontractor during invitation to tender. It should not be believed that prefabrication reduce the cost of the rack appreciably but it can save a lot of time. In the actual construction, the prefabrication is very employee because same section always kept, so TECHNIP shall make the prefabricated element similar option through out the piperack.
45
C. C.1
ANALYSIS AND DESIGN ANALYSIS C.1.1 Purpose The preliminary study of concrete piperack is to pre dimension the size of the beams and columns for piping section to detail their drawings. This predimension shall be made so as to reduce the maximum the divensite squarrings to facilitate the prefabrication. C.1.2 Method With referring to the general arrangement drawings, list out the data (average of pipes, elevation of cross beam, longitudinal beam etc. Using the tables of predimension below, determine the various sections. With all these data, establish the preliminary piperack drawing. Determination of position of anchoring bay with the position of longitudinal beam.
Note :
If possible, the dimension of the footing is carried out during the calculation for reinforcement. It is necessary to indicate the bottom level of foundation and dimension, for presence of other foundation, pipe & etc. The table of predimensions are valid for normal case, however the designer need to check it.
46
RACK WIDTH L 4500 6000 7500 7500 7500 9000 9000
COLUMN 400 x 400 400 x 400 400 x 400 400 x 400 500 x 400 500 x 400 500 x 400
TIE BEAM 400 x 300 400 x 300 400 x 300 500 x 300 600 x 300 500 x 300 600 x 300
PREDIMENSION PIPE RACK 1 LEVEL VALID FOR PIPES AVERAGE 12"
47
RACK WIDTH L 4500 6000 7500 7500 7500 9000 9000
COLUMN 400 x 400 400 x 400 500 x 400 500 x 400 600 x 400 600 x 400 600 x 400
TIE BEAM 400 x 300 400 x 300 400 x 300 500 x 300 600 x 300 500 x 300 600 x 300
PREDIMENSION PIPE RACK 2 LAYERS VALID FOR PIPES AVERAGE 12"
48
RACK WIDTH L 7500 7500 7500 9000 9000
DISTANCE BETWEEN PORTAL 6000 7500 9000 7500 9000
COLUMN 700 x 500 700 x 500 800 x 500 800 x 500 800 x 500
CROSS BEAM 700 x 400 700 x 400 800 x 400 800 x 400 800 x 400
TIE BEAM UPPER 700 x 400 700 x 400 800 x 400 800 x 400 800 x 400 LOWER 400 x 300 500 x 300 600 x 300 500 x 300 600 x 300
PREDIMENSION PIPE RACK 1 LEVEL + AEROS VALID FOR PIPES AVERAGE 12"
49
RACK WIDTH L 7500 7500 7500 9000 9000
COLUMN 700 x 500 700 x 500 800 x 500 800 x 500 800 x 500
CROSS BEAM 600 x 300 600 x 300 700 x 400 700 x 400 700 x 400
50
RACK WIDTH L 7500 7500 7500 9000 9000
COLUMN 700 x 500 700 x 500 800 x 500 800 x 500 800 x 500
CROSS BEAM 600 x 300 600 x 300 700 x 400 700 x 400 700 x 400
51
C.2.
DESIGN C.2.1 Purpose The calculation of concrete piperacks is to establish the data of loads acting on the piperack in order for the calculation of reinforcement in order to obtain the quantity of concrete, reinforcement and formwork for costing. C.2.2 Checking The Reinforcement The amount of reinforcement in the member shall not exceed 150 kg/m of the concrete. The size of the section shall be increase if the amount of reinforcement is high.
D. D.1
CONSTRUCTION DETAILING REINFORCEMENT In order to facilitate the execution of piperack at site, the reinforcement of all the elements shall be detail as follows : D.1.1 Column See sketch below. Steel for the columns are similar except for the diameter (range between 12 and 25).
12 to 25
90 45 400
45 90
COLUMN 400 x 400 REINFORCEMENT DETAIL 52
130
COLUMN 400 X 600 REINFORCEMENT DETAIL
53
54
D.1.2
Beam (Main Cross Beam or Tie Beam) The position of reinforcement at the support of the tie beam can be moved to allow for insert plate. It is necessary to inform the subcontractor that the prefabricated member shall be marked accordingly as per plan of assembly in order to prevent discrepancies during installation.
55
D.2.
FIXATION OF AIR COOLER The air coolers are installed on piperack in four different ways, i.e.: D.2.1 Cooler Directly Install on Tie Beams
D.2.2
Post of Cooler Rest on Tie Beams
56
D.2.3
The Feet of Cooler on Overhang Beam Supported on Tie-Beam
D.2.4
Feet of Cooler on Slab Supported by Tie-Beam
57
D.3
ACCESSORIES Accessories are required for fixing of small frames, piping slide, installation of electric elements. The accessories are base plate, posts, sleeves, rails. See diagram below :-
58
D.3.1
Base Plate or Insert Plates Base plate or insert plates are used for fixing (particularly the post) the secondary steel frames for supporting pipings, walkways etc.
D.3.2
Flat Plate on Cross Beam and Tie-beam It is needed for allowing slip of pipings and fixing of anchor on the cross beams or tie-beams. The flat plates are generally 150 mm wide x 10 mm thick. Flat plate must be provided on the cross beams and fix to the concrete by steel 8. Flat plates only be provided on tie-beam when required or when there is piping. Dimension could be as shown below :FLAT PLATE 150 x 10
50 4 x 8 per metre
50
150
10
120
50
Special steel-concrete adhesive can be used if the plats have not be installed during casting of concrete.
59
8 welded
These special adhesives are produce by companies such as :BOSTIK or SIKA
The products are constantly upgraded or revise, therefore the manufacturer shall be contacted for the latest product suitable for the specific condition. D.3.3 Sleeves The sleeves are made of plastic. As a guide the following are some of the brand :ARMOSIG : Elysee 2 - 78170 LA CELLE SAINT CLOUD B.P. n 2
SEPEREF - TMP - Z.I. QUINCIEUX - 69650 SAINT GERMAIN AU MONT D OR B.P. n 1
Generally, the diameter sleeves are 22.6 or 25 mm. D.3.4 Rails They are embedded in the concrete during casting. It exist in various types and manufacturers as listed below :Rails HALFEN distributed by : Societe SODIMETAL S.A. Immeuble Evolution 18, Rue Goubet 75940 PARIS Cedex 19 Tel. 200.67.01 Rails JORDHAL distributed by : ACIBAT Z.I. 68190 UNGERSHEIM Tel. (89) 48.13.03 Rails TRIMBORN distributed by : TECNER 25, Rue Trebois 92300 LEVALLOIS-PERRET It comes with various coating such as black, galvanised, paint, polymer, stainless steel. dimensions produced by many
60
As an indication, a profile 50/30, the basic load is 4.5 ton/meter length with 4 bolts 20. D.3.5 Conclusion The accessories increase the cost of the concrete piperack, therefore it shall be reduced to minimum. It is obvious that the use of anchoring rail will make it easy to fix apparatus or secondary frame. However as it is very costly, it shall not be their installed especially for turnkey contract. In the service contract, they only be used when requested by client. The used of plastic sleeves shall be maximise as it is rather cheap. The used of plats on the cross beam are compulsory. The plats on tie-beam are optional. The need is decided after studing the general drawings. The plats are anchor to the concrete, if they are install before casting of concrete or adhesive by special product. The adhesive cannot be used for slide (anchoring of lines).
61

Piperack Guide

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Piperack Guide

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CONTENTS 1.0 GENERAL A - TERMINOLOGY A.1. A.2.

B DEFINITION CRITERIA B.1. B.2. 2.0 Rack Width Number of tiers

MATERIAL SELECTION A MATERIAL USED B SELECTION CRITERIA

D CLIMATIC LOAD D.1. D.2. Snow Wind

G OTHER LOADS H COMBINATION OF LOADS H.1. Combination of Various Elementary Cases

C STUDIES AND CALCULATIONS C.1. C.2. Studies Calculations

D CONSTRUCTION ARRANGEMENT D.1. D.2. D.3. Reinforcement Fixation of Cooler Accessories

Piperack comprises of two parts :Steel or concrete structure. Concrete foundation.

INTERMEDIATE CROSS BEAM PIPE LAYER LEVEL LONGITUDINAL BEAM

COLUMN PORTAL FRAME MAIN CROSS BEAM

Longitudinal beam rested on the footing.

Longitudinal beam semi-incorporated with the footing.

D - CLIMATIC LOAD D.1. D.2. Snow Wind

G - OTHER LOADS H - LOAD COMBINATIONS H.1. Example of various elementary cases.

EXTERNAL DIAMETER (mm)

DEAD WEIGHT OF PIPES (kg)

Per m2 40 70 80 110 120 140 150

REFERENCE PIPE DIAMETER

3 - 4 6 8 10 - 12 ZONE A ZONE B Note B. :

< 2 2 <3 3 < 4 4 < 6 > 6 : :

0.5 0.5 0.5 0.4 0.3 0.3

To be confirmed by piping discipline

B.1.3 NOMINAL DIAMETER 2 3 4 6 8 10 12 B.2

Average pipe load (Dead Load + Operating Load)

Vertical load on support is proportional to the width of concerned area.

= L1 x 0.1 = 7.5 x 0.1 = 0.75 m = L2 x 0.2 = 9 x 0.2 = 1.8 m = =

For load distribution coefficient refer to A.3.3

Other cases Similar calculation as above.

Uniform distributed load + Point load

Column surface for calculation of H1 H1 2.75

Column surface for calculation of H1 and H2.

= Width of piping layer

0.05 Bottom layer 0.05 Values of B

Vertical load acting on main support (operating condition)

Transversal horizontal load Vertical load on the support (operating condition)

After reception the actual forces, assumption shall be verified.

For intermediate cross beam (longitudinal action) Anchoring : 0 Friction : 0.1 x p = Ff

Thermal loads structure expansion anchorage load longitudinal friction loads D A F

Service climatic load transverse wind load longitudinal wind load Vt Vl

SERVICE NORMAL CASE

EXTREME SERVICE CASE SEISMIC

In practice, the connection are shown below :Connection 1 POSSIBLE OVERHANG

Connection 2 GUSSET IF NECESSARY

TIE BEAM INTERMEDIATE CROSS BEAM

Intermediate cross beam on longitudinal beams

POSSIBLE OVERHANG INTERMEDIATE CROSS BEAM

Stay Wire For example :

Fixed type Advantages : -

CORRECT POSITION OF THE ISOLATION FOR THE SECTION ANCHORING PRINCIPAL

Portal Stability Bay Advantages : No obstruction

Disadvantages : Bigger weight of structure Top portion displacement is significant

MAIN CROSS BEAM

MINI ANCHOR LINE

IPE BONDS TO CROSS BEAM PRINCIPLE BY REINFORCEMENT (PROVIDE DRAINAGE)

TO BE PROSCRIBE FOR FIREPROOF CROSS BEAM

RACK WIDTH L 4500 6000 7500 7500 7500 9000 9000

PREDIMENSION PIPE RACK 1 LEVEL VALID FOR PIPES AVERAGE 12"

RACK WIDTH L 4500 6000 7500 7500 7500 9000 9000

PREDIMENSION PIPE RACK 1 LEVEL VALID FOR PIPES AVERAGE 12"

RACK WIDTH L 4500 6000 7500 7500 7500 9000 9000

PREDIMENSION PIPE RACK 2 LAYERS VALID FOR PIPES AVERAGE 12"

RACK WIDTH L 7500 7500 7500 9000 9000

DISTANCE BETWEEN PORTAL 6000 7500 9000 7500 9000

RACK WIDTH L 7500 7500 7500 9000 9000