Pipe rack Design Philosophy

(Non-conventional Pipe rack)

In this page I will talk about the Non-continuous piperack system. I hope you have read the
Conventional pipe rack system design philosophy. If not, please read that section before.
Non- Continuous Pipe rack:
This is a system comprised of independent cantilevered, freestanding 2D frames not dependent
on longitudinal beam struts for system stability. This system, where feasible, should result in
lower total installed cost (TIC).
Step-1: Data collection for pipe rack design:
Method of Data collections is same as continuous pipe rack. Please look into 3D model and
collect all the data as required.
Step-2: Design loads consideration:
Following loads are to be considered for the non-conventional pipe rack design:
Gravity load (D): For Gravity load calculation, refer Conventional pipe rack system
Wind Load (W): For Wind load calculation, refer Conventional pipe rack system,
Earthquake Loads (E): For Earth quake load calculation, refer Conventional pipe rack system.
Longitudinal seismic will be applied on anchor bay only.
Friction Loading (Tf): Friction forces caused by hot lines sliding across the pipe support during
startup and shutdown do not apply on individual frame, as frame will deflect along the pipe
direction. Therefore, this force will be considered on anchor bay only.
Anchor and Guide Loads (Ta): For Anchor and Guide load calculation, refer Conventional pipe
rack system,
Step - 3: Load Combinations and allowable deflection of pipe rack:

For Load combinations and allowable deflection of non-conventional pipe rack, refer
Conventional pipe rack system,

Step - 4: Frames of non-conventional pipe rack:

Pipe rack Design Philosophy

(Modular Pipe rack)
In this page I will talk about the Modular piperack system. I hope you have read the
Conventional pipe rack system design philosophy. If not, please read that section before.
Modular Pipe rack
Sometimes clients look for modular pieprack / modular structure for their plants. But do you
know what is a module? Module is a series of standard units that function together. Examples
are:
Building modules: Structural Frames completely fitted with Miscllaneous equipment and
architectural finishes.
Piperack Module: Structural Frames completely fitted with pipes, Cable trays and miscellaneous
equipment.
Now the question is , why do we go for modular structure sometimes? Here are some reasons:

If the project site is at remote location, then it will be very difficult to get good local
contractor.

Parallel construction activities are possible (foundation and module fabrication) and gain
in time schedule

Controlled construction environment is possible

Controlled quality controlled

In some countries, labour cost at site is more than labour cost at fabrication / module
assembly shop. So, if you fabricate and fit all the pipes , cable trays etc. at shop, then you
can save the project cost.

However, there are some disadvantages also and these are:

Late changes in design has huge effect on structure and module assembly.

Transportation cost from module shop to site may be very high.

Transportation time needs to be considered in total project schedule.

Pipe-rack Module Transportation: Module can be transported by roadways and waterways. I

have some experiences in roadways piperack module transportation. In Alberta province
(Canada) 100 ft (long) x 24 ft (wide) x 29ft-6 in (high from road surface) PRM can be
transported by truck from module yard to site. Please click here for different module shipping
envelope.
Pipe-rack Module Lifting: 4 point lifts are preferred and 8 point lifts are second preference. 6 and
10 point lifting are difficult and should be avoided. 4 point lifts reduce rigging cost and
associated man-power during setting. 4 point lifts result higher crane capacity and safer lifts due
to shorter boom requirements. Regardless of the length, typical self supporting bridge truss style
pipe rack modules use 4 lift points located at the top of the modules columns in the webs. By
lifting at the same location that the module is supported in-situ, the force distribution throughout
the module
is similar to the in-situ design, except that the module columns are in compression in-stu and
reversed to tension during a lift. Please click here for 4-point module lifting.
Following are some steps to design the Modular pipe rack:
Step-1: Data collection for pipe rack design:
Method of Data collections is same as Conventional pipe rack system. Please look into 3D model
and collect all the data as required.
Step-2: Design loads consideration:
Following loads are to be considered for the non-conventional pipe rack design:
Gravity load (D): For Gravity load calculation, refer Conventional pipe rack system
Wind Load (W): For Wind load calculation, refer Conventional pipe rack system,
Earthquake Loads (E): For Earth quake load calculation, refer Conventional pipe rack system.
Friction Loading (Tf): For Friction load calculation, refer Conventional pipe rack system.
Anchor and Guide Loads (Ta): For Anchor and Guide load calculation, refer Conventional pipe
rack system,
Transportation loads: When pipe-rack modules are transported on the road, different types of
horizontal loads are generated. During up-hill or down-hill movement of the truck , we generally
considered a horizontal load of value 30% of total load (o.30 x dead weight) acts towards the

longitudinal direction of the module. During a truck turn or due to superelevation of the road, a
horizontal load is also generated (centrfugal force) and value of that load is also 0.30 x weight of
module (30% of total dead load) acting transverse direction of modules. But both the horizontal
loads (longitudinal and transverse direction) do not act together. Other than these horizontal
loads, we also consider wind load and vertical impact load.
Summary of transportation load:

Vertical Impact Load (IV) 50% of (self weight of structure + Empty weight of pipe +
Cable tray)

Horizontal Impact in Longitudinal direction (IL) 30% of (self weight of structure +

Empty weight of pipe + Cable tray)

Horizontal Impact in Transverse direction (IT) 30% of (self weight of structure +

Empty weight of pipe + Cable tray)

Wind load (WLT) Wind load is applied on pipe rack module structure, pipe and cable
tray, in Transverse direction.

You need to check the Factor of safety againgst overturning during transportation and value
should be more than 1.5.
Erection loads and lifting points: In this case we generally consider a vertical impact load (load
factor = 1.5) on module.
Step - 3: Load Combinations and allowable deflection of pipe rack:
For Load combinations and allowable deflection of Modular pipe rack for in-situ analysis and
design, refer Conventional pipe rack system,
Modular pipe rack to be analysed for transportation and for lifting also.
Lifting load combinations: LC1 = 2.0 x Total dead load (ultimate load combinations for member
design per Canadian steel code CISC / NBC -95)
Transportation load combinations (ultimate load combinations per CISC-Canadian steel code /
NBC -95 for member design)):
LC1:
LC2:
LC3:
LC4:
LC5:

1.25 x Dead load + 1.5 x IV + 1.5 x IL

1.25 x Dead load + 1.5 x IV + 1.5 x IT
1.25 x Dead load + 1.5 x IV + 1.5 x Wind
1.25 x Dead load + 1.05 x IV + 1.05 x IT + 1.05 x Wind
1.25 x Dead load + 1.05 x IV + 1.05 x IL + 1.05 x Wind

Above load combinations are for reference only. You need to follow your project design

criteria for the pipe-rack analysis and design.

Step - 4: Frames of Modularl pipe rack: