PIPE RACK

Introduction
Piperck is the main artery of the plant connecting all equipments/ units with lines.
Normally it is erected first on before the rows of equipment becomes an
obstruction for it. Piperack carry process lines, utility lines, cables trays, air
coolers.
Attachment :- a Typical overall plot plan & Cross sectional view of a piperack.

Setting Configuration for a pipe rack

The routing is first established based on the P&ID. Due consideration should also
be taken from Plot plan, client specification, plant layout specification,
fireproofing requirement, construction material.
Extablish the width of the rack: - no of lines (dia of pipe, bent spacing, flange
requiements, additional / future requirements as specified by client / FEED
package).
Length / Module of Rack: - The constrains for establishing the length could be
expansion joints, air cooler extent, pipe loops requiments, transportation, braced /
anchor bay foundation sizing and bracing sizing.

Structural framework
It is ideal to provided elevation Bracing in both direction Transverse &
Longitudinal direction. However this is not always possible due to piping
requiements like access way (sometime forklift movement), pumps located at
below at grade level. The various options of a structural arrangement could be
1. moment resisting framework in the transverse direction
2. Partial moment resisting frame (below first tier). This is possible when
there are two bays in the transverse direction.
Longitudinal tie beams to be at 125mm below Pipe tier TOS. This is a piping
requirement for line stop plates etc.
Atachement:- cross section of piperack showing structural framework
arrangement. Module of piperack, bracing arrangement

Material of construction

1. Superstructure: - Structural steel or Concrete. Structural steel is preferred

for quick erection, more flexibility in wake of more changes from
upstream department. Various grades of steel S275 or in kashagan
S355NL). NL is a special requirement due to climatic conditions in
Kazakhstan normalization of stress (residual during manufacturing)
2. Structural bolts: - Grade 8.8 BS3692 Grade 8.8
3. Anchor bolts:- ASTM A572 Grade 50
4. Foundation Open / Pile foundation. Geotechnical report: - frost depth
requiements, ground water table

Pipe rack loading

Dead Load of the structure (Self weight of structure)

Live loads on platforms air cooler level

Cable loads

Air cooler loads

Piping load (Pipe Empty / Pipe operating / Pipe Hydrotest)

Thumb rule / approx weights(PE + PO):
Utility Racks

150 ~ 250 kg/m

Unit Rack Process Rack

300 ~350 kg/m

Main interconnecting Process rack

300~400 kg/m

Kasghan Value(min): PE = 1 kN/m; PO = 2 kN/m. (PH was

taken same as PO)
Harweel (min Loading): - PE =- 1kN/m; PO = 0.7kN/m; PH =
1.1 kN/m

Fire proof loading: - Depends upon the proximity of the

rack to hazardous equipments. Fireproofing requirement of a rack
can be understood from fireproof layout drawing. Concrete
encasing materials like fendolite are used. In case of beams
supporting pipes the top flange is not fire proofed.

Horizontal pipe forces

Piping Caesar analysis. Caesar output is input for civil. Reference
to be made to the a typical pipe layout drawing showing pipe loops
and anchor points. Anchor points, friction forces, guides forces
location in the pipe. Longitudinal anchor forces are the reaction to
the long friction forces. Anchor forces to be transferred to the
foundation.
Pipe friction forces: - Why there is a frictional force generated ?
In general coeff of friction pipe to structure is 30% but this is for a
single pipe analysis. In case of rack tier there are many pipes all of
then will not be expanding / Contracting together in the same
direction. So to consider 30% of the total pipe vertical load for
friction will be unconservative. Hence a lower value is normally
adopted Kashagan 7.5% (PE + PO)
Harweel : - 15%.
These forces are not transferred to the foundation and it shall be
resisted by the top flange of the beam for horizontal bending.
Pipe Anchor Longitudinal: - Location of anchor points to be
decided by piping they may or may be at the proposed braced bay.
Normally UC sections are used at these location due to high
horizontal forces. These forces are transferred to the foundation
like friction forces these forces too shall be resisted by the top
flange of the beam.
Each module of piperack must be designed for a minimum
horizontal anchor forces for eg 10kN/m udl on anchor bay beams
was considered in harweel.
Pipe anchor transverse : - Mainly are because of guides forces.
Location of a guide is normally adjacent to loops or pipe tapping /
branching. In case there is no guide force a 15% of vertical pipe

load is considered for this condition. These forces are transferred to

the foundation.
Temperature Forces: - climatic variation inducts temp stress in
the steel. Strain steel = adtL There by the axial forces in the
member needs to be calculated.
Sample temperature variation calculation done in kashagan
project.
Wind forces: Wind on structure, Pipe, cable trays, air coolers.
Wind of pipe explain as per harweel practice.
Seismic Load
Load Combination: - Structural Steel LRFD method Factors as
per BS5950 or concerned codes or even client specification
Sample display load combination for harweel / kashagan
Structure steel check (LRFD method). Good practice to maintain a section suitability /
replacability factor. That is to keep the stress ratio of 0.85.
Deflection checks