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PIPE RACK DESIGN GUIDELINES


www.sefindia.org Forum Index -> SEFI General Discussion View previous topic :: View next topic Author nestlejin
SEFI Member Posted: Tue Aug 31, 2010 2:37 pm

Message
Post subject: PIPE RACK DESIGN GUIDELINES

Dear all,
Joined: 16 Jul 2010 Posts: 15

Given web link is very usefull to understand pipe rack design http://www.civildesignhelp.info/pr.html

In this page I will talk about the pipe rack design philosophy. Pipe rack is the main artery of any plant. This carries the pipes and cable trays (raceways) from one equipment to another equipment within a process unit (called ISBL piperack) or carries the pipe and cable trays from one unit to another unit (called OSBL pipe rack). Some times you will also find the AIR COOLED HEAT EXCHANGERS on the pipe rack. There are different types of pipe rack:

Continuous Piperacks (conventional pipe rack) system Non-continuous Piperacks system Modular Pipe rack

Conventional / Continuous Pipe rack Continuous Piperacks (conventional pipe rack) system: This is essentially a system where multiple 2-dimensional (2D) frame assemblies (commonly called bents), comprised of two or more columns with transverse beams, are tied together in the longitudinal direction utilizing beam struts (for support of transverse pipe and raceway elements and for longitudinal stability of the system) and vertical bracing to form a 3D space frame arrangement. Piperacks supporting equipment such as air-cooled heat exchangers must utilize the continuous system approach. Step-1: Data collection for pipe rack design: Due to the fast track nature associated with most of the projects, often the final piping, raceway, and equipment information is not available at initiation of the piperack design. Therefore, as a Civil/Structural Engineer, you should coordinate with the Piping group, Electrical, Control Systems, and Mechanical groups to obtain as much preliminary information as possible. When received, all design information should be documented for future reference and verification. In the initial design, the Engineer should use judgement when applying or allowing for loads that are not known, justifying them in the design basis under "Design Philosophy" (a part of your calculation)

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The following should be reviewed for design information:

Plot plans and equipment location plans 3D model showing piping layout, cable tray layout, Piperack bent spacing and elevation of support levels in the transverse direction , Elevation of longitudinal beam struts and locations of vertical bracing. and location of pipe bridge, if any. Piping orthographic drawings. Vendor prints of equipment located on the rack, e.g., air coolers and exchangers.The vendor prints should include the equipment layout, mounting locations and details, access and maintenance requirements, and the magnitude and direction of loads being transmitted to the piperack. Electrical and control systems drawings showing the routing and location of electrical and instrumentation raceways and/or supports. Underground drawings that show the locations of buried pipes,concrete structures and foundations, duct banks, etc. in the area of the piperack. Pipe rack construction material (Steel, Cast-in-situ concrete, Pre-cast concrete) shall be as per project design criteria. Please note that, Unless specifically explained in the project design criteria, no allowance or provisions should be made for future additions for pipe or raceway space and related loading. Step-2: Design loads consideration: Following loads are to be considered for the pipe rack design: Piping Gravity load (D): In the absence of defined piping loads and locations, an assumed minimum uniform pipe load of 2.0 kPa should be used for preliminary design of piperacks. This corresponds to an equivalent load of 6 in (150 mm) lines full of water covered with 2 in (50 mm) thick insulation, and spaced on 12 in (300 mm) centers. This assumption should be verified based on coordination with the Piping Group, and concentrated loads should also be applied for any anticipated large pipes. When the actual loads and locations become known, as the project develops, the structural design should be checked against these assumed initial load parameters and revised as required. A concentrated load should then be added for pipes that are 12 in (300 mm) and larger in diameter. The concentrated load P should be: P =(W - s x p x d), s = Spacing of piperack bent, p = pipe weight considered (kPa), d = pipe diameter W = pipe concentrated load. Where consideration of uplift or system stability due to wind or seismic occurrences is required, use 60% of the design gravity loads as an "all pipes empty" load condition. Loading due to hydrostatic testing of lines should be considered in the design if applicable. Coordinate the testing plan(s) with Construction, Startup, and/or the Piping Group as necessary, in order to fully understand how such loads will be applied to the piperack structure. Under most normal conditions, multiple lines will not be simultaneously tested. The hydro-test loads do not normally need to be considered concurrently with the other non-permanent loads, such as live load, wind, earthquake, and thermal. Typical practice is to permit an overstress of 15% for the hydro-test condition. Because of these considerations, the hydro-test condition will not normally govern except for very large diameter pipes. Electrical Tray and Conduits (D): Electrical and control systems drawings and/or the project 3D model should be reviewed to determine the approximate weight and location of electrical trays, conduits, and instrumentation commodities. Unless the weight of the loaded raceways can be defined, an assumed minimum uniform load of 1.0 kPa should be used for single tier raceways. Self weight of Pipe rack (D): The weight of all structural members, including fireproofing, should be considered in the design of the piperack. Weight of Equipment on pipe rack (D): Equipment weights, including erection, empty, operating, and test (if the equipment is to be hydro-tested on the piperack), should be obtained from the vendor drawings.The equipment weight should include the dead weight of all associated platforms, ladders, and walkways, as applicable.Special Loads: Special consideration should be given to unusual loads, such aslarge valves, expansion loops, and unusual piping or electrical configurations.

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Live Load (L): Live load (L) on access platforms and walkways and on equipment platforms should be considered, as applicable. Snow Load (S): Snow load to be considered on cable tray and on large dia pipes. This load shall be calculated per project approved design code and project design criteria. Generally, you need to consider 100% snow load on top tier and 50% on other tier of pipe racks. Wind Load (W): Transverse wind load on structural members, piping, electrical trays,equipment, platforms, and ladders should be determined in accordance with project approved design code. Longitudinal wind should typically be applied to structural framing, cable tray vertical drop (if any), large dia pipes vertical drop (if any) and equipment only. The effects of longitudinal wind on piping and trays running parallel to the wind direction should be neglected. Earthquake Loads (E): Earthquake loads in the vertical, transverse, and longitudinal directions should bedetermined in accordance with the project design criteria. Vertical, transverse, and longitudinal seismic forces generated by the pipes, raceways, supported equipment, and the piperack structure should be considered and should be based on their operating weights. Pipes must be evaluated for seismic loads under both full and empty conditions and then combined with the corresponding gravity loads. Friction Loading (Tf): Friction forces caused by hot lines sliding across the pipe support during startup and shutdown are assumed to be partially resisted through friction by nearby cold lines. Therefore, in order to provide for a nominal unbalance of friction forces acting on a pipe support, a resultant longitudinal friction force equal to 7.5% of the total pipe weight or 30% of any one or more lines known to act simultaneously in the same direction, whichever is larger, is assumed for piperack design. Friction between piping and supporting steel should not be relied upon to resist wind or seismic loads. Anchor and Guide Loads (Ta): Piperacks should be checked for anchor and guide loads as determined by the Pipe Stress Group. It may be necessary to use horizontal bracing if large anchor forces are encountered. For conventional pipe rack systems, it is normally preferred to either have the anchors staggered along the piperack so that each support has only one or two anchors, or to anchor most pipes on one braced support. For initial design, when anchor and guide loads are not known, use a longitudinal anchor force of 5.0 kN acting at midspan of each bent transverse beam (refer project design criteria). Guide loads are usually small and may be ignored until they are defined by the Pipe Stress Engineer. For non-continuous pipe rack systems, piping may be transversely guided or anchored at both cantilever frames and anchor bays. Longitudinal anchors may be located only at anchor bays. Please note that, all friction forces and anchor forces with less magnitude, (say ~ 5.0 kN), applied to the top flange of the beam, may be considered as resisted by the total beam section. When anchor loads have large magnitude and are applied to the top flange of the beam, the effect of torsion must be addressed.If the beam section is inadequate to take care of this torsional force, alternatives to be considered, such as provide horizontal bracings at the load locations. Step - 3: Load Combinations and allowable deflection of pipe rack: You need to create the load combinations per your project design criteria. However, I have refered here some load combinations. Please note the following:

Earthquake load is a factored load. For load combinations that include wind or earthquake loads, use only the non-friction portion (anchor and guide portion) of the thermal loads, i.e., friction loads are not combined with wind or seismic loads. Friction loads are considered to be self-relieving during wind and earthquake and should only be combined with anchor and guide loads when wind or earth-quake loads are not considered. Hydrostatic test loads need not be combined with wind and earthquake loads unless there is a reasonable probability of the occurrence of either of these loads during hydrostatic testing. For calculation of foundation soil bearing pressures or pile loads, stability checks against overturning, sliding, and buoyancy, and deflection checks, the following unfactored load combinations (ACI 318) shall be used:

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1. 2. 3. 4. 5. 6. 7. 8. 9.

D D + L + SL + Tf + Ta D + Tf + Ta D + 1.3W + Ta D + L + 0.5SL + 1.3W +Ta D + L + S +0.65W + Ta 0.9De + 1.3W + Ta D + E/1.4 + Ta D + 0.2S + E/1.4 + Ta

10. 0.9De + E/1.4 + Ta

Load Combinations for design of foundations (ACI 318):

1. 2. 3. 4. 5. 6. 7. 8.

1.4D 1.4D + 1.7L +1.7S 1.4D + 1.4Tf +1.4Ta 0.75 (1.4D + 1.7L + 1.7S + 1.4Tf + 1.4Ta) 0.75 (1.4D + 1.7L + 1.7S + 1.4Ta) + 1.6W 1.2D + 0.2S + 1.0E + 1.2Ta 0.9De + 1.6W + 1.2Ta 0.9De + 1.0E + 1.2Ta

Steel Design load combinations: (AISC - LRFD)

1. 2. 3. 4. 5. 6. 7. 8.

1.4D 1.2D + 1.6L + 0.5S + 1.2Tf + 1.2Ta 1.2D + 1.6S + 0.5L + 1.2Tf + 1.2Ta 1.2D + 1.6S + 0.8W + 1.2Ta 1.2D + 1.6W + 0.5L + 0.5S + 1.2Ta 1.2D + 1.0E + 0.5L + 0.2S + 1.2Ta 0.9De + 1.6W + 1.2Ta 0.9De + 1.0E + 1.2Ta

De is the minimum dead load on the structure. FINAL ANCHOR AND GUIDE LOAD CHECK: Where the design of transverse beams has been based on anchor loads as explained in step-2,a final check of beams (and other affected members) should be made when final definition of these loads is available from the Pipe Stress Engineer.Based on the Engineer's experience and judgement, an overstress in any element (of up to 10%) can be considered, provided proper justification is given. Where such overstress cannot be properly justified, modifications should be made to the piperack structure in order to bring the stress levels within the normal allowables. Modifications could entail the addition of horizontal bracing to the transverse beams to resist significant loads from the anchor(s), replacing and/or adding members, strengthening members (i.e.,cover plating, etc.), and/or relocating the anchor and guide load(s). ALLOWABLE HORIZONTAL AND VERTICAL DEFLECTION: Allowable deflections of piperack structures shall be as per project design criteria. However, you can consider the following as limit of deflection:Lateral deflection produced by load combinations that include wind or seismic forces:Piperacks supporting equipment: h/100, unless a more stringent requirement is given by the manufacturer of the equipment.Piperacks supporting piping and raceway only: h/200 or as per project design criteria.Lateral deflection produced by sustained static forces such as pipe and anchor loads: h/200 or as per project design criteriaVertical deflection of beams due to gravity pipe loads:as per project design criteria h is the total height of the pipe rack structure.

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Step-4: Framing of Continuous/Conventional Pipe rack: Frames Main piperacks are usually designed as moment-resisting frames in the transverse direction. In the longitudinal direction, there should be at least one continuous level of beam struts on each side. For piperacks with more than one tier, the beam struts should be located at a level that is usually equal to one-half tier spacing above or below the bottom tier. Vertical bracing in the longitudinal direction should be provided to carry the longitudinal forces, transmitted through the beam struts, to the baseplate / foundation level. Transverse Beam Transverse beams must be capable of resisting all forces, moments, and shears produced by the load combinations. Transverse beams are generally a moment-resisting frame, modeled and analyzed as part of the frame system. The analysis model must reflect the appropriate beam end conditions. In the design of beams, consideration should be given to

Large pipes that are to be hydro-tested. Anchor and friction load with large magnitude (see step-2, anchor and friction load) Central Spine: For steel piperacks with spans of more than 6 m, a center spine consisting of a system of horizontal braces and struts located at midspan of each level of piping should be considered . This additional light horizontal framing greatly increases the capacity of the transverse pipe support beams to resist friction and anchor forces, and also serves to reduce the unbraced length of the beam compression flange in flexure and to reduce the unbraced length of the beam about the weak-axis in axial compression. This concept reduces the required beam sizes and provides a mechanism for eliminating or minimizing design, fabrication, or field modifications that could otherwise be required due to late receipt of unanticipated large pipe anchor forces. Longitudinal Beam Strut For typical continuous piperack systems, the longitudinal beam struts should be designed as axially loaded members that are provided for longitudinal loads and stability. Additionally, the longitudinal beam struts that support piping or raceway should be designed for 50% of the gravity loading assumed for the transverse pipe or raceway support beams, unless unusual loading is encountered. This 50% gravity loading will account for the usual piping and raceway take-offs. Normally, the gravity loading carried by the beam struts should not be added to the design loads for the columns or footings since pipes or raceway contributing to the load on the beam struts would be relieving an equivalent load on the transverse beams. Concentrated loads for large pipes may be treated as in step-2. For any continuous piperack system where the anticipated piping and raceway take-offs are minimal or none, the 50% loading criteria does not apply. In such cases, the beam struts should be designed primarily as axially loaded members. Do not provide beam struts if they are not needed for piping or raceway support, or for system stability. Conversely, the 3D model should be checked to verify that beam struts subjected to unusually large loads (such as at expansion loops) have been given special consideration. All longitudinal beam struts, including connections, should be designed to resist the axial loads produced by the longitudinal forces. When designing the longitudinal beam struts for flexural loads, the full length of the beam should be considered as the unbraced length for the compression flange. Vertical Bracing When moment-resisting frame design is not used in the longitudinal direction, vertical bracing should be used to transmit the longitudinal forces from the beam struts to the foundations. Knee-bracing or K-bracing is most often used for this purpose. Unless precluded by

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equipment arrangement or interferences, bracing should be placed equidistant between two expansion joints. Design calculations and drawings must reflect a break in the beam strut continuity between adjacent braced sections through the use of slotted connections or by eliminating the beam struts in the bays designated as free bays. The maximum length of a braced section should be limited to 48m to 50m. If the braced bay is not located equidistant from the free bays, the maximum distance from the braced bay to a free bay should be limited such that the maximum total longitudinal growth or shrinkage of the unrestrained segment does not exceed 40 mm. Column The columns must be capable of resisting all loads, moments, and shears produced by the load combinations.A moment-resisting frame analysis should normally be used to determine the axial load, moment, and shear at points along the columns.The frame analysis model should be based on the following:

Consider column base as hinge. Use 4 bolt connections for safety purpose

For design of steel columns subjected to flexural loads, the distance between the base and the first transverse beam or the knee brace intersection should be considered as the compression flange unbraced length.

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:

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

Step - 4: Frames of non-conventional 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:

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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: 1.25 x Dead load + 1.5 x IV + 1.5 x IL LC2: 1.25 x Dead load + 1.5 x IV + 1.5 x IT LC3: 1.25 x Dead load + 1.5 x IV + 1.5 x Wind LC4: 1.25 x Dead load + 1.05 x IV + 1.05 x IT + 1.05 x Wind LC5: 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:
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badamsundararao
SEFI Stars

Posted: Tue Aug 31, 2010 9:23 pm

Post subject: PIPE LINE RACK DESIGN

Dear friend,
Joined: 24 Dec 2009 Posts: 119 Location: KAKINADA ANDHRA PRADESH

Thank you for the information. This is very useful data for design engineers. badam sundara rao.

Back to top gpsarathyy


SEFI Stars Posted: Tue Jul 19, 2011 1:41 pm Post subject:

Dear Sefians,
Joined: 28 Jun 2010 Posts: 230 Location: chennai

For piperack, temperature load is also to be considered. For this loads each company is following different way. Can anybody confirm on this which is more appropriate. In STAAD we have to apply only the delta T (difference in Temperature). What will be the difference in Temperature?

Temperature difference between the fabrication/casting and the Max or Minimum ambient temperature? Temperature difference between the fabrication/casting and the Max or Minimum ambient temperature? + 20 degrees Temperature difference between the fabrication/casting and (Maximum Ambient Temperature + Minimum Ambient temperature)/2

Some may argue we are already providing the expansion joing between the structure and why we need to consider the thermal stresses in structure? - which is not correct, we have to consider the thermal stresses. Seniors and experts are requested to throw some light on the above topic. _________________ G.PARTHASARATHY CHENNAI GPSARATHYY@GMAIL.COM
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SEFI Stars Posted: Tue Jul 19, 2011 1:44 pm Post subject:

The Temperature effect is depends on the location also, hence we will discuss only for India, this
Joined: 28 Jun 2010 Posts: 230 Location: chennai

will confine the discussion and will give more clarity on the discussion. _________________ G.PARTHASARATHY CHENNAI GPSARATHYY@GMAIL.COM

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SEFI Stars Posted: Tue Jul 19, 2011 6:24 pm Post subject:

In General the piperack length is restricted to 50m as max. considering the thermal expansion or
Joined: 28 Jun 2010 Posts: 230 Location: chennai

thermal stresses that will develop in the piperack members. These stresses are secondary stresses which will add forces to the longitudinal bracings and the longitudinal members. For optimum design it is better to provide the braced bay at the center of the piperack, there by

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reducing the thermal expansion of the piperack at the ends. _________________ G.PARTHASARATHY CHENNAI GPSARATHYY@GMAIL.COM
Back to top gpsarathyy
SEFI Stars Posted: Sat Jul 23, 2011 9:55 pm Post subject:

Dear Sefians,
Joined: 28 Jun 2010 Posts: 230 Location: chennai

Please give your opinion on what temperature loads to be considered in the piperack design. Waiting for your postings. _________________ G.PARTHASARATHY CHENNAI GPSARATHYY@GMAIL.COM

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SEFI Stars Posted: Sun Aug 07, 2011 7:46 pm Post subject:

Senior Sefians are requested to share the knowledge on the temperature loads on piperack.
Joined: 28 Jun 2010 Posts: 230 Location: chennai

Now the different company they are following different standards of temperature loads. To get the unique solution and concept your views are essential. _________________ G.PARTHASARATHY CHENNAI GPSARATHYY@GMAIL.COM

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SEFI Stars Posted: Tue Aug 23, 2011 1:22 pm Post subject:

Senior Sefi Persons are requested to share their knowledge on Temperature loads over piperack.
Joined: 28 Jun 2010 Posts: 230 Location: chennai

Please give your opinion. _________________ G.PARTHASARATHY CHENNAI GPSARATHYY@GMAIL.COM

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