Pipe rack Design Philosophy

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)

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.

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:
1. D
2. D + L + SL + Tf + Ta
3. D + Tf + Ta
4. D + 1.3W + Ta
5. D + L + 0.5SL + 1.3W +Ta
6. D + L + S +0.65W + Ta
7. 0.9De + 1.3W + Ta
8. D + E/1.4 + Ta
9. D + 0.2S + E/1.4 + Ta
10. 0.9De + E/1.4 + Ta

Load Combinations for design of foundations (ACI 318):
1. 1.4D
2. 1.4D + 1.7L +1.7S
3. 1.4D + 1.4Tf +1.4Ta
4. 0.75 (1.4D + 1.7L + 1.7S + 1.4Tf + 1.4Ta)
5. 0.75 (1.4D + 1.7L + 1.7S + 1.4Ta) + 1.6W
6. 1.2D + 0.2S + 1.0E + 1.2Ta
7. 0.9De + 1.6W + 1.2Ta
8. 0.9De + 1.0E + 1.2Ta

Steel Design load combinations: (AISC - LRFD)
1. 1.4D
2. 1.2D + 1.6L + 0.5S + 1.2Tf + 1.2Ta
3. 1.2D + 1.6S + 0.5L + 1.2Tf + 1.2Ta
4. 1.2D + 1.6S + 0.8W + 1.2Ta
5. 1.2D + 1.6W + 0.5L + 0.5S + 1.2Ta
6. 1.2D + 1.0E + 0.5L + 0.2S + 1.2Ta
7. 0.9De + 1.6W + 1.2Ta
8. 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.

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 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.