Planning of Piping on Pipe Rack 1 General

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The pipe rack will be used to support for common headers, such as utility, and for interconnecting piping among equipment and facilities whose the distance is 6 meters and over. The planning of pipe rack, including piping, shall be severely made in consideration of route, height, span and numbers of stages as these will affect to construction cost, operation, safety and maintenance of the plant. 2 2.1 Key Point of Pipe Rack Planning Width of Pipe Rack The width will be decided in consideration of the following points; a. No. of piping installed on pipe rack, standard spaces pipe to pipe refer to attachment b. Allocated spaces c. Economical dimension, concerning beam and column size d. How to use the spaces located underneath of the pipe rack, such as walkway, maintenance road, route for underground ones (cable, piping), pump yard, etc. e. How to use the spaces located above pipe rack, such as space for equipment, operation/ maintenance floor. f. 2.2 Space for future expansion (if required, 10 to 15% to be added as for future) Height of Pipe Rack The height will be decided in consideration of the following points; a. Minimum Head clearance 1) Normal overhead: 2.4 meters 2) Plant roads in trucking areas: 4.8 meters 3) Rail-road and public main roads: 6.6 meters 4) Elevation of lighting fixture also incorporated in the consideration b. In case of muti-stages Pipe Rack. Vertical elevation gap: minimum 1.5 meters, normal 2 meters depend upon pipe and beam size c. In case of walk way and operation platform existed on pipe rack, minimum head clearance is 2.1 meters 2.3 Span (distance) between Pipe column a. Allowable pipe span refer to attachment. (maximum allowable deflection pipe is 5/8 ") b. Small size piping shall be grouped, as possible due to intermittent support will be required. c. Span shall be decided in consideration of access way and construction cost

Planning of Piping on Pipe Rack 2.4 Multi-stage pipe rack

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In case of muti-stages are required, piping distribution shall be decided as follows; a. On lowest stage, mainly Inter-connecting piping between pumps and equipment Cooling water header piping from/to pumps and other rotating equipment Heavy weight piping, such as cooling water header Process piping (heavy weight) and short distance run b. On middle stages Process piping, mainly long distance run c. On top stage Utility headers Instrument cable duct Electrical cable duct Flare header (note) High temperature line with expansion loops 2.5 Design Notes a. Gravity flow piping, such as flare header and low pressure steam condensate header, shall be adjusted the elevation by using shoes or independent pipe support. b. Heavy and large bore size piping (18" and over) shall be arranged as near to pipe rack's columns (edges of rack) to reduce moment incurred to traverse beam. c. Spaces for future expansion could be arranged at center of pipe rack. 3 3.1 Planning of Piping on Pipe Rack Step 1: Extraction of Piping to be installed on Pipe Rack a. Required information - Equipment Layout - P&ID b. Marking on Equipment Layout On equipment layout, all pipe lines shall be marked one by one with line number, including size, fluid name and insulation's requirement in accordance with P&ID Step 2: Classification of Pipeline All pipe line, which are marked on equipment layout, shall be divided into the following classes: a. Process lines - short distance run... lowest stage b. Process lines - long run distance run.... middle stage c. Process lines - heavy weight... lowest stage d. Interconnecting lines, such as pump to equipment.... lowest stage

Planning of Piping on Pipe Rack e. Utility lines - liquid fluid lines.... lower stage f. Utility lines - gas fluid lines... high stage g. Utility lines - heavy weight lines... lowest stage h. Gravity flow lines... high stage i. High temperature service line with expansion loop.... highest stage Step 3: Arrangement at each stage a. Large bore size (18" and over).... edge b. Heavy weight.... edge c. Future space.... center d. Instrument cable duct.... edge e. Electrical cable duct... edge

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Note: In principle, instrument cable duct shall be arranged at opposite side of electrical cable to avoid magnetic interference caused by electrical cable. Step 4: Group Pipe Lines Small pipelines, 2" and smaller sizes, shall be gotten together (grouped) in consideration of un-supporting length for ones. Generally, pipe rack span generally is 6 meters and larger. (refer to dimension of pipe support span) Step 5: Space Adjacent Pipe Lines In principle, it is required to keep clearance between adjacent piping ( pipe to pipe, or pipe to flange) in consideration of construction work and prevention of mutual interference at operating temperature. Attached table shows standard clearance) Step 6: Stop Axial Movement Generally, pipe rack piping will be run with long length (distance). The hot and cold pipelines shall be studied of thermal stress/ and flexibility. Before commence the study, stop points shall be preliminary planned to prevent an axial movement. In case of expansion loop(s) or contraction loop (s) is required, the placement order of pipe line will be required to adjust (change) based upon their flexibility, as large size pipe line (s) shift toward to pipe rack center due to extend arm length. Step 7: Guides Piping will move one or more axes due to bending moment or torsion caused by thermal forces and it's weight if it allow free thermal movement. Long distance running piping shall be restrained by guide supports to do expansion or contraction along an axial direction, and the movements are absorbed in expansion joint or U-loop. Step 8: Branching from/ to header piping placed on pipe rack a. Liquid service lines could be, in vertically, branched on top or bottom of header piping.

Planning of Piping on Pipe Rack

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b. Gas (vapor) lines shall be branched on top of header piping, except header's drain piping. c. Steam condensate line shall be connected to top of header piping. d. Discharge line downstream of safety/ relief valve shall be connected to top of the header piping with 45-degree angle down slope toward to flare stack. Step 9: General instruction to be taken to pipeline arrangement on pipe rack a. Minimize no. of fittings b. Minimize no. of dead apace c. Minimize up and down piping d. Unify the intersection stages e. Close-coordinate among; For civil: minimize beam and column sizes (span, width, stage, height, locations of horizontal direction stopper, bracing) For electrical: cable route, lighting fixture, receptacle For instrumentation: cable route, local instruments on pipe rack For construction: easy installation work, especially big sizes and heavy weight piping f. Pipe length to be procured As much as possible, pipe length shall be a double random length (approx. 12 m) instead of 6m or single random length to reduce no. of welding points. g. A branch point shall be taken far from expansion joint or expansion (or contraction) loop of piping where is not to restrain. h. Space between weld lines It is recommended to provide the gap between welded metals in 4 times of the run pipe thickness. i. Multiple branches When two or more branch connection are so closely spaced that their reinforcement zone overlap, the distance between centers of the openings should be at least 11/2 times their average diameter, and the area of reinforcement between any two openings shall be not less than 50% of the total that both require. 4 a. b. c. Attachments Pipe space in pipe way Pipe space at valve manifold Allowable pipe span