Prepared by: Jitendra Badgujar
Piping design engineer (+91-7208568863)
Reference: Google
CONTENT
INTRODUCTION
PIPE RACK
Pipe Rack design Criteria
Shapes
Future Space
Width of Pipe Rack
Clearance
Pipe Rack Loading
PIPE RACK PIPING
Positions of Lines (Process & Utilities)
Hot Lines & Cold Lines
Bigger Size Lines
Pipe Spacing
Anchor Bay
Unit Battery Limit
Expansion Loops
Pipe Route
Trays
INTRODUCTION
A Pipe Rack is the main artery of a process unit. It connects all equipment with lines that
cannot run through adjacent areas. Because it is located in the middle of the most
plants, the pipe rack must be erected first, before it becomes obstructed by rows of
equipment. Pipe racks carry process, utility piping and also include instrument and
electrical cable trays as well as equipment mounted over all of these.
The primary data required for detailed development of a pipe rack:-
Plot Plan
P&ID’s
Client Specification
Construction Materials
Fireproofing requirements
Statutory requirements
General arrangement of Pipe Rack
Shapes:
There are various shapes of pipe rack like L/T/U/H/Z. These shapes shall be considered
based on the area available.
Future Space:
The total width of the pipe rack shall include 25% extra space for future
expansion/modification in unit for rack-width upto 16m and 10% for rack-width above
16m. The future space %age is normally based on the client requirements.
Width of Pipe rack:
The width of the rack shall be 6m, 8m or 10m for single bay and 12m, 16m or 20m for
double bay having 4 tiers maximum. The spacing between pipe rack portals shall be
taken as 6m in general. However it can be increased to 8m depending on the size of the
pumps to be housed below pipe rack.
Rack width Selection Criteria
Different shapes of Pipe Rack
PIPE RACK DESIGN CRITERIA
Clearance
For units, clearance beneath pipe rack shall be 4m minimum both in
longitudinal and transverse directions.
For Offsite, clearance beneath pipe rack shall be 2.2m minimum both in
longitudinal and transverse directions.
Road clearance shall be 7m for main road and 5m for secondary road.
PIPE RACK LOADING
Pipe rack loads shall be given by stress group to Civil & structural discipline for
pipe rack design.
Sustain Load (Dead Load)
Weight of piping, valve and load insulation
Thermal Load
Load by thermal expansion of piping & Reaction force by internal pressure
of expansion bellows
Dynamic Load
Load by vibration of piping & by wind and earthquake
Sustained Load (Live Load)
Liquid load for hydrostatic pressure test
RACK PIPING
Position of Lines
Predominantly process lines are to be kept at lower tier and, utility & hot
process lines on upper tier.
Hot Lines & Cold Lines
Generally hot lines & cold lines are to kept at different tiers or at different
groups on a tier.
Pipe Spacing
Minimum spacing between adjacent lines shall be decided based on O.D. of
bigger size flange (minimum rating 300# to be considered), O.D. of the
smaller pipe, individual insulation thickness and additional 25mm
clearance. Even if flange is not appearing the min. spacing shall be based on
above basis only. Actual line spacing, especially at ‘L’ bend and loop
locations, shall take care thermal expansion/thermal contraction/non-
expansion of adjacent line. Non-expansion/thermal contraction may stop
the free expansion of the adjacent line at ‘L’ bend location.3
Bigger Size Lines
Large size lines (14” and larger) shall be arranged close to the column in
order to decrease the bending moment of beam. Water lines more than
30” shall not be routed over pipe rack, these shall be routed underground.
Anchor Bay
Anchors on the racks are to be provided on the anchor bay if the concept of
anchor bay is adopted. Otherwise anchor shall be distributed over two to
three consecutive bays.
Anchors shall be provided within unit on all hot lines leaving the unit.
Pipe Route
Racks shall be designed to give the piping shortest possible run and to
provide clear head rooms over main walkways, secondary walkways and
platforms.
Trays
Generally top tier is to be kept for Electrical cable trays (if not provided in
underground trench) and Instrument cable ducts/trays. Cable tray laying to
take care of necessary clearances for the fire proofing of structure.
Battery Limit (ISBL)
Process lines crossing units (within units or from unit to main pipeway) are
normally provided with a block valve, spectacle blind and drain valve. Block
valves are to be grouped and locations of block valves in vertical run of pipe
are preffered. If the block valves have to be located in an overhead pipe-
way, staircase access to a platform above the lines shall be provided.