PIPE RACK / WAYS
&
RACK PIPING
By,
Akshaya Sharma
Associate Engineer
Piping Department
Date – 16th Nov 2006
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Contents
INTRODUCTION
PIPE RACK
Pipe Rack design criteria
Shapes
Future Space
Width of Pipe Rack
Clearance
Pipe Rack Loading
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 2
INTRODUCTION
A pipe rack is the main artery of a process unit. It connects all equip
ment with lines that cannot run through adjacent areas. Because it is
located in the middle of the most plants, the pipe rack must be erect
ed first, before it becomes obstructed by rows of equipment. Pipe ra
cks carry process, utility piping and also include instrument and elec
trical 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
Fire proofing requirements
Statutory requirements
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PIPE RACK DESIGN CRITERIA
Shapes
There are various shapes of pipe rack like L/T/U/H/Z. These s
hapes 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 %a
ge 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 a
nd 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 si
ze of the pumps to be housed below pipe rack.
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RACK WIDTH SELECTION CRITERIA
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DIFFERENT SHAPES OF PIPE RACKS
DEAD END YARD LINES ENTER & STRAIGHT THROUGH YARD LINES
LEAVE ONE END OF THE RACK CAN ENTER & LEAVE BOTH ENDS
OF THE RACK
L-SHAPED YARD LINES CAN ENTE T-SHAPED RACK PIPING CAN ENT
R & LEAVE NORTH & EAST OF TH ER & LEAVE THREE SIDES OF THE
E RACK RACK 7
DIFFERENT SHAPES OF PIPE RACKS
COMPBINATION OF I & T SHAPED U-SHAPED YARD LINE CAN ENTER
RACK & LEAVE ALL FOUR SIDES OF THE
RACK
COMPLEX RACK PIPING ARRANGEMENT
FOR VERY LARGE CHEMICAL PLANT
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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.
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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 Laod
Load by thermal expansion of piping & Reaction force b
y internal pressure of expansion bellows
Dynamic Laod
Load by vibration of piping & by wind and earthquake
Sustained Load (Live Load)
Liquid load for hydrostatic pressure test
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RACK PIPING
Position of Lines
Predominantly process lines are to be kept at lowe
r tier and, utility & hot process lines on upper tier.
Hot Lines & Cold Lines
Generally hot lines & cold lines are to kept at diff
erent tiers or at different groups on a tier.
Pipe Spacing
Minimum spacing between adjacent lines shall be decided b
ased on O.D. of bigger size flange (minimum rating 300# to
be considered), O.D. of the smaller pipe, individual insulati
on thickness and additional 25mm clearance. Even if flange
is not appearing the min. spacing shall be based on above b
asis only. Actual line spacing, especially at ‘L’ bend and loo
p locations, shall take care thermal expansion/thermal contr
action/non-expansion of adjacent line. Non-expansion/the
rmal contraction may stop the free expansion of the adjacen
t line at ‘L’ bend location.
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RACK PIPING
Bigger Size Lines
Large size lines (14” and larger) shall be arranged close to t
he column in order to decrease the bending moment of bea
m. 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 leavi
ng 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.
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RACK PIPING
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 clea
rances for the fire proofing of structure.
Battery Limit (ISBL)
Process lines crossing units (within units or from unit to m
ain pipeway) are normally provided with a block valve, spe
ctacle blind and drain valve. Block valves are to be groupe
d and locations of block valves in vertical run of pipe are p
reffered. If the block valves have to be located in an overhe
ad pipe-way, staircase access to a platform above the lines
shall be provided.
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RACK PIPING
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RACK PIPING
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RACK PIPING
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EXPANSION LOOPS
Expansion loop is provided on the high temperature
lines. This information shall be given by stress group.
All the loops shall be located around one column only.
MAKE LINES INTO A GROUP AND INSTALL A LA
RGE SIZE PIPING AND HIGH TEMPERATURE PIP
ING TO THE EDGE OF THE RACK
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EXPANSION LOOPS
When necessary to install an expansion loop on the co
ndensate line, do it horizontally to prevent water ham
mering. But do as above if horizontal loop is impossibl
e.
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PIPE RACK DESIGN CRITERIA
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PIPE RACK DESIGN CRITERIA
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PIPE RACK DESIGN CRITERIA
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PIPE RACK DESIGN CRITERIA
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THANK YOU
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