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 equipment with lines that cannot run through adjacent a
reas. Because it is located in the middle of the most plants,
the pipe rack must be erected first, before it becomes obstr
ucted by rows of equipment. Pipe racks carry process, utilit
y piping and also include instrument and electrical cable tra
ys as well as equipment mounted over all of these.
The primary data required for detailed development of a pip
e rack :-
Plot Plan
P&ID’s
Client Specification
Construction Materials
Fire proofing requirements
Statutory requirements 3
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PIPE RACK DESIGN CRITERIA
Shapes
There are various shapes of pipe rack like L/T/U/H/Z.
These shapes shall be considered based on the area a
vailable.
Future Space
The total width of the pipe rack shall include 25% extr
a space for future expansion/modification in unit for r
ack-width upto 16m and 10% for rack-width above 16
m. The future space %age is normally based on the cli
ent requirements.
Width of Pipe rack
The width of the rack shall be 6m, 8m or 10m for sing
le bay and 12m, 16m or 20m for double bay having 4 t
iers maximum. The spacing between pipe rack portals
shall be taken as 6m in general. However it can be inc
reased to 8m depending on the size of the pumps to b
e housed below pipe rack. 5
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 t
o Civil & structural discipline for pipe rack desi
gn.
Sustain Load (Dead Load)
Weight of piping, valve and load insulation
Thermal Laod
Load by thermal expansion of piping & Reaction fo
rce by internal pressure of expansion bellows
Dynamic Laod
Load by vibration of piping & by wind and earthqu
ake
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 a
t lower tier and, utility & hot process lines o
n upper tier.
Hot Lines & Cold Lines
Generally hot lines & cold lines are to kept a
t different tiers or at different groups on a tie
r.
Pipe Spacing
Minimum spacing between adjacent lines shall be dec
ided based on O.D. of bigger size flange (minimum rat
ing 300# to be considered), O.D. of the smaller pipe, i
ndividual insulation thickness and additional 25mm cl
earance. Even if flange is not appearing the min. spac
ing shall be based on above basis only. Actual line spa
cing, especially at ‘L’ bend and loop locations, shall ta
ke care thermal expansion/thermal contraction/non-e
xpansion of adjacent line. Non-expansion/thermal con 11
traction may stop the free expansion of the adjacent li
RACK PIPING
Bigger Size Lines
Large size lines (14” and larger) shall be arranged cl
ose to the column in order to decrease the bending m
oment of beam. Water lines more than 30” shall not b
e routed over pipe rack, these shall be routed underg
round.
Anchor Bay
Anchors on the racks are to be provided on the ancho
r bay if the concept of anchor bay is adopted. Otherw
ise anchor shall be distributed over two to three cons
ecutive 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 p
ossible run and to provide clear head rooms over mai
n walkways, secondary walkways and platforms.
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RACK PIPING
Trays
Generally top tier is to be kept for Electrical cable tr
ays (if not provided in underground trench) and Instr
ument cable ducts/trays. Cable tray laying to take ca
re of necessary clearances for the fire proofing of str
ucture.
Battery Limit (ISBL)
Process lines crossing units (within units or from uni
t to main pipeway) are normally provided with a bloc
k valve, spectacle blind and drain valve. Block valves
are to be grouped and locations of block valves in ve
rtical run of pipe are preffered. If the block valves ha
ve to be located in an overhead pipe-way, staircase a
ccess 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 condensate line, do it horizontally to preve
nt water hammering. But do as above if horizo
ntal loop is impossible.
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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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