Industrial Training Report

2014-2015

Petrofac Engineering Services India (Pvt.) Ltd.

ON
“DESIGN AND ANALYSIS OF PRECAST CONCRETE PIPE RACK”
FOR
Mina Abdulla Refinery
Kuwait National Petroleum Corporation (KNPC)
Kuwait

Guided By- P. Govinda Reddy

Designation - Senior Engineer (Civil & Structural)

Ankit Verma (A7615811061)

B.Tech. (Civil); 3rd Year

 DECLARATION

I hereby declare that the project work entitled “DESIGN AND ANALYSIS OF PRECAST CONCRETE PIPE RACK” is
an authentic record of my own work carried out at Petrofac, Gurgaon as requirements of eight weeks project
for the award of degree of Bachelor of Technology in Civil Engineering, Amity University Uttar Pradesh,
Lucknow Campus, under the guidance of my project mentor Mr. P. Govinda Reddy during May to July 2014.

Ankit Verma
Dated: 03-07-2014 B.Tech (Civil) (2011-15)
A7615811061

Certified that the above statement made by the student is correct to the best of our knowledge and belief.

P. Govinda Reddy
Senior Engineer (Civil & Structural)

Petrofac Engineering Services India (Pvt) Ltd.

Gurgaon

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 ACKNOWLEDGEMENT

“A novice cannot do great tasks. Many great people contribute to completion of his work directly or
indirectly.”

Words fail me to express my sincerest gratitude to this esteemed organization, which has conferred on us the
privilege to pragmatically convert our theoretical knowledge into practical viable experience. During the
course of my training at Petrofac, Gurgaon so many people have guided me and I will remain indebted to them
throughout my life for making my training at Petrofac, Gurgaon a wonderful learning experience.

I would like to thank Mr. Ajay Malhotra, my project head, who gave me opportunity to work in his
department and guided me through my project time to time. The exposure to the working of the industry that
I have got here would not have been possible without his kind support.

In the end I would like to thank Mr. P. Govinda Reddy, Mr. Manish Jain, Mr. Sandeep and others for
providing me the opportunity to add a new dimension in my knowledge and helping me throughout my
training period by getting trained in this esteemed organization.

Ankit Verma
B.TECH (Civil) 2011-15
AMITY UNIVERSITY

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 TABLE OF CONTENTS

PAGE

1. INTRODUCTION ABOUT PETROFAC…………………………………………………………...... 06

2. INTRODUCTION ABOUT KNPC –MAB …………………………………………………………… 06

3. DEFINITION OF PIPE RACK……………………………………………………………………...... 06

4. PURPOSE……………………………………………………………………………………………… 06

5. REFERENCES…………………………………………………………………………………………. 06

6. INPUT DATA…………………………………………………………………………………………... 06

7. ASSUMPTIONS / CONSIDERATIONS………………………………………………………………. 06

8. MATERIAL……………………………………………………………………………….……………. 07
..
9. DESIGN METHODOLODGY…………………………………………………………………………. 08

10. DIFFERENT PIPE RACK VIEWS…………………………………………………………..…………......... 12

a. As Modeled in STAAD Pro

b. Top view
c. Longitudinal view of pipe racks
d. Transverse view of pipe racks
e. Dimensions

11. LOAD APPLICATIONS…………………………………………………………………………….… 15

a. Dead load
b. Live load
c. Equipment load
d. Piping load
e. Frictional load
f. Temperature load
g. Wind load
h. Seismic load
i. Crane (monorail) load

12. CONNECTIONS………………………………………………………………………………………….. 29

a. Bolted Moment Connection

b. Base Plate Design for pinned condition
c. RC Corbel design
d. Precast Concrete column to Precast column connection
e. Cast in situ concrete column to precast concrete column connection

13. DEFLECTION CHECK……………………………………………………………………………….…... 30

14. UTILITY RATIO CHECK………………………………………………………..…………………..…… 30

15. CONCLUSION………………………………………………………………..…………..………..……... 32

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 APPENDICES and ATTACHMENTS

 ATTACHMENT-A Pipe rack plot plan and exchanger details (05 Sheets)

 ATTACHMENT-B Wind Load Calculations (05 Sheets)

 ATTACHMENT-C Seismic Load Calculations (09 Sheets)

 ATTACHMENT-D Load Combination Calculations (02 Sheets)

 ATTACHMENT-E Abbreviations (01 Sheets)

 ATTACHMENT-F Base Plate Design for pinned condition (03 Sheets)

 ATTACHMENT-G RC Corbel design (04 Sheets)

 ATTACHMENT-H Precast Concrete column to Precast column connection (04 Sheets)

 ATTACHMENT-I Cast in situ concrete column to precast concrete column (04 Sheets)
Connection

 ATTACHMENT–J GA Drawings (03 Sheets)

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 DESIGN AND ANALYSIS OF PRECAST CONCRETE PIPE RACK

1. INTRODUCTION ABOUT PETROFAC:

Petrofac is a leading international service provider to the oil & gas production and processing industry.
Petrofac designs and builds oil & gas facilities; operates, maintains and manages facilities and trains personnel;
With more than 18,000 employees, Petrofac operates out of seven strategically located operational centers, in
Aberdeen, Sharjah, Abu Dhabi, Woking(UK), Chennai, Mumbai, Delhi and Kuala Lumpur and has a further 24
offices worldwide.

2. MINA ABDULLA REFINERY:

Kuwait National Petroleum Company, which aimed at upgrading and expanding the existing KNPC
refinery at Mina Abdulla, Mina Abdulla Refinery Established in 1958, Located in southern Kuwait about ≈ 60
KM from Kuwait City, Occupies an Area of 7.9 sq. KM, Total refining capacity of this refinery will go up to
800,000 barrels per day.

3. PIPE RACK:

Pipe rack in a refinery plant supports mainly pipelines which include Process pipe lines, flare lines and
utility lines.
Pipe rack is the main artery of any plant. This carries the pipes and cable trays (raceways) from one
equipment to equipment within a process unit (called ISBL pipe rack) or carries the pipe and cable trays from
one unit to another unit (called OSBL pipe rack). Sometimes AIR COOLED HEAT EXCHANGERS also the
part of pipe rack.
Continuous Pipe rack 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. Pipe racks
supporting equipment such as air-cooled heat exchangers must utilize the continuous system approach.

4. PURPOSE

The purpose of this calculation is to analyze and design the Precast Concrete Pipe rack for Mina Abdulla
Refinery (MAB-2) at Kuwait for Kuwait National Petroleum Corporations (KNPC).

5. REFERENCES

a. Steel Construction Manual 14th Edition - AISC 360-10

b. Minimum Design Loads for Buildings and Other Structures - ASCE 7-10
c. AISC Steel Design Guide 1 for Base Plate & Anchor Rod Design
d. Building Code Requirements for Structural Concrete and Commentary - ACI 318-11
e. Engineering Design Guide - Wind & Earthquake – Attachment B & C
f. International Building Code - IBC 2012

6. INPUT DATA

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 pipe rack design. Therefore, a Civil/Structural

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Engineer 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

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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"
The following should be reviewed for design information:
 Plot plans and equipment location plans

 3D model showing piping layout, cable tray layout, and Pipe rack 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 pipe rack.

 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 pipe rack.

 Pipe rack construction material (Steel, Cast-in-situ concrete, Pre-cast concrete) shall be as per project
design criteria.

Allowance and provision for future pipes is made for future addition of pipe and raceway as per inputs
from respected departures.

The general input for this calculation is obtained from the FEED done by Flour Corporation and
Updated by PIL Piping Discipline. All Load calculations and Load combinations done based on AISC-7-10
Petrofac Standard Practice and Design Guide.

7. ASSUMPTIONS/ CONSIDERATIONS

a. In the absence of any pipe load information, a uniform pipe load of 1.7 KN/m2 has been considered
for operating condition in Pipe rack as per pipe rack design guide & standard practice.

b. The Live Load for the platforms and walkways has been considered as 5 KN/m2 & for Staircase as 5
KN/m2 as per KNPC MAB-1 Design Basis.

c. Wind load has been calculated based on provisions of ASCE 7-10. Basic Wind Speed is 45 m/s with
Exposure Category “C” as per Project Design basis. Wind Load on piping has been estimated by
considering the piping as per KNPC Design Basis and applied on STAAD as a point load on
transverse beam and as nodal load at effected Column beam junctions.

d. Snow load has is not applicable at this site.

e. Seismic loads are calculated based on provisions of ASCE 7-10. Seismic Design Category “B” with

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 Spectral response accelerations for short period and one second periods are Ss = 0.32g, S1 = 0.13g
respectively and Importance Factor 1.25 as per Project Design Basis. For detail Seismic calculation,
Refer Attachment C_Seismic Load.

f. Load Factors and Load Combinations for Serviceability and LRFD Design are considered in
accordance with IBC 2012 section 1605 and ASCE 7-10, Chapter 2, Refer Attachment D_ Load
Combination

g. Dead load of serrated grating has been considered @ 0.5 KN/m2.

h. Piping load has been applied as per loads provided by Piping Discipline.

i. Piping friction load has been considered @30% of Vertical load for framed supports only.

j. All the supports of pipe rack structure are considered to be fixed Base.

k. Slenderness factor for Major axis i.e. "Kz" for all the steel columns has been assumed as 1.2. Values
of Lz and 1.0 for Ly in STAAD has been considered as applicable.

l. The "R" values for Pipe rack Steel structure are considered as 3.0.

m. Monorail capacity 10 KN is given by Mechanical as discussed and designed accordingly.

n. Based on Monorail Beam W18x45, Mechanical will purchase lifting hoist so that it will fit in to
Monorail Beam flange as per requirement.

8. MATERIAL

CONCRETE

 Grade of Concrete shall be M30

 Reinforcing steel shall be ASTM A615

STRUCTURAL STEEL

 W Shape shall be of ASTM A992

 Structural Bolts Shall be of ASTM A325N / A490N

 Anchor Bolts shall be of ASTM F1554 (grade as reqd.)

 Bracings shall be ASTM A992

 Base Plate & Angle shall be ASTM A36

9. DESIGN METHODOLOGY

Kuwait is having three Refineries; Mina Abdulla Refinery is one of largest refinery in Kuwait. KNPC

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wants to expand their refinery capacity to 1.2 million barrels per day, Total project is spitted into two parts, PIL,

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Samsung and CB&I won the MAB-1 consortium, Floor & Daewoo won MAB-2 projects, MAB-1 is holding
units like CDU, HCR, VRU, DHT, NHT, HOC…etc.

All unit are having Pipe racks and needs fire proofing, so that precast concrete pipe rack is more economical by
30% than steel pipe rack and speed of construction is fast as compared to Cast in situ concrete Pipe rack.

This calculations dealt for HCR (Hydrocracker ) Unit only, The width of pipe rack 12m having three columns,
i.e.; 2x6m=12m, and overall length of HCR (unit-114) pipe rack is 333.0m (North south rack=237.0m, East-
west Rack=60m and fire heater connecting Rack= 3 x 12m=36m) .
Pipe racks are carrying only process pipe lines, utility pipe lines & pipe lines for fired pre heater. All cables are
passing through underground Trenches, So no need to consider any cable tray loads in pipe rack calculations.

For construction flexibility, foundation and column up to +2.7m from ground level considered as Cast–in situ
concrete pipe rack, Level from +2.7m to +14.0m considered as Precast Concrete Pipe Rack and from +14.0m to
+21.0m considered as steel pipe rack where fire proofing is not mandatory.

The pipe rack is Five tier rack with main Elevation levels (TOS) of Steel Pipe rack at +121.0m , Top of steel
for PSV platform at +115m, Top of concrete beam elevations of fired preheated at+112.5m, Top of concrete
beam Elevation for utility piping at +110m, and Top of concrete beam elevation for Process Pipelines at
+107.5m, & +105m.

Total Precast frame is divided into four modules as Module-1(Bottom Module), Module-2, Module-3 and
Module-4(Top Module). Here Module-1and Module-2 has Frame Rack-1 and Frame Rack-2 respectively. At
elevation +115.0m there is a PSV platform. As Module-2 and Module-3 is Intermediate Module.

 The plan size of the Bottom Module is 3.3m x 12.0m (height from TOC i.e. EL+102.70m).

 The plan size of the Intermediate Module is 2.5m x 12.0m and

 The plan size of the Top Module is 3.0m x 12.0m (height).

The pipe rack shall be Concentrically Braced steel framed structure, supported on Isolated foundation. The
Columns have been considered as fixed but released moment along longitudinal direction at base.

The platform shall be designed for worst load combinations out from Primary load cases mentioned below.

FRAMING OF CONTINUOUS/CONVENTIONAL PIPE RACK:

Frames:
Main pipe racks 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 pipe racks
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 base plate / 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, modelled and analysed as part of the
frame system. The analysis model must reflect the appropriate beam end conditions. In the design of beams,

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consideration should be given to

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 • Large pipes that are to be hydro-tested.
• Anchor and friction load with large magnitude

Central Spine:
For steel pipe racks with spans of equal to or more than 6 m, a centre 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.
For Precast Concrete Pipe racks with span more than 6m, Intermediate beam may be required for
supporting small pipes (Less than 100mm) & Cable trays.

Longitudinal Beam Strut:

For typical continuous pipe rack 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. For any continuous pipe rack 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.
Considered expansion joint at every 30m interval, consider long slotted holes for free expansion and
contraction of structures for steel pipe racks & over sized holes at corbel beam connection joint for allowing
free expansion and contraction due to pipe stresses & environmental stresses for precast concrete pipe rack.

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.
Primary Load cases considered for Precast Concrete Pipe rack:
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Load 1: DSW (Self weight)
Load 2: DS (Dead surface) Not used
Load 3: DFP (Cable Tray Load) Not used
Load 4: DPE (Piping Empty)
Load 5: DPO (Piping Operating-Content)
Load 6: DPT (Piping Test-Content)
Load 7: PAL (Pipe Anchor-Long)
Load 8: PAT (Pipe Anchor-Trans)
Load 9: LF (Floor Live Load)
Load 10: LB (Live Bundle Pull)
Load 11: DE (Equipment Empty)
Load 12: DO (Equipment Operating)
Load 13: DT (Equipment Test (Content)
Load 14: PF (Thermal / Friction)
Load 15: TR (Temperature Rise)
Load 16: TF (Temperature Fall)
Load 17: WX (Wind Long)
Load 18: WZ (Wind-Transverse)
Load 19: LB1 (Left Blank for Future) Not used
Load 20: LB2 (Left Blank for Future) Not used
Load 21: EX (EQ-Long)
Load 22: EL (EQ-Trans)
Load 23: PSVV (PSV Pop Up- Vertical) Not Used
Load 24: PSVL (PSV Pop Up- Long) Not Used
Load 25: PSVT (PSV Pop Up- Trans) Not Used
Load 26: Crane (Left side)
Load 27: Crane (Right side)
Load 28: Crane (Parked) Not Used

Please Refer Attachment D_ Load Combination for load combination details.

The load combinations for serviceability and LRFD shall be as per Section 1605 of IBC 2012.

Analysis and Design of Steel frame shall be carried out in accordance with AISC LRFD using STAAD pro V8i
Software. MathCAD, Version-15 and MS Excel 2010 are used to prepare calculations.

The entire design calculation as described above is presented in the subsequent pages.

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10. DIFFERENT PIPE RACK VIEWS

As modeled in STAAD pro

Load 14

TOP VIEW

24.00m

249.00m
60.00m 12.00m

237.00m

12.00m

Longitudinal View

Load 21

28.00m
24.00m

12.00m 237.00m

12
Load 21
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  Longitudinal View of North South Pipe Rack

24.00m

237.00m

 Longitudinal View of East West Pipe Rack

Load 21

6.00m 6.00m

28.00m

60.00m
Load 21
Transverse View

 Transverse View of East South Pipe Rack

Load 28

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  Transverse View of North South Pipe Rack

Load 28

Dimensions

7.00m

1.50m

2.50m
6.00m

2.50m

1.50m
2.50m

2.50m
2.30m

2.50m

2.50m 5.70m

2.50m
6.00m

6.00m

6.00m
6.50m
6.00m

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6.00m

Load 21 14
11. LOAD APPLICATIONS

DEAD LOAD

Self Weight of structure (Except weight of Grating and handrail) is automatically generated by STAAD pro
based on member sizes and density provided. However factor of 1.1 has been provided to take care of loading
due to connection’s weight. The weight of all structural members, including fireproofing, should be considered
in the design of the pipe rack.

Self weight of serrated grating has been applied @ 0.5KN/m2 (Considering Grating Bar of size 1-1/2" X3/16)

-3.000 kN/m -3.000 kN/m

Load 1

Dead Self Weight (DSW)

LIVE LOAD

Live load (L) on access platforms and walkways and on equipment platforms should be considered, as
applicable.

Uniform live load on steel grating floor @ 5KN/m2 (As per Project Design Criteria)

Live Load on each beam = 5 KN/m2 x 6.0 m (Beam Span) = 30KN/m

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Live Load

-30.000 kN/m -30.000 kN/m

Load 9

EQUIPMENT LOAD

Equipment weights, including erection, empty, operating, and test (if the equipment is to be hydro-tested on the
pipe rack), 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 as large valves, expansion loops,
and unusual piping or electrical configurations.

Sr. No Equipment’s Vendor Vendor Name Weight of Equipment at

Name Drawing Equipment Elevation(m)
Number
1 Air Cooled Heat 307044(P-031) S&T See below +121.00
Exchanger CORPORATION(SEOUL, Table-1 & 2
KOREA)

Table-1(Exchanger Details)
No. Item No. Unit Bay Bun W(m) L(m) C(m) TW(m) TL(m)
Bay Bun
1 114-E-0108 1 1 2 4.30 2.08 12.40 11.50 4.30 14.73
2 114-E-0110 1 8 16 6.02 2.94 12.40 11.50 50.96 14.73
3 114-E-0111 1 1 1 3.65 3.65 12.40 11.50 3.65 14.73
4 114-E-0120 1 4 8 5.61 2.74 12.40 11.50 23.64 14.73
5 114-E-0121 1 4 8 6.24 3.06 12.40 11.50 26.16 14.73
6 114-E-0125 1 7 14 8.48 2.98 12.40 11.50 61.76 14.73
7 114-E-0126 1 1 1 3.04 3.04 12.40 11.50 3.04 14.73

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8 114-E-0131 1 2 4 5.07 2.79 12.40 11.50 11.80 14.73

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 9 114-E-0134 1 6 12 6.24 3.06 12.40 11.50 39.44 14.73
10 114-E-0136 1 1 2 6.27 3.07 12.40 11.50 6.27 14.73
11 114-E-0140 1 3 6 5.00 2.43 12.40 11.50 15.80 14.73
12 114-E-0143 1 1 2 5.32 2.80 12.40 11.50 5.32 14.73
13 114-E-0145 1 3 6 6.17 3.02 12.40 11.50 19.31 14.73
14 114-E-0147 1 1 2 6.81 3.34 12.40 11.50 6.81 14.73
15 114-E-0151 1 1 1 1.97 1.97 3.90 3.00 1.97 6.23

Table-2(Exchanger Description)
No. Item No. Description Weight(Ton) Volume(CBM)

1 114-E-0108 Hot flash vapor condenser 28 111

2 114-E-0110 First stage hot separator vapor condenser 278 1098
3 114-E-0111 Ip condensate cooler 20 85
4 114-E-0120 Second stage hot separator vapor 156 561
condenser
5 114-E-0121 Stripper condenser 137 575
6 114-E-0125 Product fractionators bottoms cooler 528 1689
7 114-E-0126 Diesel pump around cooler 18 76
8 114-E-0131 Kerosene pump around cooler 70 270
9 114-E-0134 Product fractionators condenser 218 861
10 114-E-0136 Debutanizer condenser 34 146
11 114-E-0140 Naphtha splitter condenser 92 352
12 114-E-0143 Heavy naphtha product cooler 29 114
13 114-E-0145 Kerosene product cooler 111 432
14 114-E-0147 Diesel product cooler 49 180
15 114-E-0151 Flash Steam condenser 7 25

For exchanger plot plan please Refer Attachment A_Pipe rack plot plan and exchanger details.

It comprises of various loads:

 Equipment Empty- It is in-situ weight of equipment along with internal piping, insulation and platforms,
but excluding weight of fluids or products.

Load Calculation Example: -

 Weight of 114-E-143 = 29 MT for 1 bays

Each bay = 29/1 = 29 MT =290 KN
Reaction on each column = 290/4 = 72.5KN

 Weight of 114-E-125 = 528 MT for 1 bays

Each bay = 528/7 = 75.43 MT =754.3 KN
Reaction on each column = 754.3/4 = 188.6KN

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Equipment Empty
-72.500 kN

-72.500 kN

-85.000 kN -72.500 kN

-50.000 kN -72.500 kN
-50.000 kN
-45.000 kN -85.000 kN
-45.000 kN -17.500 kN
-17.500 kN -50.000 kN
-50.000 kN
-45.000 kN
-45.000 kN -17.500 kN
-17.500 kN

Load 11

 Equipment Operating- It is the weight of equipment including liquid weight in operating conditions.

Load Calculation Example: - Equipment operating (content) is calculated by multiplying 1.5 with dead
equipment empty as per discussion with mechanical discipline.

 Weight of 114-E-143 = 29 MT for 1 bays

Each bay = 29/1 = 29 MT =290 KN
Reaction on each column = 290/4 = 72.5KN
Equipment Operating Load = 72.5X1.5 =108.8KN

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 -108.800 kN
Equipment Operating
-108.800 kN
-127.500 kN
-108.800 kN

-108.800 kN
-75.000 kN -127.500 kN
-75.000 kN
-67.500 kN
-67.500 kN -75.000 kN
-26.300 kN -75.000 kN
-26.300 kN
-67.500 kN
-67.500 kN
-26.300 kN
-26.300 kN

Load 12

 Equipment Test (Content) - It is the weight of equipment including hydro test liquid, usually water,
required hydro testing.

Load calculation Example: - Equipment Test (content) is calculated by multiplying 1.5 with dead
equipment empty as per discussion with Mechanical Discipline.

 Weight of 114-E-143 = 29 MT for 1 bays

Each bay = 29/1 = 29 MT =290 KN
Reaction on each column = 290/4 = 72.5KN
Equipment Operating Load = 72.5X1.5 =108.8KN

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Equipment Test (Content)

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 -108.800 kN

-108.800 kN
-127.500 kN
-108.800 kN

-108.800 kN
-75.000 kN -127.500 kN
-75.000 kN
-67.500 kN
-67.500 kN -75.000 kN
-26.300 kN -75.000 kN
-26.300 kN
-67.500 kN
-67.500 kN
-26.300 kN
-26.300 kN

Load 13

PIPING LOAD
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 pipe racks. 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)

Where: s = Spacing of pipe rack bent,

p = pipe weight considered (KPa),
d = pipe diameter,
W = pipe concentrated load.

It comprises of various loads:

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 Piping Empty- It is in-situ weight of piping along with internal piping, and insulation, but excluding weight
of fluids or products.

Uniform piping load @ 1.2KN/m2 (As per Petrofac Design Guide & Standard practice)
Piping load on each beam = 1.2KN/m2 x 6m (Beam Span) = 7.2KN/m (Acting as UDL)
Piping Empty

-7.200 kN/m -7.200 kN/m

-7.200 kN/m -7.200 kN/m

-7.200 kN/m -7.200 kN/m

-7.200 kN/m -7.200 kN/m

Load 4

 Piping Operating- It is the weight of piping including liquid weight in operating conditions.

Uniform piping load @ 1.7KN/m2 (As per Petrofac Design Guide & Standard practice)
Piping load on each beam = 1.7KN/m2 x 6m (Beam Span) = 10.2KN/m (Acting as UDL)

Piping Operating

-10.200 kN/m -10.200 kN/m

-10.200 kN/m -10.200 kN/m

-10.200 kN/m -10.200 kN/m

-10.200 kN/m -10.200 kN/m

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Load 5

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 Piping Hydro test- Loading due to hydrostatic testing of lines should be considered in the design,
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 pipe rack 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.

Considered Uniform piping load @ 1.7KN/m2 (As per Petrofac Design Guide & Standard practice)
Piping load on each beam = 1.7KN/m2 x 6m (Beam Span) = 10.2KN/m (Acting as UDL)

Piping Test Content

-10.200 kN/m -10.200 kN/m

-10.200 kN/m -10.200 kN/m

-10.200 kN/m -10.200 kN/m

-10.200 kN/m -10.200 kN/m

Load 6

FRICTIONAL (THERMAL) LOAD

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 pipe rack design. Friction between piping and supporting steel should not be relied
upon to resist wind or seismic loads.

It comprises of various loads:

 Piping Frictional Longitudinal-

a. If number of Pipes > 6 then:
Longitudinal Friction forces considered as 10% of (Operating Empty Weight of Piping)

b. If number of Pipes 3 to 6 then:

Longitudinal Friction forces considered as 20% of (Operating Empty Weight of Piping)

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 c. If number of Pipes < 3 then:
Longitudinal Friction forces considered as 30% of (Operating Empty Weight of Piping)

-1.520 kN/m

-1.520 kN/m -0.530 kN/m

-1.520 kN/m
-0.530 kN/m
-1.520 kN/m
-1.520 kN/m

-1.520 kN/m -0.530 kN/m

-1.520 kN/m
-0.530 kN/m
-1.520 kN/m

Load 14

 Piping Frictional Transverse-

Transverse Friction forces considered as 5% of (Operating Empty Weight of Piping)

-0.530 kN/m

-0.530 kN/m

-0.530 kN/m

-0.530 kN/m

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Load 14

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ANCHOR LOAD

Pipe racks 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 paperback 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 defined by the transverse anchor forces. 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.

It comprises of various loads:

 Piping Anchor Longitudinal-

Longitudinal Friction forces considered as 12% of (Operating Empty Weight of Piping)

(AS per Petrofac Design Guide & Standard practice)

Piping Anchor Longitudinal

-1.200 kN/m

-1.200 kN/m -1.200 kN/m

-1.200 kN/m -1.200 kN/m

-1.200 kN/m -1.200 kN/m

-1.200 kN/m

Load 7

 Piping Anchor Transverse-

Transverse Friction forces considered as 15% of (Operating Empty Weight of Piping)

(AS per Petrofac Design Guide & Standard practice)

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Piping Anchor Transverse

-1.520 kN/m

-1.520 kN/m

-1.520 kN/m

-1.520 kN/m

Load 8

TEMPERATURE LOAD

Pipe Rack is subjected to a thermal load due to fluctuation of ambient design temperature with respect to its
construction temperature (i.e. stress free temperature). Pipe rack shall be designed for both maximum
temperature rise (TR) and minimum temperature fall (TF) as follow:

In summer Temperature rise= TR

In winter Temperature fall= TF
Construction Temperature=Tc

Structure to be designed for-

a. Temperature Rise, T=TR-Tc

b. Temperature Fall, T= TF-Tc

In this pipe rack we have considered:

 Temperature rise = 30oC
 Temperature fall = -30oC
(AS per Petrofac Design Guide & Standard practice)

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Temperature Load

Load 15

WIND LOAD

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.

It comprises of various loads:

 Wind Longitudinal Direction(X Direction)

Load 17

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  Wind Transverse Direction(Z Direction)

Load 18

For wind load calculation please Refer Attachment B_Wind Load.

SEISMIC LOAD

Earthquake loads in the vertical, transverse, and longitudinal directions should be determined in accordance
with the project design criteria. Vertical, transverse, and longitudinal seismic forces generated by the pipes,
raceways, supported equipment, and the paperback 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.

Seismic loads are calculated based on provisions of ASCE 7-10. Seismic Design Category “B” with Spectral
response accelerations for short period and one second periods are Ss = 0.32g, S1 = 0.13g respectively and
Importance Factor 1.25 as per Project Design Basis.

It comprises of various loads:

 Seismic Longitudinal Direction

 Seismic Transverse Direction

For seismic load calculation please Refer Attachment C_Seismic Load.

CRANE (MONORAIL) LOAD:

Monorail will be used to lift the pump portion of the pump. Motor will not be lifted by the monorail, Monorail
capacity to be indicated on the drawing. Weight of chain and pulley block to be considered while designing the
monorail

Crane (Monorail) Capacity = 10 KN (Taken same for all three cases defined below)
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It comprises of various loads:

 Crane Load (Left Side)

 Crane Load (Right Side)
 Crane Load (Parked)

Crane Load (Left Side)

-10.000 kN
-10.000 kN
-10.000 kN
-10.000 kN
-10.000 kN
-10.000 kN

Load 26

Crane Load (Right Side)

-10.000 kN
-10.000 kN
-10.000 kN
-10.000 kN
-10.000 kN
-10.000 kN

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Load 27

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LOAD COMBINATIONS:

The following considering while Appling load combinations:

 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.

12. CONNECTIONS

For longitudinal beams, simple shear connections at ends and pinned connections for bracings are generally
provided. Longitudinal beams connections are designed to carry axial loads. To allow for movement in the
longitudinal direction due to thermal expansion, a break in continuity is provided in between adjacent racks.
Constructability requirements shall be considered while designing the connections.

There are three types of connections between structural elements:

 Moment Connections - This type of connection is provided in the transverse Direction of pipe rack.

 Shear Connections- This type of connection is provided in the longitudinal direction of pipe rack

 Axial Connections- This type of connection is provided for the bracing in the structure which is
provided at the anchor bay location.

a. Bolted Moment Connection

b. Base Plate Design for pinned condition

For base plate calculation please Refer Attachment F_Base Plate

c. RC Corbel design:
Corbels are cantilevers having shear span-to depth ratios not greater than unity, which tend to act as
simple trusses or deep beams, rather than flexural members designed for shear. The corbel may fail by
shearing along the interface between the column and the corbel, by yielding of the tension tie, by crushing or
splitting of the compression strut, or by localized bearing or shearing failure under the loading plate.

For RC Corbel calculation please Refer Attachment G_RC Corbel Design

d. Precast Concrete column to Precast column connection:

 Tensile forces are transferred between concrete column elements by means of sleeves which are
anchored into each side of the precast elements at the joint with continuity achieved by dowel action.

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  The method used here is grouted pipe sleeves with in-situ lapped reinforcement; generally sleeves are
20 to 30mm larger diameter than dowel diameter.
 The dowel bar is inserted into the sleeve and grout is injected through a hole at the base. Alternatively,
the grout may be placed by gravity pouring. In either case, the sleeve must be vented to prevent
formation of air pockets.
 To ensure effective force transfer, stirrups are placed along the lapping length.
 Shear forces are transferred through shear key only.
 Concrete is considered cracked while calculating reinforcement to resist Dowel tension and shear.
 In case reinforcement is provided to resist tension, the concrete breakout strength of the Sleeve /
Dowel in tension has not been considered in checking the Sleeve / Dowel size.

For Precast Concrete column to precast column connection calculation please Refer Attachment I_
Precast Concrete column to precast column connection

e. Cast in situ concrete column to precast concrete column connection:

 Tensile forces are transferred between concrete column elements by means of Anchor bolts in Cast in
situ columns and sleeves which are anchored into each side of the precast elements at the joint with
continuity achieved by dowel action.
 The method used here is grouted pipe sleeves with in-situ lapped reinforcement; generally sleeves are
20 to 30mm larger diameter than dowel diameter.
 The dowel bar is inserted into the sleeve and grout is injected through a hole at the base. Alternatively,
the grout may be placed by gravity pouring. In either case, the sleeve must be vented to prevent
formation of air pockets.
 To ensure effective force transfer, stirrups are placed along the lapping length.
 Shear forces are transferred through shear key only.
 Concrete is considered cracked while calculating reinforcement to resist Dowel tension and shear.
 In case reinforcement is provided to resist tension, the concrete breakout strength of the Sleeve /
Dowel in tension has not been considered in checking the Sleeve / Dowel size.

For Cast in situ concrete column to precast concrete column connection calculation please Refer
Attachment H_Cast in situ concrete column to precast concrete column connection

13. ALLOWABLE HORIZONTAL AND VERTICAL DEFLECTION:

Allowable deflections of pipe rack structures shall be as per project design criteria, consider the
following as limit of deflection: Lateral deflection produced by load combinations that include wind or seismic
forces: Pipe racks supporting equipment: h/100, unless a more stringent requirement is given by the
manufacturer of the equipment.
Pipe racks 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 criteria,
Vertical deflection of beams due to gravity pipe loads: as per project design criteria, where h is the total height
of the pipe rack structure.

14. UTILITY RATIO CHECK

Max. Utility ratio in members is as follows: -

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Columns
Beam Analysis Design Actual Allowable Normalized Clause L/C
Property Properety Ratio Ratio Ratio
5917 W18x86 W18x86 0.703 0.850 0.827 Clause H1/2 253

Beams
Beam Analysis Design Actual Allowable Normalized Clause L/C
Property Properety Ratio Ratio Ratio
1154 W18x76 W18x76 0.832 0.850 0.979 Clause H1/2 217

Horizontal Bracings
Beam Analysis Design Actual Allowable Normalized Clause L/C
Property Properety Ratio Ratio Ratio

Vertical Bracings
Beam Analysis Design Actual Allowable Normalized Clause L/C
Property Properety Ratio Ratio Ratio
7215 WT18x33.5 WT18x33.5 0.608 0.850 0.716 Clause E 256

Columns and Beams

0.832
0.566

0.703
0.622
0.719
0.566
0.701

0.369
0.622
0.671 0.832
0.488
0.407

0.703
0.513
0.671
0.488
0.701

0.513
0.671
Load 21

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Vertical Bracings
258
0.729
3106
0.425
257 0.0646
0.608
0.607
0.0646 0.56
3498

3499
0.567 0.609

0.608 218

0.671

217

Note:
 Normalized ratio = (Actual ratio / Allowable ratio)
 There are no horizontal bracings in this pipe rack.

15. CONCLUSION:

Design calculations have been performed as per American Standards, LRFD method & Project specifications.
Based on the design calculations, Structural drawings have been prepared. Load 21

From the member utility ratio, it is seen that all the members have utility ratio less than 1.0 but restricted utility
ration to 0.85 only because final input loads not received yet from piping discipline. It is concluded that
Members and its connections are adequate from strength as well as serviceability conditions as per American
standards.

Please refer Attachment J_GA Drawings for final output of pipe rack.

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 ATTACHMENT- A:

Pipe Rack Plot Plan and Exchanger Details

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 ATTACHMENT- B:

WIND LOAD CALCULATIONS

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 ATTACHMENT- C

SEISMIC LOAD CALCULATIONS

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 ATTACHMENT- D

LOAD COMBINATIONS CALCULATION

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 ATTACHMENT- F
ABBREVIATIONS:
 KNPC Kuwait National Petroleum Corporations

 PIL Petrofac Engineering India Private Limited

 FW Foster wheeler

 GA General Arrangement

 AISC American Institute of Steel Construction

 ASCE American Society of Civil Engineers

 ACI American Concrete Institute

 IBC International Building Code

 ASTM American Society for Testing and Materials

 CDU Crude Distillation Unit

 HCR Hydrocracker Unit

 VRU Vacuum Rerun Unit

 TOS Top of Steel

 TOC Top of Concrete

 LRFD Load & Resistance Factor Design

 ASD Allowable stress design

 FEED Front End Engineering & Design

 NHT Naphtha Hydro theater.

 DHT Diesel Hydro Theater

 CCR Continuous Catalytic reformer

 HOC Heavy oil cooling

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 ATTACHMENT -F

BASE PLATE DESIGN FOR PINNED CONDITION

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 ATTACHMENT- G

RC CORBEL DESGIN CALCULATIONS

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 ATTACHMENT- H

Precast Concrete column to precast column connection

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 ATTACHMENT- I

Cast in situ concrete column to precast concrete column connection

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 ATTACHMENT- J
GA Drawings

PIPE RACK DESIGN (useful info for beginners)

Published on May 30, 2017

Yousaf Munawar (Sr. Piping Designer)Follow

Proffessional Piping Designer Level-III & IV Certified From SPED


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PIPE RACK DESIGN CRITERIA

PIPE RACK
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

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

Fire proofing requirements

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Statutory requirements

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 up to 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.

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

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Sustained Load (Live Load)

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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 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.

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)

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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.

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