PIPE RACK / WAYS

&
RACK PIPING
By,
Akshaya Sharma
Associate Engineer
Piping Department
Date 16th Nov 2006

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

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&IDs

Client Specification

Construction Materials

Fire proofing requirements

Statutory requirements
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PIPE RACK DESIGN CRITERIA

Shapes

Future Space

There are various shapes of pipe rack like L/T/U/H/Z.

These shapes shall be considered based on the area
available.

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
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pumps to be housed below pipe rack.

RACK WIDTH SELECTION CRITERIA

DIFFERENT SHAPES OF PIPE RACKS

DEAD END YARD LINES ENTER &

LEAVE ONE END OF THE RACK

L-SHAPED YARD LINES CAN

ENTER & LEAVE NORTH & EAST
OF THE RACK

STRAIGHT THROUGH YARD LINES

CAN ENTER & LEAVE BOTH ENDS
OF THE RACK

T-SHAPED RACK PIPING CAN

ENTER & LEAVE THREE SIDES OF
THE RACK

DIFFERENT SHAPES OF PIPE RACKS

COMPBINATION OF I & T SHAPED

RACK

U-SHAPED YARD LINE CAN ENTER

& LEAVE ALL FOUR SIDES OF THE
RACK

COMPLEX RACK PIPING ARRANGEMENT

FOR VERY LARGE CHEMICAL PLANT

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)

Thermal Laod

Load by thermal expansion of piping & Reaction

force by internal pressure of expansion bellows

Dynamic Laod

Weight of piping, valve and load insulation

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

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/nonexpansion of adjacent line. Non-expansion/thermal
contraction may stop the free expansion of the
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adjacent line at L bend location.

RACK PIPING

Bigger Size Lines

Anchor Bay

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.

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.

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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 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.

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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

LARGE SIZE PIPING AND HIGH TEMPERATURE
PIPING 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
prevent water hammering. But do as above if
horizontal 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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