Professional Documents
Culture Documents
A PROJECT REPORT
Submitted by
JAYENDRAVEL.S
KESAVRAMAN.S
LARSEN SAMUEL.S
MOHAMED MUZAMIL.B.A
MOHAMED SATHIR.M
CHENNAI-600 073
BONAFIDE CERTIFICATE
Certified that this project report “DESIGNING OF STEEL PIPE RACK” Is the
bonafied work of “JAYENDRAVEL.S (U07CE058), KESAVRAMAN.S
(U07CE071), LARSEN SAMUEL.S (U07CE078), MOHAMED MUZAMIL.B.A
(U07CE094), MOHAMED SATHIR.M (U07CE096)”
SIGNATURE SIGNATURE
S.SANKARAN Mr.T.P.MEIKANDAAN
2
ACKNOWLEDGEMENT
We are privileged to thank our Principal Dr. R.Kari Thangaratnam for the
facilities extended to us during this course.
We extent our thanks to all the non-teaching staff of Civil Engg Dept those
who helped us in completing this project successfully.
3
ABSTRACT
It is common to overemphasize the structural design of pipe support structures, rather
than focus on Detailing for stability or economics and practical aspects of the steel structure and
the hanger-type pipe Supports or the trapezes supported by another structure, such as the main
building frame, are referred to as pipe support structure. For the purposes of this discussion, the
terms pipe racks, pipe supports, and pipe support structures are interchangeable. Essential
elements for limit states of pipe support systems are often ignored, since these systems are
comprised of secondary elements and rarely impact the structural integrity of any industrial
facility. Structural failures of pipe supports are neither documented nor disseminated to the
structural community. The structural design of pipe racks varies widely depending of pipe racks
varies sidely. Depending upon the plant operations and the associated plant standards. However,
pipe rack failures could cause serviceability problems for plant operations. Failures of pipe
support system could potentially impact the health, welfare, and safety of plant personnel die to
pipe breakage or leaks. The Following discussion includes a review of the considerations
involved in the design, detailing, and structural stability of pipe racks. Optimal solutions are still
4
TABLE OF CONTENTS
NO. NO.
ACKNOWLEDGEMENT i
ABSTRACT ii
LIST OF ABBREVIATION ix
1 INTRODUCTION 1
1.1 GENERAL 1
1.2 SCOPE 1
1.3 TERMINOLOGY 1
1.3.1 Structure 2
1.4 FOUNDATIONS 3
1.4.1 Footing 3
5
1.4.2 Longitudinal Beam 3
2 LITERATURE REVIEW 6
3 DESIGN PROCEDURE 7
3.1 CONVENTIONAL PIPE RACK 7
Of Pipe Rack 13
4 LOAD CALCULATION 19
4.1 PIPE LOAD 19
in grid A - (Z - Direction) 29
in grid B - (Z - Direction) 30
6
5 DESIGN OF BASE PLATE 33
5.1 LOADING 33
5.5 CALCULATIONS 35
6 DESIGN OF PEDESTAL 37
6.1 PEDESTAL MARK 37
7
8 CONCLUSION 63
REFERENCE 64
8
LIST OF TABLES
9
LIST OF FIGURES
10
LIST OF SYMBOLS AND ABBREVATIONS
SYMBOLS DESCRIPTION
Asv Total cross-sectional area of stirrup legs or bent up bars within distance sv.
a Lever arm.
ac Area of concrete.
b Width.
br Width of rib.
C Compressive force.
11
D Depth.
d Effective depth.
ds Depth of slab.
e Eccentricity.
F Shear force,
H Height.
I Moment of inertia.
L Length.
Ld Development length.
M Bending moment.
Mr Moment of resistance.
Mt Torsional moment.
12
m Modular ratio.
Pu Ultimate load.
P Percentage steel.
Q Shear resistence.
X Co –ordinate.
13
Z Distance; Co-ordinate.
α Inclination; coefficient.
β Surcharge angle.
μ Coefficient of friction.
τc Shear stress.
Ф Diameter of bar.
14
CHAPTER – 1
INTRODUCTION
1.1 GENERAL
Pipe rack is the main artery of any plant. This carries the pipes and cable trays (raceways)
from one equipment to another equipment within a process unit (called ISBL piperack) or carries
the pipe and cable trays from one unit to another unit (called OSBL pipe rack). Sometimes you
will also find the air cooled heat exchangers on the pipe rack.
1.2 SCOPE
This design guide defines the minimum requirements for the design of piperack in process
industry facilities at the sites. It covers general design philosophy and requirements to be used in
the analysis and design of piperack. Criteria presented herein pertain to loads, load combinations,
allowable stresses, and superstructure and foundation design.
1.3 TERMINOLOGY
- Concrete foundation.
15
1.3.1 Structure
The main cross beam is a horizontal beam connected to two posts to form the portal
frame and to support the pipes.
The element of piperack forms by two posts and one or more main cross beams.
The longitudinal beam is a horizontal beam connecting two portal frame in longitudinal
direction. Generally, the members are used to support the lateral forces, intermediate cross beams
and post of coolers. Especially to transmit the horizontal force to the bracing bay.
The width of piperack is the distance between the axis of the posts.
16
1.4 FOUNDATIONS
1.4.1 Footing
Footing is a member rest on good ground, in the case of pile this is called pipe cap.
17
- Longitudinal beam semi-incorporated with the footing.
• Modular Piperack
Continuous Piperack (conventional pipe rack) system: This 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. Piperacks supporting
equipment such as air-cooled heat exchangers must utilize the continuous system approach.
18
Piperack Modules: Structural Frames completely fitted with pipes, Cable trays and
miscellaneous equipment.
19
CHAPTER – 2
LITERATURE REVIEW
Kasi V. Bendapudi, P.E., S.E. Structural steel pipe supports are extensively utilized in
industrial and manufacturing facilities. Lack of uniform industry standards for this topic leads to
each organization adopting its own engineering standards, at times, without a clear understanding
of the underlying theoretical concepts and the cost implications. This is the first of a two-part
series of articles on the behavior and design of steel support structures for pipes. This article
discusses the effects of ambient temperature changes, expansion joint requirements, and an
introduction to design loads. Part 2 concludes with the continuation of design loads, structure
stability concepts and detailing for stability requirements. It is common to overemphasize the
structural design of pipe support structures, rather than focus on detailing for stability or economics and
practical aspects of the steel structure and the foundations. This is sometimes referred to as "over-
designing" and "under-detailing". Sometimes the hanger-type pipe supports or the trapezes supported by
another structure, such as the main building frame, are referred to as "pipe support structures.
Frank E. Richart. Publication: Journal Proceedings. In these tests, major emphasis has
been placed on the combined column footing. Principal attention has been given to the resistance
of footings to failure by bond, diagonal tension and tension in the steel.
Taylor and francis.January 29, 2008 ; The principal features of the new edition is the
discussion of behavior of the steel structures and exemplify details of the design process.
20
CHAPTER – 3
DESIGN PROCEDURE
Continuous Piperacks (conventional pipe rack) system: This 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. Piperacks supporting
equipment such as air-cooled heat exchangers must utilize the continuous system approach.
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 piperack design.
Therefore, as a Civil/Structural Engineer, you 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 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".
• 3D model showing piping layout, cable tray layout, Piperack 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.
• 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
21
and maintenance requirements, and the magnitude and direction of loads being transmitted to the
piperack.
• Electrical and control systems drawings showing the routing and location of
electrical and instrumentation raceways and/or supports.
Please note that, Unless specifically explained in the project design criteria, no allowance or
provisions should be made for future additions for pipe or raceway space and related loading.
Piping Gravity load (D): 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 piperacks. 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), s = Spacing of piperack bent, p = pipe weight considered (kPa), d = pipe
diameter W = pipe concentrated load.
Where consideration of uplift or system stability due to wind or seismic occurrences is required,
use 60% of the design gravity loads as an "all pipes empty" load condition.
22
Loading due to hydrostatic testing of lines should be considered in the design if
applicable. 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 piperack 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.
Electrical Tray and Conduits (D): Electrical and control systems drawings and/or the
project 3D model should be reviewed to determine the approximate weight and location of
electrical trays, conduits, and instrumentation commodities. Unless the weight of the loaded
raceways can be defined, an assumed minimum uniform load of 1.0 kPa should be used for
single tier raceways.
Self weight of Pipe rack (D): The weight of all structural members, including
fireproofing, should be considered in the design of the piperack.
Weight of Equipment on pipe rack (D): Equipment weights, including erection, empty,
operating, and test (if the equipment is to be hydro-tested on the piperack) , 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 aslarge valves, expansion loops, and unusual piping or
electrical configurations.
Live Load (L): Live load (L) on access platforms and walkways and on equipment
platforms should be considered, as applicable.
Wind Load (W): 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.
23
Friction Loading (Tf): 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 piperack design. Friction between piping and supporting steel should not be relied
upon to resist wind or seismic loads.
Anchor and Guide Loads (Ta): Piperacks 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 piperack 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 usually small and may be
ignored until they are defined by the Pipe Stress Engineer. 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.
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********FOUNDATION DESIGN********
25
LOAD COMB 29 DL+LL+FLX+FLZ-WLZ
Please note that, all friction forces and anchor forces with less magnitude, (say ~ 5.0 kN),
applied to the top flange of the beam, may be considered as resisted by the total beam section.
When anchor loads have large magnitude and are applied to the top flange of the beam, the effect
of torsion must be addressed. If the beam section is inadequate to take care of this torsional
force, alternatives to be considered, such as provide horizontal bracings at the load locations.
You need to create the load combinations per your project design criteria. However, I
have referred here some load combinations.
26
• 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.
For calculation of foundation soil bearing pressures or pile loads, stability checks against
overturning, sliding, and buoyancy, and deflection checks, the following unfactored load
combinations (ACI 318) shall be used:
1. D
2. D + L + SL + Tf + Ta
3. D + Tf + Ta
4. D + 1.3W + Ta
6. D + L + S +0.65W + Ta
7. 0.9De + 1.3W + Ta
8. D + E/1.4 + Ta
9. D + 0.2S + E/1.4 + Ta
27
Load Combinations for design of foundations
1. 1.4D
1. 1.4D
28
3.1.4 Final anchor and guide load check
Where the design of transverse beams has been based on anchor loads as explained in
design load consideration final check of beams (and other affected members) should be made
when final definition of these loads is available from the Pipe Stress Engineer. Based on the
Engineer's experience and judgement, an overstress in any element (of up to 10%) can be
considered, provided proper justification is given. Where such overstress cannot be properly
justified, modifications should be made to the piperack structure in order to bring the stress
levels within the normal allowables. Modifications could entail the addition of horizontal
bracing to the transverse beams to resist significant loads from the anchor(s), replacing and/or
adding members, strengthening members (i.e.,cover plating, etc.), and/or relocating the anchor
and guide load(s).
Frames
29
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, modeled
and analyzed as part of the frame system. The analysis model must reflect the appropriate beam
end conditions. In the design of beams, consideration should be given to
• Anchor and friction load with large magnitude (see step-2, anchor and friction
load)
Central Spine
For steel piperacks with spans of more than 6 m, a center 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 typical continuous piperack 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.
30
For any continuous piperack 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.
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.The frame analysis model should be
based on the following:
31
For design of steel columns subjected to flexural loads, the distance between the base and
the first transverse beam or the knee brace intersection should be considered as the compression
flange unbraced length.
32
CHAPTER – 4
LOAD CALCULATION
4.1 PIPE LOAD
Load Calculation for 2", 6", 12" & 16" diameter pipe (Pipe weight + Pipe filled with oil)
As per the load data obtained from the piping input, the loads for the pipes are as
tabulated below:
Table-4.1 Load Calculation For Pipe Load
Weight of
Weight Weight water +
Weight Weight of Pipe of water x Weight of Total
Pipe Dia No of of Pipe of oil x Nos Nos Pipe weight
(inches) Pipes (Kg/m) (Kg/m) (Kg/m) (Kg/m) (Kg/m) (kg/m)
33
Fig 4.1 shows the pipe bridge is analysed using a structural software program staad pro. Analysis
has been carried out on the structural model considering all loads acting over the structure.
Analysed for various load combinations as per code.
34
Fig 4.2 The nodes numbers of the pipe rack
35
Fig 4.3 The beam numbers of the pipe rack
36
Fig 4.4 The top plan view of the pipe rack
37
Fig 4.6 Shows the Grid 1 and Grid 2 of the pipe rack
38
Fig 4.7 The vertical pipe load of the pipe rack
39
4.2 WIND LOAD CALCULATIONS AS PER IS 875-3
Site wind speed, Vs = Vb x Sa x Sd x Ss x Sp
Site wind speed, Vs = Vb x Sa x Sd x Ss x Sp=33.5
Site wind speed, Vs = Vb x Sa x Sd x Ss x Sp=2.75
40
4.2.1 Wind load calculation for the second frame in grid 1&2 - (X - Direction)
Wind load applied over Beam 2 & 3 LVL as udl = 0.31 kN/m
Wind load applied over Bracing as nodal load (1B) = 0.81 kN
Wind load applied over Bracing as nodal load (2B) = 0.58 kN
Wind load for bracing applied as nodal load (2B) = 1.15 kN
41
4.2.2 Wind Load applied in (Z - Direction) 90 Degree
Exposed Area for
Column = 0.32 x 8 x 3 = 7.68 Sqm
Beam (2-3) = 0.254 x 18.55 x 1 = 4.71 Sqm
42
4.2.3 Wind load calculation for the frame in grid A - (Z - Direction)
Wind load for bracing applied as nodal load for stub = 0.35
kN
43
4.2.4 Wind load calculation for the second frame in grid B - (Z - Direction)
Wind load for bracing applied as nodal load for stub = 0.35 kN
44
Fig 4.12 Shear force diagram at (Z-direction)
45
Fig 4.14 Bending moment at (Z-direction)
46
CHAPTER – 5
DESIGN OF BASE PLATE
5.1 Loading
Maximum compression = 360.01 KN
Maximum tension = 187.67 KN
Base Plate details
Length L = 625
Width B = 450
Concrete
Dia of bolt Φ = 27 mm
Total no of bolts N = 4 nos
Permissible Axial Stress = 240 N/mm2
Permissible shear stress = 160 N/mm2
Check for compressive stress in concrete
Σc= P/(LxB)
= 360.008x1000/(625x450)
= 1.920042667 < 8.75
SAFE
47
5.2 Design for tension
Maximum tension = 187.671 KN
No of bolts taking tension = 4
Tension per bolt = 70.376625 KN
= (6x3.96x1000000)/(150x165)
= 27.06193215 mm
48
Design bending moment M = wL2/8
= 12150.27 Nmm/mm
treq = 6M/(bxσbc)
= (6x12150.27)/(1x165)
= 21.01970504 mm
Provide 30mm thick base plate.
V = 82.43 kN
Number of bolts resisting tension Nt = 4
Number of bolts resisting shear Ns = 4
Actual tension/bolt =187.67/4 = 56.30 kN
Actual shear/bolt =82.43/4 = 30.91 kN
Diameter of bolt D = 27 mm
5.5 Calculations
Actual tensile stress = T/(n*PI()*D^2/4*0.8)
49
stf,cal =56.3x1000(3.14/4x20^2x0.8) = 122.9 N/mm2
Actual shear stress= V/(n*PI()*D^2/4*0.8)
tvf,cal =30.91x1000/(3.14*27^2/4x0.8) = 67.5 N/mm2
= 0.93
Allowable stress ratio = 1.4 SAFE
50
CHAPTER – 6
DESIGN OF PEDESTAL
6.1 Pedestal Mark
B
x
Design data
Column Size
Width, B = 600 mm
Depth, D = 775 mm
cover = 40 mm
Assuming dia of bar = 16 mm
Assuming dia of link = 8 mm
fcu = 35 N/Sqmm
fy = 460 N/Sqmm
b' = 544 mm
d' = 719 mm
b' / B = = 0.907
d' / D = 0.928
51
Effective length calculation
Unsupported length, about depth = 1.80 m
Unsupported length, about width = 1.80 m
Effective length factor about depth = 2
Forces on columns
Refer staad output of member end forces
Slenderness check
Slenderness about depth, Lex / D = 4.65
Slenderness about width, Lez / B = 6.00
52
6.2 Calculation of Nuz and K
Balance load, Nb = 0.25 x fcu x B x D = 4068.75 kN
Assuming ptmin = 0.4%, Asc = 0.4 x B x D / 100 = 1860 Sq
Nuz, (0.45 x fcu x Ac) +(0.95 x Asc x fy) 8136.57 kN
Additional moments
About major axis = aux, K x D x (Lex/D )^2/20000.00 mm
Max = N*aux = 0.00 kNm
As Mx / d' >Mz/b'
Mx' = Mx + Mz x β x d' / b' = 229.64 kNm
53
6.3 Section design - Ratios for chart entry
Axial load ratio =Nratio = N / (B x D) = 0.77
For design we have considered Maximum Moment about one axis
54
CHAPTER – 7
LC 30
X
PEDESTAL MARK
Col Mark SUM 1 2 cx1
Z wrt 1 0 4.2 z z b
X wrt 1 0 0 cx2
P (kN) -84.64 360.01 Cz1 x Cz2
Pedestal Size
lZ 0.6 0.6
lX 0.775 0.78
Pped 11.04 11.04
55
Depth of foundation below ground level (FGL)
Depth of foundation below Natural Ground Level (NGL)
Unit Weight of soil
Projections of Footing (from centreline of column)
Calculations
Col Mark SUM 1 2
( Pconc = P + Pped )
Pconc 297 -73.59 371.05
56
Mxc -168 -78.9113 -88.8576
Mzc 72 35.8943 36.0789
57
7.1.2 Transverse direction ( X - dir )
Redistributed Pressure
ez / l = 0.237
ex / b = 0.059
58
Max P= KQ/BL =3.02694942934839 X 608.804 / 7.65 X 2
= 120.4456811 OK
Design Pressure
Along Z - Direction
fzmax =Pv/A*(1+6*ABS(ez/l)) =608.8/15.3x(1+6x0.237)
Along X - Direction
59
Check For Overturning
R.M O.M
3262.43 Mx 167.7689 Mx
608.804 Mz 71.9732 Mz
Along X 19.45 Ok
Along Z 8.46 Ok
60
7.1.4 Load calculations for combined Footing “F1”
61
Total downward force
40.699 x 7.7 + 0.00 + 0.00 311.345 kN
SF
62
Basic Data:
Concrete grade M30 fck = 30 N/mm²
Steel grade Fe415 fy = 415 N/mm²
Load factor ld= 1.5
Section Data:
Projection of footing from col. face l = 1000 mm
Breadth of the footing b= 1000 mm
Depth of the footing D= 350 mm
Clear cover to reinf. d' = 75 mm
Dia of bar used f= 12 mm
Load data:
Maximum pressure fmax= 53.90 kN/m2
63
Provide 12mm dia bars @ 200 mm c/c
Provided Area of steel Astp = 565.5 mm²/m
Mu/bd2, R = 0.90
% of reinforcement required (Refer BS8110-3 1985 Chart no 9 : pg 17)
= 0.25
Min .% of reinforcement required = 0.20
Cover = 75.00
Dia of bar = 20.00
Area of cross section of bar = 314.29
Area of steel required ,As = 999.67
Provide number of bar dia required = 4.18
Hence, number of dia of bar provided = 6
64
7.1.6 Check For Shear
Factored Shear Force, Fu KN = 270.00
Nominal shear stress, tv N/mm2 = 0.68
B = 7.370365484
65
7.2 Design of Combined Foundation "F2"
Load Case LC 22
Net SBC SBCnet 106.25 kN/m2
Factor for inc in BC Fbc 1
Joint No 9 11
PEDESTAL MARK
Col Mark SUM 1 2
Z wrt 1 0 4.2
X wrt 1 0 0
P (kN) -30.26 295.35
Pedestal Size
lZ 0.6 0.6
lX 0.775 0.775
Pped 16.86 16.86
66
Projections of Footing (from centreline of column)
Calculations :
Col Mark SUM 1 2
xcor 0.9 5.1
ycor 1.25 1.25
Gross SBC SBCg= Fbc * SBCnet + gs * dfngl= 134.75 kN/m2 135 kN/m2
67
Total Axial Load incl wt of pedestal ( ∑Pconc ) ∑P 298.8005 kN
Area of foundation ( Provided ) A l*b 15 m2
Load due to soil Psoil gs*(df - d)*(A - ∑(lx*ly)) 307.43 kN
Weight of foundation Fbase A*d*25 131.25 kN
68
7.2.2 Transverse direction ( X - dir )
Redistributed Pressure
ez / l = 0.194
ex / b = 0.054
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Max P= KQ/BL = 2.56794251983484 X 737.48 / 6 X
= 126.25375 OK
Design Pressure
Along Z - Direction
fzmax =Pv/A*(1+6*ABS(ez/l)) =737.5/15x(1+6x0.194)
Along X - Direction
fxmax =Pv/A*(1+6*ABS(ex/b)) =737.5/15x(1+6x0.054)
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Check For Overturning
R.M O.M
2896.23 Mx 174.5892 Mx
921.85 Mz 100.431 Mz
Along X 16.59 Ok
Along Z 9.18 Ok
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7.2.4 Load calculations for combined Footing “F2”
BM
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Max B.M= 130 kNm 126.595
Max S.F= 150 kN 149.884
SF
Basic Data:
Concrete grade M30 fck = 30 N/mm²
Steel grade Fe415 fy = 415 N/mm²
Load factor ld= 1.5
Section Data:
Projection of footing from col. face l= 1250 mm
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Load data:
Maximum pressure fmax= 65.23 kN/m2
0 126.25375
2.5 8.01
85.45932963
98.18245899
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Moment =41.90260613-11.38176563 =30.52084051
M/bd2 =0.632678663
Pt = 0.18 0.31
Ast = 821.8482124
Spacing = 137.5436465
Shear Soil
Vu= 66.60144501 18.1611 48.44034501
Tv= 0.270113448
B= 11.40125568
Tc= 0.40274325 OK
Fck= 30 N/mm2
fy= 415 N/mm2
Maximum Bending moment KN-M = 130.00
Factored Bending Moment, Mu KN-M = 195.00
Effective depth of footing, d = 665.00
Shear Force V KN = 150.00
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Dia of bar = 20.00
Area of cross section of bar = 314.29
Area of steel required ,As = 812.22
Provide number of bar dia required = 3.58
B = 7.370365484
Allowable Shear Stress = 0.4852 N/mm2
Provide shear reinforcement Vu - = 31.42
2 Legged Provide 10mm bar at = 200.00
Provide 10 mm @ 200.00 mm c/c
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CHAPTER – 8
CONCLUSION
Pipe racks or pipe supports are considered as one of the most important parts in a refinery
which need to be constructed with precision. As supports of refinery pipes, such elements are
installed numerously, to carry pipes with different size and diameters. The accessories increase
the cost of the concrete pipe rack, therefore it shall be reduced to minimum. It is obvious that the
use of anchoring rail will make it easy to fix apparatus or secondary frame. In majority of
refineries, pipe rack systems are made of steel, and thus from the construction point of view, it is
considered a simple job with no difficulty. Overall pipe rack design must meet the current needs
of a client as well as any expansion plans without making major modifications to existing
facilities. Available space in the pipe rack must be considered valuable and used to the utmost
advantage of present and future needs.
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REFERENCE
DESIGN BOOKS REFERED
1. IS: 456-2000,“ Indian standard code of practice for Plain and Reinforced concrete”,
fourth revision.
2. IS: 800-2007, “Indian standard code of practice for general construction in steel”, third
revision.
3. IS: 875 Part 1, “Indian standard code of practice for Unit weights of materials”.
4. IS: 875-1987, “Design loads (other than earthquake) for buildings and structures” ,Part
3”Wind Loads.
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