Doc No: WI/07/CS/10

WORK INSTRUCTION FOR Rev: 0

DESIGN / DETAILING OF PIPE RACK Sec. No: 07
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1.0 Scope

This work instruction covers the Design / Detailing of Pipe rack system.

2.0 Responsibility

Drafter: Receive the required details and prepare drawing based on client requirements or Prou CAD
standard and as per instructions set out by designers.

Designer: Review the details, consult with the Team Lead and guide the drafter in detailing activities.

Team Lead: Review the information received from Client. The special requirements, other disciplines
are consulted. The insufficient and missing details if any are brought to the notice of either the Project
manager or the Client.

3.0 Inputs

Reference Documents
Client Standards
Scope of Work
Equipment Layout
Load Data
Plot Plan
Legends & Symbols

4.0 Methodology

Ascertain if there is enough information available to proceed for Design / Detailing. Else ask the
project manager to get the details from the client.

Refer to (G-6 AutoCAD Design Standards)

Get the relevant drawing template from P:\xxxx\xxxx\Drawings\General\Template enter the

title block, revision and date.

Guide Lines:

Pipe rack carries the pipes and cable trays (raceways) from one equipment to another 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 we find the AIR COOLED HEAT EXCHANGERS on the pipe
rack.

Step-1: Data collection for pipe rack design:

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, as a

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WORK INSTRUCTION FOR Rev: 0
DESIGN / DETAILING OF PIPE RACK Sec. No: 07
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Civil/Structural Engineer, coordination 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" (as part of calculation)

The following should be reviewed for design information:

 Plot plans and equipment location plans

 3D model showing piping layout, cable tray layout, 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.

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.

Step-2: Design loads consideration:

Following loads are to be considered for the pipe rack design:

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 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), s = Spacing of pipe rack 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.

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 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.

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

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WORK INSTRUCTION FOR Rev: 0
DESIGN / DETAILING OF PIPE RACK Sec. No: 07
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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 pipe rack.

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 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.

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

Snow Load (S): Snow load to be considered on cable tray and on large dia pipes. This load shall be
calculated per project approved design code and project design criteria. Generally, you need to consider
100% snow load on top tier and 50% on other tier of pipe racks.

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.

Earthquake Loads (E): 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 pipe rack 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.

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

Anchor and Guide Loads (Ta): 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
pipe rack 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 mid span 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.

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.

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DESIGN / DETAILING OF PIPE RACK Sec. No: 07
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Step - 3: Load Combinations and allowable deflection of pipe rack:

Create the load combinations per project design criteria. However, some load combinations shall be followed.

Please note the following:

 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.

For calculation of foundation soil bearing pressures or pile loads, stability checks against overturning, sliding,
and buoyancy, and deflection checks, the following un-factored load combinations (ACI 318) shall be used:

1. D
2. D + L + SL + Tf + Ta
3. D + Tf + Ta
4. D + 1.3W + Ta
5. D + L + 0.5SL + 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
10. 0.9De + E/1.4 + Ta

Load Combinations for design of foundations (ACI 318):

1. 1.4D
2. 1.4D + 1.7L +1.7S
3. 1.4D + 1.4Tf +1.4Ta
4. 0.75 (1.4D + 1.7L + 1.7S + 1.4Tf + 1.4Ta)
5. 0.75 (1.4D + 1.7L + 1.7S + 1.4Ta) + 1.6W
6. 1.2D + 0.2S + 1.0E + 1.2Ta
7. 0.9De + 1.6W + 1.2Ta
8. 0.9De + 1.0E + 1.2Ta

Steel Design load combinations: (AISC - LRFD)

1. 1.4D
2. 1.2D + 1.6L + 0.5S + 1.2Tf + 1.2Ta
3. 1.2D + 1.6S + 0.5L + 1.2Tf + 1.2Ta
4. 1.2D + 1.6S + 0.8W + 1.2Ta
5. 1.2D + 1.6W + 0.5L + 0.5S + 1.2Ta
6. 1.2D + 1.0E + 0.5L + 0.2S + 1.2Ta
7. 0.9De + 1.6W + 1.2Ta
8. 0.9De + 1.0E + 1.2Ta

De is the minimum dead load on the structure.

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DESIGN / DETAILING OF PIPE RACK Sec. No: 07
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FINAL ANCHOR AND GUIDE LOAD CHECK:

Where the design of transverse beams has been based on anchor loads as explained in step-2, a 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 pipe rack 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).

ALLOWABLE HORIZONTAL AND VERTICAL DEFLECTION:

Allowable deflections of pipe rack structures shall be as per project design criteria. However, one can 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 h is the total height of the pipe rack structure.

Step-4: 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, 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

 Large pipes that are to be hydro-tested.

 Anchor and friction load with large magnitude (see step-2, anchor and friction load)

Central Spine:

For steel pipe racks with spans of more than 6 m, a center spine consisting of a system of horizontal braces
and struts located at mid span 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 un-braced length of the beam compression flange in flexure and to
reduce the un-braced 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.

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

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WORK INSTRUCTION FOR Rev: 0
DESIGN / DETAILING OF PIPE RACK Sec. No: 07
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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. Concentrated loads for large
pipes may be treated as in step-2.

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 un-braced 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:

 Consider column base as hinge.

 Use 4 bolt connections for safety purpose

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 un-
braced length.

5.0 Quality Check

Design Check (D) checked by Lead.

If no comments, pass it to Design Continuity Check or else pick up markups and resubmit for
Design Check.

Design Continuity Check (Tc) checked by Designer.

If no comments, pass it to Presentation Check or else pick up markups and resubmit for Design
Continuity Check.

Technical Peer Check (Tr) checked by Team Lead.

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DESIGN / DETAILING OF PIPE RACK Sec. No: 07
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If no comments, pass it to Design Check or else pick up markups and resubmit for Technical Peer
Check.

Presentation check (P) checked by Checker.

If no comments, prepare transmittal or else pick up markups and resubmit for Presentation
Check.

Ensure QA Tracking Form is duly signed by Designer, Checker, TeamLead & Project Manager
and store it in relevant folder.

Send the Design doc / Dwg with Transmittal to client .

Receive comments from client.

If approved, issue for Construction else pick up markups and resubmit to Design Check.

6.0 Records

Master copy to be kept in proper records and maintained

Put in place a strict follow-up, record and filing of changes.

Provide evidences/justifications for the design change.

Date : Reviewed By : Approved By :