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INDUSTRY CODES AND STANDARDS(AMERICAN)
1. American Concrete Institute (ACI)
(a) ACI 318 Building Code Requirements for Reinforced Concrete
2. American Society of Civil Engineers (ASCE)
(b) ASCE 7 Minimum Design Loads for Buildings and Other Structure
3. Wind Load and Anchor Bolt Design for Petrochemical Facilities
4. Guidelines for Seismic Evaluation and Design of Petrochemical
Facilities
5. American Institute of Steel Construction (AISC)
AISC Manual of Steel Construction – Allowable Stress Design (ASD)
INDUSTRY CODES AND STANDARDS
6. American Society for Testing and Materials (ASTM)
(a) ASTM A36 Specification for Carbon Structural Steel
(b) ASTM A325 Specification for High strength Bolts for Structural Steel
Joints, Including Suitable nuts and Plain Washers
(c) ASTM A992/A992M Specification for Steel for Structural Shapes for
Use in Building Framing
DEFINITION OF PIPE RACK
• Pipe Racks are structures that support pipes and may support auxiliary
equipment within and between process areas of industrial plants.
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STRUCTURAL STEEL MATERIAL FOR PIPE RACK
A36 CARBON STEEL ASTM A992
• It is often used for plates , Structural Shapes, • It is often used for Steel wide‐flange and I
Bars, Sheets, Girders, Angle iron, T iron etc. beams.
• Yield Strength = 36 ksi • Yield Strength = 50 to 65 ksi
• Tensile Ultimate Strength = 58‐80 ksi • Tensile Ultimate Strength =65 ksi
• A36 material is readily welded by all welding • It is currently the most available steel type for
processes. structural wide‐flange beams
‐ Shielded metal arc welding (SMAW, or stick
welding),Gas metal arc welding (GMAW, or
MIG welding), and Oxyacetylene welding.
• A36 steel can be commonly bolted and
riveted in structural applications.
The Foundation and pedestal shall be of Reinforced Cement Concrete Material with recommended
minimum 28 day compressive strength of concrete as 4000 psi.
DESIGN CONSIDERATIONS FOR SUPER STRUCTURE
STRUCTURAL STEEL
1. Pipe Racks and their Foundations shall be designed to support loads associated with
full utilization of the available pipe rack space, and any specified future expansion.
2. The recommended deflection requirements for Pipe Rack beams and transverse
bents is as follows:
(a) The recommended maximum allowable beam deflection Dmax due to total load shall
be as follows:
Dmax = L/240 (L = Span Length)
(b) The recommended maximum allowable drift limits for Pipe Rack shall not exceed
Hmax = H/150 (H = Pipe Rack height)
3. The maximum allowable seismic drift limits for Pipe Rack shall be in accordance with
ASCE 7 – 16.
DESIGN CONSIDERATIONS FOR STRUCTURAL STEEL
CONNECTIONS
1. Connections for steel Pipe Racks shall conform to the following requirements:
a. Shop connections ‐ Either bolted or welded.
b. Field connections ‐ Bolted
c. Bolted Connection is not suitable ‐ Welded Connection
2. Bolted connections for primary members shall utilize high‐strength bolts conforming
to ASTM A325N, bearing‐type connections with threads included in the shear plane.
LOAD CASES TO BE APPLIED ON PIPE RACK
1. DEAD LOAD
1. Dead load shall include the weight of all process equipment, pipes, valves and
accessories, electrical and lighting conduits, trays, switchgear, instrumentation,
fireproofing, insulation, structural steel plates etc.
2. All piping shall be considered empty of product load (any liquid) when calculating
dead load
3. Single level and double level electrical cable trays shall have a minimum uniformly
distributed weight of 20 psf (0.96 kPa) and 40 psf (1.92 kPa), respectively. The cable
tray load shall be considered as dead load.
LOAD CASES TO BE APPLIED ON PIPE RACK
1. DEAD LOAD
1. Pipe Racks needs to be designed for present and future dead loads. Unless stipulated
otherwise by Client, Piping and Electrical loads is not recommended to be less than
the following recommended values :
(a) A minimum pipe deck load of 23 psf (1.10 kPa) can be used for the design of major
Pipe Racks. (Self weight of empty pipes and fixtures)
(b) Along with the minimum pipe deck loads specified above, a concentrated load is
recommended to be added for pipes that are larger than 12 inches (300 mm) nominal
diameter on the supports. The concentrated load in pounds, PDL, can be calculated using
the following linear equation:
PDL = S (WDL ‐ pDL D)
Where:
S = Pipe support spacing (ft)
WDL = Large pipe weight per foot (plf)
pDL = Average pipe deck loading (psf)
D = Large pipe diameter (ft)
EXAMPLE OF DEAD LOAD
• Model the pipe rack as per the given arrangement
• Consider dead load on all tiers as 23 psf
• Span between two columns = 20 ft
• Uniformly distributed load acting on beam = 23 X 20 = 460 p/ft = =0.46 kip/ft
• Dead Weight of 24” outer diameter pipe = 125.49 kip/ft
• Dead Weight of 18” outer diameter pipe = 104.67 kip/ft
• Tier 1 concentrated Dead Load
PDL = S (WDL ‐ pDL D)
P2DL = 20 ft (104.67 – 23*1.5) /1000 = 1.403 kips
• Tier 2 concentrated Dead Load
PDL = S (WDL ‐ pDL D)
P1DL = 20 ft (125.49 – 23*2) /1000 = 1.59 kips
• Tier 3
• Dead Load: WD = 20 psf x 20 ft = 400 p/ft = 0.40 Kip/ft
LOAD CASES TO BE APPLIED ON PIPE RACK
2. PRODUCT LOAD
1. Product load may be defined as the gravity load imposed by liquid or viscous material that flows in
piping during the plant operation.
2. Pipe Racks are recommended to be designed for present and possible future product loads. Unless
stipulated otherwise by Client, product loads is recommended not to be less than the following:
(a) A minimum product load of 17 psf (0.81 kPa) is recommended to be used at each level for the design
of major Pipe Racks.
(b) Along with the minimum piping product loads specified above, a concentrated load is recommended to
be added at pipes that are at least larger than 12 inches (300 mm) nominal diameter on the support. The
concentrated load in pounds, PPL, shall be calculated using the following equation:
PPL = S (WPL ‐ pPL D)
Where:
S = Pipe support spacing (ft)
WPL = Large pipe product load per foot (plf)
pPL = Average product loading (psf)
D = Large pipe diameter (ft)
EXAMPLE OF PRODUCT LOAD
• Model the pipe rack as per the given arrangement
• Consider product load on all tiers as 17 psf
• Span between two columns = 20 ft
• Uniformly distributed load acting on beam = 17 X 20 = 340 p/ft = =0.34 kip/ft
• Product Load of 24” outer diameter pipe = 179.87 kip/ft
• Product Load of 18” outer diameter pipe = 96.93 kip/ft
• Tier 1 concentrated product Load
PPL = S (WPL ‐ pPL D)
P2PL = 20 ft (96.93 – 17*1.5) /1000 = 1.428 kips
• Tier 2 concentrated product Load
PPL = S (WPL ‐ pPL D)
P1PL = 20 ft (179.87 – 17*2) /1000 = 2.917 kips
LOAD CASES TO BE APPLIED ON PIPE RACK
3. TEST LOAD
The test load may be defined as the gravity load imposed by the liquid (normally water)
used to pressure test the piping before the operation of plant to detect any kind of
leakages.
It is usually recommended to test them one at a time while the other lines on the
support are empty to avoid the heavy pipe support loading.
LOAD CASES TO BE APPLIED ON PIPE RACK
4. THERMAL LOADS
1. Thermal loads may be defined as forces caused by changes in the temperature of
piping. These forces may occur due to outer temperature variation or as a result of
hot fluid that may pass through the piping and may result in thermal stresses.
2. Pipe supports must be designed to resist longitudinal loads arising from pipe
thermal expansion and contraction. On the average pipe way, the lines expand and
contract varying amounts at random times. These loads are applied to the supporting
transverse beams either through friction or through pipe anchors.
3. Thermal loads shall be considered as dead load and included in the appropriate load
combinations.
4. For Pipe Rack design, both friction forces (FF) and anchor forces (AF) shall be
considered.
LOAD CASES TO BE APPLIED ON PIPE RACK
4. THERMAL LOADS
FRICTION FORCES ANCHOR FORCES
‐ Friction forces are caused by hot lines sliding ‐ Anchor and guide forces and locations shall
across a pipe support during start‐up and be obtained from the piping stress analysis
shut‐down and are assumed to be partially
resisted by adjacent cold lines. and piping isometric drawings. Anchor and
‐ The resultant longitudinal friction force is pipe forces shall be obtained from the
recommended to be taken as the larger of the checked pipe stress analysis.
following:
‐ Anchor and guide loads (excluding their
a. 10% of the total operating weight of all friction component) are recommended to be
lines tributary to the support combined with wind or seismic loads.
b. 30% of the total operating weight of those
lines tributary to the support, which will
expand or contract simultaneously.
Pipe friction loads are recommended not to be
combined with wind or seismic loads for the
design of pipe racks because during high wind
or earthquake, the vibration and deflection of
the supports under load will likely relieve the
friction forces.
EXAMPLE OF THERMAL LOADS
Frictional Force FF (in the longitudinal direction) for Tier 1 and Tier 2
Dead Load = 23 psf ; Product Load = 17 psf ; Total = 40 psf = 0.04 kip/ ft2
Span between two columns = 20 ft
The resultant longitudinal friction force is taken as 10% of the total operating weight of all lines
tributary to the support.
FF (Uniform) = (0.04 x 20) x 0.1 = 0.08 kip/ft (FF = 10% of Operating Load)
Concentrated load in the longitudinal direction ‐ 10% of Concentrated load
Tier 1 concentrated product Load = 1.428 kips
Tier 1 concentrated Dead Load = 1.403 kips
Total concentrated load on tier 1 = 1.428 + 1.403 = 2.831 kips
Tier 2 concentrated product Load = 2.917 kips
Tier 2 concentrated Dead Load = 1.59 kips
Total concentrated load on tier 2 = 2.917 + 1.59 = 4.507 kips
Tier 1 Frictional force = 0.1 (2.831) = 0.283 kips
Tier 2 Frictional Force = 0.1 (4.507) = 0.451 kips
LOAD CASES TO BE APPLIED ON PIPE RACK
4. THERMAL LOADS
TEMPERATURE FORCES
• Thermal/Temperature forces are usually caused by the structural steel expansion
and contraction.
• Design temperature shall be defined as the difference between the highest and
lowest one day mean temperature plus the metal temperature for the sun heating
effects on structural steel.
• For pipe rack design, provisions shall be made for thermal expansion of steel, with
the structural steel checked for temperature change. Slotted connections (sliding
connection) shall be provided in each segment of the pipe rack between vertical
bracing to allow for structural steel thermal expansion.
• The maximum segment for the pipe rack is recommended at 140 feet (42.5 meters)
in length unless calculations show otherwise.
EXAMPLE OF THERMAL LOADS
The Design Temperature shall be the difference the highest and lowest one‐day mean
temperature. For pipe rack under consideration, it will be 106‐43 = 63°F plus metal
temperature for the sun hearting effects on structural steel which can be estimated at
about 40°F
Design Temperature = (63 + 40) = 103°F
5. WIND LOADS
Wind loads on all pipe, equipment, structural members, cable trays, platforms, ladders, and other
attachments to the pipe rack shall be considered in the design.
Wind pressures, wind pressure distribution, and pressure coefficients shall be computed and applied in
accordance with ASCE 7 – 10.
The total wind load per foot on pipes, F, can be determined using the following equation:
F = qz G Cf A (ASCE 7 ‐ Table 6‐1)
where:
qz = 0.00256 Kz Kzt V² I (lb/ft²) (ASCE 7 ‐10 Eq. 27.3‐1)
G = Gust Effect Factor from Section 26.9
Cf = Force Coefficients as per ASCE 7‐10
Af= Projected area normal to the wind
5. WIND LOADS
EXAMPLE OF WIND LOADS
Wind Loads
Design wind forces for the main wind force resisting system and components should be determined by the equation
F = qz G Cf A
(where F is the applied wind force)
Calculation for Cf
Risk Category 1 Table 1.5‐1 (Refer Risk Category Sheet)
Wind Speed V(mph) 102.53 Refer Figure 26.5‐1,A, B or C of ASCE 7‐10
Exposure 3 1 for B,2 for C,3 for D
Kzt 1 Topography factor as per Section 26.8 of ASCE 7‐10
Kd 0.85 Wind directionality factor (Table 26.6‐1)
heff(feet) 30.0 Effective Height of the Structure
a 11.5 Table 26.9‐1 of ASCE 7‐10
zg(feet) 700 Table 26.9‐1 of ASCE 7 ‐ 10
Kz 1.16 Table 27.3‐1 of ASCE 7‐10
qz(psf) 26.59 .00256KzKztKdV2
Gust Effect Factor , G = 0.85
EXAMPLE OF WIND LOADS
Force Coefficients
For structural members , Force Coefficient Cf = 1.8
For columns , Force Coefficient Cf = 2.0
For pipes, Force Coefficient Cf = 0.7
The force coefficient Cf for pipe is taken from ASCE 7, for a round shape, with an h/D = 25, D z q > 2.5, and a
moderately smooth surface; that is Cf = 0.7. If the largest pipe is insulated, then consider using a Cf for a rough pipe
dependent on the roughness coefficient of the insulation (D’/D).
For cable trays, Force Coefficient Cf = 2.0
Tributary Area for Piping
The tributary area for piping should be based on the diameter of the largest pipe, D, plus 10% of the width of the
pipe rack, W.
This result is multiplied by the length of the pipes (bent spacing, L) to determine the tributary area.
D = largest pipe diameter in bent (including insulation)
W = width of the bent
L = bent spacing
A = tributary area = L ( D + 10%W )
EXAMPLE OF WIND LOADS
Force Calculation Force (Kips)
F1 Cable Tray 6" Deep
Cf = 2.0
Ae = 0.5 + (10% *25 ft) = 3.0 ft²
F1 = [(26.59 psf) * (0.85) * (2.0) * (3.0)] * 20.0 bent spacing F1 = 2.712
F2 Pipe Level 25 ft – 24" Max. O.D.
Cf = 0.7
Ae = 2.0 + (10% *25 ft) = 4.5 ft²
F2 = [(26.59 psf) * (0.85) * (0.7) * (4.5)] * 20.0 bent spacing F2 = 1.424
F3 Pipe Level 20 ft – 18" Max. O.D.
Cf = 0.7
Ae = 1.5 + (10% *25 ft) = 4.0 ft²
F3 = [(26.59 psf) * (0.85) * (0.7) * (4.0)] * 20.0 bent spacing F3 = 1.266
EXAMPLE OF WIND LOADS
Use qz = 26.59 psf for the whole column (On conservative side)
Cf = 2.0
Ae = 10/12 ft (column width) * 1 ft = 0.89 ft²/linear foot
Force per column = (26.59 psf) * 0.85 * 2.0 * 0.89 = 40.23 pounds/foot = 0.041 kips/ft
6. SEISMIC LOADS
• Earthquake loads may be computed and applied in accordance with ASCE 7 ‐10.
• All plant area structures considering high risk shall be considered as essential
facilities. The Importance Factor I shall be Category IV.
• Pipe Racks may either be designed as Ordinary Concentric Braced Frame(OCBF)
or Special Concentric braced Frame. (SCBF).
• OCBFs are designed to remain in the elastic range during the design extreme
seismic event. As a result, OCBFs have relatively few special requirements for
design.
• SCBFs are designed to enter the inelastic range during the design extreme seismic
event while remaining elastic during minor earthquakes and in resisting wind
loads.
• The design of steel seismic force resisting systems must comply with the
requirements of the (AISC) Seismic Provisions for Structural Steel Buildings.AISC‐
341.
DESIGN EXAMPLE