Material Selection & Plant Design

TRAINING – 1I
PIPING LAYOUT
Guidelines for Tank Piping
Table of Contents
1. INTRODUCTION ................................................................................................................................................................... 3
2. STEPS FOR PIPERACK PIPING.......................................................................................................................................... 5
3. LOCATION OF VALVES ....................................................................................................................................................... 6
4. YARD PIPING ARRANGEMENT .......................................................................................................................................... 7
5. ILLUSTRATION DRAWINGS ............................................................................................................................................. 11
PRD1_ TYPICAL YARD PIPING ARRANGEMENTS .............................................................................................................. 12
PRD2_ TYPICAL CROSS-SECTION OF YARD PIPING ......................................................................................................... 13
PRD3_ TYPICAL CROSS-SECTION OF LAYOUT AT PIPERACKS ...................................................................................... 14
PRD4_ TYPICAL PIPERACK COMPOSITE............................................................................................................................. 15
PRD5_ LINE SPACING CHART ............................................................................................................................................... 16
PRD6_ PLANNING FOR LINE GROWTH ................................................................................................................................ 17
PRD7_ LARGE DIAMETER LINES - CHANGE IN DIRECTION .............................................................................................. 18
PRD8_ PIPERACK METER RUNS ........................................................................................................................................... 19
PRD9_ RELIEF HEADER LOCATION ..................................................................................................................................... 20
PRD10_ ALTERNATIVE PIPERACK EXPANSION ................................................................................................................. 21
PRD11_ TYPICAL HOSE STATION AT A PIPERACK COLUMN ........................................................................................... 22
PRD12_ BATTERY LIMIT VALVING : SINGLE-LEVEL RACK ............................................................................................... 23
PRD13_ FLEXIBILITY CHECK STEPS .................................................................................................................................... 24
PRD14_ PIPERACK ANCHOR STRUCTURE.......................................................................................................................... 25
PRD15_ STEAM LINE DRIP LEGS .......................................................................................................................................... 26
PRD16_ PROPER LINE SUPPORT ......................................................................................................................................... 27
PRD17_ 90° PIPERACK TURNS .............................................................................................................................................. 28
PRD18_ RACK INTERSECTION .............................................................................................................................................. 29
PRD19_ OPERATOR ACCESS ................................................................................................................................................ 30
PRD20_ TYPICAL PIPELINE DISTRIBUTION ON A SINGLE-LEVEL PIPERACK................................................................ 31
PRD21_ TYPICAL PIPERACK PIPING & EQPT. RELATIONSHIPS IN A PETROCHEMICAL PLANT ................................ 32
6. NOTES ................................................................................................................................................................................. 33
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Guidelines for Tank Piping 1I
© Pipmat 2021-22

1. INTRODUCTION

➢ The study of the tankfarm consisting of a group of tanks shall be carried out keeping the
following basic points in consideration.

➢ Grouping of tanks,
Specification of the content.
Capacity of tanks
Nature of hazard – fire / toxic / explosive / corrosive / bulk handling loading / unloading
Statutory distance
Requirement of Dykewall or curbing
Dykewall height or curb height calculation
Location of Pumps - inside dyke area / outside dyke area
Approach to tank nozzles with valve
Approach to tank roof
Drainage of dyke area - Sump and pump
Road around tankfarm
Fire hydrant / monitor requirement
Underground system connected to specific system of treatment / disposal

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➢ Storage tanks located in a safe area and grouped according to the contents are called
tankfarm. Normally, in chemical plants, the storage shall be either input raw material or output
products or intermediate chemicals storage.
➢ Storage tanks may contain acids, alkalis, oil viz. petrol, diesel, naptha, fuel oil or benzene etc.
Oil, acid, alkali are usually stored in vertical storage tanks designed as per API 650.
➢ Tanks should be grouped or segregated according to the contents. Tanks containing
hydrocarbons should be separated according to the flash point, CCE classification for space
planning, dykewall and its height requirement.
➢ Layout of the storage facility shall be based on the following considerations and systematic
approach.
✓ Statutory Regulations viz. CCE
✓ TAC/NFPA recommendations
✓ Safety requirements as per OISD, OSHA, HAZOP study
✓ Valve access platform / ladders at the piping outlet nozzles of tank.
✓ Access to top of tanks and interconnecting walkway
✓ Piping on sleepers or piperack inside dyke area.
✓ Pumps location outside dyke area

➢ The practical objective to prepare a most economical plot plan and piping arrangement for a
tankfarm should be to keep provisions of operational ease, maintenance facility, safety
arrangements and overall aesthetics.
➢ The tankfarm shall also have provisions for efficient drainage and disposal facility as required
for various kinds of fluid storage.
➢ The tankfarm should be secured against unauthorised entry by fencing, security gates
depending on the tank storage capacity or the type of hazards posed by the nature of contents.

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2. STEPS FOR PIPERACK PIPING

2.1 The first step in the development of any piperack is the generation of a line-routing diagram.
A line routing diagram is a schematic representation of all process piping systems drawn on
a copy of piperack general arrangement drawing / or on the unit plot plan where the piperack
runs in the middle of the process unit.
Based on the information available on the first issue of P&I Diagram / Process flow diagram
i.e.line size, line number, pipe material, operating temperature etc. the line routing diagram
is to be completed.
2.2 Once the routing diagram is complete, the development of rack width, structural column
spacing, road crossing span, numbers of levels and their elevations should be started.
2.3 Piperack column spacing shall be decided based on the economics of the pipe span as well
as the truss arrangement to accommodate double the span for road crossing or avoiding
underground obstructions. Piperack arrangement should be developed to suit the specific
plant requirements.
2.4 The piperack width can now be worked out with a typical cross-section of the rack with the
levels. Normally, piperack carry process lines on the lower level or levels and the utility lines
on the top level. Instrument and electrical trays are integrated on the utility level if space
permits or on a separate level above all pipe levels.
Any piperack design should provide provision for future growth to the extent of 25 to 30% on
the rack clear width. When flanges or flanged valves are required on two adjacent lines, the
flanges are to be staggered.
2.5 Thermal expansion or contraction must be accomodated by keeping sufficient clearance at
the location where the movements will occur. The clearance of the first line from the structural
piperack column is to be established based on the sizes furnished by the civil / structural
engineers.
2.6 After analysing all the requirements and arrangements, the dimensions are to be rounded
off to the next whole number. Based on the economics, the width and the number levels e.g.
two tier of 30 ft. wide or three tier of 20 ft. wide rack will be decided.
2.7 The gap between the tiers shall be decided on the basis of the largest diameter pipeline and
its branching. The difference between the bottom line of pipe in the rack and the bottom of a
branch as it leaves the rack shall be decided carefully, to avoid any interference due to
support, insulation, size of branch etc. All branch lines from the main lines on piperack shall
be taken aesthetically on a common top of steel (TOS).
With the above considerations, the conceptual arrangement of piperack are to be finalised.

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3. LOCATION OF VALVES

3.1 Various factors shall be considered while locating each line, valve and instrument in a
piperack. In a standard process unit piperack, process lines are located on the lower levels,
utility lines are on the next higher level and a separate top level is arranged for electrical and
instrument cable trays.
The requirements and locations of electrical and instrument cable trays along with their
spacing, protective cover, approach platform / walkways are to be discussed with the
electrical and instrument engineers.
3.2 The largest lines should be located near the supporting columns to reduce the overall load
on the supporting beams.
The relief headers must be located above the top level of the rack to allow the line to drain
to blowdown drum. (Refer sketch No.PRD9). The designer should avoid locating pipeline
over the centre line of structural column for support so that the columns can be extended for
future rack expansion.
3.3 Shut-off valves at utility headers are located inside the rack area in the horizontal position
directly above the header.
Valves must be accessible from platforms or by chain operators (chain to fall free of
obstructions hampering operation).
3.4 Refer sketch no.PRD12. This view highlights features requiring additional considerations.
The width of the access way is determined by the space needed to maintain the equipment
located at grade below the piperack.
3.5 The valves are staggered on either side of the catwalk and handwheel extension stems are
furnished when necessary to facilitate operation.

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4. YARD PIPING ARRANGEMENT

4.1 The plant layout determines the main-yard piping runs. Refer sketch No.PRD1 which shows
typical piperack layouts for various plant arrangements.
4.2 Smaller plants usually have the simplest yard piping as shown in sketch No.PRD1, A and B.
In Fig.A, the process and utility lines enter and leave at the same end of the plot and Fig.B,
presents a frequently adopted layout, with utility lines entering at one end and process lines
at the opposite end.
4.3 In larger plants, yard piping becomes more complicated as shown in sketch No.PRD1, D, E,
F, G. The piperack arrangement results from an overall plant arrangement, site conditions,
client's requirements and plant economy.
4.4 Pipelines in the piperack are classified as process lines, relief-line headers and utility
headers.

Process Lines
Process lines are those
(a) which interconnect nozzles on process equipment more than 20ft. apart (closer process
equipment can be directly interconnected with pipelines)
(b) Product lines which run from vessels, exchangers, or more often from pumps to the unit
limits to storage or header arrangement outside the plant.
(c) Crude or other charge lines which enter the unit and usually run in the yard before
connecting to exchangers, furnaces or other process equipment e.g. holding drums or
booster pumps.

Relief – Line Headers

Individual relief lines, blow down lines and flare lines should be self draining from all relief
valve outlets to knock-out drum, flare stack or to a point at the plant limit. A pocketed relief
line system is more expensive, because usually an extra condensate pot is required with
instruments, valves and pumps. To eleminate pockets some relief line headers must be
placed at higherelevation above the main yard usually on a tee support on the extended
piperack column. However, on some noncondensing gas systems self drainage is not so
essential. Relief lines can be individual, some with large diameters and occasionally high
temperatures.

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Utility Lines
Utility lines in the piperack can be put in two groups :
(a) Utility headers serving equipment in the whole plant. Such lines are : low and high
pressure steam lines, steam condensate, plant air and instrument air lines. If required,
cooling water supply and return and service water can also be arranged on the piperack.
(b) Utility lines serving individually one or two equipment items or a group of similar
equipment (furnaces, compressors) in the plant. Such lines are : boiler feedwater,
smoothering steam, compressor starting air, various fuel oil lines, lubricating oil, cooling oil,
fuel gas, inert gas and chemical treating lines.
Steam header should drain to the steam separator for more effective condensate collection.
Branch connections to steam headers usually connect to the top to avoid condensate
drainage to equipment.

Instrument Lines & Electrical Cables

Instrument lines and Electrical cables are often supported in the yard and extra space should
be provided for these facilities. The best instrument line arrangement eleminates almost all
elevation changes between the plant and the control room. This can be easily achieved when
instrument lines are supported outside the piperack column on a suitable elevation.

Line Location
Refer sketch No.PRD20. It shows single-level yard piping. Regardless of service, heavy lines
(very large diameter lines, large lines full of liquid) are placed over or near the piperack
columns. Centrally loaded column and reduced bending moment on the beam will result in
a lighter structural design. Next to these lines are placed all process lines and relief lines.
Utility lines are in the centre portion of the yard. A general sequence of uitility lines is also
shown on the sketch PRD20.
It is advantageous, from point of view of support, to group hot lines requiring expansion
loops. Refer sketch No.PRD13, PRD14. Loops elevated horizontally over the yard is the
most common adopted design, having the hottest and largest diameter line outside. Line
guides, line stops and anchor points are usually required along a hot line somewhere in the
piperack. Pipe expansion forces, at some of these points, will affect yard support design.
Those process lines which interconnect equipment on the same side of the yard should be
near the edges of the yard bank. Lines which interconnect equipment located on both sides
of the yard should be closer to the utility lines and can be placed either side of the yard.
Position of product lines is influenced by their routing after leaving the plant limit.

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Right(left) turning lines should be on the right(left) hand side of yard. Utility lines serving
individually one or two equipment items should be on the same side of the yard as the
equipment to which they connect.

Pipe Rack Elevation

Refer sketch No.PRD2 and PRD3 for typical cross-section of piperack piping.
Elevation of yard piping is determined by the highest requirement of the following :
a) Headroom over a main road.
b) Headroom for access to equipment under the piperack.
c) Headroom under lines interconnecting the piperack and equipment outside the piperack.
The size of beam supporting the piperack piping should also be taken into account when
considering headroom.
Generally, those process lines should be located in the top tier which interconnect two
nozzles elevated higher than the top tier. Process lines with one end lower than the bottom
tier elevation can run either in the top or the bottom rack. If both ends of a process line are
lower than the bottom tier elevation, the line should be located in the bottom tier.
The elevation of a line can also be influenced by valves and instruments in the line. Often a
more convenient access platform can be provided for valves arranged in the top tier of
piperack. The preferred location of lines with orifice runs is near the edge of the piperack
with orifice flanges near the column for more convenient protable ladder access. Refer
sketch No.PRD8.
The sketch No.PRD2, upper right corner shows platform and walkway arrangements to
valves, relief valves and instruments located in the piperack.

Piperack Piping Economy

The economy in piperack piping depends primarily on the length of lines arranged on the
rack.
Fittings, valves and instrument are relatively few in the piperack compared to pipelength.
Sketch No.PRD2 shows those critical dimensions (A,B,C,D & E) which will influence piping
cost from piperack piping layout point of view. These dimensions depend on the overall plant
layout and should be carefully considered when the plot is developed.
Dimension 'A' is the total length of the piperack and is governed by the number and size of
equipment, structure and buildings arranged along both sides of the piperack. On an
average, about 10 feet of rack length is required per process equipment (exchanger, drum,
tower, unhoused compressor etc.)

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A control room located along the rack will increase the piperack piping cost because all lines
must pass by without really being associated with the relatively long control room.
To shorten piperack length (Dimension 'A'), various methods are applied viz. equipment in
pairs, stacked exchangers, exchangers under elevated drums, drums or exchangers
supported on towers with common platforms, drums supported on exchangers, process
equipment located under the rack etc. These arrangements not only shorten the process
interconnecting equipment directly but also shorten those lines which pass through this area
and utility headers serving this area.
Dimension 'B' and 'C' should be carefully selected to minimise pipelength between the
piperack and process equipment and pipelength interconnecting equipment on opposite
sides of the piperack. 'C' is usually 6 to 7 feet.
Dimension 'D' and 'E' should be decided based on what is minimum necessary to reduce the
vertical piping lengths. For economical design of piperack structure, an evaluation by a
structural expert should be done. This expert can determine whether steel or concrete or a
combination of the two is the most desirable choice and what span and spacing will give the
most economical arrangement.

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5. ILLUSTRATION DRAWINGS

Various illustrations shown on the sketches are general guidelines to develop the piperack
arrangement specific for a plant. Free hand sketches should be made based on the analysis of the
plant and the concept visualised for the piping arrangement with its support. The piping branching
out should be taken at a specific TOS to give a aesthetic cross-sectional view as well as ease of
support.

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PRD1_ TYPICAL YARD PIPING ARRANGEMENTS

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PRD2_ TYPICAL CROSS-SECTION OF YARD PIPING

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PRD3_ TYPICAL CROSS-SECTION OF LAYOUT AT PIPERACKS

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PRD4_ TYPICAL PIPERACK COMPOSITE

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PRD5_ LINE SPACING CHART

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PRD6_ PLANNING FOR LINE GROWTH

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PRD7_ LARGE DIAMETER LINES - CHANGE IN DIRECTION

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PRD8_ PIPERACK METER RUNS

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PRD9_ RELIEF HEADER LOCATION

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PRD10_ ALTERNATIVE PIPERACK EXPANSION

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PRD11_ TYPICAL HOSE STATION AT A PIPERACK COLUMN

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PRD12_ BATTERY LIMIT VALVING : SINGLE-LEVEL RACK

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PRD13_ FLEXIBILITY CHECK STEPS

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PRD14_ PIPERACK ANCHOR STRUCTURE

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PRD15_ STEAM LINE DRIP LEGS

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PRD16_ PROPER LINE SUPPORT

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PRD17_ 90° PIPERACK TURNS

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PRD18_ RACK INTERSECTION

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PRD19_ OPERATOR ACCESS

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PRD20_ TYPICAL PIPELINE DISTRIBUTION ON A SINGLE-LEVEL PIPERACK

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PRD21_ TYPICAL PIPERACK PIPING & EQPT. RELATIONSHIPS IN A PETROCHEMICAL PLANT

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6. NOTES

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