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Pipe Ways
Steel Structures in Industry
Rutger Botermans,
Mohamed A. El-Reedy
Peter
PhD,
Smith,
in Onshore
in Advanced
Structural
PipingDesign
Design,
Calculations,
2008 2017

10.3.4Pipe
5.4.1 Pipe-Rack
Rack Design
Elevation
Guide
Pipe-rack
Pipe rackselevation
are frameisstructures
determinedthat
bysupport
the highest
pipes
requirement
and auxiliary
of equipment
the following:
in the process areas of industrial plants. Just like
loads from the over
• Headroom windtheandmain
or earthquakes,
road. piping loads can vary greatly from project to project. Clearly, it is difficult to define
specific criteria for the design of such structures. This guideline sets general requirements which the engineer should incorporate
• Headroom for access to equipment under the pipe rack.
into pipe rack designs if possible.
• Headroom under lines connecting the pipe rack and equipment located outside.
This guideline is recommended for application to the following three types of steel pipe racks:
The size of the steel or concrete beam supporting overhead piping must be taken into consideration.
• strutted main pipe racks,
Elevation atsecondary
• unstrutted Pipe-Rack Intersection pipe racks,
or miscellaneous
Where two two-tier pipe racks meet, it is essential that elevations of lateral pipe racks slot between elevations of main pipe
• “T” supports.
rack. Figure 10-2(top) illustrates this requirement. The choice of top elevation of the lateral pipe rack midway between the top and
The pipe
bottom rackpipe-rack
main superstructures and
elevation foundations
allows shall
turning up or be designed
down for the loads Generally,
at the intersection. and load combinations
lines running as specified
at right in Chapter
angles to main 2,
Loads
pipe on are
rack the assigned
Industrial elevations
Structures.500 mm–1 m higher or lower (depending on headroom requirements) than lines running
in
Themain pipework
piping rack.will
The be500 mm differential
in contact between
with the pipe rack pipe runsact
and will is as
theone
absolute minimum.
unit. Fig. 5.11 presents a piperack under construction.
The deflection should be restricted based on the design to avoid higher stress on the piping system.

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Figure 5.11. Pipe rack under construction.

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The deflection requirements for pipe rack beams and transverse bents shall be as follows:
Figure 10-2. Typical pipe rank intersection.
The maximum allowable beam deflection(Δmax) due to total load shall be as follows:
(courtesy of Red Bag/Bentley Systems, Inc.)
• Δmax=L/240
Figure 10-2B
where L isshows a pipe-rack
the span length. intersection where the respective main and lateral pipe-rack elevations do not slot between each
other. This design complicates routing of lines from one pipe rack to another, especially where lines run on the bottom levels of
• The maximum allowable drift limits for the pipe rack shall not exceed H/100
both pipe racks. Avoid this design at all cost.
where H=pipe rack height.
Where a single-tier pipe rack turns 90° and all lines can be kept in the same sequence in both directions, no elevation difference
is necessary. When the line sequence changes, introduce an elevation change at the turn (see Figure 10-3).

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Figure 10-3. Single-tier rack turning 90°.

(courtesy of Red Bag/Bentley Systems, Inc.)

Pipe racks/structures
Geoff Barker IEng.,MEI., in The Engineer's Guide to Plant Layout and Piping Design for the Oil and Gas Industries, 2018

12.1 Pipe racks—Widths, Bent Spacing’s, and Elevations of Racks

Pipe racks are the main highway in a process facility.
The Pipe racks connect all the equipment with piping that cannot run through the equipment areas.
Pipe racks are usually located in the middle of process plants.
If the racks are located in the middle of the plant then they have to be erected first, before becoming surrounded by process
equipment.
Pipe racks support not only process piping but also utility piping, cable, and instrument trays as well as any equipment that is
supported from and over the pipe rack such as air coolers.
Pipe racks require considerable planning and coordination with all disciplines to facilitate not only a logical design but also to
reduce construction costs.
Data required for pipe rack development include
• Plot plan
• P&IDs
• Piping and plant specifications
• Construction materials
• Fireproofing requirements

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Pipe rack development requires the following inputs:

• Line-routing diagram
• P&ID
Combined
• Line list
Cycle Power Plant Equipment
Kenneth Storm, in Industrial Piping and Equipment Estimating Manual, 2017
• Plot plan
• Plant layout specifications
2.19.4 Pipe Rack, Pumps, Platforms, Duct/Stack Sheet 4
• Client specifications
• Fireproofing requirements
Estimate—Pipe Rack, DA Storage Tank Silencer Historical Estimate
Once the number and size of lines plus a 25% allowance for future requirements and the amount of cable trays and any relief line
Description
requirements have been established, the rack size can be determined.
MH Quantity Unit Quantity Unit BM
Piperack
Pipe Rack/DA Storage
development Tank
requires theSilencer
following inputs: 0
•Pipe rack
P&IDs (process and instrument diagrams) 41.30 7.8 ton 0.0 ton 0
DA○Storage Tank
Indicates lineSilencer
sizes
W4○ × 13 31′ insulation requirements
Shows 24.00 0.8 ton 0.0 ton 0
W6○ × 15 4′
Indicates equipment sequences 24.00 0.2 ton 0.0 ton 0

•W4 × 13 3′
Process line list
24.00 0.2 ton 0.0 ton 0
Bolt
○ up 9 0.35 180.0 EA 0.0 EA 0
Shows line temperatures
Base
○ plates 3/16′′ Fillet weld/grout
Shows insulation requirements
4.00 4.0 EA 0.0 EA 0
Estimate—Pumps Historical
○ Plus will show any other line relevant information in the remarks column Estimate
HP and LP Boiler Feed Pumps 0
• PFDs (process flow diagrams)
HP feed pump 700 hp set/couple/grout 80.00 3.0 EA 0.0 EA 0
○ Shows operating temperatures
Estimate—Platforms
○ Shows insulation requirements Historical Estimate
Platforms 0
On completion of the line-routing exercise, the development with regard to pipe rack width, bent spacing (vertical columns and
Main deck
horizontal 48.00
structural member), numbers and levels of rack can then be finalized. 6.4 ton 0.0 ton 0
Mid level 48.00 1.9 ton 0.0 ton 0
Lower level 48.00 2.9 ton 0.0 ton 0
HP and LP drums 48.00 1.0 ton 0.0 ton 0
Stack 48.00 1.1 ton 0.0 ton 0
Deaerator and storage tank 48.00 3.2 ton 0.0 ton 0
Stair tower 48.00 13.2 ton 0.0 ton 0
Estimate—Outlet Duct, Stack Historical Estimate
Outlet Duct/Expansion Joint/Stack 0
Stack 10′-1′ ′ diameter × 118′-10′′
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Section 1 39′- 9-7/8′′ 22.00 1.0 EA 0.0 EA 0
Section
Typical 2 28′-through
section 11-3/8′′
a pipe rack 22.00 1.0 EA 0.0 EA 0
Section
The 1 48′-
first step 5-3/4′′
in the 22.00
development of any pipe rack is the generation 3.0 diagram.EA
of a line-routing 0.0diagram
A line-routing EA is 0
a schematic representation of all process piping systems drawn on a copy of pipe rack general arrangement drawing/or on the
Field weld horizontal 12.00 1.0 EA 0.0 EA 0
unit plot plan where the pipe rack runs in the middle of the process unit.
Damper

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Based on the information

Estimate—Outlet available
Duct, Stackon the first issue of P&I Diagram/Process
Historicalflow diagram, that is, line size, line number, pipe
Estimate
material, operating temperature, etc. the line-routing diagram is to be completed.
Inlet flange 11.00 2.0 EA 0.0 EA 0
Once the routing diagram is complete, the development of rack width, structural column spacing, road crossing span, numbers of
Plate 4′-8-1/2′ ′ × 52′-9-1/4′′
levels, and their elevations should be started.
11.00 2.0 EA 0.0 EA 0
Plate
Pipe 4′-8-1/2′
rack ′ × 10′-6′′
column spacing shall be decided based on the economics of the pipe span as well as the truss arrangement to
Bolt up
accommodate double the span 0.15 obstructions.
for road crossing or avoiding underground 224.0 EA 0.0 EA 0
Pipe
Sealrack arrangement
weld 3/16′′ filletshould be developed to suit the specific plant
weld 52′-1′′ 0.35requirements.
125.0 LF 0.0 LF 0
The
Boltpipe
up rack width can now
at foundation AB be worked out with a typical cross section
0.15 of the rack with the levels.
28.0 EA 0.0 EA 0
Normally,
Expansion pipeJoint
racks 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.
Flex element 22.00 1.0 EA 0.0 EA 0
Any pipe rack design should provide provision for future growth to the extent of 25%–30% on the rack clear width.
Retaining bars (two sets)
When flanges or flanged valves are required on two adjacent lines, the flanges are to be staggered.
Fasteners 0.03 1004.0 EA 0.0 EA 0
Thermal expansion or contraction must be accommodated by keeping sufficient clearance at the location where the movements
Drop
will wrap gasket
occur. 0.02 460.0 EA 0.0 EA 0
3/16″
The fillet weld
clearance of the first line from the structural pipe rack column0.35 125.0 based on
is to be established LFthe sizes 0.0 LFby the
furnished 0
civil/structural
Hydro engineers. 180.00 1.0 TEST 0.0 TEST 0
After analyzing 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, for example, two tiers of 30-ft wide or three tiers of 20-ft wide rack will be
decided.
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 pipe rack shall be taken
aesthetically on a common top of steel (TOS).
With the above considerations, the conceptual arrangement of pipe rack is to be finalized.

Standard Piping Details

Roy A. Parisher, Robert A. Rhea, in Pipe Drafting and Design (Third Edition), 2012

Drawing Pipe in the Rack

When representing pipe in a pipe rack, the careful arrangement and organization of names, dimensions, and line numbers will
make the drawing easier to read. Figure 11.2 shows a pipe rack that has been well organized. Notice how the alignment of notes,
dimensions, and other callouts makes the drawing easy to read.

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Figure 11.2. Pipe rack drawing organization.

The following guidelines will help you organize your drawing:

1. Keep flow arrows the same size and aligned.
2. Line numbers should be left justified when possible.
3. Pipe commodity should be identified on utility lines only.
4. Line spacing dimensions should align across the pipe rack from one pipe support column to the other. This
allows coordinates for each pipe to be calculated since each pipe support column is positioned using a coordinate.

Piping system design

Maurice Stewart, in Surface Production Operations, 2016

9.4.5 Width and bent spacing

The width of the pipe rack will depend on the number of pipes to be supported plus electrical/instrument cable trays plus space
for future lines. When laying out the rack, one must determine the spacing between pipes and the span or the distance between
supports. When selecting minimum spacing between parallel pipes, one must take into account any insulation to be added and
consider if the pipe will be subject to any lateral movement caused by expansion of the branches. When determining the
geometry of the pipe rack, the designer has two choices: (1) increase the width of the rack or (2) add another level. The cost of
additional and heavier steel for another level versus additional space required to widen the rack must be considered. The width of
the rack is normally limited to 15 ft. (5 m) to reduce bending moments and save on the steel. The column spacing between bents
is usually between 16 and 20 ft. (4.5 and 6 m); it is not unusual to support small lines from larger lines to permit wider spacing
between bents. Major factors determining bent spacing include the following:
• Line size—It affects pipe spans.
• Line temperature—Hot lines require a shorter span.

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• Insulation—Small-diameter insulated lines that are cold insulated must be supported at short spans.
• Equipment—Normally, two (2) pumps are located in parallel under the pipe rack. It may be necessary to increase the spacing
between yard bents to accommodate the pumps.

Cryogenic Insulation Systems for LNG Industries

Alireza Bahadori PhD, in Thermal Insulation Handbook for the Oil, Gas, and Petrochemical Industries, 2014

4.9.10 Aerogel Insulation System Advantages

Detailed
Thinness createsDesign
more space in and around pipe racks and equipment. Thinness can decrease the overall size of a production
facility, resulting in major material reductions and cost savings. Thinness results in volume and freight savings,
Richard Beale, Paul Bowers, in The Planning Guide to Piping Design (Second Edition), 2018
decreased accessory materials, minimal site storage, and simplified logistics.
5.4.2
A uniqueDetailed model
flexible form boundaries
and wrap application makes installation faster, easier, and less costly. Rigid insulation systems require
Refer to Fig.
numerous 5.3 and that
segments Fig. must
5.4. be effectively sealed.

Aerogel insulation systems will not break during shipment. They are competitive with other insulation systems on an installed
basis due to decreased material requirements, logistics improvements, reduced installation time, and shorter construction
schedules. Figure 4.5illustrates the performance of different thermal insulators.

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Figurein4.5.
Sign to Performance of different
download full-size thermal insulators.
image
(Source: Aspen Aerogels, Inc).

Figure 5.3. Detailed model boundaries.

Engineering Aspects for Plant Piping Systems

Alireza Bahadori PhD, CEng, MIChemE, CPEng, MIEAust, RPEQ, in Oil and Gas Pipelines and Piping Systems, 2017

13.2.12.2 Pipe Racks

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Overhead racks may contain more than one level. For steel pipe racks, the height of levels should have one of the following
elevation.
Figure 5.4. Model boundary section.
1. Main pipe racks: 4.60, 6.20, 7.80 m
5.4.2.1 Figure
2. Individual 5.3 notes
or secondary pipe rack: 3.80, 5.40, 7.00 m.
1. Separate models
Arrangement of pipe are
rackrequired formade
should be each pipe rack module
in accordance withand the field piping below the modules.
standards.
2. special
In Consider construction
case when
for large size dealing
pipes with piping
or concrete pipeand associated
racks, supporting.
the distance between Inthe
thisvarious
case, construction would
floors may be require the loop
increased.
spool
Except forinspecial
order to complete
cases, the pipe
minimum racks,
width andrack
of pipe therefore
shouldit be
is to be The
6 m. included
widthinofthe pipe
pipe rack
rack module
should be model, nottoinaccommodate
designed the field-
erected
all pipes piping plus
involved model.
20% space for future expansion or modification. Where the pipe rack support air coolers, the preferred

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3. In this
width should
example
be thethe
width
field-erected
of air coolers.
piping EWP has been divided into two detailed design models.
4. multilevel
In Consider pipe
construction
racks, pipe
when
carrying
dealing
corrosive
with piping
fluids
that
should
crosses
be on
thethe
model
lower
andlevel,
piping
andarrangement
utility lines should
boundary.
be atInthe
thisupper
case,floor.
Large
consider
size orcontinuing
heavy weight
the piping
pipes should
to a natural
be located
break at
such
theas
lower
a valve
levelorand
theon
limit
extreme
of the spool
sides.shipping box size. Breaking the pipe
each time a model boundary is crossed introduces unnecessary field welding and added field costs. These small piping
continuations are to be part of the model they originate in and included in the EWP.

Process Industries: Corrosion

C.P. Dillon, in Encyclopedia of Materials: Science and Technology, 2001

Large amounts of steel are used for structures, pipe racks, piping, and tanking, but about 70% of the corrosion-
control expenditures are for corrosion-resistant alloys or other materials. Substantial amounts of ferrous and nonferrous alloys,
and conventional grades of stainless steels, are used in the less demanding services (e.g., petrochemical processes,
chemical transport and storage). However, the more demanding services require expensive installations of special alloys, duplex
stainless steels, highly alloyed austenitic alloys rich in nickel, chromium, molybdenum, and other elements, copper- or nickel-
based alloys, reactive metals (titanium, zirconium, tantalum, and their alloys), and selected nonmetallic
materials (e.g., glass, brick, impervious graphite, fluorinated or other specialty plastics, or thermosetting resins).

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