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Pipe Rack
Afzal Shaikh | January 25, 2012 | 0 Comments
Introduction
The pipe rack general arrangement is finalized during the development of overall plot plan. The exact width of the pipe rack, numbers of levels and elevations, the access and maintenance platforms are finalized during pipe rack piping study. Normally, the pipe rack piping study, with its structural and platform requirements is the first priority item for detail engineering of a process unit. The pipe rack may be an integral part of a process unit located in the middle of the unit or it may be an arterial part connecting several services
of other process unit.
The following data and drawings are required to be studied before starting the detailed design of
Pipe rack piping study:
Unit Plot Plan / Overall Plot Plan
Piping and Instrumentation diagrams
Plant layout specification
Client specification
Material of construction
Fireproofing requirements
2.0 Steps to Pipe Rack Piping
2.1 The first step in the development of any pipe rack 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 pipe rack general arrangement drawing / or on the unit plot plan where the pipe rack runs in the middle of the process [Link] 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. Pipe rack 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. Pipe rack arrangement should be developed to suit the specific plant requirements.
2.3 The pipe rack width can now be worked out with a typical cross-section of the rack with the levels.
Normally, pipe 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. Any pipe rack 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. Thermal expansion or contraction must be accommodated by keeping sufficient
clearance at the location where the movements will occur. The clearance of the first line from the structural pipe rack column is to be established based on the sizes furnished by the civil / structural engineers.
2.4 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 e.g. two tier of 30 ft. wide or three tier 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 are to be finalized.
3.0 Location of Valves
3.1 Various factors shall be considered while locating each line, valve and instrument in a pipe rack. In a standard process unit pipe rack, 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 Blow down drum. 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 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 pipe rack. The valves are staggered on either side of the catwalk and hand wheel extension stems are furnished when necessary to facilitate operation.
4.0 Yard Piping Arrangement
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4.1 The plant layout determines the main-yard piping runs which show typical pipe rack layouts for various plant arrangements.
4.2 Smaller plants usually have the simplest yard piping, the process and utility lines enter and leave at the same end of the plot present 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. The pipe rack arrangement results from an overall plant arrangement, site conditions, clients requirements and plant economy.
4.4 Pipelines in the pipe rack 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
Each individual blow down lines, or relief lines, and flare lines shall be designed or routed in such a manner that it 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 eliminate pockets some relief line headers must be placed at higher elevation above the main yard usually on a tee support on the extended pipe rack column.
However, on some non-condensing gas systems self drainage is not so essential. Relief lines can be individual, some with large diameters and occasionally high temperatures.
Utility Lines
Utility lines in the pipe rack 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 pipe rack.
(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 feed water, smothering 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 and 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 eliminates almost all elevation changes between the plant and the control room. This can be easily achieved when instrument lines are supported outside the pipe rack column on a suitable elevation.
4.5 Line Location
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 pipe rack 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. It is advantageous, from point of view of support, to group hot lines requiring expansion loops. Loops elevated horizontally over the yard are
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 pipe rack. 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. 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.
4.6 Pipe Rack Elevation
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 pipe rack.
c) Headroom under lines interconnecting the pipe rack and equipment outside the pipe rack. The size of beam supporting the pipe rack piping should also be taken into account when considering headroom. Generally those process lines should be located in the top tier which interconnects 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 pipe rack. The preferred location of lines with orifice runs is near the edge of the pipe rack with orifice flanges near the column for more convenient portable ladder access.
4.7 Pipe Rack Piping Economy
The economy in pipe rack piping depends primarily on the length of lines arranged on the rack. Fittings, valves and instrument are relatively few in the pipe rack compared to pipe length which will influence piping cost from pipe rack piping layout point of view. These dimensions depend on the overall plant layout and should be carefully considered when the plot is developed.
The width of the plant is the total length of the pipe rack and is governed by the number and size of equipment, structure and buildings arranged along both sides of the pipe rack. On an average, about 10 feet of rack length is required per process equipment (exchanger, drum, tower, un-housed compressor etc.) A control room located along the rack will increase the pipe rack piping cost because all lines must pass by without really being associated with the relatively long control room. To shorten pipe rack length 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.
For economical design of pipe rack 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.
5.0 Illustrations
Various illustrations shown on the sketches are general guidelines to develop the pipe rack arrangement specific for a plant. Free hand sketches should be made based on the analysis of the plant and the concept visualized 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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Tags: design, design engineering, design piping system, detail design, history of piping, pipe rack, piping layout, process
Category: Design
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I am a Piping Designer who is passionate about Piping. I have started this site with the simple intention of sharing my knowledge and engaging in discussions with other professionals belonging to Engineering, Piping and Oil & Gas sectors. Add me to ur circles on GOOGLE+
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