Pipe rack Design Philosophy

In this page I will talk about the pipe rack design philosophy. Pipe rack is the main artery of any plant. This carries the
pipes and cable trays (raceways) from one equipment to another equipment within a process unit (called ISBL
piperack) or carries the pipe and cable trays from one unit to another unit (called OSBL pipe rack). Some times you
will also find the AIR COOLED HEAT EXCHANGERS on the pipe rack.
There are different types of pipe rack:

Continuous Piperacks (conventional pipe rack) system

Non-continuous Piperacks system

Modular Pipe rack

Conventional / Continuous Pipe rack

Continuous Piperacks (conventional pipe rack) system: This is essentially a system where multiple 2-dimensional
(2D) frame assemblies (commonly called bents), comprised of two or more columns with transverse beams, are tied
together in the longitudinal direction utilizing beam struts (for support of transverse pipe and raceway elements and
for longitudinal stability of the system) and vertical bracing to form a 3D space frame arrangement. Piperacks
supporting equipment such as air-cooled heat exchangers must utilize the continuous system approach.
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 piperack design. Therefore, as a Civil/Structural Engineer, you should
coordinate 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" (a part of your calculation)
The following should be reviewed for design information:

Plot plans and equipment location plans

3D model showing piping layout, cable tray layout, Piperack 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 piperack.

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 piperack.

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 piperacks. 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),
concentrated load.

s = Spacing of piperack bent, p = pipe weight considered (kPa), d = pipe diameter W = pipe

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 piperack 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 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 piperack.
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 piperack), 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 aslarge 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 bedetermined
in accordance with the project design criteria. Vertical, transverse, and longitudinal seismic forces generated by the
pipes, raceways, supported equipment, and the piperack 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 piperack design. Friction between piping and supporting steel should not be relied upon to resist wind or
seismic loads.
Anchor and Guide Loads (Ta): Piperacks 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 piperack 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 midspan 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.
Step - 3: Load Combinations and allowable deflection of pipe rack:
You need to create the load combinations per your project design criteria. However, I have refered here some load
combinations.
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 unfactored load combinations (ACI 318) shall be used:
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.

D
D + L + SL + Tf + Ta
D + Tf + Ta
D + 1.3W + Ta
D + L + 0.5SL + 1.3W +Ta
D + L + S +0.65W + Ta
0.9De + 1.3W + Ta
D + E/1.4 + Ta
D + 0.2S + E/1.4 + Ta
0.9De + E/1.4 + Ta

Load Combinations for design of foundations (ACI 318):

1.
2.
3.
4.
5.
6.
7.
8.

1.4D
1.4D + 1.7L +1.7S
1.4D + 1.4Tf +1.4Ta
0.75 (1.4D + 1.7L + 1.7S + 1.4Tf + 1.4Ta)
0.75 (1.4D + 1.7L + 1.7S + 1.4Ta) + 1.6W
1.2D + 0.2S + 1.0E + 1.2Ta
0.9De + 1.6W + 1.2Ta
0.9De + 1.0E + 1.2Ta

Steel Design load combinations: (AISC - LRFD)

1.
2.
3.
4.
5.
6.
7.
8.

1.4D
1.2D + 1.6L + 0.5S + 1.2Tf + 1.2Ta
1.2D + 1.6S + 0.5L + 1.2Tf + 1.2Ta
1.2D + 1.6S + 0.8W + 1.2Ta
1.2D + 1.6W + 0.5L + 0.5S + 1.2Ta
1.2D + 1.0E + 0.5L + 0.2S + 1.2Ta
0.9De + 1.6W + 1.2Ta
0.9De + 1.0E + 1.2Ta

De is the minimum dead load on the structure.

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 piperack 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 piperack structures shall be as per project design criteria. However, you can consider the
following as limit of deflection:Lateral deflection produced by load combinations that include wind or seismic
forces:Piperacks supporting equipment: h/100, unless a more stringent requirement is given by the manufacturer of
the equipment.Piperacks 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
criteriaVertical 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 piperacks 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 piperacks 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 baseplate / 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 piperacks with spans of more than 6 m, a center spine consisting of a system of horizontal braces and struts
located at midspan 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 unbraced length of the beam compression flange in flexure and to reduce the unbraced 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 piperack 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 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 piperack 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 unbraced 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 unbraced length.
Please click here for continuous piperack sketch.

Non-conventional Pipe rack

rack

Modular Pipe