Industrial Training Report

2014-2015
Petrofac Engineering Services India (Pvt.) Ltd.
ON
DESIGN AND ANALYSIS OF PRECAST CONCRETE PIPE RACK
FOR
Mina Abdulla Refinery
Kuwait National Petroleum Corporation (KNPC)
Kuwait

Guided By- P. Govinda Reddy

Designation - Senior Engineer (Civil & Structural)
Ankit Verma (A7615811061)
B.Tech. (Civil); 3rd Year

DECLARATION

I hereby declare that the project work entitled DESIGN AND ANALYSIS OF PRECAST
CONCRETE PIPE RACK is an authentic record of my own work carried out at
Petrofac, Gurgaon as requirements of eight weeks project for the award of degree of
Bachelor of Technology in Civil Engineering, Amity University Uttar Pradesh, Lucknow
Campus, under the guidance of my project mentor Mr. P. Govinda Reddy during May to
July 2014.

Ankit Verma
Dated: 03-07-2014

B.Tech (Civil) (2011-15)

A7615811061

Certified that the above statement made by the student is correct to the best of our
knowledge and belief.

P. Govinda Reddy
Senior Engineer (Civil & Structural)
Petrofac Engineering Services India (Pvt) Ltd.
Gurgaon

3
3

ACKNOWLEDGEMENT

A novice cannot do great tasks. Many great people contribute to completion

of his work directly or indirectly.
Words fail me to express my sincerest gratitude to this esteemed organization, which has
conferred on us the privilege to pragmatically convert our theoretical knowledge into
practical viable experience. During the course of my training at Petrofac, Gurgaon so
many people have guided me and I will remain indebted to them throughout my life for
making my training at Petrofac, Gurgaon a wonderful learning experience.
I would like to thank Mr. Ajay Malhotra, my project head, who gave me opportunity to
work in his department and guided me through my project time to time. The exposure to
the working of the industry that I have got here would not have been possible without his
kind support.
In the end I would like to thank Mr. P. Govinda Reddy, Mr. Manish Jain, Mr. Sandeep
and others for providing me the opportunity to add a new dimension in my knowledge
and helping me throughout my training period by getting trained in this esteemed
organization.

Ankit Verma
B.TECH
(Civil) 2011-15

AMITY
UNIVERSITY

TABLE OF CONTENTS
PAGE
1. INTRODUCTION ABOUT PETROFAC......

06

2. INTRODUCTION ABOUT KNPC MAB

06

3. DEFINITION OF PIPE RACK......

06

4. PURPOSE

06

5. REFERENCES.

06

6. INPUT DATA...

06

7. ASSUMPTIONS / CONSIDERATIONS.

06

8. MATERIAL..
..
9. DESIGN METHODOLODGY.

07

10. DIFFERENT PIPE RACK VIEWS...........

12

a.
b.
c.
d.
e.

As Modeled in STAAD Pro

Top view
Longitudinal view of pipe racks
Transverse view of pipe racks
Dimensions

11. LOAD APPLICATIONS.

a.
b.
c.
d.
e.
f.
g.
h.
i.

08

15

Dead load
Live load
Equipment load
Piping load
Frictional load
Temperature load
Wind load
Seismic load
Crane (monorail) load

12. CONNECTIONS..

29

5
a.
b.
c.
d.
e.

Bolted Moment Connection

Base Plate Design for pinned condition
5
RC Corbel design
Precast Concrete column to Precast column connection
Cast in situ concrete column to precast concrete column connection

13. DEFLECTION CHECK....

30

14. UTILITY RATIO CHECK....

30

15. CONCLUSION.........

32

APPENDICES and ATTACHMENTS

ATTACHMENT-A

Pipe rack plot plan and exchanger details

(05 Sheets)

ATTACHMENT-B

Wind Load Calculations

(05 Sheets)

ATTACHMENT-C

Seismic Load Calculations

(09 Sheets)

ATTACHMENT-D

Load Combination Calculations

(02 Sheets)

ATTACHMENT-E

Abbreviations

(01 Sheets)

ATTACHMENT-F

Base Plate Design for pinned condition

(03 Sheets)

ATTACHMENT-G

RC Corbel design

(04 Sheets)

ATTACHMENT-H

Precast Concrete column to Precast column connection

(04 Sheets)

Cast in situ concrete column to precast concrete column

(04 Sheets)

ATTACHMENT-I

Connection

ATTACHMENTJ

GA Drawings

(03 Sheets)

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6

DESIGN AND ANALYSIS OF PRECAST CONCRETE PIPE RACK

1. INTRODUCTION ABOUT PETROFAC:
Petrofac is a leading international service provider to the oil & gas production and processing industry.
Petrofac designs and builds oil & gas facilities; operates, maintains and manages facilities and trains personnel;
With more than 18,000 employees, Petrofac operates out of seven strategically located operational centers, in
Aberdeen, Sharjah, Abu Dhabi, Woking(UK), Chennai, Mumbai, Delhi and Kuala Lumpur and has a further 24
offices worldwide.
2. MINA ABDULLA REFINERY:
Kuwait National Petroleum Company, which aimed at upgrading and expanding the existing KNPC
refinery at Mina Abdulla, Mina Abdulla Refinery Established in 1958, Located in southern Kuwait about 60
KM from Kuwait City, Occupies an Area of 7.9 sq. KM, Total refining capacity of this refinery will go up to
800,000 barrels per day.
3. PIPE RACK:
Pipe rack in a refinery plant supports mainly pipelines which include Process pipe lines, flare lines and
utility lines.
Pipe rack is the main artery of any plant. This carries the pipes and cable trays (raceways) from one
equipment to equipment within a process unit (called ISBL pipe rack) or carries the pipe and cable trays from
one unit to another unit (called OSBL pipe rack). Sometimes AIR COOLED HEAT EXCHANGERS also the
part of pipe rack.
Continuous Pipe rack 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. Pipe racks
supporting equipment such as air-cooled heat exchangers must utilize the continuous system approach.
4. PURPOSE
The purpose of this calculation is to analyze and design the Precast Concrete Pipe rack for Mina Abdulla
Refinery (MAB-2) at Kuwait for Kuwait National Petroleum Corporations (KNPC).
5. REFERENCES
a. Steel Construction Manual 14th Edition - AISC 360-10
b. Minimum Design Loads for Buildings and Other Structures - ASCE 7-10
c. AISC Steel Design Guide 1 for Base Plate & Anchor Rod Design

d. Building Code Requirements for Structural Concrete and Commentary - ACI 318-11
e. Engineering Design Guide - Wind & Earthquake Attachment B & C
f. International Building 7Code - IBC 2012
6. INPUT DATA
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 pipe rack design. Therefore, a Civil/Structural
Engineer 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"
The following should be reviewed for design information:
Plot plans and equipment location plans

3D model showing piping layout, cable tray layout, and Pipe rack 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 pipe rack.

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 pipe rack.

Pipe rack construction material (Steel, Cast-in-situ concrete, Pre-cast concrete) shall be as per project
design criteria.

Allowance and provision for future pipes is made for future addition of pipe and raceway as per inputs
from respected departures.
The general input for this calculation is obtained from the FEED done by Flour Corporation and
Updated by PIL Piping Discipline. All Load calculations and Load combinations done based on AISC-7-10
Petrofac Standard Practice and Design Guide.
7.

ASSUMPTIONS/ CONSIDERATIONS
a. In the absence of any pipe load information, a uniform pipe load of 1.7 KN/m2 has been considered
for operating condition in Pipe rack as per pipe rack design guide & standard practice.
b. The Live Load for the platforms and walkways has been considered as 5 KN/m2 & for Staircase as 5
KN/m2 as per KNPC MAB-1 Design Basis.

c. Wind load has been calculated based on provisions of ASCE 7-10. Basic Wind Speed is 45 m/s with
Exposure Category C as per Project Design basis. Wind Load on piping has been estimated by
8 per KNPC Design Basis and applied on STAAD as a point load on
considering the piping as
transverse beam and as nodal load at effected Column beam junctions.
d. Snow load has is not applicable at this site.
e. Seismic loads are calculated based on provisions of ASCE 7-10. Seismic Design Category B with
Spectral response accelerations for short period and one second periods are Ss = 0.32g, S1 = 0.13g
respectively and Importance Factor 1.25 as per Project Design Basis. For detail Seismic calculation,
Refer Attachment C_Seismic Load.
f. Load Factors and Load Combinations for Serviceability and LRFD Design are considered in
accordance with IBC 2012 section 1605 and ASCE 7-10, Chapter 2, Refer Attachment D_ Load
Combination
g. Dead load of serrated grating has been considered @ 0.5 KN/m2.
h. Piping load has been applied as per loads provided by Piping Discipline.
i.

Piping friction load has been considered @30% of Vertical load for framed supports only.

j.

All the supports of pipe rack structure are considered to be fixed Base.

k. Slenderness factor for Major axis i.e. "Kz" for all the steel columns has been assumed as 1.2. Values
of Lz and 1.0 for Ly in STAAD has been considered as applicable.
l. The "R" values for Pipe rack Steel structure are considered as 3.0.
m. Monorail capacity 10 KN is given by Mechanical as discussed and designed accordingly.
n. Based on Monorail Beam W18x45, Mechanical will purchase lifting hoist so that it will fit in to
Monorail Beam flange as per requirement.
8.

MATERIAL
CONCRETE
Grade of Concrete shall be M30
Reinforcing steel shall be ASTM A615
STRUCTURAL STEEL
W Shape shall be of ASTM A992
Structural Bolts Shall be of ASTM A325N / A490N
Anchor Bolts shall be of ASTM F1554 (grade as reqd.)

Bracings shall be ASTM A992

9 be ASTM A36
Base Plate & Angle shall

9. DESIGN METHODOLOGY
Kuwait is having three Refineries; Mina Abdulla Refinery is one of largest refinery in Kuwait. KNPC
wants to expand their refinery capacity to 1.2 million barrels per day, Total project is spitted into two parts, PIL,
Samsung and CB&I won the MAB-1 consortium, Floor & Daewoo won MAB-2 projects, MAB-1 is holding
units like CDU, HCR, VRU, DHT, NHT, HOCetc.
All unit are having Pipe racks and needs fire proofing, so that precast concrete pipe rack is more economical by
30% than steel pipe rack and speed of construction is fast as compared to Cast in situ concrete Pipe rack.
This calculations dealt for HCR (Hydrocracker ) Unit only, The width of pipe rack 12m having three columns,
i.e.; 2x6m=12m, and overall length of HCR (unit-114) pipe rack is 333.0m (North south rack=237.0m, Eastwest Rack=60m and fire heater connecting Rack= 3 x 12m=36m) .
Pipe racks are carrying only process pipe lines, utility pipe lines & pipe lines for fired pre heater. All cables are
passing through underground Trenches, So no need to consider any cable tray loads in pipe rack calculations.
For construction flexibility, foundation and column up to +2.7m from ground level considered as Castin situ
concrete pipe rack, Level from +2.7m to +14.0m considered as Precast Concrete Pipe Rack and from +14.0m to
+21.0m considered as steel pipe rack where fire proofing is not mandatory.
The pipe rack is Five tier rack with main Elevation levels (TOS) of Steel Pipe rack at +121.0m , Top of steel for
PSV platform at +115m, Top of concrete beam elevations of fired preheated at+112.5m, Top of concrete beam
Elevation for utility piping at +110m, and Top of concrete beam elevation for Process Pipelines at +107.5m, &
+105m.
Total Precast frame is divided into four modules as Module-1(Bottom Module), Module-2, Module-3 and
Module-4(Top Module). Here Module-1and Module-2 has Frame Rack-1 and Frame Rack-2 respectively. At
elevation +115.0m there is a PSV platform. As Module-2 and Module-3 is Intermediate Module.
The plan size of the Bottom Module is 3.3m x 12.0m (height from TOC i.e. EL+102.70m).
The plan size of the Intermediate Module is 2.5m x 12.0m and
The plan size of the Top Module is 3.0m x 12.0m (height).
The pipe rack shall be Concentrically Braced steel framed structure, supported on Isolated foundation. The
Columns have been considered as fixed but released moment along longitudinal direction at base.
The platform shall be designed for worst load combinations out from Primary load cases mentioned below.
FRAMING OF CONTINUOUS/CONVENTIONAL PIPE RACK:
Frames:
Main pipe racks 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 pipe racks
with more than one tier, the beam struts should be located at a level that is usually equal to one-half tier spacing

10

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 base plate / foundation level.
10

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, modelled and analysed 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

Central Spine:
For steel pipe racks with spans of equal to or more than 6 m, a centre 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.
For Precast Concrete Pipe racks with span more than 6m, Intermediate beam may be required for
supporting small pipes (Less than 100mm) & Cable trays.
Longitudinal Beam Strut:
For typical continuous pipe rack 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. For any continuous pipe rack 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.

11

Considered expansion joint at every 30m interval, consider long slotted holes for free expansion and
contraction of structures for steel pipe racks & over sized holes at corbel beam connection joint for allowing
11to pipe stresses & environmental stresses for precast concrete pipe rack.
free expansion and contraction due
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.
Primary Load cases considered for Precast Concrete Pipe rack:
Load 1: DSW (Self weight)
Load 2: DS (Dead surface) Not used
Load 3: DFP (Cable Tray Load) Not used
Load 4: DPE (Piping Empty)
Load 5: DPO (Piping Operating-Content)
Load 6: DPT (Piping Test-Content)
Load 7: PAL (Pipe Anchor-Long)
Load 8: PAT (Pipe Anchor-Trans)
Load 9: LF (Floor Live Load)
Load 10: LB (Live Bundle Pull)
Load 11: DE (Equipment Empty)
Load 12: DO (Equipment Operating)
Load 13: DT (Equipment Test (Content)
Load 14: PF (Thermal / Friction)
Load 15: TR (Temperature Rise)
Load 16: TF (Temperature Fall)
Load 17: WX (Wind Long)
Load 18: WZ (Wind-Transverse)
Load 19: LB1 (Left Blank for Future) Not used
Load 20: LB2 (Left Blank for Future) Not used
Load 21: EX (EQ-Long)
Load 22: EL (EQ-Trans)
Load 23: PSVV (PSV Pop Up- Vertical) Not Used
Load 24: PSVL (PSV Pop Up- Long) Not Used
Load 25: PSVT (PSV Pop Up- Trans) Not Used
Load 26: Crane (Left side)
Load 27: Crane (Right side)
Load 28: Crane (Parked) Not Used
Please Refer Attachment D_ Load Combination for load combination details.
The load combinations for serviceability and LRFD shall be as per Section 1605 of IBC 2012.
Analysis and Design of Steel frame shall be carried out in accordance with AISC LRFD using STAAD pro V8i
Software. MathCAD, Version-15 and MS Excel 2010 are used to prepare calculations.
The entire design calculation as described above is presented in the subsequent pages.

12
12

10. DIFFERENT PIPE RACK VIEWS

As modeled in STAAD pro

X
Z

Load 14

TOP VIEW

24.00m

249.00m
60.00m

12.00m
237.00m

12.00m

Longitudinal View
Y X
Z

Load 21

13
13

28.00m

24.00m

12.00m

237.00m

Longitudinal View of North South Pipe Rack

Y
Z X

Load 21

24.00m

237.00m

Longitudinal View of East West Pipe Rack

Y
Z X

Load 21

6.00m

6.00m
28.00m

60.00m

Z X

Transverse View
Transverse View of East South Pipe Rack

Load 21

14
14

Load 28

Transverse View of North South Pipe Rack

Load 28

Dimensions

15
15
7.00m

1.50m
2.50m

6.00m

2.50m
1.50m

2.50m

2.50m
2.30m
2.50m

2.50m

5.70m

2.50m
6.00m
6.00m
6.00m

6.50m
6.00m
6.00m

11. LOAD APPLICATIONS

DEAD LOAD

Load 21

Self Weight of structure (Except weight of Grating and handrail) is automatically generated by STAAD pro
based on member sizes and density provided. However factor of 1.1 has been provided to take care of loading
due to connections weight. The weight of all structural members, including fireproofing, should be considered
in the design of the pipe rack.
Self weight of serrated grating has been applied @ 0.5KN/m2

(Considering Grating Bar of size 1-1/2" X3/16)

16
16
-3.000 kN/m

-3.000 kN/m

Load 1

Dead Self Weight (DSW)

LIVE LOAD
Live load (L) on access platforms and walkways and on equipment platforms should be considered, as
applicable.
Uniform live load on steel grating floor @ 5KN/m2
Live Load on each beam

Live Load

(As per Project Design Criteria)

= 5 KN/m2 x 6.0 m (Beam Span) = 30KN/m

17
17
-30.000 kN/m

-30.000 kN/m

Load 9

EQUIPMENT LOAD
Equipment weights, including erection, empty, operating, and test (if the equipment is to be hydro-tested on the
pipe rack), 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 as large valves, expansion loops,
and unusual piping or electrical configurations.
Sr. No

Equipments
Name

Air Cooled Heat

Exchanger

Vendor
Drawing
Number
307044(P-031)

Vendor Name

Weight of
Equipment

Equipment at
Elevation(m)

S&T
CORPORATION(SEOUL,

See below
Table-1 & 2

+121.00

KOREA)

No.

Item No.

1
2
3
4
5
6
7
8
9

114-E-0108
114-E-0110
114-E-0111
114-E-0120
114-E-0121
114-E-0125
114-E-0126
114-E-0131
114-E-0134

Uni
t
1
1
1
1
1
1
1
1
1

Table-1(Exchanger Details)
Bay
Bun
W(m)
Bay
Bun
1
2
4.30
2.08
8
16
6.02
2.94
1
1
3.65
3.65
4
8
5.61
2.74
4
8
6.24
3.06
7
14
8.48
2.98
1
1
3.04
3.04
2
4
5.07
2.79
6
12
6.24
3.06

L(m)

C(m)

12.40
12.40
12.40
12.40
12.40
12.40
12.40
12.40
12.40

11.50
11.50
11.50
11.50
11.50
11.50
11.50
11.50
11.50

TW(m
)
4.30
50.96
3.65
23.64
26.16
61.76
3.04
11.80
39.44

TL(m)
14.73
14.73
14.73
14.73
14.73
14.73
14.73
14.73
14.73

10
11
12
13
14
15

114-E-0136
114-E-0140
114-E-0143
114-E-0145
114-E-0147
114-E-0151

No.

Item No.

1
2
3
4

114-E-0108
114-E-0110
114-E-0111
114-E-0120

5
6
7
8
9
10
11
12
13
14
15

114-E-0121
114-E-0125
114-E-0126
114-E-0131
114-E-0134
114-E-0136
114-E-0140
114-E-0143
114-E-0145
114-E-0147
114-E-0151

1
1
1
1
1
1

18
1
3
181
3
1
1

2
6
2
6
2
1

6.27
5.00
5.32
6.17
6.81
1.97

3.07
2.43
2.80
3.02
3.34
1.97

12.40
12.40
12.40
12.40
12.40
3.90

11.50
11.50
11.50
11.50
11.50
3.00

Table-2(Exchanger Description)
Description
Weight(Ton)
Hot flash vapor condenser
First stage hot separator vapor condenser
Ip condensate cooler
Second stage hot separator vapor
condenser
Stripper condenser
Product fractionators bottoms cooler
Diesel pump around cooler
Kerosene pump around cooler
Product fractionators condenser
Debutanizer condenser
Naphtha splitter condenser
Heavy naphtha product cooler
Kerosene product cooler
Diesel product cooler
Flash Steam condenser

6.27
15.80
5.32
19.31
6.81
1.97

14.73
14.73
14.73
14.73
14.73
6.23

Volume(CBM)

28
278
20
156

111
1098
85
561

137
528
18
70
218
34
92
29
111
49
7

575
1689
76
270
861
146
352
114
432
180
25

For exchanger plot plan please Refer Attachment A_Pipe rack plot plan and exchanger details.
It comprises of various loads:

Equipment Empty- It is in-situ weight of equipment along with internal piping, insulation and platforms,
but excluding weight of fluids or products.
Load Calculation Example:

Weight of 114-E-143
Each bay
Reaction on each column
Weight of 114-E-125
Each bay
Reaction on each column

= 29 MT for 1 bays
= 29/1
= 290/4

= 29 MT
= 72.5KN

= 528 MT for 1 bays

= 528/7
= 754.3/4

= 75.43 MT
= 188.6KN

=290 KN

=754.3 KN

19

Equipment Empty

-72.500 kN
-72.500 kN

19

-72.500 kN

-85.000 kN
-50.000 kN

-72.500 kN

-50.000 kN
-45.000 kN
-85.000 kN
-17.500 kN
-45.000 kN
-17.500 kN

-50.000 kN

-50.000 kN
-45.000 kN
-17.500 kN
-45.000 kN
-17.500 kN

Load 11

Equipment Operating- It is the weight of equipment including liquid weight in operating conditions.
Load Calculation Example: - Equipment operating (content) is calculated by multiplying 1.5 with dead
equipment empty as per discussion with mechanical discipline.

Weight of 114-E-143
Each bay
Reaction on each column
Equipment Operating Load

= 29 MT for 1 bays
= 29/1
= 290/4
= 72.5X1.5

= 29 MT
= 72.5KN
=108.8KN

=290 KN

20

-108.800 kN

Equipment Operating

-108.800 kN

20

-127.500 kN

-108.800 kN
-108.800 kN

-75.000 kN

-127.500 kN

-75.000 kN
-67.500 kN
-67.500 kN

-75.000 kN

-26.300 kN
-26.300 kN

-75.000 kN
-67.500 kN
-67.500 kN
-26.300 kN
-26.300 kN

Load 12

Equipment Test (Content) - It is the weight of equipment including hydro test liquid, usually water,
required hydro testing.
Load calculation Example: - Equipment Test (content) is calculated by multiplying 1.5 with dead
equipment empty as per discussion with Mechanical Discipline.

Weight of 114-E-143
Each bay
Reaction on each column
Equipment Operating Load

Equipment Test (Content)

= 29 MT for 1 bays
= 29/1
= 290/4
= 72.5X1.5

= 29 MT
= 72.5KN
=108.8KN

=290 KN

21
-108.800 kN

-108.800 kN

21

-127.500 kN

-108.800 kN
-108.800 kN

-75.000 kN

-127.500 kN

-75.000 kN
-67.500 kN
-67.500 kN

-75.000 kN

-26.300 kN
-26.300 kN

-75.000 kN
-67.500 kN
-67.500 kN
-26.300 kN
-26.300 kN

Load 13

PIPING LOAD
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 pipe racks. 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)
Where:

s = Spacing of pipe rack bent,

p = pipe weight considered (KPa),
d = pipe diameter,
W = pipe concentrated load.

It comprises of various loads:

22

Piping Empty- It is in-situ weight of piping along with internal piping, and insulation, but excluding weight
of fluids or products.
22

Uniform piping load @ 1.2KN/m2

(As per Petrofac Design Guide & Standard practice)
2
Piping load on each beam = 1.2KN/m x 6m (Beam Span) = 7.2KN/m (Acting as UDL)
Piping Empty

-7.200 kN/m

-7.200 kN/m

-7.200 kN/m

-7.200 kN/m

-7.200 kN/m

-7.200 kN/m

-7.200 kN/m

-7.200 kN/m

Load 4

Piping Operating- It is the weight of piping including liquid weight in operating conditions.
Uniform piping load @ 1.7KN/m2
(As per Petrofac Design Guide & Standard practice)
Piping load on each beam = 1.7KN/m2 x 6m (Beam Span) = 10.2KN/m (Acting as UDL)

Piping Operating

-10.200 kN/m

-10.200 kN/m

-10.200 kN/m

-10.200 kN/m

-10.200 kN/m

-10.200 kN/m

-10.200 kN/m

-10.200 kN/m

Load 5

23

Piping Hydro test- Loading due to hydrostatic testing of lines should be considered in the design,
Coordinate the testing plan(s)23
with Construction, Startup, and/or the Piping Group as necessary, in order to
fully understand how such loads will be applied to the pipe rack 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.
Considered Uniform piping load @ 1.7KN/m2 (As per Petrofac Design Guide & Standard practice)
Piping load on each beam
= 1.7KN/m2 x 6m (Beam Span) = 10.2KN/m (Acting as UDL)

Piping Test Content

-10.200 kN/m

-10.200 kN/m

-10.200 kN/m

-10.200 kN/m

-10.200 kN/m

-10.200 kN/m

-10.200 kN/m

-10.200 kN/m

Load 6

FRICTIONAL (THERMAL) LOAD

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 pipe rack design. Friction between piping and supporting steel should not be relied
upon to resist wind or seismic loads.
It comprises of various loads:

Piping Frictional Longitudinala. If number of Pipes > 6 then:

Longitudinal Friction forces considered as 10% of (Operating Empty Weight of Piping)
b. If number of Pipes 3 to 6 then:
Longitudinal Friction forces considered as 20% of (Operating Empty Weight of Piping)

24

c. If number of Pipes < 3 then:

Longitudinal Friction forces considered as 30% of (Operating Empty Weight of Piping)
24

-1.520 kN/m
-1.520 kN/m
-0.530 kN/m
-1.520 kN/m

-0.530 kN/m
-1.520 kN/m

-1.520 kN/m
-1.520 kN/m
-0.530 kN/m
-1.520 kN/m

-0.530 kN/m
-1.520 kN/m

Load 14

Piping Frictional TransverseTransverse Friction forces considered as 5% of (Operating Empty Weight of Piping)

-0.530 kN/m

-0.530 kN/m

-0.530 kN/m

-0.530 kN/m

Load 14

25
ANCHOR LOAD

25

Pipe racks 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 paperback 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 defined by the transverse anchor forces. 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.
It comprises of various loads:

Piping Anchor LongitudinalLongitudinal Friction forces considered as 12% of (Operating Empty Weight of Piping)
(AS per Petrofac Design Guide & Standard practice)

Piping Anchor Longitudinal

-1.200 kN/m

-1.200 kN/m

-1.200 kN/m

-1.200 kN/m

-1.200 kN/m

-1.200 kN/m

-1.200 kN/m

-1.200 kN/m

Load 7

Piping Anchor TransverseTransverse Friction forces considered as 15% of (Operating Empty Weight of Piping)
(AS per Petrofac Design Guide & Standard practice)

26
Piping Anchor Transverse

26

-1.520 kN/m
-1.520 kN/m

-1.520 kN/m
-1.520 kN/m

Load 8

TEMPERATURE LOAD
Pipe Rack is subjected to a thermal load due to fluctuation of ambient design temperature with respect to its
construction temperature (i.e. stress free temperature). Pipe rack shall be designed for both maximum
temperature rise (TR) and minimum temperature fall (TF) as follow:
In summer Temperature rise= TR
In winter Temperature fall= TF
Construction Temperature=Tc
Structure to be designed fora. Temperature Rise, T=TR-Tc
b. Temperature Fall, T= TF-Tc
In this pipe rack we have considered:
Temperature rise = 30oC
Temperature fall = -30oC
(AS per Petrofac Design Guide & Standard practice)

Temperature Load

27
27

Load 15

WIND LOAD
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.
It comprises of various loads:

Wind Longitudinal Direction(X Direction)

Load 17

Wind Transverse Direction(Z Direction)

28
28

Load 18

For wind load calculation please Refer Attachment B_Wind Load.

SEISMIC LOAD
Earthquake loads in the vertical, transverse, and longitudinal directions should be determined in accordance
with the project design criteria. Vertical, transverse, and longitudinal seismic forces generated by the pipes,
raceways, supported equipment, and the paperback 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.
Seismic loads are calculated based on provisions of ASCE 7-10. Seismic Design Category B with Spectral
response accelerations for short period and one second periods are Ss = 0.32g, S1 = 0.13g respectively and
Importance Factor 1.25 as per Project Design Basis.
It comprises of various loads:
Seismic Longitudinal Direction
Seismic Transverse Direction
For seismic load calculation please Refer Attachment C_Seismic Load.
CRANE (MONORAIL) LOAD:
Monorail will be used to lift the pump portion of the pump. Motor will not be lifted by the monorail, Monorail
capacity to be indicated on the drawing. Weight of chain and pulley block to be considered while designing the
monorail
Crane (Monorail) Capacity = 10 KN (Taken same for all three cases defined below)
It comprises of various loads:

29
Crane Load (Left Side)
Crane Load (Right Side)29
Crane Load (Parked)
Crane Load (Left Side)
-10.000 kN
-10.000 kN
-10.000 kN
-10.000 kN
-10.000 kN
-10.000 kN

Load 26

Crane Load (Right Side)

-10.000 kN
-10.000 kN
-10.000 kN
-10.000 kN
-10.000 kN
-10.000 kN

Load 27

30
LOAD COMBINATIONS:

30

The following considering while Appling load combinations:

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.

12. CONNECTIONS
For longitudinal beams, simple shear connections at ends and pinned connections for bracings are generally
provided. Longitudinal beams connections are designed to carry axial loads. To allow for movement in the
longitudinal direction due to thermal expansion, a break in continuity is provided in between adjacent racks.
Constructability requirements shall be considered while designing the connections.
There are three types of connections between structural elements:
Moment Connections - This type of connection is provided in the transverse Direction of pipe rack.
Shear Connections- This type of connection is provided in the longitudinal direction of pipe rack
Axial Connections- This type of connection is provided for the bracing in the structure which is
provided at the anchor bay location.
a. Bolted Moment Connection
b. Base Plate Design for pinned condition
For base plate calculation please Refer Attachment F_Base Plate
c. RC Corbel design:
Corbels are cantilevers having shear span-to depth ratios not greater than unity, which tend to act as
simple trusses or deep beams, rather than flexural members designed for shear. The corbel may fail by
shearing along the interface between the column and the corbel, by yielding of the tension tie, by crushing or
splitting of the compression strut, or by localized bearing or shearing failure under the loading plate.
For RC Corbel calculation please Refer Attachment G_RC Corbel Design
d. Precast Concrete column to Precast column connection:
Tensile forces are transferred between concrete column elements by means of sleeves which are
anchored into each side of the precast elements at the joint with continuity achieved by dowel action.

31

The method used here is grouted pipe sleeves with in-situ lapped reinforcement; generally sleeves are
31 than dowel diameter.
20 to 30mm larger diameter
The dowel bar is inserted into the sleeve and grout is injected through a hole at the base. Alternatively,
the grout may be placed by gravity pouring. In either case, the sleeve must be vented to prevent
formation of air pockets.
To ensure effective force transfer, stirrups are placed along the lapping length.
Shear forces are transferred through shear key only.
Concrete is considered cracked while calculating reinforcement to resist Dowel tension and shear.
In case reinforcement is provided to resist tension, the concrete breakout strength of the Sleeve /
Dowel in tension has not been considered in checking the Sleeve / Dowel size.
For Precast Concrete column to precast column connection calculation please Refer Attachment I_
Precast Concrete column to precast column connection

e. Cast in situ concrete column to precast concrete column connection:

Tensile forces are transferred between concrete column elements by means of Anchor bolts in Cast in
situ columns and sleeves which are anchored into each side of the precast elements at the joint with
continuity achieved by dowel action.
The method used here is grouted pipe sleeves with in-situ lapped reinforcement; generally sleeves are
20 to 30mm larger diameter than dowel diameter.
The dowel bar is inserted into the sleeve and grout is injected through a hole at the base. Alternatively,
the grout may be placed by gravity pouring. In either case, the sleeve must be vented to prevent
formation of air pockets.
To ensure effective force transfer, stirrups are placed along the lapping length.
Shear forces are transferred through shear key only.
Concrete is considered cracked while calculating reinforcement to resist Dowel tension and shear.
In case reinforcement is provided to resist tension, the concrete breakout strength of the Sleeve /
Dowel in tension has not been considered in checking the Sleeve / Dowel size.
For Cast in situ concrete column to precast concrete column connection calculation please Refer
Attachment H_Cast in situ concrete column to precast concrete column connection
13. ALLOWABLE HORIZONTAL AND VERTICAL DEFLECTION:
Allowable deflections of pipe rack structures shall be as per project design criteria, consider the
following as limit of deflection: Lateral deflection produced by load combinations that include wind or seismic
forces: Pipe racks supporting equipment: h/100, unless a more stringent requirement is given by the
manufacturer of the equipment.
Pipe racks 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 criteria,
Vertical deflection of beams due to gravity pipe loads: as per project design criteria, where h is the total height
of the pipe rack structure.
14. UTILITY RATIO CHECK
Max. Utility ratio in members is as follows: -

Columns
Beam

32
Analysis
Property
W18x86

Design
32
Properety
W18x86

Actual
Ratio
0.703

Allowable
Ratio
0.850

Normalized
Ratio
0.827

Analysis
Property
W18x76

Design
Properety
W18x76

Actual
Ratio
0.832

Allowable
Ratio
0.850

Normalized
Ratio
0.979

Horizontal Bracings
Beam
Analysis
Property

Design
Properety

Actual
Ratio

Allowable
Ratio

Actual
Ratio
0.608

Allowable
Ratio
0.850

5917
Beams
Beam
1154

Vertical Bracings
Beam
Analysis
Design
Property
Properety
7215
WT18x33.5 WT18x33.5

Clause

L/C

Clause H1/2

253

Clause

L/C

Clause H1/2

217

Normalized
Ratio

Clause

L/C

Normalized
Ratio
0.716

Clause

L/C

Clause E

256

Columns and Beams

0.832
0.566

0.703

0.622

0.719
0.566

0.701

0.369

0.622
0.671

0.832
0.488

0.407

0.703

0.513
0.671
0.488

0.701

0.513
0.671

Load 21

33
33

Vertical Bracings

258
0.729
3106
0.425
0.0646

257
0.608
0.607

0.56

0.0646

Note:
Normalized ratio = (Actual ratio / Allowable
ratio)
There are no horizontal bracings in this pipe
rack.

3498

15. CONCLUSION:

3499
0.609

0.567

218

0.608
0.671

Design calculations have been performed as per

American Standards, LRFD method & Project
specifications. Based on the design calculations,
Structural drawings have been prepared.

From the member utility ratio, it is seen that all the

members have utility ratio less than 1.0 but restricted
utility ration to 0.85 only because final input loads not
received yet from piping discipline. It is concluded that Members and its connections are adequate from
strength as well as serviceability conditions as per American standards.
217

Please refer Attachment J_GA Drawings for final output of pipe rack.

Load 21

34
34

ATTACHMENT- A:
Pipe Rack Plot Plan and Exchanger Details

35
35

ATTACHMENT- B:
WIND LOAD CALCULATIONS

36
36

ATTACHMENT- C
SEISMIC LOAD CALCULATIONS

37
37

ATTACHMENT- D
LOAD COMBINATIONS CALCULATION

38 ATTACHMENT- F
38

ABBREVIATIONS:

KNPC

Kuwait National Petroleum Corporations

PIL

Petrofac Engineering India Private Limited

FW

Foster wheeler

GA

General Arrangement

AISC

American Institute of Steel Construction

ASCE

American Society of Civil Engineers

ACI

American Concrete Institute

IBC

International Building Code

ASTM

American Society for Testing and Materials

CDU

Crude Distillation Unit

HCR

Hydrocracker Unit

VRU

Vacuum Rerun Unit

TOS

Top of Steel

TOC

Top of Concrete

LRFD

Load & Resistance Factor Design

ASD

Allowable stress design

FEED

Front End Engineering & Design

NHT

Naphtha Hydro theater.

DHT

Diesel Hydro Theater

CCR

Continuous Catalytic reformer

HOC

Heavy oil cooling

39
39

ATTACHMENT -F
BASE PLATE DESIGN FOR PINNED CONDITION

40
40

ATTACHMENT- G
RC CORBEL DESGIN CALCULATIONS

41
41

ATTACHMENT- H
Precast Concrete column to precast column connection

42
42

ATTACHMENT- I
Cast in situ concrete column to precast concrete column connection

43
43

ATTACHMENT- J
GA Drawings