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STANDARDISATION OF PIPE SUPPORT STRUCTURE

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INDEX Point No. 1.0 2.0 3.0 4.0 Introduction Design consideration for Single T / Goal posts supports Design Considerations for Pipe rack Transfer of Data Sketches Annexure I Annexure II Annexure III (2 pages) Description Page Nos 3-4 45 5- 10 11 12 16 17 18 19 - 20

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STANDARDISATION OF PIPE SUPPORT STRUCTURE

1.0

Introduction :

The following procedure establishes the standardization of the Pipe Support structures such as T- Post , Goal Post and Pipe rack.

This standardization is expected to enable the Piping Engineer to plan the pipe rack layout while developing the unit plot plan itself. This will also help the Electrical Engineer in laying out the cable trays and also plan the cable rack if a separate one is required.

This procedure intends to reduce the interaction time between the Structural Engineer and the Piping Engineer. The areas where options have been provided, only need to be addressed and confirmed as required based on the Project Design Basis.

The minimum span between the support is taken as 3000 mm, which is optimum span for the minimum header size of 2 (50 mm ) nominal bore to run on the rack as well as the maximum support span for the cable tray. This is also the ideal support span for the GRP piping of the same size.

Generally pipe / cable rack shall be of structural steel. However it can fully RCC or RCC up to first tier and structural steel for above tiers. MOC of pipe rack is a project specific requirement. The same shall be decided at the start of the project based on the followings: For LSTK projects Cost considerations, procurement / fabrication of steel sections, piping activities on pipe rack at site and schedule for the completion of the work. For Cost + Fees project As per Clients requirement / specifications and / or as stated in ITB. If not, then to be discussed, at length from cost and time

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schedule point of view and shall be agreed upon with the Client at the Kick-off meeting itself.

2.0

Design considerations for Single T / Goal posts supports

2.1

Single post support can be T Type or Goal post type. When the number of pipes to supported are less in numbers and the area where

pipelines are to be laid does not require a pipe rack considering the width and the headroom, these types of single posts could be selected.

2.2

The following parameters shall be considered for the selection and design of these types of supports.

2.3

Data for single support: ( Refer Sketch SK-0001 )

Sr.No.

Type

'L' mm width

'H' (max.) Height mm 2500 --do---do---do-5000 --do---do---do--

Max. vertical load KN/sq m # 1.20 1.20 1.20 1.20 1.20 1.20 1.20 1.20

Span in 'm' (Ref.2.4) 3000 / 5500 --do---do---do---do---do---do---do--

1 2 3 4 5 6 7 8

T-Post T-Post T-Post T-Post Goal Post Goal Post Goal Post Goal Post

800 1000 1200 1500 1500 1800 2000 2500

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STANDARDISATION OF PIPE SUPPORT STRUCTURE Notes;

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# Minimum load on pipe support to be considered for specified on layout whichever is higher.

3 m span or as

For isolated pipe supports this provision does not apply. The same is to be dealt separately as per information given by PI.

2.4

Maximum span for metallic piping shall be 5500 mm for pipe sizes greater than 2 NB dia. However spacing of column shall be 3000 mm, 4000 mm , 5000 mm, 5500 mm and not in between.

2.5

Minimum size of pipe considered is 2" (50 mm )NB.

If pipes less than

2" ( 50 mm ) NB have to be routed along with, lesser dia. pipes are to be supported with each other and / or from larger diameter pipes. Pipes should be supported preferably at span on either sides of T / Goal post supports. ( Refer the schematic arrangement shown below. )

2.6

When FRP / GRP pipes 2 ( 50 mm ) NB dia. and or electrical / instrument cables trays are to be supported, the maximum span shall be 3000mm.

3.0

Design Considerations for Pipe rack. Pipe rack shall be considered when the pipes / cable are required to run on more than one tier with long run and with / without road crossings. Generally the rack shall be of structural steel. Fire proofing, if required, shall be done as per project requirement upto the BOS level of the lower tier on main columns and equipment supporting beams, vertical bracings etc. In case fire proofing is required, then pipe rack can be RCC upto 1st tier and structural steel above. Fire proofing requirement and its extent shall specified in the data communicated. Decision to use RCC for entire pipe rack shall be project specific.

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The parameters to be considered for the selection and design of the pipe rack are as follows. 3.1 Following standard widths shall be considered:a) b) c) d) e) f) g) 2000 mm 3000 mm 4000 mm 5000 mm 6000 mm 7500 mm 9000 mm

LE PI shall select the width of the rack from the above list after the inter connecting P & I diagram is prepared. The correctness of information

regarding the lines should be such that all lines on the rack which are 4 NB (100 NB) and above shall be identified. PE to confirm that the pipe size will not vary more than one size up or down after this stage. 20% extra space per tier for future shall also be considered at the planning stage.

3.2

Height between tiers (level difference) shall be standardized as 1500mm (minimum) Increase in this height shall be project specific and shall be decided after the inter connecting P&I diagrams are finalised. However increase in height shall be to 1800 mm, 2000 mm, 2200 mm, or maximum 2500 mm.

3.3

Spandrels or longitudinal beam between columns except for the top tier shall be placed minimum 500mm below the transverse beam for rack width more than 4000mm. ( Refer Sketch 0002 )

3.4

For pipe rack up to 4000 mm width, the longitudinal beam shall be provided at the same level as that of the transverse beam. ( Refer Sketch 0003 ) For pipe racks, in O & U units , running without off shoot branch for process unit, can be provided in similar manner regardless of width.

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3.5

Longitudinal tie beam shall be provided at the top of the column, the TOS elevation to match with that of the transverse beam. At road crossings, longitudinal member of pipe rack girder should be at the same level of transverse beams.

3.6

Clear height below the first tier shall be minimum 3000 mm Inside unit 4500 mm In between units 6000 mm Over the crest of road for truck movement. 7000 mm Over the crest of road for crane movement.

3.7

Normal span ( center to center distance between pipe rack columns ) shall be 6000mm. Intermediate support at mid span (3000mm maximum) shall be provided only for GRP piping and cable tray support. The pipe rack span can be increased to 7500 mm or 9000 mm only and intermediate spans are not to be considered. For Pipe rack span more than 6000 mm, intermediate transverse beam iif required is to be provided for pipe supports.

3.8

At present moment connection of transverse beam with column, generally using top and bottom flange plates is followed till date with minor modifications, project specific. However provision of flange plate near column is an obstruction to pipe routing, hence preferably knee bracing shall be provided instead of moment connection for transverse beam where rack width is 4000 mm and above. This arrangement needs to be reviewed if larger diameter pipes are routed nearer to the column. If the moment connection is unavoidable, then the same shall be achieved by

Out stand member directly welded to column to avoid flange plate at beam top. With end plate bolted moment connection ( Refer sketch 0004 ).

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Expansion joints shall be provided at every 50m to 60m on the run. Expansion joint can be achieved by providing 3m clear gap between column frames.

3.10

Elevation bracing for full height of pipe rack shall preferably be provided at mid span of expansion joint. There shall be cross (x) bracing, but can be modified to bracing for access purpose. ( Refer Sketch 0005)

3.11

Horizontal bracing at pipe tier shall be provided for anchor bay as required. Anchor points required for pipes shall be provided only on main framing beams and not secondary beams.

3.12

At road crossings, girders span shall be 10 m, 12m, 15 m and further in steps of 3m only. Longitudinal truss arrangement shall be provided for pipe rack at road crossings.

3.13

Generally cable tray supports are provided in the form of X mas tree. If these are required to be provided above top most tier of pipe rack, it shall be ensured that not more than three trays are provided on Xmas tree. As these Xmas trees are supported on longitudinal beams, and they will impart torsion on beam. If more numbers of Xmas trees are required, then full tier width option can be thought of.

3.14

Loading on the piperack Based on the inputs given as per following loading, Civil Engineer should design the pipe rack cross sections. However the same shall be issued for construction along with pipe rack layout drawings. While giving loading on pipe rack, utmost care should be taken to adhere to furnished loading and shall not be changed unless unavoidable.

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STANDARDISATION OF PIPE SUPPORT STRUCTURE 3.14.1 Vertical load:

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Vertical load on the rack shall be calculated by PI based on the number of pipe lines expected to be laid and the planned spare capacity as per the norms. This data shall be presented as KN / RM of pipe rack or KN / M2 per tier of pipe rack. Along with the vertical load, axial and lateral load expected also shall be furnished. Initially Loading on pipe rack can be stated as follows; a) Light Loaded = 1.50 KN per Sq.m.

b) Medium Loaded = 2.00KN per Sq.m. c) Heavy Loaded = 3.0 KN per Sq.m.

In additions to the above, point loads arising due to pipe sizes more than 12 ( 300 mm ) NB, should be furnished along with its locations. For calculation of Uniformly Distributed loads, those pipe lines which are considered for the point load calculation shall be excluded to avoid duplication.

3.14.2 Horizontal loads due to friction on pipe supports / Rack a) On the Pipe supports and Pipe Racks with three or less lines, the friction force shall be taken as 30% of the total pipe weight under operation.

b)

On Pipe supports and Pipe Racks with 4 to 6 pipe lines, the friction force shall be taken as 20% of the total pipe weight under operation or 30% of the three largest pipe under operation which ever is higher.

c)

On the Pipe supports and Pipe Racks with 7 or more pipe lines, the friction force shall be taken as 10% of the total pipe weight under operation or 20% of the six largest pipes under operation which ever is higher.

The above friction loads are to be considered in both longitudinal as well as transverse direction. The said loading is to be considered acting in either direction, one at a time and not simultaneously.

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STANDARDISATION OF PIPE SUPPORT STRUCTURE 3.14.3 Anchor Loads.

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As required, pipe anchors are to be provided on the Pipe supports and Pipe Racks. While specifying these loads, PI-LE shall identify these anchor loads along with its location, on pipe rack loading information drawings. This procedure is necessary to unable CI-LE to proceed with analysis and design of pipe rack with appropriate load combinations. Information regarding pipe anchors shall be furnished in the following manner.

a) Tentative location of the anchor bays, in pipe rack information drawings should be planned at the start of detail engineering. At anchor bay ,required horizontal and elevation bracings shall be provided preferably in the form of cross (X) bracing, but can be modified to bracing if it is really unavoidable to provide cross (X) bracing. As far as possible, the location of anchor bay should not be changed. However the same can be

adjusted in next or previous bay if required and CI - LE should be informed sufficiently in advance to minimize re-engineering.

b) Approximate horizontal anchor forces based on experience shall be provided on conservative side by the lead Piping Engineer, While giving loads utmost care should be taken the final loads will turn out to be less than or equal to furnished loads. The lead CI Structural Engineer shall consider these loading for the design of the members.

c) However, the final anchor load and moments shall be checked with respect to furnished loads after completing the stress analysis of the lines on the rack. Any major revisions in loads should be immediately brought to notice of concerned engineer.

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4.0

Transfer of data: This procedure does not cover the data transfer for equipments (e.g. Air

coolers, Heat exchangers etc.), supported on top tier of pipe rack above cable tier. This is to be dealt separately. Enclosed Annexures I, II, and III respectively shall be used for the transfer of data for T post , Goal post and Pipe rack . However the same can be modified if and as necessary for proper transfer of data.

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ANNEXURE - I

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Civil Information for " T " Posts

L
H
Material of Construction 1. Concrete 2. Structural Steel Preferred Values of A.) Width of post = L 1 2 3 4 800 mm 1000 mm 1200 mm 1500 mm Vertical Loading on T post 300 Kgs / Rm 350 Kgs / Rm 400 Kgs / Rm 500 Kgs / Rm B.) Height of Post = H 1 2 3 4 5 6 7 1000 mm 1250 mm 1500 mm 1800 mm 2000 mm 2250 mm 2500 mm C.) Center to center distance 1 2 3 4 3000 mm 4000 mm 5000 mm 5500 mm D. ) Horz. Loading on T post 1 2 3 30% Of Vertical loading 20% Of Vertical loading 10% Of Vertical loading

ANNEXURE - II

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Civil Information for " Goal " Posts

2500 < H < 4000

TOS at 2500

Material of Construction 1. Concrete 2. Structural Steel No bracings / intermediate beam required

Preferred Values of A.) Width of post = L 1 2 3 4 1500 mm 1800 mm 2000 mm 2500 mm

Vertical Loading on T post 500 Kgs / Rm 600 Kgs / Rm 700 Kgs / Rm 800 Kgs / Rm

B.) Height of Post = H

1 2 3 4 5 6 7 8 9

2500 mm 3000 mm 3250 mm 3500 mm 3750 mm 4000 mm 4250 mm 4500 mm 5000 mm

C.) Center to center distance

1 2 3 4

3000 mm 4000 mm 5000 mm 5500 mm

D. ) Horz. Loading on T post

1 2 3

30% Of Vertical loading 20% Of Vertical loading 10% Of Vertical loading

4000 < H < 5000

ANNEXURE - III
Civil Information for " PIPE RACK "

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H3

Overhang as required by PI. Not more than 1200 mm

H1

H2

" Cross " / " A " type bracings as required by civil, to be cleared by PI engineer. Material of Construction 1. Concrete Up to 1st Tier Entire pipe rack 2. Structural Steel Above 1st Tier Entire pipe rack No bracings / intermediate beam required

Preferred Values of A.) Width of pipe rack = L

l l l l

2000 mm 3000 mm 4000 mm 5000 mm

l l l l

6000 mm 7500 mm 9000 mm

B.) Total no. of Tiers For piping For Electrical / IC Cable trays
l l

No. of cable trays - Max. 3 nos per Xmas tree

C.) Clear Height of 1st Tier = H1

1 2 3 4

3000 mm 4500 mm 6000 mm 7000 mm

Inside Unit In between Units At Road crossing - light / heavy vehicle movement At Road crossing - crane movement

D.) Center to center distance of pipe rack columns = Span

1 2 3

6000 mm 7500 mm 9000 mm

H1

H2

H3

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ANNEXURE - III
L

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L

H3

Overhang as required by PI. Not more than 1200 mm

H1

H2

E.) Longitudinal Beams For pipe supports

1 2

Same at transverse Beam levels 500 mm below transverse Beam levels

F.) Distance between Tiers = H2 / H3

1 2 3 4 5

1500 mm 1800 mm 2000 mm 2200 mm 2500 mm

* Distance between EL / IC cable trays

H1
200 mm 250 mm 300 mm 450 mm 500 mm Please Specify for Higher dia, pipes, However these pipes are to be routed near support. Provide overhang if necessary
W1 W2 d1 W1 d2 W2 d1 d2

G.) Vertical uniformly distributed loading on pipe rack Lightly loaded Medium loaded Heavily loaded 120 Kg/Sqm. 150 Kg/Sqm. 180 Kg/Sqm. 200 Kg/Sqm. Kg/Sqm.

Vertical point loading on pipe rack - for pipe sizes > 300 mm NB

Tier Number Point Load - W Distance - d Tier Number Point Load - W Distance - d

H. ) Horz. Loading on pipe rack

1 2 3

30% Of Vertical loading 20% Of Vertical loading 10% Of Vertical loading

H2

H3

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