Pipe Rack

STANDARD
DOCUMENT SERIES NO 4602-37-CP PAGE 1

PIPING ENGINEERING STANDARDS REV NO 1
METHODS, GUIDES AND PROCEDURES
DATE ISSUED October 2004
DOCUMENT TITLE
PIPERACKS APPROVED P. Stephenson
TABLE OF CONTENTS
1.0 PURPOSE Printed: November 19, 2004

Caution: Non-Controlled copy.
2.0 APPLICATION Valid only at time of retrieval from
network source directory. User
3.0 GENERAL should verify that the revision
number is the most current.
4.0 PIPE RACK SIZING
4.1 PRELIMINARY PIPERACK SIZING

4.2 PIPE RACK LAYOUT
4.3 PIPE RACK SPACING AND CLEARANCES
5.0 LOCATION AND ARRANGEMENT
CPBU Quality Policy

To consistently exceed client
expectations through excellence of
execution and continual
improvement of our processes and
products.
/conversion/tmp/activity_task_scratch/620253137.doc
DOCUMENT NO 4602-37-CP REV NO 1 DATE ISSUED October 2004 PAGE 2
REVISION HISTORY
Revision Date Description Prepared by Approved by
Number Month Year Original Issue or NAME NAME
Describe Revision SIGNATURE SIGNATURE

N/A
0 Jan. 1996 Original Issue R. Hodgson
1 Oct 2004 General Update G. Franklin P. Stephenson
1.0 PURPOSE
This standard is intended as a guide to the designer in the piping layout and location of
Process Plant Pipe Racks
2.0 APPLICATION
When applying the guidelines outlined in this standard the designer must also review
the applicable Contract Specifications, Process Flow Diagrams (P&IDs) Line List and
also consider Maintenance, Safety and Piping Flexibility.
3.0 GENERAL
The main arterial system of a process plant is in the yard pipe rack, which contains the
long process lines for connecting distant equipment, and the lines for entering and
leaving a unit. Utility headers, supplying steam air, gas and water to process
equipment are also located in the yard, as well as relief headers and blowdown
headers. Instrument lines and electrical supply conduits are often supported on the
yard steel.
Early in plant layout, the main pipe racks must be sized to a close approximation.
Height and number of decks should be established, along with the location and
approximate size of instrument and electrical raceways. This should be done during
the plot plan phase of the project, and it establishes a basis for the initial general
arrangements.
4.0 PIPE RACK SIZING
4.1 Preliminary Pipe Rack Sizing
Frequently, it is necessary to estimate the size of pipe racks before all of the
mechanical flow sheets are available. In order to do this, the designer should obtain
estimates of instrument and electrical space requirements from the respective
disciplines. Using the Process Flow Diagrams (PFDs) the designer should discuss
process and utility requirements with the Process Group and develop a list of lines and
sizes of lines (estimated if necessary) to be included on the pipe rack. In addition to
this, the designer shall obtain from the Mechanical Group the estimated sizing for Air
Fin Exchangers (if being located above pipe rack) so that support steel for the
exchanger can be aligned with the rack pipe bents. See Figures 4.1-1 and 4.1-2
At this stage of development allow 20% extra for utility and process levels on both unit
and main plant pipe racks.
Figure 4.1-1
Air Coolers - Forced Draft
Figure 4.1-2
Air Coolers – Induced Draft
Piping Standard
Pipe Spacing
4.2 Pipe Rack Layout
In order to develop more detailed pipe rack layouts which will include firming up rack
spacing of support bents and location and routing of piping, the following information is
required.
a) Project Design Data - These give required or existing conditions inside and outside
the unit limits, such as the required location of cooling watermains, whether
below or above grade; location of furnaces, control and switch houses; location
of utility and process lines entering and leaving unit limits; main pipe runs
outside the unit; location of storage tanks relative to process units; cooling
tower location and site course level differences; safe distances between units
or between tankage, storage, loading, etc.
b) Project Specification - Only a few items in the job specifications affect yard-
piping design. Such items are: the minimum headroom between road
surfaces and overhead pipelines or steel beams; access, headroom and
handling requirements for equipment arranged under the yard; requirements
for ladders, catwalks and platforms located in the yard; details affecting piping
and structures, operating and safety requirements.
c) Plot Plan - This shows the relationship between plant units, equipment,
buildings and yard piping, and the position of incoming and outgoing lines. The
plot plan also locates major structures, buildings and all equipment, and
indicates roads crossing the yard or located under the pipe rack.
d) Mechanical Flow Diagrams - Process flow diagrams show the essential lines
that connect process equipment. Mechanical flow diagrams (developed from
process flow diagrams) indicate the complete flow systems necessary for plant
operation, and include pipe sizes, valving, manifolds, and all piping and
instrumentation details. Utility flow diagrams show the number and size of
water, steam, condensate, gas, air, etc., headers, and all equipment supplied
by these headers, with the necessary valving and piping details.
e) Modularization Paramaters, etc
By using the above information the Piping Designer can produce a

transposition (Figure 4.2-1) of the process piping and utility distribution. This
will indicate the degree of density of piping on the pipe rack. Identifying the
number of lines (if not given in project specs) and using the spacing chart (See
Figure 4.2-2), and allowing for future, the pipe rack width can be determined.
At this stage allow for 15% future for process and 15% for utility levels on the
unit and main plant pipe racks (if none stated in project specs). The number of
levels and cross-sections can also be produced at this stage.
Figure 4.2-1
Typical Transposition
4.3 Pipe Rack Spacing and Clearances – See Figures 4.3-1 and 4.3-2
If there are no project specs giving the spacing and clearances for pipe racks, use the
following:
 Spacing between pipe bents - 6000 mm min.
 Spacing between pipe stanchions - 6000 mm min..

Note: This may be increased to support the steel structure for Air Fin
Exchangers located on top of pipe rack.
 Generally the minimum clearance between the underside of the lowest pipe
rack steel or piping, whichever is lower, to the high point of grade or paving is
as follows:
a) In trucking Areas - 3650 mm
b) All other Areas - 2450 mm
c) Above Main Plant Roads - 6000 mm
d) Piping over Railroad Spurs - 6900 mm from top of rails
e) Within Process Unit Areas
i. Above internal roadways providing access for maintenance and

fire fighting equipment - 4900 mm
ii. Under pipeways where access if required

 Vehicular Equipment - 4300 mm
 Portable Service Equipment - 3000 mm
Figure 4.3-1
Pipe Rack - Cross Section
Figure 4.3-2
Pipe Rack - Isometric View
5.0 LOCATION AND ARRANGEMENT – See Figures 5.0-1, 5.0-2, 5.0-3, 5.0-4
The following are general guidelines for layout of pipe rack piping, electrical and
instrument trays:
1. The number of pipe rack levels is determined from piping transpositions. If two
levels are required then the utility piping is generally placed on the top level
and process lines on the lower level. If more than two levels are required for
process lines then add a third level.
2. All lines should be run in such a manner as to avoid pockets. Pocketed lines in
racks require low point drains.
3. Cable trays can be run on the utility level provided there is room. If not an
extra level may be required. Cable trays can also be run on outriggers outside
the rack provided the client approves. Establish requirements early in the
project.
4. Locate heavy lines regardless of service over or near pipe rack columns.
(Centrally loaded columns and reduced bending moment on beams will result
in light structural design.)
5. Process lines interconnecting equipment on the same side of the rack near
edge of pipe rack, to be kept to that side of the rack.
6. Process or utility lines with orifice runs near edge of rack with orifice flanges
near a column for access with portable ladder which allows for side tapping
(liquid).
7. Hot lines (hottest and largest) which will require expansion loops, e.g. steam
and condensate to be located on edge of pipe rack close to rack stanchions so
expansion loops can be supported from opposite side of pipe rack steel. Relief
line headers, individual relief lines, blowdown lines and flare lines shall be self
draining from all relief valve outlets to the knockout drum.
8. Consideration to be given to the selection of anchor bays. (i.e. at battery limits

and/or mid section of pipe rack. Review with Civil/Structural Group, and Piping
Stress, see Figure 5.0-1.
9. The relief header should be placed at a higher elevation than the main pipe
rack. Usually on cantilevers on the outside of the rack. Avoid using a tee post
directly above the pipe rack columns, this will limit the extension of the rack if
more space is required later.
10. Where possible utility headers should be kept to the side of the pipe rack which
effects the most economical lengths of lateral take-offs. Block valves on
branches from headers to be located at edge of rack as close to header as
possible. Accessed by portable ladder or platform.
11. Thermal movements of lines, utility and process must be considered, both in
the spacing of lines on the rack and in location of branch connections. Also
where two pipe racks join and piping changes direction the thermal movements
must always be allowed for. Lateral deflections should be limited to 100 mm in
process unit racks and 150 mm in main pipe racks.
12. The minimum pipe size in the rack should be two inches to facilitate spanning.
The exception to this is for chemical injection lines where the flow is small. In
this case the use of cable trays or other intermediate supporting should be
utilized. Occasionally, where numerous runs of small bore piping are involved
on pipe racks, intermediate support beams may be required. Normally small
bore headers should be supported, midway between pipe bent spans, by larger
bore lines.
13. Rack height between levels can vary, but is generally between 1200 and 1500
mm depending on line sizes. Allow space for two 90 L.R. elbows, or one 45
L.R. and one 90 L.R. elbow of largest pipe to determine height between rack
steel level and side stringer steel level.
14. Space requirements around pipe rack columns at grade should be allocated for
electrical panels, conduits, and switches. Check clearances with utility stations
and control stations.
15. The height of the pipe rack should be set to allow for crane access under the
pipe rack. Check clients requirements for space allocation. Clearance under
the lowest side steel elevation should be provided for crane boom access to
pumps and motors. See Section 4.3.
16. If no crane access is required, provide headroom clearance under the lowest
side steel elevation allowing for the depth of the beam including fireproofing.
See Section 4.3.
17. Branch connection for gas, air, and steam are taken from top of pipe header.
Liquid lines, water, etc. are taken off bottom of pipe header.
18. Drip legs shall be located to avoid interfering with steel work due to header
thermal movement.
19. If air coolers are located above the pipe rack, space should be allocated for two
ladders to service the air cooler platforms. Locate away from hot pumps.
20. Flat turns shall be avoided in unit pipe racks. They eliminate rack spacing
change elevation when changing direction.. This applies to all lines connecting
to yard piping. However, some large lines on entering the unit can make a flat
turn but they shall be placed at edge of the rack piping.
21. Flat turns in offsite pipe racks (outside process units) can be made provided no
change in piping sequence is required.
22. Local platforms and catwalks are to be supplied over the top lateral piping to
provide access as required to relief valves or control valves.
23. When deciding spacing between bents consideration must be given to support
locations for equipment located above the rack (e.g. air fins, drums, etc.) and
equipment located between the bents at grade (e.g. pumps, drums).
24. Location of valves at battery limits depends upon whether the pipe rack is a
single level or two level pipe rack. Consideration must be given to any Client
specifications or requirements. See Figures 5.0-2, 5.0-3, 5.0-4.
Figure 5.0-1
Flexibility Check Steps - Expansion Loops
Figure 5.0-2
Single Level Pipe Rack Battery Limit Valving
Figure 5.0-3
Battery Limit Valving- Pipe Rack Pipe Bridge
Figure 5.0-4
Battery Limit Valving- Pipe Rack & Sleeperway

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STANDARD

DOCUMENT SERIES NO 4602-37-CP PAGE 1

PIPERACKS APPROVED P. Stephenson

1.0 PURPOSE Printed: November 19, 2004

4.1 PRELIMINARY PIPERACK SIZING

5.0 LOCATION AND ARRANGEMENT

CPBU Quality Policy

Revision Date Description Prepared by Approved by

Number Month Year Original Issue or NAME NAME

Describe Revision SIGNATURE SIGNATURE

1 Oct 2004 General Update G. Franklin P. Stephenson

4.0 PIPE RACK SIZING

4.1 Preliminary Pipe Rack Sizing

4.2 Pipe Rack Layout

e) Modularization Paramaters, etc

By using the above information the Piping Designer can produce a

 Spacing between pipe bents - 6000 mm min.

 Spacing between pipe stanchions - 6000 mm min..

a) In trucking Areas - 3650 mm

b) All other Areas - 2450 mm

c) Above Main Plant Roads - 6000 mm

d) Piping over Railroad Spurs - 6900 mm from top of rails

e) Within Process Unit Areas

i. Above internal roadways providing access for maintenance and

ii. Under pipeways where access if required

8. Consideration to be given to the selection of anchor bays. (i.e. at battery limits

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