Pipe Rack Design

28-August-2013
Prepared by
Eng. Abdussalam Al-Zahrani

Outline

Introduction
Concept for Design
Steps for Design
Loading
Analysis & Design
Pipe Rack Design Flow Chart

Introduction
Pipe Racks typically support pipes, power cables
and instrument cable trays in petrochemical,
chemical and power plants. Occasionally, pipe
racks may also support mechanical equipment.

Main pipe racks generally transfer material

between equipment and storage or utility areas.

Cont.
Pipe rack is a structure made of steel, concrete or
both, i.e. hybrid structure that supporting :Layer or layers of piping.
Electrical and instrument cable tray.
Mechanical Equipment if any.

Concept of Design
Structural components of the pipe rack must be capable
of resisting the axial loads, shears, moments, and torsion
produced by the load combinations given in Section 5.0
of SABP-M-007.
The pipe support framing system is designed as rigid
frame bents with fixed or pinned bases in the transverse

direction and as braced frames in the longitudinal

direction.

Steps for Design

1. Geometry Modeling. (Dimensions, Section Properties, etc)
2. Loading. (Application of all possible loads)
3. Design Parameter (Kz, Ly, Lz, UNL, )
4. Analyzing & Design. (Check your modal, revise and change as needed)
5. Connection.

By Spread Sheet or by StaadPro if Connection Module is available.

Geometry
The main components of the Pipe Rack are
Transverse
beams

Longitudinal
beam

Columns

Vertical
bracing

Loading
Types of load can be classified as follows:
Dead Load (Ds, De, Do and Dt)
Wind Load (W, Wp)

Earthquake Loads (Eo, and Ee)

Thermal Loads (T, Tp, Af and Ff)
Other Loads (O)
REF: SABP-M-007 Para.4 Page 7

2.1

Loading Tree
Self-Weight
Operation

Dead

Types of Loads

Empty

Live
Test

Wind
Operation

Earthquake
Empty
Temperature

Thermal

Anchor
Friction

Summarized from SABP-M-007 Para.4

2.2

Piping Loads
Operating dead load (Do): A uniformly distributed load
of 40 psf (1.9 kPa, kN/m2) for piping, product, and
insulation.
Empty dead load (De): 60% of the estimated piping
operating loads shall be used. (To check uplift with Wind or Earthquake)
Test Load Dt: The test load shall be defined as the gravity

load imposed by the liquid (normally water) used to

pressure test the piping.

2.2

Piping Loads
For any pipe larger than
12-inch (304-mm) nominal
diameter, a concentrated
load, including the weight

of piping, product, valves,

fittings, and insulation shall
be used in lieu of the 40
psf (1.9 kPa).This load shall
be

uniformly

distributed

over the pipe's associated

area.
SABP-M-007 Page 59

2.3

Cable Tray Loads

Operating dead load (Do): A uniformly distributed dead

load of 20 psf (1.0 kPa) for a single level of cable trays

and 40 psf (1.9 kPa) for a double level of cable trays.
*Comment: These values estimate the full (maximum) level of cables in the trays.

Empty

dead load

(De): For checking uplift

and

components controlled by minimum loading, a reduced

level of cable tray load (i.e., the actual configuration)

should be considered as the empty dead load.

Engineering judgment

2.4

Wind load
F = qz G Cf Ae

ASCE 7 (Eq. 6-25)

qz = Velocity pressure at height z above ground.

G = Gust effect factor.
Cf = Net force coefficient.
Ae = Projected area normal to wind.

Wind Load

2.4

Velocity Pressure qz
qz = 0.613 Kz Kzt KdV I (N/m2)

Kz is the velocity pressure exposure coefficient per Sect.

6.5.6.6 & Table 6-3 of ASCE 7.
Kzt is the topographic factor per Sect. 6.5.7.2 of ASCE7.

Kzt is equal to 1.0 for Pipe Racks and Open Frame

Structures located in Saudi Aramco facilities.
Kd is the wind directionality factor per Sect. 6.5.4.4 and

Table 6-4 of ASCE 7. When used with load combinations

specified in SAES-M-001, Kd is equal to 0.85 for Pipe Racks
and Open Frame Structures.

Wind Load

2.4

V is basic wind speed of 3-second gust speed at

33ft above the ground.

I is the Importance Factor set forth in Table 6-1 of

ASCE 7. I equal 1.15 for Category IV structures. All
Pipe Racks and Open Frame Structures at Saudi
Aramco facilities are considered Category IV
structures.

Wind Load

2.4

Table 3 of SABP-M-006 (Metric Units) provides values for qz at

several heights for most Saudi Aramco sites. These values are
to be used for Pipe Racks and Open Frame Structures.
SABP-M-006 Page 23

2.5

Thermal Loads
Ff = Friction Forces: 10% of total piping loads on
local supporting beam, 5% of total piping loads
acting on struts, braced, anchor frame, column and
foundation.
Af = Anchor Forces: Anchor and guide forces and
locations shall be obtained from the piping stress
analysis.
T = Temperature Force:
Design tem. = Highest Temp. Lowest Temp. + Metal Temp
*Highest & Lowest Mean Temp can be taken from SAES-A-112.
*Metal Temp can be estimated at 20Co

2.6

Earthquake

Calculation of the Earthquake Base Shear V

V = Cs x W
Cs : The Earthquake Response Coefficient
W : The Effective Earthquake Weight.

Determination of Cs

(Ref. ASCE 7-05_Clause 12.8)

Base Earthquake Response Coefficient

CS

=SDS / ( R / I )

Maximum Earthquake Response Coefficient

CS

=SD1 / { Ta x ( R / I ) }

Minimum Earthquake Response Coefficient

Where:

CS shall not be less than 0.010

(Ref. ASCE 7-05_Eq.12.8-5)

CS shall not be less than 0.5 x S1 / ( R / I )

,when if S1 0.60g

(Ref. ASCE 7-05_Eq.12.8-6)

CS shall not be taken less than 0.030

(Ref. ASCE 7-05_Eq.15.4-1)

CS shall not be less than 0.8 x S1 / ( R / I )

,when if S1 0.60g for non-building

(Ref. ASCE 7-05_Eq.15.4-2)

Earthquake

2.6

Earthquake Data
Short Period Acceleration Ss

(Ref. SAES-A-112_Appendix)

1-sec Period Acceleration S1

Site Class
Earthquake Design Category

(Ref. ASCE 07-05_Table 11.6-1 & Table 11.6-2)

Earthquake Importance Factor

(Ref. SAES-M-001_Clause 5.5.4)

Response Modification Coefficient = 4.25

(Ref. SABP-M-007_4.4.4)

Site Coefficients : Fa & Fv

(Ref. ASCE 07-05_Table 11.4-1-Table 11.4-2)

Design Spectral Response Accelerations :

SDS

= 2/3x Fa x Ss

SD1

= 2/3x Fv x S1

(Ref. ASCE 07-05_Eq. 11.4-1 - Eq.11.4-4)

Determination of Fundamental Period the Structure. T :

TS=SD1 / SDS
Ta=Ct x hnx

(Ref. ASCE 7-05_Eq.12.8-7)

Load Combination (ASD)

Pipe Rack Allowable Stress Design (Service Loads)
#

Load Combination

Multiplier

Description

Ds + Do + Ff + T + Af

1.00

Operating Weight + Friction Force + Thermal Expansion + Anchor Force

Ds + Do + Af + (W or 0.7 Eo)

1.00

Operating Weight + Anchor + Wind or Earthquake

Ds + Dec + W

1.00

Empty Weight + Wind (Wind uplift case)

4a

0.9 Ds + 0.6 Do + 0.7 Eod

1.00

Operating Weight + Earthquake (Earthquake uplift case)

4b

0.9 (Ds + Dec) + 0.7 Ee

1.00

Empty Weight + Earthquake (Earthquake uplift case)

Ds + Dt + Wp

1.20

Test Load + Partial Winde

Notes:
a. Wind forces normally need not be considered in the longitudinal direction because friction
and anchor loads will normally govern.
b. Earthquake forces shall be applied in both transverse and longitudinal directions, but need not
be applied simultaneously.
c. 0.6Do is used as a good approximation of the empty pipe condition De.
d. Full Ds + Do value shall be used for the calculation of E in Load Comb. 4a.
e. Test Weight + Partial Wind normally is required only for local member design because hydrotest
is not normally done on all pipes simultaneously.
SABP-M-007 Page 15

Load Combination (LRFD)

Pipe Rack Loading Combinations and Load Factors - Strength Design)
#

Load Combination

Description

1.4 (Ds + Do + Ff + T + Af)

Operating Weight + Friction Force + Thermal Expansion + Anchor Force

1.2 (Ds + Do + Af) + (1.6W or 1.0E)

Operating Weight + Anchor + Wind or Earthquake

0.9 (Ds + De)+ 1.6 W

Empty Weight + Wind (Wind uplift case)

4a

0.9 Ds + 0.6 Do + 1.0 Eod

Operating Weight + Earthquake (Earthquake uplift case)

4b

0.9 (Ds + Dec) + 1.0 Ee

Empty Weight + Earthquake (Earthquake uplift case)

1.4 (Ds + Dt)

Test Weight

1.2 (Ds + Dt) + 1.6 Wp

Test Load + Partial Wind

Notes:
a. Wind forces normally need not be considered in the longitudinal direction because friction
and anchor loads will normally govern.
b. Earthquake forces shall be applied in both transverse and longitudinal directions, but need not
be applied simultaneously.
c. 0.6Do is used as a good approximation of the empty pipe condition De.
d. Full Ds + Do value shall be used for the calculation of E in Load Comb. 4a.
e. Test Weight + Partial Wind normally is required only for local member design because hydrotest
is not normally done on all pipes simultaneously.
SABP-M-007 Page 16

Analyses & Design

Check STAAD Pro output for the following:
Unity Check: Ensure that unity checks for all
structural members are less than 1.0
Beam Deflection: Ensure that maximum beams
vertical deflection is less than L/240.Where L = span
length

Lateral Drift: Ensure that maximum lateral drift for

the pipe rack is less than H/100.

PIPING

Pipe Rack Design Flow Chart

Pipe rack
piping study

2D Sketch by
piping (x-section
of pipe rack)

Preliminary 3D
modeling for pipe
rack in study zone

Support markup
or anchor bay
identification

Routing
change or loop
requirement in
layout

Pipe rack layout

development

NO
Piping load
input to
structural

Is this layout
acceptable?

PIPING
STRUCTURAL

Preliminary stress
analysis of critical
lines

STRUCTURAL

Structural design
(member size /
spacing based
on piping load
input

Change in Pipe Rack

design or member size

NO

Structural piping support

additional member
required to structural

Check if
member
span& design
by structural is
acceptable &
clash free?

Is there
any
change
in piping
load?

Re- arrange
support & system
if required

YES

Member design & 3D

update by structural

Clash check for newly

modeled structural
member

3D modeling for
pipe rack / Bridge
by structural
(StaadPro)

Communicate revised
piping load to structural

Pipe Rack
layout
finalization

Any
structure
pipe support
/ Additional
member
required?

Final analysis with

support
verification

NO
Information to
designers for DWGs

Final layout generation/ Structural stress analysis with

report generation and submission

Loading
Spread Sheet
Wind
StaadPro
Spread Sheet
Types

Seismic
StaadPro
Spread Sheet
Thermal
StaadPro

References

SAES-A-112
SABP-M-007
SABP-M-006
ASCE 7

Thank You