Pipe Rack Design for Piping : Essential Tips for Piping Engineers

Summary

This video script discusses the critical role of pipe racks in industrial plants, which support pipes, electrical and instrument cables, and air coolers. It emphasizes the importance of pipe rack design in conjunction with piping design for operational efficiency, safety, and compliance. The script outlines the design process, including determining width, spacing, and elevations, and suggests reserving space for future growth. It also covers considerations for walkways, support spacing, and avoiding flat turns. The video concludes by highlighting the balance between structural integrity and efficient piping layout for safe and cost-effective systems.

Takeaways

• 🔩 Pipe racks are essential structures that carry pipes, electrical and instrument cables, and can also support air coolers.
• 🏗️ Proper design of piping within pipe racks is crucial for operational efficiency, safety, and regulatory compliance.
• 📐 Key elements for pipe rack design include P&ID flow diagrams, plot plans, layout specifications, client specifications, construction materials, fire protection requirements, and equipment details.
• 📏 A line routing diagram is necessary for preliminary piping routing, showing all pipeline cross-sections including line size, insulation, and line numbers.
• 🔄 Grouping pipes according to their systems is important to avoid designing overly wide pipe racks, with process lines typically at lower elevations and utility lines at upper elevations.
• 🌱 It's advisable to预留10%-20% space in pipe racks for future growth of piping lines.
• 🛗 The top level of pipe racks is generally reserved for electrical and instrumentation cable trays.
• 🚶‍♂️ Walkways on pipe racks serve multiple purposes, including cable pulling during construction and maintenance access during operation.
• 📏 Support spacing calculations are based on the average line size of pipes, influencing the choice of pipe rack column distances.
• 🚫 The use of flat turns should be avoided in favor of elevation differences for pipe track turns.
• 🔥 Fireproofing is typically required for pipe racks up to lower elevations, but must extend higher if equipment is located above the pipe rack.

Q & A

What is the primary function of pipe racks?

Pipe racks are structures that carry pipes connecting process units and equipment. They also carry electrical and instrument cables and provide necessary supports for them. Additionally, they can be used to install air coolers.

What materials are pipe racks commonly made of?

Pipe racks are generally made of steel, but they can also be made of concrete or a combination of concrete and steel.

Why is the design of piping within pipe racks important?

Proper design of piping within pipe racks is crucial for ensuring operational efficiency, safety, and regulatory compliance.

What documents and details are needed to design a pipe rack?

To design a pipe rack, one needs the P&ID flow diagram, plot plan, layout specification, client specification, construction material of the rack, fire protection requirement, and equipment details to be located around the Pipe Rack.

What is a line routing diagram and why is it important?

A line routing diagram shows a preliminary piping routing between the equipment of the plant. It is important because it helps in grouping lines for process or fluid content and identifying the width of the Pipe Rack.

Why is it not advisable to line up all piping lines side by side in a pipe rack?

Lining up all piping lines side by side would lead to designing a very wide pipe rack, which is neither financially nor technically correct. Instead, pipes should be grouped according to their systems.

What is the recommended practice for future growth of piping lines?

It is suggested to keep 10% or 20% space for the possible growth of piping lines during the engineering phase of the project.

What is the purpose of the walkway on the top level of a pipe rack?

The walkway can be used for cable pulling during construction, for maintenance requirements, and as an accessible path for passage through the pipe racks during operation.

How should the column distance of a pipe rack be determined?

The column distance should be determined after deciding on the average line size and performing support spacing calculations based on that average size. It is also important to consult with civil and structural engineers.

What is the minimum height recommended for a pipe rack?

The minimum height of the pipe rack should be decided according to the vehicle, forklift, or truck passing from the road under the pipe rack, generally not less than 3,600 mm.

How should pipe racks be designed to accommodate future expansion?

Vertical risers should be kept away from the columns for horizontal expansions, and any piping line, cable tray, or support cannot be located over the pipe rack column due to future vertical expansion considerations.

Outlines

00:00

🏭 Pipe Rack Design Fundamentals

This paragraph discusses the essential role of pipe racks in industrial plants, which are structures that support pipes connecting various process units and equipment. They also accommodate electrical and instrument cables, as well as air coolers. The material of pipe racks can be steel, concrete, or a combination of both. The design of pipe racks is critical for operational efficiency, safety, and regulatory compliance. The design process involves considering the plant's P&ID flow diagram, plot plan, layout specifications, client specifications, construction materials, fire protection requirements, and equipment details. A line routing diagram is prepared to show preliminary piping routes, which includes all pipeline cross-sections with details like line size, insulation, and line numbers. The design must group pipes by system, with process lines at lower elevations and utility lines at upper elevations. The top level is typically reserved for cable trays. It's advised to allocate space for future piping line growth and to consider the width designations for civil and structural requirements and cost impact. A line spacing chart is prepared for future line additions, and the design must also consider serviceability and maintenance requirements, with a walkway often included on the top level.

05:03

🚚 Pipe Rack Design Considerations

This paragraph focuses on the specific considerations for the design of pipe racks, such as the minimum height required for vehicles like forklifts or trucks to pass underneath. It discusses the importance of determining the exit levels above and below the pipe rack, taking into account the turn heights of the largest diameter pipes and the average line size. The paragraph also advises against using flat turns and suggests using elevation differences for pipe track turns. When connecting secondary pipe racks to a main pipe rack, they should be staggered or located east of one bay to simplify branch connections. Equipment can be located over pipe racks, and fireproofing must extend to the equipment supports if necessary. The thickness of fireproofing is a factor in piping design to prevent clashes. Vertical risers should be kept away from columns for horizontal expansions, and no piping lines, cable trays, or supports should be located over the pipe rack columns to allow for vertical expansions. The video concludes by emphasizing the balance between structural integrity and efficient piping layout, highlighting the importance of factors like load distribution, support spacing, and material selection for creating safe and cost-effective piping systems.

Keywords

💡Pipe Racks

Pipe racks are structural frameworks that support pipes connecting various process units and equipment in industrial settings. They are crucial for operational efficiency, safety, and regulatory compliance. The video script emphasizes the importance of pipe rack design in conjunction with piping design, highlighting that pipe racks can also support electrical and instrument cables, as well as air coolers. The design considerations for pipe racks include width, bent spacing, elevations, and future expansion to accommodate growth in piping lines.

💡P&ID

P&ID stands for Piping and Instrumentation Diagram, which is a detailed schematic that shows the arrangement of pipes, instruments, and process equipment in a process or plant. It is mentioned in the script as an essential starting point for pipe rack design. The P&ID provides critical information for understanding the flow and connections within a system, which is then used to plot the layout and specifications for the pipe rack.

💡Line Routing Diagram

A line routing diagram is a preliminary representation of the piping layout between equipment in a plant. It is used to visualize the initial path that pipes will take and includes all pipeline cross-sections, such as line size, insulation, and line numbers. The script uses the line routing diagram as an example to explain how to group lines for process or fluid content, which aids in determining the width of the pipe rack.

💡Grouping Pipes

Grouping pipes refers to the practice of organizing pipes within a pipe rack according to their systems, typically separating process and utility lines. In the script, it is mentioned that process lines are placed at a lower elevation, while utility lines are at a higher elevation. This methodical arrangement helps in designing pipe racks that are both efficient and safe, avoiding overly wide structures that could be impractical or costly.

💡Elevations

Elevations in the context of pipe rack design refer to the vertical levels at which pipes are positioned within the rack. The script discusses how the top level of the pipe rack is generally reserved for electrical and instrumentation cable trays, while the bottom levels are for pipes. Proper elevation planning is essential for maintaining accessibility for maintenance and ensuring that the pipe rack design is practical and safe.

💡Future Growth

Future growth in the script refers to the need to anticipate and plan for additional piping lines that may be required as the plant or process expands. It is suggested to keep 10% to 20% space for this growth, which affects the width designations of the pipe racks. This concept is integral to the video's theme of efficient and adaptable pipe rack design that can accommodate changes over time.

💡Line Spacing Chart

A line spacing chart is a tool used in pipe rack design to plan for the spacing between pipes. It is necessary for the installation of additional lines during future expansions. The script mentions that this chart will be required for future growth, indicating its importance in the planning stages to ensure that there is adequate space for new lines without major structural changes.

💡Walkway

A walkway on the top level of a pipe rack serves multiple purposes as outlined in the script. It can be used for cable pulling during construction, for maintenance requirements, and as an accessible path for passage through the pipe racks during operation. The inclusion of a walkway is an example of how pipe rack design considers both practicality and safety.

💡Accessway Spacing

Accessway spacing refers to the clearance provided under the pipe rack for serviceability of equipment located on the ground. The script mentions this as an important consideration in pipe rack design, ensuring that there is enough space for maintenance and service access to equipment, which is crucial for operational efficiency.

💡Pipe Space

Pipe space is a critical consideration in pipe rack design, referring to the space between pipes. The script discusses how the average line size should be designated before deciding on the pipe rack column distance. Proper pipe space is essential for maintenance, inspection, and to prevent clashes during pipe rack design and operation.

💡Fireproofing

Fireproofing in the context of pipe rack design involves applying materials that resist fire and heat, ensuring safety and compliance with regulations. The script notes that pipe racks are generally fireproofed up to a certain elevation, but if equipment is located over the pipe rack, fireproofing must be extended. This highlights the importance of considering fire safety in the overall design of pipe racks.

Highlights

Pipe racks are essential for carrying pipes and cables, and can also support air coolers.

Pipe racks are typically made of steel, concrete, or a combination of both.

Designing pipe racks involves considering operational efficiency, safety, and regulatory compliance.

P&ID flow diagrams, plot plans, and client specifications are crucial for pipe rack design.

Line routing diagrams are used to show preliminary piping routes in a plant.

Pipes should be grouped by system for efficient pipe rack design.

It's recommended to leave 10-20% space for future piping line growth.

The width of pipe racks should consider future growth, civil, and structural requirements.

A line spacing chart is necessary for planning additional lines during future growth.

Pipe racks often include a walkway on the top level for maintenance and operation.

Accessway spacing is considered under the rack for servicing equipment on the ground.

Support spacing calculations are based on the average pipe size.

The minimum height of pipe racks is determined by the clearance needed for vehicles.

The use of flat turns should be avoided in favor of elevation differences for pipe track turns.

Secondary pipe racks should be staggered or located east of one bay when connected to a main pipe rack.

Fireproofing on pipe racks must extend to the level of any equipment located above.

Vertical risers should be kept away from columns for horizontal expansions.

A well-designed pipe rack balances structural integrity with efficient piping layout.

Transcripts

[Music]

pipe racks are structures that carry pipes  connecting process units and Equipment  

additionally pipe racks also carry electrical and  instrument cables and the necessary supports for  

them at the same time air coolers can also  be installed on pipe racks pipe racks are  

generally made of steel but also can be made  of concrete or a combination of concrete and  

steel structures proper design of piping within  pipe racks is crucial for ensuring operational  

efficiency safety and Regulatory Compliance  because of the close relation with the Pipe  

Rack structure the Pipe Rack design must be  considered together with the piping design  

to design a Pipe Rack we should have the p&id  flow diagram plot plan lay out specification  

client specification construction material  of the rack fire protection requirement and  

Equipment details to be located around the  Pipe Rack Pipe Rack design starts from the  

designation of the width bent spacing  and elevations determining all of these  

we should prepare a line routing diagram  please see an example of a line routing

diagram a line routing diagram shows us a  preliminary piping routing between the  

equipment of the plant the crosssection of  the diagram should include all the pipeline  

cross-sections including line size insulation and  line number line specific information will help  

us to group the lines for process or fluid content  and also help us to identify the width of the Pipe

Rack in a large Plant lining up all the  piping lines side by side would lead  

us to design a very wide pipe rack however  this is neither financially nor technically

correct therefore we should group the  pipes according to their systems this  

grouping is generally done in the oil and  gas industry as process and utility lines  

process lines are positioned at a lower  elevation while utility lines are located  

at an upper elevation top level of the Pipe  Rack is generally reserved for electrical and  

instrumentation cable trays at an early stage  of the process plant design it is suggested to  

keep 10% or 20% space for the possible growth  of piping lines during the engineering phase of  

the project also at the end of the project  you may need to keep distance on Pipe Rack  

width for future extensions all these are to  be considered for the width designations of  

the pipe racks once the width of the Pipe  Rack is decided future growth should be  

carefully considered in terms of civil and  structural requirements and cost impact for  

example the width would be two levels  with 10 m wide or three levels with 6 M

spacing a line spacing chart is to be  prepared because it will be required  

for the additional line during future growth  see the figure of a typical Pipe Rack there  

is a walkway on the top level the walkway  can be considered for cable pulling during  

construction but also the walkway can be used  for possible maintenance requirements moreover  

the aforementioned walkway can serve  as an accessible path for The Passage  

through the pipe racks during the operation  an accessway spacing is also considered under  

the rack because of the serviceability  of the equipment located on the ground

elevation pipe space is one of the most  important items to be considered if you  

are designing a Pipe Rack before deciding on the  Pipe Rack column distance the average line size  

is to be designated and then support spacing  calculation is to be done as per the average  

size of the pipe you can watch the previous  video about the support spacing calculation  

the calculated support spacing will be used as  guidance for choosing Pipe Rack column distance  

for this you should also consult with civil  and Structural Engineers generally 2 in is  

the smallest size that is being used  for pipe racks to avoid intermediate

supports if the lines consist  of flanges inside the rack they  

should be located as staggered  this will provide minimum line

[Music] distance

the minimum height of the Pipe Rack is  to be decided according to the vehicle  

forklift or truck passing from the road  under the Pipe Rack generally the minimum  

height is 3,600 mm determining the exit  level above and below considering the 45°  

turn height of the largest diameter and  the 90° turn height of the average line

size the highest elevation should be

preferred the exit level above and below  the rack can be 800 mm to 1,200 [Music]

mm the use of flat turns should be  avoided as they cannot serve to change  

the sequence of lines instead use the elevation  difference method for the pipe track [Music]

turns from the isometric view it is  evident that the change in sequence is

practical if two secondary pipe racks are  connected to a main Pipe Rack they should be  

staggered or located east of one Bay because  of the challenges of the branch connection

[Music]

design any equipment can be located over  the pipe racks pipe racks are generally  

fireproofed until the lower elevation but if  there is equipment located over the Pipe Rack  

the fireproofing must be extended until the  equipment supports a piping designer should  

consider the thickness of fireproofing  for piping design to prevent possible

clashes during Pipe Rack design  future expansion should also  

be considered vertical risers should be  kept away from the columns for horizontal

expansions also any piping line  cable tray or support cannot be  

located over the Pipe Rack column due  to the Future vertical expansion the  

future expansion is not only for a Pipe  Rack but also for an air cooler or heat

exchanger as we come to the end of this video  on Pipe Rack design for piping it's important  

to understand the delicate balance between  structural integrity and efficient piping  

layout by carefully considering factors  such as load distribution support spacing  

and material selection we can create safe and  costeffective piping systems it's important  

to remember that A well-designed Pipe Rack not  only supports the piping but also facilitates  

maintenance expansion and overall operational  efficiency stay tuned for more insights into  

piping stress and design engineering as we  continue to explore the fascinating world of  

piping systems thank you for watching and until  next time keep innovating in engineering with

excellence