Pipe Rack Design for Piping : Essential Tips for Piping Engineers
Summary
TLDRThis 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
- š© Pipe racks are essential structures that carry pipes, electrical and instrument cables, and can also support air coolers.
- šļø Proper design of piping within pipe racks is crucial for operational efficiency, safety, and regulatory compliance.
- š 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.
- š A line routing diagram is necessary for preliminary piping routing, showing all pipeline cross-sections including line size, insulation, and line numbers.
- š 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.
- š± It's advisable toé¢ē10%-20% space in pipe racks for future growth of piping lines.
- š The top level of pipe racks is generally reserved for electrical and instrumentation cable trays.
- š¶āāļø Walkways on pipe racks serve multiple purposes, including cable pulling during construction and maintenance access during operation.
- š Support spacing calculations are based on the average line size of pipes, influencing the choice of pipe rack column distances.
- š« The use of flat turns should be avoided in favor of elevation differences for pipe track turns.
- š„ 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
š 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.
š 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.
Mindmap
Keywords
š”Pipe Racks
š”P&ID
š”Line Routing Diagram
š”Grouping Pipes
š”Elevations
š”Future Growth
š”Line Spacing Chart
š”Walkway
š”Accessway Spacing
š”Pipe Space
š”Fireproofing
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
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pipe racks are structures that carry pipesĀ connecting process units and EquipmentĀ Ā
additionally pipe racks also carry electrical andĀ instrument cables and the necessary supports forĀ Ā
them at the same time air coolers can alsoĀ be installed on pipe racks pipe racks areĀ Ā
generally made of steel but also can be madeĀ of concrete or a combination of concrete andĀ Ā
steel structures proper design of piping withinĀ pipe racks is crucial for ensuring operationalĀ Ā
efficiency safety and Regulatory ComplianceĀ because of the close relation with the PipeĀ Ā
Rack structure the Pipe Rack design must beĀ considered together with the piping designĀ Ā
to design a Pipe Rack we should have the p&idĀ flow diagram plot plan lay out specificationĀ Ā
client specification construction materialĀ of the rack fire protection requirement andĀ Ā
Equipment details to be located around theĀ Pipe Rack Pipe Rack design starts from theĀ Ā
designation of the width bent spacingĀ and elevations determining all of theseĀ Ā
we should prepare a line routing diagramĀ please see an example of a line routing
diagram a line routing diagram shows us aĀ preliminary piping routing between theĀ Ā
equipment of the plant the crosssection ofĀ the diagram should include all the pipelineĀ Ā
cross-sections including line size insulation andĀ line number line specific information will helpĀ Ā
us to group the lines for process or fluid contentĀ and also help us to identify the width of the Pipe
Rack in a large Plant lining up all theĀ piping lines side by side would leadĀ Ā
us to design a very wide pipe rack howeverĀ this is neither financially nor technically
correct therefore we should group theĀ pipes according to their systems thisĀ Ā
grouping is generally done in the oil andĀ gas industry as process and utility linesĀ Ā
process lines are positioned at a lowerĀ elevation while utility lines are locatedĀ Ā
at an upper elevation top level of the PipeĀ Rack is generally reserved for electrical andĀ Ā
instrumentation cable trays at an early stageĀ of the process plant design it is suggested toĀ Ā
keep 10% or 20% space for the possible growthĀ of piping lines during the engineering phase ofĀ Ā
the project also at the end of the projectĀ you may need to keep distance on Pipe RackĀ Ā
width for future extensions all these are toĀ be considered for the width designations ofĀ Ā
the pipe racks once the width of the PipeĀ Rack is decided future growth should beĀ Ā
carefully considered in terms of civil andĀ structural requirements and cost impact forĀ Ā
example the width would be two levelsĀ with 10 m wide or three levels with 6 M
spacing a line spacing chart is to beĀ prepared because it will be requiredĀ Ā
for the additional line during future growthĀ see the figure of a typical Pipe Rack thereĀ Ā
is a walkway on the top level the walkwayĀ can be considered for cable pulling duringĀ Ā
construction but also the walkway can be usedĀ for possible maintenance requirements moreoverĀ Ā
the aforementioned walkway can serveĀ as an accessible path for The PassageĀ Ā
through the pipe racks during the operationĀ an accessway spacing is also considered underĀ Ā
the rack because of the serviceabilityĀ of the equipment located on the ground
elevation pipe space is one of the mostĀ important items to be considered if youĀ Ā
are designing a Pipe Rack before deciding on theĀ Pipe Rack column distance the average line sizeĀ Ā
is to be designated and then support spacingĀ calculation is to be done as per the averageĀ Ā
size of the pipe you can watch the previousĀ video about the support spacing calculationĀ Ā
the calculated support spacing will be used asĀ guidance for choosing Pipe Rack column distanceĀ Ā
for this you should also consult with civilĀ and Structural Engineers generally 2 in isĀ Ā
the smallest size that is being usedĀ for pipe racks to avoid intermediate
supports if the lines consistĀ of flanges inside the rack theyĀ Ā
should be located as staggeredĀ this will provide minimum line
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the minimum height of the Pipe Rack isĀ to be decided according to the vehicleĀ Ā
forklift or truck passing from the roadĀ under the Pipe Rack generally the minimumĀ Ā
height is 3,600 mm determining the exitĀ level above and below considering the 45Ā°Ā Ā
turn height of the largest diameter andĀ the 90Ā° turn height of the average line
size the highest elevation should be
preferred the exit level above and belowĀ the rack can be 800 mm to 1,200 [Music]
mm the use of flat turns should beĀ avoided as they cannot serve to changeĀ Ā
the sequence of lines instead use the elevationĀ difference method for the pipe track [Music]
turns from the isometric view it isĀ evident that the change in sequence is
practical if two secondary pipe racks areĀ connected to a main Pipe Rack they should beĀ Ā
staggered or located east of one Bay becauseĀ of the challenges of the branch connection
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design any equipment can be located overĀ the pipe racks pipe racks are generallyĀ Ā
fireproofed until the lower elevation but ifĀ there is equipment located over the Pipe RackĀ Ā
the fireproofing must be extended until theĀ equipment supports a piping designer shouldĀ Ā
consider the thickness of fireproofingĀ for piping design to prevent possible
clashes during Pipe Rack designĀ future expansion should alsoĀ Ā
be considered vertical risers should beĀ kept away from the columns for horizontal
expansions also any piping lineĀ cable tray or support cannot beĀ Ā
located over the Pipe Rack column dueĀ to the Future vertical expansion theĀ Ā
future expansion is not only for a PipeĀ Rack but also for an air cooler or heat
exchanger as we come to the end of this videoĀ on Pipe Rack design for piping it's importantĀ Ā
to understand the delicate balance betweenĀ structural integrity and efficient pipingĀ Ā
layout by carefully considering factorsĀ such as load distribution support spacingĀ Ā
and material selection we can create safe andĀ costeffective piping systems it's importantĀ Ā
to remember that A well-designed Pipe Rack notĀ only supports the piping but also facilitatesĀ Ā
maintenance expansion and overall operationalĀ efficiency stay tuned for more insights intoĀ Ā
piping stress and design engineering as weĀ continue to explore the fascinating world ofĀ Ā
piping systems thank you for watching and untilĀ next time keep innovating in engineering with
excellence
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