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Date : 25-June-2013
Agenda
Aim
Key Objectives Aspects of Pipe racks
Optimization Idea
Summary
Aim
To present different aspects of pipe rack
Key Objective
Purpose of Pipe rack
Materials of Construction Execution Stages
Materials of Construction
Concrete
Cast-in-situ Precast
Materials of Construction
Structural Steel
Structural Steel has been used for pipe rack in all projects executed by NPCC
Reason :
FEED requirements Other advantages are :
Speed of Construction
Better Quality Control
Execution Stages
Preliminary sizing of Pipe rack based on geometry and loading firmed up by Piping
Raise PR for procurement of items
Detailed Engineering
Construction Engineering Fabrication / Painting
Foundation Design
Planning of Beams
Planning of Elevation Bracings Planning of Plan Bracings Expansion Joint
Geometrical Planning
Grid Location : by Piping Discipline
Basis :
Width of pipe rack : No. of pipes to be routed with future allowance. Grid distance :
Geometrical Planning
Grid Location
Geometrical Planning
Geometrical Planning
Tier Elevations : by Piping Discipline
Basis :
To maintain the minimum headroom for the pipes crossing the roads Tie-in elevation Sloping lines
Geometrical Planning
Tier Elevation
Geometrical Planning
Planning of Beams :
Location of main beam as per Main Grid distances
provided by Piping
Location of secondary beam between Main Grid beams
transfer longitudinal forces to vertical braced bay and support secondary beam.
Geometrical Planning
Planning of Elevation Bracings
In the middle of pipe rack to allow thermal expansion of
pipe rack on either side thus minimizing thermal restraint in longitudinal direction
To transfer longitudinal forces to foundation To provide stability to pipe rack in longitudinal direction
Avoid multiple braced bay on same pipe rack to avoid thermal forces in longitudinal beams and braces
Geometrical Planning
Planning of Plan Bracings
Purpose :
To effectively transfer horizontal forces to column
instead of bending.
Geometrical Planning
Expansion Joint
Purpose :
Provide slotted hole connection in the longitudinal beam at all levels at identified location
Loading
Loads Generated by Civil Discipline
Dead Load (DL) Live Load (LL)
Loading
Loads Furnished by Piping Discipline
Pipe Empty Load (PE) Pipe Operating Load (PO)
Loading
Dead Load (DL)
Weight of Structure Weight of Fireproofing
Loading
Live Load (LL)
Applicable in case platform on pipe rack Normally LL = 5 kPa, but depends on platform
Loading
Temperature (Thermal) Load on structure
(TL)
Due to difference between highest and lowest mean
temperature and based on Design Basis. Typical value for UAE is taken as 60 deg C.
Thermal loads can be minimized by providing Flexible
Note : Length of slotted hole connection is based on deflection due to thermal expansion / contraction of structure.
Loading
Thermal Load
Good Design
Loading
Thermal Load
Bad Design
Loading
Pipe Empty & Cable Tray Load (PE)
< 12 Pipes : ~ 1.2 kPa >=12 Pipes : concentrated load (as per Pipe
Stress Analysis) Empty Equipment Load, if any Cable Tray Load : 1 kPa for each level of cable tray
Loading
Pipe Operating Load (PO)
< 12 Pipes : ~ 2 kPa >=12 Pipes : concentrated load (as per Pipe
Stress Analysis)
Operating Equipment Load, if any
Loading
Pipe Hydro Test Load (PT)
To account for pressure testing of pipes As per Pipe Stress Analysis
tested and other pipes empty (To be confirmed by Piping Discipline and reflected in piping isometric and hydro-test specification)
Loading
Pipe Anchor / Guide Load (PA)
Load to be defined by Piping Discipline Anchoring lug configuration to be confirmed by
Anchor Lug
Loading
Pipe Friction Load (PF)
Cause : Hot lines sliding across beam
Loading
Pipe Friction (PF)
Longitudinal direction = 5% of Pipe operating Load Transverse direction = 5% of Pipe operating Load
0.05 P
0.05 P
Loading
Pipe Friction Load
For Local beam check
0.1 P 1 5 0.1 0.3 P 0.2 P
7
3 8 4 6 2 P = Piping Operating Load
Loading
Pipe Friction Load
Longitudinal direction :
of the operating weight (no of pipes >= 7) 20% of the operating weight (no of pipes = 4 to 6) 30% of the operating weight (no of pipes <= 3) Note : Most critical load from above combination shall be considered for design
In
10%
Transverse direction :
of the operating weight
10%
Loading
Earthquake Load (EQ)
As per project geotechnical investigation and
design basis
Earthquake load to be generated for following
conditions
a) b)
Erection : DL + PE
Operating Case : DL + PO + LL
Loading
Earthquake Load (EQ)
As per IBC 2009 & ASCE-7-10, typical
Site Class = D Ss (Short period Spectral Acceleration) = 0.32 S1 (1 sec Spectral Acceleration) = 1.32 I (Importance Factor) = 1 (depends on occupancy category) R (Response Reduction Factor) = 3.5 (for ordinary moment resisting frames) = 7.0 (for special truss frames) Earthquake Load is generated in STAAD-Pro as per parameters defined in Design Basis.
Loading
Wind Load (WL)
As per project design basis
As per ASCE-7-10, typical parameters for ADCO site is as
follows :
Basic wind speed (V) = 44.7 m/sec Importance factor (I) = 1.15 Exposure Category = C Wind Directionality Factor (Kd) = 0.85
Loading
Wind Load
Gust effect factor (G) = 0.85 Force coefficient Cf = 2 for flat surface members Cf = 0.8 for tubular members
Pipe Dia = D1+D2+D3 for pipe rack width <=4m Pipe Dia = D1+D2+D3+D4 for pipe rack width > 4m
Loading
Contingency Load (CL)
To account for accidental load on members (e.g.
maintenance load)
Shall be considered for the design of local member For Beam Design = 10 kN at midspan
Loading
Miscellaneous Load, if applicable (ML)
Crane Load Dynamic Load (considered as equivalent static load) Blast Load
Structural Design
Member end releases
Support Condition at base plate level Load Combinations
Design Parameters
Support reactions
Structural Design
Member end releases
Main Grid members transverse direction : fixed Main Grid members longitudinal direction : pinned Vertical bracings : pinned (to account for local bending
Structural Design
Member end release
Structural Design
Member end release
Pinned Connection Fixed Connection
Truss Connection
Structural Design
Support Condition at base plate level
Fixed Base
Pinned Base
Structural Design
Support Condition at base plate level
Fixed in transverse and pinned in longitudinal
Reduce main frame column and beam size Reduce lateral deflection
Increase base plate size, anchor bolt, pedestal and footing size
Structural Design
Support Condition at base plate level
Choose support condition to maintain balance between structural and foundation system
Structural Design
Load Combinations
Erection Case :
Operating Case :
DL+TL+LL+PO+PA+PF+CL
DL+TL+PO+PA+PF+0.75(LL+WL) DL+TL+PO+PA+PF+0.75(LL+0.7EQ)
DL+TL+PO+PA+PF+WL
DL+TL+PO+PA+PF+0.7EQ
Structural Design
Load Combinations
Test Case :
DL+TL+PT+LL DL+TL+PT+0.75(LL+0.5WL)
DL+TL+PT+0.5WL
DL+TL+PO+PA+PF+ML
Maintenance Case :
DL+TL+PO+PA+PF+0.75(LL+ML)
DL+TL+PO+PA+PF (Full)+CL
Structural Design
Design Parameters
Design code and method of analysis Yield strength of steel
Structural Design
Support Reaction
Obtained from STAAD-Pro For base plate and anchor bolt sizing For pedestal and foundation design
End Connection
Welded Type
For onshore projects, complete welded pipe rack
Authority
Hindrances
End Connection
Shop Weld :
Field Weld :
FEED requirement
End Connection
Bolted Type
FEED requirement Easy to install and remove Easy to transport at site in small assembly
Allowable bearing stress on grout due to Compression + Bending from superstructure Anchor bolt spacing on base plate Bearing stress in grout Tensile force in anchor bolt
Design is based on support reactions from STAAD-Pro Size and arrangement depends on Tension + Bending from superstructure Designed to carry on tension force Shear from superstructure to be carried by shear key Minimum spacing >= 7 x dia of bolt Minimum edge distance from concrete >= 4 x dia of bolt
Foundation Design
Type of foundation
Depends on bearing capacity and settlement criteria Generally shallow isolated foundation
Foundation Design
Stability Checks
Bearing capacity for individual footing design Overturning and Sliding for overall pipe rack structure with foundation.
Optimization Idea
Reduce the piping load on pipe rack by using loads from
introduction of loops
Use of high yield strength steel to reduce usage of
structural steel --> reduction in foundation --> Ultimately reduction in overall cost.
Summary
Planning of beams & bracings : It plays a key role in the
base plate level, load combinations, design parameters, end connection type, base plate and foundation design
Optimization Idea
Acknowledgement
Mr. Rachid Younis (EM-Civil)
Thank You