CE 5660: DESIGN OF METAL STRUCTURES TERM PROJECT: DESIGN OF A PIPE RACK

Submitted by FAYAZ HABEEB TP CE11M096

INTRODUCTION Pipe racks are structures in petrochemical, chemical and power plants that support pipes, power cables and instrument cable trays. Occasionally, pipe racks may also support mechanical equipment, vessels and valve access platforms. Pipe racks are also referred to as pipe supports or pipe ways. Pipe layout on pipe racks should follow the Pipe Planning Study concepts, which established in the preliminary engineering phase of a project. Types of Pipe rack systems Continuous Pipe rack (conventional pipe rack) system: Comprised of two or more columns with transverse beams, are tied together in the longitudinal direction utilizing beam struts (for support of transverse pipe and for longitudinal stability of the system) and vertical bracing to form a 3D space frame arrangement.

Figure 1: Conventional Pipe Rack System

Non-continuous Pipe rack system: This is a system comprised of independent cantilevered, freestanding 2D frames not dependent on longitudinal beam struts for system stability. This system, where feasible, should result in lower total installed cost.

Figure 2: Non-continuous Pipe rack system

 Modular Pipe rack system: It is designed as modules which will be manufactured at some places and later brought to site for assembling.

Figure 3: Modular Pipe rack system

DESIGN LOADS As per International Building Code (ICC 2009) following are the loads to be considered in design of pipe racks Piping Gravity load (D): In the absence of defined piping loads and locations, an assumed minimum uniform pipe load of 2.0 kPa should be used for preliminary design of pipe racks. This corresponds to an equivalent load of six 150 mm lines full of water covered with 50 mm thick insulation, and spaced on 300 mm centers. This assumption should be verified based on coordination with the Piping Group, and concentrated loads should also be applied for any anticipated large pipes. When the actual loads and locations become known, as the project develops, the structural design should be checked against these assumed initial load parameters and revised as required. Where consideration of uplift or system stability due to wind or seismic occurrences is required, use 60% of the design gravity loads as an "all pipes empty" load condition. Loading due to hydrostatic testing of lines should be considered in the design if applicable. Under most normal conditions, multiple lines will not be simultaneously tested. The hydro-test loads do not normally need to be considered concurrently with the other non-permanent loads, such as live load, wind, earthquake, and thermal. Typical practice is to permit an overstress of 15% for the hydro-test condition. Because of these considerations, the hydro-test condition will not normally govern except for very large diameter pipes. Electrical Tray and Conduits (D): Electrical and control systems drawings and/or the project 3D model should be reviewed to determine the approximate weight and location of electrical trays, conduits, and instrumentation commodities. Unless the weight of the loaded raceways can be defined, an assumed minimum uniform load of 1.0 kPa should be used for single tier raceways. Self weight of Pipe rack (D): The weight of all structural members, including fireproofing, should be considered in the design of the pipe rack. Weight of Equipment on pipe rack (D): Equipment weights, including erection, empty, operating, and test (if the equipment is to be hydro-tested on the pipe rack), should be obtained from the vendor drawings .The equipment weight should include the dead weight of all associated platforms, ladders, and walkways, as applicable.

 Special Loads: Special consideration should be given to unusual loads, such as large valves, expansion loops, and unusual piping or electrical configurations. Live Load (L): Live load (L) on access platforms and walkways and on equipment platforms should be considered, as applicable. Snow Load (S): Snow load to be considered on cable tray and on large diameter pipes. This load shall be calculated per project approved design code and project design criteria. Generally, you need to consider 100% snow load on top tier and 50% on other tier of pipe racks. Wind Load (W): Transverse wind load on structural members, piping, electrical trays, equipment, platforms, and ladders should be determined in accordance with project approved design code. Longitudinal wind should typically be applied to structural framing, cable tray vertical drop (if any), large diameter pipes vertical drop (if any) and equipment only. The effects of longitudinal wind on piping and trays running parallel to the wind direction should be neglected. Earthquake Loads (E): Earthquake loads in the vertical, transverse, and longitudinal directions should be determined in accordance with the project design criteria. Vertical, transverse, and longitudinal seismic forces generated by the pipes, raceways, supported equipment, and the pipe rack structure should be considered and should be based on their operating weights. Pipes must be evaluated for seismic loads under both full and empty conditions and then combined with the corresponding gravity loads. Friction Loading or Temperature Loading (Tf): Friction forces caused by hot lines sliding across the pipe support during startup and shutdown are assumed to be partially resisted through friction by nearby cold lines. Therefore, in order to provide for a nominal unbalance of friction forces acting on a pipe support, a resultant longitudinal friction force equal to 7.5% of the total pipe weight or 30% of any one or more lines known to act simultaneously in the same direction, whichever is larger, is assumed for pipe rack design. Friction between piping and supporting steel should not be relied upon to resist wind or seismic loads. Anchor and Guide Loads (Ta): Pipe racks should be checked for anchor and guide loads as determined by the Pipe Stress Group. It may be necessary to use horizontal bracing if large anchor forces are encountered. For conventional pipe rack systems, it is normally preferred to either have the anchors staggered along the pipe rack so that each support has only one or two anchors, or to anchor most pipes on one braced support. For initial design, when anchor and guide loads are not known, use a longitudinal anchor force of 5.0 kN acting at mid-span of each bent transverse beam (refer project design criteria). Guide loads are usually small and may be ignored until they are defined by the Pipe Stress Engineer. For non-continuous pipe rack systems, piping may be transversely guided or anchored at both cantilever frames and anchor bays. Longitudinal anchors may be located only at anchor bays. HOW PIPES ARE PLACED ON PIPE RACK SYSTEM Pipe is rested on or secured to a support member usually of a standard structural shape (I-beam, wide flange beam, angle, channel etc.). The pipe may be secured to this member with a pipe support. Pipe supports and hangers are devices which transfer the loads from the pipe or the structural attachment to the supporting structure or equipment. Pipe supports: Pipes are clamped to the structural members, this kind of supporting is more rigid and allows less movement of pipes. Hangers: Pipes are hanged from a structural member, this kind of supports are flexible. There are two kind of hangers; spring hangers which allows limited motion in all directions and rigid hangers which allows limited motion in horizontal direction

Figure 4: Typical clamped pipe support and hanger support

PROBLEM DESCRIPTION The structure is modeled as system comprising of trestles and pipe duct placed over trestles. The system is as shown in figure 5

Figure 5: Structure

The structure consist of normal trestles as shown in figure 6a and stiffened junction trestles as shown in figure 6b, pipes are placed in the pipe duct and pipe duct are placed over trestles

Figure 6a: Normal Trestle

Figure 6b: Junction Trestle

Pipe duct is modeled as modules of 1.5m length, 1.5m height and 4m wide as shown in figure 7.

Figure 7: Pipe duct module

LOAD CALCULATION Pipe Load (Dp); uniform pipe load of 2kPa was applied. Cable tray load(Dc); assuming one cable tray, uniform load of 1 kPa was applied Temperature effect(Tf); a resultant longitudinal friction force equal to 7.5% of the total pipe weight Wind load(W); as per IS 875:1987 Chennai wind speed of 50m/s 100 years service life , there for k1=1.08 For terrain category 1 and building class c, k2=.99 k3=1 wind pressure Pz=.6*1.08*.99*1*502=1.6kPa Earth quake load(E); as per IS 1893:2002 Zone factor .36 Importance factor 1.5 Type II soil Mass source=DL+.25LL

ANALYSIS OF STRUCTURE Structure was modeled as 3D model in SAP 2000, analyzed for various load combinations as per ICC 2009 Load combinations are as follows 1.4(Dp+Dc) 1.2(Dp+Dc)+1.2Tf 1.2 (Dp+Dc)+1.6W .9 (Dp+Dc)+1.6W 1.2 (Dp+Dc)+1E

 .9 (Dp+Dc)+1E After analyzing the structure, maximum forces acting on different members were obtained and each member was designed for the maximum load.A typical design for column member in junction trestle is as shown below.

COLUMN DESIGN 1) Loads acting Axial Force, Bending Moment Mx, Bending Moment My, 2) Effective Length, =103 kN =-64.5 kNm from -32.5 kNm =-1.7 kNm from -.35 Le=0.8x4 = 3.2 m (One end pinned and other fixed) M1=64.5

Assume ISHB 200@373 N/m Cross-section properties: Flange thickness, Clear depth between flanges, Thickness of web, Flange width, Area of cross-section, Radius of gyration, Radius of gyration, Section Modulus Plastic Section Modulus Type of section

M2=32.5 tf d tw 2b Ag rx ry Zx Zy Zpx Zpy b/ tf d/tw = 9 mm = 200 (9* 2)= 182 mm = 6.1mm = 200 mm = 4754 mm2 = 87.1 mm = 45.1 mm = 360840 mm3 = 96700 mm3 = 394300 mm3 = 180000 mm3 =100/9 =11.11 i.e. semi-compact =182/6.1 =29.8 i.e. plastic

Section is Semi-Compact 3) Check for resistance of cross-section to the combined effects for yielding

Hence safe

4) Check for resistance of cross-section to the combined effects for buckling Euler's buckling stress fccx=2E/( Le /rx)2 =1462.2 MPa 2 2 fccy= E/( Le /ry) =392.08 MPa Hence non-dimensional slenderness ratio x=(250/1462.2).5 =0.413 y=(250/392.08).5 =0.798 For calculation of , major axis belongs to buckling class 'a' and minor axis belongs to buckling class 'a', from table 8(a) and table 8(b) of IS 456:2007 x=0.949 y=0.726 To calculate moment factors kx and ky x = M2/M1 = 32.5/64.5 =.504 Mx=1.8 0.7 =1.45 x = x(2Mx 4)=.413(2*1.45-4) =-0.454 kx=1- (x P/ x Ag fy) =1-(-.454*103000/.949*4754*250) =1.041 Similarly y = M2/M1 = .35/1.7 =.205 My=1.8 0.7 =1.656 y = y(2My 4)=.798(2*1.656-4) =-0.548 kx=1- (x P/ x Ag fy) =1-(-.548*103000/.726*4754*250) =1.065 Interaction equation is given by

Hence safe TYPICAL BEAM DESIGN FOR JUNCTION TRESTLE Loads Acting Maximum Bending Moment = 42.8 kNm Maximum Shear Force = 42.8 kN Section assumption Section modulus required Z = M/f =42.8*1000000*1.1/250 =188320 Assume ISMB 200 @254N/m Cross-section properties: Flange thickness, tf = 10.8 mm Clear depth between flanges, d = 200 (10.8* 2)= 178.4 mm Thickness of web, tw = 5.7mm Flange width, 2b = 100 mm

Area of cross-section, Section Modulus Plastic Section Modulus Type of section b/ tf d/tw

Ag Zx Zy Zpx Zpy

= 3233 mm2 = 223500 mm3 = 36800mm3 = 253860 mm3 = 55500mm3

= 50/10.8 =4.6 i.e. plastic =178.4/5.1 =31.3 i.e. plastic

Section is Plastic The beam is laterally supported as pipe lines are supported over it Design for shear, Here d/tw=31.3 < 67 Hence Vd=200*5.7*250/(3 *1.1)=149.56 kN > 42.8 kN Hence safe Design for Bending Capacity Here =1 as plastic section and a low shear problem Md = * Zpx*fy/mo=1*253860*250/1.1*1000000 =57.7 kNm > 42.8 kNm REFERENCES 1. ICC (2009), International Building Code, International Code Council, Whittier, CA. 2. Richard M. Drake And Robert J. Walter, Design of Structural Steel Pipe Racks, American Institute of Steel Construction, Chicago, IL