Pipe Rack Piping

TRAINING MANUAL- PIPING

PIPING STUDYPIPERACK PIPING

Uhde India Limited

DOC No. : 29040-PI-UPS-1011

Rev. : R0

Page : 1

CONTENTS

Page

0.0 Cover Sheet 1

List of illustrations 2

1.0 General 3

2.0 Steps to piperack piping 3 - 4

3.0 Location of Valves & Instruments on Piperack 4

4.0 Yard Piping Arrangement 5 - 7

5.0 Illustrations 7

Applicable Revision:Prepared:

Date:

Checked:

Date:

Approved:

Date:First Edition: R0Prepared: AKB

Date:

Checked: TNG

Date:

Approved: RUD

Date:File Name: Server: PUNE: KUMUS 207 VKO: KUMUS 209



Uhde India Limited

DOC No. : 29040-PI-UPS-1011

Rev. : R0

Page : 2

LIST OF ILLUSTRATIONS

SR.NO. DWG.NO. DESCRIPTION

1 PRP1 TYPICAL YARD PIPING ARRANGEMENTS

2 PRP2 TYPICAL CROSS-SECTION OF YARD PIPING

3 PRP3 TYPICAL CROSS-SECTION OF LAYOUT AT PIPERACKS

4 PRP4 TYPICAL PIPERACK COMPOSITE

5 PRP5 LINE SPACING CHART

6 PRP6 PLANNING FOR LINE GROWTH

7 PRP7 LARGE DIAMETER LINES - CHANGE IN DIRECTION

8 PRP8 PIPERACK METER RUNS

9 PRP9 RELIEF HEADER LOCATION

10 PRP10 ALTERNATIVE PIPERACK EXPANSION

11 PRP11 TYPICAL HOSE STATION AT A PIPERACK COLUMN

12 PRP12 BATTERY LIMIT VALVING : SINGLE-LEVEL RACK

(UNIT / OFF-SITE COMMON ELEVATION)

13 PRP13 FLEXIBILITY CHECK STEPS

14 PRP14 PIPERACK ANCHOR STRUCTURE

15 PRP15 STEAM LINE DRIP LEGS

16 PRP16 PROPER LINE SUPPORT

17 PRP17 90° PIPERACK TURNS

18 PRP18 RACK INTERSECTION

19 PRP19 OPERATOR ACCESS

20 PRP20 TYPICAL PIPELINE DISTRIBUTION ON A SINGLE-LEVEL PIPERACK

21 PRP21 TYPICAL PIPERACK PIPING & EQPT. RELATIONSHIPS IN APETROCHEMICAL PLANT



Uhde India Limited

DOC No. : 29040-PI-UPS-1011

Rev. : R0

Page : 3

1.0 GENERALThe piperack general arrangement is finalised during the development of overall plot plan. Theexact width of the piperack, numbers of levels and elevations, the access and maintenanceplatforms are finalised during piperack piping study.

Normally, the piperack piping study, with its structural and platform requirements is the first priorityitem for detail engineering of a process unit.

The piperack may be an integral part of a process unit located in the middle of the unit or it may bean arterial part connecting several services of other process unit.

The following data and drawings are required to be studied before starting the detailed design ofpiperack piping study:

Unit Plot Plan / Overall Plot Plan

Piping and Instrumentation diagrams

Plant layout specification

Client specification

Material of construction

Fireproofing requirements

2.0 STEPS TO PIPERACK PIPING2.1 The first step in the development of any piperack is the generation of a line-routing diagram. A line

routing diagram is a schematic representation of all process piping systems drawn on a copy ofpiperack general arrangement drawing / or on the unit plot plan where the piperack runs in themiddle of the process unit.

Based on the information available on the first issue of P&I Diagram / Process flow diagram i.e.line size, line number, pipe material, operating temperature etc. the line routing diagram is to becompleted.

2.2 Once the routing diagram is complete, the development of rack width, structural column spacing,road crossing span, numbers of levels and their elevations should be started.

Piperack column spacing shall be decided based on the economics of the pipe span as well as thetruss arrangement to accommodate double the span for road crossing or avoiding undergroundobstructions.

Piperack arrangement should be developed to suit the specific plant requirements.

2.3 The piperack width can now be worked out with a typical cross-section of the rack with the levels.

Normally, piperack carry process lines on the lower level or levels and the utility lines on the toplevel. Instrument and electrical trays are integrated on the utility level if space permits or on aseparate level above all pipe levels.

Any piperack design should provide provision for future growth to the extent of 25 to 30% on therack clear width.

When flanges or flanged valves are required on two adjacent lines, the flanges are to bestaggered.

Thermal expansion or contraction must be accomodated by keeping sufficient clearance at thelocation where the movements will occur.

The clearance of the first line from the structural piperack column is to be established based on thesizes furnished by the civil / structural engineers.



Uhde India Limited

DOC No. : 29040-PI-UPS-1011

Rev. : R0

Page : 4

2.4 After analysing all the requirements and arrangements, the dimensions are to be rounded off to thenext whole number. Based on the economics, the width and the number levels e.g. two tier of 30ft. wide or three tier of 20 ft. wide rack will be decided.

The gap between the tiers shall be decided on the basis of the largest diameter pipeline and itsbranching. The difference between the bottom line of pipe in the rack and the bottom of a branchas it leaves the rack shall be decided carefully, to avoid any interference due to support, insulation,size of branch etc. All branch lines from the main lines on piperack shall be taken aesthetically ona common top of steel (TOS).

With the above considerations, the conceptual arrangement of piperack are to be finalised.

3.0 LOCATION OF VALVES3.1 Various factors shall be considered while locating each line, valve and instrument in a piperack. In

a standard process unit piperack, process lines are located on the lower levels, utility lines are onthe next higher level and a separate top level is arranged for electrical and instrument cable trays.The requirements and locations of electrical and instrument cable trays alongwith their spacing,protective cover, approach platform / walkways are to be discussed with the electrical andinstrument engineers.

3.2 The largest lines should be located near the supporting columns to reduce the overall load on thesupporting beams.

The relief headers must be located above the top level of the rack to allow the line to drain toblowdown drum. (Refer sketch No.PRP9). The designer should avoid locating pipeline over thecentreline of structural column for support so that the columns can be extended for future rackexpansion.

3.3 Shut-off valves at utility headers are located inside the rack area in the horizontal position directlyabove the header.

Valves must be accessible from platforms or by chain operators (chain to fall free of obstructionshampering operation).

3.4 Refer sketch no.PRP-12. This view highlights features requiring additional considerations. Thewidth of the access way is determined by the space needed to maintain the equipment located atgrade below the piperack.

The valves are staggered on either side of the catwalk and handwheel extension stems arefurnished when necessary to facilitate operation.

4.0 YARD PIPING ARRANGEMENT

4.1 The plant layout determines the main-yard piping runs. Refer sketch No.PRP-1 which showstypical piperack layouts for various plant arrangements.

4.2 Smaller plants usually have the simplest yard piping as shown in sketch No.PRP-1, A and B. InFig.A, the process and utility lines enter and leave at the same end of the plot and Fig.B, presentsa frequently adopted layout, with utility lines entering at one end and process lines at the oppositeend.

4.3 In larger plants, yard piping becomes more complicated as shown in sketch No.PRP-1, D, E, F, G.The piperack arrangement results from an overall plant arrangement, site conditions, client'srequirements and plant economy.



Uhde India Limited

DOC No. : 29040-PI-UPS-1011

Rev. : R0

Page : 5

4.4 Pipelines in the piperack are classified as process lines, relief-line headers and utility headers.

Process lines :

Process lines are those

(a) which interconnect nozzles on process equipment more than 20ft. apart (closer processequipment can be directly interconnected with pipelines)

(b) Product lines which run from vessels, exchangers, or more often from pumps to the unit limitsto storage or header arrangement outside the plant.

(c) Crude or other charge lines which enter the unit and usually run in the yard before connectingto exchangers, furnaces or other process equipment e.g. holding drums or booster pumps.

Relief-line headers

Individual relief lines, blow down lines and flare lines should be self draining from all relief valveoutlets to knock-out drum, flare stack or to a point at the plant limit. A pocketed relief line systemis more expensive, because usually an extra condensate pot is required with instruments, valvesand pumps. To eleminate pockets some relief line headers must be placed at higher elevationabove the main yard usually on a tee support on the extended piperack column. However, onsome noncondensing gas systems self drainage is not so essential. Relief lines can be individual,some with large diameters and occasionally high temperatures.

Utility lines

Utility lines in the piperack can be put in two groups :

(a) Utility headers serving equipment in the whole plant. Such lines are : low and high pressuresteam lines, steam condensate, plant air and instrument air lines. If required, cooling watersupply and return and service water can also be arranged on the piperack.

(b) Utility lines serving individually one or two equipment items or a group of similar equipment(furnaces, compressors) in the plant. Such lines are : boiler feedwater, smoothering steam,compressor starting air, various fuel oil lines, lubricating oil, cooling oil, fuel gas, inert gas andchemical treating lines.

Steam header should drain to the steam separator for more effective condensate collection.Branch connections to steam headers usually connect to the top to avoid condensate drainageto equipment.

Instrument lines and Electrical cables

Instrument lines and Electrical cables are often supported in the yard and extra space should beprovided for these facilities. The best instrument line arrangement eleminates almost all elevationchanges between the plant and the control room. This can be easily achieved when instrumentlines are supported outside the piperack column on a suitable elevation.

4.5 Line Location

• Refer sketch No.PRP20. It shows single-level yard piping.

Regardless of service, heavy lines (very large diameter lines, large lines full of liquid) are placedover or near the piperack columns. Centrally loaded column and reduced bending moment on thebeam will result in a lighter structural design. Next to these lines are placed all process lines andrelief lines. Utility lines are in the centre portion of the yard. A general sequence of uitility lines isalso shown on the sketch PRP-20.

• It is advantageous, from point of view of support, to group hot lines requiring expansion loops.Refer sketch No.PRP-13, PRP-14. Loops elevated horizontally over the yard is the most commonadopted design, having the hottest and largest diameter line outside.

Line guides, line stops and anchor points are usually required along a hot line somewhere in thepiperack.



Uhde India Limited

DOC No. : 29040-PI-UPS-1011

Rev. : R0

Page : 6

Pipe expansion forces, at some of these points, will affect yard support design.

• Those process lines which interconnect equipment on the same side of the yard should be nearthe edges of the yard bank. Lines which interconnect equipment located on both sides of the yardshould be closer to the utility lines and can be placed either side of the yard. Position of productlines is influenced by their routing after leaving the plant limit.

Right(left) turning lines should be on the right(left) hand side of yard.

Utility lines serving individually one or two equipment items should be on the same side of the yardas the equipment to which they connect.

4.6 Piperack Elevation

Refer sketch No.PRP-2 and PRP-3 for typical cross-section of piperack piping.

Elevation of yard piping is determined by the highest requirement of the following :

a) Headroom over a main road.

b) Headroom for access to equipment under the piperack.

c) Headroom under lines interconnecting the piperack and equipment outside the piperack.

The size of beam supporting the piperack piping should also be taken into account whenconsidering headroom.

Generally those process lines should be located in the top tier which interconnect two nozzleselevated higher than the top tier. Process lines with one end lower than the bottom tier elevationcan run either in the top or the bottom rack. If both ends of a process line are lower than thebottom tier elevation, the line should be located in the bottom tier.

The elevation of a line can also be influenced by valves and instruments in the line. Often a moreconvenient access platform can be provided for valves arranged in the top tier of piperack. Thepreferred location of lines with orifice runs is near the edge of the piperack with orifice flanges nearthe column for more convenient protable ladder access. Refer sketch No.PRP-8.

The sketch No.PRP-2, upper right corner shows platform and walkway arrangements to valves,relief valves and instruments located in the piperack.

4.7 Piperack Piping Economy

The economy in piperack piping depends primarily on the length of lines arranged on the rack.Fittings, valves and instrument are relatively few in the piperack compared to pipelength.

Sketch No.PRP-2 shows those critical dimensions (A,B,C,D & E) which will influence piping costfrom piperack piping layout point of view. These dimensions depend on the overall plant layoutand should be carefully considered when the plot is developed.

Dimension 'A' is the total length of the piperack and is governed by the number and size ofequipment, structure and buildings arranged along both sides of the piperack. On an average,about 10 feet of rack length is required per process equipment (exchanger, drum, tower, unhousedcompressor etc.)

A control room located along the rack will increase the piperack piping cost because all lines mustpass by without really being associated with the relatively long control room.

To shorten piperack length (Dimension 'A'), various methods are applied viz. equipment in pairs,stacked exchangers, exchangers under elevated drums, drums or exchangers supported ontowers with common platforms, drums supported on exchangers, process equipment locatedunder the rack etc. These arrangements not only shorten the process interconnecting equipmentdirectly but also shorten those lines which pass through this area and utility headers serving thisarea.



Uhde India Limited

DOC No. : 29040-PI-UPS-1011

Rev. : R0

Page : 7

Dimension 'B' and 'C' should be carefully selected to minimise pipelength between the piperackand process equipment and pipelength interconnecting equipment on opposite sides of thepiperack. 'C' is usually 6 to 7 feet.

Dimension 'D' and 'E' should be decided based on what is minimum necessary to reduce thevertical piping lengths.

For economical design of piperack structure, an evaluation by a structural expert should be done.This expert can determine whether steel or concrete or a combination of the two is the mostdesirable choice and what span and spacing will give the most economical arrangement.

5.0 ILLUSTRATIONSVarious illustrations shown on the sketches are general guidelines to develop the piperackarrangement specific for a plant. Free hand sketches should be made based on the analysis ofthe plant and the concept visualised for the piping arrangement with its support. The pipingbranching out should be taken at a specific TOS to give a aesthetic cross-sectional view as well asease of support.

TYPICAL YARD PIPING ARRANGEMENTS

DOC NO.

Rev.

PageUhde India Limited

TRAINING MANUAL - PIPING

PIPING STUDY

DWG. NO.

PIPE RACK PIPING

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COMPR.HOUSE

PROCESS EQPT.

ROAD

ROAD

A. DEAD END YARD . LINES ENTER AND LEAVE ONE END OF YARD. ENTER AND LEAVE BOTH ENDS OF YARD.

B. STRAIGHT THROUGH YARD . LINES CAN

ROAD

PROCESS EQPT.

ROAD

CONTR. RM

AND LEAVE NORTH AND EAST OF PLOT.C. L-SHAPED YARD . LINES CAN ENTER

CONTR. RM

COMP.HO.

LEAVE ON THREE SIDES OF PLOT.D. T-SHAPED YARD . LINES CAN ENTER AND

CONTR. RM

AND LEAVE ALL FOUR SIDES OF PLOT.E. U-SHAPED YARD . LINES CAN ENTER

COMP. HO.

CONTR. HO.

COMP. HO

F. COMBINATION OF I AND T-SHAPED YARD. FOR A VERY LARGE CHEMICAL PLANT.G. COMPLEX YARD PIPING ARRANGEMENT

HEATERS

CONTR. RM

COMP. HO.

CONTR.RM HEATERS

N

TYPICAL CROSS-SECTION OF YARD PIPING

PIPE RACK PIPING

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CONTROL INSTR.LINESVALVE

STEAM

ALTERNATE ROUTE

DE

C B C

LINES WITH BOTHENDS HIGHER THANTOP YARD BANK

ABOVE YARD

LINES WITH ONE ENDBELOW AND OTHER

BOTTOM YARD BANK

LINES WITH BOTHENDS LOWER THAN

PLAN

A

LINESINSTR.

CATWALK

PLATFORM

PLATFORM

SKETCH SHOWING TYPICALPLATFORMS ON YARD STEEL

SLOT FOR ELECT. CABLES

DIMENSIONS A,B,C,D&E DEPEND ON OVERALL PLANT LAYOUT AND INFLUENCE PIPING COST.

TYPICAL CROSS-SECTION OF LAYOUT AT PIPERACKS

PIPE RACK PIPING

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ON BOTTOM ROWPROCESS LINES

6000 MAX. SPANCANTILEVER

DIM

N. T

O S

UIT

MIN

. AC

CE

SS

CLE

AR

AN

CE

1500

750

INST. & ELECT. CABLE TRAYSCANTILEVERED IF NECESSARY

GRADE

UTILITY LINESON TOP ROW

FLARE LINE (WITH SLOPE)LOOP IN STEAM LINE

LEAVE SPACE TOEXTEND STRUCTURAL COLUMN

LARGE BORE LINESCLOSE TO STRUCTURAL COLUMN

1500 MAX.

TYPICAL PIPERACK COMPOSITE

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PROCESS LINES

UTILITY LINES

ACCESS WAY

ACCESS FOR DOUBLE ROWOF EQUIPMENT

ACCESS FOR SINGLE ROW OF EQUIPMENT

INSTRUMENT CABLE TRAY ELECTRICAL CABLE TRAY

AREA RESERVEDFOR CONDUIT

AREA RESERVED FORFUTURE PIPING

ELECTRICAL CABLETO STARTER

CONTROL VALVE(TYP)

LIFTING BEAM

LINE SPACING CHART

PIPE RACK PIPING

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LINE

SIZE

AD

JAC

EN

T L

INE

SIZ

E ,

INC

H

150 # FLANGE 300 # FLANGE

NOTES:

- SPACING IS BASED ON RADIUS OF PIPE TO FLANGE OD + 1" / 25 .

- SELECT LINE WITH LARGEST FLANGE DIAMETER , FIND ADJACENT LINE SIZE AND

READ ACROSS TO FIND CENTRELINE TO CENTRELINE DIMENSIONS , IN INCHES.- ADJUST DIMENSION TO SUIT INSULATION THICKNESS.

- CALCULATE SPACING WHERE PIPE RACK REAL ESTATE IS LIMITED.

- ADJUSTMENTS TO SPACING FOR THERMAL EXPANSION OR CONTRACTION MUST BE MADE.

1" / 25

UNINSULATED FLANGES

FLANGESINSULATED

STAGGER FLANGES

SEE LINE SPACING CHART (ABOVE)( IN INCH )

PLANNING FOR LINE GROWTH

PIPE RACK PIPING

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MUST CLEARAFTER 63 MMLINE GROWTH

63 MM MOVEMENT 63 MM MOVEMENT

PIPE RACK COLUMN

NO MOVEMENT

MUST CLEARAFTER 63 MMLINE GROWTH

POSSIBLE INTER-CHECK FOR

FERENCE

LINE GUIDES *

STAGGER LOCATION* IF INSUFFICIENTSPACE BETWEEN LINES

LARGE DIAMETER LINES - CHANGE IN DIRECTION

PIPE RACK PIPING

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END VIEW

LINE "A"

A

ELEVATION 1

ELEVATION 2

LINE "B"

ELEVATION 2

ELEVATION 1

SIDE VIEW

LINE "A"

6

LINE "B"

45° ELBOW

SHOE-LINE A

SHOE-LINE B

PIPERACK METER RUNS

PIPE RACK PIPING

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ORIFICE FLANGES

LADDER

RELIEF HEADER LOCATION

PIPE RACK PIPING

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TOP LEVEL

RELIEF HEADER,

PREFERREDLOCATION NEAR CENTRE OF RACK

LOCATION

ALTERNATERELIEF HEADER,

EXTENSIONPOSSIBLE FUTURE

ALTERNATIVE PIPE RACK EXPANSION

PIPE RACK PIPING

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FUTUREPRESENT

TYPICAL HOSE STATION AT A PIPE RACK COLUMN

PIPE RACK PIPING

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PLAN

C LCOL

150 150

900

BATTERY LIMIT VALVING:SINGLE-LEVEL RACK

PIPE RACK PIPING

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( UNIT / OFF-SITE COMMON ELEVATION )

AS REQUIREDEXTENSION STEM

1000

1200

ELEVATION

COMMONCENTRELINE

PLAN

CATWALK

BA

TTE

RY

LIM

IT

FLEXIBILITY CHECK STEPS

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LINE BRANCHES

STEP 1: ESTABLISH POTENTIAL FLEXIBILITY PROBLEMS

MULTIPLY COEFFICIENT OF EXPANSION BY LENGTH OF LINE

DETERMINE LINE GROWTH FOR THREE LINESSTEP 2:

TRY ANCHOR IN CENTER OF LINE

DETERMINE WHETHER ONE ANCHOR POINT WILL SUFFICESTEP 3:

10"-CS at 450°F

ARRANGE LINES IN PROPER SEQUENCESTEP 4:

LOCATE THE LINE REQUIRING THE LARGEST LOOP ON THE OUTSIDE

1/4 DISTANCE 1/4 DISTANCE

10"8"6"

8"-CS at 390°F

6"-CS at 350°F

PIPE RACK ANCHOR STRUCTURE

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EXPANSION LOOPS

PLAN

PUMPS

PIPING ANCHORED HERE

ANCHOR STRUCTURE

ELEVATION

K-BRACING TO ALLOWPASSAGE/MOVEMENT

NOTE: GROUP LINES WITH EXPANSION LOOPS. HOTTEST AND LARGEST LINE OUTSIDE.

STEAM LINE DRIP LEGS

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EXPN. LOOP

DRIP LEG

STEAM TRAPSLOPE

SLOPE

PROPER LINE SUPPORT

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10" WELD CAP

WRONG

10" PROCESS LINE

RIGHT

6" DUMMY SUPPORT

10" PROCESS LINE

SUPPORTING LINESU-BOLT

INTERMEDIATE PIPE SUPPORT

LARGE LINES ARE USED TO SUPPORT SMALLER LINES

90° PIPE RACK TURNS

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FLAT TURNS

#1

#2

#3

#4

#5

#1

#2

#3#4

#5

ELEVATIONDIFFERENCE

RACK INTERSECTION

PIPE RACK PIPING

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PRIMARY PIPE RACKS

WRONG LOCATION RIGHT LOCATION

SECONDARYPIPE RACK

RACK INTERSECTION LAYOUT

OPERATOR ACCESS

PIPE RACK PIPING

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UTILITYSTATION

CONTROLSTATIONS

LIGHTINGPANEL

ROTAMETER

450-600

C STATIONS

L

LC COLS.

ACCESS AREA

PULL BOXELECTRICAL

TYPICAL PIPELINE DISTRIBUTION ON A SINGLE-LEVEL PIPERACK

PIPE RACK PIPING

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process)

Heavy lines(cooling water,

Process lines Process linesUtility lines blowdown)(cooling water,Heavy lines

lines lines lineschemicalFuel oil, Air, gas,

serviceSteam,condensate

Instrument Duct

Steam

TYPICAL PIPERACK PIPING AND EQUIPMENT RELATIONSHIPS

PIPE RACK PIPING

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IN A PETROCHEMICAL PLANT

1200MIN.

PUMP SUCTION

ELEVATION OF

LINES TO ADJACENT

EITHER YARD BANK

END BELOW ANDLINES WITH ONE

OTHER END ABOVE

LOCATED ONYARD CAN BE

EQUIPMENT

ACCESS TO

HE

AD

RO

OM

CONTROL

DISTANCE WILL VARY

DEPENDING ONMAX. PIPE DIA

750

TO

100

0

TOP YARD BANK LOCATED IN HIGHER LEVELLINES BOTH ENDS HIGHER THAN

TOWER

TOWER

INSTRUMENT LINES

PUMPSORIFICE INVERTICAL LINE

VALVE

ARE LOCATED ON THE LOWER LEVEL

LINES WITH BOTH ENDS LOWERTHAN BOTTOM YARD BANK

DRUM

EXCHANGERDE

C B C

Documents

Pipe Rack Piping