Pipe Rack Design Guide

Document No: KS-ST-DEG-0001 Rev 0

01 December 2019

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Table of Contents
1. Introduction ................................................................................................................................... 3
2. General Design Guidelines .............................................................................................................. 3
2.1 Rack Types ..................................................................................................................................... 3
2.2 Layout and Geometry .................................................................................................................... 3
2.3 Design Loads and Combinations .................................................................................................... 6
2.3.1 Dead Loads ................................................................................................................ 6
2.3.2 Snow Loads ............................................................................................................. 12
2.3.3 Live Loads ................................................................................................................ 12
2.3.4 Wind Loads .............................................................................................................. 13
2.3.5 Seismic Loads .......................................................................................................... 14
2.3.6 Upset Condition Loads ............................................................................................ 15
2.3.7 Load Combinations ................................................................................................. 16
2.3.8 Load Factors ............................................................................................................ 17
2.4 Analyzes and Design Considerations ........................................................................................... 17
2.4.1 Design Considerations............................................................................................. 17
2.4.2 Deflection Limits ..................................................................................................... 18

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1. Introduction

This guideline is prepared to promote consistency across projects and offices for the design of new piping
and electrical rack structures. It includes basic design methodology, layout considerations, basic loads and
combinations, and serviceability limits. The design approach is based on various industrial practices used
across the globe. The following guidelines may be overly conservative when validating the capacity of
existing rack structures.

2. General Design Guidelines

2.1 Rack Types

Pipe racks are the main artery of a process plant. Pipe racks carry process and utility piping,
instrumentation and electrical cables to connect process systems and equipment throughout the process
units. While all pipe racks serve the same basic function, they can vary in complexity of design. The pipe
rack types as defined below will be used throughout this document.

OSBL Rack:

General Pipe Rack used to connect multiple process and utility units. Contains long sections with consistent
geometry, it does not support equipment, and has minimal platforming.

ISBL Rack:

Pipe rack located within a process or utilities unit. Usually centrally located within the unit, this pipe rack
connects the equipment internal to the unit and may also connect to the OSBL rack system. This pipe rack
has generally consistent layout and may include some small isolated platforms and equipment.

Process Rack:

Pipe rack located within a process or utilities unit. Usually centrally located within the unit, this pipe rack
connects the equipment internal to the unit and may also connect to the OSBL rack system. This pipe rack
supports a significant amount of equipment and may have large platform levels to support operation and
maintenance activities.

Secondary Rack:

Small rack structures connecting OSBL, ISBL, and Process racks to adjacent racks and equipment. They
generally have consistent geometry and may be designed similar to OSBL and ISBL racks.

2.2 Layout and Geometry

Pipe racks carry the piping and cable trays required for the process unit through a series of moment frames
(i.e. “Bents”, “Portals”) oriented transverse to the piping run. The transverse beams of the frames provide
the primary support system for the weight of the pipe and cable tray. The lowest pipe level is typically
located at a top of steel approximately 15 ft. (4.6m) above finished grade. Additional transverse beams are
typically spaced at 4 ft. (1.25m) to 6 ft. (1.8m) depending on the diameter of the piping carried by the rack.
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Refer to customer/project specific spacing and layout requirements when developing pipe rack
arrangement.

Figure 1 : Typical Plan

These frames also provide the lateral stability for resisting wind and seismic loads acting transverse to the
piping run. The typical frame width is about 20 ft. (6m), however the width may be as small as 10 ft. (3m) or
as large as 40 ft. (12m) depending on the function of the pipe rack. Spacing of the frames is determined by
the allowable span of the pipe and tray that is being supported. Frames are typically spaced at 20 ft. (6m)
intervals but may be increased or decreased as necessary to optimize the design when supporting a
significant amount of large, or small diameter piping. Intermediate transverse members may be required
when supporting small bore piping, conduit, or small cable tray that may have a limited span. Coordinate
with the other design disciplines to determine the need for intermediate supports.

Figure 2: Typical "Bent" / "Portal" Elevation

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The frames are connected in the longitudinal direction through a series of longitudinal members known as
“Stringers” or “Struts”. The stringers usually connect to the column at the level midway between the main
transverse beams for the ease of pipe off-takes. The stringers also provide support for piping and cable tray
entering and exiting the pipe rack from the side and provide the longitudinal stability for the rack system.
Intermediate stringers may be required for wide pipe racks, or when small bore piping must travel across
the width to exit the rack.

Figure 3: Typical Longitudinal Elevation

Final longitudinal stability “Braced Bays” are provided to transfer the longitudinal forces down to the
foundations. Each pipe rack should have at least one braced bay to provide longitudinal stability. Braced
bays should be located at a maximum spacing of 200 ft. (60m)

The effects of thermal expansion shall be considered for pipe racks over 200 ft. (60m), and when multiple
braced bays are used. Stringer beams in at least one bay may be omitted or slotted connections used to
relieve the accumulated forces due to thermal expansion between braced sections. Slotted connections or
omitting stringers is also preferred at rack intersections to eliminate the transfer of unwanted loads.

Usually, an anchor bay located near the center of a long pipe run. It is important to coordinate with the
Piping engineer early in the design process so that anchor bay locations can be established. Anchor bay and
expansion bay locations shall be considered at the same time.

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 Figure 4: Typical Isometric View

2.3 Design Loads and Combinations

2.3.1 Dead Loads

Dead loads are those gravity loads produced by the weight of the structure, its components and all
permanent contents. These include the weight of all structural components, grating, fireproofing, etc. as
well as all permanent equipment, piping electrical, etc.

Definition of Dead Load has no direct relation to the load factors used in some building codes. Refer to
governing building codes for applicable load factors.

2.3.1.1 Structure Loads

The weight of all materials, lighting, grating, fireproofing, etc. permanently attached to the structure. In
absence of more detailed loading information, the following data should be used to estimate the self-
weight of the structure and all permanent appurtenances.

Description Load

Fireproofing – Dense Concrete 150 pcf (24 kN/m3)

Fireproofing – Lightweight Cementitious 55 pcf (9 kN/m3)

Fireproofing – Intumescent 10 pcf (1.5 kN/m3)

Access Platform framing with floor plate / grating 20 psf (1 kN/m2)

Operating Platform framing with floor plate / grating 40 psf (2 kN/m2)

Guardrail with Toe Plate 15 lb/ft (0.20 kN/m)

Ladder without Cage 11 lb/ft (0.15 kN/m)

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 Description Load

Ladder with Cage 30 lb/ft (0.45 kN/m)

1 ¼” (32mm) Grating – Standard 11 psf (0.50 kN/m2)

¼” (6mm) Floor Plate – Standard 11 psf (0.50 kN/m2)

Fire proofing load can be included as a part of self-weight or can be considered as a separate basic load
case. If “Fire Condition Analyzes” is required to be performed, then adding Fire Proofing as an independent
case is recommended. Fire Proofing applied as a separate load case can also be useful when performing
modular design analyzes to understand its effect on transportation and lifting weights.

2.3.1.2 Piping Empty / Operating Loads

Weight of all piping including valves, attached instruments, insulation, and operating contents. Piping loads
should be separated into discrete cases as necessary to develop meaningful load combination for the state
of use (Empty, Operating, Test, etc.).

For the transverse beams of the pipe rack main frames, the total applied operating pipe load (pipe plus
contents) shall be taken as a uniformly distributed load of 20 psf (1.0 kN/m2) to 60 psf (3.0 kN/m2) as
determined by engineering judgment based on the average size and schedule of piping on each level.

For a pipe rack with multiple pipes between 1” and 10”, it is generally recommended to apply a uniformly
distributed load with loading intensity of 40 psf (2.0 kN/m2) which includes full operating load, insulation,
pipe fittings etc. This is equivalent to 8” (200 mm) diameter, schedule 40 bare pipes, full of water, at 14”
(350 mm) c/c spacing.

The table below defines typical uniform piping load categories.

Piping Load Category Total Piping Load Piping Load Description

1 20 psf (1 kN/m2) Average 4” pipe at 9” c-c

(Average 100 pipe at 225mm c-c)

2 30 psf (1.5 kN/m2) Average 6” pipe at 12” c-c

(Average 150 pipe at 300mm c-c)

3 40 psf (2 kN/m2) Average 8” pipe at 14” c-c

(Average 200 pipe at 350mm c-c)

4 50 psf (2.5 kN/m2) Average 10” pipe at 17” c-c

(Average 250 pipe at 430mm c-c)

5 60 psf (3 kN/m2) Average 12” pipe at 19” c-c

(Average 300 pipe at 440mm c-c)

Note: Carbon Steel Sch 40 Bare Pipe Full of Water

For checking uplift due to wind and seismic loads during erection or shut down, the pipe “Empty” load can
be taken as 50% of the total applied operational piping weight and applied as a uniform distributed load.
The pipe “Contents” may be taken as the remaining 50%.

Piping Load Category Empty Load Contents Load

1 10 psf (0.5 kN/m2) 10 psf (0.5 kN/m2)

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 Piping Load Category Empty Load Contents Load

2 15 psf (0.75 kN/m2) 15 psf (0.75 kN/m2)

3 20 psf (1 kN/m2) 20 psf (1 kN/m2)

4 25 psf (1.25 kN/m2) 25 psf (1.25 kN/m2)

5 30 psf (1.5 kN/m2) 30 psf (1.5 kN/m2)

It is recommended to calculate the empty weights of different pipe diameters using piping standard tables
and supporting span to get accurate weights for pipe diameters 12” (300 mm) or above.

The weight of the pipe depends upon the schedule of pipe. If not known, standard schedule (schedule 40)
of pipe can be assumed. The empty load will be substantial for schedule 80 (XS) or higher than schedule 40
pipe.

For pipe racks with pipe diameters 12” or more, individual concentrated load shall be calculated and
applied at the pipe locations. The portion of the uniform load at this location may be deleted. The width of
uniform load that is removed should be based on the effective width of the pipe that will be modeled with
a concentrated load. The effective width should be taken as the overall diameter of the pipe including the
insulation plus ½ the standard minimum spacing to the next adjacent pipe on each side.

The stringers are also subjected to the vertical loads in case of pipe turning in or off the rack. Loads on
stringer beams shall include the loads from the intermediate beams if any, plus a uniformly distributed load
or a point load acting in the middle of the beam, whichever is governing. In absence of detailed design
information, a concentrated load of 2000 lbs (10 kN) located at the center of the beam may be used.

Concentrated loads for large pipes on stringers and intermediate transverse beams where pipes are turning
in and out shall be given special consideration. This loading should not normally be added to the design
load for the column or footing if the full pipe weight has already been considered on the transverse beam.
In this case the concentrated load should only be used for the local design of the stringer.

2.3.1.3 Piping Test Load (Contents)

Test dead load contents is the weight of the test medium contained in the system. The test load shall be
defined as the gravity load imposed by the liquid (normally water) used to pressure test the piping.

It should be noted that the testing of the pipe is always done one at a time so if the operating load is
considered as a load full of water for all pipes then this load case can be eliminated.

This load case is important when hydrotesting large vapor lines where operating load is almost equal to
empty load and test load with water can be substantially larger than operating. It is also possible that such
large vapor lines can be tested pneumatically. If pneumatic testing is used, this load case can be ignored,
confirm this condition with responsible discipline or project engineer.

2.3.1.4 Piping Thermal Loads

2.3.1.4.1 Friction Loads

Friction load is caused by the sliding of pipes on their supports due to thermal expansion or contraction
during start up or shutdown of piping systems. These forces are to be treated as temporary since these are
generated only at certain times as mentioned. Once the pipe expands or contracts and slides over the

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supported beam, the frictional forces disappear. Friction forces shall not be combined with “Wind” or
“Seismic” Loads.

The friction forces are generally not given by pipe stress group and will be calculated by structural group
depending upon the pipe operating loads and number of pipes.

The friction will be generated depending upon the materials which are sliding against each other. The
coefficient of static friction is given in the following table for reference.

Static Friction Coefficients

Steel to Steel 0.4

Steel to Concrete 0.6

Teflon to Steel 0.1 or as published

Because of uneven thermal strain in pipes at any given time, friction forces of individual pipes shall be
assumed to be partially resisted by adjacent pipes on the same piping level. The nominal unbalanced
friction load acting in the longitudinal direction on the piping level can be estimated as a percentage of the
total pipe weight tributary to that piping level according to the number of pipes on the piping level as
shown in the table below.

Number of Pipes Friction Load as Percentage of Pipe Weight

n
Local Beam design Overall Structure and Foundations

1 (Steel) 40% 20%

1 (Concrete) 60% 30%

1 (Teflon) 10% 5%

2-3 (Steel) 30% 15%

Number of Pipes Friction Load as Percentage of Pipe Weight

n Local Beam Design Overall Structure and Foundations

2-3 (Concrete) 40% 20%

4-6 (All) 20% 10%

n>6 (standard) 10% 5%

(full level)

Note: All lines supported on Teflon shall be treated as individual.

The standard design load should utilize a minimum friction force of 10% of the piping load at each piping
level for the design of the local member. Due to the uneven nature of friction only one half of the total
friction load should be accumulated for the design of the stringers, columns, braced bays, and foundations.
This can be accomplished by strategically applying concentrated loads in the opposite direction to offset
50% of the total friction load.

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Consideration shall be given to circumstances where heavier pipes acting alone produce a larger friction
load than the group of pipes associated with the heavy pipe on the same piping level. This can occur when
considering 40% of the heavy pipe versus 10% of the uniformly distributed dead load of the piping on the
piping level. These different friction loads can lead to different governing factors. If the heavier pipe is near
to the support, then it can govern weak axis shear while the uniform load can govern the weak axis
moment. Engineering judgment shall be used in considering such circumstances in determining the
appropriate friction loads to use for the design of the supports.

Under normal loading conditions with multiple pipes, torsional effects (from friction) on the local beam
need not be considered because the pipes supported by the beam limit the rotation of the beam to the
extent that the torsional stresses are minimal. This does not include anchors. Torsional effects from
anchors shall be specifically evaluated.

2.3.1.4.2 Pipe Anchor Loads

Anchor loads are the result of restraining or directing the movement of the pipe due to operating thermal
and pressure loads. Some anchor loads will have an overall effect on the design structure and foundations,
while others may only have a local effect on the adjacent framing members. It is important to understand
the piping arrangement to be able to determine if the effect is to the structural system, or only to local
members. Pipe anchor loads are generally supplied by the pipe stress engineering group and should be
applied at the anchor locations as specified in the 3D model or other design documents.

Anchor loads are generally considered to be permanent, acting on the pipe rack at anchor locations when
the pipe is in operating condition. Pipe anchor load should be treated as dead loads since they are present
throughout the life of the plant while in the operating condition and should be combined in the appropriate
live, wind and seismic load combinations. Anchor loads are generally applied as concentrated loads acting
at either the top flange or on the whole depth of the beam depending on the anchor design.

For straight run piping in racks, anchor loads are generally the reactions resulting from pipe friction and are
to be applied in the opposite direction. Although the anchor load is normally present only for a few lines,
the assumption of 10% friction/anchor loading will generate enough longitudinal loads for the design of
longitudinal frames, vertical bracings and foundations (refer to the Friction Load section above). This
assumption is specifically useful when the design is done for FEED (proposal stage) due to absence of
accurate stress data.

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For long racks accumulation of this 10% piping load may provide overly conservative loading applied to the
anchor beam. Accumulation of the load can be limited to 4 to 5 Bents resulting in a typical design load of
350 - 400 lb/ft (5 – 6 kN/m) for the anchor beam.

Friction and anchor forces are usually coupled and therefore cannot exist at the same place at the same
time, nor can they be in the same direction. Coupled friction and anchor forces have only an internal effect
on the structural system and do not affect the design of braced bays and foundations. Pipe anchors located
near rack intersections, locations where piping is entering and exiting the rack or cross areas of slotted
connections or discontinuous framing may have more influence on the entire structural system. Special
care should be taken with respect to the direction of application of friction and anchor forces to ensure
that summation and cancelation of forces are in alignment with the expected behavior and effects on
frames, braced bays, and foundations are properly accounted for.

All assumed and preliminary loads should be replaced with the final anchor forces provided by the Piping
Engineering group prior to releasing drawings to construction.

2.3.1.4.3 Pipe Guide Loads

Guide loads are pipe thermal loads cause by expansion or contraction of pipe at the guide support
locations. Usually guides are provided to restrict the movement of the pipe in transverse direction and
hence these loads will be generated in the transverse direction of pipe (or longitudinal direction of the
support beam)

These loads are to be supplied by the pipe stress group either in the form of Stress ISOs or any other agreed
format.

Guide load shall be treated as dead load since these are present throughout the life of the plant in
operating condition. These loads shall form a part of operating load combinations and shall be combined
with live, wind, and seismic loads.

For pipe racks, guide loads are generally considered to have only local effects on beams and should be
provided by the Pipe Stress department. Where significant loads are provided, these are to be considered
when performing the local beam checks only. Guide loads located near rack intersections and at locations
where piping is entering and exiting the rack may have more influence. At these locations care should be
taken to ensure that effects on braced bays and frames are properly accounted for.

For multiple guide loads within one structure, the loads shall be applied with positive and negative values
to establish a net zero effect of forces transferred to the foundations and lateral force resisting system.

2.3.1.5 Cable Tray

Cable tray load consists of self-weight of the cable trays, weight of electrical and instrument cables. This is
an “operating” load case for cable trays with cables installed.

Dead loads for cable trays on pipe racks can be estimated as follows unless actual load information is
available:

Cable Tray Load Category Cable Tray Load Description

I Mix of small instrumentation and electrical cables

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 Cable Tray Load Category Cable Tray Load Description

II Mix of instrumentation and electrical cables with some conduit and/or large main feed
cables

III Instrumentation and electrical cables with large percentage of main feed cables.

Cable Tray Load Category Total Cable Tray Load Empty Load Contents Load

I 20 psf (1 kN/m2) 2 psf (0.1 kN/m2) 18 psf (0.9 kN/m2)

II 30 psf (1.5 kN/m2) 3 psf (0.15 kN/m2) 27 psf (1.35 kN/m2)

III 40 psf (2 kN/m2) 4 psf (0.2 kN/m2) 36 psf (1.8 kN/m2)

Load Category I may be used as the standard loading for dedicated cable tray levels or racks. For design of
rack where levels usage may be unknown or mixed (piping and tray), Load category III should be used.

Design engineer should validate the expected cable loading with the Electrical department prior to
finalizing calculations.

2.3.1.6 Equipment Empty / Operating Loads

When the pipe rack supports equipment such as air coolers and drums, the weight of all equipment,
insulation, and operating contents shall be included. Equipment loads should be separated into discrete
cases as necessary to develop meaningful load combinations for the state of use (Empty, Operating, Test,
etc.).

For checking uplift due to wind and seismic loads during erection or shut down, the equipment contents
should not be considered.

2.3.2 Snow Loads

Snow loads shall be calculated and applied in accordance with the governing building code and customer or
local specifications for the project.

2.3.3 Live Loads

Live loads are those gravity loads produced by the use and occupancy of the structure. These include the
weight of all movable loads, such as personnel, tools, miscellaneous equipment, movable partitions, wheel
loads, parts of dismantled equipment, stored material, etc. Areas of floors that support mechanical
equipment may be designed to include loads that may be produced during maintenance by workers,
equipment, and material.

Definition of Live Load has no direct relation to the load factors used in some building codes. Refer to
governing building codes for applicable load factors.

Unless otherwise specified in the project design criteria, the following live load intensities should be used.

Live Loads

Operating Platforms – with designated laydown and storage 150 psf (7.2 kN/m2)

Operating Platforms – Standard 100 psf (4.8 kN/m2)

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 Live Loads

Access Platforms – Light 75 psf (3.6 kN/m2)

Walkways and Catwalks 60 psf (2.9 kPa)

Stairs and Landings 100 psf (4.8 kN/m2)

2.3.4 Wind Loads

All Piperack structures, equipment supported on the rack and other appurtenances shall be designed in
accordance with the requirements of the governing building code for the project. For the determination of
wind loads, new pipe rack structures are assumed to be located in open terrain unless otherwise known.

2.3.4.1 Wind Direction

For design of new pipe racks, wind loads should be applied in the transverse direction only. Wind in the
longitudinal direction can usually be ignored as friction forces will likely control the design. Wind in oblique
direction for the pipe rack is also generally ignored. However, it is recommended that the longitudinal wind
on the structural framing be calculated to validate the assumption that friction forces will control. This is
important for pipe racks designed for small average piping diameter, or large amounts of cable tray where
smaller friction forces may have been applied.

2.3.4.2 Shielding Effect

Shielding effect of structural framing shall be ignored when applying wind load on windward and leeward
frames.

Shielding effect of equipment, building or structure adjacent to the pipe rack structure shall be ignored.

2.3.4.3 Flexible Structures

For pipe racks with large (12” (300mm) and larger) piping or equipment loads on top tiers it is
recommended that the structure be checked for natural frequency to confirm the flexibility of the
structure. If the frequency is less than 1 Hz then the structure is assumed to be flexible and gust effects for
wind shall be considered.

2.3.4.4 Wind on Equipment

Wind loads on air coolers, vertical and horizontal vessels, etc. which are supported on the rack, shall
account for manways, nozzles, piping, ladders and platforms. If the vessel is insulated, the thickness of the
insulation shall be added to the vessel diameter to determine the projected wind area.

2.3.4.5 Wind on Piping

In absence of customer or local building code requirements the following information should be used as the
minimum value to determine the effective area for calculation of the wind load on piping.

The Effective Area (Ae)

Ae (Pipe) = (D + 0.1 W)

Where,

D = Diameter of largest pipe including insulation

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W = Width of pipe rack

For new rack design, all levels are to be assumed as full of cable tray and /or pipe.

2.3.4.6 Wind on Cable Trays

In absence of customer or local building code requirements the following information should be used to
determine the effective area for calculation of the wind load on the cable tray.

The Effective Area (Ae)

Ae (Tray) = (H + 0.1 W)

Where,

H = Height of cable tray

W = Width of pipe rack or total tray width at that level.

For new rack design, all levels are to be assumed as full of cable tray and /or pipe.

If multiple trays are stacked vertically, then the projected area for wind load shall be calculated by
multiplying the number of trays by H.

In absence of customer or local building code requirements the following information should be used when
determining the effective wind forces on the pipe rack and its components.

Component Wind Load Design Factors

Component Shape Factor Effective Area Ae

Pipe 0.7 (D + 0.1 W)

Cable tray 2.0 (H + 0.1 W)

Structural shapes (beams, bracing) 1.8 Exposed Area

Structural shapes (columns) 1.8 Exposed Area

Ladders (without cage) 2.0 0.5 sq. Ft./ft. (0.15 m2/m)

Ladders (with cage) 2.0 0.75 sq. Ft/ft (0.23 m2/m)

Guardrails (including toe plate) 2.0 0.8 sq. Ft/ft (0.25 m2/m)

Staircase with Guardrail (side elevation) 2.0 Guardrail area + channel depth

Staircase with Guardrail (end elevation) 2.0 50% of gross area

2.3.5 Seismic Loads

Seismic loads shall be calculated and applied in accordance with the governing building code and customer
or local specifications for the project. Seismic design parameters shall be based on specific site location and
soils information as noted in the geotechnical report. All parameters shall be calculated and applied as
specified in governing building code. Pipe racks should be considered “Non-Building” structures as there
are no specific requirements for pipe racks.

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The seismic design base shear should be calculated for the operating condition including the weight of the
structure, all piping, equipment, cable tray, and associated contents. The operating condition base shear
should be used for analyzes of both the operating and empty conditions unless determination of an empty
condition base shear can be justified.

The seismic design loads should be applied in the longitudinal and transverse directions. Seismic design in
the oblique direction shall be considered as required by the governing building code.

Seismic design loads shall not be combined with wind or friction loads.

Seismic analyzes may be performed utilizing the equivalent static load procedure unless a more stringent
analyzes method (dynamic, response spectrum, etc.) is required by the governing building code or
customer requirements.

2.3.6 Upset Condition Loads

During start up, shut down, maintenance operations, etc. some abnormal loads may be experienced. The
Process and Piping Engineering team should be able to define any possible upset conditions, and the
expected piping loads. Upset condition loads are considered temporary loads and should generally not be
combined with full wind, seismic, or test loads. Typical upset loads are defined below.

2.3.6.1 Relief Load

Loads caused during upset condition due to sudden relief of PSV’s are considered as transient loads. Relief
loads should be considered to act on an individual basis and shall be treated with care when combining
with other transient loads like live, wind and friction loads. Relief load cases should be reviewed and
coordinated with piping engineer to ensure proper understanding.

2.3.6.2 Surge Load

Loads caused by surging action of fluid, upset condition loads due to sudden closure or opening of valves
and water hammer loads are considered as Surge Loads. Such conditions are rare to and shall be treated
with care when combining with other transient loads like live, wind and friction loads.

2.3.6.3 Slug Load

Slug loads are caused by two phase / multiphase flows in piping or vessels in which case a liquid can get
trapped in the gas flow causing lot of thrust on the bends of the pipe due to momentum of the liquid. Slug
loads can be very large depending upon the process conditions and shall be determined with the assistance
of the appropriate engineering disciplines.

The slug loads shall be carefully applied with respect to direction, as indicated loads on the stress ISOs may
not act together due to time lag in the application of such loads.

Slug load condition is rare and shall be treated with care while combining with other transient loads like
live, wind and friction loads.

Stress analyzes results shall be used in the design of all structural supporting members for above
mentioned upset condition loads. These loads shall be included only in upset load combinations with the
factor of dead load for only those load combinations. Note that impact factor shall be included in the basic
load application.

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2.3.7 Load Combinations
All Load Combinations shall be developed in accordance with governing building code. Developed
combinations shall address requirements for strength and serviceability as required by the governing
design codes including all required load factors and directions. Detailed combinations shall be developed
based on the following general combinations.

a. Empty Condition

Dead Empty + Wind

Dead Empty + Seismic

b. Operating Condition

Dead Operating + Anchor

Dead Operating + Anchor + Friction + Live

Dead Operating + Anchor + Friction + Live + Snow

Dead Operating + Anchor + Wind

Dead Operating + Anchor + Wind + Snow

Dead Operating + Anchor + Live + Wind + Snow

Dead Operating + Anchor + Seismic + Snow

Dead Operating + Anchor + Live + Seismic + Snow

c. Upset Condition

Upset condition shall generally follow the same combinations for operating, with the addition of
any special anchor force conditions of “Surge” and “Slug” loads.

Dead Operating + Upset Anchor

Dead Operating + Upset Anchor + Friction + Live

Dead Operating + Upset Anchor + Friction + Live + Snow

Dead Operating + Upset Anchor + Wind

Dead Operating + Upset Anchor + Wind + Snow

Dead Operating + Upset Anchor + Live + Wind + Snow

Dead Operating + Upset Anchor + Seismic + Snow

Dead Operating + Upset Anchor + Live + Seismic + Snow

d. Test Condition

Dead Test

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 Dead Test + Live

Dead Test + Live + Snow

Dead Test + Partial Wind

Dead Test + Partial Wind + Snow

Dead Test + Live + Wind + Snow

2.3.8 Load Factors

Load factors shall be applied according local code requirements. Where those factors are not given for the
loads of a pipe rack the following should be applied:

◼ Load factor of dead load part of piping loads, empty weight of equipment, test fluid weight and cable
trays should be taken equal to the load factor of self-weight of a structure according local code.
◼ Load factor of operating load part of piping loads, operating weight of equipment, piping thermal loads
and upset condition loads shall be taken equal to the load factor of self-weight of a structure according
local code.

2.4 Analyzes and Design Considerations

Analyzes and design activities should be performed utilizing department approved software, manual
calculation methods and forms. All calculations should be prepared, checked and stored in accordance with
department standard work instructions and guidelines.

While pipe racks may have a simple function and geometry, due to the complex nature of the piping system
and associated friction and anchor loads, developing a detailed analytical model can be extremely tedious
and time consuming. For this reason, the design of pipe racks follows a more prescriptive procedure to
allow for simplified analytical model reducing the design time required.

For pipe racks that contain consistent geometry (OSBL Rack, ISBL Rack, Secondary Rack), it is preferred that
the analyzes be broken into a series of simple analytical models to represent the components of the pipe
rack. One file should be created to analyze and design the frames (“Bent”, “Portal”), and one file should be
created to analyze and design the braced bay. Additional files may be created to analyze and design specific
parts of the pipe rack such as access platforms, anchor locations and special supports.

Pipe racks that support large amounts of equipment, have large integrated platform levels, or inconsistent
geometry (Process Rack), may behave more like a process structure. In this case, the system should be
designed as a process structure where a full 3D analyzes is more appropriate. Special care should be taken
to ensure that piping friction and anchor loads are handled correctly when performing a 3D analyzes.

Pipe racks are normally designed as rigid frame bents with pinned or fixed bases in the transverse direction
and as braced frames in the longitudinal direction. Transverse braced bents shall be avoided unless clear
access ways under the pipe racks are not needed. Pipe rack layout with transverse braced bents shall
require customer's approval.

2.4.1 Design Considerations

Columns

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◼ Columns shall be designed as members subject to combined axial and bending stresses.
◼ For column axis in braced longitudinal direction of the pipe rack (normally the weak axis), the unbraced
length for allowable bending and axial stresses shall be the distance from the base plate to the first
stringer beam.
◼ For column axis in unbraced transversal direction of the pipe rack (normally the strong axis), the
unbraced length for allowable bending and axial stresses shall be the distance from the base plate to
the first transverse beam. When performing a first order analyzes or as required for the analyzes
method, an effective length buckling factor shall be calculated for each column section. The effective
length factor will vary based on member sizes, support and framing conditions.
◼ Slenderness ratio for axial compression shall not exceed 200.
◼ Concrete columns shall be 18 inches (450 mm) square minimum.

Transverse Beams

◼ Transverse beams shall be designed as members subject to combined axial and bending stresses.
◼ For flexural loads, the unbraced length shall be taken as the full length of the member.
◼ For axial loads, the unbraced length shall be taken as the full length of the member.
◼ Slenderness ratio for axial compression shall not exceed 200.
◼ For weak direction bending, beams shall be considered pinned ended members.
◼ The local deflection (in the direction of force) of beams supporting pipe anchors shall not exceed 1/4
inch (6mm) due to anchor forces without the concurrence of the pipe stress engineer.
◼ Concrete beams shall be 18 inches (450 mm) square minimum.
Stringers (“Struts”, “Longitudinal Beams”)

◼ Stringer beams shall be designed as members subject to combined axial and bending stresses.
◼ Stringer beams shall be normally pin ended.
◼ For flexural loads, the unbraced length shall be taken as the full length of the member.
◼ For axial loads, the unbraced length shall be taken as the full length of the member.
◼ Slenderness ratio for axial compression shall not exceed 200.
Longitudinal Bracing

◼ Longitudinal Bracing shall be designed as members subject to combined axial and bending stresses.
◼ For “Tee” and “Angle” profiles, member strength design shall account for P-Delta effects resulting from
connection eccentricity.
◼ For flexural loads, the unbraced length shall be taken as the full length of the member.
◼ For axial loads, the unbraced length shall be taken as the full length of the member.
◼ Slenderness ratio for axial compression shall not exceed 200.
◼ Slenderness ratio for axial Tension shall not exceed 400

2.4.2 Deflection Limits

Vertical Deflection Limits
Member Load Deflection Limit
(L=Span)

Transverse Member Supporting Pipe (1) Operating L/360

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 Vertical Deflection Limits
Member Load Deflection Limit
(L=Span)

Stringer Member Supporting Pipe (1) Operating L/360

Beam Supporting Platform Live L/360

Beam Supporting Platform Dead + Live L/240

Grating and Checkered Plate Live 1/4“(6mm)

1

Horizontal Deflection Limits

Member Load Deflection Limit
(H=Height)

OSBL Rack Wind H/100

ISBL Rack Wind H/100

Process Rack Wind H/100

Secondary Rack Wind H/100

OSBL Rack (2) Operating + Wind H/100

ISBL Rack (2) Operating + Wind H/200

Process Rack (2) Operating + Wind H/200

Secondary Rack (2) Operating + Wind H/100

Beam at Anchor Point Anchor 1/4“(6mm)

2

1 For rack members supporting short piping spans connected to equipment that is located near the rack, stricter deflection criteria
(L/500) may be required. Consult with Piping Engineering group as needed for specific situations.
2 For racks supporting short piping spans connected to equipment that is located near the rack, stricter deflection criteria may be
required. Consult with Piping Engineering group as needed for specific situations.

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