US20160007738A1 - A cabled pipe rack - Google Patents

A cabled pipe rack Download PDF

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Publication number
US20160007738A1
US20160007738A1 US14/762,571 US201314762571A US2016007738A1 US 20160007738 A1 US20160007738 A1 US 20160007738A1 US 201314762571 A US201314762571 A US 201314762571A US 2016007738 A1 US2016007738 A1 US 2016007738A1
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Prior art keywords
pipe rack
concrete
column
shall
frames
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Abandoned
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US14/762,571
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English (en)
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Rolando S. Garcia
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    • E—FIXED CONSTRUCTIONS
    • E21—EARTH OR ROCK DRILLING; MINING
    • E21B—EARTH OR ROCK DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS
    • E21B19/00—Handling rods, casings, tubes or the like outside the borehole, e.g. in the derrick; Apparatus for feeding the rods or cables
    • E21B19/14—Racks, ramps, troughs or bins, for holding the lengths of rod singly or connected; Handling between storage place and borehole
    • E21B19/15—Racking of rods in horizontal position; Handling between horizontal and vertical position
    • A—HUMAN NECESSITIES
    • A47—FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
    • A47B—TABLES; DESKS; OFFICE FURNITURE; CABINETS; DRAWERS; GENERAL DETAILS OF FURNITURE
    • A47B55/00—Cabinets, racks or shelf units, having essential features of rigid construction
    • A47B55/04—Cabinets, racks or shelf units, having essential features of rigid construction made of concrete or the like
    • A—HUMAN NECESSITIES
    • A47—FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
    • A47B—TABLES; DESKS; OFFICE FURNITURE; CABINETS; DRAWERS; GENERAL DETAILS OF FURNITURE
    • A47B47/00—Cabinets, racks or shelf units, characterised by features related to dismountability or building-up from elements
    • A47B47/02—Cabinets, racks or shelf units, characterised by features related to dismountability or building-up from elements made of metal only
    • A47B47/021—Racks or shelf units
    • A47B47/027—Racks or shelf units with frames only
    • A—HUMAN NECESSITIES
    • A47—FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
    • A47B—TABLES; DESKS; OFFICE FURNITURE; CABINETS; DRAWERS; GENERAL DETAILS OF FURNITURE
    • A47B55/00—Cabinets, racks or shelf units, having essential features of rigid construction
    • A47B55/02—Cabinets, racks or shelf units, having essential features of rigid construction made of wire
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
    • E04B1/18—Structures comprising elongated load-supporting parts, e.g. columns, girders, skeletons
    • E04B1/185—Connections not covered by E04B1/21 and E04B1/2403, e.g. connections between structural parts of different material
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
    • E04B1/18—Structures comprising elongated load-supporting parts, e.g. columns, girders, skeletons
    • E04B1/30—Structures comprising elongated load-supporting parts, e.g. columns, girders, skeletons the supporting parts being composed of two or more materials; Composite steel and concrete constructions
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
    • E04B1/35—Extraordinary methods of construction, e.g. lift-slab, jack-block
    • E04B2001/3583—Extraordinary methods of construction, e.g. lift-slab, jack-block using permanent tensioning means, e.g. cables or rods, to assemble or rigidify structures (not pre- or poststressing concrete), e.g. by tying them around the structure

Definitions

  • This invention relates to a cabled pipe rack which is seen as a solution to resolve current issues surrounding the design, fabrication, and erection of a conventional pipe rack.
  • Steel pipe rack structures are major items in the oil and gas industry, oil refinery, gas plant, liquefied natural gas plant, petrochemical plant, chemical plant, mining processing plant, and power plants.
  • Steel pipe rack structure generally support pipes use to transfer or deliver any liquid, gas, and steam between equipments, storage tanks, utility areas, and flare lines, it also serve as support to power cables trays, instrument cable trays, light mechanical equipment, vessels, and valve access platforms.
  • a conventional pipe rack is a structural steel framework mostly of multi-level in forms consisting series of transverse steel frames made up of steel H-section columns and transverse I-section beams that run along the length of the pipe system typically spaced at 6.0M intervals. Transverse frames are connected with longitudinal struts to form a 48-meter length of one conventional rack. Industry standard practice has put a 50-meter maximum limit to a one rack length to allow each rack to move independently during thermal expansion and seismic actions.
  • a steel base plate is shop welded to the base of an H-section column, during site erection it is mounted on top of concrete pedestal and directly connected to the pedestal using high strength anchor bolts with thicker base plates. Underside of base plate and the top, of concrete pedestal is serving as the interface point between concrete and steel structures.
  • Steel pipe rack technically requires transversal and longitudinal steel bracings to achieve and maintain lateral stability against lateral forces like wind and seismic loads acting in both directions.
  • the invention of a cabled pipe rack is seen as a total solution to resolve these multi-level issues; eliminating pipe clashing, minimizing workplace arguments, regaining the integrity of engineering; achieving erection quality and; meeting project delivery.
  • the invention seemed to benefit the industry big-time by saving enormous tonnage of steel, man-hours, time table, and money.
  • the invention is a disclosure of technical solutions to help multi-discipline engineers working in the industry who are continuously facing various technical challenges at their workplace from engineering design phase, shop fabrication, shop welding, and site erection of a conventional pipe rack.
  • the invention is directed to a cabled pipe rack, an invention of structural framework of pipe rack employing tension cables to support lateral movements of transverse frames along the longitudinal direction, a zero braced pipe rack, completely eliminates pipe clashing issues, resolve technical mismatch and disagreements among members of engineering, construction, and quality control teams.
  • the invention produces a robust transverse frames which are the main support of the pipe way by employing composite hallow steel section columns poured with concrete. Based on this, a solid concrete column is formed and confined within the hallow steel section column.
  • the solid concrete column is directly attached to the top of concrete pedestal passing through a cut-off hole of the base plate with same diameter of the hallow steel column, starter steel bars with minimum of 1.0 meter in height are planted on the concrete pedestal and also passing through the cut-off hole of the base plate getting into the hallow steel column, this arrangement produces a fully rigid connection at the base when concrete is already cured, if the base has rigid support connection it has the capability to withstand lateral stability. Therefore, vertical bracings at the base level is no longer required thus producing a zero braced pipe way at the ground level.
  • tonnage of steel plates, stiffener plates, and no. of anchor bolts are extremely reduced at the base level alone.
  • the invention claims to have an innovative strategy to move the splicing point away from face of column has resolved the technical mismatch because the invention has employed welded joint connection of beams directly to the face of columns, thus producing a genuine full end-moment connection capacity technically and theoretically matching with the load analysis.
  • Technical issues to the conditional requirement of 90% contact of joint surfaces during erection are no longer applicable.
  • This new arrangement produces a zero braced pipe way at the upper levels of the cabled pipe rack thus totally eliminating chances of clashing.
  • cut-off I-beam Prior to site delivery, cut-off I-beam is fully welded to a hallow steel column as a fabricated item
  • anchor structures During site erection, anchor structures must first to be established, it has to be erected at designated locations and has to be poured with concrete ahead than the frames to give sufficient time of curing, concrete must be cured before any anchoring work are to be carried-out.
  • each frame Prior to erection of frames at site, each frame is assembled by bolting the fabricated items of columns with cut-off I-beam and the main beam together at a leveled lay down position.
  • Boom crane with spreader will be used to lifting the assembled frames in either one whole or by segments into a desired position, temporary guying with turn-buckle attached on both sides of frame will be used to hold during erection to keep erected frames at vertical alignment.
  • the hallow steel columns are poured with concrete, once curing period of concrete is reached, it produces robust structural framework
  • This robustness are product of composite columns with rigid connections at the base, and with fully stiffened joint connections of columns and beams of the transverse frames.
  • These frames are physically and theoretically proven to be highly resistant to lateral forces in both transversal and longitudinal directions, having these structural benefits, tension cable rods with shackles and turn-buckles are employed innovatively to substitute conventional solid I-beam section popularly used as a longitudinal strut for the conventional pipe rack.
  • This innovative strategy to use tension cable rod as substitute to solid I-beam strut have save tremendously tonnage of structural steel, and time allotted for fabrication, shop welding, and erection. Size and strength of tension cable rod, shackle, turn-buckle, and gusset plates are determined by engineering calculations.
  • Miscellaneous non-structural components of pipe racks are connected to the main structural system through hook-ups e.g. catwalks, cable trays, stairwell, exit ladders, deflection support of smaller pipes, special pipe support beam along the longitudinal axis when needed only, upward extension of pipe rack to cater supporting frames for multi-level cable trays mounted at the top level can be done by simply using a flange to flange type of column connection.
  • Non-structural hook-up assembly will be developed independently to suit individual project requirements. Development of such could proceed using either conventional or could further employ new innovative approach to form part to this invention as potential future amendments to cater for non-structural items:
  • the invention is totally new to the industry, a disclosure of technical solutions seen to give more benefits to the industry by saving tonnage of structural steel, time, and money during engineering design phase, shop fabrication phase, and finally to site erection phase.
  • FIG. 1 is a perspective view showing cabled pipe rack structural framework with 5 level rack, tension cables are anchored at both ends using Type-1 (Diagonally braced) Anchoring structures located at both ends of one rack length.
  • Type-1 Diagonally braced
  • FIG. 2 is a perspective view showing cabled pipe rack structural framework with 7 level rack, tension cables are anchored at both ends using Type-2 (Braced-Tower) Anchoring structures located at both ends of one rack length.
  • FIG. 3 shows cabled pipe rack longitudinal elevation with 5 level rack, tension cables are anchored using Type-1 (Diagonally braced) Anchor structures located at both ends of one rack length.
  • Type-1 Diagonally braced
  • FIG. 4 shows cabled pipe rack longitudinal elevation with 7 level rack, tension cables are anchored using Type-2 (Braced-Tower) Anchor structures located at both ends of one rack length.
  • FIG. 5 shows cabled pipe rack transversal section with 5 level rack.
  • the main beam is spliced at 600 mm away from face of column at both ends of beam.
  • FIG. 6 shows cabled pipe rack transversal section with 7 level rack.
  • the main beam is spliced at 600 mm away from face of column at both ends of beam.
  • FIG. 7 shows enlarged drawing of Type-1 (Diagonally braced) Anchoring structures.
  • FIG. 8 shows enlarged drawing of Type-2 (Braced-Tower) Anchoring structures.
  • Braced Tower is primarily used as anchoring structure for most heavily loaded racks with 7 levels and above specially at project locations of high winds and high seismic forces, wherein a diagonally-braced anchor structure can no longer handle.
  • FIG. 9 shows enlarged drawing of Fully Welded Beam to Column Joint. This drawing illustrates the End Moment Connection at column joint using ring stiffeners of column as receiver of cut-off I-beam.
  • FIG. 10 shows enlarged drawing of Simple Beam Splice located at minimum distance of 600 mm from face of column. Cut-off beam is fully welded to the column is one fabricated item prior to site delivery.
  • FIG. 11 shows enlarged drawing of Gusset Plates with slotted holes fully welded to the ring stiffeners of Column to cater tension cables placed at every rack level and between frames all the way to the anchoring structures.
  • FIG. 12 shows enlarged drawing of Starter Bars planted to the concrete pedestal with minimum height of 1.0 meter passing through the hole of the base plate to allow a solid concrete column thus producing a fully rigid connection at the base using only minimal thickness of base plate, stiffener plates, and reducing the no. of anchor bolts.
  • FIG. 13 shows typical drawing of longitudinal beam installed at beam level in cases where pipes are coming in and going out from the pipe way would need special support along the longitudinal direction. Connection is a simple pin only.
  • FIG. 14 shows typical drawing of longitudinal beam installed in-between rack levels in cases where pipes are coming in and going out from the pipe way at any vertical position would need special support along the longitudinal direction.
  • Connection is a simple pin only using a clamp type tied by bolting to the steel columns, a rubber band or equivalent material may be placed in-between to avoid direct, contact of steel surfaces to minimize rust accumulation.
  • FIG. 15 shows tension cable rod with turnbuckle to serve as plan cross-bracing (see FIG. 15 ) to resist torsional forces applied at the top flange of main beam due to pipe anchor and friction forces, will be hooked-up to desired location within the rack assembly, detailed design and, pinned type connection will be developed accordingly to suit piping requirement.
  • FIG. 16 is a temporary guying used during erection of transverse frames anchored to the sides of concrete pedestal along the longitudinal axis
  • the invention is directed to rearranging things inside the box.
  • a cabled pipe rack 10 and 10 a as shown in FIGS. 1 & 2 will completely function similar to conventional pipe rack but largely of different structural composition, physical appearance and methods of creation.
  • the invention is an smart assembly of significant structural elements that have put together to form a robust structural framework simply made up of locally available construction materials, like: tubular hallow steel column 11 (circular, square, and rectangular section), a base plate 12 with a cut-off hole with same size and opening of hallow tubular column, a tension cable rod 13 with shackle 14 at one end and, turn buckle at the other end, an I-beam 15 , steel bars 16 , and a concrete-mixed material.
  • tubular hallow steel column 11 circular, square, and rectangular section
  • a base plate 12 with a cut-off hole with same size and opening of hallow tubular column
  • a tension cable rod 13 with shackle 14 at one end and, turn buckle at the other end
  • an I-beam 15 steel bars 16
  • a concrete-mixed material a concrete-mixed material.
  • anchor structures During site erection of the cabled pipe rack, anchor structures must first to be established, it has to be erected at designated locations and has to be poured with concrete ahead than the frames to give sufficient time of curing, concrete must be cured before any anchoring work are carried-out.
  • each frame Prior to erection of frames at site, each frame is assembled by bolting the fabricated items of columns and beams together at a leveled lay down position, assembly could be done either one whole piece if rack is only 3 levels and below, or could be 2 or 3 segments depending on the size or height of transverse frame, cutting point is at splicing point of columns.
  • Boom crane with spreader will be used to lift the assembled frames as a whole or by segment into a desired position, temporary guying with turn-buckle on both sides of frame will be used during erection to keep erected frames at vertical alignment.
  • the structural system of the cabled pipe rack is an assembly of 5 major components to keep the structural, system fully functional. Each component is illustrated below with their respective and collaborative functions that seemed to drive this innovation to be put forward into a real thing.
  • This invention is seen to change the face of oil refinery plants, gas plant, liquefied natural gas plant, petrochemical plant, chemical plant, mining processing plant, power plants, and other similar industrial plants projects.
  • Transverse Frames are made-up of:
  • the invention is associated to a tubular hallow steel section as the most appropriate material to be used as columns to allow a composite column technology to govern.
  • the primary intension of using hallow steel section is to produce a fully rigid connection at the base by simply employing starter bar dowels planted into the concrete pedestal (see FIG. 12 ) passing through a cut-off hole opening of the base plate all the way into the hallow steel column.
  • An average of 4 nos. of anchor bolts are enough to hold the columns during erection period, once the frames are installed and aligned, concrete will be poured to allow more robust composite column with full rigidity at the base where vertical bracings are no longer required at the ground level thus producing a zero-braced pipe way.
  • This innovation has employed a cut-off I-beam 17 of 600 mm in length to be fully welded directly to the face of column 11 .
  • This arrangement has achieved full stiffness at the joints of beam and columns thus producing a fully stiffened transverse frames.
  • the main beam is spliced at the edge of cut-off beam 17 600 mm from face of column 11 (see FIG. 10 ) which require a simpler connection design only.
  • Anchor structures 18 are playing as one of the most innovative role to this innovation, this is where all the lateral loads will be neutralized and resisted.
  • Anchor structures are serving as anchor points to all tension cables 13 , these structures are strategically located at both ends of every full length of cabled pipe rack assembly. These are categories but not limited to 2-types: Type-1 to cater for. 6-levels pipe racks and below, and Type-2 to cater for 7 levels of pipe racks and above, other types can be developed within the context of type-1 and 2.
  • Anchor structures 18 are designed to withstand longitudinal stability against anchor loads. Anchor structures must first to be established during site erection of the cabled pipe rack, this would need to be erected at designated locations and has be poured with concrete ahead than the frames to give sufficient time of concrete curing. Concrete must be cured prior to any anchoring activities. Engineering calculation will validate the lateral stiffness of the anchor structures for type 1 and 2.
  • Type-1, Diagonally-braced anchor structures ( FIG. 7 ) 19 —are made up of the same design and materials to that of transverse structural steel frame, the assembly is made up of a vertical frame 191 located at the last row and a diagonal frame 192 inclined to outward position with the 0.2 having a common joint at the top edge welded together through a connection plate 193 .
  • small sized I-beam 194 is installed at every rack level to reinforce the anchoring assembly along the longitudinal axis adopting the same joint connection strategy.
  • Gusset plates 195 with slotted holes to cater pin connection of tension cables are provided at every rack level of the anchoring structure. Assembly and erection strategy is similar to transverse frames.
  • Type-2, Braced-tower anchor structures ( FIG. 8 ) 20 are made up of the same design and materials to that of transverse main structural steel frame, the composition are made up of the last 2 rows of vertical frames 201 , 202 , connected together at all sides with small sized I beams 203 to be installed at every level and diagonal cross-bracings 204 using small sized H section to be installed between levels from top of pedestal up to the top level. Beam to column connection to use same full moment connection strategy, cross-bracing to use pinned-type joint connection. Use gusset plates 205 placements similar to type-1. Assembly and erection strategy is similar to transverse frames.
  • Tension cable rod with shackle at one end and with turn-buckle at the other end 13 and 14 This component is one of the most dramatic part of the innovation and an eye Catcher to the structural system.
  • the present invention innovates the lateral support using tension cable rods 13 to replace the conventional I-beam sections originally used as longitudinal struts to interconnect series of transverse frames along the longitudinal axis. Firstly, based on actual circumstances, it is evident that when all pipes are completely installed on the pipe rack it basically helps to strengthen the longitudinal axis of the pipe way and its supporting frames against any individual frame movement; Secondly, the interconnection arrangements of various pipes along the pipe way are proven to further reinforce the longitudinal stability of the pipe rack assembly. Thirdly, the invention took the structural benefit from the robustness of transverse frames that require only minimal longitudinal support. These basis are technically satisfied. Size and strength of tension cable material, shackle, turn-buckle, and gusset plates are to be determined by engineering calculation.
  • transversal frames guying are temporarily used to keep frames aligned at vertical positions, this can be done by providing one or more circular anchors embedded at the side portion of concrete pedestal 21 (see FIG. 12 ) to where the erection guying are to be pin-connected using shackle.
  • tension cable rods will now be installed horizontally at every rack levels to finally interconnect frames all the way down to the anchoring structures.
  • Each cable length holding the frames is pinned connected into the slotted holes of gusset plates, while at the other end is using turn-buckle to control incremental alignment.
  • Concrete material is one of a key element used to the structural system that helps to produce a robust solid vertical element.
  • the results show that the confinement effect of concrete within a steel tube section does play a big role in increasing the compressive strengths to almost 60%, thus making 4 composite column a robust vertical element.
  • Concrete is poured to hallow steel columns after all transversal frames are erected, perfectly aligned, vertically stable, and are fully anchored to the anchoring Structures. After the concrete is cured, cabled pipe rack produces a robust transverse frames with full rigid connections at the base of columns, physically and theoretically accepted as highly resistant to lateral forces in both transversal and longitudinal directions. Mixture of concrete, curing requirement, procedure and methods of pouring will be developed accordingly and separately to suit project requirements.
  • Miscellaneous Accessories are non-structural components to be developed as a separate hook-up assembly to suit individual project requirement to be connected using pinned type at desired locations during site erection. During design development, the strength of non-structural components will not be calculated, all detailed drawings of miscellaneous components are simply develop using standard drawings accepted by the industry. Extra input loads due to these components are considered in the load analysis of the main rack assembly.
  • Pipe racks miscellaneous hook-up assembly are listed below:
  • Extension of column at the top portion of racks to cater cable trays to be used for electrical and instruments lines, will be connected through a bolted flange at the top end of column, the receiving flange is already provided by structural assembly ready to received any column extension.
  • Main stairwell, catwalk and cage ladder for operational access, maintenance, and emergency exit, will easily be hooked-up by simple pinned connection to the main rack assembly, detailed design and pined type connection will be developed accordingly to suit project requirement.
  • Platforms for lighter equipments will be fabricated and hooked-up to desired location within the rack assembly, detailed design and pinned type connection will be developed accordingly to suit mechanical engineer's requirement.

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  • Engineering & Computer Science (AREA)
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US14/762,571 2013-04-05 2013-04-05 A cabled pipe rack Abandoned US20160007738A1 (en)

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PCT/PH2013/000011 WO2014163514A1 (en) 2013-04-05 2013-04-05 A cabled pipe rack

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JP (1) JP2016525489A (pt)
KR (1) KR20150093175A (pt)
CN (1) CN105283628B (pt)
AU (1) AU2013385693B2 (pt)
BR (1) BR112015025402B1 (pt)
CA (1) CA2902633C (pt)
GB (1) GB2527953B (pt)
MX (1) MX369926B (pt)
MY (1) MY178561A (pt)
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CN106848938A (zh) * 2017-02-17 2017-06-13 中国十七冶集团有限公司 一种高空平台下电缆桥架吊挂安装方法
US10633851B2 (en) * 2017-12-21 2020-04-28 Qingdao university of technology Assembled self-recovery circular concrete-filled steel-tube composite joint

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US10596060B2 (en) * 2015-11-26 2020-03-24 Samsung Electronics Co., Ltd. Frame assembly and motion assistance apparatus including the same
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KR20220162704A (ko) * 2020-04-09 2022-12-08 닛키 글로벌 가부시키가이샤 처리 플랜트 기기의 배치 방법 및 처리 플랜트의 제조 방법
CN113202090B (zh) * 2021-04-15 2024-03-12 中国葛洲坝集团第一工程有限公司 可监测变形量的张拉式锚固装置及其施工方法
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CA2902633C (en) 2019-04-16
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PH12015500136B1 (en) 2015-03-02
JP2016525489A (ja) 2016-08-25
GB201514346D0 (en) 2015-09-23
WO2014163514A1 (en) 2014-10-09
AU2013385693B2 (en) 2016-05-12
BR112015025402B1 (pt) 2021-10-13
MY178561A (en) 2020-10-16
KR20150093175A (ko) 2015-08-17
PH12015500136A1 (en) 2015-03-02
GB2527953B (en) 2021-03-31
BR112015025402A2 (pt) 2017-07-18
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CA2902633A1 (en) 2014-10-09
GB2527953A (en) 2016-01-06

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