Note: Descriptions are shown in the official language in which they were submitted.
PIPE RACKS
[0001]
FIELD OF THE INVENTION
[0002] The present subject matter relates generally to racks for supporting
pipes, especially
pipes at a refinery.
BACKGROUND OF THE INVENTION
[0003] Oil refineries include many chemical processing units, each removing
one or more
hydrocarbons from a mixture of many. Extensive piping runs between all of
these processing
units and various holding tanks. This piping is generally supported off the
ground by steel racks.
Each section of rack including two legs and at least one horizontal support
bar is generally called
a bent.
[0004] A first problem that arises with the present pipe racks is that if
one of the pipes leaks
liquid or gas that catches fire, an intense fire can cause the steel bent to
lose its structural
integrity. This will then cause the rest of the pipes on that bent to lose
support, possibly
rupturing the other pipes as well. This can cause a single leak to turn into a
catastrophic fire
and/or explosion. Thus, racks impervious to fire would avoid this problem.
[0005] Further, the location and orientation of each bent is very important
to ensure the
correct support of the pipe, including the correct slope to the pipe (if any).
Steel bents require
that the foundation of each leg be determined very accurately to ensure
accurate placement of the
bent. This is very time consuming, leading to greater cost and delay when
building the refinery.
Accordingly, a pipe rack that can be placed without such additional labor is
desired.
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SUMMARY OF THE INVENTION
[0006] The present invention broadly comprises a pipe rack and a method for
making a pipe
rack. In one embodiment, the pipe rack may include at least one foundation,
two legs, and a
horizontal support. The two legs are supported by the at least one foundation.
Each of the two
legs includes at least one aperture. The horizontal support has two ends. The
first end is located
in an aperture in a first leg of the two legs and a second end of the
horizontal support is located
in an aperture in a second leg of the two legs. The first end of the
horizontal support has a cross-
sectional area that is at most 75% of a cross-sectional area of the aperture
in the first leg and the
second end of the horizontal support has a cross-sectional area that is at
most 75% of a cross-
sectional area of the aperture in the second leg.
[0006a] In an aspect, there is provided a structure comprising: at least
one foundation; two
legs supported by the at least one foundation, each of the two legs including
at least one aperture;
a horizontal support having two ends, a first end located in an aperture in a
first leg of the two
legs and a second end of the horizontal support being located in an aperture
in a second leg of the
two legs, the first end of the horizontal support having a cross-sectional
area that is at most 75%
of a cross-sectional area of the aperture in the first leg and the second end
of the horizontal
support having a cross-sectional area that is at most 75% of a cross-sectional
area of the aperture
in the second leg; and a steel shim located between a lower surface of each
aperture and a bottom
surface of the horizontal support.
[0006b] In an aspect, there is provided a method for constructing a
structure: placing at least
one foundation; placing two legs such that they are supported by the at least
one foundation, each
of the two legs including at least one aperture; inserting a first end of a
horizontal support into an
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Date recue/date received 2021-10-22
aperture in a first leg of the two legs and a second end of the horizontal
support into an aperture
in a second leg of the two legs, the first end of the horizontal support
having a cross-sectional
area that is at most 75% of a cross-sectional area of the aperture in the
first leg and the second
end of the horizontal support having a cross-sectional area that is at most
75% of a cross-
sectional area of the aperture in the second leg; placing a steel shim between
a lower surface of
each aperture and a bottom surface of the horizontal support; and filling a
space between the at
least one aperture and the horizontal support with an adhesive.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] A
full and enabling disclosure of the present subject matter, including the best
mode
thereof, directed to one of ordinary skill in the art, is set forth in the
specification, which
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makes reference to the appended figures, in which:
[0008] FIG. 1 illustrates a perspective view of a first embodiment of the
present invention;
[0009] FIG. 2 is a perspective view of a second embodiment of the present
invention;
[0010] FIG. 3 illustrates a close up perspective view of a horizontal
strut;
[0011] FIG 4 is a top cutaway view of the joint between the leg and the
horizontal
support;
[0012] FIG. 5 is a side view of a first embodiment of the joint between the
leg and the
horizontal support;
[0013] FIG. 6 is top view of the insertion process for inserting the
horizontal support into
the two legs;
[0014] FIG. 7 is a side view of a second embodiment of the joint between
the leg and the
horizontal support;
[0015] FIG. 8 is a side view of a second embodiment of the joint between
the leg and the
foundation;
[0016] FIG. 9 is a front view of a second embodiment of the joint between
the leg and the
foundation;
[0017] FIGS. 10A-C are views of a second embodiment of the horizontal
support;
[0018] FIGS. 11A-C are views of a third embodiment of the horizontal
support;
[0019] FIGS. 12A and 12B are views of a second embodiment of the struts;
[0020] FIGS. 13A-C are views of a second embodiment of the vertical
support;
[0021] FIG. 14 is a front view of a third embodiment of the joint between
the leg and the
foundation;
[0022] FIGS. 15A and 15B are cross sectional views of the third embodiment
of the joint
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between the leg and the foundation;
[0023] FIG. 16 is a cross sectional view of the third embodiment of the
joint between the
leg and the foundation;
[0024] FIGS. 17A-C are views of a first embodiment of a method for making
the joint
between the leg and the foundation;
[0025] FIG. 18 is a view of a second embodiment of a method for making the
joint
between the leg and the foundation;
[0026] FIG. 19 is a perspective view of a fourth embodiment of the joint
between the leg
and the foundation;
[0027] FIG. 20 is a perspective view of a fourth embodiment of the joint
between the leg
and the foundation;
[0028] FIG. 21 is a perspective view of a fourth embodiment of the joint
between the leg
and the foundation;
[0029] FIG. 22 is a perspective view of an embodiment of a joint between
the leg and an
upper column;
[0030] FIG. 23 is a perspective view of the embodiment of the joint between
the leg and
the upper column;
[0031] FIGS. 24A and 24B are cross sectional views of the third embodiment
of the joint
between the leg and the upper column;
[0032] FIG. 25 is a cross sectional view of the third embodiment of the
joint between the
leg and the upper column;
[0033] FIGS. 26A-E are views of a third embodiment of a method for making
the joint
between the leg and the foundation;
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[0034] FIG. 27 is a cutaway view of an embodiment of the joint between the
leg and the
foundation; and
[0035] FIG. 28 is a cutaway view of an embodiment of a joint between the
leg and an
upper column.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0036] Reference is presently made in detail to exemplary embodiments of
the present
subject matter, one or more examples of which are illustrated in or
represented by the
drawings. Each example is provided by way of explanation of the present
subject matter, not
limitation of the present subject matter. In fact, it will be apparent to
those skilled in the art
that various modifications and variations can be made in the present subject
matter without
departing from the scope or spirit of the present subject matter. For
instance, features
illustrated or described as part of one embodiment can be used with another
embodiment to
yield a still further embodiment. Thus, it is intended that the present
subject matter covers
such modifications and variations as come within the scope of the disclosure
and equivalents
thereof.
[0037] Figure 1 shows a perspective view of a first embodiment of an
apparatus 10 for
supporting pipes in accordance with the present invention. Apparatus 10 may
also support
other equipment such as power lines, or other objects. Further, as described
herein, apparatus
is made of pre-stressed concrete so as to be impervious to fire. However, pipe
racks as
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described herein made of other materials such as other fire impervious
materials are also
within the scope of the present invention.
[0038] .. Apparatus 10 includes foundations 20, legs 30 located on foundations
20,
horizontal supports 40, and horizontal struts 50 (shown in close up in Figure
3). In the
embodiment shown in Figure 1, foundations 20 may be placed approximately 20
feet apart in
the direction of the pipe, and approximately 25 feet apart in the direction
perpendicular to the
direction of the pipe. However, different or irregular distances are also
within the scope of the
invention.
[0039] Figure 1 also shows that legs 30 have four apertures 32 for
receiving horizontal
supports 40, two of which include horizontal supports 40. Any number of
apertures 32 or
horizontal supports 40 are within the scope of the invention. Further, any
number or length of
horizontal struts 50 are also within the scope of the invention.
[0040] .. Figure 2 shows a second embodiment of the present invention,
apparatus 110.
Apparatus 110 includes foundations 20 placed at double the spacing shown in
Figure 1.
Apparatus 110 also includes legs 30, horizontal supports 40, and horizontal
struts 150.
However, horizontal support 40 may also be supported by horizontal struts 150
at locations
equidistant between foundations 20. Thus, the same spacing of horizontal
supports 30 is
maintained, while the number of foundations 20 is halved. This can
dramatically increase
construction speed, as laying the foundations can be very labor intensive.
[00411 Horizontal supports 40 may be joined to horizontal struts 150 and
legs 30 by either
of the joining methods shown in Figures 5 and 7.
[0042] Figure 4
shows a cut away top view of the joint between leg 30 and horizontal
support 40. Leg 30 may have pre-stress strands 34 extending in the vertical
direction. Both
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the inside of aperture 32 and the outside of the portion of horizontal support
40 that is received
in aperture 32 may include shear key surfaces 31 and 41 to strengthen the
adhesive bond
between leg 30 and horizontal support 40. The volume between leg 30 and
horizontal support
40 is filled with an adhesive 36, which may be an ultra-high performance
concrete or grout. In
one embodiment, leg 30 is 36 inches wide and 30 inches long (in the direction
of the
horizontal support 40).
[0043] Figure 5 shows a side view of a first embodiment of the joint
between leg 30 and
horizontal support 40. In this embodiment, horizontal support 40 is surrounded
on all sides by
adhesive 36. The only gap in adhesive 36 is due to steel shim 38. In one
embodiment,
horizontal support 40 is 18 by 32 inches, and steel shim 38 is 4 by 4 inches
in area and 2
inches thick. Thus, the steel shim lifts the horizontal support 40 off of the
bottom of aperture
32 before the adhesive 36 is added to the space between the leg 30 and the
horizontal support
40. This allows for a roughly even thickness of adhesive 36 around the four
sides of the
horizontal support 40. Horizontal support 40 may also include pre-stress
strands 42 extending
in the horizontal direction.
[0044] Accordingly, aperture 32 is significantly bigger than horizontal
support 40. For
example, aperture 32 may be 22 by 36 inches and support 40 may be 18 by 32
inches. Thus,
roughly 2 inches of space on each side can be found between the aperture 32
and horizontal
support 40. This equates to lateral dimensions of support 40 being 81-89% as
big as the
corresponding lateral dimensions of aperture 32. Supports 40 having dimensions
from 50%-
90% of the corresponding dimension of aperture 32 are within the scope of the
invention.
Further, cross-sectional areas of the support 40 are from 40%-75% of the cross-
sectional area
of aperture 32.
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[0045] This space allows for significant adjustment of the configuration of
the support 40
when connecting the support 40 to legs 30. Therefore, the location of
foundations 20 does not
need to be exact, as errors can be corrected by adjusting the amount of space
between the
support 40 and the aperture 32. The two inch allowance on each side of the
support 40
described above allows for correcting errors of up to approximately 1.75
inches in the
placement of foundations 20. In contrast, foundations for steel bents must be
placed within a
tolerance of 0.5 inches or less. Moreover, the present inventors discovered
that there is a 1:0.9
ratio of the distance allowance between the support 40 and the aperture 32 and
the distance
tolerance for the foundations 20.
[0046] In this regard, Figures 1 and 2 show foundations 20, legs 30,
horizontal support,
and apertures 32 that are rectangular prisms. However, any other shapes or
cross-sectional
shapes for the foundations 20, legs 30, horizontal supports 40, struts 50, and
apertures 32 are
within the scope of the invention.
[0047] Figure 6 shows the process for constructing the present pipe racks.
The
foundations 20 are already placed and the legs 30 are inserted therein. The
horizontal supports
40 are then inserted into the apertures 32 by inserting end 40A into aperture
32A, drawing the
support 40 into the aperture 32A until the end 40B clears the opposite leg,
and then moving the
opposite end 40B into the aperture 32B of the opposite leg.
[0048] Figure 7 shows a second embodiment of the joint between leg 30 and
horizontal
support 40. In this embodiment, aperture 32 is much longer in the height
direction than
support 40. Horizontal support 40 is then surrounded on only three sides by
adhesive 36. (A
steel shim may be used as shown in Figure 5). Then an additional portion of
concrete 39 is
poured into the aperture 32 above the support 40. As shown in Figure 7,
reinforcement 39A
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can be placed in aperture 32 before pouring the additional concrete. The
concrete portion 39
thus locks support 40 into place, while leaving the upper part of aperture 32
open. This
additional space allows for even greater adjustment of the support 40 in the
vertical direction.
The vertical adjustment may be critical when the foundations 20 are being
placed on ground
that may be uneven.
[0049] Figure 8 shows an alternative embodiment of the pipe racks of the
present
invention. In this embodiment, foundation 220 includes an aperture 221 in a
top surface
(shown in Figure 17A). Connection bolt 222 is located in that aperture and
extends into an
aperture 231 (shown in Figure 18) in a bottom surface of leg 230. Connection
bolt 222 may be
held in place with an adhesive such as grout. Figure 8 also shows the end view
of horizontal
supports 240, and also shows the extended strut 250. Strut 250 extends between
four
horizontal supports 240, two on each of adjacent legs 230. Strut 250 also
includes apertures
252. Apertures 252 can be sized and located to allow pipes splitting off from
the main pipes
on the rack to pass through. Apertures 252 may also lower the weight of strut
250 without
significantly reducing the structural integrity of the pipe racks.
[0050] Figure 9 shows another view of the pipe racks shown in Figure 8.
Legs 230 may
also include additional supports 232 to carry additional load from the
horizontal supports 240.
As shown in Figure 9, the lower two of five horizontal supports receive
additional support in
this manner. However, any configuration of additional supports 232 is within
the scope of the
invention.
[0051] Figures 10A-10C show views of horizontal support 240. Horizontal
support 240
includes a tube 241 that passes horizontally through the support. This allows
the passage of,
for example, wires through the support. The support also includes steel
reinforcement
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rectangle 242 and steel rods 244 that may run the length of the support.
Finally, a top surface
of the support includes connector 246 which allows the pipes that run over the
pipe rack to be
secured to the horizontal support 240. For example, screws could be used to
connect to
connector 246 to secure brackets (not shown) over the pipes to the horizontal
support 240.
[0052] Figures 11A-11C show an alternative embodiment of horizontal support
240, which
is labeled 248 in Figure 9. Alternative horizontal support 248 also includes a
tube 241, but the
tube is closer to a center of the support 248. Alternative horizontal support
248 includes steel
reinforcement rectangle 242, steel rods 244, and connector 246 in a similar
manner as support
240.
[0053] Figures 12A and 12B show views of strut 250. As noted previously,
apertures 252
may be sized and located in any configuration within the scope of the
invention.
[0054] Figures 13A-13C shows views of leg 230. As shown in Figure 13C legs
230
include steel reinforcement rods 234.
[0055] Figure 14 shows an alternative embodiment of the joint between the
foundation and
the leg. Foundation 220 includes an aperture 221 in a top surface that has
connecting rod 270
located therein. The space around rod 270 is filled with grout 300. Grout
bearing plate 290 is
located over the grout 300. Rod 270 extends upward from foundation 220 into an
aperture 231
in leg 230 that is bounded on the sides by rod 236. Rod 236 is cast within
precast leg 230.
The volume between rod 236 and rod 270 is also filled with grout. The grout
enters the
volume through grout inlet 237 and excess grout exits through grout exit 238.
Leg 230 also
includes passages 282 on each face of the leg. Bolts 280 pass through passages
282. Bolts
280 may be used to plumb the leg 230 by contacting rod 270 near the top of rod
270.
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[0056] In one embodiment, rods 270 and 236 may be made of hollow structural
steel. In
one embodiment, rod 270 is 7 inches by 7 inches by 3/8 inch thick and rod 236
is 9 inches by 9
inches by 3/16 inch thick. However, different dimensions are within the scope
of the
invention.
[0057] Figures 15A, 15B, and 16 are cross sectional views taken of the
structure shown in
Figure 14. Figure 16 also shows lugs 250 welded to rod 236 near the lower end
of rod 236.
[0058] Figures 17A-17C show one embodiment of a method of constructing the
joint
between foundation 220 and leg 230. Step 1 is shown in Figure 17A where
foundation 220
including circular aperture 221 is placed. Rectangular rod 222 is then
inserted in aperture 221
and an adhesive such as grout is placed in aperture 221 after rod 222 is
plumb, as shown in
Figure 17B. Grout plate 290 is then placed over the grout joint in Figure 17C,
and the
foundation is ready to receive the leg 230.
[0059] Figure 18 shows another embodiment of a method to create the joint
between the
foundation and the leg. Foundation 220 including square aperture 221 receives
rod 222, which
is then placed in aperture 231 of leg 230.
[0060] Figure 19 shows another embodiment of the present invention.
Structure 1000
includes foundation 1020, leg 1030, deck 1080 and upper leg 1130. Foundation
1020 is
connected to leg 103 by splice 1025. Leg 1030 is connected to upper leg 1130
by splice 1090.
[0061] Deck 1080 may be used to support pipes, planking for building a
floor, or any other
structure.
[0062] Figure 20 shows a close up of splice 1025. Foundation 1020 includes
an aperture
1021, which in one embodiment may be made by a corrugated duct cast into the
precast
foundation 1020. Leg 1030 includes inner rod 1236 which is the outer bound of
a volume
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filled with grout. The grout enters the volume through grout entry 1237 and
excess grout exits
through grout outlet 1238. Each face of leg 1030 includes a passage 1282
through which a
bolt 1280 passes. These bolts are used to plumb the leg 1030 as noted
hereinafter. Figure 21
shows a perspective cutaway view of this joint between the foundation and the
leg and Figure
27 shows a side cutaway view.
[0063] Figure 22 shows a perspective view of joint 1050 between leg 1030
and upper
column 1130. This allows the structure to be built in several stages, allowing
greater height
for additional structures. Joint 1050 also includes a rod 1270 that is
inserted in an aperture in
the bottom of upper column 1130. The top of leg 1030 includes inner rod 1236
which is the
outer bound of a volume filled with grout. Inner rod is precast within the
upper portion of leg
1030. The grout enters the volume through grout entry 1237 and excess grout
exits through
grout outlet 1238. Each face of leg 1030 includes a passage 1282 through which
a bolt 1280
passes. These bolts are used to plumb the leg 1030 and upper column 1120 as
noted
hereinafter. Figure 23 shows a perspective cutaway view of this joint between
the leg and the
upper column and Figure 28 shows a side cutaway view.
[0064] Figures 24A, 24B, and 25 are cross sectional views taken of the
structure shown in
Figures 20-23. Figure 25 also shows lugs 1250 welded to rod 1236 near the
lower end of rod
1236.
[0065] Figures 26A-E illustrate one method of making joint 1025 (joint 1050
is made in a
similar manner). First, foundation 1020 is placed with aperture 1021 therein,
as shown in
Figure 26A. Rod 1270 is placed within aperture 1021 and grout 1300 is placed
surrounding
the rod 1270, as shown in Figure 26B. Figure 26C shows that bearing plate 1290
is placed
over the grout to maintain the grout in the desired configuration. Figure 26D
shows leg 1030
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being placed over rod 1270. Figure 26E shows that bolts 1280 may then be
tightened into
passages 1282 to contact the rod 1270 to change the angle of the leg 1030 with
respect to
foundation 1020. This allows the leg 1030 to be quickly and easily plumbed
with respect to
foundation 1020. Finally, grout is pumped through grout entry 1237 to fill the
empty volume
within leg 1030 to solidify the joint.
[0066] Accordingly, pipe racks that are impervious to fire may be
constructed with less
labor and more adjustability, reducing cost and improving performance.
Therefore, a
substantial cost savings may be gained by using the present method and
apparatus for
constructing pipe racks.
[0067] The present written description uses examples to disclose the
present subject
matter, including the best mode, and also to enable any person skilled in the
art to practice the
present subject matter, including making and using any devices or systems and
performing any
incorporated and/or associated methods. While the present subject matter has
been described
in detail with respect to specific embodiments thereof, it will be appreciated
that those skilled
in the art, upon attaining an understanding of the foregoing may readily
produce alterations to,
variations of, and equivalents to such embodiments. Accordingly, the scope of
the present
disclosure is by way of example rather than by way of limitation, and the
subject disclosure
does not preclude inclusion of such modifications, variations and/or additions
to the present
subject matter as would be readily apparent to one of ordinary skill in the
art.
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