Optimum Design of Steel Pipe Racks SURESH C. ARYA, EDWARD G.

FENG AND GEORGE PINCUSThe availability of useroriented computer programs has hadgreat impact on engineering analysis and design of structuralsystems. This computational tool can be useful not only toobtain fast and accurate values of forces and displacementsin structural systems, but its usefulness has been extended to the economical (minimum weight) design of structural steelmembers and frames. The design phase can be made veryefficient by following an optimization process when suitablecomputer programs are available. The optimization processmay include a number of design constraints, such as: (a) attainment of overall minimum weight, (b) limiting theselection process to a given range of member sizes, and (c)limiting displacements to certain tolerable values.Current engineering practice often utilizes the capabilityof the computer for the analysis phase only, and considers thesubsequent design process a professional art to be left to thediscretion of the "Design Engineer." There are reasons forthis distinction between analysis and design. For example,the application of a design code requires experience andjudgement, the selection of member sizes should be practical, and there is usually a match among the selected membersizes. However, some computer programs available today areso versatile that they not only include code design criteria asbuilt-in algorithms, but in addition the input procedure isrelatively simple and easy to learn and apply. In fact, manyengineers are able to understand the computer code in theirfirst encounter with a coded problem even if lacking in priorcomputer experience. One user-designed computer programwhich has achieved this capability is the MIT-developedIntegrated Civil Engineering System, Structural DesignLanguage (ICES, STRUDLII). 1,2 This program is available tothe professional and is marketed by many commercialcomputer service bureaus.This paper describes the use of the STRUDL II computerprogram for the optimum design of a steel pipe rack structure commonly used in petrochemical plants. The Suresh C. Arya is Principal Design Engineer, CE Lummus Company, H o u s t o n , T e x . Edward G. Feng is Senior Design Engineer, CE Lummus Company, H o u s t o n , T e x . George Pincus is Professor and Chairman, Department of CivilEngineering, University of Houston, Houston, Tex. procedure leads to substantial weight (and cost) savings inmost situations. Considering the tonnage of steel used inpetrochemical plant pipe racks, the savings potential may betruly remarkable. STRUCTURAL SYSTEMPIPE RACK A two-dimensional frame representing a pipe rack structureis shown in Fig. 1. Even though the example presented here istwo-dimensional, most designers will consider three-dimensional action due to forces acting perpendicular to theplane of the pipe rack (temperature expansion andcontraction or longitudinal wind and/or earthquake). Forsimplicity, the example considers plane frame action. Manytypical racks will not include all the support conditions shown in this example and will, therefore, be much simpler todesign. The frame includes three levels of beams, and eachbeam has a cantilever overhang at one end. One column isextended upwards to function as a "tee" support for pipes at ahigher elevation. The lower level beam has its ends fixed(moment connection) to the columns. The intermediate levelbeam has one end hinged and the other end is allowed to slidehorizontally to provide for possible expansion (connection tothe column is through slotted holes). The upper level beam iscontinuous over the column and becomes a cantileveroverhang on one end, and is allowed to slide at the other end.The bases of the columns are considered fixed. The frame hasa 22-ft span and an overall height of 32 ft. The frames arespaced at 25 ft and are connected to adjacent frames byhorizontal longitudinal beams at each cross-beam level.These frames are restrained in the longitudinal direction byvertical cross-bracing which is usually placed at a spacing of about 100 ft or at each fourth bay. Only the inplane designof the pipe rack is considered here, although three- dimensional action can be included with minimal additionaleffort.The loads that act on the frame

are shown in Fig. 2.Three independent loadings are considered for design purposes.

Fig. 1. Typical pipe rack steel frame (computer model input ) The loadings corresponding to permanent loads,wind, and temperature changes are shown in Figs. 2a through2c. Temperature change is only considered on the lower levelbeam, since the upper level beams are free to expand orcontract longitudinally. Design loading combinations areindicated in Figs. 3a through 3d. Out-of-plane loadings, suchas longitudinal expansion and contraction forces andlongitudinal wind/earthquake loads, could be considered asadditional loading conditions. Initial sizes for the membersare selected through manual analytical procedures or thesizes might be assumed. These member sizes are then used asinitial trial sizes in the design optimization process and areindicated in Fig. 1. The selection of member sizes can also bearbitrary, as noted above. Regardless of what initial sizes areused, subsequent program iterations will converge to the s a m e final design selection. However, the exact number of iterations will vary, depending on how close the initial trialsizes are to the final computerdesigned sizes. Fig. 2. Basic loading conditions

Fig. 2. Basic loading conditions

DESIGN PROCEDURE Analysis and design optimization are accomplished by thecomputer program during the following steps (see Fig. 4 forprogram flow chart):1. Analysis of the frame for the given loadingconditions, and combining the results for the designphase.2. Trial members are checked against the provisions of the AISC Specification for strength adequacy for allloading conditions.3. Member sizes are selected by the computer programalgorithm without applying any constraint condition.The AISC Specification is used.4. The member sizes selected in step 3 are used toperform a new stiffness analysis, and again membersizes are selected by the computer programalgorithm. This step serves the purpose of optimization without applying any constraintcondition, i.e., the difference of weights between step3 and step 4 will be negligible.5.

Size of members which are continuous are madeequal for practical reasons; for example, a column is a continuous member of uniform size.6. Constraint conditions regarding a given range of member dimensions are applied, and a new set of member sizes is obtained using the AISCSpecification for all design loading conditions.Subsequently, step 5 is repeated to arrive at practicalmember sizes.7. Using the new member sizes selected in step 6, theframe is reanalyzed for all loading conditions. Usingthese new design forces, the member sizes are againselected such that the limiting deflection constraintcondition (which is applied at specific controllingpoints of the frame) is satisfied. This deflectionconstraint condition is in addition to the previousconstraint condition listed under step 6. Step 5 isagain repeated to arrive at practical member sizes.8. The member sizes obtained from the previous stepare used once more to reanalyze the frame and as a Fig. 3. Loading combinations 86ENGINEERING JOURNAL / AMERICAN INSTITUTE OF STEEL CONSTRUCTION 2003 by American Institute of Steel Construction, Inc. All rights reserved. This publication or any part thereof must not be reproduced in any form without the written permission of the publisher. final AISC Specification check. This step assuresthat the member forces obtained from the lateststiffness analysis have not changed significantly,which would require a further change in member s i z e s . 9. Finally, the member force, the reactions at thesupports, and the deflection of the frame aretabulated for subsequent design. These results arenormally required for the design of the connections,including the column base details and thefoundations, and also to further assure that therequired deflection limitations have been achieved. Summarizing the previous nine steps for the optimum designprocess:Steps 1-5 accomplish minimum weight design.Step 6 accomplishes minimum weight design with aconstraint condition on desirable dimensions (width anddepths) of members. Step 7 accomplishes minimum weight design withconstraint conditions on member dimensions and limitingdeflection criteria.Steps 8-9 document the results of steps 1-2. COMPUTER MODELING Computer modeling is a technique of frame idealization such that computer coding may be conveniently applied. Thefollowing steps are followed in coding a steel pipe rack forSTRUDL-II computer processing:1. The frame is described by a single line diagramshowing the proper end conditions, as given in Fig. 1.2. The location of the joints is selected. The joints arelocated at: (a) the support points, (b) the free end of members, (c) the intersection of beams and columns,and (d) the mid-points of beams. Joints may also be Fig. 4. Computer program input/output flow chart. ( Note: Broken lines indicate optional flow path ) 87THIRD QUARTER / 1979 2003 by American Institute of Steel Construction, Inc. All rights reserved. This publication or any part thereof must not be reproduced in any form without the written permission of the publisher. established at any other points where knowledge of displacements and forces is desired. Any joint(usually the left bottom support) is selected as theorigin and X (horizontal) and Y (vertical) global axesare indicated as shown in Fig. 1. The global Z - a x i s i s perpendicular to the frame. The coordinates of eachjoint from the origin are then computed. Joints arenumbered in ascending order such that the differencein numbering between joints at the two ends of amember is as

small as possible. For pipe racks, thejoint numbering scheme is not as critical as in astructure with many joints and, therefore, may be a r b i t r a r y . 3. A member always exists between two joints. Thesemembers are numbered in sequential order and areindicated within a circle in Fig. 1 in order to createdifferentiation between joint and member numbers.4. The loading conditions are shown in Fig. 2. Loads which may act independently are indicated onseparate sketches, e.g., as shown in Figs. 2a through 2c. Combined loadings formed from the factored sumof independent loadings are shown in Figs. 3athrough 3d. INPUT TO COMPUTER PROGRAMEXAMPLE Input data is taken from Figs. 1 through 3. The data isentered in groups in certain sequential logical order. Thisprocedure is described below using the example problem.A typical pipe rack frame which is used in thepetrochemical industry is shown in Fig. 1, and the basic anddesign loadings are shown in Figs. 2 and 3, respectively. Aconstraint condition on deflection is selected, i.e., themaximum vertical deflection in the beams at joints 4, 9, and15 should not exceed 1.0 in. and the lateral displacement of the frame at joint 3 is limited to 0.75 in. The input data iscoded on 80 column sheets, and a free format procedure maybe followed, i.e., data may be coded in any column and extraspaces between data are ignored. Each command statement orline of data should occupy a single line. There are nine setsof data, A through I, which are required to code and solvethis problem, and these are illustrated in Tables 1-9. Thesedata sets must be preceded by a command STRUDL, whichactivates the computer program stored in the system. The command statements and the input data which are keypunched on computer cards are shown on the left side of Tables 1 through 9 in capital letters. Explanation for each command is given on the right Table 1. Coordinates of Frame Geometry I n p u t D a t a S e t ' A ' E x p l a n a t i o n U N I T F E E T I n d i c a t e s l e n g t h u n i t s T Y P E P L A N E F R A M E I n d i c a t e s s t r u c t u r e t y p e JOINT C O O R D I N A T E S 120.22.0.0.S U P P O R T S U P P O R T D e s c r i b e s t h e g e o m e t r y o f theframe and points where designinformation is desired. 3 0 . 1 8 . 4 1 1 . 1 8 . 5 2 2 . 1 8 . 6 2 7 . 5 1 8 7 4 . 0 2 2 . 8 0 . 2 2 . 9 1 1 . 2 2 . 1 0 2 2 . 2 2 . 1 1 5 . 5 2 6 . 1 2 0 . 2 6 . 1 3 1 1 . 2 6 . 1 4 2 2 . 2 6 . 1 5 2 2 . 3 2 . Y-coordinate (Z-coordinate automatically set to zero)XcoordinateJoint Number 88ENGINEERING JOURNAL / AMERICAN INSTITUTE OF STEEL CONSTRUCTION 2003 by American Institute of Steel Construction, Inc. All rights reserved. This publication or any part thereof must not be reproduced in any form without the written permission of the publisher. Table 2. Connectivity of Structure Topology I n p u t D a t a S e t ' B ' E x p l a n a t i o n M E M B E R I N C I D E N C E S I n d i c a t e s c o n n e c t i o n o f m e m b e r between joints1 1 32 3 83 8 1 2 4 2 55 5 1 0 6 1 0 1 4 7 1 4 1 5 83 49 4 51 0 5 6 1 1 7 8 1 2 8 9 1 3 9 1 0 1 4 1 1 1 2 1 5 1 2 1 3 1 6 1 3 1 4 End joint number (End joint is always further awayfrom origin than start joint)Start joint numberMember number Table 3. Member Releases, Properties and Elastic Constants

I n p u t D a t a S e t ' C ' E x p l a n a t i o n M E M B E R R E L E A S E S R e l e a s e t h e e n d s o f m e m b e r t o m o d e l t h e d e s i r e d b o u n d a r y conditions.3 1 3 1 6 E N D M O M E N T Z M a k e s t h e f a r e n d o f m e m b e r s 3 , 1 3 a n d 1 6 h i n g e d . 1 2 S T A R T M O M E N T Z M a k e s t h e n e a r e n d o f m e m b e r 1 2 h i n g e d . 1 3 1 6 E N D F O R C E X M a k e s t h e f a r e n d o f m e m b e r s 1 3 a n d 1 6 f r e e t o m o v e horizontally (slotted).U N I T K I P S I N C H E S M E M B E R P R O P E R T I E S T h e s e c t i o n p r o p e r t i e s o f m e m b e r s f o l l o w . 1 T O 7 T A B L E ' S T E E L W ' ' W 8 X 2 8 ' S t r u c t u r a l s h a p e s a s s u m e d f o r m e m b e r s a s n o t e d , e . g . , 1 through 7 are W8X28.8 9 12 13 14 15 16 TABLE 'STEELW' 'W10X29'1 0 1 1 TABLE 'STEELW' 'W8X15'C O N S T A N T S E 2 9 0 0 0 . A L L M a t e r i a l m o d u l u s o f e l a s t i c i t y . C T E . 0 0 0 0 0 6 5 A L L C o e f f i c i e n t o f t h e r m a l e x p a n s i o n . B E T A 0 . A L L O r i e n t a t i o n o f m e m b e r s e c t i o n , i . e . , l o c a l m e m b e r s t r o n g axis is parallel to the global Z-axis.U N I T S I N POUNDSCONSTANTD E N S I T Y . 2 8 4 A L L W e i g h t d e n s i t y o f m a t e r i a l . 89THIRD QUARTER / 1979 2003 by American Institute of Steel Construction, Inc. All rights reserved. This publication or any part thereof must not be reproduced in any form without the written permission of the publisher. Table 4. Basic Loadings and Combinations I n p u t D a t a S e t ' D ' E x p l a n a t i o n UNITS KIPS FEET FAHRENHEITLOADING 'DED+LIVE' 'PERMANENT LOADS (DEAD+MAX LIVE)' Describes loading condition due to permanent loads.D E A D L O A D W I T H M O M E N T S Y - 1 . 0 M e m b e r d e a d l o a d i n c l u d i n g f i x e d e n d m o m e n t s . JOINT LOADS1 3 F O R C E Y - 3 . C o n c e n t r a t e d l o a d s a n d m o m e n t s a c t i n g a t j o i n t s , e . g . , a force of 3 kips at joint 13 acting down. 1 5 F O R C E Y -2. MOMENT Z 4.M E M B E R L O A D S L o a d s a c t i n g o v e r t h e l e n g t h o f t h e m e m b e r . 8 9 F O R Y U N I F O R M W - . 7 5 U n i f o r m l o a d o v e r f u l l l e n g t h o f m e m b e r s 8 a n d 9 o f intensity 0.75 kips/ft.1 1 F O R Y U N I F O R M W - . 4 L A 0 . L B 3 . 0 U n i f o r m l o a d o v e r p a r t i a l l e n g t h i . e . , f r o m s t a r t t o 3 f e e t from start.1 4 F O R Y L I N E A R W A - . 2 W B 0 . 6 L A 0 . L B 4 . 5 L i n e a r l y v a r y i n g l o a d o v e r p a r t i a l l e n g t h w i t h i n i t i a l intensity .2 kips/ft. at start to .6 kips/ft. 4.5 ft. from startacting downward (negative ydirection).1 0 F O R Y C O N C E N T R A T E D P - 2 . 0 L 4 . 0 C o n c e n t r a t e d l o a d a p p l i e d a t a d i s t a n c e f r o m s t a r t , e . g . , 2 kips on member 10, at 4 ft. from start acting down(negative y-direction). 1 2 1 3 F O R Y C O N

P -5.0 L 5.516 FOR Y CON P -4.0 L 5.016 FOR Y CON P -2.0 L 9.0L O A D I N G ' W I N D ' ' W I N D L O A D L A T E R A L D I R E C T I O N ' Describes another loading condition due to wind.J O I N T L O A D S L o a d s a p p l i e d a t t h e j o i n t s . 1 5 F O R 0 . 6 A f o r c e o f 0 . 6 k i p s i s a c t i n g i n h o r i z o n t a l d i r e c t i o n . o n joint 15.3 8 12 FOR 2.1L O A D I N G ' T E M P * 5 0 F ' ' T E M P VARIATION RISE 50F' Describes another loading condition due to temperature. M E M B E R 8 9 T E M P A X I A L 5 0 A x i a l t e m p e r a t u r e c h a n g e o f 5 0 d e g r e e s F a p p l i e d t o beams 8 and 9.L O A D I N G C O M B ' A ' ' P E R M A N E N T LOADS+WIND' - Combines two basic loading c o n d i t i o n s f o r d e s i g n o f member, i.e., 0.75 'DED+LIVE' plus 0.75 'WIND'.(the end dash indicates continued on next card).C O M B I N E ' D E D + L I V E ' 0 . 7 5 ' W I N D ' . 0 7 5 L O A D I N G C O M B ' B ' 'PERMANENT LOADS+TEMP RISE +50F' - Combines the basic l o a d i n g c o n d i t i o n w i t h t e m p e r a t u r e expansion of 50 degrees F.C O M B I N E ' D E D + L I V E ' 1 . 0 ' T E M P * 5 0 F ' 1 . 0 L O A D I N G C O M B ' C ' 'PERMANENT LOADS+TEMP FALL 50F' - Combines the basic l o a d i n g c o n d i t i o n w i t h t e m p e r a t u r e contraction of 50 degrees F.COMBINE 'DED+LIVE' 1.0 'TEMP*50F' -1.0 L O A D I N G C O M B ' A A ' 'FULL PERMANENT LOADS+WIND' - Combines two basic l o a d i n g c o n d i t i o n s f o r l i m i t i n g deflection constraint condition, i.e., 1.0 'DED+LIVE'p l u s 1 . 0 ' W I N D ' . C O M B I N E ' D E D + L I V E ' 1 . 0 'WIND' 1.0 90ENGINEERING JOURNAL / AMERICAN INSTITUTE OF STEEL CONSTRUCTION 2003 by American Institute of Steel Construction, Inc. All rights reserved. This publication or any part thereof must not be reproduced in any form without the written permission of the publisher. Table 5. Stiffness Analysis and Output Results I n p u t D a t a S e t ' E ' E x p l a n a t i o n PRINT DATA ALL Prints out input data.S T I F F N E S S A N A L Y S I S T h i s c o m m a n d p e r f o r m s s t r u c t u r a l a n a l y s i s o f t h e f r a m e . PLOT PLANE Structure geometry is printed out as a check on the i n p u t . U N I T S K I P S I N C H E S O U T P U T B Y J O I N T LIST DISPLACEMENTS ALL Results are printed out for deflections and rotations of joints. O U T P U T B Y L O A D S LIST FORCES REACTIONS ALL Results are printed out for forces, moments at joints,and reactions at supports. O U T P U T B Y M E M B E R S S E C T I O N F R A C T I O N N S 2 0 . 1 . LIST FORCE ENVELOPE ALL MEMBERS Maximum forces and moments in each member areprinted out. Considers all loading conditions, and twosections on each member, the start and the end.LIST STRESS ENVELOPE ALL MEMBERS Maximum stresses in each member is printed outsimilar to above. side of each table. Each table contains the followinginformation (capital letters are actual commands): Data Set 'A' and 'B' ( Tables 1 and 2 )Information istaken from Fig. 1 and includes a description of the framegeometry and topology. Note that for three-dimensional action, TYPE PLANE FRAME, would become TYPESPACE FRAME and three sets of coordinates ( x,y,z, )would be listed for each joint. Data Set 'C' (

Table 3 )Information on member releases(program assumes all member ends fully fixed, unlessmodified by this command) and member properties aretaken from Fig. 1. The parameters under the commandCONSTANTS are for steel material. The value of BETAis taken as zero, since the web of the sections is in theplane of paper (members are oriented such that bendingis about their strong axis). BETA becomes 90 degreeswhen the web of a member is perpendicular to the planeXY. Data Set 'D' ( Table 4 )Information for loadingconditions is as shown on Fig. 2. Three loadingcombinations 'A', 'B', 'C' are performed following currentdesign practice, and combination 'AA' is formulated tocheck for the limiting deflection criteria. Information onloading combinations is obtained from Fig. 3. Data Set 'E' ( Table 5 )This data set includes commandsfor the listing of the stiffness analysis results. The resultsinclude the forces in the members, displacements of thefree joints, and reactions at the supports for all basic and combined loading conditions. Maximum stress enveloperesults are also printed out for design purposes. Data Set 'F' ( Table 6 )This data set defines theparameters that are required for the design of steelmembers. Effective and unbraced lengths for columns aredefined, but beam and cantilever members are consideredto be totally braced along their compression flange, sincethey are attached to pipes perpendicular to their lengths.A code check on the assumed member sizes is performedfor strength adequacy. Subsequently, member sizes areselected by the computer program for the forcesgenerated by the stiffness analysis of data set 'E'.Another cycle of stiffness analysis is performed using thenew sizes as input for member properties. Then, resultsof the stiffness analysis are used to select new membersizes.The preceding steps accomplish minimum weightoptimization using the computer program withoutapplying any constraint condition. 91THIRD QUARTER / 1979 2003 by American Institute of Steel Construction, Inc. All rights reserved. This publication or any part thereof must not be reproduced in any form without the written permission of the publisher. Table 6. Prescribed Design Parameters, AISC Specification Check andComputer Design I n p u t D a t a S e t ' F 1 ' E x p l a n a t i o n L O A D I N G L I S T ' A ' ' B ' ' C ' ' D E D + L I V E ' D e s i g n l o a d i n g c o n d i t i o n s a r e c o n s i d e r e d . P A R A M E T E R S D e s i g n p a r a m e t e r s a r e p r e s c r i b e d . ' C O D E ' ' S P 6 9 ' A L L A I S C C o d e i s u s e d . ' U N L C F ' 6 6 . 0 8 9 1 2 1 3 1 5 1 6 U n b r a c e d l e n g t h o f m e m b e r c o m p r e s s i o n f l a n g e , i.e., 66 inches for members 8, 9, 12, 13, 15 and 16.' F L Y D ' 3 6 . A L L Y i e l d s t r e n g t h o f m a t e r i a l . ' S E C N D A R Y ' 1 A L L I n d i c a t e s t h a t a l l m e m b e r s a r e p r i m a r y m e m b e r s . ' P R I D T A ' 1

A L L N o d i a g n o s t i c o u t p u t i s d e s i r e d . ' K Z ' 1 . 2 M E M 1 4 E f f e c t i v e l e n g t h f a c t o r f o r c o l u m n s i n l o c a l Z - a x i s , i.e., the plane of the frame.' K Z ' 2 . 0 M E M 2 3 5 6 7 ' K Y ' 0 . 8 0 M E M 3 6 7 E f f e c t i v e l e n g t h f a c t o r f o r c o l u m n s i n l o c a l Y a x i s , i.e., perpendicular to the frame. ' K Y ' 0 . 6 5 M E M 1 2 4 5' L Z ' 2 4 0 . 0 M E M 1 4 U n b r a c e d l e n g t h a g a i n s t b u c k l i n g i n l o c a l Z - a x i s , i.e., in the plane of the frame.' L Z ' 9 6 . 0 M E M 7 Input Data Set 'F-2'C H E C K C O D E F O R M E M B E R S 1 t o 1 6 A I S C - C o d e c h e c k i s p e r f o r m e d o n a l l m e m b e r s . Input Data Set 'F-3'S E C T I O N F R N S 2 0 . 1 . M E M 1 t o 1 6 S e c t i o n s a r e s e l e c t e d f o r m e m b e r d e s i g n c o n s i d e r i n g moments and axial forces at both ends.S E L E C T M E M 1 t o 1 6 W I T H ' C O M B I N E D ' A I S C - C o d e a x i a l a n d b e n d i n g f o r c e s i n t e r a c t i v e formulae (axial load and moment) are used. Data Set 'G' (Table 7) The constraint condition on memberdimensions are given in this table. A stiffness analysis isperformed on the member sizes selected in the previous step.Member sizes are reselected for the new member forces,taking into account the constraint conditions. Segments of continuous members may be selected by the computerprogram with different sizes. Thus, segments common to asingle or continuous member are made equal, based on thelargest required moment of inertia for any one segment, sinceflexural stresses control the design process. Data Set 'H' (Table 8) The commands in this data set apply an additional constraint condition on maximum permissibledeflections at certain joints (in the vertical direction at mid-span of the beams and in the horizontal direction at theintersection of the first-level beam and column). First, thestiffness analysis is performed on the frame using themember sizes obtained in the preceding table. Redesign of those members which are affected by the constraint condition is performed by applying the constraint condition of limitingdeflection. Continuous member sizes are rationalized andsection properties are printed. Data Set 'I' (Table 9) The commands in this tablereanalyze the frame for all the loading conditions, a codecheck of the members is performed, and a printout of the finaldeflections at the joints, the support reactions, and themember properties is produced. 92ENGINEERING JOURNAL / AMERICAN INSTITUTE OF STEEL CONSTRUCTION 2003 by American Institute of Steel Construction, Inc. All rights reserved. This publication or any part thereof must not be reproduced in any form without the written permission of the publisher. Table 7. Rationalization of Sizes and Constraint Condition of Member Sizes I n p u t D a t a S e t ' G 1 ' E x p l a n a t i o n TAKE MEM 1 TO 3 AS LAR 'IZ' of MEM 1 to 3 Same section based on maximum m o m e n t o f i n e r t i a i s used on entire length of each column. T A K E MEM 4 TO 7 AS LAR 'IZ' OF MEM 4 TO 7TAKE MEM 14 15 16 AS LAR 'IZ' of MEM 14 15 16 Same section based on maximum m o m e n t o f i n e r t i a i s used on entire length of each beam. T A K E M E M 12 13 AS LAR 'IZ' OF MEM 12 13TAKE MEM 8 9 AS LAR 'IZ' OF MEM 8 9T A K E M E M 1 0 1 1 A S L A R ' I Z ' O F M E M 1 0 1 1 S a m e s e c t i o n i s u s e d f o r n o n c o n t i n u o u s c a n t i l e v e r s based on maximum moment of inertia.P R I N T M E M B E R P R O P A L L

M E M B E R S T a b l e o f m e m b e r s i z e s i s p r i n t e d o u t . S T E E L T A K E O F F S t e e l w e i g h t i s c a l c u l a t e d f o r t h e c u r r e n t sections.Input Data Set 'G-2'M E M B E R C O N S T R A I N T M e m b e r s i z e s c a n b e l i m i t e d t o d e s i r e d r a n g e o f dimensions.1 T O 7 C O N S ' Y D ' G E 7 . 5 C o l u m n l e a s t d e p t h i s i n d i c a t e d , e . g . , m e m b e r s 1 through 7 should be at least 7.5 inches deep. 1 T O 7 C O N S ' Y D ' L E 1 8 . 0 C o l u m n s m a x i m u m d e p t h b e l e s s o r e q u a l t o 1 8 i n c h e s . 1 T O 7 C O N S ' Z D ' G E 5 . 0 C o l u m n f l a n g e l e a s t w i d t h i s i n d i c a t e d , e . g . , m e m b e r s flange width should be equal or greater than 5.0 inches. 1 T O 7 C O N S ' Z D ' L E 1 0 . 0 C o l u m n ' s m a x i m u m f l a n g e w i d t h b e e q u a l o r l e s s t h a n 10 inches.8 9 1 2 1 3 1 5 1 6 C O N S ' Y D ' G E 9 . 5 M i n i m u m b e a m d e p t h o f 9 . 5 i n . o r l e s s i s i n d i c a t e d f o r members 8, 9, 12, 13, 15 and 16.8 9 1 2 1 3 1 5 1 6 C O N S ' Z D ' G E 5 . 0 M a x i m u m b e a m f l a n g e w i d t h o f 5 . 0 i n . o r g r e a t e r i s indicated for members 8, 9, 12, 13, 15 and 16. Table 8. Constraint Condition on Limiting Deflection I n p u t D a t a S e t ' H ' E x p l a n a t i o n L O A D I N G L I S T ' A A ' O n l y l o a d i n g c o m b i n a t i o n f o r w h i c h d e f l e c t i o n constraint condition is prescribed is considered.A D D I T I O N S A d d i t i o n a l d e s i g n p a r a m e t e r a r e d e s c r i b e d . PARAMETER' D E F L E C T N ' 1 3 2 . 0 8 1 2 1 5 D e f l e c t i o n c o n s t r a i n t i s d e s c r i b e d o n b e a m s , e . g . , a maximum d e f l e c t i o n o f L / 1 3 2 i s d e s i r e d , w h i c h i s 1 in.' D E F L E C T N ' 2 8 8 . 0 1 4 D e f l e c t i o n c o n s t r a i n t i s d e s c r i b e d o n c o l u m n s , e . g . , a maximum deflection of L/288 is desired, which is 0 . 7 5 i n . ' L O A D I N G ' ' A A ' 1 4 8 1 2 1 5 L o a d i n g c o n d i t i o n i s a l s o s e l e c t e d . 93THIRD QUARTER / 1979 2003 by American Institute of Steel Construction, Inc. All rights reserved. This publication or any part thereof must not be reproduced in any form without the written permission of the publisher.

Table 9. Stiffness Analysis and Output Results I n p u t D a t a S e t ' I - 1 ' E x p l a n a t i o n L O A D I N G L I S T A L L A l l b a s i c a n d c o m b i n a t i o n l o a d i n g c o n d i t i o n s are considered.S T I F F N E S S A N A L Y S I S Static analysis is performed on previouslyselected sections.LOADING LIST 'A' 'B' 'C' 'AA' 'DED + LIVE'Desired loading conditions are activated.L I S T R E A C T I O N S D I S P A L L R e a c t i o n s a t s u p p o r t s a n d d e f l e c t i o n s a t j o i n t s for the desired loadings are printed out.Input Data Set 'I-2' P R I N T M E M B E R PROPERTIES ALL MEMBERS Final section properties for all m e m b e r s a r e printed out in tabular form.S T E E L T A K E S t e e l w e i g h t f o r t h e f i n a l d e s i g n e d f r a m e i s calculated.F I N I S H

T e r m i n a t i o n o f p r o g r a m . DISCUSSION OF RESULTS A two-dimensional frame of structural steel, commonlycalled "pipe rack" in the petrochemical industry, wasdesigned using the AISC Specification by manualcomputation, and is then compared with optimum sizesobtained by using the computer program STRUDL-II. Thesizes are selected by the computer program initially withoutany constraint condition, and again using constraint conditions on member sizes and on limiting deflections. Thesizes obtained by the above investigation are shown in Fig.5b. Comparing the sizes of Fig. 5a (manually designed) withFig. 5b (designed by the computer program), it may be notedthat the former uses the same section (w828) for bothcolumns, while the latter uses different sections, i.e., w1021and w1430 for the left and right side columns, respectively.This occurs because: (1) a horizontal sliding hingeconnection is used between the two upper-level beams andcolumns, and (2) the right side column projects above the top-level beam. The beams selected by the computer programare lighter but deeper compared to those selected manually.This indicates that the computer program is organized toselect the most economical sections. Comparing the sizes shown in Fig. 5c (designed by the computer program withconstraint condition on member sizes as given in Table 7)with the sizes shown on Fig. 5b (design by the computer withno constraints), it may be noted that, except for the beams atthe two upper levels, all sizes are the same. The two upper-level beam sections w1021, are reduced in depth (from 12to 10 inches), but became slightly heavier (from 19 plf to 21plf). Thus, having a size constraint condition has a mildeffect on the weight, whereas manual vs. computer design hasa strong effect on weight. The sizes shown in Fig. 5d areobtained by the computer program with an additional constraint condition of limiting deflection to a maximumvalue of 1 in. in the vertical direction at mid-span of allbeams and 0.75 in. in the horizontal direction in the columnsat the first-level beam. Thus, the additional design constraintresults in an increase in size of the right side columncompared to the previous design (w1430 to w1434), andindicates that the previous computer designed sizes did not,in fact, meet the limiting deflection criteria in the horizontaldirection. Comparing the deflection results (caused by fulldead, live, and wind loading) corresponding to Figs. 5a and5b and which are plotted in Figs. 6 and 7, respectively, itmay be noted that the horizontal deflection at the lower-levelbeam is 1.60 in. for the manual design and 0.72 in. in thecomputer design. Thus, according to the prescribed limit of 0.75 in., the manual design is unacceptable, but thecomputer-designed sizes adequately meet the establishedcriteria. It should be noted that manual design seldom checksfor maximum tolerable deflection, due to the fact that hand orhandbook formulas or procedures do not provide a simpleway of computing deflections. Concerning the verticaldeflection in the beams, the maximum value is 0.64 in. forthe manual design and 0.94 in. for the computer design, whilethe prescribed limit is 1.0 in. This indicates that the computerprogram selects sizes which approach the limitingrequirements, while manually selected sizes areoverdesigned. Similarly, this is also true in the selectionprocess for the cantilevers. A size of w68 is selected by thecomputer program and a size of w815 is selected by themanual procedure. One fact worth clarifying in these figuresis the difference between respective horizontal deflectionvalues for the right and left side columns at the two upper-level beams. The reason that the right side column does notdeflect as much as the left side column is because the rightcolumn is allowed to slide freely in the horizontal directionwhile the left side column is not free to slide horizontally. 94ENGINEERING JOURNAL / AMERICAN INSTITUTE OF STEEL CONSTRUCTION 2003 by American Institute of Steel Construction, Inc. All rights reserved. This publication or any part thereof must not be reproduced in any form without the written permission of the publisher.

Table 10. Weight OptimizationComparative Results WEIGHT OF STEEL - POUNDSMANUAL DESIGNDESIGN BY COMPUTER PROGRAMD E S C R I P T I O N W I T H O U T C O N S T R A I N T C O N D I T I O N S NOC O N S T R A I N T C O N D I T I O N C O N S T R A I N T O N M E M B E R SIZESC O N S T R A I N T O N M E M B E R SIZESAND DEFLECTIONMEMBER S I Z E S W I T H O U T R A T I O N A L I Z A T I O N -1 s t . C Y C L E = 2 , 4 5 4 2 n d . CYCLE=2,5692 , 8 7 6 3 , 2 3 2 MEMBER SIZESW I T H RATIONALIZATION3 , 8 5 3 3 , 1 1 2 3 , 2 1 5 3 , 3 4 3 PERCENTAGESAVINGS OVERMANUAL DESIGN0 1 9 . 2 1 6 . 6 1 3 . 2 Fig. 5. Design comparison A weight comparison of the four designs in Fig. 5 isgiven in Table 10. The upper row of steel weights is for thecase when different sizes are selected by the computerprogram for different segments of a single continuous mem-ber. However, the size of a segment which has the largest moment of inertia should be selected as a common size forthe remaining segments to achieve a practical design and toreduce fabrication costs. The weight of the members after95THIRD QUARTER / 1979 2003 by American Institute of Steel Construction, Inc. All rights reserved. This publication or any part thereof must not be reproduced in any form without the written permission of the publisher.