PT PETROKIMIA GRESIK

PT. ADHI KARYA

AMMONIA-UREA II PROJECT

(Persero) Tbk

PROJ NO. 201485 REV

201485-20000-PFSL-01
SHEET

CALCULATION

1 OF

11

PIPE STRESS & FLEXIBILITY ANALYSIS OF STEAM LINE

4MS-20201-ED1-H

PT PADI HIJAU BUANA

PROJECT NAME

: AMMONIA UREA II PROJECT

OWNER

: PT. PETROKIMIA GRESIK

CONTRACTOR

: ADHI KARYA

VENDOR NAME

: PT.PADI HIJAU BUANA

PACKAGE NAME

: FILTERED WATER AND DEMINERALIZATION PACKAGE

P.O NO.

: 201485-Z02-RD-PO

VENDOR DOC NO

: PHB-20000-PFSL-01

For Approval

IPA

DJK

DDH

2-12-2016

REV

DESCRIPTION

PREPD

CHKD

APPRD

DATE

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PT. PETROKIMIA GRESIK PROJ.NO
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AMMONIA-UREA II PROJECT
CALCULATION

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TABLE CONTENT
1.

GENERAL................................................................................................................ 3

2.

CODES, STANDARD AND REFERENCES ............................................................. 3

3.

METHODOLOGY ..................................................................................................... 3

4.

DESIGN & OPERATING DATA............................................................................... 4

5.

MODELLING............................................................................................................ 5

6.

ANALYSIS RESULTS .............................................................................................. 8

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PT. PETROKIMIA GRESIK PROJ.NO
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AMMONIA-UREA II PROJECT
CALCULATION

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1. GENERAL
The main objectives of this this document is to analyze strength and flexibility of
steam-line piping 4MS-20201-ED1-H to ensure that the piping system satisfy the
required stress criteria and flexibility defined by code, standard, and company
specification.
2. CODES, STANDARD AND REFERENCES
Code,standard, and other document used as reference associated with this document
are as follow.
1. ASME B 31.3, Process Piping
2. 201485-37000-MC04, Technical Specification of Piping Stress Analysis
3. 201485-0000-MC15, Technical Specificationof Standard Piping Support
3. METHODOLOGY
ASME B31.3 Process Piping code has four loading cases to identify the piping safety.

Load Case Sustained (GR + Max {P})

Sustained Load case is the type of loading which would explain the effect of
weight and pressure of pipe and pipe components. This type of loading has a
maximum allowable strength (maximum allowable

stress).

The

ratio

is

calculated by dividing the pipe actual stress with a maximum allowable

stress.

Load Case Expansion (Amb to T1)

Expansion load case is the type of load that explains the influence of the
temperature difference between the environment and the operating temperature
of fluid in the pipe.

Load Case Occassional (GR + Max {P} + E or W)

Occasional load case is the type of load that explains the influence of the
sustain load case in combined with earth quake load (E) or wind load (W) or
temporary supporting of extra weight.

Load Case Hoop (Max {P})

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Hoop load case is the type of load that explains the influence of the internal
pressure of fluid in pipe.
4. DESIGN & OPERATING DATA
4.1

Pipe Properties Data

Pipe properties data of piping system can be seen in the table below.
Pipe Material

A335-P11 SMLS

Pipe Size

NPS 4 or DN100 mm

Pipe Schedule

SCH 80

Hot Allow. Stress

104.8 MPa

Min. Yield Strength

206.8 MPa

Ultimate Strength

413.7 MPa

Insulation Thickness 100 mm

4.2

Insulation Density

240 kg/m3

Corrosion Allow.

0 mm

Pipe operating data

The operational data of piping system can be seen in the following table.
Pressure (rated)

48 kg/cm2

Temperature (rated)

400 C

Seismic load

0.2 G

Wind load

77 kg/m2

Gresik region includes in Zone 2 of seismic zone of Indonesia, which means potentially
causing an earthquake acceleration up to 0.2 G. Whilst for wind load, according to
ASCE 7, minimum wind load pressure applied into the pipe is 77 kg/m2.

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Drawing Data
In addition of pressure load and temperature in the piping system, there are also
weight of pipe and its contents and piping components such as valves, flanges and
other component in accordance with piping drawings and data (stud bolt, nuts and
gasket).
The reference drawing is as follow :
1.

Piping layout drawing 4MS-20201-ED1-H

5. MODELLING
5.1

Pipe and Support Modelling

Flexibility and stress analysis for piping systems is conducted using Bentley AutoPIPE
software.

Fig. 1 Piping modeling in Autoipe

The piping model consists into 36 segments named with A00 to A36, in order to
easen for identifying the position, dimension, parts, etc. At some points, there are
pipe supports designed and arranged to ensure that there is no excessive deflection
in piping system. The configuration of pipe support is shown as follow.

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PT. PETROKIMIA GRESIK PROJ.NO
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AMMONIA-UREA II PROJECT
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Anchor
Guide

Fig. 2 Piping and support arrangment from A00 to A14

Shoe

Fig. 3 Piping and support arrangment from A15 to A36

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Each supports has specific functions defined as follow.

Anchor: to restrain pipe displacements in any direction.

Guide: to restrain pipe displacements in vertical and lateral direction.

Shoe: to restrain pipe displacements in downwad-vertical direction

Each pipe-support positions is summarized in a table as follow.

Point

Support

A05

Anchor

A08

Anchor

A12

Anchor

A13

Guide

A14

Guide

A15

Guide

A16

Guide

A17

Anchor

A19

Guide

A21

Shoe

A23

Guide

A25

Guide

A27

Guide

A30

Guide

A32

Guide

Based on the code B31.3 Process Piping and defaults of a Autopipe software, the
load combination for further analysis consist in several types as follow.
No
1
2
3
4
5
6
7
8
9
10

Combination
GR + Max P
Amb to T
Max P
Sus. + E1{1}
Sus. + E2{1}
Sus. + E3{1}
Sus. + E4{1}
Sus. + W1{1}
Sus. + W2{1}
GR+P+T+E/W

Load Case
Sustain
Expansion
Hoop
Occasion
Occasion
Occasion
Occasion
Occasion
Occasion
Combined Load

Description

Earth quake E1 = 0.3 g (+X)

Earth quake E2 = 0.3 g (-X)
Earth quake E3 = 0.3 g (+Y)
Earth quake E4 = 0.3 g (-Y)
Wind W1 = 77 kg/m2 global X
Wind W2 = 77 kg/m2 global Y

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6. ANALYSIS RESULTS
6.1

Stress Result
The stress analysis result at steam-line piping system is able to seen at figure as
follow.

0.84

Fig. 4 Piping stress contour

The maximum stress ratio in the piping system is 0.85 due to Expansion load case at
point A26 N. It means the occured stress does not exceed the safety criteria and the
following piping system should be safe while be operated. The summary of maximum
stress occured is presented in Table below.
Maximum
Stress
Due to
Sustain Load

Maximum
Stress
Due to
Expansion
Load

Maximum
Stress Due to
Occasional
Load

Maximum
Hoop Stress

A17

A26 N

A14

A36

Stress (MPa)

25.20

167.04

29.88

34.71

Allowable (MPa)

104.75

198.56

110.09

104.75

0.25

0.84

0.27

0.33

GR + Max P

Ambient to T

Sus + E/W

Max P

Item

Point

Ratio
Load Case

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Displacement Result

Fig. 5 Displacement analysis contour

The displacement analysis for steam-line piping system results a maximum

displacement due to combined loads at point A29 F of 13.73, 6.18, and 13.44
mm of X, Y, and Z axis respectively, as shown at Fig. 5. Since the allowable
displacement shall mot exceed 15 mm, the maximum displacements occuring
still comply the safety requirement. More detailed data could be seen at
Appendix 1.
6.3

Support load
The result of analysis maximum support loads at design condition is shown in Table
below or see detail on appendix.
Direction Force

Value (N)

Point

Load Comb

X Axis

2,577,559

A12

GT1P1E2{1}

Y Axis

-2,818,117

A05

GT1P1E3{1}

Z Axis

-4,723

A05

GT1P1E2{1}

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AMMONIA-UREA II PROJECT
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APPENDIX A
BENTLEY AUTOPIPE REPORT

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4MS-EARLY-MODIF2-COATING
12/02/2016
PTW
BENTLEY
11:01 AM
AutoPIPE Nuclear
9.4.0.19 RESULT PAGE 125
--------------------------------------------------------------------------------------------------------------R E S U L T
S U M M A R Y
----------------------------

Maximum displacements (mm)

--------------------------Maximum X :
Maximum Y :
Maximum Z :
Max. total:

14.05
14.77
13.60
20.19

Point
Point
Point
Point

:
:
:
:

A29
A31
A03
A03

F
N
N
N

Load
Load
Load
Load

Comb.:
Comb.:
Comb.:
Comb.:

Thermal 1{1}
GT1P1E3{1}
Thermal 1{1}
GT1P1E1{1}

-0.53
-0.51
-1.03
1.03

Point
Point
Point
Point

:
:
:
:

A28 F
A28 N
A21
A21

Load
Load
Load
Load

Comb.:
Comb.:
Comb.:
Comb.:

GT1P1E2{1}
Thermal 1{1}
GT1P1E4{1}
GT1P1E4{1}

Point
Point
Point
Point

:
:
:
:

A12
A08
A05
A08

Load
Load
Load
Load

Comb.:
Comb.:
Comb.:
Comb.:

GT1P1E2{1}
GT1P1E4{1}
GT1P1E2{1}
GT1P1E4{1}

2965
-4192
-6059
6065

Point
Point
Point
Point

:
:
:
:

A08
A00
A17
A17

Load
Load
Load
Load

Comb.:
Comb.:
Comb.:
Comb.:

GT1P1E3{1}
Thermal 1{1}
GT1P1E3{1}
GT1P1E3{1}

2577559
-2818117
-4723
2818117

Point
Point
Point
Point

:
:
:
:

A12
A05
A05
A05

Load
Load
Load
Load

Comb.:
Comb.:
Comb.:
Comb.:

GT1P1E2{1}
GT1P1E3{1}
GT1P1E2{1}
GT1P1E3{1}

Point
Point
Point
Point

:
:
:
:

A29 F
A00
A20 N
A20 N

Load Comb.: GT1P1E3{1}

Load Comb.: Thermal 1{1}
Load Comb.: GT1P1E4{1}
Load Comb.: GT1P1E4{1}

Maximum rotations (deg)

----------------------Maximum X :
Maximum Y :
Maximum Z :
Max. total:

Maximum restraint forces (N )

-----------------------------Maximum X :
Maximum Y :
Maximum Z :
Max. total:

-2574474
-2817594
-6085
2817598

Maximum restraint moments (N.m )

---------------------------------Maximum X :
Maximum Y :
Maximum Z :
Max. total:
Maximum pipe forces (N )
------------------------Maximum X :
Maximum Y :
Maximum Z :
Max. total:

Maximum pipe moments (N.m )

----------------------------Maximum X :
Maximum Y :
Maximum Z :
Max. total:

-3807
4192
10512
10514