DESIGN AND ANALYSIS

3.1 P & ID
Base on DB listing that we got from client (OTI), so we design for Piping & Instrument Diagram
(P&ID) for final project and got approval from OTI ( Mr.Eko) as show below

Second Stage Separator

Crude OIL

P&ID Explanation

The second stage separator is quite similar to the first stage HP separator. In addition to output
from the first stage, it will also receive production from wells connected to the Low Pressure manifold,
and second stage separator there are of three stages of separation: Gas, Crude Oil and Water.
This case we focus to explain flow of crude oil from second stage separator to third stage separator.
Below is explanation about equipment selection.

Spactacle blind is a safety device used toisolate a section of line or piece of equipment when the
line or equipment need to be inspected or removed from service
Control Valve is used to control regulation flow, velocity pressure drop, and pressure, on Control
valve we set Fail Open (FO)
Between Control Valve we apply consectric reducer to get exact velocity while vavoration
happen, so piping downsteam control valve used to bigger than upstream
Before and after Control valve we apply gate valve and one drain for maintenance necessity.
Gate valve is used as on-off valve when the process is not operation mode, and for maintenance
Control Valve. After two gave valv close they can do draining and take out control valve
Reducer Tee is used for join pipe system of Line 205-A1-CO-4 to Line 205-A1-CO-3
3.2 Piping calculation per ASME B31.3
Calculate thickness of pipe, base on ASME B31.3, about piping process. Code wich we are using
2008 edition, the purpose it to easier and standardize perception. In ASME B31.3 page 20 para 304.1.1
mentioned formula to pressure design thickness of pipe. Basicly this formula common to use to
determine thickness or schedule of pipe.
PRESSURE DESIGN OF COMPONENTS
Straight Pipe

Straight Pipe Under Internal Pressure

 Values of Coefficient Y for t < D/6

Below is parameter we got from client (OTI)

Pipe : 100-LINE-CO-A1A-B1 & 100-LINE-CO-A1A-B2

Desing Pressure : 140 Psi
Desing Temprature : 80 C
Pipe NPS : 4 & 3
Material : API 5l Gr. B
Corrosion Allowance : 3 mm
Allowable stress : 20 Ksi
Mill Tolerance : 12.5%
From the calculations above, we got value (0.4) which is a coefficient from table 304.1.1.
This figure is obtained from the table below.

A. 4 Inch Pipe Thickness Calculation

pd
=
2( + )

140(4.500)
=
2(20000 (1) (1) + 140 (0.4)

630
=
2(20000 + 56)

630
=
40112

= 0.0157 Inch
 tm = t+ c

= 0.0157 +0.1181

= 0.13381 Inch

0.13381
1 =
1 0.125

0.13381
= = 0.1533 Inch = 3.88
0.875

From this value we got schedule of pipe is standard

B. 3 Inch Pipe Thickness Calculation

pd
t=
2(SEW + PY)

140(3.500)
=
2(20000 (1) (1) + 140 (0.4)

3045
=
2(20000 + 56)

3045
=
40112

= 0.0122 inch

tm = t+ c = 0.0122 + 0.1181 = 0.1303 inch

0.1303
1 =
1 0.125

0.1303
t1 = = 0.1490 Inch = 3.78 mm
0.875

From this value we got schedule of pipe is standard

3.3 Material Selection
ASME pressure classification system meets the needs of industry by providing quantitative
performance standards for a wide range of piping components, based upon a manageable number of
operational variables. This system defines predetermined pressure-temperature ratings that
components are designed to meet.

3.3.1 Straight Pipe

To determine type of pipe to use we have to know type fluid that flow in pipe, NPS, Operating
pressure, operating temperature. In this project we got information from owner (OTI) that fluid is crude
oil in case H2S removed already. Below is detail information:
Fluid service : Crude oil (H2S removed)
Operating Pressure : 3-5 MPa, we take aprroximatly 4Mpa
Operating temperature : 4-70 C
NPS main pipe : 4
From this information we determine type of pipe Category normal is Carbon steel ASTM A53 Br.
B SMLSS

3.3.2 Flange Rating

A number of differentASME standards for piping components provide pressure temperature ratings.
The standards in current use in the piping industry are listed in the section Referen Codes and
Standards. In this section the pressure classification system in ASME B16.5, Pipe Flanges and Flanged
Fittings,1 will be used for illustration. However, the concepts covered are generally applicable to all the
ASME pressure-integrity standards.
In practice, the use of ASME B16.5 to determine a flange rating is quite simple.The procedure is
outlined below:
1. Determine the maximum operating pressure and temperature for the required flange.
In this case we determine pressure 870 Psi (6Mpa) under 194F
2. Select a flange material and therefore a material group from one of the 34 listed material groups.
Be aware that some of the qualifying notes concerning maximum operating temperatures for
various materials may influence the final material selection.
In this case material pipe is A53, this kind include in group1.1, see red rectangle in Table 3-2.
 Table 3-2 List Material Specification

3. Enter the appropriate material group table at the increment of temperature listed which is higher
than the desired maximum operating temperature. Start with the Class 150 column and proceed
to the right until a pressure rating for the desired temperature is found which equals or exceeds
the required operating pressure. The column in which this condition is satisfied dictates the
required pressure class and specifies the actual pressure-temperature rating of the flange.
In this case set parameter temperature is 200F (closed to 197F in actual), see red rectangle on
figure below, it is specify in class 400
 Table 3-3 Pressure temperature rating group 1.1

Actually we only need flange in rating 400, but because of availability in the market is very
difficult to find, for safety factor we use flange with rating above, so in this case we decide flange rating
is 600

3.3.3 Fitting
Pipe is connected by Butt weld fitting, so for all dimension for fittings we refer to ASME 16.9. This
Standard covers overall dimensions, tolerances, ratings, testing, and markings for factory-made wrought
buttwelding fittings in sizes NPS 12 through NPS 48 (DN 15 through DN 1200).

Material standards as applicable to butt welded fittings are as follows:

ASTM A234:
This specification covers wrought carbon steel & alloy steel fittings of seamless and welded
construction. Unless seamless or welded construction is specified in order, either may be furnished at
the option of the supplier. All welded construction fittings as per this standard are supplied with 100%
radiography. Under ASTM A234, several grades are available depending upon chemical composition.
Selection would depend upon pipe material connected to these fittings.
Some of the grades available under this specification and corresponding connected pipe material
specification are listed below:

ASTM A403:
This specification covers two general classes, WP & CR, of wrought austenitic stainless steel fittings of
seamless and welded construction.
Class WP fittings are manufactured to the requirements of ASME B16.9 & ASME B16.28 and are
subdivided into three subclasses as follows:
WP S Manufactured from seamless product by a seamless method of manufacture.
WP W these fittings contain welds and all welds made by the fitting manufacturer including starting
pipe weld if the pipe was welded with the addition of filler material are radiographed. However no
radiography is done for the starting pipe weld if the pipe was welded without the addition of filler
material.
WP-WX these fittings contain welds and all welds whether made by the fitting manufacturer or by the
starting material manufacturer are radiographed.
Class CR fittings are manufactured to the requirements of MSS-SP-43 and do not require non-destructive
examination.

Under ASTM A403 several grades are available depending upon chemical composition. Selection would
depend upon pipe material connected to these fittings. Some of the grades available under this
specification and corresponding connected pipe material specification are listed below:
ASTM A420:

This specification covers wrought carbon steel and alloy steel fittings of seamless & welded
construction intended for use at low temperatures. It covers four grades WPL6, WPL9, WPL3 & WPL8
depending upon chemical composition. Fittings WPL6 are impact tested at temp 50 C, WPL9 at -
75 C, WPL3 at -100 C and WPL8 at -195 C temperature.

The allowable pressure ratings for fittings may be calculated as for straight seamless pipe in
accordance with the rules established in the applicable section of ASME B31.3.

The pipe wall thickness and material type shall be that with which the fittings have been ordered to
be used, their identity on the fittings is in lieu of pressure rating markings.

Conclusion: From this explanation so for material fitting we select to ASTM A234 WPB accordance to
main pipe ASTM A53, and for dimensional under ASME B16.9

3.3.4 Bolts and Nuts

For Bolts we refer to code: ASME B18.2.1 ASTM A193 B7-HH with size - 1 . This specification
is heavily utilized in petroleum and chemical construction applications and covers alloy steel and
stainless steel bolting materials for high temperature or high pressure service.

Table 3-4 Dimension of square bolts

For Nutts we refer to code: ASME B18.2.2 ASTM A194 2H-HH with size - 1 . This specification
is heavily utilized in petroleum and chemical construction applications and covers alloy steel and
stainless steel bolting materials for high temperature or high pressure service.

Table 3-5 Dimension of square nuts

From material selection we summarize in piping class NPS 3 and NPS 4, below is the tables
3.4 3D Model/ PDMS Model

Pipe Routing Explaination:

Bypass is used for maintenance necessity without having to stop the process
Elevation 30 cm of the ground to protect pipe from corrosion
Elbow 450 is used to avoid of pipe clash
Control Valve type Globe is used because of its ability to regulate flow

3.5 Isometric Drawing

From 3D modelling pipe routing Discharge Pump to Separator System approved then we created
Isometric Drawing using PDMS software and we berak spool to be Eight (8) pipe spool. Break spool of
Shop Weld and Field Weld, the purpose for easy to fabrication, assembly and erection in the site. For
Isometric Drawing Discharge Pump System and break spool we can shown below:

3.6 Stress Analysis

3.6.1 Purpose

Purpose for the analysis is to check wether the design is:

Pass code compliance regarding stress for:

Hydro Test

Sustain load

Expansion load

Flange leakage is pass by using Pressure equivalent method

Load on the pump nozzle is still below allowable stress as API 610 standard
Load on Separator nozzle is still below allowable stress as ASME VIII Div 1 or 2

3.6.2 Data Input

3.6.2.1 Material

Material used for this model is based on piping class data. Some data for weight is taken from Pipe Data
Pro 7.2.

3.6.2.2 Dimension

Dimension si based on Pipe Isometric that is derived from PDMS model. Regarding some data
for PDMS model is not valid, there are some data taken from Pipe Data Pro 7.2 for the dimension.

3.6.2.3 Condition

Data for temperature and pressure are as below:

Design Temperature : 80 C

Operating Temperature : 60 C

Ambient Temperature : 21 C

Design Pressure : 1 bar

Wind and earthquake : ignored

Because of there are some combination of design, operating and ambient temperature, that
also effect the pump displacement, composed some scenarios as below: