Proceedings of National Conference on Piping Engineering and Its Application
Program Studi D4 Teknik Perpipaan - Politeknik Perkapalan Negeri Surabaya
Perancangan Instalasi Air Bersih Pada Gedung VVIP
The importance of piping systems in building construction cannot be ignored. Correct installation of piping will secure and maintain a healthy environment in your residence or workplace. This research aims to design a clean and dirty water piping system in the VVIP building. The design of the piping system refers to SNI 8153:2015 concerning Piping Systems in Buildings. Meeting clean water needs is planned to use water from underground tanks and use pumps to distribute clean water. The calculation result of the average water requirement in the VVIP building is 200 liters/minute. A groundwater tank with a capacity of 40,000 liters of clean water is required. The pump power required is 5.7 kW. The types of pipes planned for the clean water piping system used are High Density Polyethylene (HDPE) pipes and PVC pipes for dirty water with a total planned material cost budget of IDR 126,472,414.00.
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Redesain Jalur Pipa Hydrocarbon Gas dari Slug Catcher Menuju Pressure Safety Valve pada Proyek LNG di Sulawesi
The demand for energy increases along with economic growth, population, energy prices, and government policies. To address the growing global energy demand, particularly for LNG, a Joint Operating Body (JOB) of oil and gas company and energy company plans to develop a gas plant facility on the onshore Sulawesi, Indonesia. The main focus of this project is the analysis of the 8”HG-0556-6R pipeline, which is under overstress due to the reaction force from the pressure safety valve. The research methods include calculating the allowable pipe span, stress analysis using software, and redesigning the pipeline according to ASME B31.3 standards. The research finding indicate a 55.6% reduction in flexibility value after redesign, from 0.0074208 to 0.0032925. The highest stress value due to sustain, occasional and expansion loads also decreased significantly, with a decrease ratio of 8.6%, 153.3%, and 80.7%, respectively. As the result, the redesigned pipe effectively reduces the stress value and optimizes the pipe, enhancing its safety.
Perhitungan Head Pump Jalur Perpipaan Diesel Fuel dari Tangki Timbun menuju Stasiun Pengisian
The development of facilities within mining areas is crucial for enhancing production capabilities. A key aspect of this development is the construction of fuel facilities, with a particular focus on pipeline design. This research addresses the challenges posed by the area's topography, existing infrastructure, and road crossings. The primary objectives are to design an efficient pipeline system and determine the appropriate pump specifications. The study employs the Darcy-Weisbach theory to calculate head loss, complemented by simulations using Pipe Flow Expert software. The results indicate a total pipeline head loss of 45.79 meters, with a software error margin of 1.16%. The total head for the pump is calculated at 70.34 meters. Future research should explore different software and the operational dynamics of a dual-pump system.
Re-Desain Penambahan Expansion Loop pada Pipa Proses Distribusi Steam Low Pressure di Perusahaan Serat Kain
A textile fiber production company located in Purwakarta, West Java, experienced issues with a 206-meter-long, 8-inch diameter pipeline (540-3-206-023-200-0150ABD12-H) that transports low-pressure steam at 152°C. A displacement of 80 mm was observed in the support structure, which exceeded the contractor-specified displacement tolerance of +/- 60 mm. This issue prompted a redesign involving stress and displacement calculations using Pipe Stress Analysis software. The redesign introduced horizontal and vertical expansion loops. Analysis revealed that the horizontal loop design resulted in maximum sustained load stress of 2881.9 psi and thermal load stress of 13780.2 psi, while the vertical loop design produced maximum sustained load stress of 4130.7 psi and thermal load stress of 15257.5 psi. Both designs maintained stress levels within the permissible limits of ASME B31.1, ensuring system safety. The horizontal loop design exhibited a displacement of 12.358 mm, whereas the vertical loop showed 18.705 mm.
Perancangan Sistem Perpipaan Pemadam Kebakaran Pada Pabrik Kain Menggunakan Carbon Dioxide Extinguishing System
The fabric factory construction project in Purwakarta Regency is part of the factory's expansion. Currently, the factory does not have an effective fire extinguishing system and is only equipped with portable fire extinguishers. CO2 extinguishers were chosen because of their effectiveness against class B and C fires. The design process requires the calculation of CO2 requirements, flow rates in the system, 3D and isometric designs that are based on NFPA 12 and FIKE. Based on the calculations carried out, the total CO2 extinguishing media requirement is 29,831.9 kg. Based on the calculation, the CO2 flow rate value for each elevation is as follows: 0 m elevation of 2088.76 kg CO2/minute, 8 m elevation of 1566.57 kg CO2/minute, 14 m elevation of 1462.13 kg CO2/minute, 19 m elevation of 887.72 kg CO2/minute, 23 m elevation of 635.71 kg CO2/minute, and 23 m elevation of 1075 kg CO2/minute. The design of the discharge nozzle placement, 3D drawings, and isometric drawings for the CO2 extinguishing system were made using AutoCAD software. the pipe material used is 3" and 2" carbon steel, and the nozzle is 3?4". The selection of these materials and sizes is based on standards and technical needs to ensure the effectiveness of the extinguishing system.
Perancangan Desain Jalur Perpipaan Utility Service pada Non-Process Plant
One of the petrochemical companies in Cilegon want build of a utility service system includes potable water, industrial water, and demineralized water. The design of the utility service will start from the pump shelter. The pipe routing is adjusted to the plot plan that has been studied. Based on calculations, Potable Water Line has a total system head based on manual calculations is 30.9284 m while the total system head based on calculations using software is 29.282 m with difference value 5.3234% and the pump used is Ebara model IFW 50 x 40 1323, head total of Industrial Water Line system based on manual calculations is 60.0554 m while based on calculations using software is 56.762 m with difference 5.5439% and the pump used is Kawamoto model GEK5067.5, and the total head of Demineralized Water Line system is 96.4111 m while based on calculations using software it is 94.369 m with difference is 2.1171% and the pump used is Shinko model GJ 40-25. The allowable pipe span calculation results is get an ideal allowable pipe span with 3.6526 m. Estimated total cost of materials based of calculation and details of materials is Rp. 214.891.262.
Desain Sistem Jumperline Jalur Heavy Virgin Naptha.
In the oil refinery industry, a piping system with a temperature of 160 °C and a pressure of 6.41 kg/cm2 serves as the design specification for a Jumperline system in a revamp project. This project aims to enhance the efficiency and reliability of the Heavy Naphtha Treatment Unit by adding a bypass Jumperline to address the pump 201-P-002's pressure efficiency drop below 6.41 kg/cm2 due to increased capacity in the Heavy Naphtha Prefractination area. The tie-in to the existing NHT line includes the addition of the Jumperline system. Manual calculations and software analysis yielded a head loss of 5.55 m - 5.69 m with an error percentage of 2.64%, and a pump head of 35.80 m - 36.265 m with a pump head error percentage of 1.29%. with design basis of ASME B31.3.
Analisis Perhitungan Max Allowable Span Dan Nilai Fleksibilitas Pada Pipa Inlet Dan Outlet FAME Tank
Carbon Steel ASTM A 106 Grade B with a temperature of 392 oF and a pressure of 145,04 psi. This study aims to calculate the design of the inlet and outlet pipes, because this line is a new line and requires a calculation for the maximum allowable pipe span for determining the placement of pipe supports, obtained the results of calculation and analysis, the results of the calculation of the maximum allowable pipe span on the inlet pipe of 27.690 ft while on the outlet pipe of 33.050 ft. Then the calculation of the flexibility value is carried out to ensure that the pipe design can be said to be flexible and from the results of the flexibility calculation analysis on the inlet pipe line, it obtained 0.000004 and on the outlet pipe 0.000006. This value is still below the K1 provisions, so that the pipeline can be declared flexible and safe.
Perancangan LP CO2 Condensate Separator pada Proyek Revamp Of Ammonia Plant-2 di Bontang, Kalimantan Timur
The development of industry in Indonesia has led to an increasing demand for chemical raw materials for industry. Therefore, Revamp of Ammonia Plant-2 is a project that aims to modify an ammonia plant, where there is the addition of a pressure vessel, namely LP CO2 Condensate Separator, which functions as a separator between CO2 and water. Things that are considered when designing include internal pressure, external pressure, maximum allowable working pressure and calculation of seismic and wind loads with reference to ASME Section VIII Divison I and ASCE 7-10 and modeling is carried out with software. Based on the calculation results, the shell thickness is 0,482 inch and the head thickness is 0,325 inch. The MAWP value obtained is qualified with a value greater than the design pressure. then for the MAEP value obtained is also qualified with a value greater than 15 psi. The maximum deflection value due to wind load is 0,00845 inch and the base shear moment value does not exceed 80% of the base shear due to earthquake load of 1049,14 kips.ft > 24,395 kips.ft.
Perancangan Sistem Perpipaan Air Bersih Gedung Perkantoran 6 Lantai
Every building development usually has a problem in managing the clean water system, so the plumbing system becomes an important solution for each building. This research aims to design a plumbing system in a multi-storey building. This design refers to the SNI 8153: 2015 standard regarding plumbing systems in buildings. The distribution of clean water is carried out through a ground water tank and pumped into a clean water pipeline to each sanitary unit. The method used is to determine the flow rate based on 252 people. The results of the calculation of the average clean water demand for one day is 30240 liters / day with a peak demand of 220.5 liters / minute. The minimum ground water tank capacity required is 10.08 m3. The total pump head that occurs in this system is 26.374 meters and the pump power required to supply water is 0.272 kWatt.
Perancangan Fire Fighting Waterspray System & Hydrant untuk Future Spherical Tank Area pada FEED Plant Polypropylene
This research aims to design a fire fighting system in the future spherical tank area Known spherical tank in this project is a stockpile tank that stores hydrocarbon materials (flammable materials), therefore needs to design a fire fighting system. The method of research used darcy weisbach & bernouli equation for head calculation. The fire mitigation methods used by the author are water spray system and hydrant. The area for which the firefighting system will be designed is 15,575 m 2 with 3 units of 24 m diameter spherical tanks. The main standards used in this research include NFPA 14, 15 & API 2510. The results show that 6 hydrant pillars and 456 spray nozzles are required for the design. The pipe diameters used include 6 inch, 8 inch, 14 inch, 16 inch and 24 inch. Manual calculations obtained a head value of 143.31 m while the results of calculations using software obtained a head value of 149.21 m with a percentage error of 3.95% and pump power of 494.013 kW. Pump selection in accordance with system specifications based on the selection chart is the Standart-SDS-H400-50 brand.
Redesign Jalur Perpipaan Fire Fighting System Jenis Hydrant Pada Upgrading Pipe Ring I Integrated Terminal Surabaya
In the Fuel Oil Terminal (TBBM) area, of course, there are various systems, one of which is a fire extinguishing system. It is known that the Surabaya Integrated Terminal, especially in the Ring I area, has a fire fighting system that does not meet the standards and is sufficient in the event of a fire disaster because the terminal area is quite large and there are many tank units. This redesign aims to ensure that the water supply supplied by the available pumps is sufficient for fire fighting during a fire. This research will discuss the design of the fire fighting system pipeline by referring to the standards (API RP 1102, NFPA 14, NFPA 20, and NFPA 30), determining the number of hydrant pillars, water capacity requirements, pump head manually and using software and pump power. Based on data processing, a fire fighting system design was obtained with 33 hydrant pillars. The total water demand for the hydrant system is 567.75 m³, with a discharge requirement of 1000 gpm. Manual pump head calculation is 76.36 m, while the calculation using software shows 74.73 m with an error value of 2.13% and the required pump power is 94.10 kW.
Perencanaan Pipe Rack Struktur Baja dengan Metode LRFD (Load Resistance and Factor Design) ANSI/AISC 360-10 pada Sistem Perpipaan Air Separation Plant
The piping system designed to convey Cooling Water Return, Cooling Water Supply, and Nitrogen Gas in a specific area considers pipe design in the constraints of limited space. Thus, the pipes are designed with BOP (Bottom of Pipe) elevations of +2600 mm and +4800 mm. To accommodate these heights, a steel structure pipe rack is required. Pipe rack steel structure design are conducted according to ANSI/AISC 360-10:2010 standards using STAADPro Edition 22 software for steel structure analysis employing the LRFD (Load Resistance and Factor Design) method. For that pipe rack design requires analysis and determination of the W-shape steel structure profile that can be used in order to get optimal result in terms of technical strength, stable, serviceable, and durable. This final project aims to obtain an optimal W-shape steel structure profile from a technical perspective and in compliance with applicable standards. From the analysis results obtained the optimal pipe rack design is W-shape 6X15, with filler metal E7015 for welding joints using the SMAW process, and a base plate measuring 25.5 cm x 25.5 cm with a thickness of 1 cm, featuring 4 anchor bolts with a diameter of M18 and a minimum length of 30.6 cm.
Desain Jalur Sistem Perpipaan pada Air Panas Di Laboratorium Plumbing Gedung J Lantai 7 Politeknik Perkapalan Negeri Surabaya
The State Shipbuilding Polytechnic of Surabaya (PPNS) continuously striving to enhance student learning by planning the construction of an integrated Plumbing Laboratory. This Plumbing Laboratory is envisioned as a building with five toilet cubicles where the showers and sinks require hot water. The hot water piping system design is created using AutoCAD software, employing Polypropylene Random (PPR) pipes. The hot water piping system is designed with an overhead tank that directly supplies water to the water heater, which then distributes it to the five toilet cubicles. The design calculations and material selection adhere to the Indonesian National Standards (SNI). The analysis and calculations indicate a hot water requirement of 240 L/day. The required water heater capacity is 20L. Based on the results from the Pipe Flow Expert software, the system operates efficiently under a closed tank condition with a pressure of 5 bars, and the output water pressure is determined to be 0.2 bars.
Perancancangan Main Condensate Tank untuk Menampung Air Kondensat pada Unit Condensate Recovery System
- An oil refinery company located in Balikpapan, East Kalimantan is building a new plant, named New Crude Palm Oil (CPO) Refinery Plant. In this plant, a pressure vessel called Main Condensate Tank is required to accommodate condensate water. Main Condensate Tank design refers to ASME section VIII division I with SA 516 grade 70 material. The design pressure value is 2 barg and the design temperature value is 180?C. Modeling and stress analysis using software. Based on the results of the manual thickness calculation for the shell and head 0,438 in. For the shell and head MAWP values obtained are 144,576 psi and 170,816 psi. Meanwhile, the MAEP shell and head values obtained are 18,081 psi and 40,495 psi. The stress analysis using software obtained a max. von-mises stress value of 12959 psi and can be considered safe because it is still below the material allowable stress.
Desain Jarak Fitting Pada Instalasi Pipa Air Panas Di Lab Plumbing Gedung J Lantai 7 Politeknik Perkapalan Negeri Surabaya
Shipbuilding Institute of Polytechnic Surabaya (PPNS) is planning to construct a thermal piping system in one of its plumbing laboratories for clean and dirty water distribution to support building operations. The system will be installed in the Plumbing Laboratory, located on the 7th floor of Building J. The piping system will utilize Polypropylene Random (PPR) pipes, known for being environmentally friendly and recyclable. The connection method used is Polyfusion, adhering to the ISO21307: 2017 standard. This research focuses on several key aspects: determining the effective pipe installation distance, connecting fittings in accordance with standards, and simulating the connection process for hot water pipes. It also serves as a reference for both piping design and installation practices, providing educational value for students and supporting scientific and professional disciplines. The study calculates total pipe requirements by analyzing field data and determining the total length of the pipe segments needed. Results show that the total length required for ½ inch hot water pipes is 15,925 mm, with connection distances established using 1 cm socket. Additionally, pressure tests on the PPR pipes confirmed that they can withstand up to 19 bar (290 psi) without leakage, proving their suitability for hot water piping systems.
Analisis Pengaruh Ketebalan Pipa Terhadap Effective Stress Pada Desain Buried Pipe Tie-In Crossing Highway
In Plant Expansion Projects, the Tie-In process is often encountered, where the Tie-In process itself is a process of connecting one system to a new system. The Tie-In process itself has challenges where the road from the old system to the new system is limited, so the design of the Tie-In connection itself must be considered carefully. From these problems we are required to obtain a piping system design that complies with the codes and standards used for the Underground Pipe Crossing Highway. In this case, we will design and compare the buried pipe design and the concrete encasement design. For material selection, the minimum wall thickness value was obtained at 1.42875 mm, so ASTM A53 Gr.B with Sch.20 material with the appropriate thickness was used. In this case, a depth of 1.5 meters below the ground surface is used which is in accordance with the minimum depth in the API 1102 standard. In this condition the pipe must be designed to be able to withstand all kinds of loads such as dead load, live load and internal load. From this load, the stress that occurs in the pipe must not exceed the allowable ASME B31.4 and API 1102. For the aboveground pipe segment, providing support to prevent excessive stress on the pipe produces an allowable pipe span of 13.1232 meters for the maximum distance between supports.
Rekayasa Ulang Dan Perhitungan Sisa Umur Berdasarkan Kriteria Penerimaan Tank Settlement Pada Existing Storage Tank
This study analyzes the re-engineering and remaining life calculation of storage tanks based on the acceptance criteria for tank settlement. Re-certification of storage tanks, as regulated by the Ministerial Regulation No. 37 of 2016, is a mandatory process that must be conducted at least every five years. The primary focus of this research is a storage tank that has been in operation for 8 years. The methodology includes visual evaluation, design data collection, settlement calculation, and determining the minimum wall thickness of the tank. Additionally, damage mechanism analysis and risk assessment were conducted to estimate the remaining life of the tank. The results indicate that meeting all the required documentation for re-certification allows the tank to continue operating, with an estimated remaining life of 18.103 years for the long term (LT) and 9 years for the short term (ST). This re-engineering process not only ensures regulatory compliance but also acts as a preventive measure to identify and avert potential accidents in the future.
Redesain Onshore Crude Oil Pipeline Di Penajam Station Dari Underground Menjadi Aboveground
A new underground route will be installed, due to technical issues during construction about existing underground pipes. A redesign was carried out to place the pipeline aboveground with bend angle variations of 30°, 60°, and 90°. In this Thstudy, a comparison of the new designs with different bend angles was conducted, including calculations and analyses covering allowable pipe span, determination of the number of supports, stress values, and pipe flexibility values. From the calculations and analyses performed, the allowable pipe span value for all three designs with varying bend angles is 19.976 meters with two pipe supports. Stress analysis using software showed that the highest stress value due to sustained load was found in the design with a 90° bend angle at 20,406.8 psi, while the lowest value was in the design with a 30° bend angle at 14,503.77 psi. The highest stress value due to thermal expansion load was found in the design with a 30° bend angle at 12,125.15 psi, while the lowest value was in the design with a 90° bend angle at 1,145.8 psi. The pipe flexibility calculation results showed that the highest flexibility value was in the 90° design at 105.79 mm, while the lowest value was in the 30° design at 26.45 mm. Based on the stress and flexibility values analysis based on ASME B31.4, all three designs are declared safe and can proceed with the installation process.
Perancangan Gas Flowline Facilities Pada Wilayah Kerja Brantas
One of the oil and gas exploration companies in the Brantas Working Area aims to increase natural gas production by drilling a new gas well, TGA-19. The new TGA-19 pipeline network leading to the TGA-1/7 well area comprises 6-inch both aboveground and underground piping systems, designed to transport Process Gas (PG). Design of the piping system refers to the ASME B31.3 for aboveground piping and ASME B31.8 for underground piping. Recommendation schedule of pipe is 6” schedule 40 for aboveground piping system and 6”schedule 80 for underground piping system. Base on pipe stress analysis software, the stress value of sustained load for aboveground and underground piping system is 55,8% and 15,5% under the allowable stress value while the stress value of thermal expansion load for aboveground and underground piping system with 34,1% and 40,9% ratio that exceeding the alowable stress value.
Analisa Kebutuhan Air Pada Hydrant Dan Sprinkler Di Gedung VPSA
The VPSA Building is an office located in surabaya, East Java, which has recently been constructed and does not yet have fire protection. Therefore, the installation of a fire fighting system is necessary to prevent fire hazard in accordance with SNI. The calculations carried out include analysis of waterrequirements in the sprinkler and hydrant indoor as well as tank capacity for water distribution. From the results of the analysis, data was obtained sprinkler 15750 liter, hydrant indoor 72000. So the total water calculation for hydrant and sprikler system is 87.75 ???????? , and tank capacity requirements for hydrant and sprinkler in the VPSA building is 100 ????????.
Analisis Stabilitas Starch Slurry Storage Tank Kapasitas 1750 m3 terhadap Beban Angin dan Beban Gempa
The growth of the food and beverage industry in Indonesia is expected to increase post-COVID-19. This leads to an increased demand for corn flour, which often has to be imported from the international market. This increase in demand prompted a company in the Pasuruan area, East Java, to build a wet corn processing plant that requires several storage tanks. In this research, the design and modeling of storage tanks follow the API 650 Thirteenth Edition 2020 standard, aiming to determine the stability and use of anchorage in storage tanks. Calculation of storage tank stability against wind load, the resulting moment value of 6,673.18 N.m is smaller than 546,419,298.91 N.m (Wind + Internal Pressure < Tank Weight). For the calculation of the overtuning moment against seismic load, the anchorage ratio criterion of 0.793 is greater than 0.785 and smaller than 1.54 (0.785 < 0.793 ? 1.54). So based on API 650 standard, the criterion is considered stable and without the use of anchorage.
Fabrikasi dan Instalasi Pipa Air Panas di Laboratorium Plumbing Gedung J Lantai 7 Poloteknik perkapalan Negeri Surabaya
In the process of enhancing the learning experience for students of the D-IV Piping Engineering Study Program at the Surabaya State Shipbuilding Polytechnic (PPNS), the construction of an integrated Plumbing Laboratory is planned. The development of the Plumbing Laboratory will support hot water simulations that adhere to the Indonesian National Standard (SNI) and use Polypropylene Random (PP-R) pipe materials. The water supply to be used in the Plumbing Laboratory flows from the upper tank to the water heater and is distributed to 5 shower cubicles. The water heater required to supply hot water to the 5 shower cubicles is an electrical water heater with a capacity of 20 liters. The pipe installation includes DN 20 mm or ½” inch with a total length of 22.12 meters. The total cost needed for the fabrication and installation of hot water pipes in the Plumbing Laboratory, Building J, 7 th floor of PPNS is Rp. 4,481,550. After temperature measurements were taken using a digital thermometer, the highest temperature at the shower faucet outlet was found to be 51.3°C, and the lowest temperature at the shower hose outlet was 48.7°C. The temperature change does not exceed 10°C, in accordance with SNI 03-6481 2000.
Desain dan PemodelanDiesel Fuel Storage Tank Kapasitas 2.500 KL
One company in Port Kelanis, Central Kalimantan plans to increase the capacity of a diesel fuel storage tank to 2,500 KL using ASTM 283 grade C carbon steel material. The tank design adheres to the API 650 13th edition, 2020 standard, including minimum thickness calculations for the shell, bottom, annular bottom, roof, manhole, and nozzles. Indonesian National Standard (SNI) is utilized for seismic and wind load calculations. The modeling is done using Pemodelansoftware, and Finite Element Method analysis is performed using Ansys software. According to the one foot method calculations, the minimum thickness for course 1 is 10 mm, courses 2-3 are 8 mm, and courses 4-7 are 6 mm. The minimum plate thickness for the bottom, annular bottom, and roof is 8 mm. In 3D modeling using modeling software, there are several designs for storage tank parts starting from the bottom plate, annular bottom plate, shell and roof. Furthermore, this modeling can be used to simulate stress analysis in analysis software to determine Von Mises and deformation values.
Sistem Kontrol Suhu dan Debit Air pada Mesin Pencetak Bushing Baterai menggunakan Kontroler PID
The quality of battery bushings is significantly affected by the performance of the molding machine, which faces issues such as temperature instability in the middle mold and water flow instability in the cooling system during disturbances. These issues result in a maximum temperature overshoot of 10.5? with on-off heater control and water flow instability due to the use of a manual valve. To improve product quality and reduce defects, ongoing research focuses on maintaining temperature stability and consistent water flow in the cooling system. This project applies a PID control system to the middle mold heater using the Ziegler-Nichols tuning method and a PID Modulating Control Valve (MCV) for the cooling system, utilizing system identification and manual tuning in MATLAB. The PID heater control parameters are Kp = 4.35, Ki = 0.0090625, and Kd = 522, achieving a stable temperature at 40.3? with a rise time of 1231 seconds, maximum overshoot of 3.8?, settling time of 1351 seconds, and steady-state error of 1.43%. The PID MCV control simulation results in Kp = 5, Ki = 0, Kd = 0.25, stabilizing water flow with a maximum overshoot of 0.04 L/min, settling time of 3 seconds, and a steady-state error of 2%.
Pengaruh Variasi Suhu Preheat dan Jarak Pengelasan Terhadap Kekerasan, Struktur Mikro dan Lebar HAZ Pada Material ASTM A 106 B.
In welding, it is important to space the welds at sufficient distance so that the heat affected zones (HAZ) do not overlap. The distance between welding joints is usually determined based on needs and conditions in the field, but there are minimum requirements based on geometric and technical considerations. This includes avoiding overlapping stress concentrations, providing access for inspection, and avoiding residual stresses and distortion. This research examines the effect of variations in preheat temperature and welding distance on microstructure hardness and HAZ area in ASTM A 106 B material. The results of observations show that there is no HAZ overlap in all variations of welding distance and preheat spesimens. Vickers hardness testing indicates that material with a welding distance of "20 mm" without preheat has the highest hardness value, namely 235.08 HV on average, while the lowest hardness value is found in material with a welding distance of "32 mm" and preheat of 250°C, with an average value -average 215.55 HV. This shows that preheat and welding distance can influence the hardness of the material. Microstructural analysis shows significant differences in each spesimen variation. The ferrite structure dominates in spesimens that receive preheat treatment at higher temperatures, which contributes to a decrease in the hardness value of the material.
Pengaruh PWHT Pengelasan Dissimilar Material Stainless Steel Dengan Carbon Steel Terhadap Sifat Mekanik, Struktur Mikro Material dan Luas HAZ
This study investigates the effect of PWHT on welding different materials between SA 312 TP304L and SA 106 Grade B. Welding is not carried out PWHT which causes high residual stress and potential cracks. PWHT is part of the heat treatment process that aims to eliminate residual stresses formed due to the welding process. The research methodology includes hardness test, microstructure observation with optical microscope, and HAZ width measurement. The results showed that PWHT improved the welding quality in terms of mechanical properties, microstructure, and HAZ area. The width of HAZ in specimens with PWHT is smaller than without PWHT. Hardness test shows that the specimen without PWHT has an average hardness of 175.38 HV, while with PWHT is 167.94 HV. The microstructure shows that the CS base metal produces ferrite and pearlite phases, PWHT shows that the ferrite phase is more dominating. In SS base metal shows lamellar pearlite and austenite phases, PWHT specimen lamellar pearlite dominates. In the carbon steel HAZ, PWHT produces cementite and ferrite with weaker cementite bonds, while in the SS HAZ, PWHT shows austenite and pearlite phases, while without PWHT shows austenite, pearlite and lamellar pearlite phases. In the weld metal, the microstructure consists of pearlite and ferrite.
99 Studi Kasus Pengaruh Variasi Multiple Repair Pengelasan GTAW Pipa Baja Karbon Terhadap Struktur Mikro dan Sifat Mekanik Hardness Vickers
In the construction industry, contractor companies have a role in completing infrastructure projects, one of which is a piping system installation project. In working on a piping system installation project, the possibility of errors in the welding process cannot be avoided. The above can occur due to technical or non-technical errors resulting in defects. To overcome this, repair treatment is needed, if errors in the welding process are made repeatedly, it is necessary to do multiple repairs to the weld joint. The result of multiple repairs carried out will affect the hardness of the material itself. The purpose of this final project is to analyze the effect of multiple repairs on the microstructure and hardness of the material. The material used is A53 Grade B using the GTAW welding method with ER 70-S electrodes. The micro test results produce grain sizes that get smaller as the number of repairs increases. The amount of repair will increase the percentage of pearlite phase in the HAZ area. The hardness test results produced the highest hardness value in the Weld Metal area with 3x repair 187.50 HV, 2x repair 173.60 HV, 1x repair 164.12 HV, without repair 157.96 HV. This indicates that the more pipe joints undergo a repair process, the mechanical properties are more brittle than pipe joints without a repair process.
Analisa Laju Korosi dan Perhitungan Lifetime Material Carbon Steel API 5L X52 pada Subsea Pipeline
Corrosion is challenge and obstacle for several oil and gas industries, especially in pipeline. This problem becomes more complicated if a pipeline is corroded both externally and internally. This is the case for a subsea pipeline facility at an oil and gas company in Tuban, where external corrosion is affected by the seawater environment and internal corrosion is affected by H 2 S gas content in crude oil. API 5L X52 is general material used in this industry, with the advantage of good resistance at a low price. Corrosion in subsea pipelines has consequences such as loss of production, pipe leaks, and expensive maintenance. This study aims to determine the corrosion rate of API 5L X52 material, either caused by seawater or H2S gas in crude oil. Subsea pipelines were modeled with immersion tests conducted for 720 hours. From the results of this study, it was found that the corrosion rate in seawater with pH 7,2 has a higher value than the H2S gas content in crude oil. In addition, API 5L X52 material is not good enough in corrosion resistance in seawater environment without protection. Where, the lifetime value of API 5L X52 is only around 10 years at actual thickness.
Pengaruh Variasi Shielding Gas Pada Pengelasan Pipa Duplex Stainless Steel Terhadap Hardness , Struktur Mikro, dan Ferrite Content
Duplex Stainless Steel (DSS) is a type of stainless steel with a combination of 2 (two) phases in a balanced proportion, namely ferritic and austenitic. Duplex Stainless Steel has a balanced amount of ferritic and austenitic phases. However, unlike its parent metal, the solidification microstructure of the weld-melt zone does not have nearly equal amounts of ferritic and austenitic phases. The mechanical properties of duplex welding may decrease due to the selection of shielding gas. So, the analysis of 3 types of shielding gas variations namely Shielding Gas Pure Ar 99.999%, Shielding Trimix Gas Ar 87.5% + He11% + H2 1.5% and, Shielding Mixed Gas Ar 98% + N2 2% against duplex pipes needs to be done by testing hardness, microstructure and ferrite content. The results of these 3 tests were obtained for hardness values, trimix gas shielding variation of 288 HVN, shielding pure Ar 277 HVN, shielding mixed gas 276 HVN. In microstructure testing, it was found that shielding trimix gas got the most ferrite value, and shielding mixed gas got the most austenite value. Meanwhile, ferrite content testing obtained a shielding trimix gas value of 34.3%, shielding pure Ar of 33.2%, shielding mixed gas 32.4%. This is due to each microstructure element, such as nitrogen gas as (austenite forming) and helium gas as (ferrite forming). The higher the austenite, the lower the hardness.
Analisis Kekerasan Mekanik dan Struktur Mikro Branch With Reinforced Pad Setelah Close Range Multilayer Welding Spool 4I84-0008-01-1 Line Project
The research involved conducting Vickers hardness tests and Microstructure analysis to evaluate the material changes after welding. The research aimed to improve understanding of how the welding process impacts material integrity and performance, particularly in industrial applications. Analyzing the results obtained from the test results, this research provides valuable insights into the quality and characteristics of welded joints. The findings contribute to optimizing welding procedures and material selection to improve structural integrity and mechanical properties. In conclusion, analysis of the results from this study found that the hardness of the material is still in the safe to use category and does not need further treatment after welding.
Perbandingan Inhibitor Egg Shell Powder Dengan Ekstrak Daun Pepaya Pada Material Stainless Steel 304L Terhadap Laju Korosi Fluida Sulphuric Acid
One of the companies engaged in textiles located in Purwakarta, West Java is a producer of viscose staple fiber and sodium sulfate. One of the problems found in the viscose fiber production process is corrosion. Corrosion that occurs in the production system occurs because the fluid flowing is sulphuric acid and the operational temperature factor in the system is 40ºC. Tests using the immersion test method for 7 days or 168 hours and weight loss calculations were carried out to determine the corrosion rate and life of the pipe. The test results show that the specimen with egg shell powder inhibitor has a corrosion rate of 0.0142 mm/year and a life of 223.46847 years, while the specimen with papaya leaf extract inhibitor has a corrosion rate of 0.00201 mm/year and a life of 1309,64369 years. Based on the test results by comparing temperature variations of 40ºC, 50ºC and 60ºC, it can be seen that the effect of temperature is directly proportional to the corrosion value.
Pengaruh Variasi Tekanan, Waktu, dan Jenis Abrasive Material Terhadap Faktor Kebersihan Pada Proses Pembuatan Ducting Exhaust
A petrochemical company in Gresik, East Java plans to increase its sulfur production capacity to support fertilizer production in Indonesia. Air ducting are needed to distribute SO2, SO3 and SO4 compounds remaining from processing sulfur products which are corrosive to a designated place. In the exhaust ducting process, the fabricator requires proper handling in terms of surface preparation of the material because the material has started to rust so it needs to be cleaned so that the painting can adhere optimally to the surface of the material and create a sufficient roughness and cleanliness profile. The company wants a minimum surface cleanliness level of SA 2.5 based on the ISO 8501-1 standard. The test results show that the pressure and time variables have an effect on cleanliness, the greater the pressure, the better the cleanliness level, while the abrasive type variable has a different effect, where volcanic sand material is better in terms of roughness and silica material is better in terms of cleanliness. Based on these results, it can be recommended a pressure variation of 6 bar, a time of 20 seconds, and the type of silica sand abrasive material used because the results have reached company standards.
Analisis Tegangan Sistem Perpipaan Inlet New High Pressure Test Separator 6”-PT-230-D Pada Fasilitas Separasi
At the Gathering Station located in West Java, the replacement of the High Pressure Test Separator equipment necessitated a change in the location of the High Pressure Test Separator. Due to this relocation, a new piping system connected to the New High Pressure Test Separator will be constructed. It is necessary to conduct a stress analysis on the new piping system connected to the New High Pressure Test Separator to ensure that the stress levels within the piping system comply with the ASME B31.3 acceptance criteria. The analysis includes the calculation of allowable pipe span, pipe stress analysis, and displacement analysis, aided by stress analysis software. The analysis under design conditions revealed that the stress levels in the piping system under sustain, occasional, and thermal loads meet the ASME B31.3 allowable criteria, with the highest stress value being 19349 lb/in2, or 77.2% ratio, occurring under thermal loading. The highest displacement in the piping system was observed under thermal loading, with a value of 8.530 in the Z direction.
Analisis Tegangan Critical Line dari Discharge Scrubber Point menuju Suction Gas Compressor Train pada Booster Compression Module
The Booster Compression Module project aims to increase gas production at the Central Processing Facility (CPF), to ensure the safety of a piping system during the operational phase requires complex design calculations. The design process requires stress analysis to maintain the structural and operational safety of the piping system. This research using the static analysis method considers the effect of static loads, emphasizing the crucial role of proper support placement aligned with ASME B31.3 to prevent piping system failure or damage. The Booster Compression Module project has a complex piping system, according to DNV-RP-D101 the certain line that meets the critical line determination criteria. Specifically, the critical line analyzed connects the Discharge Scrubber Point to the Suction Gas Compressor Train with diameters of 24" & 36" with specifications of design temperature 248°F and design pressure 2016.025Psi requiring proper calculations, including the placement of supports being very important. The stress value of the piping system the sustained load obtained has a stress value of 15752.7 Psi with a ratio to the allowable stress of 43.1%, the thermal load has a stress value of 2860.2 Psi with a ratio to the allowable stress of 8.4%, and the occasional load has a stress value of 2470.8 Psi with a ratio to the allowable stress e of 5.1%. The stress analysis values of the piping system due to sustained, thermal expansion and occasional loads are still below the allowable stress limits of ASME B31.3.
Analisis Pengaruh Jarak Minimum Antar Pengelasan Terhadap Tegangan Sisa pada Material A 106 Gr B Dengan Menggunakan Simuasi Software
In the industrial world, especially pipe fabrication, there must be a connection process between pipe components. One way to connect these components is by welding. With today's developments, many applications are used to model or simulate the welding that carried out, for example modeling welded joints using Solidworks and also Ansys. In the welding process, the type of weld is something that must be considered and the welding distance is also an important thing that must be considered too. In this case the minimum welding distance between two adjacent welding edges has different standards. Welding in close proximity can affect the material, so it is important to determine the optimal distance that reduces these negative effects. The simulation was carried out by modeling various distances between welds and observing the residual stress distribution and total deformation. Therefore, this research aims to determine the effect of the minimum distance between welding joints on the distribution of welding stress using software. The research object used (test specimen) is a pipe with material A106 Gr B, dimensions outside diameter 610 mm and Thickness 17 mm. The simulation was carried out at 4 variations of distance between welds, namely 2t, 3t, 4t and 5t where t is the Thickness of the test material. From the analysis results, it was found that the maximum residual stress occurred at a welding distance of 2xThickness of 199.98 MPa, this value still meets the yield stress value of the material used, with a maximum deformation of 7.2 mm.
Analisis Teknis dan Ekonomis Metode Instalasi Highway Pipeline Crossing Jaringan Pipa PDAM
The clean water pipeline project in the Special Economic Zone (KEK) JIIPE, Gresik, Indonesia, utilizes SNI Medium material pipes with a size of 600 mm equivalent to 24-inch Sch 20 pipes. The pipeline is planned to cross a highway for a length of 17 meters. To avoid pipe damage that could lead to losses, API Standard 1102 regulates special treatment by using protection or installing the pipe at a minimum depth of 1200 mm measured from the surface to the top of the pipe. This study will analyze the pipeline crossing method using both uncased pipe and cased pipe installation methods technically based on API 1102 and ASME B31.4, as well as an economic analysis. After conducting both technical and economic analyses, it can be recommended to use the uncased carrier pipe model due to its stress values being within the allowable limits and the more affordable installation costs.
Analisis Tegangan dan Frekuensi Alami pada Penambahan Line Suction dan Discharge Centrifugal Pump P-004 GS2
The addition of a new pump at the GS2 crude oil production facility, Northern Area ONWJ (Zone 10), requires static and dynamic analysis of the pump's suction and discharge lines using stress analysis software, as these lines are classified as critical. This study includes calculations of allowable pipe span, cut-off frequency, natural frequency, pipe stress, displacement, and nozzle load. Allowable pipe span calculations are based on stress and deflection limits, while cut-off frequency values are used as inputs for modal analysis to determine the natural frequency of the piping system. Stress analysis is performed for sustained, thermal expansion, and occasional loads according to ASME B31.3 limits. Displacement analysis adheres to company limits, with a maximum allowable displacement of 19 mm. Nozzle load analysis is conducted per API 610 limits. Initial results indicate that the natural frequency of the piping system is below the company's minimum requirement of 5 Hz, with values of 2,467 Hz for the suction line and 0,788 Hz for the discharge line. Repositioning of supports is required, and after adjustments, the natural frequency, pipe stress, displacement, and pump nozzle load meet specified limits. The piping system design after support repositioning is deemed safe for operation.
Kajian Efek Konfigurasi Geometri Vertical Expansion Loop Terhadap Nilai Tegangan Di Hot Brine Geothermal Power Plant
The Geothermal FCRS and Power Plant projects focus on distributing steam and brine fluids resulting from geothermal separation processes. There is a potential for flashing in the brine fluid distribution within the vertical expansion loop area, which requires detailed evaluation of stress and displacement values due to its categorization as a critical line. This study employs computational fluid dynamics (CFD) to simulate fluid flow, based on various height and width configurations of the loop geometry, to assess the potential for flashing. The fluid simulation results are then used to compare the stress analysis of dif erent loop geometries. The results indicate that flashing occurs in geometry 2 with a height of 9 meters. Furthermore, the stress analysis shows that the stress value in geometry 1 is below the allowable stress limit, ef ectively reducing displacement values caused by thermal expansion loads.
Evaluasi Design Basis Instalasi Underground Pipeline Distribusi Minyak Hidrokarbon Bekasi Area
A hydrocarbon oil distribution pipeline construction project owned by one of a State-Owned Enterprises that engaged in oil and gas sector is in the process towards the construction phase. Pipeline is planned to be passing a road crossing on a toll road, so the pipeline should be installed buried underground. The underground pipeline will be installed at the soil depth 1500 mm from the ground surface refers to the criteria based on the owner's design basis. The potential failure of an inadequate soil depth for pipeline burial is overstress from the load on the underground pipeline. The soil depth criteria in design basis for the underground pipeline installation was evaluated towards stress of the underground pipeline for the toll road crossing. Based on the stress analysis using a software and manual calculation, it is found that stress values of underground pipeline at the soil depth of 1500 mm are still meet the criteria of allowable pipeline stress value.
Pengaruh Closing Time Valve Terhadap Aliran Fluida di Dalam Penstock Pembangkit Listrik Tenaga Air (PLTA) Proyek Pembangunan Bendungan Bener
The Bener Dam Project in Purworejo, Indonesia, aims to meet irrigation and raw water needs while constructing a 10 MW hydropower plant. With a height of 154 to 159 meters, the dam also mitigates flood risks. This study analyses the hydropower plant's operations, particularly the water hammer phenomenon, which can cause excessive pressure and damage the piping system. Using transient analysis and Computational Fluid Dynamics (CFD), the research reveals a water flow rate of 18.09 m³/s with velocities of 11.75 m/s in a 1.4-meter pipe and 16.00 m/s in a 1.2-meter pipe. Finite Element Analysis (FEA) shows that closing the valve within 50 seconds generates a pressure of 19.350 bar, safely below the 19.418 bar limit, with the highest Von Mises stress at 83.36 MPa in the pipe bending area and 79.52 MPa near the valve, both within the safe limit of 176.5 MPa. The findings confirm the hydropower plant's safe operation under the 50-second valve closure scenario, offering crucial guidance for managing water hammer risks and ensuring the project's long-term sustainability and efficiency.
Desain Cold Insulation dan Analisis Tegangan pada Pipa Outlet Cold Box menuju Inlet Residual Liquid Evaporator
Line L-31-200-1SsA with a temperature of -196 C and a pressure of 0.9 Mpa is a piping system that drains remaining fluid from the cold box goes to the remaining evaporator liquid. On this path the calculations are carried out insulation a pipe using 3 different alternative materials for get a charming design that is optimal in maintaining a constant temperature constant. It is necessary to calculate heat loss and downsteam temperature. This line is included in critical line so stress analysis must be carried out with the help of software. Based on The calculation results show that cellular glass insulating material has value The smallest heat loss is 204.8 W and the downsteam temperature is 84 K. Based on stress analysis software modeling, the continuous load value is the largest is 76782.4 Kpa with a ratio of 66.2%, the expansion load value is 48375.1 Kpa with a ratio of 89.1%, and an occasional load value of 73422.5 Kpa with a ratio 26.9%. It concluded that the stress value does not exceed the allowable limit stress based on ASME B31.3.
Re-desain Jalur Pipeline Junction-K Menuju PLTP Unit 3 dan 4 pada Proyek Debotlenecking SAGS Ulubelu, Lampung
The Debottlenecking SAGS Ulubelu project performs the addition of new pipeline junctionK line towards PLTP units 3 and 4. There's a problem with the layout. First on the support PS-7 area, because the pipeline design collides with the existing pipe. Second on the box culvert, because there's the addition of box culvert beside the exsisting box culvert. To solve these two problems, it is necessary to redesign. To carry out the re-design, the things that need to be done are calculating the allowable pipe span, flexibility in the pipe, and stress. The allowable pipe span calculation takes the smallest value between the minimum distance based on the stress limit and deflection limit as well as the table in ASME B31.1 and obtains a value of 14.3 m. The flexibility calculation has a value less than 30 SA/EC is 0.008, so this pipeline route is declared flexible. For the voltage analysis process using stress analysis software. The highest stress values on sustained load, occasional load, and thermal expansion load are less than the normal stress, with values of 3991.4, 18550.5, and 17395.9 (psi), then the re-design of this line has been in accordance with ASME B31.1 standard.
Analisis Tegangan Sistem Bypass Pada Line V-4886-LMP-C8JA0-8”
The V-4886-LMP-C8JA0-8 piping system with a temperature of 229 ?C and a pressure of 2260 kPa is a boiler steam header piping system. This line temperature and pressure values and is included in the critical line, it is necessary to carry out stress analysis based on ASME B31.1. The calculated stress analysis are sustained load and thermal load stress. The calculation results of the allowable pipe span are 33,507 ft. Based on stress analysis software modeling, the largest sustained load value is 34295.1 kPa with a ratio of 29.1%. and the largest thermal load value is 9462.6 kPa with a ratio of 3.6%. it can be concluded that the stress value does not exceed the allowable stress limit based on ASME B31.1.
Analisis Tegangan Pipa Pada Desain Sistem Perpipaan Line Discharge Acid Tank Yang Terhubung Pada Acid Transfer Pump Akibat Tank Settlement
The acid storage tank (4250-TNK-0001) is predicted to decline by 75 mm within 25 years after construction. This study analyzes pipe span, pipe stress, nozzle load, and flange leakage for the tank settlement value at the 25th year. The analysis includes calculations for allowable pipe span, bending and centralized load, stress values, nozzle loads, and flange stress. The largest sustained load value is 22,300 Psi with a ratio of 133.5%, and the largest thermal load value is 150,390.9 Psi with a ratio of 600.4%. The stress value does not exceed the allowable stress limit based on ASME B31.3. For nozzle load analysis, existing designs still exceed allowable limits, while new designs meet allowable limit values. Flange leakage analysis is not acceptable at the radial flange value. The tank is safe after design changes to the support and expansion joint.
Analisis Tegangan pada Line 086-VD-1001-34”-1SA0K-NI Akibat Penambahan Add On Gate Valve (AOGV)
An oil and gas company in West Papua will perform shutdown maintenance in the TAR-8 area with a knock-out drum to flare piping system due to the addition of a gate valve. The main objectives are to determine the allowable pipe span, stress analysis, and evaluate the nozzle load on the flare. The methods used are stress analysis based on ASME B31.3 and flare nozzle load evaluation using API 537. Calculating the allowable pipe span on the drum to flare knock-out line resulted in a value of 84.423 ft. The results of stress analysis due to the addition of add on Gate Valve for the maximum allowable stress value due to sustained load 3565.3 lb/in2, due to occasional load 2842.7 lb/in2, and due to thermal load 10394.8 lb/in2 have met the ASME B31.3 permit limit. The flare nozzle analysis results have met the load permits based on API 537. In conclusion, the new design of the knock-out drum to flare piping system with the addition of an add-on gate valve is considered safe to operate and meets applicable industry standards. This research provides a practical solution for piping system maintenance without operational disruption, highlighting the importance of technical analysis in ensuring the safety and efficiency of energy infrastructure.
Analisis Orifice plate Multilubang Menggunakan Ansys pada Pipa Natural Gas
One of the main components used to provide accurate information about the quantity of gas used or flowed in a gas distribution system is the orifice plate, with the fluid flowing in the form of natural gas and sand grains with same hole crosssectional area of orifice holes. Abrasive particles that are carried by the gas flow and also the shear stress that occurs between the moving fluid and the pipe wall cause the phenomenon of erosion of the pipe wall after passing through the orifice plate. Therefore, to continue previous research, this study will focus on optimizing the use of variations in the addition of orifice plate holes with the same hole cross-sectional area. The amount of erosion rate that occurs in each variation of 1, 2, and 3 holes refers to the DNV standard of 0.179; 0.171, and 0.157 with each variation increasing the lifetime of the pipe by 23.32; 24.40; and 26.56, respectively can meet the company standard of 20 years.
Analisis Pergeseran Peletakan Penyangga Untuk Mengurangi Tegangan dan Displacement Pada Sistem Perpipaan Heat Exchanger
The existing line piping system connected to a heat exchanger at a petrochemical company experienced an increase in cut length. The addition of the cut length makes the pipe support distance in the piping system even further. Because the distance between pipe supports is getting farther, it is necessary to carry out stress analysis and add additional pipe supports according to the results of the stress analysis. After carrying out stress analysis using software, the highest sustain stress value was 34655.6 psi with a ratio to allowable stress of 173.2%. After adding pipe supports and analyzing again using software, the sustain stress value was 3150.1 psi with a ratio to allowable stress of 15.8%. then the new design of the piping system can be declared safe.
Analisis Tegangaan Sistem Perpipaan Jalur Effluent Line di Lawe-Lawe Terminal
Based on the standard that has been set by the owner to replace the material and also change the layout from underground to aboveground on the pipe effluent line from the pig reciever area to the WWTP area Because that, contractor are required to carry out re-analysis of the change of layout and replacement of the material against max. allowable working pressure, min. wall thickness, the calculation of allowable pipe span to determine the amount and type of support appropriate and stress analysis using software and manual calculation. The value of the maximum allowable working pressure on the effluent line is still above the design pressure. For the minimum wall thickness resulting from the material change on the effluent line line is still below the minimum thicker value of the ASTM A53 Gr.B pipe material. And the highest values of sustained load (L6) and thermal expansion loads (L8) are at node 318 and also node 140, both load cases are still below allowable stress, the design of the existing piping system can be accepted according to ASME code B31.3.
Analisis Fleksibilitas dan Allowable Span Terhadap Jalur Pipa Emergency yang Terhubung pada Flare dan Pressure Vessel
This study analyzes stress on an emergency pipeline connected to a flare and pressure vessel at an oil and gas facility in West Papua. The research is necessitated by the inability to perform shutdown maintenance on the existing piping system due to high-pressure and high-temperature fluid flow. The objectives are to determine support placement and analyze stress on the new emergency pipe design. The methodology includes calculating the maximum allowable pipe span and stress analysis based on ASME B31.3 standards. Results show that the maximum distance between pipe supports is 36.967 feet, with a minimum of 2 supports required. The pipe flexibility value of 0.00146 is below the 0.02582 limit set by ASME B31.3. In conclusion, the emergency pipeline design is deemed safe for operation and complies with applicable industry standards. This research provides a practical solution for piping system maintenance without operational disruption, highlighting the importance of technical analysis in ensuring the safety and efficiency of energy infrastructure.
Analisis Tegangan Line 10”-ET-1003-1CS4-C Pada Jetty Transfer Menuju Tangki Ethylene
The petrochemical company in Indramayu is expanding its operations by constructing a jetty head and a new line pipe, 10”-ET-1003-1CS4-C, designed to transport ethylene at -108°C from the jetty head to the ethylene tank. As this is a new and critical line pipe, a stress analysis is required. This analysis is conducted under sustained, occasional, and thermal loadings based on the ASME B31.3 standard. The calculation of the maximum allowable pipe span considers the smallest value between stress and deflection limits, determined to be 36,601 ft. The highest stress values recorded for the pipe are 13,660.26 psi under sustained load, 15,353.04 psi under occasional load due to wind, and 23,256.45 psi under thermal load. All these stress values are within the allowable limits, indicating the pipeline is safe for operation. Although the pipe experiences a significant displacement of 160.402 mm in the X direction.
Pengaruh Peletakan Support Terhadap Nilai Tegangan Pada Line 482A(R)_4821-LLP-C4FA0-0178 Akibat Perbedaan Schedule Reducer Tee Dengan Header
The piping system line number 482A(R)_4821-LLP-C4FE0-0178 is a critical line that is included in the urgent line which is experiencing adjustments in the project where isometric drawings are revised due to material shortages for branch, where there is a difference in schedule with the main line. Therefore, in this Final Project, an analysis is carried out to validate the stress value, allowable pipe span, flexibility and redesign after recalculation using manual and software. The results of the allowable pipe span calculation obtained the number of pipe supports as many as 5 pieces, after adding the weight of the tee reducer, the number of supports after calculation is different from the initial isometric. The initial isometric flexibility calculation has a value greater than K_1, so the line is not flexible and a recommended design is required. The results of the stress value for the initial isometric highest value for Sustained and Thermal load are 2,683.68 psi and 28,355.1 psi. As for the recommended design, the highest values obtained for Sustained and Thermal load are 1,907.74 psi and 17,071.4 psi. So that with the new design of the existing piping system, the stress value of the piping system has decreased after adding support and it is safe to fabricate.
Analisis Tegangan Jalur Perpipaan dari Knock out Drum Menuju Gas Flare
The purpose of channeling gas from the Knock Out Drum to the Flare is to burn the gas before releasing it into the environment, requiring careful pipe design. Nozzle analysis at the Flare Inlet was conducted based on operational and sustain conditions using pipe stress analysis software. The pipe from the Knock Out Drum Outlet to the Flare Inlet has a diameter of 26 inches, a design pressure of 3.5 kg/cm²G, and a design temperature of 320?C. The initial design, which included a Z loop before the flare inlet nozzle, exceeded the allowable nozzle loads, necessitating further analysis. One option to reduce stress below the allowable nozzle load was adding a horizontal loop with a minimum length of 15.5 meters and a width of 8 meters, chosen for distance efficiency around the flare. The stress values with the horizontal loop addition under sustain load were 2414.2 psi with a ratio of 13.6%, the highest occasional load due to wind was 12,259 psi with a ratio of 51.8%, the highest occasional load due to an earthquake was 13,847.8 psi with a ratio of 58.5%, and the thermal expansion load was 40,971 psi with a ratio of 89.9%. The nozzle inlet flare load values met the allowable limits, with resultant forces and moments on the Fx, Fy, Fz, Mx, My, and Mz axes.
Analisa Tegangan Jalur perpipaan Outlet Scrubber menuju Compressor dengan Penambahan Expansion Loop Analisa Tegangan dengan Penambahan Expansion Loop
In the execution of construction projects, various issues arise, one of which is stress analysis. Stress analysis of pipes is crucial before their installation to ensure the safety of the pipeline when high-pressure or low-pressure fluids flow through it, preventing leaks or deformation. In the case study of the project delivery for the offshore FPSO time charter, specifically in the design of the outlet pipeline for the 1st stage gas lift suction scrubber, the addition of an expansion loop before reaching the 1st gas lift compressor package is necessary. This is due to clashes with the module structure and the pipeline being a critical line containing high-pressure steam to be distributed to the compressor. Therefore, the pipeline must be redesigned and stress analysis performed with the addition of an expansion loop. This analysis begins with calculating the allowable pipe span and pipe flexibility, followed by redesigning the isometric drawings with the added expansion loop. Stress analysis then reveals that the stress values for both the horizontal and vertical loop designs are within the allowable stress limits based on ASME B31.3.
Analisis Tegangan Jumper Line Penajam Station Sebagai Peningkatan Fleksibilitas Operasi Transfer Crude Oil Project RDMP RU-V Balikpapan
The Lawe-lawe Facilities project must change the routing design of the jumper line at Penajam Station due to the inflexible pipeline configuration in utilizing the existing line with the new line. Analyzed including calculation of max allowable pipe span, stress analysis due to sustained, occasional, and thermal loading, pipe flexibility and flange leakage analysis based on ASME B31.3. The max allowable pipe span got a value of 56,39 ft with a minimum number of pipe supports of 4 pieces. Stress analysis with the help of software results in stress values due to sustained, occasional and thermal loading not exceeding the allowable stress based on ASME B31.3. The pipe flexibility value in the jumper line piping system does not exceed the allowable value of 0,009 with an allowable of 0,030. The results of the flange leakage analysis get the highest value of stress on the flange of 211,54 psi. From the analysis that has been done, it is obtained that all stress values do not exceed the allowable based on the ASME B31.3 standard and can be declared safe to meet the criteria.
Analisis Tegangan pada Sistem Perpipaan Outlet 3 rd Stage Gas Lift After Cooler
The piping system Outlet 3 rd Stage Gas Lift After Cooler is a critical line that has not yet determined the location of the pipe support to be used. Based on the problems found, this Final Project will recommend the location of pipe support, stress analysis, and displacement analysis. From the results of the calculation of the maximum allowable pipe span and the pipe support location analysis, the number of pipe supports used in the 3 rd Stage Gas Lift After outlet piping system line is 23 pipe supports. After stress analysis using software, the highest stress value due to sustained load is 14482,7 psi, stress value due to occasional load is 1723,7 psi, and stress value due to thermal expansion load is 10108,5 psi. The pipe stress value and displacement value in the piping system are still below the maximum allowable. Therefore, the location of the pipe support location is declared safe and can be used based on ASME B31.3 (Process Piping).
Perbandingan Bentuk Fitting Pipa 2” dan 3” Terhadap Laju Erosi Pasir Berbasis Interpolasi Lagrange
Collisions between SiO2 particles can cause the mass flow rate of sand in the pipe fittings to increase. So, the rate of erosion of the sand material becomes faster. In this research, 2" and 3" pipes fittings were used to differences in sand erosion rates could be determined due to differences in pipe diameters. Based on the calculation results, the rate of sand erosion becomes faster when it passes through pipe fittings with a smaller diameter. Meanwhile, based on the simulation results, the Lagrange interpolation method has high accuracy for predicting sand erosion rate values ??that have not been measured. This is proven by the suitability of the level of linearity between the calculation results and the simulation results for both the 2" and 3" pipes fittings, namely 1.
Penggunaan Metode Risk Based Inspection API 581 Tahun 2000 sebagai Dasar Analisis Risiko Tangki Penyimpanan Minyak Mentah dan Bahan Bakar
This research delves into the risk assessment of storage tanks within an oil and gas company operational since 2015. Being Aboveground Storage Tanks, they present significant hazards, including fire and explosions, jeopardizing the safety of operators and nearby communities. Such risks stem from both internal factors, like corrosion-induced physical damage and aging, and external factors such as human errors, natural calamities, or unexpected incidents. Utilizing the Risk Based Inspection (RBI) approach, based on API 580 and API 581 standards from 2000, the study aims to gauge the potential risk levels associated with tank failures. The research framework encompasses identifying damage mechanisms, assessing failure probabilities, understanding the consequences of potential failures, and determining risk levels and inspection schedules. The central aim of this investigation is to comprehend the underlying damage mechanisms, quantify associated risks, and formulate robust inspection strategies to preemptively address system failures. Consequently, the study strives to offer actionable preventive recommendations to safeguard the tanks' integrity and optimize their operational performance.
Optimasi Proyek New Sulphuric Acid Plant Akibat Perubahan Progres Terhadap Alokasi Manpower Dengan Menggunakan Metode Non Linier Programming
Construction of New Sulphuric Acid Plant in Gresik in a company engaged in the textile industry to support the company's expansion process in accordance with the government's mandate in the textile industry. The construction of this project must be completed in accordance with the schedule. If this project is delayed, a penalty of 0.1% of the project value will be imposed. But in fact in the construction process, this project experienced delays caused by a shift in the allocation of manpower which resulted in disruption of progress between one work scope and another. The shift was caused by instructions from the main contractor that were not in accordance with the schedule that had been made. Therefore, it is necessary to optimize the work so that the project can be completed according to the completion schedule. In this final project, cost and duration optimization will be carried out using the Non-Linear Programming (NLP) method. The New Sulphuric Acid Plant project with WBS which includes Mechanical, Structure, and Piping work experiences field productivity that is not according to plan, so optimization is carried out. Furthermore, an analysis is carried out to obtain the optimum project duration at a minimum cost so that the best option is produced to minimize losses. The results of optimizing the duration of the 3 work scopes to 269 days in all work scopes from the initial duration of 386 days, 274 days, and 317 days. As for the cost of this optimization, it only saves Rp. 2,300,755 (0.04%) of the actual cost but in this optimization the project does not experience delays (< 360 days) and will not be subject to fines or penalties. Based on the S curve, 100% progress on the original plan ended in September 2023, the actual ended in November 2023, and after the second optimization, 100% progress was achieved at the end of October 2023.
Optimasi Penjadwalan Piping Field Installation pada Proyek Smelter Manyar Menggunakan Metode Dual Shift dan Fast Track
In project implementation, cost and duration are often not in accordance with planning. In this final project, the project object is the construction of Manyar smelter, due to material delays by the main contractor, this project is delayed which results in the company getting a fine of 0.1% of the contract value per day where the deadline on this project is July 10, 2024. This final project aims to determine the optimal time and cost to maximize the remaining duration and cost by accelerating using the Dual Shift and Fast Track methods. The two methods will be compared which one produces the optimum duration with minimum cost. First, the calculation of productivity, duration and normal costs will be carried out by making a normal network diagram and calculating the chances of completing the project according to the deadline using the PERT method, after which a cost analysis is carried out. The results of the analysis obtained the cost of completing the project for the remaining work amounting to Rp24,883,094,879.26 with the project completion time on August 19, 2024. The remaining project completion cost using the dual shift acceleration scenario is IDR 18,196,617,905.75 with a project completion time of June 27, 2024, while the remaining project completion cost using the fast track acceleration scenario is IDR 20,138,511,412.00 with a project completion time of July 17, 2024. While the available cost allocation for the completion of the remaining projects is IDR 24,139,488,290.89, so the dual shift acceleration method was chosen to be able to accommodate the completion of the remaining work projects in accordance with the costs available for the completion of the remaining work.
Perbandingan Waktu dan Biaya dengan Metode CPM dan CCPM pada Proyek Pipeline Installation from Sembayat Reservoir to Ground Water Tank JIIPE
In the implementation of construction projects, the incompatibility between plan and actual schedule that cause an additional time and cost is oftenly occurring. The Pipeline Installation Project from Sembayat Reservoir to Ground Water Tank JIIPE started in July 2022 and scheduled for completion in November 2022. However, in actuality the project finished in July 2023. Based on this case, an acceleration method needs to be implemented so that the project can be completed quickly and efficiently. One of the methods applied is Critical Chain Project Management (CCPM). Scheduling is carried out using Critical Path Method (CPM) and the results of which will be compared with the Critical Chain Project Management (CCPM). The calculation results from the CPM show that the duration is 318 days and the total labor costs are IDR 1,689,984,000.00. Furthermore, using the CCPM, the duration is 216 days and the total labor costs are IDR 1,184,256,000.00. So, by using the CCPM, the project is completed 32.08% faster and requires 29.93% labor costs saved than the CPM. Based on the results of the analysis, by applying the CCPM method is able to make an optimal duration and efficient costs of the project.
Analisis Efektivitas Waktu Dan Biaya Instalasi Sistem Perpipaan Vacuum Pressure Swing Adsorption (VPSA) Plant
- Every construction company must be able to complete work as cost effectively and as efficiently as possible, while still producing good quality work. One company operating in the oxygen production sector, where the work was carried out by a contractor for four months, experienced a delay of 64 days in building a new Vacuum Pressure Swing Adsorption (VPSA) Plant project. Delays in construction work were caused by vendor errors in cost estimates. So, to find out the cost effectiveness of the project, it is necessary to analyze the project costs from the start of the project to the end of the project according to the predetermined budget. The results of the analysis obtained effectiveness values for the amount of labor, materials, equipment as well as overall time and costs. Based on the effectiveness results obtained, the time effectiveness of 40,46% is in the "ineffective" ratio and the cost effectiveness of 93,52% is in the "effective" ratio. This ratio is measured based on the effectiveness criteria according to Decree of the Minister of Home Affairs No. 600.900.327 of 1996. The most significant cost overruns occurred in the heavy equipment rental component
Analisis Keterlambatan Piping Installation Berbasis Manajemen Risiko Pada Proyek Pembangunan Smelter di Gresik
Performance issues are commonly encountered in construction projects, particularly concerning delays, which are a prevalent, costly, complex, and risky problem. For instance, a delay in piping installation in the construction project of the Smelter in Gresik was experienced by one of its subcontractors. These risks have the potential for both positive and negative impacts on the project. Therefore, research was conducted to identify, assess, and analyze the potential risks in the project and formulate strategies for their management. The research aimed to determine the extent of the risks present and the strategies for managing the dominant risks in the project. The method involved distributing questionnaires to 10 respondents and applying the Severity Index (SI) and Probability-Impact Matrix for risk data analysis. The research findings identified 42 risk variables, including external, technical, legal, and internal risks, evaluated based on their impact on project schedule, project targets, safety, and costs. Risk evaluation resulted in 1 category very high risk, 2 categories of high risk, 21 categories of moderate risk, and 18 categories of low risk. Among these 42 risks, strategies for managing risk variables were determined in 4 categories: 8 risk retention, 19 risk reduction, 8 risk transfer, and 7 risk avoidance.
Manajemen Proyek Sistem Perpipaan Pastillator Plant Menggunakan Metode PERT
The construction of the Pastillator Factory piping system installation scheduled with a duration of 78 days in 3 months was delayed to 142 days. The delay was caused by several factors. In this study, identification of delays using the Fishbone Diagram method is used to visualize the factors causing delays in this project. By using PERT method, the probability of success of this project is only 22.06%. The total cost incurred reached Rp 3,887,796,715.32, which exceeded the contract value of the project. To overcome this problem, the study recommends the implementation of project acceleration through more efficient rescheduling, as well as optimizing the use of existing resources and tools. The implementation of this acceleration is expected to not only complete the project on schedule, but also assist in better cost control.
Analisis Waktu Dan Biaya Proyek Pembangunan NSAP (New Sulphuric Acid Plant) Dengan Metode Earned Value.
In Gresik, East Java, a New Sulphuric Acid Plant (NSAP) construction project with a capacity of 1.350 TPD is underway. However, the project has faced delays due to labor shifts across different work areas, leading to a decline in project performance. If the project is delayed, the company faces a penalty of 0,1% per day of the contract value. This study evaluates the performance of the NSAP project at a copper smelting company in Gresik using the Earned Value method. The Earned Value method is crucial in managing construction projects like NSAP to enhance control, monitoring, and efficiency. The project, with a budget of Rp 44.450.000.000, is scheduled to be completed in 13 months. By the 13th month, the Schedule Performance Index (SPI) was 0,90 (<1), indicating a delay of 9,512%. The Cost Performance Index (CPI) was 1,03 (>1), showing that the actual cost of Rp 38.896.768.171 was below the budget, making the project more cost-efficient despite the extended timeline. The project is expected to be delayed by 38 days, with a final estimated cost of Rp 42.985.536.316. After rescheduling using the PDM method, it was determined that the project could be completed on schedule without incurring late fees.
Analisis Waktu dan Biaya Pada Proyek Sistem Perpipaan Area L23 Industri Viscouse Purwakarta Dengan Metode Fast Track
In the implementation of construction projects, there are often deviations between the planned schedule and the realization in the field, causing delays. The Area l23 Quality Improvement Project Piping System construction project is planned to be completed in 133 days but in actuality the project is completed in 169 days. this is due to delays in Support Installation activities. Therefore, the delay in this project analyzed with Fast Track method so that the resulting time and cost are optimal. The analysis is carried out only on the work that is on the critical path using the CPM (Critical Path Method). the actual cost of the project with penalties is Rp.3,387,124,792 for 169 days, After this project is analyzed by Fast Track method, the optimal duration is obtained for 132 days with a total cost of Rp.3,144,347,950 Thus, the Fast Track method can be used as an alternative to optimize the time and cost of this project.
Evaluasi Proyek Instalasi Perpipaan pada Quality Improvement Project dengan Menggunakan Metode PERT dan Crash Program
The pipeline installation project, initially planned to start in October 2022 and estimated to be completed by May 2023, experienced delays extending to June 2023. These delays resulted in non-compliance with the predetermined schedule and budget overruns. To address this issue, the severity of the delays was identified using the Severity Index method, and a scheduling evaluation was conducted using the PERT method and the Crash Program method. The PERT method was employed to determine the probability of success, while the Crash Program method was utilized to optimize work time at the lowest cost. Based in the analysis, the Severity Index method identified the primary delay factor as low manpower productivity. The PERT method revealed only a 15.62% probability of completing the project on schedule, with a total duration of 193 days and a cost of Rp4,784,963,413.36. By applying the Crash Program method, the project duration could be reduced to 169 days by increasing manpower and overtime, lowering the cost to Rp4,686,783,913.36. The Crash Program approach was recommended for its shorter duration and cost efficiency.
Studi Kelayakan Teknis dan Biaya pada Proyek Pembangunan Tangki Bahan Bakar di Samarinda
The fuel logistic company built a storage tank containing diesel fuel with a capacity of 1x5000 Kl. Construction will be carried out from November 2023 to September 2024. If the development is said to be succes, it requires a feasibility analysis to determine whether the development is feasible or not. Technical and cost focused feasibility. Technical feasibility of reviewing tank and pipe calculations with images of the Term Of Reference (TOR) and tank code/standard API 650 12th Edition 2013 and ASME B31.3 2012 pipe standards. Cost feasibility of analyz project benefits using the Benefit Cost Ratio (BCR) and Net Present Value (NPV) methods, by reviewing the price of draft cost budget materials with standard market prices. The results of the technical feasibility of reviewing the tanks and pipes calculation with images Term Of Reference (TOR) and code/standard declared WORTHY with fasibility 75%. The results of the feasibility of calculating costs using the Benefit Cost Ratio (BCR) are 4,02 > 1, Net Present Value (NPV) is IDR. 466.051.111.788 > 0 and 43,81% feasibility reviewed price, so it has been declared WOTHY. Recommendations technical feasibility and costs review technical specifications and review cost budget determined by contractor and market.
Analisis Kinerja Proyek dengan Metode EARN VALUE Management dan CRASH COST
In the smelter construction project, various supporting aspects were involved in its continuation, one of which was the piping work package. The Shop Fabrication for Metallic Pipe was expected to be completed within 13 months, from November 2022 to November 2023. Delays were experienced from the beginning of the work, resulting in a setback from the initial schedule. By the final month of the contract, the work had only reached 92.47%, indicating that 7.53% of the work remained unfinished. An analysis of worker quality, as well as cost and time, was conducted. The analysis of time and cost was carried out using the Earned Value method. The CPI and SPI values obtained were 0.97 and 0.92, respectively, both below 1,, indicating delays and cost overruns. The Earned Value analysis determined that an additional 33 days were required to complete the project, with an estimated additional cost of Rp4,232,813,489.24. Therefore, the estimated completion time was 412 days. Subsequently, a Crash Cost analysis was performed to shorten the project completion time by adding overtime hours, resulting in an optimal duration of 26 days with a cost of Rp 4,022,188,929.67. The cost for this completion method was lower than the Earned Value completion cost, and the project duration was shorter.