piping stress analysis design basis

PROJECT Contract No.:

Descrintion: 84529 - SUMPAL EXPANSION PROJECT

sponsible Person: Paul Mc Elligott

Document Number Status Status Rev R-ived

Title

.84529-SU-LO-BODGN-00-OW1 1 AFC - Plplng Stress Analysls Design Basis

Responsible Person to mark the action code column "RA,&R,I,IA"

r" "' -' = I I

d o n Harjuna 06/03/12 09/03/12 R aul Mc Elligott 06/03/12 09/03/12 RIA

TION CODES:

, - Reviewer Approval (Action, Rwew and ~ollect Commenk), A - Accountable, R - Reviewer, I - Informahon, I A - Informahon W/O Atl

DOCUMENT REVIEW STATUS SIGNATURE (RESPONSIBLE

Not Approved. Revise and Re-Issue Inmrporatlng Commenk PERSON):

Returned without Comments Returned with Comments

xt Issue as follow: - - - - - - - - - - - - - - - - . - - - . - - - - . - . - . - - -. - for Approval for Constmdlon for Purchase for Use for Bld for Deslgn Q Others 2' Approved:

@ DATE

for Approval for Construdlon for Purchase for Use for Bid for Deslgn Others 7 1 j / ~ l l ,

EASE RETURN THE DOCUMEM TO RESPONSIBLE PERSON BY : I

PT. SEMPEC- PT. PU - P U CONSORTIUM

Document Title : Piping Stress Analysis Design Basis

CPGL DOC NO. : C-84529-SU-LLO-BOD-GN-00-0001

Originator

CPGL Group Owner Area Locatlon System Document Type Discipline I Subdiscipline Old CPGL Document No.

: PT. Sempec Indonesia - PT. Punj Lloyd Indonesia - Punj Lloyd Ltd. Consortium

: Projects ' : Sumpal '

: General : General System : Basis of Design : PlplnglPlplng : NIA

- OA

Rev Checked

IFC

Status

'als in the approval bo The originals are he1

, . . . . , . , , . , ,, . ,~ . ,

. . : , . . 9 .,

Approvad

OB-Jan-2012

Issue Date CPQL Approvale

Issued for Comment

Reason for Issue ,:

P m a Wldakso I Posma Purba ---------

Prepared

Awn K Mldha

Mhok K, s l n ~ n

PE PM

Piping Stress Analys is Design Bas is ConocoPhi l l ips (Grissik) Ltd.

C-84529-SU-LLO-BOD-GN-00-0001 Rev. 1 Page 2 o f 37

w &?a "., ...... ConocoPhillips a63a fig,"eL

Revision Sheet PI. SEMPEC- PI. PLI - PLL ConocoPhillips (Grissik) Ltd. CONSORTIUM

DESCRIPTION OF CHANGE 1 Issued for Comment 1 Revised "Contractor" Definition as per Client comment I Added Project Documents References as per Client comment

Revised Seismic Loads as

Added Solar Radiation as per Client comment

Revised the definition of "S,," in para. 8.1 as per Client comment ....--..-....-.p-..-...-pp--.--.....----

Deleted "ASME 816.47 Series B" in para 8.2 as per Client comment

Changed the title of para. 9.0 as per Client comment 1 Added Appendix E and F as per Clie~it comment 1 Revised the definition of "S,," in para. 0.1 as per Client comment I Added "ASME B16.47 Series A" in para. 8.2 as per Client comment 1 Revised Moments unit

...................................... ....... ...........................................

Addi t ional Approvers (If Appl icable)

1 Name

... ....... I?. Scnlpcc Indonesia - IPT. I'ilnj Lloyd 1tidollosi;r - Punj Iloyd L l r l Cc)~~sorl i \~~!~

Piping Stress Analysis Design Basis ConocoPhillips (Grissik) Ltd.

C-84529-SU-LLO-BOD-GN-00-0001 Rev. 1 Page 3 of 37

Contents

Introduction ............................................................................................................................. 5

Definition .................................................................................................................................. 6 Codes, Standards, and References ....................................................................................... 7 Company Standards and Specificatio ConocoPhillips Grissik LTD Stand International Codes and Standard

ASME ........................................................................................................................................ 7

Computer Software ................................................................................................................. I 0 . . Design Cond~ t~ons ................................................................................................................ I 0 Global Axis for Stress Study

Transient Loads

Piping Stress Criteri Flange Leakage Cri

Air-Cooled Heat Excha

Rotary Type Positive Displacemen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Restraint Load

Stress Calculation Notes ...................................................................................................... I 5

l'r. Scmpcc Indonesia - I'T. I'i~nj Lloyd lri~lai~~!si;i - I3tiiij l.loyd I ld . (:onsoiliriiir



APPENDICES

Appendix A Critical Lines Selection Criteria ........................................................................................ I 6 Appendix B Approximate Methods for Simplified Analysis ........................................................... 19 Appendix C Allowable Nozzle Loads for Vessels, Columns, Heat Exchangers, Storage Tanks,

and Package Equipments .................................................................................................. 21 Appendix D Tanks Allowable Nozzle Loads .................................... ... .................................................. 25 Appendix E Pumps Allowable Nozzle Loads ........................................................................................ 27 Appendix F Air-Cooled Heat Exchangers Allowable Nozzle Loads .................................................. 32 Appendix G Sample Calculation Notes ................................................................................................. 34

IT. Se~npec liidonesin - ITr. I'lltij i loyd li>do~Icsiii - i ' i~~>j Lloyd l i d . (:iifii:;o~iiiini



1 .O Introduction

The Basis of Design describes the requirements of ConocoPhillips Grissik LTD (CPGL) for the development of the Sumpal Expansion Project.

The Sumpal Gas Station is a part of the Corridor Block PSC (Production Sharing Contract), located 40 km South-West of Grissik in South Sumatra. The Corridor Block PSC is a 54:36:10 joint ventures between ConocoPhillips Grissik Ltd, Talisman Energy and Pertamina. CPGL is the field operator.

The existing Sumpal Facilities have been designed to process 165 MMSCFD of raw gas from the Sumpal field and to produce 155 MMSCFD of dehydrated gas which is further exported to CGP at Grissik for gas sweetening and onward sales. In order to meet GSPL contracted gas delivery and maximize the recovery of remaining gas resources from the Sumpal field, the Sumpal Facilities will be increased to export the dehydrated gas from 155 to 310 MMSCFD by first quarter 2013.

The results of the concept selection study, has suggested that an identical gas processing facilities with the same capacity as the existing Sumpal Phase 1 (155 MMSCFD) is required to be installed to meet the above targeted dehydrated gas rates to CGP.

Figure 1.1 Corridor ~ l o c k k ~ and the Location Sumpal Gas Station

The Sumpal Expansion Project involves the iristallation of addiliorial woll fluid processing capacity in the Sumpal Gathering Station. 'The project requires tie-in of Sumpt~I well N7, a new 1 6 Duplex SS flowline and extension of l l ie existing inanifold, a new second gas processing train, a new 1 6 pipeline loop trunklirie from tlie S~~rnpal Gas Gatlieririg Station lo the Sumpal Junction and the associated utilities and offsites facilities. The tlehydt-alccl gas will be delivered to the Grissik Central Gas Plant tlirougli the 20" trunk line from Sumpal Junction for further processing.

The Surnpal Expansion Project is a brown field rmiodilication irerice ilio insisllaliori of equipment will be undertaken while the existing plant is it1 oporotiorl a11d will1 minimal disruption to tlie existing operations.

1 7 . Seinpnc Indonesia .. IF?. Pun; Lloyd indoncsin - l'uilj Lloyd I.I<I. (;on.;o~ti\r~r~



2.0 Scope

This Specification is to define the minimum criteria, technical requirements, and procedure for performing the stress analysis of piping systems required for Sumpal Expansion Project.

This document provides general guidelines. If there are any specific stress analysis requirements, that requirements shall be taken into consideration by the relevant Sub- contractor or Vendor.

The stress analysis aims to achieve the following:

To confirm that piping system stresses are within those allowed by the applicable code. To confirm that piping system deflectionsldisplacements are within reasonable limits. To verifylprovide piping loads at rnajor supports to enable the design of supports, anchors, guides, line stops, etc. To identify support locationsltypes and to specify special support requirements such as springs, sliding plates, rigid struts, etc. To ascertain that flanges are not susceptible to leakage. . To confirm that calculated piping loads acting on equipment nozzles are acceptable as per the applicable codelstandardlproprietary Vendor data.

The following are excluded from the scope of this specification:

GRE piping stress analysis (static) and surge analysis (dynamic) shall be performed by the designated Vendor. . Transportation loads due to roadlsea transportation for Vendor supplied skids shall be reviewed by the Vendor.

3.0 Definition

Term

Company

Contractor

Manufacturer

MlGAS

Project Specification

Project Data Sheets

Purchaser

Shall

Should

Standard Specification

Vendor

Work

Definition

ConocoPhillips Grissik LTD

PT. Sernpec lndonesia - PT. Punj Lloyd Indonesia - Purlj Lloyd Ltd. Consortium

Manufacturer of major equipment, and or components

Direktorat Jenderal Minyak dan Gas Bumi

Directorate General of Oil and Gas

Referenced Specification shall be Project specific

Referenced Data Sheets shall be Project specific

Persons responsible lot- procurerrrent of equipment, materials and or services

Shall is an absolute requirement which shall be followetl strictly when referenced

Strongly recommended suggestion

Standard Technical Specification for Onshore Projects

Persor~(s), cornpany, firm, manufacttrrer, or fabricator who is a supplier of materials, supplies, arrtllor services to the Purcliaser

Shall be supervisior~, administration, labor, srlaterials, transportation, supplies, tools equiprnctil a ~ i d activity reqt~ircd to comply with Llre rt?ql,~iren~t?rlls of Co~r~p;\liy Project Specificatiori ,?rid C o s ~ t ~ i c t

I'T. Selnpec Indonesia - I'T. Punj Lloyd Indonesia - Punj l i o y ~ l ILI1I. (:onsc)~lii~,,~



Codes, Standards, and References The latest editions and revisions of each Codes and/or Specifications, as of the Contract Document date, shall apply, unless otherwise specifically noted on the Contract Documents or approved, in writing, by the Company. The following documents shall be complied with, unless stated otherwise in this Standard specification.

Company Standards and Specification

ConocoPhillips Grissik LTD Standard Specifications

Latest revision of the Company standard specifications shall be used. [.

ltem NO I Document Title Document Number Approved 6 7

1 Onshore Facility Piping Design

2 Document Numbering Procedure ID-G-BU-00000-00000.00003 Technical Authority

Engineering Document and ID-G-BU-GGO-STS-GN-00-0001 Technical Authority Revision Numbering

-- .................... . .........................

Documentation & Data ID-G-BU-00000-00000-00012 Techtiicai Authority Required By Operations (DFO) - ...................................

4.2 International Codes and Standard

4.2.1 API

Latest revision of API Standard to be referred to:

Standard .......

Description

Fired Heaters for General Services I APi 610 Centrifugal Pumps for Petroleum, Iioavy Duty Cliemicais & Gas

industry Service .-.. ., .......................................................... ~,~ ...................................... 1 ; I API 612 Sr~ecial Puroose Stoam Turbines kjr liofinarv Services

API 617 Centrifugal Compressors for Potroloum, Clie~iiical anrl Gas Industry

...... ...

API 620

API 650

API 661 I API 662

API 672 -

API 6'74

Packaged lriterrially Geared CentriIug;%l Co11li)ressors lor General liolincry Services ....................... .................................................................... .-

API 676 I'ositive IJisptacement Ptlmps - Rotary . .......... .- ...........................................................

liecotnmendod I'ractice lor Sizittg, Soloction, and itistalli3lion of l~ressilre-l'ielievino lDevict!s in l'iufinaries

Tecliriical lieport on Capabililies of AIJl 1i;lngcs i l r ido~ Combinations of Load

..........................................................

4.2.2 ASME

Latest revision of ASME Standard to bo referred to:

Slandard . . . . . . . . I

I'T. Selnpec Indonesia - IPT. Pun; Lloyd Indonosin . l"u11; i.loyd i.td (:onsortiiln,

Piping Stress Analysis Design Basis C-84529-SU-LLO-BOD-GN-00-0001 Rev. 1 ConocoPhillips (Grissik) Ltd. Page 8 of 37

ASME 536.10 +- Welded and Seamless Wrought Steel Pipe

ASME 836.19 I Stainless Steel Pioe

5

ASfilE SEC V I . .

10 ASNE RTP-1 t ie nforcca Tncrfncset Past c Corros on tics stant Ea. u'nc~it

MSS

ASME 816.5 Pipe Flanges and Fianged Fittings

6

Other CodeslStandards

Latest revision of MSS Standard to be referred to:

Latest revision of CodeslStandards to be referred to: .- ....................................................................

1 ltem NO I Descriation

ASME B16.47

Item No

1

2

3

1 ASCE 7 ...........

- Large Diameter Steel Flanges (NPS 2 6 through NOS 60 )

...... NEMA SM-23 - PD 5500

Standard

MSS-SP-58

MSS-SP-69

MSS-SP-89

I 5 1 UBC I

Description

Pipe Hangers and Supports - Material, Design, and Manufacture pppp--.-

Pipe Hangers and Supports -Selection and Application

Pine Hanaers and Suonorts - Fabrication and Installation Practice

Local SlresScs in Sptlerical and Cylitidrical Shells due to Extortial Loadings on Nozzles

Project Documents

In addition to above mentioned Codes, Standards, and Company specifications, the latest revision of the following project doculnents shall also form a basis for the stress analysis:

C-84520-SlJ-LLO-SPC-GN-00-0001 l:'iping Material Spocilicirtion ................ ........................................

C-84529-SU-I'PO-RLL-Sr-00-0001 I I:'it~ina Line List

I : , I

Conflicting Requirements

In the event of conflict of precedetice betweeti docutnents the niore stringent requirerrietils shall be applied. Generally tlie order of precedence shall be in this order lop lo bottom.

Indonesian Government Legislation and Regulations This Standard Specification Referenced Industry Codes and Staridards

Contractor shall obtain writtert approval fro111 Cornpany hc?lorc? corrimo~icin<] witti work affected by a conflict of precedence.

In all cases Company shall reserve tlie riqht to apllly tlic? liiosl stringc-!nl rcc.lirirc?~rietits,

I'T. Sernpec Indonesia - P i . IPunj Lloyd iil(lor1csia - I'illij Ltoyil I l r l . Co~tsottiritn



4.5 Units

International Systems of Units (SI) shall be used for stress analysis works. However, pipe sizes, pressure, and temperature can be stated in imperial Units.

5.0 Critical Lines Selection The classification of lines for stress analysis involves a review of the critical features of the piping system. The following features of piping provide general guidelines for critical lines selection:

Fluid in service Pipe size Pipe material Design temperature Design pressure Displacement External ioads Lines connected to equipment with allowable loads Lines exposed to transient loads such as slug, PSV, blow-down, regeneration, recycle, water hammer, etc Lines having interface with other operating centers or Vendors

5.1 Lines Category

The lines are classified into three categories. Each category shall dictate the type of stress analysis required.

5.1 .I Category 1 (Visual Analysis)

These lines are exempted from the formal stress analysis. The lines are reviewed by piping designer by means of visual inspection. This applies to non-critical lines such as utility piping, lines that possess adequate flexibility by virtue of stnall size, moderate temperature or flexible configuration etc.

5.1.2 Category 2 (Simplified Analysis)

These lines are reviewed by stress engineer using guided cantilever method, graphical method or method outlined in para. 319.4 of ASME B31.3 (Appendix B). if the lines under review fail, the lines shall be upgraded to Category 3.

5.1.3 Category 3 (Detailed Analysis)

Lines under this category shall be analyzed by Computer Prograrn and proper calculation notes shall be prepared.

The critical lines selection criteria are tabulated in Appendix A.

6.0 Analysis Procedure As a general rule, the phases of piping stress analysis are developed as follows:

Line geometry definition Definition of supports and restraints Verification of longitudinal stresses and deflections producc?d hy sirstaitied (no11 sell- limiting) permanent ioads and occasional loads (wind, seismic, etc.) Verification of longitudinal stresses and deflectiotis prodirce(i by sc?ll..litnilitlg loads such as thermal loads, etc. Verification of piping loads for support design Verification of piping loads on equiprnc?nt nozzles and conneclior~s Check for flange leakage

Piping Stress Analysis Design Basis ConocoPhill ips (Grissik) Ltd.


The analysis shall cover all possible cases, such as normal operation and un-normal operation (start-up and vibration, blow-down case, etc).

Computer Software

Computer software to be used for the piping stress analysis shall be CAESAR II latest version with latest build or others if the analysis is performed by the Vendor.

CAESAR II units file SUMPAL.FIL shall be defined as per Section 4.5. The units file and the configuration file CAESAR.cfg file shall be maintained same for all the calculation notes.

Design Conditions

Global Axis for Stress Study

Y

"North" indicates platform north direction and X, Y, & Z are three perpendicular axis

Environmental Loads

Wind Loads

The piping system shall be subjected to wind loads. Wind loads will be implemented in horizontal axis, X or Z, whichever is more stringent. Wind profile will be considered as wind velocity vs. elevation and a shape reduction factor of 0.8 (for circular piping sections) shall be applied in the stress analysis.

The maximum wind speed of 80 kmlhr, taken frorn Process Basis of Design (document no. B- 84529-SU-PPO-BOD-ST-00-0001), shall be defined for pipe elevation 210 m.

Seismic Loads

The piping system shall be designed to withstand seisniic loads and no failure identified. The recommended vertical design spectra shall be taken as 213 of the llorizontal design spectra. Seismic loads are considered based on Zone 2 it1 SNI-03-1726-2003. The following values shall be used in the stress analysis:

Horizontal accelerations in X and Z directions = 0.15g Vertical accelerations in Y directions = 0.10g

Operational Loads

During operation, the lines and pipirig componc?nts are subjected (o various loatling conditions such as:

Weight

Weight of pipe, piping components, fluid content, itisr~latiot~ weighl, otc, shall be considered along with other in-line components to calcolate t11e longitrtdinal st~stii~ined stresses.

Pressure

Design pressure shall be used for longitudinal and i~oop strc:!;s cirlct~I;rtions.

For stress stiffening due to pressure, operating pressure? is considered il-1 11113 nn:llysis.

13. Sempec lndoriesia - I T . 1:'unj i.loyd 11ldoncsi:r - I'ilnj Lloyd i k l . Corl:;~<lio~n


7.3.3 Temperature

All code stresses shall be checked at design temperatures of the piping system. However, ASME 831.3 requires evaluation of code stresses at maximum or minimum metal temperatures occurring during the thermal cycle. In case use of design temperatures results in major revision in piping IayouVsupporting then in consultation with Process Department, maximum or minimum operating temperatures can be used for stress analysis. Ambient temperatures below shall be used as references to calculate thermal stress range:

Maximum ambient temperature = 95°F Average ground temperature = 85°F Minimum ambient temperature = 65°F

7.3.4 Solar Radiation

Thermal stress due to solar radiation is not considered in this stress analysis.

7.3.5 Friction

The frictional forces at the pipe supports have a significant effect on the behavior on the piping system. To reduce frictional loads on equipment nozzles or to reduce frictional forces at welded supports where local stresses exceed allowable stresses, use of low friction sliding plates may be considered at supports.

Based on the pairing of contact surfaces following frictional factors shall be used:

0.10 for PTFE (Polytetrafluoroethylene) to stainless steel surface contact 0.30 for carbon steel to carbon steel surface contact

Wherever low friction sliding plates are required at supports the stress isotnetrics shall highlight such requirements.

7.3.6 Displacements

The impact of terminal displacements shall be considered into stress analysis. These shall include equipment nozzle thermal growth, tank seltlements, differential settlement between structures, thermal growth of Vendor interface piping, the lines displacements of other stress anaiysis calculation notes, etc.

If possible, when analyzing piping around equipment with thermal growth displacements or settlements, pipe rigid support should be modeled connecting to equipment structure.

7.3.7 Hydro Test

Hydro test pressure shall be considered as 1.5 times of design pressure.

Spring supports are considered as rigid support during hydro test case. On the field, these spring supports shall be locked to prevent excessive deflection and over-.stressing of the system.

7.3.8 Transient Loads

Transient loads can have adverse effect on the lines and those loads aro also required to be reviewed.

a) Two phase flow causing slug loads at bends and tees sliall be reviewed in consultalion with the Process Department.

b) Relief valve kick forces for gas lines shall be calcirlatecl as lper API 151320. PSV reaction forces shall only be considered for process PSVs in gas1vapou1- services witli a Dycianiic Amplification Factor (DAF) = 2.0. However, Vendor datas will be used later upon receipt.

c) The impact of hydraulic transient (surgelwater hammer) e.g. in firc wator network piping, if any, shall be considered in the static stress analysis.

7.3.9 Multi Equiplnent Operating Philosophy

Varioirs load cases shall be considered for analysis dopc!ndilig 011 !lie operating pliilosopliy of multi equipment e.g, two pumps with one being spare:

Operating condition 1: both putnps A and B opemlirig Operating condition 2: pomp A opel-ating, pc~riip B stand-by

1'1. Sernpcc Indonesia - Ir1. I 'uf~j Lloyd 1ndonosi;i - I"Ui1J Lloy~l l l d Consorlit~,~l



Operating condition 3: pump A stand-by, pump B operating

For piping systems with portions of stagnant fluid and without hot by-pass the temperature gradient along the piping length shall be considered as per following:

For insulated lines, average ground temperature from block valve to the equipment. For un-insulated lines, average ground temperature from tee junction to the equipment

8.0 Stress Analysis Acceptance Criteria The criterion mentioned below is as per the code requirements at the time of issuance of this document.

8.1 Piping Stress Criteria

In accordance with ASME 831.3, section 302.3:

a) S, sSl, x W ref. 302.3.5 (c); for primary sustained loads

b) SE ~ S A ref. 302.3.5 (d); for thermal expansionldisplacement loads.

Where: SL = sum of longitudinal stress due to sustained loads St, = basic allowable stress at metal temperature, taken from Appendix A, ASME

831.3 SE = calculated displacement stress range SA = allowable displacement stress range

= f (1 .25Sc + 0.25SI,) or f [(I .25Sc + 1.25Sl,) - S,] Sc = basic allowable stress at minimum metal temperature W = weld joint strength reduction factor (wherever applicable as per 831.3) f = stress range reduction factor (value shall be as per plant life of 30 years.

Number or actual operating cycles shall be obtained from the Process Department)

c) The allowable stress due to occasional loads such as wind, earthquake, PSV reaction forces, etc. shall not be greater than 1.33 times the hot allowable stress, SI, (ref. ASME B31.3, para. 302.3.6). These occasional loads shall not be considered to act concurrently.

For other codes such as ASME B31.4 or 831.8 where orishore piping maybe involved, relevant stress calculation equations shall be utilized (exact code shall be chosen in CAESAR II input).

8.2 Flange Leakage Criteria

a) ASME Flanges

Critical flange joints shall be assessed for leakage as per tlie equivaletlt pressure method.

Flange leakage calculation is required when flange joint is connected to equiptnent nozzle and flange joints located in lines carrying service fluids dee~ned as hazardous by Process Safety Department.

The flange leakage formula is as below:

The Total Pressure: PI. = P,,, -I- P

417 10A.1 The Equivalent Pressure: P,,t = - - - - - - - - - . I. .. .

(; " jr

Where: P,?, = equivalent pressure due to pipe loadirig olrly F = tensile axial force acting at the I'larig(? M = bending lnornent acting at the flange G = effective gasket diarneter (I-eactive load location) P = operatitig pressure P, <;rating pressure of tlie flange as [Jer ASMlI I3l(i.!jlASME I:316.4'7 Sories

A -- ~

I"r. Sernpec Indonesia - P i . Pun; Lloyd lhliloi~<!si;i . i'oti; Lloyd i..ltl. Co~isorl i~izi~


In cases where the total pressure exceed the allowable pressure, a second verification shall be performed at the maximum operating conditions or a detailed flange calculations shall be carried out as per requirements of Section Vlll Div. 1, Appendix 2 of ASME Boiler and Pressure Vessel Codes (using CAESAR II module).

b) Clamp Connectors/Compact Flanges

The piping loads at clamp connectors and compact flanges shall be limited to the Vendor allowable limits.

Allowable Loads on Equipment Nozzles

Forces and moments induced by piping system on nozzles of major equipment shall not exceed the values stated in the various standards mentioned below.

For piping connected to strain sensitivelrotating equipments, the nozzle loads calculation shall be based on operating temperature. For all other nozzle loads, calculation shall be based on design temperature. Air fin cooler shall be considered as strain sensitive equipment.

Vessels, Columns, and Heat Exchangers

Piping loads applied at the shell-nozzle junction shall not exceed the criteria set in Appendix C. In case the loads are exceeded, then a WRC 107 checking shall be carried out to check the magnitude of local stresses due to piping loads. Subsequently, the loads shall be submitted to the Mechanical Department for onward transmission to the Vendor for approval.

For welded plate frame and plate heat exchangers, the allowable loads at nozzles shall be as per Table-I of API 662.

For shell and tube heat exchangers, the allowable piping loads at nozzles shall be as per the table specified in Appendix C.

Air-Cooled Heat Exchangers

Piping loads on Air-Cooled Heat Exchangers nozzles shall satisfy requirements ~nentioned in Appendix F.

API Centrifugal Pumps

The allowable forces and moments for API Centrifugal Pumps shall meet the criteria explained in Appendix E.

Non API PumpslManufacturer Standard

Vendor allowable loads shall be followed. Mechanical Department shall obtain confirmation from Piping Department for the allowable loads provided by Vendor.

Centrifugal Compressors/Turbines

The allowable nozzle loads on centrifugal compressorslturbinos for individual and combined loads shall be as per API 6171NEMA SM-23 equations respectivcly.

Rotary Type Positive Displacement Compressors

The loads on rotary type positive displacement compressors shall be in accordance with API 619 Section 5.4.

Reciprocating Compressors

Supplier shall provide maxiinurn individcial and resultant allowable forces and moments of both inlet and outlet nozzles. API 618 and NEMA SM-23 are crsed lor gt~itlance only.

Flat-Sided Tanks

Unless agreed with Purchaser, the allowable nozzle loads lor ll:il..sidad latnlts shall be as per table specified in Apperidix O.

Storage Tanks

The minimum allowable external loads on tanks shc?Il operiings shall I)(? as slated in Al)l)endix C.

lTr. Scmpoc lndoncsia - I T Pilnj Lloyd lndoncsin .. l.'~~rij Lloyd l.l<J. (;o~~sc)~lii~n)

Piping Stress Analysis Design Basis ConocoPh i l l i ~s (Grissik) Ltd.

C-84529-SU-LLO-BOD-GN-00-0001 Rev. 1 Page I d of 37

8.3.10 Unlisted Equipments

For equipments that are either not mentioned or governed by any of the codes stated in Section 4.0, the equipment manufacturer's recommendation shall be considered.

8.3.1 1 Package Equipments

For package equipments, where Contractor has a piping interface with Vendor's piping, allowable piping loads shall be as per Appendix C.

9.0 Design Considerations

9.1 Restraint Loads

Any piping loads in excess of 5 kN acting horizontally or 20 kN acting vertically andlor supports more than 2 meters in height shall be issued to Civil Department for support member design.

9.2 High Pipe Deflections

The pipe deflection of free span shall not exceed % inch or 12.7 mm. For sloping lines, maximum deflection shall be % inch or 6.25 mm. Exceptions to this shall be approved by the stress engineer.

Pipe lateral deflections should not be excessive as to cause clashing with surrounding pipe work, structural or equipment. Stress engineer shall mark pipe horizontal displacements 275 mm on the stress isometrics for providing longer shoe lengths and checking of pipe spacing clearance by piping designer.

9.3 GRE Piping

p. Supporting of GRE piping systems shall be as rigid as possible while respecting the thermal ..' ,*<; ,.s e.*jv analysis criteria.

A combined thermal flexibility and water hammerlsurge analysis shall be performed by Vendor. Detailed piping design by Contractor shall follow recotnmendations made by Vendor.

9.4 Spring Supports

Use of spring supports shall be minimized and considered only wlien the piping layout cannot be configured to add extra flexibility to mitigate vertical thermal displacements or relative movement e.g. tank settletnent.

For the piping connected to rotatinglstrain sensitive equipment, tlie maxinluln load variation shall be 10%. The maximum load variation for piping cocinected to other c?quipment shall be 25%.

Constant spring supports shall be selected in either of tlie following cases:

The load variation exceeds the above specified limits To reduce the transfer of load to nozzles on fragile equipment 0.g. GRE tilaterial of construction

Spring support vertical displacements shall be calculated for the operatir~g cotiditions i.e. at operating temperature. However, the working range of selected spring nlotlel sliall also be suitable for vertical displacement at design temperattrrc?.

When used on liquid lines a WNC (Wei(ghl No Conterits) checking shall be c;:lrried out to ensure that the equipment nozzles are not overloadeti, or the pipe is no1 overslressetl wlien the pipe is empty. Otherwise, spring sliaII bc rnarkod lo be locltetl wllell t l ~ e liilc? is emptylunder maintenance.

The selected size of spring support shall be suitabie lol- hydro tcst loads will1 spri~lg ill loclted position. Vendor shall confirm suitability of tho selc>clod size for hydro lest load!^ tll.lring technical bid evaluation.

"

I'T. Sornpec Indonesia - 1'1.. l'unj l..loyd lndoncsia - IPoni Lloyrl i.LI. Co~i:;o~lliriii



9.5 Expansion Joints

Expansion joints shall be avoided unless those are required as per Process requirements. In case piping layout constraints do not permit addition of flexibility by means of providing loops, etc., then expansion joints shall be utilized only after obtaining Company approval. For piping systems utilizing expansion joints, recommendations of EJMA standard shall be followed.

10.0 Stress Calculation Notes Each stress calculation note (lines category 3 only) shall obtain as a minimum the following data:

a) Summary sheets indicating lines covered, maximum code stresses, flange leakage report, and piping loads on equipment nozzles

b) Stress isometrics with node numbers, restraints type, process design data for each lines, remarks by stress engineer, etc.

c) Computer input data d) Computer output data containing:

Load case report . Restraint loads Spring design data (if required) Code compliance report

Sample of stress calculation note refer to Appendix G.

ly r . Sernpec Indo~losia .. 1'1.. I'ucJ Lloyd lndoilesia - I'unj l.loyd ILliI. Con!;cxlitl&r~


Appendix A

Critical Lines Selection Criteria

i:vI'. Sc~npcc Indonesia - PT. Punj Lloyd 1ndonc:;i;i - I'uiU Iloyii i.I,I. Co8rso1liu1n

Piping Stress Analysis Design Basis ConocoPhillius (Grissik) Ltd.

C-84529-SU-LLO-BOD-GN-00-0001 Rev. 1 Page I? of 37

Critical Line Selection Criteria

TYPES OF PIPING SYSTEM

Vessels, Drums, Spheres, Columns, Shell &Tube Heat Exchangers, Non-critical Static Equipment (Note 2) Pumps, Turbines, Compressors

(Note 2) Air Cooled Heat ~xchangers, Plate Heat Exchangers, Tanks. Fired Heaters (Note 2) Flare LinesIBlow Down Lines (Inlet Pipe Size) (Note 3). Jacketed - PBing -- .-

High Alloy, Exotic, Thin Wall Stainless Steel, Non-ferrous Metallic Piping

INo te 2) .

RacklSleeper Piping (not connected to any equipment) (Note 2) High Pressure Piping 12900#)

I Piping with Expansion Joints 4.- Buried Piping Iklnto A \

Pipe Dia. (@)

(Inches)

LINE DESIGN TEMPERATURES

-49°F TO

199°F (Note 1)

200°F 300°F TO TO

299°F 499°F (Note 1) (Note 1)

LINES CATEGORY

>5OO0F (Note 1)

....................... 3 , ......... .....................................

c- -.......... 2 (Desigti Temperature (-50°F) ........ --, .- ............................ ........................... ................. <.-. ......... --3 (Desigti Temperature 5-50°F) ......-. - + ............................................................................................... ......-. 3 (Subject to Approval bycompany)-,--::;-). ....................... ...................................

+.. ............ 3 (Stress Allalysis by Vendor) . -.+ _ ._,. ........................ , ........................... ..-.................

NOTES:

1. Minimum Ambient Temperature = 65 "F Average Ambient Temperature = 85 "1- Maximum Ambient Temperature = 95 "I'

For Thermal Stress Range: . Line Design Temperature > 95 "F: Stress range frorn Mini~iitrm A~nbic?nt Tcrnpc?ralur(? . Line Design Temperature < 65 "F: Stress range from Maxin-~nn-I Ambieril Tempc?rahrre

For Nozzle Loads: . Nozzle loads shall be calculated with respect to Average Ambient "Tenipernlrrre

2. For process connections only (excluding vents, drairis, & low tornporaluro ~i l i l i t i r?~).

..............

i'T. Sempec Indonesia - PT. Punj Lloyd 1ndonesi;r . I'ullj l.loyd ILtrl. Col,:;(jlliliril



3. PSV reaction forces shall be considered for gaslvapour lines only.

4. Underground Fire Water metallic piping shall be exempted from formal stress analysis and shall be assigned Lines Category 1.

ADDITIONAL NOTES:

1. Large reciprocating equipment (if any) which requires dynamic analysis for induced vibration shall be covered by a separate study done by a Specialist Consultant.

2. The following lines do not need to be stress analyzed: . Non-hydrocarbon lines such as air lines and water lines including potable water, service water, etc. . All lines which discharge directly to atmosphere and which are not subjected to large thermal gradients, including atmospheric tanklvessel vents. . All lines which are part of skid mounted packages (i.e. under the scope of package Vendors). All small diameter piping (1% inches and below) unless subjected to surging such as relief and blow down (to be clearly identified on the P&IDs). . All drain systems piping including open drain and closed drain systems.

-- i'i. Sernpec Indonesia - PI, i'u~rj Lioyd l~~rloi~r!:;i;l .. illlllj i.ioyd I..Iii. Consarliol~r



Appendix B

Approximate Methods for Simplified Analysis

l"T. Sempec Indonesia - I 3 T 131111j l.loytl I i l t l~li(?~i:l - I'1111j i ioytl l..lti. Co~~sr),l iur~(

Piping Stress Analysis Design Basis C-84529-SU-LLO-BOD-GN-00-0001 Rev. 1 ConocoPhill ips (Grissik) Ltd. Page 20 of 37

Approximate Methods for Simplified Analysis

1.0 Guided Cantilever Method

For an 'L' shaped pipe work, from the structural theory, the permissible deflection, 6 is given as:

Where: 6 = lateral deflection (mm) L = deflected leg (mm) S = bending stress due to lateral deflection (Nlmm2)

= 137.9 N/mm2 as allowable bending stress for CS materials D = outside diameter of pipe imm) E = Young's modulus (Nlmm ) = 203400 ~ l m m ' (for CS materials)

The leg required for lateral deflection is:

Knowing diameter and deflection the flexible leg can be determined

Example: What is the length of the flexibie leg if the pipe size is 12 inch and the required deflection is 60 mm?

<,><*<< 6:: $. ' '

Notes: ........ ..... *, Do not use for piping connected to strain sensitive equipment

Do not use for larger line ending in reducer to smaller size. Do not use for lines ending in tees. Expansion length must be taken from fixed point.

2.0 ASME B31.3 Developed Length Method

For a two anchor piping system, the following criteria must be satisfied:

Where: D = outside diameter of pipe (mm) Y = resultant of total displacement strains (mm) L = developed length of piping between anchors (in) U = anchor distance, straight line distance between anchors (m) K, = 208000 SA/EA (mm/m)'" S, = allowable displacement stress range (MPa)

= f (1 .25Sc + 0.25SI,) E, = reference modulus of elasticity at average ambient temperature (MPa)

ref. 319.4.1 (c)

1'1. Seilnpec Indonesia - l'i. I'ilnj Lloyrl Illdonosin - i'ilnj Lloyil l l d Cotj!;otli~l~rl



Appendix C

Allowable Nozzle Loads for Vessels, Columns, Heat Exchangers, Storage Tanks, and

Package Equipments

l'i. Sempec Indonesia - IPT. i-'irnj Lloyd 1ndoircsi;i - 01111j i l ~ y i l l.ltl. C~r,!;o!lit~~n


Allowable Nozzle Loads for Vessels, Columns, Heat Exchangers, Storage Tanks, and

Package Equipments

Allowable nozzle loads for pressure vessels, columns, shell & tube heat exchangers, storage tanks, and piping interface in package units.

Unless otherwise specified, the maximum allowable forces and moments shall be as per table below. These forces and moments are assumed to be acting at the intersection of the vessel and nozzle.

x Where: *:. >,<$ . D = Nozzle Nominal Diameter

FA = Axial Force FL = Longitudinal Force Fc = Circumferential Force ML = Longitudinal Bending Moment Mc = Circumferential Bending Moment MT = Torsion

Piping Stress Analysis Design Basis ConocoPhillius (Grissik) Ltd.


Rating

..... PT. Ss~npec Indonesia - PT. Punj Lloyd 1ndonesi;l . I'unj 1.Ioyd 1.l1l. Cor lso~ l i~ r~ l~


D -- (in' Rating Fc, FL

..............

I'T. Sempec Indonesia - Irr. Punj L.layd lildonc:;i;~ - I'ullj i loyd l l d (;i,nsollitr~~\



Appendix D

Tanks Allowable Nozzle Loads

""

i T . S e m p ~ c lridonesia - I:T Punj Lloyd Indoi1esi;i - I'ilnj Lloyd Lld. Coi~so~l iu in



Tanks Allowable Nozzle Loads

The allowable nozzle loads for flat-sided tanks are as tabulated below

1.. , -. 1 Forces I Moments Nozzle slze I .. . I (N) I (Nm)

Notes:

1. All loads stated above act at the tank shell and nozzle intersection. In assumption, the loads act simultaneously.

2. The Supplier shall provide sufficient local reinforcement. This is to ensure that the stress due to pressure head, radial load, and applied moment does not exceed 1.5 times the allowable design stress for plate material.

3. Nozzle size larger than 8 , allowable loads shall be agreed by Purchaser.

I'l. Sc~npec Indonesia - Irl. I'uid Iloyd lndoocsi:r - l'ritij l.loyd Lid. Conso!litlm

Piping Stress Analysis Design Basis ConocoPhilli~s (Grissik) Ltd.


Appendix E

Pumps Allowable Nozzle Loads

I T Sempec Indonesia - i'i, l.'unj Lloyd lndollesia - Puiij I ioyrl I..Ld. (:ollso~li~i~ll



Pumps Allowable Nozzle Loads

The allowable forces and moments for nozzle sizes 16" and below shall meet the criteria of values in table below. Those values are taken from Table 4 of API 610, 10"' edition. When the calculated loads exceed these values, Annex F in API 610, lofh edition may apply.

Fx

FY

Fz

FR

Each side nozzle

Fx

FY

Fz

FR

Each top nozzle

Each end nozzle

890 1330 1780 3110 4890 6670 8000 8900

710 1070 1420 2490 3780 5340 6670 7120

580 890 1160 2050 3110 4450 5340 5780

1280 1930 2560 4480 6920 9630 11700 12780 .......... .. -

Moments (Nm)

Nominal size of flange (inch)

Each nozzle

Mx

MY

MZ

MR

S2

The coordinate system(s) shown in figures below shall be used to apply forces and moments in table above.

Forces (N)

3 4 6 8



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Isr. Se~npec Indonesia - I'T. Punj Lloyd indonesi;) - i'ilnj 1.layd 1-Id. l.:onrorlir!~ri



For nozzle sizes above 1 6 , Vendor shall specify the allowable loads, or actual loads due to piping reaction shall be submitted to Vendor for approval.

Allowable nozzle loads for vertical in-line pumps shall be twice the values in table above for side nozzles.

~

i'l. Seliipcc Indonesia - I'T Punj Lloyd Indonesi;~ .. I'CJII~ L.Ioy11 l..lt l. (:o~i!;<)rlit~tn


Appendix F

Air-Cooled Heat Exchangers Allowable Nozzle Loads

~"..".~ ~

1'1. Sempec Indonesia - PT. Piinj Lioyri lndonc!;i;l - I'ulij I-loyd Llrl. Con:;oi!itl~n



Air-Cooled Heat Exchangers Allowable Nozzle Loads

Air-Cooled Heat Exchangers shall be considered as strain sensitive equipment and each nozzle shall be capable of withstanding the simultaneous application of the moments and forces defined in table below. These values are taken from Table 4 in API 661. The total of all nozzle loads on one multi-bundle bay shall not exceed 3 times that allowed for a single header.

Moments Forces I (Nm, (N)

Nozzle size (inch) ...

The application of coordinate system(s) is shown below ,: Y

r r , # C L..i,.J

I

. - ..... I T . Sempec Indonesia - 1'1'. l'unj Lloyd indoiicsiki - i:'uiij Lloyd L l d Conso8liir1rr



Appendix G

Sample Calculation Note

"

PT. Sernpec Indonesia - I?. I'unj I..loyd Itidoncsi;~ - S ' i i ~ ~ j I l o y~ l l.lrJ. Cotl:;olli~io~



CONTENTS

1. COVER SHEET

2. COMPUTER INPUT LISTING

3. COMPUTER OUTPUT (RESTRAINT LOAD SUMMARY REPORT)

4. COMPUTER OUTPUT (STRESS COMPLIANCE REPORT)

5. COMPUTER OUTPUT (SPRING DATA - IF ANY)

LINES COVERED IN THIS CALCULATION NOTE:

LINE NO (s) REV. NO.

.-

I"". 0, : .-* - ........ ......... .............. ........... ....& 9

.. ...............................

......

.. "

1'5. Sempcc indonesia - 1'7. Pun; Lloyd I8idoiiesia - l'ilnj I loyd II<I (:on.:oiliiliii



REFERENCES:

CODE : PROCESS PIPING ASME 831.3

JOB SPEC : C-84529-SU-LLO-BOD-GN-0001

UNIT FILE : SUMPAL.FIL

AMBIENT TEMPERATURE : 65°F (MIN)/95"F (MAX) (FOR STRESS RANGE PURPOSE)

85°F (FOR NOZZLE LOAD PURPOSE)

CAESAR INPUT FILE : C-84529-XX-XXX-XXX-XX-XXXX-0.C2

DESIGN DATA:

CODE STRESS COMPLIANCE:

For calculated stresses refer to the stress compliance report attached with the calculation note.

CASE DESCRIPTION

/ SUSTAINED I S , = W + P + H 1 1 OCC. (SUSTAINED +WIND) S,I;~=W+P+H+WIN I <I .33 SI.,

~ ~ ~ . . ........., ,.....

OCC. (SUSTAINED +SEISMIC) Socc " W + P+ H + U 51.33 S,.,

EXPANSION (THERMAL + DISPLACEMENT)

W= WEIGHT, P = PRESSURE, D = DISPLACEMENT, T = TEMPERATURE, H = SPRING FORCE, WIN = WIND, U = SEISMIC, SL = SUSTAINED STRESS, Socc = OCCASIONAL STRESS, St: = EXPANSIONAL STRESS. SH = HOT ALLOWABLE STRESS. Sc = COLD ALLOWABLE STRESS, f = STRESS RANGE REDUCTION FACTOR

~ ". ir. Scmpec Indonesia - 12T. Punj Lloyd lndonosia - i'unj ILloyij l l r l . (:o~!;c>~liil~n


EQUIPMENT NOZZLE LOAD CHECK:

EQUIPMENT

TAG NO.

CALCULATED

-- 13T. Seinpec lnclotiesia - PT. Pui j Iloyd lniiorlc!;ia - I'tlnj I loyil Lid. (:rxi:;<ulit~~n