MK.

SISTEM PERKAPALAN

Oleh:
Muhammad Ainurrohim Surya Nugraha
NIM. 09121018

PROGRAM STUDI TEKNIK PERKAPALAN

JURUSAN SAINS, TEKNOLOGI PANGAN DAN KEMARITIMAN
INSTITUT TEKNOLOGI KALIMANTAN
BALIKPAPAN
2016

DAFTAR ISI

DAFTAR ISI....................................................................................................i
DAFTAR GAMBAR.........................................................................................ii
MODULE 1 PIPING SYSTEM COMPONENTS...................................................1
1.
2.
3.
4.
5.
6.

INTRODUCTION...................................................................................1
TUBULAR PRODUCT CLASSIFICATION.................................................2
SEAMLESS AND WELDED PIPES AND TUBES........................................3
MATERIALS, CORROSION & EROSION OF PIPES AND FITTINGS.............3
COCKS AND VALVES...........................................................................13
OTHER FITTINGS.................................................................................23

Reference..................................................................................................26

DAFTAR GAMBAR

MODULE 1
PIPING SYSTEM COMPONENTS
1. INTRODUCTION
The various pipe systems for commercial ships must comply with any
applicable rules of the responsible government department and those of
the designated classification society. Guidance is provided in
government and classification society publications and it is required
that plans for principal systems are submitted for approval.
The safety and reliability of critical individual fittings is ensured by a
requirement that they are made to specification by an approved
manufacturer. Materials are tested, welds are inspected, major fittings
are tested and marked (see Fig. 1), and systems are pressure tested by
or in the presence of a representative of the appropriate authority.
Efforts to ensure safety and reliability are extremely important.
Replacement components for pipe systems must be of the same
standard and obtained if necessary, from an approved maker. Some
accidents have been the result of replacement valves and other
components being of inferior quality [1]

Figure. 1.Relief

Valve

Figure. 2.Piping System: General Defination

2. TUBULAR PRODUCT CLASSIFICATION

Tubular products infers cylindrical products which are hollow, and
the classification of pipe or tube is determined by the end use.
Pipe and tubing are considered to be separate products, although
geometrically they are quite similar.
Piping Classification
Tubular products called pipe include standard pipe, conduit pipe,
transmission (line) pipe, water-main pipe, water-well pipe, pressure
pipe, etc.
Standard pipe, available in welded (ERW) or seamless, is produced
in three weight (wall-thickness) classifications: standard, extra
strong, and double extra strong (either seamless or welded).
Tubing Classification
Pressure tubes are differentiated from pressure pipe in that they are
used in externally fired applications while carrying pressurized fluid
inside the tube.
2

 Structural tubing is used for general structural purposes related to

the construction industry.
ASTM provides specifications for this type of tubing.
Mechanical tubing is produced to meet particular dimensional,
chemical, and mechanical property and finish specifications which
are a function of the end use, such as machinery and automotive
parts.
The examples of final finishing method include the hot finished and
cold finished.
This category of tubing is available in welded (ERW) and seamless
form.

3. SEAMLESS AND WELDED PIPES AND TUBES

There are basically two types of pipe and tube forming processes,
namely, seamless and welded. Each process imparts unique properties
to the pipe or tube. Seamless pipe or tube does not have the presence
of a welded seam along the length of the pipe. This seam has
traditionally been believed to be a potential weakness.
The development of automated welding processes and quality control,
however, has made this a virtually nonexistent concern. The control of
thickness uniformity and concentricity is relatively easy with welded
pipe and tube. In general, the seamless pipe is more expensive to
produce [2]

4. MATERIALS, CORROSION &

EROSION

OF PIPES

AND

FITTINGS
The term fittings covers valves, cocks, branch and bulkhead pieces,
reducers, strainers and filters, separators and expansion pieces, in
short, everything in a system which is not a pipe. Galvanic corrosion is a
major challenge for any pipes which carry sea water.
Rust is a particular corrosion problem for steel pipes exposed to contact
with sea water or moisture generally and air. Pipe runs along tank tops
or on deck, are examples of the latter. Steel pipes in these areas require
external as well as internal protection.

Sea water is an electrolyte and therefore a conductor of electricity,

because the molecules of its dissolved salts split into positive and
negative ions which are available as current carriers. Electrolytic action
can result if there are different metals or even differences in the same
metal in a pipeline.
Galvanic corrosion can occur if the different metals are connected
electrically and mutually in contact with the sea water. A corrosion cell
formed between steel and brass in contact with sea water results in
wastage of the less noble steel. A list is given in the galvanic series, in
which the more noble metals are placed in order after the less noble
thus: zinc, aluminium, carbon steels, cast iron, leadtin alloys, lead,
brass, copper, bronze, gunmetal, copper-nickel iron, monel metal.
A metal in contact with another metal occurring later in the series, as
with steel and brass, may corrode rapidly in sea water. Because the
action is galvanic, less noble sacrificial anodes can give protection.
1) STEEL
Steel being subject not only to galvanic corrosion but also to rusting,
appears to be a poor material to select for sea water pipes or for
installation in tank top or deck areas. Mild steel pipes for sea water
are protected by being galvanized or rubber lined. Welding and pipe
bending should be completed before galvanizing or application of a
lining.
The mild steel, electric resistance welded (ERW) or hot rolled pipes
are galvanized by hot dipping. Inadequate protection of steel, results
if there are pinholes or discontinuities in protective linings. Linings
should always be carried over the flange faces. Mild steel welded
fabrications, similarly lined, are also used for large ship side fittings.
Seamless mild steel is used for steam, high pressure air, feed
discharges and all oil fuel pressure piping. Its strength reduces
however, at about 460C and above this figure, steels require small
additions of alloying materials such as molybdenum or chromium.
Flanges are secured to steel pipes by fusion welding or by screwing
and expanding.
2) CAST IRON

Cast iron has poor corrosion resistance in sea water, being especially
vulnerable to graphitization.This form of attack gradually removes the
iron from the surface in contact with sea water to leave black
graphite.
The weakness of ordinary grey cast iron in tension and under shock
loading limits its use to low pressure applications, and the brittle
nature of ordinary grey cast iron excludes its use for side shell fittings
where failure could result in flooding of the machinery space. Ease of
casting makes the material ideal for the production of fittings and
fortunately techniques for improving strength have been developed.
Spheroidal graphite cast iron (SG iron) and meehanite are examples
of high strength versions of the material. These are suitable for use in
ship

side

valves

if

made

to

specification

by

an

approved

manufacturer. SG iron may be used for high pressure services and for
steam below 461C.Cast iron with its high carbon content and
consequent low melting temperature is ideal for the production of
fittings by casting.
3) COPPER
Copper pipes are suitable for moderate pressures and temperatu-res.
Flanges are not secured to copper and its alloys by welding, yet it is
done by brazing or sweating.
4) NON-FERROUS ALLOYS
Basically, brass is an alloy of copper and zinc; bronze an alloy of
copper and tin. In both cases there may be additions of other metals
and there is some confusion of nomenclature; some high-tensile
brasses are called 'bronze' and the practice has prevailed for so long
as to be accepted.
Aluminium brass (76% copper, 22% zinc, 2% aluminium) and other
non-ferrous pipelines, are considered very resistant to corrosion in
sea water, but concentrated galvanic corrosion can occur if some part
of the pipe system has a different make up.
Pipe systems are ideally of the same material throughout but nonferrous alloys are protected against corrosion by the deposition of
iron ions so that use of iron or steel fittings is beneficial.
Iron ion protection can alternatively be supplied from sacrificial or
driven iron anodes or by dosing with ferrous sulphate. An example for
5

each of these corrosion protection methods is the one applied to the

tube type cooler at the ships cooling and lubricating oil systems

Figure. 3.Shell and tube cooler [3]

Figure. 4.Shell and tube cooler [1]

.
6

Figure. 5. Shell and tube cooler [3]

Fig. 6. Lubricating Oil System [4

Fig. 7. Conventional Sea-Water Cooling System [1]

Fig. 8. Boiling Process Evaporator [4]

8

Table 1. Saturation pressures of water at various temperatures

Source: Yunus A. Cengel, John M. Cimbala (2006), Fluid Mechanics

Fundamentals and Applications, The McGraw-Hill Companies, Inc.

Fig. 9. Conventional Sea Water Cooling System [4]

Fig. 10. Conventional Fresh Water Cooling System [4]

Fig. 11. Ship Central Cooling System [4]

10

Fig.

12. Ship
Central
Cooling
System

[1]
Tubes

of
aluminium

brass

(76%

copper,

22%

2%

aluminium)

are

commonly

zinc,

employed
and the

successful

use

this

of

material
has apparently depended on the presence of a protective film of iron
ions, formed along the tube length, by corrosion of iron in the system.
Unprotected iron in water boxes and in parts of the pipe system, while
itself corroding, does assist in prolonging tube life. This factor is well
known (Cotton and Scholes, 1972) but has been made apparent when
iron and steel in pipe systems have been replaced by non-ferrous
metals or shielded by a protective coating.
The remedy in non-ferrous systems, has been to supply iron ions from
other sources. Thus, soft iron sacrificial anodes have been fitted in
water boxes, iron sections have been inserted in pipe systems and iron
has been introduced into the sea water, in the form of ferrous sulphate.
The latter treatment consists of dosing the sea water to a strength of 1
ppm for an hour per day for a few weeks and subsequently dosing again
before entering and after leaving port for a short period. This is because
the pollution level at coastal area is generally higher than at sea.
Dezincification of brasses is a particular type of corrosion that occurs in
the presence of sea water. The attack removes zinc from the alloy,
11

leaving porous copper which is soft. The problem is marked by a patch

of copper colour in the brass. Dezincification is inhibited in brasses
which are intended for sea-water contact by additions of a very small
amount of arsenic (0.04%) or other elements.
5) STAINLESS STEEL
A different problem is presented by corrosive liquids and those that
contain hard particles and are therefore likely to cause erosion. These
can cause differing rates of wastage in conventional metal pipes or
cargo tanks. With some corrosive liquids wastage is slow enough,
lasting over a period of years, to permit the use of common metals.
Expensive stainless steel is widely used for the cargo pipes of chemical
tankers intended for carriage of very corrosive cargoes.
6) EROSION
Erosion of metal may be the result of abrasives or of high water speeds,
entrained air, turbulence and cavitation. Erosion from turbulent flow
(see Fig. 12) and cavitation also aids corrosion (corrosion/erosion) by
removing the oxide film that assists in the protection of metal surfaces.
The exposed metal surfaces can form galvanic corrosion cells with
adjacent areas where oxide film is still present. Erosion is reduced by
limiting speed of flow and avoiding sharp bends, abrupt changes of pipe
cross sectional area, and impediments to flow such as weld deposits.
Speed of liquid flow should be no greater than 1 m/s for copper, 3 m/s
for galvanised steel and aluminium brass, 3.5 m/s for 90/10 cupronickel, and 4 m/s for 70/30 cupro-nickel.
Fig. 13. Laminar and Turbulent Fluid Flow

12

It

must be noted that for aluminium-brass tubes used in shell and tube
coolers (see previous figures), the liquid flow also must be ensured to
have value of not less than 1 m/s [1]. This is because a more than
minimum flow is vital to produce moderate turbulence (see Fig. 12)
which is essential to the heat exchange process and to reduce silting
and settlement in the tubes.

5. COCKS AND VALVES

The valves commonly used in marine applications are as follows :
1. Gate valve
2. Butterfly valve
3. Globe valve
4. Angle valve
5. Non-return (check) valve
6. SDNR valve
7. Flap check valve
8. Angle non-return valve
9. Relief valve

13

Fig. 14.Cock

Fig. 15. Gate Valve

14

Fig.16.Gate (or Sluice) Valve

Fig.17.Butterfly Valve

15

Fig.18.Butterfly Valve
Fig.19.Globe
Fig.20.Angle Valve

Valve

Fig.21.non-return

valve

(check valve)
Fig.22.Angle non-

return

valve
Fig.23.Globe &

Screw-

down non-return

(SDNR)

Valves
Fig.24.Ball Valve
A ball valve is

generally

the
of

least
any

expensive

valve

configuration and

has

maintenance

costs.

addition to quick,

quarter

turn

operation,

on-off

low
In

16

ball valves are compact, require no lubrication, and give tight sealing
with low torque.
Conventional ball valves have relatively poor throttling characteristics.
In a throttling position, the partially exposed seat rapidly erodes
because of the impingement of high velocity flow. The ball valves are
almost never used in marine applications.

Fig.25.Flap Check Valve (Swing Check Valve)

Fig.26.Flap Check Valve (Swing Check Valve)

17

Fig.27.Relief Valve

Fig.28.Relief Valve

18

Fig.29.Quick Closing Valve (Wire Operated)

Fig.30.Quick Closing Valve (Hydraulically Operated)

19

6. OTHER FITTINGS

Fig.31. Mud Box

Fig.32.Ystrainer

20

Fig.33.Single strainer

Fig.34.

Cartridge Filter

21

Fig.35.Expansion Bellows

Fig.36.Bulkhead Fitting

22

Reference
McGeorge, H. D. (1995), Marine Auxiliary Machinery, 7th edition,
Butterworth-Heinemann.
Lahmeier, A., Avery, D. R. (2000), Manufacturing of Metallic Piping, in
Piping Handbook, ed. Nayyar, M. L., The McGraw-Hill Companies, Inc.
Mechanical Science, Vol. 2 (1993), U.S. Department of Energy.
Taylor, D. A. (1996), Introduction to Marine Engineering, 2nd edition,
Elsevier, Ltd.

23