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Gate valve
Ball Valve
Globe Valve
Pipeline Component
Tie in
Flange
Swivel Flange
Missalignment flange
Missalignment flange
Smart Flange
Pipeline Component
Typical Flange
Facings
Pipeline Component
Flanges:
Subsea use high integrity ring type joints (RTJ)
Pipelines usually use standard ASME/ANSI B16.5 or API
For subsea use swivel ring and possibly misalignment flanges
Tees:
Standard Tee
Inspection pigging of run only possible if branch size is less than 60% of run (No Inspection
pigging from branch)
Barred Tee
Inspection pigging of run possible for all branch sizes (No Inspection pigging from branch)
Normal flow
Normal flow
1. Grades A25
2. A
3. B
4. X42
5. X46
6. X52
7. X56
8. X60
9. X65
10. X70
11. X80
Steel Material
Baja untuk struktur dengan tempa panas dapat diklasifikasikan sebagai:
Baja karbon (carbon steel),
Baja paduan rendah berkekuatan tinggi (high strength low alloy steel), dan
Baja karbon struktural termasuk. dalam kategori karbon lunak. Suatu baja, misalnya
A36, memiliki karbon maksimum antara 0.25- sampai 0.29% tergantung dari
ketebalannya. Peningkatan persentase karbon akan meningkatkan kekerasannya
namun akan mengurangi kekenyalannya, hingga lebih sulit dilas.
Baja karbon dibagi menjadi empat kategori berdasarkan presentase karbonnya:
Karbon rendah (kurang dari 0.15%);
Karbon lunak (0.15-0.29%);
Karbon sedang (0.30-0.59%); dan
Karbon tinggi (0.60-1.70%).
Steel Material
Baja paduan rendah berkekuatan tinggi (high strength low alloy steel)
Kategori ini meliputi baja-baja yang memiliki tegangan leleh dari 40 sampai dengan
70 ksi (275 sampai dengan 480 MPa).
Penambahan sejumlah elemen paduan terhadap baja karbon seperti krom,
kolumbium, tembaga, mangan, molibden, nikel, fosfor, vanadium, atau zirkonim,
akan memperbaiki sifat-sifat mekanisnya.
Bila baja karbon mendapatkan kekuatan dengan penambahan kandungan
karbonnya, elemenelemen paduan menciptakan tambahan kekuatan lebih dengan
mikrostruktur yang halus ketimbang mikrostruktur yang kasar yang diperoleh
selama proses pendinginan baja.
Baja paduan rendah berkekuatan tinggi digunakan dalam kondisi seperti tempaan
atau kondisi normal; yakni kondisi di mana tidak digunakan perlakuan panas.
Steel Material
Baja paduan (alloy steel).
Baja paduan rendah dapat didinginkan dan disepuh supaya dapat mencapai
kekuatan leleh sebesar 80 sampai dengan 110 ksi (550 sampai dengan 760 MPa).
Kekuatan leleh biasanya didefinisikan sebagai tegangan pada regangan offset 0.2%,
karena baja ini tidak menunjukkan titik leleh yang jelas
Baja paduan rendah ini pada umumnya memiliki kandungan karbon sekitar 0.20%
supaya dapat membatasi kekerasan mikrostruktur butilan kasar (martensit) yang
mungkin terbentuk selama perlakuan panas atau pengelasan, sehingga dapat
mengurangi bahaya retakan.
Steel Material
Steel Material
Steel Material
Steel Material
Steel Material
PIPE DIAMETER
SELECTION
Pipe Sizing
Penentuan diameter pipa biasanya dilakukan oleh tim proses, dengan simulasi. Biasanya
dengan software pipesim, olga, hysis.
Banyak pertimbangannya, salah satunya flow assurance
Flow assurance is required to determine the optimum flowline pipe size based on reservoir
well fluid test results for the required flowrate and pressure. As the pipe size increases, the
arrival pressure and temperature decrease. Then, the fluid may not reach the destination
and hydrate, wax, and asphaltene may be formed in the flowline. If the pipe size is too
small, the arrival pressure and temperature may be too high and resultantly a thick wall
pipe may be required and a large thermal expansion is expected.
It is important to determine the optimum pipe size to avoid erosional velocity and hydrate/
wax/asphaltene deposition. Based on the hydrate/wax/asphaltene appearance
temperature, the required OHTC is determined to choose a desired insulation system (type,
material, and thickness.) If the flowline is to transport a sour fluid containing H2S, CO2,
etc., the line should be chemically treated or a special corrosion resistant alloy (CRA) pipe
material should be used.
Pipe Sizing
The blue solid line represents inlet pressure at wellhead and the red dotted
line represents outlet fluid temperature. The 8 ID pipe may require a heavy
(thick) wall and the 12 ID pipe may require a thick insulation coating
depending on hydrate (wax or asphaltene) formation temperature.
Pipe Sizing
The blue solid line represents inlet pressure at wellhead and the red dotted
line represents outlet fluid temperature. The 8 ID pipe may require a heavy
(thick) wall and the 12 ID pipe may require a thick insulation coating
depending on hydrate (wax or asphaltene) formation temperature.
WALL THICKNESS
CALCULATION
Wall Thickness Calculation
References:
1. A.H. Mouselli, Introduction to Submarine Pipeline Design Installation, and
Construction, 1976
2. Andrew Palmer, Roger A King, Subsea Pipeline Engineering, Penwell 2004
3. Yong Bai, Pipeline and Riser, 2000
Mechanical Design
Subsea Pipeline:
sy
Pi
Pe
sL sR
sL
Pe
sy
sL
Pi sR
L
Hoop Stress
Perhatikan silinder bebas dengan jari-jari a ,
ketebalan dinding t , dan panjang L
F P A
L
2 F P ( (a t ) sin d )( dz )
0 0 L
2 F P(a t ) sin d dz 0
0 0
y y
sin (a) sin d
r a 0
L
dz
0
L
2 F P(a t ) sin d dz
0 0
Hoop Stress
Perhatikan silinder bebas dengan jari-jari a ,
ketebalan dinding t , dan panjang L
Struktur silinder tersebut dikenai beban tekanan
P, P = Po Pi
Po, tekanan luar; Pi, tekanan dalam
Dari free-body pada gambar tersebut,
keseimbangan gaya dalam arah vertikal adalah:
L
2 F P(a t ) sin d dz 0
0 0
t
L 1
2 F P a sin d dz 0 a
0 0
L
2 F P a cos dz 0
0
0 Tekanan tangensial (hoop stress)
L
2 F P a (1 1)dz 0 A Lt
0 F PaL Pa PD
s
2F 2PaL F PaL A Lt t 2t
Hoop Stress
Perhatikan silinder bebas dengan jari-jari a ,
ketebalan dinding t , dan panjang L
Struktur silinder tersebut dikenai beban tekanan
P, P = Po Pi
Po, tekanan luar; Pi, tekanan dalam
Dari free-body pada gambar tersebut,
keseimbangan gaya dalam arah vertikal adalah:
L
2 F P(a t ) sin d dz 0
0 0
t
L 1
2 F P a sin d dz 0 a
0 0
L
2 F P a cos dz 0
0
0 Tekanan tangensial (hoop stress)
L
2 F P a (1 1)dz 0 A Lt
0 F PaL Pa PD
s
2F 2PaL F PaL A Lt t 2t
Longitudinal Stress
Silinder juga mengalami tegangan aksial yang disebabkan oleh beban tekanan
pada kedua ujungnya dimana gaya aksial yang terjadi adalah:
F P A Fa P a 2
Luas penampang melintang silinder adalah 2at . Maka, tegangan aksial yang terjadi
adalah:
Fz P a 2 Pa PD
sz
A 2 at 2t 4t
Longitudinal Stress
Longitudinal Stress:
Pressure (two effects dependent
on pipeline restraint)
Fully restrained pipeline gives
Poissons Effect
Unrestrained pipeline gives
End Cap Effect
Temperature/Thermal Stress
e.g. 6-inch x 14.3mm wt 60 degrees above ambient results in a stress of 145 MPa
full restraint force = 1017 kN or 100 tonnes
to prevent expansion this restraining force would be required
always avoid restraining pipe if possible
typical anchor length = 1 to 5 km and expansion 0.5 to 1.5m
Longitudinal Stress
Longitudinal Stress due to Bending
P
d txy
t = P/A
g = tan = d/L
G =t/g
Combined Stress
Von Mises (maximum distortion energy theory)
Allowable design factor for combined equivalent pipeline stress is high, can be 0.96
Von Mises equivalent Stress, se , is given by:
s e s y s L (s ys L )3t
2 2 2 Von Mises Failure Envelope
600
0
-600 0 600
-600
Principal Stress - h (HOOP)
Stress Strain Analysis
SMYS = Specified Minimum Yield Strength/Stress
SMTS = Specified Minimum Tensile Strength
The parameters, which are used to describe the stress-strain curve of a metal, are
the tensile strength, yield strength or yield point, percent elongation, and
reduction of area. The first two are strength parameters; the last two indicate
ductility.
Stress Strain Analysis
Untuk material yg sangat getas/rapuh (brittle), seperti keramik, tidak mungkin mengalami
necking sama sekali SMTS sama dengan tegangan pd saat putus
Pada umumnya baja merupakan material yg tangguh/dapat dibentuk (ductile), maka akan
terjadi necking sebelum material putus dimana titik tertinggi stress terjadi sesaat sebelum
necking titik tersebut merupakan SMTS dari baja
p i ri a l
pa
e
at
M
ut
Cont lim
e Se rosi
(isi) nt ko
Selimut
beton
ID
Ds
Ds+2tcorr
Ds+2tcorr+2tcc = Dtot
Anti Corrosion Coating
Wall Thickness Calculation
Note :
Zone 2, is the region within 500m from either
platform or facility.
Zone 1, otherwise
The required wall thickness is
determined in order to satisfied pressure ZONE
containment as well as local and global
buckling criteria.
Zone 1
500m
Zone 2
500m
Zone 2 (Riser & Tie-in Spool) the region within 500m from 0.5
either platform or facility
Wall Thickness Calculation
Allowable Stress Criteria
ALLOWABLE STRESS AS A
LOAD COMBINATION FACTOR SMYS
LOAD CONDITION
PIPELINE RISER
A B C D E F E F
1 OPERATING (Functional) X X X 0.72 0.72 0.5 0.5
2 OPERATING + 100 YR
ENVIRONMENTAL X X X X 0.72 0.96 0.5 0.67
3 HYDROTEST (Functional) X X X 0.90 1.00 0.90 1.00
4 HYDROTEST + 1 YR
ENVIRONMENTAL X X X 0.90 1.00 0.90 1.00
5 INSTALLATION (Functional) 0.72 0.72
Note 1 X - 0.96 - 0.96
6 INSTALLATION + 1 YR
ENVIRONMENTAL X X - 0.96 - 0.96
7 ONSHORE PIPELINE X X X 0.6
A: Weight; B: Pressure; C: Temperature; D: Environment; E: Hoop Stress; F: Von Mises Equivalent Stress;
Note 1- Allowable stresses are : 0.72 at Sagbend and 0.96 at Stinger Overbend
Wall Thickness Calculation
Additional Considerations
Propagation Buckling
Calc 3
Local Buckling
Calc 4
Pe .g.h ( Pi Pe ) D
t
2St 2 S F E T
P FET
D
Where,
D = Outside Diameter of Pipe
E = Longitudinal Joint Factor
F = Design Factor
P = Design Pressure (Pi), Pe = Ext Pressure
S = Specified Min. Yield Strength (SMYS)
T = Temperature Derating Factor
t = Nominal Wall Thickness
CR = Corrosion Rate (mmpy)
DL = Design Life (20-25years)
MT = Mill Tolerances (12.5%)
t selected > t req (Lihat Tabel Standard Pipa)
Wall Thickness Calculation
1. Internal Pressure Containment
ASME B31.4
Where,
D = Outside Diameter of Pipe
E = Longitudinal Joint Factor
F = Design Factor
P = Design Pressure (Pi), Pe = Ext Pressure
S = Specified Min. Yield Strength (SMYS)
T = Temperature Derating Factor
t = Nominal Wall Thickness
t A CR .D L
CR = Corrosion Rate (mmpy)
t tA
DL = Design Life (20-25years)
MT = Mill Tolerances (12.5%)
treq
t selected > t req (Lihat Tabel Standard Pipa)
(1 MT )
Wall Thickness Calculation
1. Internal Pressure Containment
API RP 1111 The specified minimum burst pressure (Pb) is
determined by one of the following formulae:
The following equations must be satisfied:
a) Pt f d f t f e Pb Pb 0.45( S U ) ln
D
(1)
Di
b) Pd 0.80 Pt t
Pb 0.90( S U ) (2)
D t
c) Pa 0.90 Pt
Where
Where, D = outside diameter of pipe
fd = Internal Pressure Design Factor Di = D 2t = inside diameter of pipe
fe = Weld Joint Factor Factor S = Specified minimum yield strength of pipe
ft = Internal Pressure Design Factor t = Nominal wall thickness of pipe
Pa = Incidental Overpressure U = Specified ultimate tensile strength of pipe
Pb = Specified Minimum Burst Pressure
Pd = Pipeline Design Pressure For low D/t pipe (D/t < 15),
formula (2) is recommended
Pt = Hydrostatic Test Pressure
Wall Thickness Calculation
1. Internal Pressure Containment
DnV OS-F101
The pressure containment shall fulfill the
following criteria: pb t
pli pe
g SC g m
Where
2t 2
Pb,s (t ) SMYS .
D t 3
pb,s(t) = Yielding Limit State
2t 2 pb,u(t) = Bursting Limit Limit State
Pb,u (t ) SMTS
D t 3 pli = Local Incidental Pressure
gSC = Safety Class Resistance Factor
pb t Min( pb,s t ; pb,u t Gm = Material Resistance Factor
Wall Thickness Calculation
2. External Pressure Collapse
API RP 1111
The following criteria must be satisfied:
Po Pi f o Pc
Where Where,
Py Pe
Pc
fo = Collapse Factor
Py Pe
2 2
pc pe1 pc 2
pp
2
pc pe1 p p f o
D
t
Where 3
t
2E
pe1 D
1 v2
t
p p 2 S fab
D
Dmax Dmin
fo
D
Wall Thickness Calculation
2. External Pressure Collapse
DnV OS-F101
pc
pe
1.1 g m g SC
Where,
pc = Characteristic Collapse Pressure
pe1 = Elastic Collapse Pressure
pp = Plastic Collapse Pressure
fo = Ovality
fab = Fabrication Factor
Wall Thickness Calculation
3. Local Buckling
Pipeline buckling and collapse may occur from :
Hydrostatic (external) pressure
Axial compression
Applied bending
Combination of all of the above
The allowable stress for pipeline subjected to both functional and environmental loads during
installation, in accordance with DNV 1981, is 96%. However, for a conservative design margin,
the following stress criteria are adopted in line with standard industry practice:
Always size wall for collapse, initiation checked during lay analysis
Propagation can be limited by use of buckle arrestors (thicker section of pipe), see
A.H. Mouselli Book
sx sy
1
xps xcr yps ycr
Dimana :
s x = Longitudinal Stress (MPa)
s y = Hoop Stress (MPa)
sxcr = Critical Longitudinal Stress (MPa)
sycr = Critical Hoop Stress (MPa)
nxp = Permissible Usage Factor for Longitudinal Stress
nyp = Permissible Usage Factor for Hoop Stress
300 s y
= 1 D .
s ycr
t
DnV 1981 (combination between internal pressure and longitudinal pressure)
Wall Thickness Calculation
3. Local Buckling
DNV 1981
a) s x s x s xN M
FA
b) sx
N
A
c) s x 0.72S
M
Wall Thickness Calculation
3. Local Buckling
DNV 1981
sx N
sx M
d) s xcr s xcr
N
s xcr M
sx sx
D
e) s xcr N
S 1 0.001 20
t
D
s xcr M
S 1.35 0.0045
f)
t
Wall Thickness Calculation
3. Local Buckling
DNV 1981
The following criteria must be satisfied:
300 s y
g) 1
D / t s ycr
s y pe pi
D
h)
2t
2
t
s ycr E
i)
D t
sx sy
j) 1
s s
xp xcr yp ycr
Wall Thickness Calculation
3. Local Buckling
DNV 1981
Where,
x = Longitudinal Stress
xN = Longitudinal Stress (Axial)
xM = Longitudinal Stress (Bending)
xcr = Critical Longitudinal Stress
xcrN = Critical Longitudinal Stress (Axial)
xcrM = Critical Longitudinal Stress (Bending)
ycr = Critical Hoop Stress (Pressure)
Wall Thickness Calculation
4. Buckle Propagation
Propagating pressure based on DnV 1981
2
t
p pr 1,15 SMYS
D t
Ppr > Pe OK
Pe_max
k
1.15 SMY S
k D
t nom
1k
Wall Thickness Calculation
4. Buckle Propagation
Initiation & Propagation Buckle based on API RP 1111
Buckle cannot be initiated or
propagated within a portion of pipe
where the maximum external
overpressure is less than the
propagation of the pipe:
2.5
t
a) p pr 35S fab
D
p pr
b) pe
g mg SC
Wall Thickness Calculation
Comparison Table
OD = 914.4 mm; P = 15 MPa; WD = 50 100m;
Content density = 200 kg/m3 ; Wave Ht = 3.8 m