Part 1 Design Process CLUE DREAM JOB OPPORTUNITY COMPETITION GLOBAL ECONOMIC CRISIS
PT. FADILAH TEKNIKA ENERGI Part 1 Design Process WHAT IS PIPING ENGINEERING DESIGN DOING IN REAL INDUSTRIAL WORKS OVERVIEW OF PROCESS PLANT PIPING SYSTEM DESIGN PT. FADILAH TEKNIKA ENERGI Part 1 Design Process OVER ALL PROGRAM PART 1: DESIGN PROCESS
PART 2: FABRICATION AND ERECTION PROCESS
PART 3: QUALITY INSPECTION PT. FADILAH TEKNIKA ENERGI Part 1 Design Process OBJECTIVES PART 1: A. PIPING COMPONENT B. PROCESS PLANT C. PIPING MATERIALS AND ITS PROPERTIES D. BASIC DESIGN PT. FADILAH TEKNIKA ENERGI Part 1 Design Process OBJECTIVES PART 2: A. STORAGE AND HANDLING B. FIT UP AND TOLERANCES C. PIPE ALIGNMENT D. JOINTS ASSEMBLY E. INSTALLATION F. MDR PT. FADILAH TEKNIKA ENERGI Part 1 Design Process OBJECTIVES PART 3: A. DEFECT IDENTIFICATION B. WELDING INSPECTION C. TESTING D. INSPECTION RECORDS/REPORT
PT. FADILAH TEKNIKA ENERGI Part 1 Design Process BACK GROUND Q: WHAT IS THE DEFINITION OF PIPING SYSTEM? A: CONVEYS FLUID BETWEEN LOCATIONS PT. FADILAH TEKNIKA ENERGI Part 1 Design Process PIPING COMPONENTS 1. PIPE 2. FITTINGS 3. PIPE SUPPORTS PT. FADILAH TEKNIKA ENERGI Part 1 Design Process PROCESS PLANT PIPING 1. Petroleum refineries 2. Power plants 3. Paper and Chemical plants 4. Semiconductor plants 5. Pharmaceutical plants 6. Textile plants 7. Cryogenic plants PT. FADILAH TEKNIKA ENERGI Part 1 Design Process PIPE & FITTINGS MATERIALS BASED ON RAW MATERIALS 1. STEEL PIPE A. FERROUS MATERIAL PIPE CARBON AND FERRITIC ALLOY STEEL
B. NON FERROUS MATERIAL PIPE STAINLESS AND ALLOY STEEL PT. FADILAH TEKNIKA ENERGI Part 1 Design Process 2. NON STEEL PIPE A. CONCRETE PIPE B. FIBER GLASS PIPE C. POLY VINIL CHLORIDE PIPE D. POLYETHELENE PIPE PIPE & FITTINGS MATERIALS BASED ON RAW MATERIALS PT. FADILAH TEKNIKA ENERGI Part 1 Design Process PIPE & FITTINGS MATERIALS BASED ON MANUFACTURING PROCESS 1. STEEL PIPE A. SEAMLESS PIPE B. WELDED PIPE ERW PIPE EFW PIPE C. CENTRIFUGAL CASTING PIPE D. FORGING STEEL PIPE PT. FADILAH TEKNIKA ENERGI Part 1 Design Process REFERENCE: ASME B3.3 Provides requirements for: - Design - Materials - Fabrication - Erection - Inspection - Testing PIPING SYSTEM DESIGN PT. FADILAH TEKNIKA ENERGI Part 1 Design Process DESIGN CONDITIONS General - Normal operating conditions - Design conditions Design pressure and temperature - Identify connected equipment and associated design conditions - Consider contingent conditions - Verify conditions with process engineer PIPING SYSTEM DESIGN PT. FADILAH TEKNIKA ENERGI Part 1 Design Process PIPING SYSTEM DESIGN THREE BASIC DESIGN Parameters - Kind of fluid to be convey - Design service temperature - Design service pressure PT. FADILAH TEKNIKA ENERGI Part 1 Design Process STRENGTH Yield and Tensile Strength Creep Strength Fatigue Strength CORROSION RESISTANCE Uniform corrosion Pitting corrosion Galvanic corrosion Concentration cell corrosion Graphitic corrosion MATERIAL CONSIDERATION PT. FADILAH TEKNIKA ENERGI Part 1 Design Process MATERIAL FRACTURE THOUGHNESS Chemical composition Heat treatment Grain size MATERIAL CONSIDERATION PT. FADILAH TEKNIKA ENERGI Part 1 Design Process FABRICABILITY Ease of construction Material must be weldable Common shapes and forms include: - Seamless pipe - Plate welded pipe - Wrought or forged elbows, tees, reducers, crosses - Forged flanges, couplings, valves - Cast valves MATERIAL CONSIDERATION PT. FADILAH TEKNIKA ENERGI Part 1 Design Process LAY OUT CONSIDERATION Operational Maintenance Safety PIPING SYSTEM DETAIL DESIGN PT. FADILAH TEKNIKA ENERGI Part 1 Design Process STRESS CATEGORIZATION Primary Stresses - Direct - Shear - Bending Secondary Stresses - Act across pipe wall thickness - Cause local yielding and minor distortions - Not a source of direct failure PIPING SYSTEM DETAIL DESIGN PT. FADILAH TEKNIKA ENERGI Part 1 Design Process LOADING CONDITIONS Principal pipe load types Sustained load - Act on system all or most of time - Consist pressure and total weigth load Thermal expansion loads - Caused by thermal displacements - Result from restrained movement Occasional load - Act for short portion of operating time - Seismic and/or dynamic loading PIPING SYSTEM DETAIL DESIGN PT. FADILAH TEKNIKA ENERGI Part 1 Design Process PIPE SUPPORT AND RESTRAINTS Supports - Absorb system weight - Reduce - Longitudinal pipe stress - Pipe sag and - End point reaction load Restraints Control or direct thermal movement due to: Thermal expansion Imposed load
PIPING SYSTEM DETAIL DESIGN PT. FADILAH TEKNIKA ENERGI Part 1 Design Process SUPPORT AND RESTRAINT SELECTION FACTORS Weight load Available clearance Availability of structural steel Direction of load and/or movement Design temperature Vertical thermal movement at hanger/support PIPING SYSTEM DETAIL DESIGN PT. FADILAH TEKNIKA ENERGI Part 1 Design Process PIPING FLEXIBILITY Systems MUST accommodate thermal movement Inadequate flexibility will cause: Leaky flanges Fatigue failure Excessive maintenance Operation problem Damaged equipments PIPING SYSTEM DETAIL DESIGN PT. FADILAH TEKNIKA ENERGI Part 1 Design Process FLEXIBILITY ANALYSIS Consider layout, support and restraint Ensure thermal stresses and reaction load are within allowable limits Anticipate stress due to Elevated design temperature Increase pipe thermal stress and reaction loads Reduce material strength Pipe movements Supports and restraints PIPING SYSTEM DETAIL DESIGN PT. FADILAH TEKNIKA ENERGI Part 1 Design Process FLEXIBILITY ANALYSIS (Continued) Evaluate loads imposed on equipments Determines imposed load on piping system and associated structures Load compared to industry standards Based on tables Calculated PIPING SYSTEM DETAIL DESIGN PT. FADILAH TEKNIKA ENERGI Part 1 Design Process USING COMPUTER ANALYSIS Used to perform detailed piping stress analysis Can perform numerous analyses Accurately completes unique and difficult function Time-history analyses Seismic and wind motion Support motion Finite element analysis Animation effect PIPING SYSTEM DETAIL DESIGN PT. FADILAH TEKNIKA ENERGI Part 1 Design Process TERIMA KASIH END OF PART 1 For detail question please forward to: budi.santoso@ftenergi.com