pipe wall thickness calc ifa_a

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FRONT END ENGINEERING DESIGN (FEED) MAKING

TOTAL PROJECT KAMOJANG UNIT 5 (1 x 30 MW) – WEST JAVA

CALCULATIONS OF PIPE WALL THICKNESS

AJune 26 ,

2012Issued for Approval RX GIB OOK TJA WDR

PREPARED CHECKED APPROVED CHECKED APPROVED

REV DATE DESCRIPTIONPT. LAPI ITB PT. PGE

STATUS CODE : IFR = Issued for Review, IFA = Issued for Approval, IFU = Issued for Use

Total or Partial Reproduction and/or utilization of this document are forbidden without prior written authorization of PT.PGE

DOCUMENT NUMBER REVISION STATUS

KMJ5-SG-PI-CSH-001 A IFA



FRONT END ENGINEERING DESIGN (FEED) MAKINGTOTAL PROJECT KAMOJANG UNIT 5 (1 x 30 MW) –

WEST JAVA

TITLE DOCUMENT NUMBER PAGE

CALCULATION OF PIPE WALLTHICKNESS

KMJ5-SG-PI-CSH-001 2 OF 32

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COMMENT SHEET

COMMENT:

NO

REFERENCE,

PARAGRAPH,

OR CHAPTER

COMMENT OF PT. PGE RESPONSE OF PT. LAPI ITB

COMPANY PT. PGE PT. LAPI ITB

BY <Name> <Name>

POSITION <Position> <Position>

DATE

DOCUMENT STATUS: IFR IFA IFU




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TABLE OF CONTENTS

1.

INTRODUCTION ..........................................................................................................5

2. PURPOSE ....................................................................................................................5

3. DEFINITION ..................................................................................................................5

4. CODE, STANDARD, DAN REFERENCES ..................................................................5

5. OPERATION DATA ......................................................................................................6

6. DESIGN DATA .............................................................................................................6

7. CALCULATION OF PIPE THICKNESS VERIFICATION .............................................7

7.1 CALCULATION OF PIPE WALL THICKNESS BASED ON ASME B31.1 TERMS

..........................................................................................................................7

7.2 MINIMUM THICKNESS (TMIN) OF PIPE WALL ................................................. 8

7.3 DESIGN PRESSURE (P) AND DESIGN TEMPERATURE (T) ......................... 8

7.4 PIPE OUTER DIAMETER (DO) .........................................................................8

7.5 ALLOWABLE STRESS VALUES BASED ON THE WORKING TEMPERATURE8

7.6

JOINT EFICIENCY (E) ......................................................................................8

7.7 CORROSION ALLOWANCES (CA) ..................................................................9

7.8 ADDITIONAL THICKNESS ...............................................................................9

7.9 MILL TOLERANCES .........................................................................................9

8. CALCULATION OF PIPE WALL THICKNESS RESULT AND PIPE SCHEDULE

SELECTION ............................................................................................................................. 9

PIPE WALL THICKNESS RESULT AND PIPE SCHEDULE SELECTION ...........................11

PIPE WALL THICKNESS CALCULATION SHEET ..............................................................12




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1. INTRODUCTION

PT. Pertamina Geothermal (PGE) intends to implement the Project of Geothermal Power

Plant (GPP) Unit 5 in order to approach capacity of 30 MW with steam production from the

Cluster A and Cluster C wells. Therefore, the "Front End Engineering Design (FEED) Total

Project Kamojang Unit 5 (1x30 MW) - West Java” conducted.

2. PURPOSE

This calculation aims to determine the pressurized pipes wall thickness for steam fluidpipelines piping systems and condensat on the "Front End Engineering Design (FEED)

Total Project Kamojang Unit 5 (1x30 MW) - West Java".

3. DEFINITION

These definitions are to be applied for within the parties involved in the Kamojang 5 Project:

PT. Pertamina Geothermal Energy (PGE) as Employer.

PT. LAPI ITB (LAPI) is the Consultant.

ELC-Electroconsult (ELC) is the Subconsultant.

4. CODE, STANDARD, DAN REFERENCES

As a guideline in the design for this project will be used the appropriate codes and

standards. Here is the code, standards and references used.

Tabel 4.1. Code, Standard dan References.

No. Code, Standard and References Descript ion

1 ASME B31.1 Power Piping

2 API 5 L Specification for Line Pipe

3 API 1104 Welding of Pipelines and Related Facilities

5 ASTM A53

Standard Specification for Pipe, Steel, Black and

Hot – Dipped, Zinc - Coated, Welded and

Seamless

6 ASME B36.10 Welded and Seamless Wrought Steel Pipe

7 SK No. 103.K/008/M.PE/1994

Monitoring of Implementation of the

Environmental Monitoring Plan in the scopeof Mines and Energy

8 P.P No.27 Tahun 1999 Environmental Impact Analysis




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No. Code, Standard and References Descript ion

9 API RP 581 Risk-Based Inspection Technology

5. OPERATION DATA

Recently, the drillings to 5 wells have been conducted but the characteristics of each well

have not been obtained yet. The result of temporary discharge shows the 30MW of well’s

potency from three wells (Well of KMJ-79, KMJ-80 and KMJ-84).

Chemical composition of the production wells is shown in the following table.

Table 5.1. Production wells chemical composition.

Sodium

(ppm)

Kalium

(ppm)

Calsium

(ppm)

Silica

(ppm)

Natrium

(ppm)

Magnesium

(ppm)

Bicarbonate

(ppm)

Sulphate

(ppm)

Chloride

(ppm)

pH

0.5 0.26 2.9 < 1.0 3.1 0.1 4 11 < 1.0 5

Table 5.2. Average composition of gas content.

CO2 (ppm) H2S (ppm) Residual (H2, CH4, N2, dll)

6.2

0.3

< 2 %

6. DESIGN DATA

Design data to be used as the basis for the analysis described in the following table.

Table 6.1. Design data piping/pipeline FCRS Kamojang 5.

Stream Line Number NPS

(in) Service Material

Tekanan

Operasi

(psig)

Tekanan

Desain

(psig)

Temperatur

Operasi

(oF)

Temperatur

Desain

(oF)

1 8"‐ST‐K85‐C1‐H 8 steam API 5L 287,26 347,59 413,42 500,24

2 8"‐ST‐K85‐B2‐H 8 steam API 5L 145,04 175,50 370,76 448,62

3 16"‐ST‐K84‐C1‐H 16 steam API 5L 287,26 347,59 413,42 500,24

4 24"‐ST‐K84‐B2‐H 24 steam API 5L 113,11 136,87 357,26 432,28

5 10"‐ST‐K80‐C1‐H 10 steam API 5L 287,26 347,59 415,22 502,42

6 16"‐ST‐K80‐B2‐H 16 steam API 5L 113,65 137,52 344,12 416,39

7 30"‐ST‐KWKC‐B4‐H 30 steam API 5L 109,39 132,36 355,82 430,54

8

8"‐

ST‐

K86‐

C1‐

H

8

steam API

5L 145,04 175,50 370,76

448,629 12"‐ST‐K86‐B2‐H 12 steam API 5L 113,11 136,87 357,26 432,28

10 8"‐ST‐K79‐C1‐H 8 steam API 5L 113,65 137,52 344,12 416,39




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(in)

Service Material

Tekanan

Operasi

si

Tekanan

Desain

si

Temperatur

Operasi

oF

Temperatur

Desain

oF

11 8"‐ST‐K79‐B2‐H 8 steam API 5L 112,56 136,20 361,76 437,73

12 12"‐ST‐SLA‐B4‐H 12 steam API 5L 258,82 313,17 461,30 558,17

13 30"‐ST‐MPL‐B4‐H 30 steam API 5L 109,76 132,82 426,38 515,92

14 8"‐ST‐K85‐A1‐H 8 steam API 5L 258,82 313,17 497,30 601,73

15 24"‐ST‐K84‐A1‐H 24 steam API 5L 108,63 131,45 466,88 564,92

16 16"‐ST‐K80‐A1‐H 16 steam API 5L 107,78 130,41 433,94 525,07

17 30"‐ST‐SLC‐A1‐H 24 steam API 5L 109,76 132,82 426,38 515,92

18 12"‐ST‐K86‐A1‐H 12 steam API 5L 258,75 313,08 497,30 601,73

19 8"‐ST‐K79‐A1‐H 10 steam API 5L 108,63 131,45 466,88 564,92

20 12"‐ST‐SLA‐A3‐H 8 steam API 5L 109,18 132,11 368,24 445,57

7. CALCULATION OF PIPE THICKNESS VERIFICATION

7.1 Calculation of Pipe Wall Thickness Based on ASME B31.1 Terms

Minimum pipe wall thickness for steam pipelines will be calculated by a formula

based on the provision of ASME B31.1, as follows:

Where;

P : design pressure

DO : pipe outer diameter

S : allowable stress values based on the working temperature

E : welding joint eficiency

y : carbon steel coefficient

A : additional thickness for corrosion and erosion anticipation, theaddition of mechanical strength, material wasted due to the

machining process

For case Do/tmin < 6 , the value of y must be sought with the following formula:

Under the terms of ASME B36.10, the value of minimum pipe wall thickness must be

added with the mill tolerances so that the formula used become:




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7.2 Minimum Thickness (Tmin) of Pipe Wall

Minimum pipe wall thickness is the thickness of the pipe requisite by ASME B31.1

by considering additional thickness because of the mechanical allowances for

anticipation and corrosion allowance, machining tolerances for the surface material

at machining and a depth threaded tolerance to the threaded pipe components.

7.3 Design Pressure (P) and Design Temperature (T)

Design pressure and design temperature that will be used for the calculation of the

pipe wall thickness is planned for 1.21 times the operating pressure and operating

temperature on each pipe that refers Design Basis and Hydraulic Analysis, Heat &

Material Balance.

7.4 Pipe Outer Diameter (Do)

Pipe outer diameter (DO) is the outer diameter of the pipe refers to the Line Sizing

document DNG-DTNK-PR-CSH-007 with a Nominal Pipe Size (NPS) obtained from

the sizing result using HYSYS software.

7.5 Allowable Stress Values Based on the Working Temperature

Allowable Stress Values Based on the Working Temperature for the pipe material

that will be used in the calculation of the pipe wall thickness is taken according to

the material to be used as follows:

Table 7.1. Allowable Stress Values Based on the Working Temperature.

Maximum Allowable Stress Values in Tension, ksi, for Metal Temperatur, o F,

Not Exceeding

Seamless

Spec No. Grade ‐20 to 650 700 750 800

API 5L B 15,0 14,4 13,0 10,8

Elecric Resistance Welding

Spec No. Grade ‐20 to 650 700 750 800

API 5L B 12,8 12,2 11,0 9,2

7.6 Join t Eficiency (E)

Pipe joint welding efficiency values are as shown next page:




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Table 7.2. Joint efficiency for carbon steel.

Material

Joint Efficiency

Carbon steel Seamless ERW

1 0,85

7.7 Corrosion Allowances (CA)

Two-phase fluid and steam experience corrosion due to hydrochloric acid content found

in fluid. Corrosion allowance is selected based on code API RP 581 Annex 2.B table

2.B.2.3 Estimated Corrosion Rates for Carbon Steel that influenced by pH and

temperature of brine. Corrosion allowance selected so that pipes could operate for 30years shown in the following table.

Well

Corrosion

rate (mpy)

Corrosion

Allowance (in)

KMJ 84 12 0,360

KMJ 85 12 0,360

KMJ 86 12 0,360

KMJ 79 12 0,360

KMJ 80 12 0,360

7.8 Addi tional Thickness

Additional thickness at the pipe thickness calculation consists of:

Additional thickness for mechanical allowances for the pipe which are undergoing

a process thread or grove will occur a reduction in the thickness of the pipe

material. For the grove process where machining tolerances are not mentioned

then use the assumption of 1/64 inch for ASME B31.1 para 104.1.2 (A.6.1).

Additional thickness for anticipated erosion of the pipe due to compounds that

are abrasive on the working fluid.

Additional thickness for corrosion allowances.

7.9 Mill Tolerances

Mill tolerances that used were ± 12.5% from the nominal pipe thickness, which is

according to ASME B36.10.

8. CALCULATION OF PIPE WALL THICKNESS RESULT AND PIPE SCHEDULE

SELECTION

The results of the pipe thickness calculation and selection of pipeline schedule for the

project "Front End Engineering Design (FEED) Total Project Kamojang Unit 5 (1x30 MW) -




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West Java" can be seen from the calculation resume table can be found in Appendix A.

Calculation sheet for calculation of pipe wall thickness can be found in Appendix B.



APPENDIX A

PIPE WALL THICKNESS RESULT AND PIPE SCHEDULE SELECTION


(in) Service Material

Tekanan

Operasi

(psig)

Tekanan

Desain

(psig)

Temperatur

Operasi

(oF)

Temperatur

Desain (oF)

Corrosion Rate Based on API 581

(mpy)

Corrosion Allowance

(in)

Calculcat

Wall Thickn(in)

1 8"‐ST‐K85‐C1‐H 8 steam API 5L 287,26 347,59 413,42 500,24 12 0,360 0,549

2 8"‐ST‐K85‐B2‐H 8 steam API 5L 145,04 175,50 370,76 448,62 12 0,360 0,474

3 16"‐ST‐K84‐C1‐H 16 steam API 5L 287,26 347,59 413,42 500,24 12 0,360 0,680

4 24"‐ST‐K84‐B2‐H 24 steam API 5L 113,11 136,87 357,26 432,28 12 0,360 0,565

5 10"‐ST‐K80‐C1‐H 10 steam API 5L 287,26 347,59 415,22 502,42 12 0,360 0,587

6

16"‐ST

‐K80

‐B2

‐H

16

steam

API

5L

113,65

137,52

344,12

416,39

12

0,360

0,509

7 30"‐ST‐KWKC‐B4‐H 30 steam API 5L 109,39 132,36 355,82 430,54 12 0,360 0,601

8 8"‐ST‐K86‐C1‐H 8 steam API 5L 145,04 175,50 370,76 448,62 12 0,360 0,474

9 12"‐ST‐K86‐B2‐H 12 steam API 5L 113,11 136,87 357,26 432,28 12 0,360 0,485

10 8"‐ST‐K79‐C1‐H 8 steam API 5L 113,65 137,52 344,12 416,39 12 0,360 0,472

11 8"‐ST‐K79‐B2‐H 8 steam API 5L 112,56 136,20 361,76 437,73 12 0,360 0,471

12 12"‐ST‐SLA‐B4‐H 12 steam API 5L 258,82 313,17 461,30 558,17 12 0,360 0,600

13 30"‐ST‐MPL‐B4‐H 30 steam API 5L 109,76 132,82 426,38 515,92 12 0,360 0,601

14 8"‐ST‐K85‐A1‐H 8 steam API 5L 258,82 313,17 497,30 601,73 12 0,360 0,534

15 24"‐ST‐K84‐A1‐H 24 steam API 5L 108,63 131,45 466,88 564,92 12 0,360 0,559

16 16"‐ST‐K80‐A1‐H 16 steam API

5L

107,78

130,41

433,94

525,07

12 0,360 0,503

17 30"‐ST‐SLC‐A1‐H 24 steam API 5L 109,76 132,82 426,38 515,92 12 0,360 0,601

18 12"‐ST‐K86‐A1‐H 12 steam API 5L 258,75 313,08 497,30 601,73 12 0,360 0,600

19 8"‐ST‐K79‐A1‐H 10 steam API 5L 108,63 131,45 466,88 564,92 12 0,360 0,454

20 12"‐ST‐SLA‐A3‐H 8 steam API 5L 109,18 132,11 368,24 445,57 12 0,360 0,483

Note : Corrosion allowance ditentukan berdasarkan kandungan Cl dan lifetime 30 tahun



APPENDIX B

PIPE WALL THICKNESS CALCULATION SHEET

pipe wall thickness calc ifa_a

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