Lumut Balai Unit 2 Geothermal

FCRS and Power Plant Project

C 2024.03.28 Re-Issued for Approval AR IS RBY YANG YU

B 2024.01.25 Re-Issued for Approval AR IS RBY YANG YU
A 2023.11.15 Issued for Approval AR IS RBY YANG YU
Rev. Date Modification Content Prepare Check Review Approval

OWNER:

CONSULTANT:

EPC CONTRACTOR:

Lumut Balai Unit 2 Geothermal FCRS and Power Plant Project

Approval RBY/HZ Check AR PIPE STRESS AND FLEXIBILITY ANALYSIS

REPORT FOR STEAM FROM LMB-A TO STEAM
Review IS Design ASW VESSEL

LMB2-E-FC-PIP-OCS-
Date 2024.03.28 Scale N/A Doc. No. Rev. C
MS1-0015
 PIPE STRESS AND FLEXIBILITY ANALYSIS REPORT FOR STEAM FROM LMB-A TO
STEAM VESSEL
Document No. Rev No. Contract No.
LMB2-E-FC-PIP-OCS-MS1-0015 C 459/PGE000/2022-S0

REVISION CONTROL SHEET

Rev. No Date Description

A 2023.11.15 Issued for Approval

B 2024.01.25 Re-Issued for Approval

C 2024.03.28 Re-Issued for Approval

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CONTENTS

REVISION CONTROL SHEET.....................................................................................2

CONTENTS..................................................................................................................3
1. INTRODUCTION.................................................................................................4
1.1 Scope.........................................................................................................5
1.2 Term...........................................................................................................5
2. CODES & SPECIFICATIONS.............................................................................6
2.1. Codes and Standards................................................................................6
2.2. Project Specifications & References..........................................................6
3. DESIGN CRITERIA.............................................................................................7
3.1. Pipe System Coordinate............................................................................7
3.2. Design Parameters....................................................................................7
3.3. Pipeline Data..............................................................................................8
3.4. Environmental Data....................................................................................8
4. LOAD CASES.....................................................................................................8
5. SRESS ANALYSIS RESULTS..........................................................................11
5.1. Code Compliance....................................................................................11
5.2. Maximum Stress Summary......................................................................11
5.3. Maximum Displacement Summary..........................................................12
5.4. Maximum Pipe Support Load and Moment Summary.............................13
5.5 Flange Check (NC-3658.3 Method).........................................................15
5.6 Nozzle Check...........................................................................................15
6. SUMMARY AND RECOMMENDATION...........................................................17
6.1. Conclusion...............................................................................................17
6.2. Recommendation.....................................................................................17
7. ATTACHMENT..................................................................................................17

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1. INTRODUCTION

PT. Pertamina Geothermal Energy (PGE) Area Lumut Balai intends to build

the 2nd unit of Geothermal Power Plant (GPP) to utilize steam for generation

source. Geothermal Area Lumut Balai is located at about 290 km southwest

of Palembang in the southern region of Sumatra with elevation around 1,000

masl, Indonesia.

Figure 1.1 Overview of PGE Area Lumut Balai 2

The power plant development is a single flash generation system. Limited to

scope of work, this project intends FCRS (Fluid Collecting & Reinjenction

System) design which are including mechanical equipment, piping systems,

control & instrumentation systems, electrical system, transmission systems,

utility system, and civil infrastructures.

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1.1 Scope
The scope of this document is to perform the piping stress analysis of the new

piping for Steam from Steam LMB-A to Steam Vessel for "FCRS LUMUT

BALAI PROJECT GEOTHERMAL”. The analysis is performed to check the

compliance of pipeline system with ASME B31.1 by using CAESAR II version

12.

1.2 Term
The following terms as used in this document, assume the meanings given

below:
EMPLOYER PT. Pertamina Geothermal Energy (PGE), the

owner of the PGE Lumut Balai FCRS Project

CONTRACTOR Konsorsium Mitsubishi Corporation, WIKA and

SepcoIII, appointed by EMPLOYER to execute

and to complete overall works EPC

(Engineering, Procurement, Construction) for

the PGE Lumut Balai FCRS Project

Vendor/Manufacturer The party which supply materials, equipment,

technical document/ drawing, and service to

perform the duties by the CONTRACTOR.

Third Party Inspector A third party inspector to be appointed by

EMPLOYER to inspect the works of

CONTRACTOR.

Project Documents All documents which are prepared, revised,

and issued for accelerating the project

execution, such as correspondence, drawings,

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specifications, requisitions, purchase orders,

vendor prints, etc.

2. CODES & SPECIFICATIONS

The following references and documents are used for the stress analysis of

line piping for Steam LMB-A to Steam Vessel.

2.1. Codes and Standards

No Code & Standard Description

1 ASME B 31.1 Power Piping

2 API 5L Specification of Line Pipe

4 ASME B16.5 Pipe Flanges and Flange Fittings

Large Diameter Steel Flanges NPS 26 Through

5 ASME B16.47
NPS 60
Factory-Made Wrought Steel Butt-Welding
6 ASME B16.9
Fittings
Face to Face and End to End Dimensions of
7 ASME B16.10
Valves
Forged Steel Fittings, Socket-Welding and
8 ASME B16.11
Threaded

9 ASME B16.34 Valve – Flange Threaded and Welding End

Metallic Gaskets for Pipe Flanges, Ring Joint,

12 ASME B 16.20
Spiral Wound and Jacketed

2.2. Project Specifications & References

No Document Number Document Title

LMB2-E-FC-PIP-BES-
1 Specification For Thermal Insulation Of FCRS
MS2-0002
LMB2-E-FC-PRO-OEL-
2 Line List
MS0-0002
LMB2-E-FC-PIP-BES- Specification For Piping and Valve Material Of
4
MS2-0001 FCRS
5 LMB2-E-FC-PIP-OCS- Pipeline Span Calculation

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No Document Number Document Title

MS1-0002
LMB2-E-FC-PIP-BES- Specification for Piping Flexibility Analysis of
6
MS1-003 FCRS
LMB2-E-FC-CIV-BES- General Specification/Design Criteria for Civil and
7
AA0-0001 Structural of FCRS
LMB2-E-FC-PIP-AIM-
8 Piping Arrangement Drawing for Cluster LMB-A
MS1-011
LMB2-E-FC-PIP-ADW-
9 Isometric Drawing for Cluster LMB-A
MS9-0022
LMB2-E-FC-PIP-ADI- Pipeline Alignment Sheet For Steam Cluster
10
MS1-0046 LMB-A To Steam Vessel Unit-2

3. DESIGN CRITERIA

This section provides the required data for stress analysis of line piping for

Steam LMB-A to Steam Vessel Unit 2.

3.1. Pipe System Coordinate

Pipe system coordinate used in the analysis is as follow:

Figure 4.1 CAESAR II Model Axis

Y : South Direction
X : West Direction
Z : Vertical Direction
3.2. Design Parameters
Table 3.1 Design Parameters

Pipe Wall Design Design

Line Pipe Size Thickness Pressure Temperature
(inch) (mm) (barg) (°C)
Steam LMB-A to Steam 44 9.52 9.00 179
Vessel Unit-2

Steam LMB-A to Silencer 30 7.14 9.00 179

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For detail of the design parameters used in this analysis are summarized in

Appendix A (Line List Stress Analysis)

3.3. Pipeline Data

The pipe data used in this analysis are summarized in appendix A (Line List

Stress Analysis).

3.4. Environmental Data

The environmental data used in this analysis are summarized in Table 3.1

below.
Table 3.1 Environmental Data

Parameters Unit Value

Average Ambient Temperature °C 20.3

Average Wind Speed m/s 35

Seismic g 0.3398

4. LOAD CASES

The piping system has been analyzed for the load cases described in Table

4.1.
Table 4.1 - Load Cases

Numbe
Load Combination Description
r
1 (SUS) WNC Sustain Load Case 1 – Weight No Content

Hydrostatic Load Case 2 - full of water weight for

2 (HYD) WW
the hydrotest (Case No Active)

Hydrostatic Load Case 3 – Hydrotest Pressure

3 (HYD) HP
(Case No Active)

Hydrostatic Load Case 4 - the line will be full of

4 (HYD) WW+HP
water for the hydrotest (Case No Active)

5 W (OPE) Sustain Load Case 5 – Full of Fluids Weight

Operating Load Case 6 - at Design Pressure and

6 (OPE) W+D1+T1+P1
Max Operation Temperature

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Numbe
Load Combination Description
r
Operational Load Case 7 - at Design Pressure
(OPE)
7 and Temperature with seismic acceleration along
W+D1+T1+P1+U1
(+) X axis

Operational Load Case 8 - at Design Pressure

(OPE) W+D1+T1+P1-
8 and Temperature with seismic acceleration along
U1
(-) X axis

Operational Load Case 9 - at Design Pressure

(OPE)
9 and Temperature with seismic acceleration along
W+D1+T1+P1+U2
(+) Y axis

Operational Load Case 10 - at Design Pressure

(OPE) W+D1+T1+P1-
10 and Temperature with seismic acceleration along
U2
(-) Y axis

(OPE) Operational Load Case 11 - at Design Pressure

11
W+D1+T1+P1+WIN1 and Temperature with Wind Load X direction

(OPE) Operational Load Case 12 - at Design Pressure

12
W+D1+T1+P1+WIN2 and Temperature with Wind Load –X direction

(OPE) Operational Load Case 13 - at Design Pressure

13
W+D1+T1+P1+WIN3 and Temperature with Wind Load +Y direction

(OPE) Operational Load Case 14 - at Design Pressure

14
W+D1+T1+P1+WIN4 and Temperature with Wind Load –Y direction

Sustained Load Case 15 - the combination

15 (SUS) W+P1 between Internal Pressure (Design) and pipe
weight

Expansion Load Case 16 - at Thermal

16 (EXP) L16=L6-L15
Temperature Design

Occasional Load Case 17 – Taken load seismic

17 (OCC) L17=L7-L6
acceleration along (+) X axis. (Code compliance)

Occasional Load Case 18 – Taken load seismic

18 (OCC) L18=L8-L6
acceleration along (-) X axis. (Code compliance)

Occasional Load Case 19 – Taken load seismic

19 (OCC) L19=L9-L6
acceleration along (+) Y axis. (Code compliance)

Occasional Load Case 20 - Taken load seismic

20 (OCC) L20=L10-L6
acceleration along (-) Y axis. (Code compliance)

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Numbe
Load Combination Description
r
Occasional Load Case 21 – Taken load Wind
21 (OCC) L21=L11-L6 acceleration of Wind X direction. (Code
compliance)

Occasional Load Case 22 – Taken load Wind

22 (OCC) L22=L12-L6 acceleration of Wind –X direction. (Code
compliance)

Occasional Load Case 23 – Taken load Wind

23 (OCC) L23=L13-L6 acceleration of Wind Load +Y direction. (Code
compliance)

Occasional Load Case 24 – Taken load Wind

24 (OCC) L24=L14-L6 acceleration of Wind Load –Y direction. (Code
compliance)

Occasional Load Case 25 – Sustain + Seismic

25 (OCC) L25=L17+L15
acceleration along (+) X axis. (Code compliance)

Occasional Load Case 26 – Sustain + Seismic

26 (OCC) L26=L18+L15
acceleration along (-) X axis. (Code compliance)

Occasional Load Case 27 – Sustain + Seismic

27 (OCC) L27=L19+L15
acceleration along (+) Y axis. (Code compliance)

Occasional Load Case 28 – Sustain + Seismic

28 (OCC) L28=L20+L15
acceleration along (-) Y axis. (Code compliance)

Occasional Load Case 29 – Sustain + Wind

29 (OCC) L29=L21+L15
acceleration along (+) X axis. (Code compliance)

Occasional Load Case 30 – Sustain + Wind

30 (OCC) L30=L22+L15
acceleration along (-) X axis. (Code compliance)

31 Occasional Load Case 31 – Sustain + Wind

(OCC) L31=L23+L15
acceleration along (+) Y axis. (Code compliance)

32 Occasional Load Case 32 – Sustain + Wind

(OCC) L32=L24+L15
acceleration along (-) Y axis. (Code compliance)

33 (OCC) Occasional Load Case 33– Max seismic

L33=L25.L26,L27,L28 acceleration + Sustain

34 (OCC) Occasional Load Case 34 – Max Wind

L34=L29,L30,L31,L32 acceleration + Sustain

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5. SRESS ANALYSIS RESULTS

5.1. Code Compliance

The Steam LMB-A to Steam Vessel design of Lumut Balai Geothermal FCRS

Project described above was found to be code compliant to ASME B31.1.

Power Piping. The pipe stress and flexibility analysis results are provided in

Appendix F.

5.2. Maximum Stress Summary

Table 5.1 – Maximum Stress Summary

Code
Numbe Allowable Ratio
Load Combination Node Stress Remarks
r (lb/in2) (%)
(lb/in2)

1 (SUS) W+P1 550 4888.9 17100.0 43.3 PASS

2 (EXP) L16=L6-L15 610 40522.0 46216.8 87.0 PASS

3 (OCC) L33=L25.L26,L27,L28 589 8447.1 19665.0 43.0 PASS

4 (OCC) L34=L29,L30,L31,L32 568 7621.4 19665.0 38.8 PASS

Note :
1. For All Case Ratio = (Calculated stress/Allowable Stress) Must Less than 100%
2. For ASME B 31.1, the operating case has no allowable stress value

40522.0 lb/in2
(Node = 160)

Figure 5.1 Maximum Stress

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5.3. Maximum Displacement Summary

Table 5.2 - Maximum Displacement Summary

Displacement - X Displacement - Y Displacement Z

No Load Case
Value Value Value
Node Node Node
(mm) (mm) (mm)

1 (EXP) L15=L5-L14 1329 -86.258 588 -122.817 610 59.620

-86.258 mm
(Node = 1329)

Figure 5.2 Maximum Axial Displacement (X Direction)

-122.817 mm
(Node = 588)

Figure 5.3 Maximum Axial Displacement (Y Direction)

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59.620 mm
(Node = 610)

Figure 5.4 Maximum Vertical Displacement at (Z Direction)

5.4. Maximum Pipe Support Load and Moment Summary

From Table 5.3 - 5.4 are shown the summary load restraint for non-anchor pipe

support. The results are provided in Attachment K.

Table 5.3 - Maximum Pipe Support Load Summary Operating Case

No.
Maximum Force Load Case Node Force (N)
Support

Maximum X (OPE) W+D1+T1+P1 170 220256.8 SP-325

Maximum Y (OPE) W+D1+T1+P1 30 308227.8 SP-330

Maximum Z (OPE) W+D1+T1+P1 1990 -1672823 SP-265

Table 5.4 - Maximum Pipe Support Load Summary Occasional Load Case

Maximum Nod No.

Load Case Force (N)
Force e Support

(OCC) PS-750-
Maximum X 5077 84547.2
L33=L25.L26,L27,L28 025

(OCC)
Maximum Y 1990 -91728.32 SP-265
L33=L25.L26,L27,L28

(OCC)
Maximum Z 1990 -1030360 SP-265
L33=L25.L26,L27,L28

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From Table 5.5 - 5.8 are shown the summary load and moment restraint for

anchor pipe support. The results are provided in Attachment.

Table 5.5 - Maximum Anchor Load Summary Operating Case

No.
Maximum Force Load Case Node Force (N)
Support
Maximum X (OPE) W+D1+T1+P1 1130 278359.9 SP-294

Maximum Y (OPE) W+D1+T1+P1 1130 73054.5 SP-294

Maximum Z (OPE) W+D1+T1+P1 1130 5373.2 SP-294

Table 5.6 - Maximum Anchor Moment Summary Operating Case

Maximum Moment No.

Load Case Node
Moment (N.m) Support
Maximum X (OPE) W+D1+T1+P1 1130 290014.2 SP-294

Maximum Y (OPE) W+D1+T1+P1 1510 -68655.2 SP-281

Maximum Z (OPE) W+D1+T1+P1 1510 65738.7 SP-281

Table 5.7 - Maximum Anchor Load Summary Occasional Case

No.
Maximum Force Load Case Node Force (N)
Support
(OCC)
Maximum X 5096 -80045.6 PS-750-
L33=L25.L26,L27,L28
024

(OCC)
Maximum Y 1190 -91728.3 SP-265
L33=L25.L26,L27,L28

(OCC)
Maximum Z 1990 -1030360 SP-265
L33=L25.L26,L27,L28

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Table 5.8 - Maximum Anchor Moment Summary Occasional Case

Maximum Moment No.
Load Case Node
Moment (N.m) Support
(OCC)
Maximum X 1130 -71189.6 SP-294
L33=L25.L26,L27,L28

(OCC)
Maximum Y 1130 -195774.9 SP-294
L33=L25.L26,L27,L28

(OCC)
Maximum Z 1510 -197072.7 SP-281
L33=L25.L26,L27,L28

5.5 Flange Check (NC-3658.3 Method)

Table 5.7 - Flange Check NC-3658.3

Bendin Allowabl
Torsion Flange
g G/C e Ratio
Node Momen AB (mm²) Stress
Moment (mm) Pressure %
t (N.m.) (psig)
(N.m.) /Stress
1000.0 16772.00
5092 7776 85452 8513.1 36000.0 23.65
0 0
1000.0 16772.00
5089 7776 82638 8232.7 36000.0 22.87
0 0
1000.0 16772.00
5086 7776 69892 6963.0 36000.0 19.34
0 0
1000.0 16772.00
5083 7776 70940 7067.4 36000.0 19.63
0 0
1000.0 16772.00
5082 7776 75824 7553.9 36000.0 20.98
0 0
1000.0 16772.00
5085 7776 68094 6783.8 36000.0 18.84
0 0

5.6 Nozzle Check

Table 5.8 – Nozzle Check at Separator LMB-A

Nod Ma Mb Mc Remark
Condition Fa N. Fb N. Fc N.
e N.m. N.m. N.m.
(OPE)
N2 -198205 338877 1126 7491 -19887 741402 Note 1
W+D1+T1+P1

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Thermal Displacement
Vertical = 2.388 mm
Horizontal = 5.328 mm

Figure 5.5 Nozzle N2 Separator LMB-A

Table 5.8 – Nozzle Check at Steam Vessel

Nod Ma Mb Mc Remark
Condition Fa N. Fb N. Fc N.
e N.m. N.m. N.m.
(OPE)
N4 44362 -9022 -6987 98386 7156 -3961 Note 1
W+D1+T1+P1

Thermal Displacement
Vertical = 5.128 mm
Horizontal = 11.034 mm

Figure 5.6 Nozzle N4 Steam Vessel

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Notes :
1. Summary for separator (N2) & steam vessel (N4) nozzle analysis have been
evaluated and the result are acceptable as per WRC 107 from recommendarion
ASME VIII Section 2 in para 4.5.15. The results as presented in Attachment L.
2. The nozzle allowable will be increased by mechanical to accomocate the load from
piping.
3. Piping recommended for the thickness and diameter of reinforcing pad at Nozzle (N1)
of separator shall be follow as per WRC calculation in attachment L.

6. SUMMARY AND RECOMMENDATION

6.1. Conclusion

Summary from Pipeline Stress Analysis for Steam LMB-A to Steam Vessel

design of Lumut Balai Geothermal FCRS showing that maximum pipeline stress

still less than Allowable Stress based on ASME B31.1.

6.2. Recommendation

Based on the result summary presented it is recommended:

 Using design pressure and temperature as the input for the analysis.

 Caused of thermal expansion, looping shall be provided.

 Pipe support shall be followed the detailed input types and locations of the

pipe support.

 The nozzle strength shall be increased to accommodate the load from piping.

7. ATTACHMENT

Attachment A – Line Stress Analysis

Attachment B – P&ID Markup
Attachment C – Alignment Sheet Drawing
Attachment D – Isometric Drawing
Attachment E – Isometric Extract Drawing
Attachment F – General Arrangement Mechanical Equipment
Attachment G – Caesar Model and Data Input
Attachment H – Input Echo
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Attachment I – Stress Summary

Attachment J – Displacement
Attachment K – Restraint Summary
Attachment L – Flange Leakage
Attachment M – Nozzle Check

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Attachment A – Line Stress Analysis

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Attachment B – P&ID Markup

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Attachment C – Alignment Sheet Drawing

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Attachment D – Isometric Drawing

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Attachment E – General Arrangement Separator

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Attachment F – Caesar Model and Data Input

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Attachment G – Input Echo

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Attachment H – Stress Summary

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Attachment I – Displacement

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Attachment J – Restraint Summary

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PIPE STRESS AND FLEXIBILITY ANALYSIS REPORT FOR STEAM FROM LMB-A TO
STEAM VESSEL
Document No. Rev No. Contract No.
LMB2-E-FC-PIP-OCS-MS1-0015 C 459/PGE000/2022-S0

Attachment K – Flange Leakage

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PIPE STRESS AND FLEXIBILITY ANALYSIS REPORT FOR STEAM FROM LMB-A TO
STEAM VESSEL
Document No. Rev No. Contract No.
LMB2-E-FC-PIP-OCS-MS1-0015 C 459/PGE000/2022-S0

Attachment L – Nozzle Check

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