STRESS ANALISIS PADA SISTEM PERPIPAAN DENGAN PROGRAM CAESAR II Pustandyo Widodo

KENAPA KITA PERLU MELAKUKAN ANALISIS TEGANAGAN PIPA ?

Mencegah terjadinya kegagalan pipa / support akibat overstress atau fatique Untuk menjaga agar tegangan di dalam pipa dan fitting memenuhi code yang diijinkan. Untuk menjaga beban pada peralatan yang dipasang memenuhi code yg diijinkan dari pabrik atau sesuai dg standar (spt API 661, API 650 dll) Untuk menghitung design beban/load untuk support dan restraints Untuk menentukan piping displacement. Untuk memecahkan permasalahan dinamik di dalam memasang pipa, yaitu.: mechanical and acoustic vibration , transient flow and relief valve discharge Untuk mengoptimalkan desain perpipaan. Untuk mencegah kebocoran pada flange joint / sambungan pipa.

Design of Piping
Typically piping is categorised:
Hot system , design temp. > 1500F (660C) Cold system, design temp. < 1500F (660C)

Piping loads:
Sustained Load, seperti pressure, weight/berat. Expansion Load, seperti thermal expansion, diff. anchor displacement.

Occasional Load, seperti. wind, earthquake

The stresses on the piping:

Normal stresses: longitudinal stress, hoop stress, radial stress Shear stresses, berkaitan dg shear load and torsion.

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E x p a n s i o n j o i n t

DESIGN SISTEM PERPIPAAN MEMPERTIMBANGKAN FLEKSIBILITAS

Pipe Stress Analysis Category

Method of Analysis:
1. Category 3 Using computer program such as: Caesar II (Coade), Autopipe (Bentley), PIPANL-3 (SSD) etc. Category 4 Using approximate methods such as: the Kellogg, Grinnell or Tube Turn methods. Category 5 Visual inspection with or without the aid of guided cantilever chart or similar short cut methods.

2.

3.

Ref: KBR Design Manual Subject No: 4100

 x E
Where: = Stress (kg/cm2) = Strain

E=YoungsModulus(kg/cm2)
Allowable stress is the yield strength divided by safety factor. I.E : Carbon Steel Pipe below creep range commonly has allowable stress is 2/3* y or * u. For detail see Table A-1 in B31.3

Tegangan akibat gaya axial = F/A

F = Axial force acting on cross section (kg) A = Cross-sectional of pipe (mm2)

Tegangan akibat bending & Torsi b = Mb / Z t = Mt / 2Z

Mb = Bending moment (kg-mm) Mt = Torsional moment (kg-mm) Z = Section modulus of pipe (mm3)

M
t

Mb

Tegangan akibat tekanan internal

H = PDi / 2t (Hoop)

L = PDi / 4t (Longitudinal)
P = Design pressure (kg/mm2) Di = Inner diameter (mm) t = Thickness of pipe (mm)

Ekspansi Thermal
= T x x L ; (mm) Carbon Steel +/- 1 mm/m for 100oC Stainless Steel +/- 1.35 mm/m for 100oC

Tegangan Thermal = x = /L x E
= T x x E

(Pushed)

Reaction Force F=xA

Example:1meterlengthof8NPSCSPipeSTD at 100oC. T ambient = 20oC 1. = (100-20)x12x10-6x1000 = 0.96 mm 2. = (100-20)x12x10-6x20000 = 19.2 kg/mm2 3. F = 19.2 x x (2192-2032)/4 = 27.6 ton

Force

Piping Design Code

ASME B31.1 Power Piping ASME B31.3 Process Piping ASME B31.4 Pipeline (Hydrocarbon) ASME B31.8 Pipeline (Gas) ASME Section III Nuclear Component Design

Related Code for Nozzle Evaluation

API Std 610 Centrifugal Pump API Std 611 Steam Turbines API Std 617 Centrifugal Compressor API Std 618 Reciprocating Compressor API Std 650 Welded Steel Tanks API Std 560 Fired Heaters (Furnace) API STD 661 Air-Cooled Heat Exchangers (AFC) NEMA SM23 Steam Turbines ASME SEC VIII Pressure Vessel WRC 107, WRC 297 Local Stress on Nozzles

ASME: The American Society of Mechanical Engineers API: American Petroleum Institute NEMA: National Electrical Manufacturers Association WRC: Welding Research Council

7.2. Code Stress Equations

7.2.1. B31.1 Power Piping 7.2.2. B31.3 Process Piping
2 2 1 / 2 F [( i M ) ( i M ) ] Pd ax i i o o o S S sus H A Z 4 t m

0 . 75 iM A Pd S o S sus H Z 4 t

2 2 2 1 / 2 iM C [( i M ) ( i M ) 4 M ] i i * o o * T S S f ( 1 . 25 S 1 . 25 S S ) S S f ( 1 . 25 S 1 . 25 S S ) EXP A C H SUS EXP A C H S Z Z

Pd 0 . 75 iM 0 . 75 iM S S S 1 . 33 S o A B OCC SUS l H S kS OCC H Z Z 4 t

Where:
MA = Resultant moment due to sustained, kg-mm SH = Allowable stress at operating temperature, i = Intensification factor kg/mm2

Where:
Fax= Axial force due to sustained, kg Mi = In-plane bending moment due to sustained, kg-mm Mo = Out-plane bending moment due to sustained, kg-mm Mi* = Range of in-plane bending moment due to expansion, kg-mm Mo* = Range of out-plane bending moment due to expansion, kg-mm SH = Allowable stress at operating temperature, kg/mm2 ii ,io = In-plane, out-plane intensification factor MT = Torsional moment due to expansion, kg-mm SA = Allowable expansion stress, kg/mm2 SC = Allowable stress at installation temperature, kg/mm2 Sl = Bending stress due to occasional loads such as wind/earthquake f = Stress range reduction factor

Mc = Resultant moment due to expansion, kg-mm SA = Allowable expansion stress, kg/mm2 MB = Resultant moment due to occasional, kg-mm k = occasional factor = 1.2 for loads occurring less than 1% of the time = 1.15 for loads occurring less than 10% of the time SC = Allowable stress at installation temperature, kg/mm2

7.2.3. B31.4 Liquid Transportation Piping

7.2.4. B31.8 Gas Transportation Piping

S S S 0 . 75 0 x . 72 x S sus lp b Yield
1 / 2 S ( S 4 S 0 . 72 S EXP b * t) Yield 2 2

S S S 0 . 75 S T x sus lp b
1 / 2 S ( S 4 S 0 . 72 S EXP b * t) 2 2

F x

S S S S S F Ea T v S S S ( 1 F ) 0 . 9 S OPE EXP SUS OPE H EXP SUS Yield

S S S 0 . 75 0 x . 72 x k x S S S S 0 . 75 xx S T OCC lp b * * Yield OCC lp b**

Where:
Slp = Longitudinal pressure stress, kg/mm2 kg/mm2 kg/mm2 Sb = Bending stress due to sustained,

Where:
Slp = Longitudinal pressure stress, kg/mm2 Sb = Bending stress due to sustained, kg/mm2 Sb* = Range of bending stress due to expansion, kg/mm 2 St = Range of torsional stress due to expansion, kg/mm 2 Sb** = Bending stress due occasional, kg/mm2 S = Specified minimum yield stress material, kg/mm2 F = Construction type

Sb* = Range of bending stress due to expansion,

St = Range of torsional stress due to expansion, kg/mm2 Sb** = Bending stress due occasional, kg/mm2

Syield = Specified minimum yield stress material, kg/mm2 F E a = 1 (under ground pipeline); 0 (above ground pipeline) = Modulus of Elasticity = Thermal expansion coefficient

T = Temperature derating factor k = Occasional load factor

T = Temperature change of pipe from ambient v =Poissonsratio

SH = Hoop stress kg/mm2 k = Occasional load factor

Kriteria Analisis Tegangan

3 5 0 3 0 0 2 5 0
o

C 2 0 0 1 5 0 1 0 0

D e t a i lc a l c u l a t i o n r e q u i r e d

8 N P S

1 0

1 2

1 4

3 0 0 2 5 0
o

D e t a i lc a l c u l a t i o n r e q u i r e d

D e t a i lc a l c u l a t i o n r e q u i r e d C l a s s 6 0 0 a n d h i g h e r

2 0 0 C 1 5 0 1 0 0 8 0 C a l c u l a t i o n n o t r e q u i r e d 2 3 4 6 8 1 0 1 2 1 4 2 3

C a l c u l a t i o n n o t r e q u i r e d 4 6 8 1 0 1 2 1 4

N P S

N P S

Kriteria Desain Support

Pad Shoe

Anchor
Structure Eye Bolt Spring Hanger Turnbuckle Pipe Clamp

Spring Hanger Assembly

Adjustable Support

Tiga macam hanger yg biasa digunakan adlh : Rigid support atau rod hanger yang harus dapat menahan setiap gerakkan sepanjang sumbu hanger. Variabel support atau spring hanger menyediakan gaya support yang sama dengan hot load dan memungkinkan defleksi. Constant support atau constant effort hangers yang menyediakan gaya konstan saat terjadinya siklus termal. Idealnya support hanger yang konstan tidak akan meregang saat gerakkan bebas dari system dan tidak akan menimbulkan tegangan pada pipa.

Sliding Support

Control Valve Tight Support Variable Spring Support

Adjustable Guide

Support Around Control Valve

Spring and Adjustable Support

Stress Analysis using Caesar II

Required Data: Spring Support Vertical Guide

Piping Configuration complete with dimension.

Material Spec. :Size, Thickness, Material Properties, method of bracing, etc. LDT (Line Designation Table): Pressure, Temperature, Insulation Thickness, Density etc. Equipment Drawing to determine nozzle movement. Wind and earthquake loading. Standard valve and flange weight. Number of operating cycles if any. Misc. item drawing such as silencer etc.

Spring Hanger (Typ. 12ea)

V1002 Trunnion (Typ.

3ea)

Guide (Typ. 3ea)

V1001 K3301C

Item need to be concerned: Boundary Condition. Operating Case, i.e: pump, run or standby.

K3301A

K3301B

Friction.

START
DATA : 1. Sistem Proses 2. Gb P & ID 3. Gb Isometric 4. Dok.Kontrak 5. Pipeline List

PENGGUNAAN PROGRAM CAESAR II

INPUT / EDIT DATA

PROSES & ANALISIS DG CAESAR II : -Analisis beban, Displacemen, Stress

PROSES ULANG *

KRITERIA PENERIMA AN

Tdk Sesuai

Sesuai
VALIDASI

SELESAI

PIPING INPUT DENGAN PROGRAM CAESAR II

Restraint Summary Static Output

Displacement Static Output

Stress Static Output

PRAKTIKUM DG CAESAR II

LIHAT FILE PRAKTIKUM