Piping & Pipeline in Oil and Gas (1)

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TRIPATRA ENGINEERS & CONSTRUCTORS

Jl. R. A Kartini No. 34 (Outer Ring Road)

Cilandak Barat, Jakarta Selatan 12430

By

Aditya Ahmad Darusalam

Piping Design Engineer

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Komponen Pipa

Piping & Pipeline

Manufacture

Pendahuluan

Klasifikasi Pipa

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• Ribuan tahun yang lalu digunakan untuk mengalirkan air sebagai kebutuhan air minum dan irigasi.

• Bambu digunakan di Cina sedangkan orang Persia dan Romawi menggunakan aqueducts sebagai bahan pipa.

• 400 SM Cina memakai bambu untuk mengalirkan gas alam.

• Mulai awal abad ke 18 teknologi bahan pipa mengalami perkembangan yang pesat.

• Saat ini penggunaan sistem perpipaan sangat luas.

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1000 SMPipa gas pertama,dari bambu di Jepang

1878

Pipa minyak pertama dibangun untuk Nobel bersaudara di Baku

• Panjang 76 km

• Mengurangi biaya distribusi hingga 95%

• Balik modal pembangunan dalam setahun

1905

Pipa dari Baku ke laut hitam, diameter 8 inch & panjang 800

km.

1859Pengeboran minyak pertama, di Titusville Pennsylvania.

1905Pipa minyak mentahSejarah bisnis minyak, telah mampu memisahkan minyak tanah dan bensin.

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1970 – 1977Perpipaan trans Alaska

• Mendistribusi minyak 1.6 juta barel per hari • Melintasi 800 mil daerah dingin, pegunungan

bersalju

1970s – 1990Masa perpipaan modern:• Mendistribusi migas dibawah laut dengan kedalaman 1 mil• Mengumpulkan minyak dan gas dari dalam permukaan bumi• Men-transportasi-kan fluida-fluida lain• Men-transportasi-kan gas alam untuk keperluan industri • Men-transportasi-kan cairan kimia untuk industri

1950s – 1960sPengembangan pipa komposit (GRP) awal

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Pipa :Alat untuk mengalirkan fluida (zat cair, gas) dari satuatau beberapa titik ke satu atau beberapa titik lainnya

Pengaliran Fluida• Tidak boleh bocor• Untuk mengalirkan fluida perlu perbedaan tekanan antara titik awal dan titik akhir• Harus di atasinya perlawanan/gesekan pipa pada fluida• Kedua hal di atas memerlukan energi

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Pemakaian Pipa.Dipakai pada banyak industri, pabrik/instalasi

pipa adalah urat nadi dari industri proses, petroleum, power, etc

Sistem PipaSistem perpipaan selalu dilengkapi komponen-komponen seperti katup, flens, belokan, percabangan, isolasi, dll

Gambar 1.1. Contoh model komputer sistem perpipaan

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Gambar 1.2. Sistem perpipaan pada industri kimia/refining plant

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Gambar 1.3. Model komputer pembangkit nuklir

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Company Logowww.themegallery.com

Piping VS Pipeline

• Piping memiliki ukuran panjang total dan diameter relatif lebih pendek dan kecil.•Piping digunakan untuk mengalirkan fluida dari satu atau beberapa peralatan ke satu atau beberapa peralatan lainnya pada suatu fasilitas pengolahan.

• Pipeline merupakan pipa yang berukuran sangat panjang dan biasanya berdiameter besar • Pipeline berfungsi menghubungkan suatu sistem (facility) ke sistem (facility) yang lain dan lebih digunakan untuk kebutuhan transmisi dan distribusi

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Pipe Terminology1. Nominal Pipe Size (NPS) :

The Nominal Standard Sizes of pipes are standardizes pipe diameter sizes that are commonly used in piping systems. The sizes refer to the outside diameter (OD)

of the pipe. Example. NPS 8” Sch 40

2. Pipe Schedule :Pipe schedules are actually standardized wall thicknesses for NPS. These schedules are listed as numbers and vary for each NPS. Beside these numeric schedules there are also three common classifications to pipe wall thicknesses: Standard (STD), Extra Strong (XS) and Double Extra Strong (XXS)Example. NPS 10” Sch XS

3. Rating: Flanged components are classified in several pressure classes, which relate to

working pressures in pound per square inches, like 150 lb., 300 lb., 600 lb., and others.

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1. Code : A group of general rules or systematic standards for design, materials, fabrication, installation and inspection prepared in such a manner that it can be adopted by legal jurisdiction and made into law.

2. Standard : Documents prepared by a professional group having requirements believed to be good and proper engineering practice and which are written with mandatory requirements (i.e., the verb shall is used.)

3. Recommended Practice : Documents prepared by a professional group indicating good engineering practices but which are optional (i.e., the verb should is used)

4. Guides and Guidelines : Documents by agencies, organizations, and committees enumerating various engineering methods which are considered good practice, without any specific recommendation or requirement. These guides may be used at engineer’s discretation.

Code & Standard

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1. Piping

ASME/ANSI B31 CommitteesPower piping B31.1Fuel gas piping B31.2Chemical plant & Petr.Ref.piping B31.3Liquid-petr.transportation piping syst. B31.4Refrigeration piping B31.5Nuclear power piping (superseded by ASME,dll) B31.7Gas transmission & distribution piping B31.8Building services piping B31.9

2. Pipeline

• ASME B31.8 “Gas Transmission and Distribution Pipeline”• ASME B31.4 “Liquid-petr.transportation piping syst.”• DnV 1981 “Rules For Submarine Pipeline Systems”• DnV OS-F101 “Submarine Pipeline Systems”• DnV RP F105 “Free Spanning Pipelines”• DnV Rp E305 “On Bottom Stability Design of Submarine Pipeline”• DnV RP B401 “Cathodic Protection Design”• DnV RP F106 “Coating Types”• API 5L “Specification for linepipe”• ANSI B16.5 “Pipe Flange and Flanged Fitting”• BS 8010 “Pipeline Subsea: Design, Constuction and Installation”• BS 4515 “Field Welding of Pipelines on Land and Offshore”

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1. Material Pembentuk1. Pipa Metal/Steel : terbuat dari metal/steel2. Pipa Non-Metal : terbuat dari non metal 3. Pipa Komposite : terbuat dari komposite

2. Diameter1. Pipe : Outside Diameter (OD) nya mengikuti standard yg berlaku 2. Tubing : OD nya tidak mengikuti standard yg berlaku dan OD nya

sama dengan NPS nya.

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3. Manufacture1. Welded Pipe : pembuatannya menggunakan las (welding)2. Seamless : pembuatannya tidak menggunakan las (welding)

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Bolting.

Metallic Fittings, Valves, and Flanges.

Metallic Pipe & Tubes.

Miscelianeous

Komponen – Komponen Pada Sistem Perpipaan

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1.Flanges

Type of Flange Faces

1. Flat Face (FF)

As the name indicates, this type is flat with no raised parts or grooves on the surface. Flat face is normally used for cast iron flanges or galvanized flanges.

Normally gaskets of the type flat sheet, or full faced are used.

Flanges are used to join pipes, valves, or vessels within a piping system through a mechanical joint. This mechanical joint makes use of bolts and nuts connection that can be easily assembled and dissembled, so the joined components can be modified, serviced, or replaced.

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Type of Flange Faces

2. Raised Face (RF)

This flange has a raised part in the center of the face. It is commonly used in low

pressure flanges from C150 ~ CL900. The gasket used are normally spiral wound gaskets.

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Type of Flange Faces

2. Ring Joint (RJ)

Normally used for high pressure flanges from CL900 up, this kind has a groove on its surface to accommodate the ring joint gasket used for it.

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Type of ANSI Flange

1. Weldneck Flanges

This flange has a bore matching the dimensions of the opposite pipe. It is the most common type and normally used for high pressure, cold or hot temperature.

2. Slip-On and Lap-joint Flanges

Normally used for high pressure flanges from CL900 up, this kind has a groove on its surface to accommodate the ring joint gasket used for it.

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Type of ANSI Flange

3. Threaded Flanges

This flange has female threaded end as the connection to the matching pipe. This type of flange is used in systems not involving temperature or stresses of any magnitude.

4. Socket Weld Flanges

This flange looks similar to the slip-on flange. The bottom of flange has the same ID as the matching pipe.

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Type of ANSI Flange

5. Reducing Flanges

This flange is described in the same manner as a reducer, the large end first, the reduction second.

6. Blind Flanges

A blind flange has no bore, and is used to close ends of piping systems. It also permits easy access to a line once it has been sealed.

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Miscellaneous Flange

1. Orifice Flanges

The orifice flange is functioned to meter the flow of liquids and gases through a pipe line.

2. Long Weldneck Flanges

A special flange used for nozzles on pressure vessels. The hub is always straight, and the hub thickness is greater than the diameter of any piping that may be bolted to the flange

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2. Gasket

Type of Gasket

The gasket is mostly a compressible material that will permit the leak-proof coupling of flanges or other surfaces, even if they contain irregularities.

For high pressure/high temperature applications, gaskets are machined from steel in such a design that they fit into a prescribed sealing cavities.

2. Ring Gasket For ring-type gasket only the ID is the same, the OD may equal the inner bolt circle to facilitate installation.

1. Full Face Gasket Normally used for flat faced flanges, covers the entire flange face and OD and ID of flange and gasket are the same

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3. Bolt & NutBolts may generally be classified as machine bolts, stud bolts, or bolt studs.

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Bolting materials, which have been standardized by ASTM include:

A-193 Alloy and SS bolts for HT serviceA-194 Carbon and alloy nuts for HT serviceA-307 Low carbon steel threaded fastenersA-320 Alloy steel bolting material for LT serviceA-354 Quenched and tempered alloy steel bolts and studsA-437 Alloy steel turbine type material for HT service

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4. ValveValves are the components in a fluid flow or pressure system which regulate either

the flow or the pressure of the fluid. These tasks are performed by adjusting the position of the closure member in the valve. This may be done manually or automatically. In this section we concern ourselves on to manual operated valves and check valves.

Valves in any piping system serve three elementary functions:- Shut off or open a system to fluid flow- Regulate or throttle any fluid flow- Prevent backflow

Manual valves may be grouped according to the way the closure member movesonto the seat:1. Closing down valves : A stopper-like closure member is moved to and from the seat in the direction of the seat axis.2. Slide valves : A gate-like closure member is moved across the flow passage.3. Rotary valves : A plug-like closure member is rotated within the flow passage, around an axis normal to the flow stream.4. Flex-body valves : The closure member flexes the valve body.

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Valve End Connection

- Threaded End Connection : Valves with these ends are commonly used in sizes up to 2".- Flanged End Connections : These connections enable the valve to be easily installed and removed from the pipelin- Welding End Connections : Welding end valves up to 2" are usually provided with sockets which receive plin end pipes. Pipe vibrations may also fatigue the joint.

1. GATE VALVES

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2. Globe VALVES

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3. Ball VALVES

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4. Butterfly VALVES

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5. Check VALVES

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3. P&ID Symbols

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1. Buttweld

1. Elbow

The elbow is the most commonly used fitting. The main manufactured elbows are 90º and 45º elbows, although other types exist like 60º elbows. To obtain a custom angled elbow, a standard elbow may be trimmed. The most commonly used elbow is the long radius elbow, where the center-to- face dimension is one 1½ times the size of the elbow size/NPS. The short radius elbow, with center-to-face dimension same as the elbow size, is used in systems with tight spaces like offshore platforms and skid units.

Fittings are used to change the direction or join parts of a piping system. Fittings are mostly identified or specified in accordance with the method of connection, most commonly threading, butt welding and socket welding.

These type of fittings are specially manufactured fittings that are by means of material composition and end preparation suitable for welding. The material composition of these fittings is mostly similar to that of the pipe to which they are connected.The most common used fittings are :

5. Fittings

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2. Reducing Elbow

The 90º reducing elbow is used to change direction and reduce the flow in the piping system at the same time.

3. 180o Returns

The return is used for direction changes of 180 degrees. Like elbows, returns may be long radius or short radius.

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4. Tee

At a straight tee, the branch size is the same as the main size of the tee. While for a reducing tee, the branch size is smaller (up

to half the size) than the main size.

5. Crosses

Straight or reducing crosses are seldom used in systems, except in special cases, like when there is a limitation of space. Crosses are usually made of sizes 12" or smaller.

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6. Reducer

Reducers are used to reduce a line to a smaller size.

Concentric reducers have inlets and outlets that are on a center line. While eccentric

reducers have off-center outlets, and are flat on one side.

7. Cap

Pipe caps are used to block off the end of a line, by welding it to a pipe to create a dead

end.

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2. Threaded

Threaded ended fittings exist to sizes up to 4". Components covered by threaded fittings are generally the same as for welded fittings,with additional components as followed:- Plugs - hexagon, round, square or flush- Bushings - hexagon or flush- Street elbow, tee, or union- Unions- Couplings and half couplings

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3. Socket Weld

Like threaded fittings, socket weld fittings are mostly restricted to sizes up to 4".

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Olet Connection

Olet connections are an alternative choice to make branches that have a big sizedifference with the main line size (usually for branch sizes less than half the size of the main size).The most common used are:- Thredolet - uses with a threaded outlet, size ranges up to 4".- Sockolet - same as thredolet but has a socket weld output.- Weldolet - with buttweld outlet, used for large branch sizes (2" up)- Sweepolet - resembles a saddle, can support the branch line welded on it.- Elbolet - welded to a 90º elbow to form an outlet

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4. Miscelianeous

Spectacle Blinds and Spacers

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Safety or Relief Valve

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Strainer

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Piping SystemMain Aspects

PFD – P&IDRouting Design Loads Fluid Flow AnalysisWall Thickness Calculation Stress AnalysisFlexibility & Exp AnalysisSupport SystemsMaterial & Coating SystemFitting & AccessoriesMetering

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1. Fluidanya / Fungsinya• Flow lines• Inter-field lines• Export lines/trunk lines• Water injection/gas lift• Product lines

2.Lokasinya• Onshore Pipeline (di darat)• Offshore Pipeline (di laut)

Pipeline SystemJenis-jenis Pipeline

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PIPELINE DESIGN

Parameter Design

Wall Thickness

Buckling

Route Selection

On Bottom-Stability Material Selection

Spanning

Proteksi Kathodik

Fatigue

Thermal Expansion

Enviromental Data

Route Survey

Perancangan Pipeline

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Buried Pipeline

Fundamentals of Pipeline Installation Shipping, Handling & Storage Inspection of Pipe Interiors Trench Excavation Groundwater Control Foundation & Bedding Laying & Joining Appurtenances & Fittings Embedment & Backfill Soil Classification Soil Properties Compaction of Soil Installation of Flowable Fill Acceptance Testing Safety Concerns

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There are some methods that used in

sub sea pipeline installation :- S Lay Method- J Lay Method- Reel Lay Method

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• Shallow water: S-lay• Deep water: J-lay

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Trenchsetter

SolitaireSolitaire

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Tower

Tension

Departure angle

Sagbend

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