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PRESSURE VESSELL ASSESSMENT REPORT

3 PHASE PRODUCTION SEPARATOR


TAG NO. C-321 / SERIAL NO. 28829

PT. BINTANG ENERGI PRATAMA

PT BIRO KLASIFIKASI INDONESIA (BKI)

PT DINAMIKA TEKNIK PERSADA

Document no. : DTP/2015/R.

1
0
Revision

02/05/15
17/03/15
Date

Issued For Review


Issued For Review
Description

FE
FE
Prepared

BD
BD
Checked

Approved

3 Phase Production Separator


(Tag No. C-321 / SN. 28829)
SP III Limau

SUMMARY OF CHANGE SHEET

Rev No

Date

Page

Description

17/03/15

All

Issued For Review

02/04/15

37

Assummed Initial Thickness for


Shell

Approve

Page 2 of 42

3 Phase Production Separator


(Tag No. C-321 / SN. 28829)
SP III Limau
DAFTAR ISI

TABLE OF CONTENTS

1. PENDAHULUAN

1.

2. LINGKUP PEKERJAAN

2. SCOPE OF WORK

3. DATA UMUM

3.

GENERAL DATA

4. HASIL INSPEKSI

4.

INSPECTION RESULTS

INTRODUCTION

4.1 Inspeksi Visual

4.1 Visual Inspection

4.2 Pengukuran ketebalan UT

4.2 UT Thickness Measurements

5. ENGINEERING CALCULATIONS

5. PERHITUNGAN TEKNIS
5.1 Kondisi Desain - Nameplate

6. MEKANISME KERUSAKAN &

5.1 Design Condition - Nameplate

6. DAMAGE MECHANISMS &

PERENCANAAN INSPEKSI

22

INSPECTION PLAN

22

6.1. Mekanisme kerusakan

22

6.1. Damage Mechanisms

22

6.2. Perancenaan Inspeksi

28

6.2. Inspection Plan

28

34

7. CONDITION ASSESSMENT

34

7.1 Ketebalan Yang Diperlukan

35

7.1 Thickness Requirements

35

7.2 Sisa Umur

36

7.2 Remaining Life

36

7. PENILAIAN KONDISI

8.KESIMPULAN & SARAN

38

8. CONCLUSION &
38

RECOMMENDATIONS

LAMPIRAN A

REPORT UT THICKNESS

APPENDIX A

REPORT UT THICKNESS

LAMPIRAN B

PERHITUNGAN SISA UMUR

APPENDIX B

REMAINING LIFE CALCULATION

LAMPIRAN C

DRAWING

APPENDIX C

DRAWING

Page 3 of 42

3 Phase Production Separator


(Tag No. C-321 / SN. 28829)
SP III Limau

1. PENDAHULUAN

1.

INTRODUCTION

Laporan ini berisikan penilaian teknis untuk


integritas mekanikal bejana tekan 3 Phase
Production Separator Tag no. C-321.
penilaian ini sesuai dengan peraturan dan
code/standard yang berlaku:

This report outlines the engineering calculations


for mechanical integrity of pressure vessels 3
Phase Production Separator Tag no. C-321.
This
report
according
to
applicable
code/standards.

Peraturan Menteri pertambangan No.


06P/0746/M.PE/1991
tentang
Pemeriksaan Keselamatan Kerja atas
Instalasi Peralatan dan Teknis yang
Dipergunakan dalam Pertambangan
MIGAS dan Pengusahaan Sumber Daya
Panas Bumi.

Peraturan Menteri pertambangan No.


06P/0746/M.PE/1991 tentang Pemeriksaan
Keselamatan Kerja atas Instalasi Peralatan
dan Teknis yang Dipergunakan dalam
Pertambangan MIGAS dan Pengusahaan
Sumber Daya Panas Bumi.

Dir.
Jen.
MIGAS
No
SK
84.K/38/DJM/1998 tentang Pedoman
dan
Tata
Cara
Pemeriksaan
Keselamatan Kerja atas Instalasi,
Peralatan
dan
Teknik
yang
Dipergunakan
dalam
Usaha
Pertambangan Minyak dan Gas Bumi
dan Pengusahaan Sumber Daya Panas
Bumi.

SK Dir. Jen. MIGAS No 84.K/38/DJM/1998


tentang
Pedoman
dan
Tata
Cara
Pemeriksaan Keselamatan Kerja atas
Instalasi, Peralatan dan Teknik yang
Dipergunakan dalam Usaha Pertambangan
Minyak dan Gas Bumi dan Pengusahaan
Sumber Daya Panas Bumi.

Surat edaran Dir. Jen. MIGAS No.


12024/18.05/DMT/2013
perihal
Pemeriksaan Peralatan Operasi Migas
yang telah melewati umur desain
(Design Life) dan yang tidak memiliki
data.

Surat edaran Dir. Jen. MIGAS No.


12024/18.05/DMT/2013
perihal
Pemeriksaan Peralatan Operasi Migas yang
telah melewati umur desain (Design Life)
dan yang tidak memiliki data.

ASME BPV Section VIII, Rules for


Construction of Pressure Vessels

ASME BPV Section VIII, Rules


Construction of Pressure Vessels

API Publication 510, Pressure Vessel


Inspection Code: Inspection, Rating,
Repair, and Alteration

API Publication 510, Pressure Vessel


Inspection Code: Inspection, Rating, Repair,
and Alteration

API 572, Inspection


Pressure Vessels

for

API 572, Inspection Practices for Pressure


Vessels

ASME PCC 3, Inspection Planning


Using Risk-Based Methods

ASME PCC 3, Inspection Planning Using


Risk-Based Methods

API 571, Damage Mechanisms Affecting


Fixed Equipment in the Refining Industry

API 571, Damage Mechanisms Affecting


Fixed Equipment in the Refining Industry

API
581,
Technology

API 581, Risk-Based Inspection Technology

Practices

Risk-Based

Inspection

Page 4 of 42

for

3 Phase Production Separator


(Tag No. C-321 / SN. 28829)
SP III Limau
ASME BPV section V, Nondestructive
Examination.

ASME BPV
Examination.

Perhitungan
menentukan
tekan yaitu :

teknis diperlukan untuk


integritas mekanik bejana

The engineering calculations required to


determine the mechanical integrity of pressure
vessel are:

Tekanan kerja maksimal yang diijinkan


(MAWP) pada shell, head dan nozelnozel.

Maximum allowable working pressure


(MAWP) for shell, head and nozzles

section

V,

Nondestructive

Page 5 of 42

3 Phase Production Separator


(Tag No. C-321 / SN. 28829)
SP III Limau

2. LINGKUP PEKERJAAN

2. SCOPE OF WORK

MAWP untuk suatu operasi bejana tekan


didasarkan
pada
perhitungan
yang
ditentukan dengan menggunakan edisi
terbaru yang berlaku dari kode ASME atau
kode konstruksi untuk bejana tekan yang
dibangun. MAWP dari hasil perhitungan ini
tidak boleh lebih besar dari MAWP desain
awal.

The MAWP for the continued use of a


pressure vessel shall be based on
computations that are determined using the
latest applicable edition of the ASME Code or
the construction code to which the vessel
was built. The resulting MAWP from these
computations shall not be greater than the
original MAWP.

Perhitungan dapat dilakukan jika disain


parameter berikut memenuhi persyaratan
code yang digunakan: head, shell, dan
nozzle, spesifikasi material, tegangan yang
diijinkan, efisiensi sambungan, persyaratan
inspeksi yang diterima.

Computations may be made only if the


following essential details comply with the
applicable requirements of the code being
used: head, shell, and nozzle reinforcement
designs; material specifications; allowable
stresses; weld efficiencies;
inspection
acceptance requirements.

3. DATA UMUM

3.

GENERAL DATA

Data bejana tekan secara umum dideskripsikan

General pressure vesssel data are described at

pada nameplate sebagai berikut :

nameplate as follow :

User

PT. Bintang Energi Pratama

Operation

3 Phase Production Separator

Item no.

C-321

Year Built

2006

MAWP

600 psig nameplate

Material

SA 516 70

Dimension

72 OD x 276 (S/S)

Code

ASME Sec. VIII Div. 1

RT/Joint Eff.

Full / 1.00

Page 6 of 42

3 Phase Production Separator


(Tag No. C-321 / SN. 28829)
SP III Limau

4. HASIL INSPEKSI

4.

INSPECTION RESULTS

4.1 Inspeksi Visual

4.1 Visual Inspection

Inspeksi visual dilakukan untuk memastikan


kondisi pada bejana tekan (meliputi flange, shell,
heads, nozzles cat, coating, penyangga, dan
safety devices) oleh PV Inspector.
Secara
umum ditunjukkan gambar berikut.

The visual inspection performed to make


sure that PV condition (flange, shell, heads,
nozzles, painting, coating, support and
safety devices) by Inspector. Generally,
visual inspection of pressure vessel shown
in the following pictures.

No.

Inspection Task

Shell, head,
support,
nozzles, and
ladder.

Pressure and
Temperature
Gauge

PSV

Nameplate

Photograph

Remarks

Generally, this PV
is in good
condition.

N/A

No temperature
and pressure
gauge are installed
at this PV.

N/A

No PSV found at
this Pressure
Vessel.

Nameplate is
installed at this PV,
and it is in good
condition.

Page 7 of 42

3 Phase Production Separator


(Tag No. C-321 / SN. 28829)
SP III Limau

4.2

Pengukuran ketebalan UT

4.2 UT Thickness Measurements

API 510 memungkinkan inspeksi on-stream


dilakukan sebagai pengganti inspeksi internal
pada kondisi tertentu. Pengukuran ketebalan
dinding bejana tekan, head, dan nozzle
diperlukan pada setiap pemeriksaan bejana
tekan.
Jumlah pengambilan titik pengukuran tebal yang
dilakukan
pada
bejana
tekan
harus
memenuhi/mewakili
persyaratan
dalam
pemeriksaan internal. Jumlah dan lokasi titik
pengukuran ketebalan harus mempertimbangkan
hasil dari pemeriksaan sebelumnya, jika tersedia,
dan potensi konsekuensi akibat kebocoran.
Secara umum, bejana tekan dengan laju korosi
rendah akan memerlukan lokasi pengukuran
ketebalan lebih sedikit dibandingkan dengan
bejana tekan dengan laju korosi tinggi.

API 510 permits an on-stream inspection to be


conducted in lieu of an internal inspection under
certain conditions. Thickness measurements of
the vessel walls, heads, and nozzles are usually
required at each complete vessel inspection.

Tabel dibawah menunjukkan nilai ketebalan


minimum pada tiap bagian bejana tekan yang
akan
digunakan sebagai masukan
dalam
perhitungan teknis pada bab selanjutnya.

Minimum actual thickness each part of pressure


vessel which used to perform engineering
calculation at next chapter, are shown at table
below.

When this approach is used, a representative


number of thickness measurements must be
conducted on the vessel to satisfy the
requirements for an internal inspection. A
decision on the number and location of
thickness measurements should consider
results from previous inspections, if available,
and the potential consequences of loss of
containment. In general, vessels with low
corrosion rates will require fewer thickness
measurement locations compared to vessels
with higher corrosion rates.
Hasil pengujian ketebalan UT dirangkum dalam UT thickness results were summarised in
Lampiran A.
Appendix A.

Component

Min. Actual Thickness


(mm)

Head I - Left

34.35

Shell 1

33.12

Shell 2

32.84

Shell 3

32.48

Shell 4

33.05

Head II - Right

34.72

Thickness actual (min.) data used for calculation

Page 8 of 42

3 Phase Production Separator


(Tag No. C-321 / SN. 28829)
SP III Limau

5. PERHITUNGAN TEKNIS

5. ENGINEERING CALCULATIONS

5.1 Kondisi Desain - Nameplate

5.1 Design Condition - Nameplate

PV Elite Vessel Analysis Program: Input Data


Design Internal Pressure (for Hydrotest)
Design Internal Temperature
Type of Hydrotest
Hydrotest Position
Projection of Nozzle from Vessel Top
Projection of Nozzle from Vessel Bottom
Minimum Design Metal Temperature
Type of Construction
Special Service
Degree of Radiography
Use Higher Longitudinal Stresses (Flag)
Select t for Internal Pressure (Flag)
Select t for External Pressure (Flag)
Select t for Axial Stress (Flag)
Select Location for Stiff. Rings (Flag)
Consider Vortex Shedding
Perform a Corroded Hydrotest
Is this a Heat Exchanger
User Defined Hydro. Press. (Used if > 0)

600.00
300
UG-99(b)
Horizontal
0.0000
0.0000
50
Welded
None
RT 1
Y
N
N
N
N
N
N
No
0.0000

psig
F
in
in
F

psig

Page 9 of 42

3 Phase Production Separator


(Tag No. C-321 / SN. 28829)
SP III Limau
User defined MAWP
User defined MAPnc
Load
Load
Load
Load
Load
Load
Load
Load
Load
Load
Load
Load
Load
Load
Load
Load
Load
Load
Load

Case
Case
Case
Case
Case
Case
Case
Case
Case
Case
Case
Case
Case
Case
Case
Case
Case
Case
Case

0.0000
0.0000

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19

NP+EW+WI+FW+BW
NP+EW+EE+FS+BS
NP+OW+WI+FW+BW
NP+OW+EQ+FS+BS
NP+HW+HI
NP+HW+HE
IP+OW+WI+FW+BW
IP+OW+EQ+FS+BS
EP+OW+WI+FW+BW
EP+OW+EQ+FS+BS
HP+HW+HI
HP+HW+HE
IP+WE+EW
IP+WF+CW
IP+VO+OW
IP+VE+EW
NP+VO+OW
FS+BS+IP+OW
FS+BS+EP+OW

Wind Design Code


Basic Wind Speed
Surface Roughness Category
Importance Factor
Type of Surface
Base Elevation
Percent Wind for Hydrotest
Using User defined Wind Press.
Damping Factor (Beta) for Wind
Damping Factor (Beta) for Wind
Damping Factor (Beta) for Wind

[V]

Vs Elev.
(Ope)
(Empty)
(Filled)

ASCE-7 93
70.000
C: Open Terrain
1.0
Moderately Smooth
0.0000
33.0
N
0.0100
0.0000
0.0000

Seismic Design Code


UBC Seismic Zone (1=1,2=2a,3=2b,4=3,5=4)
UBC Importance Factor
UBC Soil Type
UBC Horizontal Force Factor
UBC Percent Seismic for Hydrotest

UBC 94
0.000
1.000
S1
3.000
0.000

Design Nozzle for Des. Press. + St. Head


Consider MAP New and Cold in Noz. Design
Consider External Loads for Nozzle Des.
Use ASME VIII-1 Appendix 1-9

Y
N
Y
N

Material Database Year

psig
psig

mile/hr

in

Current w/Addenda or Code Year

Configuration Directives:
Do not use Nozzle MDMT Interpretation VIII-1 01-37
Use Table G instead of exact equation for "A"
Shell Head Joints are Tapered
Compute "K" in corroded condition
Use Code Case 2286
Use the MAWP to compute the MDMT
Using Metric Material Databases, ASME II D

No
Yes
Yes
Yes
No
Yes
No

Complete Listing of Vessel Elements and Details:


Element From Node
Element To Node
Element Type
Description
Distance "FROM" to "TO"

10
20
Elliptical
Head I - Left
2.0000 in

Page 10 of 42

3 Phase Production Separator


(Tag No. C-321 / SN. 28829)
SP III Limau
Element Outside Diameter
Element Thickness
Internal Corrosion Allowance
Nominal Thickness
External Corrosion Allowance
Design Internal Pressure
Design Temperature Internal Pressure
Design External Pressure
Design Temperature External Pressure
Effective Diameter Multiplier
Material Name
Allowable Stress, Ambient
Allowable Stress, Operating
Allowable Stress, Hydrotest
Material Density
P Number Thickness
Yield Stress, Operating
UCS-66 Chart Curve Designation
External Pressure Chart Name
UNS Number
Product Form
Efficiency, Longitudinal Seam
Efficiency, Circumferential Seam
Elliptical Head Factor

72.000
34.350
3.1750
0.0000
0.0000
600.00
300
0.0000
0
1.2
SA-516 70
20000.
20000.
26000.
0.2800
31.750
33600.
B
CS-2
K02700
Plate
1.0
1.0
2.0

in
mm
mm
mm
mm
psig
F
psig
F
psi
psi
psi
lb/in
mm
psi

-------------------------------------------------------------------Element From Node


Element To Node
Element Type
Description
Distance "FROM" to "TO"
Element Outside Diameter
Element Thickness
Internal Corrosion Allowance
Nominal Thickness
External Corrosion Allowance
Design Internal Pressure
Design Temperature Internal Pressure
Design External Pressure
Design Temperature External Pressure
Effective Diameter Multiplier
Material Name
Efficiency, Longitudinal Seam
Efficiency, Circumferential Seam

20
30
Cylinder
Shell 1
72.000
72.000
33.120
3.1750
0.0000
0.0000
600.00
300
0.0000
0
1.2
SA-516 70
1.0
1.0

Element From Node


Detail Type
Detail ID
Dist. from "FROM" Node / Offset dist
Nozzle Diameter
Nozzle Schedule
Nozzle Class
Layout Angle
Blind Flange (Y/N)
Weight of Nozzle ( Used if > 0 )
Grade of Attached Flange
Nozzle Matl

20
Nozzle
N4 3"
5.0000
3.0
None
300
90.0
N
0.0000
GR 1.1
SA-106 B

Element From Node


Detail Type
Detail ID
Dist. from "FROM" Node / Offset dist
Nozzle Diameter
Nozzle Schedule
Nozzle Class

20
Nozzle
N3 4"
15.000
4.0
None
300

in
in
mm
mm
mm
mm
psig
F
psig
F

in
in.

lbf

in
in.

Page 11 of 42

3 Phase Production Separator


(Tag No. C-321 / SN. 28829)
SP III Limau
Layout Angle
Blind Flange (Y/N)
Weight of Nozzle ( Used if > 0 )
Grade of Attached Flange
Nozzle Matl

270.0
N
0.0000
GR 1.1
SA-106 B

lbf

-------------------------------------------------------------------Element From Node


Element To Node
Element Type
Description
Distance "FROM" to "TO"
Element Outside Diameter
Element Thickness
Internal Corrosion Allowance
Nominal Thickness
External Corrosion Allowance
Design Internal Pressure
Design Temperature Internal Pressure
Design External Pressure
Design Temperature External Pressure
Effective Diameter Multiplier
Material Name
Efficiency, Longitudinal Seam
Efficiency, Circumferential Seam
Element From Node
Detail Type
Detail ID
Dist. from "FROM" Node / Offset dist
Nozzle Diameter
Nozzle Schedule
Nozzle Class
Layout Angle
Blind Flange (Y/N)
Weight of Nozzle ( Used if > 0 )
Grade of Attached Flange
Nozzle Matl

30
40
Cylinder
Shell 2
72.000
72.000
32.840
3.1750
0.0000
0.0000
600.00
300
0.0000
0
1.2
SA-516 70
1.0
1.0
30
Nozzle
N1 8"
12.000
8.0
None
300
270.0
N
0.0000
GR 1.1
SA-106 B

in
in
mm
mm
mm
mm
psig
F
psig
F

in
in.

lbf

-------------------------------------------------------------------Element From Node


Element To Node
Element Type
Description
Distance "FROM" to "TO"
Element Outside Diameter
Element Thickness
Internal Corrosion Allowance
Nominal Thickness
External Corrosion Allowance
Design Internal Pressure
Design Temperature Internal Pressure
Design External Pressure
Design Temperature External Pressure
Effective Diameter Multiplier
Material Name
Efficiency, Longitudinal Seam
Efficiency, Circumferential Seam

40
50
Cylinder
Shell 3
72.000
72.000
32.480
3.1750
0.0000
0.0000
600.00
300
0.0000
0
1.2
SA-516 70
1.0
1.0

in
in
mm
mm
mm
mm
psig
F
psig
F

-------------------------------------------------------------------Element From Node


Element To Node
Element Type

50
60
Cylinder

Page 12 of 42

3 Phase Production Separator


(Tag No. C-321 / SN. 28829)
SP III Limau
Description
Distance "FROM" to "TO"
Element Outside Diameter
Element Thickness
Internal Corrosion Allowance
Nominal Thickness
External Corrosion Allowance
Design Internal Pressure
Design Temperature Internal Pressure
Design External Pressure
Design Temperature External Pressure
Effective Diameter Multiplier
Material Name
Efficiency, Longitudinal Seam
Efficiency, Circumferential Seam

Shell 4
60.000
72.000
33.050
3.1750
0.0000
0.0000
600.00
300
0.0000
0
1.2
SA-516 70
1.0
1.0

in
in
mm
mm
mm
mm
psig
F
psig
F

-------------------------------------------------------------------Element From Node


Element To Node
Element Type
Description
Distance "FROM" to "TO"
Element Outside Diameter
Element Thickness
Internal Corrosion Allowance
Nominal Thickness
External Corrosion Allowance
Design Internal Pressure
Design Temperature Internal Pressure
Design External Pressure
Design Temperature External Pressure
Effective Diameter Multiplier
Material Name
Efficiency, Longitudinal Seam
Efficiency, Circumferential Seam
Elliptical Head Factor

60
70
Elliptical
Head II - Right
2.0000 in
72.000 in
34.720 mm
3.1750 mm
0.0000 mm
0.0000 mm
600.00 psig
300 F
0.0000 psig
0 F
1.2
SA-516 70
1.0
1.0
2.0

Element From Node


Detail Type
Detail ID
Dist. from "FROM" Node / Offset dist
Nozzle Diameter
Nozzle Schedule
Nozzle Class
Layout Angle
Blind Flange (Y/N)
Weight of Nozzle ( Used if > 0 )
Grade of Attached Flange
Nozzle Matl

60
Nozzle
N2 8"
20.000
8.0
None
300
90.0
N
0.0000
GR 1.1
SA-106 B

in
in.

lbf

Element Thickness, Pressure, Diameter and Allowable Stress :


|
| Int. Press |
Nominal | Total Corr|
Element | Allowable |
From| To | + Liq. Hd | Thickness | Allowance |
Diameter | Stress(SE)|
|
|
psig
|
mm
|
mm
|
in
|
psi
|
--------------------------------------------------------------------------Head I - L|
600.00 |
... |
3.1750 |
72.000 |
20000. |
Shell 1|
600.00 |
... |
3.1750 |
72.000 |
20000. |
Shell 2|
600.00 |
... |
3.1750 |
72.000 |
20000. |
Shell 3|
600.00 |
... |
3.1750 |
72.000 |
20000. |
Shell 4|
600.00 |
... |
3.1750 |
72.000 |
20000. |
Head II -|
600.00 |
... |
3.1750 |
72.000 |
20000. |
Element Required Thickness and MAWP :

Page 13 of 42

3 Phase Production Separator


(Tag No. C-321 / SN. 28829)
SP III Limau
|
|
Design |
M.A.W.P. |
M.A.P. |
Minimum |
Required |
From| To |
Pressure | Corroded | New & Cold | Thickness | Thickness |
|
|
psig
|
psig
|
psig
|
mm
|
mm
|
---------------------------------------------------------------------------Head I - L|
600.000 |
691.295 |
777.602 |
34.3500 |
29.7622 |
Shell 1|
600.000 |
663.659 |
735.059 |
33.1200 |
30.2817 |
Shell 2|
600.000 |
657.371 |
728.754 |
32.8400 |
30.2817 |
Shell 3|
600.000 |
649.290 |
720.650 |
32.4800 |
30.2817 |
Shell 4|
600.000 |
662.087 |
733.483 |
33.0500 |
30.2817 |
Head II -|
600.000 |
699.615 |
786.275 |
34.7200 |
29.7621 |
Minimum
649.290
720.649
MAWP: 649.290 psig, limited by: Shell 3.
Internal Pressure Calculation Results :
ASME Code, Section VIII, Division 1, 2013
Elliptical Head From 10 To 20 SA-516 70 , UCS-66 Crv. B at 300 F
Head I - Left
Material UNS Number:

K02700

Required Thickness due to Internal Pressure [tr]:


= (P*Do*Kcor)/(2*S*E+2*P*(Kcor-0.1)) per Appendix 1-4 (c)
= (600.000*72.0000*0.995)/(2*20000.00*1.00+2*600.000*(0.995-0.1))
= 26.5872 + 3.1750 = 29.7622 mm
Max.
=
=
=

Allowable Working Pressure at given Thickness, corroded [MAWP]:


(2*S*E*t)/(Kcor*Do-2*t*(Kcor-0.1)) per Appendix 1-4 (c)
(2*20000.00*1.00*31.1750)/(0.995*72.0000-2*31.1750*(1.00-0.1))
706.810 psig

Maximum Allowable Pressure, New and Cold [MAPNC]:


= (2*S*E*t)/(K*Do-2*t*(K-0.1)) per Appendix 1-4 (c)
= (2*20000.00*1.00*34.3500)/(1.000*72.0000-2*34.3500*(1.000-0.1))
= 777.602 psig
Actual stress at given pressure and thickness, corroded [Sact]:
= (P*(Kcor*Do-2*t*(Kcor-0.1)))/(2*E*t)
= (600.000*(0.995*72.0000-2*31.1750*(0.995-0.1)))/(2*1.00*31.1750)
= 16977.678 psi
Straight Flange Required Thickness:
= (P*Ro)/(S*E+0.4*P) + ca
per Appendix 1-1 (a)(1)
= (600.000*36.0000)/(20000.00*1.00+0.4*600.000)+3.175
= 30.282 mm
Straight Flange Maximum Allowable Working Pressure:
= (S*E*t)/(Ro-0.4*t) per Appendix 1-1 (a)(1)
= (20000.00 * 1.00 * 31.1750 )/(36.0000 - 0.4 * 31.1750 )
= 691.295 psig
Factor K, corroded condition [Kcor]:
= ( 2 + ( Inside Diameter/( 2 * Inside Head Depth ))2)/6
= ( 2 + ( 1766.450/( 2 * 443.200 ))2)/6
= 0.995233
Percent Elong. per UCS-79, VIII-1-01-57 (75*tnom/Rf)*(1-Rf/Ro)
Note: Please Check Requirements of UCS-79 as Elongation is > 5%.

8.143 %

MDMT Calculations in the Knuckle Portion:


Govrn. thk, tg = 34.350 , tr = 28.710 , c = 3.1750 mm , E* = 1.00

Page 14 of 42

3 Phase Production Separator


(Tag No. C-321 / SN. 28829)
SP III Limau
Stress Ratio = tr * (E*)/(tg - c) = 0.921 , Temp. Reduction = 8 F
46 F
38 F

Min Metal Temp. w/o impact per UCS-66, Curve B


Min Metal Temp. at Required thickness (UCS 66.1)
MDMT Calculations in the Head Straight Flange:
Govrn. thk, tg = 34.350 , tr = 29.305 , c = 3.1750 mm , E* = 1.00
Stress Ratio = tr * (E*)/(tg - c) = 0.940 , Temp. Reduction = 6 F

46 F
40 F

Min Metal Temp. w/o impact per UCS-66, Curve B


Min Metal Temp. at Required thickness (UCS 66.1)
Cylindrical Shell From 20 To 30 SA-516 70 , UCS-66 Crv. B at 300 F
Shell 1
Material UNS Number:

K02700

Required Thickness due to Internal Pressure [tr]:


= (P*Ro) / (S*E+0.4*P) per Appendix 1-1 (a)(1)
= (600.000*36.0000)/(20000.00*1.00+0.4*600.000)
= 27.1067 + 3.1750 = 30.2817 mm
Max.
=
=
=

Allowable Working Pressure at given Thickness, corroded [MAWP]:


(S*E*t)/(Ro-0.4*t) per Appendix 1-1 (a)(1)
(20000.00*1.00*29.9450)/(36.0000-0.4*29.9450)
663.659 psig

Maximum Allowable Pressure, New and Cold [MAPNC]:


= (S*E*t)/(Ro-0.4*t) per Appendix 1-1 (a)(1)
= (20000.00*1.00*33.1200)/(36.0000-0.4*33.1200)
= 735.059 psig
Actual stress at given pressure and thickness, corroded [Sact]:
= (P*(Ro-0.4*t))/(E*t)
= (600.000*((36.0000-0.4*29.9450))/(1.00*29.9450)
= 18081.588 psi
Percent Elongation per UCS-79

(50*tnom/Rf)*(1-Rf/Ro)

1.844 %

Minimum Design Metal Temperature Results:


Govrn. thk, tg = 33.120 , tr = 29.305 , c = 3.1750 mm , E* = 1.00
Stress Ratio = tr * (E*)/(tg - c) = 0.979 , Temp. Reduction = 2 F
Min Metal Temp. w/o impact per UCS-66, Curve B
Min Metal Temp. at Required thickness (UCS 66.1)

44 F
42 F

Cylindrical Shell From 30 To 40 SA-516 70 , UCS-66 Crv. B at 300 F


Shell 2
Material UNS Number:

K02700

Required Thickness due to Internal Pressure [tr]:


= (P*Ro) / (S*E+0.4*P) per Appendix 1-1 (a)(1)
= (600.000*36.0000)/(20000.00*1.00+0.4*600.000)
= 27.1067 + 3.1750 = 30.2817 mm
Max.
=
=
=

Allowable Working Pressure at given Thickness, corroded [MAWP]:


(S*E*t)/(Ro-0.4*t) per Appendix 1-1 (a)(1)
(20000.00*1.00*29.6650)/(36.0000-0.4*29.6650)
657.371 psig

Page 15 of 42

3 Phase Production Separator


(Tag No. C-321 / SN. 28829)
SP III Limau
Maximum Allowable Pressure, New and Cold [MAPNC]:
= (S*E*t)/(Ro-0.4*t) per Appendix 1-1 (a)(1)
= (20000.00*1.00*32.8400)/(36.0000-0.4*32.8400)
= 728.754 psig
Actual stress at given pressure and thickness, corroded [Sact]:
= (P*(Ro-0.4*t))/(E*t)
= (600.000*((36.0000-0.4*29.6650))/(1.00*29.6650)
= 18254.521 psi
Percent Elongation per UCS-79

(50*tnom/Rf)*(1-Rf/Ro)

1.829 %

Minimum Design Metal Temperature Results:


Govrn. thk, tg = 32.840 , tr = 29.305 , c = 3.1750 mm , E* = 1.00
Stress Ratio = tr * (E*)/(tg - c) = 0.988 , Temp. Reduction = 1 F
44 F
42 F

Min Metal Temp. w/o impact per UCS-66, Curve B


Min Metal Temp. at Required thickness (UCS 66.1)
Cylindrical Shell From 40 To 50 SA-516 70 , UCS-66 Crv. B at 300 F
Shell 3
Material UNS Number:

K02700

Required Thickness due to Internal Pressure [tr]:


= (P*Ro) / (S*E+0.4*P) per Appendix 1-1 (a)(1)
= (600.000*36.0000)/(20000.00*1.00+0.4*600.000)
= 27.1067 + 3.1750 = 30.2817 mm
Max.
=
=
=

Allowable Working Pressure at given Thickness, corroded [MAWP]:


(S*E*t)/(Ro-0.4*t) per Appendix 1-1 (a)(1)
(20000.00*1.00*29.3050)/(36.0000-0.4*29.3050)
649.290 psig

Maximum Allowable Pressure, New and Cold [MAPNC]:


= (S*E*t)/(Ro-0.4*t) per Appendix 1-1 (a)(1)
= (20000.00*1.00*32.4800)/(36.0000-0.4*32.4800)
= 720.650 psig
Actual stress at given pressure and thickness, corroded [Sact]:
= (P*(Ro-0.4*t))/(E*t)
= (600.000*((36.0000-0.4*29.3050))/(1.00*29.3050)
= 18481.719 psi
Percent Elongation per UCS-79

(50*tnom/Rf)*(1-Rf/Ro)

1.808 %

Minimum Design Metal Temperature Results:


Govrn. thk, tg = 32.480 , tr = 29.305 , c = 3.1750 mm , E* = 1.00
Stress Ratio = tr * (E*)/(tg - c) = 1.000 , Temp. Reduction = 0 F
Min Metal Temp. w/o impact per UCS-66, Curve B

43 F

Cylindrical Shell From 50 To 60 SA-516 70 , UCS-66 Crv. B at 300 F


Shell 4
Material UNS Number:

K02700

Required Thickness due to Internal Pressure [tr]:


= (P*Ro) / (S*E+0.4*P) per Appendix 1-1 (a)(1)
= (600.000*36.0000)/(20000.00*1.00+0.4*600.000)
= 27.1067 + 3.1750 = 30.2817 mm

Page 16 of 42

3 Phase Production Separator


(Tag No. C-321 / SN. 28829)
SP III Limau
Max.
=
=
=

Allowable Working Pressure at given Thickness, corroded [MAWP]:


(S*E*t)/(Ro-0.4*t) per Appendix 1-1 (a)(1)
(20000.00*1.00*29.8750)/(36.0000-0.4*29.8750)
662.087 psig

Maximum Allowable Pressure, New and Cold [MAPNC]:


= (S*E*t)/(Ro-0.4*t) per Appendix 1-1 (a)(1)
= (20000.00*1.00*33.0500)/(36.0000-0.4*33.0500)
= 733.483 psig
Actual stress at given pressure and thickness, corroded [Sact]:
= (P*(Ro-0.4*t))/(E*t)
= (600.000*((36.0000-0.4*29.8750))/(1.00*29.8750)
= 18124.520 psi
Percent Elongation per UCS-79

(50*tnom/Rf)*(1-Rf/Ro)

1.840 %

Minimum Design Metal Temperature Results:


Govrn. thk, tg = 33.050 , tr = 29.305 , c = 3.1750 mm , E* = 1.00
Stress Ratio = tr * (E*)/(tg - c) = 0.981 , Temp. Reduction = 2 F
Min Metal Temp. w/o impact per UCS-66, Curve B
Min Metal Temp. at Required thickness (UCS 66.1)

44 F
42 F

Elliptical Head From 60 To 70 SA-516 70 , UCS-66 Crv. B at 300 F


Head II - Right
Material UNS Number:

K02700

Required Thickness due to Internal Pressure [tr]:


= (P*Do*Kcor)/(2*S*E+2*P*(Kcor-0.1)) per Appendix 1-4 (c)
= (600.000*72.0000*0.995)/(2*20000.00*1.00+2*600.000*(0.995-0.1))
= 26.5871 + 3.1750 = 29.7621 mm
Max.
=
=
=

Allowable Working Pressure at given Thickness, corroded [MAWP]:


(2*S*E*t)/(Kcor*Do-2*t*(Kcor-0.1)) per Appendix 1-4 (c)
(2*20000.00*1.00*31.5450)/(0.995*72.0000-2*31.5450*(1.00-0.1))
715.469 psig

Maximum Allowable Pressure, New and Cold [MAPNC]:


= (2*S*E*t)/(K*Do-2*t*(K-0.1)) per Appendix 1-4 (c)
= (2*20000.00*1.00*34.7200)/(1.000*72.0000-2*34.7200*(1.000-0.1))
= 786.275 psig
Actual stress at given pressure and thickness, corroded [Sact]:
= (P*(Kcor*Do-2*t*(Kcor-0.1)))/(2*E*t)
= (600.000*(0.995*72.0000-2*31.5450*(0.995-0.1)))/(2*1.00*31.5450)
= 16772.209 psi
Straight Flange Required Thickness:
= (P*Ro)/(S*E+0.4*P) + ca
per Appendix 1-1 (a)(1)
= (600.000*36.0000)/(20000.00*1.00+0.4*600.000)+3.175
= 30.282 mm
Straight Flange Maximum Allowable Working Pressure:
= (S*E*t)/(Ro-0.4*t) per Appendix 1-1 (a)(1)
= (20000.00 * 1.00 * 31.5450 )/(36.0000 - 0.4 * 31.5450 )
= 699.615 psig
Factor K, corroded condition [Kcor]:
= ( 2 + ( Inside Diameter/( 2 * Inside Head Depth ))2)/6
= ( 2 + ( 1765.710/( 2 * 443.015 ))2)/6
= 0.995231

Page 17 of 42

3 Phase Production Separator


(Tag No. C-321 / SN. 28829)
SP III Limau
Percent Elong. per UCS-79, VIII-1-01-57 (75*tnom/Rf)*(1-Rf/Ro)
Note: Please Check Requirements of UCS-79 as Elongation is > 5%.

8.229 %

MDMT Calculations in the Knuckle Portion:


Govrn. thk, tg = 34.720 , tr = 28.710 , c = 3.1750 mm , E* = 1.00
Stress Ratio = tr * (E*)/(tg - c) = 0.910 , Temp. Reduction = 9 F
46 F
37 F

Min Metal Temp. w/o impact per UCS-66, Curve B


Min Metal Temp. at Required thickness (UCS 66.1)
MDMT Calculations in the Head Straight Flange:
Govrn. thk, tg = 34.720 , tr = 29.305 , c = 3.1750 mm , E* = 1.00
Stress Ratio = tr * (E*)/(tg - c) = 0.929 , Temp. Reduction = 7 F

46 F
39 F

Min Metal Temp. w/o impact per UCS-66, Curve B


Min Metal Temp. at Required thickness (UCS 66.1)
Hydrostatic Test Pressure Results:
Pressure
Pressure
Pressure
Pressure
Pressure

per
per
per
per
per

UG99b
UG99b[36]
UG99c
UG100
PED

=
=
=
=
=

1.3 * M.A.W.P. * Sa/S


1.3 * Design Pres * Sa/S
1.3 * M.A.P. - Head(Hyd)
1.1 * M.A.W.P. * Sa/S
1.43 * MAWP

844.077
780.000
934.244
714.219
928.485

psig
psig
psig
psig
psig

UG-99(b), Test Pressure Calculation:


= Test Factor * MAWP * Stress Ratio
= 1.3 * 649.290 * 1.000
= 844.077 psig
Horizontal Test performed per: UG-99b
Please note that Nozzle, Shell, Head, Flange, etc MAWPs are all considered
when determining the hydrotest pressure for those test types that are based
on the MAWP of the vessel.
Stresses on Elements due to Test Pressure:
From To
Stress
Allowable
Ratio
Pressure
---------------------------------------------------------------------Head I - Left
21776.6
26000.0
0.838
846.68
Shell 1
23037.0
26000.0
0.886
846.68
Shell 2
23236.3
26000.0
0.894
846.68
Shell 3
23497.6
26000.0
0.904
846.68
Shell 4
23086.5
26000.0
0.888
846.68
Head II - Right
21536.4
26000.0
0.828
846.68
---------------------------------------------------------------------Stress ratios for Nozzle and Pad Materials:
Description
Pad/Nozzle
Ambient
Operating
ratio
---------------------------------------------------------------------N4 3"
Nozzle 17100.00
17100.00
1.000
N4 3"
Pad 20000.00
20000.00
1.000
N3 4"
Nozzle 17100.00
17100.00
1.000
N3 4"
Pad 20000.00
20000.00
1.000
N1 8"
Nozzle 17100.00
17100.00
1.000
N1 8"
Pad 20000.00
20000.00
1.000
N2 8"
Nozzle 17100.00
17100.00
1.000
N2 8"
Pad 20000.00
20000.00
1.000
---------------------------------------------------------------------Minimum
1.000

Page 18 of 42

3 Phase Production Separator


(Tag No. C-321 / SN. 28829)
SP III Limau
Stress ratios for Vessel Elements:
Description
Ambient
Operating
ratio
---------------------------------------------------------------------Head I - Left
20000.00
20000.00
1.000
Shell 1
20000.00
20000.00
1.000
Shell 2
20000.00
20000.00
1.000
Shell 3
20000.00
20000.00
1.000
Shell 4
20000.00
20000.00
1.000
Head II - Right
20000.00
20000.00
1.000
---------------------------------------------------------------------Minimum
1.000
Elements Suitable for Internal Pressure.
Nozzle Flange MAWP Results :
Nozzle
Description

----- Flange Rating


Operating
Ambient
Temperature
Class
Grade|Group
psig
psig
F
---------------------------------------------------------------------------N4 3"
655.0
740.0
300
300
GR 1.1
N3 4"
655.0
740.0
300
300
GR 1.1
N1 8"
655.0
740.0
300
300
GR 1.1
N2 8"
655.0
740.0
300
300
GR 1.1
---------------------------------------------------------------------------Minimum Rating 655.000
740.000 psig
(for Core Elements)

Note: ANSI Ratings are per ANSI/ASME B16.5 2009 Edition

Nozzle Schedule:
Nominal Flange
Noz.
Wall
Re-Pad
Cut
Size Sch/Type
O/Dia
Thk
ODia Thick Length
in. Cls
in.
mm
mm
mm
mm
-----------------------------------------------------------------------------N4 3"
3.000 300 WNF
3.000 6.120
8.00 33.160 110.14
N3 4"
4.000 300 WNF
4.000 12.720
8.00 33.200 110.79
N1 8"
8.000 300 WNF
8.000 13.400
12.00 32.230 114.91
N2 8"
8.000 300 WNF
8.000 13.080
12.00 32.200 226.54
Description

General Notes for the above table:


The Cut Length is the Outside Projection + Inside Projection + Drop +
In Plane Shell Thickness. This value does not include weld gaps,
nor does it account for shrinkage.
In the case of Oblique Nozzles, the Outside Diameter must
be increased. The Re-Pad WIDTH around the nozzle is calculated as follows:
Width of Pad = (Pad Outside Dia. (per above) - Nozzle Outside Dia.)/2
For hub nozzles, the thickness and diameter shown are those of the smaller
and thinner section.
Nozzle Material and Weld Fillet Leg Size Details:
Shl Grve Noz Shl/Pad Pad OD Pad Grve Inside
Nozzle
Material
Weld
Weld
Weld
Weld
Weld
mm
mm
mm
mm
mm
-----------------------------------------------------------------------------N4 3"
SA-106 B
12.700
7.620
15.240 254.000
N3 4"
SA-106 B
12.700
12.700
25.400 254.000
N1 8"
SA-106 B
32.840
12.700
25.400 660.400
-

Page 19 of 42

3 Phase Production Separator


(Tag No. C-321 / SN. 28829)
SP III Limau
N2 8"

SA-106 B

34.719

12.700

25.400

711.200

Note: The Outside projections below do not include the flange thickness.
Nozzle Miscellaneous Data:
Elevation/Distance
Layout
Projection
Installed In
From Datum
Angle
Outside
Inside
Component
in
deg.
mm
mm
---------------------------------------------------------------------------N4 3"
5.000
90.00
76.20
0.00
Shell 1
N3 4"
15.000
270.00
76.20
0.00
Shell 1
N1 8"
84.000
270.00
76.20
0.00
Shell 2
N2 8"
90.00
152.40
0.00
Head II - Ri
Nozzle

Nozzle Calculation Summary:


Description

MAWP
Ext
MAPNC
UG45 [tr] Weld
Areas or
psig
psig
Path
Stresses
--------------------------------------------------------------------------N4 3"
663.66
...
...
OK 4.80
OK
Passed
N3 4"
663.66
...
...
OK 5.02
OK
Passed
N1 8"
657.37
...
...
OK 7.16
OK
Passed
N2 8"
675.55
...
...
OK 7.16
OK
Passed
N2 8"
689.90
...
...
OK 7.16
OK
Passed
--------------------------------------------------------------------------Min. - Nozzles
657.37 N1 8"
Min. Shell&Flgs
649.29 40
50
720.65
Computed Vessel M.A.W.P.

649.29

psig

Note: MAWPs (Internal Case) shown above are at the High Point.
Check the Spatial Relationship between the Nozzles
From Node
20
20
30
60

Nozzle Description
N4 3"
N3 4"
N1 8"
N2 8"

X Coordinate,
7.000
17.000
86.000
0.000

Layout Angle,
90.000
270.000
270.000
90.000

Dia. Limit
26.579
22.863
26.687
13.940

The nozzle spacing is computed by the following:


= Sqrt( ll + lc ) where
ll - Arc length along the inside vessel surface in the long. direction.
lc - Arc length along the inside vessel surface in the circ. direction
If any interferences/violations are found, they will be noted below.
No interference violations have been detected !
ASME Code, Section VIII, Division 1, 2013
Diameter Spec : 72.000 in OD
Vessel Design Length, Tangent to Tangent
Specified Datum Line Distance
Shell Material
Nozzle Material
Re-Pad Material
Internal Design Temperature
Internal Design Pressure

280.00

in

2.00

in

SA-516 70
SA-106 B
SA-516 70
300
600.000

F
psig

Page 20 of 42

3 Phase Production Separator


(Tag No. C-321 / SN. 28829)
SP III Limau
External Design Temperature
Maximum Allowable Working Pressure
Hydrostatic Test Pressure
Required Minimum Design Metal Temperature
Warmest Computed Minimum Design Metal Temperature

0
649.290
844.077
50
43

F
psig
psig
F
F

Wind Design Code


Earthquake Design Code

ASCE-93
UBC-94

Element Pressures and MAWP: psig


Element Desc

| Design Pres. | External | M.A.W.P | Corrosion


| + Stat. head | Pressure |
| Allowance
--------------------------------------------------------------------Head I - Left
600.000
0.000
691.295
3.1750
Shell 1
600.000
0.000
663.659
3.1750
Shell 2
600.000
0.000
657.371
3.1750
Shell 3
600.000
0.000
649.290
3.1750
Shell 4
600.000
0.000
662.087
3.1750
Head II - Right
600.000
0.000
699.615
3.1750
Element
"To" Elev Length
Element Thk
R e q d T h k
Joint Eff
Type
in
in
mm
Int.
Ext. Long Circ
----------------------------------------------------------------------Ellipse
0.0
2.0
34.4
29.8
4.7
1.00 1.00
Cylinder
72.0
72.0
33.1
30.3
No Calc 1.00 1.00
Cylinder
144.0
72.0
32.8
30.3
No Calc 1.00 1.00
Cylinder
216.0
72.0
32.5
30.3
No Calc 1.00 1.00
Cylinder
276.0
60.0
33.0
30.3
No Calc 1.00 1.00
Ellipse
278.0
2.0
34.7
29.8
4.7
1.00 1.00
Element thicknesses are shown as Nominal if specified, otherwise are Minimum
Weights:
Fabricated
Shop Test
Shipping
Erected
Empty
Operating
Field Test

Bare W/O Removable Internals


Fabricated + Water ( Full )
Fab. + Rem. Intls.+ Shipping App.
Fab. + Rem. Intls.+ Insul. (etc)
Fab. + Intls. + Details + Wghts.
Empty + Operating Liquid (No CA)
Empty Weight + Water (Full)

28782.1
70185.2
28782.1
28782.1
28782.1
28782.1
70185.2

lbm
lbm
lbm
lbm
lbm
lbm
lbm

Page 21 of 42

3 Phase Production Separator


(Tag No. C-321 / SN. 28829)
SP III Limau

6. MEKANISME KERUSAKAN &


PERENCANAAN INSPEKSI

6. DAMAGE MECHANISMS &


INSPECTION PLAN

6.1. Mekanisme kerusakan

6.1. Damage Mechanisms

Bejana tekan rentan terhadap berbagai jenis


kerusakan oleh beberapa mekanisme. Jenis
kerusakan umum dan mekanisme adalah
sebagai berikut:

Pressure vessels are susceptible to various


types of damage by several mechanisms.
Typical damage types and mechanisms are
as follows:

A. General and local metal loss:

A. General and local metal loss:

Sulfidation;
Oxidation;
Microbiologically induced corrosion;
Naphthenic acid corrosion;
Erosion/erosion-corrosion;
Galvanic.

Sulfidation;
Oxidation;
Microbiologically induced corrosion;
Naphthenic acid corrosion;
Erosion/erosion-corrosion;
Galvanic.

B. Surface connected cracking:

B. Surface connected cracking:

Fatigue;
Caustic stress corrosion cracking;
Sulfide stress corrosion cracking.

Fatigue;
Caustic stress corrosion cracking;
Sulfide stress corrosion cracking.

C. Subsurface cracking:

C. Subsurface cracking:

Hydrogen induced cracking.

Hydrogen induced cracking.

D. Microfissuring/microvoid formation:

D. Microfissuring/microvoid formation:

High temperature hydrogen attack;


Creep.

High temperature hydrogen attack;


Creep.

E. Metallurgical changes:

E. Metallurgical changes:

Graphitization;
Temper embrittlement.

Graphitization;
Temper embrittlement.

F. Blistering:

F. Blistering:

Hydrogen blistering.

Hydrogen blistering.

G. Dimensional changes:

G. Dimensional changes:

Creep and stress rupture


Thermal.

Creep and stress rupture


Thermal.

Page 22 of 42

3 Phase Production Separator


(Tag No. C-321 / SN. 28829)
SP III Limau

H. Material Properties Changes

H. Material Properties Changes

Brittle fracture.

Brittle fracture.

Pressure vessel and Fluid data as following:

Pressure vessel and Fluid data as following:

No

Description

Data

Service

Gas & Oil

Material

Carbon Steel

Design Pressure (psig)

600

Operating Pressure (psig)

Design Temperature (0F)

300

Operating Temperature ( F)

Flow

Hydrodinamic

Loading

Static

Insulation

No

10

PH

11

CO2 (mole%)

Yes

12

H2S (mole%)

Yes

13

H2O (mole%)

Yes

Page 23 of 42

3 Phase Production Separator


(Tag No. C-321 / SN. 28829)
SP III Limau
Damage Mechanisms Screening Table:

Page 24 of 42

3 Phase Production Separator


(Tag No. C-321 / SN. 28829)
SP III Limau

Page 25 of 42

3 Phase Production Separator


(Tag No. C-321 / SN. 28829)
SP III Limau

Page 26 of 42

3 Phase Production Separator


(Tag No. C-321 / SN. 28829)
SP III Limau

Dari tabel diatas, beberapa kemungkinan jenis From the above screening table, the following
damage mechanisms yang diduga terjadi pada damage mechanisms are expected to occurs at
bejana tekan adalah sebagai berikut :
pressure vessel:

No

Damage Mechanisms

Mode

Possibility

Uniform Corrosion

Thinning

Medium

Pitting Corrosion

Thinning

Low

Erosion - Corrosion

Thinning

Low

Sulfide Stress Cracking

Cracking

Low

Page 27 of 42

3 Phase Production Separator


(Tag No. C-321 / SN. 28829)
SP III Limau

6.2.

Perancenaan Inspeksi

6.2.

Inspection Plan

Perencenaan
inspeksi
dilakukan
berdasarkan pada kemungkinan dari
damage mechanisms. Metode serta
pelaksanaan NDE akan di evaluasi untuk
meyakinkan bahwa metode tersebut dapat
mengidentifikasi
damage mechanisms
dan beberapa kemungkinan kerusakan
yang lain.

The inspection plan is developed based


on present or possible types of damage
mechanisms. The methods and the extent
of NDE shall be evaluated to assure they
can adequately identify the damage
mechanism and the severity of damage.

Pemeriksaan berjangka harus dijadwalkan,


berdasarkan berikut :
Jenis kerusakan
Laju dari kerusakan
Toleransi peralatan kepada jenis
kerusakan
Kemungkinan dari metode NDE yang
digunakan
untuk
identifikasi
kerusakan.
Jangka waktu maksimum yang
disebutkan pada codes dan standart.

Examinations must be scheduled at


intervals that consider the:
Type of damage
Rate of damage progression
Tolerance of the equipment to the
type of damage
Probability of the NDE method to
identify the damage

Maximum intervals as defined in


codes and standards

Page 28 of 42

3 Phase Production Separator


(Tag No. C-321 / SN. 28829)
SP III Limau
Inspection and Monitoring Methods

Page 29 of 42

3 Phase Production Separator


(Tag No. C-321 / SN. 28829)
SP III Limau

Page 30 of 42

3 Phase Production Separator


(Tag No. C-321 / SN. 28829)
SP III Limau

Page 31 of 42

3 Phase Production Separator


(Tag No. C-321 / SN. 28829)
SP III Limau

Page 32 of 42

3 Phase Production Separator


(Tag No. C-321 / SN. 28829)
SP III Limau

Berdasarkan dari metode inspeksi dan monitoring Based on the above inspection and monitoring
diatas, perencanaan inspeksi yang diajukan untuk methods, the proposed inspection plan for this
bejana tekan ini adalah sebagai berikut :
pressure vessel as follow:

No

Damage

Inspection

Mechanisms

methods

Uniform corrossion

Pitting Corrosion

Visual Inspection

UT Thickness
3

Erosion-Corrosion

Sulfide
Cracking

Stress

Scanning

UT Flaw Scanning
of MPI

Coverage

Interval

Visual inspection of 100% of the


exposed surface area with followup by UT or pit gauge as required.
(Shell, head, nozzle and supports)
Minimal 20% examination, and Next 3 years,
followed
by
spot
external
for next
ultrasonic
thickness
SKPP
measurements. (Shell, head and
nozzle)
Minimal 20% examination of
weldments (Nozzles to shell, Tjoints)

Page 33 of 42

3 Phase Production Separator


(Tag No. C-321 / SN. 28829)
SP III Limau

7. PENILAIAN KONDISI

7. CONDITION ASSESSMENT

Salah satu fokus utama dari inspeksi bejana


tekan adalah pembentukan kemampuan
bejana tekanan untuk aman melanjutkan
operasi
.

One of the primary focuses of the pressure


vessel inspection is the establishment of a
pressure vessels ability to safely continue
operation.

Kondisi penilaian harus menjadi bagian resmi


dari setiap pemeriksaan, dan penentuan
kondisi bejana tekan yang diterima harus
didokumentasikan secara resmi . Kondisi ini
umumnya akan didefinisikan sebagai :

Condition assessment should be a formal


part of every inspection, and the
determination of acceptable vessel condition
should be formally documented. The
condition will generally be defined as:

1) kondisi "seperti baru", tidak memerlukan


tindakan
tambahan
sebelum
jadwal
pemeriksaan
berikutnya;
2) perbaikan kecil seperti mengecat,
membersihkan, atau pekerjaan permukaan
3) membutuhkan perbaikan besar atau
penggantian semua atau bagian bejana tekan.

1) like new condition, not requiring any


additional actions before the next
scheduled inspection;
2) requiring minor repairs such as repainting,
cleaning, or minor surface work;
3) requiring major repair or replacement of all
or a section of the vessel.

Membandingkan parameter desain dan


kondisi asli (atau kondisi pada saat penilaian
formal terakhir) dari bejana tekan dengan
kondisi saat ini , adalah bentuk paling dasar
penilaian
kondisi
.

Comparing design parameters and original


conditions (or conditions at the time of the last
formal assessment) of the pressure vessel to
current conditions, is the most basic form of
condition assessment.

Inspektur harus mengevaluasi apakah bejana


tekan memenuhi parameter konstruksi asli
dengan memeriksa kondisi dinding bejana
tekan, lasan, internal , peralatan pendukung ,
dll Jika inspektur menentukan bejana tekan
memenuhi spesifikasi awal , bejana tekan
dapat diidentifikasi berada di kondisi
memuaskan. Namun, degradasi , kerusakan ,
atau masalah potensial lainnya harus
diperhatikan.

The inspector should evaluate if the vessel


meets the original construction parameters by
inspecting the condition of the vessel walls,
welds, internals, supporting equipment, etc. If
the inspector determines the vessel to meet
the original specifications, the vessel may be
identified to be in satisfactory condition.
However, any degradation, damage, or other
potential issues should be noted.

Dalam kasus saat seorang inspektur


menempatkan degradasi bejana tekan,
perawatan harus dilakukan untuk memastikan
bahwa
degradasi
ini
baik:

In cases where an inspector locates


degradation in a pressure vessel, care must
be taken to ensure that this degradation either:

1) Tidak mempengaruhi kemampuan bejana


tekan untuk melanjutkan operasi yang aman ,
2) Apakah diganti oleh perbaikan atau

1) Does not affect the ability of the vessel to


continue safe operation,
2) Is removed by repair or replacement of the
Page 34 of 42

3 Phase Production Separator


(Tag No. C-321 / SN. 28829)
SP III Limau
penggantian komponen bejana tekan yang
mengalami
degradasi.
3) bahwa integritas struktur dan parameter
desain bejan tekan dipertahankan atau
dievaluasi kembali untuk memastikan bejana
tekan tersebut memenuhi kode konstruksi
yang berlaku.

vessel component experiencing the


degradation.
3) that the structural integrity and design
parameters of the vessel are maintained
or reevaluated to ensure the vessel meets
the applicable code of construction.

7.1 Ketebalan Yang Diperlukan

7.1 Thickness Requirements

Dari hasil inspeksi di atas dan perhitungan


teknis yang telah dilakukan, kondisi bejana
tekan pada saat ini ditampilkan dalam tabel
berikut.

From the above inspection results and


engineering calculations performed, the
current conditions of pressure vessel was
presented in the following table.

Design Condition = 600 psig


Component

Min. Actual
Thickness (mm)

Required
Thickness (mm)

Remarks

Head I Left

34.35

29.76

Acceptable

Shell 1

33.12

30.28

Acceptable

Shell 2

32.84

30.28

Acceptable

Shell 3

32.48

30.28

Acceptable

Shell 4

33.05

30.28

Acceptable

Head II - Right

34.72

29.76

Acceptable

Component

Min. Actual
Thickness (mm)

Required
Thickness (mm)

Areas or stresses

N1 8

13.40

7.16

Passed

N2 8

13.08

7.16

Passed

N3 4

12.72

5.02

Passed

N4 3

6.12

4.80

Passed

MPI
Pengujian ini tidak dilakukan pada bejana
tekan ini.

MPI
This test is not performed at this pressure
vessel.

Page 35 of 42

3 Phase Production Separator


(Tag No. C-321 / SN. 28829)
SP III Limau

7.2 Sisa Umur

7.2 Remaining Life

Laju Korosi
Laju korosi untuk penipisan penyebab
kerusakan mekanis ditentukan dengan
perbedaan antara pembacaan dua ketebalan
dibagi dengan interval waktu antara
pembacaan.
Laju korosi dihitung berdasar rumus berikut :

Corrosion Rate
Corrosion rate for thinning damage
mechanisms is determined by the
difference between two thickness readings
divided by the time interval between the
readings.
The corrosion rate was calculated from the
following formula:

Corrosion
Rate (ST)

Corrosion
Rate (LT)

t previous - t actual
time between t previous and t actual (years)
Or
t initial - t actual
time between t initial and t actual (years)

Dimana :
t awal : tebal awal sama dengan CML sebagai
t aktual. Baik pada pengukuran ketebalan
pertama pada saat CML atau ketebalan pada
saat awal sebuah laju korosi lingkungan baru,
dalam mm.

Where :
t initial : the initial thickness at the same CML
as t actual. Its either the first thickness
measurement at this CML or the thickness at
the start of a new corrosion rate environment,
in mm.

t aktual : ketebalan sebenarnya sebuah CML,


dalam mm, diukur saat inspeksi terakhir.

t actual : the actual thickness of a CML, in mm,


measured during the last inspection.

ST (Short Term): Laju korosi yang dihitung


menggunakan ketebalan hasil pengukuran
inspeksi sebelumnya (Short Term).

ST (Short Term): The corrosion rate is


calculated using the previous inspection
thickness measurement results (Short Term).

LT (Long Term) : laju korosi yang dihitung dari


ketebalan nominal (awal dibangun).
CML (Condition Monitoring Location) : titik
yang dianjurkan /difokuskan untuk diambil nilai
ketebalan dindingnya (pada umumnya titik
yang diangap kritis).

LT (Long Term) : corrotion rate which is


calculated from initial thickness.
CML (Condition Monitoring Location) :
measurement point which is where is wall
thickness measurement are taken (usually
critical point) .

Sisa Umur
Sisa umur dari bejana tekan (dalam tahun)
dapat dihitung dengan rumus berikut ini :

Remaining Life
The remaining life of the pressure vessel (in
years) shall be calculated from the following
formula:

Page 36 of 42

3 Phase Production Separator


(Tag No. C-321 / SN. 28829)
SP III Limau
Remaining
Life

t actual - t required
corrosion rate

Dimana :

Where :

t aktual : tebal aktual pada sebuah CML,


dalam mm, diukur saat inspeksi terakhir

t actual : the actual thickness of a CML, in mm,


measured during the last inspection.

t dibutuhkan : tebal yang diperlukan pada CML


atau komponen, dalam mm, sebagai
pengukuran t aktual. Dihitung dengan rumus
desain.

t required : the required thickness at the same


CML or component, in mm, as the t actual
measurement. It is computed by the design
formulas.

CML (Condition Monitoring Location) : titik


yang dianjurkan /difokuskan untuk diambil nilai
ketebalan dindingnya (pada umumnya titik
yang diangap kritis).

CML (Condition Monitoring Location) : titik


yang dianjurkan /difokuskan untuk diambil nilai
ketebalan dindingnya (pada umumnya titik
yang diangap kritis).

Hasil perhitungan laju korosi dan sisa umur Calculation results of corrosion rate and
ditampilkan dalam tabel berikut :
remaining life was summarised in the following
table :

Component

Initial
Thickness
1
(mm)

Min. Actual
Thickness (mm)

Required
Thickness (mm)

Corrosion rate
2
(mm/year)

Remaining
Life
3
(Years)

Head I Left

34.93

34.35

29.76

0.072

63

Shell 1

34.93

33.12

30.28

0.226

12

Shell 2

34.93

32.84

30.28

0.261

Shell 3

34.93

32.48

30.28

0.306

Shell 4

34.93

33.05

30.28

0.235

11

Head II - Right

34.93

34.72

29.76

0.026

193

Note

1: Initial thickness based on nameplate for shell, initial thickness assummed from head .
2: Because T initial > T actual, Corr. rate and RL calculation can not be performed.
3:This calculation performed using API 510

Page 37 of 42

3 Phase Production Separator


(Tag No. C-321 / SN. 28829)
SP III Limau
8. CONCLUSION & RECOMMENDATIONS

8.KESIMPULAN & SARAN


Dapat disimpulkan bahwa 3 Phase Production
Separator (Tag no. C-321 / Sn. 28829) dalam
kondisi yang baik untuk beroperasi dengan
parameter sebagai berikut :

This 3 Phase Production Separator (Tag no.


C-321 / Sn. 28829) is in good condition to safely
operated based on parameter below :

MAWP

Design Temperature :

600 PSIG
300 oF

Tidak ada temuan signifikan selama inspeksi


yang berpengaruh terhadap kinerja bejana
tekan untuk lanjut beroperasi.

There was no significant anomaly found uring


inspection that might affect the ability of the
pressure vessel to continue safe operation.

Direkomendasikan untuk merawat kondisi


bejana tekan dalam keadaan siap beroperasi
seperti rekomendasi berikut:

It is recommended to maintain the vessel


conditions to stay in fit for services as the
following recommendations:

Inspeksi
rutin
oleh
operator
untuk
mendeteksi dini kebocoran, tumpahan dan
kondisi operasi tidak normal yang lain (API
Std 510 5.5.4)

Perform routine inspection by operator to


detect early stage of leakage, spills and
other abnormal operating conditions (API Std
510 5.5.4)

Melakukan pemasangan serta perawatan


rutin dan re-setting pada katup pengaman
tekanan (API Std 510- 6.6, API RP 576)

Install PSV and perform routine maintenance


(re-setting) of pressure safety valves.(API
Std 510- 6.6, API RP 576).

Inspeksi internal pada bejana tekan sesuai


rekomendasi API Standards, termasuk
perbaikan jika diperlukan (API Std 510
5.5.2, 6.5)

Perform internal inspection of pressure


vessel as per recommendations of API
Standards, including repair as required (API
Std 510 5.5.2, 6.5).

Melakukan
pemasangan alat pengukur
tekanan dan suhu pada bejana tekan.

Install pressure and temperature gauge at


this pressure vessel.

Melakukan pemasangan sistem grounding


untuk beroperasi dengan aman
Melakukan
verifikasi
ulang
untuk
pengambilan titik UT thickness dikarenakan
ketebalan dinding minimum > ketebalan
dinding pada saat awal pembuatan.

Install grounding system for safe operation

Perform verification for UT thickness


measurement, found that minimum actual
thickness > thickness nominal (initial).

Page 38 of 42

3 Phase Production Separator


(Tag No. C-321 / SN. 28829)
SP III Limau
Perencanaan inspeksi yang dianjurkan :

Damage

Inspection

Mechanisms

methods

Uniform corrossion

Visual Inspection

Pitting Corrosion

No

UT Thickness
3

Erosion-Corrosion

Scanning

Sulfide

UT Flaw

Cracking

Stress

Scanning of MPI

Recommeded next Inspection Plan:

Coverage

Interval

Visual inspection of 100% of


the exposed surface area with
follow-up by UT or pit gauge
as required. (Shell, head,
nozzle and supports)
Minimal 20% examination,
and followed by spot external
ultrasonic
thickness
measurements. (Shell, head
and nozzle)

Next 3 years,
for next
SKPP

Minimal 20% examination of


weldments (Nozzles to shell,
T- joints)

Page 39 of 42

3 Phase Production Separator


(Tag No. C-321 / SN. 28829)
SP III Limau

LAMPIRAN A
LAPORAN NDT

Page 40 of 42

3 Phase Production Separator


(Tag No. C-321 / SN. 28829)
SP III Limau

LAMPIRAN B
PERHITUNGAN SISA UMUR

Page 41 of 42

REMAINING LIFE CALCULATION


PRESSURE EQUIPMENT
EQUIPMENT
TAG No
Operator
Location

:
:
:
:

Data Head I (Left)


- t initial
- t actual
- t required
- year built / operate
- year last inspection

:
:
:
:
:

34,93 mm
34,35 mm
29,76 mm
2006
2014

Corrosion rate

0,072 mm/year

Remaining Life

63,86 years

Remarks

3 Phase Production Separator


C-321
PT Bintang Energi Pratama
-

REMAINING LIFE CALCULATION


PRESSURE EQUIPMENT
EQUIPMENT
TAG No
Operator
Location

:
:
:
:

Data Shell 3
- t initial
- t actual
- t required
- year built / operate
- year last inspection

:
:
:
:
:

34,93 mm
32,48 mm
30,28 mm
2006
2014

Corrosion rate

0,306 mm/year

Remaining Life

3 Phase Production Separator


C-321
PT Bintang Energi Pratama
-

7,18 years

Remarks
- Thickness actual is greater than initial, assumed T shell = T Heads

REMAINING LIFE CALCULATION


PRESSURE EQUIPMENT
EQUIPMENT
TAG No
Operator
Location

:
:
:
:

Data Shell 1
- t initial
- t actual
- t required
- year built / operate
- year last inspection

:
:
:
:
:

34,93 mm
33,12 mm
30,28 mm
2006
2014

Corrosion rate

0,226 mm/year

Remaining Life

12,55 years

3 Phase Production Separator


C-321
PT Bintang Energi Pratama
-

Remarks
- Thickness actual is greater than initial, assumed T shell = T Heads

REMAINING LIFE CALCULATION


PRESSURE EQUIPMENT
EQUIPMENT
TAG No
Operator
Location

:
:
:
:

Data Shell 4
- t initial
- t actual
- t required
- year built / operate
- year last inspection

:
:
:
:
:

34,93 mm
33,05 mm
30,28 mm
2006
2014

Corrosion rate

0,235 mm/year

Remaining Life

11,79 years

3 Phase Production Separator


C-321
PT Bintang Energi Pratama
-

Remarks
- Thickness actual is greater than initial, assumed T shell = T Heads

REMAINING LIFE CALCULATION


PRESSURE EQUIPMENT
EQUIPMENT
TAG No
Operator
Location

:
:
:
:

Data Shell 2
- t initial
- t actual
- t required
- year built / operate
- year last inspection

:
:
:
:
:

34,93 mm
32,84 mm
30,28 mm
2006
2014

Corrosion rate

0,261 mm/year

Remaining Life

3 Phase Production Separator


C-321
PT Bintang Energi Pratama
-

9,80 years

Remarks
- Thickness actual is greater than initial, assumed T shell = T Heads

REMAINING LIFE CALCULATION


PRESSURE EQUIPMENT
EQUIPMENT
TAG No
Operator
Location

:
:
:
:

Data Head II (Right)


- t initial
- t actual
- t required
- year built / operate
- year last inspection

:
:
:
:
:

34,93 mm
34,72 mm
29,76 mm
2006
2014

Corrosion rate

0,026 mm/year

Remaining Life

Remarks

3 Phase Production Separator


C-321
PT Bintang Energi Pratama
-

193,56 years

3 Phase Production Separator


(Tag No. C-321 / SN. 28829)
SP III Limau

LAMPIRAN C
DRAWING

Page 42 of 42

C-321
PRODUCTION SEPARATOR (NEW)
CAPACITY
: 40.000 BFPD
SIZE
: 72" OD X 276" S/S
DESIGN
: 600 PSIG/300OF
OPERASI
: 310 PSIG/227OF

PI
C321

2"

SET @ 600 PSIG


2"-300# X 3"-150#

-VG-30
(TYP-2)

2"

1"

3"

2"

8"

72"

C-321

2"

8"

2"

4"

2"

2"-VB-30

276"
DRAWING TITLE
SELATAN FACILITIES MODIFICATION
PRODUCTION SEPARATOR (C-321)

EMP MALACCA STRAIT S.A