o- wom O ADHI KARYA, (Persero) Tbk or permoxima orsrx PROJ No. } 201485 | REV ANMONTA-UREA TI PROJECT 201485-37000-"C04 TECHNICAL SPECIFICATION SHEET 1 OF 14 TECHNICAL SPECIFICATION OF PIPING STRESS ANALYSIS APPROVAL STATUS ; Le ‘APPROVED Ly r_ "APPROVED WITH COMMENTS 5 NOT APPROVED cid AS-FINAL AS-PINAL TRRAR F wipva N ZZ |wisnu A L FOR_APPROVAL | IKRAR FIP wipyaN | wisnu tt 0 FOR APPROVAL (KRAR FHP WIDYA N. WISNU I 2015-04-17 REV DESCRIPTION PREPD. CHKD APPRD, DATEAMWONTA-UREA IT PROJ PROJ NO. | 201485 | REV | 2 PT. ADHIKARYA | piping STRESS ANALYSIS (Utility Area) 201485~37000-MC04 TECHNICAL SPECIFICATION SHEET 2 OF 14 (Persero) Tok TABLE OF CONTENTS SCOPE REFERENCES. (CATEGORY OF STRESS ANALYSES... DESIGN PROCEDURES. REQUIREMENTS OF STRESS CALCULATION. 5.1 DESIGN CONDITIONS AND ALLOWABLE STRESSES. 5.2. LONGITUDINAL STRESSES AND DEFORMATIONS... 5.3 FLEXIBILITY STRESSES. 5.4 PIPING SUPPORTS... - a 6 EQUIPMENT REACTION VERIFICATION ceernenennn BL 6.1 EQUIPMENT WITH ROATING PARTS a 6.2 FURNACES & BOILERS . 12 63° AIRFINs. 6.4 PRESSURE VESSELS & EXCHANGERS. 7 STABILITY VERIFICATION... 8 DYNAMIC ANALYSIS...AMMONTA-UREA 11 PROJECT PROJ NO. | 201485 | REV PT. ADHIKARYA | p(pING STRESS ANALYSIS (Utility Area) 201485-37000-MCO4 (Persero) Tbk ‘TECHNICAL SPECIFICATION SHEET 3 OP 14 1 SCOPE This specification presents general information and design criteria concerning piping flexibility ‘stress analysis in AMMONIA-UREA I PROJECT. The software CAESAR I, Version 5.3, shall be used for pipe stress analyses. This Design Rules is the specifications containing general design criteria as well as the technical requirements for Piping Stress Analysis. All piping stress shall be conducted in accordance with ASME 631.3, the latest edition. Analysis shall follow this specification if there is not otherwise noted by Client. The following cases shall be considered in the stress analysis input data: 2) Cryogenic lines will ake into account the formation of ice due to the fow line temperature and the high atmospheric b) Rotatingequipment. ©) Throttling valves. d) Staticequipment nozzles, especially high column, tower, high pressure vessel and so on. ) Blowdown connection points f) Steam lines 8) All pipe lines that have cyclic temperature 2 REFERENCES The following codes and documents shall form a part ofthis specification: ASME B31.3 "Process Piping” - ASME B31.1"Power Piping" ~ ASME Section “Rules for Construction of Power Bollers” - ASME Section Vill “Rules for Construction of Pressure Vessels” - _APIRP520 "Recommended Practice for the Design and Installation of Pressure: Relieving System in Refineries” - __ APISTANDARD 610 "Centrifugal pumps for general refinery services" - _ APISTANDARD 560 "Fired Heater for General Refinery services" - _NEMASM-23 "National Electrical Manufacturers Association” = EJMA“Standard of the Expansion Joint Manufacturers Association” = WRC 107/297 “Local Stresses in Cylindrical Shells Due to External Loadings on Nozzles” = APISTANDARD 611 "General purpose steam turbine for refinery services" - __ APISTANDARD 612 "Special purpose steam turbine for refinery services" - _APISTANDARD 617 "Centrifugal compressor for general refinery services” = APISTANDARD 618 "Reciprocating compressor for General Refinery Services” = API STANDARD 619 "Rotary-type positive displacement compressors for general refinery services”ANWONTA-UREA IT PROJECT roy No. | 201486 | rev | 2 ® PT. ADHIKARYA | pipiyg STRESS ANALYSIS (Utility Area) 201485-37000-#C04 (Persero) Tok TECHNICAL SPECIFICATION SHEET 4 OF 14 - _ APISTANDARD 650 "Steel Welded Tanks for Oil Storage” ~ __ APISTANDARD 661 "Aircooled heat exchangers for general refinery services" - __ APISTANDARD 662 Plate heat exchanger. 3. CATEGORY OF STRESS ANALYSES 1) 2) 3) 4) All the plant lines shall be submitted to stress analysis to comply with these Design Rules. ‘The stress analysisis to be executed to determine the degree of criticality of piping systems and thus to establish the accuracy of the calculation methods to be adopted for verifying piping system reliability and safety. Unless other stricter rules are contractually required, flexibility verification shall be performed by mean of: - Carefully structural analysis, using computerized system in all cases considered ‘complex and critical and for all piping connected to rotating machinery (pumps, turbines, compressors, etc.) and to furnaces and boilers. ~ Simplified structural analysis by mean of calculation procedure for configuration whose validity can be demonstrated and as long as conservative assumptions are used for the system's flexibility. = Tables, graphics and monographs for recurrent and very simple configuration as well as system configurations equivalent or similar to other already verified. Based on design temperature, all pipelines shall be classified into three levels as follows: = Level 1: engineering judgment method. Approximate visual inspection method shall be restricted to lines that are similar to ‘other, or lines clearly possessing adequate flexibility. - Level 2: Simplified analysis method. ‘Simplified analysis shall be based on short cut calculation by computer program in conservative configuration, or on chart, cantilever method provided these methods are used within their range of validity for which their accuracy is known, ~ Level 3: Detail analysis method. Detail analysis by certified computer program shall be carried out to meet requirement of the piping code. A calculation note is required Refer to Table 1, Stress Checking Level, for details. Inaddition to the above checking level, stress engineers may add the following piping systems into level 3 based on the actual pipe routings and judgments, a) Lines having local reduction in strength due to installation of special fittings. bb) Lines which may create large forces or moments on structures. ©). Piping subject to settlement or higher displacements d) Lines with special design requirements. €) Lines having substantial concentrated loads such as valves, fittings, unsupported vertical risers and branches.@ PT. ADHIKARYA | piping STRESS ANALYSIS (Utility Area) 201485-37000-C04 (Persero) Tbk 5) 6) ) 8) Lines not having an obvious fle» No formal analysis of adequate flexibility is required for a piping system which: a) b) ¢ d) The Calculation Sheet will include the following minimum information: AMMONTA-UREA I PROJECT proj NO. | 201485 J rev | 2 TECHNICAL SPECIFICATION SHEE 5 oF 14 Piping with pressure surge, slug and two phase flow (bowing effect) v. Has the maximum temperature change not exceed 10°C from ambient. Conforms to the description given in ASME B31.3, paragraph 319.4.1(C). Duplicates, or replaces without significant change, a system operating with a successful service record, Can readily be judged adequate by comparison with previously analyzed systems. Basic design data and conditions, always including the design conditions Isometric layout of the complete piping system being analysis ‘Support positions and types ‘Anchor positions and displacements Load cases and calculated member stresses Forces and moments at supports and nozzles on equipment Reactions at supports, forces, moments, deflection, displacements at supports for necessary load cases,AYWONTA-UREA IT PROJECT. Roy No. } 201485 | REV PT. ADHIKARYA | piping STRESS ANALYSIS (Utility Area) 201485~37000-NCOd (Persero) Tok TECHNICAL SPECIFICATION SHEET 6 OF 14 LINE MAXIMUM CONNECTION TYPE pipe size Neu) ueveta LEVEL 2 Levels Dea" T< 260% Te 260%C Alltypes except as noted ebay" e758" WCst< % 1 eee ar ors asic 7 ‘Buried lines allo yeiso% | Teis0% asteT< 5 8 Cryogenic Dez" eta | TE26C 9 Cyclic Temperature Allo Any ps temperatu Deir" T<150% T3150 10 Storage tank 7, Dei yems"e | T3275 Psoeir T<150°% | T2i50°C 11 | High pressure > class 600 ‘Any Dea femperatu DESIGN PROCEDURES ‘Asa general rule, the phases of the piping stress analysis activity are developed during theANDMONIA-UREA 11 PROJECT. pros No. T 201485 [ Rev PT. ADHIKARYA | piping STRESS ANALYSIS (Utility Area) 201485-37000-§CO4 (Persero) Tbk TECHNICAL SPECIFICATION SHEET 7 OF 14 following stages: a) line geometry definition b) definition of restraints & anchors ©) _ verification of longitudinal stresses and deformations produced by sustained {non-self-limiting) permanent loads 4) verification of longitudinal stresses and deformations produced by sel thermal loads €) verification of occasional loads f) verification of reaction on terminal equipment nozzles and connections 2) verification of elastic stability limiting loads such as REQUIREMENTS OF STRESS CALCULATION The scope of Piping Stress Analysis isto verify the following requirements: h) to keep piping stresses lower than allowable stress at design temperatures i) to guarantee stability against any external pressure conditions J) toavoid excessive piping deformation or pocket formation in piping requiring slopes for Grainage k)__ to guarantee the elastic stability of the piping system |) to avoid excessive reactions on restraints and anchors m)_ to avoid excessive reactions on equipment connected to piping 1n) to avoid the piping’s thermal expansion and/or contraction causing interference between adjacent pipes and between piping, structures and equipment. DESIGN CONDITIONS AND ALLOWABLE STRESSES Design conditions are those defined by the design temperatures and pressures for the line, as indicated in the Piping Lines List. = For design temperature and pressure, refer to para 301 (Design Conditions) of ASME 8 31.3 code. = Inaccordance with para.302.2.4 of ASME B31.3 code, temperature and pressure or both may occasionally exceed their respective design value so tong as pipe wall stress, calculated for the maximum foreseeable pressure, does not exceed the allowable stress at the ‘maximum allowable temperature: a) By 33% when each of the single conditions does not last than 10 hours and does not reach more than 100 hours per year of operation b) By 20% when each of the said conditions does not last than 50 hours and does not reach more than 500 hours per year of operation. - The allowable stress due to loads acting on piping, during the phased described in the design procedure, shall be defined in accordance with para.302.3 (allowable stress and. other stress limits) of ASME B31.3. - Inthe allowable stress calculation, the efficiency of £ welds shall be taker into account fore 5.2 = AMMONTA-UREA LT PROJECT PROJ NO. | 201485 } Rev | 2 PT. ADHIKARYA | piping STRESS ANALYSIS (Utility Area) 201485~37000-MC04 (Persero) Tok ‘TECHNICAL SPECIFICATION SHEET 8 OF 14 mechanical pressure sizing and shall be numerically defined in accordance with table 302.3.4 (longitudinal and spiral weld joint factors, E) of ASME 831.3. The efficiency of E weld shall not be considered in verifying longitudinal stresses caused by non-self-limiting and self- limiting toad. LONGITUDINAL STRESSES AND DEFORMATIONS Longitudinal stresses due to sustained loads (non-self occasional, are to be verified. imiting loads), whether permanent or 5.2.1 VERIFICATION OF PERMANENT LOADS The sustained permanent loads to be considered in verifying longitudinal stresses and deformations as follows: ~ pressure effect (internal or external) ~ weight of piping and internal fluid under the various conditions foreseen - other sustained loads 5.2.2 VERIFICATION OF OCCASIONAL LOADS Sustained occasional loads to which piping may be subject shaff be taken into account in verifying longitustinal stresses and deformations. Occasional loads include: - wind loads = snow loads (permanent where applicable) - loads caused by opening safety valves - impulsive loads ~ Impact loads due to sudden flow stoppage caused by rapid valve closure or power failure A thorough analysis shall therefore be made to evaluate which of these loads act on the piping ‘and to permit 2 qualitative examination of any effects to be compensated, mainly by means of 2 proper selection and arrangement of the supports. 5.2.3 VERIFICATION OF TEST CONDITION Inverifying longitudinal stresses under test condition (hydraulic or pneumatic) incidental loads shall not be into account. Nominal piping thickness shall be considered for the said condition. Allowable stress shall be assumed to be 0.9 of Yield strength. 5.2.4 VERIFICATION OF DEFORMATION Maximum deflection between two consecutive supports due to permanent loads shall not exceed 1/250 [normally 15mm] of the distance between the supports, For sloping lines, maximum deflection shall be % of the difference in elevation between the two supports. 5.2.5 VERIFICATION OF THERMAL STRESS Friction at support point shall not be taken into account in calculating thermal stress. ‘Thermal stress SE, shall be evaluated and combined as per ASME 831.3,AMMONIA-UREA [1 PROJECT PROJ_NO. PT. ADHIKARYA | prping STRESS ANALYSIS (Utility Area) 20148: (Persero) Tbk TECHNICAL SPECIFICATION SHEET 9 OF 5.3. FLEXIBILITY STRESSES The verification of piping flexibility stresses consists of analyzing the stresses and reactions deriving both from the temperature variation to which they are subject in the various operational stages, and to the movements to which they are subjected by the connected equipment (self-limiting loads) As far as concepts, definitions, and properties of the metal materials {and in particular to allowable stresses) are concerned, the criteria for combining stresses and determining reactions are indicated in ASME 631.3. 5.3.1 CALCULATION CONDITIONS 2) Flexibility calculations shall be performed taking into account any significant phases in the following line operating conditions: = design - operation - decoking - regeneration = line drying - Anomalous conditions (steam flushing, line tracing, piping with no-load, etc.) b) Calculation temperature: = The operating temperature shown in the fine list shall be used to evaluate force and moments at equipment nozzles. = The design temperature shall be used to evaluate the pipe stresses. ) Installation temperature is specified as follows: ~ 36.5°C (Maximum air temperature) - for cold lines. = 22°C (Minimum air temperature) - for hot lines. ~ unless otherwise specified. 4) Coefficient of friction are specified as follows: = 0,3 for Steel to Steel ~ 0.1 for Stainless steel to PTFE = 0.5 for Steel to concrete surface ) _Inverifying flexibility fora piping system, the flexibility coefficient for bends shall be taken into account as indicated in ASME B 31.3 appendix D. Valves, flanges, filters and other elements for which no flexibility evaluations may be made shall be considered infinitely rigid. Pipes, joints and T-pieces shall be assumed to have a flexibility coefficient of 1.AMMONTA-UREA_1T_ PROJECT. roy No. | 201485 | REV © PT. ADHIEKARYA | piping STRESS ANALYSIS (Utility Area) 20148: (Persero) Tok ;7000-MCO4 TECHNICAL SPECIFICATION SHEET 10 OF 14 5.3.2 EXPANSION JOINT a) Line flexibility requirements shall as far as possible be satisfied by changes of direction, loops, etc. The use of expansion joints shall be limited to those cases in which routing modifications are more difficult or impossible for the following reasons: + excessive pressure drops = reduced availability of space ~ excessive loads on structures or terminal equipment b) The following employment hierarchy shall be observed for metal bellows type expansion joints: - hinged - gimbal - lateral expansion joints = universal expansion joints = axial expansion joints. ) The use of expansion joints without tle-rods requires guides, stops and anchors for the highest pressure to which the system may be subject {in many cases, test pressure is higher than design pressure). d) _Incases where the fluid conveyed may cause deposits or fouling between the bellows, conveyors shall be utilized, together with the possibility of connection with steam or similar systems. In such cases it is preferable to arrange the expansion joints on vertical stretches of piping. e) The selection, arrangement, limits of employment, reactions and specifications for expansion joints shall be as per EJMA (Expansion Joint Manufacturer Association) standards, f) Special care shall be taken for expansion joints operating under vacuum. Such a condition shall be clearly indicated in specifications and bid documents. In such a case, the values for ‘operational and design pressure shall also be indicated. g) Expansion joint supply shall be determined as follows: c= 104 1.,1Ce(mm) a= 1+ 1.lac (sexagesimal degrees) Where Cc and ac are respectively calculated the linear and angular movements. 5.4 PIPING SUPPORTS Pipe supports and restraints shall be positioned in the piping system and de: following conditions: = _Maintain pipe stresses below admissible values at the design temperature stated in the° 61 62 AWONTA-UREA IT PROJECT PROJ NO. | 201485 | REV PT. ADHIKARYA | pipING STRESS ANALYSIS (Utility Area) 201485~37000-NCO1 (Persero) Tbk. TECHNICAL SPECIFICATION SBET i oOF 14 Project's Code. = Avoid undue deformation of piping and formation of sags in piping requiring a drain slope. Inall cases maximum vertical deflection between two adjacent supports, duly evaluated using standard construction formulae, shall not exceed 1/250 [normally 15mm] of the distance between supports or, in the cases of sloping lines, 1/4 of the difference in elevation between supports, = Ensure the elastic stability of piping. - Avoid undue stress on nozzles of connected equipment or machinery. = Avoid resonance due to imposed vibrations. As a general rule, a check shall determine that the first natural frequency of the line is not less than 150% of the frequency of the imposed force. = Prevent thermal expansion and contraction from causing interference between gives and between pipe and structure. EQUIPMENT REACTION VERIFICATION Equipment reactions shall be calculated considering the piping's thermal expansion, other external forces acting on the piping (weight, friction, wind, etc.) and the movements to which the piping is subjected by connected equipment. - Reaction shall be calculated using the elasticity modules at the calculation’s reference temperature. ~The actual value of the part of the reaction due to a thermal origin shall be determined by reducing the range of reactions between erection and operation according to the degree of. pre-stressing to which the erection is subject. EQUIPMENT WITH ROTATING PARTS Nozzle reaction for equipment with rotating parts (pumps, turbines and compressors) shall be lower than the allowable values established by the vendor. Where these are not available, the following standard shail be used as a requirement. The said values shall be defined at the bid stage and shall in no way be conflict with the values specified by the appropriate standards for the equipment, as required by design specifications: = Pumps APISTANDARD 610 Turbines NEMA SM-23 and API 611 and API 612 = Compressors AP STANDARD 617 For the evaluation of rotating equipment nozzle load, the normal operating conditions shall be used. AIR FINS Allowable reactions for air-fin gates shall be two times the allowable loads according to API 661.AMMONSA-UREA LL PROJECT PROJ_NO. | 201485 | REV | 2 PT. ADHEKARYA | piping sTRES: (Persero) Tbk ANALYSIS (Utility Area) 201485~37000-NCO4 TECHNICAL SPECIFICATION SHEET 12 OF 14 PRESSURE VESSELS & EXCHANGERS Loads acting on pressure vessels and heat exchanger nozzles shall, as a general rule, be lower than the nozzles allowable reactions accepted as safe by the EQ Department. In general, the nozzle loads and moments shall be refer to the values specified in the corresponding code and standard, where these are not available, the values in table 2 will be applied. Allowable piping loads acting on equipment nozzles of TOYO & KBR Special equipment shall be specified by vendor. If not available, nozzle stiffness and nozzle allowable reactions shall meet the criteria as per WRC 107 or WRC297 as applicable. If nozzle and/or vessel geometry is outside the limit of WRC 107 or WAC 297, other acceptable local stiffness and stress calculation methods shall be adopted prior to £Q Department approval. 7 STABILITY VERIFICATION ‘The stability of piping subject to external pressure shalll be guaranteed according to para 304.1 {Pressure Design of Components - Straight Pipe) of ASME code B31.3. ‘Stability shall be verified against axial twist, limiting the slenderness of piping to values less than 200 with the use of lateral constraints. For thin-walled piping, stability shall be verified against pipe ovalization in sections with maximum bending moment (thin-walled piping és defined as having a ratio of De/So between the external diameter and the corroded nominal thickness of more than 72). 8 DYNAMIC ANALYSIS Lines connected to alternative machinery, subject to pressure pulsation, and/or subject to other pulsating forces, shal! be designed and supported so as to limit as far as possible any dynamic amplification of the relevant shape deflection and to avoid mechanical resonance between the imposed external dynamic loads and the natural frequencies of the piping system. Dynamic analysis does not involve fluid dynamic phenomena induced by the process fluids flow to be analyzed by the Process Department.AMMONTA-UREA 11 PROJE 1 PROJ_NO. | 201485 | REV | 2 PT. ADH KARYA | prpiNG STRESS ANALYSIS (Utility Area) 201485~37000-Mo04 (Persero) Tk ‘TECHNICAL SPECIFICATION SHEET 13 OF 14 Table 2 -Nozzle loads and moments Nozzle PN20 PN 50 PNIIO Dia, Class 150 Class 300 Class 600 DN FE M PN 260 Class 1500 F M ume sus {sun asos57 wis | renee | rossee | aneoss | ssa30 asii04 resoro | igsaz f rssea7 | raszv0 | 393602 an zesse | os2 | yi ess | suse sorors | nec0s | aris sowres | seos0 2s0se.2 | sovios 1253051 soins sei areas | is7020s Note: (1) Directions of Loads and moments with definition refer to Figure 2. (2). For intermediate nozzle diameter or pressure rating it’s necessary to be interpolated to determine loads and moments values from this table. Where VC=V2=VLeVi (M=IMC=M1=MLsM2=MT (3) The allowable force moment shall be based on vendor informationAMMONTA-UREA TT PROJECT Prog NO. | 201485 | REV PT. ADHIKARYA | pIPING STRESS ANALYSIS (Utility Area) 201485-37000-MO04 (Persero) Tbk ‘TECHNICAL SPECIFICATION SHEET 14 OF 14 —- Figure2 Directions of loads and moments on connection Note: Loads anc moments shall be considered to be acting at the mtersection between nozzle ax's and ‘external surface, Where Pe - Radial Load. whien 's trying to push or pull the nozzle iniout of the shell VC or V2 ---=- Circumferential shear load VC from B to A for Cyindncal shell Creumferential shear oad V2 from D 10 C for Spherical shell YL or VI-—=- Longitudinal shear load VL from D to C for Cyimdrical shell Crreumferental shear load V1 f n B to A for Spherical shell MC orMt Cireumferential moment MC for Cylindrical shell Circumferential moment MMI for Spherical shel ML for Cylindrical shell #2 for Spherical shell Longitudinal mom Longitudinal ome: Torsional moment