i HALAMAN JUDUL............................................................................................. ii HALAMAN PENGESAHAN............................................................................... iii HALAMAN PERNYATAAN.............................................................................. iv NASKAH SOAL................................................................................................... vi HALAMAN PERSEMBAHAN........................................................................... v INTISARI.............................................................................................................. vii KATA PENGANTAR.......................................................................................... ix DAFTAR ISI......................................................................................................... DAFTAR GAMBAR............................................................................................ xiii xv DAFTAR TABEL................................................................................................. DAFTAR LAMPIRAN......................................................................................... xvi DAFTAR NOTASI DAN SINGKATAN............................................................ xvii BAB I PENDAHULUAN...................................................................................... 1.1 Latar Belakang............................................................................................ 1.2 Latar Belakang Penulisan........................................................................... 1.3 Rumusan Masalah....................................................................................... 1.4 Batasan Masalah......................................................................................... 1.5 Tujuan Penelitian........................................................................................ 1.6 Manfaat Penelitian......................................................................................
1 1 3 6 6 7 7
BAB II TINJAUAN PUSTAKA......................................................................... 2.1 Perancangan Bejana Tekan......................................................................... 2.2 Analisis Tegangan Lokal pada Nozzle........................................................
8 8 10
BAB III DASAR TEORI...................................................................................... 3.1 Perancangan Shell....................................................................................... 3.1.1 Pemilihan material...................................................................... 3.1.2 Tebal minimum shell................................................................... 3.1.3 MAWP shell................................................................................ 3.1.4 MAPNC shell.............................................................................. 3.1.5 Tegangan pada shell.................................................................... 3.2 Perancangan Head...................................................................................... 3.2.1 Pemilihan material...................................................................... 3.2.2 Tebal minimum head.................................................................. 3.2.3 MAWP head................................................................................ 3.2.4 MAPNC head.............................................................................. 3.2.5 Tegangan pada head.................................................................... 3.2.6 Tekanan pengujian hydrotest......................................................
13 13 13 13 14 15 15 16 16 16 17 18 18 19
ix
3.3
Perancangan Nozzle.................................................................................... 3.3.1 Perancangan flange..................................................................... 3.3.2 Pemilihan material pipa nozzle.................................................... 3.3.3 Tebal minimum nozzle................................................................ 3.3.4 Luasan penguat............................................................................ 3.3.5 Tegangan yang diijinkan pada pengelasan.................................. 3.3.6 Analisis kekuatan pengelasan..................................................... Berat Bejana Tekan dan Komponennya..................................................... 3.4.1 Berat shell.................................................................................... 3.4.2 Berat head................................................................................... 3.4.3 Berat nozzle................................................................................. 3.4.4 Berat fluida kerja......................................................................... Titik Berat Bejana Tekan............................................................................ Perancangan Saddle…………...................................................................... 3.6.1 Tegangan lengkung longitudinal................................................. 3.6.2 Tegangan geser tangensial.......................................................... 3.6.3 Tegangan sirkumferensial........................................................... Perancangan Lifting lug.............................................................................. 3.7.1 Gaya pada lifting lug................................................................... 3.7.2 Tegangan pada lifting lug............................................................ 3.7.3 Gaya pada sambungan las lifting lug.......................................... 3.7.4 Tegangan pada lubang pin.......................................................... Analisis Tegangan Perpipaan..................................................................... 3.8.1 Pembebanan sistem perpipaan.................................................... 3.8.2 Kriteria analisis tegangan perpipaan........................................... 3.8.3 Solusi analisis tegangan perpipaan............................................. Analisis Tegangan Lokal pada Nozzle (WRC 107) .................................. 3.9.1 Rumus umum….......................................................................... 3.9.2 Tegangan karena beban dan momen eksternal........................... 3.9.3 Solusi analisis tegangan lokal pada nozzle.................................
BAB IV METODOLOGI PENELITIAN.......................................................... Diagram alir perancangan bejana tekan...................................................... 4.1 4.2 Diagram alir analisis tegangan lokal karena pembebanan eksternal .........
62 62 65
BAB V PERANCANGAN SLUG CACTHER..................................................... 5.1 Data Perancangan....................................................................................... 5.1.1 Penentuan kondisi desain............................................................ 5.2 Perancangan Shell....................................................................................... Perhitungan tebal minimum shell. .............................................. 5.2.1
68 68 69 69 69
3.4
3.5 3.6
3.7
3.8
3.9
x
5.2.2 Perhitungan MAWP shell........................................................... 5.2.3 Perhitungan MAPNC shell.......................................................... 5.2.4 Tegangan pada shell kondisi operasi........................................... Perancangan Head...................................................................................... 5.3.1 Perhitungan tebal minimum head............................................... 5.3.2 Perhitungan MAWP head........................................................... 5.3.3 Perhitungan MAPNC head......................................................... 5.3.4 Tegangan pada head kondisi operasi.......................................... 5.3.5 Tegangan pada hydrotest............................................................. 5.3.6 Data hasil perhitungan desain shell dan head............................. Perancangan Nozzle.................................................................................... 5.4.1 Data nozzle.................................................................................. 5.4.2 Pemilihan rating flange............................................................... 5.4.3 Perancangan nozzle gas inlet 24” ............................................... 5.4.4 Perancangan nozzle liquid outlet 6” ........................................... 5.4.5 Perancangan nozzle PI 2” ........................................................... Perhitungan Berat Slug cacther.................................................................. 5.5.1 Perhitungan berat shell................................................................ 5.5.2 Perhitungan berat head................................................................ 5.5.3 Perhitungan berat nozzle............................................................. 5.5.4 Perhitungan berat fluida kerja..................................................... Berat Perlengkapan Lainnya....................................................................... Perhitungan Titik Berat Bejana.................................................................. Perancangan Saddle………....................................................................... 5.8.1 Tegangan lengkung longitudinal................................................. 5.8.2 Tegangan geser tangensial pada permukaan saddle.................... Tegangan sirkumferensial pada horn saddle............................... 5.8.3 Perancangan Lifting lug.............................................................................. 5.9.1 Perhitungan gaya di lifting lug.................................................... Perhitungan tegangan pada lifting lug......................................... 5.9.2 5.9.3 Gaya pada sambungan las lifting lug lifting lug.......................... Perhitungan tegangan pada lubang pin........................................ 5.9.4
BAB VI ANALISIS TEGANGAN LOKAL PADA NOZZLE GAS INLET..................................................................................................... 6.1 Sistem Perpipaan Gas di sekitar Slug cacther............................................ 6.2 Analisis Tegangan Sistem Perpipaan......................................................... 6.3 Gaya dan Momen pada Nozzle Gas Inlet……............................................ 6.4 Analisis Tegangan pada Nozzle Gas Inlet.................................................. 6.5 Analisis Tegangan dengan Variasi Pembebanan pada Nozzle Gas Inlet ...
117 120 118 122 123 126
5.3
5.4
5.5
5.6 5.7 5.8
5.9
xi
BAB VII PENUTUP..................................................................................................... 7.1 Kesimpulan................................................................................................. 7.1.1 Perancangan slug cacther............................................................ Analisis tegangan lokal pada nozzle........................................... 7.1.2 7.2 Saran...........................................................................................................
131 131 131 132 134
DAFTAR PUSTAKA...................................................................................................
Sketsa slug cacther pada pengangkatan........................................ 110
Gambar 6.1
Jalur pipa gas FSRU pipeline slug cacther...................................
Gambar 6.2
Plot plan disekitar slug cacther berserta pipe support-nya........... 118
Gambar 6.3
Pemodelan sistem perpipaan sekitar slug cacther beserta tipe
110
117
pipe suppport-nya.......................................................................... 119 Gambar 6.4
Rasio tegangan pada perpipaan FSRU pipeline- slug cacther......
121
Gambar 6.5
Penyesuaian vektor beban pada Autopipe dan PV Elite...............
122
Gambar 6.6
Kondisi pembebanan pada nozzle yang menempel di shell..........
124
Gambar 6.7
Hasil perhitungan tegangan pada nozzle dan reinforcement pad..
125
Gambar 6.8
Rasio tegangan yang terhitung pada software PV Elite...............
126
Gambar 6.9
Urutan pelepasan pipe support pada jalur pipa gas nozzle inlet...
127
Gambar 6.10
Grafik antara jumlah pipe support yang dilepas dan rasio tegangan.......................................................................................
xiv
130
DAFTAR TABEL
Tabel 1.1
Skema debit gas dari Semarang ke Gresik..........................................
Data sheet slug cacther...................................................... Procces Flow Diagram ORF............................................. Piping and Instrument Diagram Slug cacther.................. Gambar plot plan ORF....................................................... Tabel construction stell for non corroded service............. Saddle standard drawing................................................... Pipe support detail di sekitar nozzle gas inlet slug cacther................................................................................ Contoh gambar isometrik perpipaaan ORF........................ Koefisien pengali volume shell (Tabel 418 Megysey)...... Koefisien pengali volume head (Tabel 422 Megysey)...... Grafik 3C WRC 107........................................................... Grafik 4C WRC 107........................................................... Grafik 1C WRC 107........................................................... Grafik 2C-1 WRC 107....................................................... Grafik 3A WRC 107.......................................................... Grafik 1A WRC 107.......................................................... Grafik 4A WRC 107.......................................................... Grafik 2A WRC 107.......................................................... Grafik 4B WRC 107.......................................................... Grafik 1B WRC 107.......................................................... Grafik 2B WRC 107........................................................... Grafik 3B WRC 107........................................................... Operasi Software Autopipe................................................. Operasi Software PV Elite.................................................. Laporan Perhitungan WRC 107......................................... Gaya dan momen pada kasus pelepasan pipe support................................................................................ Gambar teknik slug cacther...............................................
A A A1 A2 A41 A42 A5 b b BA BFx BFy C CA Ch d Dp f f1 f2 f3 f4 f1 FB FT FS FW Fy h h Hxl Hxr Hyl Hyr Ii Io K K
Luas penguat yang dibutuhkan Jarak garis tangen kiri ke saddle kiri Luas yang tersedia pada shell Luas yang tersedia pada nozzle Luas yang tersedia di pengelasan antara nozzle dan reinforcement pad Luas yang tersedia di pengelasan antara reinforcement pad dan shell Luas yang tersedia di reinforcement pad Lebar saddle Tinggi dari plat ke pusat lubang pin Area bearing Gaya lengkung pada arah x axis Gaya lengkung pada arah y axis Titik pusat gravitasi dihitung dari garis tangen kiri Corrosion allowance Ketebalan las leg Radius dalam nozzle dalam keadaan terkorosi Radius luar reinforcement pad Faktor pengurangan tegangan Faktor pengurangan kekuatan nozzle dan shell Faktor pengurangan kekuatan nozzle dan shell Faktor pengurangan kekuatan nozzle dan reinforcement pad Faktor pengurangan kekuatan nozzle dan reinforcement pad Faktor pengurangan kekuatan nozzle dan shell Tegangan lengkung yang diijinkan Tegangan yang diijinkan pad Tegangan geser yang diijinkan Tegangan pengelasan maksimum yang diijinkan Tegangan yield Panjang dari lug Panjang head Gaya horisontal arah x (lug kiri) Gaya horisontal arah x (lug kanan) Gaya horisontal arah y (lug kiri) Gaya horisontal arah y(lug kanan) In-plane stress intensification factor Out-of-plane stress intensification factor faktor pengali head elips Faktor tegangan occasional xvii
K K2 K3 K6 K7 Kn Kb L Leg Ln MC Mch Mcs Mh ML Mi Mo Mpipa Mpad MT Ms Msf MAWP MAPNC MΦ Ni N NΦ P P P Pb Pm PL Pl Q Q R Rn
konstanta saddle konstanta saddle konstanta saddle konstanta saddle konstanta saddle Konsentrasi tegangan tekan atau tarik Konsentrasi tegangan lengkung Panjang garis tangen lebar kaki las Jarak dari tangen line ke titik berat tiap komponen Momen sirkumferensial Berat kondensat dalam head Berat kondensat dalam shell Berat head Momen longitudinal In-plane bending moment Out-of-plane bending moment Berat pipa Berat reinforcement pad Momen torsional Berat shell Berat straight flange Maximum allowable working pressure Maximum allowable pressure new and cold Momen lengkung pada dinding shell pada arah sirkumferensial Gaya membran pada dinding shell pada arah sirkumferensial Jumlah lifting lug Gaya membran pada dinding shell pada arah sirkumferensial Tekanan internal Beban sling Beban radial Tegangan lengkung primer lokal Tegangan membran primer global Panjang sambungan las Tegangan membran primer lokal Beban terbesar pada saddle Total tegangan sekunder Radius dalam shell kondisi terkorosi Radius dalam nozzle pada kondisi terkorosi
xviii
Ro Rm S S1 S2 S4 S5 S Sa Sa SA Sb Sc SFy Sh Sl Slf Smh Smc Smavg St T Tf tn tr trn ts Vh Vpad Vs Vsf VC VL VL VR Wh WT Z α
Radius luar shell Radius rata-rata shell Tebal yang diijinkan oleh shell Tegangan lengkung longitudinal Tegangan geser tangensial Tegangan sirkumferensial pada horn saddle Tegangan sirkumferensial pada shell bagian bawah Tegangan maksimum yang diijinkan pada kondisi lingkungan Tegangan yang diijinkan untuk ekspansi termal Tegangan maksimum yang diijinkan pada kondisi temperatur operasi Area geser Resultan tegangan akibat beban lentur Tegangan pada pipa dalam keadaan dingin Gaya geser pada arah y axis Tegangan pada pipa dalam keadaan temperatur tertentu Tegangan sustain yang terhitung Skew load factor Tegangan yang diijinkan pada kondisi operasi Tegangan yang diijinkan pada kondisi lingkungan Tegangan rata-rata (Smh + Smc)/2 Tegangan puntir Tebal wear plate Gaya tarik Tebal nominal pipa nozzle (nozzle neck) Tebal minimum shell dan head Tebal minimum pipa nozzle Tebal nominal shell Volume head Volume reinforcement pad Volume shell Volume straight flange Gaya geser sirkumferensial Gaya pada lifting lug kiri Gaya geser longitudinal Gaya pada lifting lug kanan Ketebalan las Berat ereksi slug cacther Modulus elastisitas pipa Sudut sling (0)
xix
Φ σBx σBy σT σs
Sudut swing (0) Tegangan lengkung pada sumbu horisontal axis x Tegangan lengkung pada sumbu horisontal axis y Tegangan tarik Tegangan karena tekanan internal