LAPORAN MAGANG INDUSTRI BULAN KEDUA OKTOBER 2011 DI

OLEH : PRATIWI, ST 1984 0225 2009 122002

BALAI BESAR TEKNOLOGI ENERGI BADAN PENGKAJIAN DAN PENERAPAN TEKNOLOGI TANGERANG SELATAN 2011

Lembar Pengesahan

Kata Pengantar
Pada laporan bulan pertama, telah dilakukan kegiatan internal sizing design yaitu : 1. sizing design dari Horizontal 3 Phase Separator with weir, dari proyek South Sembakung yang telah berjalan pada bulan April 2011 lalu, 2. sizing design dari Horizontal 3 Phase Separator with weir, dari proyek Petrochina (sedang dalam proses penawaran), 3. sizing design Heat Exchanger dari proyek Smelting (sedang dalam proses penawaran) dengan menggunakan software Hysys dan HTSF. Sedangkan untuk bulan kedua ini dilakukan pembelajaran tentang Departemen Produksi dan Quality Control, serta melanjutkan tugas yang telah diberikan pada bulan pertama sampai pada strength calculation dengan software PV Elite.

DAFTAR ISI
Lembar Pengesahan...................................................................................................................2 Kata Pengantar..........................................................................................................................4 DAFTAR ISI.............................................................................................................................5 BAB I STRENGTH CALCULATION.....................................................................................5 BAB II PRODUCTION DEPARTMENT..............................................................................40 BAB III QUALITY CONTROL ............................................................................................47 BAB IV PRODUCTION & FABRICATION HEAT EXCHANGER...................................57 BAB IV RENCANA KEGIATAN SELANJUTNYA............................................................71 DAFTAR PUSTAKA.............................................................................................................72 Kegiatan Harian di PT. PUSPETINDO bulan Kedua.............................................................73

BAB I STRENGTH CALCULATION

Setelah mendapatkan data-data kalkulasi dari internal sizing mencakup dimensi utama equipment (contoh diameter dan length dari vessel, jumlah dan diameter tube untuk HE, tinggi level untuk separator, dll), maka langkah selanjutnya adalah melakukan strength calculation (perhitungan kekuatan material) sesuai dengan standard dan code yang dipakai yaitu ASME. Strength calculation menentukan kemampuan material itu untuk menahan tekanan yang diberikan tanpa adanya kerusakan. Tekanan yang diberikan berupa tensile, compressive, atau 5

shear. Kekuatan material berhubungan dengan load (beban), deformasi, dan gaya yang bekerja pada material. Hal ini diperlukan dalam studi dan desain struktur. Strength calculation ini menggunakan software PV Elite 2011 yang merupakan software untuk perhitungan analisis vessel yang secara garis besarnya mencakup perhitungan tentang : 1. Thickness 2. Reinforcement 3. External Load 4. Support & Structure 5. Stress Analysis Sedangkan secara rinci meliputi perhitungan dan analisis terhadap : - Internal pressure untuk setiap elemen, yaitu required thickness, MAWP (Maximum Allowable working Pressure), MAPnc, MDMT (Mean Design Metal Temperature), % Elongation, dan Hydrotest Pressure. - External pressure untuk setiap elemen, yaitu required thickness, EMAWP, Max. Stiffened length. - Berat tiap elemen dan detailnya - ANSI B 16.5 Flange - Vessel Natural Frequency - Vortex Shedding Load - Wind & Seismic Load - Wind Deflection - Vessel cross sectional area & moment inertia check - Allowable Stress - Vessel Longitudinal Stress check - Vessel Support check - Fatique Analysis - Rigging Analysis - Vessel Center of Gravity

1.1. Hasil Strength Calculation untuk Heat Exchanger dengan PV Elite 2011
Dari bab sebelumnya telah dilakukan perhitungan internal sizing terhadap proyek HE smelting dimana terdapat 2 case perhitungan, yaitu : A. Ukuran HE dengan kondisi proses seperti persyaratan customer (Natural Gas yang dipakai tidak terbakar sempurna karena flow rate udara pembakaran masih kurang, dan flow rate natural gas terlalu besar) B. Ukuran HE dengan kondisi Natural Gas terbakar sempurna dengan mengatur flow rate udara bakar dan natural gas itu sendiri. 6

Hasil tersebut dapat dilihat pada tabel dibawah ini : Tabel 1.1. Perbandingan sizing result case 1 dan case 2 Item Case 1 Case 2 Design Pressure (Mpa) 0.3 / 0.3 0.3 / 0.3 Shell side / Tube side Design Temperature (C) 620 / 650 620 / 650 Shell side / Tube side Combustion air flow (Nm3/h) 9000 4428 Natural Gas flow (Nm3/h) 900 356.7 SO2 flow (Nm3/h) 1190 1190 T in - out 30 470 30 - 470 (Shell side - SO2) C T in - out 500 429.08 500 - 348.74 (Tube side Flue Gas) C ID nozzle in / Out 155.57 / 206.38 155.57 / 206.38 (Shell side) mm ID nozzle in / Out 444.5 / 393.7 311.15 / 260.35 (Tube side) mm No of tube 936 717 Tube OD (mm) 19.05 15.587 Tube Thickness (mm) 2.11 2.11 Tube Length (mm) 1950 3150 Tube Pitch (mm) 25.4 19.49 Shell ID / OD (mm) 925 / 939 625 / 635 double segmental / single segmental / Buffle Type / cut (%) 15.68 29.68 Baffle spacing (mm) 185 295 Setelah didapatkan data-data diatas, maka dilakukan strength calculation dengan software PV Elite 2011, dimana secara sederhana tahapan-tahapannya (flowchart) dapat dilihat pada gambar 1.1 pada halaman selanjutnya.

Berikut adalah flowchart strength calculation untuk heat exchanger secara umum :

- Data sheet - Customer Spec

Verify - Nominal Diameter - Tube Length - TEMA type & Class No Tube Lay-Out - Tube OD - Pitch & Pattern - Number

Shell Side Calculate - Shell Thickness - Shell Cover

Tube Side Calculate : - Channel Thickness - Channel Cover

Calculate Tube Thickness

No

Fix Tubesheet Type Yes Checking Mean Metal Temperature of - Tubes wall - Shell Wall

No

U-Tube

Yes

Calculated min thickness after bending

No

Calculate - Tubesheet - Baffle Thk & Spacing

Yes

Calculate - Tubesheet - Tubes - Shell - Baffle Spacing - Expansion Provide Expansion Joint if required

Floating Head

Yes

Calculate - Floating Head - Flange - Backing Ring

No Overstress on -Tubesheet -Tubes - Shell

Yes

No

Calculated - Pass Partition - Channel flange - Shell Flange

End

Gambar 1.1. Flowchart strength calculation untuk Heat Exchanger 8

Dalam perhitungan strength perlu dilakukan pemilihan jenis material yang sesuai dengan design temperature, dan tabel dibawah ini dipakai sebagai acuannya : Tabel 1.2. Appendix H Material Selection Guide (Pressure Vessel Design Handbook)

Sesuai dengan data pada tabel 1.1., untuk suhu 620 / 650C atau setara dengan 1148 / 1202F maka dipilih material stainless steel SA-240-347H untuk plate, SA-182-347H untuk Forging,SB-443 1 untuk shell, SB-444 2 untuk tube, SB-446 2 untuk tubesheet, dan SA-193B8 untuk Bolt.

Berikut adalah hasil strength calculation dengan menggunakan software PV-Elite 2011 : A. Untuk case 1.

Gambar 1.2. Hasil Design dengan PV Elite 2011

Rincian hasil perhitungannya : 1.Input data

PV Elite Vessel Analysis Program: Input Data Exchanger Design Pressures and Temperatures Shell Side Design Pressure Channel Side Design Pressure Shell Side Design Temperature Channel Side Design 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 Miscellaneous Weight Percent 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) 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 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 [V] 0.3000 0.3000 620 650 UG99-b Horizontal 0.0000 0.0000 0 Welded None RT 1 0. Y Y N N N N N Yes 0.0000 0.0000 0.0000 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 ASCE-7 93 150.00 C: Open Terrain 1. Moderately Smooth 0.0000 70. N 0.0100 0.0000 0.0000 UBC 94 1.000 1.250 km/hr MPa MPa C C

mm mm C

MPa MPa MPa

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

mm

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

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 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 Material Database 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 Complete Listing of Vessel Elements and Details: Element From Node Element To Node Element Type Description Distance "FROM" to "TO" Flange Inside 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 External Pressure Chart Name UNS Number Class / Thickness / Grade :: > 5 Product Form Perform Flange Stress Calculation (Y/N) Weight of ANSI B16.5/B16.47 Flange Class of ANSI B16.5/B16.47 Flange Grade of ANSI B16.5/B16.47 Flange

S1 3.000 0.000 Y N Y N

Current w/Addenda or Code Year

No Yes Yes Yes No Yes No

10 20 Flange btm blind flange 42.000 1045.0 42.000 0.0000 42.000 0.0000 0.3000 650 0.0000 650 1.2 SA-182 F347H 137.90 53.945 186.17 0.008027 0.0000 140.24 HA-2 S34709 Forgings Y 0.0000 mm mm mm mm mm mm MPa C MPa C MPa MPa MPa kg/cm mm MPa

-------------------------------------------------------------------Element From Node Element To Node Element Type Description Distance "FROM" to "TO" Flange Inside Diameter Element Thickness Internal Corrosion Allowance Nominal Thickness External Corrosion Allowance Design Internal Pressure Design Temperature Internal Pressure 20 30 Flange btm flange 70.000 925.00 70.000 0.0000 70.000 0.0000 0.3000 650 mm mm mm mm mm mm MPa C

Design External Pressure Design Temperature External Pressure Effective Diameter Multiplier Material Name Perform Flange Stress Calculation (Y/N) Weight of ANSI B16.5/B16.47 Flange Class of ANSI B16.5/B16.47 Flange Grade of ANSI B16.5/B16.47 Flange

0.0000 650 1.2 SA-182 F347H Y 0.0000

MPa C

-------------------------------------------------------------------Element From Node Element To Node Element Type Description Distance "FROM" to "TO" Inside 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 External Pressure Chart Name UNS Number Product Form Efficiency, Longitudinal Seam Efficiency, Circumferential Seam Element From Node Detail Type Detail ID Dist. from "FROM" Node / Offset dist Height/Length of Liquid Liquid Density 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 channel tube inlet 1016.0 925.00 5.0000 0.0000 5.0000 0.0000 0.3000 650 0.0000 650 1.2 SA-240 347H 137.90 53.945 186.17 0.008027 0.0000 140.24 HA-2 S34709 Plate 1. 1. 30 Liquid FLUE GAS 0.0000 1016.0 0.0000 30 Nozzle Tube Inlet 509.00 18. None 300 180. N 0.0000 GR 2.5 SA-240 347H

mm mm mm mm mm mm MPa C MPa C MPa MPa MPa kg/cm mm MPa

mm mm kg/cm

mm in.

-------------------------------------------------------------------Element From Node Element To Node Element Type Description Distance "FROM" to "TO" Inside Diameter Element Thickness 40 50 Cylinder shell side 1900.0 925.00 5.0000

mm mm mm

Internal Corrosion Allowance 0.0000 Nominal Thickness 5.0000 External Corrosion Allowance 0.0000 Design Internal Pressure 0.3000 Design Temperature Internal Pressure 620 Design External Pressure 0.0000 Design Temperature External Pressure 620 Effective Diameter Multiplier 1.2 Material Name SB-443 1 Allowable Stress, Ambient 236.50 Allowable Stress, Operating 147.10 Allowable Stress, Hydrotest 372.33 Material Density 0.008442 P Number Thickness 0.0000 Yield Stress, Operating 282.70 External Pressure Chart Name NFN-17 UNS Number N06625 Class / Thickness / Grade Annealed:: Product Form Plate, sheet, strip Efficiency, Longitudinal Seam 1. Efficiency, Circumferential Seam 1. Element From Node Detail Type Detail ID Dist. from "FROM" Node / Offset dist Height/Length of Liquid Liquid Density 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 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 40 Liquid SO2 GAS 0.0000 1900.0 0.0000 40 Nozzle Shell Outlet 450.00 10. None 300 0. N 0.0000 GR 2.5 SA-240 347H 40 Nozzle Shell Inlet 1551.0 8. 40 300 180. N 0.0000 GR 2.5 SA-240 347H

mm mm mm MPa C MPa C MPa MPa MPa kg/cm mm MPa

mm mm kg/cm

mm in.

mm in.

-------------------------------------------------------------------Element From Node Element To Node Element Type Description Distance "FROM" to "TO" Inside Diameter Element Thickness Internal Corrosion Allowance Nominal Thickness External Corrosion Allowance Design Internal Pressure 50 60 Cylinder channel tube outlet 915.00 925.00 5.0000 0.0000 5.0000 0.0000 0.3000

mm mm mm mm mm mm MPa

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 External Pressure Chart Name UNS Number Product Form Efficiency, Longitudinal Seam Efficiency, Circumferential Seam Element From Node Detail Type Detail ID Dist. from "FROM" Node / Offset dist Height/Length of Liquid Liquid Density

650 0.0000 650 1.2 SA-240 347H 137.90 53.945 186.17 0.008027 0.0000 140.24 HA-2 S34709 Plate 1. 1. 50 Liquid FLUE GAS 0.0000 915.00 0.0000

C MPa C MPa MPa MPa kg/cm mm MPa

mm mm kg/cm

Element From Node 50 Detail Type Nozzle Detail ID Tube Outlet Dist. from "FROM" Node / Offset dist 459.00 mm Nozzle Diameter 16. in. Nozzle Schedule None Nozzle Class 300 Layout Angle 0. Blind Flange (Y/N) N Weight of Nozzle ( Used if > 0 ) 0.0000 N Grade of Attached Flange GR 2.5 Nozzle Matl SA-240 347H -------------------------------------------------------------------Element From Node 60 Element To Node 70 Element Type Flange Description top flange Distance "FROM" to "TO" 70.000 mm Flange Inside Diameter 925.00 mm Element Thickness 70.000 mm Internal Corrosion Allowance 0.0000 mm Nominal Thickness 70.000 mm External Corrosion Allowance 0.0000 mm Design Internal Pressure 0.3000 MPa Design Temperature Internal Pressure 650 C Design External Pressure 0.0000 MPa Design Temperature External Pressure 650 C Effective Diameter Multiplier 1.2 Material Name SA-182 F347H Allowable Stress, Ambient 137.90 MPa Allowable Stress, Operating 53.945 MPa Allowable Stress, Hydrotest 186.17 MPa Material Density 0.008027 kg/cm P Number Thickness 0.0000 mm Yield Stress, Operating 140.24 MPa External Pressure Chart Name HA-2 UNS Number S34709 Class / Thickness / Grade :: > 5 Product Form Forgings Perform Flange Stress Calculation (Y/N) Y Weight of ANSI B16.5/B16.47 Flange 0.0000 N Class of ANSI B16.5/B16.47 Flange Grade of ANSI B16.5/B16.47 Flange --------------------------------------------------------------------

Element From Node Element To Node Element Type Description Distance "FROM" to "TO" Flange Inside 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 Perform Flange Stress Calculation (Y/N) Weight of ANSI B16.5/B16.47 Flange Class of ANSI B16.5/B16.47 Flange Grade of ANSI B16.5/B16.47 Flange

70 80 Flange top blind flange 42.000 1045.0 42.000 0.0000 42.000 0.0000 0.3000 650 0.0000 650 1.2 SA-182 F347H Y 0.0000 mm mm mm mm mm mm MPa C MPa C

PV Elite is a trademark of Intergraph CADWorx & Analysis Solutions, Inc. 2011

2.Internal Pressure Calculations

Element Thickness, Pressure, Diameter and Allowable Stress : | | Int. Press | Nominal | Total Corr| Element | Allowable | From| To | + Liq. Hd | Thickness | Allowance | Diameter | Stress(SE)| | | MPa | mm | mm | mm | MPa | --------------------------------------------------------------------------btm blind| 0.3000 | 42.000 | ... | 1045.0 | 53.945 | btm flange| 0.3000 | 70.000 | ... | 925.00 | 53.945 | channel tu| 0.3000 | 5.0000 | ... | 925.00 | 53.945 | shell side| 0.3000 | 5.0000 | ... | 925.00 | 147.10 | channel tu| 0.3000 | 5.0000 | ... | 925.00 | 53.945 | top flange| 0.3000 | 70.000 | ... | 925.00 | 53.945 | top blind| 0.3000 | 42.000 | ... | 1045.0 | 53.945 | Element Required Thickness and MAWP : | | Design | M.A.W.P. | M.A.P. | Minimum | Required | From| To | Pressure | Corroded | New & Cold | Thickness | Thickness | | | MPa | MPa | MPa | mm | mm | ---------------------------------------------------------------------------btm blind| 0.30000 | 1.16032 | 4.96440 | 42.0000 | No Calc | btm flange| 0.30000 | 1.16032 | 4.96440 | 70.0000 | No Calc | channel tu| 0.30000 | 0.57942 | 1.48120 | 5.00000 | 2.58075 | shell side| 0.30000 | 1.58002 | 2.54026 | 5.00000 | 1.50000 | channel tu| 0.30000 | 0.57943 | 1.48120 | 5.00000 | 2.58068 | top flange| 0.30000 | 1.16034 | 4.96440 | 70.0000 | No Calc | top blind| 0.30000 | 1.16034 | 4.96440 | 42.0000 | No Calc | Summary of Heat Exchanger Maximum Allowable Working Pressures : Note: The MAWPs and MAPs for the Exchanger elements all appear to be zero or some could not be calculated. Please fill these values in on the main tubesheet tab.

Internal Pressure Calculation Results : ASME Code, Section VIII, Division 1, 2010 Cylindrical Shell From 30 To 40 SA-240 347H at 650 C channel tube inlet Longitudinal Joint: Full Radiography per UW-11(a) Type 1 Circumferential Joint: Full Radiography per UW-11(a) Type 1 Material UNS Number: S34709 Required Thickness due to Internal Pressure [tr]: = (P*R)/(S*E-0.6*P) per UG-27 (c)(1) = (0.300*462.5000)/(53.95*1.00-0.6*0.300) = 2.5808 + 0.0000 = 2.5808 mm Max. Allowable Working Pressure at given Thickness, corroded [MAWP]: Less Operating Hydrostatic Head Pressure of 0.000 MPa = (S*E*t)/(R+0.6*t) per UG-27 (c)(1) = (53.95*1.00*5.0000)/(462.5000+0.6*5.0000) = 0.579 - 0.000 = 0.579 MPa Maximum Allowable Pressure, New and Cold [MAPNC]: = (S*E*t)/(R+0.6*t) per UG-27 (c)(1) = (137.90*1.00*5.0000)/(462.5000+0.6*5.0000) = 1.481 MPa Actual stress at given pressure and thickness, corroded [Sact]: = (P*(R+0.6*t))/(E*t) = (0.300*(462.5000+0.6*5.0000))/(1.00*5.0000) = 27.931 MPa Percent Elongation per UHA-44 (50*tnom/Rf)*(1-Rf/Ro) 0.538 % Note: Please Check Requirements of Table UHA-44 for Elongation limits. Cylindrical Shell From 40 To 50 SB-443 1 at 620 C shell side Longitudinal Joint: Full Radiography per UW-11(a) Type 1 Circumferential Joint: Full Radiography per UW-11(a) Type 1 Material UNS Number: N06625

Required Thickness due to Internal Pressure [tr]: = (P*R)/(S*E-0.6*P) per UG-27 (c)(1) = (0.300*462.5000)/(147.10*1.00-0.6*0.300) = 0.9445 + 0.0000 = 0.9445 mm Note: The thickness required was less than the Code Minimum, therefore the Code Minimum value of 1.5000 mm per UG-16 will be used. Max. Allowable Working Pressure at given Thickness, corroded [MAWP]: Less Operating Hydrostatic Head Pressure of 0.000 MPa = (S*E*t)/(R+0.6*t) per UG-27 (c)(1) = (147.10*1.00*5.0000)/(462.5000+0.6*5.0000) = 1.580 - 0.000 = 1.580 MPa Maximum Allowable Pressure, New and Cold [MAPNC]: = (S*E*t)/(R+0.6*t) per UG-27 (c)(1) = (236.50*1.00*5.0000)/(462.5000+0.6*5.0000) = 2.540 MPa Actual stress at given pressure and thickness, corroded [Sact]: = (P*(R+0.6*t))/(E*t) = (0.300*(462.5000+0.6*5.0000))/(1.00*5.0000) = 27.933 MPa

Cylindrical Shell From 50 To 60 SA-240 347H at 650 C channel tube outlet Longitudinal Joint: Full Radiography per UW-11(a) Type 1 Circumferential Joint: Full Radiography per UW-11(a) Type 1 Material UNS Number: S34709

Required Thickness due to Internal Pressure [tr]: = (P*R)/(S*E-0.6*P) per UG-27 (c)(1) = (0.300*462.5000)/(53.95*1.00-0.6*0.300) = 2.5807 + 0.0000 = 2.5807 mm Max. Allowable Working Pressure at given Thickness, corroded [MAWP]: Less Operating Hydrostatic Head Pressure of 0.000 MPa = (S*E*t)/(R+0.6*t) per UG-27 (c)(1) = (53.95*1.00*5.0000)/(462.5000+0.6*5.0000) = 0.579 - 0.000 = 0.579 MPa Maximum Allowable Pressure, New and Cold [MAPNC]: = (S*E*t)/(R+0.6*t) per UG-27 (c)(1) = (137.90*1.00*5.0000)/(462.5000+0.6*5.0000) = 1.481 MPa Actual stress at given pressure and thickness, corroded [Sact]: = (P*(R+0.6*t))/(E*t) = (0.300*(462.5000+0.6*5.0000))/(1.00*5.0000) = 27.930 MPa Percent Elongation per UHA-44 (50*tnom/Rf)*(1-Rf/Ro) 0.538 % Note: Please Check Requirements of Table UHA-44 for Elongation limits. Hydrostatic Test Pressure Results: Exchanger Shell Side Hydrostatic Test Pressures: Pressure Pressure Pressure Pressure Pressure per per per per per UG99b UG99b[34] 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 0.000 0.627 0.000 0.000 0.000 MPa MPa MPa MPa MPa

Exchanger Channel Side Hydrostatic Test Pressures: Pressure Pressure Pressure Pressure Pressure per per per per per UG99b UG99b[34] 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 0.000 0.997 0.000 0.000 0.000 MPa MPa MPa MPa MPa

Horizontal Test performed per: UG-99b Stresses on Elements due to Hydrostatic Test Pressure: From To Stress Allowable Ratio Pressure Elements Suitable for Internal Pressure. PV Elite is a trademark of Intergraph CADWorx & Analysis Solutions, Inc. 2011

3.TEMA TubeSheet Calculation

Input Echo, TubeSheet Item 1, Description: tubesheet TEMA shell side 0.30 MPa 620.00 C SB-443 1 Tubesheet Design Code Shell Desc. Shell Design Pressure Shell Temperature for Internal Pressure Shell Material

Ps TEMPS

Shell Material UNS Number Shell Allowable Stress at Temperature Shell Allowable Stress at Ambient Shell Thickness Shell Corrosion Allowance Inside Diameter of Shell Mean Metal Temperature for Shell Channel Desc. Channel Design Pressure Channel Temperature for Internal Pressure Channel Material Channel Material UNS Number Channel Allowable Stress at Temperature Channel Allowable Stress at Ambient Channel Thickness Channel Corrosion Allowance Inside Diameter of Channel Mean Metal Temperature for Tubes

Sos Sas Ts Cas Ds Tm Pc TEMPC Soc Sac Tc Cac Dc tm

N06625 147.10 236.50 5.0000 0.0000 925.000 250.00 channel tube 0.30 650.00 SA-240 347H S34709 53.95 137.90 5.0000 0.0000 925.000 361.00

MPa MPa mm mm mm C inlet MPa C MPa MPa mm mm mm C C

Tube Design Temperature Tubtmp 650.00 Tube Material SB-444 2 Tube Material UNS Number N06625 Is This a Welded Tube No Tube Material Specification used Smls. pipe & tube Tube Allowable Stress at Temperature Sot 136.59 Tube Allowable Stress At Ambient Sat 184.10 Tube Yield Stress At Operating Temperature Syt 201.33 Tube Wall Thickness Tt 2.1107 Tube Corrosion Allowance Catt 0.0000 Number of Tubes Holes Ntubs 1049 Tube Layout Pattern Square Tube Outside Diameter do 19.0500 Tube Pitch (Center to Center Spacing) PTube 24.0000 Fillet Weld Leg Groove Weld Leg Design Strength of Weld Tube-Tubesheet Joint Weld Type Is Tube-Tubesheet Joint Tested Tube-Tubesheet Joint Classification Tube Joint Reliability Factor Interface Pressure, after tube expansion Interface Pressure, due to diff. thermal exp. af ag Fd

MPa MPa MPa mm mm mm mm

fr Po Pt

0.0000 mm 0.0000 mm 0.0000 N Seal/No Weld No i 0.7000 1.00 MPa 1.00 MPa 1950.000 1830.000 521.0000 0.8000 48.0000 2779.020 579456.0 mm mm mm mm mm mm

Total Straight Tube Length Lt Straight Tube Length, bet. inner tubsht faces RL Unsupported Tube Length for max. (k*SL) SL Tube end condition corres. to span (SL) k Length of Expanded Portion of Tube l Perimeter of Tube Layout PERI Area of Tube Layout AREA Tubesheet type: Fixed Tubesheet Exchanger Tubesheet Design Metal Temperature TEMPTS Tubesheet Material Tubesheet Material UNS Number Tubesheet Allowable Stress at Temperature Sots Tubesheet Allowable Stress at Ambient Sats Thickness of Tubesheet Tts Tubesheet Corr. Allowance (Shell side) Cats Tubesheet Corr. Allowance (Channel side) Catc Depth of Groove in Tube Sheet hg TEMA Tubesheet class Additional Data for Fixed Tubesheet Exchangers Mean Metal Temperature for Tubesheet Tshm

650.00 SB-446 2 N06625 131.94 184.10 60.0000 0.0000 0.0000 0.0000

C MPa MPa mm mm mm mm R C

407.70

Run Multiple Load Cases for Fixed Tubesheets Is this a Kettle-type configuration Tubesheet Analysis, Tubesheet number 1,Description:tubesheet TEMA Standards, Eighth Edition, 1999, RCB-7 Tubesheets TEMA R-7.131 Minimum Tubesheet Thickness for R-type: TMIN = MAX( do, CONST - ( CATS + CATC ) ) TMIN = MAX( 19.050 , 19.050 - ( 0.000 + 0.000 ) ) TMIN = 19.0500 mm Min. Thickness + CATS + CATC TREQMIN = 19.0500 mm Shellside Fixity Factor, F, per RCB Shellside Effective Diameter, per RCB Tubeside Fixity Factor, F, per RCB Tubeside Effective Diameter, per RCB TEMA Eta factor used in calculation Material Properties for Thermal Expansion Analysis: 7.132 7.132 7.132 7.132 FS GS FC GC ETA

No No

1.0000 925.000 1.0000 925.000 0.5054

mm mm

Shell - TE-4 N06625 Shell - TM-4 N06625 ----------------------------------------------------------------Th. Exp. Coeff. Metal Temperature 250.0 C 0.0000132540 /C Elastic Mod. at Metal Temperature 250.0 C 0.19425E+06 MPa Tubes - TE-4 N06625 Tubes - TM-4 N06625 ----------------------------------------------------------------Th. Exp. Coeff. Metal Temperature 361.0 C 0.0000134332 /C Elastic Mod. at Metal Temperature 361.0 C 0.18805E+06 MPa TubeSheet - TE-4 N06625 TubeSheet - TM-4 N06625 ----------------------------------------------------------------Th. Exp. Coeff. Metal Temperature 407.7 C 0.0000135558 /C Elastic Mod. at Metal Temperature 407.7 C 0.18528E+06 MPa Note: Iterating to compute the required Tubesheet Thickness TEMA RCB-7.132 Required Thickness for Shellside Pressure [Trs]: = FS * GS * SQRT ( PSU / ( ETA * SOTS ) ) / 3.0 = 1.0000 * 925.0000 * SQRT( 1.92 / ( 0.5054 * 131 ) ) / 3.0 = 52.2687 mm TEMA RCB-7.132 Required Thickness for Tubeside Pressure [Trc]: = FC * GC * SQRT ( PTU / ( ETA * SOTS ) ) / 3.0 = 1.0000 * 925.0000 * SQRT( 1.76 / ( 0.5054 * 131 ) ) / 3.0 = 50.0881 mm TEMA RCB-7.132 Required Thickness for Bending + Cats + MAX(Catc, hg): [Treq] = 52.2687 mm Note: Recomputing Eff. pressures (PTU, PSU) at given Tubesheet thickness. TEMA RCB-7.161 J Factor for Thermal Expansion = 1.0 (No TEMA RCB-7.161 K Factor for Thermal Expansion TEMA RCB-7.161 Fq Factor for Thermal Expansion TEMA RCB-7.161 Differential Expansion / Length Expansion Jt.)

0.1281 5.2589 -0.15E-02

TEMA RCB-7.161 Equivalent Differential Thermal Expansion Pressure: PD = 4 * J * ES * TS * DLL / ( DOS - 3.0*TS ) * ( 1.0 + J * RK * FQ ) PD = 4 * 1.0000 * 194247 * 5.0000 * -0.0015 / ( 935.0000 - 3.0 * 5.0000 ) * ( 1.0 + 1.0000 * 0.1281 * 5.2589 ) PD = -3.866 MPa

TEMA RCB 7.163 Effective Shellside Design Pressure: TEMA RCB-7.163 FFs Factor for Shellside Design 0.5551 PSP1 = 0.4 * J * ( 1.5 + K * (1.5 + FFS ) ) = 0.4 * 1.0000 * ( 1.5 + 0.1281 * (1.5 + 0.5551 ) ) PSP2 = ( ( 0.5 - J / 2.0 ) * ( DJ2 / G2 - 1.0 ) = ( ( 0.5 - 1.0000 / 2.0 ) * ( 925.0000 2 /925.0000 PSP3 = 1.0 + J * K * FQ = 1.0 + 1.0000 * 0.1281 * 5.2589 PSP = PS * ( ( PSP1 - PSP2 ) / PSP3 ) = 0.30 * ( ( 0.7053 - 0.0000 ) / 1.6735 ) PSP = 0.126 MPa TEMA RCB-7.163 Effective Shell Side Design Pressure: PSU = Max (absolute) of PSP : 0.13 or PBS : 0.00 or ( PSP - PD ) / 2 : ( 0.13 - -3.87 ) / 2.0 or ( PSP - PD - PBS ) / 2 : ( 0.13 --3.87 -0.00 ) / 2.0 or ( PBS + PD ) / 2 : ( 0.00 + -3.87 ) / 2.0 or ( PSP - PBS ) : ( 0.13 - 0.00 ) PSU = : 1.996 MPa TEMA RCB 7.163 Shellside Shear Design Pressure, PBS=0: PSS = : 1.996 MPa

- 1.0 )

TEMA RCB 7.164 Effective Tubeside Design Pressure: TEMA RCB-7.164, FFt Factor for Tubeside Design 0.7304 PTP1 = 1.0 + 0.4 * J * K * ( 1.5 + FFT ) = 1.0 + 0.4 * 1.0000 * 0.1281 * ( 1.5 + 0.7304 ) PTP2 = 1.0 + J * K * FQ = 1.0 + 1.0000 * 0.1281 * 5.2589 PTP = PT * PTP1 / PTP2 = 0.30 * 1.1143 / 1.6735 PTP = 0.200 MPa TEMA RCB-7.164 Effective Tube Side Design Pressure: PTU = Max (absolute) of : ( PTP + PBT + PD ) / 2 : ( 0.20 +0.00 +-3.87 ) / 2.0 or ( PTP + PBT ) : ( 0.20 + 0.00 ) PTU = : 1.833 MPa TEMA RCB 7.164 Tubeside Shear Design Pressure (PBT=0): PTS = : 1.833 MPa No Shear Calculation, since Pressure is less than 8.9805 MPa MPa

TEMA RCB-7.22 Shell Longitudinal Stress : Max. Effective Pressure for Longitudinal Stress, 3.966

TEMA RCB-7.22 Maximum Shell Longitudinal Stress : STSMAX = PSSMAX * CS * ( DOS - TS )/( 4 * TS ) STSMAX = 3.97 * 0.50 * ( 935.0000 - 5.0000 ) / ( 4 * 5.0000 ) STSMAX = 92. MPa TEMA RCB-7.22 Allowable Shell Longitudinal Stress : STSALL = 147. MPa TEMA RCB-7.23 Tube Longitudinal Stress Results : Max. Effective Pressure for Longitudinal Stress, 0.158 MPa Min. Effective Pressure for Longitudinal Stress, -3.961 MPa TEMA RCB-7.23 Maximum Tube Long. Stress (Tension): STTMAX = PTTMAX*CT*FQ*G*G /(4*NTUBS*TT*(do-TT)) STTMAX = 0.16 *1.00 *5.26 *925.0000 *925.0000 / ( 4*1049 *2.1107 *(19.0500 -2.1107 ) ) STTMAX = 4.74 MPa TEMA RCB-7.23 Allowable Tube Long. Stress (Tension): STTALL = 136.59 MPa TEMA RCB-7.23 Minimum Tube Comp. Longitudinal Stress :

STTMIN = PTTMIN*CT*FQ*G*G/(4*NTUBS*TT*(do-TT)) STTMIN = -3.96 *1.00 *5.26 *925.0000 *925.0000 / ( 4*1049 *2.1107 *(19.0500 -2.1107 ) ) STTMIN = -118.79 MPa TEMA RCB-7.24 Allowable Tube Compressive Stress : STTCOM = -SYT*(1-RKLR/(2*CC))/FSAF STTCOM = -201 * ( 1.0 -69.0610 / ( 2.0 *135.7813 ) ) / 1.25 STTCOM = -120.11 MPa TEMA RCB-7.25 Tube-To-Tubesheet Joint Load : Effective Pressure for Tube-to-Tubesheet Load : 0.158 MPa

TEMA RCB-7.25 Actual Tube-To-Tubesheet Load : WJ = PI * FQ * PTLOAD * G * G / ( 4.0 * NTUBS ) WJ = 3.14 * 5.26 * 0.158 * 925.00 * 925.00 / ( 4.0 * 1049 ) WJ = 532.52 N Allowable Tube-To-Tubesheet Load per ASME App. A [Lmax]: = (PI/4)*(DT-(DT-2*TT))*SOT*fr*fe*fy*ft = .785*(19.050-(19.050-2*2.1107))*136*0.70*1.00*1.00*2.00 = 21477.33 N Summary of Tubesheet Results: -----------------------------------------------------------------------Condition Req Thk Actual Thk Actual Allow Result (+CA) (mm) Stress (MPa) -----------------------------------------------------------------------Bending 52.269 60.000 156.45 197.92 Ok -----------------------------------------------------------------------Longitudinal stresses: -------------------------------------------------------------------Compressive Tensile Condition Actual Allow Actual Allow Result -------------------------------------------------------------------Shell 0.000 0.000 92.216 147.103 Ok Long Tubes -118.793 120.106 4.741 136.587 Ok Tube Load 532.516 21477.330 Ok -------------------------------------------------------------------Equivalent Differential Ther. Expansion Pressure -3.8660 MPa Shellside Prime Pressure 0.1264 MPa Tubeside Prime Pressure 0.1997 MPa Maximum Axial Differential Thermal Expansion between Shell and Tubes: Tube has higher Thermal growth (Exp. Jt. Extension) : +2.804 mm PV Elite is a trademark of Intergraph CADWorx & Analysis Solutions, Inc. 2011

4.Vessel Design Summary

Design Code: ASME Code Section VIII Division 1, 2010 Diameter Spec : 925.000 mm ID Vessel Design Length, Tangent to Tangent Distance of Bottom Tangent above Grade Distance of Base above Grade Specified Datum Line Distance Shell Material Specification Shell Material Specification Stiffening Ring Material Specification Shell Side Design Temperature Channel Side Design Temperature 4115.00 0.00 0.00 0.00 mm mm mm mm

SA-240 347H SB-443 1 620 650 C C

Shell Side Design Pressure Channel Side Design Pressure Shell Side Hydrostatic Test Pressure Channel Side Hydrostatic Test Pressure Wind Design Code Earthquake Design Code Element Pressures and MAWP: MPa Element Desc

0.300 0.300 0.000 0.000

MPa MPa MPa MPa ASCE-93 UBC-94

| Design Pres. | External | M.A.W.P | Corrosion | + Stat. head | Pressure | | Allowance --------------------------------------------------------------------btm blind flange 0.300 0.000 1.160 0.0000 btm flange 0.300 0.000 1.160 0.0000 channel tube inlet 0.300 0.000 0.579 0.0000 shell side 0.300 0.000 1.580 0.0000 channel tube outlet 0.300 0.000 0.579 0.0000 top flange 0.300 0.000 1.160 0.0000 top blind flange 0.300 0.000 1.160 0.0000 Liquid Level: 3831.00 mm Dens.: 0.000 kg/cm Sp. Gr.: 0.000

Stiffener Ring Specifications: Elevation mm Selected Type 1128.00 3077.97

User Description

Element "To" Elev Length Element Thk R e q d T h k Joint Eff Type mm mm mm Int. Ext. Long Circ ----------------------------------------------------------------------Body Flg 42.0 42.0 42.0 No Cal ------- 1.00 1.00 Body Flg 112.0 70.0 70.0 No Cal ------- 1.00 1.00 Cylinder 1128.0 1016.0 5.0 2.6 ------- 1.00 1.00 Cylinder 3028.0 1900.0 5.0 1.5 ------- 1.00 1.00 Cylinder 4003.0 915.0 5.0 2.6 ------- 1.00 1.00 Body Flg 4073.0 70.0 70.0 No Cal ------- 1.00 1.00 Body Flg 4115.0 42.0 42.0 No Cal ------- 1.00 1.00 Element thicknesses are shown as Nominal if specified, otherwise are Minimum

Note: Wind and Earthquake moments include the effects of user defined forces and moments if any exist in the job and were specified to act (compute loads and stresses) during these cases. Also included are moment effects due to eccentric weights if any are present in the input. 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)

4058.7 6192.4 4058.7 4058.7 4058.7 4060.2 6545.5

kg kg kg kg kg kg kg

PV Elite is a trademark of Intergraph CADWorx & Analysis Solutions, Inc. 2011

5.Perhitungan Hydrostatic Test Pressure : untuk shell side dibatasi oleh MAWP dari Nozzle shell inlet yaitu 0.729 MPa, maka hydrostatic test pressurenya adalah : = 1.3 * MAWP * (Sa/S) = 1.3 * 0.729 * (137.9 / 73.44) = 1.78 MPa Untuk channel side dibatasi oleh MAWP dari Channel tube inlet yaitu 0.57942 MPa, maka hydrostatic test pressurenya adalah : = 1.3 * MAWP * (Sa/S) = 1.3 * 0.57942 * (2.556) = 1.925 MPa

B. Untuk case 2.

Gambar 1.3. Hasil Design dengan PV Elite 2011

Rincian hasil perhitungannya : 1.Input Data

PV Elite Vessel Analysis Program: Input Data Exchanger Design Pressures and Temperatures Shell Side Design Pressure Channel Side Design Pressure Shell Side Design Temperature Channel Side Design 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 Miscellaneous Weight Percent 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) 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 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 [V] 0.3000 0.3000 620 650 UG99-b Horizontal 0.0000 0.0000 0 Welded None RT 1 0. Y Y N N N N N Yes 0.0000 0.0000 0.0000 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 ASCE-7 93 150.00 C: Open Terrain 1. Moderately Smooth 0.0000 70. N 0.0100 0.0000 0.0000 UBC 94 1.000 1.250 km/hr MPa MPa C C

mm mm C

MPa MPa MPa

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

mm

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

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 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 Material Database 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 Complete Listing of Vessel Elements and Details: Element From Node Element To Node Element Type Description Distance "FROM" to "TO" Flange Inside 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 External Pressure Chart Name UNS Number Class / Thickness / Grade :: > 5 Product Form Perform Flange Stress Calculation (Y/N) Weight of ANSI B16.5/B16.47 Flange Class of ANSI B16.5/B16.47 Flange Grade of ANSI B16.5/B16.47 Flange

S1 3.000 0.000 Y N Y N

Current w/Addenda or Code Year

No Yes Yes Yes No Yes No

10 20 Flange btm blind flange 30.000 740.00 30.000 0.0000 30.000 0.0000 0.3000 650 0.0000 650 1.2 SA-182 F347H 137.90 53.945 186.17 0.008027 0.0000 140.24 HA-2 S34709 Forgings Y 0.0000 mm mm mm mm mm mm MPa C MPa C MPa MPa MPa kg/cm mm MPa

-------------------------------------------------------------------Element From Node Element To Node Element Type Description Distance "FROM" to "TO" Flange Inside Diameter Element Thickness Internal Corrosion Allowance Nominal Thickness External Corrosion Allowance Design Internal Pressure Design Temperature Internal Pressure 20 30 Flange btm flange 55.000 625.00 55.000 0.0000 55.000 0.0000 0.3000 650 mm mm mm mm mm mm MPa C

Design External Pressure Design Temperature External Pressure Effective Diameter Multiplier Material Name Perform Flange Stress Calculation (Y/N) Weight of ANSI B16.5/B16.47 Flange Class of ANSI B16.5/B16.47 Flange Grade of ANSI B16.5/B16.47 Flange

0.0000 650 1.2 SA-182 F347H Y 0.0000

MPa C

-------------------------------------------------------------------Element From Node Element To Node Element Type Description Distance "FROM" to "TO" Inside 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 External Pressure Chart Name UNS Number Product Form Efficiency, Longitudinal Seam Efficiency, Circumferential Seam Element From Node Detail Type Detail ID Dist. from "FROM" Node / Offset dist Height/Length of Liquid Liquid Density 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 channel tube inlet 815.00 625.00 5.0000 0.0000 5.0000 0.0000 0.3000 650 0.0000 650 1.2 SA-240 347H 137.90 53.945 186.17 0.008027 0.0000 140.24 HA-2 S34709 Plate 1. 1. 30 Liquid FLUE GAS 0.0000 815.00 0.0000 30 Nozzle Tube Inlet 407.50 14. None 300 180. N 0.0000 GR 2.5 SA-240 347H

mm mm mm mm mm mm MPa C MPa C MPa MPa MPa kg/cm mm MPa

mm mm kg/cm

mm in.

-------------------------------------------------------------------Element From Node Element To Node Element Type Description Distance "FROM" to "TO" Inside Diameter Element Thickness 40 50 Cylinder shell side 2900.0 625.00 5.0000

mm mm mm

Internal Corrosion Allowance 0.0000 Nominal Thickness 5.0000 External Corrosion Allowance 0.0000 Design Internal Pressure 0.3000 Design Temperature Internal Pressure 620 Design External Pressure 0.0000 Design Temperature External Pressure 620 Effective Diameter Multiplier 1.2 Material Name SB-443 1 Allowable Stress, Ambient 236.50 Allowable Stress, Operating 147.10 Allowable Stress, Hydrotest 372.33 Material Density 0.008442 P Number Thickness 0.0000 Yield Stress, Operating 282.70 External Pressure Chart Name NFN-17 UNS Number N06625 Class / Thickness / Grade Annealed:: Product Form Plate, sheet, strip Efficiency, Longitudinal Seam 1. Efficiency, Circumferential Seam 1. Element From Node Detail Type Detail ID Dist. from "FROM" Node / Offset dist Height/Length of Liquid Liquid Density 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 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 40 Liquid SO2 GAS 0.0000 2900.0 0.0000 40 Nozzle Shell Outlet 285.75 10. None 300 0. N 0.0000 GR 2.5 SA-240 347H 40 Nozzle Shell Inlet 2700.0 8. 40 300 180. N 0.0000 GR 2.5 SA-240 347H

mm mm mm MPa C MPa C MPa MPa MPa kg/cm mm MPa

mm mm kg/cm

mm in.

mm in.

-------------------------------------------------------------------Element From Node Element To Node Element Type Description Distance "FROM" to "TO" Inside Diameter Element Thickness Internal Corrosion Allowance Nominal Thickness External Corrosion Allowance Design Internal Pressure 50 60 Cylinder channel tube outlet 711.00 625.00 5.0000 0.0000 5.0000 0.0000 0.3000

mm mm mm mm mm mm MPa

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 External Pressure Chart Name UNS Number Product Form Efficiency, Longitudinal Seam Efficiency, Circumferential Seam Element From Node Detail Type Detail ID Dist. from "FROM" Node / Offset dist Height/Length of Liquid Liquid Density

650 0.0000 650 1.2 SA-240 347H 137.90 53.945 186.17 0.008027 0.0000 140.24 HA-2 S34709 Plate 1. 1. 50 Liquid FLUE GAS 0.0000 711.00 0.0000

C MPa C MPa MPa MPa kg/cm mm MPa

mm mm kg/cm

Element From Node 50 Detail Type Nozzle Detail ID Tube Outlet Dist. from "FROM" Node / Offset dist 356.00 mm Nozzle Diameter 12. in. Nozzle Schedule None Nozzle Class 300 Layout Angle 0. Blind Flange (Y/N) N Weight of Nozzle ( Used if > 0 ) 0.0000 N Grade of Attached Flange GR 2.5 Nozzle Matl SA-240 347H -------------------------------------------------------------------Element From Node 60 Element To Node 70 Element Type Flange Description top flange Distance "FROM" to "TO" 55.000 mm Flange Inside Diameter 625.00 mm Element Thickness 55.000 mm Internal Corrosion Allowance 0.0000 mm Nominal Thickness 55.000 mm External Corrosion Allowance 0.0000 mm Design Internal Pressure 0.3000 MPa Design Temperature Internal Pressure 650 C Design External Pressure 0.0000 MPa Design Temperature External Pressure 650 C Effective Diameter Multiplier 1.2 Material Name SA-182 F347H Allowable Stress, Ambient 137.90 MPa Allowable Stress, Operating 53.945 MPa Allowable Stress, Hydrotest 186.17 MPa Material Density 0.008027 kg/cm P Number Thickness 0.0000 mm Yield Stress, Operating 140.24 MPa External Pressure Chart Name HA-2 UNS Number S34709 Class / Thickness / Grade :: > 5 Product Form Forgings Perform Flange Stress Calculation (Y/N) Y Weight of ANSI B16.5/B16.47 Flange 0.0000 N Class of ANSI B16.5/B16.47 Flange Grade of ANSI B16.5/B16.47 Flange --------------------------------------------------------------------

Element From Node Element To Node Element Type Description Distance "FROM" to "TO" Flange Inside 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 Perform Flange Stress Calculation (Y/N) Weight of ANSI B16.5/B16.47 Flange Class of ANSI B16.5/B16.47 Flange Grade of ANSI B16.5/B16.47 Flange

70 80 Flange top blind flange 30.000 740.00 30.000 0.0000 30.000 0.0000 0.3000 650 0.0000 650 1.2 SA-182 F347H Y 0.0000 mm mm mm mm mm mm MPa C MPa C

PV Elite is a trademark of Intergraph CADWorx & Analysis Solutions, Inc. 2011

2.Internal Pressure Calculation

Element Thickness, Pressure, Diameter and Allowable Stress : | | Int. Press | Nominal | Total Corr| Element | Allowable | From| To | + Liq. Hd | Thickness | Allowance | Diameter | Stress(SE)| | | MPa | mm | mm | mm | MPa | --------------------------------------------------------------------------btm blind| 0.3000 | 30.000 | ... | 740.00 | 53.945 | btm flange| 0.3000 | 55.000 | ... | 625.00 | 53.945 | channel tu| 0.3000 | 5.0000 | ... | 625.00 | 53.945 | shell side| 0.3000 | 5.0000 | ... | 625.00 | 147.10 | channel tu| 0.3000 | 5.0000 | ... | 625.00 | 53.945 | top flange| 0.3000 | 55.000 | ... | 625.00 | 53.945 | top blind| 0.3000 | 30.000 | ... | 740.00 | 53.945 | Element Required Thickness and MAWP : | | Design | M.A.W.P. | M.A.P. | Minimum | Required | From| To | Pressure | Corroded | New & Cold | Thickness | Thickness | | | MPa | MPa | MPa | mm | mm | ---------------------------------------------------------------------------btm blind| 0.30000 | 1.16032 | 4.96440 | 30.0000 | No Calc | btm flange| 0.30000 | 1.40690 | 4.96440 | 55.0000 | No Calc | channel tu| 0.30000 | 0.85491 | 2.18542 | 5.00000 | 1.74377 | shell side| 0.30000 | 2.33122 | 3.74800 | 5.00000 | 1.50000 | channel tu| 0.30000 | 0.85492 | 2.18542 | 5.00000 | 1.74370 | top flange| 0.30000 | 1.40691 | 4.96440 | 55.0000 | No Calc | top blind| 0.30000 | 1.16034 | 4.96440 | 30.0000 | No Calc | Summary of Heat Exchanger Maximum Allowable Working Pressures : Note: The MAWPs and MAPs for the Exchanger elements all appear to be zero or some could not be calculated. Please fill these values in on the main tubesheet tab.

Internal Pressure Calculation Results : ASME Code, Section VIII, Division 1, 2010 Cylindrical Shell From 30 To 40 SA-240 347H at 650 C channel tube inlet Longitudinal Joint: Full Radiography per UW-11(a) Type 1 Circumferential Joint: Full Radiography per UW-11(a) Type 1 Material UNS Number: S34709 Required Thickness due to Internal Pressure [tr]: = (P*R)/(S*E-0.6*P) per UG-27 (c)(1) = (0.300*312.5000)/(53.95*1.00-0.6*0.300) = 1.7438 + 0.0000 = 1.7438 mm Max. Allowable Working Pressure at given Thickness, corroded [MAWP]: Less Operating Hydrostatic Head Pressure of 0.000 MPa = (S*E*t)/(R+0.6*t) per UG-27 (c)(1) = (53.95*1.00*5.0000)/(312.5000+0.6*5.0000) = 0.855 - 0.000 = 0.855 MPa Maximum Allowable Pressure, New and Cold [MAPNC]: = (S*E*t)/(R+0.6*t) per UG-27 (c)(1) = (137.90*1.00*5.0000)/(312.5000+0.6*5.0000) = 2.185 MPa Actual stress at given pressure and thickness, corroded [Sact]: = (P*(R+0.6*t))/(E*t) = (0.300*(312.5000+0.6*5.0000))/(1.00*5.0000) = 18.931 MPa Percent Elongation per UHA-44 (50*tnom/Rf)*(1-Rf/Ro) 0.794 % Note: Please Check Requirements of Table UHA-44 for Elongation limits. Cylindrical Shell From 40 To 50 SB-443 1 at 620 C shell side Longitudinal Joint: Full Radiography per UW-11(a) Type 1 Circumferential Joint: Full Radiography per UW-11(a) Type 1 Material UNS Number: N06625

Required Thickness due to Internal Pressure [tr]: = (P*R)/(S*E-0.6*P) per UG-27 (c)(1) = (0.300*312.5000)/(147.10*1.00-0.6*0.300) = 0.6382 + 0.0000 = 0.6382 mm Note: The thickness required was less than the Code Minimum, therefore the Code Minimum value of 1.5000 mm per UG-16 will be used. Max. Allowable Working Pressure at given Thickness, corroded [MAWP]: Less Operating Hydrostatic Head Pressure of 0.000 MPa = (S*E*t)/(R+0.6*t) per UG-27 (c)(1) = (147.10*1.00*5.0000)/(312.5000+0.6*5.0000) = 2.331 - 0.000 = 2.331 MPa Maximum Allowable Pressure, New and Cold [MAPNC]: = (S*E*t)/(R+0.6*t) per UG-27 (c)(1) = (236.50*1.00*5.0000)/(312.5000+0.6*5.0000) = 3.748 MPa Actual stress at given pressure and thickness, corroded [Sact]: = (P*(R+0.6*t))/(E*t) = (0.300*(312.5000+0.6*5.0000))/(1.00*5.0000) = 18.933 MPa

Cylindrical Shell From 50 To 60 SA-240 347H at 650 C channel tube outlet Longitudinal Joint: Full Radiography per UW-11(a) Type 1 Circumferential Joint: Full Radiography per UW-11(a) Type 1 Material UNS Number: S34709

Required Thickness due to Internal Pressure [tr]: = (P*R)/(S*E-0.6*P) per UG-27 (c)(1) = (0.300*312.5000)/(53.95*1.00-0.6*0.300) = 1.7437 + 0.0000 = 1.7437 mm Max. Allowable Working Pressure at given Thickness, corroded [MAWP]: Less Operating Hydrostatic Head Pressure of 0.000 MPa = (S*E*t)/(R+0.6*t) per UG-27 (c)(1) = (53.95*1.00*5.0000)/(312.5000+0.6*5.0000) = 0.855 - 0.000 = 0.855 MPa Maximum Allowable Pressure, New and Cold [MAPNC]: = (S*E*t)/(R+0.6*t) per UG-27 (c)(1) = (137.90*1.00*5.0000)/(312.5000+0.6*5.0000) = 2.185 MPa Actual stress at given pressure and thickness, corroded [Sact]: = (P*(R+0.6*t))/(E*t) = (0.300*(312.5000+0.6*5.0000))/(1.00*5.0000) = 18.930 MPa Percent Elongation per UHA-44 (50*tnom/Rf)*(1-Rf/Ro) 0.794 % Note: Please Check Requirements of Table UHA-44 for Elongation limits. Hydrostatic Test Pressure Results: Exchanger Shell Side Hydrostatic Test Pressures: Pressure Pressure Pressure Pressure Pressure per per per per per UG99b UG99b[34] 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 0.000 0.627 0.000 0.000 0.000 MPa MPa MPa MPa MPa

Exchanger Channel Side Hydrostatic Test Pressures: Pressure Pressure Pressure Pressure Pressure per per per per per UG99b UG99b[34] 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 0.000 0.997 0.000 0.000 0.000 MPa MPa MPa MPa MPa

Horizontal Test performed per: UG-99b Stresses on Elements due to Hydrostatic Test Pressure: From To Stress Elements Suitable for Internal Pressure. Allowable Ratio Pressure

PV Elite is a trademark of Intergraph CADWorx & Analysis Solutions, Inc. 2011

3.TEMA Tubesheet Calculation

Input Echo, TubeSheet Item 1, Description: tubesheet TEMA shell side 0.30 MPa 620.00 C SB-443 1 N06625 Tubesheet Design Code Shell Desc. Shell Design Pressure Shell Temperature for Internal Pressure Shell Material Shell Material UNS Number

Ps TEMPS

Shell Allowable Stress at Temperature Shell Allowable Stress at Ambient Shell Thickness Shell Corrosion Allowance Inside Diameter of Shell Mean Metal Temperature for Shell Channel Desc. Channel Design Pressure Channel Temperature for Internal Pressure Channel Material Channel Material UNS Number Channel Allowable Stress at Temperature Channel Allowable Stress at Ambient Channel Thickness Channel Corrosion Allowance Inside Diameter of Channel Mean Metal Temperature for Tubes

Sos Sas Ts Cas Ds Tm Pc TEMPC Soc Sac Tc Cac Dc tm

147.10 236.50 5.0000 0.0000 625.000 250.00 channel tube 0.30 650.00 SA-240 347H S34709 53.95 137.90 5.0000 0.0000 625.000 356.10

MPa MPa mm mm mm C inlet MPa C MPa MPa mm mm mm C C

Tube Design Temperature Tubtmp 650.00 Tube Material SB-444 2 Tube Material UNS Number N06625 Is This a Welded Tube No Tube Material Specification used Smls. pipe & tube Tube Allowable Stress at Temperature Sot 131.94 Tube Allowable Stress At Ambient Sat 184.10 Tube Yield Stress At Operating Temperature Syt 201.33 Tube Wall Thickness Tt 2.1107 Tube Corrosion Allowance Catt 0.0000 Number of Tubes Holes Ntubs 749 Tube Layout Pattern Square Tube Outside Diameter do 12.7000 Tube Pitch (Center to Center Spacing) PTube 19.0500 Fillet Weld Leg Groove Weld Leg Design Strength of Weld Tube-Tubesheet Joint Weld Type Is Tube-Tubesheet Joint Tested Tube-Tubesheet Joint Classification Tube Joint Reliability Factor Interface Pressure, after tube expansion Interface Pressure, due to diff. thermal exp. af ag Fd

MPa MPa MPa mm mm mm mm

fr Po Pt

0.0000 mm 0.0000 mm 0.0000 N Seal/No Weld No i 0.7000 1.00 MPa 1.00 MPa 3150.000 2650.000 500.0000 0.8000 200.0000 1851.500 258387.0 650.00 SB-446 2 N06625 131.94 184.10 250.0000 0.0000 0.0000 0.0000 mm mm mm mm mm mm C MPa MPa mm mm mm mm R C

Total Straight Tube Length Lt Straight Tube Length, bet. inner tubsht faces RL Unsupported Tube Length for max. (k*SL) SL Tube end condition corres. to span (SL) k Length of Expanded Portion of Tube l Perimeter of Tube Layout PERI Area of Tube Layout AREA Tubesheet type: Fixed Tubesheet Exchanger Tubesheet Design Metal Temperature TEMPTS Tubesheet Material Tubesheet Material UNS Number Tubesheet Allowable Stress at Temperature Sots Tubesheet Allowable Stress at Ambient Sats Thickness of Tubesheet Tts Tubesheet Corr. Allowance (Shell side) Cats Tubesheet Corr. Allowance (Channel side) Catc Depth of Groove in Tube Sheet hg TEMA Tubesheet class Additional Data for Fixed Tubesheet Exchangers Mean Metal Temperature for Tubesheet Tshm Run Multiple Load Cases for Fixed Tubesheets Is this a Kettle-type configuration

403.05 No No

Tubesheet Analysis, Tubesheet number 1,Description:tubesheet TEMA Standards, Eighth Edition, 1999, RCB-7 Tubesheets TEMA R-7.131 Minimum Tubesheet Thickness for R-type: TMIN = MAX( do, CONST - ( CATS + CATC ) ) TMIN = MAX( 12.700 , 19.050 - ( 0.000 + 0.000 ) ) TMIN = 19.0500 mm Min. Thickness + CATS + CATC TREQMIN = 19.0500 mm Shellside Fixity Factor, F, per RCB Shellside Effective Diameter, per RCB Tubeside Fixity Factor, F, per RCB Tubeside Effective Diameter, per RCB TEMA Eta factor used in calculation Material Properties for Thermal Expansion Analysis: Shell - TE-4 N06625 Shell - TM-4 N06625 ----------------------------------------------------------------Th. Exp. Coeff. Metal Temperature 250.0 C 0.0000132540 /C Elastic Mod. at Metal Temperature 250.0 C 0.19425E+06 MPa Tubes - TE-4 N06625 Tubes - TM-4 N06625 ----------------------------------------------------------------Th. Exp. Coeff. Metal Temperature 356.1 C 0.0000134015 /C Elastic Mod. at Metal Temperature 356.1 C 0.18829E+06 MPa TubeSheet - TE-4 N06625 TubeSheet - TM-4 N06625 ----------------------------------------------------------------Th. Exp. Coeff. Metal Temperature 403.0 C 0.0000135257 /C Elastic Mod. at Metal Temperature 403.0 C 0.18556E+06 MPa Note: Iterating to compute the required Tubesheet Thickness TEMA RCB-7.132 Required Thickness for Shellside Pressure [Trs]: = FS * GS * SQRT ( PSU / ( ETA * SOTS ) ) / 3.0 = 1.0000 * 625.0000 * SQRT( 2.41 / ( 0.6511 * 131 ) ) / 3.0 = 34.8802 mm TEMA RCB-7.132 Required Thickness for Tubeside Pressure [Trc]: = FC * GC * SQRT ( PTU / ( ETA * SOTS ) ) / 3.0 = 1.0000 * 625.0000 * SQRT( 2.26 / ( 0.6511 * 131 ) ) / 3.0 = 33.7696 mm TEMA RCB-7.132 Required Thickness for Bending + Cats + MAX(Catc, hg): [Treq] = 34.8802 mm Note: Recomputing Eff. pressures (PTU, PSU) at given Tubesheet thickness. TEMA RCB-7.161 J Factor for Thermal Expansion = 1.0 (No TEMA RCB-7.161 K Factor for Thermal Expansion TEMA RCB-7.161 Fq Factor for Thermal Expansion TEMA RCB-7.161 Differential Expansion / Length Expansion Jt.) 7.132 7.132 7.132 7.132 FS GS FC GC ETA 1.0000 625.000 1.0000 625.000 0.6511 mm mm

0.1941 1.3012 -0.15E-02

TEMA RCB-7.161 Equivalent Differential Thermal Expansion Pressure: PD = 4 * J * ES * TS * DLL / ( DOS - 3.0*TS ) * ( 1.0 + J * RK * FQ ) PD = 4 * 1.0000 * 194247 * 5.0000 * -0.0015 / ( 635.0001 - 3.0 * 5.0000 ) * ( 1.0 + 1.0000 * 0.1941 * 1.3012 ) PD = -7.282 MPa TEMA RCB 7.163 Effective Shellside Design Pressure: TEMA RCB-7.163 FFs Factor for Shellside Design 0.6907

PSP1 = = PSP2 = = PSP3 = = PSP = = PSP =

0.4 * J * ( 1.5 + K * (1.5 + FFS ) ) 0.4 * 1.0000 * ( 1.5 + 0.1941 * (1.5 + 0.6907 ) ) ( ( 0.5 - J / 2.0 ) * ( DJ2 / G2 - 1.0 ) ( ( 0.5 - 1.0000 / 2.0 ) * ( 625.0000 2 /625.0000 1.0 + J * K * FQ 1.0 + 1.0000 * 0.1941 * 1.3012 PS * ( ( PSP1 - PSP2 ) / PSP3 ) 0.30 * ( ( 0.7701 - 0.0000 ) / 1.2526 ) 0.184 MPa

- 1.0 )

TEMA RCB-7.163 Effective Shell Side Design Pressure: PSU = Max (absolute) of PSP : 0.18 or PBS : 0.00 or ( PSP - PD ) / 2 : ( 0.18 - -7.28 ) / 2.0 or ( PSP - PD - PBS ) / 2 : ( 0.18 --7.28 -0.00 ) / 2.0 or ( PBS + PD ) / 2 : ( 0.00 + -7.28 ) / 2.0 or ( PSP - PBS ) : ( 0.18 - 0.00 ) PSU = : 3.733 MPa TEMA RCB 7.163 Shellside Shear Design Pressure, PBS=0: PSS = : 3.733 MPa TEMA RCB 7.164 Effective Tubeside Design Pressure: TEMA RCB-7.164, FFt Factor for Tubeside Design 0.8622 PTP1 = 1.0 + 0.4 * J * K * ( 1.5 + FFT ) = 1.0 + 0.4 * 1.0000 * 0.1941 * ( 1.5 + 0.8622 ) PTP2 = 1.0 + J * K * FQ = 1.0 + 1.0000 * 0.1941 * 1.3012 PTP = PT * PTP1 / PTP2 = 0.30 * 1.1834 / 1.2526 PTP = 0.283 MPa TEMA RCB-7.164 Effective Tube Side Design Pressure: PTU = Max (absolute) of : ( PTP + PBT + PD ) / 2 : ( 0.28 +0.00 +-7.28 ) / 2.0 or ( PTP + PBT ) : ( 0.28 + 0.00 ) PTU = : 3.499 MPa TEMA RCB 7.164 Tubeside Shear Design Pressure (PBT=0): PTS = : 3.499 MPa No Shear Calculation, since Pressure is less than 23.4568 MPa TEMA RCB-7.22 Shell Longitudinal Stress : Max. Effective Pressure for Longitudinal Stress, 7.298 MPa TEMA RCB-7.22 Maximum Shell Longitudinal Stress : STSMAX = PSSMAX * CS * ( DOS - TS )/( 4 * TS ) STSMAX = 7.30 * 0.50 * ( 635.0001 - 5.0000 ) / ( 4 * 5.0000 ) STSMAX = 115. MPa TEMA RCB-7.22 Allowable Shell Longitudinal Stress : STSALL = 147. MPa TEMA RCB-7.23 Tube Longitudinal Stress Results : Max. Effective Pressure for Longitudinal Stress, 0.085 MPa Min. Effective Pressure for Longitudinal Stress, -7.307 MPa TEMA RCB-7.23 Maximum Tube Long. Stress (Tension): STTMAX = PTTMAX*CT*FQ*G*G /(4*NTUBS*TT*(do-TT)) STTMAX = 0.08 *1.00 *1.30 *625.0000 *625.0000 / ( 4*749 *2.1107 *(12.7000 -2.1107 ) ) STTMAX = 0.64 MPa TEMA RCB-7.23 Allowable Tube Long. Stress (Tension): STTALL = 131.94 MPa TEMA RCB-7.23 Minimum Tube Comp. Longitudinal Stress : STTMIN = PTTMIN*CT*FQ*G*G/(4*NTUBS*TT*(do-TT)) STTMIN = -7.31 *1.00 *1.30 *625.0000 *625.0000 / ( 4*749 *2.1107 *(12.7000 -2.1107 ) ) STTMIN = -55.46 MPa

TEMA RCB-7.24 Allowable Tube Compressive Stress : STTCOM = -SYT*(1-RKLR/(2*CC))/FSAF STTCOM = -201 * ( 1.0 -104.7801 / ( 2.0 *135.8691 ) ) / 2.00 STTCOM = -61.85 MPa TEMA RCB-7.25 Tube-To-Tubesheet Joint Load : Effective Pressure for Tube-to-Tubesheet Load : 0.085 MPa

TEMA RCB-7.25 Actual Tube-To-Tubesheet Load : WJ = PI * FQ * PTLOAD * G * G / ( 4.0 * NTUBS ) WJ = 3.14 * 1.30 * 0.085 * 625.00 * 625.00 / ( 4.0 * 749 ) WJ = 45.11 N Allowable Tube-To-Tubesheet Load per ASME App. A [Lmax]: = (PI/4)*(DT-(DT-2*TT))*SOT*fr*fe*fy*ft = .785*(12.700-(12.700-2*2.1107))*131*0.70*1.00*1.00*2.00 = 12969.78 N Summary of Tubesheet Results: -----------------------------------------------------------------------Condition Req Thk Actual Thk Actual Allow Result (+CA) (mm) Stress (MPa) -----------------------------------------------------------------------Bending 34.880 250.000 5.97 197.92 Ok -----------------------------------------------------------------------Longitudinal stresses: -------------------------------------------------------------------Compressive Tensile Condition Actual Allow Actual Allow Result -------------------------------------------------------------------Shell 0.000 0.000 114.951 147.103 Ok Long Tubes -55.463 61.851 0.643 131.945 Ok Tube Load 45.115 12969.783 Ok -------------------------------------------------------------------Equivalent Differential Ther. Expansion Pressure -7.2819 MPa Shellside Prime Pressure 0.1844 MPa Tubeside Prime Pressure 0.2834 MPa Maximum Axial Differential Thermal Expansion between Shell and Tubes: Tube has higher Thermal growth (Exp. Jt. Extension) : +3.857 mm PV Elite is a trademark of Intergraph CADWorx & Analysis Solutions, Inc. 2011

4.Vessel Design Summary

Design Code: ASME Code Section VIII Division 1, 2010 Diameter Spec : 625.000 mm ID Vessel Design Length, Tangent to Tangent Distance of Bottom Tangent above Grade Distance of Base above Grade Specified Datum Line Distance Shell Material Specification Shell Material Specification Stiffening Ring Material Specification Shell Side Design Temperature Channel Side Design Temperature Shell Side Design Pressure Channel Side Design Pressure Shell Side Hydrostatic Test Pressure Channel Side Hydrostatic Test Pressure 4846.00 0.00 0.00 0.00 mm mm mm mm

SA-240 347H SB-443 1 620 650 0.300 0.300 0.000 0.000 C C MPa MPa MPa MPa

Wind Design Code Earthquake Design Code Element Pressures and MAWP: MPa Element Desc

ASCE-93 UBC-94

| Design Pres. | External | M.A.W.P | Corrosion | + Stat. head | Pressure | | Allowance --------------------------------------------------------------------btm blind flange 0.300 0.000 1.160 0.0000 btm flange 0.300 0.000 1.407 0.0000 channel tube inlet 0.300 0.000 0.855 0.0000 shell side 0.300 0.000 2.331 0.0000 channel tube outlet 0.300 0.000 0.855 0.0000 top flange 0.300 0.000 1.407 0.0000 top blind flange 0.300 0.000 1.160 0.0000 Liquid Level: 4426.00 mm Dens.: 0.000 kg/cm Sp. Gr.: 0.000

Stiffener Ring Specifications: Elevation mm Selected Type 900.00 4049.96

User Description

Element "To" Elev Length Element Thk R e q d T h k Joint Eff Type mm mm mm Int. Ext. Long Circ ----------------------------------------------------------------------Body Flg 30.0 30.0 30.0 No Cal ------- 1.00 1.00 Body Flg 85.0 55.0 55.0 No Cal ------- 1.00 1.00 Cylinder 900.0 815.0 5.0 1.7 ------- 1.00 1.00 Cylinder 3800.0 2900.0 5.0 1.5 ------- 1.00 1.00 Cylinder 4761.0 711.0 5.0 1.7 ------- 1.00 1.00 Body Flg 4816.0 55.0 55.0 No Cal ------- 1.00 1.00 Body Flg 4846.0 30.0 30.0 No Cal ------- 1.00 1.00 Element thicknesses are shown as Nominal if specified, otherwise are Minimum

Note: Wind and Earthquake moments include the effects of user defined forces and moments if any exist in the job and were specified to act (compute loads and stresses) during these cases. Also included are moment effects due to eccentric weights if any are present in the input. 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)

3341.9 4476.3 3341.9 3341.9 3341.9 3342.9 4609.4

kg kg kg kg kg kg kg

PV Elite is a trademark of Intergraph CADWorx & Analysis Solutions, Inc. 2011

5.Perhitungan Hydrostatic Test Pressure : untuk shell side dibatasi oleh MAWP dari Nozzle shell inlet yaitu 1.062 MPa, maka hydrostatic test pressurenya adalah : = 1.3 * MAWP * (Sa/S) = 1.3 * 1.062 * (137.9 / 53.95) = 3.529 MPa Untuk channel side dibatasi oleh MAWP dari channel tube inlet yaitu 0.85491 MPa, maka hydrostatic test pressurenya adalah : = 1.3 * MAWP * (Sa/S) = 1.3 * 0.85491 * (2.556) = 2.84 MPa

BAB II PRODUCTION DEPARTMENT

Departemen produksi terdiri dari 3 unit, yaitu : 1. Unit PPC (Production Planning Control) 2. Unit Fabrication 3. Unit PMS (Production Maintenance & Service) Dimana bagan organisasinya dapat dilihat pada gambar 2.1. di halaman selanjutnya.

2.1. Unit PPC

Sesuai namanya unit ini terdiri dari 2 bagian yaitu Planning (Perencanaan Produksi) dan Control. Bagian Planning membuat perencanaan tentang : 1. Schedule General untuk fabrikasi 2. Detail Fabrication Schedule 3. Fabrication Sequence Diagram 4. Equipment List Sedangkan bagian Control : 1. Membuat Machining List Mengecek kesiapan mesin / peralatan agar tidak terjadi pemakaian ganda pada waktu yang bersamaan. 2. Mengecek Kesiapan teknologi (kemampuan kapasitas produksi) Dalam arti berdasarkan schedule pengerjaan proyek jika kapasitas equipment yang ada tidak mampu lagi menampung suatu pekerjaan atau jika teknologi yang dibutuhkan tidak dimiliki oleh perusahaan maka bisa dikerjakan di luar dalam bentuk subvendor. Penentuan subvendor ditentukan oleh bagian pengadaan barang. 3. Mengecek Aplikasi di lapangan Mengontrol kesesuaian schedule dengan aplikasi pengerjaan di lapangan. 4. Membuat rincian Man Hour dan Machine Hour Selain itu Unit PPC ini juga membuat : 1. Weekly progress report 2. Weekly loading machine 3. Machine Hour 4. Workshop Loading Kendala yang terjadi di unit ini adalah : - Untuk bagian planning terkadang adanya salah satu dokumen yang belum diapprove sehingga harus menunggu untuk estimasi schedule pabrikasi - Oleh karena inventory tidak masuk menjadi bagian dari PPC, maka tidak dapat mengontrol persediaan material sewaktu-waktu, dalam arti jika terjadi kekurangan material bagian ini selalu terkendala mengestimasi schedule produksi.

PRODUKSI
ADMIN

PPC
STAFF STAFF

PFB
STAFF

PMS

PLANNING

CONTROL

MAINTENANCE MEKANIKAL ELEKTRIKAL

SERVICE

WELDING SECTION

ASSEMBLY

PREPARATION SECTION

COORDINATOR SHIFT

AREA IN CHARGE

MARKING CUTTING MACHINING

SHIFT I SHIFT II

WS III A WS III B

Gambar 2.1. Bagan Organisasi Departemen Produksi PT. Puspetindo

2.2. Unit Production Fabrication (PFB)

Unit ini bertugas dan bertanggung jawab dalam hal : 1. Merangkai komponen sesuai drawing dari bagian Engineering 2. Mengontrol penggunaan material las 3. Mengontrol pengelasan selama fabrikasi sesuai WPS dan drawing 4. Menentukan welder ahli dan operator welding 5. Memelihara material sisa selama fabrikasi 6. Melatih dan mengkualifikasi welder ahli dan operator welding 7. Menerbitkan, memperbaharui, dan memelihara daftar kualifikasi welder dan operator welding 8. Memelihara daftar rincian keahlian welder dan operator welding 9. Memelihara pelaksanaan safety 10. Mengontrol lay out marking dan cutting material sesuai inspeksi, test plan dan drawing 11. Machining dan metal forming sesuai drawing dan prosedur Unit ini memiliki 3 workshop, yaitu workshop I, workshop II, dan workshop III. Workshop I Kemampuan handling 20 ton, terdapat berbagai mesin antara lain : 1. bending machine 2. bending roll machine 25mm 3. bending press machine 500 ton (untuk ukuran yang lebih kecil) 4. flanging (untuk membuat head) 5. press machine 6. milling machine 7. drilling machine 8. dan area untuk fabrikasi Saat ini di workshop I terdapat proyek Exterran yaitu repair 2 unit HP suction bottle for EPF 3 Banyu Urip. Workshop II Kemampuan handling 5 ton, disini hanya terdapat area untuk fabrikasi. Workshop III Luas workshop ini adalah 50 x 200 meter dan dibagi menjadi 2 area yaitu III A dan III B. Area III A memiliki kemampuan handling 225 ton, 100 ton, dan 40 ton, sedangkan area III B memiliki kemampuan handling 40 ton (terdapat 3 buah crane) terdapat berbagai mesin antara lain : 1. bending tube machine 2. finning tube machine 3. CNC (computerized numerical cutter) machine 4. phototracing (memotong ukuran sesuai aslinya/menjiplak pola) 5. bending press machine 3000 ton 6. bending roll machine 120 mm 7. mesin las (SAW, SMAW, GTAW, FCAW, dan GMAW) 8. Furnace PWHT 15x5x5 (T = 950C) biasanya dipakai pada suhu 625C 9. Furnace PWHT 24x8x8 (T = 800C) 10. CNC drilling (high speed 4x speed CNC yg pertama)

Saat ini di workshop III sedang mengerjakan proyek : 1. Ammonia Receiver Tank PUSRI 2. Shell Kiln Semen Padang 3. Retubing HPH-6 Unit 2 PJB paiton Selain workshop juga terdapat Gantry area seluas 2500 x 200 m, dimana pada area ini terdapat crane 40 ton setinggi 25 meter. Kegunaan area ini adalah untuk asse,bling equipment yang panjangnya lebih dari 50 meter. Jika terdapat sisa material (scrap) dari proyek maka ada batasan dalam prosentase untuk dijual atau dibuang ke gudang (ditentukan dari cutting plan). Unit PFB (Production Fabrication) terbagi ke dalam berbagai seksi antara lain :
1. Welding Section :

Unit ini bertanggung jawab terhadap pengerjaan pengelasan, yaitu : 1. Menetapkan dan menugaskan welder yang berkualifikasi untuk melakukan proses welding berdasarkan qualifikasi masing-masing dalam sebuah daftar qualifikasi welder (List of Welder Qualification) dan WPQ, serta memberikan instruksi dengan mengacu pada kebutuhan WPS. 2. Supervisi atau pengawasan terhadap welder. 3. Menjelaskan kepada welder tentang spesifikasi syarat-syarat yang dijelaskan dalam WPS. 4. Semua pekerjaan pengelasan harus dimuat sesuai dengan WPS/WP yang telah disahkan, dan welder ahli. Hal ini harus diverifikasi oleh bagian QC (Quality Control). 5. Masing-masing welder harus melampirkan identifikasinya selama pengelasan pada setiap interval maksimum 3 feet (0.9 meter) dengan stempel atau paint mark sebagai tanda identitas pengelasan secara jelas. 6. Tack weld pada bagian pressure harus dilakukan oleh welder ahli dengan menggunakan WPS yang telah terkualifikasi. Tack weld ini harus diuji secara visual untuk mendeteksi cacat dan harus dihilangkan jika cacat ditemukan. Di bagian welding section ini terdapat welding consumables material dengan mengeluarkan bon consumables material (welding material bill) sebanyak 3 rangkap. Form ini dapat digunakan untuk melacak kebenaran identitas material untuk keperluan repair jika suatu saat terjadi suatu masalah, seperti contoh kebocoran pada bejana/vessel.
2. Assembly Section :

Merangkai atau menyambung hasil kerja dari preparation section berdasarkan fabrication procedure yang diperoleh dari departemen engineering kemudian diserahkan ke bagian inspeksi (Quality Control) untuk pengecekan. Dan adakalanya dari assembly section ini dikembalikan ke welding section untuk dilas kembali dan dirangkai kembali di unit ini.
3. Preparation Section :

Di unit ini terdiri dari 3 bagian yaitu : 1. Marking 2. Cutting 3. Machining

Unit Marking bertugas untuk membuat pola pada material berdasarkan cutting plan yang diperoleh dari bagian engineering. Pada material terdapat transfer heat number yang berfungsi untuk identifikasi material. Pada bagian transfer heat number ini tidak boleh dipotong jika ada sisa dan harus ditulis kembali/ditransfer untuk pembedaan identitas dengan material-material yang lain. Unit Cutting bertugas untuk memotong material yang telah diberi pola oleh unit marking baik dengan cara manual atau dengan mesin potong CNC dan phototracer. Setelah melalui proses cutting ada yang dilanjutkan ke unit Machining seperti proses bending, rolling, dan forming sesuai prosedur dari engineering, dan jika tidak diperlukan proses machining maka bisa diteruskan ke Assembly section. Semua pekerjaan welding, assembly, dan preparation terus berkaitan satu sama lainnya dan continue dengan melibatkan inspeksi dari QC.
4. Coordinator Shift Section :

Unit ini terdapat 2 orang yaitu satu orang bertugas menjadi coordinator shift I dan yang lainnya coordinator shift II. Tugas coordinator shift I adalah lebih melayani kebutuhan seksi welding, assembly, dan preparation, sedangkan pengawasan dilakukan oleh kepala seksi masing-masing. Sedangkan tugas coordinator shift II adalah melanjutkan dan mengawasi kinerja seksi welding, assembly, dan preparation karena pada shift II tidak ada kepala masing-masing seksi sehingga dengan adanya coordinator shift II dianggap sangat efektif.
5. Area in Charge Section :

Seksi ini hanya terdapat pada workshop 3, dan area pada workshop 3 dibagi jadi 2 wilayah, sehingga area in charge section ada 2 bagian yaitu Workshop III A dan Workshop III B. Tugas seksi ini lebih kepada penguasaan keberadaan personel siapa saja yang bertugas menjalankan pekerjaan pada saat itu, sehingga mengetahui siapa person in charge pada waktu yang bersangkutan. Secara sederhana tahapan produksi sebuah Vessel atau Equipment adalah :
- STRENGTH CALC ULATION - DRAWING C UTTING PLAN PROS UR ED FABRIC ATION & INSPECTION

Gambar 2.2. Tahapan produksi equipment secara sederhana

Sedangkan flowchart tahapan produksi secara keseluruhan adalah sebagai berikut :

Receiving material

Marking

Cutting

Bending, rolling, machining

Assembling

Welding

NDE & DT

PWHT (As Required)

HST 1,3 x MAWP X S at test temperature S at dsgn temperature

Painting

Packing

Delivery

Gambar 2.3. Tahapan produksi equipment secara menyeluruh

Kendala yang terjadi di unit pabrikasi adalah : - Terkadang ada suatu prosedur pengelasan yang tidak sesuai dengan pengerjaan di lapangan, akan tetapi hasil akhir yang didapat sesuai dan lolos inspeksi. - Terkadang welder salah ambil material las. - Cutting plan dari bagian engineering terkadang susah diterapkan di lapangan.

2.3. Unit Maintenance & Service

Unit ini terbagi menjadi 2 bagian yaitu : 1. Maintenance elektrikal dan mekanikal (pemeliharaan mesin dan equipment) 2. Service, dimana bagian ini juga bekerjasama dengan unit quality control dalam hal: - Kalibrasi alat tes dan alat ukur serta memelihara dokumen hasil kalibrasi, - Heat Treatment (uji PWHT), - Pressure Testing (Hydrotest Pressure), - Painting, - dan handling untuk packing equipment.

BAB III QUALITY CONTROL

Secara umum unit ini memiliki tugas dan tanggung-jawab dalam hal : 1. Inspeksi penerimaan material 2. In-process dan final inspection sesuai inspeksi dan test plan 3. Memastikan penggunaan alat tes dan alat ukur yang terkalibrasi 4. Menyediakan prosedur DE (destructive examination) / NDE (non-destructive examination) 5. Melakukan NDE sesuai prosedur 6. Memastikan NDE dilakukan oleh personal ahli NDE yang berkualifikasi 7. Mengevaluasi hasil NDE 8. Mengontrol safety dalam hal radiasi 9. Memelihara praktek tertulis untuk pelatihan, qualifikasi, dan sertifikasi operator NDE dan memastikan pelaksanaannya serta memelihara dokumen 10. Menyaksikan tes mekanikal 11. Menyaksikan dan meninjau kembali NDE di tempat subcontractor, jika dibutuhkan. 12. Membuat dokumen dari hasil semua inspeksi (dimensi, penerimaan material, NDE, dan welding). Berikut adalah letak unit Quality Control dalam struktur organisasi :
QUALITY & SAFETY DEPARTMENT DEPARTMENT HEA D

QUALITY ASSURANC E UNIT UNIT HEAD

QUALITY CONTROL UNIT UNIT HEAD

HEALTH & SAFETY SECTION SECTION HEAD

Gambar 3.1. Struktur Organisasi Quality Department Sedangkan unit QC sendiri dibagi menjadi 3 bagian yaitu : 1. Preparation 2. Assembly 3. Testing
1. QC Preparation

Saat penerimaan material, berdasarkan dokumen dari engineering terutama MR & MS (material requirement & material specification) QC preparation mengecek kesesuaian identifikasi material dengan sertifikat material yang didapat dari pabrik pembuat dengan mengacu pada standard dan code yang dipakai. Pengecekan ini meliputi cek dimensi material (mulai panjang, lebar, dan thickness), komposisi material dan uji mekanikal yang diperlukan.

2. QC Assembly :

Bagian ini melakukan : 1. cek aplikasi marking & cutting sesuai dengan general drawing 2. cek dimensi setelah dilakukan rolling atau machining agar sesuai dengan spec data sheet & drawing general 3. cek masing-masing dimensi nozzle, dll Standard yang umum dipakai dalam QC adalah ASME, yaitu : 1. ASME section I : Boiler 2. ASME section II : Material Specification 3. ASME section V : Pemeriksaan NDE 4. ASME section VIII : Acceptance criteria untuk NDE 5. ASME section IX : Welder Qualfication
3. QC Testing :

Dibagi menjadi 2 yaitu : 1. DT (Destructive Test), yang terdiri dari : a. hardness test b. impact test 2. NDT (Non Destructive Test), yang terdiri dari : a. magnetic particle test (MT) b. liquid penetrant test (PT) c. radiographic test (RT) d. ultrasonic test (UT) e. pneumatic test (uji kebocoran) f. eddy current test (khusus pipa) g. TOFD (time of flight difraction)

A.

Destructive Testing

Sesuai dengan namanya uji ini bersifat merusak material, maka dalam melakukan uji ini dilakukan dengan mengambil sebagian kecil specimen dari material yang akan diuji untuk mewakili sifat dari keseluruhan material. Hardness test : menguji kekerasan suatu material. Impact test : menguji kekuatan material dengan jalan menekan sampai bengkok Baik hardness test dan impact test mengacu pada ASME II.

B.

Non Destructive Testing

Uji ini tidak bersifat merusak material. Prosedur NDT diminta oleh clien biasanya tertera di dalam data sheet dan tidak semua NDT dilakukan untuk semua equipment. Standar umum yang dipakai untuk semua uji NDT adalah ASME V, ASME VIII, API, TEMA, dan spesifikasi dari clien. Diantara semua standard tersebut, spesifikasi yang diminta dari clien adalah yang paling diutamakan. 1. Magnetic Particle Test (MT) Atau uji untuk mengetahui cacat material atau luasan cacat dengan metode induksi magnet sesuai dengan metode ASME V artikel 7. Jika terdapat indikasi cacat atau untuk penerimaannya mengacu berdasarkan ASME VIII. Bagian yang diuji adalah : - edge preparation (untuk tebal > 38mm biasanya dilakukan uji MT) - Hanya dilakukan terhadap material ferromagnetic saja

Jika MT tidak dapat dilakukan maka dilakukan Liquid Penetrant Test (PT) sebagai ganti Uji MT sendiri ada 2 yaitu: a. Visible (cacat terdeteksi dengan adanya pergerakan atau garis-garis yang ditimbulkan oleh serbuk besi / MPI ink) b. Fluorescent (cacat terdeteksi dengan adanya perpendaran cahaya dengan bantuan sinar Ultra Violet) Material untuk pengujian ini adalah : 1. Field Gauge Indicator Indikator ini digunakan untuk kalibrasi.
garis2 cacat buatan untuk indikasi garis gaya magnet

Gambar 3.2. Field gauge indicator 2. Yoke Merupakan instrument untuk menimbulkan medan magnet sehingga garis-garis gaya magnet bisa diidentifikasi dengan pemberian material yaitu : a. WCP-2 (white contrast paint) b. MPI Ink (black magnetic ink) 7 HF (untuk visible test) dan 14 HF (untuk fluorescent test) atau bisa dikatakan serbuk besi

kutub selatan

kutub utara

(1)

(2)

Gambar 3.3. (1)Yoke (Magnaflux), (2) Material Uji MT WCP-2 & MPI-ink 7HF Alat uji dan material tersebut dengan instrument uji harus berasal dari satu merk yang sama. PT. Puspetindo menggunakan merk Magnaflux.

Berikut adalah skema pengujian MT :

garis gaya magnet yang timbul akibat adanya medan magnet yang diberikan oleh Yoke, garis gaya tersebut diperjelas setelah material disemprot dengan WCP -2 dan MPI ink

cacat

semprotan WCP-ink field gauge

object uji

U (2) (2)

setelah disemprot dgn MPI-Ink terlihat adanya garis2 pada field gauge

(3) Gambar 3.5. Langkah kerja uji MT Langkah kerja uji MT secara sederhana adalah : (1). Pertama-tama bersihkan material atau object uji, letakkan field gauge indicator diatas object uji yang diduga ada cacat lalu semprotkan WCP-2 diatasnya, (2). Letakkan Yoke (yang sudah dihubungkan dengan sumber listrik) dengan arah melintang seperti pada gambar, (3). Lalu semprotkan MPI-Ink 7HF, cacat terdeteksi jika ada pergerakan atau terbentuknya garis oleh serbuk besi tersebut yang terlihat pada field indicator (garis gaya yang terlihat adalah yang melintang terhadap arah garis kutub Utara-Selatan). Setelah object dilakukan MT, maka harus di-demagnetisasi untuk menghilangkan sumber magnet yang telah tertinggal di object tersebut dengan jalan membalik kutub U menjadi S atau S menjadi U (membalik posisi Yoke berlawanan dengan posisi waktu uji), lalu menarik Yoke perlahan-lahan dan dilakukan berulang-ulang. Cara yang kedua adalah mengecilkan tegangan pada travo sumber listrik perlahan-lahan sesaat setelah dilakukan uji MT. Selain itu demagnetisasi bisa dilakukan dengan perlakuan PWHT (post weld heat treatment). Demagnetisasi sangat penting dilakukan karena pada saat painting dilakukan, jika daya magnet masih tertinggal dalam object / material maka cat mudah akan pecah atau rusak.

2. Liquid Penetrant Test (PT) Merupakan deteksi untuk cacat yang terbuka pada suatu material yang bersifat nonporous baik ferromagnetic maupun non-ferromagnetic. Uji PT ini mengacu pada standard ASME sect V artikel 6 dan sect VIII. PT sendiri terbagi menjadi 3 yaitu : a. Visible (untuk surface yg areanya tidak terlalu besar) b. Waterwashable (untuk surface area yang besar dan lebar) c. Emulsion Material yang digunakan untuk uji PT adalah : 1. Penetrant SKL SP1 (cairan berwarna merah) 2. Developer SKD S2 (berwarna putih) 3. Cleaner / remover SKC S

Gambar 3.6. material untuk uji PT Secara sederhana cara pengujian PT adalah: Bersihkan object yang akan diuji dengan menggunakan cleaner / remover sampai benarbenar bersih, lalu semprotkan penetrant pada brush dan oleskan pada object, dan biarkan selama 10 menit agar cairan penetrant ini meresap ke dalam permukaan. Setelah itu bersihkan kembali sampai benar-benar bersih (sampai warna merah tidak terlihat) dengan menggunakan kain yang berwarna putih. Semprotkan developer pada luasan object yang telah disemprot dengan penetrant, lalu cacat akan terdeteksi jika terdapat spot, crack, ataupun bintik-bintik berwarna merah. Agar tidak terjadi confuseness pada hasil uji PT maka permukaan object harus smooth. Batasan spot diameter min 4.6mm, jika melebihi maka harus segera direpair. Sedangkan jika berupa bintik-bintik merata, maka akumulasikan ukuran diameternya sepanjang 1 inchi jika melebihi 4.6mm maka harus segera direpair. Setelah selesai maka bersihkan kembali object dengan cleaner / remover. Berikut adalah skemanya :
surf ace material pengujian PT cacat terbuka cacat yang teridentifikasi oleh cairan uji PT surf ace material

pore (cacat)

Gambar 3.7. Cacat yang teridentifikasi oleh uji PT

3. Radiographic Test (RT) Merupakan uji untuk mendeteksi cacat pada surface, subsurface, dan internal dengan menggunakan radiasi dari sinar X atau sinar gamma. Sinar gamma yang umum digunakan adalah Iridium, Selenium, dan Cobalt. Dilihat dari sifatnya radiasi dari sinar X lebih berbahaya daripada dinar gamma karena massa peluruhan sinar X lebih lama daripada sinar gamma. Standard yang dipakai untuk uji RT adalah ASME sect V artikel 2 dan VIII. Uji radiografi ada 2 macam yaitu spot radiorafi dan full radiografi. Bagian yang dilakukan uji RT adalah pada bagian joint yang mengacu pada ASME sec VIII div I. Sedangkan untuk keperluan training personal RT ada 2 sumber yaitu : 1. Negara, yaitu BATAN untuk perijinan personel yang terbagi menjadi 3 tingkat yaitu : - PPR (petugas proteksi radiasi) - AR (ahli radiografi) - OR (operator radiografi) 2. ASNT, juga terdapat 3 tingkatan yaitu : - Level I yang setara dengan OR - Level II yang setara dengan AR - Level III Batasan terpapar radiasi adalah minimal 1.5miliRad. Jika seseorang telah terpapar mencapai atau melebihi dari nilai ini maka orang tersebut harus diistirahatkan sementara selama 1 bulan untuk tidak berinteraksi lagi dengan aktivitas uji radiasi. Material untuk uji RT ini terdiri dari : 1. film, yang terbagi menjadi 3 kelas yaitu :
No 1 2 3 jenis film tingkat kerapatan besar tingkat kerapatan sedang, 0.5x dari yg pertama tingkat kerapatan kecil, 0.25x dari yang kedua AGFA D7 D4 D3 kesetaraan merk Kodak Fuji harga AA x100 murah M M x1000 x1000 mahal lebih mahal

Kualitas dari film ini harus : - bebas fogging - bebas process defect, dan watermark - tidak terdapat bekas guratan, crimp mark, dirtiness, dan static, sehingga untuk mengambil film baru dari tempatnya harus diangkat perlahan-lahan tidak boleh ditarik sehingga menimbulkan bekas gesekan. - bebas cacat lainnya sehingga menyebabkan false indication 2. image quality indicator (IQI), ada 2 jenis yaitu tipe kawat dengan diameter tertentu, dan plat yang memiliki diameter hole tertentu. Sensitivity dari IQI ini menunjukkan kemampuan kawat untuk mendeteksi cacat sampai pada diameter yang paling terkecil.

Gambar 3.8. IQI jenis kawat

3. location marker yang terbuat dari material Pb (timbal) 4. densitometer (alat untuk cek kehitaman suatu film). Maximum density untuk x-ray adalah 1,8 4, dan 2 4 untuk gamma ray. Sedangkan untuk film komposit (film yang ditumpuk) adalah 1,3. 5. viewer (alat untuk membaca film) Standar acceptance untuk hasil RT mengacu pada : 1. ASME sec 8 Div I part UW 51 untuk full radiografi 2. ASME sec 8 Div I part UW 52 untuk spot radiografi System identifikasi hasil RT harus tertera dengan jelas hal-hal berikut: - nama fabrikator - nama proyek - jenis sambungan las - thickness material - IQI yang dipakai - Welder identification - Welding process (SAW, SMAW, GTAW, dll) - Interest area - Tanggal uji Saat pengujian dilakukan jarak tumpukan film dari satu ke lainnya adalah 1 inchi, berikut adalah skemanya :
1" 1" 1" object yg diuji 0 1 2 3 film

Sedangkan skema pengujian adalah :

4. Ultrasonic Test Merupakan pengujian ultrasonic dengan teknik piso-elektrik yang mengacu pada standard ASME section V artikel 4 dan ASME VIII. UT ini dilakukan pada area joint nozzle to shell, channel, dan head, serta area dimana RT tidak bisa dilakukan, seperti pada area closing joint. Instrument yang digunakan untuk UT ada 2 macam yaitu manual (analog) dan digital. Kalibrasi alat uji UT manual dilakukan setiap 3 bulan sekali, dan 1 tahun sekali untuk UT digital. Yang dikalibrasi adalah : 1. screen height linearity yang mengacu pada ASME sec V artikel 4 2. amplitude control linearity yang juga mengacu pada ASME sec V artikel 4 Pengujian ini dilakukan dengan menggunakan probe dengan frekuensi 1 5MHz, dan couplant (penghantar) biasanya dipakai CMC (carboxy methyl cellulose), oil SAE, atau gliceryn. Penggunaan oil sebagai couplant karena dari sisi cleaning lebih merepotkan (misal perlu chemical lain untuk menghilangkan bekas oil tersebut) daripada CMC dan gliceryn (karena cukup dibersihkan dengan air saja). Jenis probe yang digunakan ada 2 macam yaitu probe sudut (yang dipakai biasanya ada 3 yaitu 45, 60, 70) dan probe normal (lurus).

Sebelum probe digunakan, maka harus dikalibrasi terlebih dahulu dengan menggunakan calibration block yaitu : 1. type V1 5. block dengan bentuk lingkaran 2. type V2 untuk diameter > 500mm, dan < 3. step wap 500 mm. 4. DAC Berikut adalah contoh calibration block :
lubang cacat buatan dengan dia 15 mm

reflector utk cek sudut

(1)
thickness cacat buatan pada kedalaman t

(2) (3) Gambar 3.9. bentuk calibration block (1) V1, (2) step wap, (3) DAC Material untuk calibration block yang digunakan ada 2 : - similar weld material (sama dengan material object yang akan diuji) - dissimilar weld material (digunakan material yang jenisnya paling sulit, jika beda ketebalan maka dilakukan dari yang paling tipis dahulu. Dan object adalah material cladding, maka block juga harus di-clad dengan prosedur yang sama) Kualitas dari block harus bagus. Jika object material dilakukan PWHT (post weld heat treatment), maka block juga harus di-PWHT. 5. Pneumatic test Atau yang disebut dengan test kebocoran, dimana suatu equipment diisi dengan angin lalu pada bagian joint disemprot dengan air sabun, jika timbul gelembung maka didaerah tersebut terindikasi adanya kebocoran maka harus segera dilakukan repair. Setelah uji diatas, tugas QC testing selanjutnya adalah bersama-sama dengan bagian service (PMS Unit) untuk melakukan : 1. PWHT (post weld heat treatment) Merupakan perlakuan pemberian panas pada suatu material atau equipment pada suhu tertentu dengan menggunakan furnace. Standard perlakuan PWHT yang digunakan mengacu pada ASME sec VIII div 1. Hal ini dilakukan untuk mengurangi konsentrasi tegangan sisa atau stress yang masih tertinggal akibat proses pengelasan, ataupun bekas area uji MT (magnetic particle test).

Spesifikasi furnace yang digunakan PT. Puspetindo adalah : 1. Furnace type : Modular Furnace with 6 LPG burners 2. Thermometer recorder : Max. available 12 thermocouples connected to automatic time temperature chart recorder 3. Dimensions : 15500 mm x 5400 mm x 5400 mm 4. Maximum operating Temp. : 950 C 5. Maximum furnace load Weight : 150 Ton PWHT dilakukan terhadap : 1. semua material carbon steel yang memiliki carbon content minimal 0,3% 2. semua material carbon steel yang memiliki thickness 1 inch meskipun carbon contentnya <0,3% 3. material khusus karena digunakan untuk proses panas dan dingin 4. PWHT dilakukan terhadap equipment yang telah difabrikasi lengkap dimasukkan ke dalam sebuah furnace, dimana pada bagian tertentu ditempelkan sebuah termocouple yang berjumlah 6 buah (lokasi mengikuti geometri dari equipment). Perekaman data PWHT dilakukan pada saat temperature termocouple yang terbaca pada layar mencapai angka 425C sampai pada batasan suhu yang diijinkan sesuai dengan sifat dan jenis material itu sendiri, dan pada angka tersebut ditahan selama minimal 15 menit, lalu diturunkan perlahan sesuai dengan prosedur PWHT. Berikut adalah contoh kurva PWHT :

Gambar 3.10. Kurva PWHT 2. Hidrostatic Test Uji ini mengikuti standard ASME sec VIII div 1. Hal yang harus sudah dilakukan sebelum hidrotest adalah : 1. uji NDE 2. inspeksi dimensi equipment 3. tes kebocoran udara untuk reinforcement pad pada 50 psig 4. inspeksi pengelasan visual 5. fabrikasi lengkap Untuk test pressure yang lebih dari 568,9 psig, pemberian tekanan dilakukan secara gradual (bertahap) dengan jeda 10 menit, tahapan tekanan yang direkomendasikan adalah : - 0 1/3 P - 1/3 P 2/3 P - 2/3 P P

Tekanan maksimum yang digunakan adalah 1.3 MAWP yang merupakan hasil dari strength calculation. Berikut adalah kurva uji hydrotest :

Gambar 3.11. Kurva Hydrotest Setelah melewati tekanan MAWP baru yang dilakukan adalah : 1. cek kesesuaian pressure indikator apakah bekerja sesuai range. 2. cek kebocoran dari equipment 3. cek peregangan material yang menyebabkan material berubah dimensi atau tidak. 4. cek kekuatan komponen material dalam arti apakah pada tekanan yang diberikan terjadi baut lepas, atau ring dan komponen lainnya lepas. 5. Dalam konteks tangki / vessel, untuk menguji pondasi apakah turun dari posisi semula atau tidak karena adanya gaya berat sebuah volume yang bekerja pada tangki tersebut. Masalah-masalah yang terjadi saat testing dilakukan diantaranya terbagi menjadi 2 yaitu masalah teknis dan non teknis. Masalah teknis diantaranya adalah : 1. Sering terjadi deformasi pengelasan akibat kesalahan pelaksanaan sequence (urutan) pengelasan karena operator tidak memperhatikan faktor pre-heat dan post heat. 2. Pemasangan support brassing yang salah karena dilas pada kedua sisi sehingga menimbulkan bekas pada bagian yang ditempeli oleh support brassing tersebut yang berpotensi cacat ataupun bentuk-bentuk deformasi lainnya dan mengakibatkan repair. Dan masalah yang terjadi kebanyakan bersumber dari non-teknis, seperti : 1. psikologis pekerja, dimana emosi pekerja sangat mempengaruhi kualitas hasil kerja, 2. kesalahan transfer info urutan maupun hasil pekerjaan pada shift I ke shift berikutnya maupun sebaliknya (hal ini dikarenakan susunan sistem manajemen), 3. adanya kebijakan manajemen yang menuntut penghematan di segala bidang seperti penggunaan material karena harganya murah tapi dengan thickness melebihi spesifikasi dari MR/MS sehingga terpaksa dilakukan penipisan material, dan pemakaian support brassing carbon steel pada material stainless steel, 4. dan lain-lain. Setelah melakukan Testing, maka tahap selanjutnya kembali pada QC assembling yang mencakup painting dan packing yang bekerjasama dengan unit Service (PMS). Pada inspeksi painting dilakukan pengecekan terhadap thickness paint sudah benar (sesuai yang dituliskan di prosedur) atau tidak, dan cek ada tidaknya gelembung dalam paint (holiday test). Pada inspeksi packing, dilakukan pengawasan tata cara packing sesuai dengan prosedur dari bagian PPC (production planning control). Setelah semua dilakukan, maka tugas selanjutnya adalah membuat manufacturing data report yang dilakukan oleh QA (Quality Assurance).

BAB IV PRODUCTION & FABRICATION HEAT EXCHANGER

Dalam bab ini dijelaskan tentang contoh produksi dan pabrikasi Heat Exchanger secara umum dan untuk itu diambil contoh proyek PUSRI yaitu Ammonia Recovery Absorber yang telah selesai pada akhir tahun 2009. Sesuai tahapan produksi pada bab II di atas maka produksi Heat Exchanger tersebut dapat dilihat pada halaman selanjutnya.

Berikut adalah As Built Drawingnya :

Gambar 3.1. As Built Drawing General Arangement & Detail Heat Exchanger

Gambar 3.2. As Built Drawing Name Plate & Bracket Detail

Gambar 3.3. As Built Drawing Pass Partition & Cover Detail

Gambar 3.4. Cutting Plan Detail

Gambar 3.5. Cutting Plan Pipe

Gambar 3.6. Cutting Plan Plate

A. Prosedur Fabrikasi Prosedur Fabrikasi (Fabrication Procedure) untuk project JE 090700 adalah sebagai berikut : A. Receiving Inspection of Material 1. Material Certificate All materials containing pressure part and all internal part materials shall have mill certificate issued by mill maker or inspection agencies. Material certificate shall identify charge no. and/or heat no. of material. It shall contain following states: a. Chemical compositions. b. Mechanical properties. c. Dimension. d. Other tests as specified by applicable codes / standard and material specification. 2. Material Inspection All received material shall be checked by QC inspector includes the following : a. Visual check. b. Dimensional check. c. Conforming to material specification and material certificate. 3. Storing Material shall be stored in appropriate place and gives clear identification by mean of label (for small parts) and color mark / lettering (for plates, pipes, tubes, bars, etc.). B. Marking and Cutting 1. Marking and mark shift Prior to cut material plates, pipes, tubes, bars, etc. they shall be layout marking and material identification (heat number / charge number and material quality) shall be transferred to each parts by low stress stamping, sharp hard stamping shall not be acceptable. 2. Marking check Prior to cut, QC shall inspect the marking to conform with cutting plan and ensure correct dimension and the material identification is transferred properly. 3. Cutting Plates, pipes, tubes, bars shall be cut by using saw or gas cutting. For retaining plate material, shear cutting shall not be utilized. 4. Drilling Baffle plate shall be drilled as per approved drawing. C. Bending of Tube Tube shall be cold bending to perform U-tube as per required dimension. For tube flowed by fluid that contain Caustic, Chlor and its similar shall be stress relieved after bending. U-tube shall be of one piece construction. The following examination shall be conducted for U-Bend Tube : - Flattening - Bend Radius - Crimping

1. Tolerance Plane Bend for U-tube After bend tube dimension shall not exceed the following tolerances:

Location of measurement Outside diameter ( D ) Wall thickness ( t ) Straight leg portion Straight leg ( SL ) Leg spacing ( P ) Reduction of Wall thickness ( to ) U - bend portion Flattening Deviation ( s )

Tolerances 0.10 mm. 10 %. + 3.2 mm : - 0 , Exclude cut after bend. 1.0 mm ( R < 5do ). 1.5 mm ( R > 5do ). Reduction thickness in bend portion shall not exceed 17% of original tube wall thickness. 10 % for 1.5do <R< 2do. 6 % for R> 2do. Measurement from the point of tangency 1.5 mm.

2. List of U-Tube

D. Tube to tubesheet expansion 1. Outside surface of tube, edge of inside tube and tubesheet holes shall be thoroughly cleaned to remove any foreign particle/material. 2. After assembly tube to tubesheet, the edge of tube shall be arranged using wooden hammer. 3. Hydraulic expand shall be carried out to the required depth of tube using the wall reduction ratio percentages as procedure. 4. Tube to tubesheet expansion shall be performed by hydraulic expand as per Tube to Tubesheet Expansion Procedure. The document to be submitted separately. E. Welding 1. Welder qualification Welders and welding operators shall be qualified as per Section IX ASME Code and to be certified by DEPNAKER. 2. Welding Procedure shall be performed as per WPS / PQR which shall be qualified in according with Section IX of ASME Code. 3. Edge preparation and joint preparation for welding joint may be made by machining or gas cutting. When gas cutting is performed, the joint surface shall be ground to obtain sound metal. It shall be a curtained that shapes and dimensions of edges to be joined are as per approved drawing. Tolerance of weld joint preparation unless noted in approved drawings the following tolerance are to be considered satisfactorily. a. Groove angle 5 b. Root gap 2.0 mm c. Alignment of section at edge per UW 33 ASME Section VIII Div.1 :

Note : t is nominal thickness of the thinner section at the joint. 4. Tack welding Tack welds shall be made to a qualified welding procedure and by approved welders. Tack weld shall be completely removed prior to welding. 5. Temporary welding Temporary welds for temporary handling attachments, lug, etc. shall be minimized. When temporary welding is deemed necessary, welding shall be performed with the same approved procedures as for main fabrication welding and shall be done by approved welders. The temporary welds shall subsequently be ground flush and then inspected by liquid penetrant test. The method of removing attachments shall not injure the metal surface (i.e. removing by hammering off is not permitted). 6. Prior to start welding, QC shall check the edge preparation and cleanliness of edge. All surfaces to be welded shall be visually inspected to ensure free from lamination or other injurious defect.

7. After completion of welding the spatters or slag shall be removed by wire brush or grinding. Visual inspection shall be performed to the surface of weld and it should meet the following allowance : a. The joint shall have completed penetration and full fusion. b. Crack or pit : none c. Undercut : none The thickness of reinforcement on each side of all butt welded joint is as per UW35 ASME Section VIII Div.1 as follow :

8. Repair of welding defects Any rejectable discontinuities found in the welding on visual and nondestructive examination shall be repaired. The repair shall be done according to repair procedure by welding that is described in Welding Procedure separately submitted. F. Nondestructive Examination 1. Visual inspection The complete welded shell shall be visually inspected to ensure no harmful defect. Inspection shall include the followings : Visual appearance of the weld bead (under cut, porosity, bead overlap, spatter, objectionable form, arc strikes, etc). Any defect on surface of material. Dent or deformation. Height of weld bead. Alignment of weld joint. 2. Liquid Penetrant test (PT) Liquid Penetrant test shall be done as per Liquid Penetrant Procedure". Part to be examined. Back Chipping, if done. Tube to tube sheet welds before PWHT. Weld overlay if any before PWHT. Nozzle and Manhole neck to Vessel attachment welds (for non ferromagnetic material) before PWHT. All areas where temporary lugs have been removed shall be ground flush. (for non ferromagnetic material) before PWHT. G. Dimensional Inspection The manufacture shall prepare dimensional inspection data for the equipment. Dimensional check shall conform to permissible tolerance as per tolerance and approved drawing.

H. Hydrostatic Test Application of pressure : 1. Application Pressure for the Heat exchanger shall be increased slowly and a quick change of the pressure shall be avoided (as per pressure chart attached). 2. Pressurization shall be gradual, for test pressures higher than (568.9 Psi G) 40 kg/cm2, pressurization shall be in stages, with a pause of a 10 minutes between stages. Pressurization stages is recommended to use as following: - 0 to 1/3 P - 2/3 P to P - 1/3 P to 2/3 P 3. There after, the pressure shall be gradually increased up to the required test pressure with holding time of 60 minutes for required test pressure. 4. The visual examination for leakage shall be made for all connections and welded seam at pressure as per sketch. During visual examination, the pressure shall be held sufficiently for which will be performed by inspection PSP and client inspection. 5. After the visual inspection examination, the pressure test reduced slowly to zero (0) through the vent. Note: a. Leakage from temporary seals shall be directed away to as to avoid masking leaks from other joints.

Gambar 3.7. Skema uji hidrotest I. Transportation Style After completing for manufacturing, the shipping preparation shall be carried out in accordance to Transportation Style. Rust prevention shall be performed by Nitrogen gas purging. J. Fabrication Sequence Diagram urutan fabrikasi dapat dilihat pada gambar 3.8.

PT . PUSPETINDO
GRESIK - INDONESIA

FABRICATION SEQUENCE DIAGRAM

FT F WL

PSP JOB NO . JE - 0907 00 Customer PT. PUSRI

DOCUMENT NO .

Revision Prepared by Checked by Approved by

0 TEP KN DS

0907 00/DSD /01

Page 2 of 2

SHELL PN .2

RI

MC

MT

C1.02
FT
MT

- NOZZLE S 1 & S2 [ INCLUDE TEMP .BLIND FLANGE ] - TRUNNION [ 2 EA ] - LUGS [ 4 EA ] F WL RT MK M CT & GR

FOR S 1 & S2

SHELL PN .3

RI

MC

FT

WL

FINISHING

PWHT

HT

FT

WL
NDE : UT & HT

NOZZLE S 3

C1.01

NOZZLE HOLES

NDE : UT, PT , HT

C1.03

HEMISP . HEAD PN .1

RI

MK

CT & GR

MT

FT

WL TIE ROD , SPACER , DUMMY TUBE , SUPPORT PLATE , SEAL BARS & PERFORATED PLATE

NOZZLE HOLE

TUBE SHEET

RI

PRE -MC

WL
OVERLAY INCO NEL

MC
600

PT

PWHT

MK

DR

DR & TAP

ASSEM BLING

WL

PT

LOCAL PWHT

EXPAND

- TUBE HOLES , TIE ROD , GROOVING - NOZZLES HOLE T 4 & S4

TUBE TO TUBE SHEET

BAFFLE PLATE

RI

MK

CT & GR

DR
FOR TUBE S, DUMMY TUBE S & TIE RODS

MC

CHAMFER

MK

CT & GR

LOCAL PWHT

HT

H.S.T.
SHELL SIDE

FT

WL

FINISHING

LOCAL PWHT

HT

H.S.T.
TUBE SIDE

FOR SEAL BAR

C1.04 & NOZZLE

NDE : RT , UT, PT, HT

U-TUBES [ PN . 12 ~ 78 ]

RI

MK

BENDING

CT
END OF TUBE

LOKAL PWHT

PT

POLISHING

NOZZLES T 4 & S4 - BEVEL S 1 & S2 - INSTALL COVER SANDBLAST & PAINTING PACKING & SHIPPING MARK [ FILLING N 2 ]

RT D

BEND ING AREA + 300 MM FOR ALL TUBES

HEMISP . HEAD PN .5

RI

MK

CT & GR

MT

FT

WL

NOZZLE HOLE

NOZZLE M 1

CHANNEL SHELL PN .4

RI

MC

MT

FT

WL

RT

FT

WL

CT & MC
PASS PARTITION

FINISHING

PWHT

HT

C1.05
NOZZLE T 1, T2, PASS PARTITION

NDE : UT, PT , HT

BLIND FLANGE NOZZLE M1

RI

MK

DR

FT

WL

NOZZLE HOLE

NOZZLE T 3 DR & TAP

PASS PARTITIO N

RI

MK

CT & GR

FT

WL

MC

ALL PART

#
RI RT HST

REMARKS : SIZE : 1853 ID x 3048 L TYPE : NXU MATERIAL : Forging Shell : SA 336 -F11 -CL 2 Tube Sheet : SA 336 -F11 -CL 2 + Inconel 600 Tube : SA 213 -T11 Tube Size : OD. 19 .05 x 2.76 t ( 1805 U-Tube ) WEIGHT : 70.36 Tons RADIOGRAPHYC : FULL PWHT : YES

MK CT GR FT WL BR

: : : : : :

MARKING CUTTING GRINDING FITTING UP WELDING BENDING ROLL

RR BP TAP MC DR PA

: : : : : :

REROUNDING BENDING PRESS TAPPING MACHINING DRILLING PAINTING

M F V D

: : : :

MARKING INSPECTION FIT - UP INSPECTION VISUAL CHECK DIMENSIONAL CHECK

: : : :

INSPECTION RECEIVING INSPECTION RADIOGRAPHIC TEST HYDRO TEST

PROJECT TITLE REPLACEMENT AMMONIA CONVERTER EFFLUENT BFW EXCHANGER

ITEM NAME

/ NO

AMMONIA CONVERTER EFFLUENT BFW EXCHANGER [ 3A-123 -C ]

V isioDocument ~ Page -1

DF / A4 / 10 / 0

Gambar 3.8. Fabrication sequence diagram

BAB IV RENCANA KEGIATAN SELANJUTNYA

Rencana kegiatan selanjutnya adalah melanjutkan tugas yang telah diberikan yaitu membuat sebuah panduan design sizing Heat Exchanger dan Test Separator.

DAFTAR PUSTAKA
Engineering Department. 2009. Fabrication & Inspection Procedure JE 090700. Replacement of Ammonia Converter Effluent / BFW Exchanger ordered by PT. PUPUK SRIWIDJAJA. Puspetindo. 2010. Quality Control Manual For Shop Construction and field assembly of Boilers, Pressure Vessels & Heat Exchangers in accordance with : ASME Boiler & Pressure Vessel Code Section I, VIII Div. 1 & 2 ASME B31.1 and Repair & Alteration of Pressure Retaining Items in Accordance with National Board Inspection Code (NBIC). Document No : QCM P 01. Gresik. www.wikipedia.com

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