3 Phase Production Separator C-321

PRESSURE VESSELL ASSESSMENT REPORT
3 PHASE PRODUCTION SEPARATOR

TAG NO. C-321 / SERIAL NO. 28829
PT. BINTANG ENERGI PRATAMA
PT BIRO KLASIFIKASI INDONESIA (BKI)
PT DINAMIKA TEKNIK PERSADA
Document no. : DTP/2015/R.
1
0
Revision
02/05/15
17/03/15
Date
Issued For Review

Issued For Review
Description
FE
FE
Prepared
BD
BD
Checked
Approved
3 Phase Production Separator

(Tag No. C-321 / SN. 28829)
SP III Limau
SUMMARY OF CHANGE SHEET
Rev No
Date
Page
Description
17/03/15
All
Issued For Review
02/04/15
37
Assummed Initial Thickness for

Shell
Approve
Page 2 of 42

(Tag No. C-321 / SN. 28829)
SP III Limau
DAFTAR ISI
TABLE OF CONTENTS
1. PENDAHULUAN
1.
2. LINGKUP PEKERJAAN
2. SCOPE OF WORK
3. DATA UMUM
3.
GENERAL DATA
4. HASIL INSPEKSI
4.
INSPECTION RESULTS
INTRODUCTION
4.1 Inspeksi Visual
4.1 Visual Inspection
4.2 Pengukuran ketebalan UT
4.2 UT Thickness Measurements
5. ENGINEERING CALCULATIONS
5. PERHITUNGAN TEKNIS
5.1 Kondisi Desain - Nameplate
6. MEKANISME KERUSAKAN &
5.1 Design Condition - Nameplate
6. DAMAGE MECHANISMS &
PERENCANAAN INSPEKSI
22
INSPECTION PLAN
22
6.1. Mekanisme kerusakan
22
6.1. Damage Mechanisms
22
6.2. Perancenaan Inspeksi
28
6.2. Inspection Plan
28
34
7. CONDITION ASSESSMENT
34
7.1 Ketebalan Yang Diperlukan
35
7.1 Thickness Requirements
35
7.2 Sisa Umur
36
7.2 Remaining Life
36
7. PENILAIAN KONDISI
8.KESIMPULAN & SARAN
38
8. CONCLUSION &
38
RECOMMENDATIONS
LAMPIRAN A
REPORT UT THICKNESS
APPENDIX A
REPORT UT THICKNESS
LAMPIRAN B
PERHITUNGAN SISA UMUR
APPENDIX B
REMAINING LIFE CALCULATION
LAMPIRAN C
DRAWING
APPENDIX C
DRAWING
Page 3 of 42

(Tag No. C-321 / SN. 28829)
SP III Limau
1. PENDAHULUAN
1.
INTRODUCTION
Laporan ini berisikan penilaian teknis untuk

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

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

06P/0746/M.PE/1991
tentang
Pemeriksaan Keselamatan Kerja atas
Instalasi Peralatan dan Teknis yang
Dipergunakan dalam Pertambangan
MIGAS dan Pengusahaan Sumber Daya
Panas Bumi.
Peraturan Menteri pertambangan No.

06P/0746/M.PE/1991 tentang Pemeriksaan
Keselamatan Kerja atas Instalasi Peralatan
dan Teknis yang Dipergunakan dalam
Pertambangan MIGAS dan Pengusahaan
Sumber Daya Panas Bumi.
Dir.
Jen.
MIGAS
No
SK
84.K/38/DJM/1998 tentang Pedoman
dan
Tata
Cara
Pemeriksaan
Keselamatan Kerja atas Instalasi,
Peralatan
dan
Teknik
yang
Dipergunakan
dalam
Usaha
Pertambangan Minyak dan Gas Bumi
dan Pengusahaan Sumber Daya Panas
Bumi.
SK Dir. Jen. MIGAS No 84.K/38/DJM/1998

tentang
Pedoman
dan
Tata
Cara
Pemeriksaan Keselamatan Kerja atas
Instalasi, Peralatan dan Teknik yang
Dipergunakan dalam Usaha Pertambangan
Minyak dan Gas Bumi dan Pengusahaan
Sumber Daya Panas Bumi.
Surat edaran Dir. Jen. MIGAS No.

12024/18.05/DMT/2013
perihal
Pemeriksaan Peralatan Operasi Migas
yang telah melewati umur desain
(Design Life) dan yang tidak memiliki
data.
Surat edaran Dir. Jen. MIGAS No.

12024/18.05/DMT/2013
perihal
Pemeriksaan Peralatan Operasi Migas yang
telah melewati umur desain (Design Life)
dan yang tidak memiliki data.
ASME BPV Section VIII, Rules for

Construction of Pressure Vessels
ASME BPV Section VIII, Rules

Construction of Pressure Vessels
API Publication 510, Pressure Vessel

Inspection Code: Inspection, Rating,
Repair, and Alteration
API Publication 510, Pressure Vessel

Inspection Code: Inspection, Rating, Repair,
and Alteration
API 572, Inspection

Pressure Vessels
for
API 572, Inspection Practices for Pressure

Vessels
ASME PCC 3, Inspection Planning

Using Risk-Based Methods
ASME PCC 3, Inspection Planning Using

Risk-Based Methods
API 571, Damage Mechanisms Affecting

Fixed Equipment in the Refining Industry
API 571, Damage Mechanisms Affecting

Fixed Equipment in the Refining Industry
API
581,
Technology
API 581, Risk-Based Inspection Technology
Practices
Risk-Based
Inspection
Page 4 of 42
for

(Tag No. C-321 / SN. 28829)
SP III Limau
ASME BPV section V, Nondestructive
Examination.
ASME BPV
Examination.
Perhitungan
menentukan
tekan yaitu :
teknis diperlukan untuk

integritas mekanik bejana
The engineering calculations required to

determine the mechanical integrity of pressure
vessel are:
Tekanan kerja maksimal yang diijinkan

(MAWP) pada shell, head dan nozelnozel.
Maximum allowable working pressure

(MAWP) for shell, head and nozzles
section
V,
Nondestructive
Page 5 of 42

(Tag No. C-321 / SN. 28829)
SP III Limau
2. LINGKUP PEKERJAAN
2. SCOPE OF WORK
MAWP untuk suatu operasi bejana tekan

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

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

parameter berikut memenuhi persyaratan
code yang digunakan: head, shell, dan
nozzle, spesifikasi material, tegangan yang
diijinkan, efisiensi sambungan, persyaratan
inspeksi yang diterima.
Computations may be made only if the

following essential details comply with the
applicable requirements of the code being
used: head, shell, and nozzle reinforcement
designs; material specifications; allowable
stresses; weld efficiencies;
inspection
acceptance requirements.
3. DATA UMUM
3.
GENERAL DATA
Data bejana tekan secara umum dideskripsikan
General pressure vesssel data are described at
pada nameplate sebagai berikut :
nameplate as follow :
User
PT. Bintang Energi Pratama
Operation
Item no.
C-321
Year Built
2006
MAWP
600 psig nameplate
Material
SA 516 70
Dimension
72 OD x 276 (S/S)
Code
ASME Sec. VIII Div. 1
RT/Joint Eff.
Full / 1.00
Page 6 of 42

(Tag No. C-321 / SN. 28829)
SP III Limau
4. HASIL INSPEKSI
4.
INSPECTION RESULTS
4.1 Inspeksi Visual
4.1 Visual Inspection
Inspeksi visual dilakukan untuk memastikan

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

sure that PV condition (flange, shell, heads,
nozzles, painting, coating, support and
safety devices) by Inspector. Generally,
visual inspection of pressure vessel shown
in the following pictures.
No.
Inspection Task
Shell, head,
support,
nozzles, and
ladder.
Pressure and
Temperature
Gauge
PSV
Nameplate
Photograph
Remarks
Generally, this PV
is in good
condition.
N/A
No temperature
and pressure
gauge are installed
at this PV.
N/A
No PSV found at
this Pressure
Vessel.
Nameplate is
installed at this PV,
and it is in good
condition.
Page 7 of 42

(Tag No. C-321 / SN. 28829)
SP III Limau
4.2
Pengukuran ketebalan UT
4.2 UT Thickness Measurements
API 510 memungkinkan inspeksi on-stream

dilakukan sebagai pengganti inspeksi internal
pada kondisi tertentu. Pengukuran ketebalan
dinding bejana tekan, head, dan nozzle
diperlukan pada setiap pemeriksaan bejana
tekan.
Jumlah pengambilan titik pengukuran tebal yang
dilakukan
pada
bejana
tekan
harus
memenuhi/mewakili
persyaratan
dalam
pemeriksaan internal. Jumlah dan lokasi titik
pengukuran ketebalan harus mempertimbangkan
hasil dari pemeriksaan sebelumnya, jika tersedia,
dan potensi konsekuensi akibat kebocoran.
Secara umum, bejana tekan dengan laju korosi
rendah akan memerlukan lokasi pengukuran
ketebalan lebih sedikit dibandingkan dengan
bejana tekan dengan laju korosi tinggi.
API 510 permits an on-stream inspection to be

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

minimum pada tiap bagian bejana tekan yang
akan
digunakan sebagai masukan
dalam
perhitungan teknis pada bab selanjutnya.
Minimum actual thickness each part of pressure

vessel which used to perform engineering
calculation at next chapter, are shown at table
below.
When this approach is used, a representative

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

(mm)
Head I - Left
34.35
Shell 1
33.12
Shell 2
32.84
Shell 3
32.48
Shell 4
33.05
Head II - Right
34.72
Thickness actual (min.) data used for calculation
Page 8 of 42

(Tag No. C-321 / SN. 28829)
SP III Limau
5. PERHITUNGAN TEKNIS
5. ENGINEERING CALCULATIONS
5.1 Kondisi Desain - Nameplate
5.1 Design Condition - Nameplate
PV Elite Vessel Analysis Program: Input Data

Design Internal Pressure (for Hydrotest)
Design Internal Temperature
Type of Hydrotest
Hydrotest Position
Projection of Nozzle from Vessel Top
Projection of Nozzle from Vessel Bottom
Minimum Design Metal Temperature
Type of Construction
Special Service
Degree of Radiography
Use Higher Longitudinal Stresses (Flag)
Select t for Internal Pressure (Flag)
Select t for External Pressure (Flag)
Select t for Axial Stress (Flag)
Select Location for Stiff. Rings (Flag)
Consider Vortex Shedding
Perform a Corroded Hydrotest
Is this a Heat Exchanger
User Defined Hydro. Press. (Used if > 0)
600.00
300
UG-99(b)
Horizontal
0.0000
0.0000
50
Welded
None
RT 1
Y
N
N
N
N
N
N
No
0.0000
psig
F
in
in
F
psig
Page 9 of 42

(Tag No. C-321 / SN. 28829)
SP III Limau
User defined MAWP
User defined MAPnc
Load
Load
Load
Load
Load
Load
Load
Load
Load
Load
Load
Load
Load
Load
Load
Load
Load
Load
Load
Case
Case
Case
Case
Case
Case
Case
Case
Case
Case
Case
Case
Case
Case
Case
Case
Case
Case
Case
0.0000
0.0000
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
NP+EW+WI+FW+BW
NP+EW+EE+FS+BS
NP+OW+WI+FW+BW
NP+OW+EQ+FS+BS
NP+HW+HI
NP+HW+HE
IP+OW+WI+FW+BW
IP+OW+EQ+FS+BS
EP+OW+WI+FW+BW
EP+OW+EQ+FS+BS
HP+HW+HI
HP+HW+HE
IP+WE+EW
IP+WF+CW
IP+VO+OW
IP+VE+EW
NP+VO+OW
FS+BS+IP+OW
FS+BS+EP+OW
Wind Design Code

Basic Wind Speed
Surface Roughness Category
Importance Factor
Type of Surface
Base Elevation
Percent Wind for Hydrotest
Using User defined Wind Press.
Damping Factor (Beta) for Wind
[V]
Vs Elev.
(Ope)
(Empty)
(Filled)
ASCE-7 93
70.000
C: Open Terrain
1.0
Moderately Smooth
0.0000
33.0
N
0.0100
0.0000
0.0000
Seismic Design Code

UBC Seismic Zone (1=1,2=2a,3=2b,4=3,5=4)
UBC Importance Factor
UBC Soil Type
UBC Horizontal Force Factor
UBC Percent Seismic for Hydrotest
UBC 94
0.000
1.000
S1
3.000
0.000
Design Nozzle for Des. Press. + St. Head

Consider MAP New and Cold in Noz. Design
Consider External Loads for Nozzle Des.
Use ASME VIII-1 Appendix 1-9
Y
N
Y
N
Material Database Year
psig
psig
mile/hr
in
Current w/Addenda or Code Year
Configuration Directives:
Do not use Nozzle MDMT Interpretation VIII-1 01-37
Use Table G instead of exact equation for "A"
Shell Head Joints are Tapered
Compute "K" in corroded condition
Use Code Case 2286
Use the MAWP to compute the MDMT
Using Metric Material Databases, ASME II D
No
Yes
Yes
Yes
No
Yes
No
Complete Listing of Vessel Elements and Details:

Element From Node
Element To Node
Element Type
Description
Distance "FROM" to "TO"
10
20
Elliptical
Head I - Left
2.0000 in
Page 10 of 42

(Tag No. C-321 / SN. 28829)
SP III Limau
Element Outside Diameter
Element Thickness
Internal Corrosion Allowance
Nominal Thickness
External Corrosion Allowance
Design Internal Pressure
Design Temperature Internal Pressure
Design External Pressure
Design Temperature External Pressure
Effective Diameter Multiplier
Material Name
Allowable Stress, Ambient
Allowable Stress, Operating
Allowable Stress, Hydrotest
Material Density
P Number Thickness
Yield Stress, Operating
UCS-66 Chart Curve Designation
External Pressure Chart Name
UNS Number
Product Form
Efficiency, Longitudinal Seam
Efficiency, Circumferential Seam
Elliptical Head Factor
72.000
34.350
3.1750
0.0000
0.0000
600.00
300
0.0000
0
1.2
SA-516 70
20000.
20000.
26000.
0.2800
31.750
33600.
B
CS-2
K02700
Plate
1.0
1.0
2.0
in
mm
mm
mm
mm
psig
F
psig
F
psi
psi
psi
lb/in
mm
psi
-------------------------------------------------------------------Element From Node

Element To Node
Element Type
Description
Element Thickness
Nominal Thickness
Material Name
20
30
Cylinder
Shell 1
72.000
72.000
33.120
3.1750
0.0000
0.0000
600.00
300
0.0000
0
1.2
SA-516 70
1.0
1.0
Element From Node

Detail Type
Detail ID
Dist. from "FROM" Node / Offset dist
Nozzle Diameter
Nozzle Schedule
Nozzle Class
Layout Angle
Blind Flange (Y/N)
Weight of Nozzle ( Used if > 0 )
Grade of Attached Flange
Nozzle Matl
20
Nozzle
N4 3"
5.0000
3.0
None
300
90.0
N
0.0000
GR 1.1
SA-106 B
Element From Node

Detail Type
Detail ID
Nozzle Diameter
Nozzle Schedule
Nozzle Class
20
Nozzle
N3 4"
15.000
4.0
None
300
in
in
mm
mm
mm
mm
psig
F
psig
F
in
in.
lbf
in
in.
Page 11 of 42

(Tag No. C-321 / SN. 28829)
SP III Limau
Layout Angle
Blind Flange (Y/N)
Nozzle Matl
270.0
N
0.0000
GR 1.1
SA-106 B
lbf

Element To Node
Element Type
Description
Element Thickness
Nominal Thickness
Material Name
Element From Node
Detail Type
Detail ID
Nozzle Diameter
Nozzle Schedule
Nozzle Class
Layout Angle
Blind Flange (Y/N)
Nozzle Matl
30
40
Cylinder
Shell 2
72.000
72.000
32.840
3.1750
0.0000
0.0000
600.00
300
0.0000
0
1.2
SA-516 70
1.0
1.0
30
Nozzle
N1 8"
12.000
8.0
None
300
270.0
N
0.0000
GR 1.1
SA-106 B
in
in
mm
mm
mm
mm
psig
F
psig
F
in
in.
lbf

Element To Node
Element Type
Description
Element Thickness
Nominal Thickness
Material Name
40
50
Cylinder
Shell 3
72.000
72.000
32.480
3.1750
0.0000
0.0000
600.00
300
0.0000
0
1.2
SA-516 70
1.0
1.0
in
in
mm
mm
mm
mm
psig
F
psig
F

Element To Node
Element Type
50
60
Cylinder
Page 12 of 42

(Tag No. C-321 / SN. 28829)
SP III Limau
Description
Element Thickness
Nominal Thickness
Material Name
Shell 4
60.000
72.000
33.050
3.1750
0.0000
0.0000
600.00
300
0.0000
0
1.2
SA-516 70
1.0
1.0
in
in
mm
mm
mm
mm
psig
F
psig
F

Element To Node
Element Type
Description
Element Thickness
Nominal Thickness
Material Name
Elliptical Head Factor
60
70
Elliptical
Head II - Right
2.0000 in
72.000 in
34.720 mm
3.1750 mm
0.0000 mm
0.0000 mm
600.00 psig
300 F
0.0000 psig
0 F
1.2
SA-516 70
1.0
1.0
2.0
Element From Node

Detail Type
Detail ID
Nozzle Diameter
Nozzle Schedule
Nozzle Class
Layout Angle
Blind Flange (Y/N)
Nozzle Matl
60
Nozzle
N2 8"
20.000
8.0
None
300
90.0
N
0.0000
GR 1.1
SA-106 B
in
in.
lbf
Element Thickness, Pressure, Diameter and Allowable Stress :

|
| Int. Press |
Nominal | Total Corr|
Element | Allowable |
From| To | + Liq. Hd | Thickness | Allowance |
Diameter | Stress(SE)|
|
|
psig
|
mm
|
mm
|
in
|
psi
|
--------------------------------------------------------------------------Head I - L|
600.00 |
... |
3.1750 |
72.000 |
20000. |
Shell 1|
600.00 |
... |
3.1750 |
72.000 |
20000. |
Shell 2|
600.00 |
... |
3.1750 |
72.000 |
20000. |
Shell 3|
600.00 |
... |
3.1750 |
72.000 |
20000. |
Shell 4|
600.00 |
... |
3.1750 |
72.000 |
20000. |
Head II -|
600.00 |
... |
3.1750 |
72.000 |
20000. |
Element Required Thickness and MAWP :
Page 13 of 42

(Tag No. C-321 / SN. 28829)
SP III Limau
|
|
Design |
M.A.W.P. |
M.A.P. |
Minimum |
Required |
From| To |
Pressure | Corroded | New & Cold | Thickness | Thickness |
|
|
psig
|
psig
|
psig
|
mm
|
mm
|
---------------------------------------------------------------------------Head I - L|
600.000 |
691.295 |
777.602 |
34.3500 |
29.7622 |
Shell 1|
600.000 |
663.659 |
735.059 |
33.1200 |
30.2817 |
Shell 2|
600.000 |
657.371 |
728.754 |
32.8400 |
30.2817 |
Shell 3|
600.000 |
649.290 |
720.650 |
32.4800 |
30.2817 |
Shell 4|
600.000 |
662.087 |
733.483 |
33.0500 |
30.2817 |
Head II -|
600.000 |
699.615 |
786.275 |
34.7200 |
29.7621 |
Minimum
649.290
720.649
MAWP: 649.290 psig, limited by: Shell 3.
Internal Pressure Calculation Results :
ASME Code, Section VIII, Division 1, 2013
Elliptical Head From 10 To 20 SA-516 70 , UCS-66 Crv. B at 300 F
Head I - Left
Material UNS Number:
K02700
Required Thickness due to Internal Pressure [tr]:

= (P*Do*Kcor)/(2*S*E+2*P*(Kcor-0.1)) per Appendix 1-4 (c)
= (600.000*72.0000*0.995)/(2*20000.00*1.00+2*600.000*(0.995-0.1))
= 26.5872 + 3.1750 = 29.7622 mm
Max.
=
=
=
Allowable Working Pressure at given Thickness, corroded [MAWP]:

(2*S*E*t)/(Kcor*Do-2*t*(Kcor-0.1)) per Appendix 1-4 (c)
(2*20000.00*1.00*31.1750)/(0.995*72.0000-2*31.1750*(1.00-0.1))
706.810 psig
Maximum Allowable Pressure, New and Cold [MAPNC]:

= (2*S*E*t)/(K*Do-2*t*(K-0.1)) per Appendix 1-4 (c)
= (2*20000.00*1.00*34.3500)/(1.000*72.0000-2*34.3500*(1.000-0.1))
= 777.602 psig
Actual stress at given pressure and thickness, corroded [Sact]:
= (P*(Kcor*Do-2*t*(Kcor-0.1)))/(2*E*t)
= (600.000*(0.995*72.0000-2*31.1750*(0.995-0.1)))/(2*1.00*31.1750)
= 16977.678 psi
Straight Flange Required Thickness:
= (P*Ro)/(S*E+0.4*P) + ca
per Appendix 1-1 (a)(1)
= (600.000*36.0000)/(20000.00*1.00+0.4*600.000)+3.175
= 30.282 mm
Straight Flange Maximum Allowable Working Pressure:
= (S*E*t)/(Ro-0.4*t) per Appendix 1-1 (a)(1)
= (20000.00 * 1.00 * 31.1750 )/(36.0000 - 0.4 * 31.1750 )
= 691.295 psig
Factor K, corroded condition [Kcor]:
= ( 2 + ( Inside Diameter/( 2 * Inside Head Depth ))2)/6
= ( 2 + ( 1766.450/( 2 * 443.200 ))2)/6
= 0.995233
Percent Elong. per UCS-79, VIII-1-01-57 (75*tnom/Rf)*(1-Rf/Ro)
Note: Please Check Requirements of UCS-79 as Elongation is > 5%.
8.143 %
MDMT Calculations in the Knuckle Portion:

Govrn. thk, tg = 34.350 , tr = 28.710 , c = 3.1750 mm , E* = 1.00
Page 14 of 42

(Tag No. C-321 / SN. 28829)
SP III Limau
Stress Ratio = tr * (E*)/(tg - c) = 0.921 , Temp. Reduction = 8 F
46 F
38 F
Min Metal Temp. w/o impact per UCS-66, Curve B

Min Metal Temp. at Required thickness (UCS 66.1)
MDMT Calculations in the Head Straight Flange:
46 F
40 F

Cylindrical Shell From 20 To 30 SA-516 70 , UCS-66 Crv. B at 300 F
Shell 1
K02700

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

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

= (20000.00*1.00*33.1200)/(36.0000-0.4*33.1200)
= 735.059 psig
= (P*(Ro-0.4*t))/(E*t)
= (600.000*((36.0000-0.4*29.9450))/(1.00*29.9450)
= 18081.588 psi
Percent Elongation per UCS-79
(50*tnom/Rf)*(1-Rf/Ro)
1.844 %
Minimum Design Metal Temperature Results:

44 F
42 F

Shell 2
K02700

= (600.000*36.0000)/(20000.00*1.00+0.4*600.000)
= 27.1067 + 3.1750 = 30.2817 mm
Max.
=
=
=

(20000.00*1.00*29.6650)/(36.0000-0.4*29.6650)
657.371 psig
Page 15 of 42

(Tag No. C-321 / SN. 28829)
SP III Limau
= (20000.00*1.00*32.8400)/(36.0000-0.4*32.8400)
= 728.754 psig
= (P*(Ro-0.4*t))/(E*t)
= (600.000*((36.0000-0.4*29.6650))/(1.00*29.6650)
= 18254.521 psi
1.829 %

44 F
42 F

Shell 3
K02700

= (600.000*36.0000)/(20000.00*1.00+0.4*600.000)
= 27.1067 + 3.1750 = 30.2817 mm
Max.
=
=
=

(20000.00*1.00*29.3050)/(36.0000-0.4*29.3050)
649.290 psig

= (20000.00*1.00*32.4800)/(36.0000-0.4*32.4800)
= 720.650 psig
= (P*(Ro-0.4*t))/(E*t)
= (600.000*((36.0000-0.4*29.3050))/(1.00*29.3050)
= 18481.719 psi
1.808 %

43 F

Shell 4
K02700

= (600.000*36.0000)/(20000.00*1.00+0.4*600.000)
= 27.1067 + 3.1750 = 30.2817 mm
Page 16 of 42

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

(20000.00*1.00*29.8750)/(36.0000-0.4*29.8750)
662.087 psig

= (20000.00*1.00*33.0500)/(36.0000-0.4*33.0500)
= 733.483 psig
= (P*(Ro-0.4*t))/(E*t)
= (600.000*((36.0000-0.4*29.8750))/(1.00*29.8750)
= 18124.520 psi
1.840 %

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

Head II - Right
K02700

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

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

= (2*S*E*t)/(K*Do-2*t*(K-0.1)) per Appendix 1-4 (c)
= (2*20000.00*1.00*34.7200)/(1.000*72.0000-2*34.7200*(1.000-0.1))
= 786.275 psig
= (P*(Kcor*Do-2*t*(Kcor-0.1)))/(2*E*t)
= (600.000*(0.995*72.0000-2*31.5450*(0.995-0.1)))/(2*1.00*31.5450)
= 16772.209 psi
Straight Flange Required Thickness:
= (P*Ro)/(S*E+0.4*P) + ca
per Appendix 1-1 (a)(1)
= (600.000*36.0000)/(20000.00*1.00+0.4*600.000)+3.175
= 30.282 mm
Straight Flange Maximum Allowable Working Pressure:
= (20000.00 * 1.00 * 31.5450 )/(36.0000 - 0.4 * 31.5450 )
= 699.615 psig
Factor K, corroded condition [Kcor]:
= ( 2 + ( Inside Diameter/( 2 * Inside Head Depth ))2)/6
= ( 2 + ( 1765.710/( 2 * 443.015 ))2)/6
= 0.995231
Page 17 of 42

(Tag No. C-321 / SN. 28829)
SP III Limau
Percent Elong. per UCS-79, VIII-1-01-57 (75*tnom/Rf)*(1-Rf/Ro)
Note: Please Check Requirements of UCS-79 as Elongation is > 5%.
8.229 %
MDMT Calculations in the Knuckle Portion:

46 F
37 F

MDMT Calculations in the Head Straight Flange:
46 F
39 F

Hydrostatic Test Pressure Results:
Pressure
Pressure
Pressure
Pressure
Pressure
per
per
per
per
per
UG99b
UG99b[36]
UG99c
UG100
PED
=
=
=
=
=
1.3 * M.A.W.P. * Sa/S

1.3 * Design Pres * Sa/S
1.3 * M.A.P. - Head(Hyd)
1.1 * M.A.W.P. * Sa/S
1.43 * MAWP
844.077
780.000
934.244
714.219
928.485
psig
psig
psig
psig
psig
UG-99(b), Test Pressure Calculation:

= Test Factor * MAWP * Stress Ratio
= 1.3 * 649.290 * 1.000
= 844.077 psig
Horizontal Test performed per: UG-99b
Please note that Nozzle, Shell, Head, Flange, etc MAWPs are all considered
when determining the hydrotest pressure for those test types that are based
on the MAWP of the vessel.
Stresses on Elements due to Test Pressure:
From To
Stress
Allowable
Ratio
Pressure
---------------------------------------------------------------------Head I - Left
21776.6
26000.0
0.838
846.68
Shell 1
23037.0
26000.0
0.886
846.68
Shell 2
23236.3
26000.0
0.894
846.68
Shell 3
23497.6
26000.0
0.904
846.68
Shell 4
23086.5
26000.0
0.888
846.68
Head II - Right
21536.4
26000.0
0.828
846.68
---------------------------------------------------------------------Stress ratios for Nozzle and Pad Materials:
Description
Pad/Nozzle
Ambient
Operating
ratio
---------------------------------------------------------------------N4 3"
Nozzle 17100.00
17100.00
1.000
N4 3"
Pad 20000.00
20000.00
1.000
N3 4"
Nozzle 17100.00
17100.00
1.000
N3 4"
Pad 20000.00
20000.00
1.000
N1 8"
Nozzle 17100.00
17100.00
1.000
N1 8"
Pad 20000.00
20000.00
1.000
N2 8"
Nozzle 17100.00
17100.00
1.000
N2 8"
Pad 20000.00
20000.00
1.000
---------------------------------------------------------------------Minimum
1.000
Page 18 of 42

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

Operating
Ambient
Temperature
Class
Grade|Group
psig
psig
F
---------------------------------------------------------------------------N4 3"
655.0
740.0
300
300
GR 1.1
N3 4"
655.0
740.0
300
300
GR 1.1
N1 8"
655.0
740.0
300
300
GR 1.1
N2 8"
655.0
740.0
300
300
GR 1.1
---------------------------------------------------------------------------Minimum Rating 655.000
740.000 psig
(for Core Elements)
Note: ANSI Ratings are per ANSI/ASME B16.5 2009 Edition
Nozzle Schedule:
Nominal Flange
Noz.
Wall
Re-Pad
Cut
Size Sch/Type
O/Dia
Thk
ODia Thick Length
in. Cls
in.
mm
mm
mm
mm
-----------------------------------------------------------------------------N4 3"
3.000 300 WNF
3.000 6.120
8.00 33.160 110.14
N3 4"
4.000 300 WNF
4.000 12.720
8.00 33.200 110.79
N1 8"
8.000 300 WNF
8.000 13.400
12.00 32.230 114.91
N2 8"
8.000 300 WNF
8.000 13.080
12.00 32.200 226.54
Description
General Notes for the above table:

The Cut Length is the Outside Projection + Inside Projection + Drop +
In Plane Shell Thickness. This value does not include weld gaps,
nor does it account for shrinkage.
In the case of Oblique Nozzles, the Outside Diameter must
be increased. The Re-Pad WIDTH around the nozzle is calculated as follows:
Width of Pad = (Pad Outside Dia. (per above) - Nozzle Outside Dia.)/2
For hub nozzles, the thickness and diameter shown are those of the smaller
and thinner section.
Nozzle Material and Weld Fillet Leg Size Details:
Shl Grve Noz Shl/Pad Pad OD Pad Grve Inside
Nozzle
Material
Weld
Weld
Weld
Weld
Weld
mm
mm
mm
mm
mm
-----------------------------------------------------------------------------N4 3"
SA-106 B
12.700
7.620
15.240 254.000
N3 4"
SA-106 B
12.700
12.700
25.400 254.000
N1 8"
SA-106 B
32.840
12.700
25.400 660.400
-
Page 19 of 42

(Tag No. C-321 / SN. 28829)
SP III Limau
N2 8"
SA-106 B
34.719
12.700
25.400
711.200
Note: The Outside projections below do not include the flange thickness.
Nozzle Miscellaneous Data:
Elevation/Distance
Layout
Projection
Installed In
From Datum
Angle
Outside
Inside
Component
in
deg.
mm
mm
---------------------------------------------------------------------------N4 3"
5.000
90.00
76.20
0.00
Shell 1
N3 4"
15.000
270.00
76.20
0.00
Shell 1
N1 8"
84.000
270.00
76.20
0.00
Shell 2
N2 8"
90.00
152.40
0.00
Head II - Ri
Nozzle
Nozzle Calculation Summary:

Description
MAWP
Ext
MAPNC
UG45 [tr] Weld
Areas or
psig
psig
Path
Stresses
--------------------------------------------------------------------------N4 3"
663.66
...
...
OK 4.80
OK
Passed
N3 4"
663.66
...
...
OK 5.02
OK
Passed
N1 8"
657.37
...
...
OK 7.16
OK
Passed
N2 8"
675.55
...
...
OK 7.16
OK
Passed
N2 8"
689.90
...
...
OK 7.16
OK
Passed
--------------------------------------------------------------------------Min. - Nozzles
657.37 N1 8"
Min. Shell&Flgs
649.29 40
50
720.65
Computed Vessel M.A.W.P.
649.29
psig
Note: MAWPs (Internal Case) shown above are at the High Point.
Check the Spatial Relationship between the Nozzles
From Node
20
20
30
60
Nozzle Description
N4 3"
N3 4"
N1 8"
N2 8"
X Coordinate,
7.000
17.000
86.000
0.000
Layout Angle,
90.000
270.000
270.000
90.000
Dia. Limit
26.579
22.863
26.687
13.940
The nozzle spacing is computed by the following:

= Sqrt( ll + lc ) where
ll - Arc length along the inside vessel surface in the long. direction.
lc - Arc length along the inside vessel surface in the circ. direction
If any interferences/violations are found, they will be noted below.
No interference violations have been detected !
ASME Code, Section VIII, Division 1, 2013
Diameter Spec : 72.000 in OD
Vessel Design Length, Tangent to Tangent
Specified Datum Line Distance
Shell Material
Nozzle Material
Re-Pad Material
Internal Design Temperature
Internal Design Pressure
280.00
in
2.00
in
SA-516 70
SA-106 B
SA-516 70
300
600.000
F
psig
Page 20 of 42

(Tag No. C-321 / SN. 28829)
SP III Limau
External Design Temperature
Maximum Allowable Working Pressure
Hydrostatic Test Pressure
Required Minimum Design Metal Temperature
Warmest Computed Minimum Design Metal Temperature
0
649.290
844.077
50
43
F
psig
psig
F
F
Wind Design Code

Earthquake Design Code
ASCE-93
UBC-94
Element Pressures and MAWP: psig

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

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

Fabricated + Water ( Full )
Fab. + Rem. Intls.+ Shipping App.
Fab. + Rem. Intls.+ Insul. (etc)
Fab. + Intls. + Details + Wghts.
Empty + Operating Liquid (No CA)
Empty Weight + Water (Full)
28782.1
70185.2
28782.1
28782.1
28782.1
28782.1
70185.2
lbm
lbm
lbm
lbm
lbm
lbm
lbm
Page 21 of 42

(Tag No. C-321 / SN. 28829)
SP III Limau
6. MEKANISME KERUSAKAN &

PERENCANAAN INSPEKSI
6. DAMAGE MECHANISMS &

INSPECTION PLAN
6.1. Mekanisme kerusakan
6.1. Damage Mechanisms
Bejana tekan rentan terhadap berbagai jenis

kerusakan oleh beberapa mekanisme. Jenis
kerusakan umum dan mekanisme adalah
sebagai berikut:
Pressure vessels are susceptible to various

types of damage by several mechanisms.
Typical damage types and mechanisms are
as follows:
A. General and local metal loss:
A. General and local metal loss:
Sulfidation;
Oxidation;
Microbiologically induced corrosion;
Naphthenic acid corrosion;
Erosion/erosion-corrosion;
Galvanic.
Sulfidation;
Oxidation;
Microbiologically induced corrosion;
Naphthenic acid corrosion;
Erosion/erosion-corrosion;
Galvanic.
B. Surface connected cracking:
B. Surface connected cracking:
Fatigue;
Caustic stress corrosion cracking;
Sulfide stress corrosion cracking.
Fatigue;
Caustic stress corrosion cracking;
Sulfide stress corrosion cracking.
C. Subsurface cracking:
C. Subsurface cracking:
Hydrogen induced cracking.
Hydrogen induced cracking.
D. Microfissuring/microvoid formation:
D. Microfissuring/microvoid formation:
High temperature hydrogen attack;

Creep.
High temperature hydrogen attack;

Creep.
E. Metallurgical changes:
E. Metallurgical changes:
Graphitization;
Temper embrittlement.
Graphitization;
Temper embrittlement.
F. Blistering:
F. Blistering:
Hydrogen blistering.
Hydrogen blistering.
G. Dimensional changes:
G. Dimensional changes:
Creep and stress rupture

Thermal.
Creep and stress rupture

Thermal.
Page 22 of 42

(Tag No. C-321 / SN. 28829)
SP III Limau
H. Material Properties Changes
H. Material Properties Changes
Brittle fracture.
Brittle fracture.
Pressure vessel and Fluid data as following:
Pressure vessel and Fluid data as following:
No
Description
Data
Service
Gas & Oil
Material
Carbon Steel
Design Pressure (psig)
600
Operating Pressure (psig)
Design Temperature (0F)
300
Operating Temperature ( F)
Flow
Hydrodinamic
Loading
Static
Insulation
No
10
PH
11
CO2 (mole%)
Yes
12
H2S (mole%)
Yes
13
H2O (mole%)
Yes
Page 23 of 42

(Tag No. C-321 / SN. 28829)
SP III Limau
Damage Mechanisms Screening Table:
Page 24 of 42

(Tag No. C-321 / SN. 28829)
SP III Limau
Page 25 of 42

(Tag No. C-321 / SN. 28829)
SP III Limau
Page 26 of 42

(Tag No. C-321 / SN. 28829)
SP III Limau
Dari tabel diatas, beberapa kemungkinan jenis From the above screening table, the following
damage mechanisms yang diduga terjadi pada damage mechanisms are expected to occurs at
bejana tekan adalah sebagai berikut :
pressure vessel:
No
Damage Mechanisms
Mode
Possibility
Uniform Corrosion
Thinning
Medium
Pitting Corrosion
Thinning
Low
Erosion - Corrosion
Thinning
Low
Sulfide Stress Cracking
Cracking
Low
Page 27 of 42

(Tag No. C-321 / SN. 28829)
SP III Limau
6.2.
Perancenaan Inspeksi
6.2.
Inspection Plan
Perencenaan
inspeksi
dilakukan
berdasarkan pada kemungkinan dari
damage mechanisms. Metode serta
pelaksanaan NDE akan di evaluasi untuk
meyakinkan bahwa metode tersebut dapat
mengidentifikasi
damage mechanisms
dan beberapa kemungkinan kerusakan
yang lain.
The inspection plan is developed based

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

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

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

codes and standards
Page 28 of 42

(Tag No. C-321 / SN. 28829)
SP III Limau
Inspection and Monitoring Methods
Page 29 of 42

(Tag No. C-321 / SN. 28829)
SP III Limau
Page 30 of 42

(Tag No. C-321 / SN. 28829)
SP III Limau
Page 31 of 42

(Tag No. C-321 / SN. 28829)
SP III Limau
Page 32 of 42

(Tag No. C-321 / SN. 28829)
SP III Limau
Berdasarkan dari metode inspeksi dan monitoring Based on the above inspection and monitoring
diatas, perencanaan inspeksi yang diajukan untuk methods, the proposed inspection plan for this
bejana tekan ini adalah sebagai berikut :
pressure vessel as follow:
No
Damage
Inspection
Mechanisms
methods
Uniform corrossion
Pitting Corrosion
Visual Inspection
UT Thickness
3
Erosion-Corrosion
Sulfide
Cracking
Stress
Scanning
UT Flaw Scanning
of MPI
Coverage
Interval
Visual inspection of 100% of the

exposed surface area with followup by UT or pit gauge as required.
(Shell, head, nozzle and supports)
Minimal 20% examination, and Next 3 years,
followed
by
spot
external
for next
ultrasonic
thickness
SKPP
measurements. (Shell, head and
nozzle)
Minimal 20% examination of
weldments (Nozzles to shell, Tjoints)
Page 33 of 42

(Tag No. C-321 / SN. 28829)
SP III Limau
7. PENILAIAN KONDISI
7. CONDITION ASSESSMENT
Salah satu fokus utama dari inspeksi bejana

tekan adalah pembentukan kemampuan
bejana tekanan untuk aman melanjutkan
operasi
.
One of the primary focuses of the pressure

vessel inspection is the establishment of a
pressure vessels ability to safely continue
operation.
Kondisi penilaian harus menjadi bagian resmi

dari setiap pemeriksaan, dan penentuan
kondisi bejana tekan yang diterima harus
didokumentasikan secara resmi . Kondisi ini
umumnya akan didefinisikan sebagai :
Condition assessment should be a formal

part of every inspection, and the
determination of acceptable vessel condition
should be formally documented. The
condition will generally be defined as:
1) kondisi "seperti baru", tidak memerlukan

tindakan
tambahan
sebelum
jadwal
pemeriksaan
berikutnya;
2) perbaikan kecil seperti mengecat,
membersihkan, atau pekerjaan permukaan
3) membutuhkan perbaikan besar atau
penggantian semua atau bagian bejana tekan.
1) like new condition, not requiring any

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

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

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

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

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

menempatkan degradasi bejana tekan,
perawatan harus dilakukan untuk memastikan
bahwa
degradasi
ini
baik:
In cases where an inspector locates

degradation in a pressure vessel, care must
be taken to ensure that this degradation either:
1) Tidak mempengaruhi kemampuan bejana

tekan untuk melanjutkan operasi yang aman ,
2) Apakah diganti oleh perbaikan atau
1) Does not affect the ability of the vessel to

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

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

degradation.
3) that the structural integrity and design
parameters of the vessel are maintained
or reevaluated to ensure the vessel meets
the applicable code of construction.
7.1 Ketebalan Yang Diperlukan
7.1 Thickness Requirements
Dari hasil inspeksi di atas dan perhitungan

teknis yang telah dilakukan, kondisi bejana
tekan pada saat ini ditampilkan dalam tabel
berikut.
From the above inspection results and

engineering calculations performed, the
current conditions of pressure vessel was
presented in the following table.
Design Condition = 600 psig

Component
Min. Actual
Thickness (mm)
Required
Thickness (mm)
Remarks
Head I Left
34.35
29.76
Acceptable
Shell 1
33.12
30.28
Acceptable
Shell 2
32.84
30.28
Acceptable
Shell 3
32.48
30.28
Acceptable
Shell 4
33.05
30.28
Acceptable
Head II - Right
34.72
29.76
Acceptable
Component
Min. Actual
Thickness (mm)
Required
Thickness (mm)
Areas or stresses
N1 8
13.40
7.16
Passed
N2 8
13.08
7.16
Passed
N3 4
12.72
5.02
Passed
N4 3
6.12
4.80
Passed
MPI
Pengujian ini tidak dilakukan pada bejana
tekan ini.
MPI
This test is not performed at this pressure
vessel.
Page 35 of 42

(Tag No. C-321 / SN. 28829)
SP III Limau
7.2 Sisa Umur
7.2 Remaining Life
Laju Korosi
Laju korosi untuk penipisan penyebab
kerusakan mekanis ditentukan dengan
perbedaan antara pembacaan dua ketebalan
dibagi dengan interval waktu antara
pembacaan.
Laju korosi dihitung berdasar rumus berikut :
Corrosion Rate
Corrosion rate for thinning damage
mechanisms is determined by the
difference between two thickness readings
divided by the time interval between the
readings.
The corrosion rate was calculated from the
following formula:
Corrosion
Rate (ST)
Corrosion
Rate (LT)
t previous - t actual
time between t previous and t actual (years)
Or
t initial - t actual
time between t initial and t actual (years)
Dimana :
t awal : tebal awal sama dengan CML sebagai
t aktual. Baik pada pengukuran ketebalan
pertama pada saat CML atau ketebalan pada
saat awal sebuah laju korosi lingkungan baru,
dalam mm.
Where :
t initial : the initial thickness at the same CML
as t actual. Its either the first thickness
measurement at this CML or the thickness at
the start of a new corrosion rate environment,
in mm.
t aktual : ketebalan sebenarnya sebuah CML,

dalam mm, diukur saat inspeksi terakhir.
t actual : the actual thickness of a CML, in mm,

measured during the last inspection.
ST (Short Term): Laju korosi yang dihitung

menggunakan ketebalan hasil pengukuran
inspeksi sebelumnya (Short Term).
ST (Short Term): The corrosion rate is

calculated using the previous inspection
thickness measurement results (Short Term).
LT (Long Term) : laju korosi yang dihitung dari

ketebalan nominal (awal dibangun).
CML (Condition Monitoring Location) : titik
yang dianjurkan /difokuskan untuk diambil nilai
ketebalan dindingnya (pada umumnya titik
yang diangap kritis).
LT (Long Term) : corrotion rate which is

calculated from initial thickness.
CML (Condition Monitoring Location) :
measurement point which is where is wall
thickness measurement are taken (usually
critical point) .
Sisa Umur
Sisa umur dari bejana tekan (dalam tahun)
dapat dihitung dengan rumus berikut ini :
Remaining Life
The remaining life of the pressure vessel (in
years) shall be calculated from the following
formula:
Page 36 of 42

(Tag No. C-321 / SN. 28829)
SP III Limau
Remaining
Life
t actual - t required
corrosion rate
Dimana :
Where :
t aktual : tebal aktual pada sebuah CML,

dalam mm, diukur saat inspeksi terakhir
t actual : the actual thickness of a CML, in mm,

measured during the last inspection.
t dibutuhkan : tebal yang diperlukan pada CML

atau komponen, dalam mm, sebagai
pengukuran t aktual. Dihitung dengan rumus
desain.
t required : the required thickness at the same

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


Hasil perhitungan laju korosi dan sisa umur Calculation results of corrosion rate and
ditampilkan dalam tabel berikut :
remaining life was summarised in the following
table :
Component
Initial
Thickness
1
(mm)
Min. Actual
Thickness (mm)
Required
Thickness (mm)
Corrosion rate
2
(mm/year)
Remaining
Life
3
(Years)
Head I Left
34.93
34.35
29.76
0.072
63
Shell 1
34.93
33.12
30.28
0.226
12
Shell 2
34.93
32.84
30.28
0.261
Shell 3
34.93
32.48
30.28
0.306
Shell 4
34.93
33.05
30.28
0.235
11
Head II - Right
34.93
34.72
29.76
0.026
193
Note
1: Initial thickness based on nameplate for shell, initial thickness assummed from head .
2: Because T initial > T actual, Corr. rate and RL calculation can not be performed.
3:This calculation performed using API 510
Page 37 of 42

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

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

C-321 / Sn. 28829) is in good condition to safely
operated based on parameter below :
MAWP
Design Temperature :
600 PSIG
300 oF
Tidak ada temuan signifikan selama inspeksi

yang berpengaruh terhadap kinerja bejana
tekan untuk lanjut beroperasi.
There was no significant anomaly found uring

inspection that might affect the ability of the
pressure vessel to continue safe operation.
Direkomendasikan untuk merawat kondisi

bejana tekan dalam keadaan siap beroperasi
seperti rekomendasi berikut:
It is recommended to maintain the vessel

conditions to stay in fit for services as the
following recommendations:
Inspeksi
rutin
oleh
operator
untuk
mendeteksi dini kebocoran, tumpahan dan
kondisi operasi tidak normal yang lain (API
Std 510 5.5.4)
Perform routine inspection by operator to

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

rutin dan re-setting pada katup pengaman
tekanan (API Std 510- 6.6, API RP 576)
Install PSV and perform routine maintenance

(re-setting) of pressure safety valves.(API
Std 510- 6.6, API RP 576).
Inspeksi internal pada bejana tekan sesuai

rekomendasi API Standards, termasuk
perbaikan jika diperlukan (API Std 510
5.5.2, 6.5)
Perform internal inspection of pressure

vessel as per recommendations of API
Standards, including repair as required (API
Std 510 5.5.2, 6.5).
Melakukan
pemasangan alat pengukur
tekanan dan suhu pada bejana tekan.
Install pressure and temperature gauge at

this pressure vessel.
Melakukan pemasangan sistem grounding

untuk beroperasi dengan aman
Melakukan
verifikasi
ulang
untuk
pengambilan titik UT thickness dikarenakan
ketebalan dinding minimum > ketebalan
dinding pada saat awal pembuatan.
Install grounding system for safe operation
Perform verification for UT thickness

measurement, found that minimum actual
thickness > thickness nominal (initial).
Page 38 of 42

(Tag No. C-321 / SN. 28829)
SP III Limau
Perencanaan inspeksi yang dianjurkan :
Damage
Inspection
Mechanisms
methods
Uniform corrossion
Visual Inspection
Pitting Corrosion
No
UT Thickness
3
Erosion-Corrosion
Scanning
Sulfide
UT Flaw
Cracking
Stress
Scanning of MPI
Recommeded next Inspection Plan:
Coverage
Interval
Visual inspection of 100% of

the exposed surface area with
follow-up by UT or pit gauge
as required. (Shell, head,
nozzle and supports)
Minimal 20% examination,
and followed by spot external
ultrasonic
thickness
measurements. (Shell, head
and nozzle)
Next 3 years,
for next
SKPP
Minimal 20% examination of

weldments (Nozzles to shell,
T- joints)
Page 39 of 42

(Tag No. C-321 / SN. 28829)
SP III Limau
LAMPIRAN A
LAPORAN NDT
Page 40 of 42

(Tag No. C-321 / SN. 28829)
SP III Limau
LAMPIRAN B
PERHITUNGAN SISA UMUR
Page 41 of 42

PRESSURE EQUIPMENT
EQUIPMENT
TAG No
Operator
Location
:
:
:
:
Data Head I (Left)

- t initial
- t actual
- t required
- year built / operate
- year last inspection
:
:
:
:
:
34,93 mm
34,35 mm
29,76 mm
2006
2014
Corrosion rate
0,072 mm/year
Remaining Life
63,86 years
Remarks

C-321
PT Bintang Energi Pratama
-

PRESSURE EQUIPMENT
EQUIPMENT
TAG No
Operator
Location
:
:
:
:
Data Shell 3
- t initial
- t actual
- t required
:
:
:
:
:
34,93 mm
32,48 mm
30,28 mm
2006
2014
Corrosion rate
0,306 mm/year
Remaining Life

C-321
-
7,18 years
Remarks
- Thickness actual is greater than initial, assumed T shell = T Heads

PRESSURE EQUIPMENT
EQUIPMENT
TAG No
Operator
Location
:
:
:
:
Data Shell 1
- t initial
- t actual
- t required
:
:
:
:
:
34,93 mm
33,12 mm
30,28 mm
2006
2014
Corrosion rate
0,226 mm/year
Remaining Life
12,55 years

C-321
-
Remarks

PRESSURE EQUIPMENT
EQUIPMENT
TAG No
Operator
Location
:
:
:
:
Data Shell 4
- t initial
- t actual
- t required
:
:
:
:
:
34,93 mm
33,05 mm
30,28 mm
2006
2014
Corrosion rate
0,235 mm/year
Remaining Life
11,79 years

C-321
-
Remarks

PRESSURE EQUIPMENT
EQUIPMENT
TAG No
Operator
Location
:
:
:
:
Data Shell 2
- t initial
- t actual
- t required
:
:
:
:
:
34,93 mm
32,84 mm
30,28 mm
2006
2014
Corrosion rate
0,261 mm/year
Remaining Life

C-321
-
9,80 years
Remarks

PRESSURE EQUIPMENT
EQUIPMENT
TAG No
Operator
Location
:
:
:
:
Data Head II (Right)

- t initial
- t actual
- t required
:
:
:
:
:
34,93 mm
34,72 mm
29,76 mm
2006
2014
Corrosion rate
0,026 mm/year
Remaining Life
Remarks

C-321
-
193,56 years

(Tag No. C-321 / SN. 28829)
SP III Limau
LAMPIRAN C
DRAWING
Page 42 of 42
C-321
PRODUCTION SEPARATOR (NEW)
CAPACITY
: 40.000 BFPD
SIZE
: 72" OD X 276" S/S
DESIGN
: 600 PSIG/300OF
OPERASI
: 310 PSIG/227OF
PI
C321
2"
SET @ 600 PSIG

2"-300# X 3"-150#
-VG-30
(TYP-2)
2"
1"
3"
2"
8"
72"
C-321
2"
8"
2"
4"
2"
2"-VB-30
276"
DRAWING TITLE
SELATAN FACILITIES MODIFICATION
PRODUCTION SEPARATOR (C-321)
EMP MALACCA STRAIT S.A

3 Phase Production Separator C-321

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PRESSURE VESSELL ASSESSMENT REPORT

3 PHASE PRODUCTION SEPARATOR

PT. BINTANG ENERGI PRATAMA

PT BIRO KLASIFIKASI INDONESIA (BKI)

PT DINAMIKA TEKNIK PERSADA

Document no. : DTP/2015/R.

Issued For Review

3 Phase Production Separator

SUMMARY OF CHANGE SHEET

Issued For Review

Assummed Initial Thickness for

3 Phase Production Separator

4.1 Inspeksi Visual

4.1 Visual Inspection

4.2 Pengukuran ketebalan UT

4.2 UT Thickness Measurements

6. MEKANISME KERUSAKAN &

5.1 Design Condition - Nameplate

6. DAMAGE MECHANISMS &

6.1. Mekanisme kerusakan

6.1. Damage Mechanisms

6.2. Perancenaan Inspeksi

6.2. Inspection Plan

7.1 Ketebalan Yang Diperlukan

7.1 Thickness Requirements

7.2 Sisa Umur

7.2 Remaining Life

8.KESIMPULAN & SARAN

PERHITUNGAN SISA UMUR

REMAINING LIFE CALCULATION

3 Phase Production Separator

Laporan ini berisikan penilaian teknis untuk

This report outlines the engineering calculations

Peraturan Menteri pertambangan No.

Peraturan Menteri pertambangan No.

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

Surat edaran Dir. Jen. MIGAS No.

Surat edaran Dir. Jen. MIGAS No.

ASME BPV Section VIII, Rules for

ASME BPV Section VIII, Rules

API Publication 510, Pressure Vessel

API Publication 510, Pressure Vessel

API 572, Inspection

API 572, Inspection Practices for Pressure

ASME PCC 3, Inspection Planning

ASME PCC 3, Inspection Planning Using

API 571, Damage Mechanisms Affecting

API 571, Damage Mechanisms Affecting

API 581, Risk-Based Inspection Technology

3 Phase Production Separator

teknis diperlukan untuk

The engineering calculations required to

Tekanan kerja maksimal yang diijinkan

Maximum allowable working pressure

3 Phase Production Separator

MAWP untuk suatu operasi bejana tekan

The MAWP for the continued use of a

Perhitungan dapat dilakukan jika disain

Computations may be made only if the