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1.0 INTRODUCTION
1.1 Project Overview
ENI Muara Bakau is currently exploring Jangkrik Field and has founded a new reserve located
in Kutai Basin, 10 km offshore of East Kalimantan at a water depth of 450 m. The Jangkrik
field capacity is 608 MMSCFD, which is exported to domestic consumers by utilizing the
existing pipeline via tie-in to East Kalimantan System (EKS) Network. The gas from Jangkrik
field is lean gas with 300 MMSCFD will be segregated to flow to domestic consumers through
this project and small amount of rich gas (currently approximately 25 MMSCFD) from VICO’s
Nilam field will also be transported in the same segregation route. Segregation of the pipelines
and the most flexible configurations are needed to support the additional source of gas from
ENI that will not affect the sustainability of the existing exporters which are already using EKS
network.
The gases from ENI Jangkrik field and VICO Nilam export will flow through an existing 36”
Nilam-Badak Pipeline and it is connected to all of the existing Badak-Bontang Pipeline at
VICO’s Badak Export Maniforld (BEM) Area: 36”A,42”CD, 36”F, 42”H Badak-Bontang Gas
Pipeline. Several modifications are needed to facilitate the ENI Jangkrik lean gas into EKS
network in segregation mode.
1.2 Document Scope
This report describes the result of piping stress analysis for the selected piping system of
Badak Export Manifold (BEM) area, Balikpapan, East Kalimantan.
The purpose of the calculation is to check the compliance with the code ASME B31.8 for
stresses due to hydro test, sustained load, expansion load, occasional load and to obtain
loads on support for support design.
2.0 REFERENCES
The references, codes, and standards herein will be applied unless otherwise specified.
2.1. Project Document References
- Design Specification for civil and Structural
- Soil Investigation Bontang KM 53 (1131/UN17.9/TU/2018)
2.2. International Codes and Standards
American Concrete Institute Building Code Requirement for Reinforced
- ACI 318
Concrete and Commentary
- UBC 1997 Uniform Building Code 1997 Edition
ANSI/ASCE
- Minimum Design Loads for Buildings and other Structures
7-02
- AASHTO American Association of State Highway and Transportation Officials
2.3. National Codes and Standards
- SNI 03.1726.2012 Tata cara Perencanaan Ketahanan Gempa untuk Gedung
2.4 Unit of Measurement
Shall be in metric system
Used of Computer Software in Design Analysis
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- Staad Pro
- Microsoft Excel
3.0 ABBREVIATION
Abbreviation Description
EMB Eni Muara Bakau B.V.
EKS East Kalimantan System
BEM Badak Manifold Export
4.0 MATERIAL REQUIREMENTS
a) Concrete
2
Structural min. compressive strength f'c = 21 Mpa ≈ 210 kg/cm
2
Lean Concrete min. compressive strength f'c = 13 Mpa ≈ 130 kg/cm
b) Reinforcing Steel
2
Deformed bar ASTM A615 Gr.60 or equal fy = 400 Mpa ≈ 4000 kg/cm
Plain bar ASTM A615 Gr.40 or equal fyt = 235 Mpa ≈ 2400 kg/cm2
2
c) Structural Steel: : SS400, Yield Stress (Fy) = 2400 kg/cm (245 Mpa)
d) High Strength Bolt : ASTM A325 ≥ M-16
fT = 44 ksi ≈ 3000 kg/cm2 ≈ 300 Mpa
fV = 21 ksi ≈ 1470 kg/cm2 ≈ 147 Mpa
e) Ordinary Strength Bolt : ASTM A307 < M-16
fT = 20 ksi ≈ 1400 kg/cm2 ≈ 140 Mpa
fV = 10 ksi ≈ 700 kg/cm2 ≈ 70 Mpa
f) Anchor Bolt : ASTM 307
fT = 20 ksi ≈ 1400 kg/cm2 ≈ 140 Mpa
fV = 10 ksi ≈ 700 kg/cm2 ≈ 70 Mpa
g) Welding Code : AWS D1.1
h) Welding Electrode : AWS A5.1
i) Unit Weight
3 3
- Soil (compacted) gs = 1.70 ton/m = 1700 kN/m
3
- Concrete gc = 2.50 ton/m3 = 2500 kN/m
3 3
- Steel gst = 7.85 ton/m = 7850 kN/m
5.0 LOADING
5.1 From Piping Stress analysis
BONTANG KM53 LOADING DATA
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CASE 6 (OPE) W+T1+P1+U2
CASE 7 (OPE) W+T1+P1-U1
CASE 8 (OPE) W+T1+P1-U2
CASE 9 (OPE) W+T1+P1+WIN1
CASE 10 (OPE) W+T1+P1+WIN2
CASE 11 (OPE) W+T1+P1+WIN3
CASE 12 (OPE) W+T1+P1+WIN4
CASE 13 (SUS) W+P1
Note :
-X = Plant North
+Y = Upward
+Z = Perpendicular XY Plant
Load for Operating Platform is not indicated in this list
GLOBAL (S.PRO)
PS NUMBER Node Load Case FX KN. FY KN. FZ KN. FX KN. FY KN. FZ KN.
/PS-50A-048-05. 360 Rigid +Y; Rigid GUI
1(HYD) 6.703 -76.872 -3.319 3.319 -76.872 6.703
2(OPE) 5.582 -64.856 -2.508 2.508 -64.856 5.582
3(OPE) -2.305 -28.875 1.739 -1.739 -28.875 -2.305
4(OPE) -2.735 -37.099 2.506 -2.506 -37.099 -2.735
5(OPE) -1.414 -25.685 2.144 -2.144 -25.685 -1.414
6(OPE) -1.912 -28.024 2.049 -2.049 -28.024 -1.912
7(OPE) -2.908 -31.806 1.289 -1.289 -31.806 -2.908
8(OPE) -3.057 -31.073 0.555 -0.555 -31.073 -3.057
9(OPE) -2.255 -29.033 1.828 -1.828 -29.033 -2.255
10(OPE) -2.336 -28.635 1.656 -1.656 -28.635 -2.336
11(OPE) -2.246 -28.732 1.792 -1.792 -28.732 -2.246
12(OPE) -2.351 -28.96 1.691 -1.691 -28.960 -2.351
13(SUS) 5.583 -64.872 -2.509 2.509 -64.872 5.583
GLOBAL (S.PRO)
PS NUMBER Node Load Case FX KN. FY KN. FZ KN. FX KN. FY KN. FZ KN.
/PS-50A-048-04. 610 Rigid +Y; Rigid GUI
1(HYD) -2.863 -86.319 -2.769 2.769 -86.319 -2.863
2(OPE) -2.26 -76.866 -2.09 2.090 -76.866 -2.260
3(OPE) -0.428 -75.389 -7.539 7.539 -75.389 -0.428
4(OPE) -0.317 -76.099 -7.61 7.610 -76.099 -0.317
5(OPE) 26.34 -76.426 -7.643 7.643 -76.426 26.340
6(OPE) -2.89 -74.091 7.409 -7.409 -74.091 -2.890
7(OPE) -28.028 -74.526 -7.453 7.453 -74.526 -28.028
8(OPE) 3.425 -77.768 -7.777 7.777 -77.768 3.425
9(OPE) 4.76 -75.49 -7.549 7.549 -75.490 4.760
10(OPE) -5.508 -75.26 -7.526 7.526 -75.260 -5.508
11(OPE) -0.635 -75.154 -7.515 7.515 -75.154 -0.635
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12(OPE) -0.278 -75.585 -7.558 7.558 -75.585 -0.278
13(SUS) -2.261 -76.878 -2.091 2.091 -76.878 -2.261
GLOBAL (S.PRO)
PS NUMBER Node Load Case FX KN. FY KN. FZ KN. FX KN. FY KN. FZ KN.
/PS-50A-048-03. 860 Rigid +Y; Rigid GUI
1(HYD) 0.456 -46.735 -2.578 2.578 -46.74 0.456
2(OPE) 0.354 -29.666 -1.945 1.945 -29.67 0.354
3(OPE) 2.333 -36.118 -2.757 2.757 -36.12 2.333
4(OPE) 2.017 -34.256 -2.769 2.769 -34.26 2.017
5(OPE) 2.605 -35.029 -2.342 2.342 -35.03 2.605
6(OPE) 2.879 -36.561 -2.253 2.253 -36.56 2.879
7(OPE) 1.977 -36.904 -3.116 3.116 -36.90 1.977
8(OPE) 1.619 -35.68 -3.18 3.180 -35.68 1.619
9(OPE) 2.438 -35.835 -2.626 2.626 -35.84 2.438
10(OPE) 2.199 -36.395 -2.9 2.900 -36.40 2.199
11(OPE) 2.411 -36.28 -2.711 2.711 -36.28 2.411
12(OPE) 2.272 -35.957 -2.787 2.787 -35.96 2.272
13(SUS) 0.354 -29.688 -1.945 1.945 -29.69 0.354
GLOBAL (S.PRO)
PS NUMBER Node Load Case FX KN. FY KN. FZ KN. FX KN. FY KN. FZ KN.
/PS-50A-048-02. 960 Rigid +Y; Rigid GUI
1(HYD) -0.303 -39.613 -0.75 0.750 -39.613 -0.303
2(OPE) -0.191 -19.24 -0.632 0.632 -19.240 -0.191
3(OPE) 0.187 -3.264 -0.268 0.268 -3.264 0.187
4(OPE) 0.343 -7.085 -0.62 0.620 -7.085 0.343
5(OPE) 0.507 -6.674 -0.434 0.434 -6.674 0.507
6(OPE) 0.173 -2.622 -0.197 0.197 -2.622 0.173
7(OPE) 0 0 0 0.000 0.000 0.000
8(OPE) 0.156 -3.714 -0.337 0.337 -3.714 0.156
9(OPE) 0.28 -4.381 -0.337 0.337 -4.381 0.280
10(OPE) 0.1 -2.072 -0.181 0.181 -2.072 0.100
11(OPE) 0.176 -3.011 -0.244 0.244 -3.011 0.176
12(OPE) 0.198 -3.517 -0.291 0.291 -3.517 0.198
13(SUS) -0.191 -19.267 -0.632 0.632 -19.267 -0.191
Case GLOBAL (S.PRO)
StaadPro FX KN. FY KN. FZ KN.
2 2.509 -76.878 5.583
3 7.61 -76.099 -2.735
4 3.319 -86.319 6.703
5 7.643 -76.426 -28.028
6 7.777 -77.768 3.425
7 7.549 -75.49 -5.508
8 7.558 -75.585 2.411
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5.2 STAAD PRO Input
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Stress Ratio
5.3 LOAD COMBINATION
UNFACTORED LOAD COMBINATION FOR ALLOWABLE STRESS DESIGN & BEARING CAPACITY
101 SW + P(E)
102 (SW + P (E)) + P (O)
103 (SW + P (E)) + P (T)
104 (SW + P (E)) + 0.6 W (X+)
105 (SW + P (E)) + 0.6 W (X-)
106 (SW + P (E)) + 0.7 E (X+)
107 (SW + P (E)) + 0.7 E (X-)
108 (SW + P (E)) + 0.75 P (O) + 0.75 (0.6 W(X+))
109 (SW + P (E)) + 0.75 P (O) + 0.75 (0.6 W(Z+))
110 (SW + P (E)) + 0.75 P (T) + 0.75 (0.6 W(X+))
111 (SW + P (E)) + 0.75 P (T) + 0.75 (0.6 W(Z+))
112 (SW + P (E)) + 0.75 P (O) + 0.75 (0.6 E(X+))
113 (SW + P (E)) + 0.75 P (O) + 0.75 (0.6 E(Z+))
114 (SW + P (E)) + 0.75 P (T) + 0.75 (0.6 E(X+))
115 (SW + P (E)) + 0.75 P (T) + 0.75 (0.6 E(Z+))
116 0.6 (SW + P(E )) + 0.6 (W(X+)
117 0.6 (SW + P(E )) + 0.6 (W(Z+)
118 0.6 (SW + P(E )) + 0.6 (E(X+)
119 0.6 (SW + P(E )) + 0.6 (E(Z+)
FACTORED LOAD COMBINATION FOR REINFORCED CONCRETE DESIGN
ERECTION CONDITION
201 1.4 (SW + P (E))
202 0.9 (SW + P (E)) +1.3 W(X+)
203 0.9 (SW + P (E)) +1.3 W(Z+)
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204 0.9 (SW + P (E)) +1.3 (1.1 E(X+))
205 0.9 (SW + P (E)) +1.3 (1.1 E(Z+))
OPERATING CONDITION
206 1.4 (SW + P (E) + P(O))
207 1.4 (SW + P (E) + P(O)) +1.7 W(X+)
208 1.4 (SW + P (E) + P(O)) +1.7 W(Z+)
209 1.4 (SW + P (E) + P(O)) +1.7 E(X+)
210 1.4 (SW + P (E) + P(O)) +1.7 E(Z+)
211 0.9 (SW + P (E) + P(O)) +1.3 W(X+)
212 0.9 (SW + P (E) + P(O)) +1.3 W(Z+)
213 0.9 (SW + P (E) + P(O)) +1.3 E(X+)
214 0.9 (SW + P (E) + P(O)) +1.3 E(Z+)
TESTING CONDITION
215 1.4 (SW + P (E) + P(T)) +1.7 (0.25 W(X+))
216 1.4 (SW + P (E) + P(T)) +1.7 (0.25 W(Z+))
Where:
SELF WEIGHT = SW
PIPING EMPTY = P(E)
PIPING OPERATING = P(O)
PIPING TESTING = P(T)
SEISMIC LOAD = E(X+); E(Z+)
WIND LOAD = W(X+); W(Z+)
5.4 REACTION FROM STAAD PRO
6.0 SOIL BEARING CAPACITY
For soil data please See Attachment A : Soil Investigation data
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Calculation using "Soil Investigation for Modification of Eks Pipeline Project, Muara Badak dan
Bontang KM53 Area, East Kalimantan, 20 Maret 2018 (Doc.No. 1131/UN 17.9/TU/2018)".
6.1 Allowable soil bearing capacity :
El. Bot. Qall (ton/m2)
Soil Test No. El. Soil Invest. Grade El
Footing Permanent Temporary
S1/S2 (KM-53) +0.00 +0.00 -1.00 27.43 36.48
Soil data assumption is obtained from soil investigation report (see Attachment-4)
2
Cohession soil (using N-SPT correlation) c = 3.75 ton/m
Soil angle of friction (conservatively set to 0) = 16 °
Terzaghi's Bearing Capacity Factors Nc = 13.70 (table 4-2, Bowles)
Nq = 4.90
Ng = 2.50
Ip : 1 + (B/L)x(Nq/Nc) = 1.36
Iq : 1 + (B/L)xtanf = 1.09
Ig : 1 - (B/L) = 0.60
2
Qult = c.Nc.Ip+ ysoil.D.Nq.Iq + 0.5.ysoil.B.Ny.Iy = 82.28 ton/m
2
Qall = Q/SF (used SF = 3) = 27.43 ton/m
6.2 Factor of safety for stability :
Allowable Safety Factor for Sliding : SFall = 1.50
Allowable Safety Factor for Overtuning Moment : SFall = 2.00
Allowable Safety Factor for Bouyancy : SFall = 1.20
6.3 Soil Spring Constant :
Used Soil Bearing Capacity (SBC) to calculate Modulus Subgrade Reaction (ks)
Modulus of Subgrade Reaction (ks) = SBC x SF / 25 mm (t/m2/m')
ks = 3291.07 t/m2/m'
Vertical soil spring constant (KSY) from calculation of Modulus Subgrade Reaction
(ks) with each plate area that automaticly calculate by Staad Pro program.
KSY = ks x plate area
7.0 FOUNDATION CALCULATION
7.1. Loading Data
P
Mx Loading : a. Permanent Load b. Temporary Load
Vx P = Axial Load
( w/o foundation weight )
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= 17.02 ton P = 18.39 ton
Vx = Shear ( x - direction )
Df H = 1.03 ton Vx = 1.01 ton
Vz = Shear ( z - direction )
= 0.85 ton Vz = 2.02 ton
Mx = Moment ( x - direction )
= 2.56 ton. m Mx = 6.09 ton.m
B (L)
Mz = Moment ( z - direction )
= 3.11 ton.m Mz = 3.04 ton.m
7.2. Foundation Dimension
b
h
Foundation Size Data :
H = 130 cm
Df = 100 cm
B = 250 cm
L = 250 cm
H Df
hf = 30 cm
d = 23 cm
d hf b = 70 cm
h = 70 cm
c1
b1
z c2 b1 = b70
+ dcm =
b2 = h70
+ dcm =
x
c1 = b/2
35 +cm
d =
c2 = h/2
35 +cm
d =
7.3. Check of Soil Reaction "fe"
Design Loads :
a) Vertical Loads (P)
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Where,Wf = Wp + Wb + Ws = 12530 Kg
Wp = Pedestal weight = 1176 Kg
Wb = Footing weight = 4500 Kg
Ws = Soil weight on Footing = 6854.4 Kg
b) Moment due to Horizontal Force (M)
Permanent : Temporary :
Mx1 = Vx . H Mx1 = Vx . H
= 1341.5 kg m = 1308.7 kg m
Mz1 = Vz . H Mz1 = Vz . H
= 1102.7 kg m = 2625.6 kg m
ex (ez)
c) Eccentricity (e)
P tot
d) Compute "fe" :
aP tot
B.L
Take " α " depend on " e " condition below :
α = 1 + factor x + factor z
Xn < B
Where : ex(ez) < B(L)/6, factor x (z) = 6 ex(ez)/ B (L)
ex(ez) > B(L)/6, factor x (z) = 2/ [3{0.5-ex(ez)/ B (L)}]
e) Allowable soil stress "Fe" :
- Permanent - Temporary
2 2
Fe = 2.743 kg/cm Fe = 3.648 kg/cm
f) Soil stress "fe" :
- Permanent - Temporary
fe = P tot = fe =
a = 0.78 kg/cm2 a P tot =
=
1.00 kg/cm2
B*L B*L
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< Fe OK ! < Fe OK !
α = 1.659 a = 2.014
7.4. Check of Stability
Permanent : Temporary :
Overturning Moment ( OM ) : Mx tot = 3900.6 kg m Mx tot = 7402.3 kg m
Mz tot = 4216 kg m Mz tot = 5662.9 kg m
Permanent Load : RM / OM = Ptot . B
= 3.8 > 2.0
2 . Mx tot
Ptot . L
= 8.8 > 2.0
2 . Mz tot
Temporary Load : RM / OM = Ptot . B
= 2.1 > 1.5
2 . Mx tot
Ptot . L =
= 6.8 > 1.5
2 . Mz tot
7.5. Footing Reinforcement Design
7.5.1 Design Soil Reaction "qus"
7.5.2 Required Re-bar due to Bending Moment
a. Design Moment :
b. Steel Ratio, ρ :
2
fy = 4000 kg/cm
2
fc' = 210 kg/cm
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m= fy = ; Ø = 0.9
= 22.4
0.85 fc'
- About x - direction :
ρ req
1 1 2 ρ min
= 1 = 0.0036 >
2
As = ρ o * L * d = 27.2 cm
2
D = 16 mm ; Ab = 2.01 cm
n = A s / Ab = 14
Spacing, s = 169 mm ; whichever is smaller.
Spacing Limit : S max = 2d = 600 mm Spacing s = 150 mm
take : D 16 @ 150
- About z - dirrection :
Rn = Muz 2
2 = 11.3 kg/ cm
ø B d
1 1 2
ρ req = 1 = 0.0029 < ρ min
As = ρ o * B * d = 21.9 cm2
2
D = 16 mm ; Ab = 2.01 cm
n = A s / Ab = 11
spacing, s = 224 mm Whichever is smaller.
Spacing Limit : S max = 2d = 600 mm spacing s = 200 mm
take : D 16 @ 200
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7.5.3 Check of Shear Stress
Vup = qus * ( B*L - b1*b2) = 11.64 kg/cm2 < ø (1.06 vfc') = 13.057 kg/cm
2
2 * ( b1 + b2 ) * d
Ok !!
7.6. Sketch :
D 16 @ 150 D 16 @ 200
7.7. Pedestal :
Check requirement :
Rebar requirement :
2
ρo = 0.01 As = ρ o Ag = 49.00 cm
2
Used 20 D-19 As = 56.71 cm Ok!
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