CALCULATION FOR

CONDENSATE DRAIN TANK

PT PUPUK INDONESIA ENERGI

GRESIK GAS COGENERATION PLAN PROJECT
CONTRACT NO : 010/SP/DIR/XI/2015
PROJECT CODE : P-6001
JOB NO

: 781502

DOC NO

: GGCP-04-M2-CS-003-PP

PURPOSE

: IFA

CONTRACTOR

PT PP (Persero) Tbk DIVISI EPC

CONSULTANT

Pt Rekayasa Engineering
REV.
NO.

DATE

30/09/2016

Issued For Approval

JA

SAW

GWN/FIA

FP

16/09/2016

Issued For Approval

JA

SAW

GWN/FIA

FP

13/06/2016

Issued For Review

JA

SAW

GWN/FIA

FP

DESCRIPTION

PREPARED

CHECKED

APPROVED

JOB NO

CALCULATION FOR
CONDENSATE DRAIN TANK
(01-HD-12703)

: 781502

DOCUMENT NO : GGCP-04-M2-CS-003-PP
DATE

: 30/09/2016

REV

:2

REVISION CONTROL SHEET

REV. NO.

DATE

DESCRIPTION

13/06/2016

Issued For Review

16/09/2016

Issued For Approval

-Revised for 2.1 Design (page 4)
-Revised for 2.3 Hydrotest (page 5)
-Revised for 3.1 Shell thickness (page 5)
-Revised for 3.2 Head thickness (page 5)
-Revised for 3.3 Straight Flange on head (page 6)
-Revised for 3.4 Summary Vessel Thickness (page 7)
-Revised for 4. Weight and capacity summary (page 7)
-Shell thickness included Safety factor

30/09/2016

Issued For Approval

DISTRIBUTION ORDER

EXTERNAL ISSUE

PT PP (Persero) Tbk - INTERNAL ISSUE

PT PUPUK INDONESIA ENERGI

PROJECT MANAGER

CHIEF ADMINISTRATION

TRACTEBEL / CONNUSA

ENGINEERING MANAGER

CHIEF SHE

CONSTRUCTION MANAGER
PROCUREMENT MANAGER
PROJECT CONTROL MANAGER
SHE MANAGER
QC MANAGER
CHIEF ENGINEERING
CHIEF PROJECT CONTROL

Page 2 of 8

JOB NO

CALCULATION FOR
CONDENSATE DRAIN TANK
(01-HD-12703)

: 781502

DOCUMENT NO : GGCP-04-M2-CS-003-PP
DATE

: 30/09/2016

REV

:2

TABLE OF CONTENT
1.

2.

3.

4.

INTRODUCTION ............................................................................................................................................ 4
1.1. Scope ...................................................................................................................................................... 4
1.2. Definition ................................................................................................................................................. 4
1.3. Applicable Code & Standard .................................................................................................................. 4
1.4. Project Reference Document ................................................................................................................. 4
DESIGN DATA ............................................................................................................................................... 4
2.1. Design ..................................................................................................................................................... 4
2.2. Material of Construction (MOC) .............................................................................................................. 5
2.3. Hydrotest ................................................................................................................................................ 5
CALCULATION .............................................................................................................................................. 5
3.1. Shell Thickness....................................................................................................................................... 5
3.2. Head Thickness ...................................................................................................................................... 5
3.3. Straight Flange on head ......................................................................................................................... 6
3.4. Summary Vessel Thickness ................................................................................................................... 7
WEIGHT AND CAPACITY SUMMARY ......................................................................................................... 7
APPENDIX ..................................................................................................................................................... 8

Page 3 of 8

JOB NO

CALCULATION FOR
CONDENSATE DRAIN TANK
(01-HD-12703)

: 781502

DOCUMENT NO : GGCP-04-M2-CS-003-PP
DATE

: 30/09/2016

REV

:2

1. INTRODUCTION
1.1.

Scope
This document covers the calculation for Condensate Drain Tank (01-HD-12703) for Natural Gas
Feed System of the Gresik Gas Cogeneration Plant (GGCP) Project of PT Pupuk Indonesia Energi,
Gresik, East Java, Indonesia.

1.2.

Definition
The following words shall have the meaning indicated when used herein:
Owner
: PT. PUPUK INDONESIA ENERGI
Consultant PMC
: TRACTEBEL ENGINEERING S.A. &
CONNUSA ENERGINDO
Contractor
: PT. PP (Persero) Tbk DIVISI EPC
Eng. Consultant
: PT. REKAYASA ENGINEERING
Vendor / Subcontractor
: The party that manufactures or supplies equipment and services to
perform the duties specified by the Owner or Contractor.

1.3.

Applicable Code & Standard

Unless otherwise stated, latest edition and amendments of below mentioned codes & standards shall
be applicable for this calculation
American Society of Mechanical Engineers (ASME)
ASME II
ASME V
ASME VIII Div.1
ASME IX

1.4.

Material
Nondestructive Examinations
Rules for Construction of Pressure Vessel
Welding and Brazing Qualifications

Project Reference Document

Basic Engineering Design Data
Piping and Instrumentation Diagram For
Natural Gas Feed System
MDS for Condensate Drain Tank

GGCP-00-P0-ES-001-PP
GGCP-04-P0-PI-001-PP
GGCP-04-M2-DS-003-PP

2. DESIGN DATA
The Basic design code for this calculation is ASME Section VIII Division 1, 2013 Edition
2.1.

Design
Horizontal Vessel with 2 : 1 Ellipsoidal Head
Vessel Inside Diameter
(D)
= 300 mm
Vessel Radius
(R)
= 150 mm
Vessel T/T Length
(L)
= 1000 mm
Internal Design Pressure
(P)
= 3.5 kg/cm2 = 343.23 kPa
Operating Pressure
= ATM
o
Design Temperature
(T)
= 60 C
Joint Efficiency
(E)
= 0.85 (shell), 1 (head)
Head Ratio
(D/2h) = 2 (New), 1.99 (corroded)
Corrosion Allowance
(CA)
= 1.7 mm
Height
(h)
= 75
Page 4 of 8

JOB NO

CALCULATION FOR
CONDENSATE DRAIN TANK
(01-HD-12703)

Actual Corrosion Allowance (CA)

Minimum thickness as per UG-16
Actual thickness

: 781502

DOCUMENT NO : GGCP-04-M2-CS-003-PP
DATE

: 30/09/2016

REV

:2

= 1.7 mm
= 1.5 mm
= 6 mm

2.2.

Material of Construction (MOC)

Plate Material = SA-516 Gr. 70; Maximum Allowable Stress (S) = 138,000 kPa
Shell Plate
= SA-516 Gr. 70
Head Plate = SA-516 Gr. 70
Nozzle
= SA-106
Flange
= SA-105
Support
= SA-36

2.3.

Hydrotest
Shop Hydrotest Pressure

= 1.5 times vessel Operating Pressure

3. CALCULATION
3.1.

Shell Thickness
Design thickness (t) due to internal pressure, (at 60 C) as per UG-27(c)(1)
t
= P*R / (S*E - 0.60*P) + Corrosion Allowance
= 343.23 * (150 + 1.7) / (138,000 * 0.85 - 0.60 * 343.23) + 1.7
= 2.15 mm
Minimum Design Thickness (t) = 2.15 mm.
actual thickness from calculation used (t) = 6 mm
Maximum allowable working pressure (MAWP), (Corroded at 60 C) as per UG-27(c)(1)
MAWP = S*E*t / (R + 0.60*t)
= 138,000 * 0.85 * (6 1.7) / ((150 + 1.7) + 0.60 * (6 1.7))
= 3,269.88 kPa
The maximum allowable working pressure (MAWP) = 3,269.88 kPa.
Maximum allowable pressure (MAP), (New at Testing Temperature) as per UG-27(c)(1)
MAP
= S*E*t / (R + 0.60*t)
= 138,000 * 0.85 * 6 / (150 + 0.60 * 6)
= 4,582.03 kPa
The maximum allowable pressure (MAP) = 4,582.03 kPa.
Since MAP > MAWP, so selected actual thickness (t) = 6 mm can be used.

3.2.

Head Thickness
Design thickness (t) due to internal pressure, (at 60 C) as per Appendix 1-4(c)
t
= P*D*K / (2*S*E - 0.2*P) + Corrosion Allowance
Where,
2
K (Corroded) = (1/6)*[2 + (D / (2*h)) ]
= (1 / 6) * [2 + ((300 + 3.4) / (2 * (75 + 1.7))2]
= 0.985312
Thus,
t
= 343.23 * (300 + 3.4) * 0.985312 / (2 * 138,000 * 1 - 0.2 * 343.23) + 1.7
Page 5 of 8

JOB NO

CALCULATION FOR
CONDENSATE DRAIN TANK
(01-HD-12703)

: 781502

DOCUMENT NO : GGCP-04-M2-CS-003-PP
DATE

: 30/09/2016

REV

:2

= 2.07 mm
Design Thickness (t) = 2.07 mm, thus Actual Thickness used (t) = 6 mm is adequate.
Maximum allowable working pressure (MAWP), (Corroded at 60 C) as per Appendix 1-4(c)
MAWP
= 2*S*E*t / (K*D + 0.2*t) Ps
= 2 * 138,000 * 1 * (6 1.7) / (0.985312 * (300 + 3.4) + 0.2 * (6 -1.7))
= 3,959.29 kPa
The maximum allowable working pressure (MAWP) = 3,959.29 kPa.
Maximum allowable pressure (MAP), (New at Testing Temperature) as per Appendix 1-4(c)
MAP
= 2*S*E*t / (D + 0.2*t)
Where,
K (New) = (1/6)*[2 + (D / (2*h))2]
2
= (1 / 6) * [2 + (300 / (2 * 75)) ]
=1
Thus,
MAP
= 2 * 138,000 * 1 * 6 / (1 * 300 + 0.2 * 6)
= 5,498.01 kPa
The maximum allowable pressure (MAP) = 5,498.01 kPa.
Since MAP > MAWP, so selected actual thickness (t) = 6 mm can be used.
3.3.

Straight Flange on head

Design thickness (t) due to internal pressure, (at 60 C) as per UG-27(c)(1)
t
= P*R / (S*E - 0.60*P) + Corrosion Allowance
= 343.23 * (150+1.7) / (138,000 * 1 - 0.60 * 343.23) + 1.7
= 2.08 mm
Design Thickness (t) = 2.08 mm, thus Actual Thickness used (t) = 6 mm is adequate.
Maximum allowable working pressure (MAWP), (Corroded at 60 C) as per UG-27(c)(1)
MAWP = S*E*t / (R + 0.60*t)
= 138,000 * 1 * (6 1.7) / ((150 + 1.7) + 0.60 * (6 1.7))
= 3,846.92 kPa
The maximum allowable working pressure (MAWP) = 3,846.92 kPa.
Maximum allowable pressure (MAP), (New at Testing Temperature) as per UG-27(c)(1)
MAP
= S*E*t / (R + 0.60*t)
= 138,000 * 1 * 6 / (150 + 0.60 * 6)
= 5,390.63 kPa
The maximum allowable pressure (MAP) = 5,390.63 kPa.
Since MAP > MAWP, so selected actual thickness (t) = 6 mm can be used.

Page 6 of 8

JOB NO

CALCULATION FOR
CONDENSATE DRAIN TANK
(01-HD-12703)

: 781502

DOCUMENT NO : GGCP-04-M2-CS-003-PP
DATE

: 30/09/2016

REV

:2

3.4.

Summary Vessel Thickness

These table are shown summary of vessel thickness calculation
Diameter Length Nominal Selected
Component
Material
t (mm)
t (mm)
(mm)
(mm)

Left Head
Straight Flange
on Left head
Cylinder #1
Straight Flange
on Right head
Right Head

SA-516
Gr.70
SA-516
Gr.70
SA-516
Gr.70
SA-516
Gr.70
SA-516
Gr.70

Design
t (mm)

C.A

Joint
Efficiency

300 ID

81

2.15

2.07

1.7

300 ID

50.8

2.15

2.08

1.7

300 ID

898.4

2.15

2.15

1.7

0.85

300 ID

50.8

2.15

2.08

1.7

300 ID

81

2.15

2.07

1.7

4. WEIGHT AND CAPACITY SUMMARY

These table below are shown summary of weight of the pressure vessel.
Weight (Kg) Contributed by Vessel Element
Component

New*

Corroded*

Test Liquid
New

Test Liquid

Corroded

New

Corroded

Left Head

7.4

5.4

7.1

7.4

Cylinder #1

40.6

29.3

63.5

64.9

Right Head

7.4

5.4

7.1

7.4

Support Saddle

16.3

16.3

Total :
71.7
56.3
0
0
77.7
* Shells with attached nozzles have weight reduced by material cut out for opening.

0
79.6

Vessel Weight
Vessel operating weight, Corroded
= 56 kg
Vessel operating weight**, New
= 72 kg
Vessel empty weight, Corroded
= 56 kg
Vessel empty weight, New
= 72 kg
Vessel test weight, Corroded
= 136 kg
Vessel test weight, New
= 149 kg
** The vessel weight should be added with 10 % for estimated weight for appurtenance and
Accessories
Vessel Capacity
Vessel Capacity** (New)
= 78 liters
Vessel Capacity** (Corroded)
= 80 liters
**The vessel capacity does not include volume of nozzle, piping or other attachments.

Page 7 of 8

JOB NO

CALCULATION FOR
CONDENSATE DRAIN TANK
(01-HD-12703)

: 781502

DOCUMENT NO : GGCP-04-M2-CS-003-PP
DATE

: 30/09/2016

REV

:2

APPENDIX

Page 8 of 8

Thickness Summary
Component
Identifier

Material

Diameter
(mm)

Length
(mm)

Selected t Design t
(mm)
(mm)

Total Corrosion
(mm)

Joint
E

Load

Left Head

SA-516 70

300 ID

81

6*

2.07

1.7

1.00

Internal

Straight Flange on Left Head

SA-516 70

300 ID

50.8

2.08

1.7

1.00

Internal

Cylinder #1

SA-516 70

300 ID

898.4

2.15

1.7

0.85

Internal

Straight Flange on Right Head

SA-516 70

300 ID

50.8

2.08

1.7

1.00

Internal

Right Head

SA-516 70

300 ID

81

6*

2.07

1.7

1.00

Internal

Nominal t: Vessel wall nominal thickness

Design t:

Required vessel thickness due to governing loading + corrosion

Joint E:

Longitudinal seam joint efficiency

Head minimum thickness after forming

Load
internal:

Circumferential stress due to internal pressure governs

external:

External pressure governs

Wind:

Combined longitudinal stress of pressure + weight + wind governs

Seismic:

Combined longitudinal stress of pressure + weight + seismic governs

8/33

Weight Summary
Weight ( kg) Contributed by Vessel Elements
Component

Operating
Liquid

Surface Area
m2

Metal
Metal
New* Corroded*

Insulation

Piping
Insulation
Lining
+ Liquid
Supports

Left Head

7.4

5.4

7.1

7.4

Cylinder #1

40.6

29.3

63.5

64.9

0.88

Right Head

7.4

5.4

7.1

7.4

0.17

Saddle 24" Dia

16.3

16.3

0.49

TOTAL:

71.7

56.3

77.7

79.6

1.71

Test Liquid

New Corroded New Corroded

0.17

* Shells with attached nozzles have weight reduced by material cut out for opening.
Weight ( kg) Contributed by Attachments
Component

Nozzles &
Flanges

Body Flanges

Packed
Beds

Trays

Tray
Supports

Rings &
Clips

Vertical
Loads

Surface
Area
m2

New

Corroded

New

Corroded

Left Head

Cylinder #1

Right Head

TOTAL:

Vessel operating weight, Corroded:

Vessel operating weight, New:
Vessel empty weight, Corroded:
Vessel empty weight, New:
Vessel test weight, New:
Vessel test weight, Corroded:
Vessel surface area:

56 kg
72 kg
56 kg
72 kg
149 kg
136 kg
1.71 m2

Vessel center of gravity location - from datum - lift condition

Vessel Lift Weight, New: 72 kg
Center of Gravity:
449.2 mm
Vessel Capacity
Vessel Capacity** (New):
78 liters
Vessel Capacity** (Corroded): 80 liters
**The vessel capacity does not include volume of nozzle, piping or other attachments.

9/33