Fabrication And Analysis Of Joining Parts For Oil And Gas Piping System.
UNIVERSITI TEKNIKAL MALAYSIA MELAKA
FABRICATION AND ANALYSIS OF JOINING PARTS FOR OIL
AND GAS PIPING SYSTEM
This report submitted in accordance with requirement of the Universiti Teknikal Malaysia Melaka (UTeM) for the Bachelor Degree of Manufacturing Engineering
(Manufacturing Process) (Hons.)
by
MUHAMMAD HAFIZ BIN SAMSUDIN B050910062
900726145887
FACULTY OF MANUFACTURING ENGINEERING 2013
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FABRICATION AND ANALYSIS OF JOINING PARTS
FOR OIL AND GAS PIPING SYSTEM
MUHAMMAD HAFIZ BIN SAMSUDIN
B050910062
UNIVERSITI TEKNIKAL MALAYSIA MELAKA 2013
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I hereby, declared this report entitled “Fabrication and Analysis of Joining Parts for Oil and Gas Piping System” is the results of my own research except as cited in references.
Signature : ………
Author’s Name : Muhammad Hafiz Bin Samsudin
Date : 28th June 2013
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APPROVAL
This report is submitted to the Faculty of Manufacturing Engineering of UTeM as a partial fulfillment of the requirements for the degree of Bachelor of Manufacturing Engineering (Manufacturing Process) Hons. The member of the supervisory is as follow:
……… (Project Supervisor)
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ABSTRAK
Sistem perpaipan di Petronas Sdn Bhd Melaka telah digunakan secara meluas dalam penghantaran, pengedaran dan pemprosesan pengeluaran minyak dan gas. Sistem perpaipan telah digunakan dalam jangka masa yang panjang menyebabkan sistem perpaipan yang sudah lama. Dalam keadaan ini, Petronas memerlukan proses fabrikasi baru di beberapa bahagian paip. Oleh itu, kajian ini membentangkan tentang teknik fabrikasi pada bahagian sistem perpaipan minyak dan gas. Di samping itu, terdapat analisis produk baru yang yang direka. Proses analisis yang dijalankan ke atas produk baru yang direka berdasarkan reka bentuk, ciri-ciri dan kos pembuatan. Sistem reka bentuk paip terdiri daripada bebibir dan paip berongga sebagai satu komponen. Satu teknik fabrikasi baru untuk fabrikasi sebahagian bahan kerja telah diperkenalkan dengan menggunakan keluli ringan dan bahan Teflon sebagai bahan terpilih bagi sistem perpaipan. Teknik fabrikasi yang yang dirujuk daripada reka bentuk komponen dan keperluan dimensi. Proses fabrikasi khusus untuk produk baru yang berbeza daripada produk yang sedia ada yang terdiri daripada bahagian-bahagian bahan Teflon sahaja. Bahagian lama sedia ada digantikan dengan produk baru yang direka. Siasatan pada produk yang direka ditambah dengan maklumat tambahan berbanding dengan produk yang sedia ada.
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ABSTRACT
Piping system in Petronas Sdn Bhd Melaka has been widely used in transmission, distribution and processing of oil and gas production. The piping system has been used in such a long time resulting of the seasoned piping system. In this condition, Petronas requires a new fabrication process on some of its piping parts. Therefore, this research presents the fabrication technique of joining parts for oil and gas piping system. In addition, there are analyses of the new fabricated product provided. The analysis process is conducted on the new fabricated product based on the design, properties and manufacturing cost. The pipe system fabrication design consists of a flange and hollow pipes as a component. A fabrication technique to fabricate a joining part has been introduced by applying mild steel and Teflon material as selected material of piping system components. Fabrication techniques referred from the component design and the dimensional requirement. This fabrication process proposes for the new product that differs from the existing product that consists of Teflon material parts only. The existing seasoned part is replaced with the new fabricated product. Investigation on fabricated product turn out the additional information compared with the existing product.
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ACKNOWLEDGEMENT
I would like to express my sincere gratitude to my advisor, Dr. Mohd Hadzley Bin Abu Bakar for his guidance, constant motivation and research support throughout my degree program. His technical advice and suggestions helped me overcome hurdles and kept me enthusiastic and made this work a wonderful learning experience. I am grateful to my parents Mr. Samsudin Ahmad and Mrs. Mariah Matros and my sister Siti Nurayuni for their love, support and guidance. They have always been supportive of my academic pursuits and stood by me every step of the way regardless of my decisions.I would also like to acknowledge the support received from the University Teknikal Malaysia Melaka towards the successful completion of this thesis.
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TABLE OF CONTENT
Abstrak i
Abstract ii
Acknowledgement iii
Table of Content iv-vii
List of Tables viii
List of Figures ix-x
CHAPTER 1: INTRODUCTION 1
1.1 Introduction 1-4
1.2 Aim and Objectives of research work 4
1.3 Scope of the report 5
1.4 Gantt Chart of the Report 6
CHAPTER 2: LITERATURE REVIEW 7
2.1 Piping system 7
2.2 Design of the piping system 9
2.2.1 Detailed Part Drawing 10
2.2.1.1 Part 1A 10
2.2.1.2 Part 1B 11
2.2.1.3 Part 2A 12
2.2.1.4 Part 2B 13
2.2.1.5 Part 3A 14
2.2.1.6 Part 3B 15
2.2.2 Pipe Size 16
2.2.3 Component of Pipe System 17
2.2.3.1 Joints 17
2.2.3.2 Flange 18
2.2.3.3 Valve 19
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v
2.3 Piping Material 21
2.3.1 Plastic Pipe Material 21
2.3.1.1 Polytetrafluorethylene (PTFE) Teflon Material 23
2.3.1.2 Preparation of PTFE Monomer 23
2.3.1.3 Structure and Properties of PTFE Material 24-26
2.3.1.4 Processing of PTFE Material 27
2.3.1.5 Application of PTFE Material 28
2.3.2 Metallic Pipe 28
2.3.2.1 Low Carbon Steel (CS) Mild Steel Pipe 29
2.3.3 Component Selection Criteria of Piping 30
2.3.3.1 Corrosion 30
2.3.3.2 Availability 31
2.3.3.3 Physical Strength 31
2.3.3.4 Fatigue Behaviour 32
2.3.3.5 Aging and Long Term Degradation 32
2.3.3.6 Acoustic Transmission 32
2.3.3.7 Abrasion 32
2.3.3.8 Permeability 33
2.3.3.9 Leeching 33
2.3.3.10 Elevated Temperature Considerations 33
2.3.3.11 Long Term Hydrostatic Strength 34
2.3.3.12 Corrosion Resistance 34
2.2.3.13 Stress 35
2.4 Fabrication of Pipe 36
2.4.1 Turning 36
2.4.1.1 Cutting condition in turning 37
2.4.1.2 Operation in turning 37
2.4.2 Threading 38
2.4.2.1 Thread Basic 38
2.4.2.2 Thread Cutting 39
2.4.2.3 Tap and Die 39
2.4.2.4 Single Point Thread 40
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vi
2.4.4 Machining and Finishing of Pipe 41
2.5 Manufacturing Cost 42
2.5.1 Direct Cost 42
2.5.2 Indirect Cost 43
CHAPTER 3: METHODOLOGY 44
3.0 Introduction of methodology 44
3.1 Fabrication of Joining parts for piping system 44
3.1.1 Fabrication Process Flow 45
3.1.2 Preparing the equipment and instrument 46
3.1.2.1 Vernier Calliper 46
3.1.2.2 Ruler 46
3.1.2.3 Measuring Tape 47
3.1.2.4 Sand paper 47
3.1.3 Preparing machine and tool specification 48
3.1.3.1 Lathe machine 48
3.1.3.2 Hydraulic Press machine 49
3.1.3.3 Bandsaw machine 49
3.1.4 Design and Dimension of fabricated pipe 50-52
3.1.5 Part Preparation 53
3.1.6 Material Preparation 54-55
3.1.7 Original Part Dimension recorded 56-57
3.1.8 Part 2B machining 58-63
3.1.9 Part 3A machining 63
3.1.10 Part 3B machining 65
3.1.11 Part 1A machining 65- 66
3.1.12 Threading Process 67
3.1.13 Assembly Process 68
3.1.10 Analysis of new product 68
3.1.10.1 Design 68
3.1.10.2 Properties 69
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vii
CHAPTER 4: RESULT AND DISCUSSION 70
4.0 Definitions of result and discussion 70
4.1 Complete Fabricated Product 71
4.1.1 Discussion on Fabrication Process of Prefabricated Product 72
4.2 Analysis of Part Weight 73-75 4.2.1 Discussion on Part Weight 76
4.3 Analysis of Stress Distribution by Finite Element Modeling 77 4.3.1 Stress distribution on Existing Piping Part 77-81 4.3.2 Stress Distribution on Prefabricated Pipe Part 82-84 4.3.3 Discussion on Stress Distribution by Finite Element Modeling 85 4.4 Analysis of Strain of Pipe Part 86 4.4.1 Strain Hardening Part Modeling 86-88 4.4.2 Discussion on strain Distribution by Finite Element Modeling 89 4.5 Analysis of Thermal Distribution by Finite Element Modeling 89-94 4.5.1 Discussion on Thermal Distribution 95
4.6 Analysis of total cost in pipe fabrication process 96
4.6.1 Direct Costs Associated with Piping 96
4.6.1.1 Material Cost 96
4.6.1.2 Labor and Fabrication Cost 97
4.6.2 Cost of old Product and Prefabricated Product 98
4.6.3 Indirect Cost Associated with Piping 99
4.6.4 Discussion on total cost in pipe fabrication process 100
CHAPTER 5: CONCLUSION 101
5.0 Conclusion 101
5.1 Recommendation for Future Work 102
5.1.1 Provide a Support System 102
5.1.2 Connection Design Optimization 103
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viii
LIST OF TABLES
1.1 Gantt Chart For Final Year Report 1&2 6
2.1 Typical Properties of PTFE 25-27
3.1 Measuring Process of Provided Part 56
3.2 Machining process of part 2B 58-63
3.3 Machining process of part 3A 64
3.4 Machining of Part 3B 65
3.5 Machining of Part 1A 66
3.6 Threading process of Teflon and part 1B, 3B and 2A 67
4.1 Overview of the complete fabricated product 71
4.2 Analysis of weight value properties of old design pipe part 73-74
4.3 Analysis of weight value properties of prefabricated pipe part 74-75
4.4 Movement of displacement vector under certain scaling factor 79
4.5 Von Misses Stress 81
4.6 Von Misses Stress 84
4.7 The evolution of plastic strain to the propagation of the shear
band
87
4.8 The evolution of plastic strain to the propagation of shear band on
the new part
88
4.9 Teflon Properties correspond of thermal distribution analysis 90
4.10 Teflon Properties correspond of thermal distribution analysis 90
4.11 Analysis based on thermal properties on the part 92
4.12 Typical price rate based on the material apply 96
4.13 Labor Cost of Old and Prefabricated Product 97
4.14 Total Part Cost of Old Product 98
4.15 Total Part Cost of Prefabricated Product 98
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ix
LIST OF FIGURES
1.1 Ejector Part 2
1.2 Specific Drawing of joining parts 3
1.3 Existing part of Ejector 4
2.1 Piping System 8
2.2 Pipe Design 9
2.3 Detailed Drawing Part 1 A 10
2.4 Detailed Drawing Part 1 B 11
2.5 Detailed Drawing Part 2 A 12
2.6 Detailed Drawing Part 2 B 13
2.7 Detailed Drawing Part 3 A 14
2.8 Detailed Drawing Part 3 B 15
2.9 Compression Joint 17
2.10 Quick Connect Joint 17
2.11 Butt Fusion Joint 17
2.12 Self Restrained Joint 17
2.13 Flange Pipe component 18
2.14 Flange Joint 18
2.15 Pipe valve 19
2.16 Nut and Bolt Pipe 20
2.17 Pipe Flange Bolt 20
2.18 Plastic Pipe Material 21
2.19 Structure of PTFE Material 25
2.20 Low Carbon Steel Pipe 30
2.21 Turning motion 36
2.22 Different turning operations 37
2.23 Drawing of threads 38
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x
3.2 Vernier Calliper 46
3.3 Ruler 46
3.4 Measuring Tape 47
3.5 Sandpaper 47
3.6 Lathe Machine 48
3.7 Hydraulic Press machine 49
3.8 Band saw machine 49
3.9 Complete design of fabrication of joining part 52
3.10 Part Preparations 53
3.11 Mild steel hollow pipe 54
3.12 Teflon Pipe 55
3.13 Flange Part 55
4.1 Apply load and restraint 77
4.2 Part deformation (Front Side) 78
4.3 Colour coded of displace vector 79
4.4 Boundary displacement area 79
4.5 Principle stress on boundary 80
4.6 Edge and Point mode 80
4.7 Stress generate process 81
4.8 Steel Material as outer part and Teflon as inner part material 82
4.9 Apply load and restraint 83
4.10 Part Deformation 83
4.11 Principle stress acting on the part 84
4.12 Strain-Hardening Material Models of Old and Prefabricated Part 86
4.13 Pipe Analysis of Heating around old pipe parts and prefabricated
parts
91
4.14 Nodal Solution 93
4.15 Thermal flux diffusion 93
4.16 Thermal flux in vectorial presentation 94
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CHAPTER 1
INTRODUCTION
1.1 Introduction
Pipe system plays a key role in the day-to-day activities while making possible the delivery of available fuels, including natural gas. They are used in a wide range of transportation services. The major and most important use of pipelines is undoubtedly the energy transportation, such as oil and natural gas [George (2003)]. An interesting use of the pipes can be found in, example, in the Malaysia- Thailand Joint Development Area (JDA), Trans Asean Pipeline system, where gas transportation lines are interconnected by a 1540 km long pipeline system.
In industry and engineering discipline, a pipe is a round-stiff tubular section of the gas system that is made of carbon steel or plastic in function of the inner, outer or nominal diameter and the wall thickness. These measures are imposed by applicable industrial standards, such as ASME/ANSI B36.10/B36.19. The size of a pipe is based on its function and may vary from around 5 cm (2 in) to over 150 cm (60 in) in diameter [Henry (2003)].
Gas pipelines are usually buried underground about 1-2 meters (3-6 ft) in lands or rights-of-way acquired by, or granted to the pipeline company. Whenever burying the pipe becomes less convenient, the strategy is to place the pipeline 5-6 feet above the ground (under strict specifications to withstand environmental conditions) in order to allow for wildlife or any other factor that might damage the pipe [Mohitpur (2007)].
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In Petronas Penapisan Melaka, there are sections of operation processing, transmission and testing section. Each section was set up a piping system to operate the plant. Operations are carried out without continuously every day for gas processing and transmission because of the requirement by the customer in the power, industrial and commercial sectors throughout Peninsular and East Malaysia. However, because of the long time usage, some parts are already seasoned thereby require some fabrication of those parts.
Therefore, the aim of this study will be on the fabrication of joining parts for oil and gas piping system as shown in figure 1.1 below. The study involves with the investigation of existing products in term of design, properties, and manufacturing cost. The existing product will be redesigned with the additional of strengthening structures to improve the product. The fabrications then take place after the design is conform. The figure 1.2 below had shown the specific drawing of the parts.
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Figure 1.2: Specific Drawing of joining parts [Petronas (2012)].
The method approach of this study based on the fabrication technique for assembly the ejector part by existing product and drawing provided as a reference material. Figure 1.3 below had shown the existing product that from the ejector part that required for investigation process. Analysis of existing product design, properties and manufacturing cost will be conducted comparing with the new joining part fabrication after the fabrication process. Analysis of the result contributes to the improvement of the existing part with the new fabricated product.
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Figure 1.3: Existing Part of Ejector [Petronas (2012)].
This study's important to the oil and gas company where it can be a guideline for the company in implementing the suitable design and pipe fabrication processing and future work for piping fabrication. Besides that, the application of the proposed piping system can help them to increase the productivity and maintain high piping resistibility. In addition, this study's importance to become reference material for further piping development research and studying.
1.2 Aim and Objectives of the Research Work
This study essentially consisted of the following major categories which encompass,
I. Fabrication of joining parts for oil and gas piping system
II. Investigation of the existing product in terms of design, properties and
manufacturing cost.
Part 2A Part 3B
Part 1B
Part 3A
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1.3 Scope of the Report
This report is divided into two phases which is Final Year Project (FYP 1) and 2. Overall, this report contains 6 chapters. There are introduced, literature review, methodology, result and discussion, and conclusion and recommendation.
In Chapter 1: Introduction, is briefly explained the background of the study, the design and fabrication of joining part for oil and gas piping system, followed with the problem statement, objective of the study, scope, importance of this study and the organization of the report.
In chapter 2: Literature review, the theory of piping selection and selected component with support ideas that taken from journal, books, and articles are explained in detail.
In Chapter 3: Methodology, all methods that will be discussed to achieve objectives and obtained the result explained. The systematic planning and process flow diagram (PFD) also provided to show the overall study flow.
In Chapter 4: Result and Discussion focuses on the result and data being collected from the study. Beside, the discussion of the result been gained is explained further in this chapter.
In Chapter 5: Finding and Conclusion, the final chapter of this report concludes all the finding of the study and present the suggestion and recommendation in order to improve this study in future.
1.4 Gantt Chart of the report
Table 1 shows the Gantt chart of the study for FYP 1 and 2. It illustrates the duration of the study start from August 2012 until Jun 2013. The Gantt chart pictured the whole tasks that are needed to be done for the specific of the project.
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No. Year 2012 2013
Activity August September October November December January February March April May
1 PSM title confirmation
2 Problem statement identification
3 Objective and scope of the study
4 Finding literature review
5 PSM 1 report writing
6 PSM 1 report review
7 PSM report submission
8 Prepare for PSM 1 presentation
9 PSM 1 presentation
10 Improvement on PSM 1
11 Data collection
12 Design development
13 Data analysis
14 PSM report writing
15 PSM 2 review
16 PSM 2 submission
17 Preparation PSM 2 Presentation
18 PSM 2 Presentation
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CHAPTER 2
LITERATURE REVIEW
2.1 Piping System
Term pipe is defined herein as a closed conduit, usually a circular cross section. It can be made of any appropriate material such as steel or plastic. The term pipeline refers to a long line connected segments of pipe, with pump valve control devices, and other equipment need for operating the system [Henry (2003)].
Piping system is a set of components including pipe, pipe fittings, flange, bolting, gasket, relief devices and the pressure retaining parts included in any stress analysis. It also includes the hangers, supports, and any other equipment necessary to prevent over stressing of the pressure retaining parts. It does not include the structure and equipment and foundations, except they may affect the stress analysis. That reason to define the design and fabrication of a system that offers a reasonable expectation of being safe when operated as intended [Philip (2005)].
When selecting a piping material for any component of piping-related system, the applicable piping code is of primary importance. Here, the allowable piping materials
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had be listed as well as any restriction for their use. In addition the code will also stipulate various accepted standards that govern the manufacture, tolerance and installation of all components [Micheal (2003)].
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Figure 1.2: Specific Drawing of joining parts [Petronas (2012)].
The method approach of this study based on the fabrication technique for assembly the ejector part by existing product and drawing provided as a reference material. Figure 1.3 below had shown the existing product that from the ejector part that required for investigation process. Analysis of existing product design, properties and manufacturing cost will be conducted comparing with the new joining part fabrication after the fabrication process. Analysis of the result contributes to the improvement of the existing part with the new fabricated product.
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4
Figure 1.3: Existing Part of Ejector [Petronas (2012)].
This study's important to the oil and gas company where it can be a guideline for the company in implementing the suitable design and pipe fabrication processing and future work for piping fabrication. Besides that, the application of the proposed piping system can help them to increase the productivity and maintain high piping resistibility. In addition, this study's importance to become reference material for further piping development research and studying.
1.2 Aim and Objectives of the Research Work
This study essentially consisted of the following major categories which encompass,
I. Fabrication of joining parts for oil and gas piping system
II. Investigation of the existing product in terms of design, properties and
manufacturing cost.
Part 2A Part 3B
Part 1B
Part 3A
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5
1.3 Scope of the Report
This report is divided into two phases which is Final Year Project (FYP 1) and 2. Overall, this report contains 6 chapters. There are introduced, literature review, methodology, result and discussion, and conclusion and recommendation.
In Chapter 1: Introduction, is briefly explained the background of the study, the design and fabrication of joining part for oil and gas piping system, followed with the problem statement, objective of the study, scope, importance of this study and the organization of the report.
In chapter 2: Literature review, the theory of piping selection and selected component with support ideas that taken from journal, books, and articles are explained in detail.
In Chapter 3: Methodology, all methods that will be discussed to achieve objectives and obtained the result explained. The systematic planning and process flow diagram (PFD) also provided to show the overall study flow.
In Chapter 4: Result and Discussion focuses on the result and data being collected from the study. Beside, the discussion of the result been gained is explained further in this chapter.
In Chapter 5: Finding and Conclusion, the final chapter of this report concludes all the finding of the study and present the suggestion and recommendation in order to improve this study in future.
1.4 Gantt Chart of the report
Table 1 shows the Gantt chart of the study for FYP 1 and 2. It illustrates the duration of the study start from August 2012 until Jun 2013. The Gantt chart pictured the whole tasks that are needed to be done for the specific of the project.
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6
No. Year 2012 2013
Activity August September October November December January February March April May
1 PSM title confirmation
2 Problem statement identification
3 Objective and scope of the study
4 Finding literature review
5 PSM 1 report writing
6 PSM 1 report review
7 PSM report submission
8 Prepare for PSM 1 presentation
9 PSM 1 presentation
10 Improvement on PSM 1
11 Data collection
12 Design development
13 Data analysis
14 PSM report writing
15 PSM 2 review
16 PSM 2 submission
17 Preparation PSM 2 Presentation
18 PSM 2 Presentation
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CHAPTER 2
LITERATURE REVIEW
2.1 Piping System
Term pipe is defined herein as a closed conduit, usually a circular cross section. It can be made of any appropriate material such as steel or plastic. The term pipeline refers to a long line connected segments of pipe, with pump valve control devices, and other equipment need for operating the system [Henry (2003)].
Piping system is a set of components including pipe, pipe fittings, flange, bolting, gasket, relief devices and the pressure retaining parts included in any stress analysis. It also includes the hangers, supports, and any other equipment necessary to prevent over stressing of the pressure retaining parts. It does not include the structure and equipment and foundations, except they may affect the stress analysis. That reason to define the design and fabrication of a system that offers a reasonable expectation of being safe when operated as intended [Philip (2005)].
When selecting a piping material for any component of piping-related system, the applicable piping code is of primary importance. Here, the allowable piping materials
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8
had be listed as well as any restriction for their use. In addition the code will also stipulate various accepted standards that govern the manufacture, tolerance and installation of all components [Micheal (2003)].