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INTRODUCTION

TO MATERIAL
CORROSION &
INSPECTION
DEPARTMENT
Presentation Outline
MCI Organizational Chart
Mission
Roles & Responsibilities
QA & QC Process
Non Destructive Testing
Risk Based Inspection (RBI)
Objectives
By the end of the session
the participant shall be
able:
(1)To describe the functions,
roles & responsibility of MCI
Department
(2) To have an awareness on
Material, Corrosion &
inspection work activities
Organization Chart
RBI/Inspection
Engineer
Ben Faizal
Snr Mtrl/Corrosion
Engineer
Nurul Asni Mohd
AREA 1
Snr Executive
Inspection Engineer
Roziman Yahya
AREA 2
Snr Executive
Inspection Engineer
Zainol Abidin Mohd
AREA 3
Snr Executive
Inspection Engineer
Shuhaily Yusoff
AREA 4
Snr Executive
Inspection Engineer
Aznam Mohd Som
AREA 5
Snr Executive
Inspection Engineer
Choo Wei Lee
OS & QI
Snr Inspection
Planning Engineer
Azman Ab. Rahim
Snr Inspection
Tech.
Mohd Fadzli
Inspection Tech.
Hafizan
Snr Inspection Tech.
Tengku Jasbi
Inspection Tech.
Madi Ahmad
Inspection Tech.
Md Fairuz
Inspection Tech.
Shazly Iryawan
Snr Insp. Tech.
Niezam AbRahman
General Manager
Technical Services Division
Neil Anthony Morgan
Inspection Manager
Ab. Ghani Ismail
-Functional-
Admin Clerk
Sharifah Samsudin
Snr Inspection Tech.
Teh Siong Aik
Inspection Tech.
Zaimi Harun
Snr Inspection Tech.
Kamaruddin
Snr Inspection Tech.
Hairis Jaafar
Inspection Tech.
Hairul Azly
Inspection Tech.
Ab.Karim Majid
MCI Mission
To manage the plant static equipment integrity
program in accordance with the appropriate
codes, standards and regulations to ensure
reliable and safe operation.
Develop a scheme that will guarantee the safe
use of registered static equipment with its
continued use beyond the statutory inspection
period
Ensure that the equipment is and will be
properly inspected and maintained
Assess the probability and mode of failure
including the remaining life of the equipment
Setup and maintaining comprehensive database
on registered static equipment
Roles & Responsibilities
To carry out inspection of all equipment in
accordance with the applicable codes and
standards.
To classify equipment and allocate appropriate
Inspection Grades to that equipment as
necessary.
To maintain a register of all equipment including
with detailed and comprehensive records of each
item for statutory requirements with DOSH.
To ensure that adequate notice is given when
items of equipment are due for inspection.
To advise the management whenever the
inspection intervals of any item of equipment are
reduced or if abnormal conditions of corrosion
erosion or other form of deterioration are
detected.
Quality Control & Quality Assurance
Process of measuring, comparing & correcting
in accordance with planned requirement
Design Stage
Manufacturing/Fabrication Stage
Incoming Material Inspection
Installation Stage
Periodic Inspection & Testing
Design Stage
Metallurgy & Materials Selection
Steps in the material selection process
(1) Analysis of the material requirement
(2) Screening of the candidate materials
(3)Selection of candidate materials
(4) Development of design data
Technical points to be considered I.e tensile
strength, toughness, environmental assisted
cracking, corrosion resistance, weldability,
cost, specific weight etc
Manufacturing/Fabrication
Stage
Inspection/verification activities
that will be performs includes:
The use of appropriate materials
The welding method and welders
qualification
The proper application of heat
treatment
The proper execution of heat
exchangers tube-tube sheet
connection I.e expansion, seal
weld
Hoisting lugs require special
attention to ensure correct size,
welding and point of attachment.
Incoming Material
Inspection
Material failed to comply with refinery
standards will impact directly on the
integrity, reliability and availability of the
plant.
Verifying materials certificates and if
necessary execution of positive material
identification.
Installation Stage
Quality Control activities during
installation includes:
Proper execution of specified
field NDT (X-ray, DPT, MPT,
UTTM, alloy verification, etc)
Proper execution of piping
system pressure test
Proper installation of column,
reactor, boiler, furnace and
pressure vessel.
Proper mounting of protection
devices
Use of correct water quality for
testing and flushing
Pop testing of safety relief
devices
Periodic Inspection
To monitor the equipment
condition and ensure the
integrity, reliabity &
availability
To comply with the Statutory
Regulation in accordance
FMD 1967
To detect any abnormal
condition or unexpected
deterioration
Basic NDT
1. Dye Penetrant Testing
2. Magnetic Particle Testing
3. Ultrasonic Testing
4. Radiography Testing
Non
Destructive
Testing
Method of
detecting
discontinuities or
flaws within a
material or a
product without
impairing the
usefulness of the
material
Advance NDT
1. Acoustic Emission
2. Time of Flight Diffraction
3. Guided Wave Inspection
4. IR Thermography
5. Tubular Inspection
- Eddy Current Testing
- RFET
- IRIS
Dye Penetrant Testing
To detect surface discontinuities
Working principle-
Capillary action
into cavities that
open to the surface
Advantages;
1. Portable,simple & fast
2.Able to inspect on a small area
3.Any materials ferrous or non ferrous
4.Not affected by material magnetic properties
5. Any defect size, configuration, internal
structure or chemical composition
6. Orientation of the discontinuity is not a factor
Disadvantages;
1.Detect surface defect only
2.Surface coating, grease, oil and dirt must be
removed
3.Poor or rough surface affects result
4.No information on the depth of the defect
5. Not applicable to porous materials
Working Principle-
Detect the presence of
magnetic fields
leakage from
discontinuities
A
B
C
D
E
Magnetic Particle Testing
To detect surface and sub-surface discontinuities
in ferromagnetic materials
Advantages;
1. Simple and fast technique
2. Most sensitive technique in detecting small
surface and sub-surface defects
3. Able to detect surface discontinuities that are
not open to the surface,
4. Able to detect sub-surface crack up to 1.5mm
below the surface
Disadvantages;
1.Cannot detect defects more than 1.5mm below
the surface
2. Applicable only to ferromagnetic materials
3. Thick surface coatings must be removed
Radiography Testing
To detect material defects, structural
discontinuities, using a visual image on the
interior of materials or non-accessible areas
Radioactive
Isotope
Specimen
Radiography Film
2mm Sl ag In c l us i on
0.01mm Cr ac k
10mm Wel d
9.9mm Indi c at i on
10mm Ind i c at i on
8mm In di c at i o n
Working Principle: The more dense a material
is, the more radiation it will be absorb and the
thicker a material is, the more radiation will be
absorb
Advantages:
1. Results in a form of a picture
2. Good for detecting non-planar defects
3-D : slag inclusion, porosity
4. Shows defects in plan view (2-Dimension)
Disadvantages:
1. Radiation hazard
2. Require access to both sides of specimen
3. Limited by material thickness
4. Not good for detecting planar defects
2-D : cracks, lack of fusion
5.Does not indicate defect depth
Ultrasonic Testing
To measure the thickness of a material or to
examine the internal structure of material for
possible discontinuities such as voids and
cracks.
transducer
front surface back surface
4"
1.5"
defect
0 1 2 3 4
Initial pulse
Back surface
of plate echo
Time
transducer
front surface back surface
4"
0 1 2 3 4
Initial pulse
Back surface
of plate echo
Time
The use of Ultrasonic to measure the
thickness of a material or to examine the
internal structure of material for possible
discontinuities such as voids and cracks
Advantages
Detects planar and non-planar defects
Able to pinpoint defect location
Not affected by increase in thickness
Require access from one side only
No safety precautions required
No hardcopy of result available
Disadvantages
Specialized skill required - technician
dependent
For flaw detection of welds :
normally not suitable for surface and near
surface defect detection (dead zone)
normally not suitable for wall thickness <
3mm
Time of Flight Diffraction
To detects relevant defect and measure their
location and position with defects recorded as
permanent image format
Microplus
Scanning
head
TOFD Set-up
DCU Amplifier
Scan Direction
(a) Detection & monitoring corrosion & erosion
(b) Weld examination during construction
(c)Weld examination during service
(d) Monitoring of defect growth
(e) Inter Granular Stress Corrosion Cracking
R e f l e c t e d e n e r g y
D i f f r a c t e d e n e r g y
f r o m b o t h e x t r e m i t i e s
o f f l a w
T x R x
I n s p e c t i o n s u r f a c e
Advantages:
1. Rapid scan rates - Up to 12 meters per hour
2. Used in lieu of manual UT & radiography
3. No need to move vessel from welding station
4. Real time display - instant sentencing
5. Accurate flaw sizing - no unnecessary repairs
6. Cost effective with significant time savings
7. Permanent record
Tubular Inspection
To detect relevant defects and wall loss due to
corrosion-erosion in any tubular applications
such as heat exchangers and boilers
EDDY CURRENT
(ECT)
FLUX LEAKAGE
(MFL)
REMOTE FIELD
(RFET)
ULTRASONICS
(IRIS)
Ferrous No
Very low
permeability
ferrous
Yes Yes
Non-Ferrous Yes N/A Yes Yes
Couplant No No No Yes
Tube
Cleanliness
Good Good Modest to Poor Good to Excellent
Magnets None Yes None N/A
Test Speed 1~2 ft/sec 1 ft/sec 1~2 ft/sec Slow
SIgnals around
Bends
Good Poor Excellent ?
Finned Tubes No No Yes Yes
Large Pipes No No 9" OD ?
RBI is a methodology using RISK to prioritize
and manage inspection plan
Risk Based Inspection
A systematic methodology of evaluating risk and
factoring it into decision concerning how,
where and when to inspect
Risk Based Inspection
A proactive tools that identifies and focus
attention on critical areas of plant
Objectives:
1. To produce effective inspection
programme by focusing on high
risk equipment and eliminating
unnecessary
2. Identifies particular degradation
mechanism and most effective
inspection technique
3. Increased interval between
shutdown and reduced shutdown
inspection scope,therefore
optimize operation and reduce
cost.
4. Fully transparent and auditable
inspection process
Risk Based Inspection
S-RBI is a workshop approach consist of RBI In
House Team with Shell RBI Team
1. Shell RBI Facilitator
2. Shell Corrosion
Expert
3. RBI Engineer
4. Area Inspection
Engineer
5. Corrosion Materials
Engineer
6. Technologist
7. Operation Engineer
ASSET INTEGRITY
DATABASE
CORROSION LOOP
DESCRIPTIONS
CRITICALITY
ASSESSMENT
CONFIDENCE
ASESSMENT
INSPECTION / MONITORING
PLANNING
TASK EXECUTION
ANALYSIS / REVIEW
FEEDBACK
S
-
R
B
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a
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Risk Based Inspection
A smarter way in continually optimized
the inspection plan
Regulated Inspection Self-Regulated Inspection
(a) Time based (a) Condition based
(b) Focus on registered equipment (b) Focus on entire pressure envelop
(c) Focus spread all over
equipment
(c) Focus on critical high risk areas of
the plant
(d) Only time based internal
inspection specified
(d) Most appropriate inspection
method, scope & interval
(e) DOSH control through renewal
of CF
(e) DOSH control through review &
approval of SOE followed by
compliance audits
(f) Based on Factories & Machinery
Act 1967
(f) Enforces Act 514-1994 & requires a
new act for self regulation
(g) DOSH income based on CF
renewal
(g) DOSH income based on initial
review & approval of SOE and
compliance audit
Estimated Cost Saving
Extending the CF validity period from 15
months to 51 months contributes to improve
Maintenance Index (MI)
Estimated Cost Saving by Extending CF Interval
TA Package TA Duration
Loss Production
Opportunity
TA Expenditure
PSR-1 Refinery TA 30 days RM 58.0 million RM 20.1 million
PSR-2 Phase I TA 14 days - RM 1.25 million
PSR-2 Phase II TA 20 days RM 12.6 million RM 17.0 million
PSR-2 Phase III TA 42 days RM 36.2 million RM 46.7 million
Total RM 106.8 millionRM 85.05 million
Thanks For Your
Attention