MANAGEMENT AND
STRATEGY FOR CORROSION HANDLING
HISTORY MATERIAL/PERALATAN
• Design
• Pemilihan material TANGGUNG
JAWAB
• Proses manufaktur MANUFACTURER
• Proses assembling
• DELIVERY
• Proses pemakaian
• Proses penggunaan TANGGUNG
JAWAB USER
• Proses perawatan
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5
CORROSION MANAGEMENT by BW/AS 18/09/2011
6 DEFINISI KOROSI
PARAMETER PENYEBAB
7
KEGAGALAN
CREEP
BEBAN TEMPERATUR
KOROSI
WAKTU LINGKUNGAN
8
CORROSION MANAGEMENT by BW/AS
Bijih logam 18/09/2011
Peleburan
9
Pemurnian Pemaduan/
pencampuran
Penambangan Pengecoran
bahan galian Barang
setengah
Daur jadi
ulang
Eksplorasi
Pembentukan
Barang
Bumi jadi
Pembuangan Barang Pemakaian
rusak
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BENTUK-BENTUK KOROSI
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11
Penggetasan hidrogen
12
Metoda penanggulangan korosi
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Cleaning
Design improvement
Material selection
Coating and lining
– organic coatings, metallic coatings,
ceramic coatings.
Cathodic protection
Anodic protection
Inhibitors
Surface modification
CORROSION MANAGEMENT by BW/AS 18/09/2011
• Cleaning
– Mengurangi waktu kontak logam dengan media
• Design Improvement
– Memperbaiki bentuk konstruksi untuk menghindarkan kondisi yang
memfasilitasi terjadinya reaksi korosi
• Material Selection
– Memakai material yang sesuai dan kurang sensitif terhadap
lingkungankerja
• Coating
– Mencegah kontak antara logam dan lingkungannya
CORROSION MANAGEMENT by BW/AS 18/09/2011
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• Cathodic Protection
• Membuat logam bertindak sebagai katoda
• Anodic Protection
• Membuat logam bertindak sebagai anoda yang daapat
menciptakan lapisan pasif
• Inhibitors
• Mengurangi keagresifan lingkungan
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PERMASALAHAN DI INDUSTRI SEARA
UMUM MATERIAL, KEGAGALAN DAN
KOROSI
KEGAGALAN KOROSI
KESALAHAN MATERIAL
CORROSION MANAGEMENT by BW/AS 18/09/2011
18 BENTUK-BENTUK KERUSAKAN
KARENA KOROSI
Penipisan
Pembentukan retakan/sumuran
perubahan penampilan
Penurunan daya dukung
Penggetasan
CORROSION MANAGEMENT by BW/AS 18/09/2011
1.5-2.5%
dari GDP !!
CORROSION MANAGEMENT by BW/AS 18/09/2011
1975 1995
21
All industries
Total (billions of 1995 dollars) $82.5 $296.0
Avoidable $33.0 $104.0
Avoidable 40% 35%
Motor vehicles
Total $31.4 $94.0
Avoidable $23.1 $65.0
Avoidable 73% 69%
Aircraft
Total $3.0 $13.0
Avoidable $0.6 $3.0
Avoidable 20% 23%
Other industries
Total $47.6 $189.0
Avoidable $9.3 $36.0
Avoidable 19% 19%
CORROSION MANAGEMENT by BW/AS 18/09/2011
22 SEKTOR-SEKTORYANG
TERPENGARUH OLEH KOROSI
24
CORROSION MANAGEMENT by BW/AS 18/09/2011
25
GOALS
• “Corrosion management is that part of the overall
management system, which is concerned with the
development, implementation, review and
maintenance of the corrosion policy.”
CONCERNS OF
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26
CORROSION HANDLING
•RELIABILITY
•PRODUKTIVITY
•SAFETY &
ENVIRONMENT
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INTEGRATED CORROSION
MANAGEMENT CHARTS
PENGENDALIAN OLEH TOP
MANAGEMENT
USAHA
PENGENDALIAN
KOROSI
TERPADU DI
INDUSTRI DIVISI
DIVISI LOGISTIK MAINTENANCE DAN
INSPEKSI
Tahu/ Permasalahan cukup serius
CORROSION MANAGEMENT by BW/AS 18/09/2011
(BERBAHAYA, MERUGIKAN,
KONDITE DLL)
30
Tertarik untuk mengetahui lebih
lanjut/interest
Kesadaran/awareness
33 SYSTEM
ROHRBACK COSASCO SYSTEM
TOOLS: Corrosion circuit
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SW.WANDA-A N.WANDA-B N.WANDA-A WANDA-A GITA-A RETNO
CINTA-A
9,728 ft, Ø12” (1984)
)
ak ) ak
1 le 1 le Mar’95 (J-Bow; 1 leak)
Pin = 273 psi Fluid Comp. : A; A;
GIT GIT
Pou t= 254 psi S = 47 ppm ft fr 6 ft fr
CNOOC - 114 Tin = 123 oF Cl = 3010 ppm
(2296(229
CNOOC - 114
0
t’89 ’9
=
CO3 = 1533 ppm
Tout = 117 oF Oc Feb
CINTA-B CINTA-C V = 0.72 fps TAN = 0.576
BSW = 72.21 % pH = 7.36 Pin = 238 psi Fluid Comp. :
Leak Record = 8 Sand = low S = 102 ppm
Pou t= 170 psi
Pin = 120 psi Fluid Comp. : Tin = 192 oF Cl = 1152 ppm
Date : August, 1st 1989. Location : N/A. Leak : =
S = 55 ppm 1" leak diameter on 1 joint. Treatment : N/A. Tout = 117 oF CO3 = 3042 ppm
Pou t= 43 psi
o
Cl = 3550 ppm Date : Oct, 17th 1989. Location : 700 m from V = 1.57 fps TAN = 1.045
Tin = 112 F Gita A. Leak : 2" leak diameter on 1 joint.
o CO3= = 2604 ppm BSW = 81.76 % pH = 7.07
Tout = 163 F
TAN = 0.883
Treatment : N/A.
Leak Record = 3 Sand = low Pin = 120 psi Fluid Comp. :
V = 1.87 fps Date : Feb, 18th 1990. Location : 700 m from
Pou t= 43 psi S = 55 ppm
)
bow, Leak: 7 Leakholes at 6 o’clock.
ak
D;
Date : 23 August 03. Location : close to
IN
Location : 24 August 2003. Location : At
rC
Cinta P1 riser, 3 ft from concrete. Leak : at 6 Cinta P. Leak : at 6 o'clock, one hole.
t. f
30,180 ft, Ø16” (1979)
o'clock. Treatment : Wrapped with Syntho 8f
CINTA-F RAMA-I RAMA-D Treatment : installed modified Clamp.
32
Glass 8 layers and press test 150 psi.
3(
Date : 14 March 2004. Location : Cinta P J Date : 20 Sept 03. Location : 100 m from
p’0
Se
S
bow. Treatment : 12" x 1 ft Plidco clamp
Date: 18 Feb 2005. Location: 230m from
E-RAMA CINP, 3 holes 6 O’clock.Treatment : 12" x 1
6,800 ft, Ø 6” (1999) ft Plidco clamp
CINTA-D
Pin = 356 psi Fluid Comp. :
Pou t= 210 psi S = 31 ppm
SELATAN-A
o
Tin = 203 F Cl = 2775 ppm LITA-A
CO3= = 3042 ppm
PABELOKAN ISLAND
o
Tout = 183 F
V = 7.50 fps TAN = 0.717
BSW = 94.86 % pH = 7.4
Leak Record = - Sand = low
SELATAN-B
Pemetaan data korosi dan kondisi operasi pilelines di CNOOC SES, Ltd
SELATAN
TOOLS: Corrosion mapping
Contoh : Corrosion Mapping Crude Distillation Unit
CORROSION MANAGEMENT by BW/AS 18/09/2011
37 LEGISLATIVE FRAMEWORK
The main current applicable UK legislation governing activities on topsides processing facilities for offshore
installations includes:
• • Health and Safety at Work etc Act 1974 (HSW Act)
• • Management of Health and Safety at Work Regulations 1992 (SI 1999/3242) (MHSWR)
• • Offshore Installations (Safety Case) Regulations (SI 1992/2885) (SCR)
• • Offshore Installations and Wells (Design and Construction, etc) Regulations 1996 (SI 1996/913) (DCR)
• • Offshore Installations (Prevention of Fire and Explosion, and Emergency Response) Regulations 1995 (SI
1995/743) (PFEER)
• • Provision and Use of Work Equipment Regulations 1998 (SI 1998/2306)
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CORROSION MANAGEMENT by BW/AS 18/09/2011
39
EQUIPMENTS AND UNITS NEEDS &
CORROSION MANAGEMENT by BW/AS 18/09/2011
CORROSION MAPPING
?
SOP
Inspection,
Maintenance &
Mitigation
Maintenance strategy
CORROSION PREVENTION
PLAN GUIDANCE
GOALS!!
RELIABILITY,
CORROSION MANAGEMENT SAFETY &
MANAGEMENT CONCERN
(IMPLEMENTATION & POLICY) PRODUCTIVITY
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18/09/2011
45 SUMMARY
• The infrastructure of the nation is essential to the quality of life, industrial
productivity, international competitiveness, and security
• Each component of the national infrastructure, such as highways, airports,
water supply, waste treatment, energy supply, and power generation,
represents a complex system and large investments.
• Corrosion is damage that results from the interaction of structures and
materials with their environment, corrosion can result in catastrophic
failures, with loss of life and disruption of essential services
• The principal challenges in realizing the significant savings that result from
improved corrosion control include an unfortunate lack of awareness of
corrosion costs by the public and policymakers and a widely held
misconception that nothing can be done about corrosion.
CORROSION MANAGEMENT by BW/AS 18/09/2011
46 CONT’D
This invisible infrastructure includes items such as water mains, gas and oil
pipelines, power plants, and telecommunications systems
The preservation and the extension of the useful life of an existing infrastructure is
a great challenge because of the long service lives that are desired.The operating
life of critical components of the infrastructure is often extended well beyond the
original design service life.
While the focus may recently have shifted from building a new infrastructure to
the preservation and extended use of the existing infrastructure, the necessary
changes in public attitudes, adjustments to the allocation of resources, changes to
the industrial, government, and academic institutions, and revisions to policies,
practices, and procedures.
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CORROSION PREVENTION STRATEGIES
48 KALIMAT KUNCI
Korosi tidak pernah berhenti
Semakin canggih penggunaan peralatan, akan
semakin canggih pula masalahnya
Pembelajaran harus dilakukan secara
berkesinambungan
Usaha penanggulangan korosi bukan Waste,
tapi adalah INVESTASI
Kerjasama antar stake holder mutlak
diperlukan
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