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 sessionthe participant shall beable:(1)To describe the functions,roles & responsibility of MCIDepartment(2) To have an awareness onMaterial, Corrosion &inspection work activities

Organization Chart

RBI/Inspection Engineer

Ben Faizal

Snr Mtrl/Corrosion Engineer

Nurul Asni Mohd

AREA 1Snr Executive

Inspection EngineerRoziman Yahya

AREA 2Snr Executive

Inspection EngineerZainol Abidin Mohd

AREA 3Snr Executive

Inspection EngineerShuhaily Yusoff

AREA 4Snr Executive

Inspection EngineerAznam Mohd Som

AREA 5Snr Executive

Inspection EngineerChoo Wei Lee

OS & QISnr Inspection

Planning EngineerAzman 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 ManagerTechnical Services Division Neil Anthony Morgan

Inspection ManagerAb. Ghani Ismail

-Functional-

Admin ClerkSharifah 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 AssuranceProcess of measuring, comparing & correcting in accordance with planned requirement

• Design Stage• Manufacturing/Fabrication Stage• Incoming Material Inspection• Installation Stage• Periodic Inspection & Testing

Design StageMetallurgy & 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 NDT1. Dye Penetrant Testing2. Magnetic Particle Testing3. Ultrasonic Testing4. Radiography Testing

Non Destructive

TestingMethod of detecting

discontinuities or flaws within a material or a

product without impairing the

usefulness of the material

Advance NDT1. Acoustic Emission2. Time of Flight Diffraction3. Guided Wave Inspection4. IR Thermography5. Tubular Inspection

- Eddy Current Testing- RFET- IRIS

Dye Penetrant TestingTo detect surface discontinuities

Working principle-Capillary action into cavities that open to the surface

Advantages;1. Portable,simple & fast2.Able to inspect on a small area3.Any materials ferrous or non ferrous4.Not affected by material magnetic properties5. Any defect size, configuration, internal structure or chemical composition6. Orientation of the discontinuity is not a factor

Disadvantages;1.Detect surface defect only2.Surface coating, grease, oil and dirt must be removed3.Poor or rough surface affects result4.No information on the depth of the defect5. Not applicable to porous materials

Working Principle-Detect the presence of magnetic fields leakage from discontinuities

A BC

DE

Magnetic Particle TestingTo detect surface and sub-surface discontinuities in ferromagnetic materials

Advantages;1. Simple and fast technique2. Most sensitive technique in detecting small surface and sub-surface defects3. 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 surface2. Applicable only to ferromagnetic materials 3. Thick surface coatings must be removed

Radiography TestingTo detect material defects, structural discontinuities, using a visual image on the interior of materials or non-accessible areas

RadioactiveIsotope

Specimen

Radiography Film

2m m Slag Inclusion0.01m m Crack

10m m W eld

9.9m m Indication10m m Indication

8m m Indication

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 picture2. Good for detecting non-planar defects3-D : slag inclusion, porosity4. Shows defects in plan view (2-Dimension)

Disadvantages:1. Radiation hazard2. Require access to both sides of specimen3. Limited by material thickness4. Not good for detecting planar defects2-D : cracks, lack of fusion5.Does not indicate defect depth

Ultrasonic TestingTo 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 surfaceof plate echo

Time

transducer

front surface back surface

4"

0 1 2 3 4

Initial pulse

Back surfaceof 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 DiffractionTo detects relevant defect and measure their

location and position with defects recorded as permanent image format

M icroplus

Scanninghead

TO FD Set-up

D C U A m plifier

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 le 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 yf r o m b o t h e x t r e m i t ie so f f la w

T x R x

In s p e c t io n s u r f a c e

Advantages:1. Rapid scan rates - Up to 12 meters per hour2. Used in lieu of manual UT & radiography3. No need to move vessel from welding station4. Real time display - instant sentencing5. Accurate flaw sizing - no unnecessary repairs6. Cost effective with significant time savings7. Permanent record

Tubular InspectionTo 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 NoVery low

permeability ferrous

Yes Yes

Non-Ferrous Yes N/A Yes Yes

Couplant No No No YesTube

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 SlowSIgnals 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 InspectionA systematic methodology of evaluating risk and

factoring it into decision concerning how, where and when to inspect

Risk Based InspectionA proactive tools that identifies and focus

attention on critical areas of plantObjectives:

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 InspectionS-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 INTEGRITYDATABASE

CORROSION LOOPDESCRIPTIONS

CRITICALITYASSESSMENT

CONFIDENCEASESSMENT

INSPECTION / MONITORINGPLANNING

TASK EXECUTION

ANALYSIS / REVIEWFEEDBACK

S-R

BI p

acka

ge

Risk Based InspectionA 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 SavingExtending 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 DurationLoss Production

OpportunityTA Expenditure

PSR-1 Refinery TA 30 days RM 58.0 million RM 20.1 millionPSR-2 Phase I TA 14 days - RM 1.25 millionPSR-2 Phase II TA 20 days RM 12.6 million RM 17.0 millionPSR-2 Phase III TA 42 days RM 36.2 million RM 46.7 millionTotal RM 106.8 million RM 85.05 million

Thanks For Your Attention