ADVANCE ENGINEERED INTEGRATED RISK ASSESSMENT USING PHONON DIAGNOSTIC TECHNOLOGY (PDT) FOR ASSET INTEGRITY MANAGAMENT MRA INTERNATIONAL SDN.BHD
HOW PHONON DIAGNOSTICS TECHNOLOGY CAN BENEFIT CLIENTS IN THEIR MAINTENANCE AND REPAIR PROGRAM?
WITHIN A SHORT DURATION, PDT IS ABLE TO GENERATE VALUABLE DATA TO MAKE KEY INVESTMENT DECISION, REFINEMENT OF MAINTENANCE AND REPAIR WORKS AND OPTIMIZING SHUTDOWN WINDOW.
Conceptual Design Disposal/ Abandonment
Detailed Engineering
Decommissioning Procurement
Maintenance & Reliability Construction/ Installation Operations
AIMS AND LIFE CYCLE COST :
Operatorship Handover
Commissioning/ Start-up
THE FUNDAMENTALS
PHONON ENERGY DIAGNOSTIC TECHNOLOGY:
CORROSION TYPE OF DEFECTS:
MECHANICAL METALLURGICAL CRACKS
TECHNOLOGY MAIN FUNCTIONS : To identify location of defect
To identify number of defect
To identify type of defect
To identify severity of defect To identify sizing of defect Depth
Width
Length
Maximum 2kms length end to end inspection per run for piping/pipeline/tubulars.
Maximum 200 meters one end inspection per run for piping/pipelines/tubulars.
Not able to detect features, i.e. flanges, bends, fittings, girth welds, valves, etc.
LIMITATIONS :
Not able to detect dormant/ inactive defects/ anomalies; i.e. ovality, repaired defects etc. Transducer require direct contact with parent metal. Portion of insulation/coating needs to be removed to install the transducer. The accuracy (allowable tolerance) of defect location and dimension of defect depends on the accessibility of the object and accuracy of the as built drawings.
PHONON DIAGNOSTIC SETUP FOR PIPELINES/TUBULARS
PHONON DIAGNOSTIC SETUP FOR RISERS AND OFFSHORE STRUCTURAL TUBULARS (ACCESS AT 1 END)
Phonon Diagnostic Scheme for plane assets, e.g. Conductors, Piles, Jacket Legs, risers
PHONON DIAGNOSTIC SETUP FOR TANKS
Phonon Diagnostic Scheme for plane assets, e.g. bottom plate and roof
Description
Dimension Accuracy
Circumferential positioning accuracy
To the nearest 4 azimuth hours (3, 6, 9, 12 o’clock)
Size of defect
80% +/- 25 mm from defect center point
Depth of defect
80% +/- 0.1 t (t = pipe wall thickness)
Location
80% +/- 200 mm to reference point
Probability of Identification (POI)*
90%
(*Active Defects)
ALLOWABLE TOLERANCE :
Object inspected under normal operating conditions. Accessible to install transducers at required points.
PDT provides upfront, comprehensive and current inspection based data for better decision making and cost savings TECHNOLOGY
ENGINEERING
Online Inspection, Zero Shutdown
Accurate and real time data acquisition
No modification and minimal preparatory work
Detail asset integrity study on active defects
Workable over wide temperature and pressure range. Independent of environmental conditions
Reduce downtime, volume and labor intensity in asset repair and maintenance
Addresses shortcomings of existing technology
Prolong service intervals
Phonon Diagnostic Technology as Decision Making Tool Critical Decision Area
Phonon Diagnostic Technology Result & Assessment
YES Shutdown With Shutdown
NO
Repair & Maintenance
Repair Without Shutdown
Cleaning Inspection
External Repair
Repair
END
NO
KEY ELEMENTS ZERO SHUTDOWN
QUANTITATIVE ASSESSMENT
FFS IN A SINGLE RUN.
UPFRONT RESULTS FOR DECISION MAKING
MINIMIZE WORK ACTIVITIES THUS REDUCING HSE RISKS
COMPREHENSIVE COVERAGE
TABLE OF CONTENTS Pre Diagnostic Works The objectives of Phonon team mobilization to the site work: Equipment for the surface preparation: Post Diagnostic: Result of Phonon Monitoring Post Diagnostic: Processing and Analyzing the Result of Phonon Diagnostics and Monitoring
Required data for the available documents and Pre Diagnostic Works drawings related to the asset prior to the diagnostic works. Year of construction and commissioning
Working product (content, composition, gravity, specific gravity, corrosivity, etc.) Asset service data for last 5 years (temperature, stress, rate of flow, cycle of loading and unloading, operating parameter, purpose, etc.)
Previous inspection report
Data on emergencies, repairs and breakdowns
The Objectives Of Phonon Team Mobilization To The Site Work: To verify the data obtained by client To identify physical condition of the asset To visual inspection of the asset insulation/coating. To identify location to install transducer Auxiliary testing : Local UT Test, local UT Scanning Test, Stress Test, Hardness Test For surface preparation
Equipment VISUAL INSPECTION
SURFACE PREPARATION
• • • • • • •
• • • • • • •
Measuring tape (Manual and Laser Type) Manual thickness gauges (Pit Gauge) Magnetic holder Metal ruler Paint marker Digital Camera Cotton rags
Scrapper Copper brush Paint remover Paint brush Sand paper Cotton gloves Grinder (Battery Operated)
The Following Equipment For Pre Phonon Diagnostic: Pipeline Tracing Pipeline current mapping system PCM-Tx Set
Cable Avoidance Tools C.A.T4TM and GennyTM Range
Stress Diagnostics Stressvision-2
The Following Equipment For Pre Phonon Diagnostic (2): Mechanical property Diagnostics Dono hardness tester
Soil resistivity testing kit F4103-M1
UT Diagnostics Ultrasonic Thickness gauge Olympus 38 DL Plus
The Following Equipment For Phonon Inspection: Jack for connection to cable
Labeling of transducer
Magnet Transducer
Gasket
Magnetic holder
Working surface
Phonon system Phonon transducer set Jack No.1 Spool
Jack No.2 Cable RJ-58
Phonon acoustic cable set
Phonon Diagnostic Scheme Phonon diagnostics (PD) of the asset shall be carried out according to the scheme prepared during the pre-diagnostic activity, including allocation of phonon diagnostics stations (PDS), determination of locations for installation of phonon emission transducers (PET) and procedure for executing diagnostics operations.
The diagnostic shall be divided into sections. Points of PD installation are placed at strategic location to cover the entire surface of the asset.
PD shall be operated in pairs or quadrants to cover a certain asset sector. For cylindrical assets, 4 linear phonon scheme lines are formed, which cover all the length and all the surface of the sections and provide linear and azimuthal localization of any place on the asset. For single plane surfaces, a planar scheme is developed to cover the complete section of the asset.
Phonon Diagnostic Scheme for Cylindrical assets (linear scheme)
Phonon Diagnostic Scheme - Linear Scheme
Phonon Diagnostic Scheme for Cylindrical assets (planar scheme)
Phonon Diagnostic Scheme - Planar Scheme
The developed scheme shall be implemented using: •4 or 8 phonon sensors, • 4 or 8 cable routes, •one system for phonon diagnostics “PHONON-8”. •Phonon sensors were connected by cable routes with phonon systems, which were located at phonon diagnostics stations. Phonon diagnostics preparation, calibration for each section of tested assets is carried out.
Scaled phonon drawing and phonon development on the basis of phonon calibrations are developed. Phonon system shall perform the phonon energy monitoring in real time and all the data shall be stored in the system. • Sufficient phonon energy monitoring shall be allowed to take place with duration of up to 2-3 hours per section.
Post Diagnostic: Result of Phonon Monitoring The phonon diagnostic monitoring detected in real time shall programmatically superimpose the phonon energy emission – Phonon-Active Areas (PhAA), onto the phonon calibration drawings. • The areas of defect formation and the location of the defects are generated.
Then the results of phonon monitoring were combined on scaled phonon drawings.
Results of phonon diagnostics are superimposed on scaled phonon developments of the asset.
• Some PhAA are combined and additional analysis of phonon energy distribution in PhAA is carried out. • Additional qualifying identification of PhAA and final numbering of detected defects is carried out.
Sample Defect List Report
No.
Defects distance to ref weld, m
Defect designation
Distance from section start, m
Ref. Weld
DF-2
7.235
DF-7
DF-10
Defect dimensions, mm
Orientation
Distance Length from Width, Depth hh:mm , 12 o'clock, W L mm
Distribution of phonon energy
Activit y coefficient
Defect type
Level of defect hazard
Internal/ External
U/S
D/S
Rotations direction
WJ 6
-
0.225
Сlockwise
344
6:00
154
63
5.0
12.15
Local metal loss
significant
external
21.873
WJ 6
14.863
-
Сlockwise
207
3:36
281
156
4.4
11.13
Local metal loss
significant
external
33.409
WJ 6
26.399
-
Counter Clockwise
38
11:21
416
234
4
10.42
Local metal loss
significant
external
Post Diagnostic: Processing and Analyzing the Result of Phonon Diagnostics and Monitoring Analysis of phonon diagnostics results shall be carried out for each PhAA.
The analysis shall determine the quantitative characteristics, concentration, regularities of phonon energy distribution in PhAA.
Running physical processes are identified.
Geometric characteristics are evaluated.
THANK YOU
MRA International Sdn Bhd (1035028-D) No. 27 Jalan Wangsa Delima 10, D'Wangsa, Wangsa Maju, 53300 Kuala Lumpur, MALAYSIA. Websites: www.mra-sb.com | email:
[email protected] | Tel: +603 4149 6664 | Fax: +603 4149 5112
