MRA INTERNATIONAL SDN.BHD

ADVANCE ENGINEERED INTEGRATED RISK ASSESSMENT USING

PHONON DIAGNOSTIC TECHNOLOGY (PDT) FOR

ASSET INTEGRITY MANAGAMENT

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.

AIMS AND LIFE CYCLE COST :

Conceptual Design

Detailed Engineering

Procurement

Construction/ Installation

Commissioning/ Start-up Operatorship

Handover

Operations

Decommissioning

Disposal/ Abandonment

Maintenance

& Reliability

THE FUNDAMENTALS

PHONON ENERGY DIAGNOSTIC TECHNOLOGY:

CORROSION

MECHANICAL

METALLURGICAL

CRACKS

TYPE OF DEFECTS:

To identify sizing of defect

Depth Width Length

To identify severity of defect

To identify type of defect

To identify number of defect

To identify location of defect

TECHNOLOGY MAIN FUNCTIONS :

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.

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.

LIMITATIONS :

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 oclock)

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)*

(*Active Defects)

90%

ALLOWABLE TOLERANCE :

Object inspected under normal operating conditions. Accessible to install transducers at required points.

TECHNOLOGY

Online Inspection, Zero Shutdown

No modification and minimal preparatory work

Addresses shortcomings of existing technology

Workable over wide temperature and pressure range. Independent

of environmental conditions

ENGINEERING

Accurate and real time data acquisition

Detail asset integrity study on active defects

Reduce downtime, volume and labor intensity in asset repair and

maintenance

Prolong service intervals

PDT provides upfront, comprehensive and current inspection based data for better decision making and cost savings

Phonon Diagnostic Technology

Result & Assessment

Shutdown

Repair Without Shutdown

With Shutdown

END

Repair & Maintenance

Cleaning

Inspection External Repair

Repair

Phonon Diagnostic Technology as Decision Making Tool

YES NO

Critical Decision Area

NO

FFS IN A SINGLE RUN.

COMPREHENSIVE COVERAGE

QUANTITATIVE ASSESSMENT

ZERO SHUTDOWN

UPFRONT RESULTS FOR DECISION MAKING

MINIMIZE WORK ACTIVITIES THUS

REDUCING HSE RISKS

KEY ELEMENTS

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

TABLE OF CONTENTS

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

Pre Diagnostic Works

Required data for the available documents and drawings related to the asset prior to the diagnostic works.

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

The Objectives Of Phonon Team Mobilization To The Site Work:

Equipment VISUAL INSPECTION Measuring tape (Manual and Laser Type) Manual thickness gauges (Pit Gauge) Magnetic holder Metal ruler Paint marker Digital Camera Cotton rags

SURFACE PREPARATION Scrapper Copper brush Paint remover Paint brush Sand paper Cotton gloves Grinder (Battery Operated)

The Following Equipment For Pre Phonon Diagnostic:

Pipeline Tracing Stress Diagnostics

Pipeline current mapping system PCM-Tx Set

Cable Avoidance Tools C.A.T4TM and GennyTM Range

Stressvision-2

The Following Equipment For Pre Phonon Diagnostic (2):

Mechanical property Diagnostics UT Diagnostics

Dono hardness tester Soil resistivity testing kit F4103-M1

Ultrasonic Thickness gauge Olympus 38 DL Plus

The Following Equipment For Phonon Inspection:

Jack for connection to cable Labeling of transducer

Magnet

Transducer

Working surface Magnetic holder Gasket

Jack No.1

Jack No.2

Spool

Cable RJ-58

Phonon system Phonon transducer set

Phonon acoustic cable set

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

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

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.

The developed scheme shall be implemented using:

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.

Sufficient phonon energy monitoring shall be allowed to take place with duration of up to 2-3 hours per section.

Phonon system shall perform the phonon energy monitoring in real time and all the data shall be stored in the system.

The areas of defect formation and the location of the defects are generated.

The phonon diagnostic monitoring detected in real time shall programmatically superimpose the phonon energy emission Phonon-Active Areas (PhAA), onto the phonon calibration drawings.

Then the results of phonon monitoring were combined on scaled phonon drawings.

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.

Results of phonon diagnostics are superimposed on scaled phonon developments of the asset.

Post Diagnostic: Result of Phonon Monitoring

Sample Defect List Report

No. Defect desig-nation

Distance from

section start, m

Ref. Weld

Defects distance to ref weld, m Orientation

Defect dimensions, mm

Distribution of phonon energy

Activity

coeffi-cient

Defect type Level of defect hazard

Internal/ External

U/S D/S Rotations direction

Distance from

12 o'clock, mm

hh:mm Length

, L

Width, W Depth

DF-2 7.235 WJ 6 - 0.225 lockwise 344 6:00 154 63 5.0 12.15 Local metal loss significant external

DF-7 21.873 WJ 6 14.863 - lockwise 207 3:36 281 156 4.4 11.13 Local metal loss significant external

DF-10 33.409 WJ 6 26.399 - Counter Clockwise 38 11:21 416 234 4 10.42

Local metal loss significant external

Geometric characteristics are evaluated.

Running physical processes are identified.

The analysis shall determine the quantitative characteristics, concentration, regularities of phonon energy distribution in PhAA.

Analysis of phonon diagnostics results shall be carried out for each PhAA.

Post Diagnostic: Processing and Analyzing the Result of Phonon Diagnostics and Monitoring

THANK YOU

No. 27 Jalan Wangsa Delima 10, D'Wangsa, Wangsa Maju, 53300 Kuala Lumpur, MALAYSIA. Websites: www.mra-sb.com | email: enquiry@mra-sb.com | Tel: +603 4149 6664 | Fax: +603 4149 5112

MRA International Sdn Bhd (1035028-D)

ADVANCE ENGINEERED INTEGRATED RISK ASSESSMENT USING PHONON DIAGNOSTIC TECHNOLOGY (PDT) FORASSET INTEGRITY MANAGAMENTHOW PHONON DIAGNOSTICS TECHNOLOGY CAN BENEFIT CLIENTS IN THEIR MAINTENANCE AND REPAIR PROGRAM?AIMS AND LIFE CYCLE COST :Slide Number 4TYPE OF DEFECTS:TECHNOLOGY MAIN FUNCTIONS :LIMITATIONS :Slide Number 8Slide Number 9Phonon Diagnostic Scheme for plane assets, e.g. Conductors, Piles, Jacket Legs, risersSlide Number 11Phonon Diagnostic Scheme for plane assets, e.g. bottom plate and roofALLOWABLE TOLERANCE :Slide Number 14Slide Number 15SAMPLE WORKING PROCEDURE FOR SITE WORKTABLE OF CONTENTSPre Diagnostic WorksSlide Number 20Slide Number 21The Following Equipment For Pre Phonon Diagnostic:The Following Equipment For Pre Phonon Diagnostic (2):The Following Equipment For Phonon Inspection:Phonon Diagnostic SchemePhonon Diagnostic Scheme for Cylindrical assets (linear scheme)Phonon Diagnostic Scheme - Linear SchemePhonon Diagnostic Scheme for Cylindrical assets (planar scheme)Phonon Diagnostic Scheme - Planar SchemeSlide Number 30Post Diagnostic: Result of Phonon MonitoringSample Defect List ReportPost Diagnostic: Processing and Analyzing the Result of Phonon Diagnostics and MonitoringTHANK YOU