DEPARTMENT OF MECHANICAL ENGINEERING UNIVERSITI TEKNOLOGI PETRONAS

STATEMENT OF VERIFICATION INDUSTRIAL INTERNSHIP REPORT

STUDENTS NAME MATRIC NUMBER

: WAN IBRAHIM BIN WAN MAMAT : 11526

This is to certify that the above mentioned report is approved and all information and project involved are NOT confidential.

Supervisors Signature Supervisors Name

: .. : Ir. Hj Khairil Nizam b. Khirudin Senior Inspection Engineer Gas Plant Processing B, Petronas Gas Berhad

Date

ACKNOWLEDGEMENT EXECUTIVE SUMMARY TABLE OF CONTENT 1. INTRODUCTION 1.1 Introduction to Industrial Internship Program 1.1.1 1.1.2 Objective of Industrial Program Scope of Work 1 1 3 4 4 6

1.2 Introduction to Host Company (Petronas Gas Berhad) 1.2.1 1.2.2 Company Profile PETRONAS Corporate Value

1.3 Organization Background 1.3.1 1.3.2 Inspection Section Jobscopes Department Organization Chart 6 7

2. WORK EXPOSURES 2.1 Damage Mechanisms (Refinery and Process Industry) 2.1.1 2.1.2 Corrosion Under Insulation Galvanic Corrosion

8 10

2.2 Non Destructive Testings (NDT) 2.2.1 2.2.2 2.2.3 2.2.4 Dye Penetrant Testing Magnetic Particle Testing Ultrasonic Testing Radiography Testing 11 15 18 19

2.3 PETRONAS Risk-Based Inspection (P-RBI) 2.4 Inspection Reference Plan

21 24

3. PROJECT AND ASSIGNMENT 3.1 Project Background 3.2 Objectives 3.3 Root Cause Failure Analysis (RCFA) 5 Why Analysis on Wet Gas Separator 3.4 RCFA Problem Statement 3.5 Conclusion 29 31 33 27 29

4. OTHER INVOLVEMENTS 5. LESSON LEARNT 5.1 Challenges faced and solutions to overcome 6. RECOMMENDATION 7. CONCLUSION

34

35 36 37

REFERENCES APPENDICES Appendix 1: Piping Integrity Management System Appendix 2: Simplified Block Flow Diagram of gas processing Appendix 3: DOSH Registered Equipments for Gas Plant Processing B Appendix 4: Equipment Certificate of Fitness (CF) Appendix 5: RBI Criticality Ranking Appendix 6: Laboratory Analysis Test result Appendix 7: External Visual Inspection equipment report

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39 40 41 42 43 43 44

LIST OF FIGURES Figure 1 : Inspection Section GPPB Figure 2 : Application of penetrant on the surface Figure 3 : Removal of excess penetrant Figure 4 : Application of developer 7 12 13 13

Figure 5 : Indications of surface breaking Figure 6 : Indication on the weldment Figure 7 : Student demonstrating DPI Figure 8 : Working principle of MPT Figure 9 : Dry method Figure 10 : Wet method Figure 11 : Crane Hook with service induced crack Figure 12 : Gear with service induced crack Figure 13 : Drive Shaft with heat treatment induced crack Figure 14: Lack of fusion in SMAW weld Figure 15: The sound reflected to the probe is displayed on the flaw detector Figure 16 : Illustration of Radiographic test Figure 17 : Result produced Figure 18 : RBI Risk Matrix Figure 19 : Three distinct level namely qualitative , semi-quantitative and quantitative Figure 20: Simplified Block diagram of RBI Process Figure 21: Before and after internal modification in 2008 Figure 22: 2008- No erosion observed Figure 23: 2010 severe corrosion observed Figure 24: Chronology of Events (Events and Causal Factors) Figure 25: 5 WHY Analysis

14 14 14 15 16 16 17 17 17 17 18 19 20 21

22 23 29 30 30 32 32

LIST OF TABLES Table 1 : Scopes of Works Table 2 : Yearly Inspection Service Program Table 3 : Comparison of Gamma rays and X-rays Table 4: Continuum of RBI approaches Table 5: Wet Gas Separator equipment data Table 6 : Lab Analysis as per taken on 2 April 2011 at V6-0401 boot Table 7 : Others involvement 3 7 20 22 28 33 34

ACKNOWLEDGEMENT Alhamdulillah. I would like to express my greatest gratitude to Allah SWT for His will upon the completion of this final internship report. My deepest appreciation to PETRONAS Gas Berhad (Gas Plant Processing B) for the opportunity given to me in order to acquire knowledge during the eight months of industrial training. Greatful acknowledgement to my personal guidance and dedicated supervisor Ir. Hj Khairil Nizam B Khirudin, Senior Inspection Engineer of GPPB who has helping and influence me a lot on my personnal development. During my internship, I have also received many guidance and assistance from many colleagues in Inspection Section, and my special thanks goes to all of them. 1- Mr. Khairul b Ismail - Inspection Manager, GPPB

2- Mr. Rozaimee Ahamad Zakaria - Senior Inspection Engineer (GPP5) 3- Mr. Zubir b Mat Dahan - Inspection Engineer (DPCU3)

4- Ms. Fatihanum Abdul Rahman - Technical Clerk 5- Mr. Anis B Jusoh 6- Mr. M Kamah Md Noor 7- Mr. M Azman b Jusoh 8- Mr. M Syuraihan b Aziz 9- Mr. M Nazeri Ahmad Sofian 10- Mr. Raja Anuar Raja Ahmad - Inspection Technician (GPP6) - Inspection Technician (GPP5) - Inspection Technician (GPP5) - Inspection Technician (DPCU3) - Inspection Technician (Common) - Inspection Technician (DPCU3

My appreciation also goes to Mechanical Engineering Department and Student Industrial Internship Unit (SIIU) of Universiti Teknologi PETRONAS for arranging and guiding me from the beginning till the end of internship program. I also would like to express special thanks to my UTP supervisor, Dr. Ridzuan Abdul Latif for his supervision and advice. Not to be forgotten, my appreciation also goes to my colleagues and family for their continuos supports upon my completion of internship. Thank you. I

EXECUTIVE SUMMARY Industrial Internship Program coordinated by the Student Industrial Internship Unit of Universiti Teknologi Petronas (UTP) is aimed to produce well rounded students which is part of the effort in achieving UTPs mission. Despite of as an exposure towards the working life, the rationale of this program is to provide undergraduates with necessary technical and soft skills. This Industrial Internship Final Report compiles all activities and tasks that the author had undergone through during the Industrial Internship Period. The final report is divided into few sections whereby the first section briefly introduce the host company background, objectives as well as the scope of work done during the Industrial Internship Program. Next, the main section illustrate in details of the projects and tasks involved during the internship period as following: I. II. III. IV. V. Damage Mechanisms Non-Destructive Testing Risk-Based Inspection Inspection Reference Plan Analysis of the Project

Lastly, the final section contains the lesson learned, discussions, conclusions and recommendations to the Host Company and UTP. All related standards, tables, figures and references are attached in the appendices section for better overview of the tasks explained.

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1. INTRODUCTION

1.1 Introduction to Industrial Internship Program 1.1.1 Objective of Industrial Program

The Industrial Internship Training Programme (IITP) is a core course offered to all third-year student of Universiti Teknologi Petronas (UTP). The students undergo practical training from 6th December 2010 until 15th July 2011 prior to the completion of their study. During these 32 weeks of training programme, UTP students are exposed to the real working environment where they can relate theoretical knowledge with application in industry. It is the University hopes that the students will be able to develop skills in work ethics, communication, leadership, management and other skills during these 32 weeks. There are five main objectives of the IITP:

1) To integrate theory with practice In University, student had studied so many theories and the IITP is the chances for the students to apply and see the application of all those theories. The experience gain in integrating the theory and hands-on during this IITP had given the author a better understanding towards the theories and enables the author to appreciate the theories learnt at the University.

2) To introduce students to work culture and industrial practices The period of 32 weeks of training programme is a good start for the student to prepare themselves before entering the real life working environment. Students have the opportunity to improved the communication and interpersonal skills among the staffs and advance themselves in using the software and tools related.

3) To give opportunity to students to work with industrial practitioners The involvement of students in several projects will give them the opportunities to work with various industrial practitioners from different engineering background. This will help the students in identi1 their interest and choosing 8 their career path later on.

4) To expose students to potential employers During these 32 weeks of internship period, students will be working not only with the staff from the host company itself but also with the client, staff from other company. With this experience, student will know lots of people from different companies which later can be the potential employer when students finished their study.

5) To acquaint UTP students with industry and its programs Students who undergo the internship program will have the experience of working in the industry. This is a good opportunity for students to create good acquaintances with the host company. Students have chances to apply the knowledge they gain in University and see the applications of every program that they had learnt.

1.1.2

Scope of Work

Generally, the scope of works, tasks or projects undertaken during this period is according to the training shcedule planned at the very first week of internship period. Both supervisor and author had agreed on several fields to be covered at respective weeks. The training schedule is as follows : Scopes Month Dis Jan Feb Mac Apr May June July the

Introduction to POD/PGB P-Risk Based Inspection (PRBI) Damage Mechanisms Non-Destructive Testing (NDT) Dye Penetrant Testing (DPT) Thermography Welding Pressure Test Ultrasonic Thickness Test (UT) Steam Condensate Line Corrosion Under Insulation Stress Corrosion Cracking Pressure Relief Device (PRD) Plant Turnaround/Shutdown Extra Tasks Root Cause Failure Analysis (RCFA) Inspection Confidence Inspection Reference Plan (IRP) Piping Integrity Management System DOSH Packages Piping Circuit Corrosion Monitoring Internship Project (Wet Gas Separator) Final Presentation Table 1 : Scopes of Works

1.2 Introduction to Host Company (GPP Complex B, Petronas Gas Berhad) 1.2.1 Company Profile

PETRONAS Gas Berhad (PGB) PETRONAS Gas Berhad (PGB) was incorporated on 23rd May 1983 and being among the top subsidiaries of PETRONAS since establishment. PGBs main business porfolio is divided into four major divisions namely Plant Operations, Transmission Operations, Centralised Utility Facilities and Technical and Facilities Division. The principle activities of the company are processing of natural gas produced from the gas fields and transmission of the processed gas to end-users throughout peninsular Malaysia and some for export to Singapore. The first two are directly related , the third division supports the gas value chain by supplying industrial utilities to the various petrochemical plants operating in Kerteh and Gebeng and the fourth division is a technical services outfit for PGB, which also extend its expertise in engineering and project management to other entities within the PETRONAS Group of Companies.

As the sole supplier of processed gad, PGB plays a prominent role in the gas business value chain. PGB operates as a throughout service company providing the services of processing and transmission of gas to the various customers on behalf of PETRONAS for a fee as set out in the gas Processing Transmission Agreement (GPTA).

Sales gas (Methane, ethane, propane , butane and condensates ) are delivered through the peninsular Gas Utilisation pipeline system. PGB supplies sales gas to power stations which account for more than 70% of the consumption of processed gas. The balance is for the non0-power sector and export to Singapore. The Plant Operations Division (POD) handles all activities pertaining to the processing of feed gas whilst the Transmission Operation Division (TOD) comprising of a chain of regional offices, is responsible for the transmission and delivery of sales gas to end customers. Apart from the PGU system in Peninsular Malaysia, PGB also owns and operates two gas distribution systems in Miri and Bintulu, Sarawak.

The third division involves marketing, manufacturing and supplying of industrial utility products to the Integrated Petrochemical Complexes (IPCs) in Kerteh and Gebeng through the Centralised Utilities Facilities (CUF) Operations. With regard to its CUF business, PGB operates as a commercial provider of industrial utility products services to its own customers. The commercial operations of CUF has commenced in January 2000.

The fourth division involves in engineering and project management services. Technical and Facilities Development Division (TFDD) is the engineering and project management arm of PETRONAS Gas Berhad. TFDD also provides services to other companies within the Petronas Group such as Petronas Carigali Sdn Bhd for the Sabah-Sarawak Gas Pipeline. Due to integrated nature and interdependence of the gas business, it is crusial for PGB to ensure its operations support the requirement of its customers. The company will continue to focus on sustaining the reliability and efficiency of its facilities with optimal utilization of resourced.

Gas Plant Processing (GPP) Since the implementation of the PGU Project 1984, PGBs gas processing operations are an integral component of this project. Feedgas from offshore Terengganu is landed at the GPPs in Kerteh and extracted into various component namely salesgas, ethane, propane, butane and condensate. The GPP Complex in Kerteh comprises GPP 1,2,3,4 with a combined salesgas production capacity of 1000 million standard cubic feet per day (mmscfd).

To ensure reliability and availability of gas supply to end users, PGB has constructed two additional GPPs in Kg Tok Arun, which is approximately 15 km to the north of existing GPP Complex in Kerteh. The completion of GPP 5 and 6 in December 1998 and July 1999 respectively each with a 500 mmscfd salegas processing capacity has boosted PGBs total gas processing capacity to 2000 mmscfd.

Function/Design Basis of a GPP 1. To produce on-specification products in accordance with customers requirements namely methane, propane, butane and condensate. 2. To process a wide range of feedstocks from the offshore fields and offgas from a crude oil terminal

1.2.2

PETRONAS Vision and Mission, Corporate Value PETRONAS has its very clear vision and achievable mission statement

which define its organisation, guiding our corporate activities and policies. Vision : To be a Leading Oil and Gas Multinational of Choice

Mission : - We are a business entity - Petroleum is our core business - Our primary responsibility is to develop and add value to this national resource - Our objective is to contribute to the well-being of the people and the nation. Shared Values : Loyalty Integrity - Loyal to nation and corporation - Honest and Upright

Professionalism - Committed, Innovative & Proactive and always striving for Excellence Cohesiveness - United in Purpose and Fellowship

1.3 Organization Background 1.3.1 Inspection Section Jobscope

The author has been attached to the Inspection Section of Technical Services Department. Inspection section is an important section in oil and gas industry in order to enable the operation is complying with The Factory and Machinery Act 1967 and Occupational Safety and Health Association OSHA and working closely with the Department of Occupational Safety and Health DOSH to ensure plant and operation integrity.

Inspection focus areas are as below : Yearly Inspection Service Program (ISIP) DOSH registered equipment Managing Loss of Containment, LOC Non-DOSH registered equipment Piping : P-PIMS Tankage Non Standard Repair Turnaround, TA Certificate of Fitness Renewal Statutory/Insurance/Audit Certificate of Fitness Extension P- Risk Based Inspection, RBI PRD : ECA Initiatives WP/WI Updates 5S PMT Day-to-day ad-hoc Ad-Hoc Slowdown Mini-shutdown Others Contract Renewal Table 2: Yearly Inspection Service Program 1.3.2 Department Organization Chart 5S PMT Number Condensate Tank Assessment

Figure 1: Inspection Section GPPB 7

2. WORK EXPOSURES

2.1 Damage Mechanisms 2.1.1 Corrosion Under Insulation (CUI)

Desciption of Damage Corrosion of piping, pressure vessels and structure componnets resulting from water trapped under insulation or fireproofing Affected Materials Carbon steel. Low alloy steels, 300 series SS and duplex stainless steels. Critical Factors a) Design of insulation (humidity, system, rainfall insulation and type, temperature, from marine

environment

chlorides

environment, industrial environments containing SO2) are critical factors b) Poor design and/or installations that allow water to become trapped will increase CUI c) Corrosion rates increase with increasing metal temperature up to the point where the water evaporates quickly. d) Corrosion become more severe at metal temperature between the boiling 1000C-1200C, where water is less likely to vaporize and insulation stays wet longer. e) Insulating materials that hold moisture can be more of the problem. f) Equipment that opertaes below the water dewpoint tends to condense water on the metal surface thus providing a wet environment and increasing the risk of corrosion. g) Damage is aggravated by containants that may be leached out of the insulation such as chlorides. h) Plants located in areas with high annual rainfall or warmer, marine location are more prone to CUI i) Environment that provide airborne contaminants such as chlorides or SO2 can accelerate corrosion.

Affected units or equipment a) Carbon and alloy steels are subject to pitting and loss in thickness b) 300 series SS, 400 series SS and duplex SS are subject to pitting and localized corrosion. Causal Factors a) Location issues Common area of concern in process units are higher moisture areas such as those areas down-wind from cooling towers, near stream vents, deluge systems, acid vapors, or near supplemental cooling with water spray. b) Design issues i. CUI can be found on equipment with damaged insulation, vapor barriers, weatherproofing or mastic, or prostrusions through the insulation or at insulation termination points such as flanges. ii. Equipment design with insulation support rings welded directly to the vessel wall, particularly around ladder and platform clips, and lifting lugs, nozzles and stiffener rings. iii. iv. v. Piping or equipment with damage/leaking steam tracing Localized damage at paint and/or coating systems. Locations where moisture will naturally collected and improperly terminated fireproofing. vi. The first few feet of a horizontal pipe run adjacent to the bottom of a vertical run is a typical CUI location. Morphology of Damage a) After insulation is removed from carbon and low alloy steels, CUI damage often appears as loose, falky scale covering the corroded component. Damage may be highly localized. b) In some localized cases, the corrosion can be appear to carbuncle type pitting c) Tell tale signs of insulation and/paint damage often accompany CUI

Prevention/ Mitigation a) Since the majority of construction materials used in plants are susceptible to CUI degradation, mitigation is best achieved by using appropriate paint/coating and maintaining the insulation barriers to prevent moisture ingress. b) High quality coatings, properly applied can provide long term protection c) Careful selection of insulating materials is important d) Low chloride insulation should be used on 300 SS to minimize the potential for pitting and chloride SCC e) It is not usually possible to modify operating conditions. Consideration should be given to removing the insulation on equipment where heat conservation is not as important. f) Utilize multiple inspection techniques to produce the most cost effective approach, including: i. ii. iii. iv. v. vi. Partial or full stripping of insulation for visual examination UT for thickness verification Real-time profile x-ray for small bore piping Neutron backscatter techniques for identifying wet insulation Deep penetrating eddy-current inspection IR thermography looking for wet insulation and/or damaged and missing insulation under the jacket. 2.1.1 Galvanic Corrosion Description of Damage A form of corrosion that can occur at the junction of dissimilar metals when they are joined together in a suitable electrolyte such as a moist or aqueous environment, or soils containing moisture Affected Materials All metals with the exception of noble metals Critical factors a) For galvanic corrosion, three conditions must be met: i. Presence of an electrolyte, a fluid that can conduct a current. 10

Moisture or a separate water phase is usually required for the solution to have enough conductivity. ii. Two different materials or alloys known as the anode and the cathode in contact with an electrolyte. iii. An electrical connection must exist between the anode and the cathode. b) The more noble material (cathode) is protected by sacrificial corrosion of the more active material (anode). The anode corrodes at a higher rate than it would if it were not connected to the cathode. c) The farther the alloys are apart in the galvanic series, the higher the driving force for corrosion. d) The relative exposed surface areas between anodic material and the cathodic material has a significant affect. i. Corrosion rate at the anode can be high if there is a small anode to cathode ratio ii. Corrosion rates of the anode will be less affected if there is a large anode to cathode ratio iii. If there is a galvanic couple, the more noble material may need to be coated. If the active material were coated, a large cathode to anode area can accelerate corrosion of the anodes at any breaks in the coating. iv. The same alloy may act as both and anode and a cathode due to surface films, scale or local environment. Affected equipment a) Heat xchangers are susceptible if the tube material is

different from the tubesheet, particularly if salt water cooling is utilized. b) Buried pipeline, electrical transmission support towers and ship hulls are a typical location for galvanic corrosion.

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2.2 Non Destructive Testings (NDT) 2.2.1 Dye Penetrant Test DPT

Dye Penetrant Testing is a surface testing method mainly for detecting surface breaking defects (opened to surface). This method is easy to handle and applicable to all materials, except for excessively porous materials like ceramic Working principle of DPT are: 1. It can only detect surface breaking defects 2. Penetrant must be able to enter the defect to form indication 3. Not suitable for porous or very absorbent materials (wood, cloth, ceramic) 4. Migrating by capillary action (cohesive force, adhesive force, surface tension) into discontinuities opened to surface 5. Reverse capillary action due to equilibrium action 6. Blotter effect by developer 7. Contrast between the liquid dye and the developer Basic steps: 1. Pre-cleaning (surface preparation) Prevent capillary action from taking place Ensure crack is not filled by debris and no surface contaminant Pre-cleaning can be done by applying mechanical cleaning, detergent cleaning, steam cleaning, ultrasonic cleaning etc.
2. Penetrant application on the surface

Figure 2 : Application of penetrant on the surface Penetrating fluid (penetrant) applied to component and drawn into defect by capillary action Provide a contrast for detection of indication and apply in excess Can be done by spraying, immersion and pouring 12

Allow time for penetration into cracks within 5-15 minutes and not to long for it to dry up

3. Removal of excess penetrant Remove excess penetrant that is not relevant to crack indication during development.

Figure 3: Removal of excess penetrant 4. Application of developer Provide medium for reverse capillary action to take place Provide contrast to the indication (typically white color against red color of penetrant) Developing time is depends on the size of discontinuities (wide crack immediate result)

Figure 4: Application of developer 5. Inspection Penetrant which pulled out from the defect by the developer forms indication of the defect 13

6. Post-cleaning Removing of penetrant and developer after testing To avoid potential corrosion to occur

7. Results Final interpretation shall be made after 7-30 minutes after the development process are satisfied. -

Indications due to reverse capillary action

Figure 5: Indications of surface breaking

Figure 6: Indication on the weldment

Figure 7: Student demonstrating DPI

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2.2.2

Magnetic Particle Test (MPT)

Working Principle A ferromagnetic test specimen is magnetized with a strong field created by a magnet or special equipment. If the specimen has a discontinuity, the magnetic field flowing through the specimen will be interrupted and a leakage field will occur. Finely milled iron particles coated with a dye pigment are applied to the test specimen. These particles are attracted to leakage fields and will cluster to form an indication directly over the discontinuity. This indication can be visually detected under proper lighting conditions.

Figure 8 : Working principle of MPT

Basic procedures involved the following steps: 1. Component pre-cleaning When inspecting a test part with the magnetic particle method it is essential for the particles to have an unimpeded path for migration to both strong and weak leakage fields alike. The surface should be clean and dry before inspecting. Contaminants such as oil, grease or scale may not only prevent particles from being attracted to leakage field, they may also interfere with interpretation of indications.

2. Introduction of magnetic field The required magnetic field can be introduced into a component in a number of different ways. a) Using a permanent magnet or an electromagnet that contacts the test piece

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b) Flowing an electrical current through the specimen c) Flowing an electrical current through a coil of wire around the part or through a central conductor running near the part Two general types of magnetic fields (longitudinal and circular) may be established within the specimen. The type of magnetic field established is determined by the method used to magnetize the specimen. A longitudinal magnetic field has magnetic lines of force that run parallel to the long axis of the part. A circular magnetic field has magnetic lines of force that run circumferentially around the perimeter of a part.

3. Application of magnetic media Magnetic Particle Test can be performed using either dry particles or particles suspended in a liquid. With the dry method, the particles are lightly dusted on to the surface. With the wet method, the part is flooded with a solution carrying the particles. The dry wet is however more portable. The wet method is generally more sensitive since the liquid carrier gives the magnetic particles additional mobility.

Figure 9: Dry method

Figure 10: Wet method

4. Interpretation of magnetic particle indications After applying the magnetic field, indications that form must interpreted. This process requires that the inspector distinguish between relevant and nonrelevant indications. The following series of images depict relevant indications produced from a variety of components inspected with the magnetic particle method.

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Figure 11: Crane Hook with service induced crack

Figure 12: Gear with service Induced Crack

Figure 13: Drive Shaft with heat Treatment Induced Cracks

Figure 14: Lack of fusion in SMAW weld 17

Advantages of Magnetic Particle Inspection: 1. Can detect both surface and near sub-surface defects. 2. Can inspect parts with irregular shapes easily. 3. Precleaning of components is not as critical as it for some other methods 4. Fast method of inspection and indications are visibly directly on the specimen surface 5. Is a very portable inspection method especially when used with battery powered equipment Limitations of Magnetic Particle inspection: 1. Cannot inspect non-ferrous materials such as aluminium, magnesium or most stainless steels. 2. Inspection of large parts may require use of equipment with special power requirements. 3. Some parts may require removal of coating or plating to achieve desired inspection sensitivity. 4. Limited subsurface discontinuity detection capabilities. ( maximum depth 0.6 under ideal conditions) 5. Post cleaning and post demagnetization is often necessary 6. Alignment between magnetic flux and defect is important.

2.2.3 Ultrasonic Testing Working Principle Ultrasonic Test apply the principle of high frequency sound waves which are introduced into a material. The reflected sound gives information on the material under test and signals displayed on a CRT. The sound is transmitted in the material to be tested.

Figure 15: The sound reflected back to the probe is displayed on the Flaw Detector 18

The distance the sound travel can be displayed on the flaw detector. The screen can be calibrated to give accurate readings of the distance. The presence of a defect in the material shows up on the screen of the flaw detector with a less distance than the bottom of the material. The closer the reflector to the surface, the signal will be more to the left of the screen. The thinner the material the less distance of sound travel. Advantages of UT 1. Sensitive to cracks at various orientations 2. Portability 3. Safety 4. Able to penetrate thick sections 5. Measures depth and through wall extent Disadvantages of UT 1. No permanent record (unless automated) 2. Not easily applied to complex geometries and rough surfaces 3. Unsuited to course grained materials 4. Requires highly skilled and experience technicians.

2.2.4 Radiographic Test The radiographic testing applied the electromagnetic radiation which is imposed upon a test object. Radiation is transmitted to varying degrees dependent upon the density of the material through which it is travelling. Variations in transmission detected by photographic film or fluorescent screens. Applicable to metal, non-metals and composites

Figure 16: Illustration of Radiographic Test 19

There are two common radiographic source which are Isotopes produces Gamma rays and X-ray tube.

Gamma Rays Safety Capabilities Quality of images Handling Constraint emission Very high penetrating power Lower quality

X-Rays Can be switched off/on Intensity and wavelength can be adjusted Better quality X-ray machine are bulky, fragile and requires electricity Expensive

Easier to handle

Cost

Cheap Table 3 : Comparison of Gamma Rays and X-Rays

Figure 17: Result produced

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The advantages of RT are: 1. Permanent record 2. Detection of internal flaws 3. Can be used on most materials 4. Direct image of flaws 5. Real-time imaging 6. Can detect very thin thickness (small bore piping) The disadvantages of RT are: 1. Health hazard 2. Sensitive to defect orientation 3. Limited ability to detect fine cracks 4. Access to both sides required 5. Limited by material thickness 6. Skilled interpretation required 7. Relatively slow 8. High capital outlay and running costs.

2.3 PETRONAS Risk-Based Inspection (P-RBI) Introduction to RBI Risk-based Inspection is a systematic data analysis of equipment condition to determine the associated risk with its operation. It is a method for prioritising equipment for inspection based on risk. RBI will determine risk associated with operation of specific items of equipment and the key issues driving the risk. Other than that RBI is an important decision making tool for inspection planning.

Figure 18: RBI Risk Matrix 21

Risk Definition Risk is simply a multiplication of probability of failure and Consequences of Failure.

Probability of failure is a measure of events per year and is referring to types of equipment, deterioration of the equipment and the uncertainty in the equipment condition. While consequence of failure is a measure of impact per event and is based on the loss of containment (process safety, environmental impact, reputation and asset)

Continuum of RBI Approaches

Figure 19: Three distinct level namely qualitative , semi-quantitative and quantitative

Balance is required to select most suitable approach Qualitative Ease of implementation Less costly Require presence of SME Difficult to audit results Sensitive to expert view Quantitative Data intensive Sensitive to data quality Costly Able to audit Executed as part of large exercise

Table 4: Continuum of RBI approaches 22

RBI Process Simplified block diagram of RBI process showing essential elements of inspection planning based on risk analysis regardless of approach is a below:

Figure 20: Simplified Block diagram of RBI Process

The RBI process consists of performing a risk assessment of the equipment, then determining inspection frequencies and scopes. Many types of RBI methods exist and are currently being applied throughout industry.

Technologies behind RBI In developing the Risk Based Inspection, there are technologies involve in order to enhance the reliability of the data analysis. a) Materials and construction b) Corrosion and failure mechanisms c) Process and operations d) Inspection and maintenace e) Safety and risk analysis f) ICT

The need of Risk Based Inspection a) Reduce risk of high consequence failures b) Manage risks associated with inspection programs c) Facilitates reallocation of resources from lower to higher risk equipment d) Plant optimization ( inspection techniques and maintenance 23

RBI Benefits to plant/end users The RBI approach gives benefits to the plant operation and the end users. It provides the capability to define and measure risk, creating a powerful tool for managing many of the important elements of a process plant. It allows management to review safety in an integrated, cost effective manner. On the other hand, it systematically reduces the probability of failures by making better use of the inspection resources and finally improves the integrity of plant equipement.

Impacts of RBI a) Improves communication across organization b) Able to translate engineering concern into management interest c) Emphasis on importance of data management d) Improved inspection work quality.

2.4 Inspection Reference Plan (IRP) IRP Management Inspection Reference Plan Management is another management practice for inspection activities and effectiveness. This practice will relate to equipment type and criticality category from the RBI and provide linkage to identify failure modes. It will also create a dynamic inspection plan by concerning the methods, location, extent and frequency. Other than that, by practicing IRP, the condition of monitoring confidence can be evaluated and also proposed recommendation of reducing or increasing inspection frequency. The IRP should be designed with other mitigation plan so that all equipment will have resultant risks that are acceptable. There are few considerations in developing IRP which includes the following; 1. Risk ranking and drivers 2. Inspection history 3. Number and results of inspection 4. Type and effectiveness of inspection 5. Equipment in similar service 6. Remaining life 24

Risk ranking and drivers Risk ranking is used to prioritize equipment in an inspection program. Risk drivers ( consequence factors and probability factors) will determine the possibilities for risk management by inspection.

Number and effectiveness of inspection Inspection will only effective if the inspection technique chosen is sufficient for detecting the deterioration mechanism and its severity. The level of risk reduction will depend on : a) Mode of failure of the deterioration mechanism b) Rate of deterioration c) Detection capability of the inspection technique d) Scope of inspection e) Frequency of inspection

Inspection Strategy Effectiveness of past inspection impact on present risk. Future risk can only be impacted by future inspection. The key parameters of the inspection strategy are: a) Type of NDT selected Types of NDT selected will depend on: 1. The deterioration mechanism to be detected and/or monitored 2. Accessibility to expected deterioration 3. Operational constraint such as temperature Any equipment maybe subjected to a number of deterioration mechanism each of which will impose its own requirements for frequency and coverage. b) Location and extent of inspection The consequence of failure (CoF) of an equipment may be used as a determinant in determining the appropriate location and extent, for example a high consequence may be related to a high degree of coverage. The location and extent shall relate to the particular part of the equipment where the deterioration is most likely to take place. The nature of the inspection technique chosen will also influence the location or extent of inspection. 25

c) Frequency of inspection Frequency of inspection should have a relationship to the rate of deterioration and the remaining life of the equipment. Increasing the frequency may not contribute to risk reduction d) Internal of external inspection Risk reduction by both internal and external inspection should be assessed. Often external inspection with effective on-stream inspection and process monitoring can replace the need for intrusive inspection without unduly increasing the risk. Invasive inspection may in some case, increase the risk of the item for example: a) Moisture ingress b) Lining damage c) Risks associated with shutting down and start-up

e) Procedures and practices. Inspection procedures and the actual inspection practices can impact on the ability of inspection activities to identify, measure and monitor deterioration mechanisms. Comprehensive procedures and practices applied by a competent staff can be highly effective. Poor procedure and practices applied by competent staff may give moderately acceptable results. Poor procedures and practices applied by inexperience and poorly trained staff will only serve to greatly increase any risk.

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3. PROJECT AND ASSIGNMENT

3.1 Project Background In several processes for manufacturing chemicals or for processing materials gas streams are produced that are subject to entrainment of droplets of liquid carried over from prior processing, for example droplets of water or liquid hydrocarbons. Entrained droplets of small size are referred to as mist. The streams containing entrained droplets are term wet gas. Frequently, it is desirable to remove entrained liquid as it will adversely affect further processing of the gas stream. In these cases it is necessary to remove the entrained droplets, one method for which is to use a wet gas separator. Such a process also may be termed de-entraining, entrainment separation or demisting. Several designs are known for separation of entrained droplets of liquid from gas stream. A wet gas separator typically uses a contact system to cause the entrained droplets to accumulate into a stream of liquid that is separated from the gas stream. Frequently the liquid droplets are treated as particulate matter and removed using filters, cyclones and other means, as outlined. The internal of Wet Gas Separator was revamped to improve its separation efficiency by installing new VDX3-4M Inlet Diffuser Device and Z-Pack Deentraining Device. VDX3-4M Inlet Diffuser Device is installed at the inlet of the vessel. Its function is to diffuse, distribute and deliver a uniform horizontal gas flow above liquid level towards mist elimination internals. Z-Pack Deentraining Device is vertically installed at the center in front of existing wire mesh pad. Its function is to separate coarse droplets and suspended solids from the feed gas stream. It offers first stage mist elimination and reduces the load on the wire mesh. Wire Mesh Mist Eliminator is installed at the center of the vessel after the Z-pack device. It is made of fine wire mesh partitions which are arranged together vertically. Its function is to draw liquid from the gas stream and channel it downwards.

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Equipment Data ITEM NAME : WET GAS SEPARATOR ITEM NO : V6-0401 CODE : ASME SEC. VIII DIV. 1 1992ED. 1994ADD OTHER SPEC. : PTS 31.22.20.31 W/AD. SPC NO. 056/3000/005-02, SPC NO. 056/3000/027-01 & RELEVANT PTS SPEC. W/ADD DESIGN PRESSURE : (INTERNAL) 8.1700 MPA.G (EXTERNAL) 0.0000 MPA.G DESIGN TEMPERATURE : (INTERNAL) 70.00 DEG.C (EXTERNAL) 0.00 DEG.C OPERATING PRESSURE : 6.58 MPA.G OPERATING TEMPERATURE : (NORM./MAX) 26.7/30.0 DEG.C CORROSION ALLOWANCE : SHELL HEAD : 3.000 MM (5.0 WELD OVERLAY : BTM 150 MM) : 3.000 MM (5.0 WELD OVERLAY : BTM 150 MM)

NOZZLE : 3.000 MM RADIOGRAPHY : SHELL : FULL HEAD : FULL SHELL TO HEAD : FULL WIND : PTS 34.00.01.30 (V10XF = 40.3 m/s EARTHQUAKE : UBC (1994) ZONE 1, I = 1.O MATERIAL : SHELL : SA 516-70 & 304L PARTIAL OVERLAY HEAD : SA 516-70 & 304L PARTIAL OVERLAY NOZZLE : SA 350-LF2, SA350-LF2+WELD OVERLAY SUPPORT : SA 516-70 MAX. ALLOWANCE WORKING PRESSURE (MAWP) : 8.1912 MPA.G HYDROSTATIC TEST PRESSURE : 12.2868 MPA.G Table 5: Wet Gas Separator equipment data During the 2010 GPP 6 Major TA, accelerated metal loss near to the SS weld Overlay was observed inside the GPP 6 Wet Gas Separator (V6-0401). The initial findings indicated this could be due to pitting and Inspection team decided to apply Belzona metal coating to mitigate the issue. 28

As the GPP 5 Wet Gas Separator also will undergo an internal revamp in January 2012, an investigation team was formed to investigate the root cause of this accelerated metal loss. The equipment internals were modified in the June 2008 to address separation efficiency. The failure has caused the remnant life of the wet gas separator reduced by 4 years and an extensive repair work needs to be performed.

Figure 21: Before and after internal modification in 2008 3.2 Objective The objective of this project is to identify the root cause of the accelerated metal loss at the internal of Wet Gas Separator by applying the Root Cause Failure Analysis (RCFA). 3.3 Root Cause Failure Analysis (RCFA) 5 Why Analysis on Wet Gas Separator 3.3.1 Inspection report findings

By comparison between the internal condition of the separator within 2 years of revamp from 2008 to 2010, a very significant increase of metal loss was found. In 2008, pitting corrosion was observed to be less than 1.5 mm. However, the pitting corrosion has accelerated to be 4.0 mm to 5.0 mm after 2 years in 2010. Below are the image of visual inspection at the internal of the separator. 29

Figure 22: 2008- No erosion observe Figure 23: 2010 severe corrosion observed Findings at the internal (2008): c) Pitting corrosion was noted along the bottom part of internal shell wall, adjacent to cladding) with maximum depth approximately < 1.5 mm

d) internal weldment noted in satisfactory condition

e) manhole noted in satisfactory condition

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Findings at the internal (2010):

1) East side dish head, sustain with severe pitting corrosion on area adjacent to cladding, measured with maximum depth of 4.0 mm. Appearance like wash away of metal 2) East side shell wall. Corrosion attack up to 1500mm from area adjacent to cladding.

3.4 RCFA Problem Statement V6-0401 Wet Gas Separator has experienced accelerated corrosion rate of 0.45 mm/yr compared to 0.15mm/yr allowed since 2008 after major modification performed on internals of the vessel. The impact over that period had been RM 480 000 loss profit opportunity and RM39 000 maintenance costs.

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Figure 24: Chronology of Events (Events and Causal Factors)

Figure 25: 5 WHY Analysis

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No. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10.

Analysis parameters pH Oil & Grease COD Conductivity TDS NH3 FRC Chloride Total Hardness Amine

Result 5.5 30.7 ppm 243 ppm 53.9 uS/cm 24 ppm 0.614 ppm 0.03 ppm 2.05 ppm 36 ppm As attached

Table 6 : Lab Analysis as per taken on 2 April 2011 at V6-0401 boot

3.5 Conclusion From the Root Cause Failure Analysis, the erosion-corrosion was identified to be the major damage mechanism of metal loss. The failure of the equipment is mainly contributed by the new inlet device which promotes the above damage mechanisms by changing the floe direction at the inlet region. It has also caused splashing of water beyond cladded area, consequently bottom vane too close to liquid surface and acidic water formation.

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4. OTHER INVOLVEMENTS Throughout the eight months of internship, the host company had arranged several programmes and courses which had given the author the opportunities to experience an extra learning and knowledge. Followings are the involvements of the author :

Events/Training
P-RBI Training at NIOSH Kemaman POD-GPPB Away Day at Peladang Agro Setiu Resort SAPTE Process Piping Workshop at GPPA GPP4 & KCSB TA SOE Development Workshop at Kelab Golf Rantau Petronas Centralized Utility Facilities (CUF) ASU2 Mini Turn Around GPP B Boiler Refresher Training GPPB Football Tournament HSE Workgroup Champion PGB PETRONAS Family Festival, KGRP Table 7 : Others involvement

Date
December 2010 January 2011 January 2011 January-February 2011 20th February 4th March 2011 March 2011 March 2011 May 2011 Jun 2011

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5. LESSONS LEARNT

Throughout the industrial training, the author had been given tasks and assignment which are new and not familiar. In industrial application, good

theoritical and technical knowledges are very important. Thus the author has always building positive attitudes in learning new things. The effort of learning is required while getting information by reading and researching in completing the tasks beside the discussion with supervisor and technical staffs. Other than that, the decision making skills are also being practiced. During discussion and meeting, decision must be done in the limitation of time and circumstances. Experience and good understanding about particular subject are helpful in making decision. However, some of the decision made are with the guidance from many parties. In addition, being in working environment require one to deal with many people of various background and level. Here, and excellence discipline and self control must be developed such as to obey the companys regulation, dress code and others. Professionalism is one of the aspects that must be enhanced. Apart from that, the chance to get involve with industry has encouraged the author to always adopt good communication and management skills

5.1 Challenges faced and Solutions to overcome

a) First time working experience The author had never worked in industry, and this industrial training is the first exposure to the real working environment. The author had taken some times to adapt with this new environment and had gained new things and experience from day to day.

b) Learning hands-on engineering aspect In inspection department jobscopes, one need to have good understanding and knowledege about the engineering aspects. One must have the ability to execute the technical jobs. Thus, the author had gain such a great experience handling engineering problems and calculation. 35

6. RECOMMENDATION The host company ( PETRONAS Gas Berhad) has provided the author a wide range of opportunity during internship training in engineering aspects. The author had been given many involvements and exposures which mostly related to Inspection field. Credits also should be given to Universiti

Teknologi PETRONAS for enabling such a great medium for students in attaining real working environment. This industrial training is sufficient for students to lean and fit themselves in the industry. 6.1 Recommendation to the Host Company The author would like to suggest the host company to provide trainee with ample hands-on technical jobs and allow the students to handle the tasks. It is also suggest that the trainee could be entertained as staff rather than a students to create self-belonging to the company and the task given. Besides that, proper assistance for trainee by preparing the practical handbook would be helpful to the trainee. 6.2 Recommendation to the University The author feels that the university should improve the monitoring system in order to monitor the training program that the student is undergoing. The supervision which usually done during the first and second visit is not sufficient. Thus, SIIU should also updated on the student welfare at the respective company. This will make the training programme more effective. Apart from that, the university may revise the internship policies so that students can get involve with confined space equipment especially for those working at the processing and refining plant. By allowing the students to do so, it is believe students could grab more experience throughout the challenging work exposures.

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7. CONCLUSION The eight months period of Industrial Internship Training Programme (IITP) had given the author the opportunities to learn new things and gained many experiences through the involvement of various projects and tasks. The IITP also had allowed the author to developed working skills and work ethics that needed by current employers. IITP is the best platform to expose the student with the real-life working experience besides giving them the rough picture of what to be expected when they have graduate from the University and start a working life. The eight months duration has not only benefit the author, but also the UTP and the Host Company. The UTP has managed to build a good rapport with the Host Company through this programme and the Host Company meanwhile has the opportunity to evaluate and train their future employees. The author believes that all the objectives of the IITP that been set by SITU were achieved during the eight months of the industrial training with close supervision by both sides, the Host Company (PETRONAS Gas Berhad) and also the University (UTP). Some recommendations were made to both the Host Company and UTP in order to improve the training programme in future. This to ensure that future trainee will not encounter the same problems that the author had. The improvement made will enhance relationship between both of the parties involved. The author hopes the IITP will be keep offer in the future due to its voluminous benefit to all.

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REFERENCES 1. API Publication 580 Recommended Practice for Risk Based Inspection 2. George Antaki, Risk based Inspection in Refineries, Petrochemical Plants and Oil/Gas Plants. 3. API 571 Damage Mechanisms Affecting Fixed Equipment in the Refining Industry. Recommended Practice 571 First Edition, December 2003 4. Petronas Technical Standard (PTS) 5. API Recommended Practice 579, Fitness for Service, First Edition. 6. Principles of Magnetic Particle testing, American Society for Nondestructive Testing 7. Charles Hellier (2003). Chapter 7 Ultrasonic Testing. Handbook of Nondestructive Evaluation 8. Petronas Gas Berhad, Paka, Terengganu. www.petronasgas.com 9. UTP Internship Guidelines for Student Industrial Internship Programme

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APPENDICES Appendix 1: Piping Integrity Management System

Responsible Party
START

Interface

Corrosion Engineer
(

DEVELOPMENT OF CORROSION GROUP (MARK-UP ON PFD)

Operation/Technologist

Piping Inspector

CLASSIFICATION OF PIPING CIRCUIT (MARK-UP ON P&ID)

Inspection Engineer

Inspection/Maintenance/ Operation/Engineering/PPL

SELECTION OF PIPING REPRESENTATIVE

Department Manager

Piping Inspector/NDE Examiner

Confirm to Requirement

INSPECTION EXAMINATIO N

Inspection Engineer

NCR

Inspection Engineer/ TP Inspection

Confirm to Requirement

FFS

NCR

Inspection Engineer/Operation Engineer/Maint.Eng/PPL

RERATE/MOC

REASSESSMENT PROCESS

TP Inspection (Principle/Custodian)

Plant Manager

INPUT IN RBI

Piping Inspector
RUN ANALYSIS/CRITICALITY

RBI/GTS Engineer

RBI/GTS Engineer

None

Inspection Eng/ TP Inspection

REVIEW INSPECTION EFFECTIVENESS

RBI/GTS Engineer

Inspection Eng/TP Inspection

DEVELOPMENT OF IRP/MITIGATION PLAN

RBI/GTS Engineer

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Appendix 2: Simplified Block Flow Diagram of gas processing

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Appendix 3: DOSH Registered Equipments for Gas Plant Processing B

NO 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 DOSH NO PMT107915 PMT107916 PMT107917 PMT107918 PMT107919 PMT107920 PMT107921 PMT107922 PMT107924 PMT107925 PMT107926 PMT107927 PMT107928 PMT107929 PMT107930 PMT107931 PMT107932 PMT107933 PMT107934 PMT107935 PMT107936 PMT107937 PMT107939 PMT107940 PMT107941 PMT107942 PMT107943 PMT107944 PMT107945 PMT107946 PMT107947 PMT107951 PMT107953 PMT107954 PMT107955 PMT107956 PMT107957 PMT107958 PMT107959 PMT107961 EQUIPMENT C6-0101 E6-0101 S6-0101A S6-0101B S6-0102A S6-0102B S6-0103 V6-0101 V6-0103 C6-0201A C6-0201B E6-0201 E6-0202 E6-0203A E6-0204A E6-0205 S6-0201A S6-0201B S6-0202A S6-0202B S6-0203A S6-0203B V6-0202 V6-0203 V6-0204 V6-0205 V6-0206 V6-0207 E6-0301A S6-0301A S6-0301B V6-0301 D V6-0302A V6-0302B V6-0303 C6-0401 E6-0401 E6-0402 E6-0403 E6-0406 DESCRIPTION HYDROCARBON STRIPPER HYDROCARBON STRIPPER FEED PREHEATER FEED GAS FILTER FEED GAS FILTER FEED LIQUID FILTER FEED LIQUID FILTER FILTER SEPARATOR INLET SEPARATOR CONDENSATE/WATER SEPARATOR ABSORBER ABSORBER FEED/PURE GAS EXCHANGER SOLUTION HEATER CO2 OFF GAS COOLER SOLUTION COOLER FLASH GAS COOLER MECHANICAL FILTERS MECHANICAL FILTERS CARBON FILTERS CARBON FILTERS GUARD FILTERS GUARD FILTERS LOW PRESSURE FLASH DRUM ABSORBER OVERHEAD K.O. DRUM CO2 OFF GAS K.O. DRUM SOLUTION HEATER COND. K.O. DRUM SOLUTION SUMP TANK FLASH GAS SEPARATOR REGENERATION OFF GAS COOLER DUST FILTERS DUST FILTERS DEHYDRATOR MERCURY REMOVAL VESSELS MERCURY REMOVAL VESSELS REGENERATION OFF GAS K.O. DRUM DEMETHANIZER WARM GAS EXCHANGER HOT GAS CHILLER DEETHANIZER STEAM REBOILER REBOILER

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Appendix 4: Equipment Certificate of Fitness (CF)

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Appendix 5: RBI Criticality Ranking

Appendix 6: Laboratory Analysis Test result

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Appendix 7: External Visual Inspection equipment report

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