Perspective Note from KMI to Support Corrosion in Indonesia

Perspective Note from KMI to Support Corrosion in Indonesia...

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Unformatted text preview: Seminar, Workshop and The Second National Conference Coating Inspector Indonesia UNJANI Bandung, 25 April 2009 Swastioko Budhi Suryanto KMI Chairman Activities of Oil and Gas High Risk, High Cost, High Technology. Must Be In Operation Continuously Without Obstacle. Impact On Environment and Society. High Probability to Cause Incident and Accident. Crude Oil Transportation & Storage Seismic/Drilling Oil Production Transportation UPSTREAM End Consumer Refining & Blending Transport of refined products Terminal loading & offloading Distribution DOWNSTREAM Causes of Asset Failure Mechanical Environmental Service / Operation 7 MOST EXPENSIVE ACCIDENTS Piper Alpha (1988) $1,270,000,000 Petrobras P36 (2001) $515,000,000 Enchova Central (1998) $461,000,000 Sleipner A P/F (1991) $365,000,000 Mighty Servant 2 (1999) $220,000,000 Bombay High North (2005) Steelhead Platform (1987) $173,000,000 $171,000,000 8 DEADLIEST ACCIDENTS Piper Alpha (1988) Alexander L. Kielland (1980) 167 workers were killed 123 workers were killed Seacrest Drillship (1989) 97 workers were killed Ocean Ranger (1982) 84 workers were killed Glomar Java Sea (1983) 81 workers were killed Brent Field Helicopter (1986) 45 workers were killed Enchova Central (1988) 37 workers were killed Bombay High North (2005) 37 workers were killed Damage Mechanism and Failure Mode Corrosion / Erosion / Environment Factors Damage Specifics Id Failure Mode I. Corrosion / erosion / environment related damage, equating or leading to : I.A1 I.A2 I.B1 I.B2 I.B3 I.C1 I.C2 Volumetric loss of material on surface (e.g. thinning) General corrosion, oxidation, erosion, wear Localized (pitting, crevice or galvanic) corrosion Stress corrosion (chloride, caustic, etc.) Cracking (on surface, mainly) Hydrogen induced damage (incl. Blistering and HT hydrogen attack) Corrosion fatigue Thermal degradation (spheroidization, graphitization, etc. incl. Incipient melting) Material weakening and/or embrittlement Carburization, decarburization, dealloying Embrittlement (incl. Hardening, strain aging, temper embitterment, liquid metal embitterment, etc.) I.C3 Mechanical, Metallurgy or Thermo-mechanical Factors Id. Failure Mode Damage Specifics Damage Mechanism and Failure Mode II. Mechanical, Metallurgy or Thermo-mechanical loads related, leading to : II.A II.B II.C Wear Strain / dimensional changes Micro void formation Sliding wear, cavitational wear Overloading, creep, handling damage Creep, creep-fatigue Fatigue (HCF, LCF), thermal fatigue, (corrosion fatigue), thermal shock, creep, creep fatigue Overloading, brittle fracture II.D Micro cracking, cracking II.E Fracture Layer of Protection Prevention EVENT Mitigation Gas Leak Prevention: - Integrity Improvement Detection: F&G Detector (leak reducing) to prevent leakage from Control: the system (piping/ - SIS connection/ - ICSS equipment/ pipeline) - SDV metal seated - Reducing screwed - DBIB connection - Riser guard Detection Control Emergency Response Mitigation: -Explosion control -Blast & fire wall -Fire Water -Deluge system Emergency response: -ERP procedure -Muster area protection - Life boat Damage Appearance degradation Increase maintenance cost Plant shutdown Product contamination Decrease of safety Cleaning Material Selection Design improvement Coating Inhibitor Thinning Cracking and Pitting formation Appearance modification Decrease of structure strength Embrittlement Cathodic Protection Anodic Protection Surface Modification Replacement/Repair Damage or Corroded on Structural Issue : Medium Corroded on Plate Floor Action : Repair & Repaint Issue : Heavy Corroded on Grating Action : Replace Issue : Medium Corroded on Building Wall Action : Repair & Repaint Vessel Repair (Bolt & Nut Heavy Corroded and Replace Gasket) Issue : Slightly Corroded on Vessel Action : Repaint Issue : Heavy Corroded Bolt & Nut and Blind/Skillet Action : Replace Bolt & Nut, Blind/Skillet and Gasket Issue : Medium Corroded on Bolt & Nut and Flange Action : Replace Bolt, Nut and Gasket and Repaint Flange Field Instrument Repair (Replace, Repair or Repaint) Issue : Heavy Corroded on Level Switch Low Action : Replace Issue : Slightly Corroded on Level Gauge Action : Repaint and Clean the Glass Issue : Medium Corroded on Body and Bolt & Nut Action : Repaint and Replace Bolt & Nut and Gasket Heavy Corroded Vessel, Piping, Flange and Valve Offshore Pipeline and Risks Associated with it Corrosion, Buckling, Leak and Rupture 80m NDT RT UT MT PT ET VT LT LASER AE TR VA NRT X-RAY A-Scan Prod Solvent Removal Eddy Current Direct Visual Bubble Test Profilo metry Tank Floor GAMMA RAY B-Scan Yoke Water washable Remote Field Remote Visual Pressure Change Holography VPAC Refiner C-Scan SELENIUM RAY P-Scan Circular Post Emulsified Magnetic Flux Leakage LOTIS Halogen Diode Longitudinal GAMMA RAYCRAWLER Floor Scanner IRIS Multi Direction FSM-IT Mass Spectrometer Phased Array X RAY CRAWLER TOFD In /off-line inspection preparation & verification No one inspection technique can cover all, it may required more than 1 technique to give optimal result Thinning Sur. Con. Crack Subsurf. Cracking Microvoid Formation Metal change Dimensi. Change Blistering Inspection Technique Visual Examination UT Straight Beam UT Shear Wave (Fllourescent) MT Dye Penetrant Acoustic Emission Eddy Current Flux Leakage Radiography Dimensional Measur. Metallography 13 13 X X X X 12 12 13 13 X 23 3X 12 12 13 13 12 X 3X X 23 X 3X 12 3X X 1 -3 1-2 X 3X X 23 X 23 23 X X 3-X 3-X X X X 23 X X X X X X X X X X 12 13 X X X X X X X 12 12 X 13 12 X X X 3X X X X X X 1= Highly effective ; 2 = Moderately effective ; 3 = Possibly effective ; X = Not normally used Conventional NDT Radiography Testing (RT) : widely used for both welding examinations during construction and corrosion/erosion detection after facilities are placed in service Ultrasonic Testing (UT) : performed to take simple thickness readings of material for on stream inspection, perform more sophisticated weld examinations for inherent flaws in the welds. Magnetic Particle Testing (MT) : electromagnetic examination that used to locate and estimate the size of defects that are either open to the surface, such as cracks, and delaminations or very near subsurface defects such as gas holes and inclusions. Dye Penetrant Testing (PT) is an extension of visual inspection and is used for detecting surface-breaking flaws, such as cracks, laps and folds, on any non-absorbent material's surface. Visual Testing (VT) : the most frequently used and most overlooked conventional NDT method, can very simple and very complex. Simply looking a part and identifying areas of concern. Remote Visual Inspection using boroscope, fiberscope, robotic videoscopes is the far more complex part. X / rays Test piece Film Advance NDT Advance NDT Method and Application : Guided Wave Ultrasonic (Long Range UT) Pulse Eddy Current (PEC) Tubing Inspection (used Eddy Current, RFT, MFL, IRIS) Acoustic Emission Testing TOFD (Time of Flight Diffraction) Knowledge Management Knowledge is a synthesis of data, information, and experience. A common approach to Knowledge Management (KM) is critical to ensure fast transfer of knowledge around the organization. Knowledge Management (KM) is an effort to increase useful knowledge within the organization. Ways to do this include encouraging communication, offering opportunities to learn, and promoting the sharing of appropriate knowledge artifacts. The prime objective of knowledge management in KMI is to improve member performance by transferring relevant knowledge and learning from people who have completed an activity to people about to undertake a similar activity. As knowledge is re-cycled, it becomes refined and improved. KMI focuses on : People who create and use knowledge. Processes and technologies by which knowledge is created, maintained and accessed. Artifacts in which knowledge is stored (manuals, databases, internet, books, heads). What is the Migas Indonesia Forum ? The Migas Indonesia Forum is a simple, web based method or via email for members of KMI to expand their knowledge and expertise by interacting with one another in the form of questions and responses. The Migas Indonesia Forum is a communication system which is available to the members of Migas Indonesia Networks. By providing instant access to people's knowledge and experience, the Forum creates an environment where people can proactively seek early input to issues. Participants gain the equivalent of a mini-Peer Assist on every question posed to the Forum. The Projects Forum also enables a dynamic dialogue between Migas Indonesia Network members as they explore and debate topics of emerging knowledge. Why use Migas Indonesia Forum ? Through the Migas Indonesia Forum, you will not only gain access to the host of information and experience being shared, but you will also allow other members to benefit from your experiences. Contrast this to typical requests for assistance sent via email, where only the originating author benefits. The Migas Indonesia Forum also offers an archive for future reference to benefit the KMI's member. KMI as a professional organization always refers to its value, vision, mission and strategy to achieve its objectives as written on the organization constitution and rules. These value, vision, mission and strategy become the reference for implementation in every activities done by the organization. KMI Values : Honesty Transparency Awareness Equivalency Independent Competency Cooperation KMI is an organization with the following properties : Prioritizing the nation and country interest Non profit Not doing any practical political activity Not discriminative Multi-discipline Independent from any binding with any other organization The Indonesian Oil & Gas Community (KMI) would like to be the most reliable independent partner in the oil & gas related areas for the maximum benefit of the all Indonesian people. The professional organization will operate as a non profit basis, multi-discipline and provide full commitment to improving competencies of Indonesia human resources in winning global competition. Mission The Institution would like to provide total solution for the nation in the oil & gas related issues including but not limited to : provide strategic recommendations for developing policies in managing the national oil & gas reserve for the maximum benefit of the all Indonesian people. provide overall leading strategies, technology, and practices in the oil & gas business and related supporting industries. provide leading invention and/or innovation, technology, and practices in oil & gas derivative products. 1. 2. 3. 4. 5. 6. 7. 8. 9. Reservoir Drilling & Production Geology Geophysics Mining Process Process Safety Applied Chemistry Electrical 14. Pipeline 15. Structure 16. Civil 17. Material 18. Corrosion 19. Reliability 20. Geodesy 21. Welding 22. Marine 23. Laboratory 24. Technical Inspection 25. Project Management 26. Supply Chain Management 26. HSE 27. Quality Management 29. Standardization 30. Telecommunication 31. Information Technology 32. Maintenance 33. Energy 34. Oil & Gas Economy 35. Oil & Gas Downstream 36. Management 37. Business Law 38. Community Development 39. Human Resources 10. Instrumentation 11. Mechanical 12. Rotating 13. Piping INDONESIA 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. Chapter Jakarta Chapter Banten Chapter West Java Chapter Central Java Chapter East Java Chapter South Sumatera Chapter Riau Chapter Batam Chapter East Kalimantan Chapter South Sulawesi Chapter Papua OVERSEAS 1. 2. 3. 4. 5. Chapter America Chapter Europe Chapter Middle East Chapter Asia Chapter Australia 6 Administrators + 111 Moderators ( 39 Disciplines ) 12.050 Members from 2500 Companies Eventhough KMI has Oil & Gas in its name, KMI scope grows are not only in Oil & Gas Industry, but also in other industry such as Energy, Mining, Electricity, Petrochemical, Manufacturing, Automotive, Telecommunication, IT, and many others supporting industries until Universities and Research Institutions. This way KMI can strengthen its existance and independence as an organisation of professionals and experts in their disciplines. Primary Language : Indonesian Listed in Directory Restricted Membership Moderated for new members Email Address Display All members may post Archives for members only Email Attachment are not permitted Jan 2009 2008 2007 2006 2005 2004 2003 2002 2001 1208 1339 859 889 866 1107 751 427 - Feb 1329 1188 986 662 834 836 480 390 - Mar 1467 1028 1070 803 905 1038 658 229 - Apr 1000 1237 989 628 770 753 606 514 - May Jun Jul Aug Sep Oct Nov Dec 1156 1138 619 589 836 538 384 - 1356 964 642 909 757 630 425 - 1664 1203 672 773 791 578 638 - 1416 1272 1068 710 932 626 619 30 1255 1062 1076 1026 888 845 610 166 1394 848 889 761 877 808 604 326 1352 1022 990 589 569 661 395 223 1156 1033 612 996 795 811 310 54 POSTING STATISTIC 2004 2005 2003 2002 2006 2001 2009 2009 2008 2007 2006 2005 2004 2003 2002 2001 TOTAL = 76.784 1 Days = 30 Posting 2007 2008 2004 2006 2007 SS 1829-9466 In Progress : KMI Journal Volume IV - 2008 And Volume V - 2009 BUKU PINTAR MIGAS INDONESIA DARI HULU KE HILIR 17 November 2003 Visitors 2002 - 2009 8.807.797 Hit Rate 10.000 / day Visitors 2006 - 2009 570.211 Hit Rate 400 / days Bandwidth 100 GB / month 2002 2003 2005 2006 2007 2008 MAPREC 11-13 March 2008 MAPREC 10-12 May 2005 Cilegon Crisis Center 22 Jan 2009 Hazardous Material & Migas Transportation 27 Nov 2008 Wireless Plant Seminar 10 June 2008 Cost Recovery 10 August 2007 WPS Designer Course 5-9 March 2007 Welding Seminar 28 November 2006 Munas API 1 April 2008 Fiber Optic 26 September 2007 Fire & Explosion 7 November 2007 Electrical Cable 12 November 2007 Corrosion Control 21 November 2007 Liquid Filtration 5 December 2007 Polnes Samarinda 24 Jan 2009 Unjani Bandung 23-28 Jun 2008 ITS Surabaya 7 May 2008 STT Migas Balikpapan 17 May 2008 PetroGas Day UI 17 March 2006 Universitas Islam Riau 5 March 2005 Universitas Int. Batam 16 April 2004 UNTIRTA Cilegon 15 January 2005 Sengkang Gas Field 25 May 2004 Studium Generale II ITB 13 March 2004 Studium Generale I Bandung, 22 February 2002 ...
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This note was uploaded on 03/17/2010 for the course ME ME78212 taught by Professor Prof.sulis during the Spring '10 term at Institut Teknologi Bandung.

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