Final Report Practical

7/27/2019 Final Report Practical

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CHAPTER 1

INTRODUCTION

In this chapter some general information about practical training, research

objectives, and the scope of the practical training and the summary are elaborated.

1.1 Introduction of Practical Training

Every undergraduate studying for a Bachelor Degree of Mechanical in UTM is

required to undergo Industrial Training for 10 weeks. The training is one of the courses

that would give students exposure to the profession in the real world as well as provide

them opportunities to make the connection between their theoretical understanding and

the reality of the profession. This exposure would be part of the preparation for their

future profession.


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1.2 Objective

Main objectives are:

1. Expose students to the work and its environment related to their profession.

2. Provide opportunities for students to acquire working experience in an

industry/organization related to their field of study.

3. Assist the students to practice lifelong learning when they return to the

university.

4. Train students to interact and communicate effectively at every level in the

working situation.

5. Train students to write technical reports after they have undergone the

practical training.

6. Develop group work camaraderie.

7. Appreciate and internalize professional ethics.


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1.3 Practical Training Scope

Scope of the training is the experience that the students should obtain during the

training that involves with these aspects:

1. Exposure to different types of jobs in the industry/organization by

performing tasks such as data collection, testing, fixing and managing

equipment, designing, develops systems, managing resources etc. while

under supervision.

2. Understand the whole process and operational system such as production

operation, evaluation and analysis.

3. To be trained in management and administration according to the field of

study inclusive of training students to work in group projects.


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1.4 Summary of Practical Training

For the practical training, I was fortunate to get the opportunity to work at

Germanischer Lloyd (GL) Noble Denton, a world class technical service provider for the

oil and gas industry located in Kuala Lumpur. GL Noble Denton help to design, build,

install and operate oil and gas onshore, maritime and offshore assets to ensure safety,

sustainability and superior value. I was able to get hands-on view of what it was like to

work in the oil and gas industry. My supervisors were more than willing to let me get

involved and I was able to help them out on many different fronts. In addition to collect all

relevant documents from client, scanning, photocopying and filling, I was taught how to

use Galiom which is a combined asset integrity management and risk-based inspection

and maintenance tool that can be used for any oil, gas, or petrochemical facility. I learned

how to go through and taking a relevant data from process flow diagram (PFD), piping

and instrumentation diagram (PNID), prepare minute of meeting and schedule planning

and learned the overall process in oil and gas production. I learned how to select thickness

measurement locations as well as utilize relevant information from the previous data to

create the desired output. I set up and took part in meeting and meet the clients. I even got

to take part in a project where I was assigned to select inspection test points for Balal Field

Development Project. Moreover, I also involve with Murphy RBI Development Project

2010 at Bintulu Onshore Receiving Facilities (BORF). At the end of the practical training,

I was to present what I had learned and also come up with my personal opinions of the

lessons that I learned during the practical training period. I presented my finished practical

training in the form of a Power-Point presentation on the final day of my internship and it

was received extremely well. I feel so lucky that I got this opportunity, especially at such a

turbulent time in GL. I feel that I experienced a very unique point in the engineering field

and that experience will make me well prepared for the real world that I am about to

enter into. I greatly enjoyed and thrived in the fast-paced lifestyle that comes with this

kind of job and the Kuala Lumpur environment where it was located. I really appreciate

the people who have helped me to make this happen, and I wouldnt trade this practical

training experience for anything.


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CHAPTER 2

ORGANIZATION BACKGROUND

An organization is a social arrangement which pursues collective goals, controls

its own performance, and has a boundary separating it from its environment. This chapter

focusing on the company profile, organizations structure, information of the department

and the scope of work.

2.1 Company Profile

2.1.1 About Germanischer Lloyd (GL)

GL offers assurance, consulting and classification for the maritime and energy

industries.


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2.1.2 Vision

GLs vision is to become the world-class technical advisor and trusted partner in

assurance, consulting and classification. Safety, quality, sustainability and environmental

protection enjoy the utmost priority at GL.

2.1.3 Mission

Smarter, greener and safer working processes deliver world-class services to the

global maritime, energy and industrial sectors:

1. Smarter - using our global expertise and networks to deliver industry-

leading services.

2. Greener - ensuring sustainability and efficiency through our services and

products for our clients.

3. Safer - understanding and supporting our clients needs to produce

superior and reliable services.


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2.1.4 The Staff

The backbone of GLs safety and quality philosophy is its highly skilled, well-

trained, internationally minded experts who understand the needs of clients and

stakeholders. GLs staff works in a group-wide culture of:

1. Open-mindedness

2. Orientation towards service and results

3. Willingness to go the extra mile.

4. Delivering solutions for our clients

5. Not ignoring the merits of thoroughness and strictness when it comes to

promoting quality and safety.

On a global basis nearly 6,800 engineers and experts offer high-end engineering,

combined with in-depth analysis and strong operational experience.


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2.1.5 Service Approach

GL deliver superior value and safe, efficient and innovative solutions,

uncompromising quality and world-class service for their clients around the world. Their

qualification, know-how and experience allow them to be a trusted partner, a truly

independent advisor and a third-party organization. They are constantly anticipating

future challenges and provide feasible, commercially sound solutions.

2.1.6 Global Network

The global GL network consists of 208 locations in 80 countries. GL maintain

stations and country and site offices whenever and wherever its clients need direct

contact to our GL experts. GLs head office is located in Hamburg.

2.1.7 Business Segments

The GL Group consists of three major business segments: Ship Classification, Oil

& Gas and Renewable.


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2.1.7.1 Germanischer Lloyd Ship ClassificationMaritime Services

Germanischer Lloyd belongs to the top five classification societies. GL is

dedicated to ensuring the safety of life and property at sea, and the prevention of

pollution of the marine environment. As an independent third party, Germanischer Lloyd

develops state-of-the-art rules, procedures and guidance for shipowners, shipyards and

the maritime supply industry in order to offer commercially sound answers in times of

economic challenges and tight regulatory regimes.

Germanischer Lloyd is strong in the classification of container ships, tankers, bulk

carriers, multi-purpose vessels, high speed ferries, cruise ships, mega yachts and sports

boats. GLs fleet in service amounts to 83 million gross tons. More than 6,890 ships are

currently surveyed on a regular basis by GL surveyors. Besides traditional classification

services of plan approval, inspection and certification of materials and components as

well as technical assessment of ships in service, GL put particular emphasis on ship

energy efficiency and environmental issues. The new business line Maritime Solutions

provides expert advice for optimising hull design, propeller performance, engine output,

energy management and even crew performance. In addition, GLs scope of services

covers consultancy, advanced engineering, certification, training and software solutions.

GL maritime experts are advisors to governments, the IMO, flag states and port states.


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2.1.7.2 GL Oil & Gas / Noble Denton

For the worldwide energy industries GL acts as an international technical

assurance and consulting company. GL provides assurance, inspection, consulting,

project management and execution. It focuses on technical services and solutions along

the entire life cycle of oil and gas (upstream, midstream and downstream) and energy

installations onshore and offshore. The scope of technical services includes safety,

integrity, and reliability and performance management. In April 2009 Noble Denton, a

premier provider of life cycle marine and offshore engineering services, joined GL and

reinforced GLs offshore expertise. From January 2010, GLs Oil & Gas business

segment has merged with Noble Denton to form one company. With its global reach in

the oil and gas centers of the world, GL Noble Denton provides assurance, consulting,

designs and execution services.

2.1.7.3 GL Renewable / Garrad Hassan

GLs Renewable business segment has been significantly expanded by the merger

with Garrad Hassan and Partners Limited in August 2009. Garrad Hassan, the

international renewable consultancy is the number one address for independent expert

advice on wind energy and other renewable. In conjunction with the certification and

measurements services provided by GL Renewable, Garrad Hassan will become a

worldwide leading independent provider of consulting, engineering, turbine design,

certification, measurement, project management, strategic advice, inspection services and

software products for renewable energies. The new company will provide technical

services over the entire life cycle of wind, solar, marine and other renewable energies,

both onshore and offshore. For the first time, a unique level of service expertise and

global presence across the whole project life cycle will be available in the renewable

industry. Over 600 highly qualified engineers and technical experts at 34 locations

around the world will offer a full-service approach, with a broad range of consulting


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services. The service portfolio includes optimal design of wind farms, improvement in

the performance of existing wind farms, measurement projects (wind resources, wind

turbine performance and structural behavior), inspection and certification of turbines as

well as a large array of software products and turbine design services.

2.1.7.4 GL in a nutshell

Germanischer Lloyd was founded in 1867 by German ship owners in Hamburg.

Today, GL serves a range of industries with a special focus on the maritime and energy

sectors, combining its technology expertise and industry knowledge. Due to its in-depth

knowledge and role as an independent partner, GL facilitates a great number of standards

and joint industry and research projects each year. It develops new tools, methodologies,

standards and recommended practices to solve technical questions while reinforcing high

safety and quality standards.

2.1.8GLs Clients

Basically GL clients are from the oil and gas company. We are giving them

consultant services. Figure 1 shows our clients:

Figure 1: GLs Clients


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2.2 Organization

The organization chart below is GL Noble Denton organization.

Figure 2: GL Noble Denton Organization


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2.3 Asset Integrity Management Department

Asset integrity is an asset has integrity when it performs as specified and is being

operated and maintained as specified so that the combination of the likelihood of failure

and the consequence of failure makes the risk to people, environment, assets and

company reputation arising from its failure is as low as reasonably practicable. Plant

integrity, safety, and reliability are major concerns to all plant operators and managers.

The primary objective of AIM is to maintain the asset in a fit-for-service condition while

extending its remaining life in the most reliable, safe, and cost-effective manner. AIM for

an operating facility, is focused on the operating and technical integrity:

1. Is the facility being operated within the design parameters?

2. Is the facility being maintained as required within the time frame required?

3. Is the facility being inspected as required with an effective, planned and written

inspection scheme?

In addition to regulatory and company requirements, operators of facilities and

pipelines have the following business needs:

1. Maximizing production

2. Reducing lost income due to unplanned shutdown

3. Optimizing inspection and maintenance costs.

4. Maximizing asset value.

5. Maintaining an auditable system


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2.3.1 Risk Based Inspection

RBI is an approach to AIM which seeks to optimize inspection activities based on

the likelihood and consequence of failure of components and systems. Using this

methodology, inspection frequency is highest for the highest risk systems, and the

interval between inspections if lengthened for those systems which have the lowest risk.

This common-sense approach to inspection can significantly increase a plants on-stream

availability.

The primary objective in implementing an RBI programme is to produce an

inspection strategy that clearly states:

1. Which equipment needs to be inspected?

2. The optimum interval between inspections.

3. To use the right technique to detect the defects likely to develop for that a

particular component.

In a typical RBI, study will involve:

1. Establish the qualitative or quantitative risk-ranking level of existing equipment,

and determine the respective risk acceptance level based on standard industry

practice and customer defined criteria.

2. Assess the process operating parameters of CO2 mole fraction which impact

production, mechanical integrity, and rates of corrosion or degradation.

3. Review technical specifications and materials of construction, and provide gap

analysis, recommendations, and turn-around prioritization.


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4. Assessment of risks associated with equipment degradation and corrosion rates

using industry standards, such as API-580, API-579, and API-581.

5. Determine remaining life for each component, and determine the appropriate

inspection intervals.

6. Specify the necessary inspection and maintenance tasks and intervals based on the

risk ranking.

2.3.2 Data Management Solution

Even moderate scale Asset Integrity Management programmes produce massive

quantities of data that must be effectively managed. Because the databases that result

from AIM implementations can be so large, even simple data entry tasks can involve so

many data points that they overwhelm even well staffed inspection departments.

Furthermore, most standard corrosion monitoring software packages are limited in

their ability to dynamically link data in the database to CAD drawings or field sketches.

Also standard systems typically identify visual observations as open or closed, but do not

effectively track status in terms of whether or not the remediation deadline is imminent or

overdue.

GL provides services which can address these common data management issues.

GL applies an AIM approach with a sophisticated RBI and AIM tool (GALIOM). Galiom

can be utilized as a one-off RBI equipment risk assessment software generating reports

that identify the associated risk ranking of each piece of equipment, or as a fully

integrated application.


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Galiom starts by establishing an asset hierarchy for the facility by breaking down

each business unit into an area, complex, location, platform, functional group, tag, piece

of equipment, feature or component and measuring or test points. The next step involves

entering the design and operating data for each equipment tag into a database for the

specific facility.

Galiom calculates risk by multiplying the consequences of failure (CoF) by the

probability of failure (PoF). CoF is assessed in four categories the consequences for

people (safety), the environment, the asset (cost of damage or downtime) and the owner's

or operator's reputation. PoF is appraised by considering factors such as the operation and

design of an asset, corrosion, the impact on third parties, seismic activity, process

stability and probability of failure modes.

Galiom uses the CoF-PoF equation to identify the resultant risk and display it on a

5x5 risk matrix. At the same time the asset hierarchy is colour-coded to display the level

of risk for each piece of equipment, enabling the operator or owner to immediately

identify the asset risk status. Risk within GALIOM is displayed on a 5 by 5 Matrix. The

red colour areas are classed as Higher Risk, unacceptable risk, which should be addressed

with some form of Mitigation Measure immediately. Risk increases from the Top Left to

the Bottom Right. Ideally the aim is to have all equipment in the Green zones however;

this is not realistic and is where an ALARP (As Low As Reasonably Practicable)

principle is used.

ALARP stands for As Low As Reasonably Practicable, and is a term often used in

safety-critical and high-integrity systems. The ALARP principle is that the residual risk

shall be as low as reasonably practicable.

ForRiskto be ALARP it must be possible to demonstrate that the cost involved in

reducing the risk further would be grossly disproportionate to the benefit gained. The

ALARP principle arises from the fact that it would be possible to spend infinite time,

effort and money attempting to reduce a risk to zero however it should not be understood

as simply a quantitative measure of benefit against detriment. It is a judgement of the
http://en.wikipedia.org/wiki/Riskhttp://en.wikipedia.org/wiki/Risk


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balance of risk and societal benefit. Risk being the multiplication of CoF and PoF can be

displayed on a 5x5 matrix in table 1 below.

Table 1: Risk Display

GALIOM also uses the same color coding in the Asset Hierarchy to display Risk.

Each piece of equipment is Risk Ranked and that ranking is rolled up to the highest level

so that at a glance the Facility Risk can be seen. Just light a Traffic Light. Asset

Hierarchy to display risk can be seen from figure 3 below:

Figure 3: Asset Hierarchy


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CHAPTER 3

OVERALL PRACTICAL TRAINING

3.1 Briefing

In the first week of my practical training, I was introduced to all of the staff in the

company. I also had a briefing session about company profile and about AIM department

that I was attached to for my practical training.


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3.2 Assignment

There are two assignments that had been given:

1. Definition of AIM, RBI, MAWP and MAWT. The details can be viewed in

Appendix I.

2. Material Selection. The details can be viewed in Appendix II.

3.3 Galiom Training

I learned about Galiom software in term of understanding asset hierarchy at first.

Functional groups, tag and test point need to be assigned. A part of that, I was taught to

insert the data into Galiom. There are some functions that need to be understood first

before we input any data that related with calculation. As an engineer, we need to

understand why the selected data had been chosen and input to Galiom. Understanding

the operating manual for the facilities is very important in order to understand the process

flow diagram or any related drawings and documents. By doing that, we analyze and can

detect any error in Galiom so the result of RBI can be accurate.


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3.4 Introduction of Oil and Gas Production

Oil and gas industry is a massive industry. We need to know how oil and gas

being produced in order to know the system and the functions for all of the equipments

that are used in oil and gas industry. Wellhead, piping, separation, pump, compressor,

christmas tree are some of the main components in oil and gas production.

3.5 Meeting

AIM department has weekly meetings. The purpose conducting such meeting is to

update our tasks and to discuss any problem that need to be solved so we are on track on

our project schedule. In the meeting, one person will be the chairman and another person

will write the minutes of meeting. A sample minute of meeting can be viewed in

Appendix III.

3.5 Summary

I gained a lot of experience in this practical training. The most important aspect

that I have learned is I know what oil and gas industry is about. A lot of company are

involved and depends on each other. From the geologist that find reservoir and the

engineer that drills and build platform until the refinery to process oil, these whole

processes needs a lot of man power. The summary of my practical training in 10 weeks

can be seen from table 2 below:


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Types of Training Learning Session

Week 1Review of the AIM,RBI,API

and corrosion study

Knowing the importance of AIM

in the industry

Week 2 Galiom SoftwareThe importance of the software

to arrange asset and conduct

analysis for RBI

Week 3 Material Selection

Material selection is important to

identify and recommend the most

suitable and economically viable

materials

Week 4Review introduction of oil

and gas production

Understanding the overall process

how oil be produced

Week 5Review the operating

manual for Balal Oil Field

Understanding the process in

Balal Oil Field.

Week 6 & 7Thickness Monitoring

Location for vessel

Finding MAWP, MAWT and

remaining life. Purpose: To come

out with inspection plan. Focusing

the critical area to be inspected

Week 7 & 8Thickness Monitoring

Location for piping

Finding MAWP, MAWT and

remaining life. Purpose: To come

out with inspection plan. Focusing

the critical area to be inspected

Week 9 & 10 Heat and Material BalanceHMB is important to know the

parameters of operating facilities.

Table 2: Summary of Practical Training


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CHAPTER 4

IOOC PROJECT

4.1 Introduction

After the victory of the Islamic Revolution of Iran, all partnership contracts with

aforementioned companies were abolished at the decree or the Supreme Council of the

Islamic Revolution in 1979, and a year later, the Iranian Offshore Oil Company (IOOC)

was established by combining those companies. The objective underlying establishment

of IOOC was to achieve an optimized production as well as safeguarding oil and gas

reservoirs in the Persian Gulf area along with an increase in the production rate and

prevention of oil and gas migration in the common fields, and in a word, to administer

the entire oil and gas fields in the Persian Gulf where the American and European

companies had previously carried out the oil activities.


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The Balal Oil Field is the one of field in the Persian Gulf. The Balal field is a

dome structure analogous to a circle with a diameter of 2.5 km. The area of the field, at

top of Hith-Arab formation, is about 16 km2. The main reservoir of this field is Arab

formation composed of carbonate, and subdivided into 7 layers. The secondary structures

in this field are Khatiyah, Shuaiba and Khuf respectively. The average depth of reservoir

is about 6000 ft containing a light and relatively good quality crude oil with API of 44

degrees. The ultimate recoverable oil reserve is estimated to be 117 MMSTB which will

be achieved by daily water injection rate of 50000 BWPD and considering the original oil

in place of 293 million barrels, the recovery factor will be 40% for a period of 14 years

which is envisaged to be a very good recovery factor.

4.2 Project Description

Our team has to conduct AIM and RBI for Balal Offshore Oil Complex for IOOC.

The scope of work shall be done in Balals facilities specified below:

1. One wellhead platform

2. One flare platform

3. One living quarter

4. 10 risers


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The facility details are summarized below:

Facility age 2002

Field BalalNumber of complex 1

Number of complex platform 3

Number of satellite platforms Non

Number of onshore facilities Non

Satellite production wells Non

Local production wells 5

Water injection wells 5

Table 3: Facility details

4.3 Project Organization Chart

Below is the figure of project organization chart:

Figure 4: Project Organization Chart


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As you can see from the table, our department will cover the reliability engineer

and corrosion engineer based on scope of work.

4.4 Scope of Work

Our scope of work is:

1. Populate the GALIOM Database with Mechanical and process data.

2. Define Equipment Functional (inventory) Groups (When an equipment item is

evaluated. Its contained inventory is combined with other attached equipment

which can realistically contribute to the fluid mass leaking from said item.

3. Develop corrosion loops (A corrosion loop is defined as a grouping of the piping

which is exposed to similar corrosion mechanisms, operating conditions and

materials).

4. Develop failure modes and mechanisms for each equipment tag.

5. Develop Consequence if Failure and Probability of Failure at the corrosion loop

level.

6. Enter Historical NDE data into GALIOM.

7. Develop and report first pass Risk Assessment for client review. Update COF and

POF based on client comments.

8. Develop Next Inspection Due Date.


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9. Implementations of GALIOM requirements on Human Asset (organization chart,

qualification training, etc).

10. Implementation of GALIOM requirements on information, data and procedures

asset (Including: operation, safety procedure change managementetc).

Proposed work flow as shown in Figure 5 below.

Figure 5: Proposed Work Flow


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4.5 Deliverables

We also deliver:

1. A document data folder containing any attached Documents.

2. RBI Study for Piping, Vessels, PSVs & Risers.

3. Corrosion Monitoring test points attached to Features within Tagged Equipment.

4. Next Inspection Corrosion Monitoring Work Scope with marked up construction

isometric drawings.

5. Entry of Existing corrosion monitoring results provided by IOOC. In absence of

prior results, NDE work pack will be developed for IOOC.

6. Assignment of Failure Modes & Mechanisms.

7. Preventive Maintenance Schedule, Visual % NDE, identifying Next Inspection

Due Date and Inspection Methodology.

4.6 Project Schedule

In order to complete all of the tasks in this project on time, scheduling all of the

tasks are necessary. This project schedule is also required by the clients to see theprogress of our work. Project schedule can be seen from figure 7 below:


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Figure 6: Project Schedule

4.7 Thickness Measurement Locations

My scope of work is to develop the next inspection due date. In order to do that,

we need to identify thickness measurement locations (TMLs). TMLs are specific areas

along the piping circuit where inspections are to be made. The nature of the TML varies

according to its location in the piping system. For selection of TMLs, we consider the

potential for localized corrosion and service-specific corrosion. Each piping system need

to be monitored by taking thickness measurements at TMLs. Based on piping inspection

code, piping circuit with high potential consequences if failure should occur and those

subject to higher corrosion rates or localized corrosion will normally have more TMLs

and be monitored more frequently. In order to develop next inspection due date, the

interval between piping inspections shall be established and maintained using corrosion

rate, remaining life calculations, piping service classification, applicable jurisdictional


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requirements, judgment of the inspector, the piping engineer, the piping engineer

supervisor, or a corrosion specialist, based on operating conditions, previous inspection

history, current inspection results, and conditions that may warrant supplemental

inspections.

The minimum thickness at each TML can be located by ultrasonic scanning or

radiography. The thinnest reading or an average of several measurements readings taken

within the area of a test point need to be recorded and used to calculate corrosion rates,

remaining life, and the next inspection date. TMLs need to be marked on inspection

drawings and on the piping system to allow repetitive measurements at the same TMLs.

This recording procedure provides data for more accurate corrosion rate determination.

We decide that more TMLs need to be selected for piping system with any of the

following characteristics:

1. Higher potential for creating a safety or environmental emergency in the event of

a leak.

2. Higher expected or experienced corrosion rates.

3. Higher potential for localized corrosion

4. More complexity in terms of fittings, branches, deadlegs, injection points, and

other similar items.

5. Higher potential for corrosion under insulation (CUI).


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Fewer TMLs can be selected for piping systems with any of the following three

characteristics:

1. Low potential for creating a safety or environmental emergency in the event of a

leak.

2. Relatively noncorrosive piping systems.

3. Long, straight-run piping systems.

TMLs can be eliminated for piping system with either of the following two

characteristics:

1. Extremely low potential for creating a safety or environmental emergency in the

event of a leak.

2. Noncorrosive systems, as demonstrated by history or similar service, and system

not subject to changes that could cause corrosion.

Based on design code; we can calculate MAWP and MAWT. All of the

calculation will be calculated by Galiom which is the software for asset integrity

management. The data for design pressure, design temperature, quality factor, design code

and nominal wall thickness are mandatory for any tag that we want to select TML. The

main objective for all of this process is to know the remaining life. This remaining life can

be known by knowing the remaining wall thickness, MAWT, and corrosion rate. The datacan be seen from figure 7 and mark-up drawing from figure 8 below:


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Figure 7: Data Sheet in Galiom Database


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Figure 8: Mark-up Drawing


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CHAPTER 5

CONCLUSION

5.1 Conclusion

This internship was very fruitful to me because I learn new concepts and new

ways of working. It was interesting to see how business works, how it is vital to spare

money and to make strategic choices. Moreover, I know the importance of inspection at

facilities. I was also given opportunity to involve with projects.

Concerning the project that I was involved with, it was interesting to discover the

concepts that I was taught in my engineering school such as statics, solid of mechanics,

material engineering and component design. The work in itself was also interesting in

different point of views. Handling the PFD, PNID and isometric drawing allows me to

learn more in oil and gas field. Also, another interesting part was that I started from

scratch. Indeed, I have to mark-up drawings to find critical location for corrosion.

Moreover, I learned to use Galiom to do analysis. Even though that was

something new for me, I was able use this software and could understand the functions of


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this software. Thanks to the staff of AIM department that were willing to teach me the

steps to understand this software.

This internship was a great experience. It was a real pleasure to work with GL.

Carrying out this internship in multi-national company allows me to experience different

culture and faced the problem of living and working entirely in a non-native language,

English. I also had the opportunity to meet interesting people in and out of the office such

as engineer, software engineer, as well as other people not connected with science.

5.2 Recommendation

I was grateful to be able to gain internship in GL. However there is one

recommendation to make the internship program more challenging and more organized.

One suggestion to make the project more organized is to plan for the whole internship

programme for the interns. The interns can be more focus towards the assignment that

had given rather than just accepting any assignment.


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REFERENCES

Balal Platform EPCI Contract Operations Manual. Kvaener E&C Singapore Pte.Ltd.

Balal Platform EPCI Contract Specification for Pipe Material. Kvaener E&C Singapore

Pte.Ltd.

GLM. (2009, March). IOOC Project Management Slides. Kuala Lumpur, Malaysia.

(2009).Material Selection Study Report PM329 East Piatu Development Project. Kuala

Lumpur: AKER Engineering Malaysia.

Pipe Threads, General Purpose (Inch); ASME B1.20.1. The American Society of

Mechanical Engineer.

Piping Inspection Code;API 570. (2003). Washington: API Publishing Services.

Risk-Based Inspection Base Resource Document. (2000). Washington: API Publication

581.

Selter, N. (2010, January 25). 2010 GL Noble Denton Presentation. Kuala Lumpur,

Malaysia.

Thomas, G. (2008, November). What is AIM & RBI . Kuala Lumpur, Malaysia.


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APPENDIX I: ASSIGNMENT 1

APPENDIX A


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Overview

1. Find a definition of:

i. Asset Integrity Management

ii. Risk Based Inspection

iii. Minimum Allowable Wall Thickness

iv. Remaining Life

v. Maximum Allowable Working Pressure

2. Find a formula for:

i. MAWT for Straight Pipe according to B31.3

ii. MAWT for Shell according to ASME VIII

iii. MAWT for Head according to ASME VIII

iv. MAWT for Nozzle according to ASME VIII

3. Provide an explanation of plant life cycle

Objective

1. To understand about AIM, RBI, MAWT, Remaining life and MAWP

2. To be able to familiar with B31.3 and ASME VIII and can state the right equation for anycomponents especially pipe, shell, head and nozzle.

3. To understand about the plant life cycle.

Significance of Study

1. AIM is very important because it is focused on the operating and technical integrity which

means is the facilities being operated, maintained and being inspected as required.

2. The ability to understand RBI will make a huge impact to develop cost-effective inspection and

maintenance programs that provide assurance of acceptable Technical Integrity, Reliability and

Availability.

3. MAWP & MAWT are important because these data can be used to maintain a minimum integrity

level so the pipeline is operated safely and economical.


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4. By knowing plant life cycle, we can manage the integrity of an oil & gas facility that needs to

consider the fundamental performance of materials in the oilfield environment in addition to

the economics of the oil industry and local operations and acceptable.

Answer

Asset Integrity Management

An asset has integrity when it performs as specified and is being operated and maintained as specified

so that the Risk to People, Environment, Assets and Company Reputation arising from its failure

is As Low As Reasonably Practicable.

Risk Based Inspection

The application of Risk Analysis principles to develop and manage inspection programs for plant

equipment.

Risk is the potential consequence based on a specific Hazard or Danger driven by its individual

probability of occurrence.

Minimum allowable wall thickness

The minimum required thickness, including mechanical, corrosion, and erosion allowances for wall

thickness.

Wall Thickness is a value that indicates the thickness of the tubing wall. It may remain unchanged as the

outside diameter and inner diameter change.


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Remaining Life

The prediction of the occurrence of failure events for process equipment based on a clear definition of

load history, damage accumulated to date, projected operations and material properties.

Maximum Allowable Working Pressure

A maximum gauge pressure permissible by an equipment/device (at coincident temperature specified

for that pressure) and is governed by code i.e. ASME, JIS,GB, etc.

Formula

Straight Pipe according to B31.3

tm = t + c

tm = minimum required thickness, including mechanical, corrosion, and erosion

allowance

t = pressure design thickness, as calculated for internal pressure or as

determined for external pressure


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c = the sum of the mechanical allowances (thread or groove path) plus

corrosion and erosion allowances. For threaded components, the nominal

thread depth (dimension h of ASME B1.20.1, or equivalent) shall apply.

For machined surfaces or grooves where the tolerance is not specified, the

tolerance shall be assumed to be 0.5 mm in addition to the specified depth

of the cut.

Straight Pipe Under Internal Pressure

For t < D/6, the internal pressure design thickness for straight pipe shall be not less than that calculated

in these equations:

P = internal design gage pressure


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d = inside diameter of pipe. For pressure design calculations, the inside

diameter of the pipe is the maximum value allowable under the purchase

specification.

D = outside diameter of pipe as listed in tables of standards or specifications

or as measured.

E = quality factor from Table A-1A or A-1B (pages 231&232)

S = stress value for material from Table A-1 (pages 182)

For t D/6 or for P/SE > 0.385, calculation of pressure design thickness for straight pipe requires special

consideration of factors such as theory of failure, effects of fatigue, and thermal stress.

Y = coefficient from Table 304.1.1, valid for t < D/6 and for materials shown.

The value of Y may be interpolated for intermediate temperatures.

For t D/6,

Straight Pipe Under External Pressure


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Shell according to ASME VIII (Refer UG-27 & UG-28)


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APPENDIX II: ASSIGNMENT 2


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APPENDIX II

Project Background

The Balal Field is located in the Iranian Sector of the Persian Gulf, at approximately 100 km to

the south-west (SW) of lavan island at a geographic location approximately 2619 N,

5232 E, in a water depth of approximately 66 m.

Introduction

The Balal Field is intended to drill 5 wells to produce from this interval at an initial total

production rate of 40,000 BOPD. Water injection will ultimately be required for pressure

maintenance and 5 injection are planned. The key design production rate is as follows:

Maximum crude oil production : 40,000 STBOPD

Maximum produced water rate : 33,000 BWPD

Maximum injection water rate : 50,000 BWPD Maximum total produced fluid rate : 45,000 BFPD

The development plan is based on a central complex comprising a combined Process and Living

Quarters (PLQ) platform, a single 16 slot drilling/wellhead platform (WHP) and a flare

tower, all bridge linked.


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Objectives

The objectives of this study are to:

1. Identify and recommend the most suitable and economically viable materials for the

wellhead platform, process and living quarters platform based on the well fluid

characteristic / properties, platform operating and design conditions.

2. Recommend corrosion control through the use of corrosion allowance and the use of

suitable material and deployment inhibitors.

Scope

The purpose of this report is to review the material selection philosophy based on

document as issued by Elf Petroleum Iran. The review will incorporate the Process Flow

Diagrams and equipment list along with the Data Sheets.

Only major items of vessels, equipment and piping are consider and the work is

targeted at establishing correct materials selection for the particular operating

environments with emphasis on corrosion mitigation.

Methodology

Reference

The material selection report refers to the following Project Documents as the

basis of its content.

1) BL-EF-EPR-DB-PPDK-1001-Process Design Basis

2) BL-EF-EPR-MA-PLQ-1001 (operating manual) -A01

3) BL-EF-EPR-MA-PLQ-1001 (operating manual ) -A02


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4) BL-EF-EPR-TR-PPDK-1001-Material Selection

5) BL-EF-EPI-SP-PPDK-1005_rev C1_Specification for Pipe Material

6) BL-EF-EPI-SP-PPDK- Pipe Material

7) BL-EF-PER-PF-PLQ-1001 TO 1013

8) Scope of Inclusion and Exclusion Rev 1

9) Piping and Instrumentation Drawing

10)Process Flow Diagram

Fluid Composition

Details of the fluid composition are taken from the Heat and Material Balance

(HMB). The fluid contains substantial amounts of CO2 and H2S.


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Question

Title : Material applications in Offshore Platform Top side process and utility facilities

Reference : Operating Manual of Balal Platform

Trainee is requested to make a summary from the above operating manual for the various types of

materials that have been used on the Balal oil fields such as piping, equipment, valve and

pump . The summary to be done in tabulate form consists of following

- Tag ( equipment, piping, valve, pump)

- Description of tag

- Service medium

- Operating temperature and pressure

- Materials in used

- Remarks


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Equipment/

Pip

ing

Description Service medium

Operating

Material in

usedRemarksTemp Pressure

C Barg

HE-6110A/B

Feed heater

Fuel Gas Cooler channel Fluid containing 2 %

CO2 , 1%

H2S .

(140/65) -

CS+ 3.0mm +

int.

coating

DSS

Fresh water in tube

side

Fuel Gas Cooler Tube Fresh water (140/65) - Fresh water

Fuel Gas Cooler Shell Wet Fuel gas 140 - CS+ SS clad

PipingFuel gas KO drum to 2nd stage

separator

Wet gas- - CS + 6.0 mm

V-101

Test separador Multiphase fluid

containingxco2 % , y

h2s, Cl

50,000 ppm

60CS+ 3.0 mm+

epoxy

coating

Piping Inlet to Test separator Multiphase fluid 65 A106 + 3.0mm .

Piping Fuel gas from production

system to VN-6120 via

Wet gas - - DSS


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HE61110A/B

Piping

Fuel gas from KO Drum to

filter vessels and

superheater

Wet gas

- - SS

SS316L cladding if

clean gas

requires.

Piping Gas outlet of superheater Dry gas CS + 1.0 mm

It is important to break down the critical component of each equipment to capture the details of material used.

Eg Pump : casing , impellar, shaft


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Answer

Crude Production &Pumping Unit, Oily Water System, Close Drain System, Flare Sytem

Equipment/ Piping


Operating

Material in used RemarksTemp Pressure

C Barg

V-101 Test Separator

Multiphase fluid,

1.75 mole% CO2,

1.13 mole% H2S

58.3 14.79

CS+epoxy coating+

NACE

MR01257

5

Piping Inlet to Production Separator

Multiphase fluid,

1.75 mole% CO2,

1.13 mole% H2S

58.3 13.8 CS(sour) + 3.0 mm

V-102

Production Separator Multiphase fluid

58.3 13.79

CS+epoxy coating+

NACE

MR0175

Piping

Oil from V-102 to export pumps Oil

58.3 13.8 CS(sour) + 3.0mm

.


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P-1024A/B

Export pumps

Casing Crude Oil

58-74 14.8

A436Gr3

Impeller A747 Gr CB7

Shaft AISI 4140 Cr/Mo Alloy steel

Piping

Gas outlet from Production

Separator

Gas

2.63 mole% CO2

1.92 mole% H2S

58.3 13.8 CS(sour) + 3.0 mm

V-103 Oily water Degassing Drum

Water

with dissolve

HC

Piping Outlet from V-103 water 58.3 0.7 A106-B/API 5L-B

V-104 Closed Drain Drum 58.3 0.4 Cs+int. coating epoxy

P-103A/B

Closed Drain

Pumps

Casing

Oily water 58 0.2

CS

Impeller CI

V-105 Flare Knock Out DrumWet Gas

48.5 0.1-0.3 CS+ int. coatingCoating with

epoxy

Piping Gas outlet of V-105 Gas 50.2 0.3


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Fuel Gas System

Equipment/ Piping Description Service medium

Operating


C Barg

PK-301-V-1 Fuel Gas Compressor Suction Drum

Gas n bulk liquid

2.63 mole% CO2

1.92 mole% H2S

58 13.3 SA 516 GR 70N

Piping Fuel Gas to Compressor Wet Gas 58 13.3 SS(sour)

PK-301-C-1A/B

Gas Compressor

CasingWet Gas

58-111.4 13.3-26.5

A395 Grade 60-40-

18

Piston A278 Class 30

PK-301-E-1A/B Gas Air Cooler Gas 55111.2 N.A A213-316L SS

PK-301-V-2 Gas HP Scrubber Wet Gas 55 26.5 A 516 Gr 70N

PK-301-F-1A/B Gas Filter Gas 55 26 SA 516 GR 70N


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aerosols

PK-301-H-1 Gas Super Heater Dry Gas 55 25.5 A 516 Gr 70N

Potable Water & Package

Equipment/ Piping


Operating


C Barg

PK-307A/B

Water Maker

Packages

PK-307-T-3 Water 50 atm polypropylene

PK-307-P-4 Water 40 12 SS316L/ PTFE

PK-307-F-1A/B Sand Filter 35 10 GRP

Piping Outlet of water maker 8-45 1

Galvanised CS+

1.6mm

TK-303A/B Water Storage Tank Water 45 atm CS+lining Epoxy

P-302A/B Impeller Potable Water 45 16 SS316L


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Water pump casing SS316L

F-303A/B Water Filters Water with solid particles 8-35 6 SS316

V-302 Water pressure POT Potable water 60 3.5-4 CS+lining Epoxy


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APPENDIX III: MINUTE MEETING


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Attendance: Chairman - Tan Cheong Ming

Minutes Taken By - Shah Reza Mohd Sarif

Attendants - Raja Juriah Raja Jaafar; AzlinaKairudin, Abd Jalil Saadin, Choo Siang Wen,Aidie Syafrin Bahardudin, Mohd Zakiyuddin MohdZahari

No Issue Description Action by Dateline

1 BORF a. Functional Group discussion, done write up tobe completed

Jalil 18/06/2010

b. Document Status- Master list not available, but document list

available - to search documents at Murphy Jalil 25/06/2010

- Op manual available - to check content Tan 18/06/2010

c. GALIOM setup - 20% completed Ju/Aidi W2 July

d. Other issue

- To check HMB case to use Jalil 18/06/2010

- Documents to print/available - Engineers to

advise Jalil 18/06/2010

2 West Patricia a. Document Status- Left over 20% - close until restart of project Lina Closed

- To make hardcopy of list available Lina 18/06/2010

3 PCPP a. Meeting with PCPP- MOM 03/06/2010 sent- To provide follow up email on pending items Choo 18/06/2010

b. CMP- Target completion of report by mid of August Tan

c. CML- Baseline UT procedure submitted, PCPP to

review Choo Closed

- TML marked-up 40% completed (total 400TMLs

x 4 quadrants), Choo to provide plan Choo 18/06/2010

- Discussion with Idris/ Jaafar - procedure, etc Reza 22/06/2010

4 IOOC a. Piping Tags Markup- 100% completion- Zaki to complete excel sheet data check

Zaki 17/06/2010

b. Vessel Tags data check/attach to GALIOMLina

16/06/2010c. Pipe isometric softcopy mark-up, attachGALIOM

Lina17/06/2010

d. RBI report Reza 25/06/2010

e. Lesson learned from IOOC project presentation Reza 25/06/2010

5 Financial a. KIKEH USD 90K - close Jalil Closed

b. Status dinner with Murphy Jalil 18/06/2010


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c. Tan to update his man hours spend ondocument review and reported in financial

sheetLina/ Tan

6 Bidding a. Dulang 2 (CDBM) Tan

b. Erb West Tan

c. Talisman (CMP) Tan

7 Others a. Department request for external training, tosubmit

form and get Jothi's approval All/Jothi ASAP

b. Mid year appraisal due All/Jothi ASAP

c. Internal training - subject to request, to inform

in advance if required All

d. 2010 increment issue - to follow up with mgt All 30/06/2010

e. Staff turnover issue - Siva/Reza resigned

- Jeopardize Murphy contract - Staff retentionissue

AllASAP

f. Aidi's supervisor visit - preparation Aidi 17/06/2010

g. Trainee to advise project topic if interested Aidi/Zaki 30/06/2010

Final Report Practical

Documents

Transcript of Final Report Practical