ASSET INTEGRITY

MANAGEMENT

Prepared by:

Zakaria MOHDHI

Asset Integrity Engineer

CERTIFIED:
API 510
API 570
NACE CP1
TBOSIET
..

Email: Zakaria.mohdhi@gmail.com

Sfax,
Asset Integrity is the ability of an asset:

To perform its function effectively and efficiently

To protect health, safety and the environment

AIM is a holistic approach to:

Preserving and assuring the condition and

operability
Complying with company policies and
standards
Meeting regulatory requirements
Optimizing operational performance
 DEGRADATION AND
FAILURE MODES
1- Corrosion

Rust Never Sleeps

External Corrosion

Internal Corrosion

Microbiologically Influenced Corrosion (MIC)

Corrosion Under Insulation

Erosion Corrosion
EXTERNAL
CORROSION
Preventing and Mitigation

• Paint for external protection

• Cathodic Protection
INTERNAL
CORROSION
Preventing and Mitigation
• Inhibitors
• Internal Coatings
• Cleaning Pigs
DEGRADATION AND
FAILURE MODES
2- Fatigue
Fatigue is a degradation process where cyclic loads
over an extended period reduce the strength of a
material and eventually cause failure.
FATIGUE
Prevention and Mitigation
Select a metal with a design fatigue life sufficient for
its intended cyclic service. Allow for a generous
radius along edges and corners.
Minimize grinding marks, nicks and gouges on the
surface of components. Insure good fit up and
smooth transitions for welds.
Minimize weld defects as these can accelerate fatigue
cracking.
Remove any burrs or lips caused by machining.
Use low stress stamps and marking tools.
INSPECTION AND
MONITORING
Visual Inspection

Ultrasonic Testing

Radiography
Dye Penetrant / Liquid Penetrant

Eddy Current Testing

Magnetic Particle Inspection

Magnetic Flux Leakage

Thermography

Acoustic Emission

Corrosion Coupons and Probes

 ASSET INTEGRITY

Prepared by:

Zakaria MOHDHI

Asset Integrity Engineer

Email: Zakaria.mohdhi@gmail.com

Sfax,
SURFACE PREPARATION
METHODS & STANDARDS
Two factors need to be considered when inspecting a surface
preparation.
1. Degree of cleanliness
2. Surface Profile (degree of roughness)
SURFACE PREPARATION
METHODS & STANDARDS
Surfaces can be prepared for paint application in several different
ways, each one varies in cost, efficiency, ease and suitability.
a) Dry Abrasive Blast Cleaning
b) Water Blasting
c) Hand and Power Tool Cleaning
d) Flame Cleaning
e) Pickling
f) Vapour Degreasing
DRY ABRASIVE BLAST
CLEANING
Dry abrasive blast cleaning involves compressing air and forcing it
along a hose and out of a small aperture called a nozzle. A
pressure of 100 psi results in the air exiting the nozzle at
approximately 450 mph.
ABRASIVES

Sand
SI 1657 states that any mineral used as an abrasive must release less than 1%
free silica on impact. (Silica causes preumonicosis or silicosis). COSHH REGS
does not allow the use of sand containing silica for dry blasting. Sand itself is
perfectly safe, but
shattering on impact releases silica which can be inhaled.
ADHESION AND
PROFILE
A commonly used definition of adhesion is: - The force required to
separate two surfaces in touch
If a profile requirement is specified, it is the inspector’s duty to
ensure that the specification requirements are met. This can be
done in two ways.
a) By measuring – using gauges with and without replica tape.

b) By assessing – using surface comparators.

.
ABRASIVE BLASTING
GRADES

Sa 1 - Light Blast Cleaning. When viewed without

magnification, the surface shall be free from visible oil grease and dirt and
from poorly adhering mill scale, rust, paint coatings and foreign matter.
Sa 2 - Thorough Blast Cleaning. When viewed without
magnification, the surface shall be free from visible oil grease and dirt and
most of the millscale, rust, paint coatings and foreign matter. Any residual
contamination shall be firmly adhering.
Sa 21/2 - Very Thorough Blast Cleaning. When viewed without
magnification, the surface shall be free from visible oil grease and dirt and
from millscale, rust, paint coatings and foreign matter. Any remaining traces
of contamination shall show only as slight stains in the form of spots or
stripes.
Sa 3 - Blast Cleaning to Visually Clean Steel. When viewed
without magnification the surface shall be free from visible oil grease and dirt,
and shall be free from millscale, rust, paint coatings and foreign matter. It
shall have a uniform metallic colour.
SURFACE
CONTAMINANTS AND
TESTS FOR DETECTION
Test for soluble iron salts
This is a qualitative test, it will not even differentiate between the salts. It will detect the
presence of either Sulphates or Chlorides.
This test is known as the Potassium Ferricyanide test, although it is now under a new universal
naming system, known as Potassium Hexa-cyanoferrate, a name more descriptive of its
formula.
Test to detect soluble chlorides
The test for detecting chloride salts is known as the Silver Nitrate Test.
Test to detect the presence of dust on a substrate
If a piece of self adhesive tape is stuck onto the surface and snatched off, the dust/finings
sticks to the tape. By then sticking the tape onto white paper the dust can easily be seen.
Test to detect the presence of moisture on a substrate
A very simple test for the presence of moisture is to sprinkle with talc or powdered chalk and
then lightly blow away. The powder will stick to areas where moisture is.
Test to detect the presence of oil or grease
Other than ultra violet light, oil and grease can be detected by dropping solvent onto the
suspect area, and absorbing the solution on Whatman or blotting paper
PAINT SYSTEMS
Primer Anti corrosive to protect the steel
Mid-coats
Mid-coats are mainly barrier coats. They are applied over the
primers to prevent further water passing into the film and leaching
out the inhibitive pigmentation,
Finishing coats
Finishing coats of a system are mainly aesthetic,
TESTING OF PAINTS FOR
PROPERTIES AND
PERFORMANCE
Determination of volatile, non volatile
This test, done to BS 3900 part B2
Flash point determination
As per BS 3900 part A9, using a closed Abel cup
Paint density
Defined as being weight per unit of volume, density is calculated by weighing
a know volume of material and using the formula: -
Density = Weight / Volume
Hegman grind gauge

Viscosity
Viscosity is a very important property for paint, it affects the manufacturing
process and application and levelling properties.
FILM THICKNESSES
Wet film thickness measurement WFT:
Eccentric wheel
Comb gauges

WFTs can be calculated by using the following formulae,

according to information given.

WFT = 100 / Vs x DFT

WFT = V / A = Volume / Area
FILM THICKNESSES
Dry film thickness DFT

1 Test panels : Test panels are usually 150mm square plates of the
same material as the component being processed
2 Calculations
DFT = WFT x VS / 100
3 Destructive test gauges
As the name implies these types of gauges cause damage to the film
which then needs to be repaired.
4 Non destructive test gauges
Electronic
Magnetic
TESTS FOR MECHANICAL
PROPERTIES ON PAINT
FILMS

Abrasion resistance
Hardness
Flexibility BS 3900 E1
Impact resistance
Accelerated testing
Drying and curing tests
Degree of Gloss
Adhesion …
SPECIFIED COATING
CONDITIONS
It is not permissible to apply paints
1. During rain, snow, or high winds”. This clause would be sensible
even in modern specifications.
2. When the air or metal temperature is down to within 3oc above
the dew point temperature”. Still common in specification now, but
can be overridden by giving alternate systems.
3. When the air or metal temperature is below 5oc”. Solvent
evaporates very slowly at low temperatures and chemical cure rates
used to be static.
4. When the relative humidity is more than 90%”. Still a very
common restraint, and sometimes the benchmark for using moisture
curing polyurethane’s.

From the above, two very important phrases arise, Relative Humidity
and Dew Point.
PAINT APPLICATION
- Brush application
- Roller application
- Spray application
Conventional spray
The paint container is underneath the gun, usually
aluminium about one litre capacity, and the paint is
drawn up by venturi principle to the gun.
Airless spray
These systems are called airless because air is
not used for atomisation. Atomisation occurs by
forcing the paint at extremely high pressure,
usually 2000 to 2500 psi through a very small
aperture, 12 to 23 thou diameter, into a volume of
air offering a resistance to the paint flow. As the air
and paint meet, the paint atomises.
COATING FAULTS
Bittiness
Blistering
Chalking
The formation of a friable, powdery layer on the surface of the film
of a coating material caused by disintegration of the binding
medium due to disruptive factors during weathering.
Cracking
HEALTH AND SAFETY
 ASSET INTEGRITY

Prepared by:

Zakaria MOHDHI

Asset Integrity Engineer

Email: Zakaria.mohdhi@gmail.com

Sfax,
ELECTROCHEMICAL
APPROACH TO
CORROSION
Corrosion reactions
• A typical type of corrosion reaction: attack of iron by an acid

2 HCl + Fe → H 2 + Fe Cl 2
• In the language of the chemist this reaction is one of
oxidation-reduction in which
• The hydrogen ions H+ play the part of the oxidant
• The iron plays the part of the reducing agent

• Except in exceptional circumstances we find this mechanism

in all the cases of corrosion that we meet in Oil & Gas
production industry (wet corrosion)
ELECTROCHEMICAL
APPROACH TO
CORROSION
Corrosion cells
• To understand the mechanism of charge transfer we generally
split the corrosion reaction into two electrochemical reactions:
• Reduction or cathodic reaction
2 H + + 2 e- → 2 H → H 2
2+
• Oxidation or anodic reaction Fe → Fe + 2 e −
Na+
Fe2+
Cl- Current flow in
Electrolyte Electrolyte
H+ H+

H+ + e - 1/2 H2 H+ + e- 1/2 H2
Fe Fe2+ + 2e-

Metal Current flow in

Metal
ELECTROCHEMICAL
APPROACH TO
CORROSION
Corrosion cells
• The positive areas from which current flows into the sea or
soil are called ANODES (or anodic areas), and the negative
areas into which the current flows are CATHODES (or
cathodic areas)

• As the iron metal is removed,

atom by atom, from the anode
and deposited at the cathode,
a corrosion pit is formed.
Hundreds of thousands of such
pits are formed, which appear
as general corrosion of the
structure member or pipe
POTENTIAL SCALES
Metal-Metal Electrode potential
Status Metal name equilibrium vs. normal Hydrogen
(unit - activity) electrode at 25°C

Zinc Zn – Zn2+ - 0.763 V

Active or Chromium Cr – Cr3+ - 0.744 V
anodic
Iron Fe – Fe2+ - 0.440 V

Nickel Ni – Ni2+ - 0.250 V

Hydrogen H – H+ 0. 000 V

Copper Cu – Cu2+ + 0.337 V

Noble or
Platinum Pt – Pt2+ + 1.200 V
cathodic
Gold Au – Au3+ + 1.498 V
POTENTIAL SCALES
THE ELECTROCHEMICAL
CELL ON SITE
Analogy chemical cell (battery) and pipe
• An electrochemical cell contains four
main components:
• Electrolyte: a solution or
conducting medium such as soil
(contains water, oxygen and
dissolved chemicals)
• Anode: a metal electrode in
contact with the electrolyte which
corrodes
• Cathode: a metal electrode in
Corrosion Hydrogen Film contact with the electrolyte which
Steel pipeline is protected
“External” circuit against corrosion
Anode - Cathode + • External circuit: a metal conductor
connecting the anode and the
Corrosion cathode
Electrolyte / Soil
THE ELECTROCHEMICAL
CELL ON SITE
Analogy chemical cell (battery) and pipe
• In each of these cells (galvanic and pipe electrochemical), the
anode is consumed while the cathode is protected against
corrosion

• In each diagram
• The electric current flows from the cathode to the anode in the
external circuit
• The current leaves the anode to enter the electrolyte and in so
doing produces a chemical reaction at the surface of the anode
(formation of a compound of the metal as a product of corrosion)
• The current migrates through the electrolyte and enters the
cathode. At the surface of the cathode, positive ions from the
solution are liberated, generally in the form of atomic hydrogen
THE ELECTROCHEMICAL
CELL ON SITE
The galvanic corrosion on site
• The steel electrochemical cell
• The galvanic corrosion is an accelerated corrosion of a metal
because of an electrical contact with a more noble metal or
non-metallic conductor in a corrosive electrolyte
CATHODIC PROTECTION
PRINCIPLES
Objective:
• Annihilate or cancel or reverse the “damaging” current, which
is destroying the structure or pipe

If there is something to be destroyed or “eaten” by the

electrochemical reaction, it has to be something else than the
structure!

The protected part is the cathode, so the structure or pipe

has to be entirely the cathode and let’s get an external, other
material which can be “destroyed”
CATHODIC PROTECTION
PRINCIPLES
General basic principles of cathodic protection
• “Injection" of a DC from the corrosive environment into the
structure to be protected; this current entry reduces corrosion
through metal/electrolyte electrochemical potential
decrease

• Providing a sufficient current density (mA/m²) to the

surface to reach a sufficiently negative potential, below which
the corrosion is completely negligible

• Coating applied to the surface to be cathodically protected

allows to minimize the current needed to assure this potential,
by reducing the surface receiving this current density
CATHODIC PROTECTION
PRINCIPLES
General basic principles of cathodic protection
THE SACRIFICIAL
ANODE SYSTEM
Cathodic current is supplied by galvanic coupling with an
alloy which is easier to be oxidised than the structure to be
protected

Galvanic anodes are applicable and effective where:

• Current requirements are low
• Structures to be protected are usually well coated
• Localized protection is required
• Relatively low resistivity soils exist
THE SACRIFICIAL
ANODE SYSTEM
Main advantages of sacrificial anodes:
• No external power supply necessary
• Minimum maintenance costs after installation
• Rarely cause interference problems to foreign structures
• Installation costs are low
• Little or no rights-of-way or easements costs
• More efficient utilization of protective current

Main disadvantages:
• Limited driving potentials
• Lower and limited current outputs
• Soil resistivity limitations
• Not applicable for protecting large diameter bare or poorly coated pipe
THE SACRIFICIAL
ANODE SYSTEM
Sacrificial anodes offshore
• The anode is in the form of an array, plates
or cylinder placed in the sea near to, and
dispersed at points all along the metal to be
protected
• It is made of a material which is 'based'
relative to iron (zinc is usually the material
chosen)
• If the anodes chosen are of sufficient area, their current can be
made to cancel the natural electrolytic currents exactly; if made
larger they will reverse it
• As the current from the zinc anode is accompanied by
continuous loss of metal, the anodes eventually become too
small to be effective and must be replaced (a life of ten years is
envisaged)
THE SACRIFICIAL
ANODE SYSTEM
Monitoring sacrificial anodes onshore
• Reference electrode onshore is in copper (Cu-CUSO4) and is
buried once for all
• It is not connected to the structure but to a “measuring box”
ending generally on a terminal, the voltmeter being brought by
the control technician doing its verification campaign
THE IMPRESSED
CURRENT SYSTEM
Unlike the sacrificial anode system, the impressed current
system (= groundbed) uses an external power source to
provide the protection current
This current is applied in a direction opposite to that of the
natural outward electrolytic
currents and can be
regulated at will
THE IMPRESSED
CURRENT SYSTEM
Main advantages
• Larger driving voltages
• Higher current outputs
• Applicable in almost any resistivity soil environment
• Flexibility of current output control
• Applicable for bare and poorly coated structures
• Protects larger and more expansive structures
• No anode to change / replace

Main disavantages
• Higher installation costs
• Higher maintenance costs
• Monthly power costs
• Interference problems with foreign lines
THE IMPRESSED
CURRENT SYSTEM Ground wire
link

Grounding interconnections
• The ground linking wire is not only for the
electrician to care about: it is a ‘really’ protecting
wire as it helps to avoid corrosion
Gasket and bolts can
be in insulated material
Rectifier panel
Anode bed

No corrosion

Protected pipe
No corrosion

Protected pipe

No corrosion
THE IMPRESSED
CURRENT SYSTEM
Typical installation of a 1.50 m length anode in soil
1.00 m
Natural soil level
• The electric cable routing is,
as other any other electrical 0.60 m
Soil

cable, laid on sand at least Brick

0.80 m, then 0.20 m of sand; 0.20 m
Sand
above the mechanical 0.30 m

protection such as a brick Anode cable 50 mm²

0.60 m to bonding box
and rest of the trench filled
with natural soil
Soil and backfill

1.50 m
Anode and backfill

0.20 m
Utilities – Cathodic protection
0.60 m
THE IMPRESSED
CURRENT SYSTEM
Power supply and control
• Power supply rectifier panel
• Size adapted to the power required
• Onshore power is coming for available AC in
vicinity or from other sources such as
photovoltaic cells, wind turbine, …
THE IMPRESSED
CURRENT SYSTEM
Power supply and control
• Power supply rectifier panel
• All types of supplies have anyway in common, possibilities of
adjustment for
voltage (variable transformer
or autotransformer on
AC side) and for current

Utilities – Cathodic protection

Le besoin total en courant
I = (500 x 0,090) + (10000 x 0,060) + (400 x 0,030) I = 657 A
La masse d'anode à installer pour assurer la protection pendant la durée de vie prévue
Masse consommée pendant 20 ans = (657 x 3,4 x 20) / 0,9 = 49640 kg
Masse anodique à installer = 49640 / 0,85 = 58400 kg
Le nombre d'anodes
N = 58400 / 90 soit 649 anodes.

Remarque
Le calcul complet nécessite ensuite de vérifier que le débit de chaque anode, compte tenu de la
résistance de celle-ci dans le milieu (ici eau de mer de résistivité ρ = 30 Ω.cm) permet d'abaisser
effectivement le potentiel de la structure sous le seuil d'immunité, soit -0,8 V / Ag-Ag-Cl.
Résistance d'anode : R= (ρ/2πL)[ln(4L/r) - 1] avec :
L : longueur de l'anode = 2,50 m
r : rayon extérieur de l'anode = 7 cm (en début de vie)
On trouve ici R = 0,076 Ω
Débit individuel de chaque anode : i = 657 / 649 = 1,012 A
Dans le circuit électrique structure - anode - électrolyte, le potentiel de la structure
Es après polarisation peut être évalué par la formule : Es = Ea + Ri avec Ea =
potentiel de l'anode, ici -1,05 V/Ag-AgCl (on néglige la résistance de la connexion
structure - anode).
Donc : Es = -1,05 + 0,076 x 1,012 = -0,973 V
Es est inférieur au seuil de -0,8 V/Ag-AgCl, le dimensionnement est satisfaisant.
Note : le même calcul, effectué en fin de vie des anodes (r = 3 cm), conduit à Es = -
0,957 V
Le besoin total en courant
Surface à protéger = 0,3239 x 3.14 x 60000 = 61023 m2
Besoin total en courant = 61023 x 0,05.10-3= 3,05 A
La tension nécessaire à chaque poste pour fournir le courant de
protection, en
considérant que la résistance du circuit structure - électrolyte -
déversoir est de 5 Ω
Intensité débitée I = 3,05 / 2 = 1,52 A
Résistance du circuit = 5 ohms
Tension : U = 5 x 1,52 = 7,6 V
La puissance délivrée par chaque poste de soutirage
P = U x I = 7,6 x 1,52 = 11,6 watts
La masse anodique à installer pour assurer une durée de vie de
25 ans
M = 0,5 x 1,52 x 25 = 19 kg
 ASSET INTEGRITY MANAGEMENT

Prepared by:

Zakaria MOHDHI

Asset Integrity Engineer

Email: Zakaria.mohdhi@gmail.com

Sfax,
MECHANICAL INTEGRITY
INSPECTION & CERTIFICATION
To assure the integrity of offshore installations you
have to perform the inspection of the minimum
following :
Pressure Equipments ( Process Piping,
Pressure Vessels)
Lifting equipments ( Cranes, offshore
containers, lifting tools)
Offshore jackets
Offshore structures
Manifolds
Platform certification
Barge classification
INTRODUCTION
 INSPECTION, MONITORING
AND TESTING
• Inspection is used to determine the condition of a system

• Monitoring is used as a tool for assessing the need for corrosion

control or the effectiveness thereof

• Testing has two definitions :

• Hydrostatic testing to determine if it has an adequate strength to
withstand the desired stresses or pressures
• Other tests are performed to determine the suitability of equipment,
materials, chemicals; these tests are often performed in laboratories

• Certification is a system for safeguarding life, is aim to evaluate

the level of conformity of such installations with regard to reference rules
and standards applicable, is carried out by Third Party
 TYPE OF INSPECTION
There are two basic types of inspection:
• Shop/workshop inspection which is involved with
inspection of equipment either during manufacture or
Shop repair
Inspection • Example = ITP

In-Service • In service inspection of equipment that is already in

Inspection use
• Example = During plant SD, on stream

Both types of inspection involve similar skills, but the technical

scope of the in service inspector is slightly wider, incorporating
corrosion and degradation mechanism, which are not an issue with
works inspection of new plant
TYPE OF INSPECTION
INSPECTION TEST
PLAN ITP

Mark-up codes:
H = Hold Point: The manufacture will not proceed
until all the parties shown on the ITP have witnessed
the activity
W= Witness Point: All parties will be informed about
the inspection/test but if they don’t attend, the work will
continue
S= Surveillance: All parties can visit the works at any
time and carry out surveillance of any work/test etc
that are in progress
R =Review: The parties will review the relevant
documentation at some convenient time
SHOP/WORKSHOP
INSPECTION
IN-SERVICE
INSPECTION

It is necessary to inspect the pressure equipment

throughout its working life to make sure it
continues to be safe and fit for purpose

Most inspections are intended to be

IN-SERVICE
INSPECTION
NON-DESTRUCTIVE
TESTING
A welding inspector should have a working knowledge of NDT
methods and their applications, advantages and disadvantages.

• Magnetic particle inspection (MT)

• Dye penetrant inspection (PT)
• Radiographic inspection (RT)
• Ultrasonic inspection (UT)
NON-DESTRUCTIVE
TESTING
Surface Crack Detection
• Liquid Penetrant (PT or Dye-Penetrant)
• Magnetic Particle Inspection (MT or MPI)
Volumetric Inspection
• Ultrasonics (UT)
• Radiography (RT)
Each technique has advantages & disadvantages with respect
to:
• Technical Capability and Cost
Note: The choice of NDT techniques is based on consideration
of these advantages and disadvantages
NON-DESTRUCTIVE
TESTING
Main features:
Detection of surface breaking defects only.
This test method uses the forces of capillary action
Applicable on any material type, as long they are non porous.
Penetrants are available in many different types:
• Water washable contrast
• Solvent removable contrast
• Water washable fluorescent
• Solvent removable fluorescent
• Post-emulsifiable fluorescent
Ensure surface is very Clean normally with the use of a solvent
After the application, the penetrant is normally left on the
components surface for approximately 15-20 minutes (dwell time).
The penetrant enters any defects that may be present by capillary
action.
the penetrant is removed after sufficient penetration time (dwell
time).
Care must be taken not to wash any penetrant out off any defects
present
After the penetrant has be cleaned sufficiently, a thin layer of
developer is applied.
The developer acts as a contrast against the penetrant and allows
for reverse capillary action to take place.
Inspection should take place immediately after the developer has
been applied.
any defects present will show as a bleed out during development
time.
After full inspection has been carried out post cleaning is generally
required.
Fluorescent Penetrant Bleed out viewed
under a UV-A light
source

Bleed out viewed

under white light
Colour contrast Penetrant
Simple to use Surface breaking defect only
little indication of depths
Inexpensive
Penetrant may contaminate
Quick results component
Can be used on any non- Surface preparation critical
porous material
Post cleaning required
Portability
Temperature dependant
Low operator skill required
Penetrant Testing

e
Magnetic Particle testing (MT)
Main features:
Surface and slight sub-surface detection
Relies on magnetization of component being tested
Only Ferro-magnetic materials can be tested
Fine particles of iron powder are applied to the test area
Any defect which interrupts the magnetic field, will create a
leakage field, which attracts the particles
Any defect will show up as either a dark indication or in the case of
fluorescent particles under UV-A light a green/yellow indication
Flux Leakage
Being able to magnetize the part in two
directions is important because the best
detection of defects occurs when the
lines of magnetic force are established
at right angles to the longest dimension
of the defect.
This orientation creates the largest
disruption of the magnetic field within the
part and the greatest flux leakage at the
surface of the part. An orientation of 45
to 90 degrees between the magnetic
No Flux Leakage
field and the defect is necessary to form
an indication.

A crack like
indication
 PRODUCING A LONGITUDINAL FIELD USING
PERMANENT OR ELECTROMAGNETIC MAGNETS

Permanent magnets and

electromagnetic yokes are
also often used to produce
a longitudinal magnetic
field. The magnetic lines
of force run from one pole
to the other, and the poles
are positioned such that
any flaws present run
normal to these lines of
force.
Typical sequence of operations to inspect a weld

• Clean area to be tested

• Apply contrast paint
• Apply magnetisism to the component
• Iterpret the test area
• Post clean and de-magnatise if required
Advantages Disadvantages
• Simple to use • Surface or slight sub-surface
detection only
• Inexpensive
• Magnetic materials only
• Rapid results
• No indication of defects depths
• Little surface preparation
required • Only suitable for linear defects

• Possible to inspect through • Detection is required in two

thin coatings directions
 Comparison with Penetrant Testing
ADVANTAGES
• much quicker than PT
• instant results
• can detect near-surface imperfections (by current flow technique)
• less surface preparation needed
DISADVANTAGES
• only suitable for ferromagnetic materials
• electrical power for most techniques
• may need to de-magnetise (machine components)
Ultrasonic Testing (UT)
Main Features:
• Surface and sub-surface detection
• This detection method uses high frequency sound waves,
typically above 2MHz to pass through a material
• A probe is used which contains a piezo electric crystal to
transmit and receive ultrasonic pulses and display the signals on
digital display
• The actual display relates to the time taken for the ultrasonic
pulses to travel the distance to the interface and back
• An interface could be the back of a plate material or a defect
Pulse echo Digital
signals UT Set,
A scan
Display

Compression probe checking the material Thickness

 defect Back wall
initial pulse echo echo

Material Thk
defect

0 10 20 30 40 50

Compression Probe CRT Display

 UT Set
A Scan
Display

Angle Probe
Advantages
Disadvantages
Rapid results
Trained and skilled operator
Both surface and required
sub-surface detection Requires high operator skill
Safe Good surface finish required
Capable of measuring the Couplant may contaminate
depth of defects
No permanent record
May be battery powered
Calibration Required
Portable
Ferritic Material (Mostly)
 Comparison with Radiography

ADVANTAGES
•good for planar defects
•good for thick sections
•instant results
•can use on complex joints
•can automate
•very portable
•no safety problems (‘parallel’ working is possible)
•low capital & running costs
 Comparison with Radiography
DISADVANTAGES
no permanent record (with standard equipment)
not suitable for very thin joints <8mm
reliant on operator interpretation
not good for sizing Porosity
good/smooth surface profile needed
Radiographic Testing (RT)
The principles of radiography
• X or Gamma radiation is imposed upon a test object
• Radiation is transmitted to varying degrees dependant upon the
density of the material through which it is travelling
• Thinner areas and materials of a less density show as darker
areas on the radiograph
• Thicker areas and materials of a greater density show as lighter
areas on a radiograph
• Applicable to metals,non-metals and composites
 X – Rays Gamma Rays
Electrically generated Generated by the decay of
unstable atoms
 Source

Image quality indicator

Radiation beam

Radiographic film Test specimen

 GAMMA SOURCES
Isotope Typical Thickness Range
• Iridium 192 10 to 50 mm (mostly used)

• Cobalt 60 > 50 mm

• Ytterbium < 10 mm
• Thulium < 10 mm
• Caesium < 10 mm
Advantages
Disadvantages
• Permanent record
• Expensive consumables
• Little surface preparation
• Harmful radiation
• Defect identification
• Defect require significant
• No material type limitation depth in relation to the
radiation beam (not good for
• Not so reliant upon operator
planar defects)
skill
• Slow results
• Thin materials
• Very little indication of depths
• Access to both sides required
 Comparison with Ultrasonic Examination
ADVANTAGES
good for non-planar defects
good for thin sections
gives permanent record
easier for 2nd party interpretation
can use on all material types
high productivity
direct image of imperfections
 Comparison with Ultrasonic Examination
DISADVANTAGES
health & safety hazard
not good for thick sections
high capital and relatively high running costs
not good for planar defects
X-ray sets not very portable
requires access to both sides of weld
frequent replacement of gamma source needed (half life)
• Imperfections are classed as defects when they are of a type,
or size, not allowed by the Acceptance Standard
A defect is an unacceptable imperfection
• A weld imperfection may be allowed by one Acceptance
Standard but be classed as a defect by another Standard and
require removal/rectification
Imperfections are classified into 6 groups, namely:
1 Cracks
2 Cavities
3 Solid inclusions
4 Lack of fusion and penetration
5 Imperfect shape and dimensions
6 Miscellaneous imperfections
 Porosity

Root piping
Causes
Loss of slag control because of
incorrect manipulation of electrode.
Narrow, deep edge preparations.
Convex profile in multi-run welds.
Lack of interpass cleaning.
DEFINITION:
Lack of union in a weld.

CAUSES:
Contaminated weld prep
Amperage too low / high
insufficient cleaning

NDT inspection
. If the imperfections are surface
breaking, they can be detected using a
PT or MT
For sub-surface imperfections,
detection is by radiography or ultrasonic
inspection
 ASSET INTEGRITY
MANAGEMENT

Prepared by:

Zakaria MOHDHI

Asset Integrity Engineer

Email: Zakaria.mohdhi@gmail.com

Sfax,
•Pressure Vessels P>04 bars & P*V>80

• Separator, Scrubber
•Process Piping
•PSV
•Heat Exchangers
•Boilers
•Storage tanks
What is Pressure Vessel ?
•PV : A container designed to withstand internal or external pressure
• PV can be dangerous, in use, they contain large amounts of stored
energy
How do you verify the integrity of PV ?
Over the past 100 years or so, industry has developed a set of norms,
which have the objective of assuring the integrity of PV
The system for assuring the integrity of PV is obtained by :
1. Design appraisal
2. Using traceable materials
3. Applying proven NDT examinations
4. Doing a hydrostatic Pressure testing
•Perform official certification of PV: through internal and
external inspection
•Carry out the baseline survey
Most pipe in process plants has a regular periodicity of inspection
It shall be inspected and tested, in accordance to API 570

API-570 is applicable for repair, alteration and re rating of

METALIC PIPING that are IN INSERVIVE.
It is developed for petroleum refining & chemical process
industries, may be used where practical for other piping system
INSPECTION PRACTICES
OF PROCESS PIPING
The outline content of API 570
1. Inspection and testing practices
2. Frequency and extent of inspections
3. Thickness calculations
4. Repair , alteration and re-rating
5. Inspection of buried pipelines

The scope of API 570:

Included: Excluded:
Almost any metallic piping system: •Water, steam
• Raw and finished oil products •Piping related to mechanical
• Raw and finished chemical products equipment (compressor, pumps,..)
• Hydrogen, fuel and flare gas systems • Pressure vessel
• Sour , waste systems etc •Domestic sewers
•Everything <1/2 inch
•Non metallic piping
The main technical content of API 570 covers the
11 separate risk areas shown below:

1. Injection points
2. Dead legs
3. CUI
4. Soil/Air interfaces
5. Erosion and erosion/corrosion
6. Environmental cracking
7. Corrosion under linings
8. Fatigue cracking
9. Creep cracking
10. Brittle fracture
11. Freeze damage
The frequency and extents of inspection depends on the form of
degradation. It affect the piping and consequence of the piping
failure
API 570 defines three levels of piping class:
Class 1: Highest risk/consequence
Class 2 : Medium risk
Class 3 : Low risk

Class – 1 piping: Immediate emergency of a leak occurs.

• Flammable services
• Pressurized services that may rapidly vaporize
• Hydrogen sulphide (H2S) greater than 3% in a gaseous stream
• An hydrous hydrogen chloride
• Hydro fluoric acid
• Piping through public through ways and over water
• Class – 2: majority of unit process piping and selected
off site piping
– Hydro carbons that will slowly vaporize
– Hydrogen, fuel gas and natural gas
– Strong acid and caustics (on site)
• Class – 3: Flammable but do not significantly vaporize
and not located at high affectivity areas.
– Hydrogen that will not significantly vaporize
– Distillate and product line
– Offsite acids and caustics.
 Max Inspection Intervals
CLASS THK INSP EXT VISUAL

1 5 5

2 10 5

3 10 10

Injection Point 3 by class

 CUI Inspection EXTENT
CLASS NDE Follow up or INSUL NDE AT Suspect area
Removal at a damaged piping with susceptible
areas temp

1 75% 50%

2 50% 33%

3 20% 10%
 INTRODUCTION TO
INSPECTION
RISK BASED

RISK BASED INSPECTION

(RBI)
 RBI DEVELOPMENT

Initially developed for Nuclear Industry

Probabilistic Risk Assessment (PRA’s) used following NRC
Reactor Safety Study
(Wash-1400) in 1975
1985 ASME formed Risk Analysis Task Force
Task Force recommended research program
1991 published Risk Based Inspection - Development of
INSPECTION
RISK BASED

Guidelines Volume 1
API released Pub. 581 - Base Resource Document on Risk
Based Inspection in 1996
API 580 – Risk Based Inspection Recommended Practices
(2002)
API RECOMMENDED PRACTICE 581 SECOND EDITION,
SEPTEMBER 2008
 WHAT IS RBI

• A systematic data analysis of equipment condition, to

determine the associated risk with its operation
• Prioritise Inspection based on the Assessment of Risk
 WHAT IS RBI

The principles of RBI :

It considers the consequences
and likelihood of failure
Identifies the highest-risk
equipment
Quantifies the risk
Reflects the risk in the Written
Scheme of Examination

RISK = PROBABILITY OF FAILURE X CONSEQUENCE OF FAILURE

 THE MAIN STEPS OF AN RBI
ANALYSIS
1. Data Gathering by listing the equipment
2. Evaluate each with regard to
consequence and probability of failure :
a) Inspection History Review
b) RBI Specific Input (Inspection Records,
Piping circuit, Corrosion Loop)
3. Criticality Analysis by compiling Risk
Matrices
4. Review results
5. Decide new inspection periods or
practices
 RBI CONCEPT
ASSESS
IDENTIFY THREATS/ INSPECTION
HAZARDS HISTORY
to EQUIPMENT

(Pipework, Vessels etc)

SUSCEPTIBILITY to
FAILURE MODE
THREAT

MITIGATION
MEASURES to
REDUCE
SUSCEPTIBILITY

LIKELIHOOD of CONSEQUENCES of
FAILURE FAILURE

REMAINING LIFE or
RISK FACTOR
INSPECTION GRADE

INSPECTION
SCHEME
STANDARDS AND
CODES LINKED TO RBI
API Risk-Based Inspection
• API 580 & 581

API In-Service Inspection Recommended Practices (RP)

• API 510, 570, 576, 653, 574, 572,577, 578

Equipment Design, Fabrication, and Repair

• ASME Section VIII, Division 1,
• ASME B31.3
• ASME B16.5
• ASME V
• ASME IX

137
 INSPECTION HISTORY

API RP
570 & 510

Quantitative Qualitative

Calculate time to failure based on Effectiveness and results of

wall thickness measurements. inspections are graded. IP
guidelines set out
Maximum inspection interval = ½ recommended maximum
remaining service life intervals based on
inspection grade
 TYPE OF DATA
GATHERED
1. Data Gathering
PFD
• P&ID
Inspection Record
• G.A Drawing
EVALUATE EACH WITH REGARD TO
CONSEQUENCE AND PROBABILITY OF FAILURE (
CORROSION LOOPS)
DATA MANAGEMENT
PROCESS
3. Criticality Analysis (by using RBI)

Creating new vessel

 DATA MANAGEMENT
PROCESS
CONT…
3. Criticality Analysis (by using RBI)
INSPECTION
RISK BASED

Criticality Analysis
 DATA MANAGEMENT
PROCESS
CONT…

4. Review of Results
a) Review and approval the results
b) To revise any deviation and to
re-enter parameter values for
INSPECTION
RISK BASED

final risk run.

 DATA MANAGEMENT
PROCESS
CONT…
5.
INSPECTION Preparation of Final RBI Report
RISK BASED

Sample results extracted from RBI database

RBMI RISK MATRIX

1 HIGH Consequence

Probability Ranking
A-Catastrophic
B-Very Serious
2 MED HIGH C-Serious
D-Significant
E-Minor
3 MEDIUM
Probability
1-Very High
2-High 4 LOW
3-Moderate
4-Low
5-Very Low 5

E D C B A
Consequence Ranking
PROBABILITY OF
FAILURE (POF)

Probability
of Failure

Internal External Environment Creep Other Damage

Corrosion Corrosion Cracking (for fired heaters) Mechanisms
CONSEQUENCE OF
FAILURE (COF)

Consequence
of Failure

Safety Economics Environment

Burst Loss of Leak Clean Leak

Flammability Toxic Reactive
Model production inventory up cost volume
 CONSEQUENCES OF FAILURE
Manning Fluid Type Toxicity
Temperature Levels Toxicity
and Pressure
Flammability

Safety Environment
Location
Failure
Mode

Size of
Flammability
Fluid Type Release
Temperature

Production
Commercial
Criticality Loss of
Production

Back up
systems?
EXAMPLE OF CRITICALITY
INSPECTION
PLANNING
Based on equipment type and risk rating
Create inspection for each damage mechanism
Provide : method, location, extent and frequency of the
inspection
Evaluate the condition monitoring
Recommend the reduce/deletion or the increase /change of
the inspections.

153
INSPECTION
PLANNING

154
INSPECTION
METHODS
The number of inspection methods has increased and are
being used in the process industry.
The most used method of inspections in the industry still
consist of a relatively few methods:
• Visual Inspections
• Ultrasonic Thickness Testing
• Radiography
• Magnetic Particle Testing
• Penetrant testing
• Ultrasonic angle beam testing
• Acoustic Emission Testing

155