ADVANCE ENGINEERED INTEGRATED RISK ASSESSMENT

USING
PHONON DIAGNOSTIC TECHNOLOGY (PDT)
FOR
ASSET INTEGRITY MANAGAMENT
MRA INTERNATIONAL SDN.BHD

HOW PHONON DIAGNOSTICS TECHNOLOGY CAN BENEFIT

CLIENTS IN THEIR MAINTENANCE AND REPAIR PROGRAM?

WITHIN A SHORT DURATION, PDT IS ABLE TO GENERATE

VALUABLE DATA TO MAKE KEY INVESTMENT DECISION,
REFINEMENT OF MAINTENANCE AND REPAIR WORKS
AND OPTIMIZING SHUTDOWN WINDOW.

Conceptual Design
Disposal/
Abandonment

Detailed Engineering

Decommissioning
Procurement

Maintenance
&
Reliability
Construction/
Installation
Operations

AIMS AND LIFE

CYCLE COST :

Operatorship
Handover

Commissioning/
Start-up

THE FUNDAMENTALS

PHONON
ENERGY
DIAGNOSTIC
TECHNOLOGY:

CORROSION
TYPE
OF
DEFECTS:

MECHANICAL
METALLURGICAL
CRACKS

TECHNOLOGY MAIN FUNCTIONS :

To identify location of defect

To identify number of defect

To identify type of defect

To identify severity of defect

To identify sizing of defect
Depth

Width

Length

Maximum 2kms length end to end inspection per run for piping/pipeline/tubulars.

Maximum 200 meters one end inspection per run for piping/pipelines/tubulars.

Not able to detect features, i.e. flanges, bends, fittings, girth welds, valves, etc.

LIMITATIONS :

Not able to detect dormant/ inactive defects/ anomalies; i.e. ovality, repaired
defects etc.
Transducer require direct contact with parent metal. Portion of insulation/coating
needs to be removed to install the transducer.
The accuracy (allowable tolerance) of defect location and dimension of defect
depends on the accessibility of the object and accuracy of the as built drawings.

PHONON DIAGNOSTIC SETUP FOR PIPELINES/TUBULARS

PHONON DIAGNOSTIC SETUP FOR RISERS AND OFFSHORE

STRUCTURAL TUBULARS (ACCESS AT 1 END)

Phonon Diagnostic Scheme for plane assets, e.g.

Conductors, Piles, Jacket Legs, risers

PHONON DIAGNOSTIC SETUP FOR TANKS

Phonon Diagnostic Scheme for plane assets, e.g. bottom

plate and roof

Description

Dimension
Accuracy

Circumferential positioning accuracy

To the nearest 4 azimuth hours (3, 6, 9, 12 oclock)

Size of defect

80% +/- 25 mm from defect center point

Depth of defect

80% +/- 0.1 t (t = pipe wall thickness)

Location

80% +/- 200 mm to reference point

Probability of Identification (POI)*

90%

(*Active Defects)

ALLOWABLE
TOLERANCE :

Object inspected under normal operating conditions.

Accessible to install transducers at required points.

PDT provides upfront, comprehensive and current inspection

based data for better decision making and cost savings
TECHNOLOGY

ENGINEERING

Online Inspection, Zero Shutdown

Accurate and real time data

acquisition

No modification and minimal

preparatory work

Detail asset integrity study on

active defects

Workable over wide temperature

and pressure range. Independent
of environmental conditions

Reduce downtime, volume and

labor intensity in asset repair and
maintenance

Addresses shortcomings of
existing technology

Prolong service intervals

Phonon Diagnostic Technology as Decision Making Tool

Critical Decision Area

Phonon Diagnostic
Technology
Result & Assessment

YES
Shutdown
With Shutdown

NO

Repair &
Maintenance

Repair Without
Shutdown

Cleaning
Inspection

External Repair

Repair

END

NO

KEY ELEMENTS
ZERO SHUTDOWN

QUANTITATIVE
ASSESSMENT

FFS IN A SINGLE RUN.

UPFRONT RESULTS
FOR DECISION MAKING

MINIMIZE WORK
ACTIVITIES THUS
REDUCING HSE RISKS

COMPREHENSIVE COVERAGE

TABLE OF CONTENTS
Pre Diagnostic Works
The objectives of Phonon team mobilization to the site work:
Equipment for the surface preparation:
Post Diagnostic: Result of Phonon Monitoring
Post Diagnostic: Processing and Analyzing the Result of Phonon
Diagnostics and Monitoring

Required data for the available documents and

Pre
Diagnostic
Works
drawings related to the asset prior to the diagnostic works.
Year of construction and commissioning

Working product (content, composition, gravity, specific gravity, corrosivity,

etc.)
Asset service data for last 5 years (temperature, stress, rate of flow, cycle of
loading and unloading, operating parameter, purpose, etc.)

Previous inspection report

Data on emergencies, repairs and breakdowns

The Objectives Of Phonon Team Mobilization To The

Site Work:
To verify the data obtained by client
To identify physical condition of the asset
To visual inspection of the asset insulation/coating.
To identify location to install transducer
Auxiliary testing : Local UT Test, local UT Scanning Test, Stress Test, Hardness Test
For surface preparation

Equipment
VISUAL INSPECTION

SURFACE PREPARATION

Measuring tape (Manual and Laser Type)

Manual thickness gauges (Pit Gauge)
Magnetic holder
Metal ruler
Paint marker
Digital Camera
Cotton rags

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

The Following Equipment For Pre Phonon Diagnostic:

Pipeline Tracing
Pipeline current mapping system
PCM-Tx Set

Cable Avoidance Tools C.A.T4TM

and GennyTM Range

Stress Diagnostics
Stressvision-2

The Following Equipment For Pre Phonon Diagnostic (2):

Mechanical property Diagnostics
Dono hardness tester

Soil resistivity testing kit F4103-M1

UT Diagnostics
Ultrasonic Thickness gauge
Olympus 38 DL Plus

The Following Equipment For Phonon Inspection:

Jack for connection to cable

Labeling of transducer

Magnet
Transducer

Gasket

Magnetic holder

Working surface

Phonon system
Phonon transducer set
Jack No.1
Spool

Jack No.2
Cable RJ-58

Phonon acoustic cable set

Phonon Diagnostic Scheme

Phonon diagnostics (PD) of the asset shall be carried out according to the scheme
prepared during the pre-diagnostic activity, including allocation of phonon diagnostics
stations (PDS), determination of locations for installation of phonon emission
transducers (PET) and procedure for executing diagnostics operations.

The diagnostic shall be divided into sections. Points of PD installation are placed at
strategic location to cover the entire surface of the asset.

PD shall be operated in pairs or quadrants to cover a certain asset sector. For cylindrical
assets, 4 linear phonon scheme lines are formed, which cover all the length and all the
surface of the sections and provide linear and azimuthal localization of any place on the
asset. For single plane surfaces, a planar scheme is developed to cover the complete
section of the asset.

Phonon Diagnostic Scheme for Cylindrical assets

(linear scheme)

Phonon Diagnostic Scheme - Linear Scheme

Phonon Diagnostic Scheme for Cylindrical assets

(planar scheme)

Phonon Diagnostic Scheme - Planar Scheme

The developed scheme shall be implemented using:

4 or 8 phonon sensors,
4 or 8 cable routes,
one system for phonon diagnostics PHONON-8.
Phonon sensors were connected by cable routes with phonon systems, which were
located at phonon diagnostics stations.
Phonon diagnostics preparation, calibration for each section of tested assets is carried out.

Scaled phonon drawing and phonon development on the basis of phonon calibrations are
developed.
Phonon system shall perform the phonon energy monitoring in real time and all the data
shall be stored in the system.
Sufficient phonon energy monitoring shall be allowed to take place with duration of
up to 2-3 hours per section.

Post Diagnostic: Result of Phonon Monitoring

The phonon diagnostic monitoring detected in real time shall programmatically superimpose
the phonon energy emission Phonon-Active Areas (PhAA), onto the phonon calibration
drawings.
The areas of defect formation and the location of the defects are generated.

Then the results of phonon monitoring were combined on scaled phonon

drawings.

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

asset.

Some PhAA are combined and additional analysis of phonon energy distribution in PhAA is carried out.
Additional qualifying identification of PhAA and final numbering of detected defects is carried out.

Sample Defect List Report

No.

Defects distance to
ref weld, m

Defect
designation

Distance
from
section
start, m

Ref.
Weld

DF-2

7.235

DF-7

DF-10

Defect dimensions,
mm

Orientation

Distance
Length
from
Width,
Depth
hh:mm
,
12 o'clock,
W
L
mm

Distribution
of phonon energy

Activit
y
coefficient

Defect type

Level of
defect
hazard

Internal/
External

U/S

D/S

Rotations
direction

WJ 6

0.225

lockwise

344

6:00

154

63

5.0

12.15

Local metal
loss

significant

external

21.873

WJ 6

14.863

lockwise

207

3:36

281

156

4.4

11.13

Local metal
loss

significant

external

33.409

WJ 6

26.399

Counter
Clockwise

38

11:21

416

234

10.42

Local metal
loss

significant

external

Post Diagnostic: Processing and Analyzing the Result of

Phonon Diagnostics and Monitoring
Analysis of phonon diagnostics results shall be carried out for each PhAA.

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

Running physical processes are identified.

Geometric characteristics are evaluated.

THANK YOU

MRA International Sdn Bhd (1035028-D)

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