Draft-Steam Separator Assesment Report

ASSESSMENT REPORT
STEAM SEPARATOR
60” ID. X 30’ T/T
By
xx
COMPANY
CONTRACTOR
Multifab GDE Document No. :

REV. DATE DESCRIPTION
BY CHK. APP ACK ACK ACK INSP-PV-GDP-001
0 Sept 6th,2019 ISSUE FOR BID

Revision No: 0
Contract No. :
---
ASSESSMENT REPORT DOC NO:
CONTRACT NO : STEAM SEPARATOR INSP-PV-GDE-001
60” ID. X 30’ T/T
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Table of Contents
1. Executive Summary.................................................................................................................................................... 3
2. References ................................................................................................................................................................... 3
3. Assessment Equipment / Tools ................................................................................................................................... 3
4. General ........................................................................................................................................................................ 3
5. Inspection Details........................................................................................................................................................ 4
5.1. External Visual Inspection .................................................................................................................................. 4
5.2. Internal Visual Inspection ................................................................................................................................... 5
6. Ultrasonic Thickness Inspection ................................................................................................................................. 7

6.1. Summary Information......................................................................................................................................... 7
6.2. UT Thickness Measurement Location ................................................................................................................ 7
6.3. UT Thickness Data ............................................................................................................................................. 8
APPENDIX 1 – AVAILABLE DESIGN DRAWING ...................................................................................................... 13

60” ID. X 30’ T/T
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1. Executive Summary
In Compliance with the invitation from PT. xx (Persero), We Attended their Geothermal Site at Dieng
th
(Pad 9) September 6 , 2019. An internal & external visual inspection and ultrasonic thickness
examination was performed on Steam Separator 60” ID x 30’ T/T. This vessel was out of service at
the time of inspection and was place at laydown area since 2010.
The Available documentation assessment was only Design Drawing of the Vessel with revision status
th
“FOR REVIEW & COMMENT” dated February 27 , 1997. There was no U1 or other documentation
available prior to performing the assessment.
Inspection team comprised of the following personnel :

- Hxx – Quality Control Manager
- xx – Proposal Engineer
- xx – Project Engineer
2. References
Ref # Reference Title

[1] ASME Section VIII Division 1
3. Assessment Equipment / Tools

Following equipments were used for assessment :
- Ultrasonic Thickness Meter
- Meter Tape
- Portable Gas Detector
- Digital Camera
- Personel Protection Equipment
4. General
The contents of this report are based on the data acquired during the visual inspection and ultrasonic
thickness inspection results. UT data was taken at specific locations to determine the remaining
thickness . The internal and external visual inspection results provide an account of the visual
condition and presence of any visual degradation.
There was no mechanical calculation available for review minimum required thickness (excluding
corrosion allowance) of each pressure part of the vessel.
There was not any historical inspection available for review that positively identifies the thickness of the
vessel on its last operation.
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5. Inspection Details
5.1. External Visual Inspection
N Item Condition Picture

o No
1. Name Plate Name plate was not, Only name plate bracket 01
2. Skirt Base Plate xxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxx
and Skirt Top xxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxx
Plate xxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxx
xxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxx
xxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxx
3. Skirt xxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxx
4. Shell xxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxx
5. Nozzles N1-18” SCH.40 :
xxxxxxxxxxxxxxxxxxxxx
N2-18” SCH.40 :
N3-10” SCH.80 :
N4A-2” SCH.160 :
N4B-2” SCH.160 :
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N5-3” SCH.160 :
N6-24” SCH.XS :
6. Head xxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxx
7. Lifting Lug xxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxx
8. Insulation xxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxx
9. Ladder & xxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxx
Platform xxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxx
10. Insulation xxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxx
11. Others Xxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxx
5.2. Internal Visual Inspection
No Item Condition Picture

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No
1. Shell xxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxx
2. Head xxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxx
3. Internal Ladder xxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxx
4. Welds xxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxx
5. Vortex Breaker xxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxx
6. Spiral Entry xxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxx
7. Purifier Piping xxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxx
8. Purifier Piping xxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxx
Supports & Clips xxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxx
9. Others xxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxx
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6. Ultrasonic Thickness Inspection
Details:
Straight beam ultrasonic thickness measurements were taken at various separate locations on the
shell plate material and the ellipsoidal heads. UT readings were taken utilizing a xxxx instrument with
a xxxx
xx” single element transducer, calibrated on xxxx” mild carbon steel step block. .
The thickness measurements shown below utilize the orientation of the vessel at the time of
inspection.
6.1.Summary Information
Probe xxxx
Calibration Comment xxxx
Assessor xxxx
Instrument Type xxxx
Instrument S/N xxxx
Units xxxx
Description tact.max. tact.min. t0 Remark

Shell
Top Head
Bottom Head
Skirt
Skirt Base Plate
Skirt Top Plate
Lifting Lug
6.2.UT Thickness Measurement Location

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6.3.UT Thickness Data

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Longitudinal (tact) Circumferencial (tact) tdwg tmin(RT3)

0˚ 45˚ 90˚ 135˚ 180˚ 225˚ 270˚ 315˚
Top Head A 21.11
B 23.8 24.9 23.8 23.8 21.11
C 24.4 24.5 24.6 24.2 21.11
D 21.11
Shell E 22.3 22.23
F 22.8 21.9 22.2 22.23
G 22.4 21.8 22.2 22.23
H 22.23
I 34.5 34.1 34.93
J 34.7 34.2 34.93
K 22.6 22.9 22.23
L 22.5 22.2 22.5 22.5 22.23
M 22.23
N 22.23
O 22.6 21.9 22.5 22.23
P 22.23
Q 21.8 21.6 21.9 22.23
R 21 21.6 20.9 20.7 21 22.23
S 21 21 22.23
Bottom Head T 21.11
U 21.11
V 24.8 21.11 Test from
inside,
caused
insulation
still attached
W 21.11
Skirt X 9.1 9.1 9.2 7.2 9.53
Y 9.53
Z 9.5 9.53
AA 9.3 9.3 6.6 9.5 9.53
Skirt Base Plate AB
Skirt Top Plate AC 33 33
Lifting Lug 38.4 37.6
Re-Pad N1 25.1
Re-Pad N2 25.1
Re-Pad N6 (MH) 26.2
Pipe N3 8.1
Elbow N3 9.6
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Nozzle thk. Data table in progress

LIFTING LUG thk. Data table in progress
7. Conclusion
The UT data shows a xx mm maximum deviation from the lowest to highest remaining thickness
obtained on the shell and xx mm deviation on the heads.
The corrosion observed and noted above does not appear to be service related, it is mild in nature
and a result of atmospheric corrosion and a period of time out of service without an inert purge.
Corrotion pitting
1. Overview of Pitting Corrosion
Contribute to Definition
Pitting Corrosion is a fairly localized form of corrosion which is characterized by small holes,
known as pits, forming in materials, most often metal piping. While these pits may be small on
the surface, they can be larger underneath, potentially being more damaging than they appear.
The materials that are most vulnerable to this type of corrosion include stainless steels, nickel
alloys, and aluminum alloys.
This type of corrosion can be particularly dangerous to facilities due to multiple factors. One of
the reasons is because the pits formed as a result of this mechanism are so small, they are
fairly difficult to detect. Even more than that, the pits can be hidden from view by
thin coatings or membranes. It can also cause damage to materials very rapidly, making it
particularly insidious.
Pitting corrosion tends to be caused by environmental factors. It can be caused by certain

corrosive materials such as chloride, hypochlorite, or bromide. Fluorides and iodides can also
be harmful. The development of pitting can be sped up by the presence of water or sulfides in
the environment. These chemicals cause anodic and cathodic reactions when in contact with
certain metals which results in localized galvanic corrosion.
Thankfully there are several ways in which pitting can be mitigated and prevented. The best
way to prevent pitting is construct your piping out of materials that are resistant to any pitting
causing chemicals in the environment it will be working in. In general, higher alloys tend to be
better at resisting pitting corrosion. If that isn’t possible, cathodic or anodic protection can
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also be used to prevent the chemical reactions that are occurring in the environment that cause
pitting from affecting the pipes. Controlling the pH, chloride concentration, and temperature of
the environment is another possible way to prevent pitting.
https://inspectioneering.com/tag/pitting
https://www.corrosionclinic.com/types_of_corrosion/pitting_corrosion.htm
8. Recommendations
Xxxxxxxxxxxxxxxxxxxxxxxxxxxxx
1. Terkait Point 1 MoM di site dan Email dari Pak Tashril dibawah, terlampir MoM dengan AI ASME.
- Secara teknis Separator tersebut masih bisa di repair. Namun beberapa hal perlu menjadi
perhatian Multifab terutama terkait warranty.
- Jika di kerjakan di site estimasi cost untuk AI adalah Rp. 123.000.000,-, dengan durasi 10 hari
terdiri dari :
a. 3 x trip (after 1st blasting, fit up & hydrotest) kesite dengan durasi @ 3 hari, sudah termasuk
durasi perjalanan dari dan ke site dan over time.
b. 1 hari review document/MDR di Workshop Cilegon
Biaya tersebut belum termasuk transportasi dan akomodasi selama trip ke site.
2. Adapun aktivitas repairnya kurang lebih sbb :

a. Blasting (1st) / Cleaning external & Internal
b. PMI karena tidak adanya bukti otentik (name plate sudah tidak ada) untuk memastikan drawing
yang ada benar benar document vessel yang akan di repair
c. UT Thickness Test dan Pitting Assesment untuk semua component terutama pressure part.
d. RT untuk semua Long & Circ. Seam/Joint
e. Dari Hasil UT, RT dan Pitting Assesment, ditentukan component yang harus di repair dan
methode repairnya
f. Melakukan repair berdasarkan hasil point d, untuk costing budgetary/tender bisa di asumsikan
:
- Repair Longseam 30 %
- Repair Circ.seam 100%
- Overlay dengan opsi :
 Overlay kurangan thickness dari gambar asumsi semua 100% luas permukaan over all
shell dan thk 1.5 mm. ini jika requirement HIC di pertimbangkan dan di analisa lebih
lanjut berdasarkan recomendasi AI ASME
 Overlay kurangan thickness dari minimum required thickness mechanical calculation

asumsi 30% luas permukaan over all shell dan thk 2 mm. ini Jika requirement factor HIC
di abaikan.
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- Pitting Repair 30 spot

- Repair demister (SS316L) by Welding
- Penggantian 2 Nozzle 2”, 1 Nozzle 3”, 1 Nozzle 10” (neck & flange)
- Penggantian Neck untuk 2 Nozzle 18” dan 1 MH 24”
- Repair Face Flange untuk 2 Nozzle 18”, 1 MH 24” dan 1 Blind Flange 24”
- Penggantian Hinge, Stud bolt Man Hole
- Penggantian vortex breaker
- Penggantian internal clip, support (CS) dan Internal Pipe, Tee, reducer, coupling (SS 316 L)
- Overlay or replace internal spiral entry component
- Repair insulation clip di shell
- penggantian insulation bolt clip (welded to head)
- menambahkan reinforcement plat pada area skirt yang thiknessnya kurang dari thk pada
drawing.
- menambahkan reinforcement plate pada skirt base plate, gusset, top plate yang thknessnya
kurang dari min. required thk.
- menambahkan reinforcement plate pada lifiting lug (butuh diskusi lebih lanjut)
- menambahkan reinforcement plate pada re-pad nozzles
- menambah re-pad pada nozzle 2” dan 3” (diameter 180)
g. NDE setelah repair
h. Hydrotest
i. Blasting (2nd) & Painting
j. Pemasangan Insulasi
9. Assessment Pictures
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APPENDIX 1 – AVAILABLE DESIGN DRAWING

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ASSESSMENT REPORT

Multifab GDE Document No. :

0 Sept 6th,2019 ISSUE FOR BID

5.2. Internal Visual Inspection ................................................................................................................................... 5

6. Ultrasonic Thickness Inspection ................................................................................................................................. 7

6.2. UT Thickness Measurement Location ................................................................................................................ 7

6.3. UT Thickness Data ............................................................................................................................................. 8

APPENDIX 1 – AVAILABLE DESIGN DRAWING ...................................................................................................... 13

Inspection team comprised of the following personnel :

Ref # Reference Title

3. Assessment Equipment / Tools

5.1. External Visual Inspection

N Item Condition Picture

5.2. Internal Visual Inspection

No Item Condition Picture

6. Ultrasonic Thickness Inspection

Description tact.max. tact.min. t0 Remark

6.2.UT Thickness Measurement Location

6.3.UT Thickness Data

Longitudinal (tact) Circumferencial (tact) tdwg tmin(RT3)

Nozzle thk. Data table in progress

Pitting corrosion tends to be caused by environmental factors. It can be caused by certain

2. Adapun aktivitas repairnya kurang lebih sbb :

 Overlay kurangan thickness dari minimum required thickness mechanical calculation

- Pitting Repair 30 spot

APPENDIX 1 – AVAILABLE DESIGN DRAWING

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