INDUSTRIAL TRAINING REPORT

CHAPTER 1

PROFILE COMPANY

1.0

Background of BIH Heater Malaysia Sdn. Bhd. (BIH)

BIH was established in May 1997 and has significant international experience in the

management team, supported by a highly qualified international team of engineers,

technicians and project managers to ensure that our expertise is growing and diversified.
Many of the BIH team are multi cultural and multi lingual.
BIH is a leading player in the Energy Group of the Boustead Singapore Group of
companies. The support from Boustead Singapore enables BIH to have strong financial
backing while enabling us to retain our independence from contractors. Boustead Singapore
is the oldest engineering company in South East Asia having celebrated its 180th year
anniversary in 2008.
BIH are specialists in all aspects of fired heaters and waste heat recovery units
(WHRUs) serving the global market place in the oil, gas, petrochemical & energy
industries. Design, supply and construction of process furnaces and WHRU's designed to API
560 or other international standards form the core of our dedicated business to the
hydrocarbons market.
BIH also carry out design studies, revamp work and supply engineering personnel to
existing and new refineries and petrochemical plants worldwide. From the regional operation
centres in Europe, Asia and the Americas we supply equipment and expertise to
internationally recognised clients for most refining applications including crude, vacuum,
reboilers, feed, hydrocrackers, hydrotreaters, cokers, charge heaters, etc. for applications as
diverse as refineries, GTL, LNG, FPSOs, methanol/hydrogen plants among others.

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In order to service BIH clients in the global economy BIH have operating centers in
UK, Saudi Arabia, Canada & Malaysia. BIH also have regional offices throughout South
America. This enables the BIH team to understand the local cultures and requirements and
provide a ready service.
Utilizing this global approach we have unlimited capacity to assess each clients
requirement. We can then work to ensure that we plan our projects to work with suitable
global companies for the supply and fabrication of the equipment.
BIH are a total quality company with our quality department being pro-actively
involved with all aspects of our operation from design, through project management,
procurement and fabrication. We are fully accredited to BS EN ISO 9001, TS 29001, EN
1090 and PED 97/23/EC.
BIHs quality system is based on an international structure, organization and
procedures to ensure high levels of safety, control, reliability and efficiency of all areas of our
global operation. Quality is the cornerstone of all of our activities. The uncontrolled BIH
Quality Manual is available for review by prospective clients on request.
Following on from our global experience we have supplied heaters to countries where
compliance with national regulatory bodies is required. BIH have successfully provided the
correct documentation and received the approvals. This has applied to Europe, Algeria,
Canada, Russia, South America, Middle East, China etc.
BIH are committed to designing, planning and running projects with Health, Safety
and the Environment as a priority. BIH have established and implemented HSE Management
Systems to manage the risks associated with our premises and activities.
Above all BIH ensures compliance with all relevant HS&E legislation and regulation
together with customer requirements / specifications.

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1.1 Organizational Structure

BIH HEATERS MALAYSIA SDN.BHD.
ORGANISATION CHART

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1.2

BIH Heaters Mission Statements

BIH is a global supplier of direct fired process heaters (including high temperature

specialist furnaces), reformers, crackers, heat recovery steam generators (HRSG) and waste
heat recovery units (WHRU). Our aim is to be world market leader in our chosen field,
recognised by our clients for engineering excellence, quality, timely delivery, cost effective
solutions, the development of all staff to their full potential and for operating in an
environmentally conscious manner with health and safety as the highest priority.
1.3

BIH Heaters Quality Objectives

a. QUALITY Maintain the highest levels of quality on all aspects of contract

execution and to exceed customer expectations.

b. COST be mindful of cost position through duration and act diligently to deliver
projects within acceptable limits with full progress visibility to customer.
c. DELIVERY Deliver projects against agreed milestones through effective planning
and control mechanisms. Manage structured reviews with vendors and clients to close out
issues with minimal impact on schedule.
1.4

BIH Heaters Product and Services

BIH main products are design, supply and construction (EPC) of various types of

fired heaters and waste heat recovery units (WHRUs) serving for the oil, gas, petrochemical
& energy industries.
Beside the above product BIH also provide service to the customer where covered as
below:a) Process design simulations

b) Evaluations of existing equipment including using process design models for new
applications on existing equipment and making recommendations for changes to meet
these new requirements.
c) Budget pricing to establish the viability and preparation of overall estimates for
plants worldwide.
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d) Project Management Utilizing BIH in house systems to ensure that the logistics
management of projects is undertaken on time and on budget.
e) Revamp, optimization work BIH offer cost effective innovative solutions to
increase the capacity, and / or efficiency of an existing unit perhaps with the addition
of a preheat system, installation of low NoX burners or a new convection section or
SCR system.
f) Spare parts BIH have a complete record of heaters we have built and can supply
any spare parts requirements that you may have. We have a proven record of assisting
Clients across the world and even if the existing equipment was not supplied by BIH,
we can use our extensive knowledge and expertise to source your spare part
requirements.
g) Site Services Provision of experienced personnel to supervise the installation and
commissioning of new / revamped equipment.
h) Training Provision of specifically tailored classroom training courses for client
specific heaters and WHRUs.

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CHAPTER 2

WORK EXPERIENCE AND ACHIEVEMENTS

2.0

Chronology Services in BIH Heaters Malaysia Sdn. Bhd.

Chronologies of my services are as follows:
(i)

01st December 2012 jointed BIH Heaters as a position as QA/QC Engineer in

Quality department.

2.1

Achievement and success

The following is a list of projects Ive been involved:

Owner
Client
Project
Description

INPEX Operation Australia PTY. Ltd.

JKC Australia LNG PTY. Ltd.
Ichthys Onshore LNG Facilities Australia LNG (Dec.12 Nov.14)
EPC 4 of Waste Heat Recovery Units (WHRU) with ancillaries
equipments (Damper & Instrumentation)

Owner
Client
Project
Description

Canadian Natural Resources Limited (CNRL)

Snamprogetti Canada
Hydrotreaters Phase 2B, Fort McMurray Alberta, Canada (Dec.12EPC 1 Recycle Gas Heater & 1 HP Steam Drum with ancillaries
equipments (Burner, Fuel Skid, BMS & Instrumentation)

Owner
Client
Project
Description

INPEX Browse Limited.

GE Oil & Gas (Nuovo Pignone)
Ichthys Gas Field Development (FPSO) Australia (Dec 2012-Present)
EPC 3 of Waste Heat Recovery Units (WHRU). with ancillaries
equipments (Damper/Silencer/Instrumentation)

Owner
Client
Project
Description

Petronas Carigali Sdn. Bhd. (PCSB)

Technip/DSME
Petronas FLNG Malaysia(Dec 2012-Nov 2013)
EPC 2 of Waste Heat Recovery Units (WHRU). with ancillaries
equipments (Damper/Silencer/Instrumentation)

Owner
Client
Project
Description

Oil & Gas Development Company Ltd.(OGDCL)

SIEMENS Industrial Turbomachinery Ltd.
DAKHNI Expansion Project Pakistan (Dec 2012-Oct 2013)
EPC 1 of Waste Heat Recovery Units (WHRU). with ancillaries
equipments (Duct Burner/Damper/Fuel Skid/Fan/Instrumentation)
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Owner
Client
Project
Description

Oil & Gas Development Company Ltd.(OGDCL)

SIEMENS Industrial Turbomachinery Ltd.
UCH-II Development Project Pakistan (Dec 2012-Oct 2013)
EPC 1 of Waste Heat Recovery Units (WHRU). with ancillaries
equipments (Duct Burner/Damper/Fuel Skid/Fan/Instrumentation)

Owner
Client
Project
Description

Dow Chemical Company

Fluor Enterprise Inc.
USGC PDH-1 Propane De-Hydro generation USA (Dec 2012-Present)
EPC 4 of Fired Heaters with ancillaries equipments
(Damper/Fan/Burner/Ammonia Injection Grid/Instrumentation)

Owner
Client
Project
Description

YAMAL LNG
GE Oil & Gas/YAMGAZ
YAMAL LNG Project, Russia (Dec 2012-Present)
EPC 6 of Waste Heat Recovery Units (WHRU) with ancillaries
equipments (Silencer/Instrumentation)

Owner
Client
Project
Description

Pertamina EP/ SKK Migas

Rekayasa Industries (REKIND)
Proyek Pengembangan Gas Matindok, Indonesia (Dec 2012-Present)
EPC 2 of Hot Oil Heaters with ancillaries equipments (Damper/Fuel
Skid/Burner/Instrumentation)

Owner
Client
Project
Description

Petroleos de Venezuela, S.A. (PDVSA)

Industrias Metalurgicas Van Dam (IMVD)
RPLC Deep Conversion, Venezuela (Dec 2012-Present)
EPC 1 of Fired Heaters with ancillaries equipments (Damper
/Burner/Instrumentation)

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CHAPTER 3

DUTIES AND RESPONSIBILITIES

3.0

Duties of QA/QC Engineer

The role and duties of QA/QC engineer, Quality Department is as the followings:

Direct reporting to Sr. QA/QC Engineer pertained all quality matters and ensuring
each project meet statutory, contractual and specification or code and standard apply
on that project.

Preparation Project Quality Plan (PQP) and final dossier index accordance to
ITB/contract, project specification and agreement for client approval.

Review sub-vendor QA/QC procedure for each project inclusive Inspection Test Plan,
NDE procedure,WPS/PQR, WPQ and etc. as per ITB/contract, project specification,
codes and standard.

Perform, prepare an assesmnet audit to all sub-vendor and follow up any outstanding
issue raise during audit.

Perform surviellance inspection to sub-vendors to ensure effective implementation of

relevant QA/QC procedure during project execution and comply to ITB/contract,
project specification, approved construction drawings code and standards and issue
inspection report for each visit done.

Review inspection report done by inspector to ensure the inspection was done based
on purchase order and compliance to project/contract requirements.

Review all sub vendor test certificate prior make any release to ensure compliance to
project/contract requirements and issue recommendations to inspection coordinator
for release.

Prepare pre-inspection meeting and agenda prior meeting take place for all major
fabrication to highlight applicable project requirements prior fabrication begin.

Issuance/reviewing Non-Conformance Reports (NCR) Corrective Action Reports

(CAR) upon having identified a process or procedural breach against the
ITB/contract, construction drawing, project specification, code and standard.

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3.1

Perform internal audit following audit schedule to ensure effectiveness of the quality
managements system and issue audit report to Quality Manager for review and
approval.

To monitor, review the arrangement and compilation of all sub vendor MDR and
compile as a final dossier before hand over to project engineer for client approval.

Review procedure commented by client and provide clarification if any required to

ensure its satisfied by all party involve.

Prepare discrepency log for each project involved and submitted to Quality Manager
for review and approval and also as a lesson learnt and continous improvements.

Quality Management System

Quality Management System (QMS) is a set of co-ordinated activities to direct and

control an organisation in order to continually improve the effectiveness and efficiency of its
performance.

These activities interact and are affected by being in the system, so the isolation and
study of each one in detail will not necessarily lead to an understanding of the system as a
whole. The main thrust of a QMS is in defining the processes, which will result in the
production of quality products and services, rather than in detecting defective products or
services after they have been produced.

The organization shall establish, document, implement and maintain a quality

management system and continually improve its effectiveness in accordance with the
requirements set within the international standard.

BIH Quality Management System for the Design and Project Management of the
equipment supplied by BIH is operated in accordance with all the elements of BS EN ISO
9001, TS 29001 and, in addition, has documented procedures for the Pressure Equipment
Directive (PED) 97/23/EC required under Modules H/H1, Construction Products Regulations
(CPR) CPR 305/2011/EU (EN1090) and applicable legislative requirements.

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The quality management system documentation shall include:a) Documented statements of a quality policy and quality objectives,
b) A quality manual,
c) Documented procedures and records required by international standard of
organization (ISO)
d) Documents, including records, determined by the organization to be necessary to
ensure the effective planning, operation and control of its processes.

a) Quality Policy & Quality Objective

Quality policy is document jointly developed by management and quality experts to
express the quality objectives of the organization, the acceptable level of quality and the
duties of specific departments to ensure quality meeting company expectations.
The purpose of quality objectives is to determine conformity to (customer and
regulatory) requirements, and facilitate the effective deployment and improvement of the
quality management system (QMS).
Quality policy and objectives must be consistent with the scope of QMS and must
complement business objectives of organization such as those related to growth, finance,
profitability, the environment and occupational health and safety.
Quality policy must be appropriate to the purpose of the organization, a commitment
to comply with requirements and continually improve the effectiveness of the quality
management system, specified time framework for establishing and reviewing quality
objectives, communicated and understood within the organization, reviewed for continuing
suitability.
In order to achieve these objectives, the BIH operates a documented Quality
Assurance system, based on BS EN ISO 9001 and DO CEN ISO/TS29001 placing emphasis
on expert product design, Project Engineering, safety and continuous improvement. To
ensure that products and services comply with the needs and expectations of its customers,
BIH:
Uses quality plans, fabrication procedures and material specifications to identify the
requirements. BIH will then plan fabrication and manufacture, to ensure client
delivery of milestones are achieved.

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Uses inspection of product and certification to monitor compliance. Data dossiers

will provide documented evidence of compliance.
Ensures products meet all applicable client specifications and statutory regulation
requirements.
Ensures that products supplied to the European Economic Area shall be designed,
manufactured, final inspected and tested fully in accordance with the Pressure
Equipment Directive (PED) 97/23/EC, Construction Products Regulations (CPR)
CPR 305/2011/EU and all other applicable European Directives.

b) Quality Manual
Quality Manual defines the Company's Management policies with regard to the
application of Quality Assurance systems in all areas of activity which have influence on the
quality of the product. The objectives are to:
Provide products with fitness for purpose at acceptable cost, in accordance with the
Contract Specifications
Identify and meet the needs and expectations of its customers and other interested
parties
Achieve, maintain and improve overall organisational performance and capability.
The functions of BIH Quality Manual are to:
a) Define the management policies with respect to Quality Assurance, and to enable
identification of the series of procedures, which specify the controls for the various
elements of the QA system.
b) Ensure uniformity of understanding and performance.
c) Provide a training document and to ensure continuity of the systems, when
personnel change.
d) Act as a reference base, against which the practices and procedures can be audited
both internally and externally and corrective action taken when non-conformance is
found.

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c) Documented Procedure and Records

Documented procedure or quality procedure is the written documents that require for
each department within the organization as assurance ensure the effective planning, operation
and control of its processes required by ISO which is a mandatory procedure to be developed.
The procedure is to provide a guideline to the user or employee and or employer on
how the specific task to be carried out in general up to completion of the specific stages with
supplementary by additional documented procedure or work instruction.
Any records required by documented procedure to provide evidence of conformity to
requirements and of the effective operation of the quality management system shall be
controlled.

d) Supplementary Documented Procedure (Work Instruction)

Work Instruction is the fourth level of documented procedure which is act as
supplemental to mandatory required procedure. Typically work instruction specified more
detail on how each process being done from beginning up to finishing.

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3.2

Project Quality Plan (PQP)

PQP is a tool to ensure the end product and or services provided is meeting company

quality objective as well as customer expectations and needs. Contains of the PQP is
generally describing the activities, applicable procedure to be referred, acceptance of the
activities, record as verifying evidence and also responsible person for each activities.
Development of PQP is under QA/QC Engineer in conjunction with Quality Manager
in order to ensure all customer requirements are fully transfer and adhere to.
BIH PQP are divided by seven part covered for in house activities, pressure part
material, instrumentation and controls, non-pressure part components, refractory materials,
ancillaries equipment as well as minimum inspection and test required for the package
purchased items.
3.2.1

In-House Activities-part A

As in Tepat Teknik system, all the project being awarded to Tepat Teknik Sdn
will be given the contract number for company record and ease filing
being made as to follow the order of the project being

Bhd

and the numbering

awarded. There are two type of

contract number being used in Tepat Teknik. One is the number with CT and another one is
the number with CTK.

The different between both is CT where the jobs being awarded

direct to Tepat Teknik Sdn Bhd Shah Alam office while the job with contract number CTK is
the job that being awarded through Tepat Teknik (Kejuruteraan) Sdn Bhd located in
Kemaman, Terengganu.

3.2.2

Project Phase

Before the project being awarded to Tepat Teknik, a few phase need to be through
first. This is a phase where every project awarded to the company going to through:
1)

Bidding

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This is the first stage of the job before it being awarded.

Estimation Department and Marketing Department joined the invitation to bid

by client.

The job is being estimated, designed, planned, and sent for bid.

Client carried out the Letter of Award once the project being awarded.

2)

Project Hand Over

-

After all the contract, estimation and documentation done and ready to be
execute, the project being hand over to Project Department to start the
execution.

Project Department will have an internal meeting that being attended Project
Manager, Project Engineer, QA/QC and Design Engineer.

Project Engineer will be the responsible person to execute the job and being
monitored by the Project Manager.

3)

Planning & Preparing

-

Project Engineer starts planning the next step to be taken by preparing the
project schedule. The schedule will be mentioned the job to be done followed
the sequence:

3.3

(i)

Engineering/Procurement.

(ii)

Fabrication & QA/QC.

Project Engineer preparing the budget by compared with Estimation Budget.

Engineering/Procurement
In one project, engineering is the most important part. Before a product going to

bidding or being produced, engineering will take the first part. The fabricator will prepare a
drawing together with the strength calculation based on suitable code and standard of

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fabricating such as ASME CODE, SHELL DEP, ANSI, ASTM, and etcetera to be use for
manufacturing. This will be done if the customer did not provide their drawing.

3.3.1

Drawing

The details of the items such as item designs, size, material specification, welding
process, orientation of the vessel, showed in the drawing.
3.3.2

Strength Calculation

Strength calculation purpose is to determine whether the product that being fabricate
can run smoothly during operation without any defect. It applies certain engineering
standards like ASME, API and sometime structural analysis.
With the strength calculation, all the information and calculation of stress, tensile,
allowable temperature, internal and external pressure of the vessel, materials

specification,

process to be done, can be obtained.

3.3.3

D.O.S.H. Approval

All fabricated pressure vessel for local purpose required a certificate from Deputy
Safety and Health (DOSH) as to ensure that the pressure vessel is fit to be operated in this
country for the purpose of safety.
The strength calculation and drawing being submitted to DOSH as to get the approval
to fabricate the items. This will be done once the engineering section has done their job to
design the item according to the standard.
After the items completed fabrication, there will be held a hydrostatic test to helps
maintain safety standards and durability of a vessel over time.

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3.3.4

Procurement

Once Project Department received the drawing from Design, the Material Take Off
(MTO) will be executed. Project Engineer will reviewed and analyzed the drawing to take
out all materials required followed the requirement and specification. The drawing sometime
did not show the actual size of the material, especially size of a sheet of plate for the shell
course and formed dish head. Hence, to purchase the plate, it needs to have the length and
width. The material to be purchase shall be utilize the used material to avoid wastage
material.
After the Material take Off (MTO) finished, Material Requisition or in the short name
called MR, being raised to Procurement Department to source and purchase the materials. If
the materials are hard to be find or got any balanced materials from other project, buyer will
come back with Approval Requisition (AR) form to offer other material identical with the
required and to confirmed if the price could be appropriate price.
Once the buyer (Procurement Department) purchased the material, a copy of Purchase
Order (P.O) will be give to Project Engineer as a record for project filing. This going to be
needed to be the reference if there will happen something unexpected such as wrong material
received, or late delivery of the material.

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CHAPTER 4

PROCESS MANUFACTURING

4.0

Fabrication
Once the materials received, the fabrication job could be start. Usually, plates and

forging materials should be comes first because plate need to be roll to be the shell course
and forging material such as flange need to be pre-fabricate before being fit-up to the shell.
4.1

Activity
The fabrication activities include:
1. Mark & cut

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All the received plates being marked followed the size as shown in the
drawing. QC Inspector then did the dimension check after marking. Once the
marking activity had done, the plate being cut into the size.

Fig. 4.1.1 Plate marking

Fig. 4.1.2 Plate cutting

The plates meant to be the shell course being rolled to the I.D required after
cut.

Fig. 4.1.3 Plate rolling

As for the dish head, after being marked and cut, the plates being delivered to
Soon Lien Fatt, to performed dish head forming.

Fig. 4.1.4 Formed dish heads

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2. Pre-fabrication.
All nozzles and leg support being pre-fab before being attached to the shell.
Pre-fab means, for the nozzle, the flange and nozzle neck (rolled plate or pipe)
being fit-up and weld.

Fig. 4.1.5 Pre-fab

Nozzle opening being done on the shell and formed head.

Fig. 4.1.6 Nozzle opening

3. Fit-up & welding.

After all the marking, cutting, rolling, edge preparation and nozzle prefabrication finished, the vessel being fit-up and weld.
First, fit-up and weld top shell and lower shell
Then, fit-up and weld the nozzle plate and vortex breaker inside the vessel (as
required in the drawing).
Next, fit-up and weld top head and lower head with shell
Then, fit-up and weld nozzles on the dish head and shell.
Next, fit-up and welding 2 unit of sight glass on the shell course.
Finally, support leg being attached and weld on lower head since the vessels
were vertical vessel.
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Fig. 4.1.7 Fit-up & welding lower head

Fig. 4.1.9 Nozzle Pad fit-up

Fig. 4.1.8 Nozzle fit-up on upper head

Fig. 4.1.10 Sight glass attachment

There were five types of welding process that have been used in this project include:
1. GTAW
Gas tungsten arc welding (GTAW), also known as tungsten inert gas
(TIG) welding, is an arc welding process that uses a nonconsumable tungsten
electrode to produce the weld. The weld area is protected from atmospheric
contamination by a shielding gas (usually an inert gas such as argon), and a
filler metal is normally used, though some welds, known as autogenous welds,
do not require it. A constant-current welding power supply produces energy
which is conducted across the arc through a column of highly ionized gas and
metal vapors known as plasma.
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GTAW (WPS No. TT-A-O-N-1) has been applied to all the nozzles with size
less than DN 50.

2. SMAW

Shielded metal arc welding (SMAW), also known as manual metal arc
(MMA) welding or informally as stick welding, is a manual arc welding
process that uses a consumable electrode coated in flux to lay the weld. An
electric current, in the form of either alternating current or direct current from
a welding power supply, is used to form an electric arc between the electrode
and the metals to be joined. As the weld is laid, the flux coating of the
electrode disintegrates, giving off vapors that serve as a shielding gas and
providing a layer of slag, both of which protect the weld area from
atmospheric contamination.
SMAW (WPS No. TT-A-O-N-2) has been applied on all attachment to
pressure parts, longitudinal weld (LW) and circumferences weld (CW).

3. FCAW
Process that joint two or more material using flux cored wire consists of metal
sheath containing a granular flux
FCAW (WPS No. TT-A-O-N-8A) has been applied on all non-pressure part of
the vessels.

4. GTAW/SMAW
GTAW/SMAW is a combined process between GTAW and SMAW process
that made GTAW as a root, thickness of weld more or less of 6mm and
SMAW became the caping.

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This combination happened when the gap between welding edge that required
SMAW process is small. SMAW using a rod as the arc which having a big
diameter while GTAW using a wire to perform as the arc which the diameter
smaller than a rod.
This process (WPS No. TT-A-O-N-4B) being applied on all nozzles with size
greater than DN 50.

5. SAW

Submerged Arc Welding (SAW) is a common arc welding process. It

requires a continuously fed consumable solid or tubular (flux cored) electrode.
The molten weld and the arc zone are protected from atmospheric
contamination by being submerged under a blanket of granular fusible flux.
When molten, the flux becomes conductive, and provides a current path
between the electrode and the work.
SAW (WPS No. TT-A-O-N-3A) has been applied to longitudinal weld (LW)
and circumferences weld (CW) and welding on nozzle plate.

The welding location and process used in the project showed in a weld map as
a guide to welder to perform the welding.

4.2

Blasting & Painting

Blasting & painting being applied according to the Client Specification and

Applicable Code and Standard and the process being made after all the

fabrication

activities including rubber lining and hydrostatic test have been done.

Blasting to be applied once the surface has been cleaned before proceed with
the painting to clear all the contamination.

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Paint materials being prepared and applied according to the paint

Manufacturers recommendations after the surface being cleaned with oxygen
free compressed air once the grift blasting being applied.

4.3

Packing & Delivery

Once the 2 units of vessels finished blasting and painting, the items ready to be

deliver to site.
Packing
Before the items being delivered, they need to be pack as to maintain the
appearance and to avoid unexpected thing happened on their way to the site.

Fig. 4.3.1 Bare packing, saddle type

Delivery
The items being delivered after the packing job finished. All the delivered
items being mentioned in the packing list and ship invoice that will be send
together with the items.

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4.4

QA/QC
In QA/QC section, the welding, hydrostatic test, non-destructive examination (NDE)

and all the procedures and documentation are under QA controlled as to assure everything
being prepared according to appropriate standard and code. Whereas QC is to ensure that the
quality being achieved by carrying out the inspection on the appropriate matter such as the
inspection on NDE, material inspection, etc according to the standard and specification.

1.4.1

NON-DESTRUCTIVE TESTING

NDE or Non Destructive Examination is used to assess the quality of a

component

without destroying it.

There are many methods of NDE some of which require a very high level of skill in
both application and analysis.
The four basic methods of NDE are:
1. Liquid Penetrant testing (LPT)
2. Ultrasonic testing (UT)
3. Radiographic testing (RT)
4. Magnetic particle testing (MPT)

As for this project, all four methods being used during the fabrication activity
to detect any defect.
1. Liquid Penetrant Test (LPT)
The liquid penetrant examination method is an effective means for detecting
discontinuities which are open to the surface of nonporous metals and other materials.
Typical discontinuities detectable by this method are cracks, seam, laps, cold shuts,
laminations, and porosity.

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In principle, a liquid penetrant is applied to the surface to be examined and allowed to

enter discontinuities. All excess penetrant is then removed, the part is dried, and a developer
is applied.
The developer functions both as a blotter to absorb penetrant that has been trapped in
discontinuities, and as a contrasting background to enhance the visibility of penetrant
indications. The dyes in penetrants are either color contrast (visible under white light) or
fluorescent (visible under ultraviolet light).

Procedure:

1. Surface preparation
- the component being thoroughly cleaned by grinding, machining and detergents.
- the surface then being dried by normal evaporation and being applied ELY S-72
Remover for pre-examination cleaning by spraying the entire area being tested.
- the dirt being wiped out by clean, lint-free cloth, repeating the operation until all
the dirt has been removed.

2. Penetrant application
- penetrant being applied by spraying to the entire surface to be inspected. The
excess penetrant being allowed to drain from the after application, while allowing
for proper penetrant dwell time of 5 to 10 minutes.
3. Removal of excess penetrant
- excess penetrant then being wiped out by clean, lint-free cloth, repeating the
operation until most traces of penetrant have been removed. The remaining traces
being removed by lightly wiping the surface with cloth or absorbent paper
moistened with solvent.
- the excess penetrant removal being dried by normal evaporation.
4. Application of developer
- non-aqueous wet developer being sprayed to the part once the excess penetrant
being dried.
5. Inspection

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- inspection being performed on the parts within 5 to 10 minutes of development

time as to assure the penetrant properly bleed-out from discontinuities onto the
developer coating.

Method : Color contrast and solvent removable.

Advantages & Disadvantages

Advantages
i.

low operator skill level

ii.

applicable to non-ferromagnetic materials

iii.

low cost

iv.

simple, cheap and easy to interpret

v.

portability

Disadvantages
i.

careful surface preparation required

ii.

surface breaking flaws only

iii.

not applicable to porous materials

iv.

no permanent record

v.

potentially hazardous chemical

Fig. 4.4.1.1 LPT on circ seam (CW)

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Fig. 4.4.1.2 LPT on dish head

2. Ultrasonic Testing (UT)

In ultrasonic testing, very short ultrasonic pulse-waves with center frequencies

ranging from 0.1-15 MHz and occasionally up to 50 MHz are launched into materials to
detect internal flaws or to characterize materials. It is also commonly used to determine the
thickness of the test object - monitoring pipework corrosion being a good example.
Ultrasonic Inspection is often performed on steel and other metals and alloys, though
it can be used on concrete and other materials such as composites.

Method

A transducer being connected to a diagnostic machine is passed over the object being
inspected. In reflection (or pulse-echo) mode, the transducer sends pulsed waves through a
couplant (such as water or oil) on the surface of the object, and receives the "sound" reflected
back to the device. Reflected ultrasound comes from an interface - such as the back wall of
the object or from an imperfection. The screen on the calibrated diagnostic machine displays
these results in the form of a signal with an amplitude representing the intensity of the
reflection and the distance taken for the reflection to return to the transducer. In attenuation
(or through-transmission) mode, a transmitter sends ultrasound through one surface, and a
separate receiver detects the amount that has reached it on another surface after travelling
through the medium. Imperfections or other conditions in the space between the transmitter
and receiver reduce the amount of sound transmitted thus indicating their presence.
Couplant applied

Sound wave applied

Result displayed

Procedure

1. Component being cleaned by light grinding to remove spatter, pitting, etc in order
to obtain a smooth surface.

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2. Couplant is then being applied to the test surface. (water, oil, grease, etc)
This enable the ultrasound to be transmitted from the probe into the component
under test.
3. A range of angle probes being used to examine the weld root region and fusion
faces.
(Ultrasound must strike the fusion faces or any discontinuities present in the weld
at 90 in order to obtain the best reflection of ultrasound back to the probe for
display on the cathode ray tube).

Advantages & Disadvantages

Advantages
i.

Can easily detect lack of sidewall fusion

ii.

Ferrous & Non-ferrous alloy

iii.

No major safety requirements

iv.

Portable with instant result

v.

Able to detect sub-surface defects.

Measures depth and through wall excellent

Disadvantages
i.

High operator skill level

ii.

Difficult to interpret

iii.

Requires calibration

iv.

No permanent record

v.

Not easily applied to complex geometry

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INDUSTRIAL TRAINING REPORT

Fig. 4.4.1.3 UT on side drilled hole

3. Radiographic Testing (RT)

Radiographing is a process of passing electronics radiation through an object and

obtaining a record of its soundness upon a sensitized film.
Radiographic Testing is:

A highly effective and sensitive method for thick wall welded pipe

Only capable of defecting defects which extend in the direction of the

radiographic beam.

Also confined to the actual weld and the immediately adjacent area.

The base for welding factor 1.0 according to European and ASME rule

Fig. 4.4.1.4 RT arrangement sketch

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In principle, there are no limitations to this method when it comes to sizes and
consequently radiographic testing constitutes the normal non-destructive method of testing
for tubes with wall thickness greater than 3-4mm.
Radiographic testing frequently used as partial inspection, for instance with one film
per tube or one film from each end of each tube.

Procedure

1. X or gamma radiation is imposed upon a test object.

2. Radiation is transmitted in varying degrees dependent upon the density of the
material through which it is travelling.
3. Variations in transmission detected by photographic film or fluorescent screens.
(Film placed between lead screens then placed inside a cassette)
4. An IQI (image quality indicator) should always be placed on top of the specimen
to record the sensitivity of the radiograph.

Method

a. Load film cassette

b. Exposure to radiation
c. Developed graph

Advantages and Disadvantages

Advantages

i.

Permanent record

ii.

Most materials can be tested

iii.

Detects internal flaws.

iv.

Gives a direct image of flaws

v.

Fluoroscopy can give real time imaging

Disadvantages

i.

Skilled interpretation required.

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INDUSTRIAL TRAINING REPORT

ii.

Access to both sides required

iii.

Sensitive to defect orientation

(Possible to miss planar flaws)

iv.

Health hazard

v.

High capital cost

4. Magnetic Particle Testing (MPT)

The magnetic particle examination method being applied to detect cracks and other
discontinuities on or near the surfaces of ferromagnetic materials. The sensitivity is greatest
for surface discontinuities and diminishes rapidly with increasing depth of subsurface
discontinuities below the surface.
Typical types of discontinuities that can be detected by this method are cracks, laps,
seams, cold shuts, and laminations.
In principle, this method involves magnetizing an area to be examined, and applying
ferromagnetic particles (the examinations medium) to the surface. The particles will form
patterns on the surface where cracks and other discontinuities cause distortions in the normal
magnetic field. These patterns usually characteristic of the type of discontinuity that being
detected.
Method
Contrast paint applied

Magnet & ink applied

Result achieved

Procedure

1. Method being test to detect surface and sub-surface defects in ferromagnetic

materials.
2. Magnetic field being induced in component (permanent magnet)
3. The magnetic flux being disrupted by defects.
4. Ferromagnetic particles being applied to revealed defects.

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INDUSTRIAL TRAINING REPORT

Advantages & Disadvantages

Advantages

i.

Pre-cleaning not as critical as with DPI

ii.

Will detect some sub-surface defects

iii.

Relatively low cost

iv.

Simple equipment

v.

Possible to inspect through thin coatings

Disadvantages

i.

Ferromagnetic materials only

ii.

Demagnetization may be required

iii.

Direct current flow may produce Arc strikes

iv.

No permanent record

v.

Required to test in 2 directions

Fig. 4.4.1.5 Contrast paint applied (left)

Fig. 4.4.1.5 Black magnetic particle &

magnet applied (left)

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INDUSTRIAL TRAINING REPORT

Fig.4.4.1.6 White Contrast Paint &

Black Magnetic Particle (right)

4.5

Fig. 4.4.1.7 MPT Magnet (left)

HYDROSTATIC TEST (HT)

A hydrostatic test is the common way in which leaks can be found in pressure

vessels such as pipelines and plumbing. Hydrostatic tests, on the other hand, performance
verify fluid pressure vessels. Using this test helps maintain safety standards and durability
of a vessel over time. Newly manufactured pieces are initially qualified using the hydrostatic
test and continually re-qualified at regular intervals using the proof pressure test, which
also called the modified hydrostatic test. Hydrostatic testing is also a way in

is

which

gas pressure vessel such as a gas cylinder or a boiler is checked for leaks or flaws. Testing is
very important because such containers can explode

if they fail when containing

compressed gas.
The completed vessel filled with water shall be subjected to a test pressure
which is equal to 1 times the maximum allowable working pressure
the vessel or 1 times the design pressure by agreement

between

to be marked on
the

user

and

the

manufacturer.

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CHAPTER 5

CONCLUSION

Experiences in Tepat Teknik Sdn Bhd, the job of project management in the field of
oil & gas fabricator are challenging task. This required a very high commitment and selfconfident, willing to learn to complete all the job being given which might facing a lot of
problems and difficulties.

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