ANALISA KEGAGALAN CUI (Corrosion Under...
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ANALISA KEGAGALAN CUI (Corrosion Under Insulation)PADA PIPA A234-WPB
Haqi Muftia
2708 100 030
Jurusan Teknik Material dan Metalurgi
FTI-ITS
Dosen pembimbing:Prof. Dr.Ir. Sulistijono, DEA
Budi Agung Kurniawan S.T, MSc.
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OUTLINE
BAB 1
BAB 2
BAB 3
BAB 4
BAB 5
Metodologi Penelitian
Hasil PenelitianPembahasan
Latar Belakang TujuanRumusan Masalah Manfaat
Tinjauan Pustaka
KesimpulanRekomendasi
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LATAR BELAKANG
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IDENTIFIKASI PERMASALAHAN
LOKASI KOROSI
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Faktor?
Mekanisme?
RUMUSAN MASALAH
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Faktor?
Mekanisme?
TUJUAN
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1. Tekanan, temperatur, kecepatan aliran gas dan komposisi gas yang mengalir pada pipa adalah keadaan operasional normal selama pipa tersebut beroperasi.
2. Sifat mekanik material komponen pipa A234-WPB dianggap homogen karena proses manufaktur.
BATASAN MASALAH
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1. Dapat memahami lebih dalam tentang fenomena korosi dibawah insulasi.
2. Memberikan masukan untuk dapat meminimalisir korosi yang terjadi.
MANFAAT PENELITIAN
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• Penamaan pipa menurut ASTM
• A234 adalah Carbon Steel- Low Alloy
• WPB (Wrought Pipe Bend)
PIPA ELBOW A234-WPB
Elemen Komposisi (%)
KarbonManganPhosforSulfurSilikon
KromiumMolibdenum
NikelTembagaVanadium
Columbium
Maksimum 0,300,29 – 1,06
Maksimum 0,050Maksimum 0,058
Minimum 0,10Maksimum 0,40Minimum 0,15
Maksimum 0,40Maksimum 0,40Maksimum 0,08Maksimum 0,02
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INSULASI PIPA
• Insulasi biasanya diaplikasikan oleh dunia industri khusunya Oil and Gaspada pipa-pipa dengan temperatur operasi sekitar
20o - 175oC.
Sumber: API Recommended 530
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FUNGSI INSULASI
• Mereduksi laju dari heat loss.• Menjaga agar tetap pada temperatur yang optimum.• Memastikan temperatur luaran pipa aman saat ada kontak
dengan pekerja.• Memperpanjang jangka waktu pipa saat adanya kebakaran
dengan menunda tekukan atau retakan saat ada peningkatan temperatur.
Sumber: Jurnal “Corrosion Under Insulants”, W. J. Batty, P. W. O'Callaghan and S. D. Probert
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CUIJenis korosi ini menjadi perhatian yang khusus dan utama untuk di lingkungan industri petroleum dan petrokimia yang memanfaatkan energi panas dalam proses produksinya (API 570, 1993)
Jenis korosi yang terjadi localized corrosion.
Korosi ini menyerang Carbon Steel pada temperatur-12 oC – 175 oC dan Stainless Steel 60 oC – 205 oC.
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1. Air
Adanya air yang terperangkap akan memulai untuk dapat terjadinya korosi.
2. Ketersediaan oksigen
Semakin sedikit oksigen maka kelembaban lingkungan akan meningkat.
3. Unsur-unsur subtansi korosif
Apabila terdapat unsur substansi korosif yang berdifusi melalui celah maka laju korosi akan semakin tinggi.
4. Temperatur
Semakin tinggi temperatur maka kemungkinan terjadinya CUI akan semakin besar.
***) Menurut statistik, kegagalan utama CUI disebabkan oleh pemilihan material dan insulasi yang tidak tepat.
Sumber: Jurnal “Failure analysis of a stainless steel pipeline”, M. Suresh Kumar; M. Sujata; M.A. Venkataswamy, S.K. Bhaumik
FAKTOR TERJADINYA CUI
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Uap air yang hadir di antara logam dan material insulasi kemungkinandisebabkan oleh :
• Insulasi yang tidak terpasang dengan baik, sehingga ada lingkungan luaryang masuk, baik itu udara basah maupun air.
• Density material insulasi yang rendah sehingga banyak celah yang dapatdilalui oleh lingkungan luar.
• Jika vapour barier rusak atau tidak terpasang dengan benar juga akan dilalui oleh lingkungan luar.
KEMUNGKINAN KEGAGALAN
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LANGKAH PENTING ANALISA
• Sumber : Shin ichi Nishida.1992.failure analysis in engineering application. Jordan Hill. Oxford.Butterworth-Heinemann Ltd.
FTA(Fault Tree Analysis)
Identifikasi Permasalahan
Investigasi Material yang Mengalami Kegagalan
Akar Permasalahan
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METODOLOGIPENELITIAN
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Peralatan Penunjang Penelitian
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Material Pipa
• Servis : Steam Condensate• Material : 90o Elbow CS A234-WPB• Ukuran : Diameter 2”• Jacket : Aluminium Jacketing• Isolasi : Calcium Silicat• Coating : Intermediate: silicon acrylic, Finish: zinc rich primer
Desain Operasional• Desain Tekanan : 19,334 kg/cm2
• Desain Temperatur : 398,89 oc• Tebal Nomimal : 3,91 mm
Kondisi Operasional• Tekanan Operasi : 3,5 kg/cm2
• Temperatur Operasi : 50 oc
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Tabel Pengukuran Pipa (mm)
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Pengamatan Makro
Bagian yang tidak terdeteksi cacat
Bagian yang terdeteksi cacat
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Uji NDT
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Unsur (%) ASTM
Elbow A234-WPB terkorosi
Karbon 0,3 max 0,291
Mangan 0,29 – 1,06 0,401
Nikel 0,40 max 0,027
Molibdenum 0,15 min 0,001
Silikon 0,10 min 0,359
Kromium 0,40 max 0,021
Phosfor 0,050 max 0,027
Sulfur 0,058 max 0,020
Ceq 0,485 0,380
Perbandingan Komposisi Kimia
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Posisi HV (0,5)
1 160,3
2 153,6
3 152,3
4 151,3
5 148,3
6 159,4
7 137,2
8 134,9
9 141,8
10 145,1
Rata-rata 148,4
ASTM 197,0
Uji Kekerasan
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Uji XRD
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Bagian yang mengalami perbesaran
Sampai dengan perbesaran 500x
SEM
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Perlit
Ferit
Metallography
Perbesaran 200x Perbesaran 500x
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1. Faktor-faktor:
a. Adanya air yang terendap pada pipa
b. Pipa Under Specification
2. Mekanisme:
KESIMPULAN
PenipisanKetebalan
Korosi Pipa
InsulasiAluminiumJacketing
Air
Coating
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1. Memperhatikan faktor-faktor yang dapat menyebabkan pipa elbow A234-WPB yang terinsulasi terserang korosi, antara lain:
a. Memastikan prosedur pemasangan insulasi dengan benar atau sesuaistandart, sehingga meminimalkan adanya air yang masuk.
b . Memastikan material pipa sesuai dengan spesifikasi yang terdapat dalamstandart.
2. Diperlukan adanya inspeksi berkala pada pipa yang rentan mengalami CUI. Inspeksi yang dilakukan sebaiknya menggunakan NDT agar tidak merusakinsulasi pada pipa.
REKOMENDASI
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TERIMA KASIH