Special Testing Facility

Transcription

1 Special Testing Facility OUR CUSTOMERS: TESTING CAPABILITIES: Pressure range: vacuum to 1034 bar Temperature range: -196 C to 300 C Test gasses: Helium, Nitrogen, Mixtures TYPES OF TESTS: Overpressure and Underpressure Testing Low Temperature Test / Cryogenic Test Fugitive Emission Test Type / Production Gas Shell Test Dynamic Gas Shell Test Gas Seat Leakage Test Function Test Under Pressure HIGLIGHTS: Automatic Cooling/Heating system with overpressure protection FE Type Test acc. EN ISO :2006, ANSI 2500, BH certified packing API 6A PR2 Design validation test for Choke 9 x 9, API 10000

2 Special Testing Facility DIRECT SNIFFING METHOD - Ambient & Cryogenic Leakage Testing HOW WE DID DIRECT TESTING IN THE PAST? During observing the leakage Test Engineer was in direct contact with pressurized valve! As a safety barrier just bullet proof glas was used which was obviously insuficient protection! HOW WE DO DIRECT TESTING FROM 2013 ONWARDS? Testing is done remotely by Test Engineer from control room Safe and sophisticated solution Sniffing probe and camera mounted on robotic arm Local sniffing around the valve

3 Special Testing Facility WHY TO REDUCE FUGITIVE EMISSIONS? Defend Health and Safety of people inside and outside plants Comply with Local Environmental Regulations (Defend Environment) Save money on Personal Protective Equipment and Safety Devices Increase efficiency of the plant (lost revenues) Colin Beckett, Chevron Australia, General Manager: What we ve been doing here on Barrow Island is an example of how it s possible for Oil and Gas industry to coexist with the environment. The environment on Barrow Island is exceptional, but it remains exceptional 40 years after we started producing oil here, and that s because we have planned what we do on Barrow Island to make sure that the environment is unchanged by our presence.

4 Material Management SUPPLY CHAIN STRATEGY continuous work on Material management projects continuous work supply chain strategy using vendor managed inventory consignment stock in order to reduce inventory value to improve inventory turns MATERIAL FLOW from stock based on the pull-in system 100 m 2 to avoid unnecessary material movements better control the process creating straight, uninterrupted continuous flow BENEFITS 50 m 2 improving the cash flow, inventory inventory turns reducing lead times CONTINUOUS IMPROVEMENT Kaizen: WIP parts storage elimination 0 m 2 between material cutting and machining, which by direct supplies based on PULL system with replenishment Kanban.

5 Packing & Quality Assurance THE IMPROVEMENT PROPOSALS OF OUR EMPLOYEES HELP US TO PROTECT OUR COMPANY! PHOTO DOCUMENTATION Goods and Packaging photo documentation Before packing During packing After packing Loaded on truck Give us proven evidence about goods condition and completeness. This helps to prevent unjustified complains SHOCK WATCH & TILT WATCH Indicates any potential hits exceeding specified safe force to keep goods protected Indicates any potential tilt exceeding specified safe angle to keep goods protected. Forwarders consider the goods as fragile and pay higher attention to careful manipulation Helps to prevent unjustified complains

6 NDT NDT DEFINITION Non-destructive testing or Non-destructive examination (NDT/NDE) is a wide group of analysis techniques used in science and industry to evaluate the properties of a material, component, or system without causing their damage. WE ARE ALL RESPONSIBLE FOR SAFETY AND QUALITY OF OUR PRODUCTS AND GOODWILL OF OUR COMPANY! WHY TO PERFORM NDT? SAFETY LEGAL FINANCIAL Pressure > 1000 bars Standards Norms Customer requirements COPQ < VA

7 NDT Techniques WE HAVE THE OBLIGATION TO PROTECT LIVES, HEALTH, ENVIRONMENT, PROPERTY AND COMPANY GOODWILL BY RELEASING ONLY 100% SAFE AND FUNCTIONAL PRODUCTS. Penetrant testing (PT) is a method of non-destructive testing, which is suitable forthe detection of surface defects. By PT method can be detected all kinds of cracks, porosity, inclusions. It is applicable for almost all kinds of metallic materials. Magnetic particle testing (MT) is a method of non-destructive testing, which is suitable for the detection of surface and subsurface defects. By MT method can be detected all kinds of cracks, porosity, inclusions. It is applicable only to ferromagnetic (magnetic) materials.

8 NDT Techniques WE HAVE THE OBLIGATION TO PROTECT LIVES, HEALTH, ENVIRONMENT, PROPERTY AND COMPANY GOODWILL BY RELEASING ONLY 100% SAFE AND FUNCTIONAL PRODUCTS. Visual testing (VT) is a method of non-destructive testing, focuses on identifying and evaluating the products surfaces and parts by eye visual inspection, or by using special equipment. By VT method can be detected cracks, inclusions, weld defects, undercut, surface porosity and form deviations, weld shape standard deviations. Ultrasonic testing (UT) is a method of non-destructive testing, detecting internal defects of materials like cracks, laminar, cavities, porosity, even at depths below the surface. UT method has the largest range of NDT methods. It is used for testing molded blanks, plates, forgings, bars, welds and castings. It is used also for testing of nonmetallic materials, such as plastics and composites.

9 NDT Techniques WE HAVE THE OBLIGATION TO PROTECT LIVES, HEALTH, ENVIRONMENT, PROPERTY AND COMPANY GOODWILL BY RELEASING ONLY 100% SAFE AND FUNCTIONAL PRODUCTS. Radiographic testing (RT) allows you to obtain a permanent image of internal defects of materials, linear and rounded indications. Usually the use of the method are inspection of welds and castings. Due to its conclusiveness and permanent record is one of the most important methods in the control of equipment in severe services (e.g. pressure boundary parts) in the aerospace, petrochemical and nuclear industries.

10 Disk Stack Manufacturing DRAG VALVE WITH DISK STACK Using for heavy duty aplications Control the flow and pressure Elimination cavitation, erosion, vibration and noise inside the valve Use for large pressure drops 50 years of working and proven design AXA milling machine forelectrodes GROMAX EDM machine

11 Disk Stack Manufacturing EDM - Electric Discharge Machining EDM Straightening Sand blasting Cleaning Powder application Before brazing in oven Brazed DS before machining