Providing Engineering Solutions

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ESR Technology

• Providing Engineering Solutions

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What we do

• Helping owner/operators.
• Ensure asset integrity
• Improve plant reliability.
• Through the provision of expert engineering
  services with..
• breadth and depth in the technical skill base
• long standing oil gas experience
• independence of OEMs and the supply chain

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Capabilities

• Inspection Technology
• Engineering Assessment
• Materials Engineering
• Machine Systems
• Forensic Engineering
• Risk Based Methods

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Inspection Technology Our Pedigree
NNDTC - National Non-Destructive Testing Centre
established in 1967 HOIS JIP - Currently 19
members comprising operators, equipment
suppliers, regulatory agencies service companies
NNDTC is a registered trademark of ESR
Technology
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Example - Inspection for Inaccessible Regions

• CHIME
• medium range
• 1m probe separation
• 100 wall coverage
• qualitative detection of wall loss
• fast screening
• Multi-skip TOFD
• quantitative wall loss measurement
• 1m probe separation
• accuracy 1mm

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Inspection Technology - Future
Inspection at the heart of the integrity
management process not more, but less. of the
right techniques and the right time..
quantified performance with measurable
benefits..
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Saving costs and increasing safety
Development of non-intrusive inspection schemes

• Combining key skills
• inspection technology
• corrosion assessment
• integrity FFS
• data analysis
• independence
• Less inspection, reduced timescales, fewer
  people, easier logistics, greater safety

1.2 M cost savings achieved during shutdown

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Fitness for Service Remnant Life
Unity pipeline.a strategic asset. is it ok or
not?

• Steps in our process
• analysis of inspection data
• probabilistic assessment of corrosion rate
• probability of failure with respect to flaw size
• risk based life assessment
• robust case for 2 yr further life provided

Allowing operators time to plan future asset
strategy
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New Material Options Composites (GRP)

• Defining the standards...
• pipework (ISO 14692 BS7159)
• vessels (EN 13121 BS4994, ASME X)
• composite repair (ASME PCC2)
• steelwork strengthening (TR55, CIRIA 585)
• Application
• material selection
• design
• specification
• product qualification
• supplier audit
• inspection

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Pumps and Pump Systems

• Pump Centre JIP
• established in 1993
• 69 members including users, equipment suppliers,
  service providers
• Solving problems.
• specification
• system design
• whole life costs
• failure analysis
• bearing and seal technology
• condition monitoring

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Machine Systems

• National Centre of Tribology
• established in 1968
• focus on machine components bearings, gears,
  seals, valves, transmissions, engines, pumps,
  hydraulics, rotating and reciprocating machines
• Services provided.
• root cause failure analysis
• bearing design
• material assessment
• condition monitoring
• maintenance planning

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Forensic Engineering

• Identification of root cause
• from component to plant
• What, where, when..
• .. and how not to let it happen again
• Interaction with OEMs and
• regulators
• Expert evidence for legal and insurance cases

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Example Integrity Mgt Framework
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ESR Technologys Track Record
Present Project Abu Dhabi Company for Onshore
Oil Operations (ADCO) Development of an Asset
Integrity Management System (AIMS)
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AXSYS.Integrity

• Risk based integrity management software
• Providing the link between plant performance and
  equipment integrity ..
• Collaborative venture with Bentley Systems

Reference sales of AXSYS.Integrity
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Getting the design right..

• Corrosion risk assessment to review material
  selection
• 3 plants, 6000 items, informn taken from PFDs
• Over 50 design changes recommended
• Fully auditable process passed to detailed
  design
• gt M saving through failure avoidance

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Dealing with the complexity

• Gas to liquid plant
• Extreme process conditions, full range of
  materials
• Cryogenic to 1400oC
• vac to 110 bar
• benign environments, to mineral acids to HF to
  organics
• cast iron to carbon steel to alloyed steel to
  austenitics to nickel alloys to titanium to GRP

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Validating the plan

• Process plant
• 70 critical items re-assessed, 69 downgraded
• 3 new issues raised
• Validated from the plant experience
• Production savings estimated at gt 0.5M per
  year/unit
• Outage period increased
• from 2 to 3 years

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MAPSStress Measurement Technology
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MAPS Stress Measurement Technology

• Patented method of stress measurement
• ferromagnetic materials
• absolute biaxial stress
• stress magnitude and direction
• stress depth profiling
• accurate to a few MPa
• Portable, rapid, non-contacting, non-destructive

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Validation

• Neutron diffraction
• weldments surface treatments
• X-ray diffraction
• on aerospace bearing rail heads
• Hole drilling
• weldments rail
• Strain gauging
• engineering components test specimens

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Independent Testing
48.1
18.9
49.8
68.2
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Competitive Technologies

• Relative techniques
• strain gauges
• displacement transducers
• Laboratory techniques
• X-ray diffraction
• neutron diffraction
• Destructive techniques
• hole drilling
• Other magnetic techniques
• confounded by effects of material condition
• prohibitive burden of calibration
• stress magnitude poorly resolved

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Applications

• Stress - a ubiquitous parameter in integrity
  management
• component inspection
• residual stress measurement
• in-service measurement
• on-line measurements
• material testing
• Ferromagnetic materials
• ferritic steels
• cast iron
• many stainless steels
• some nickel super alloys

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Chassis Crossmember
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Chassis Cross-MemberFatigue results
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Chassis Cross-MemberFatigue Results
Crack appears at this point and time
Life
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Not just the determination of stress
Stress Measurement
Defect Management
Assessment of Material Condition
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MAPS - PIG

• MAPS-PIG for the detection of
• subsidence
• heave
• buckling
• local wall loss
• cracking and other defects
• Can be used in tandem with other defects

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MAPS - FR

• Flexible risers on all deep water assets
• Complex design - inspection not possible by other
  means
• Loss of integrity
• business risk through unplanned loss of
  availability
• environmental risk thro large hydrocarbon
  inventory
• high safety risk and possible loss of asset

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MAPS - FR
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MAPS - SFT

• Measurement of rail stress free temperature a
  network integrity issue
• Measurement a compliance requirement (90 of rail
  network unmeasured)
• Competing techniques invasive, limited slow
• Application of MAPS allows measurement anytime,
  anywhere

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MAPS Steel

• Residual stress a variable from rolling process
• Acceptance levels being set as condition of
  supply
• Existing methods can only be used off-line and
  are destructive
• Development of a MAPS inspection device allows
  in-line process capability

MAPS-Steel being proposed for the new rolling
plant at Scunthorpe
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MAPS - Post-weld Heat Treatment
Potential SCC problem
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MAPS Shot-peen
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Opportunities

• Oil Gas
• Stress Pig
• External measurement
• Down-hole tools.
• Flexible riser integrity monitoring
• Monitoring system
• Inspection system
• Fatigue measurement
• In built sensors
• Jacket structure
• Post weld heat treatment verification
• Fatigue life measurement of drill strings
• Casing coil tubing integrity