Factory Acceptance Test Research Articles

Failure Mode and Effect Analysis (FMEA) of Pipeline Ball Valves in the Offshore Industry

This article provides a practical method for applying failure mode and effect analysis (FMEA) on oil export pipeline ball valves. These valves have been selected for analysis because they are the largest, heaviest, and most important valves on topside platforms in the offshore sector of the oil and gas industry. FMEA is a systematic approach for evaluation and identification of potential failures associated with the design and operation of pipeline valves. A literature review is included to provide more detailed information about the operation, components, and failure modes of pipeline ball valves. Five failure possibilities associated with pipeline ball valves have been identified, including leakage from the body and seat of a valve during operation; lack of a proper factory acceptance test; valve body damage due to pipeline loads because of insufficient thickness; missing the finite element analysis on the body of the valves; and seat damages as a result of wax ingress. The severity and possibility of occurrence have been defined and assigned to each possible failure. A risk priority number has been calculated for each failure mode on a scale of 1–100. Two risk items have been recognized as critical, with score values between 50 and 60. The outcome of FMEA shows that seats of pipeline valves are the most exposed components at risk of failure. The most critical identified failure related to the seats is accumulation of wax in the seat area. The proposed solution is to apply flushing ports and double-isolate them with modular valves to minimize the risk of leakage to the environment. The second critical failure is related to damage of the valve body due to pipeline loads. Valve wall thickness calculations according to ASME Sec. VII Div. 02, as well as stress analysis on the valve body based on different loads, are proposed to minimize the risk of the second failure.

Application of the First Replica Controller in Korean Power Systems

The purpose of this paper is to introduce, examine, and evaluate the industrial experiences and effectiveness of a Thyristor Controlled Series Compensator (TCSC) replica controller installed in Korea in 2019 through a review of its configuration, test platform, and practical application, and further to propose operational guidelines for replica controllers. Four representative practical cases were conducted: a Dynamic Performance Test (DPT) under a sufficiently large-scale power system prior to the Site Acceptance Test (SAT), pre-verification for on-site controller modification during operation stage, parameter tuning to mitigate the control interaction, and time domain simulation for Sub-Synchronous Torsional Interaction (SSTI). None of these four cases can be performed in a Factory Acceptance Test (FAT) or on-site. Therefore, TCSC control performance was accurately verified under the entire Korean power system based on a large-scale real-time simulator, which demonstrated its effectiveness as a powerful tool for operations including multiple power electronics devices. Our review herein of these four practical cases is expected to show the usefulness of replica controllers, to demonstrate their strength to deal with practical field events, and to contribute to the further expansion of the application area from a perspective of electric utility.

Fabrication and factory acceptance test of ITER UPSE installation tool

Abstract The ITER upper port stub extension (UPSE) which is welded on the upper position of the vacuum vessel (VV) is classified into 2 categories; one is called as the central (even) UPSE which is welded at upper central position of the VV sector at factory. The other is called as the lateral (odd) UPSE which is welded at upper lateral position of the VV sector. The central UPSE is welded at factory before delivery, but the lateral UPSE is welded after whole nine VVs welded in Tokamak pit. The final design including analysis considering design factor and mock-up test for the lateral UPSE assembly have been developed by the Korean domestic agency (KODA). For the final welding between UPSE and VV, alignment system to adjust the UPSE to its final position is also required to meet the functional requirements requested by IO-CT (ITER Organization Central Team). For the verification of the final design to check alignment system and traveling mechanism, a full scaled mock-up was fabricated and tested according to the technical requirement of the UPSE installation tool [ 8 , 9 ]. In this paper, the structural analysis to verify the structural integrity according to Machinery Directive and factory acceptance test (FAT), full load test to check the maximum bending deflection in the worst case, will be introduced.

Numerical analysis of stress concentration factors on tensile armour wires inside the end-fitting of an axially tensed unbonded flexible pipe

ABSTRACT The present paper examines the case of a metal based unbonded flexible pipe under a number of axial tensile operational loads of varying intensity, expressly focusing on the response of the segments of the pipe’s tensile armour wires that lie inside the pipe’s End-Fitting (EF), with intent to track the development of high stress concentration areas there and assess the stress concentration factors (SCF) involved. Additionally, a parametric study is performed, to identify potential factors that might affect the maximum SCF values measured on these wire segments inside the EF. Based on the parametric study’s findings, an approximate relationship for evaluating the expected maximum SCF on the tensile wire inside the EF is developed. The paper adopts a numerical approach to the problem, based on the development of a two-dimensional finite element model for evaluating the wire’s response to axial tensile operational loads. The model considers both the effects the EF’s assembling procedure and the Factory Acceptance Test (FAT) have on the behavior of wire segments lying inside the EF. An analytical approach is employed as a benchmarking tool of the numerical model’s performance.

Experiences during Design, Fabrication, Assembly and Factory Acceptance Test of the ITER Cryoplant Termination Cold Box

The ITER Cryodistribution (CD) system distributes cryogenic power from the cryoplant to the applications, namely superconducting magnets, cryopumps, etc. The ITER CD system comprises seven cold boxes of which the Cryoplant Termination Cold Box (CTCB) is the largest one. The CTCB plays a pivotal role in distributing the cold helium fluid with the highest mass flow rates of 4 kg/s coming from one of the 80 K plants to the applications. The physical connection between the CTCB and different applications is through nine cryolines (CLs) having diameters ranging from 0.45 m to 1.0 m. The CTCB has been manufactured and assembled with various large size components such as electrical heater system of 600 kW capacity, cryogenic control valves of size DN200, bubble panel thermal shield (TS) made of stainless steel, etc. The CTCB, which withstands interface loads of ∼1.4 times of its own weight, has been analysed for its functional and thermo-structural requirements under various load conditions. Components & subsystems were manufactured and factory tested individually in various locations in Europe and India to be finally assembled in one place. The CTCB has also been integrally tested, of which major activities were the pressure and helium leak tightness tests, followed by functionality checks of all instruments. The present paper describes the challenges involved and how they were resolved as well as lesson learnt during the design, fabrication, assembly, and factory acceptance test (FAT) phase of the CTCB project.

Hot Helium Leak Test of ITER blanket shield block

To ensure successful operation of the International Thermonuclear Experimental Reactor (ITER), the blanket shield block modules are required to demonstrate the vacuum performance by Hot Helium Leak Test (HHLT), which is performed at the relevant ITER operational conditions and is one of the Factory Acceptance Tests (FAT) of the product. A specific facility is developed in China to perform these demanding tests, which has a 10 m3 vacuum chamber to accommodate the large size of shield blocks and achieved an overall system leak detect sensitivity of 7.19 × 10−11Pa. m3/s at 235 °C. A full-scale proto-type of ITER shield block was tested in this facility, which showed maximum helium leak rate is less than 1.74 × 10-10Pa. m3/s under 4.2 MPa pure helium gas pressure at 235 °C. The HHLT was performed with cyclic pressure and temperature process and the results were given in this paper. The behavior of the background leak rate during these processes were also monitored and discussed.

Preparation and characterization of 10B targets at JRC-Geel

Measurements of neutron-induced cross sections to generate nuclear data are a core activity of the JRC-Directorate G Standards for Nuclear Safety, Security and Safeguards unit in Geel. Thin 10B layers are of great importance in this activity as they are used to measure the absolute neutron flux in the beam using the standard 10B(n,α)7Li reaction cross-section as a reference. After a period of reduced activity and in line with a renewed interest for nuclear data, the demand for high quality 10B targets increased. In this paper we describe the design and features of a new e-beam evaporator specifically customized for the preparation of boron targets as replacement of the old dysfunctional equipment. Several 10B targets of varying thicknesses were prepared and characterized as part of the factory acceptance tests and implementation in the JRC-Geel target preparation laboratory. Differential substitution weighing was applied for mass determination and in order to calibrate the thickness monitor. Comparative time-of-flight measurements relative to 10B and 235U standard targets were conducted at the GELINA neutron time-of-flight facility at the JRC-Geel site as second methodology for the determination of 10B areal density. The morphology of the layers was assessed by means of Scanning Electron Microscopy (SEM). The determination of impurities was realized by means of Energy Dispersive X-ray (EDX). Finally, two boron targets were prepared in the frame of the measurement of the neutron induced fission cross-section of 230Th at the n_TOF neutron time-of-flight facility at CERN.

Dynamic simulation of a vessel drive system with dual fuel engines and energy storage

Dredging operations result in severe load changes, and the transient capability of natural gas-fuelled dual fuel engines in gas mode is not sufficient to cope with them. An energy storage system may compensate the difference depending on the system size and control strategy. Previously developed component models are adapted and expanded with natural gas combustion and a kinetic energy storage system. The dual fuel engine’s performance and transient behaviour in gas mode is validated with data from a factory acceptance test. Both the effect of increasing the available engine power and increasing the power of the energy storage system are investigated. The simulation results show the trade-off between the transient capability and lower harmful emissions on one side, and the operational costs and system efficiency on the other side. Increasing the available engine power, enhances the drive system’s transient capability by reducing load change experienced by each engine, but it also increases the fuel energy consumption and global warming potential. A kinetic energy storage system increases the average engine load and fuel energy consumption slightly. The higher engine load results in a lower methane slip and does, therefore, not result in a net increase of the global warming potential.

Simple and robust speckle detection method for fire and heat detection in harsh environments.

Standard laser-based fire detection systems are often based on measuring the variation of optical signal amplitude. However, mechanical noise interference and loss from dust and steam can obscure the detection signal, resulting in faulty results or the inability to detect a potential fire. The presented fire detection technology will allow the detection of fire in harsh and dusty areas, which are prone to fires, where current systems show limited performance or are unable to operate. It is not the amount of light or its wavelength that is used for detecting fire, but how the refractive index randomly fluctuates due to heat convection from the fire. In practical terms, this means that light obstruction from ambient dust particles will not be a problem as long as a small fraction of the light is detected and that fires without visible flames can still be detected. The standalone laser system consists of a Linux-based Red Pitaya system, a cheap 650nm laser diode, and a positive-intrinsic-negative photo-detector. Laser light propagates through the monitored area and reflects off a retroreflector generating a speckle pattern. Every 3s, time traces and frequency noise spectra are measured, and eight descriptors are deduced to identify a potential fire. Both laboratory and factory acceptance tests have been performed with success.

IGBT Power Stack Integrity Assessment Method for High-Power Magnet Supplies

This paper proposes a method for assessing the integrity of a series of insulated-gate bipolar transistor (IGBT) power stacks during factory-acceptance tests and service stops. The key challenge that is addressed in this paper is detecting common assembly issues that affect the power stack thermal path as well as distinguishing the acute aging effects of bond-wire lift-off and solder delamination. The method combines offline ${V_{\boldsymbol{ce}}}$ measurements with current in the extended Zero Temperature Coefficient (ZTC) operating region as well as with sensing current without modifications to the power stack. It also employs on-the-stack ${V_{\boldsymbol{ce}}} $ calibration for both the measurements. Additionally, only a fixed duty cycle pattern is needed to control the switches. The paper also presents a sensitivity analysis of the method to various parameters such as the current level in the extended ZTC operating region, the precision of the ${V_{\boldsymbol{ce}}}$ measurement, as well as the ambient, the cooling-water, and the junction temperatures. The experimental results are obtained from a high-current IGBT power stack used in a magnet power supply for particle accelerators and are compared favorably to results from finite element method and lumped parameter network simulations confirming the applicability of the method.

Testing and validation of safety logic in the virtual environment

This paper presents an approach for testing safety PLC logic in a virtual environment, using the IOCO testing relation as validation criteria. Manufacturing companies more and more rely on virtual commissioning to reduce the physical commissioning time by testing and debugging the PLC logic of the nominal behavior prior to physical commissioning. However, safety PLC logic testing is still carried out on real systems manually. This manual practice of safety logic validation hinders industry to exploit the full potential of virtual commissioning to reduce the physical commissioning time. The proposed approach assists manufacturing companies in the validation of safety PLC logic using a simulation model before the factory acceptance testing phase. Using the proposed approach, a simulation model can be used to test the safety PLC logic and prepare better for the factory acceptance testing phase, hence, further reduction in physical commissioning time can be achieved.

Receiving inspection and tests of the ITER poloidal field #4 cryostat feed-through

The ITER Magnets are in the procurement and assembly phases. During these phases, critical components need to be tested and assembly procedures need to be developed and qualified on mockups. To this end, ITER Organization (IO) and the Commissariat à l’Energie Atomique (CEA) have built up a support structure with space, expertise and equipment: MIFI – Magnet Infrastructure Facilities for ITER. In this framework, IO and CEA perform Receiving Inspection and Tests (RIT) on components delivered to IO by the Domestic Agencies (DA). RIT is a critical stage in the life process of components. These tests are meant to ensure the good quality of components and occur between the Factory Acceptance Test (performed before delivery to IO) and the Site Acceptance Tests that are performed after installation in the tokamak pit. The paper explains the RIT sequence managed on the Poloidal Field #4 Cryostat Feedthrough (PF4 CFT), the first ITER Magnets component to be delivered by a Domestic Agency to ITER Organization, and details leak tests, metrology tests and High Voltage tests performed.

Converting data into knowledge for preventing failures in power transformers

This research is performed in order to estimate the overall condition of power Transformers, it is considered for 60 power transformers and 10,198 electrical test: Factory and site acceptance test, quality oil test, insulation test, among others. The Health Index (HI) is useful for maintenance strategy planning. The aim of this research is to represent the new method to assess the conditions of transformer by applying a new developed HI method; it has been improved from the traditional method by using orthogonal Wavelet network for long-term degradation factors, that cumulatively lead to the transformer span life and validate by the data mining process. It has been proved with machine learning algorithms with high accuracy. Rich metadata is required to find and understand the measurements, from modern experiments with their immense and complex data stores, the new method allows to structure a more practical way to categorization with various components, for a better decision science with a multi planning strategy. To store and manage these metadata have improved over time, but, mostly of the cases are ad-hoc collections of data relationships, often, represented in domain or site specific application code.A case study with 60 power transformer is made to evaluate the performance of the new develop HI. Therefore, the proposed method can create an efficient preventive maintenance plans for power transformers; it is an important contribution for knowledge, because the data is converting into knowledge.

Fabrication and factory acceptance test of ITER sector sub-assembly tool

An ITER Tokamak machine with a torus shape is composed of nine units of 40◦ sectors. The sector sub-assembly tool (SSAT) is dedicated assembly tool to integrate vacuum vessel (VV) sector, VV thermal shield (VVTS) segments, VVTS port shrouds, two toroidal field coils (TFC) and various intercoil structures into 40◦ sector. For the sub-assembly process of 40° sector, SSAT shall have sufficient strength to support and handle heavy components up to 1250 t. And fine alignment system to adjust components considering assembly tolerance should be designed and verified by appropriate means. Although the structural analysis and mock-up tests were completed, structural stability and alignment system should be verified through factory acceptance test with real component and system. In this paper, the factory acceptance test results of the sector sub-assembly tool including VV load simulation and partial load test of VVTS outboard (OB) sector frame will be presented to verify the structural assessment and adjustment of the component.

Control and operation strategy design of ITER coil power supply system

The large-scale ITER coil power supply system will generate huge current for superconducting magnets by plenty of AC/DC converters, which are based on thyristor technology on various circuits. A comprehensive consideration on design, manufacturing, testing and commissioning is the foundation to guarantee the safety operation of the CPSS system. This paper presents the design of converters control and operation strategies according to different typical circuit topologies. As well as illustrate the corresponding operation systems with associated functions to achieve those operation strategies. 2-Quadrant, 4-Quadrant and sequential control operation strategies are applied in corresponding PF (Poloidal Field), CS (Central Solenoid), CC (Correction Coil) and VS1 (Vertical Stability) converters with associated current closed-loop or voltage open-loop control during plasma operation. Three individual operation systems are comprised of TF, PF/CS and CC conventional systems with two architecture hierarchies to perform the control strategies and fulfill the real-time communication with central system. Typical simulation and test results are presented to verify the control strategies in accordance with the manufacturing and factory acceptance test. The converters will be installed in the ITER site soon and all the control strategies will be tested on the following commissioning phase.

Convective baking test of the ITER lower port for factory acceptance

The Factory Acceptance Test (FAT) for ITER components should be complied with the RCC-MR 2007 code and French regulations of nuclear pressure equipment (ESPN) to assure quality of nuclear pressure equipment. The procedure of FAT for lower port has been set to that visual test, pressure test, baking, vacuum leak test, and final dimensional inspection. Especially, the baking is critical cleaning method to satisfy required vacuum condition. The baking condition should be satisfied with both the given ramp-up/down condition, which is 5 °C/hr, and the temperature difference of the object within 40 °C, simultaneously. The air heating and circulating furnace has been specially designed to apply convective heating and cooling method. In this study, using the mock-up of the lower port stub extension, convective baking test is performed with the maximum holding temperature of 220 °C during 24 h. As a result, the maximum temperature difference of the mock-up is appeared 15.4 °C at the ramp-down condition. Using the measured result, transient thermo-structural analysis is performed. The maximum stress of 85.8 MPa is occurred, and this is reasonable stress intensity comparing to the allowable stress 195 MPa. It is proven that applying convective baking is feasible for the baking of lower port FAT.

Equipment Qualification of a New Laboratory Tray Dryer

This qualification study deals with the Installation and Qualification of a New Tray Dryer. Granules in the pharmaceutical industry are dried using the different equipment like Fluid Bed Dryer, Belt Dryer, Tray Dryer, Vacuum Tray Dryer, Spray Dryer and Rotary Dryer. In this case, the study was conducted on the newly installed laboratory Tray Dryer. Various documentation requirements like User Requirement Specification, Factory Acceptance Test, Site Acceptance Test, Installation Qualification, Operational Qualification and Performance Qualification were carried out for the equipment. Calibration of measuring devices, the prepared granules were dried using the tray drier and noted the time required to dry the granules. Equipment qualification of newly installed laboratory Tray Dryer was performed meeting all the qualification parameters.

Faultlessness of composite enclosing structures with thin-sheet linings and effective thermal insulation

Fencing composite structures with thin-sheet metal cladding and effective thermal insulation are widely used. They are especially effective in hard to reach, remote, seismic areas, in areas with harsh climates. There is a problem of estimating the real random loading of snow, wind, ice, temperature loads and others according to Roshydromet, when the strength, heat engineering, dielectric, and other structural parameters are random and changes in which from the allowable area lead to failures.The paper provides an assessment of the reliability of enclosing structures of buildings based on quantitative signs of impacts (wind, snow and permanent), as well as the results of statistical evaluation of factory acceptance tests. This paper discusses to exhaust the resource - the strength of the middle layer of the structure during shear.

Recommendation of site commissioning tests for rapid recovery transformers with an installation time less than 30 hours

Transformer testing is an indispensable procedure to guarantee that transformers are fulfilling all requirements and guaranteed values. After completed FAT (Factory Acceptance Test), to proof the transformer design, site commissioning test shall be performed to detect potential transport damages or faults at site installation before energizing the transformer.

In Implementing a Metal 3D AM Machine

Additive Manufacturing (AM) does not yet have a standardized way to measure performance. Here a AM machines dimensional accuracy is measured trough acceptance test (AT) and AM machines capability is tested trough test parts. Test parts are created with specific geometrical features using a 3D AM machine. Performance of the machine is then evaluated trough accuracy of test parts geometry. AM machine here uses selective laser melting (SLM) process. This machine has done Factory acceptance test (FAT) to ascertain this machine ́s geometrical accuracy with material AISI 316L. Manufacturer promises accuracy of ±0.05 mm. These parts are used as comparison to AT parts made in this study. After installation two AT parts are manufactured with AM machine. One with AISI 316L and one AlSi10Mg. Dimensional accuracy of geometrical features on these parts are then compared to FAT part and to one another. Machines capability is measured trough two test parts done with material AlSi10Mg. Two of the test parts are done at the same time using same model as the FAT. Parts are printed without supports and with features facing same directions. Features of these parts were then evaluated. Another test to find out AM machines capability was to create part consisting of pipes doing 90˚ angle resulting in horizontal and vertical holes. Dimensional accuracy and circularity of holes was measured. Through these tests machines capability is benchmarked.