NDT KONFERANSEN 2011 ZENOVIEA VOROSCIUC
Short about FMC Expectations Requirements New Challenges. New Solutions. 2
FMC Technologies Subsea Eastern ~ 150% growth from 2004-2010 MUSD Revenue Employees ER Revenue 1730 MUSD Revenue 1550 MUSD Revenue 2045 MUSD ER Employees Revenue 1750 MUSD Revenue 1000 MUSD Revenue 1370 MUSD 3200 Employees 3500 Employees Revenue 900 MUSD 2400 Employees Revenue 349 MUSD 1650 Employees 1450 Employees 1300 Employees 3
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Subsea production system building blocks 6
Enhanced Horizontal Tree (EHXT) Features: 5 x 2 10,000 & 15,000 psi Modular design based on EVXT and EHXT Most cost-effective and reliable Reduction in installation time 7
Manifold Systems Water depths to 10,000 ft Pressures to 15,000 psi Temperatures to 350F Sizes from 6 to 30 diameter Retrievable pigging loops Foundations for all soil conditions Multi-phase flow meters Optional manifold-mounted SCMs and chokes 8
Completion & Workover Riser Systems 5 15K C&WO riser system World s first 15K open water C&WO riser 5 10K monobore C&WO riser system 4 x 2 10K dual tubing C&WO riser system (rental) Riser systems can be used for light well intervention on both vertical and horizontal trees 9
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Subsea Processing Systems Solids Separator Cooler Multi-Well Water Injection Pump Separator Tank Liquid Pump HV Transformer Compressor Single Well Ultrasonic Level Indicator Control Valve Control Module 11
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Manifold Systems 13
Manifold Systems 14
Manifold Systems 15
Manifold Systems 16
små tuer velter stort lass Piping with visual indications: Lack of penetration, excessive penetration. 17
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Short about FMC Expectations Requirements New Solutions. 23
Trust Measured Confidence 24
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New focus Culture Environment Thinking Action 26
Short about FMC Expectations Requirements New Solutions. 27
New focus: NDT Quality= Conformance to the Requirements NDT Conformance to the Requirements=Quality 28
APPLICATIONS OF NDT METHODS. Control of weld quality (surface and volumetric). Control of forging and casting quality. metalurgical investigation of materials structure. Detection of bore hole eccentricity; Rate of fatigue crack growth; Investigation of corrosion rates; 29
REQUIREMENTS ULTRASONIC EXAMINATION ASME V Article 4 and 5 RADIOGRAPHIC EXAMINATION ASME V Article 2 VISUAL EXAMINATION ASME V Article 9 MAGNETC PARTICLE EXAMINATION ASME V Article 7 LIQUID PENETRANT EXAMINATION ASME V Article 6 EDDY CURRENT EXAMINATION ASME V Article 8 POSITIVE MATERIAL IDENTIFICATION NORSOK M-601 LEAK TESTING ASME V Article 10 Other standards used: EN; NORSOK; DNV; API; Customer Specifications. 30
REQUIREMENTS-ULTRASONIC INSPECTION Ultrasonic Examination is the preferred method for the welds with material thicknesses above 40 mm. Subsea Equipments are designed to allow 100% surface and volumetric inspection. Scanning distances full skip or halh skip are calculated based on the material thickness, the quality of the materials and bevels configuration. 31
REQUIREMENTS-ULTRASONIC INSPECTION Calibration blocks are used for sensitivity setting. Calibration blocks are produced in the same conditions as the welds to be tested. Artificial reflectors as side drilled holes, flat botommed holes and notches are machined at different depths from surfaces to simulate real defects. For welds with complicated configuration: dissimilar materials (22Cr, 25Cr, filer material- Inconel based, butter welds, internal cladding) the scanning distances are calculated and taked in consideration for each particular case. 32
REQUIREMENTS-ULTRASONIC INSPECTION Calibration block 33
REQUIREMENTS-ULTRASONIC INSPECTION Calibration block- Weld deposit. 34
REQUIREMENTS-RADIOGRAPHIC EXAMINATION Radiographic Examination is the recommended method for the welds in material thicknesses below 40mm to detect volumetric discontinuities and also surface discontinuities. Is applicable for but-welds, filet welds (where possible) and critical areas of casted components. Subsea equipments are designed to allow exposure geometry and to achieve examination parameters: sensitivity, density, Ug requirements. The radiographs are stored in special conditions, and represent quality records. 35
REQUIREMENTS- SURFACE EXAMINATION Visual is the first examination applicable and is related to the followings: dimensions, surface roughness, surface status (painting, coating), visual discontinuities. Direct visual and remote visual examination are used for subsea equipments. Ferromagnetic materials : welds, forgings, castings are tested using magnetic particle techniques in order to detect surface discontinuities. Magnetic Particle Examination is applicable for structural welds, forged and casted parts in final machining conditions, fasteners, etc. 36
REQUIREMENTS- SURFACE EXAMINATION Nonferromagnetic maerials are tested using dye penetrant techniques to detect discontinuities open to the surface. Dye Penetrant Examination is applicable for CR butter welds, CR cladded surfaces, fasteners, welds in nonferromagnetic materials, etc 37
REQUIREMENTS-EDDY CURRENT Eddy current Examination is applied to detect: corrosion, erosion, cracking and other changes in tubing, Discontinuities located in near surface layer outside and inside of seamless pipes. 38
REQUIREMENTS-POSITIVE MATERIAL IDENTIFICATION. Positive Material Identification is used on base materials and welds to provide information regarding the chemistry of the material. The examination is applicable for: piping systems in stainless steel and Ni-base alloys to be installed subsea. Inconel based weld overlay. 39
REQUIREMENTS-LEAK TEST AND PRESSURE TEST These methods are applicable for piping system, pipelines, storage tanks, etc. Helium leaking test is an efficient method of evaluation for EB welds without full penetration. 40
Short about FMC Expectations Requirements New Challenges. New Solutions. 41
NDT: SCIENCE, SKILL AND ART NDT is becoming a vital factor in the effective conduct of: research, development, design and manufacturing programs. 42
NDT- SCIENCE, SKILL, ART. The factors that influences the successful use of NDE mehods: high level of understanding of the process and the limits, clear definition of the test problem, adequate reference standards, realistic acceptance standards, qualification of operators, adequate equipments, practical test specifications and procedures, detailed test records and frequent testing where required,, 43
NDT- SCIENCE, SKILL, ART. The result consists in: High Detectability. Accuracy in discontinuity estimation. 44
NDT- SCIENCE, SKILL, ART.. Amplitude sizing technique; (a) small planar discontinuities; (b) rough planar discontinuity; (c) volumetric discontinuity; (d) oriented discontinuity; (e) Signal amplitude versus discontinuity size. 45
NDT- SCIENCE, SKILL, ART. 46
NDT- NDT- SCIENCE, SKILL, ART. 47
NDT- SCIENCE, SKILL, ART. 48
NDT- Skill DIGITAL RADIOGRAPHY (DR) 49
NDT- Skill Real Time Radiography. 50
NDT- Skill EDDY CURRENT 51
NDT- Skill 52
NDT- Skill VISUAL EXAMINATION. 53
NDT- SCIENCE, SKILL, ART. Thickness Measurement-In service 54
NDT- SCIENCE, SKILL, ART. Thickness Measurement-In service. 55
NDT- SCIENCE, SKILL, ART. GHIDED WAVES-In service 56
NDT- SCIENCE, SKILL, ART. GHIDED WAVES-In servi 57
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