PowerPoint Presentation

YINI Student - Azam GhaffarContribution to the Business Awards

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Nature of Doosan Babcocks BusinessComponent Testing

Nuclear

Civil EngineeringAerospace

Oil and Gas

Thermal Power

Leading provider of engineering and asset management services to energy sector

Builds, maintains and improves power stations, pharmaceutical facilities and gas plants

Component Testing contains a variety of full scale testing rigs

Testing rigs are able to be tailored to clients needs

Structural integrity of components can be qualified before clients assets are deployed

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4More testing availabilities

3Increase axial and compressive loads

Ease of access for loading and unloading

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Safer conditions around rig

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Project DetailsCentraliser Slippage RigDesign and manufacture a Centraliser Slippage Rig for the department

Current setup is outdated and needs replacedAxial load is causing damage to current test machineLimiting capabilities affect current setup

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Department performs tests for subsea pipeline components

To become a market leader for subsea pipeline component qualification

Contributes to wider organisation objectives of growth aspirations

Company plans to increase its current turnover of 35 million to 50 million

Component Testing contributes 5 million

Expansion of department allows us to increase our contribution to double within 5 years

Business Case for ProjectSubsea Pipeline Component QualificationExpansion Programme

Real Life Application of CentralisersCentraliser clamps along length of inner pipe

Inner pipe passes through carrier pipe centraliser keeps it central

Centraliser must be able to withstand installation and operational forces

Centraliser is tested to ensure it wont slip when passing over weld

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DesignPropose ideas that meets project criteria

CalculationsJustify final design

MaterialsSource appropriate materials and components

Manufacture & AssemblyMachine and weld materials to complete assembly

CommissioningConclude finished testing rig works successfully

Initiating the Project Project StagesObserved current test setup

Understood the concept of the test

Understood what issues current setup was experiencing

Understood what changes needed to be made

Helped stimulate ideas on tackling the project

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Design and CalculationsEstablishing Final Design92

START

1Design

2Calculations

Review MeetingsFinish

Design

Used idea generation techniques

Transferred concept from existing setup

Incorporated external parts into design

Calculations

Structural engineer guided me in right direction

Bolt sizes and lengths, steel thickness and bending moments

Failure to satisfy calculations results in new design required

Review Meetings

Between myself, line managers and senior engineers

Made any design changes

Approval of design led to next stage of project

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Materials

Choice of materials based on availability and required strengthOver 50 different parts and standard components in the design3 supplier quotation system to ensure cheapest option3D Model and Technical Drawings Implementing Standardised Drawing System

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Manufacture and AssemblyCentraliser Slippage Rig

Turn this pile of metal into a testing rigTechnical drawings assisted in communicating informationDeveloped knowledge in welding and machining

Step by step process of welding and machining assemblies

Minor design changes occurred

Used problem solving skills to overcome challenges

Assembly of rig is now complete

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CommissioningCentraliser Slippage RigCentraliser clamped to inner pipe and sits in carrier pipe

750kN Hydraulic Cylinder applies compressive load down onto centraliser

300kN Hydraulic Cylinder applies horizontal axial load and pushes against carrier pipe

CostsCapital Expenditure of Centraliser Slippage RigMaterialsMaterials such as steel and any component parts were purchased from suppliers SubcontractorsParts made for us such as steel profiling, machining and welding of parts.LabourWelders, machinists and fitters tasked to the project had hourly rates when manufacturing and assembling rig

40,286 Budget

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2311,226

8,124

5,025=15,625 Budget RemainingCost of standard test: - 5,510Additional day testing - 1,562

Current SetupNew SetupRunning Cost40003000Savings per test = 1000Total annual savings = 9000Payback PeriodTesting Rig Cost = 24375243759000= 3 years9 or 10 project completed annually Payback period is 3 years

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ConclusionDoosan Babcock YINI Placement28Thank you to EDT Scotland and Doosan Babcock for making this placement possible

Project Completion

Ease of access for loading and unloadingSafer conditions around the rigIncrease in compressive and axial loadsMore testing availabilities

Personal Development

Knowledge of engineering both theoretical and practicalCommunication skillsResponsibility and reliability to work independentlyProfessionalism in the workplaceOrganisation and planning

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Thank You All For ListeningAny Questions?

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