Plant Integrity

Doosan Power Systems

enabling energy
Its what we bring together that sets us apart
Doosan Power Systems
Doosan Power Systems is a multi-specialist services company operating in the Oil & Gas, Petrochemical, Thermal
Power, Nuclear, and Pharmaceutical industries. We provide innovative technology that supports and enhances the
service life of energy assets across the globe.
With over 110 years experience in the energy sector, our team has the experience and knowledge to identify,
prioritise and effectively manage the risks associated with in-service degradation that can compromise plant integrity.
Accreditation
ISO 9001: Quality Management Systems
ISO 14001: Environmental Management Systems
Pressure Equipment Directive 97/23/EC (CE Mark)
ASME Boiler & Pressure Vessel Code: S, U, U2, PP
ASME Boiler & Pressure Vessel Code: NBBI Repair R & NB
UKAS Inspection Body (Type C): BS EN ISO/IEC 17020
UKAS Testing Laboratory: BS EN ISO/IEC 17025
Capability
Technology, integrated
process plant solutions
and services that are
focused on your
business priorities.
People
Industry experts who
understand your
challenges and deliver
on their promises.
Global Reach
Strength and security
from a global business
that maintains the highest
standards of quality,
safety and environmental
practices.
Across the oil, gas and petrochemical industries youll find the Doosan Power
Systems team of specialists working with asset operators to effectively manage
the integrity of plant.
Our Plant Integrity business not only provides asset operators with a full suite of
products to minimise plant downtime and maximise safety but can access a range
of services within the Doosan Power Systems organisation including specialist NDT,
plant inspection, manufacturing and fabrication, welding services, metallurgical
testing laboratory and a UKAS accredited material testing laboratory.
Through our innovation we support and enhance the service life of energy assets
across the world.
Plant Integrity
Plant Integrity Services
and Engineering
Vibration and Noise Management Services
Monitoring Systems
Fitness for Service
Pressure System Repair & Plant Modication
Plant Integrity Management Products
Complimentary Services
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Improving Safety
Vibration induced fatigue is one of the most common
causes of failure in process pipework. The unplanned
release of hydrocarbon gas or liquid is primarily a
safety concern but also has severe financial and
environmental consequences, and risks lasting
damage to reputations.
A co-author of the leading industry guidance on the pipework
fatigue Guidelines for the Avoidance of Vibration Induced
Fatigue Failure (published by the Energy Institute), Doosan
Power Systems provides a complete solution based on application
of its expert vibration knowledge and understanding its
customers needs.
Vibration & Noise
Management
Services
From pro-active screening
surveys to in-depth failure
analysis, Doosan is an
industry leader in vibration
management services.
04 Doosan Power Systems Plant Integrity Vibration & Noise Management Services
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The necessary capability
Unacceptable cyclic stress levels in pipework and pressure
systems can be induced by many excitation factors including
flow, machinery induced pressure pulsation, acoustic,
environmental and structural transmission. Doosan Power
Systems have significant experience (>250 man-years) of
identifying and resolving acoustic and vibration issues found
on both offshore and onshore process plant. Our solution is
to quantify the risk posed by excessive vibration, identify the
cause, and propose and implement a remedial strategy to
remove or control the excitation energy as appropriate.
An unrivalled service
Risk Based Piping/Structural Vibration Assessments
at design, commissioning and throughout the asset's
life cycle
Piping / Structural Vibration Investigations
Transient Vibration Assessment
Pipework Stress Analysis (Static & Advanced Dynamic)
Subsea Pipework Fatigue Risk Assessment & Monitoring
Design, Fabrication and Installation of pipe supports /
viscous damper solutions
Acoustic Analysis
Noise Assessment and Control (including regulatory
compliance)
1 Offshore Flare Stack
2 Finite Element Analysis of Small Bore Connection Bracing
at High Frequency
3 Vibration Analysis of Piping System using Smart Office Analyser
4 Doosan designed and fabricated anti-vibration clamp for small
bore connection experiencing high vibration.
5 Transient vibration assessment of pressure relief pipework
Doosan Power Systems Plant Integrity Vibration & Noise Management Services 05
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Quantify Analyse Solve Remedy
Improving Visibility
Mobilising specialist engineers is an effective
method of carrying out risk assessment and
analysing problems at known process conditions.
Unfortunately the risks to your pipework and
structure will not always manifest themselves in
front of an audience.
Doosan Plant Integrity Services can provide a range of multi-
channel monitoring systems to watch your plant 24 hours a day,
7 days a week for extended periods.
Fully integrated service system specification, design,
installation, commissioning, data analysis and importantly,
recommendation of remedial measures when required
Manned & unmanned systems
Laptop based safe area or ATEX Zone 1 & 2 rated systems
available with USB and wireless data recovery options.
Measuring vibration, strain, pressure pulsation
Short term installation for one off events, or integrated
into the platforms control system for the lifespan of
the asset
Whole time history recording or trigger level recording
Data analysed by our expert engineers against plant
operating & environmental conditions to determine
root cause
System configurable to provide remote viewing of data
by office based engineers in real time
06 Doosan Power Systems Plant Integrity Monitoring Systems
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Monitoring
systems
Temporary, manned systems
to temporary or permanent
unmanned systems for piping
and structural monitoring
Doosan Power Systems Plant Integrity Monitoring Systems 07
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1 Signal Conditioning Cabinets - 128 Channel Pipework
Vibration Monitoring System
2 Online Data Analysis - Temporary Pipework Vibration
Monitoring System
3 Accelerometers - Temporary Pipework Vibration
Monitoring System
4 Hazardous Area Logger (HAL) System (ATEX Zone 1 / 2)
Improving Understanding
Understanding the likelihood of any detected
flaw to result in failure of the component is
crucial in ensuring safe continued operation of
any asset. The knowledge that a flaw can remain
safely in place, or alternatively the timescale to
which any repair or replacement is required
allows optimisation of plant downtime and
repair costs.
Doosan Power Systems will not only assess the fitness for
services of defects to the relevant codes. We can assist with
determining remaining lifespan and managing the defect to
the end of the design life of the component, or advise on and
design appropriate and practical repair methods.
Combined with our extensive in house metallurgy and component
testing department, Doosan Power Systems also provides a
comprehensive fracture mechanics testing and assessment
facility.
08 Doosan Power Systems Plant Integrity Fitness for Service
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Fitness
For
Service
Doosan Power Systems are
providers of defect and remnant
life assessment services for all
vessels, piping, tanks and
process plant.
Doosan Power Systems has extensive experience in
all types of defect assessment based on 30 years of
experience in the oil and gas sector. For example:
General and local metal loss
Assessment of metal loss in piping, vessels and tanks, to all
levels of assessment, giving guidance on remaining operating
lifespan. Where non-standard problems are encountered or
an API579 level 3 assessment is required, finite element
analysis can be used to provide a solution.
Fatigue Failure
Doosan Power Systems can asses the fitness for service
of components where it is believed the fatigue life may be
compromised by changes in design or the presence of
defects. On site measurement and/or analysis (including
non-linear and harmonic FEA) can be used to determine a
more accurate fatigue life and understanding of the
components fitness for service.
Manufacture Defects/Code compliance issues
Assessment of in service mechanical damage and of out of
design code components, specifically pressure parts.
Crack Like Flaws
Doosan Power Systems has extensive experience in fracture
mechanics assessment. Initially gaining experience in the
nuclear industry, our services have been expanded to the
oil and gas sector. Through the use of both in house software
and proprietary software, we can carry out assessment to R6,
BS 9710 and API 579 fitness for service codes.
Doosan Power Systems Plant Integrity Fitness for Service 09
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1 Severely Corroded Pipework Flange Joint
2 Fitness for Service Assessment Software
3 Fitness for Service Level 3 Assessment using FEA
4 Fitness for Service Level 3 Assessment using FEA
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Improving Availability
Further enhancing the Plant Integrity consultancy
services is our ability to provide fully engineered
solutions to solve piping and structural integrity
issues. What sets us apart from our competitors
is that our consultants who performed any
integrity investigation, for example following a
fatigue failure, sit in-house with our piping,
pressure part, structural and civil engineers.
With an increasing number of oil and gas installations reaching
the end of their original intended design life, the frequency of
defects found in pressure parts is increasing. Although preferable,
replacement can be impractical and carry unacceptable risk,
leading to the need for safe repair to these pressure systems.
Repairs need to be carried out with the least downtime or disruption
to the plant, frequently either on or close to live plant.
From complex high integrity nuclear pressure parts to fast turn-
around repairs of standard piping, Doosan Power Systems has
over 110 years experience in the design, supply and repair of
pressure parts. This includes design to code formulae and also
design using in house or other methods to comply with code
stated but unformulated requirements. To compliment any repair
of pressure parts, our in-house civil and structural department
can carry out any necessary design repair of associated structures.
Doosan Power Systems assists our clients from initial flaw
assessment through design of the repair and guidance on future
inspection regime. Furthermore our experienced site personnel
can carry out the repair implementation.
10 Doosan Power Systems Plant Integrity Pressure System Repair & Plant Modification
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Pressure System
Repair & Plant
Modification
Utilising our in-house civil,
structural and piping engineer
resource in support of our plant
integrity services.
Repair Services
Design of welded repairs and replacements of nozzles,
ends, thermal sleeves and other details
Design of both temporary and permanent non-welded
repair of pressure parts
Civil and structural design and repair
Provide an independent advice service on selection of
third party repair methods
Weld procedure qualification
Case study: Flowline Modifications
High levels of vibration were noted on an offshore installation
flowline. Dynamic stress measurements by Doosan and a
fatigue analysis to BS7608 had indicated that the piping was
at risk of high cycle fatigue failure. The excitation source was
due to multiphase / turbulent flow. This broadband excitation
source excites all natural frequencies of the pipework. Adding
stiffness (i.e. a support) would have restricted the thermal
expansion requirements of the piping and not substantially
altered the level of vibration as it does not remove the energy
from the system.
The solution was to increase the damping, i.e. dissipation
of energy present in each of the dominant modes. Doosan
achieved this by the installation of viscous pipework
dampers. These units extract energy from the piping by
converting the excitation energy into heat energy within
the damper. Installation required no re-calculation of the
piping stresses.
The following scope of work was carried out by Doosan:
Specification of the required damper unit size and type
Site dimensional and constructability survey
Design of the appropriate secondary mounting steelwork
verified using STAAD Pro and drafted in Seimens Solid Edge
Performance of the damper support validated using finite
element analysis to ensure design is of sufficient stiffness
Steelwork was fabricated to agreed industry code (EEMUA
197) and delivered to the client in kit form requiring only
bolted construction on site
Doosan Power Systems Plant Integrity Pressure System Repair & Plant Modification 11
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1 Vessel blast restrain steelwork design
2 Welded sleeve repair of In-Service Pipework
3 Piping Viscous Dampers
4 3D Model of Damper Design
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12 Doosan Power Systems Plant Integrity Plant Integrity Management Products
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Plant Integrity
Management
Products
At Doosan Power Systems we
provide an unrivalled service to
our customers. In support of our
consultancy services our engi-
neers have developed award
winning products to meet our
clients requirements
Improving Commitment
Pipe Vibration Meter (PVM)
Historically, any piping vibration concerns raised on site
would result in the mobilisation of a specialist consultant
engineer to investigate, with the associated cost and
time delay.
Doosan Power Systems unique solution is the Pipe
Vibration Meter (PVM). The PVM is a hand held, single
channel vibration measurement and analysis system for
quantifying and classifying pipework vibration levels.
Developed for use by non-expert personnel on client
assets, the PVM combines proven FFT analyser technology
with industry standard vibration criteria.
Readings can be stored and trended using PVM Manager
software on the clients PC. The software allows results to
be displayed and reports generated as well as individual or
data set readings to be e-mailed directly to an onshore
Doosan engineer for further analysis.
The PVM provides the ideal balance between expenditure
and integrity assurance safeguarding your assets,
utilising your personnel and providing access to the best
in technical support.
www.pipevibrationmeter.co.uk
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Hazardous Area Logger (HAL)
Events that induce excessive levels of cyclic stress in a
piping system can fall into two categories; steady state and
transient. By their very nature transient events can be difficult
to predict and capture. This can prevent the identification
of fatigue inducing levels of stress and hamper the identifi-
cation of the root cause of the damaging energy.
The Hazardous Area Logger (HAL) is a configurable data
acquisition system that is certified for deployment in a
Zone 1 or 2, Gas Group IIC area. Using Ex certified ICP sensors
it can monitor multiple channels of vibration, dynamic
strain and pressure pulsation for extended periods.
The system provides a cost effective local monitoring
system without the need for routing cables to platform safe
areas. Data can be retrieved from the units storage hard
drive by platform personnel, removing the need for specialist
engineers to be mobilised during the HALs deployment.
The HAL provides reliable time history data that forms the
basis of fatigue life assessments, root cause analysis and
failure investigations and process optimisation trials.
Vibration Awareness Training
Initially developed at the request of our customers, Doosan
Power Systems can provide bespoke classroom or site
based training in pipework vibration awareness. Covering
vibration theory, measurement, assessment criteria and
warning flags the training will provide asset personnel
with invaluable knowledge to identify risks to their
plants integrity.
Also available are training sessions in the use of the Pipe
Vibration Meter (PVM), the hand held vibration measurement
and analysis system for use by non-expert personnel.
Training is provided by our consultant engineers who are
experts in the field of pipework vibration.
Vibration Risk Management
In support of our pipework vibration management,
Doosan Power Systems has developed an RBI database.
This proprietary software allows the Likelihood of Failure
(LOF) associated with all piping on the asset to be registered
and quantified (in line with the Energy Institute AVIFF
guidelines). The database also allows Piping Vibration
Concerns (PVCs) to be created, reported and managed.
For real time management of pipework vibration concerns
and associated remedial work, the database can be hosted
securely on Doosans website for access by approved
client personnel.
Doosan Power Systems Plant Integrity Plant Integrity Management Products 13
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1 Doosan Babcock Pipe Vibration Meter
2 Doosan Babcock Pipe Vibration
3 Vibration Awareness Training
4 Hazardous Area Logger in use on Site
Finite Element Analysis (FEA)
As a stand alone product delivery or part of a full fitness
for service assessment process we can use the latest
FEA techniques and software to model and analyse
pressure system components.
Specialist NDT
The key to understanding your asset integrity is the
ability to be able to accurately measure the degradation
levels present. When parts of the system are normally
inaccessible to standard NDT techniques how do you
determine fitness for service? We can deploy the latest
NDT techniques such as Phased Array, Chime & TOFD
with the appropriate pre-qualification testing and
modelling to ensure the technique will accurately
assess your materials and geometry
Welding Services
Our specialist knowledge in welding and joining
technologies is a vital aspect of our business, and
access to this experience is offered to customers in the
form of a comprehensive welding engineering consultancy
service. From on-line repair to component replacement
we can provide Weld Procedure Specifications (WPS)
and supporting Procedure Qualification Report (PQR)
from design to implementation.
Metallurgical & Component
Testing Laboratories
Doosan has a full range of in house UKAS accredited
metallurgical and component test laboratory services.
These include metallurgical failure investigations,
full scale tensile tests, four point bend test to Charpy
toughness tests and Positive Material Identification (PMI)
essential in developing Weld Procedure Specifications.
14 Doosan Power Systems Plant Integrity Complimentary Services
Complimentary
Services
As part of Doosan Power Systems,
we have access to a range of
highly regarded departments
providing asset management
service in their own right.
When combined, we can provide
a powerful one-stop-shop for
integrity services.
Doosan Power Systems
Porterfield Road, Renfrew, PA4 8DJ, United Kingdom
Tel: +44 (0) 141 886 441 Fax: +44 (0) 141 885 3338
Doosan Power Systems Ltd
Doosan House, Crawley Business Quarter, Manor Royal, Crawley,
West Sussex, RH10 9AD, United Kingdom
Tel: +44 (0) 1293 612888 Fax: +44 (0) 1293 584321
Doosan Power Systems (Europe)
Friedrichstrasse 45-47, 45128 Essen, Germany
Tel: +49 (0) 201 747 99 100 Fax: +49 (0) 201 365 88 647
Doosan Power Systems (North America)
1050 Crown Pointe Parkway, Suite 1200, Atlanta GA 30338, US
Tel: +1 (770) 551 5750 Fax: +1 ( 770) 551 5753
Skoda PowerTylova
1/57, 301 28 Plzen, Czech Republic
Tel: +420 378 185 939 Fax: +420 378 185 910
Skoda PowerTylova
1/57, 301 28 Plzen, Czech Republic
Tel: +420 378 185 939 Fax: +420 378 185 910
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www.doosanpowersystems.com
Doosan Power Systems