Wednesday, May 23, 2018

3-D Metal Printing

New machines are making 3-D printing of metal parts practical for the first time.



While 3-D printing has been around for decades, it has remained largely in the domain of hobbyists and designers producing one-o prototypes. And printing objects with anything other than plastics—in particular, metal—has been expensive and painfully slow. Now, however, it’s becoming cheap and easy enough to be a potentially practical way of manufacturing parts. If widely adopted, it could change the way we massproduce many products. In the short term, manufacturers wouldn’t need to maintain large inventories—they could simply print an object, such as a replacement part for an aging car, whenever someone needs it. In the longer term, large factories that mass-produce a limited range of parts might be replaced by smaller ones that make a wider variety, adapting to customers’ changing needs. The technology can create lighter, stronger parts, and complex shapes that aren’t possible with conventional metal fabrication methods. It can also provide more precise control of the microstructure of metals. In 2017, researchers from the Lawrence Livermore National Laboratory announced they had developed a 3-D-printing method for creating stainless-steel parts twice as strong as traditionally made ones. Also in 2017, 3-D-printing company Markforged, a small startup based outside Boston, released the first 3-D metal printer for under $100,000. Another Boston-area startup, Desktop Metal, began to ship its first metal prototyping machines in December 2017. It plans to begin selling larger machines, designed for manufacturing, that are 100 times faster than older metal printing methods. The printing of metal parts is also getting easier. Desktop Metal now offers software that generates designs ready for 3-D printing. Users tell the program the specs of the object they want to print, and the software produces a computer model suitable for printing. GE, which has long been a proponent of using 3-D printing in its aviation products (see “10 Breakthrough Technologies of 2013: Additive Manufacturing”), has a test version of its new metal printer that is fast enough to make large parts. The company plans to begin selling the printer in 2018.
—Erin Winick

Monday, May 21, 2018

IP got the Electric Shock while opening a Container Door

What happened?

Injured Person (IP) was walking to canteen during a heavy rain. While he was walking up on a ladder, he caught the door handle and opened the container door by his right hand and still held the handrail with his left hand. Suddenly, he got an electric shock that leaked from a flood light. 

What went wrong?

-The flood light on the top of container had water inside, causing an electric current leak to container door.

Factors contributing to this incident: 

-The cable gland seal of junction box was cracked and the enclosure of flood light was deteriorated.
-There was no detail of preventive maintenance program for the flood light and all facilities.
-The flood light was relocated from mobile pole to the top of container without management of change (MOC).
-Grounding system of the container was substandard causing grounding resistance > 5Ω.
-Insufficient resources provided to manage electrical hazards e.g. no dedicated electrician, no spare part.

Recommendations:

-Shutdown the workover unit for overall re-inspection by qualified third party to ensure that it is safe to operate.
-Perform workover rig acceptance, readiness to drill, and pre-spud audit for every rig move.
-Build an additional permanent ground pit at well location to cover the drilling and well intervention activities.
-Improve Preventive Maintenance (PM) program for electrical system and all safety systems.
-Develop an inventory list of critical spare parts to be available on site.
-Provide a qualified electricians dedicated to individual rig.
-Verify the compliance of contract and legal requirements by contract holder.
-Implement Management of Change (MOC) for all equipment modification.
-Provide AED (Automated External Defibrillator) for remote site clinic.

Learning from this incident:

-All equipment and safety systems must be properly installed, maintained and inspected at all time.

Tuesday, June 27, 2017

Wednesday, November 18, 2015

How PSV works ?

Basic Operation

Below Set Pressure With Main Valve Closed


At Set Pressure


Set Pressure at 110%


Below Set Pressure


POP Action Pilot


Modulating Action Pilot


Thursday, October 22, 2015

Pressure Safety Valve(PSV) Test Incident

What happened?

A Pressure Safety Valve (PSV) was taken to the PSV workshop to be re-certified. The PSV was attached to the bench with a Teflon adapter and pressurized for leak test.
Initially all PSV testing crew remained outside the PSV test container, while air increasing pressure to the PSV. Once the pressure reached 140 bars and stabilized, 3 PSV testers went into the PSV container and used soapy water to test the leak around the PSV. Shortly after the commencement of the leak check, the Teflon (PTFE) adapter failed resulting in ejecting. 



What went wrong? 

Using substandard material, e.g., self-made PTFE adapter gasket (failure to identify the limitations and characteristics of PTFE). 

Factors contributing to this incident:

-PSV tester indicated that they had used similar adapters on other jobs before.
-There was no technical evaluation or Management Of Change (MOC) applied to the use of Teflon (PTFE) as a adapter piece.
-The machining of the adapter piece did not conform to designs to reduce stress points.
-The location of the Test bench did not allow ease of alignment of the PSV.
-The Contractor does not have a written and approved Procedure for the testing of PSV’s.

Recommendation:

-Only standard material shall be used for the PSV testing and high pressure operations.
-Relocate test bench to center of the container, ensuring full assembling/removal of clamp arms is possible.
-Management of Change procedures shall be applied if there must be any changes from standard procedures, requiring full evaluation of the proposal, including Risk Assessment.
-Written & approved Procedures shall be in place for all activities and communicated to concerned parties.


Wednesday, October 21, 2015