The document summarizes a student's contribution to designing and building a new centraliser slippage testing rig for Doosan Babcock's Component Testing department. The key points are: 1) The student helped design and build a new centraliser slippage testing rig to replace an outdated current setup, incorporating ideas from meetings and calculations to ensure structural integrity. 2) Materials were sourced and technical drawings created to manufacture over 50 parts, which were welded and machined by the student according to drawings and procedures. 3) The completed rig allows for increased testing loads and safer, easier component loading compared to the previous setup, and has a payback period of 3 years based on reduced running costs.

1. YINI Student - Azam Ghaffar
Contribution to the Business Awards

2. Nature of Doosan Babcock’s Business
Component Testing
Nuclear
Civil Engineering
Aerospace
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
1
2
3
4
5

3. 4
More testing availabilities
3
Increase axial and
compressive loads
Ease of access for
loading and unloading
1
Safer conditions around rig
2
Project Details
Centraliser Slippage Rig
Design and manufacture a Centraliser Slippage Rig for the department
• Current setup is outdated and needs replaced
• Axial load is causing damage to current test machine
• Limiting capabilities affect current setup

4. • 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 Project
Subsea Pipeline Component Qualification
Expansion Programme
Real Life Application of Centralisers
• Centraliser 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 won’t slip when passing
over weld

5. Design
Propose ideas that meets project criteria
Calculations
Justify final design
Materials
Source appropriate materials and components
Manufacture & Assembly
Machine and weld materials to complete assembly
Commissioning
Conclude finished testing rig works successfully
Initiating the Project
Project Stages
Observed 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

6. Design and Calculations
Establishing Final Design
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START 1
Design
2
Calculations
Review Meetings
Finish
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

7. Materials
• Choice of materials based on availability and required strength
• Over 50 different parts and standard components in the design
• 3 supplier quotation system to ensure cheapest option
3D Model and Technical Drawings
Implementing Standardised Drawing System

8. Manufacture and Assembly
Centraliser Slippage Rig
• Turn this pile of metal into a testing rig
• Technical drawings assisted in communicating information
• Developed 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

9. Commissioning
Centraliser Slippage Rig
Centraliser 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

10. Costs
Capital Expenditure of Centraliser Slippage Rig
Materials
Materials such as steel and any component
parts were purchased from suppliers
Subcontractors
Parts made for us such as steel profiling,
machining and welding of parts.
Labour
Welders, machinists and fitters tasked to the
project had hourly rates when manufacturing
and assembling rig
£40,286
Budget
1
2
3
£11,226
£8,124
£5,025
=
£15,625
Budget Remaining
• Cost of standard test: - £5,510
• Additional day testing - £1,562
Current Setup New Setup
Running Cost £4000 £3000
Savings per test = £1000
Total annual savings = £9000
Payback Period
Testing Rig Cost = £24375
£24375
£9000
= 3 years
• 9 or 10 project completed annually
• Payback period is 3 years

11. Conclusion
Doosan Babcock YINI Placement
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Thank you to EDT Scotland and Doosan Babcock for making this placement possible
Project Completion
Ease of access for loading and unloading
Safer conditions around the rig
Increase in compressive and axial loads
More testing availabilities
Personal Development
• Knowledge of engineering both theoretical and
practical
• Communication skills
• Responsibility and reliability to work
independently
• Professionalism in the workplace
• Organisation and planning

12. Thank You All For Listening
Any Questions?