Live Online Training for Non-Intrusive Inspection according to HOIS-RP-103

Join us on the 13th and 14th of July for our live, online training course for non-intrusive inspection (NII) according to the HOI Recommended Practice for Non-Intrusive Inspection of Pressure Vessels (HOIS-RP-103). 

The course will be led by Dr Susan Osbeck, who has extensive experience of undertaking NII for various operators around the world and was one of the authors to the updated version of the recommended practice, and the guidance notes for the recommended practice (HOIS-G-103).

This course is ideal for integrity or inspection engineers. Spread over two half days, the course is £500 per person and will cover:

  • Integrity and the role of inspection
  • Inspection methods
  • Non-intrusive inspection (NII)
    • The NII process
    • NII assessment
    • NII planning
    • Inspection techniques
    • NII inspection
    • NII evaluation
  • Case Studies
  • NIIMax Demo
  • Summary

Contact This email address is being protected from spambots. You need JavaScript enabled to view it. for more information or to book.

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ESR Technology to exhibit at the OEUK HSE Conference, 28-29 June 2022

ESR Technology are delighted to confirm that we will be attending and exhibiting at the Offshore Energies UK (OEUK) HSE Conference in Aberdeen 28-29 June 2022. We are pleased that this will be a face-to-face event after so many virtual meetings and conferences over the last two years and we’re looking forward to meeting colleagues old and new at our stand.

Serving the Energy Sector for over 30 years and as one of the UK’s leading engineering, safety and risk consultancies, ESR Technology provides essential advice to operators, designers and contractors to ensure safety and reliability in high hazard industries. Recent projects include: Safety Case support to late-life operators and decommissioning projects, CCUS and hydrogen risk assessments, CFD analysis for offshore wind substations, safety assessments for battery systems, data centre reliability assessments, biofuel facilities risk assessments and bearing studies for wind turbines.

For further information please contact our Aberdeen Lead Chris Proud at This email address is being protected from spambots. You need JavaScript enabled to view it., Terry Atkinson at This email address is being protected from spambots. You need JavaScript enabled to view it. or visit https://oeuk.org.uk/event/hse-conference-2022/

 

OEUK HSE Conference

CABARET 3 Beyond the First Year and CABARET Beyond its First 3 Decades

What is more emblematic of modern engineering than a space rocket?

It takes an extreme concentration of power to lift a payload out of Earth’s gravity well. Each liquid-fuelled rocket engine will burn through hundreds of tons of fuel and oxidizer within minutes. The heart of the rocket engine is the turbopump that will push all that mass into the combustion chamber at extremely high pressure. At the heart of the turbopump are ball bearings that support the pump rotor as it spins at tens of thousands of rpm. Under cryogenic conditions. With no oil.

Launch of the first Space Shuttle mission STS-1 on April 12 1981 Launch of James Webb Space Telescope on Ariane 5 VA-256 on December 25 2021

31 years ago, NASA’s Space Shuttle with its RS-25 main engines stood as the epitome of this achievement having been launching for a decade already. In Europe, the Shuttle-inspired Ariane 5 launcher with its Vulcain engine was still at the drawing board. Turbopump development required careful bearing design, but testing was hard and expensive. By developing CABARET (Code for Analysis of BeArings in Rocket Engine Turbopumps), ESTL provided ESA and the European industry with engineering software capable of modelling the special conditions of turbopump bearings: centrifugal and thermal strains, coulombic friction, flash temperature, start-up behaviour and hydrodynamic drag and churn losses. The software was validated largely with RS-25 and Vulcain data.

What environment is more unforgiving for a bearing than the inside of a turbopump?

Oddly enough, the very place a space rocket allows us to reach: the vacuum of space. Satellites and space probes are full of mechanisms (reaction wheels, solar array drives, antenna pointing mechanisms, deployment actuators, and others). These must operate reliably for years instead of minutes; with a few W of power instead of MW; in temperature extremes ranging from the heat of Mercury to the cold of the Outer Planets; at speeds as low as a single revolution per day or thousands of rpm; with a solid lubricant or a fluid lubricant with very specific properties. Most crucially, they operate in high vacuum and zero-g during flight, in air and 1-g during testing on Earth, as well as persist under high-g acceleration during launch. The bearings in them will have to be designed for all of that and testing is still hard and expensive.

Ever since CABARET was made available, the space industry has extended its use beyond turbopumps and towards space bearings, to assess the thermal envelope, torque margins, preload, stress, stiffness, gapping, and truncation requirements; fluid lubrication regime and cage stability were also addressed. To keep up with modern requirements, a new version, based on the versatile Matlab platform, with a modern GUI and significant feature improvements, has been developed on behalf of ESA: CABARET 3 was launched 1 year ago.

In early 2022, the Space Shuttle has been long retired, but the SLS is about to launch using the same RS-25 engines. After a successful career, culminating in the successful launch of JWST, Ariane 5 is handing over to Ariane 6 and reusable Prometheus lies in the future for Europe. New Space launch companies are coming up with new rockets at an unforeseen pace. As space agencies are preparing our return to the Moon, mega-constellations of satellites are being built; but also access to space is being democratised by the activity of hundreds of space start-ups, with great prowess but little experience at designing space mechanisms.

What lies ahead for space bearing modelling?

To remain relevant, CABARET has had to pick up this fast pace of development. Recognising this, ESA and ESTL are following up the software’s release with continuous user support, for troubleshooting, bug reports, training, and bearing analysis consultancy. In parallel, further development of features follows industry needs, with focus on supporting users through the bearing sizing process for space mechanism development (a.k.a. “Guided Mode”), and multi-bearing support. Significant thermal and torque modelling improvements are being researched.

One year after its launch, CABARET 3 has had its first feature update to v.3.1.7.0. The update contains significant fixes to bugs found by the ever-increasing user base throughout the year and some handy feature improvements. We aim to continue updating CABARET, with a launch cadence measuring up to the pace of the space industry.

Improved contact report (v.3.1.7) Improved thermal conductance model Quad bearing configuration 

ESR Technology sponsors Hazards 32 Conference

ESR Technology is proud to confirm our Silver Sponsorship of the forthcoming IChemE Hazards 32 Conference on 18-20 October 2022 in Harrogate. Following the last two previous virtual Hazards conferences it is great that this year’s event will be back to a live, face-to-face format.

ESR Technology has supported this prestigious conference since its inception, exhibiting and presenting technical papers on a wide range of important topics from Gas Dispersion modelling work, to research on Ageing Plant and developing clear ALARP justifications for continued plant operation. Most recently we have presented papers on Hydrogen and Carbon Dioxide modelling in support of Energy Transition projects and Linking Critical Competencies to Major Accident Hazards using Bow Ties.

We are proud of our long-term support to this important industry conference and are delighted to confirm our attendance at Hazards 32. We look forward to welcoming colleagues old and new on our exhibition stand.

For further information please contact Terry Atkinson at This email address is being protected from spambots. You need JavaScript enabled to view it. or visit https://www.icheme.org/hazards32

totalhseawards

TotalEnergies HSE Awards

ESR Technology is proud to announce that one of our Senior Consultants, Victoria Wallace, was part of a team which received the TotalEnergies HSE Award for “Best Safety Improvement”. 

totalhseawards

Victoria was seconded into the TotalEnergies Northern North Sea (NNS) HSE Team from September 2020 – December 2021 primarily working on the Safety Case updates for the Gryphon, Dunbar, and Alwyn North assets.  During her time in the NNS HSE Team she contributed to the development of a programme of Major Accident Hazard (MAH) awareness for the NNS sites.  The programme consisted of three parts:

  • Animated videos outlining the sequence of events for previous incidents with major accident potential.
  • Videos featuring offshore crew members describing major accidents and their role in preventing them.
  • Interactive Bow-Tie exercises relating to the major accidents to identify the causes and consequences.

The MAH Awareness Programme was presented at the Offshore Installation Manager’s (OIM) weekly safety meetings with the intention to increase the understanding and awareness of major accidents, how they are managed and how each individual offshore plays their part in keeping the installations, and their colleagues, safe. 

The NNS HSE Team was nominated for the “Best Safety Improvement” award at the TotalEnergies HSE Awards Ceremony for their work on the MAH Awareness Programme.  This award is “…awarded to an individual or team considered to have made an outstanding improvement to safety or to have contributed to reducing major accident hazards, using the TotalEnergies HSE systems (safety observation, stop card, TotalEnergies Safety practices) or any initiative they've initiated or implemented.”  Victoria, along with Stacy Bridgewater, Aleksandra Kania, and Richard Bailey are delighted to have won this award. 

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