Factory Acceptance Testing: Ensuring Precision and Performance

Amanda Johnson

The INCITIAS Melbourne team is working on a renewable energy project for our French client. As key members, Bastiaan and Alice recently undertook Factory Acceptance Testing (FAT) for the critical technological components, which INCITIAS created and refer to as ‘Noble parts’. As system integrators, we select and use readily available components (off-the-shelf) and modify/integrate them into our original products. 

Confirming the Operation and Assembly of Noble parts

The foundation of any successful project lies in its construction. INCITIAS comprehensively tested and confirmed the operation and assembly process of the drive system. 

This is the moment when we bring together the drive and control components to assemble them and test their functionality and the software programming. We consider this the critical component of our Reels. 

This testing day is essential in our service to ensure our unwavering commitment to providing quality products and engineering solutions.

Precision Testing: A Closer Look

Factory Acceptance Testing (FAT) for our control system is a pivotal moment in the project’s timeline. 

Control system test

Our team was on-site with Marcus Cook, an Automation Engineer; we checked our system’s various aspects. Testing the functionality and capabilities of the servo motors, drive system and wireless controller. Remote control systems are integral to many industrial operations. We subjected our remote-control system to rigorous testing, ensuring it met the highest standards of functionality and reliability. 

Testing confirmed that the control system met the specifications. Integration with the off-the-shelf products worked in the intended fashion and delivered the expected performance, speed and torque. 

Torque Test

Our torque testing included: 

  1. Without Gearbox: We checked the torque of the motor, without the gearbox, ensuring optimal performance at this stage.
  2. With Gearbox: We repeated the tests to guarantee seamless integration and smooth operation with the gearbox in place.
  3. Slewring Assessment: The slewring, a critical component, was also subjected to meticulous testing, ensuring it met our rigorous standards.

 

Tackling Friction Loss 

Ensuring our RPM and torque values accurately aligned with the control panel’s indications was a non-negotiable step. Managing different settings for the drive system, including the operation of the reels and emergency procedures, was crucial for a successful outcome. 

The two inputs include:

  1. Setting a speed for the server motor (RPM) and physically observing and confirming the system speed.
  2. Introducing a tool to input a specific torque to confirm the ability of the motor to withstand the load, based on the settings. 

When different components come together, friction losses can become a concern. We addressed this by confirming the accuracy of our control system readings, by verifying onscreen panels with manual read-outs. 

Melbourne’s Testing Advantage 

By testing our noble parts in Melbourne before integration with our Fabrication partners in Dubai, we ensure a cost-effective solution for our clients. 

For this project, we built a dedicated test rig in Melbourne. The control system, steel parts and drive components will be tested again at the FAT on-site in Dubai once the remaining components have been integrated, assembled and delivered to the fabrication yard before delivering the entire system to France. 

INCITIAS noble parts Factory Acceptance Testing is a pivotal phase in our Original Equipment projects, where every detail matters. This FAT was successful and complied with the project specifications. 

At INCITIAS, we are committed to engineering excellence and client satisfaction. Our Melbourne-based team, in collaboration with our global partners, ensures every aspect of our project meets the highest standards of precision and performance. We look forward to delivering excellence in engineering for our French clients on this project. 

For more insights into our projects and capabilities, visit Projects page.

For more information please contact: Bastiaan Scheepers

Engineering Services

INCITIAS Services and Original Products are supported by in-house team of engineers and designers:

  • Naval architects
  • Process engineers
  • Mechanical and Marine engineers
  • Safety and risk engineers
  • Structural and civil engineers
  • Electrical and instrumentation engineers
  • Subsea engineers
  • Construction supervisors
 

Naval Architecture services:

  • Hydrodynamic analysis
  • Hydrostatic analysis
  • Offshore and nearshore mooring systems design 
  • Design in accordance with IMO and class requirements

Process Engineering services:

  • Cryogenic system engineering for LNG, ethane, LPG, and hydrogen
  • Chemical engineering for olefins, biodiesel, and chemical bulk handling
  • Natural gas networks
  • Fuel systems
  • Jetty topsides for conventional oil and LNG
  • FPSO topsides design
  • Process system commissioning
 

Mechanical and Marine Engineering services:

  • Original equipment and machinery design
  • Hydraulic and pneumatic system design
  • Cryogenic pressure vessel design
  • Piping systems design
  • Package engineering
  • Marine systems integrations
  • Cargo and ballast systems, HVAC, and cooling propulsion solutions
 

Safety and Risk Engineering services:

  • Explosion studies
  • Gas dispersion studies
  • Cooling water dispersion studies
  • QRA, HAZOP and HAZID coordination
 

Structural Engineering services:

  • Marine and offshore structure design
  • Structure life extension
  • Fatigue studies
  • Asset integrity
 

Electrical and Instrumentation Engineering services:

  • Load lists
  • Shore-to-ship power connections
  • Power system design
  • LV and MV engineering
  • Subsea electrical systems engineering
  • Process and machinery instrumentation design
 

Subsea Engineering services:

  • ROV operations engineering
  • Subsea intervention engineering
  • Subsea pipeline system design
  • Flexible flowline and umbilical design

FPSO External Riser turret mooring

Mooring Handling LIFTING BEAM GENERAL ASSEMBLY Original Equipment

Hose Reel 3D hybrid render

FPSO Bow Extension 3D modelling

FPSO Decommissioning

Our clients find our experience invaluable during FPSO decommissioning planning and execution, using the INCITIAS teams’ ability to assess the most suitable strategy, based on the project and local authority’s requirements. Our team has extensive experience in the design and installation of FPSO mooring systems, risers and umbilicals.

 

We can support the client decommissioning plan with the following services:

 

  • Decommissioning option selection study and recommendation
  • Cost estimate and assessment of cost escalation
  • Contracting strategy options selection and recommendation
  • Integrated owner engineering team
  • Original equipment to unlock value in the decommissioning plan
  • Project management of decommissioning team and sub-contractor

 

Examples of typical deliverables for FPSO Decommissioning are:

 

  • Execution plan and cost estimation
  • Riser, umbilical and mooring disconnection analysis
  • Vessel spread selection and market enquiry
  • Decommissioning story board, tools and resource lists 
  • Design and build of original equipment 
  • ROV campaign support
  • Decommissioning schedule and procedure
  • Request for quotation, bid assessment and recommendation 
  • HAZID and HAZOP

Single Point Mooring system

Turret Mooring

Independent Verification Design

Working together with INCITIAS, clients can obtain objective evidence of asset compliance with project requirements.

With our independent verification design process, INCITIAS applies an efficient risk-based assessment method to prioritise critical elements of the asset.

 

An INCITIAS comprehensive review can include:

 

  • Desktop review of design documents
  • Review of HAZID, EIA and QRA findings
  • Risk ranking of asset elements
  • Preparation of review plan
  • Client approval of review plan
  • Execute review plan, including on-site performance verification
  • Issue of certification certificate
 

We work together with our clients to ensure the appropriate level of review is carried out.

Operations & Maintenance Support

INCITIAS combines our Engineering expertise with real world Operations and Maintenance experience.  We support our clients with O&M development and management activities including:

 

  • Enterprise management system development
  • Organisation structure development and evaluation
  • Systems and procedures development and review, including detailed procedures, permits and work systems
  • Emergency response systems
  • Defining specific port operations requirements
  • Operation and maintenance training and competency assessment
  • Commissioning activities

Integrated Owner’s Engineering Services

We support Owners with engineering, technical, and project management expertise across LNG, marine, and vessel conversion projects. Our clients can minimise risk and maximise opportunities earlier in project execution, with INCITIAS Owner’s engineering services. 

 

INCITIAS can provide integrated owner’s engineering services for onshore and offshore projects from a client office, site location or remotely from our offices in Melbourne. 

 

Typical services are:

 

  • Design and construction management
  • Customised risk management solutions
  • Specialist LNG process and marine engineering
  • Budget implementation, scheduling, and cost control
  • Non-permanent on-site dedicated offices for project

 

 

Indicative deliverables are:

 

  • Technical document reviews
  • Project bankability documents 
  • Basis of design
  • Functional performance specification
  • Resource plan and project schedule
  • Request for quotation and technical bid evaluation
  • Participation in HAZID, HAZOP, QRA, design reviews
  • FAT (Factory Acceptance Tests) certification
  • Work packs for installation contractor
 

We can be as involved as you require. From specialist resources who consultant on specific aspects of your project, to the provision of a fully integrated Owners team. 

At INCITIAS we develop tailor-made delivery solutions to match your project’s execution strategy and risk profile. Offering a full range of alternative delivery methods enables us to deliver the most effective project outcomes for you.

CLP Jetty Installation during the daytime

Advisory Services

INCITIAS offers integrated technical and commercial advisory services to assist clients advance their projects and provide support for their decision-making process. Clients can reduce risk and maximise opportunities by accessing our team of advisory specialists’ wealth of experience.

 

Typical advisory services are:

 

  • Technology assessment and selection. 
  • Commercial risk assessment.
  • Pre-feasibility, feasibility, and pre-FEED and FEED studies.
  • Contract review against the project technical performance.
  • Independent review of project execution plan.
 

INCITIAS techno-commercial advisory services aligns commercial drivers with feasible and proven technical solutions. Our team’s experience includes facility selection, financial assessment, contracting strategies, construction management and project operations. Assisting clients meet their business objectives using our capabilities to provide insights and solutions. 

 

Indicative deliverables are:

 

  • Site selection study
  • Environmental pre-assessment 
  • Technology options, recommendations and definition
  • Review of contract commitment against the facility performance
  • CAPEX and OPEX estimates
  • Financial models, NPV calculation, tolling model, and sensitivity assessment 
  • Project bankability document pack
  • Probabilistic models combining queueing and Monte Carlo assessment for logistic studies
  • HAZID, HAZOP, QRA and project risk assessment 
  • Operations and training requirements definition