INNOVATION WITHOUT BOUNDARIES www.nustar-tech.com TESTING AND ASSEMBLY NuStar Technologies Pte Ltd 1 Gul Road Singapore 629362 Tel : (65) 6684 7250 Fax : (65) 6778 1871 Email : [email protected]® API QR Registraon 2085 HYDROSTATIC TEST Hydrostac Tests are performed for valves and other equipment with accordance to API 6A and 17D requirements. The facility test bays are enclosed with bunker walls as safety barriers. Pressure control panels are located on the outside of the test area for easy access. All hydrostac tests are performed using inhibited water, pumped into the test products at prescribed pressures. Tests results and leakages are monitored from pressure gauges and pressure over me charts using chart recorder devices. KEY FEATURES [ Pressure up to 22500 psi [ Bunker Walls as safety barriers [ Warning Light during tesng [ Large structures mounted on flat plates for distributed loading SUBMERGED GAS TEST Submerged Gas Tests are performed in our dedicated test pits. Nitrogen is the gas medium for high pressure tests, pumping valves and other products to pressures of up to 30,000psi. Submerged tests are done with gas pumped into the products placed underwater in our test tanks. Leakages are monitored from the tank and as required, leak detecon systems are setup to detect minute leakage. KEY FEATURES [ Two water tank sizes for tesng of large test pieces [ Cylindrical tank allows for tesng of assemblies up to 90” height [ Cameras mounted for real me recording [ Ladder structures for safe access DYNAMIC CYCLING AND ENDURANCE TEST Dynamic Cycling Tests are performed in accordance to API 6A includes a 600 operang cycles test for valves ambient condions. NuStar’s gate valve DAQ system is able to perform endurance cyclic tests by pressuring and opening valves systemacally to simulate the valve’s operang cycle. Endurance tesng with the system is done automac and requires minimal manual inputs. KEY FEATURES [ Rotaon of valve using hydraulic torque tool [ Air powered tool controlled by DAQ system via solenoid valves [ Rotaon counters and posion sensors automates counng process [ Limit sengs prevent overtorque of valve [ Quick and hassle-free operaon types of tests At NuStar Technologies, all our tests are conducted by our experience and highly trained personnel. TEMPERATURE CYCLING TEST Pressure Temperature Cycling Tests are an integral part of the API 6A Appendic F PR2 qualificaon process. These are conducted in controlled insulaon chambers and are subjected to temperature extremes with our temperature controller and liquid LN2 tanks. High pressure is supplied by hydro pumps and gas booster and all signals from sensors and thermocouples are logged with the DAQ system and displayed real me in our HMI unit of the DAQ system. KEY FEATURES [ Fully automated during tesng [ Easy user interface for monitoring and control BENDING TEST Bend Structure Tests are performed on subsea equipment which are exposed to high bending moments in the environment. The test arcle is bolted onto one end of an ‘I’ beam and subjected to a force upwards on the other end of the beam. Pistons are employed to provide the required force on the product to subject it to the required bending moment based on the length of the beam. Prior to tests, FEA is used to verify the crical planes of the tested product when subjected to the required bending moment. Verificaon is done using strain gages placed on the crical planes and connected to an in-house data logger. KEY FEATURES [ Bend test structure allows for tesng in accordance to API 6FB and TR6AF requirements. [ Maximum bending moment of 2M ſt-lbs. [ Hydraulic cylinder and load cell with rangs of 100MT [ Configurable for different connector sizes [ Liſt points and weldment fully proof load tested API Q1 Registraon No. Q1-1975 API 17D License No. 17D-0126 API 6A License No. 6A-1580 our commitments to quality NuStar Technologies has been awarded API Q1, ISO9001 and accredited with API 6A and 17D license. Awards Licenses
HYDROSTATIC TESTHydrostatic Tests are performed for valves and other equipment with accordance to API 6A and 17D requirements. The facility test bays are enclosed with bunker walls as safety barriers. Pressure control panels are located on the outside of the test area for easy access. All hydrostatic tests are performed using inhibited water, pumped into the test products at prescribed pressures. Tests results and leakages are monitored from pressure gauges and pressure over time charts using chart recorder devices.
KEY FEATURES [Pressure up to 22500 psi[Bunker Walls as safety
barriers[Warning Light during
testing[Large structures mounted
on flat plates fordistributed loading
SUBMERGED GAS TESTSubmerged Gas Tests are performed in our dedicated test pits. Nitrogen is the gas medium for high pressure tests, pumping valves and other products to pressures of up to 30,000psi. Submerged tests are done with gas pumped into the products placed underwater in our test tanks. Leakages are monitored from the tank and as required, leak detection systems are setup to detect minute leakage.
KEY FEATURES [Two water tank sizes for
testing of large test pieces[Cylindrical tank allows for
testing of assemblies upto 90” height
[Cameras mounted forreal time recording
[Ladder structures for safeaccess
DYNAMIC CYCLING AND ENDURANCE TEST
Dynamic Cycling Tests are performed in accordance to API 6A includes a 600 operating cycles test for valves ambient conditions. NuStar’s gate valve DAQ system is able to perform endurance cyclic tests by pressuring and opening valves systematically to simulate the valve’s operating cycle. Endurance testing with the system is done automatic and requires minimal manual inputs.
KEY FEATURES [Rotation of valve using hydraulic
torque tool[Air powered tool controlled by DAQ
system via solenoid valves[Rotation counters and position
sensors automates counting process[Limit settings prevent overtorque of
valve[Quick and hassle-free operation
types of testsAt NuStar Technologies, all our tests are conducted by our experience and highly trained personnel.
TEMPERATURE CYCLING TESTPressure Temperature Cycling Tests are an integral part of the API 6A Appendic F PR2 qualification process. These are conducted in controlled insulation chambers and are subjected to temperature extremes with our temperature controller and liquid LN2 tanks. High pressure is supplied by hydro pumps and gas booster and all signals from sensors and thermocouples are logged with the DAQ system and displayed real time in our HMI unit of the DAQ system.
KEY FEATURES [Fully automated during testing[Easy user interface for monitoring and
control
BENDING TESTBend Structure Tests are performed on subsea equipment which are exposed to high bending moments in the environment. The test article is bolted onto one end of an ‘I’ beam and subjected to a force upwards on the other end of the beam. Pistons are employed to provide the required force on the product to subject it to the required bending moment based on the length of the beam. Prior to tests, FEA is used to verify the critical planes of the tested product when subjected to the required bending moment. Verification is done using strain gages placed on the critical planes and connected to an in-house data logger.
KEY FEATURES [Bend test structure allows for testing
in accordance to API 6FB and TR6AFrequirements.
[Maximum bending moment of 2M ft-lbs.[Hydraulic cylinder and load cell with
ratings of 100MT[Configurable for different connector sizes[Lift points and weldment fully proof load
tested
API Q1 Registration No. Q1-1975
API 17D License No. 17D-0126
API 6A License No. 6A-1580
our commitments to qualityNuStar Technologies has been awarded API Q1, ISO9001 and accredited with API 6A and 17D license.
Awards
Licenses
www.nustar-tech.com
®
our focusTo be the independent one-stop solution for critical in-house product design validation testing of oil and gas equipment, in accordance to the latest industrial standards and maintaining highest quality safety standards at all times.
our commitmentNuStar Test Facility is commissioned as a test and assembly center for our Surface and Subsea Wellhead Equipment, to ensure that all equipment conforms to the latest industrial standards and meets our objectives in providing reliable, high performance products for our customers. NuStar Test Facility demonstrates strong emphasis on in-house product development and product qualification testing to enhance our product offering and to test-bed cutting edge technology.
our capabilitiesNuStar Technologies facility at 1 Gul Road is capable of handling large scale installation, assembly and testing work with a range of equipment/instrumentation and test fixtures in place, to support a full range of tests for oilfield equipment. Specially built test chambers or test pits and reinforced blast shields allow for testing in a safe and controlled environment. A programmable data acquisition system ensures the effective logging of real time test information and automates critical processes to establish effective and accurate control over test programs.
FACILITY FACT SHEET PERSONNEL
Floor Area 15000 Sq Ft On-site Staff QA/QC Supervisor
Ceiling Height 6 m Senior Planner and Cost Estimator
Property Type Factory / Workshop (B2) Field Service Technician
Usage Test and Assembly Assembly and Test Technician
Off-site Staff (Support)
Engineering Manager
Engineering Group Leader
Design Engineer (FEA Trained)
QA/QC Director
The following are the tests conducted at the facility.
[ Hydrostatic Pressure Test [ Tension/Compression Load Test
[ Submerged Gas Test [ Valve Blow-down Test
[ Pressure Temperature Cycling Test
[ Bend Structure Test*
[ Dynamic Cycling Test
our equipmentEQUIPMENT DE-SCRIPTION
SPECIFICATION
Forklift 1.8 to 8.0T loading capacity2 Stage – 3 Stage mast3.5m – 6.5m Lifting Height4Y, 1FS Petrol Engine
Gantry Crane 10T RatingSpan: 30mElevation: 6mChain Hoist with hook equipped with motor trolley
Type: Single Stage Double Acting Gas BoosterMaximum Rated Gas Supply: 25,000 psig (1725 bar)Maximum Rated Gas Outlet: 25,000 psig (1725 bar)Maximum Compression Ratio: 25:1Displacement per Stroke: 2.4 in3 per cycle
Temperature Controller
31”W x 39”L X 62”HChamber Heater – 9kWBlower Motor – 5HPUElectrical Power 460V/3 Phase/60HzTemperature Range: - 29Deg C to 180Deg CAirflow: 450 – 900 CFM (12.7 to 25.5 cubic meters / min-ute)
Gas Test Pit Water Tank, 96”L x 60”B x 48”HWater Tank, 75” OD x 96” H
Insulation Chamber Envelop (Internal) Dimension (Single) : 44” (L) × 44” (W) × 47” (H)Envelop (Internal) Dimension (Stacked) : 44” (L) × 44” (W) × 82” (H)Equipped with rockwool insulation.Port holes for temperature conditioner and hydraulic fit-tings and sensors
Torque Wrench (Hydraulic)
Torque up to 5000 ft-lbsEquipped with Electric power packAccomodates different bolt and nut sizes.
Hydraulic Cylinders – 25MT, 100MT
2 x Powerteam Hydraulic Cylinder, 100Ton 6-5/8” Stroke, General Purpose2 x Enerpac Hydraulic Cylinder, 25 Ton S/A Cyl. Model RC254
NUSTAR GATE VALVE TEST CHAMBER is commissioned as the one stop integrated solutions to fulfiling the fulltesting requirements of API 6A Appendix F PR2 testing requirements. From hydrostatic testing, gas submerged testing to pressure temperature cycling tests and dynamic cycling tests, the chamber allows for testing of gate valve assemblies across most sizes from 2-1/16” nominal to 7 1/16” nominal, from -46°C to 180°C, 3’000 psi up to 15,000 psi. The modular chamber allows for configuration to an extended height of 82”, and can accommodate a 7-1/16” gate valve assembly mounted with hydraulic actuator. Entire chamber is also enclosed within a test area with reinforced bunker walls to ensure safety of personnel.
KEY FEATURES [Capable of performing
entire sequence of API 6A Annex F PR2 tests
[Large envelop dimensions
[Safe working environment
[Large scope of test capabilities
[Pressure containment
HIGH PERFORMANCE DATA ACQUISITION SYSTEM WITH HMI CONTROLData Acquisition System for gate valve testing serves as the command and control centre for automating the process of gate valve testing. Test functions such as hydrostatic body test, working and low pressure seat tests, blowdown tests are programmed into the system and the touch screen human machine interface allows for easy control and monitoring during the tests. Signal inputs , such as temperature conditioner settings, bore pressure, chamber temperature, supply pressure, valve position are monitored real time, and signal outputs to solenoid valves allow for full control of gas booster, torque tool during the tests. This encapsulates a smart test regime that saves on equipment and instrument setup time and maximises testing efficiency.
KEY FEATURES [ Pre-programmed with
major test plans, i.e. working pressure seat tests, blowdown tests, etc.
[ Receives signal from instruments and sensors
[ Outputs signal to operate torque tools and control gas boosters
