Professional Documents
Culture Documents
Qualification of New
Technology
Session 1
Introduction to Risk, Reliability and
Qualification
www.astrimar.com
What is Technology Qualification?
• Technology Qualification is a demonstration process
– Equipment meets function and performance requirements
– Technology/product is robust and reliable
– Acceptable safety and environmental risk and uncertainty
• Prior knowledge and data will not normally be sufficient
• Evidence comes from testing, analysis and modelling
– More extensive than functional test at the factory or in the customer’s system
integration test
“The process of providing the “The process of confirming, by
evidence that the technology examination and provision of
will function reliably within evidence, that equipment meets
specified operational limits with specified requirements for the
an acceptable level of intended use” [API]
confidence.” [DNV]
© Astrimar 2018 1
Qualification and Technology Readiness
• Many technology developers (suppliers) and technology users
(customers) use concept of Technology Readiness Level (TRL)
• First developed by NASA
• Now used by other sectors including Defence, Renewables
and Oil and Gas
• Different sectors have developed their own TRL ladders
Example TRL Ladders
TRL ladder generic descriptors will require
“interpretation” and are likely to require
“adaptation” when applied to a specific technology
© Astrimar 2018 2
How is a TRL ladder used
• TRL used to:
– Indicate the stage of development: It’s a measure of where you are in
the overall development of a technology
– Indicate the type of qualification activity required at each TRL: from
basic R&D through to reliability growth monitoring in operation
• TRL is not a qualification process
• However Qualification process should address the progress
from the initial TRL to the required TRL
Product
Validation
System
System
Operation
Installation
6 TQP
System Installed
4 Integration 9
8
Prototype
Development
7
Prototype
TRL Ladder Descriptions
TRL
0‐7 1‐9
Development Stage Completed
Basic Research 0 1 Technology Developer:
Basic principles observed and reported
Research
Concept • TRL 1,2: R&D, formulates concepts and potential applications
1 2 Technology concept and/or application formulated World
Formulation
Analytical and experimental critical function and/or characteristic
3 • TRL 3,4,5: Activities to validate and demonstrate concept. Builds and
Concept proof‐of‐concept
Demonstration
2 tests model or prototype to create robust and reliable device
Component and/or breadboard functional verification in a
4
laboratory environment
Component and/or breadboard critical functional verification in a Simulated
Prototype
3 5 relevant environment. Prototype is function, performance and
• TRL 6: Full scale model (version) of product to be deployed in World
Development
reliability tested.
intended application. Tests in applicable environment to validate
Full Scale model of product demonstrating critical functions of the
Product Validation 4 6
technology before release to customer.
element in a relevant environment but not necessarily connected
to the wider system
Full scale model or product demonstrating the element
End User:
System Integration
5 7 performance in a relevant environment while integrated into the
Testing • TRL 7,8: Integrates validated product into system or application.
system
Verifies functions and performance requirements in operational
System Installed Real World
Actual system completed & accepted for mission / operation.
environment. Commissions for operation.
Ready for 6 8
Installed, hooked up, commissioned and ready for operation.
Operation • TRL 9: Monitors in Operation to provide evidence of extent to which
System Operation 7 9 performance/reliability/integrity requirements met.
Actual system proven through successful mission / operation
© Astrimar 2018 3
Key TRL Milestones
Developer ‐ Customer Transitions
Based on 1 to 9 TRL ladder Technology ready Technology ready for
to build prototype end user application
Development world
Technology TRL TRL TRL TRL TRL TRL
Development 1 2 3 4 5 6
Project Research Stage Technology Development Stage
Technology ready Technology
for operation field proven
Real world
TRL TRL TRL
Application 7 8 9
Project / Process
Integration Stage Operation
Meeting Performance Requirements
Risk Matrix
• New technology needs acceptable level of
5
reliability and safety
Probability of failure
Unqualified
4 Existing Technology
• The greater the adverse consequences of Technology
3
failure, the more reliable the technology
should be 2
Qualified
Technology
1
1 2 3 4 5
• Where new technology is replacing or Consequence Severity
displacing an existing technology it will often only be successful if:
– Reliability is as good or better than the existing technology
– Has acceptable safety and environmental risk
• Key qualification goal is demonstrating technology will meet reliability,
availability, maintainability, integrity and health and safety requirements
– Addressed from TRL 4 to 9 (API TRL 2 to 7)
© Astrimar 2018 4
TRL Goals
TRL
0 ‐ 7 1‐9
Development Stage Completed
Basic Research 0 1 Basic principles observed and reported
Research
Concept World
1 2 Technology concept and/or application formulated
Formulation Understand Function and Performance
Analytical and experimental critical function and/or characteristic
Concept
3 Requirements
proof‐of‐concept
2
Demonstration Component and/or breadboard functional verification in a
4
laboratory environment
Component and/or breadboard critical functional verification in a Simulated
Prototype
3 5 relevant environment. Prototype is function, performance and World
Development
reliability tested.
Make it reliable as a device
Full Scale model of product demonstrating critical functions of the
Product Validation 4 6 element in a relevant environment but not necessarily connected
to the wider system
Full scale model or product demonstrating the element
System Integration
5 7 performance in a relevant environment while integrated into the
Testing
Reliability Growth & Uncertainty Reduction
system
System Installed Real World
Actual system completed & accepted for mission / operation.
Ready for 6 8
Installed, hooked up, commissioned and ready for operation.
Operation
System Operation 7 9 Actual system proven through successful mission / operation
Reliability & Technology Assurance
through Qualification
Increase Durability
Remove Early Life Minimise Random Failures Minimise Wear out
Failures Failures
goal
© Astrimar 2018 5
Qualification Challenges
• Scale of the technology
– Not always possible to build full scale model or prototype
• Specific application
– Technology bespoke
– Specific application risks
– Qualification activities driven by application requirements
– No standard technology qualification procedures exist
• TRL advancement challenges
– Schedule:
• May need to progress TRLs in parallel
• Need to accelerate life testing for fatigue, wear or corrosion
– Cost:
• Large investments in testing equipment
• Difficulty of simulating realistic testing conditions
• Need customer to fund developments
Subsea Industry Considerations
API 0‐7 TRL ladder used by many operators/suppliers
• Subsea architecture usually bespoke, with large one‐off items
• Technology development often linked to specific field development
– Introduces significant field development project technical risks
– In the past, qualification activities have been omitted to deliver on schedule
with resulting failures in the field
• Qualification programme may need to drive project schedule
– API TRL 3 before end of Concept Selection
– API TRL 4 before end of FEED
• Identify initial high level qualification plan during concept selection
– Enables activities to be scheduled and appropriate resourcing
• Qualification testing integral with FAT, SIT and commission activities
– Schedule must recognise risk of test failing at this stage, include recycle time
© Astrimar 2018 6
Offshore Renewables Considerations
Standard 1‐9 TRL approach used by EMEC
• Unlike subsea oil and gas, marine
renewable prototypes and pre‐ Technology Maturity Levels may also used
production units undergo long
term sea trial qualification in
representative operating
environments
Renewables Standards – EMEC, Equimar
• EMEC – several standards for developing/testing marine
renewables http://www.emec.org.uk/standards
• Equimar ‐ Protocols for the Equitable Assessment of Marine
Energy Converters http://www.equimar.org
– marine energy converters testing and evaluation procedures
© Astrimar 2018 7
Renewables Standards – IEC
• Technical Committee 114 developing standards for Marine
Energy – wave, tidal and other water current converters
http://www.iec.ch/dyn/www/f?p=103:23:0::::FSP_ORG_ID,FSP
_LANG_ID:1316,25
– E.g. IEC/TS 62600‐103 Ed. 1.0
Guidelines for the early stage
development of wave energy
converters: Best practices &
recommended procedures for the
testing of pre‐prototype scale
devices
– Some standards already available
Equipment Standards
• Many industries have equipment specific qualification
standards, e.g.
– API 17 Series, NORSOK, DNV, ISO, EN, IPC, ASTM
• Provide testing requirements for standard technology e.g.
valves, electronics, controls, pipelines, coatings, etc.
• Need to take care in using standards beyond their area of
application, e.g.:
– “onshore” equipment standards for “offshore” or “underwater”
applications
– oil and gas “topside” equipment standards for “subsea” and “down‐
hole” equipment
© Astrimar 2018 8
Technology Qualification Process
• Four industry RPs provide generic TQP guidance
– DNVGL RP A203 (2017)
• Process applied to range of industries / guidance docs
follow
similar
– API RP 17N / API RP 17Q (2nd editions 2017/18) TQP
• Aimed at subsea to address high reliability requirement at high
• Applicable to other industries level
– LR: Guidance Notes for Technology Qualification (2017)
• Range of industries
• Additional guidance on system / interface qualification
– BV: Guidance Note NI 525 DT R00 E (2010)
Technology Qualification Process
Technology Maturity
Technology Assessment
Assessment
Modifications
Qualification FMECA Threat Assessment
Qualification Plan Qualification Plan
Plan Execution Execution of Plan
Results Evaluation Performance Assessment
Requirements No Requirements No
Met? Met?
Yes Yes
Qualification Assurance Technology Qualified
© Astrimar 2018 9
API RP 17N and 17Q
17N 17Q
D 1: Requirements Planning 1: Requirements Planning Supplier
focus
2: Technology 2: Technology Maturity
Categorization Assessment
3: Detailed Technology 3: Select Qualification
Assessment Program
8: Modifications
8: Modifications
Management
Management
4: Qualification FMECA 4: Qualification FMECA
P 5: Qualification Plan 5: Qualification Plan
I 6: Plan Execution 6: Qualification Execution
E 7: Results Evaluation 7: Results Evaluation
Requirements No Requirements No
Met? Met?
Yes Yes
10: End Users
F 9: Qualification Assurance 9: Qualification Assurance
Qualification Program
Customer – OEM role
• Customer (End User) requires evidence that:
– Technology (equipment) is ready for application or
– Additional qualification is needed for use in their application
• OEM (Supplier) Demonstrates that
• Technology (equipment) is ready for application or
• Extent to which it is ready for application
• End Customer must be clear on requirements
– Technical requirements e.g. function, performance, environment, etc..
– Uncertainties need to be identified
© Astrimar 2018 10
Reliability Qualification for New
Technology
• Qualification for reliability or availability specification
includes:
– Assessment of reliability performance through tests or models
– Assessment of uncertainty in reliability performance
• Statistical data required for reliability prediction
– Replicated tests
– Range of environments
• Much more than standard quality functional testing e.g.
– Understanding how failures occur
– Determining operability and destruct limits
How Failures Occur
• Load exceeds strength
– Loads higher than anticipated
• Designer failed to anticipate high loads?
– Strengths lower than required
• Design or manufacture introduces flaws in the product?
• Strength deteriorates over time
}
– Corrosion
Material degradation causes
– Wear defects to initiate and grow
– Fatigue
Unacceptable rates of deterioration are not inevitable. Designers
can introduce “barriers” to control or prevent deterioration.
© Astrimar 2018 11
Load ‐ Strength Interference
Loading Stress Material Strength
Distribution of distribution distribution
Strength ‐ Load f(L) f(S)
pdf
σL σS Load Parameter
(Kg/M2,Volts, 0C etc.)
Stress/strength
μL μS
Region where load overcomes strength
Failure can occur if component is over loaded or component
is under strength
Effect of Distribution Tails
f(Load) f(Strength)
Strength ‐ Load
Distribution of
Large proportion of low
strength items: a long low tail of
the strength distribution
Stress/strength
f(Load) f(Strength)
Strength ‐ Load
Distribution of
Large proportion of extreme
pdf
loads: a long high tail of the
load distribution
Stress/strength
© Astrimar 2018 12
Time Dependent Reliability
Variation in Material Strength
Distribution over time f(S(t))
as a result of material degradation
Loading Stress Time
Distribution of
distribution increasing
Strength ‐ Load f(L)
t0
pdf
t1
t2
Stress/strength
Upper and Lower Operating and Destruct Limits
• Operating limit: the level of stress above (below) which the product will
not operate properly (i.e. in accordance with the specification)
• Destruct limit: the level of stress above (below) which the product suffers
permanent failure from which it does not recover when the stress is
removed
Lower Lower Upper Upper
Destruct Operating Operating Destruct
Product
Limit Limit Limit Limit
Specs
Operating Operating
Margin Margin
Destruct Margin Destruct Margin
Stress
© Astrimar 2018 13
Delivering Reliable Technology through
Qualification
• Ensures reliability, robustness and integrity is an inherent part of the
design
– Materials testing to understand degradation rates
– Robustness testing to remove weaknesses in the design
– Reliability growth testing to demonstrate inherent reliability
– Testing of multiple units for improved statistical data
• Defines required FAT/SIT tests for manufactured products to ensure
inherent reliability not compromised
– E.g. stress screening for defective components
• Enables necessary through life integrity monitoring to be designed‐in
Reducing Risk and Uncertainty
Uncertainty
Performance and Uncertainty
Time/TRL
© Astrimar 2018 14
Reducing Risk and Uncertainty
Uncertainty
Performance and Uncertainty
Modified
Technology or
Application
Time/TRL
Summary
• TRL: Measure of technology maturity
– NASA/DoD/EU/EMEC/OGTC/ISO16290 TRL Scale 1‐9
– API/ISO20815 TRL Scale 0‐7
• TQP: Technology qualification process used to raise TRL and
provide traceable evidence of the extent to which equipment
meets function and performance requirements
– More extensive than functional testing at the factory or as part of
customer’s system integration test
– Involves understanding how failures can occur
© Astrimar 2018 15