Loose Part Retrieval Know-How Matters

Caution.  Acronyms Ahead. 

Depending on your industry and/or your military experience FME, FOD and FOSAR can have varying meanings. However you spell it or define it, XCEL is here to help.

Foreign Material Extraction (FME) is defined as an effort to remove non-native material from an asset.  Conversely, Foreign Material Exclusion (FME) generally refers to a system of measures to protect sensitive industry components, systems and equipment from foreign material. It is often supported by Foreign Material Exclusion Zones. Establishing an FME zone is the process of creating boundaries and work processes to protect exposed systems during repair or maintenance evolutions. The FME zone limits access to the controlled area to necessary personnel, often via a qualified FME zone monitor. Tools that are tied off via lanyard are permitted only after being logged into the area and loose items or items that may become loose: hard hats, buttons, etc., are secured or excluded from entry. 

Foreign Object Damage (FOD) is typically defined as damage incurred as a result of foreign material introduced to sensitive systems or components.  Depending on your industry or branch of the military, FOD may also be defined as Foreign Object Debris.  In this sense, it refers exclusively to the foreign material.  In many cases, the terms and acronyms are used synonymously throughout a myriad of industries and applications sensitive to foreign material.

Sources of Foreign Object Damage may be further subclassified as:

• Domestic: Items germane to the system introduced via upstream failures such as detached strainers, nozzles, valve discs, etc. Depending on size, severity, system significance, plant operator experience, and instrumentation this may or may not be immediately noticeable.
• Internal: Component specific failure i.e. impeller material, turbine or compressor blade migration.
• External: Material foreign to both system and components i.e. tools, welding rods, personal items, consumables.

Foreign Object Debris, regardless of source, may cause inefficient plant operations, plant trips or catastrophic damage. Common industry ailments include plant water chemistry anomalies, heat exchanger efficiency loss, poor boiler operation and extensive damage to rotating equipment. The cost implications are extensive from both a lost revenue and emergent repair perspectives. Additional costs may be realized via contractual, safety, environmental and regulatory obligations.

FME zones, while extremely effective, are not an all-encompassing solution due to aforementioned domestic and internal sources. A very effective means of protecting sensitive systems and components after a construction, repair or maintenance activity is executing an effective Foreign Object Search and Retrieval (FOSAR) effort. FOSAR involves the use of robotic cameras and retrieval tools to locate, identify and remove foreign material with minimal system access. FOSAR not only addresses the external items introduced to the system but also domestic and internal items. Prior to closing the system XCEL’s FOSAR technicians inspect all accessible areas to record an as-left condition. This becomes a powerful testament to the system cleanliness, surface appearance, as-left status and general condition of the unit.

Effectively and efficiently performing this work requires industry-specific experience. Take a look below to see the industries and applications XCEL has previously supported.