wp3 – field testing of pressure vessel robots

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WP3 members – Dekra, Innospection, GE Inspection Robotics, OC Robotics, Gassco, Chevron, Quasset, Shell

WP3 – Field testing of pressure vessel robots

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Objectives and scope of WP3 Approach and test plan Key results Summary

Outline of presentation

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WP3 – DOW scope

• Scope• To demonstrate pressure vessel internal inspection robot in real field use case.• To evaluate the demonstration results against specifications and requirements

• Tasks • Organise and execute field testing • Identify and prepare test location -> Risk analysis and procedures -> Inspection -> Analysis of results

and comparison -> Adaption of prototype and procedures (as required)

• Deliverables• Report on risk analysis and inspection program (D3.1)• Report of results of field testing (D3.2)

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Approach

Visual testing Ultrasonic

testing (UT)

tool

Eddy current (EC)

tool

Surface profilometry tool

FAST

platform

Good visual camera +

lighting

UT corrosion

mapping tool

EC corrosion

mapping tool

Gocator (structured white light

tool)

Bike

platform

Relatively low

resolution camera +

lighting

N/A EC crack

detection tool

Gocator(structured white light

tool)

Snake arm Good visual camera +

lighting

UT corrosion

mapping tool

EC crack

detection tool

Gocator (structured white light

tool)

• The testing program -> combination of tests on real field pressure vessels and redundant vessels with artificial defects.

• This testing approach was necessary to cater to the needs of three different robots and variety of NDT tools.

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Approach – testing program

Test Reference Robot and NDT tools Vessel/location

T1 - Shell Europoort test site, Netherlands [Oct – Dec 2015]FAST platform, Bike platform and Snake arm; All NDT tools

Redundant vessels at test location (inside plant)

T2 - Shell Refinery, Netherlands [November 2015] FAST platform ; Visual, GocatorIn-service vessel at a petrochemical facility

T3 - Chevron test, Aberdeen [Feb-March 2016] Snake arm; UT, ECT, Visual, Gocator Redundant vessels at test location

T4.1 - Gassco test site, Karsto, Norway [April 2016] Bike platform; Gocator, Visual

Redundant vessels at test location T4.2 - Gassco test site, Karsto, Norway[April 2016] Bike platform; Visual

T4.3 - Gassco test site, Karsto, Norway[April 2016]Bike + FAST; Bike + Snake arm; Visual and Gocator

T4.4 - Gassco test site, Karsto, Norway[April 2016] FAST and Snake arm; Visual, Gocator, UT

T5 - Gassco real field deployment, Belgium [May 2016] Bike platform; Visual, GocatorIn-service pressure vessel at a inpetrochemical facility

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T-1 : Shell Europoort trials (1)

Test ReferenceRobot and NDT

toolsVessel, MOC, defects Background/Objective

T1 - Shell Europoort test site, Netherlands[Oct – Dec 2015]

FAST platform, Bike platform and Snake arm

All NDT tools

2 horizontal and 2 vertical vessels, all carbon steel, no defects

1) 4 redundant (offline) vessels; different entry options (side/top manway)2) All Shell site safety rules were followed for site entry3) Objective was to check deployability, navigation and retrieval aspects of each robot4) Vessels had no defects or prior degradation

• Specific aspects of testing • Testing was seen as joint activity between WP1 (integration of robots and NDT tools was completed)

and WP3 (integrated solutions need to be field tested)

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All the robots were able to enter in horizontal and vertical vessels through various entry option (side and top manway) and demonstrated acceptable level of operational readiness.

Trials prepared the robots for the real field testing. Positive engagement with Lloyds Register and Shell Pernis inspection team

was achieved during a demonstration at test location. Site entry training, preparation of vessels, Task Risk Assessments and

permission to work on site took considerable efforts and collaboration between Petrobot partners and Europoort operations, HSE.

Detailed reporting on the trials is done in WP1.

T-1 : Shell Europoort trials (2)

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T- 2: Shell refinery, real field trial (1)



T2 - Shell Refinery, Netherlands[November 2015]

FAST platform

Visual, Gocator

CS vessel, horizontal orientation, side manway entry, pitting defects expected (history of corrosion defects)

1) A real field inspection during a turn around 2) Objective was to deploy the FAST robot mounted with camera and Gocator to detect and size pitting type of defects in the vessel.3)A (conventional) manual inspection was also planned - compare the results with robotic inspection.4) This testing activity followed all the tasks outlined in WP3

• Specific aspects of testing • Limited amount of time window was made available during turn around• General corrosion and pitting damage was expected based on prior inspection history• The scope of the activity was to (a) select appropriate robot and tool combination (b) demonstrate

safety aspects of the robot and satisfy site entry requirements (c) deploy the robot in a stipulated time period allowed for the activity (d) inspect the susceptible areas, identify and characterize the defects (e) issue a report on robotic inspection and compare the findings with manual inspection.

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Inspection of vessel at Shell Pernis refinery using FAST platform (visual and Gocator)

Vessel was cleaned prior to robotic inspection No information about possible defects and locations was

available as manual inspection happened after robotic inspection

Successful and safe deployment following all the safety norms at Pernis site, including gas tests.

Visual inspection of critical areas (vessel bottom) completed in a stipulated period of 6 hours.

Number of indications (pitting) were found and recorded. Measurement of pit depths using structured white light.

Only limited comparison with manual inspection was possible due to difference in coverage

Lighting, scanning using Gocator and ability to revisit the same location after NDT tool change needs improvement.

T- 2: Shell refinery, real field trial (2)

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T- 3: Chevron test (1)



T3 - Chevron test location, Aberdeen[Feb-March 2016]

Snake arm

UT, ECT, Visual, Gocator

Horizontal vessel, carbon steel, artificial defects were made in the vessel

1) Objective was to assess performance of NDT tools to detection and size the defects2) An inspection procedure was developed and followed. 3) Ability to locate the same defect after the tool change from camera to GOCATOR was tested.

• Specific aspects of testing Scope of testing was to deploy the robot inside the vessel, detect/characterise/size the defects

inside the vessel and compare the defects detected with the list of artificial defects (inspection report by manual inspection) prepared before the robotic inspection.

It’s important to note that the positions and type of the defects were not disclosed to the robotic inspection before the testing (blind test).

An assessment on the reach of the Snake arm in various areas of interest in the vessel was done by OC Robotics

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Inspection of pressure vessel with artificial defects using Snake arm (Visual, Gocator, UT, ECT)

Procedure was written at the beginning of inspection

All the artificial defects were detected Same areas within the vessel could be found using

Gocator after the tool change. Procedure proved to be good for defect detection.

T- 3: Chevron test (2)

Manual insp. Robotic insp.

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T- 4.1 & 4.2: Gassco test (1)

Test ReferenceRobot andNDT tools

Vessel, MOC, defects Background/Objective/Details

T4.1 - Gassco test site, Karsto, Norway[April 2016]

Bike platformGocator, Visual

Pig trap, carbon steel, no defects, reducer type of design (conical entry)

1) A proof of concept test - enter, navigate and inspect a pig trap with a reducer design (Conical entry). 2) This trial was done with a view of supporting a real field deployment at Gassco.

T4.2 - Gassco testsite, Karsto, Norway

Bike platformPressure vessel, carbon steel. No defects.

1) Objective was to evaluate Bike platform's capability to handle obstacles, to test umbilical management.2) Vessel had lot of debris to test maneuvering and navigation aspects.

• Specific aspects of testing Three redundant pressure vessels made available. All the robots and

most of the NDT tools were available.

Object

No.

Description Diameter x

Length (m)

Entry option

1 Heat Exchanger 2.3 x 12 Top entry through 24” manway (A4); side entry

through large opening at one of the ends

2 Pressure Vessel 2.8 x 6 Side entry through 24” manway

3 Pig Trap 1.25 x 8 Entry through opening at one of the ends

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T-4.1: Proof of concept test - bike platform in pig trap with a reducer design (Conical entry).

Bike could successfully enter and manoeuvre inside the pig trap –promising results for field deployment (T5). Integration of Gocator tool on bike platform (originally not in Petrobot scope) was successfully demonstrated.

T- 4.1 & 4.2: Gassco test (2)

T-4.2: Bike platform's capability to handle obstacles in pressure vessel.

Bike platform could handle the obstacles and navigate inside the vessel with the help of navigation cameras.

Debris handling was good, however magnetic debris needed to be cleaned periodically.

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T- 4.3: Gassco test (1)



T4.3 - Gassco test site, Karsto, Norway

Bike + FAST; Bike + Snake arm

Heat Exchanger with tube bundle removed, carbon steel, artificial defects.

1)Using two robots in conjunction - if and how a combination of the robots would aid inspection. 2)FAST or Snake arm used visual camera to identify a defect. Then Bike platform, mounted with another NDT tool, would reach to same location.

• Specific aspects of testing • Scope - Use two robots in conjunction. FAST or Snake arm used visual camera to identify a defect. Bike

platform would reach to same location and use Gocator to size the defects.

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Inspection of heat exchanger with artificial defects using Fast and Bike platform and Snake arm and Bike platform (Visual, Gocator)

FAST/Snake arm guided bike towards a defect and bike could position close to the defect and measure size/depth of the defects.

To be able to effectively inspect an area, it can be beneficial to use a combination of tools. This can be achieved by a robot capable of carrying multiple tools OR by a combination of robots with different tools.

Complementary features of the pressure vessel robots helped to achieve the latter.


A number of artificial defects can be seen (a) shows the Gocator image using Bike platform and (b) visual camera image of the same area using inspection camera on Snake arm. Laser spots are 100mm apart.

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T4.4 - Gassco testsite, Karsto, Norway

FAST and Snake armVisual, GOCATOR, UT

Heat Exchanger with tube bundle removed, carbon steel, artificial defects.

1) Objective was to assess performance of NDT tools for defect detection/sizing.2) Test repeatability aspects; demonstrate use of improved lighting arrangement (lighting at an angle) during visual inspection.

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Inspection of heat exchanger with artificial defects using Fast platform and Snake arm (Visual, Gocator, UT)

Scope - assess performance of NDT tools for defect detection/sizing. Test repeatability aspects; demonstrate use of improved lighting arrangement (lighting at an angle) during visual inspection.

Most of the artificial defects were detected by both the robots mounted with various NDT tools.

Improved visual inspection by the use of shadowing effects of lighting (a combination of direct light around camera and light from the manway/nozzles was used)

Repeatability of the FAST platform and Snake arm (robot + NDT tool) was found to be within hundreds of mm (~200mm).

Visual camera of the Snake arm had sufficient resolution to inspect the surface of vessel from a distance of around 4m.

The thickness of the pressure vessel was measured in an area using the ultrasonic tool mounted on the FAST crawler. The measured strip (780 mm) started from a thinner section of the heat exchanger, up to a weld and then continued into a thicker section of the heat exchanger. From the A-scan, the thickness is estimated to be 18 mm.

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T- 5 : Gassco real field deployment (1)



T5 - Gassco real field deployment, Belgium[May 2016]

Bike platformVisual, Gocator

Pig trap, carbon steel, Surface variation was expected.

1) This was a real field deployment. 2) Aim of the inspection was surface mapping of conical and cylindrical areas of pig trap using Gocator (full circumferential scanning) to detect any surface variations.

• Specific aspects of testing • Scope of this deployment was to use the Bike platform for real life use case and scan large area of the

pig trap with the surface profilometer tool (Gocator). • The site was live but the pig trap was sealed off by valves. • The challenging part of the inspection with the Gocator was to capture data on a conical and cylindrical

section of a pig trap whilst moving in a straight line (the procedure was trialled in T4.1 and needed some refinement).

• There was no expectation of any degradation in this vessel; however, surface variations were expected.

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Inspection of pig trap (real field inspection) using Bike platform (Visual, Gocator).

The deployment was successful in entry, navigation and retrieval aspects. All the site entry requirements on the asset were satisfied.

In order to achieve step-by-step incremental motion in a straight line, the Bike platform was updated with new software and a special guidance tool was developed.

It was possible to cover an area of 2.5m2 per hour with a surface resolution of 0.2 x 0.2mm and depth accuracy of 0.05mm. Surface variations were noticed and sized by Gocator in several regions in the pig trap

T- 5 : Gassco real field deployment (2)

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Summary – FAST and BIKE platform

Robot functionality Visual testing Ultrasonic testing

(UT) tool

Eddy current (EC) tool Surface profilometry tool

FAST Robot: Capable of navigating

in the vessels above 1.8m

diameter.

Able to crawl on coatings of

thickness less than 2mm.

Able to locate defects within

200mm.

The camera and lighting

quality is proven to be fit-

for-purpose and is

considered matured for real

field use.

UT tool successfully

integrated with the

robot and capable

of obtaining spot

and line

measurements.

EC tool is successfully

integrated with the robot

and capable of obtaining

corrosion mapping data.

Gocator is successfully

integrated with the robot and

capable of measuring pit

depths and surface

irregularities.

Bike robot: More nimble platform

compared to FAST and Snake arm.

Able to crawl on coatings of

thickness less than 2mm.

Able to pass relatively small

openings.

Average quality camera

(compared to FAST and

Snake platforms) - due to

payload limitations.

Available camera and

lighting combination works

adequately within the

limitations of camera.

N/A The eddy current crack

detection tool meets the

D1.1 requirements. Some

issues regarding

interference with magnetic

wheels of the robot.

Possible to supress the

unwanted noise (e.g. Filter

settings, shielding and

sensor offset).

Not originally in Petrobot

project scope but developed

during the project due to

request from end users.

Successful integration as

demonstrated in real field

deployment at Gassco.

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Summary – Snake arm

Robot functionality Visual testing Ultrasonic testing

(UT) tool

Eddy current (EC) tool Surface profilometry

tool

Able to navigate

through internals

and reach of the arm

is around 4m.

Able to enter

through opening

greater than 6”.

Able to locate

defects within

200mm.

Good quality

inspection data was

obtained during field

tests at Chevron,

Gassco and Shell.

The camera and

lighting quality is

adequate for real

field use.

UT tool successfully

integrated with the

robot and capable of

obtaining spot UT

measurements as well

as scanning long

sections (~2m).

The tool is considered

to be ready for field

deployment.

The eddy current tool meets the D1.1

requirements, however, have some

issues regarding stability of the scan

frame whilst scanning.

Although there are various ways to

stabilise the scan frame (e.g. using

spacer pins, appropriate gain

settings), further work is necessary

before using the tool for a real field

deployment.

Gocator is successfully

integrated with the

robot and capable of

measuring pit depths

and surface

irregularities.

The tool is considered

to be ready for field

deployment.

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Participation from all the end users providing test facilities and other required support Elaborate testing program providing opportunity to test all robots and NDT tool combinations Testing program successful in demonstrating that robot and NDT tools are ready for real field

deployment Gassco – two onshore pressure vessels were inspected using Snake arm in September 2016 Similar robotic inspection activities are getting planned with other end users

Documentation ATEX mitigation documents for all the robots Inspection procedure for Pernis testing Inspection procedure for Chevron testing Robot specification sheet Pressure vessel selection sheet Risk register for robots Template for inspection procedure (WP5 work - collaboration with WP3 and WP1) Individual reports from all the testing activities Lab test reports for all NDT tools D3.1 – report on risk analysis and procedure D3.2 – report on field testing

Summary – WP3

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Show the video on WP3 trials : WP6_PETROBOT_Trials_PRO_16x9_25fps_1080p_English_V3.03.mp4

Video

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www.petrobotproject.eu

wp3 – field testing of pressure vessel robots

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