Development of robotic inspections for pressure vessels

Martin van den Heuvel

Shell Global Solutions

Content of the presentation

• Introduction to Minimum Intervention Strategy for Inspection

• Value of Robotic Inspection

• Development of Robotic Inspection

• State of development

• Deployments, trials and challenges

• Conclusions

Slide 2

Development of Robotic Inspections for Pressure Vessels

Shell Projects & Technology – Engineering

Combining operating experience with proven implementation skills and advanced technologies

• Global coverage

• Diverse cultures and nationalities

• Over 50 years of implementing business and engineering solutions

• Continued investment in technology innovation

Regional Materials & Mechanical Integrity groups

Regional Inspection Technology teams

What is Minimum Intervention Strategy for Inspection?

• Minimum Intervention Strategy for Inspection (MISI) is a methodology aimed

at maturing an assets risk based inspection strategies in a structured manner

• Robotic internal inspection • inside vessels, tanks

• Non-intrusive inspection

• Use of permanently installed sensors

• Materials Selections and Enhanced RBI • to eliminate corrosion threats and

optimizing corrosion control

• MISI aims at reducing the impact of inspection on:

• Turn Around scope and time of the installation

• Intervention costs for preparation of vessels

• HSE impact of confined space entry

Production optimization from an inspection point of view

Insp

ectio

n Ef

ficie

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(line

) ->

In

trusiv

e in

spec

tion

sco

pe (b

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s) -

>

Inspection maturity and Effectiveness ->

Preventing unplanned downtime

Redu

cing

pla

nned

dow

ntim

e

Initial RBI

Mature RBI

MISI

Reg

ulat

ory

Insp

ectio

n

Mat

ure

RBI

Conventional Intrusive

Inspection

Robotic internal Inspection

Permanent Sensors

Max T/A scope

Current T/A scope

Min T/A scope

pot

entia

l

Initi

al R

isk

Base

d In

spec

tion

(RBI

)

Out

side

T/A

Advanced NII

Non-Intrusive/ On-Stream Inspection

Scope reduction value drivers: deferment, direct cost, HSE

- Bedding/lifeboat capacity limitation

- Any scope reduction leads to reduced turnaround duration

- Saves production deferment

Person on Board

limitation

- Large inspection items define critical path

- Reducing scope item with Robotic Inspection shortens critical path and turnaround

- Saves production deferment

Critical path items

- High direct cost for preparatory work

- Reducing scope reduces cost

Direct costs

- Human entry in confined spaces is hazardous (H2S, mercury and N2)

- Robotic Inspection replaces human entry

HSE risk

Remote Operated Areal Vehicles

Benefits

Aerial Inspection with significant bottom-line impact:

• Improved data quality to better time shutdowns

• Reduced staffing requirements and HSE exposure

• Reduced production deferment

Application

• Visual inspection

• Gas detection

• Thermal imaging

Heat signature showing uniform heating and sufficient gas lift.

Close up view of spider & pilot burners on HP system. No detectable cracks on welds. Maneuvering ROAV from helideck

RESTRICTED

Deployment and operation Flare inspection

Chimney inspection

Vent stack inspection

Flares including “live flare” inspection

Chimneys, Vent stacks

Communication masts

Waste heat boiler ducting

Geomatics – aerial surveys

Emergency response to situations

Structural inspection

Geological studies November 15 8

Remote Operated Areal Vehicles: Applications

Development of Robotic Inspection in Joint Industry Projects

• Petrobot JIP

– Under EU FP7 framework, Shell leading partner

– Two use cases: Internal vessel inspection (off-line, 3 robots); storage tank inspection (in-service, 1 robot)

• Robot qualification trials in progressTelbot2 Demo2000 JIP

– PREZIOSO Lynjebigg leading partner and operator of Telbot2

• EuRobotics topic group Maintenance and Inspection

• SPRINT Robotics

• Deployed first in Norway in 2012

• Adapted to O&G in Demo2000 Joint Industry Project in Norway

• Heavy but stable deployments

• Extensive preparations needed

• ATEX certified solutions available

• Cleaning and visual inspection tools

Large stand-off type robotic arms

• Lightweight retractable snake arm developed by OC Robotics under the Petrobot program

• Deployments require less preparation (no manhole adaptor), still require hoisting

• ATEX zone 1 certification capable

• Quick intrusive inspection with visual, UT, EC sensors

Smaller flexible arm type robots

In-service storage tank robot systems

In-service inspection allows storage tank to remain in-service with product inside

Sub-sea ROVs available for visual inspection

Visibility is challenge

Visual inspection scope for tanks is limited

Tank bottom inspection UT and SLOFEC being developed in Petrobot project

ATEX is a challenge

Combinations of robots with NDE applications

Trialed and tested in Petrobot project

UT sensors for spot wall thickness measurement

EC sensors for crack detection and array wall thickness measurement

Structured white light camera for sizing of pitting

Pit gauge not available

SLOFEC tool for tank bottom inspection

Cleaning tools tested in Telbot project

Use of NDT on Robots requires understanding of corrosion zones

State of development

Many robots not yet available and still in development stage

Cost of deployment is high for newer robots

Learning and experience should reduce inspection time and cost

Intrinsic safety/ATEX remains issue

Surface cleaning and preparation is a challenge, development of non-intrusive cleaning is a necessity

Application of NDT tools on robots requires testing and validation

Acceptance with inspection community still low

In November 2015 first robotic inspection under revised Dutch regulations on Robotic Inspection took place on Pernis

Robotics – sharing and capturing knowledge

Conclusions: state of Robotic Inspection

Many developments ongoing

First available solutions entering market

Uptake is needed for further development and competitive pricing

Thank You / Questions

Slide 17