PIPE ROBOTS FOR INTERNAL INSPECTION, NON ......PIPE ROBOTS FOR INTERNAL INSPECTION, NON-DESTRUCTIVE TESTING AND MACHINING OF PIPELINES Alexander Reiss INSPECTOR S Y S T E M S Copyright

PIPE ROBOTS FOR INTERNAL INSPECTION,

NON-DESTRUCTIVE TESTING AND MACHINING OF PIPELINES

Alexander Reiss

INSPECTORS Y S T E M S

Copyright © – All rights reserved

1INSPECTOR SYSTEMS Rainer Hitzel GmbH – Johann Friedrich Böttgerstr. 19 – 63322 Rödermark – Germany

ALEXANDER REISS

PIPE ROBOTS FOR INTERNAL

INSPECTION, NON-DESTRUCTIVE TESTING

AND

MACHINING OF PIPELINES



Alexander Reiss



2

…SPECIALIZED

COMPANY PROFILE

Fabrication of self propelledrobots for internal inspection, non-destructivetesting and machining ofpipelines

Service worldwide

Private owned company

Founded 1983

ISO 9001, KTA 1401

In-House production



Alexander Reiss



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COMPANY PROFILE

Nuclear power plants Offshore

Chem.-/Petrochemical plants Water-/Waste water

Gas & Oil, Refineries District heating pipelines

Conventional power plants Miscellaneous

…INDUSTRIAL SECTORS



Alexander Reiss



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COMPANY PROFILE

Rödermark, approx. 30 kmsouth of Frankfurt / Germany

…HEADQUARTERS AND PRODUCTION



Alexander Reiss



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In general applicable forall kind of pipe systems

APPLICATION

…PIGGABLE, UNPIGGABLE, BURIED & COMPLEX PIPELINES

Particularly suitable forpipeline systems with:

difficult external accesslike buried pipelines etc.

complex and-/or non-piggable structure

etc.



Alexander Reiss



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…BASIS STRUCTURE

SYSTEM CONCEPT PIPE-ROBOTS

Drive Units

Flexible Folding BellowsI-T-M-Module

RETRACTED

Modular Construction

ElectricalHousing

Control Unit,Monitor, HDD-Recorder

Special cable



Alexander Reiss



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EXTENDED

Drive Units

Flexible Folding BellowsI-T-M-Module

ElectricalHousing

Control Unit,Monitor, HDD-Recorder

Special cable

…BASIS STRUCTURE

Modular Construction




Alexander Reiss



8

Bendable / Adjustable in height

Insertion through poor accesspoints, e.g. dismantledvalves, flanges etc.

To pass

- numerous bends with small

arc radii (≥1.5D)

- Diameter deviations

- Weld roots, T-Branches etc.

Bi-Drectional Travelling

Access only from one side necessary

Long distances (up to 500 m)


…BASIS PERFORMANCE



Alexander Reiss



9

Horizontal – Vertical Travelling

Downward-/Upward slopes/Turns (up to 90° and more)

Self-Propelled

Stop at any time

No ext. drive medium (Water/Air)

No launcher-receiver station

Online Results / Monitoring

Direct identification and sizing of defects(live survey)

…BASIS PERFORMANCE




Alexander Reiss



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TYPE mm inch

1.000 75 - 110 3 - 4

2.000 100 - 140 4 - 6

3.000 130 - 200 6 - 8

4.000 190 - 325 8 - 12

5.000 310 - 510 12 - 20

6.000 440 - 800 18 - 32

7.000 750 - 1.200 34 - 48

…DIAMETER RANGE PIPE ROBOTS (STANDARD)




Alexander Reiss



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TYPE mm inch

1.000 75 - 110 3 - 4

2.000 100 - 140 4 - 6

3.000 130 - 200 6 - 8

4.000 190 - 325 8 - 12

5.000 310 - 510 12 - 20

6.000 440 - 800 18 - 32

7.000 750 - 1.200 34 - 48

…DIAMETER RANGE PIPE ROBOTS (STANDARD)




Alexander Reiss



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SLOFECTM ULTRASONIC/EDDY CURRENT

…MODULES (EXAMPLES)

INSPECTION- AND NDT - ROBOTS

VIDEO, VIDEO/LASER

ULTRASONIC



Alexander Reiss



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…MODULE

VIDEO, VIDEO/LASER

Visual Inspection Inner Conditions

Size/Assess Damaged Areas, Anomalies etc.

High Picture Resolution Front CCD-Color Camera(>460TVL), 10x Optical Zoom, Powerful LEDIllumination

Point-Laser, Classification and Evaluation of theCamera Picture (Cracks, Anomalies, Weld Roots, etc.– Measurments Ø ≥2 mm, Accuracy ±0,1 mm)

Camera Pan.- (360°) and Tilt Mechanism(120°)

Insp.-report: HDD-Record, Tabular, Graphical




Alexander Reiss



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…MODULE

VIDEO, VIDEO/LASER

Visual Inspection Inner Conditions

Size/Assess Damaged Areas, Anomalies etc.




Alexander Reiss



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…MODULE

VIDEO, VIDEO/LASER

360°Profile Scanning

Pipe Classification – Ovality, Areas of Corrosion

Laser-scan recording- Pipe XY

incl. angle: 1 INSPECTORS Y S T E M Sclient: xxx

name operator:

xxx

measuring point

angle [°]

Measurement [mm] distance [m]

0 0,2 88,72 2,861 1,8 88,69 2,862 3,8 88,69 2,863 5,5 88,72 2,864 7,3 88,64 2,865 9,2 88,58 2,866 11,0 88,47 2,867 12,8 88,44 2,86„ „ „ „

Wrinkleat 270°




Alexander Reiss



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…MODULE

VIDEO, VIDEO/LASER

Deviation OD 1 – ID 1

Deviation ID 1 – ID 2

Addition Deviation/Misalignment ID 1 – ID 2


360°Profile Scanning

Pipe End Matching



Alexander Reiss



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…MODULE

VIDEO, VIDEO/LASER

Axial Drive Unit

Laser / Axial Scan

Rotating Unit (360°)

Axial Profile Scanning e.g. NPP in France

Verification of grinded girth welds of joined pipes

Prior pipe laying, measurements at several positions

weld seam profile, angle < 7°

Clamping- andCentering Unit




Alexander Reiss



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ULTRASONIC

…MODULE

Application: All Echo Capable Materials

100% Mapping Wall Thickness (Volume)

Detection Corrosion Areas / Holes etc. - Distinguish between inner/outer pipe surface

UT-Evaluationsystem & Software - Fraunhofer Institut IZFP




Alexander Reiss



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…MODULE

Retainer with water chamber andholder for UT-sensor (spring mounted)

PivotingSensor Arm

Centering Unit

Module rotates while

travelling through the

pipes

Gimbal Suspension

System – allows an

orthogonally impact to

the surface (90°)

Independent continous

water supply (echo

couple medium)


ULTRASONIC



Alexander Reiss



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SLOFECTM

…MODULE

Saturated LOw Frequency Eddy Current

Application: Ferromagnetic Materials

Sensitive Detection of Material Reductions

Detection and Differentiation of Inner & OuterDefects (Pitting Corrosion)

Measurement through Non-Conductive Coatings

Measurement of Cast Iron and SpheroidalGraphite Cast Iron Pipes (Ductile Materials)

Slofec Evaluation-

system & Software -

Kontrolltechnik




Alexander Reiss



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Saturated LOw Frequency Eddy CurrentSLOFECTM

…MODULE

Eddy Current principle

with superimposed

DC field magnetizationΔ μrel

Change of rel. Permeability,

Magnetic Flux Density

Magnet

Eddy Current-Sensors

MagneticAlternatingFields

Magnetic Bias Field

Magnet Coil

DefectFerromagneticSample




Alexander Reiss



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DOCUMENTATION

Defect: Color Classified

…SLOFECTM - ULTRASONIC

Pipe - Section

Position



Alexander Reiss



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VACUUMCLEANING

COATING

…MODULES (EXAMPLES)

MACHINING - ROBOTS

GRINDING/POLISHING

MILLING



Alexander Reiss



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Two Step Process: Grinding, Polishing

Weld Roots:

Removal of weld roots or weld undercut

Increasement load capacity of weld seam (fatigue life)

Prevention cracking

Conditioning of misalignment between pipes

Inner Wall Surface:

Removal of local corrosion areas or any kind of debris

Removal of local surface cracks

Accuracy 0.1 mm, Surface Roughness Ra 1.6 µm

…MODULE

GRINDING/POLISHING

MACHINING - ROBOTS



Alexander Reiss



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Controlled via Monitor and Control Desk

HDD-Record

…MODULE

GRINDING/POLISHING

Clamping & Centering Unit

Radial-Axial Positioning

380° Rotating Unit withGrinding Motor & Disc

Grinding Camera & LED Illumination

MACHINING - ROBOTS



Alexander Reiss



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…MODULE

After Grinding/Polishing Cross SectionPrior Grinding/Polishing

MACHINING - ROBOTS

Controlled via Monitor and Control Desk

HDD-Record

GRINDING/POLISHING



Alexander Reiss



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IMPRESSIONS



Alexander Reiss



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INSPECTOR SYSTEMS Rainer Hitzel GmbH

Johann Friedrich Böttgerstr. 19

63322 Rödermark

+49 (0) 6074 917 123 0

[email protected]

www.inspectorsystems.de

mailto:[email protected]

http://www.inspectorsystems.de/

Documents

PIPE ROBOTS FOR INTERNAL INSPECTION, NON ......PIPE ROBOTS FOR INTERNAL INSPECTION, NON-DESTRUCTIVE TESTING AND MACHINING OF PIPELINES Alexander Reiss INSPECTOR S Y S T E M S Copyright