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
ncy
(line
) ->
In
trusiv
e in
spec
tion
sco
pe (b
lock
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