3d laser imaging for inspection, repair, and …...2013/01/22 · 1 rpsea.org high resolution 3d...
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High Resolution 3D Laser Imaging for Inspection, Maintenance, Repair, and Operations09121-3300-06Carl Embry3D at Depth
Ultra-Deepwater Subsea Systems TAC MeetingJanuary 22, 2013Greater Fort Bend EDC Boardroom, Sugar Land, TX
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Outline
• Main objective
• Update on schedule vs. original base line with target end date
• Update on spend vs. budget and any points on discrepancies
• Major achievements
• Significant obstacles - and what mitigation plans are being considered
• Anything the Working group or the TAC can do to assist
• Next Steps
• Conclusions
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Main Objective – Enable Better / Safer Management of Deepwater Assets
• The lack of timely and accurate survey quality 3D measurements poses an integrity management challenge for deep water assets
• A lack of accurate data results in higher risks and/or higher costs to build and maintain environmentally safe production and product transportation systems
Better measurements Better management
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Proposed Solution
• Leverage the recent successes of the multi‐billion dollar land based LiDAR industry and adapt to the ultra‐deepwater environmento Develop unique hardware and concepts of operation for the ultra‐deepwater
environment and perform open water trials o Define specific impact and values for industry
• This program is investigating three specific applicationso As‐builts of existing structures and seabed from a static platform o Survey of new and existing sites and assets from a static platformo 3D image and model creation of existing structures and seabed from a moving ROV
platform
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Phase 1: 1/11 – 2/12 Raise TRL from 2 to 5 Demonstrated 3D imaging while submerged in a pool Demonstrated 3D imaging from static platform while integrated with
ROV in ROV test tank
Phase 2: 3/12 – 8/14 (No cost extension granted last week to extend contract 9 months to 8/14)• Develop technology and open water trial of static 3D imaging and 3D
model generation• Develop technology and open water trial of high precision metrology• Develop technology and open water trial of 3D imaging from a moving
platform
3D Laser ImagingProject Overview
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2012 2013Sensor Design, Build, Lab Test
Field Asset Modeling & Inspection – System Update
Phase 2 – In Process
1st In-Water Trial (Pool)
Static Open Water Trial –Development and execution
Rapid survey for subsea tieback –System Development
Full Range Pool Verification
Phase 1
Field Asset Modeling and Inspection from Mobile Platform – System Update
ROV Tank Test
System Update
Open Water Trial of Mobile Platform Scanning
2011
ROV Integration & Tank Trial
Program Progress – Original Schedule Impacted by Availability of Open Water Trial
Open water trials negatively impacted by:
1) BP unable to provide open water trial
2) Technip offering but wants pool test first
3) Pool test delayed in Dec 2012 due to hurricane Sandy
Result: 9 month no cost extension granted last week extending program to August 2014
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Updated Major Milestones
• Survey Sensor Verification Pool Tests Complete 3/26/13o Offshore Technology Research Center 45m pool in College Station, TX
• Present at OTC 2013 4/30/13• Static Platform Open Water Test Completed 7/24/13• Present at UDW Technology Conference 9/18/13• INU Motion Compensation Pool Test 11/28/13• Motion Compensation Test on ROV 3/28/14• Present at OTC 2014 4/30/14• Open Water Moving Platform Test Con‐Ops Plan Finalized 5/1/14• Present at UDW Subsea Systems TAC 5/21/14• Moving Platform Open Water Test Completed 7/19/14• Phase 2 Final Presentation 8/19/14
News Flash: Possibility for an open water test in February 2013 with Technip in GoM
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Financial Performance –Cumulative Costs for Year 2
• RPSEA contract awarded January 20, 2011• Phase 1 completed on time and budget Feb. 19, 2012• Cost under‐run primarily due to open water trial cost share not occurring in 2012
Dec 2012 Actual = $1.4M
Total Contract Goal = $3.518M w/ Cost Share (Baseline)
Contract RPSEA funding = $2.18M
Dec 2012 Delta = $613k
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Financial Performance – Cost Share for Year 2
• Cost under‐run primarily due to open water trial cost share not occurring in 2012
Dec 2012 = $340.5k
Cost Share Goal = $1.3M
Dec 2012 Delta = $443k
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Financial Performance –Surpassing Tech Transfer for Year 2
Tech Transfer Goal = $52.77k
Dec 2012 = $33.6k
Upcoming Tech Transfer for 2013 Laser scanner displayed at CDL booth at Subsea Tieback ‐March, 2013 Presenting paper at OTC ‐May, 2013 Presenting at UDW Technology Conference ‐ Sept, 2013
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Major Achievements – 1/3
3000m window implemented Iterative mechanical and optical design process to ensure not only the survival of the
window but also integrity of optical performance at 3000m Finite Element Analysis for deflection, deformation, and yield strength violations of
metal endcap and sapphire window at 3000m ‐ fed back into optical models Result was 15mm thick sapphire window Applied custom anti‐reflection coating Window integrated with endcap
Eye‐safe mode implemented Class 1 (eye‐safe) mode for lab or ship‐board testing of sensor Can be configured to switch to Class IIIb only at safe depths
Sapphire window in interferometer for flatness testing
FEA shows area of greatest deflection in endcap
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Major Achievements – 2/3
Re‐design of optical front‐endo Reduced inner‐diameter requirement from 7 inch to 6.1 inch – smaller diameter housingo Finite Element Modal Analysis of new optical truss shows 1st mode at > 200Hz
Stable since MIL‐SPEC for shipboard equipment is up to 33Hz
Upgraded laser from 7,500 to 20,000 pulses per secondo Upgradeable to 40,000 pulses per second
Upgraded receiver to > 25x higher sensitivity Second revision of power board designed – in board layout
o Improves noise filtering, transient suppression, power to externals
Second revision of 3000m housing designed and in fabricationo Reduces length by 3.5” (24” long) and improves housing mounting to tripod or ROV
Custom design transit case delivered and successful 24” drop tests for shock protection Custom spherical targets developed for image stitching in ultra‐deepwater Pressure chamber designed to test optical endcap at pressure and measure
tilt induced in window
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Major Achievements – 3/3
Salt water tank test – demonstrated same accuracy in fresh or salt water Turbidity tank tests – demonstrated the basic rule that the sensor range is the same range as
an underwater camera for any water condition (Secchi depth)o Demonstrated with old receiver. New receiver will have greater range then Secchi depth
Full operational temperature testing of sensor in water from 3°C to 33°C water temp Ability to make point to point measurements on‐screen within minutes of acquiring data Successful pressure test to 2000m depth (2900psi) in Houston Integrated rotation stage to enable 360° azimuth FOV
Demo model tested Purchased pan stage to be delivered and integrated in Feb 2013 Angular accuracy will be slightly worse than 30° FOV
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• Obstacle – locating and gaining time in a large pool to perform measurement accuracy validations by comparing to terrestrial laser measurements
o Test at Ohmsett in Dec. 2012 canceled due to hurricane Sandyo Re‐scheduling to OTRC, but they cannot commit to a date
• Obstacle – getting boat time for open water trialo Technip is providing first opportunity, possibly in Feb. 2013o Will need another opportunity prior to July 2013
• Primary Mitigation – 9 month no‐cost extension granted last week o Currently no risk for cost overrun (program is currently under‐run)
• Anything the Working group or the TAC can do to assisto Boat time for open water trials
Significant Obstacles and Mitigations
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• Pressure testing of 3000m optical endcap for optical performance• Completely integrate and test 360° rotation stage• Fabricate, integrate and test Rev 2 housing and power board• Pool trial to compare 3D scanner data accuracy to terrestrial survey
measurements• Open water trial to test 3D scanning and 3D model development
from a static platform• Open water trial to test metrology from a static platform
Next Steps
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• [email protected] 720‐209‐0323• [email protected] 303‐619‐6589• [email protected] 832‐785‐8440
Developed by:
www.3DatDepth.com