High Resolution 3D Laser Imaging for Inspection, Maintenance, Repair, and Operations

Transcription

1 High Resolution 3D Laser Imaging for Inspection, Maintenance, Repair, and Operations Carl Embry 3D at Depth Ultra-Deepwater Subsea Systems TAC Meeting January 22, 2013 Greater Fort Bend EDC Boardroom, Sugar Land, TX 1 rpsea.org

2 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 2

3 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 3

4 Proposed Solution Leverage the recent successes of the multi billion dollar land based LiDAR industry and adapt to the ultra deepwater environment o 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 applications o As builts of existing structures and seabed from a static platform o Survey of new and existing sites and assets from a static platform o 3D image and model creation of existing structures and seabed from a moving ROV platform 4

5 3D Laser Imaging Project Overview 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 5

6 Program Progress Original Schedule Impacted by Availability of Open Water Trial Phase 1 Sensor Design, Build, Lab Test 1st In-Water Trial (Pool) ROV Integration & Tank Trial Phase 2 In Process Field Asset Modeling & Inspection System Update Full Range Pool Verification Rapid survey for subsea tieback System Development Static Open Water Trial Development and execution Field Asset Modeling and Inspection from Mobile Platform System Update ROV Tank Test 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 System Update 6 Open Water Trial of Mobile Platform Scanning Result: 9 month no cost extension granted last week extending program to August 2014

7 Updated Major Milestones Survey Sensor Verification Pool Tests Complete 3/26/13 o Offshore Technology Research Center 45m pool in College Station, TX Present at OTC /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 /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 7 News Flash: Possibility for an open water test in February 2013 with Technip in GoM

8 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 Total Contract Goal = $3.518M w/ Cost Share (Baseline) Contract RPSEA funding = $2.18M Dec 2012 Delta = $613k Dec 2012 Actual = $1.4M 8

9 Financial Performance Cost Share for Year 2 Cost under run primarily due to open water trial cost share not occurring in 2012 Cost Share Goal = $1.3M Dec 2012 Delta = $443k Dec 2012 = $340.5k 9

10 Financial Performance Surpassing Tech Transfer for Year 2 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 Tech Transfer Goal = $52.77k Dec 2012 = $33.6k 10

11 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 11 FEA shows area of greatest deflection in endcap Sapphire window in interferometer for flatness testing

12 Major Achievements 2/3 Re design of optical front end o Reduced inner diameter requirement from 7 inch to 6.1 inch smaller diameter housing o Finite Element Modal Analysis of new optical truss shows 1 st mode at > 200Hz Stable since MIL SPEC for shipboard equipment is up to 33Hz Upgraded laser from 7,500 to 20,000 pulses per second o 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 fabrication o 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 12

13 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 13

14 Significant Obstacles and Mitigations Obstacle locating and gaining time in a large pool to perform measurement accuracy validations by comparing to terrestrial laser measurements o o Test at Ohmsett in Dec canceled due to hurricane Sandy Re scheduling to OTRC, but they cannot commit to a date Obstacle getting boat time for open water trial o Technip is providing first opportunity, possibly in Feb o 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 assist o Boat time for open water trials 14

15 Next Steps 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 15

16 Developed by: 16

17 Contact PI: Carl Embry 3D at Depth