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
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
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
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
3
COMPANY PROFILE
Nuclear power plants Offshore
Chem.-/Petrochemical plants Water-/Waste water
Gas & Oil, Refineries District heating pipelines
Conventional power plants Miscellaneous
…INDUSTRIAL SECTORS
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
4
COMPANY PROFILE
Rödermark, approx. 30 kmsouth of Frankfurt / Germany
…HEADQUARTERS AND PRODUCTION
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
5
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.
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
6
…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
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
7
EXTENDED
Drive Units
Flexible Folding BellowsI-T-M-Module
ElectricalHousing
Control Unit,Monitor, HDD-Recorder
Special cable
…BASIS STRUCTURE
Modular Construction
SYSTEM CONCEPT PIPE-ROBOTS
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
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)
SYSTEM CONCEPT PIPE-ROBOTS
…BASIS PERFORMANCE
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
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
SYSTEM CONCEPT PIPE-ROBOTS
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
10
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)
SYSTEM CONCEPT PIPE-ROBOTS
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
11
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)
SYSTEM CONCEPT PIPE-ROBOTS
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
12
SLOFECTM ULTRASONIC/EDDY CURRENT
…MODULES (EXAMPLES)
INSPECTION- AND NDT - ROBOTS
VIDEO, VIDEO/LASER
ULTRASONIC
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
13
…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
INSPECTION- AND NDT - ROBOTS
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
14
…MODULE
VIDEO, VIDEO/LASER
Visual Inspection Inner Conditions
Size/Assess Damaged Areas, Anomalies etc.
INSPECTION- AND NDT - ROBOTS
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
15
…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°
INSPECTION- AND NDT - ROBOTS
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
16
…MODULE
VIDEO, VIDEO/LASER
Deviation OD 1 – ID 1
Deviation ID 1 – ID 2
Addition Deviation/Misalignment ID 1 – ID 2
INSPECTION- AND NDT - ROBOTS
360°Profile Scanning
Pipe End Matching
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
17
…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
INSPECTION- AND NDT - ROBOTS
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
18
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
INSPECTION- AND NDT - ROBOTS
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
19
…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)
INSPECTION- AND NDT - ROBOTS
ULTRASONIC
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
20
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
INSPECTION- AND NDT - ROBOTS
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
21
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
INSPECTION- AND NDT - ROBOTS
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
22
DOCUMENTATION
Defect: Color Classified
…SLOFECTM - ULTRASONIC
Pipe - Section
Position
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
23
VACUUMCLEANING
COATING
…MODULES (EXAMPLES)
MACHINING - ROBOTS
GRINDING/POLISHING
MILLING
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
24
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
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
25
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
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
26
…MODULE
After Grinding/Polishing Cross SectionPrior Grinding/Polishing
MACHINING - ROBOTS
Controlled via Monitor and Control Desk
HDD-Record
GRINDING/POLISHING
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
27
IMPRESSIONS
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
28
INSPECTOR SYSTEMS Rainer Hitzel GmbH
Johann Friedrich Böttgerstr. 19
63322 Rödermark
+49 (0) 6074 917 123 0
www.inspectorsystems.de
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