Obiettivo The aim of the Project was to develop, build and test a fully integrated pipe preparation and welding system, "THOR 2", which could be used for both advanced diver-assisted and future diverless hyperbaric welding tie-ins."THOR 2" is the first automatic welding system which can be used in a diverless mode and as such, it has a significant impact on both costs and personnel safety for deepwater tie-ins and repairs.WORK PACKAGE NR 1 : REMOTELY CONTROLLED PIPE PREPARATION* Development of the hardware and software for the reduction of pipe ovality : Hardware and software designed, built and tested in COMEX workshops.* Development of a remotely controlled pipe cutting and bevelling tool which can be installed by a remotely controlled manipulating arm : Hardware and software built and tested in COMEX workshops.WORK PACKAGE NR 2 : DEVELOPMENT OF "THOR-2" WELDING EQUIPMENT* Development of multi-process weld heads which can be installed and serviced by either a diver or a remotely controlled manipulating arm : - Two weld heads built and tested (including the mechanism for remotely controlled electrode replacement, and weld pool observation).* Development of multi-process welding power source which can be used efficiently down to depths of at least 500 m. s. w. : - Two power source units built, integrated into the subsea module, and tested.WORK PACKAGE NR 3 : DEVELOPMENT OF "THOR-2" WELD CONTROL SYSTEM, SYSTEM OF DIAGNOSTICS INTELLIGENCE SYSTEM AND FUNCTION TESTS* Development of an advanced weld control system (software and hardware) for alternate control of two weld heads and induction preheating : - System built and factory acceptance tests complete. Integration into the module done, * Development of a system status data logging and equipment fault finding (diagnostics) facility based on the "marriage" of the weld control system amd an Expert system (artificial intelligence) : - Work concentrating on diagnostics function. Tested on "THOR-1", data transfer for "THOR-2" as a live process during equipment utilisation.* Function tests of the complete "THOR-2" weld system (weld control, diagnostics, clamps/orbital carrier and weld heads, welding power sources).WORK PACKAGE NR 4 : AUTOMATIC REAL TIME GENERATION OF WELDING PARAMETERS* Development of existing laser sensors for use in hyperbaric conditions : - Marinised prototype built for 300 m. s. w. and tested.* Consolidation using algorithms of a welding parameters databank as a function of joint metrology gained through welding tests, interfaced with the weld control system software and the laser unit, completed.WORK PACKAGE NR 5 : ONSHORE AND OFFSHORE TESTS OF COMPLETE SYSTEM* All umbilicals linking the subsea module to the surface control cabin and the habitat, were manufactured and tested.* Integration of all the surface control equipment into a 20' cabin was completed.* Onshore and shallow water tests of the complete system.* As built, dossier and operational procedures established.* Offshore trial performed, April 1991, from MSV AMETHYST, in 70 msw, North of the FRASERBURG Trench in the North Sea.First generation hyperbaric welding systems offered the following advantages to offshore contractors and operators when compared with manual welding:* improved weld quality,* improved quality assurance,* improved habitat diver working conditions,* cost savings on onshore welding qualifications.However, these first generation systems were limited in that:* they are dependent on a habitat diver for their installation and servicing,* the pipe preparation and chamfer metrology are performed by the habitat divers and are subject to human error/inaccuracies,* the surface operator is responsible for the realtime adjustments of parameters during welding to take into account local irregularities of pipe preparation and is thus equally subject to human error/inaccuracies.The "THOR-2" system consists of :* An hydraulic round-up clamp (TOC) remotely controlled from the surface, is positioned over one pipe-end and used to remove pipe ovality. It features an electrically driven turn table, which can carry the different tools for pipe machining, metrology, welding, etc...* A series of tools which can be placed on the TOC either by a manipulating arm or by the diver, to perform pipe cutting/bevelling, joint metrology and welding (weld heads) under remote control.* An advanced welding system consisting of two weld heads suitable for operation without diver-assistance, two multi-process power sources (possibility TIG and MIG), and advanced weld control system which allows welding with two weld heads alternatively (faster welding), an automatic demagnetisation system, an automatic induction pre-heating system, 2 cameras for weld pool observation.* A laser based real time data processing of the root pass welding parameters which automatically updates them as a function of the groove shrinkage during the hot pass.* A misfunction diagnostic intelligence software, for operator, trouble shooting assistance.* All equipment being integrated into a surface control cabin, and a subsea module, with linking umbilicals.The "THOR-2" programme consisted of :PHASE 1* Design and manufacturing of the pipe round-up and tool support clamp, pipe machining tools, metrology systems and associated software,* Development of the welding equipment and weld control system,* Development of the artificial intelligence capacity of "THOR-2".PHASE 2* Onshore and shallow water tests of the above equipment, integration into a welding spread (habitat, module, etc...).* Full offshore test of the "THOR-2" system which proved the feasability of diverless hyperbaric welding concept and allowed the different components of the "THOR-2" system to be tested in real operational conditions.The trials were performed in April 1991, offshore Scotland in the North Sea, in 70 msw open water from the MSV AMETHYST using a COMEX welding habitat system. Programma(i) ENG-HYDROCARB 1C - Programme (EEC) of Community projects in the hydrocarbons sector, 1973-1985 Argomento(i) Data not available Invito a presentare proposte Data not available Meccanismo di finanziamento DEM - Demonstration contracts Coordinatore STOLT COMEX SEAWAY SA Contributo UE Nessun dato Indirizzo CHEMIN DU LITTORAL 467 - B.P. 69 13321 Marseille Cedex Francia Mostra sulla mappa Costo totale Nessun dato
