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Affordable underwater robotic welding repair system

Objective



Initiatives to maximize safety and reduce cost are leading to the phasing out, as far as possible, of manned diving operations in the North Sea. But at the present time there is no fully mechanized orrobotic, diverless underwater welding system available to the industry for use at any depth, deep or shallow (Ref 4). So welding systems for underwater repair of fatigue cracks are presently dependent on the use of divers in a dry hyperbaric "habitat" to manually weld complex geometries on large thick tubular intersections (called ''nodes"). This project will develop underwater robotic welding repair equipment for inspection and maintenance contractors, operating in the offshore, maritime and nuclear industries. The "state of the art" hydraulic manipulators, currently in use offshore, are not capable of moving with the degree of precision required for welding operations. The necessary precision (+/ 0.2 mm) can only be achieved on a practical basis using an electric robot. Teleoperated electric robot arm welding systems developed for repairs in the nuclear industry are capable of producing only single pass welds on thin materials and have not yet been adapted for repairing cracks in thick steel (typically 25 mm thick) underwater. In this project a submersible welding electric robot arm with a controller, will be developed to deploy and move the welding system. For offshore work the prototype robotic welding system will be delivered and clamped to underwater node sections on platforms by a large ROV (Remotely Operated Vehicle), of the type presently used by inspection and maintenance contractors. The welding process used will be friction stitch welding which has recently been developed for repairing thick steels and can be used in water to produce sound welds.

This technique involves drilling a hole in the crack and filling it by rotating a consumable bar in the hole and producing a friction weld. Cracks are repaired by producing a series of such welds overlapping each other. During this project hydraulically powered stitch welding head will be developed for deployment on the submersible electric robot arm. The broad project partnership includes a robot manufacturer (Sweden), a friction welding equipment manufacturer (UK), a contractor who will use the equipment in the offshore and maritime industries (Norway) centres for welding research in the offshore, maritime and nuclear industries (Germany and Portugal), a robotic software company, and a testing centre for the offshore industry (UK). The total budget is 3.7MECU. Cost savings of approximately 8 MECU over 5 years in the offshore industry and approximately 4 MECU in the maritime transportation industry will be possible if the technology is successfully developed. Safety will be enhanced by replacing men in the hazardous under water environment with a robotic system. Furthermore the quality and repeatability of welds will be improved by replacing manual welding with a fully mechanised system. This project complies with 1.1.3M (Area 1 Medium term) of the Workprogramme and the Maritime systems of the future Task Force.

Funding Scheme

CSC - Cost-sharing contracts

Coordinator

National Hyperbaric Centre Ltd
Address
123 Ashgrove Road West
AB2 5FA Aberdeen
United Kingdom

Participants (7)

CIRCLE TECHNICAL SERVICES LTD
United Kingdom
Address
Well Heads Place, Wellheads Industrial Estate, Dyc
AB21 7GB Aberdeen
GENERAL ROBOTICS LTD.
United Kingdom
Address
Mill Square 6
MK12 5RB Milton Keynes
GKSS - FORSCHUNGSZENTRUM GEESTHACHT GMBH
Germany
Address
Max-planck-stra?e
21502 Geesthacht
Instituto de Soldadura e Qualidade
Portugal
Address
Tagus Park
2781 Oeiras
Pressure Products Group Ltd.
United Kingdom
Address

AB32 6TQ Aberdeen
SMT TRICEPT
Sweden
Address
22A,ritarslingan 22A
187 66 Taeby
Stolt Comex Seaway AS
Norway
Address
1,Stoltenberggt
5501 Haugesund