Dual Degree Project (2013-2014) Remote Operated Vehicle (ROV) for Underwater Ultrasonic Non Destructive Testing Project Guide: Dr. Prabhu Rajagopal Students: -Tanuj Jhunjhunwala (ME09B097) -shehzaman khatib (ME09B130) Dual Degree Project (2013-2014)

Contents Motivation Goals Proposed Concept Design Timeline Budget Further Research Project

1. Motivation Rover required for inspecting offshore pipes Currently diver based  expensive Deep water capability Diver taking pipeline CP reading Source:- www.jcsubsea.com Underwater ROV Source:- www.bluebird-electric.net

2. Goals Capable of navigating underwater Manually (wired) operated Camera vision for live streaming to operator Gripper to clamp pipes NDT using Ultrasonic sensors on clamps

3. Proposed Concept Source:- Norsk Elektro Optikk AS (www.neo.in) ROV (wired) is controlled by operator ROV navigates underwater to reach pipe using thrusters Camera on the ROV provide visual feedback to operator Gripper on rover clamps the pipe (to be inspected) Performs Ultrasonic NDT Send back sensor data to the operator Analyses and detection of defects Source:- Norsk Elektro Optikk AS (www.neo.in)

4. Design 4.1 Design Considerations Motors for propulsion (no ballast) Thrust requirement (assuming velocity=0.33m/s) = 1kgf Hull – Cylindrically Shaped Ellipsoidal Profile of Hull cap (least drag) Dual hull, multiple thrusters design Bottom heavy  Elimination of Roll Motion Positively Buoyant Waterproofing O-ring Sealants - Araldite

4. Design 4.2 Decision Matrix – Hull and Thruster Configuration Different design attributes Single Hull Dual Hull Single thruster Multiple thruster Azimuthal Thruster Power consumption Less High Medium Space available Ease of fabrication Ease of Control Maneuverability Access to inside components Stability Desired Moderate Not desired

4. Design 4.3 Gripper Design Dual gripper (DC motor controlled/Pneumatic actuator) 4 bar mechanism Sensors to be attached on the inner side of the gripper

4. Design 4.4 Electronics and Vision Stability – PID based stability control using multiple sensors and microprocessor(will be internal to the system) Motor Drivers – Drive all the required thrusters Vision system for manual control – medium resolution camera with external light source Water proof wires – Cables to be well insulated Portability – Control the entire ROV with a single laptop(minimal software) and prevailing UT testing systems

4. Design 4.5 Prototype I [Dual Hull, 4 thrusters] Bilge pump motors for propulsion For Surge For Heave PVC Cylindrical Hull Neutrally Buoyant Waterproofing (O-ring; Araldite)

4. Design - 4.5 Prototype I (Video)

4. Design 4.6 Analysis of Prototype I The overall weight without gripper was 12 kgs The major contributor were the thrusters 5.5 kgs The motor response was as expected Sharp maneuvers were possible No leakage problem Balancing it required a “hit and trial” approach

4. Design 4.7 Thrusters for Prototype 2 Suggestion to buy new thrusters used in AUVs Only few companies in the world make those Seabotix thruster – BTD 150 is of our requirement Voltage:- 12 VDC Weight:- 720 gms Thrust: 2.9 kgf (required – 1 kgf) Cost per thruster: $700

5. Timeline of proposed project Aug Sept Oct Nov Dec Jan Feb Mar Prototype 1-Design & fabrication Gripper design, prototyping & testing Prototype 2 Design Fabrication & Testing ROV testing Arranging sponsorship Ordering Thrusters

6. Budget 6.1 Mechanical Component Quantity Cost(INR) Thrusters Note:- If we go through IC&SR customs duty can be avoided Component Quantity Cost(INR) Thrusters 5 (1 USD = 62 INR) 2,20,000 Shipping and customs $200+$100 18,000 Gripper 3 15,000 Hull 2 10,000 Manufacturing(machining, welding) Miscellaneous and Buffer 12,000 Total - 2,90,000

6. Budget 6.2 Electronics and Vision Component Quantity Cost(INR) Microcontroller – Arduino Mega 2 7,500 Accelerometer 2,500 IMU Sensor 1 70,000 Digital Compass 5,000 Motor Driver 5 14,000 Water Proof Wires 6 6,000 Printer Circuit Board Camera 15,000 Miscellaneous Components - Total 1,30,000

Conferences/ Paper Presentations 6. Budget 6.3 Overall Budget Mechanical 2,90,000 Electrical 1,30,000 Conferences/ Paper Presentations 50,000 Overall Buffer 30,000 Total 5,00,000

7. Further Research Project This will lay down the framework for building underwater NDE machines in IITM and can be developed in later years to: Integrate more NDE techniques - such as guided waves in underwater pipes Stimulate research in stability and control techniques for underwater vehicles Build autonomous NDE machines for underwater pipes

Thank You