Mechanical Hand Book

 Page 1 CHAPTER -01 1. INTRODUCTION 1.1 Overview: All pipelines needs cleaning at some point in their service life. Pipeline cleaning is an important method to improve the efficiency of the pipeline. In most distribution pipes, sediments accumulate and bio films develop which increases the risk of color, taste and odor problems in water. Before cleaning pipe initial data should be collected and analyzed. To the engineers the challenge is in the servicing and maintenance of the underground pipelines without disrupting or stopping the flow of the product. According to the ILS Standards use of pipeline pigs as maintenance tools is the solution to tackling these problems. To define pigging, it is a process in which a properly sized device, be it spherical or cylindrical is propelled through a pipeline by manipulating the pressure and flow of the existing media (fluid or gas) with the specific purpose of cleaning, inspecting, distributing an inhibitor and or as a plug to isolate a section of the pipeline. Pipeline pigging has become an important part of pipeline maintenance programs since the first pigs were run to keep an opening in the pipeline. From the first simple pigs that were run, consisting of straw balls wrapped in leather, they have evolved to the interesting and complicated designs we see today. Specific pigs have been developed to perform different. Functions such as drying, cleaning, batching, gauging, applying films etc. etc. The efficiency they perform these tasks has improved over time to a point where further improvement may be beyond the design of the pigs themselves. During the pipeline cleaning runs a number of common solvents have been added and run in conjunction with the pigs to aid in the cleaning of these lines. These products help in certain aspects of the cleaning runs but were never designed to do more than dissolve some of the materials that were trying to be removed from the interior surface of the pipe wall. With special fluids that have been developed, which are designed to breakdown, suspend solids, and reduce surface tension, the cleaning programs can be enhanced.[02] 1.2 Objectives The main objective of this project is-  design and construction of a smart pipe cleaning, painting and inspection system. Page 2 CHAPTER -02 2. LITERATURE REVIEW 2.1 PIPE CLEANING METHODS Three principal methods of cleaning pipelines in-place that are used today are described in detail: (1) Mechanical (2) Hydraulic (3) Chemical Mechanical cleaning The commonly agreed and accepted practice among pipeline owners to remove such deposits is by mechanical pigging. The pig is repeatedly sent through the pipeline to swap deposits from that pipeline until hardly any deposit can be found in the pig receiving station. It is, however, hard to determine if this implies that the pipeline is clean[5]. 2.2 Rodding: This method is mainly used to break up grease deposits, cutting roots and debris loosening. It is also used for emergency removal of blockages to create way for TV inspection equipment in the pipeline. Fig. 01 Rodding Page 3 This equipment is available in two ways either power rodding machine or hand rods. Power rodding equipment involves applying a torque to the steel rod as it is pushed through the pipeline, rotating the cleaning device attached to the lead end of the rod. This method can be used for routine preventive maintenance.[6] 2.3 Balling: This equipment consists of sewer balls to fit different diameters of pipes, a tag line, winch, cable, reels, water source and a dump pick up. Fig. 02 Balling When the balls are passed in to the sewer, water will be forced with high pressure and velocity to clean the pipe. Balling is effective in removing heavy concentrations of sand, grit, rock and grease from the sewers. This method is not suggested for basement fixtures and pipe having steep grade. 2.4. Power Bucket: Power bucket machines are another type of mechanical cleaning device used to remove debris, roots, grease or sediments from main line sewers. A bucket machine is equipped with a set of specialized winches that pull a special bucket through a pipe to collect debris. The captured materials are then physically removed from the pipe. These machines are very powerful and offer the best output with the least opportunity for operator’s error that could affect the results. Since a full-size cutter and brush can be pulled through the line, each cleaning should be thorough and no residual debris should be left in the sewer main. Page 4 Fig .03 Power Bucket Operating bucket machines is a very labor-intensive process. Therefore, power buckets are normally used only for specific cleaning purposes, especially removing large amounts of debris from larger sewers.[8] 2.5. General characteristics of cleaning pigs : Cleaning pigs are generally designed to push any loose material through the pipeline and to apply a mechanical force between the pig and the pipe wall surface to remove debris that can be easily removed. Fig 04 Pigs cleaning Page 5 They typically will be composed of a combination of a wiping/sealing surfaces made up of discs, cups or foam with brushes mounted on them made out various materials. Some pig designs will have controlled by-pass to try and keep some solids in suspension. 2.6 Internal pipe inspection . Positive impact in plant performance Improvement of plant efficiency, through better inspection practices o Minimal modifications in current practices o Compatibility with manual operations (it is easy to shift from robotized to manual operations) Improvement of working conditions Overall cost reduction. Fig.05 Internal pipe inspection 2.7 Camera 12V Wireless Camera System. Water-resistant Wide, 110-degree viewing angle; Wireless transmitter; LCD screen has Standby and Auto-On; Adjustable arm with suction cup. Page 6 Fig .06 Camera 1 LED illumination. 2 Radio TX RX This module is used for the wireless transmission and reception of signals mainly used for controlling the PIAC. 3 Wi-Fi streaming (Optional) Wifi stream has the application of streaming the video. 2.8 Internal pipe painting Outline The objective of painting is to form a coating film on the surface of an object in order to protect the object and give a fine appearance. Painting may also have other special functions. There are various types of painting methods, and spray painting is currently used in many types of industry A flow diagram of the spray painting process “Spray painting” consists of the painting operation itself followed by coated film drying. The paint used in the painting process is diluted with thinner, and solid portions in the paint form the coating film after the spraying operation. [7] Page 7 Fig 07 Pipe painting Annual amount of handled Class I Chemical Substances in paints and thinners is calculated based on the content of each chemical in paints and thinners, which should be obtained by MSDS and etc .al painting. Fig 08 painting system Page 8 CHAPTER 03 DEVELOPMENT OF SYSTEM 3.1 Operating Manuals: At a minimum, operating manuals should include the following documentation as applicable: • Operating pressures • Communications. • Line location and markers. • ROW maintenance. • Patrolling. • Integrity assessments and repair. • Pump station, terminal, and tank farm maintenance and operations. • Controls and protective equipment. • Storage vessels. • Fencing. • Signs. • Prevention of accidental ignition. • Corrosion control. • Emergency plan. • Records. • Training. • Modify plans when changes are made in the system. Page 9 3.2 DC motor controller 1. RF-1220 electrical dc motor 2. Round shape and plastic end cap 3. Lower noise and high speed 4. Dia12*L20mm 5. Long lifetime Fig .09 DC Motor 3.3 Voltage specification: The maximum voltage for motor driver minimum voltage is 12 V. We have applied 12V of voltage in out project. Page 10 3.4 Working mechanism: Rotation of motor depends on Enable Pins. When Enable 1/2 is HIGH, motor connected to left part of IC will rotate according to following manner: Input 1 Input 2Result 0 0 Stop 0 1 Anti Clockwise 1 0 Clockwise 1 1 Stop fig.10 Circuit Diagram Page 11 3.5 Implementation This project is divided into the following sub-systems 1. Video monitoring 2. Cleaning system 3. Structural design 4. Wireless video streaming control 5. Mechanical design CHAPTER 04 METHODOLOGY /WORKING PRINCIPLE Design consists of application of scientific principle, technical information, and imagination for development of new mechanism to perform specific function with maximum economy and efficiency. Hence careful design approach has to be adopted. The total design work has been split into two parts. 1. System design Page 12 2. Mechanical design Fig.11 Mechanical design 4.1 System Design: System design is mainly concerns the various physical constraints and ergonomics, space requirements, arrangement of various components on frame at system, man-machine interaction, no. of controls, position of controls, working environments, of maintenance, scope of improvement, weight if machine from ground level, total weight of machine and a lot more. In system design we mainly concentrated on the following parameter:- System selection based on constraints Our machine is used in small-scale so space is major constrain. The system is to be very compact so that it can be adjusted in small space. Fig 12 System Design Page 13 Arrangement of various components Keeping into view the space restrictions all components should be laid such that their easy removal or servicing is possible. Every possible space is utilized in component arrangements. Man machine interaction Friendliness of machine with the operated that is operating is an important criterion of design. ? Chances of failure Losses incurred by owner in case of any failure are important criterion of design. Factor of safety while doing design should be kept high so that there are less chances of failure. Moreover periodic maintenance is required to keep unit healthy. [4] 4.2 Static Analysis In order to decide the actuator size, it is Necessary to perform the static analysis. Assume did in Figure, F cx and F cz denote the reaction force and the traction force exerted on the four-bar by the driving wheel, respectively. Fig.13 Static Analysis Inspection Process A run to be inspected will either start from an access pipe leading at an angle down to the sewer and then run downstream to a manhole, or will run between manholes. The service truck is parked above the access point of the pipe. The camera tractor, with a flexible cable attached to the rear, is then lowered into the pipeline. The tractor is moved forward so that it is barely inside of the pipeline. A "down-hole roller" is set up between the camera tractor and the cable reel in the service truck, preventing cable damage from rubbing the top of the pipeline. The operator then retires to the inside of the truck and begins the inspection, remotely operating the camera tractor from the truck.[1] Page 14 CHAPTER 05 FIGURE OF MY PROJECT Page 15 Page 16 Fig . (a) Fig.14 Figure of My project Page 17 CHAPTER 06 6.0 Advantage 1. It able to easy to find defects and cracks. 2. It able to give fast response. 3. It’s useful for pipe cleaning. 4. It is warless operated and easy to control. 5. It’s able to easy internal painting. 6.1 Disadvantage 1. High rotation of sharp blade tends to damage pipe wall. 2. Length of device is limited to few meters only. 3. High maintenance cost. 4. Able to clean soft clogs only. Need to be connected with water supply thus limited to few meters. 6.2 Applications The application of our system is very specific. It can be used in the following industries: 1. Oil and gas (To clean slug and other deposits formed in the pipes) 2. Water pipes (To detect leakage and save the water) 3. Survey (To relay video information) 4. Allow inspection of inaccessible and / or hazardous equipment or work areas. 4. Provide on-line inspection / maintenance without loss of equipment / plant availability & remove 5. Humans from potentially hazardous work situations. 6. Provide information about the health and condition of critical plant components to Facilitate decision- Page 18 7. Making regarding plant life management 8. Reduce equipment / plant downtime and improve maintenance and inspection procedure thorough better 9. Coverage and documentation. 10. The robot has great application in accessing the regions of pipe in which human doesn’t have reach. It could be mounted with a camera which would send us pictures of inside and would help in our inspection. 11. It could be fitted with ultrasonic sensors and can pin point us the location of a hole. 12. It even has an application in painting up the old installed pipe from the inside very easily. 13. It could be even used for the dosing purpose through a pipe as its pitch is fixed we could attach some material to be dosed and control the feeding of the material inside where we want. CHAPTER 07 7.0 Conclusions The use of pipeline pigging as a maintenance tool serves a great purpose in increasing the life span of the highly pressurized pipelines as well as saving costs and maintenance time. The design of such a device when implemented will help in meeting the demands for an efficient production as the fuel uses in the country keeps on increasing. One of the objectives of this study is to design and develop an inspection for oil and gas applications, which has the abilities to maneuver or crawl in the pipe’s interior. Another objective is to integrate the design with a controlling system to handle. The first objective was tackled by researching about robots for inside the pipe purposes. As a result, the caterpillar type of in-pipe was selected. A few changes were done to the caterpillar type design compared to the benchmark of this project.[3] 7.1 Future Recommendations This is the first implementation of the project and hence there is huge scope of improvement in the future. Some of the areas where improvement should be sought include the following: Page 19 1. Versatility: currently the PIAC only works with pipes of fixed diameter. This has to be corrected in the future enabling the robot to work with different sizes of pipes and even at horizontal and vertical angles. 2. Battery life: currently a 1.2 AH 12V lead acid battery is used to power the system. Due to the low capacity of the battery the system runs out of charge relatively quickly. This should be corrected in the future with the use of larger size batteries and also by improving the over efficiency. 3. Engineering standards: since this build is the first prototype just to prove the concept no engineering standards are approved. In the later build basic electrical NEC, IEEE and mechanical ASME standards should be included certification. CHAPTER 08 MY PROJECT Fig .19 my project Page 20 REFERENCE 1. R. Ferna´ndez-Rodr´iguez, V. Felieu, and A. Gonza´lez-Rodr´iguez. ”A Pro- posed Wall Climbing Robot For Oil Thank Inspection”. 2. W. Fischer, G. Caprari, and R. Siegwart. ”Preseentation G3:New locomotion concept for stem chest inspection and similar applications”. ASL 3. Horodinca M, Dorftei I, Mignon E and Preumont A , “A Simple Architecture for in Pipe Inspection Robots”, in Proc. Int. Colloq. Mobile, Autonomous Systems, pp. 61-64. 4. JadranLenari and Roth B , Advances in Robot Kinematics: Mechanisms and Motion, 1st Edition Defect Identification In Pipe Lines Using Pipe Inspection Robot 5. Nayak A & Pradhan S, “Design of a New In-Pipe Inspection Robot”, Procedia Engineering, Vol.97, (2014), pp:2081-2091 6. Schoonahd J, Gould J, & Miller L, “Studies of Visual Inspection”, Ergonomics, Vol.16, No.4, (1973), pp:365-379. 7. Min J, Setiawan Y, Pratama P, Kim S, & Kim H, “Development and Controller Design of Wheeled-Type Pipe Inspection Robot”, 2014 International Conference on Advances in Computing, Communications and Informatics (ICACCI), (2014). 8. Kwon YS, Lee B, Whang IC, Kim WK, & Yi BJ, “A Flat Pipeline Inspection Robot with Two Wheel Chains”, IEEE Int. Conf. on Robotics and Automation, (2011), pp:5141- 5146. 9. Kakogawa A & Ma S, “Mobility of an In-Pipe Robot with Screw Drive Mechanism Inside Curved Pipes”, IEEE Int. Conference of Robotics and Bimimetics, (2010), pp:1530-1535. 10. Zhang Y, Zhang M, & Sun H, “Design and Motion Analysis of a Flexible Squirm Type Robot”, IEEE Int. Conf. on Intelligent System Design and Engineering Application, (2010), pp:527-531.