by HADI AlMAN BIN HAMIDON

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MOBILE ROBOT FOR INSPECTIONS OF GAS PIPELINE

by

HADI AlMAN BIN HAMIDON

FINAL REPORT

Submitted to the Electrical & Electronics Engineering Programme in Partial Fulfillment of the Requirements

for the Degree

Bachelor of Engineering (Hons) (Electrical & Electronics Engineering)

APRIL2011

Universiti Teknologi PETRONAS Bandar Seri Iskandar

31750 Tronoh Perak Darul Ridzuan

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CERTIFICATION OF APPROVAL

MOBILE ROBOT FOR INSPECTIONS OF GAS PIPELINE

Approved:

by

HAD! AlMAN BIN HAMIDON

A Final report submitted to the

Electrical & Electronics Engineering Programme Universiti Teknologi PETRONAS

in partial fulfilment of the requirement for the Bachelor of Engineering (Hons) (Electrical & Electronics Engineering)

Project Supervisor

UNIVERSITI TEKNOLOGI PETRONAS TRONOH, PERAK

April2011

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CERTIFICATION OF ORIGINALITY

This is to certify that I am responsible for the work submitted in this project, that the original work is my own except as specified in the references and acknowledgements, and that the original work contained herein have not been undertaken or done by unspecified sources or persons.

(HadiAiman b Hamidon)

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ABSTRACT

This report initially introduces the author perception on fully autonomous robotics. He relates how many science fiction movies in the past predicted today' s technology and relate it to the future of robotics. Then this report discusses about robotics in the pipeline domain. Many pipe line robots like Tractor L500, KARO, KANTARO and a few more are discussed and classified in categories in the literature review. The categories are none, semi and fully autonomous robots. Fully autonomous robots are discussed in more detailed. Most of the fully autonomous robots have complex navigating mechanism and multiple sensors for motion control and yet none of the models implemented guarantee the reliability of the system. So ARIS is born to make this category of robot more reliable. Before entering the discussion on the proto type, this report states the method and approach that the author do the project. The mechanical, design, and control system specification that were set before building the prototype and control system are also stated in the section. Next this report introduces the first prototype (DDO.l ). This prototype is design base on the wheeled type. After many hours of testing, design flaws are discovered when few mechanical and control problems occur and can't be solve.

This leads to a big move by the author to redo the chassis design. This report also discusses on the new prototype Advance Robotics Inspection System (ARIS). It is designed base on previous failed attempts. Its design is base on the caterpillar type which allows the robot to turn 360 degrees and climb over obstacles without getting stuck. Finally fuzzy logic control was implemented. All the experimental modeling procedure and results are discussed in detail in this report. The report discusses on full detail on how to get parameters for the autonomous system in curving pipe and pipe with obstacles most commonly section of pipe with brackets. Experiments on fully autonomous movement when robot entering a Tor L junction hasn't been done due to no such facility of junction pipe in UTP. Because of that, this report have state a recommendation for UTP to have a proper facility for in pipe robotic testing.

This scope of research have great potential as it gives the world a solution on pipeline inspection that is very crucial especially in the oil and gas industry where safety is a big issue.

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TABLE OF CONTENTS

CERTIFICATION OF APPROV AL.-... i

CERTIFICATION OF ORIGIN ALIT¥--- ii

ABSTRACT ... iii

TABLE OF CONTENT ... iv

LIST 0 F FIGURES ... __ _vii LIST 0 F FIGURES ... _ ... _ ... _viii CHAPTER 1- INTRODUCTION ... l I .I : Background ... __ ... _ ... _ ... _________ I 1.2 :Problem Statement ... _ ... ____ ... _ 2 1.3 :Objectives ___ ... _ ... _ ... _ ... _ ... _ ... _ ... ____ ... _ .... 2

CHAPTER 2- IN PIPELINE MOBILE ROBOT ... 3

2.1: Pipe Line Inspection Robots ... ) 2.2: Autonomy Based Classifications __________________________________________________________ 3 2.2.1 : Non Autonomous Robots---3

2.2.2: Semi-Autonomous Robots ... 4

2.2.3: Fully Autonomous Robots ... 5

CHAPTER 3-METHODOLOGY •.•..•....•...••...••..•... 7

3.1: Procedure Identification FYP 1 ... 8

3.2: Procedure Identification FYP 1 ... 9

3.3: Mechanical Design and Specification ... J 0 3.4: Control system specification ... l l 3.4.1: Transfer function of the robot ---_1 I 3. 4.2: Experimental design_ ... ________ 13 3. 4.3 : Robot experimentation ... _____ ... _ ... 13

3. 4.4: Determine model structure ... 13

3.4 .5: Parameter estimation ... 14 3.4.6: Diagnostic evaluation and model verification _______________________________ _l4

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CHAPTER 4 -EXPERIMENTAL PROTOTYPE l(DD0.1) ... ..15

4.1: Design and application studies ...

..!

5

4.1.1: Choice of mechanical design ...

..!

6

4.2: Mechanical part ... 17

4.2.1 : Chassis design ... 15

4.2 .2: Steering mechanism,···"·"···,_,''·',·'"·"·',_._,·"'·"·'·"·"···"·"·'·"·'"·''·'·"·'", 15 4.3: Inputs ... l6 4.4: Power and weight distribution ...

..!

9

4.5: Input and Output testing Control mechanism ... 19

4.5.1: Input ... 19

4.5.2: Output ... 20

4.6: Control Mechanism ... 20

4.7: Wireless Communication ... 22

4. 7.1: Xbee protocol.. ... 23

4.7.2: Wireless analogue contro1 ... 21

4.8: Motor speed contro1s ... 24

4.9: Main board casing ... 25

CHAPTER 5- Advance Robotic Inspection System (ARISL ... 26

5.1 : Preview ... 26

5.2: Mechanical design ... 27

5.3 Monitoring applications ... 29

5.3.1 Roundness computation ... 29

5.3.2 Visual inspection ... 31

5.3.3 Communication ... 32

5.4 ARIS navigation system ... 33

5.4.1 Pipeline curve contro1 ... 33

5 .4.2 Positioning computation ... 34

5.4.3 Control mode1 ... 37

5.4.3.1 Transfer function of the robot ... 39

5.4.3.2 Fuzzy logic control implementation ... 39

5.4.4: Pipe brackets and obstacles in pipe ... 44

5.4.5: Pipeline junction control.. ... 43

5.5 ARIS experimentations result and discussion ... 44 v

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5.5.1 Transfer function computation function results ... 44 5.5 .2 Pipe bracket climbing experimentation ... 4 7

CHAPTER 6- CONCLUSION AND RECOMMEND A TION ... Sl 6.1 Conclusion ... -... 51 6.2 Recommendation ... 51

REFERENCES ... 52 APPENDICES ... SS

APPENDIX A: Chassis

APPENDIX B: Steering mechanism

APPENDIX C: Wireless communication interface APPENDIX D: Experimental chassis

APPENDIX E: Mechanical gyro APPENDIX F: Gann chart FYPI APPENDIX G: Gann chart FYP2

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