1. 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 ( )

2. Contents Motivation Goals Proposed Concept Design Timeline Budget
Further Research Project

3. 1. Motivation Rover required for inspecting offshore pipes
Currently diver based  expensive
Deep water capability
Diver taking pipeline CP reading
Source:-
Underwater ROV
Source:-

4. 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

5. 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 (

6. 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

7. 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

8. 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

9. 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

10. 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)

11. 4. Design - 4.5 Prototype I (Video)

12. 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

13. 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

14. 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

15. 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

16. 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

17. 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

18. 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

19. Thank You