Tele-Manufacturing for Fabrication or Inspection in Pipelines

Abstract Tele-manufacturing is the ability to accurately transfer manual skillsets from local personnel to remote automation. Tele-manufacturing technologies allow skilled technicians the ability to weld or inspect from a remote location, while guiding the welding torch or inspection probe attached to a collaborative robot (cobot) or machinery. During tele-welding, a local haptic stylus device attached to a PC is manipulated by an operator who is watching a livestream video of the part to be welded. During tele-inspection, the same stylus device is used to control an inspection probe or device that is moving on or around the part to be inspected. Whether welding or inspection, the stylus device allows the operator to guide the remote cobot by transferring the stylus motions in real-time to the cobot. The haptic sensations from the stylus device provides a sense and feel of the remote environment, allowing the operator the sensation of touching surfaces and feeling the application of pressure from the process or from the probe interacting with a surface. The over-arching intent of tele-manufacturing is to allow anyone who desires to do the work – older, younger, disabled – access to the technology and equipment that allows them to remain or become fully productive and safe in critical inspection and manufacturing roles. For the pipeline and pressure vessel industry, tele-welding and tele-inspection are two technologies that are being further developed and deployed. Tele-technologies can increase production, protect the current skilled workforce, and prepare for the next generation of workers who will arrive with years of experience in hand-held controllers and interaction within digital environments. For example, fabrication or repair welding for pipelines is often done in extreme temperatures and in locations requiring the welder to crawl under and around the pipe, often in an excavated area. Manual welders for this skill level and ability to work in this terrain are always in demand. Tele-welding allows the existing and upcoming workforce to operate these welding processes from a remote location, while still in virtual control of the welding process and torch movements. Remotely operating live welding allows a worker to remain safe but still feel immersed in the welding process. Existing skills are required to complete the welding job; however, welders can do it in a more comfortable environment leading to increased arc-on time. Tele-manufacturing is also expected to aid in filling regional gaps in skilled trade workers. Pipeline corrosion causes immense damage, degrades structural integrity, and has led to catastrophic pipeline failures. Furthermore, treatment of corrosion requires countless hours of additional labor costing millions of dollars. Assessing the remaining pipeline strength, determining the required repair, and then inspecting the quality of the repair is also important to saving time and money. However, this evaluation is complex and requires specialized skillsets and experience not available in all locations and regions. Advances are being made in tele-presence operation of increasingly intricate processes, and tele-inspection of pipelines and other pressure-containing systems is an important part of the future of integrity management and safety.