SmartGrind - targeted, accurate, measurable weld repair
OMS SmartGrind, launched in 2023, is a state-of-the-art robotic grinding system that identifies weld defects such as excess penetration, spatter and wire inclusion, solves them and then rescans to validate the removal process. Laser and camera measurements produce a 3D map of the weld, which is then used to carry out accurate, targeted and efficient grinding, leaving the pipe surface stronger and in better condition for coating. Once repairs are finalised, the weld is scanned again to confirm quality and specification. Safety is improved because no man-entry is required and clients save money because expensive, time-consuming cut-outs can be avoided and production efficiency maintained.
SmartGrind is already in use in global energy projects, including one wind farm where we were able to identify, quantify and solve weld issues in J-tubes reaching over 80m in height. We have also recently added the ability to grind long-seam welds to our service portfolio. This gives clients more options when purchasing pipe for their projects, particularly where internally lined pipe and large diameters are involved, as they can consider more cost-effective LSW pipe without compromising asset integrity.
OMS innovation
Innovation is at the heart of OMS’s business. We are always challenging ourselves to come up with advances that will improve our technology and we always listen to our customers when they talk to us about what they would find useful.
As our award-winning weld inspection service developed over the last fifteen years or so, it became clear to us that adding the ability to remedy weld defects to our ability to detect them would be very welcome to our clients. In most cases, we inspect our clients’ welds and confirm that they are within design specifications. However, occasionally we are able to alert them that a weld is not up to standard and needs remedial attention. Bringing SmartGrind online means we can now solve the problem.
5 years in the making
We started working on SmartGrind several years ago. Our dedicated R&D department invested considerable time and effort into finding the right design and grinding method. We spent a long time talking to our clients to work out what they were looking for and between ourselves to decide how we could achieve it. Clients needed the system to remove excess weld penetration to within 1.5mm of the parent pipe material without any loss of wall thickness. They wanted to be able to operate it remotely from the pipe’s exterior using a GUI. In practical terms, clients wanted an adjustable grinding disc that could be easily installed and removed and a system that could be easily integrated with their other technology.
Through several iterations and much trial and error, our R&D team arrived at the final plans. At our facilities in Stansted, Essex, we are lucky enough to have extensive testing facilities and a full demonstration rig. This investment of time has allowed us to finalise a grinding system that we were confident would meet all our clients’ expectations.
SmartGrind: the technical details
SmartGrind is a remotely operated, adjustable grinding system. As a modular addition to our award-winning AUGA.node weld inspection system, it uses laser and camera technology to identify problem areas then applies targeted, localised grinding to remedy any issues. The software uses 2D axial and radial laser profiles to generate a 3D map which provides accurate locations to the grinder, which automatically moves from location to location until all features are solved. Radial force and rotation speed are monitored, and disc degradation observed, with an alarm alerting the operator when a new disc is required. Laser profiles and HD images can be recorded for pre- and post-grinding activities. Manual grinding in specific locations can be carried out if necessary, but AI is preferred by our clients.
SmartGrind can deploy via our AGILITY range of robotic crawlers or attach to the ILUC. It is operated remotely via an Xbox controller or through a GUI and laptop.
Next steps
Currently SmartGrind can travel around 100m and navigate some bends, depending on diameter. Our R&D team is working round the clock to ensure the system will shortly be able to access all the locations our AGILITY range of crawlers can reach – travelling up to 1km from point of entry and through multiple bends and 1.5D elbows.
We are demonstrating SmartGrind at our offices in Stansted and expect to be exhibiting at several trade shows later in the year. We also plan to take the system on a ‘roadshow’ to various locations throughout the world in the coming months. If you would like to book a demonstration or to have more information on our upcoming exhibitions please contact us on info@omsmeasure.com or +44 1279 656038.
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Published: 03.01.24
[5 minute read]
By Marcus Smiles, Global Manager