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Supporting Integrity Management with a CP Digital Twin

Picture for Supporting Integrity Management with a CP Digital Twin
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Product Number: 51321-16401-SG
Author: Cristina Peratta/Robert Adey/John Baynham/Tim Froome
Publication Date: 2021
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Integrating inspection data with a CP simulation model enables the creation of a “digital twin” of the structure which can be used to predict the present and future protection provided to all parts of the structure. The design of marine structures is typically based on design guidelines that specify the protection potentials on the structure to be achieved by the CP system and the rate at which elements of the protection system such as coatings are to be assumed to degrade over the life of the structure. As part of the design study, the performance of the CP system can be evaluated and optimised using a CP simulation model which predicts year by year the protection potentials, the depletion of the anodes, and in the case of ICCP the current to be required by the system. While this type of simulation provides valuable information to the design engineer by confirming that the required protection will be achieved. In reality, the actual performance of the CP system will be often different as coatings for example often degrade at different rates to that described in the design rules, environmental conditions may vary, the “as-built” structure may be different and changes and retrofits are made over time. Integrating the CP data collected during the routine inspection surveys with a CP simulation model enables a “digital twin” of the structure to be created by adjusting the model to match the inspection data. In this way, the simulation digital twin represents the behaviour of the structure and the CP system at the time the inspection survey was performed. This then provides the ability to predict the present and future protection for all parts of the structure. By repeating the process with each new inspection report the engineer can easily monitor the differences between the model predictions and survey data systematically to assess current “health” of the structure, identify anomalies, predict and plan for future risks, optimise the inspection strategy and provide early identification of problems which will require actions. In this paper, a case study is presented where the approach is used as part of the integrity management of an FPSO. The paper will describe the system developed and applications of both the 3D corrosion data visualisation and the simulation-based digital twin.

Key words: Corrosion, Corrosion Data Management, Digital Twin, Cathodic Protection

Integrating inspection data with a CP simulation model enables the creation of a “digital twin” of the structure which can be used to predict the present and future protection provided to all parts of the structure. The design of marine structures is typically based on design guidelines that specify the protection potentials on the structure to be achieved by the CP system and the rate at which elements of the protection system such as coatings are to be assumed to degrade over the life of the structure. As part of the design study, the performance of the CP system can be evaluated and optimised using a CP simulation model which predicts year by year the protection potentials, the depletion of the anodes, and in the case of ICCP the current to be required by the system. While this type of simulation provides valuable information to the design engineer by confirming that the required protection will be achieved. In reality, the actual performance of the CP system will be often different as coatings for example often degrade at different rates to that described in the design rules, environmental conditions may vary, the “as-built” structure may be different and changes and retrofits are made over time. Integrating the CP data collected during the routine inspection surveys with a CP simulation model enables a “digital twin” of the structure to be created by adjusting the model to match the inspection data. In this way, the simulation digital twin represents the behaviour of the structure and the CP system at the time the inspection survey was performed. This then provides the ability to predict the present and future protection for all parts of the structure. By repeating the process with each new inspection report the engineer can easily monitor the differences between the model predictions and survey data systematically to assess current “health” of the structure, identify anomalies, predict and plan for future risks, optimise the inspection strategy and provide early identification of problems which will require actions. In this paper, a case study is presented where the approach is used as part of the integrity management of an FPSO. The paper will describe the system developed and applications of both the 3D corrosion data visualisation and the simulation-based digital twin.

Key words: Corrosion, Corrosion Data Management, Digital Twin, Cathodic Protection

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Picture for Corrosion Data Management Using 3D Visualisation and a Digital Twin
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Corrosion Data Management Using 3D Visualisation and a Digital Twin

Product Number: 51320-14535-SG
Author: Robert Adey, Cristina Peratta, John Baynham
Publication Date: 2020
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There is a gap between the Integrity management systems used by companies to manage their assets and the needs of the CP engineer. Integrity management systems do not fully meet the needs of the engineer responsible for corrosion as they do not provide access and visualizations of all the data the engineer needs to make fast and informed decisions. There is also often no easy way to see the trends in the data, or easily access the relevant video and photographic data also recorded during the survey.

Data from surveys is normally contained in reports and EXCEL spreadsheets often with different measurement locations and inconsistent naming of the locations between reports. In this paper a system is introduced which enables engineers to manage and visualise in 3D CP survey data and provide access to all the relevant information through a 3D visual interface to any member of the teams. The software gives the engineer the ability to visualize in 3D the historical and predicted CP protection on the structure and the status of the anodes in the CP system. It also provides information on long term trends in the survey data.

By integrating the corrosion data with a simulation model a “digital twin” of the structure can be created to make predictions of the present and future protection of all parts of the structure. For example the engineer can easily use the software to systematically monitor the differences between the model predictions and survey data to identify anomalies and give early identification of problems which will require action.

The paper will describe the system developed and present applications of both the 3D corrosion data visualisation and the simulation based digital twin
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