The fabrication of complex new energy industry assets used for carbon capture technologies that SLB Capturi builds, demands meticulous attention to detail and rigorous quality control to ensure safety, functionality, and adherence to stringent industry standards. Traditional inspection workflows in this sector often rely heavily on manual processes, which can be time-consuming, prone to human error, and challenging to coordinate, especially when dealing with multiple partners, diverse teams across different geographies, and complex projects. These challenges highlight a critical need for more effective and efficient inspection methodologies during fabrication.
Our team is adopting a transformative approach by leveraging "prototype digital twins" and advanced AI-powered visual inspection during fabrication to address these limitations. The core concept involves the regular and systematic capture of visual inspection data throughout the fabrication process. Instead of relying solely on periodic manual checks, this method employs advanced imaging technologies (like high-resolution cameras and 3D scanners) to document the asset's construction at various stages.
The 3D data captured in the process is then fed into sophisticated AI software. This software performs a detailed comparison between the "as-built" physical asset and its corresponding digital blueprint, a Computer-Aided Design (CAD) model. A CAD model represents the intended design, specifying precise dimensions, component locations, and structural configurations. The AI engine meticulously analyzes the visual data, identifying any discrepancies, anomalies, or deviations from the design specifications. These deviations can manifest in various ways, including dimensional inaccuracies (e.g., incorrect lengths or diameters), misaligned structural components (e.g., improperly oriented supports), or incorrect placement of critical components (e.g., valves, nozzles, or instrumentation), to name a few. The identified anomalies are then highlighted within a collaborative 3D virtual environment.
This "prototype digital twin" serves as a central hub, accessible to all key stakeholders involved in the fabrication process, including construction managers, contractors, third-party vendors, engineers, quality inspectors, experts, and even end-clients. This virtual 3D space facilitates remote review of identified issues, enabling stakeholders to provide feedback and collaboratively determine the necessary corrective actions early in the fabrication lifecycle. This proactive approach offers several significant advantages that directly impact the principles of nondestructive testing (NDT) and nondestructive evaluation (NDE).
The immediate application of this technology will offer significant insights to attendees:
• Enhanced Defect Detection and Prevention: Attendees will learn how continuous visual monitoring and AI-driven anomaly detection act as a powerful preventative measure against fabrication errors. By identifying deviations in real-time, teams can intervene before errors escalate into significant defects.
• Streamlined Quality Assurance: The continuous digital capture of inspection data throughout fabrication provides a comprehensive record of the asset's construction. Attendees can understand how this digital documentation reduces reliance on time-consuming manual inspections, streamlining the overall quality assurance process.
• Facilitating Remote Collaboration: The 3D collaborative environment transcends geographical barriers, enabling remote participation of experts. This is particularly relevant for attendees working on projects with globally dispersed diverse teams, offering a solution for improving communication and access to specialized expertise.
In conclusion, the implementation of prototype digital twins and AI-powered visual inspection represents a significant advancement in new energy industry asset fabrication. This technology offers a powerful learning experience for attendees, providing them with applicable knowledge and tools to enhance their work in quality control, inspection, and project management. By embracing these innovative approaches, the industry can move towards safer, more efficient, and more reliable fabrication processes.
In the future, such digital engineering applications can be tailored to adhere to OSHA, ASTM, ASME VIII, and V regulations, Compliances, and PIP (Piping Industry) Standards during fabrication.