SICAMS

Formerly Blom Maritime AS

DOCUMENT TITLE

METROLOGY SUBSEA USING SICAMS

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Summary
The purpose of this document is to give an introduction to the methodology of underwater Close Range Photogrammetry developed by Parker Maritime AS. Details about spool metrology specifically can be found in a separate chapter. Photogrammetry is the science where images can be used to create a true scale model where three-dimensional co-ordinates and related quantities like spatial distances, spatial angles, surface description or volumes can be extracted. The normal total achievable point accuracy is better than 1 in 5 000 parts of the length of the object if all issues regarding accuracy are handled correctly, meaning that a 50 meter survey will have an accuracy better than 10 mm at 1 sigma from the photogrammetric model. If required, a total point accuracy of 1 to 15 000 can be achieved. Today photogrammetry is the only method providing this accuracy under water. Photogrammetry is a very efficient metrology method. Photogrammetry may often be used where other methods fails. Mobilisation time is short. Field time is short. Considerable cost savings may be achieved. Very flexible and adaptable in the field. Level of details is higher than with other methods. Special mechanical jigs/tools are not required. Objects/obstructions discovered in the field may be surveyed on the fly. Additional quantities can be extracted from the model without new field work. Results are delivered in 3D CAD models. Images can be used for engineering and planning.

Please refer to our document Photogrammetry - Track record for details regarding executed projects, the project type, size and the accuracies achieved.

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09000285 08000601
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25.03.2009 Nov 07
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CONTENTS
1. 2. METHOD PRINCIPLE ................................................................................................................................................3 ACCURACY ..................................................................................................................................................................3 2.1 2.2 3. GENERAL COMMENTS REGARDING ACCURACY ........................................................................................................3 ACCURACY ACHIEVED UNDER WATER .....................................................................................................................4

ONSHORE PREPARATIONS.....................................................................................................................................5 3.1 3.2 ENGINEERING ..........................................................................................................................................................5 ONSHORE PREPARATION OF EQUIPMENT ..................................................................................................................5

4. 5.

OFFSHORE OPERATION ..........................................................................................................................................6 PHOTOGRAPHING, PROCESSING AND REPORTING ......................................................................................6 5.1 5.2 PHOTOGRAPHING .....................................................................................................................................................6 PROCESSING AND REPORTING ..................................................................................................................................6

6.

EQUIPMENT ................................................................................................................................................................7 6.1 6.2 6.3 METROLOGY CAMERA SYSTEM ................................................................................................................................7 LIGHTING.................................................................................................................................................................8 MARKING EQUIPMENT .............................................................................................................................................8

7.

EQUIPMENT HANDLING........................................................................................................................................11 7.1 7.2 7.3 SURFACE TO SEABED EQUIPMENT HANDLING.........................................................................................................11 TIME CONSUMPTION FOR SETTING OUT MARKERS ..................................................................................................13 TIME CONSUMPTION FOR CAPTURING THE IMAGES ................................................................................................14

8. 9.

CLIENT PROVIDED ITEMS....................................................................................................................................14 SICAMS SPOOL METROLOGY .............................................................................................................................14 9.1 9.2 9.3 9.4 9.5 9.6 9.7 9.8 9.9 9.10 9.11 PRINCIPLE ..............................................................................................................................................................15 PROJECT TASK LISTS ..............................................................................................................................................15 PERSONNEL REQUIREMENTS ..................................................................................................................................16 MOBILISATION TIME ..............................................................................................................................................16 PRE-MARKING ONSHORE ........................................................................................................................................16 OPERATIONAL TIME SCHEDULE ESTIMATE .............................................................................................................16 PROCESSING, CALCULATIONS AND PRELIMINARY REPORT .....................................................................................16 ACCURACY ............................................................................................................................................................17 IMAGE QC .............................................................................................................................................................17 DATA QC ..............................................................................................................................................................17 LIMITATIONS .........................................................................................................................................................17

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1.

METHOD PRINCIPLE
Photogrammetry is the method of obtaining three-dimensional geometric and thematic data of objects by means of a set of images taken of the object. With images as input photogrammetry produces threedimensional co-ordinates and related quantities like spatial distances, spatial angles, surface description or volumes. The principle of photogrammetry can be described as a three-step procedure: 1 - Image acquisition Images of the object are acquired with one camera. Depending on the desired accuracy of the 3Dobject description the necessary parameters are defined (see below). For a 3D computation of the location of an object point, it must be visible in at least two (partially) overlapping images. 2 - Image analysis When the images have been recorded, measurements are performed in the images. Generally, twodimensional positions of object points are measured in each image separately. The points are expressed with respect to each individual image co-ordinate system. Depending on the specific measurement task and software system, the measurements are executed automatically with pattern recognition software or executed manually. 3 - Object reconstruction The object reconstruction step is purely computational. Measured 2D image co-ordinates are converted into 3D object co-ordinates. Depending on the measurement set-up and the software system, statistical quality properties of each measurement and object point can be computed. The obtainable accuracy is dependent on the camera used, the geometry and overlap between the images, the number and the quality of known distances and the number of control points in the images.

2.
2.1

ACCURACY
General comments regarding accuracy There are a number of factors involved in determining the accuracy of close range photogrammetry projects. Image Resolution: The higher the resolution of the images, the better chance of achieving high accuracy because items can be more precisely located. Image resolution is defined by the capabilities of the digital camera. Higher resolution will result in better accuracy. Camera Calibration: Calibration is the process of determining the camera's focal length, format size, principal point, and lens distortion. There are a number of ways of obtaining this camera information and using a fully calibrated camera will give the best results. Angles Between Photos: Points and objects that appear only on photographs with very low subtended angles (for example a point which appears in only two photographs that were taken very close to each other) have much lower accuracy than objects on photos that are closer to 90 degrees apart. Making sure the camera positions have good spread will provide the best results.

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Photo Orientation Quality: The processing software computes the location and angle of the camera for each photo - this is called orientation. One factor that contributes a lot to the accuracy of a project is an accurate orientation for every camera position. The orientation quality improves as the number of well-positioned points increase and also as the points covers a greater percentage of the area in each image. Photo Redundancy: A point's or object's position is usually more accurately computed when it appears on many images - rather than the minimum two images. Targets: The accuracy of a point is connected with the precision of the marking in the images. This positioning can be improved further by using targets. The software uses the image data to sub-pixel mark the point and this increases the precision of the marking and the overall accuracy of the point's computed 3D position. Figure 1 illustrates this:

Accuracy factors The blue lines indicates the accuracy factors implemented by Parker Maritime *) When field calibration photos are taken correctly (i.e. with rotated photos).

The accuracy figures "1 part in NNN" is the one-sigma standard deviation accuracies. At 1 part in 30,000 on a 3m object, point positions would be accurate to 0.1 mm at 68% probability (one sigma). Moving down each column one gets increased accuracy given that the other items remain constant. For example, the lowest accuracy is achieved with a low-resolution un-calibrated camera, unfavourable angles between photos, low coverage of every photo, points only on two photos, and no sub pixel targets. Conversely, the highest accuracy is achieved with a high-resolution field calibrated camera, with favourable angles between photos, most photos have good coverage, most points appear on eight or more photos, and all points are circular targets. 2.2 Accuracy achieved under water In addition to the General comments regarding accuracy above, the accuracy is influenced by environmental conditions under water. For example the visibility influences on the ability to define markers accurately and the current influences on the ROVs ability to keep the camera steady while shooting. Rapid movements of the camera will degrade image sharpness.
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The normal total achievable point accuracy is better than 1 in 5 000 parts of the length of the object if all issues regarding accuracy are handled correctly, meaning that a 50 meter survey will have an accuracy better than 10 mm at 1 sigma from the photogrammetric model. If required, a total point accuracy of 1 to 15 000 can be achieved. Today photogrammetry is the only method providing this accuracy under water.

3.

ONSHORE PREPARATIONS
Prior to the offshore work a project procedure that incorporates the photogrammetry photo plan will be made, marking equipment must be prepared and the camera systems must be tested.

3.1

Engineering All the information from the client is assembled in a 3D CAD model. This is the foundation for making the project procedure.

3.1.1

Field Procedure A typical project procedure will include the following items: 1. 2. 3. 4. 5. 6. 7. 8. 9. References (ref. to all documents received from the client) Introduction Scope of work Schedule and organisation List of equipment, with provider Personnel Sequence of work Marking plan Photogrammetry photo plan

The photogrammetry photo plan is the basis for estimating the need for marking equipment and how the images will be captured. 3.2 3.2.1 Onshore preparation of equipment Marking material Parker Maritime has in stock single targets, scale bars and other marking equipment. The marking equipment is described in section 6.3. The preparation of these involves new marking tape and calibration. Purpose marking equipment may be required, taking from days to weeks to produce based on the design and the capacity of our suppliers. 3.2.2 Camera systems The complete camera systems including flash or lights and the control PC are tested prior to shipping. The camera system is described in section 6.1.

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4.

OFFSHORE OPERATION
A typical offshore operation consists of: 1. Going through field procedure with survey- and ROV/diver-crew 2. Interfacing of camera system to the ROV system (The diver system does not require any interfacing) 3. Interfacing of camera lights to the ROV system 4. Assembly of marking equipment 5. Inspection of survey areas and cleaning 6. Placing of marking equipment 7. Inspection after marking 8. Photographing 9. Downloading of images from camera system to PC 10. Quality Control of image quality and object coverage 11. Reporting onboard the vessel if agreed upon in advance The survey area has to be cleaned by the Client if this shows necessary.

5.
5.1

PHOTOGRAPHING, PROCESSING AND REPORTING

Photographing The images are acquired using one camera. Parker Maritime personnel will instruct and guide the ROV pilot / diver where to position and point the camera. The position and direction of the camera is approximate and indicated in the photo plan. Calibration of the camera is performed by using the images acquired for the work. Consequently, no extra time is required for this, onshore or offshore. The result of the photographing session is overlapping images covering the total survey area.

5.2

Processing and reporting The images are processed with a photogrammetric software package. The result of the processing (image analysis and calculation) is a 3D photogrammetric model. The information from the 3D model is exported to 3D and CAD software for calculations and reporting. The report is normally delivered in writing with a digitally enclosed CAD file with all the measured objects included. The processing time is dependent, amongst other things, on the following: 1. Size of the object 2. Number of images 3. Quality of the images 4. Level of details to extract from the images 5. Accuracy required Comments regarding quality of the images: Parker Maritime uses artificial targets as described in section 6.3. If more than 80% of these are automatically recognised by the processing software, we consider these as good quality images. If 6080% is recognised, we consider these to have medium quality. If less than 60% is recognised, we consider these to have poor quality. Targets that are not automatically recognised by the processing software must be manually marked, hence the processing time increases.

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6.

EQUIPMENT
The survey spread generally consists of: 1. Metrology camera system 2. Lighting 3. Metrology marking equipment

6.1

Metrology camera system The metrology camera system consists of a digital camera with a quality wide-angle lens, a video camera and a computer with LAN and serial communication built into an aluminium flask.

Camera details: Power requirements are 24V at 3 Amp. Weight of camera in water: approximately 2 kg. Weight of camera in air: approximately 20 kg. Size of camera (cylinder shape): 525 mm x 230 mm. Depth rate: 1500 meters.
Image 1 Camera with ROV handle

The camera flask has connectors for 3 different interfaces: Ethernet RS232 RS422 or flash In addition there is one connector to supply power to the flash.
Image 2 - Camera connectors

The wire diagram is included in our document Pin configuration for 8-pin mini Burton 5506-1508 on camera pod and will be forwarded before project commence.

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6.2

Lighting Preferred lighting is a standard flash built into an aluminium flask. The flash flask has one connector for camera interface and power. A small 200W halogen light used to continuously illuminate the scene for the built in video camera is normally added as well. Both flash and video light can be powered at 110 Volt. Weight of flash flask in water: approximately 0 kg. Weight of flash flask in air: approximately 3 kg. Size of flask (cylinder shape): 300 mm x 100 mm.

Image 3 Flash flask

Optionally the camera flask can be fitted with 2 x 150W (or more) gas lamps or one 400W gas lamp (depth rate 2000 meters). The wire diagram for gas lamps are included in our document 150 w gas light - HID light system wiring diagram and will be forwarded before project commence if gas lamps are used. 6.3 Marking equipment Parker Maritime uses artificial markers to increase the accuracy of the measured points and hence the photogrammetric model. Artificial targets are up to 10 times more accurately determined than natural points. Experience has shown that in addition to the required marking equipment identified from the photo plan, additional marking equipment may be needed. This may be caused by change in scope of work, environmental conditions or an insufficient level of details of the material provided for planning. Consequently approximately 20% more markers than identified in the photo plan is brought offshore. Parker Maritime uses standard markers such as scale bars, rubber bands with targets and single targets. Alternative purpose made markers is fabricated if required. 6.3.1 Single targets and bracelets Single targets are made of aluminium square plates with mounted magnets and may have the size of up to 100 mm. On cylinders with known diameters these are often more efficiently placed using bracelets. Targets may also be fitted on rubber bands where suitable, i.e. for survey of non-magnetic cylinders. If some or all of the objects which will be part of the survey are available onshore before installation they can be pre-marked to improve both efficiency and accuracy.

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Image 4 - Single targets and scale bars

Image 5 - Single targets installed in bracelets

Image 6 - Sub sea structure marked onshore before installation

Image 7 - Markers on two rubber bands

6.3.2

Scale bars Generally the scale bars are aluminium profiles up to 100x100 mm and up to 3 meters length. The size of the bars is decided based on handling limitations of the ROV and the object to be measured. For marking of longer distances single scalebars welded together as an H-Frame (see image below) has proven very efficient. The scale bars are normally fitted with ROV handles and are attached to the object using magnets. Where magnets are not suitable, purpose made clamping mechanisms can be fabricated. Scale bars placed on the seabed normally need footings at both ends for stability reasons and to be elevated above the seabed.

Image 8 Single scalebar with ROV handle and footings

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Image 9 Scalebar H-Frame with ROV handle

Image 10 H-frame scale bars with magnets on footings and bracelet frames mounted on jacket

Image 11 - Scale bars mounted on a riser with purpose made clamping mechanism

Image 12 - Scale bars with footings placed on the seabed along spool piece route

Image 13 - Scale bars attached to structure with single magnets,

6.3.3

Purpose made marking equipment On each job the need for purpose made marking equipment is assessed.

6.3.4

Magnets Magnets for attaching equipment with pull force of 35 to 175 kilograms are available.

6.3.5

Marking of irregular shapes Survey of damaged areas like dents or other irregular shapes can be done by using natural points, but there is no guarantee that enough natural points are visible, or that they are evenly spread. Projecting

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dots arranged in a grid by using a powerful laser combined with single targets and scalebars will achieve a very accurate result.

Image 14 - Laser dots projected on a dent

Image 15 - Survey of dent with scalebars, single targets and laser dots (not visible here)

7.

EQUIPMENT HANDLING
A work class ROV or a diver is needed to place the equipment and handle the camera under water. If smaller ROVs will be used all equipment must be engineered for this.

7.1

Surface to seabed equipment handling Normally the ROV operators prefer to pick up the marking equipment from the seabed where it sits still. A purpose made rack, a grating basket or a garbage container (with holes cut for flooding) may be used to deploy the equipment to the seabed with the ships crane. Parker Maritime have developed a scalebar deployment frame for single scalebars which has been successfully used several times. It has room for about 26 scalebars and can be locked and unlocked by the ROV manipulator arm.

Image 16 - Scalebar deployment frame

Image 17 - Scalebar deployment frame with 2 scalebars

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Marking equipment handles Parker Maritime use a custom made ROV handle which can easily be fitted to scalebars without obstructing the view, makes it possible to stack scalebars on top of each other, fits the scalebar deployment frame and occupies less volume when shipped. It has been used on several projects and is our preferred ROV handle. Alternatively, depending on the environment and ROV preferences, fish-tails, T-bars or E-bars can be used.

Image 18 - Custom made ROV handle

Image 19 - Custom made ROV handle on scalebar

Image 20 - T-bar and fish tail handles

Image 21 - E-bar handle

Single targets are fitted with a wire loop if not mounted in a bracelet.

Image 22 - 100x100 mm single target with wire handle

Image 23 - 60x60 mm single target with wire handle

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Camera handles

Image 24 - Camera flask fitted to ROV 7function manipulator

Image 25 - Camera handle for diver operation

7.2

Time consumption for setting out markers The time needed for setting out the marking equipment will be dependant on the number of markers needed, distance between the object and the location of the deployed markers and the time to attach the marker to the object.

7.2.1

Number of markers required The number of markers required is dependant on the following: 1. Level of details: The more details that are to be extracted from the model, the more markers must be placed. 2. Accuracy required: In general high accuracy requires more marking equipment than lower accuracy. 3. Size of the object to be surveyed: The survey area must be marked in such a way that the images can be connected. Therefore the number of markers is a function of the area to be covered. 4. Visibility in the water: If the visibility is poor, the images must be taken closer to the object and consequently the markers must be placed with a higher density. If the visibility is good the distance between the markers can be increased.

7.2.2

Time consumption for setting out one marker The time needed to set out one marker is dependant on the following: 1. ROV travel distance: The distance from where the markers are deployed to the object to be measured, influences greatly on the time setting out the marking equipment. 2. ROV handling capabilities: The ROVs performance with respect to station keeping and speed influences on the operation time. 3. ROV operator experience: The ROV operators experience influences greatly on the operation speed especially in difficult environmental conditions.

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4. Environmental conditions: Strong current, swell and poor visibility slows down the operation. We have experienced that the ROV may be influenced by swell down to 25 meters or more depending on sea state. 7.3 Time consumption for capturing the images By experience the images are most effectively captured when the ROV is moving around with a steady slow speed and distance to the object. All the markers must be photographed from different angles. The following influences on the time consumption for capturing the images: 1. Size of the object and number of markers. 2. Environmental conditions: Strong current, swell and poor visibility slows down the operation. 3. ROV handling capabilities: The ROVs performance with respect to station keeping and speed influences on the operation time. 4. ROV operator experience: The ROV operators experience influences greatly on the operation speed especially in difficult environmental conditions. 5. Organic obstructions: Shoals of fish or shrimps etc. between the camera and the object to be measured will increase the time to get the necessary coverage of the object with good quality overlapping images.

8.

CLIENT PROVIDED ITEMS

The following equipment must be provided by the client: 1. Work class ROV with 5- and 7-function manipulator. Alternatively divers. 2. Metrology camera to ROV interface cable. One cable for connecting the metrology camera to the computer onboard the vessel via the ROV system according to Parker Maritimes wiring diagram Pin configuration for 8-pin mini Burton 5506-1508 on camera pod. This is a standard cable using 8-pin Mini Burton connector. 3. Power cable for flash and video light. One power cable for powering the flash and video light, Parker Maritime will provide Y-split pigtail with connectors to our system. One connector for the flash and one for the halogen video light. Optionally a cable for gas lights according to Parker Maritimes wiring diagram. This is a MCIL3F Seaconn Micro Connector cable. 4. System for deploying the marking equipment. 5. Desk space for laptop computer. The Parker Maritime engineer(s) must sit next to the ROV pilot while setting out markers and photographing. Item 2, 3 and 4 may be provided by Parker Maritime on request.

9.

SICAMS SPOOL METROLOGY

The first spool metrologies performed by Parker Maritime using close range photogrammetry was done in 2004. Fieldwork for the three 50-60m long spools took about 17 hours effective time per spool, while processing time was 95 to 184 hours per spool.

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The new and improved SICAMS photogrammetry system was introduced for the first time in October 2007 during a 50 meter spool metrology. The time from request until we were on site was 4 days. Marking and image acquisition in field took 15 hours. The processing and calculation were done in 20 hours. The result was handed over to the Client at site. The description below is to a large extent also applicable to other types of photogrammetry projects. 9.1 Principle The entire spool route has to be pre-marked with scale bars, which will then be imaged from various angles and positions using a single camera operated by diver or ROV. Marking equipment need to be placed by Work Class ROV or diver. The images will be post-processed in dedicated photogrammetry software; the result will be a scaled 3D point cloud in an arbitrary local coordinate system. Relative flange to flange distances and angles can then be calculated. If required the points will be rotated to true horizontal level using a combination of inclinometers and depth sensors before calculation of distances and attitude angles. For long spool routes it is recommended to use an inclinometer in both ends to achieve the best accuracy possible. If true heading is needed this can optionally be found using additional sensors or established references on existing structures. Heading is normally not part of the scope. 9.2 Project task lists Below is a list of tasks that need to be performed for a typical spool metrology (most tasks are also applicable to other photogrammetry metrology operations). For more details see Onshore Preparations, Offshore Operation and Photographing, processing and reporting. 9.2.1 Pre-Operational Phase 1. 2. 3. 4. 5. 6. 7. 8. 9.2.2 Preparing marking equipment Calibration of marking equipment Calibrate and test inclinometers and depth sensors Prepare and test the SICAMS camera system Shipping all equipment to mobilisation site Provide details of equipment interfacing Prepare subsea metrology field procedure Conduct onshore dimensional control and fit metrology targets on structures to be installed

Operational Phase 1. 2. 3. 4. 5. 6. 7. 8. Preparing marking equipment Inspection and cleaning of metrology area if needed Placing of marking equipment Image acquisition Image QC Removal of metrology markers Processing and Calculation Issue preliminary report with final results (if time allows offshore)

9.2.3

Post-Operational Phase 1. Demobilise all personnel and equipment

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2. 3. 9.3

Issue preliminary report with final results (if not done offshore) Issue final report

Personnel requirements For a 24 hour operation where quick delivery of the results onboard is important four (4) qualified engineers will be required for the metrology. They will work 12 hour shift covering 24 hours i.e. two shifts per day. If the processing needs to be done in parallel with the data acquisition one extra person is needed as a dedicated data processor. If longer processing time is acceptable 3 engineers may be sufficient. For dayshift operations only at least 2 engineers are required.

9.4

Mobilisation time Normally we prefer at least two weeks notice before we need to ship the equipment from our office. We are however able to mobilize quicker if enough experienced personnel are available both for the mobilization period and the offshore operation.

9.5

Pre-marking onshore Photogrammetry metrology targets should be fitted on all related structures to be installed and be part of an onshore dimensional control survey. These targets will improve both the efficiency when placing metrology markers subsea as well as improve the accuracy during final metrology computations. Parker Maritime can perform the dimensional control or at least provide and guide where to locate the targets.

9.6

Operational time schedule estimate The following table shows the time schedule estimate for a 60 m spool route based on previous experience. The time is effective working time without down time for the ROV and similar. The estimate is built on using one ROV with experienced ROV pilots.
Activity Placing the marking equipment Image acquisition Image quality control Removing the marking equipment Total estimated time Description Placing the scale bars and single targets along the survey area Capturing the images The images are downloaded to a laptop and a quality control is performed to ensure that the quality of the images is acceptable Removing the scale bars and single targets Based on previous experience Effective time (hrs) 9 3 2 6 20

9.7

Processing, calculations and preliminary report The result of the processing will be a 3D photogrammetric model. This is exported to 3D and CAD software for calculations. If time and conditions allow, the processing and calculation will start on board the vessel. A preliminary report with final results may then be handed over to the Client representative onboard the vessel. Construction data will otherwise be provided as soon as possible after the crew has returned to our office in Stavanger.

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Experience so far have proven that we can deliver a result within 24-48 working hours, depending on size, complexity, water visibility and a few other factors like the number of experienced personnel available for the project. 9.8 Accuracy The metrology system is capable of an accuracy between 1/5 000 and 1/10 000 over the distance surveyed. That is, the accuracy for any point measured to artificial targets is between 1 and 2 mm in 10 meters. The accuracy for all measured points is equal in all three axes. Depth sensors and inclinometers are used to accurately establish vertical distances and pitch angles. 9.9 Image QC Initial image QC is done by uploading a test image to the topside PC (checking sharpness, lighting and other camera settings). The following images will be stored on the camera flask PC, while a thumbnail for every image is sent to the topside laptop in real time for visual control. Final image QC is performed when all images are downloaded to our topside laptop, where they are checked for sharpness, overlap and coverage. No marking equipment should be moved before Parker engineers have approved the quality of the images. 9.10 Data QC QC evaluation is performed through statistical software especially developed for SICAMS photogrammetry, and output from this software is included in the final report. In addition to the above mentioned statistics which is based on the results from the photogrammetry software the 3D photogrammetry model is checked against independent readings from inclinometers and depth sensors whenever they are included in the project. 9.11 Limitations A limiting factor is visibility, however this has not prevented us from getting results so far. At least 1 meter visibility is needed to the metrology markers, preferably 3 meters or more. If the visibility is limited more images will be acquired, leading to an increase in processing time.

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