Optimizing Subsea Operations Through Digital Twin Based Monitoring of Flexible Products

Abstract

Monitoring of flexible products, such as flexible risers (FRs) and inter-array cables (IACs), is crucial to ensure the structural integrity of the product to be sure it is not damaged during the installation operation. Particularly important is the monitoring of the bend radius of the product, which should never exceed the minimum bend radius (MBR).

Traditional methods for monitoring the flexible products involve remotely operated vehicles (ROVs) for spot checks and continuous monitoring of the touch down point (TDP). Calculations are carried out through OrcaFlex to set requirements and limitations for the weather condition for the operation. In this way, they have some control over the operation. However, the ROV has a very limited view, and the images can often be poor due to murky waters. Today's solution for monitoring has potential for improvement. With real-time measurements of the product's condition, the operation will be considerably made more efficient and optimized considerably.

In collaboration with DeepOcean, this thesis develops a digital twin (DT) framework designed to enhance the monitoring of flexible products. Utilizing OrcaFlex for dynamic analysis and Unreal Engine 5 (UE5) for advanced visualization, the system provides real-time data collection and processing that significantly improve operational accuracy and awareness. The proposed DT framework also includes an integrated alarm system to immediately address critical situations, such as bending radius beyond the MBR.

This research demonstrates the potential of DT technology in subsea operations, ensuring higher safety standards and operational efficiency, and suggests future pathways for enhancing digital monitoring systems. The study focuses on step 2 (Concept Development) of the Integrated Product Development (IPD) process. In this phase, the prototype serves as a proof of concept, demonstrating the data flow and viability of the proposed solution. The DT prototype is divided into four key modules – real-world data collection, analysis program, live view, and storage system – each of which are responsible for their own tasks within the DT system.

Monitoring of flexible products, such as flexible risers (FRs) and inter-array cables (IACs), is crucial to ensure the structural integrity of the product to be sure it is not damaged during the installation operation. Particularly important is the monitoring of the bend radius of the product, which should never exceed the minimum bend radius (MBR).

Traditional methods for monitoring the flexible products involve remotely operated vehicles (ROVs) for spot checks and continuous monitoring of the touch down point (TDP). Calculations are carried out through OrcaFlex to set requirements and limitations for the weather condition for the operation. In this way, they have some control over the operation. However, the ROV has a very limited view, and the images can often be poor due to murky waters. Today's solution for monitoring has potential for improvement. With real-time measurements of the product's condition, the operation will be considerably made more efficient and optimized considerably.

In collaboration with DeepOcean, this thesis develops a digital twin (DT) framework designed to enhance the monitoring of flexible products. Utilizing OrcaFlex for dynamic analysis and Unreal Engine 5 (UE5) for advanced visualization, the system provides real-time data collection and processing that significantly improve operational accuracy and awareness. The proposed DT framework also includes an integrated alarm system to immediately address critical situations, such as bending radius beyond the MBR.

This research demonstrates the potential of DT technology in subsea operations, ensuring higher safety standards and operational efficiency, and suggests future pathways for enhancing digital monitoring systems. The study focuses on step 2 (Concept Development) of the Integrated Product Development (IPD) process. In this phase, the prototype serves as a proof of concept, demonstrating the data flow and viability of the proposed solution. The DT prototype is divided into four key modules – real-world data collection, analysis program, live view, and storage system – each of which are responsible for their own tasks within the DT system.