International Dam Safety Conference 2019

13-14 February 2018, Bhubaneswar, Odisha (India)

A NOVEL METHODOLOGY OF ASSESSMEMENT OF STRUCTURAL

INTEGRITY OF DAMS AND WATER RESERVOIRS USING REMOTELY
OPERATED VEHICLES (ROVs)
1
A. Antony Jacob, 1M. Gallipali, 1, (a)V. Upadhyay, 1,2P. Rajagopal and 1,2K. Balasubramaniam
1
Planys Technologies Pvt. Ltd., Chennai, Tamil Nadu – 600091, India
2
Centre for Nondestructive Evaluation, Dept. of Mechanical Engineering, IIT Madras, Chennai, Tamil
Nadu – 600036, India
a)
vineet@planystech.com

ABSTRACT

Dams are critical from the perspectives of power, irrigational and non-irrigational needs, food
security and flood hazards. Recent advancements in technology, regulatory requirements and the
increasing need for improved management of energy and water resources for both industrial and
civilian consumption have led to heavier reliability on steady production of power, and the need
to develop improved maintenance and assessment regimes. Conventionally, dams are inspected
by professional divers. However, this methodology is limited to accessible and safe zones for the
divers; further, a depth limit of 30-40 m is also imposed. In this paper, a novel and the first of its
kind in the country, remotely operated robotic inspection methodology by Planys Technologies
Pvt. Ltd. is presented for inspection of dams and water reservoirs. This methodology of
inspection has various advantages over manner operations including the ability to inspect in dark
and flooded, otherwise constricted and risky zones with unlimited endurance, enhanced stability,
data acquisition, and repeatability. This paper also presents a robotic bathymetric survey
conducted to assess the quantity of rubble blocking the tailrace pool of a dam. The case studies in
the paper present high definition images of several deformations, debonding, and leakages
observed during the survey. The results can aid the authorities rapidly make key decisions
concerning repair, maintenance, and safety of the structure.
Keywords: Dams, inspection, underwater, ROV, bathymetry

1. INTRODUCTION

In India, there are over 5000 dams are constructed for various purposes including hydroelectric
power generation, water resource development for civilian and industrial needs, and flood
control. Most of these dams have been working for several decades. These ageing infrastructures
require periodic inspection and integrity assessment to prevent catastrophic failures, especially
under natural disasters. Dams and water reservoirs are inspected are conventionally inspected by
professional divers carrying the various payloads including cameras and lights. However,
inspection of various critical components is extremely dangerous for manned inspection and
hence, are seldom inspected. Divers are also limited to depths of 30 to 40 m. In this paper, a
novel methodology of inspecting dams is presented, the first of its kind in the country using
compact and portable remotely operated vehicles (ROVs) to traverse extremely narrow
underwater pathways and tunnels.

1
 International Dam Safety Conference 2019
13-14 February 2018, Bhubaneswar, Odisha (India)

ROVs are unmanned robots that can be designed to reach target immersed narrow and restricted
locations and perform immersed structural inspection in the form of visual and non-destructive
evaluation, and assessment of water quality. Further, the operation of ROVs has fewer
limitations in terms of depth of operation, communication, and endurance as compared to human
divers. Apart from such advantages, ROVs offer the possibility of streaming live data back to the
control station (along with end user and surveyor), 24x7 operation in hazardous conditions and
high-speed on-board or onsite data processing capability.

This paper is organized as follows. Following a brief introduction, the methodology of inspection
is described wherein key features and capabilities of the ROVs developed by Planys
Technologies Pvt. Ltd. are described. Following two case studies of inspection survey project in
dams undertaken by Planys Technologies are detailed, with key observations and findings. The
paper concludes with a summary and conclusion.

2. METHODOLOGY
Planys Technologies is an IIT Madras incubated start-up that provides submersible robotic
inspection and survey solutions using indigenously designed and manufactured remotely
operated and automated underwater vehicles. Founders of the company are IIT Madras Alumni
and faculty from the Department of Mechanical Engineering. Planys Technologies aims to cover
the whole breadth of automated inspection solutions starting from customized design and
fabrication of robotic platforms to integrated sensing and diagnostics.

2.1 ROV Mike

‘Mike’, shown in Figure 1, is a compact electric underwater robot specifically built for robust
and calibrated visual inspection of immersed structures and narrow pathways [1]. ROV Mike,
840 x 450 x 400 mm3 weighing less than 30 kg, is perfect to traverse through narrow tunnels and
gates of dams. Mike has the capability of reaching 100 m depth with 6 degrees of freedom and
possesses unlimited endurance. Multiple onboard HD cameras with high intensity LED
illumination provide live and stable visual feedback to robot pilot and surveyor. The design
allows for control station to be positioned at a safe on-shore/on-ship site and rapid assembly and
operation at field conditions. Enhanced navigation and active control algorithms are used for live
video and photo recordings under wave action and ocean currents.

2.2 ROV Beluga

ROV Beluga, an illustration of which is shown in Fig. 2, is a compact, modular and portable
observation-class ROV that can sustain 2-4 meters of wave height, moderately rough swell, up to
1 m/s of sea currents and can dive up to 200 meters of depth [2]. Beluga has dual hulls with a
heavy bottom hydrodynamic design, which provides it with static and dynamic stability in the
harsh underwater environment. It is equipped with eight thrusters, providing control in 5 degrees
of freedom along with forward thrust of 17.5 kg-f and operating speeds of 3-4 knots. It consists
of an IMU for orientation feedback, a pressure sensor for depth feedback and a GPS module for
position feedback on the water surface. Its modular architecture allows it to carry a variety of
payloads including RTK GPS modules, high-definition cameras, high-intensity lights, LASERs
as crack measurement unit, Altimeter, Side-Scan SONAR, Ultrasonic thickness measurement

2
 International Dam Safety Conference 2019
13-14 February 2018, Bhubaneswar, Odisha (India)

unit, Cathodic Potential measurement unit, bio-fouling cleaning equipment, 2D & 3D

Imaging/Scanning SONARs [3].

Figure 1 An illustration of ROV Mike and its key features

Figure 2 An illustration of ROV Beluga and its key features

2.3 Key Inspection Capabilities

Some of the key inspection capabilities which have been developed are, as follows,
● HD live underwater visual inspection (photography and videography) of submerged
structures [4] for detection of corrosion, cracks, cavities, collision damage, and anode
loss

3
 International Dam Safety Conference 2019
13-14 February 2018, Bhubaneswar, Odisha (India)

● Highly accurate GPS modules

● Capabilities for clear inspection in extremely turbid waters using patented vision and
video processing techniques
● Laser scaling for assessing dimensions of cracks, cavities, and other defects
● Inspection of interiors and exteriors of the well foundations
● Side scan sonar surveys, bathymetric surveys, electric spot-cleaning or cavitation
cleaning tool for marine growth cleaning (soft to medium hardness)
● Wide range underwater metallic ultrasonic thickness measurement [5]

3. RESULTS AND DISCUSSION

3.1 Underwater Dam Inspection of Gate Grooves and Tunnels

Introduction and Scope: Planys Technologies Pvt. Ltd. was invited to perform a remotely
operated robotic survey and visually inspect the gates, gate grooves, and tunnels connecting the
gates of a composite earth cum masonry dam undertaken by the National Water Management
Project located on a tributary of Tungabhadra river. The scope of the robotic inspection survey
was to inspect the bottom of the emergency and sluice gate, grooves and tunnels in the upstream
and downstream face of the dam for blockages, leakages, and damages at depth of about 50 m
underwater. The plan was to use ROV Mike which could fit into the tight spaces and sharp turns.

Methodology: A crew of 6 personnel including supervisors, pilots and engineers performed the
survey. The setup is described as follows. The ROV is connected the command module via a
tether which transfers data and power to and from the ROV. The command module can be placed
in a safe position and displays live video feed from the ROV and other metadata from sensors
and related payloads.

(a) (b)
Figure 3 Photographs during the robotic inspection survey showing (a) configuration of the
command module to control the ROV, and (b) deploying the ROV

4
 International Dam Safety Conference 2019
13-14 February 2018, Bhubaneswar, Odisha (India)

Observations and Key Findings: Several major defects indicating damage to concrete, major
ruptures, cavities creating suction holes and leakages, severe damages to gate seal and debonding
were observed; some of which are indicated in figure 4.

(a) (b)

(c) (d)
Figure 4 Photographs recorded during the survey indicating (a) cracks on the gate rail groove (b)
debris blocking the bottom of the gate (c) damage and exposed rebars (d) cavity and
deterioration on the scouring sluice gate at about 50 m underwater

3.2 Bathymetric Survey

Introduction and Scope: Planys Technologies Pvt. Ltd. was invited to conduct a robotic
inspection survey and assess conditions of a dam on the Narmada river. The scope of the project
was to conduct a bathymetric survey of the tailrace pool in a dam in the Narmada river and
assess the amount of rubble spilled into for the dam authorities to plan for their subsequent
removal since the water head is related to the power generated by the turbine. Further, a
bathymetric survey of the tailrace pool was also required.
Methodology: A bathymetric survey involves measuring and contouring water depth at various
locations of interest to understand the topography of the surface. The topography can reveal
various features including floor elevation and presence of debris. ROV Beluga was used for this
project equipped with high accuracy GPS modules and echo sounders. The GPS modules had
two units; one on suitable ground location and one the ROV. Suitable locations for placement of
the base GPS module were pre-identified and set up ahead of the commencement of the project.
The combined horizontal accuracy achieved was 0.2 m. Several key challenges were faced in the
site including harsh rain and deploymental issues of the ROV from a cliff about 40 m above the
tailrace pool. Several photographs taken during the survey are shown in figure 5.

5
 International Dam Safety Conference 2019
13-14 February 2018, Bhubaneswar, Odisha (India)

(a) (b)

(c)
Figure 5 Photographs showing (a) deployment of a boat from a crane on a cliff to the water body
40 m below, on which the bathymetric survey was conducted (b) boat from which the ROV was
controlled (c) ROV based bathymetric survey in-progress
Observations and Key Findings: Bathymetric depth contour was generated combined depth data
and GPS data as shown in figure 6. The image in figure 6 (a) indicates shallow and deep regions
by dark and light shades of blue, respectively. Further, an interactive 3D representation of the
plot is generated to enable easy location and quantification of the rubble fallen inside the pool, as
shown in figure 6 (b). Based on these findings, an accurate estimate of the quantity of the rubble
was obtained.

(a) (b)
Figure 6 Illustrations showing (a) depth contours overlaid onto to a CAD model (b) a 3D
representation of the acquired data indicating surface topology and areas of fallen debris

6
 International Dam Safety Conference 2019
13-14 February 2018, Bhubaneswar, Odisha (India)

4. SUMMARY AND CONCLUSION

This paper presents an underwater assessment survey of dam structures and components using
remotely operated vehicles. Methodology and key features of the ROVs developed by Planys
Technologies are described. Case studies showing underwater inspection of tunnels, gate,
grooves, and bathymetric surveys are presented. Further key observations and findings aiding the
authorities to make key decisions on repair and maintenance are also described.

5. REFERENCES

[1] T. Jhunjhunwala et al., MIKE: A remotely operated vehicle (ROV) for visual inspection
of underwater structures, in: Natl. Semin. Exhib. Non-Destructive Eval. NDE 2015, Hyderabad,
2016.
[2] T. Jhunjhunwala and P. Rajagopal, Remotely operated vehicle (ROV) for inspection of
underwater pipelines using bulk and guided ultrasonic waves, in: Natl. Semin. Exhib. Non-
Destructive Eval. NDE 2015, Hyderabad, 2016.
[3] V. Upadhyay, S. Gupta and P. Agarwal, Patent filed with the Indian Patent Office, Multi-
functional Remotely Operated Submersible Vehicle (ROV) System, Application Number:
201741022485, Planys Technologies, 2016.
[4] V. Upadhyay, T. Jhunjhunwala and P. Rajagopal, Patent filed with the Indian Patent
Office, Underwater lights, Application Number: 201741000411, Planys Technologies, 2016.

[5] A. Antony Jacob, M. Gallipali and V. Upadhyay, Patent filed with the Indian Patent
Office, Ultrasonic thickness measurement unit, Application Number: 201641041814, Planys
Technologies, 2016