Integrity Management Technologies Public Funded Projects

INTEGRITY MANAGEMENT TECHNOLOGIES

2019

twi-global.com

TWI is extensively involved in collaborative research and technology transfer projects across all of its technologies and industry sectors. These projects are generally undertaken in response to calls for proposals issued by public sector funding agencies. Most common amongst these are the European Commission (Framework research projects), Innovate UK (part of UK Research and Innovation) and regional funding agencies within the UK (research, infrastructure and technology transfer).

Collaborative projects currently represent some 30% of TWI’s total project activity and therefore are a very important source of knowledge for TWI’s Industrial Members and project partners alike.

TECHNOLOGY INNOVATION MANAGEMENT TWI has an experienced team of specialist personnel focused on securing public funded projects in the area of engineering research and innovation. Its Technology Innovation Management team works closely with TWI’s technical experts, its Industrial Members and external partners to develop concepts, build reputable consortiums and quality proposals to secure funding to take forward the next generation of advanced engineering technologies.

INTEGRITY MANAGEMENT TWI’s multi-disciplinary Integrity Management team of consultants, engineers and technicians provides cost savings and reliability assurance through the development and application of advanced innovative inspection, assessment and risk management solutions for any practical industrial situation on a worldwide basis.

The diverse interests of our members, from printed circuit boards and offshore platforms, to medical implants and nuclear reactor pressure vessels, have been the driving force behind the development of a comprehensive range of technologies to ensure the integrity of their products or infrastructure.

The Integrity Management team is currently involved in research and development projects covering the following techniques: Additive manufacturing

Fatigue assessment and testing

Advanced NDT and inspection solutions

Internet of Things (IoT)

Artificial Intelligence (AI)

Finite element analysis

Computational fluid dynamics

Machine learning

Condition and structural health monitoring

Mechanical testing (small and full-scale)

Data analytics

Fitness-for-service

Digital twin technology

NDT qualification and validation

Engineering critical assessment

Risk based inspection

Engineering services

Third party inspection

Failure investigation Products and Software CrackWISE® (BS 7910)

Railect™

IntegriWISE (API 579-1/ASME FFS-1)

VARA vibration monitoring and risk analysis

RiskWISE® (API RP 580/581:2016)

AEHIC acoustic emission hydrogen induced cracking

®

PolyTest™

detection system

ABOUT TWI Established in 1946, TWI is a world leading research and technology organisation. From bases in the UK, Greece, the USA, China, Malaysia, the Middle East, India and Australia, over 900 staff provide technical support in joining and technologies including material science, structural integrity, NDT, surfacing, additive manufacturing, robotics and Industry 4.0. Services include generic research, contract R&D, technical information, consultancy, standards drafting, training and qualification.

TWI offers a single, impartial source of service for joining engineering materials.

TWI provides services and solutions to some 1800 Industrial member companies, including some of the world’s biggest engineering firms, from 80 countries. Member companies engage with TWI through single client consultancy projects aimed at solving critical engineering problems or developing new products, and joint industry projects where several Member companies join forces to solve a complex common problem, as well as industry sector meetings, conferences and visits to Members’ sites.

ACCURATE

Aerospace composite components – ultrasonic robot assisted testing

PROJECT PARTNERS TWI Ltd, RECENDT GmbH, InnoLas Laser GmbH, KUKA Systems UK Ltd

BACKGROUND

OBJECTIVES

The overall goal of the ACCURATe project is to achieve the

The three main objectives of this project are to:

optimum technology for the non-destructive inspection

design a LUT prototype system for the NDI of the

(NDI) of both present and future generation hybrid and

fuselage barrel demonstrator component panel. This

thick composite aircraft structures, containing acoustic

will involve the innovative design of a generating laser

damping materials and materials which highly attenuate

system, detection laser system, analysis software (with

ultrasound, with 100% volume coverage. The developed

post processing applications) and the design of an

prototype system will be validated by deploying it to

inspection cell with a robotic arm to manipulate the

inspect a long barrel demonstrator component panel being

laser systems

developed under Clean Sky 2 by Topic Manager Leonardo’s Aircraft Division.

develop the prototype LUT system to meet the NDI requirements specified by the Topic Manager. This will involve assembly and integration of the sub-systems,

The project concept is a robot deployed NDI system for fast and contactless testing of large carbon fibre reinforced

as well as optimisation of the system using test samples supplied by Leonardo’s Aircraft Division

polymer (CFRP) aircraft structures during manufacture. The

install the prototype system at Leonardo’s Aircraft

approach is based on a non-contact laser generated and

Division’s facility and perform a final validation of

detected pulsed ultrasound technique (LUT) with delivery

the system with the inspection of the fuselage barrel

of both the laser ultrasound excitation and detection

demonstrator component panel.

pulses through flexible optical fibres.

The measurement head, which contains the two beam outputs and the light collection optics, is scanned over the surface by a 6-axis lightweight robot arm to provide an area coverage (scan window) exceeding 1.5m x 1m from a single location of the robot base. The robot arm will move along a rail track that runs the length of one side of the barrel demonstrator panel which will be positioned and fixed within the system cell. The robot arm will raster the laser head system over the part surface and move in increments along the track to inspect the whole component.

BENEFITS ACCURATe aims to provide significant advancement over current inspection systems which utilise LUT. The excitation and detection lasers are based on diode pumped Nd:YAG lasers which enable a low profile casing with low weight, a very long lifetime with little maintenance and a high scanning speed of around 500Hz. On completion, the system designed and tested within this project will offer an immediate solution to Leonardo’s Aircraft Division and increase the capabilities and competitiveness of the European aircraft industry.

www.accurate-project.eu The research leading to these results has received funding from CLEANSKY2 under grant agreement no. 755616.

aerospace

1

CITCOM

A complementary inspection technique based on computer tomography and plenoptic camera for microelectromechanical systems (MEMS) components

Manipulator

Detector

Mem’s Wafer X-Ray Source

PROJECT PARTNERS Centre Suisse D’Electronique Et De Microtechnique SA, Philips Electronics Nederland B.V., Microsemi Semiconductor Ltd, Raytrix GmbH, Teknologian Tutkimuskeskus VTT Oy, TWI Ltd, Excillum AB aixACCT Systems GmbH, Polytec Ltd, AcondicionamientoTarrasense Associacion (LEITAT), Innovative Technology and Science Ltd, Brunel University London

BACKGROUND

OBJECTIVES

The aim of the CITCOM project is to develop a ‘near-line’

The three main objectives of CITCOM are to:

inspection method for ‘high end’ micro-electromechanical

develop a near-line inspection method for MEMS and

systems (MEMS) devices while on the manufacturing line.

Currently there is no fit-for-function, near-line inspection equipment to inspect micro-fabricated devices and this is a critical issue as it prevents the achievement of high yield production.

micro manufacturing to increase the yield develop existing technologies to improve sensitivity and repeatability of inspection demonstrate

a

fully

functional

system

in

the

manufacturing environment of one of the project’s end-user partners.

MEMS and micro manufacturing have developed hugely over the last 20 years and with the large increase in production, as well as MEMS continuing to be integrated

BENEFITS CITCOM will offer a system with automated knowledge and

into more and more technologies, research has to be

inspection-data based process feedback that will allow the

undertaken to improve the manufacturing process.

detection and traceability of faults that may occur in MEMS production.

CITCOM will address the industrial needs of MEMS and micro manufacturing by offering a near-line production

It is intended to help cut manufacturing costs by up to 60%

inspection and measurement system for micro-components.

and will be especially suited to critical applications in the

The final system will be developed and demonstrated at

aerospace, space and healthcare industries.

TRL7.

The system will be constructed of two parts: 1) the

www.citcom.eu

optical camera, and 2) the X-ray system. These will be combined with computer tomography, and an advanced robotic system capable of analysing defects that occur in production of micro components such as stains, debris, fracture, abnormal displacements, chemical composition of surface coatings and surface traces, enabling a 98% yield and 100% reliability.

This project has received funding from the European Union’s Horizon 2020 research and innovation programme under grant agreement No 768883.

aerospace

2

FRICTIONHARMONICS Automated scanner for kissing bond detection in friction stir welded materials

PROJECT PARTNERS Vermon SA, TWI Ltd, IKnowHow SA, Research Institutes of Sweden (RISE), Coşkunöz Holding

BACKGROUND

OBJECTIVES

“Kissing bond” defects are of great concern in the friction

The FrictionHarmonics project will focus on finalising

stir weld (FSW) joining process for aluminium components.

this novel inspection system which will provide reliable

Such defects correspond to a transition region where

detection of micro defects in FSW joints in flat and curved

the bond exists but is very weak. During service these

components. The objectives are to:

regions can frequently transform into cracks, reducing

optimize the prototype scanner system that can detect

the fatigue performance of joints and eventually leading

kissing bonds of <0.3mm diameter with 100% accuracy;

to component failure. Kissing bonds are very difficult to

scan curved surfaces to a 4mm radius; increase scan

detect or accurately size using existing NDT methods and

speeds to 25mm/s

the fatigue life of FSWs is significantly reduced if kissing bonds exist. Specifically, it was shown that a 0.67 mm

validate the FrictionHarmonics system prototype in an operational environment

kissing bond reduces fatigue life by 91% in comparison to

establish a dedicated FrictionHarmonics distribution

the base metal, with the kissing bond being responsible for

network in Europe and North America with agents in

crack initiation.

the US, Canada and Germany gain certification to the Electromagnetic Compatibility

Despite this critical problem, friction stir welding is used

Certificate (89/336/EEC) and obtain the EU CE marking

by many original equipment manufacturers (OEMs) in

hold demonstrations and training sessions to ensure

the aerospace industry, such as Boeing, Eclipse, NASA,

quick market uptake and establish an aftersales

Lockheed Martin and United Launch Alliance, in the

support team.

production of thousands of kilometres of welding each year. Fatigue performance is particularly crucial so it is a factor for concern that there is currently no reliable method for identifying kissing bonds.

It is difficult to detect kissing bonds using conventional NDT techniques, for example, pulse-echo ultrasonic testing, because the resulting change in amplitude is often very small.

However, through extensive R&D activities, we

were able to develop a customised, non-linear, ultrasonic technique for the inspection of kissing bonds in FSWs.

BENEFITS Benefits of FrictionHarmonics to industry: reliable detection of defects in FSW joints which could not previously be identified, leading to critical components of better quality provision of a highly portable scanning system that can easily be integrated into the production line of FSW components, saving manufacturing time and costs increase manufacturers’ confidence in using FSW leading to wider adoption, which will aid light-weighting and thus reduce fuel costs.

This project has received funding from the European Union’s Horizon 2020 research and innovation programme under grant agreement No 820531.

www.frictionharmonics.com

aerospace

3

HEGEL

High cycle fatigue prediction methodology for fibre reinforced laminates for aircraft structures in CROR environment – development and validation

PROJECT PARTNERS TWI Ltd, Netherlands Aerospace Centre (NLR), University of Bristol

BACKGROUND The Advisory Council for Aviation Research and Innovation

specimens to high sound pressures representative of

in Europe’s (ACARE) Strategic Research and Innovation

the acoustics and vibrations generated by a CROR

Agenda (SRIA) agenda is to achieve a 75% reduction in

to develop and validate a semi-empirical high cycle

CO2 emissions per passenger kilometre by 2050, reduce

fatigue (HCF) prediction methodology based on master

NOx emissions by 90% and perceived noise by 65%.

curves and shift factors, able to account for the effects

These targets have led to the exploration of new material

of temperature and humidity in fatigue life, and the

technologies and innovative advanced engine solutions.

influence of the factors of high frequencies

Among the engine solutions that are being considered, one

to develop and implement fatigue numerical FE models

of the most valuable technologies is the Contra Rotating

as virtual tools able to replicate the experimental

Open Rotor (CROR) propulsion system.

testing, and extend the parametric study to cases not covered by the experimental programme.

The CROR propulsion technology offers a 15-20% improvement in fuel burn efficiency compared to current best technology. Successful integration of CROR requires changes in aircraft architecture; where high dynamic loads are transferred to the aircraft’s primary structure, the fuselage can have highly stressed interfaces, there are high demands for vibration loading and potential fatigue issues.

The HEGEL project aims to develop and validate an advanced fatigue prediction methodology. This will include experimental testing and virtual approaches for predicting the long-term fatigue life of the composite laminates used in new structural architectures, and subjected to high sound pressure loading in a CROR environment.

BENEFITS HEGEL technologies will provide a significant advance over current structural integrity assessments of composite materials during the design process. Current accelerated fatigue prediction methodologies are not fully validated for aerospace applications and only consider a limited number of parameters. This project will expand the potential of existing fatigue prediction methodology to additional environmental parameters, as well as to frequency dependent factors occurring at high frequencies during HCF. This will increase the capabilities and competitiveness of the European aircraft industry.

OBJECTIVES The project has the following objectives: to develop and manufacture a sound source and amplification system to investigate the response of

The research leading to these results has received funding from CLEANSKY2 under grant agreement no. 738130.

aerospace

4

MOTIVE

Multi-physics modelling of high temperature engine valves

PROJECT PARTNERS TWI Ltd, Scitek Consultants Ltd, Ventil Test Equipment B.V., MECAS ESI SRO

BACKGROUND

OBJECTIVES

Engine bleed air systems include components that

The MOTIVE project will:

deliver, and control, compressed engine bleed air from

commission a state-of-the-art friction test bench to

the main engine to downstream systems including:

measure the frictional effort produced by aircraft

cabin air conditioning, aircraft and hydraulic reservoir

pneumatic actuation pistons and butterfly valves

pressurisation, engine start, and wing and engine cowl ice

commission a state-of-the-art aerodynamic torque test

removal. The design and integration of aircraft pneumatic bleed air valves is becoming ever more challenging due

bench for pneumatic butterfly valves develop

a

complete,

to the aggressive environment in which the valves must

based

model

to

operate close to the aircraft engine. High temperatures,

and

controllability,

high pressures and non-homogenous air flow all contribute

mechanical

and

analytical

predict

multi-physics

valve

based

aerodynamic

performance on

thermal,

considerations.

to the performance of pneumatic engine valves and their actuators.

BENEFITS The MOTIVE project will, for the first time, create an

Design optimisation of pneumatic valves and their

industry disruptive, virtual prototyping framework for

associated actuation mechanisms is critical to keeping

optimising valve and actuator piston design which can be

unscheduled costly delays to a minimum. Although they can

easily integrated into multi-physics modelling software

be optimised in-situ the associated costs are substantial,

such as MODELICA. This will maximise the functionality

therefore, the ability to predict valve performance during

and predictively of the multi-physics modelling solution

the design phase would reduce these costs considerably.

and enable the immediate exploitation of that model for optimisation of subsequent valve designs, reducing the

Simple models based on flow coefficients, relating mass

incidents of engine bleed air valve malfunction.

flow to pressure drop across a valve, are typically used to predict the behaviour of pneumatic valves. However, when internal valve phenomena are present, such as non-linear frictional effort and fluid flow effects near to the valve-closure position, these simple models fail.

In order to facilitate valve design optimisation, a complete description of the fundamental physical phenomena encountered within the engine environment is necessary.

The research leading to these results has received funding from CLEANSKY2 under grant agreement no. 785530.

aerospace

5

NDTONAIR

Training network in non-destructive testing and structural health monitoring of aircraft structures

PROJECT PARTNERS Brussels Airlines NV, Commissariat à l’énergie atomique et aux énergies alternatives, Fraunhofer-Gesellschaft zur Förderung der angewandten, Forschung e. V., Kauno Technologijos Universitetas, Katholieke Universiteit Leuven, Université de Nantes, University of Newcastle upon Tyne, Universita degli Studi di Perugia, Research Center for Non Destructive Testing GmbH, TWI Ltd

BACKGROUND

Twenty-first century industries continually adopt new

NDT and SHM techniques for aerospace through

materials and design methods to face challenging

research training at host institutions and participation

technological and sociological targets. This ensures

in internal and external conferences

improved in-service performance, increased sustainability and greater safety.

technology transfer and entrepreneurship with short courses and seminars organised by the consortium.

The application of non destructive testing (NDT) and

BENEFITS

structural health monitoring (SHM) techniques is necessary

The NDTonAIR consortium involves universities, research

to prevent failures that could cause economic losses and,

organisations and major European companies working on

above all, hazards for people.

new NDT and SHM techniques for aerospace, both of which are key technologies. The goal is to train a new generation

SHM techniques evolve by studying and developing

of scientists and engineers in theoretical and experimental

innovative solutions to cope with new materials, and

skills, enable them to develop their research and

by exploiting the continuous progress in digital devices.

entrepreneurial activities in both academia and industry,

Research in NDT is therefore a key ingredient for the safe

and encourage them to play an active role in promoting the

and sustainable future of many sectors of EU industry

importance of quality inspection and structural monitoring

including power generation, oil and gas, aerospace,

in aerospace components.

defence and high value manufacturing.

www.ndtonair.eu OBJECTIVES The training programme will provide researchers with extensive and varied training in: fundamentals skills for NDT and SHM by participating in short-courses and seminars organised by NDTonAIR

This project has received funding from the European Union’s Horizon 2020 research and innovation programme under grant agreement No 722134.

aerospace

6

PASSPORT

Part specific process optimisation for selective laser melting of aluminium AlSi10Mg

PROJECT PARTNERS TWI Ltd, Granta Design Ltd

BACKGROUND has

produce a bespoke, stand-alone process parameter

developed rapidly in the last decade, providing the

selection software solution for AlSi10Mg SLM parts

potential to significantly reduce costs whilst improving

that can communicate with multiple vendors’ SLM

the quality and efficiency of aerospace components. This

machines

Metal

additive

manufacturing

(AM)

technology

can be realised through: improved design freedom and

improve the time-to-market for SLM parts by removing

light-weighting via topology optimisation; improved buy-to-fly

significant cost and time-intensive burdens associated

ratios; and a reduction of tooling cost, all of which have a

with optimising SLM builds.

demonstrable impact on manufacturing waste reduction.

BENEFITS With growth in the European AM industry and design

PASSPORT aligns with the Clean Sky2 goal to deliver

optimisation applications, the lead times and financial

high-TRL technologies that will help achieve The Advisory

costs associated with improving process parameters to

Council for Aeronautical Research in Europe (ACARE)’s

ensure production of high-quality, aluminium AlSi10Mg

global targets for aircraft technology maturing in 2020,

parts with complex geometry, are a significant barrier to

which include a 50% reduction per passenger kilometre in

widespread adoption.

fuel consumption and CO2 emissions.

PASSPORT seeks to remove this barrier through the delivery

The project will deliver technology developments related

of an ambitious, experimental and analytical software

to the manufacturability and qualification of additively-

development programme.

manufactured AlSi10Mg aerospace components, helping to maintain competitive advantage in European aircraft

OBJECTIVES The objectives of PASSPORT are to: undertake detailed characterisation of AlSi10Mg selective laser melting (SLM) parts using a unique laboratory setup employ advanced process simulations to understand and quantify the relationship between different scan strategies and part attributes

develop state-of-the-art, optimised process parameters that vary with local part topology and geometry characteristics to ensure homogeneous mechanical properties, high density and a smooth build surface

manufacturing and offering a more sustainable process for producing components. It will enable the European aerospace industry to: reduce production costs, especially for “one-offs” and small-batch production increase design freedom, leading to a reduction in component weight and environmental impact during manufacture and service life rapidly respond to customer needs, wider trends and market fluctuations lessen the environmental impact of production, such as material consumption and number of repeats, and subsequent logistics.

The research leading to these results has received funding from CLEANSKY2 under grant agreement no. 785562.

aerospace

7

QBARKA

Microstructural characterisation using Quantum enabled Barkhausen noise analysis

PROJECT PARTNERS Advanced Hall Sensors Ltd, TWI Ltd, Compound Semiconductor Centre (CSC), Microsemi Semiconductor Ltd

BACKGROUND

OBJECTIVES

The existence of Barkhausen noise (BHN) was first

The objectives of this project are to:

discovered in 1919 and since then the phenomenon has

push the sensor geometries to a new limit in order to

been implemented as a relatively ‘gross’ non-destructive

offer the potential for real time monitoring of materials

evaluation technique. Typically the BHN spectra of a

microstructure in the form of high resolution BHN

material is compared before and after a stress event, such as fabrication or environmental stressing, and the value lies in a relative quality evaluation pre- and post-event.

magneto-imaging introduce the Quantum sensing advantage into the relatively conservative area of materials nondestructive examination, in the spirit of the UK

This has resulted in BHN analysis becoming a very niche

Quantum Technology programme.

technique that requires context dependent data analysis and interpretation. For several decades, more advanced, useful

BHN

microstructure

characterisation

systems

BENEFITS QBARKA brings together a consortium which is capable of

have been proposed using coil-based detection of

realising many specific applications, therefore, it aims to

magnetic signals. However, the inherent drawbacks and

address the project objectives by using advanced Quantum

limitations of coils are: relatively large sizes in comparison

Well Hall Effect sensors as a novel solution. These sensors

to microstructure dimensions; frequency dependent

have several advantages such as: miniaturised size;

operation; and strong dependence on total magnetic flux

responsivity to both AC+DC; sensitivities independent of

sampled rather than flux density.

frequency; and a very wide dynamic range. The project will implement this novel, Quantum enabled sensor resulting in

Magnetic BHN measurements are used in non-destructive

a new paradigm in high resolution microstructural analysis

inspection of strain and stress in a range of materials.

of materials.

BHN occurs when an AC magnetic field is applied to a ferromagnetic material, and happens due to the sudden, irreversible motion of magnetic domain walls as they are released from microstructural obstacles such as dislocations and grain boundaries BHN can provide high resolution microstructure related information but classical detection techniques that are used do not have the resolution, both spatial and magnetic, to extract the wealth of data available.

aerospace

8

RIB-AM

Research of innovative and breakthrough additive manufactured leading-edge concept

PROJECT PARTNERS TWI Ltd, The Andalusian Foundation for Aerospace Development (FADA-CATEC), Advanced Manufacturing Research Centre (AMRC) - The University of Sheffield, Direct Manufacturing Research Center - The Paderborn University

BACKGROUND

OBJECTIVES

In the next few years, the European aerospace industry

The aim of RIB-AM is to develop novel manufacturing

must face the challenges of reducing the weight of aircraft,

technologies which can be applied to large size components

the cost of aircraft production and the environmental

belonging to the primary structure of aircrafts. Specific

impact caused by aerospace products throughout their

objectives are:

lifecycle. This scenario will become even more challenging

to manufacture a leading edge skin with long fibre

as a result of the expected contraction in market share of the big original equipment manufacturers (OEMs), such as AIRBUS, due to the growth of new players from developing countries.

reinforced

thermoplastic

using

automatic

fibre

replacement to develop short fibre reinforced high temperature and high performance polymers and a fused deposition modelling (FDM) process for them

Therefore, in order to maintain its competitiveness, the

topology optimisation of leading edge ribs

European aerospace industry must assume the challenge

inductive welding for reinforced thermoplastic ribs to

of efficiently implementing additive manufacturing (AM)

the skin

technology in order to address the above challenges.

hybrid structure integration

This will involve the development of new materials with

to develop an inspection methodology for hybrid and

high performance properties that are suitable for use in

complex geometries based on fast non-destructive

aeronautical applications and a new component assembly process that does not require the manufacture of expensive and specific tools.

Having originally been applied to the production of prototypes, small components and mock-ups, AM is recognised as a technology that has the capacity to create

techniques to create a novel, leading edge concept based on advanced manufacturing and integration techniques.

BENEFITS RIB-AM will provide the following benefits to industry: structural weight reduction of aircraft components

functional parts for the aerospace industry. In addition, it

leading to improved performance

has the potential to be used in other applications in the

a reduction in manufacturing time

near future such as satellites, probes, manned spacecraft

lower costs including non-recurrent costs

and reusable vehicles.

minimised and simplified inspection protocols greater waste reduction better supply chain management.

The research leading to these results has received funding from CLEANSKY2 under grant agreement no. 785562.

aerospace

9

CS MAGIC

Compound semiconductor magnetic integrated circuits

PROJECT PARTNERS Advanced Hall Sensors Ltd, Compound Semiconductor Centre (CSC), TWI Ltd, Swansea University, Renishaw Plc

BACKGROUND Magnetic sensors are fundamental to engineering and

CS MAGIC will address four key areas of technical innovation:

physical sciences. They are indispensable components

complementary metal-oxide-semiconductor (CMOS)

in many systems across several industries including

like technology in gallium arsenide (GaAs). This

automotive, aerospace, metrology and medical. Given

technology is both high yielding and low cost and thus

the ease of rendering a functional sensor by monolithic integration with ancillary electronics, the majority of

very competitive with high-end silicon creation

of

the

first

compound

semiconductor

the market is serviced by magnetic sensors that are

Hall sensor magnetic integrated circuit (MAG IC),

manufactured from silicon. However, silicon sensors are

demonstrating

limited in terms of sensitivity and temperature operating

integrated, high mobility, two-dimensional electron gas

range, as a result of their fundamental material properties.

(2DEG) GaAs MAG IC

the

world’s

first

monolithically

design, manufacture and characterisation of the Advanced Hall Sensors Ltd (AHS) has developed a ‘Hall effect’ magnetic field sensor component that is made from the

world’s first gallium nitride (GaN), magnetic sensitive, high-electron mobility transistor

compound semiconductor gallium arsenide (GaAs) rather

technology for compound semiconductor sensor

than the traditional silicon (Si) material. The Hall sensors

devices capable of operating in extremely harsh

are several orders of magnitude more sensitive than those

environments, particularly high voltages and high

made from Si, consume very low power making them

temperatures.

ideal candidates for battery powered systems and their performance is not affected by variations in temperature.

BENEFITS The project will aim to deliver commercial grade sensing

OBJECTIVES

solutions for a diverse range of challenging applications.

The CS MAGIC project will focus on the development of new

The opportunities for magnetic sensors that can operate

ultra-sensitive magneto-sensors with integrated electronics.

in high temperature environments (>200C) are immense,

In doing so, it will leverage core technology based on Gallium

particularly in industries such as automotive and aerospace

Arsenide Quantum Well Hall Effect (QWHE) magnetic

where there is demand for more accurate control, due

sensing technology Developed by AHS, and a novel gallium

to sensors being in close proximity to working parts that

nitride device based on a high electron mobility transistor:

are subject to high ambient temperatures and thermal

‘magHEMT’ concept developed at Swansea University.

gradients due to frictional and mechanical stresses.

automotive

10

DREAM

Distortion reduction and elimination for additive manufacturing

PROJECT PARTNERS Granta Design Ltd, TWI Ltd, NquiringMinds Ltd, Materialise UK Ltd

BACKGROUND Selective Laser Melting (SLM) is a powder bed fusion

This leads to companies undertaking in-house R&D and/or

additive manufacturing (AM) process that is capable of

SME acquisitions activity in order implement AM confidently

generating metallic parts in a layer-by-layer fashion directly

in to their portfolios. As a result, competition can be muted

from CAD data. It can produce complex components with

in the wider AM community. Therefore, a key challenge

near-full density and mechanical properties comparable

for SLM is the establishment of a robust, repeatable and

to those provided by conventional casting and forming.

reliable build process.

However, one of the key challenges to the widespread adoption of SLM is the inability to achieve repeatable, high-

DREAM outputs will include:

quality parts from every SLM build.

a software application for adaptive process parameter control of SLM machines that is integrated with project

A fundamental barrier to the widespread adoption of

partner Materialise UK’s existing offerings

metal AM is the prediction and control of process-induced

a connected, digital, cloud-based service for adaptive

distortion. Whilst SLM is an increasingly mature technology,

process parameter control of internet-enabled SLM

the mitigation of distortion is a technical challenge that

machines

must be addressed before its full potential can be realised.

a data acquisition system for collection of build process analytics and information

OBJECTIVES The DREAM project will address this challenge through a multidisciplinary digital approach coupling: real-time data acquisition; advanced modelling; cloud-based computing; and adaptive machine process parameter control to achieve zero-distortion builds.

fundamental technology developments, with the potential to enhance and enable other technology streams,

related

to:

real-time

data

analytics;

additive manufacturing systems integration and measurements; cloud-based forecasting; algorithm development and decision-making; and advanced simulations.

BENEFITS Despite the potential benefits that SLM offers, it is only used to a limited extent in safety-critical applications, in part because there are still large numbers of unsuccessful SLM builds that increase production costs, many of which are due to distortion by cracking from the substrate during manufacture.

automotive

11

OPTIPRESS

Stepped change in precision and strength optimisation capability for steel fabrications

PROJECT PARTNERS Unipart Powertrain Applications Ltd, Coventry University, TWI Ltd

BACKGROUND Stringent emissions legislation is forcing automotive

Advanced

manufacturers to develop disruptive powertrain technology.

comprehensively and dimensionally define components,

metrology

techniques

will

be

used

to:

For petrol engines, improvements in Gasoline Direct

the manufacturing facilities, and the effect of processes;

Injection fuel system technology have helped to meet these

and to identify significant influences on the productâ&#x20AC;&#x2122;s critical

targets. The result is high pressure fuel systems varying

characteristics and capabilities.

from 150 Bar to 500 Bar. The most efficient, economic way to manufacture the fuel rail component of a high pressure

New process simulation tools will be developed to predict

fuel rail system is by fabrication, using welding and brazing

the influence of joining (heat) processes on the geometry

to join modular component parts. The market opportunity

of a high precision assembly. Linking metrology and joining

is to deliver a manufacturing solution which can provide

studies to these tools will provide a complete, connected

precision products for extreme pressure requirements with

capability that includes simulation tools for fatigue design.

minimal weight and cost.

In combination, new levels of autonomous optimisation will be enabled for these products.

Optipress will deliver improvements in manufacturing productivity by characterising and quantifying factors

BENEFITS

which significantly influence the fatigue strength and

Vehicle and injector manufacturers will be able to supply

stability of fabricated part geometry. New best practice

the market with new products: low pressure fuel rails that

for material and process selection will be developed,

have 15% lower costs and high pressure fuel rails that have

enhancing the manufacturing design of precision steel

improved strength. as well as achieving lower environmental

fabricated assemblies, and simulations will reduce new

limits (95 g CO2/km by 2021), leading to increased sales

product introduction times and provide more reliable

and turnover. Automotive owners will benefit from

optimisation capability. These will enable the production of

lower component costs, reduced fuel consumption and

modular fabricated fuel rail solutions for all strength and

decreased pollution taxes due to the optimised engineering

cost requirements.

and performance of high pressure fuel rail systems.

OBJECTIVES The objective is to connect design and manufacturing tools to efficiently optimise performance for each pressure specification and for manufacture. Digital simulations will be validated by manufacturing and testing samples using industry standards.

automotive

12

ULTRA LIGHTWEIGHT AUTOMOTIVE Additive reinforced friction stir welding of ultra lightweight automotive structures

PROJECT PARTNERS Cambridge Nanosystems, TATA Technologies, TWI Ltd, University of Nottingham

BACKGROUND Friction stir processing involves the mechanical stirring of

The project will address four different areas of processing:

metals using a none consumable tool to join components

FSW; the joining of both similar and dissimilar

and/or attain new material properties, including elevated

aluminium, high strength and magnesium alloys as a

strength. The most common process is friction stir welding

means of achieving further lightweighting

(FSW).

friction stir spot welding with the identified “ideal” welding applied to produce a high strength weld

The development of lightweight structures is a key priority within the automotive sector in order to meet future CO2 emissions targets. FSW has been adopted by many original equipment manufacturers as a key enabler of lightweight

the ability of high conductivity additives to aid non-destructive testing of the weld zones the ability of friction stir additive processing to produce new functionally graded components.

structures. However, within the UK, the Automotive Council estimates that the combination of new lightweight

BENEFITS

materials and manufacturing processes such as FSW

The project will demonstrate an enhanced FSW process

could be developed further to reduce the mass of a typical

capable of joining difficult and/or dissimilar lightweight

family sized car by up to 35%, thereby improving its fuel

materials, including aluminium, high strength steels and

consumption by 7% for every 150kg reduction in weight.

magnesium alloys, that will also give rise to more durable, stronger and/or lighter joints, for future automotive

OBJECTIVES

applications.

Ultra Lightweight Automotive will investigate new methods of FSW to join automotive body structures made of novel

Ultra Lightweight Automotive will support the development

lightweight alloys. The aim is to demonstrate high strength

of novel manufacturing processes, based upon existing UK

joints by doping the weld with different grades and

intellectual property, that will accelerate wider adoption of

concentrations of additives, which may positively influence

lightweight automotive structures to help meet future fleet

the structure of the material in the weld and improve

emissions target.

strength.

During manufacture, a colloid solution containing different grades and concentrations of additives, such as silica carbide and graphene, will be introduced around the tool interface to achieve additional control over the weld temperature, grain structure and ultimate strength.

automotive

13

ASSAI

Development of an unmanned aerial system for advanced contact inspection of civil structures

PROJECT PARTNERS Air Control Entech Ltd, James Fisher Testing Services, TWI Ltd, Brunel University London, JR Dynamics Ltd

BACKGROUND Unmanned aerial systems (UAS) offer industry a potentially reliable and safe solution to help with accessing areas

a risk prediction method and algorithm to assist in asset integrity management

that are otherwise too difficult to reach without extensive

a combined image processing algorithm and signal

manpower and support. Although rapid gains have been

processing module with machine learning capability

made in this field of technology, UAS cannot truly become

to enable intelligent evaluation of a bridge structure’s

the primary method for inspection and monitoring without

health condition.

the incorporation of advanced contact, non-destructive testing (NDT) capacity, which will enable effective corrosion investigation.

The sensor equipment currently being produced for use with UAS is limited to various imaging techniques such as video or thermal cameras and surveying and mapping technologies. As a result, human inspection is still required in parallel, especially for critical infrastructure investigation, meaning that UAS are not realising their performance potential including increasing productivity and generating cost savings.

OBJECTIVES

BENEFITS ASSAI will incorporate smart data analysis, providing a highly detailed, cost effective and safe alternative to current conventional bridge inspection techniques.

Benefits include: the ability to perform unmanned, remote, advanced UT inspection on critical infrastructure delivery of a smart, safe inspection technique that minimises labour-intensive practices, reduces the level of human risk and helps make assets safer provision of a risk-based inspection approach to inform intelligent maintenance operations

The objective of the project is to create an unmanned aerial

a resultant better understanding of lifecycle and

system for advanced contact inspection (ASSAI) which

degradation behaviour of bridges in different operating

will initially be tailored to suit civil structures, specifically bridges, and have further potential for a wider range of future applications. The following will be developed for the system:

conditions output data that will enable bridge operators to avoid failure and plan mitigation strategies in advance production of bridge performance statistics that can be

a novel flight path approach and docking technology

input to databases in order to illustrate scenarios that

a low power electromagnetic attachment and traction

will assist in making life extension decisions on bridges

system

in the future.

civil engineering

14

CRANESCAN

Continuous, reliable, advanced, novel and efficient structural health monitoring system for crane inspection applications

PROJECT PARTNERS NDT Consultants Ltd, NquiringMinds Ltd, Sparrows Ltd, TWI Ltd, Rcm2 Ltd

BACKGROUND Cranes used offshore face heavy load operations up to

Data will be transmitted by an optimised wireless system

10,000ton, and environmental challenges such as wind and

for remote data transfer of AE/ LRU signals; this will improve

vessel motion can increase the risk of structural failure. In

monitoring, and make installation and use straightforward.

large cranes, structural failures can lead to serious damage

The target is a scale-up data rate up to 500 Mbits/sec. The

or total collapse and can result in high financial losses and

transmission of data to a land based control station using

injuries or fatalities. Current manual inspection methods

existing infrastructures, and/or creating a private trusted

are time consuming and expensive and can be dangerous

data exchange (TDX) will be also evaluated according to

to operatives.

end-user needs. In addition, user friendly software will be designed and integrated into a typical crane operator’s

OBJECTIVES The CraneScan project will provide an innovative,

inspection guidelines.

reliable and cost-effective structural health monitoring

BENEFITS

(SHM) system that will continuously monitor the crane

CraneScan will provide the following benefits:

remotely and automatically detect structural integrity

a 75% reduction in unplanned downtime attributed to

defects before they lead to failure. This will be achieved

structural failure of cranes

by developing technology incorporating mountable dual

capital and insurance cost reduction

acoustic emission (AE) sensors, long range ultrasonic (LRU)

a 25% reduction in possible accidents due to structural

transducers, a wireless system for data transmission and

failure, fatigue or corrosion in cranes

signal processing software.

job creation of a workforce specialising in the

An operational prototype (demonstrator) will be developed

a saving of €375 million annually and a reduction in

showing the reliability of a combined AE sensor and LRU

failure rate of 25% to the global offshore crane industry

transducer, capable of identifying the location of defects

if deployed universally

continuous monitoring of cranes

within a +/- 5cm error, and with a detection accuracy

a system fit for commercialisation and market uptake,

probability of more than 90% for a 10mm crack on the

due to being designed to meet end user specifications,

safety critical components of a crane. The number and

which complies with current standards for NDT

position of sensors, and fitting technique, will be derived

systems/inspection.

from identification of the crane’s critical parts, installation requirements and monitoring needs.

civil engineering

15

HILEAK

Innovative monitoring system for early leak detection in water distribution systems

PROJECT PARTNERS STL Technology Solutions Ltd, TWI Ltd, Brunel University London, Inter-Granite Sendirian Berhad

BACKGROUND Current government initiatives in Malaysia aim to raise

This capability will be extended to condition monitoring of

the financial and environmental sustainability of the water

distribution pipes by permanently installing transducers.

services industry by 2020, reaching 99% coverage for

The following aspects will be optimised and validated:

clean and treated water, and reducing non-revenue water

damage recognition in both unburied and buried

(water that is pumped and then lost or unaccounted for) to 25%. Pipe failures contributing to Malaysia’s non-revenue water (NRW) currently stand at 39%, of which around 26% is lost through damaged water pipes and around 6% through inaccurate meter reading. The Ministry of Works estimates that around 25bn RM will be required for water pipeline rehabilitation over the next 50 years, including the

conditions wireless

data

communication

for

remote

data

collection and processing software for data analysis, management and risk based assessment (RBI) environmental protection (Ingress Protection rate according to IEC standard 60529).

replacement of over 44,000km of old asbestos-cement (AC) pipes with polyethylene (PE) pipes.

BENEFITS HiLeak will provide the following benefits:

Current methods used to identify leaks in the pipeline

water loss reduction leading to improved financial and

network include establishing district metered areas, visual

environmental sustainability for the water services

inspection, insertion surveys and correlation surveys, all of

industry in both large and small cities

which are labour intensive. In addition, there is a lack of experienced operators to carry out inspections. Therefore, the industry is looking at new technologies that can enable the monitoring of leaks without human intervention.

non-intrusive water leak detection and management, and monitoring techniques ability to identify and locate: narrow-band leak noise characteristic of non-ferrous pipes; low pressures; multiple leak situations; and excessive background

OBJECTIVES The HiLeak project aims to foster industrial research

noise created, for example, by traffic an

opening

up

of

industrial

research

and

collaboration in urban innovation, between UK and

commercialisation opportunities, contributing to both

Malaysian organisations, in order to develop an innovative

the UK and Malaysia becoming more competitive in

leak monitoring system. This will help water utilities in

smart water management

Malaysia to save water by dramatically improving their

full adherence to the official development assistance

effectiveness in locating leaks. Acoustic emission (AE) and

(ODA) criteria by improving the welfare of the Newton

guided wave (GW) ultrasonic techniques are proven at

Partner country’s population with the ultimate goals

screening pipelines for corrosion and erosion, with long

of contributing to its economic and sustainable

lengths of pipes being screened from a single location.

development.

civil engineering

16

PILESENSE

Innovative ultrasonic guided wave technology for intelligent sensing of defects in steel sheet pile infrastructure

PROJECT PARTNERS Integrity NDT Limited, TWI Ltd, Brunel University London, Kingston Computer Consultancy Ltd, CH2M Hill United Kingdom, REACH Engineering & Diving Services Ltd, JR Dynamics Ltd

BACKGROUND Steel sheet piling is the material of choice in the vast

a portable electronic pulser/receiver device to generate

majority of structures in coastal and offshore locations

the required electrical signal and receive the inputs

because it combines durability with ease of fabrication

from the ultrasonic tool

and is a relatively cost-effective solution. However, despite

software that incorporates signal processing to control

its many benefits, steel is prone to corrosion, which is

the pulser/receiver hardware, and enable the operator

the principal cause of deterioration in steel waterfront

to evaluate structural integrity by analysing the data

structures. A phenomenon known as accelerated-low-

collected.

water-corrosion (ALWC) is of particular concern as it can rapidly compromise the integrity of affected structures,

The system will operate on the accessible regions of the

leading to significant repair or replacement costs and

structure, above water and above ground. It will provide

major implications for safe operation.

screening of the sheet pile by generating an ultrasonic signal that will travel along the pile length and detect any

Carrying out preventive maintenance on coastal and

significant losses of material in the structure.

offshore structures is challenging because it is difficult to create access for inspection due to the majority of

BENEFITS

structural elements being partially buried and underwater.

The PILESENSE system will:

Currently, the only reliable non-destructive testing (NDT)

offer operators an inspection technique for the

method of detecting ALWC is visual inspection, accessed

performance of safe and cost effective preventative

by rope, boat or using divers, combined with wall-thickness

maintenance on steel sheet piling waterfront structures

measurements taken using conventional ultrasonic testing.

provide output data enabling operators to better

Unfortunately, this is a dangerous, time-consuming and

predict

expensive process.

maintenance before incidents occur

failure,

and

therefore

plan

corrective

lead to a better understanding of the lifecycle and

OBJECTIVES

degradation behaviour of structures in different

The PILESENSE project aims to create a novel system for

operating conditions.

the inspection of steel sheet piling waterfront structures to detect ALWC and other corrosion issues in areas that are difficult to access.The project will focus on the development of three main technologies: the capacity to propagate several metres along the sheet piling and detect corrosion

civil engineering

17

S-SHM

Satellite structural health monitoring

PROJECT PARTNERS Telespazio VEGA UK, THINKlab, TWI Ltd, STLTech, Transport for London

BACKGROUND At present, satellite data derived using techniques such as

The new system will enable the assessment of a multitude

interferometric synthetic aperture radar (InSAR) cannot

of assets simultaneously, since satellites can image many

directly assess the health of civil infrastructure assets such

thousands of km2 in one pass. Assets are currently assessed

as bridges, railways and buildings. Satellite measurements

individually so the monitoring cost per structure will reduce

taken using InSAR alone provide only pointers of movement.

as well as the overall time it takes to monitor multiple assets.

Therefore, to achieve an assessment of structural health,

The enabling tools will calculate interactions between the

the satellite derived measurements would need to be

elements of the structure, providing data on its health

assigned to the sub-elements or components of the

and highlighting any areas of concern. Three technology

structure within a building information model (BIM).

areas are being incorporated to achieve S-SHM: civil and structural engineering; satellite earth data observation;

The Satellite Structural Health Monitoring (S-SHM) project

and virtual environments.

is motivated by: growing recognition of the need for a structural health

BENEFITS

monitoring solution for infrastructure that can be used

The S-SHM project addresses the opportunity to exploit the

to understand and manage the asset’s lifetime and

use of space derived data to provide significant cost savings

inform maintenance programmes

in the provision of structural health monitoring services.

the ability to analyse many assets simultaneously enabling a wide area and top down view of the satellite

The UK Government’s Strategy for BIM Level 3 foresees the

data

combination of BIM with advanced data analytics “to plan

provision of a structural health monitoring system that

new infrastructure more effectively, build at lower cost

is lower cost than existing conventional methods.

and operate and maintain it more effectively”. In addition stating “in operation it provides customers with real-time

OBJECTIVES

information about available services and maintainers with

The aim of the S-SHM project is to create a new structural

accurate assessments of the condition of assets”.

health monitoring approach for civil engineering assets.

It will utilise InSAR data, including measurements of displacement; structural integrity analysis; and 3D BIM modelling of the structure.

civil engineering

18

SIRCAUR

Inspection of reinforced concrete structures by autonomous umbilical free robot

PROJECT PARTNERS Innovative Technology and Science Ltd, TWI Ltd, London South Bank University

BACKGROUND

BENEFITS

Corrosion of materials and structures accounts for 3.5%

SIRCAUR will result in the following benefits:

per annum of the global gross domestic product (GDP)

lower

inspection

setup

time

for

infrastructure

with reinforced concrete specifically contributing 8%

operators by 50% as a result of using climbing robots

(£158 billion) of this bill. A step improvement in reinforced

rather than erecting, and removing again, scaffolding

concrete structural repair at a much earlier stage than is

reduced costs for infrastructure operators when

currently implemented, incorporating complete structural

inspection is scaled up to much larger structures, due

diagnostics, could lead to lower repair costs and reduce

to the scaffolding and manual scanning requirements

risk of structural failures.

being replaced by climbing robots a potential reduction in the corrosion defect error of

Current inspection of reinforced concrete structures is

reinforced concrete structures of up to 50%. Manual

largely carried out manually by a person either positioned

operators miss about 50% of defects until they require

on scaffolding or abseiling. The former is a costly approach

major repair. The use of climbing robots would reduce

and the latter has a high safety risk. In addition, the quality of results can be variable.

the error rate a subsequent worldwide total industry saving of 25% on corrosion bills, equating to £40 billion per annum

OBJECTIVES The SIRCAUR project will address the issues associated with current inspection of reinforced concrete structures with the development of a prototype climbing robot that will:

globally, if this error rate is reduced the 25% reduction in corrosion costs enabled by the SIRCAUR robot would equate to a 25% increase in building life.

deploy a precision, none contact, ground penetrating radar (GPR) sensor for the detection of rebar and concrete corrosion and related defects, with 100% volume coverage requiring no scaffolding or abseiling

be umbilical free enabling it to climb to unlimited heights

work autonomously in GPS/ultra-wideband controlled trajectories, adjustable by GPR sensor feedback for avoidance of rebar-poor regions transfer NDT data by wireless link to a ground based central processing unit be fail-safe and easily recoverable.

civil engineering

19

SMARTBRIDGE Smart monitoring and inspection of bridges infrastructure

PROJECT PARTNERS James Fisher Testing Services Ltd, TWI Ltd, Brunel University London, Knowledge-Now Ltd

BACKGROUND There are approximately 80,904 bridges in the UK

condition

monitoring

sensors

including

accelerometers,

material aging, deterioration, widespread corrosion in

temperature sensors, strain gauges, barometers and

concrete and metal infrastructure, increased traffic volume

hygrometers will be placed on the bridge

and overloading. Of the many factors which have led to the

displacement

wireless

continuously subjected to the destructive effects of

transducers,

output data will be collected, processed and transferred

unsatisfactory condition of existing bridges, one that has

to the digital twin, continuously replicating and showing

been neglected is to address how they are inspected and

the

real-time

condition

of

the

bridge.

monitored.

BENEFITS There is a need to monitor bridges to obtain quantitative

The SmartBridge platform will allow bridge operators to

data about structural behaviour in order to confirm design

undertake lifecycle and behaviour analysis of a bridge’s

assumptions,

during

degradation, reflecting the growth in recent years of using

construction and to evaluate the current condition of

structural health monitoring systems to control lifetime

existing bridges. These enable engineers to make informed

extension of bridges with known problems.

to

provide

real-time

feedback

decisions about the future, and to plan maintenance or repair activities for existing bridges.

OBJECTIVES The SmartBridge project aims to revolutionise the monitoring and maintenance of bridges infrastructure by developing an innovative, knowledge-based digital platform that will enable the visualisation of a bridge’s condition and degradation. The project will address three different areas of processing: a virtual model, or twin, will combine a multiscale 3D numerical model with sensor data collected and processed from a real bridge infrastructure, incorporating environmental conditions and inspection history

Benefits include: continuous remote condition monitoring of a bridge’s infrastructure

provision of a risk-based inspection approach to inform intelligent maintenance operations

output data that will enable bridge operators to better predict failure and therefore plan maintenance before incidents occur leading to a better understanding of lifecycle and degradation behaviour of bridges in different operating conditions maintenance costs reduced by 20% and operational downtime by 60%.

civil engineering

20

ADDCAD

Development of software add-on for laser blown deposition additive manufacturing to improve design accuracy

PROJECT PARTNERS Computerised Information Technology Ltd, High Speed Sustainable Manufacturing Institute Ltd, Advanced Laser Technology Ltd, TWI Ltd, Innovative Technology and Science Ltd

BACKGROUND Additive Manufacturing (AM) describes a process that uses

End user requirements will be determined via dimensional

Computer Aided Design (CAD) data to produce components

analysis and mechanical testing using the available or

in layers by material deposition. The interface between

appropriate techniques, depending on the geometries and

CAD packages and the AM process is a stereolithography

flaws to be detected.

file (STL); a faceted representation of the model which is the industry type standard for 3D printing. STL files are

The aforementioned analysis and results will constitute

considered to have many weaknesses that make them

the basis for the software coding for accurate design.

inefficient to describe a number of AM features, leading to

The new software add-on will be validated by producing

the production of parts with inaccurate design.

components to allow further analysis, thereby checking the repeatability of the results.

Industries such as aerospace, automotive and medical are hesitant to adopt AM technologies due to the design

The final software add-on will be ready for commercialisation

inaccuracy potential when manufacturing components

and introduce a new era to the additive manufacturing

with complex features or different materials. As the AM

industry.

industry is anticipated to grow by up to ÂŁ13 billion by 2021, there is an immediate need to identify and investigate the

BENEFITS

issues and errors associated with the software, and to take

ADDCAD will provide the industry with a software add-on

forward steps to control, minimise and even eliminate

for laser blown deposition additive manufacturing that will

these errors.

streamline and optimise the design accuracy by 90%. This will: open up new horizons for additive manufacturing in fast paced industries such as aerospace and automotive;

OBJECTIVES The ADDCAD project aims to provide a software addon for CAD platforms which will enable CAD drawings to accurately represent the constructed item.

The

project

will

address

design

parameters

that

quality

and

accuracy

design

the

are

geometrical

important of

the

for

boost manufacturing operations; reduce post processing time, material waste and energy consumption; enhance market growth; and create new job opportunities.

and the

components.

manufacturing

21

EM-REST

Smart residual stresses monitoring for metal additive manufacturing

PROJECT PARTNERS Ether NDE Ltd, TWI Ltd, Brunel University London, Hybrid Manufacturing Technologies Ltd, Innvotek Ltd, Sonemat Ltd

BACKGROUND Metal Additive Manufacturing (AM) is an emerging

non-destructive testing techniques for the detection of

technology for rapid prototype manufacturing that benefits

residual stress.

aerospace and medical devices, as the immediate manufacturing

of

high-value,

complex

structured

components is usually necessary in these industries.

The prototype will be built on a laser powder deposition system with an add-on robotic arm comprising two sets of ultrasonic transducers:

Hence, the structural integrity of printed structures is of great importance and should meet the specifications and high standards of the above industries. However growth in the uptake of AM parts is inhibited by a lack of intregrated and effective quality control.

electromagnetic

acoustic

transducers

which

are

enhanced on ferromagnetic materials, like steel, to paramagnetics; and eddy current testing which can be efficiently applied for the monitoring of any electric conductive material regardless of its magnetic properties.

In several metal AM techniques, e.g. selective laser melting (SLM), electron beam additive manufacturing (EBAM) and

The combination of the two sensors will enable increased

wire arc additive manufacturing (WAAM), residual stresses

accuracy

and micro-cracks that occur during the manufacturing

Assessment of the structural integrity of components

procedure can result in irreversible damage and structural

printed by any form of AM techniques will be accomplished

failure of the object after it is manufactured.

at the early stage of manufacturing.

When, rarely, 100% end of line inspection is expensively

BENEFITS

performed, 6-8% of components are scrapped. Repetitive

EM-ReSt addresses two of the most important barriers for

faults that occur during manufacture, due to the incorrect

the widespread adoption of AM: component quality and

estimation of the appropriate operating conditions of the

material properties, therefore contributing to realising

manufacturing system, should be eliminated as any waste

AM’s overall economic potential.

of

inspection

for

the

printed

feedstock.

is undesirable and costly for a company.

OBJECTIVES This project will develop and validate, in a relevant environment, an EM-ReSt prototype: an online structural integrity monitoring system based on electromagnetic

manufacturing

22

GRAPHOSITE

A graphene sensor for defect detection and predictive maintenance in composite materials

PROJECT PARTNERS ADVISE-DETA Ltd, Brunel University London, Haydale Composite Solutions Ltd, DZP Technologies Ltd, Cambridge Nanomaterials Technology (CNT) Ltd, TWI Ltd

BACKGROUND Defects can inadvertently be produced in composite

To address such defects, the sensor to be developed within

materials, either during the manufacturing process or

the project will have the following characteristics:

during the normal service life of the component.

enhanced detection limit embedded between two composite layers

Some non-destructive testing methods exist for defect

monitoring that is both predictive and continuous.

detection in composites, such as ultrasonic testing and strain gauging however these have limitations, including

In the final sensor, graphene will serve as the sensing

cost, that have prevented them from being used extensively.

element and act as the gate through which the electric

In addition, the Department for Business Innovation &

current will pass.

Skills (BIS)’ UK Composites Strategy states that the UK needs to focus on advancing the reliability of composites and increasing market share in existing sectors.

BENEFITS The Graphosite project focuses on the sensing principle and will be applicable to a wide range of sectors in which

OBJECTIVES

composites are used such as automotive, aerospace and

The Graphosite project seeks to develop a graphene

the wind energy industry.

sensor for defect detection and predictive maintenance in composite materials, for use as a highly efficient and more

There are several benefits to be derived from the graphene

convenient monitoring tool than existing techniques.

sensor including: the ability to predictively and continuously monitor

Defects

occur

in

composite

materials

during

the

manufacturing process and/or during the normal service-

composites during manufacture and after their normal life

life of a component. The most common manufacturing

invaluable reductions in in-use failure, and in

process defect is porosity; levels can become critical

immediate after-manufacture scrappages due to

when they affect mechanical performance, such as

missed defects in composites

causing inter-laminar shear stress.

The most frequent

a reduction in downtime of 20% in aviation

reason for in-service damage is impact, for example,

capacity to install the sensor in a high stress area

sandwich structures can suffer from matrix cracking

of interest, enabling calculation of the strain, and

and

identification of where the maximum bending moment

delaminations

in

the

skins

when

impacted.

is and where cracks could occur.

manufacturing

23

OLEDSOLAR

Innovative manufacturing processes and in-line monitoring techniques for the organic light-emitting diodes, thin film and organic photovoltaic industries

PROJECT PARTNERS VTT Technical Research Centre of Finland Ltd, TWI Ltd, Leitat Technological Center, Fraunhofer-Gesellschaft, Netherlands Organisation for Applied Scientific Research (TNO), Centre Suisse d’ Electronique et de Microtechnique SA, Carinthian Tech Research AG, Brunel University London, OPVIUS GmbH, Solibro Hi-Tech GmbH, INURU GmbH, Advent Technologies Inc., DuPont Teijin Films UK Ltd, Meyer Burger B.V., Innovació i Recerca Industrial i Sostenible, S.L., Coatema Coating Machinery GmbH

BACKGROUND Opto-electronic devices, that source, detect and control

Project results will be integrated, and shown, in a single

light, are currently the focus of exciting new developments.

pilot line for the continuous and high-volume production

For example, a wide range of applications in lighting and

of CIGS photovoltaics.

display, using substrates such as plastic and flexible glass, are being introduced by organic light-emitting diodes

OBJECTIVES

(OLEDs) manufacturers.

The objectives of the project are to achieve:

Prior to these, the emergence

of thin film technologies in the solar cells market resulted in new uses such as installation on curved surfaces and integration of solar photovoltaics into buildings.

However, in order to meet industry requirements for mass

innovative new manufacturing processes that are robust, scalable and high yield: >15% a fully functional, inline hybrid system for inspection and quality control

production, including price points, manufacturing volumes

new recycling and re-use strategies

and efficiency, many challenges still need to be addressed.

automation and advanced processing software.

OLEDSOLAR will design, build and scale, roll-to-roll

BENEFITS

manufacturing

processes

and

technologies

aimed

at: the complete protection of solar cells and OLEDs against humidity; a higher degree of automation and throughput; and reducing costs. This will involve creating and implementing, in two pilot lines, a real-time quality monitoring process based on hybrid optical measurement techniques. The aim will be to monitor, control and improve the production quality of opto-electronic organic devices.

The pilot lines will address the up-scaling challenges being faced by the OLEDs industrial market in building integrated organic solar cells and manufacturing copper-indiumgallium-selenide (CIGS) photovoltaics.

OLEDSOLAR will offer the following benefits: provision of real-time thin film thickness measurements and continuous yield monitoring that are directly integrated into the production line lower power generation due to using OLED lighting rather than alternatives such as LEDs uniformity of light output, reducing the need for reflectors as used in other lighting techniques a potential alternative to conventional, inorganic photovoltaic technologies in the form of thin film photovoltaic cells based on solution-processable organic semiconductors.

www.oledsolarproject.eu This project has received funding from the European Union’s Horizon 2020 research and innovation programme under grant agreement No 820789.

manufacturing

24

ROBO-PACK

Development of an advanced robotic manipulator for rapid inspection and packing of fresh produce

PROJECT PARTNERS RSK ADAS Ltd, Shadow Robot Company Ltd, Suncrop Produce Ltd, Wootzano Ltd, Impact Laboratories Ltd, TWI Ltd, London South Bank University

BACKGROUND Agricultural and food production companies are processing £13billion worth of fresh food annually including fruit and

unique ability to detect both the position of an applied force and its direction

vegetables, 70% of which is imported to meet consumer demand. Due to the fragile nature of these foods, they

a robot end effector with dynamically guided grasp

require delicate handling, particularly during quality

that adapts its grip based on the electronic skin, sense-

inspection.

of-touch feedback loop

Therefore, the food processing industry is

dominated by the use of manual labour and packaging

a vision system for positioning and inspection, achieved

companies and suppliers largely employ personnel to fulfil

by implementing 3D-capable, point cloud cameras.

these processes.

These will create point clouds to rapidly identify the position and distance of objects, and detect any

A major challenge now facing the industry is high labour

changes in their colour, size and/or shape.

demand due to a shortfall in available man-power. However, a solution would be to introduce robotic manipulator

All these subsystems will be integrated into a functional

systems into food packaging processes that have both a

prototype. Following subsequent trials, the results will be

sense of touch and the ability to select unblemished fresh

analysed to determine the impact on packaging speeds

produce autonomously. Current, state-of-the-art systems

and efficacy compared to existing methods.

are open-loop so they lack the ability to successfully grasp an object if the mechanical interaction between the endeffector and the grasped object is not well predicted; such is the case with the handling of fresh produce.

OBJECTIVES

BENEFITS The Robo-Pack project will: meet the needs of industry by providing dexterous handling robotic systems address the shortfalls in manual labour supply of

The Robo-Pack project aims to develop an advanced robotic

personnel who identify defects in fruit handling

manipulator for the inspection and packing of fresh foods.

facilities, leading to increased productivity over time promote the take-up and use of robotics in food

Robo-Pack will deliver the following technical innovations:

production.

an “electronic skin” that provides sense of touch; patent filed

manufacturing

25

DIMOS

Artificial intelligence-based prescriptive maintenance of ships

PROJECT PARTNERS Vibtek Ltd, TWI Ltd, ICON Research Ltd, Relmar Ltd, Kingston Computer Consultancy Ltd, Brunel University London

BACKGROUND The average annual lifecycle cost of operating a ship is

Specific objectives are to:

approximately £53m, of which 30% (£16m) is spent on

establish the monitoring and maintenance needs of

maintenance and repair.

Therefore, there is a strong

need to reduce the overall maintenance cost. This could be achieved by improving operational efficiency and,

end-users specify the software platform parameters based on requirements

over time, lead to cost savings and increased profits. On

design and develop an intelligent monitoring software

average, the manual inspection component can cost up

module that includes risk-based failure detection and

to £700k per ship, according to ship type and size, and requires dry-docking, downtime and loss of revenue.

AI based algorithms integrate the module into the DiMOS platform and carry out tests.

Previous studies have revealed that 63% of all maintenance is unnecessary, causing more problems than solutions.

Only 15-20% of equipment failures are age-related, and 85% of those happen on a time-random basis, regardless of inspection and service.

Consequently, there is a

requirement for an intelligent, continuous, accurate and automated condition monitoring and maintenance platform.

Benefits include: real-time prescriptive maintenance solutions based on output condition monitoring data from ship structures optimised operational performance and safety, and prevention of failures, via automated maintenance planning a reduction in inspection and maintenance costs by

OBJECTIVES

35% leading to savings of over £700k per ship, per

DiMOS will create an integrated software platform for undertaking prescriptive maintenance on a ship’s machinery, structure and auxiliary systems.

BENEFITS

This will

be achieved by using data from condition monitoring, diagnostic sensors and systems, the implementation of big data analytics and the integration of a maintenance actions/

year, for operators and owners immediate fault monitoring and prescription of best maintenance strategy without manual diagnostics and data interpretation enhanced maintenance accuracy and a reduction in the annual downtime of ships from 7 to 1.5 days

prescription database. Advanced, artificial intelligence (AI)

support for operators, owners and maintenance

based, deep learning algorithms will select, or prescribe,

providers in fulfilling their regulatory and legal

a best maintenance strategy based on faults or condition

obligations for safe operation and maintenance of

found and the risk profile of the ship asset.

seagoing vessels.

marine

26

FIBRESHIP

Engineering, production and life-cycle management for the complete construction of large-length fibre-based ships

PROJECT PARTNERS TWI Ltd, Técnicas y Servicios de Ingeniería, Compass Ingeniería y Sistemas, Centre Internacional de Mètodes Numèrics en Enginyeria, Lloyd’s Register EMEA, Bureau Veritas, RINA Services, Danaos Corporation, Anonymous Shipping Company of Crete, FOINIKAS Shipping Company, Instituto Español de Oceanografía, Tuco Marine Group, Navrom Shipyard, Fundación Centro Tecnológico SOERMAR, Teknologian tutkimuskeskus VTT Oy, H2X, Ateknea Solutions, University of Limerick (Irish Centre for Composites Research)

BACKGROUND

OBJECTIVE

FIBRESHIP seeks to create a new EU market for building

The objective of the FIBRESHIP project is to enable the

entire, large-length ships using fibre-reinforced polymers

building of the complete hull and superstructure of large-

(FRPs). Currently, FRPs are used in the building of some ship

length, seagoing and inland ships using FRP materials.

parts but not all, therefore, this project will demonstrate the wider application of FRPs in ship building to encompass the complete hull and superstructure of the vessel.

BENEFITS FIBRESHIP will take advantage of using FRP materials in large-length ships to achieve better whole life performance

The core research of the project will develop, identify and

and a reduction in maintenance costs.

qualify FRP materials for different applications in ship building, in particular for long-term structural strength

Benefits include:

and fire resistance. This will include developing innovative

a significant decrease in the weight of the ship with

design of

procedures

standardised,

and

efficient

guidelines; production

implementation methodologies

demonstrated by delivering a proof of concept; and clear

greater stability a reduction in environmental impact, specifically greenhouse gas emissions and underwater noise

performance indicators designed and applied in the

fuel savings

evaluation of three targeted vessel categories: container

increased cargo capacity and better performance

ship, ferry and fishing research vessel.

under fatigue type loads enhanced immunity to corrosion.

FIBRESHIP will also analyse the life cycle cost benefits of incorporating FRP materials into large-length ships. In addition, a business plan will be developed for the various

www.fibreship.eu

stakeholders in the value chain covering the different stages in a ship’s life-cycle from design engineering, material production and ship building through to the final dismantling of the vessel.

This project has received funding from the European Union’s Horizon 2020 research and innovation programme under grant agreement No 723360.

marine

27

ROBUST

Robotic subsea exploration technologies

PROJECT PARTNERS TWI Ltd, CGGVeritas Services SA, ALS MARINE CONSULTANTS Ltd, Laser Zentrum Hannover e.V., HelmholtzZentrum für Ozeanforschung Kiel, Graal Tech Srl, NeoLASE GmbH, Università degli Studi di. Genova – ISME, Coronis Computing SL

BACKGROUND There is a need to develop an autonomous, reliable, cost

to fuse laser sensors technology along with video/

effective technology to map vast underwater terrains, in

image observations, to get high resolution 3D

terms of mineral and raw material contents, which will

information of the seafloor and targeted materials at a

aid in reducing the cost of mineral exploration currently

distance of <~7m

performed by remotely operated vehicles, and dedicated

the further advancement of LIBS for deep water applications (6000m) for fast material identification by

special service vehicles and crew.

in-situ application Furthermore there is a need to identify, in an efficient and

to develop hovering and control capabilities for the AUV

non-intrusive manner which will have minimum impact

carrying the LIBS, for hovering and seamless synergy

to the environment, the most rich mineral sites. This

between AUV movement and LIBS manipulator

technology will aid the seabed mining industry, reducing the

to develop a life cycle cost analysis plan for the

cost of exploration, especially the detailed identification of

developed technologies, to include how the ROBUST

the raw materials contained in a mining site, and enabling

technologies will benefit the sea bed mining industry

targeted mining only of the richest resources existing.

in terms of reducing exploration costs and time.

The ROBUST project aims to tackle the aforementioned

BENEFITS

issue by developing sea bed in-situ material identification

ROBUST will significantly reduce the costs of sea bed mining

through the fusion of two technologies, namely laser-

exploration and reduce the environmental impact. The

based in-situ element-analysing capability merged with

ROBUST technologies are contributing to the objectives and

underwater

targets of the European Innovation Partnership (EIP), which

AUV

(Autonomous

Underwater

Vehicle)

technologies for sea bed 3D mapping.

aims to increase the share of the raw materials industry to 20% of GDP and ensure the sustainable supply of raw

OBJECTIVES to

develop

materials to the European economy whilst increasing the real

time

3D

sea

bed

mapping

algorithms in order to detect the desired mineral resources, and to manoeuvre and position the

benefits for society as a whole.

www.eu-robust.eu

manipulator with the Laser Induced Breakdown Spectroscopy

(LIBS)

on

the

mineral

deposit

This project has received funding from the European Union’s Horizon 2020 research and innovation programme under grant agreement No 690416.

marine

28

SHIPLYS

Ship lifecycle software solutions

PROJECT PARTNERS TWI Ltd, Fundación Centro Tecnológico SOERMAR, Atlantec Enterprise Solutions GmbH, University of Strathclyde, Astilleros de Santander SA, National Technical University of Athens, Instituto Superior Técnico, Varna Maritime Ltd, Ferguson Marine, Alveus Ltd, BMT Group Ltd, Lloyd’s Register EMEA IP

BACKGROUND

BENEFITS

Small and medium-sized enterprise (SME) naval architects,

Architects, shipbuilders and ship-owners by supporting:

shipbuilders and ship owners need to compete in a global

rapid early design assessments regarding scope and

market. The calculations and modelling they are required

costs of new build ships or repair/retrofitting activities

to perform during the early design stage, when they are

production and optimisation relating to designs being

responding to tenders for new build ships or repair/ retrofitting, are often difficult and time consuming. This is particularly true for SMEs without large numbers of trained

considered assessments of risk and environmental sustainability involved from a through life perspective

staff and tools.

assessments of life cycle costs based on early design

The overarching aim of this project is to develop software

optimisation of early design based on user defined

stage data solutions to support stakeholders during the early stages of new build design or repair, so that they can make reliable

criteria assessment of alternative design.

estimates of the scope of work and the costs involved.

OBJECTIVES

www.shiplys.com

the development of a virtual prototyping system to incorporate life cycle cost assessments, and environmental risk and assessment criteria, for the fast and cost effective evaluation of alternatives the addition of multi-criterion decision analysis techniques to support decision making across the short/long term, based on explicit user defined decision criteria the development of a set of good practice guidelines for the life cycle management of ships.

This project has received funding from the European Union’s Horizon 2020 research and innovation programme under grant agreement No 690770.

marine

29

SHIPTEST

Fully automated laser guided inspection robot for weld defect detection on ship hulls

PROJECT PARTNERS TWI Ltd, Spectrum-Labs, Tecnitest Ingenieros SL, Innora Robotics and Automation SA, Lloyd’s Register EMEA

BACKGROUND The European ship fleet counts 23,000 vessels, accounting for 40% of the global gross tonnage. The marine industry is a major prosperity engine of the EU contributing a total of €147bn to its GDP and supporting more than 1.7m jobs.

make the process safer by removing staff presence from dangerous sites inspect welds on metal plates thinner than 10mm avoiding risks of industrial radiography collect inspection data and make them accessible to be

However, the structural integrity verification of vessels

processed and analysed afterwards

is a major issue for the shipping industry. Ship hull weld

enable performing the entire inspection process while

inspection is a challenging process as safety-critical welds

the ship is in service, greatly reducing the need for

length exceeds 120km in large vessels, and involves human inspectors on site using scaffolding or cherry-pickers. These

dry-dock time provide a commercial inspection system to industry.

procedures require long periods of dry-docking, incurring loss of revenue and costs. This necessitates the use of

BENEFITS

dangerous radiographic techniques which pose health and

The benefits are:

safety issues.

economic efficiency for both NDT inspection companies and ship owners when vessels are in dry dock

We aim to redefine ship non-destructive testing (NDT) inspection by commercialising ShipTest, a laser-guided robotic crawler able to automatically track the weld and inspect the hull while the ship is at sea. Through a

combination

of

bleeding-edge

ultrasonic

ability to inspect high reaching weld points - no need for any additional supporting equipment NDT costs will be reduced, scanning efficiency increased and the safety of personnel improved

and

negates the need for use of radiographic scanning

electromagnetic techniques, ShipTest can accurately

equipment which is hazardous due to ionising

inspect metal plates of <10mm thickness, thereby

radiation.

eliminating the need for radiography.

www.shiptest.eu OBJECTIVES The objectives are to: reach areas on the hull inaccessible for the human inspector make inspection faster – 38% more so than the com­ mon practice

This project has received funding from the European Union’s Horizon 2020 research and innovation programme under grant agreement No 690770.

marine

30

A-PATH

Affordable preventative and assistive technology for healthcare

PROJECT PARTNERS Innovative Technology and Science Ltd, Advance Tech India Pvt. Ltd, IIT Ropar, India, TWI Ltd

BACKGROUND The population of elderly people over 60 in India and the

Ways of achieving improved passive/active components to

UK is projected to climb from 8 and 17.1% recorded in

improve the effectiveness of the human-robot interactions

2010, to 19 and 24.9% in 2050 (UN 2011). It is important

will be identified by means of new â&#x20AC;&#x2DC;robot skinâ&#x20AC;&#x2122; sensors and

to provide increased mobility for the elderly as well as

adaptive learning approaches motions.

augment the capabilities of workers performing heavy labour; these being two examples of groups of people for

BENEFITS

whom exoskeleton suits can provide significant benefits

The project will incorporate test sensors for inclusion

to health and improve quality of life. Current commercial

in bio-sensing suits; adaption of wearable bio-sensor

exoskeleton devices are expensive, tend to be slow and

and data analysis algorithms; software development;

cumbersome and have limited usefulness. Activities are

materials selection for structural and human interfaces;

needed to improve the effectiveness of these products,

and structural testing of the prototypes. This will enable

therefore, A-PATH will develop affordable, commercial,

the project to develop affordable, preventive and assistive

wearable robot solutions fit for the UK and Indian

techniques that will benefit elderly people and those

healthcare markets.

workers undertaking labour intensive tasks. For elderly people, their quality of life will be improved by added

OBJECTIVES

mobility as a result of the exoskeleton. For labour intensive

A-PATH aims to develop affordable, wearable, bio-sensing

workers, their work efficiency will be enhanced and their

and human motion monitoring suits, and passive and

hardship reduced accordingly.

active exoskeletons, to assist essential human motion. The new technologies will target elderly people and workers for medical and non-medical applications. Exploitable outputs comprise sensing suits to assess health and physical activity levels, both of which can decline due to ageing. The decline in physical activity can be addressed by providing supporting technologies such as assistive exoskeletons.

A-PATH targets the research needed to meet emerging medical and non-medical standards (ISO13482 and IEC 80601-2-78) for assistive and rehabilitation robots, and will design passive, affordable, upper and active lowerbody exoskeleton that will be tested on end users and commercialised in the UK and India.

medical

31

SOCKETMASTER

Developing a new technique for rapid design and manufacturing of optimised prosthetic sockets for lower limb amputees

PROJECT PARTNERS TWI Ltd, Innora Robotics and Automation SA, Fondazione Bruno Kessler, Veneto Nanotech SCPA, Polkom Badania SP ZOO, Sensing Future Technologies Lda, University of Surrey, Hugh Steeper Ltd

BACKGROUND In developed countries more than 90% of limb amputees

The digital 3D data of the optimised socket design will be

achieve their mobility through the use of prostheses. The

fed into a rapid prototyping machine for fast fabrication.

comfort of a prosthetic limb is a key consideration for both

At least 50 clinical trials will be carried out to validate the

manufacturers and service providers, as they are keen to

SocketMaster technique. It is envisaged that SocketMaster

help the prosthetic limb user – who will have to wear the

will enable same-day socket fabrication with optimised

prosthetic indefinitely – regain a good quality of life.

quality, and the fit and function of the prosthetic socket will be less dependent on the skills of the prosthetist.

OBJECTIVES To overcome the challenges, TWI is leading a consortium

www.socketmaster.eu

of eight partners from Greece, Italy, Poland, Portugal and the UK to develop a new technique, entitled SocketMaster.

The consortium aims to integrate various micro sensors into a medical tool, which will help prosthetists achieve fast, customised design and manufacturing of prosthetic sockets for lower limb (trans-femoral and trans-tibial) amputees.

BENEFITS It is expected that by wearing the SocketMaster tool, comprehensive data characteristics of the patient during typical activities will be able to be measured and collected.

This data will then be used to optimise the socket design to maximise the patient’s comfort.

This project has received funding from the European Union’s Horizon 2020 research and innovation programme under grant agreement No 645239.

medical

32

THERMOTECT

Development of a portable thermographybased health detection application for breast cancer screening in India

PROJECT PARTNERS Innovative Technology and Science Ltd, TWI Ltd, Elion Technologies & Consulting Private Ltd, Indian Institute of Technology Ropa

BACKGROUND Breast cancer is the most common cancer in women

This approach will improve the user experience and

worldwide, with nearly 1.7 million new cases diagnosed

optimise convenience, safety and efficiency based on

in 2012, and the second most common cancer overall. In

provision of information from a thermography camera and

addition, breast cancer represents about 12% of all new

an interpretation platform. A cloud server will host an AI

cancer cases and 25% of all cancers in women. According

model, providing additional data to help in the assessment

to the World Health Organisation, although breast cancer

of the output images.

is thought to be a disease of the developed world, almost 50% of breast cancer cases and 58% of deaths occur in developing countries. This includes India where for every two women newly diagnosed with breast cancer, statistically one of them will not survive.

BENEFITS The technology will provide a much better means of monitoring female Indian patients for signs of breast cancer. Therefore, its application will contribute to preventing the disease and will empower medical clinicians

OBJECTIVES

with the information required to make early decisions on

This innovative project will develop a novel, portable

courses of treatment, based on quantitative non-invasive

thermographyâ&#x20AC;&#x201C;based health detection application for use

imaging.

as a highly efficient, less invasive, more convenient and safer breast cancer screening tool, specifically for use in

THERMOTECT will help bring to the healthcare industry

rural parts of India as well as other developing countries.

new expertise in breast cancer prevention and artificial intelligence, together with enhanced hardware capability

The new screening system will be based on a portable

in thermography and communications.

mobile device application that is connected to a cloud server that will host an artificial intelligent (AI) model classifier. Hence the project makes a direct contribution to early detection of breast cancer and, therefore, towards the improvement of the welfare of Indiaâ&#x20AC;&#x2122;s female population.

The technical objective of this project is to implement a novel, user-friendly application to capture, interpret, analyse,

encrypt,

transmit,

receive

and

decrypt

thermographic breast images between a user and a health management facility.

medical

33

ASPIRE

Assessment strategy for upstream plant inspection and repair

PROJECT PARTNERS Innospection Germany GMBH, TWI Ltd, Transport Systems Catapult Ltd, Assist Software SRL, IKnowHow AE

BACKGROUND Upstream oil and gas subsea assets on offshore platforms

provides assessments to BS 7910 and API 579.)

are hazardous and expensive to inspect, however this

optimum repair technologies which will provide

is essential for effective integrity management. Current

operators with the means to establish the most

practice is to use a combination of inspection and analysis

cost-effective approach to reclaiming a damaged

tools from different suppliers. These assets are typically

component.

inspected infrequently and this leads analysis tools to calculate high levels of uncertainty on asset integrity.

Subsequently high levels of perceived risk mean operators must take conservative maintenance decisions, increasing the overall costs while still leaving uncertainty in asset integrity.

OBJECTIVES The objectives are: to finalise the integration of robotic inspection system with the enhanced analysis and decision support tool optimise the customisable, probabilistic based software in order to use advanced reliability methods with

ASPIRE will take a multi-disciplinary approach to solving the integrity problems of ageing assets by incorporating existing

solutions,

using

state-of-the-art

engineering

techniques, into an integrated decision-support tool. It will encompass:

built-in FEA capabilities validate the complete system through demonstration at customer sites finalise

commercial

product

against

standards,

regulations and best practice guidelines

Innospection’s state of the art robotic inspection

launch ASPIRE product for commercial sale.

system MEC-MPS200+ for hard to access assets risk-based inspection (RBI) as a methodology for identification of high risk scenarios by review of active/ potential damage mechanisms and the suitability of mitigation methods total quality inspection (TQI) covering NDT technique selection, qualification of equipment, procedures, inspection

personnel,

and

data

recording

and

interpretation Fitness for service (FFS), which may allow for flaws that are classed as unacceptable, based on advanced mechanical engineering using built in Finite Element Analysis (FEA) capabilities to evaluate complicated geometries and loadings (TWI has been active in developing ECA/FFS/FFP procedures for 50 years and This project has received funding from the European Union’s Horizon 2020 research and innovation programme under grant agreement No 760460.

BENEFITS ASPIRE will provide a new tool to operators to increase knowledge of asset integrity and reduce the risks of unplanned failure and maintenance streamlined process will provide faster analysis and maintenance recommendations detailed analysis will enable improved prediction of asset life, allowing improved scheduling of future outages and optimising plant downtime flexible systematic approach allows the system to be adapted to future challenges and tailored to each operator’s requirements.

www.aspire-analysis.com

oil and gas

34

MONITANK

Underground storage tanks risk mitigation system for petrol fuel stations

PROJECT PARTNERS Integrity NDT Muhendislik San.Tic.Ltd.Sti., Innovacio i. Recerca Industrial I Sostenible SL, Floteks Plastik San. Tic.A.Ş., TWI Ltd, Brunel University London

BACKGROUND

OBJECTIVES

The underground storage of petrol in tanks, especially in

The project aims to commercialise the existing MoniTank

close vicinity of urban and rural environment at petrol fuel

system (already proven at TRL6); a low cost solution that

stations, may pose several risks such as fire/explosion,

actively monitors the UST’s health online and can flag

environmental damage and health effects when handled

changes in condition before fuel leakage occurs. It will offer

by individuals. Due to the vast volumes of petrol used daily

an innovative system for the early detection of leakage,

(in the EU >400 million litres), the large service stations

through assessment of the structural integrity of USTs in

network (in the EU>100,000) and storage capacity, surface

order to predict their maintenance requirements. It will

and subsurface releases are likely to occur.

combine risk based assessment and continuous structural health monitoring utilising acoustic emission and guided

Service stations carry a risk of fire or explosion due to

waves.

petrol vapours which are highly flammable even at low temperatures. In addition, when petrol escapes from an underground storage tank (UST) or pipeline, it can travel

BENEFITS The project will provide the following benefits:

significant distances. Petrol vapour tends to sink and

increased reliability and performance of USTs at fuel

gather in the lowest points of its surroundings. It can travel

stations making them more secure and cost efficient to

downhill due to gravity or be carried in the direction of the

operate, and reducing inspection costs by 75%

wind. If petrol vapour finds its way into building basements

ability to detect all structural faults in tanks and

or public drains and comes into contact with an ignition

transmit monitoring data showing risk profile, faults

source, there can be serious consequences. If released into

and maintenance priority areas via a sensor network

the environment, petrol and diesel may also pollute soil and water supplies.

to central cloud based software minimises the chance of UST failure going undetected by more than 90% providing preventive maintenance

The level of risk associated with fuel leakage means early

and avoiding leakages and fuel loss

detection of leaks is essential. The very high cost of fuel also

enhanced safety for operators who will be able to see

means there is a monetory loss to the business concerned.

the condition of fuel storage tanks at any time and,

MoniTank will addess these factors by developing a

therefore, avoid leaks or failure before occurrence

continous condition monitoring system for the observation

provides 99% accuracy for probability of defect

and inspection of USTs.

recognition, exceeding the 98% compliance required by standards and legislation for monitoring systems for USTs.

www.monitankproject.eu This project has received funding from the European Union’s Horizon 2020 research and innovation programme under grant agreement No 760528.

oil and gas

35

NAUTILUS

Bathyscaphic robotic floor thickness monitoring of hazardous liquid storage tanks

PROJECT PARTNERS Monition Ltd, Innovative Technology and Science Ltd, Diagnostic Sonar Ltd, TWI Ltd, London South Bank University

BACKGROUND

OBJECTIVES

Aboveground storage tanks (ASTs) made of carbon steel

The NautilUS project will develop a robot system to

degrade due to the materials they hold such as crude oil

perform in-service NDT inspection and meet the ATEX

and petroleum chemicals. Corrosion can form over time,

Workplace Directive. The bathyscaphic robot will use active

leading the contents to leak, resulting in severe economic

buoyancy control methods to move around the tank and

losses and environmental pollution. To avoid such impact,

will be battery powered. A zero-degree ultrasound probe,

periodic inspection, evaluation, and repair activities are

mounted on the underside of the lower chamber, will take

undertaken, in accordance with safety regulations API 653;

measurements of floor plate thickness as it moves around

American Petroleum Institute, 2014.

inspection surfaces. The robot will record data on upper and lower surface thinning from corrosion, including its

Current manual inspection methods require a tank to be

nature and location, which it will retain on board for post-

out of service for weeks. The tank must be cleaned and

processing after it has been retrieved.

the product it holds moved to another container before a human inspector can perform non-destructive testing

The robot will be designed with a compact footprint to

(NDT). For operatives, there is a high-risk of exposure to

enable entry via the small manholes commonly found

chemicals during the tank cleaning operation. The NDT

on liquid storage tanks. In order to perform inspections

inspection task is limited because only wall corrosion

in explosive and flammable environments, the robotâ&#x20AC;&#x2122;s

and welds can be inspected from outside the tank, while

operation will avoid sparking which could create an

internal and external corrosion on the tank floor can only

explosion in a tank due to heat and the presence of vapour.

be inspected from the inside.

Robotic inspection of ASTs is being used as a solution to

BENEFITS The NautilUS bathyscaphic robot will improve health and

the problems associated with inspection. This avoids the

safety, lower personal and environmental risk and reduce

dangers involved in a person entering the tank and the need

costs in respect of periodic petrochemical storage tank

to empty it. However in practice, commercially available

inspections, particularly corrosion thinning of the tank

robots have become stuck in the sludge and are difficult to

floor, required to meet American Petroleum Institute (API)

make intrinsically safe for use in flammable and explosive

industry regulations. Simultaneously, the shortcomings

environments. Consequently, a need continues to exist for

of existing robotic solutions will be overcome due to the

improved methods of inspecting ASTs.

unique motion characteristics of the robotic NautilUS platform.

oil and gas

36

RIMCAW

Robotic inspection of mooring chains in air and water

PROJECT PARTNERS Computerised Information Technology Ltd, Innovative Technology and Science Ltd, London South Bank University, TWI Ltd

BACKGROUND Failure of mooring chain systems for offshore structures

design, develop and demonstrate a robotic system to

in the oil and gas industry represents a critical threat to

travel on a mooring chain, inspecting critical areas of

the assets themselves, human life and the environment.

each link for fatigue cracking.

Considerable effort is made to ensure that the integrity of the chains is maintained to high standards, and a key

BENEFITS

part of this is increasing the precision and reliability of

The RIMCAW project will deliver a robotic system for

inspection methods.

mooring chains that will operate autonomously from the top side of a vessel to subsea. This will aid systematic

TWI has recently been involved in the inspection of a critical

inspection schemes for critical mooring systems, with

chain link on a floating production storage and offloading

the ability to rapidly deploy the systems on demand and,

(FPSO) vessel and developed a specific inspection tool for

importantly, maintain traceability on the condition of a

implementation by divers. This tool is able to detect critical

mooring system for lifetime monitoring for the emergence

fatigue cracking which has developed during service.

of critical fatigue cracking.

The RIMCAW project takes this further by aiming to: size and accurately map fatigue cracks within the body of a chain replace the diver with robotic systems to meet evolving health and safety regulations assess all the links of a mooring chain system whether subsea, at the splash zone or in the air.

OBJECTIVES This project aims to: develop a mechanised scanning trajectory and technique for critical areas of a mooring chain develop ultrasonic transducers and instruments for marine conditions

oil and gas

37

RISERSURE

Rapid integrity assessment of flexible risers for offshore oil and gas installations

PROJECT PARTNERS Innovative Technology and Science Ltd, WLB Ltd, MISTRAS Group, London South Bank University, TWI Ltd

BACKGROUND Flexible risers are used to carry oil and gas from subsea

RISERSURE seeks to address this by deploying an

oil wells to floating production storage and offloading

underwater digital x-ray detector and gamma source

(FPSO) vessels. They are expected to operate for the life

mounted on a computer controlled scanner.

of the oil field, which may be up to 30 years. Flexible risers are complex structures operating under severe conditions. The catastrophic failure of a subsea flexible riser could have disastrous environmental and economic consequences, and major oil companies consider it an ‘un-thinkable’ accident. The RiserSure project will bring a unique inspection product for assessing the condition of flexible risers to market.

Existing techniques for the inspection of flexible riser integrity are either visual inspection deployed by divers or remotely operated vehicles, automated systems using electromagnetic (eddy current) or ultrasonic techniques.

All of these methods have serious limitations. Visual inspections are slow and expensive, and can only detect gross damage after it has occurred. Eddy current techniques only provide information on the outermost region of the steel components. Ultrasound cannot penetrate the air filled annulus or other discontinuities in the structure.

Subsea radiography is recognised by many FPSO operators as the only inspection method to provide the type of information required to detect defects of concern to major oil companies operating FPSOs. Previous underwater radiography has typically been achieved with film and imaging plates. The disadvantage is that after each exposure the film or imaging plate must be returned to the surface for developing and processing.

This project has received funding from the European Union’s Horizon 2020 research and innovation programme under grant agreement No 730753.

OBJECTIVES The overall project objective is to bring RISERSURE to market, based on a novel radiographic sensor already developed by the consortium and certified to 100m depth rating (TRL6). This will be achieved by: developing the technology to deployment stage so that it can be demonstrated and proven on in-field subsea risers developing a manufacturing and commercial approach for the exploitation of RISERSURE deploying RISERSURE in European markets, and in due course globally, by expanding the customer and agent base in key geographical areas.

BENEFITS Benefits of the RISERSURE project are: reduced risk of accidents and environmental damage, and improved safety of personnel a

cost-effective

solution

enabling

an

intensive

continuous inspection regime for high risk areas no downtime or loss of operating revenue due to not having to remove the riser from service eight times faster than ultrasound and can be completed in days rather than weeks accommodates a wide range of riser diameters (200mm to 300mm) and is tolerant of fouling.

www.risersure.eu

oil and gas

38

SHALESAFE Development of a monitoring system embedded in a sonic drilling pipe for inspection of soil and aquifer contamination by shale gas and fracking chemicals

PROJECT PARTNERS Oikon Zelena Infrastruktura, HGL Dynamics Ltd, TWI Ltd, Teknologisk Institut (DTI), META Group S.R.L

BACKGROUND The fundamental way in which natural gas is produced

This will include:

from shale gas plays presents some different technical and

development of an automated, reliable and real-time

environmental challenges in comparison with conventional

in-situ aquifer monitoring system by integrating a suite

gas plays. The key issues relate to the management of the

of sensors to detect methane, organic compounds

hydraulic fracturing process.

(including VOCs and organic additives used in the hydraulic fracturing) and radioactive substances

The environmental impacts in shale gas extraction include

transfer of the project results into the marketplace by

underground water contamination, water abstraction,

designing an efficient and actionable business plan for

greenhouse gas emissions, and the effect on landscapes

the exploitation and commercialisation of ShaleSafe

and local communities.

technology.

The most imminent challenge for the oil and gas industry in

BENEFITS

Europe is to demonstrate and guarantee safe exploration

ShaleSafe technology allows contamination related to shale

and extraction to address the associated environmental

gas activities to be detected immediately and accurately.

concerns. There is a need, therefore, to develop and

It is a technology that meets the needs of the shale gas

implement technologies to continuously, reliably and

industry while addressing the need for environmental

cost effectively monitor the environmental risks of the

risk management. Furthermore, the Shalesafe project

exploration and production of shale gas.

contributes to the objectives and targets of the European Commission, which aims to support projects that undertake

OBJECTIVES

innovation from the demonstration stage through to

The ShaleSafe project aims to provide shale gas exploration

market uptake.

companies with the technology to meet the compulsory environmental impact assessment regulations during

www.shalesafe.com

sub-surface operations. This will be achieved through development and commercialisation of a system to monitor the quality of the underground water.

The main objective of the ShaleSafe project is to take the SOIMON system developed at TRL6 (as a result of an FP7 project, Grant Agreement 605065) to TRL9 in the context of the shale gas industry.

This project has received funding from the European Union’s Horizon 2020 research and innovation programme under grant agreement No 691527.

oil and gas

39

TANKROB

In-service intrusive non-destructive testing of above ground and underground petrochemical storage tank floors and walls to detect corrosion

PROJECT PARTNERS TWI Ltd, Innovative Technology and Science Ltd, London South Bank University, Technic-Control Sp. z o.o., Integrity NDT Muhendislik SAN.TIC.LTD.ST

BACKGROUND Storage tanks constitute a crucial piece of infrastructure

Specific technical objectives include:

for the modern economy. Crude oil and derivative product

optimise mechanical design and hardware while

storage tanks are prone to accidents, accounting for over

maintaining the size of 300mm

80% of storage tank failures. Cracks or raptures on the

suitable for inspection for 90% of storage tanks

tank structure are estimated to be the origin of 20% of the

obtain ATEX certification to be able to carry out in-service inspections.

accidents.

Timely detection of corrosion induced defects is integral

BENEFITS

in ensuring safe storage tank operation. Unfortunately, a

The TankRob system provides the end-user with the

typical inspection procedure requires human operators

following key benefits:

to enter the tank after it has been properly shut-down,

significant inspection cost reductions through negating

cleaned and vented. Despite the safety measures taken

the need to empty and vent the tank

during these processes accidents still happen, and as result

100% inspection coverage providing operators with

there is a strong incentive to keep humans away from such

detailed structural integrity information, thereby

dangerous environments.

increasing tank safety and reducing the risk of tank failures.

Eliminating the need for human entry into tanks during inspection, significantly reduces the downtime-related

www.tankrob.eu

costs for the end-user and eliminates threats to human health. This is made feasible by carrying out the inspection process using a robotic platform that will carry the necessary instrumentation and be able to scan the tank surfaces for defect and corrosion detection.

OBJECTIVES The ambition of this project is to redefine non-destructive testing (NDT) inspection of storage tanks with a cuttingedge NDT inspection robot and provide a commercially available solution to industry.

This project has received funding from the European Union’s Horizon 2020 research and innovation programme under grant agreement No 701007.

oil and gas

40

BLADESAVE

Risk based technology for blade structural assessment

PROJECT PARTNERS Renewable Advice Ltd, Smart Fibres Ltd, ASSIST Software SRL, EWT B.V.

BACKGROUND

OBJECTIVES

Reliability of wind turbines is a pre-requisite for ensuring

validate the acoustic emission functionality of a fibre

the healthy growth of the wind energy industry and intrinsically linked to this is the integrity of wind turbine blades.

optic SHM system create a fusion between a fibre optic SHM system providing

multi-sensing

capability;

temperature,

strain, vibration and acoustic emission; and blade The following factors highlight the need for a new type

management software. This will link the data from

of condition monitoring system capable of detecting the

inspection and maintenance to the SHM data, offering

condition of, and predicting potential failure in, megawatt-

a comprehensive solution for wind turbine blade

class (2MW) wind turbine blades:

monitoring, repair and management.

most 2MW wind turbines are designed with inbuilt condition monitoring systems based on conventional sensors which are proven to be adversely affected

BENEFITS BLADESAVE will reduce the risks related to blade failure. It

by harsh environments, namely static electricity and

will contribute to the growth and competitiveness of wind

lightening

energy in the world’s energy markets by commercialising

the industry currently relies on conventional inspection

an innovative solution that will:

technologies such as visual inspection, ultrasonic

provide a competitive, comprehensive and reliable

and shearography therefore, it is reluctant to install

blade SHM system, linking results to cloud-based

structural health monitoring (SHM) systems for wind

software incorporating risk based inspection data

turbines specifically as this would require alternative

analysis to minimise inspection costs

disruptive technologies which are more expensive than sensors the European wind turbine standard EN 50308 (Wind turbines – safety requirements for design, operation and maintenance) is currently being updated ISO standards for wind turbine condition monitoring are established for wind turbine machinery, but there are no specific standards for wind turbine blades life-extension programmes require the installation of condition monitoring systems or frequent inspection

meet stricter regulations which are to be imposed throughout the EU (which will comply with the amended EN 50308 standard) offer a truly blade-specific SHM system for wind turbines, thereby supporting the call to amend current ISO standards for the diagnosis of wind turbines defects provide operators with more confidence when formulation life extension strategies for older wind turbines.

of critical components.

www.bladesave.eu This project has received funding from the European Union’s Horizon 2020 research and innovation programme under grant agreement No 760353.

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41

CREEPUT An ultrasonic non-destructive testing system for detection and quantification of early-stage subsurface creep damage in the thermal power generation industry

PROJECT PARTNERS The Institute for Nuclear Technology, The Testing, Research & Standards Centre, Applied Inspection Ltd, Kaunas University of Technology, TWI Ltd

BACKGROUND Creep

is

the

time-dependent,

OBJECTIVES assisted

further develop the prototype system developed by

deformation of a component operating under stress. It is

thermally

the earlier CreepTest project and provide a commercial

often a key factor not only in the design of components

product for the market

used in the power generation industry, particularly in fossil

develop an industrially viable tool for inspecting

fuel and nuclear plant, but also in the assessment of their

existing pipework to detect subsurface damage due to

remaining life. Pressurised components such as boiler

creep. It will be validated for detection of this damage

tubing, headers and steam piping in fossil-fuel power plants operate at temperatures of 538ºC up to about 570ºC

mechanism in its early stages establish marketing mechanisms and after-sales

and this is conducive to causing creep damage over the

infrastructure

operating life of the component. Although creep in this

customers.

to

support

the

product

and

its

material has been known about for some time, it has only become a pressing issue over the past few years due to:

BENEFITS Early detection of creep damage allows operators to

failure occurring at a much earlier stage than

better plan for effective maintenance of their power plants

previously anticipated, i.e., in some cases about half

by organising for suitable materials, repair schedules

to three quarters the number of years that were first

and service providers in a timely fashion, as opposed

anticipated; and

to implementing a repair procedure when the plant is

large fossil fuelled power plants are now being

shut down by an unforeseen failure event, which could

expected to work beyond their original design life

be catastrophic in terms of human lives, economic and

(plant life extension programmes) and therefore creep

environmental damage.

damage is becoming more likely during the extension

www.creeput.com

period.

Hence the early detection of creep damage in components which are in-service, stands to aid in better management of the power plant and to prevent often catastrophic failures which can lead to severely adverse human, environmental and economic consequences for society.

This project has received funding from the European Union’s Horizon 2020 research and innovation programme under grant agreement No 760232.

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42

HYMET

Hybrid metrology for thin films in energy applications

PROJECT PARTNERS TWI Ltd, NPL Management Ltd, Bundesanstalt fuer Materialforschung und –pruefung, Commissariat à l’énergie atomique et aux énergies alternatives, Cesky Metrologicky Institut, Physikalisch-Technische Bundesanstalt, VSL B.V., Aalto-korkeakoulusäätiö sr, Centre for Process Innovation Ltd, Helmholtz-Zentrum Berlin für Materialien und Energie GmbH, University of Surrey, Technische Universität Berlin, Accurion GmbH, Eidgenoessische Materialpruefungs- und Forschungsanstalt, Flisom AG, Horiba France S.A.S., Eidgenössisches Institut für Metrologie METAS, Oxford Photovoltaics Ltd

BACKGROUND

BENEFITS

The EU’s 2050 targets for energy efficiency and renewable

The project will delvier the following benefits:

energy generation are stimulating the fast growth of a

knowledge sharing across industry by the provision

multibillion Euro, multi-technology industry based on

of three case studies covering stability of solar cells,

innovation. Two key challenges in the development of new

impact of porosity and chemical composition on

technologies for energy generation, distribution and

electrocatalytic activity and quality assessment of

storage/conversion are ensuring long-term durability at

thin film power electronics. These will demonstrate

the required performance level and facilitating a short

the general applicability of the advanced metrology

time-to-market for innovative products.

developed; facilitate uptake of results by equipment manufacturers, device manufacturers and end-users;

This project will develop a cross-cutting, European hybrid metrology capability for the characterisation of thin film

and generate demonstrable impact within the project lifetime

performance and durability in energy applications. It

accelerated time to market of more cost-efficient

will advance experimental and mathematical methods,

technologies. This will be enabled by the development

combining datasets from multiple measurements in order

of failure mechanism identification and production

to deliver new or better results than the sum of individual methods.

quality (both in process and post process) generation of new calibration facilities, new reference samples and innovative new measurement methods to support the EU energy community

OBJECTIVES develop hybrid experimental methods for improved analysis of complex energy thin film material properties and study their impact on the performance of energy products formulate data analysis, data fusion and mathematical models to implement the hybrid metrology methods develop measurement methods for 2D and 3D chemical,

structural,

optical

and

optoelectronic

properties of nano-structured thin film energy materials

free access to instrumentation, secondments and training to enable uptake of the technology by industry instrument manufacturers will be able to demonstrate customer value based on validation of experimental methods and standardisation activities that will strengthen the reputation and acceptance of the new measurement technologies.

www.hymet.ptb.eu

and devices, capable of identifying inhomogeneities at multiple scales.

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43

IFROG

Amphibious robot for inspection and predictive maintenance of offshore wind assets

PROJECT PARTNERS Innovative Technology and Science Ltd, Brunel University London, The Underwater Centre (Fort William) Ltd, TWI Ltd

BACKGROUND Offshore wind energy is increasingly preferred by societies

develop a risk based inspection (RBI) and preventative

because of its reduction in CO2 emissions. However,

maintenance system which also incorporates total

it still needs enhanced inspection and maintenance

quality inspection, fitness-for-service and optimum

technologies to ensure that green energy installations

repair technologies

remain operational over their full working lives, as well

enhance operational expenditure management as

as to reduce the operational expenditure associated with

a result of applying the above techniques which are

them sufficiently enough to make offshore wind energy

based on BS 7910 and API 579 for structural integrity

competitive against conventional energy sources such as

and API 580 for RBI provide substantial economical optimums through

oil and gas, coal and nuclear.

input/output cross relations. Financial cost opportunity, IFROG proposes to combine enabling capabilities in

interest coverage, operator’s financial gearing and

electronics, sensors and photonics to produce a mobile

weighted average cost of capital will facilitate the

robotic inspection system capable of delivering advanced

undertaking of new investment opportunities.

marinised

systems

for

inspection

and

predictive

maintenance of offshore wind turbine foundations, both above and below the waterline, down to 60m water depth.

Consequently, the early detection of damage in components which are in-service, stands to aid in better management of wind power plants and to prevent often catastrophic failures such as wind turbine collapse which can lead to severely adverse human, environmental and economic consequences for society.

BENEFITS Early detection of damage to offshore wind turbine foundations with IFROG will enable operators to better plan for effective maintenance of their wind power plants including the selection of suitable materials, formulation of repair schedules and the appointment of service providers in a timely fashion. As a result, the need to implement a repair procedure when the turbine is shut down by an unforeseen failure event will be mitigated.

OBJECTIVES

In addition, with the appropriate implementation, the

The IFROG project aims to:

IFROG system will become a project management tool that

further develop the earlier prototype system to provide

can accelerate enhanced decision making at the financial

a commercial product for the market that will provide

level.

remote underwater inspection, non-destructive testing analysis and an efficient management decision tool

power

44

INTEL-LINE

System for improved and efficient power line cable management

PROJECT PARTNERS NESNE Elektronik Ltd, Montage Cablage Installation, Plant Integrity Ltd, Brunel University London

BACKGROUND

BENEFITS

Across Europe there are hundreds of thousands of

The Intel-Line system will have numerous benefits:

kilometres

a long inspection range (possible defect detection from

of

overhead

transmission

lines

which,

throughout their service lifetime, are continuously exposed to various operational stresses (voltage and tension) and environmental factors (wind-induced vibrations, icing and lightning strikes). This causes wear and breakdown of these overhead cables.

pylon to pylon) capable of operating in a wide range of temperatures and most climates energy harvesting to provide a continuous power supply wireless data transmission for remote monitoring and

Current

inspection

techniques

are

expensive,

time

consuming and hazardous, but regular controls are required so there is a strong need for a safe maintenance

defect warnings a cost effective solution compared with current methods

and inspection technique.

continuous

OBJECTIVES

simple to install on existing or new cables

The Intel-Line project aims to develop an automatic system

suitable for the majority of power cables

for the inspection of power line cables, utilising ultrasonic

immediate data collection and analysis of results

guided waves and incorporating wireless transmission and

maintenance/repair teams can be directed to the exact

monitoring

to

prevent

unscheduled

maintenance due to unexpected cable failure

energy harvesting. The system should also provide a ‘fit

location of faults.

and forget’ condition monitoring option to work as a failure alarm system.

www.intel-line.eu

This project has received funding from the European Union’s Horizon 2020 research and innovation programme under grant agreement No 720402.

power

45

NVISA

High speed inspection of nuclear assets using virtual source aperture techniques and advanced ultrasonic equipment

PROJECT PARTNERS Peak NDT, TWI Ltd, EDF Energy

BACKGROUND The overall goal of the NVISA project is to make significant

cycles necessary to produce an image while maintaining

improvements to the ultrasonic testing (UT) techniques that

the image quality and raw data benefits of FMC, with

are currently used for the inspection of nuclear assets. This

total focusing method algorithms

will be achieved by utilising the latest UT developments,

benchmarking of results and validation of outputs

such as fully focused imagery and improved defect

against radiographs to demonstrate the system’s

recognition and sizing, while simultaneously maintaining

benefits.

high inspection speeds.

Virtual source aperture (VSA) is a new UT inspection technique which uses a combination of conventional phased array (PA) transmit focal law and full matrix capture (FMC) receive focal law. This hybrid approach is designed to provide a superior focus capability similar to that of FMC as well as an inspection speed that is many times faster than FMC, conventional UT and PA.

OBJECTIVES The project’s aim is to increase the speed, reliability and sizing accuracy of the nuclear asset inspection process.

Therefore, a flexible system will be developed which offers the potential to both improve productivity and help prevent unplanned nuclear plant shutdowns. Three areas

BENEFITS Benefits include: highly detailed, real-time fault analysis of complex geometries with an estimated 0.5 hour saving per component under inspection improved asset reliability for the UK civil nuclear industry leading to cost reductions detection and sizing of flaws that is more accurate and reliable relative to conventional UT techniques for a wide range of applications an easier to use inspection technique that consequently requires a lower skill-level of operator and reduces NDT qualification requirements rapid inspection with minimal ultrasonic setup.

of development will be addressed: re-architecture of the PeakNDT MicroPulse hardware, upgrading from 1GB to 10GB Ethernet to increase the hardware data transfer speed to 1.25GBps development and optimisation of the system for nuclear scenarios to offer rapid scan speeds – this will be achieved by reducing the number of transmission

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46

POLYTEST Ultrasonic phased array non-destructive testing and inservice inspection system for high integrity polyethylene pipe welds with automated analysis software

PROJECT PARTNERS TWI Ltd, M2M, Tecnitest Ingenieros SL, Palad H.Y. Industries Ltd

BACKGROUND

OBJECTIVES

There is an estimated 11.5 billion metres of plastic pipe

The objectives of the PolyTest project are to commercialise

installed globally carrying essential gases and fluids. With

the PolyTest inspection system, including robust scanning

plastic piping being seen as an attractive solution for

and automated data analysis, equipment manuals and

replacement of existing steel installations, there is a growing

training courses.

need for a reliable non-destructive testing (NDT) method to ensure the integrity of the joints. The welded joints are the weakest part of a plastic pipe fabrication because of the higher probability of introducing unwanted defects. In the EU, plastic pipes are used in the energy, utility (water and gas) and mining industries. These industries are asking for an NDT inspection method that is validated to industry standards.

BENEFITS The PolyTest system has the following benefits: modular and flexible – can inspect a wide range of sizes (90-800mm outer diameter and 8-65mm wall thickness) and types (electrofusion and butt fusion joints) robust – can be used with minimal training in the trench (meet IP67 and one week of data acquisition training)

The PolyTest system is a field inspection system for volumetric NDT of electrofusion and butt fusion joints in polyethylene (PE) pipes. It utilises Phased Array Ultrasonic Testing (PAUT) technology and novel hardware solutions to meet the demanding in-situ inspection of plastic pipe joints.

Currently, the PolyTest system requires a trained and experienced operator for the inspection and the analysis

green/red light decision tool – will give immediate decision on joint integrity (minimises analysis time by more than ten times) training course for data acquisition operator – enables specific training for data acquisition only, which minimises time and cost.

www.polytestsystem.com

of the data.

This project has received funding from the European Union’s Horizon 2020 research and innovation programme under grant agreement No 701194.

power

47

REDRESS

Development of radiation resilient sensors for nuclear power plants

PROJECT PARTNERS Precision Acoustics Ltd, Ionix Advanced, Technologies Ltd, TWI Ltd, University of Sheffield

BACKGROUND

OBJECTIVES

If ultrasonic testing (UT) close to the core of nuclear reactors

The project objectives are to:

is to be undertaken, then radiation resilient ultrasonic

assess piezo-ceramic and piezo polymer materials

sensors must be developed that can withstand expected

which have the potential for use at high temperatures

temperatures of up to 350°C with gamma and neutron

and radiation doses

radiation levels up to 500MGy. Currently, no commercially available UT sensors are be able to survive these operating conditions without sudden and catastrophic failure.

critically review current UT sensor designs and identify areas for improvement determine suitable high radiation facilities for the testing of radiation resilient UT sensors

The reDRESS project seeks to address this issue by developing novel, high temperature radiation resilient, piezo-ceramic UT sensors with a defined operation period.

The work will be complimented by defining the maximum operating window, temperature and radiation dose of

model prototype, radiation resilient probes and develop a suitable manufacturing route test the prototype, radiation resilient UT sensors at the identified research facility investigate cabling options to maximise signal integrity.

currently available piezo-polymer materials. Construction of UT sensors will be analysed and then steps taken to modify the design to extend their operating window. This may involve the use of different technologies such as thermal barrier coating.

BENEFITS Benefits include: increased safety of nuclear power plants through continuous condition monitoring at strategic locations reduced plant shutdown times for routine maintenance

An alternative technology to piezo-electric sensors is

resulting in lowering operating costs and the capacity

fibre optic sensors, which may be suited to high radiation

to sustain power output over longer periods

conditions but are currently unfit for high temperature applications. The project will investigate options for enhancing their thermal operating window. Equally important to the development of a high temperature sensor

better plant integrity management based on real time data rather than modelling and projected shutdowns improved perceptions of plant safety in the public sector as a result of real time monitoring.

is the ability to transmit and receive signals through a cable. Therefore, cabling options will be investigated and developed to ensure signal integrity under high temperature conditions.

power

48

RISKMAN

An online, risk driven, condition monitoring, predictive maintenance management and design upscaling tool for wave energy devices

PROJECT PARTNERS Albatern Ltd, TWI Ltd, Brunel University London

BACKGROUND A wave energy convertor (WEC) uses marine energy

mathematical models in order to determine a

conversion technology to generate electricity from the

probability distribution function for each component,

hydrokinetic energy in waves. RISKMAN is a maintenance

providing the risk of failure over any given period.

management tool which will be developed as an enabling technology for reducing the levelised cost of electricity

OBJECTIVES

(LCOE) of WEC devices.

Development of a robust and cost-effective system that uses an innovative combination of condition monitoring

LCOE is the level of sales revenue per kilowatt-hour (kWh)

sensors and mathematical models to predict the remaining

of grid-tied electricity production needed for an electricity-

life of WEC devices and reduce the associated levelised

generating venture to break even, covering all capital and

cost of electricity. Critical components of wave energy

operating expenses, and satisfying a minimum rate of

will be monitored in real time using various sensors, and

return for investors over the project’s lifetime. As such,

a risk driven, predictive maintenance system combining

RISKMAN aims to make WECs a more competitive form of

mathematical models and big data analysis will be included.

renewable energy production.

Using project partner Albatern’s ‘WaveNet’ wave energy device, that captures energy from ocean waves and converts it into sustainable low-carbon electricity, RISKMAN aims to provide a step reduction in the capital and operational expenditure (CAPEX/OPEX) associated with it by increasing its availability to produce electricity through: condition monitoring of critical components of the WEC arrays by a suite of embedded complementary sensors transmitting sensor output (electrical) signals onshore in real time through electro-optical conversion and

BENEFITS RISKMAN will result in: optimisation of predictive maintenance by using a risk-driven model better prognosis of the remaining useful life of WECs improved security of power supply a reduction in the levelised cost of electricity a lessening of the CAPEX/OPEX associated with WECs as a result of the application of condition monitoring WECs being able to compete better with other renewable energy systems.

fibre optic cables for cloud computing construction of a risk driven, predictive maintenance system which will combine the database with

power

49

RRUS

Radiation resilient sensors for nuclear waste monitoring

PROJECT PARTNERS Innovative Science and Technology Ltd, Precision Acoustics Ltd, TWI Ltd, University of Sheffield

BACKGROUND Failure of an intermediate level nuclear waste (ILW)

their suitability for this application and the possible design

container or a low level nuclear waste (LLW) container could

changes that will increase their radiation resilience.

be catastrophic, endangering human life and destroying the environment.

OBJECTIVES

Computer modelling of the radiation damage to ILW and LLW containers can be performed but is difficult so, ultimately, only physical monitoring can demonstrate their integrity. Currently, ILW and LLW container assessments are done by hand using ultrasonic techniques. During assessment, the operator is exposed to gamma radiation and this contributes to their maximum annual work exposure of 10mSv. The maximum contact dose during handling of LLW and ILW containers is 10mSv/hr, and 2mSv/hr during long-term storage. As a result, radiation workers could be exposed to their annual radiation dose within one hour whilst inspecting such storage containers.

Commercially

available

ultrasonic

sensors

generally

fail after relatively low, accumulative gamma radiation doses and if these sensors are remotely deployed, their replacement is time consuming and expensive. Therefore, the goal is to develop construction techniques that will enable the manufacture of sensors which are capable of withstanding high radiation doses delivered over an extended time. This will ensure that sensors are compatible with the requirements for longer term monitoring of LLW and ILW material at ambient temperatures.

The RRUS project will investigate and assess commercial,

The objectives are to: identify

the

most

suitable

radiation

resilient

piezo-electric material for nuclear waste management applications development a suitable bonding technique for ultrasonic sensor manufacture manufacture and test a prototype radiation resilient ultrasonic sensor review current state-of-the-art COTS fibre optic technologies investigate integrity

cabling

to

and

options from

to

the

maximise ultrasonic

signal sensor.

BENEFITS The project aims to deliver the following benefits: a

long-term,

non-invasive

solution

for

in-situ

monitoring of ILW and LLW containers increased health and safety by lessening human interaction with ILW and LLW, leading to lower operating costs lower overhead costs by reducing the number of replacement sensors required provision of evidence from sensors that can be used to improve integrity management strategies and support the viability of long-term nuclear waste storage.

off the shelf (COTS), fibre optic technologies to determine

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50

SHEARIOS

Wind turbine shearography robotic inspection on-blade system

PROJECT PARTNERS Renewable Technical Services Ltd, Visatec Gesellschaft fur Visuelle Inspecktionsanlagen GmbH, EDF Energy Renewables Ltd, EDF Energy R&D UK Centre Ltd, Ainoochaou Pliroforiki AE (IKH), Acondicionamiento Tarrasense Associacion (LEITAT), TWI Ltd

BACKGROUND Wind energy is a rapidly expanding sector which has seen

The deployment platform will also act as the power and

an average growth of over 10% per annum since 2001.

data link. The entire system will be safely controlled from

Global investment in 2016 was €268bn, of which the EU

either the ground when inspecting on-shore wind farms or

comprised €43bn, and newly installed capacity was 54

from a vessel for off-shore wind farms.

gigawatt (GW) of power, of which the EU accounted for 12.5 GW. Overall, there are currently over 300,000 active wind turbines around the world.

Wind turbines need regular inspection and maintenance in order for wind farm operators to maximise the revenue arising from their wind energy assets. However, most existing non-destructive testing techniques are not suitable for wind turbine inspection on-site. For example, ultrasonic techniques need proper coupling and work only for homogeneous materials. Shearography has been widely used by industry for composite materials inspection, but these application are restricted to on-the-ground usage where the objects to be inspected are under stable conditions.

BENEFITS The benefits arising from the application of the SheaRIOS system are: identification of surface and sub-service defects on the wind turbine provision of advance warning of manufacturing, service or fatigue defects likely to cause catastrophic structural failure the ability to undertake in-situ inspection of wind energy assets with no need to remove the wind turbine’s blades provision of the means to avoid the potentially hazardous activity of operatives undertaking inspection work on wind turbines at height.

OBJECTIVES

www.shearios.eu

The SheaRIOS project aims to provide a solution for in-situ wind turbine inspection by integrating shearography with robotics.

A deployment platform will ascend along the wind turbine’s tower and position a compact climbing robot, carrying a shearography kit, which will roam across the wind turbine’s surface to conduct an inspection.

This project has received funding from the European Union’s Horizon 2020 research and innovation programme under grant agreement No 780662.

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51

S4CE

Science for clean energy

PROJECT PARTNERS University College London, Haelixa LLC, Nis Ad Novi Sad, St. Galler Stadtwerke, Imperial College London, Mirico Ltd, Geothermal Engineering Ltd, Orkuveita Reykjavikkur SF, TWI Ltd, GeoThermal Engineering GmbH, University Claude Bernard Lyon 1, Association Pour la Recherche et le Developpement des Methodes et Processus Industriels, Analisi e Monitoraggio del Rischio Ambientale Scarl, Eidgenoessische Technische Hochschule Zuerich, Institut De Physique Du Globe De Paris, Instytut Geofizyki Polskiej Akademii Nauk, Université de Bretagne Occidentale, Ita-Suomen Yliopisto, Scientific Computing & Modelling N.V., Geomecon GmbH, Haskoli Islands

BACKGROUND Geo-energy operations such as carbon capture and storage, enhanced geothermal systems and enhanced oil recovery can have an impact on the subsurface. Although

thermogenic methane; fingerprint fracturing fluids; and identify fluid flow in the subsurface developing

robust

mitigation

strategies

based

different

on interpretation of the data gathered during

technologies, they all deal with deep heterogeneous

the project. The data will be integrated into a life

geological formations and all require the injection of

cycle assessment and multi risk framework by

potentially hazardous fluids at relatively high pressures.

developing software that estimates the lifetime

This can lead to potential risks which include induced micro-

environmental impacts of each geo-energy operation.

these

operations

constitute

fundamentally

seismicity, emissions of stray gases, faulty well casings and underground water contamination.

BENEFITS The S4CE project will provide:

OBJECTIVES The overall goal for S4CE is to develop, test and implement technologies needed for successfully detecting, quantifying and mitigating the risks associated with geo-energy operations in a sustainable manner. This will be achieved by: developing synergistic experiments and models and applying them to overcome current disparities in: the detection of failure of casings; the quantification of fluid transport pathways in rock formations and cement based materials; the mechanisms of CO2 fixation; and the extent of microbial interactions with host rocks deploying cutting-edge instruments which will be tested at laboratory and field sites for their ability to: detect stray gases; distinguish between biogenic and

This project has received funding from the European Union’s Horizon 2020 research and innovation programme under grant agreement No 764810.

policy makers with a tool kit for undertaking sciencebased independent assessments of the environmental footprint

and

risks

associated

with

geo-energy

operations as well as suggestions for best practice procedures a better understanding of subsurface operations as a result of monitoring and validation of technologies at four field sites across Europe hands-on

research

experience

in

geo-energy

operations to European students through expansion of the new Master’s program ‘Global Management of Natural Resources’ at UCL as well as multi-disciplinary training opportunities for post-doctoral researchers and PhD students involved in the project.

www.science4cleanenergy.eu

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52

WINDTWIN

Digital twin of wind turbines for real-time continuous monitoring and simulations

PROJECT PARTNERS ESI UK Ltd, AGILITY3 Ltd, DashBoard Ltd, TWI Ltd, Brunel University London

BACKGROUND With an estimated 216,000 wind turbines in operation

Condition monitoring sensors will collect and process data

globally, there are approximately 38,000 incidents of

that, when combined with algorithms, high performance

turbine failure reported annually. Research has shown that

cloud computing, system faults and degradation modelling,

preventative maintenance costs 25% less than reactive

data analytics and 3D visualisation, will result in a close-to-

maintenance and predictive maintenance costs 47% less.

live representation of the wind turbine showing real time condition and performance.

Furthermore, there is potential to increase wind turbine reliability to 99.5%. This can be achieved by developing new

Application of the WindTwin platform will include:

data analytic techniques, processing and visualisation for

design using data and knowledge based tools and

effective maintenance and operations. WindTwin offers an

simulated testing of wind turbines before manufacture

innovative digital platform for preventive and predictive

continuous predictive and preventive maintenance

maintenance. Intelligent data processing of the wind

and condition monitoring of wind turbine assets

turbine’s behaviour and condition will be visualised in a

different power setting operation scenarios analysis,

digital twin, and will combine nominal and degraded multi-

and associated wear and tear at different power

domain models with real-time operational data collected

outputs.

from sensors placed on the physical wind turbine.

BENEFITS OBJECTIVES

The digital twin models will allow wind turbine operators

The WindTwin project aims to revolutionise the monitoring

to better diagnose performance variations, anticipate

and maintenance of wind turbines, both onshore and

degradation and failures and deploy condition-based

offshore, by developing an innovative digital platform that

maintenance instead of schedule-based strategies. These

will virtualise the wind turbine’s behaviour and operation

advancements will reduce downtime and inspection

with a digital twin. These virtual models, or twins, will

and maintenance costs, enabling operators to virtually

combine the mathematical models describing the physics

assess maintenance upgrades before deployment and to

of the turbine’s operation with sensor data collected

better control wind turbine settings in order to optimise

and processed from physical assets during real world

performance and energy output.

operations.

power

53

AUTOSCAN

Rail inspection by autonomous systems

PROJECT PARTNERS I-Moss NV, TWI Ltd, Automatitzacio De Processos i Mediambent S.L., (Promaut), Nomad Tech, Lda, University of Birmingham

BACKGROUND There are more than 200,000km of rail track in Europe,

Key project objectives include:

suffering more than 4,000 broken rails each year. Rail

enhance

an

existing,

autonomous

lightweight

breaks are a significant contributing factor in derailments

prototype inspection cart capable of identifying track

which can lead to catastrophic failures. Maintenance costs

faults through a rapid detection system

associated with managing rail currently exceed €2bn.

exploit a rapid non-contact ultrasound NDT technology

These costs are set to increase in line with forecasted,

to

rapid increases in train traffic, train speeds and loads

complemented by robotic raster scanning for detailed

carried. Supporting these increases generates a drive to

defect characterisation

optimise maintenance regimes and increase reliability of rail infrastructure.

detect

defects

during

large

area

scanning

demonstrate the capability to operate the cart autonomously and remotely provide a commercially available solution to the

Track maintenance is underpinned by routine non-

industry.

destructive inspection. This process can utilise dedicated inspection trains which provide coarse measurements of

BENEFITS

the rail. Handheld conventional inspection devices are

The primary benefits for users resulting from the

manually deployed by operators to relocate and more

commercialisation of AutoScan are:

accurately measure defects detected by the inspection

improved levels of safety due to increased probability

train. AutoScan is a Horizon 2020 funded project seeking to improve the efficiency and effectiveness of inspection through the provision of an autonomous inspection cart.

This cart would undertake course and accurate inspection under self-powered and autonomous control.

of detection of defects a significant targeted reduction in track maintenance costs increased availability of network due to increased reliability and reduced maintenance downtime extended asset life time and reduced life cycle costs

OBJECTIVES The objective of AutoScan is to increase the efficiency of track defect inspection, through a more effective inspection solution that is rapidly deployable and autonomous in its

reduced requirement for track access for personnel leading to increased safety.

www.autoscanproject.eu

operations.

This project has received funding from the European Union’s Horizon 2020 research and innovation programme under grant agreement No 720506.

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54

MONAXLE

Live monitoring of train axles with autonomous wireless systems

PROJECT PARTNERS Perpetuum Ltd, TWI Ltd, University of Southampton

BACKGROUND UK passenger fleets are expected to double over the next

The current methods of inspection, and their frequency,

25 years (5th Long Term Passenger Rolling Stock Strategy

leave uncertainty about both fault detection probability and

for the Rail Industry, RDG March 2017). Fewer personnel

whether the frequency is adequate. Therefore, this project

are available to maintain these trains, so there is a need

intends to show that very significant cost reductions, as

to eliminate unnecessary inspection and maintenance

well as more certainty on safety, could be achieved by train

regimes. Currently trains are retrieved from service every

operators.

30,000km so that axles can be stripped and inspected. This is done using non-destructive-testing (NDT) techniques,

BENEFITS

but such processes are labour intensive so it would be

The development of a continuous, live monitoring system

beneficial to train operators if inspection between major

of axles with low-cost, self-powered wireless units that are

overhauls could be removed.

easy to install, replacing expensive and disruptive NDT methods in maintenance sheds, and eliminating inspection

The proposed solution would use on-board condition

between major overhauls. Additional benefits include:

monitoring, enabling predictive maintenance and leading

economic: the systems developed within the project

to reduced maintenance costs and improved, in-service

will lead to improved train availability with cost savings

train availability.

Train axle inspections are currently

on labour and fleet component changes

required annually on every axle because any failure can

social impact: a reduction in road freight, and the

lead to a train derailment and significant damage. Axle

potential for lower public transport fares, due to

failures have caused major loss of life, the consequences

increased train reliability, benefitting both train

of which have led to an increase in both NDT and manual inspections that are expensive and disruptive to efficient rolling stock maintenance.

operators and passenger users government priorities: the wireless systems will lead to higher reliability, greater track capacity and reduced costs, which are all in line with Government policy for

OBJECTIVES

the rail industry.

This project will research the feasibility of detecting axle cracks on trains with on-board self-powered monitoring.

The vision is to use continuous live monitoring of axles with low-cost, self-powered, wireless systems that are easy to install and will replace expensive and disruptive NDT methods in maintenance sheds.

rail

55

OPTRAIL

Multi-sensor condition monitoring for predictive maintenance of rail infrastructure using optical fibre sensor

PROJECT PARTNERS RCM2 Ltd, TWI Ltd, Brunel University London, Yeltech Ltd, Surrey Advanced Control Ltd

BACKGROUND Maintenance of rail infrastructure is a major cost to the

fibre-optic sensors that will link to the internet of

railway industry, costing over £1billion p.a. in the UK and

things (IoT) infrastructure, providing fast, real time

representing 18% of Network Rail’s expenditure. It is also

monitoring and generating comprehensive data on the

a major source of network disruption caused by both

condition of extended lengths of rail track; up to 20km

planned and unplanned maintenance operations. Railway usage and demand for services is increasing rapidly, placing more traffic on the rails and increasing the requirement for

use

of

mathematical

models

and

cloud-based

computing resources to develop predictive modelling and maintenance optimisation tools development of advanced machine learning algorithms

maintenance.

for data analysis; pattern recognition and anomaly The focus of this project is to apply novel, fibre-optic sensor

detection. These will be used within the expert

technology, and combine it with advanced communications,

system to provide decision support, prognostics and

artificial intelligence (AI) and risk-based inspection tools, to

automated maintenance optimisation to operational

provide a unique system that will monitor rail condition

and maintenance staff.

and provide data to inform maintenance planning.

BENEFITS This project applies state-of-the-art technologies to provide

OBJECTIVES The OptRail project aims to deliver a step change in the quality and convenience of rail asset management by enabling the health of assets to be monitored in real time: using smart, built-in sensors or novel technology; developing risk based predictive models; and applying AIsupported decision making tools.

world-class, predictive, risk-based maintenance strategies to the railway industry that will deliver a range of benefits including: 25-35% reduction in maintenance costs such as track renewal 70%+ reduction in the number of service failures such as broken rails which are the main cause of derailment 35-45% reduction in down time following failure

System specification includes: use of fibre-optic sensors bonded to rail tracks to monitor rail stress, train speed, direction, axle spacing and wheel condition.

This technology is

20%+ increase in workforce productivity fewer unplanned, reactive interventions leading to enhanced workforce safety.

novel in being used for rail monitoring and could also be applied to other elements of infrastructure such

as

the

track

bed,

tunnels

and

bridges

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56

TRACKBOT

Automatic full weld inspection system for high speed rail

PROJECT PARTNERS Shanghai Oriental Marine Engineering Technology Co. Ltd, Innovative Technology and Science Ltd, TWI Ltd

BACKGROUND Our railways are vital for the smooth operation of internal

The resulting TrackBot system will lead to a reduction

and trans border markets, and for the development of a

in the number of skilled personnel required to deliver

sustainable and clean transport system. Therefore, building

efficient inspection and rail networks. In consequence, the

modern, competitive railway networks is becoming a top

consortium partners will generate a combined revenue of

priority for the UK, China and the rest of the world.

£22.6million and deliver a significant, >5x fold return on investment.

To build and maintain safe, high speed networks brings its own challenges. According to Scientific American, most rail accidents are due to broken rails and welds with failure generally initiating from defects in the weld such as fatigue cracks, dead zones and flat spots.

Despite these worrying statistics, some countries such as China still rely mainly on manual weld inspection which is a slow, inconsistent and inadequate approach that is prone to human error. For detection of defects in rail, the most common methods are ultrasonic and magnetic induction

BENEFITS TrackBot aims to deliver the following benefits: improved safety and reliability of high speed rail an electronic record of inspection results detection of flaws that current inspection methods cannot find provision of a database for inspection and asset management automatic acquisition and storage of data.

but these are slow and lack the ability to inspect the full volume of the weld. Phased array ultrasonic testing (PAUT) is an advanced NDT technique that has the capability to detect any faults within a weld.

OBJECTIVES TrackBot aims to address the need for the development of an automated, universal weld inspection system that can rapidly detect all types of flaws in the full weld volume. It will be based upon proprietary PAUT technology as well as systems developed by each of the project consortium partners.

rail

57

TRAINNDT

A novel non-destructive testing training system based on wireless probe tracking

PROJECT PARTNERS Uniper Technologies Ltd, Innovative Technology and Science Ltd, TWI Ltd, Eastpoint Software Ltd

BACKGROUND

OBJECTIVES

Non-destructive testing (NDT) is essential for ensuring and

The project’s aim is to replace current NDT training methods

maintaining the integrity of structures and systems, from

that rely on the availability of real representative samples

aircraft to power stations. The market for NDT products

with a simpler and more versatile approach. This will take

and services; £10 billion, 8% compound annual growth

the form of using an instrumented NDT probe together with

rate (CAGR) depends on the availability of highly trained

electronically recorded data from a real sample that can be

NDT technicians, so the market for training is also growing

displayed in real-time. This will provide realistic training for

rapidly; £200 million, 4.3% CAGR.

any flaw or defect type, anywhere in the world.

The current, state-of-the-art approach for training NDT

BENEFITS

technicians is to use real samples with either actual flaws or artificially created flaws. Live NDT probes, e.g. ultrasonic phased array, are used making it necessary to have samples made of exactly the same material with defect size, structure and geometry representative of the real thing.

Probe manipulation, including position and orientation, is critical in obtaining high quality inspection results, and realtime trainer feedback is an important aspect of the training.

The TrainNDT approach will: provide more exercise samples for use in training courses enable

flexibility

of

training

location

and

the

organisation of training at shorter notice allow trainees to practice with rare and challenging flaws provide for 2D display with manual ultrasonic testing be applicable to other NDT techniques such as eddy

The availability of suitable samples is a major limitation in

current and phased array testing

current training. For large structures it is often impractical to

result in much lower associated costs.

take samples to the trainee, so training must be organised where the samples are located. In many cases, flaws are rare or difficult to recreate. Therefore, it is very difficult to provide flexible training or to tailor it to individual requirements because training programmes are designed around sample location and availability.

There have been some recent advances to try and alleviate this problem, such as blended learning using simulated test data, however, these are not real data so provide a limited learning experience.

rail

58

TRAKSYS

Track inspection by autonomous system

TRAKSYS

PROJECT PARTNERS Technical Software Consultants Ltd, Centre for Advanced Transport Engineering Research (C.A.T.E.R EU), TWI Ltd

BACKGROUND TrakSys aims to address the challenges of increased

TrackSys makes provision for integration with other

availability and capacity of railway infrastructure through

information systems within stakeholder organisations in

the provision of automated, integrated track inspection

order to close the loop between inspection and decision

capability. A supervised autonomous inspection system

making. This approach supports better defect and damage

will reduce the time personnel spend on track while

management across the organisation, leading to improved

significantly increasing the quality and richness of data

safety for travellers and employees and more efficient,

supporting maintenance decisions.

productive rail networks.

Building on previous development work undertaken by

BENEFITS

TWI Ltd, Technical Software Consultants (TSC) and CATER EU, TrakSys will develop a rail head alternating current field measurement (ACFM) inspection system, coupled with volumetric ultrasound inspection and high fidelity visual inspection, all mounted on an autonomous cart to accurately detect defects, enabling predictive and preventative maintenance.

track greater accuracy and availability of inspection data, including on rail head condition, thereby helping to renewal

innovations by enhancing large scale, vehicle mounted inspection

will lessen the amount of time needed to be spent on

enabling

TrakSys aims to produce high value, low cost railway track

increased safety of maintenance personnel as TrakSys

reduce unplanned maintenance and unnecessary rail

OBJECTIVES

railway

The project benefits are:

with

localised

automated

predictive

maintenance

regimes

that

maximise value from data improved reliability and availability of infrastructure whilst maintaining the same level of safety.

inspection, to create a state-of-the-art autonomous vehicle that can generate greater amounts of information.

Enhanced value from inspection will be supported by combining this information with position data to form a map of scanned areas as well as linking measurements to locations within these areas. This will provide a much richer and more accurate depiction of the condition of track sections.

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59

VA-RCM

Vibration analysis for rail car monitoring

PROJECT PARTNERS Hitex Ltd, Transport Catapult Systems Ltd, Transports Metropolitans de Barcelona SA, TWI Ltd, Innovative Technology and Science Ltd

BACKGROUND

BENEFITS

It is crucial to reduce rail operational costs as well as

Train operators and train passenger car manufacturers will

increase the reliability of services, especially in terms of

benefit from the VA-RCM system due to improvements in

punctuality. Train doors are a critical element in the causes

the efficiency of train doors and a reduction in the failure

of train delays and they have high maintenance costs.

rate or downtime of trains thus reducing maintenance costs.

Defects in door actuators are the most common faced

Furthermore, users of railways will benefit from improved

by train operators, especially in older trains where

safety

door malfunctions amount to 25-50% of rolling stock

correspondingly increase the number of users. This will

defects. To overcome this, a consortium led by German

then reduce congestion and CO2 emissions in urban areas.

SME Hitex has come together to commercialise the VA-RCM system.

and

reliability

of

transportation,

which

www.va-rcm.com

VA-RCM is an innovative condition monitoring system, based on cutting-edge technology, involving advanced vibration analysis techniques. Its unique features enable accurate assessment of train door actuators, as well as targeted feedback on subsystem malfunctions well in advance of their potential occurrence.

OBJECTIVES The VA-RCM project has three primary goals: lower the maintenance costs of underground train railways due to door malfunctioning increase door safety and reduce accidents caused by door failure improve underground railway transportation reliability and increase its use among the public.

This project has received funding from the European Union’s Horizon 2020 research and innovation programme under grant agreement No 730766.

rail

60

will

1344.04/18