Final Report Summary - CHAPLIN (High Power Transmission Line Cable Inspection)
Executive Summary:
There are many thousands of miles of overhead high power line transmission cables dispersed around Europe, some of which are installed in remote areas where access is restricted. Furthermore, the cables operate in severe conditions and are subject to many environmental and operational factors such as moisture, voltage stress, vibration, overloads and structural imperfections.
Currently, inspection is undertaken using visual techniques to detect defects (such as arcing, corrosion and overheating). However, visual inspection is highly subjective and requires very experienced personnel. Furthermore, given the many hundreds of thousands of kilometres of cables that require inspection, often in remote and inaccessible areas, current labour-intensive techniques are very expensive, often unreliable and dangerous to perform, since most inspections have to include an operator transfer from helicopter to live cables.
The Chaplin project has developed an efficient and cost-effective inspection technology based on ultrasonic guided wave testing to identify the presence and the location of defects in the conductor cables (phase and ground wire) including areas where accessibility is an issue. The project has developed the technology to produce long term monitoring systems that can be installed on cables for continuous collection of data or systems that have been developed to be used as an inspection aid and lowered on to the cable via helicopter or robot for quick testing of the cable. In both cases the Chaplin system will reduce the inspection costs compared to the present systems and at the same time reduce down time due to failures.
Project Context and Objectives:
To accomplish the project objectives, the work activities have been organised into a number of Discrete Work Packages and those were divided into research (WPs 1 to 5), integration and final testing (WP6 and 7) and Consortium Management & reporting to the REA (WP8) Dissemination & Exploitation (WP9).
The description for work packages and deliverables are shown below:
WP1 – System specification
Del 1.1 Report on the Project specifications and requirements
Del 1.2 Report on test piece selection for laboratory trials
WP2 – NDT theoretical study and modelling
Del 2.1 Report on guided waves in high power line cables
WP3 – Sensors and laboratory trials
Del 3.1 Report on the development of optimum sensors arrays
Del 3.2 Report on the ability of ultrasonic guided waves to propagate in cables
WP4 – Wireless data communication and signal processing
Del 4.1 Report on the signal quality enhancement using signal processing
Del 4.2 Report on the communication hardware and softwareWP5 – Power electronics and encapsulation
Del 5.1 Report on the development of energy harvesting system
Del 5.2 Hardware electronic protection (Encapsulation)
Del 5.2a Motorised inspection tool
WP6 – System integration and testing
Del 6.1 Prototype inspection system capable of carrying out the laboratory trials
WP7 – Site trials and demonstration
Del 7.1 Report on the validation of prototype system and large scale trials
WP8 – Consortium Management & Reporting to the REA
Del 8.1 Signed Consortium Agreement
WP9 – Dissemination & Exploitation
Del 9.2 Draft PUDF / PUDF
Project Results:
The details of technical and scientific results for each work package are presented as follows:
WP1 – System specification and Industrial requirements is 100% complete at the end of the Project and Deliverable D1.1 and D1.2 submitted. Del 1.1 Report on the Project specifications and requirements was prepared with the collaboration of consortium - specifically the end users Albatroz and other SMEs. The overall objective of this Work Package (WP) was to arrive at detailed specifications for the modelling, transducers, electronics, software and possible end of project prototype including testing. Del 1.2 Report on test piece selection for laboratory trials is 100% complete at the end of the Project. It was prepared with the collaboration of consortium - specifically the end users Albatroz and other SMEs. The overall objective of this Work Package was to review the world cable standard, research typical defects and causes, select possible cables suitable for samples to be used during the testing and contact possible suppliers of cables. The testing requirements were also reviewed and stated.
WP2 – NDT theoretical study and modelling is 100% complete at the end of the Project and D2.1 - Report on the Modelling of ultrasonic guided waves and defect detection was successfully submitted. The overall objective of this Work Package was to carry out theoretical modelling of Ultrasonic Guided Waves (UGW) in cables and to select the best propagation modes. A major part of this study examined how the guided waves propagate along the cable. In general, the results are consistent with what was expected based on other papers and research work studied during this project. The theoretical work in this work package was used as a tool to assist in designing the transducers and arrays and defining the detailed experimental plan covering practical ultrasonic tests.
WP3 – Sensors and laboratory trials is 100% complete at the end of the Project and D3.1 Deliverable D3.2 Report on the development of optimum sensors arrays reviewed all the possible transducers that could be used to propagate guided waves with the cables, this resulted in the PZT shear wave transducers being selected for the project. D3.2 used these PZT transducers and elements as components in the arrays designs that were worked on during this period.
The transducer arrays were designed to propagate and receive the optimum mode or modes as determined from the modelling and experiments in WP2. Once the ultrasonic testing ofthe cables was completed, the level of ultrasonic wave energy was fully understood and the power level that was required for the ultrasonic transducers and electronics could be used in the design of the power electronic amplifiers that were also being developed at this point
WP4 – Wireless data communication and signal processing is 100% complete at the end of the Project and D4.1 and D4.2 were submitted. The aim of this work package was to develop a working wireless data communication and protocol and the software for the Maxim embedded ultrasonic system and for the GUI and signal processing on the Chaplin Laptop.
Both systems worked very well throughout the project.
WP5 – Power electronics and encapsulation is 100% complete at the end of the Project. D5.1 – delivered the design for an Energy Harvesting System that will not be used in the final prototype and deliverable D5.2 delivered the design for a sealed enclosure for use in a monitoring application and not in the final prototype. D5.2a As reported a new design for the final prototype was started at the end of WP5 and delivered late in to WP6. This change was as per the SMEs request after the consortium meeting in early Dec, 2013.
WP6 – System Integration and testing is 100% complete at the end of the Project. D6.1 delivered a fully integrated working Chaplin hardware system that was fitted on to the cable and produced improved results that were achieved in the previous work packages. The Maxim embedded C code and the Matlab based GUI and signal processing software are all state of the art for NDT applications and allowed the hardware to perform many times better than we had expected. The signal processing improved the signal to noise by at least twice and some times as much as four times when TCG was used.
The motorised inspection tool design was also tested on the cable for the first time and the results are fully covered in the Apendix2 of Del 6.1. Its performance was acceptable at this stage of the project but there were a few problems are these are listed in Del 6.1 and the appendix and were all corrected before WP7.
WP7 – Site trials and demonstration is 100% complete at the end of the Project. D7.1 concentrated on conducting site trials on cables that were as close to those found in the real world. A pair of 50m long Bear sample cables were connected together with the correct spacer bars and stung between two lard pipes. Testing was carried out to check the prototypes ultrasonic performance and to compare the results with those obtained under lab conditions.
The final design of the Innora motorised inspection tool fitted with its polycarbonate cover was also tested on the 50m cable and all the problems noted in deliverable 6.1 were checked and found to be correct and the system was to be fully functional.
Potential Impact:
The successful implementation of the Chaplin system aims significant reduction in inspection time when compared with existing state of the art inspection techniques and due to the use of guided waves allow a much greater range of inspection from one single location than has ever been achieved. It also aims to minimise the need for corrective maintenance thus
leading to a substantial decrease of the overall operational costs. This will revolutionise cable inspection and maintenance procedures.
List of Websites:
Chaplin is collaboration between the following organisations: TWI Limited, Innora, Albatroz, DTK Electronics, Brunel University, and Dasel.
The project has received funding from the European Union’s Seventh Framework Programme for research; technological development and demonstration under grant agreement no 315130
The project website, www.chaplin-project.eu presents introductions to all Chaplin consortium members with links to their respective websites.
This website will be kept as the main platform for any communications related to the Chaplin project beyond the project term.
Project Co-ordinator
Rafael López (ROBOTNIK)
Tel: (+34) 963383835
Fax: (+34) 963383580
E-mail: rlopez@robotnik.es
Project website address: http://www.chaplin-project.eu
There are many thousands of miles of overhead high power line transmission cables dispersed around Europe, some of which are installed in remote areas where access is restricted. Furthermore, the cables operate in severe conditions and are subject to many environmental and operational factors such as moisture, voltage stress, vibration, overloads and structural imperfections.
Currently, inspection is undertaken using visual techniques to detect defects (such as arcing, corrosion and overheating). However, visual inspection is highly subjective and requires very experienced personnel. Furthermore, given the many hundreds of thousands of kilometres of cables that require inspection, often in remote and inaccessible areas, current labour-intensive techniques are very expensive, often unreliable and dangerous to perform, since most inspections have to include an operator transfer from helicopter to live cables.
The Chaplin project has developed an efficient and cost-effective inspection technology based on ultrasonic guided wave testing to identify the presence and the location of defects in the conductor cables (phase and ground wire) including areas where accessibility is an issue. The project has developed the technology to produce long term monitoring systems that can be installed on cables for continuous collection of data or systems that have been developed to be used as an inspection aid and lowered on to the cable via helicopter or robot for quick testing of the cable. In both cases the Chaplin system will reduce the inspection costs compared to the present systems and at the same time reduce down time due to failures.
Project Context and Objectives:
To accomplish the project objectives, the work activities have been organised into a number of Discrete Work Packages and those were divided into research (WPs 1 to 5), integration and final testing (WP6 and 7) and Consortium Management & reporting to the REA (WP8) Dissemination & Exploitation (WP9).
The description for work packages and deliverables are shown below:
WP1 – System specification
Del 1.1 Report on the Project specifications and requirements
Del 1.2 Report on test piece selection for laboratory trials
WP2 – NDT theoretical study and modelling
Del 2.1 Report on guided waves in high power line cables
WP3 – Sensors and laboratory trials
Del 3.1 Report on the development of optimum sensors arrays
Del 3.2 Report on the ability of ultrasonic guided waves to propagate in cables
WP4 – Wireless data communication and signal processing
Del 4.1 Report on the signal quality enhancement using signal processing
Del 4.2 Report on the communication hardware and softwareWP5 – Power electronics and encapsulation
Del 5.1 Report on the development of energy harvesting system
Del 5.2 Hardware electronic protection (Encapsulation)
Del 5.2a Motorised inspection tool
WP6 – System integration and testing
Del 6.1 Prototype inspection system capable of carrying out the laboratory trials
WP7 – Site trials and demonstration
Del 7.1 Report on the validation of prototype system and large scale trials
WP8 – Consortium Management & Reporting to the REA
Del 8.1 Signed Consortium Agreement
WP9 – Dissemination & Exploitation
Del 9.2 Draft PUDF / PUDF
Project Results:
The details of technical and scientific results for each work package are presented as follows:
WP1 – System specification and Industrial requirements is 100% complete at the end of the Project and Deliverable D1.1 and D1.2 submitted. Del 1.1 Report on the Project specifications and requirements was prepared with the collaboration of consortium - specifically the end users Albatroz and other SMEs. The overall objective of this Work Package (WP) was to arrive at detailed specifications for the modelling, transducers, electronics, software and possible end of project prototype including testing. Del 1.2 Report on test piece selection for laboratory trials is 100% complete at the end of the Project. It was prepared with the collaboration of consortium - specifically the end users Albatroz and other SMEs. The overall objective of this Work Package was to review the world cable standard, research typical defects and causes, select possible cables suitable for samples to be used during the testing and contact possible suppliers of cables. The testing requirements were also reviewed and stated.
WP2 – NDT theoretical study and modelling is 100% complete at the end of the Project and D2.1 - Report on the Modelling of ultrasonic guided waves and defect detection was successfully submitted. The overall objective of this Work Package was to carry out theoretical modelling of Ultrasonic Guided Waves (UGW) in cables and to select the best propagation modes. A major part of this study examined how the guided waves propagate along the cable. In general, the results are consistent with what was expected based on other papers and research work studied during this project. The theoretical work in this work package was used as a tool to assist in designing the transducers and arrays and defining the detailed experimental plan covering practical ultrasonic tests.
WP3 – Sensors and laboratory trials is 100% complete at the end of the Project and D3.1 Deliverable D3.2 Report on the development of optimum sensors arrays reviewed all the possible transducers that could be used to propagate guided waves with the cables, this resulted in the PZT shear wave transducers being selected for the project. D3.2 used these PZT transducers and elements as components in the arrays designs that were worked on during this period.
The transducer arrays were designed to propagate and receive the optimum mode or modes as determined from the modelling and experiments in WP2. Once the ultrasonic testing ofthe cables was completed, the level of ultrasonic wave energy was fully understood and the power level that was required for the ultrasonic transducers and electronics could be used in the design of the power electronic amplifiers that were also being developed at this point
WP4 – Wireless data communication and signal processing is 100% complete at the end of the Project and D4.1 and D4.2 were submitted. The aim of this work package was to develop a working wireless data communication and protocol and the software for the Maxim embedded ultrasonic system and for the GUI and signal processing on the Chaplin Laptop.
Both systems worked very well throughout the project.
WP5 – Power electronics and encapsulation is 100% complete at the end of the Project. D5.1 – delivered the design for an Energy Harvesting System that will not be used in the final prototype and deliverable D5.2 delivered the design for a sealed enclosure for use in a monitoring application and not in the final prototype. D5.2a As reported a new design for the final prototype was started at the end of WP5 and delivered late in to WP6. This change was as per the SMEs request after the consortium meeting in early Dec, 2013.
WP6 – System Integration and testing is 100% complete at the end of the Project. D6.1 delivered a fully integrated working Chaplin hardware system that was fitted on to the cable and produced improved results that were achieved in the previous work packages. The Maxim embedded C code and the Matlab based GUI and signal processing software are all state of the art for NDT applications and allowed the hardware to perform many times better than we had expected. The signal processing improved the signal to noise by at least twice and some times as much as four times when TCG was used.
The motorised inspection tool design was also tested on the cable for the first time and the results are fully covered in the Apendix2 of Del 6.1. Its performance was acceptable at this stage of the project but there were a few problems are these are listed in Del 6.1 and the appendix and were all corrected before WP7.
WP7 – Site trials and demonstration is 100% complete at the end of the Project. D7.1 concentrated on conducting site trials on cables that were as close to those found in the real world. A pair of 50m long Bear sample cables were connected together with the correct spacer bars and stung between two lard pipes. Testing was carried out to check the prototypes ultrasonic performance and to compare the results with those obtained under lab conditions.
The final design of the Innora motorised inspection tool fitted with its polycarbonate cover was also tested on the 50m cable and all the problems noted in deliverable 6.1 were checked and found to be correct and the system was to be fully functional.
Potential Impact:
The successful implementation of the Chaplin system aims significant reduction in inspection time when compared with existing state of the art inspection techniques and due to the use of guided waves allow a much greater range of inspection from one single location than has ever been achieved. It also aims to minimise the need for corrective maintenance thus
leading to a substantial decrease of the overall operational costs. This will revolutionise cable inspection and maintenance procedures.
List of Websites:
Chaplin is collaboration between the following organisations: TWI Limited, Innora, Albatroz, DTK Electronics, Brunel University, and Dasel.
The project has received funding from the European Union’s Seventh Framework Programme for research; technological development and demonstration under grant agreement no 315130
The project website, www.chaplin-project.eu presents introductions to all Chaplin consortium members with links to their respective websites.
This website will be kept as the main platform for any communications related to the Chaplin project beyond the project term.
Project Co-ordinator
Rafael López (ROBOTNIK)
Tel: (+34) 963383835
Fax: (+34) 963383580
E-mail: rlopez@robotnik.es
Project website address: http://www.chaplin-project.eu