Final Report Summary - X-SCAN (Laser-guided inspection robot for the Non-Destructive Testing of thin steel gauge welds in the shipping industry)
Executive Summary:
Ocean going ships are the most cost effective form of transporting bulk goods around the world. To date, Europe owns nearly 40% of the world’s fleet of ships, which account for 90% of its external trade and 40% of its internal trade. Moreover, in the supply of ship building components and services, the EU is a world leader. As a result, the maritime industry, which includes ship building and ship operation, are vital to Europe’s economy.
In this industry sector, structural failure is a major cause of the loss of ships, vessels and tankers resulting in loss of life and pollution of the world’s oceans, seas and coastal waters of Europe. Indeed, it has been reported in 2006, that each year over 400 ocean going ships sink, many as a result of weakened structures due to corrosion and inadequate/poor welding quality.
Most of the inspection techniques used to date proved to be disruptive to the manufacturing process and far from being cost effective. Additionally, as the current generation of ships are being built from thinner section steels (10mm or less) to lower the cost of build and ship operation, typical assessment methods are not as effective as for thicker sections. Therefore, there is a real need for more reliable, faster, cost effective and safer inspection techniques.
The X-Scan project aims to respond to this need by developing novel automated NDT techniques (ultrasonic and electromagnetic) for ship structures. The objective of the project is (1) to concentrate on solving the problem of inspecting thin steel welds using Phased Array Ultrasonic Testing (PAUT) and Alternating Current Field Measurement (ACFM) techniques and (2) tackle the automated inspection of inaccessible welds by means of a laser guided manipulator.
The X-scan project seeks to open up a new inspection market for the service inspection SMEs based in Europe, as it will allow end-users to further decrease the thickness of their steel structures without jeopardising quality or resorting to radiography. It also seeks to allow the SME proposers to tap into the niche market at a point where inspections are becoming ever more necessary but ever more difficult to achieve safely. Moreover by providing technological advancements it seeks to help European SMEs to increase their competitiveness and stave off the competitive threat from China and SE Asia, without jeopardising safety.
Project Context and Objectives:
The project concept originated with Tecnitest, the Spanish supplier of specialist, custom made NDT equipment and systems for the European inspection market. Their customers are small NDT inspection companies who provide inspection services to larger organisations. European shipyards typically sub-contract out the bulk of their inspection work to SMEs, and expect them to maintain their competitive costs while adapting to the customers changing needs, without compromising safety. These three driving forces have now created a clash that could see either European SME competiveness or safety being jeopardised. The worst situation would see the standard of weld inspection falling, resulting in an increase of hull failures. It was seen as an opportunity to increase sales of equipment for state-of-the-art ship weld inspection. In order to exploit this opportunity, the X-Scan consortium was formed, consisting of various European SMEs in the ship inspection supply chain.
The main objectives of the project are two:
1) to concentrate on solving the problem of inspecting thin steel welds using Phased Array Ultrasonic Testing (PAUT) and Alternating Current Field Measurement (ACFM) techniques
2) to tackle the automated inspection of inaccessible welds by means of a laser guided manipulator.
Splitting down in more targeted goals we have the following list of obectives:
a) To create a specification document on the end user requirements
b) To create a series of welded samples that accurately mirrors the end-users requirements
c) To develop PAUT technique and inspection methodology
d) To design and manufacture PAUT probes
e) To develop an ACFM technique and inspection methodology
f) To design and manufacture ACFM probes
g) To develop the laser seam tracker technique and weld visualistaion
h) To validate the ACFM and PAUT inspection methodologies
i) To compare the results with radiographic inspections
j) To design and manufacture the laser seam tracker subsystem and weld visualisation subsystem
k) To design the electronics, instrumentation and software
l) To design the mechanical components of the system
m) To create the obstacle detection and avoidance system
n) To manufacture and assemble the manipulator components
o) To design and manufacture the sensor holder
p) To integrate all the separate subsystems
q) To validate the integrated prototype’s functionality
r) To demonstrate the functionality of the system in lab and in the field
s) To transfer the foreground IP and technology created to the project partners by training
t) To disseminate and exploit the project results and update the project website
Project Results:
-Phased Array and ACFM techniques development for thin weld inspection-
Work was carried out by TWI on the development of the ultrasonic phased array and ACFM techniques that will be incorporated into the final X-Scan prototype for the weld inspection. A specification of the sensors was produced and their manufacturing commenced. Modelling was initially used to demonstrate the performance of the inspection technique and the sensors. Laboratory trials were performed on the use of the developed inspection techniques on the weld sample for both PAUT and ACFM. The results were compared with radiographic inspection and it was proven that the techniques could successfully substitute it.
Figure 1 shows some of the modelling results. Tables A to F show the inspection results from the mock-up plates’. Figure 2 shows the ACFM probe arrangement and Figures 3 to 5 show the inspection results from the mock-up plates’
Figure 1: sound beam profile generating by the array PA3, 7MHz, 32 elements, focussed at 9mm in depth a) Full sector b) along 45° c) along 60° d) along 70°
Table A PAUT results of 20mm butt weld testing.
Table B PAUT results of 10mm butt weld testing.
Table C PAUT results of 6mm butt weld testing
Table D PAUT results of 20mm fillet weld testing
Table E PAUT results of 10mm fillet weld testing
Table F PAUT results of 6mm fillet weld testing.
Figure 2: ACFM probes arrangement
Figure 3: Difference in position between the ACFM and the MPI/DPI testing.
Figure 4: Difference in length sizing between the ACFM and the MPI/DPI testing.
Figure 5: Difference in depth sizing between the ACFM and the MPI/DPI testing.
-Laser Weld tracking and visualisation-
In addition, the laser tracking technique, an essential part of the inspection robot, was developed by Brunel University. This system will be used to guide the robot and find surface flaws along welds or in their vicinity. The laser profile sensor for weld tracking was evaluated and a detection technique for surface flaws was tested. Initially a weld centre location algorithm was created based on wavelet transforms and experimental data showed that the sensor system was functioning optimally (Figures 6 and 7). Also flaws on the surface of a test work piece can be observed on the acquired weld profiles (Figure 9). Later during integration, the tracking algorithm was split for butt (bisection after thresholding, Figure 8) and fillet (low order polynomial) weld configurations to achieve better real time seam following.
Figure 6: User interface of offline profile analysis programme
Figure 7: Weld being scanned by the laser profile sensor
Figure 8: An example of butt weld tracking algorithm to find the error deviation from the current central weld seam position.
Figure 9: Visualisation software (GUI) for butt weld displayed on the visualisation inspection PC (ground station).
-Robot Development-
Moreover, the X-Scan robot’s systems and operations for the transportation and automated deployment of the NDT systems were developed by Innora. Preliminary design work defined initial design solutions, the optimal ones were chosen after many laboratory tests. These tests can be seen in Figures 10 to 14 and tables G and F. The design work finished and the mechanical parts of the robot were manufactured (Figure 15). Meantime the software to control the robot was developed and all electrical, electronics and pneumatic apparatus were assembled.
Figure 10: The magnets pulling force set-up.
Figure 11: Magnet pulling force.
Figure 12: Set-up for measurement of the friction between the belt and the magnet.
Figure 13: Motion recorded from encoder and acceleration part of the recorded data.
Figure 14: Acceleration part of the recorded data.
Table G: Static and kinetic friction coefficient between inner side of the belt and antifriction materials.
Table F: Kinetic friction coefficient between belt coating and painted plate.
Figure 15: The main manipulator.
-Integration-
All individual subsystems of the final prototype were brought together to create a meaningful whole. As all integration activities a lot of problems arose but they were successfully overcome with the combined effort of all RTDs and the extension of the project for two months. A number of integration meetings took place each one adding improvements on the previous one. The prototype was tested on a demo plate (Figure 16) that included the mock up plates created at the start of the project. Near the project’s end the plate was coated and a new set of tests was performed. Selected images from the test can be seen in Figures 17 and 18. Some results from the tests are show in Figures 19 to 21.
Figure 16: The demo plate uncoated and coated
Figure 17: Mounting points of the sensor holder on the robot
Figure 18: The integrated system automatically scanning the 20mm fillet weld
Figure 19: Visualisation on the ground station (inspector PC). Top: surface plot build up for the weld region. Bottom: time build up for the plates region. Right: current 2D profile.
Figure 20: Butt weld 10mm, 20mm/s speed (indication on weld side wall)
Figure 21: Butt weld 6mm, 20mm/s speed
-Demonstration-
Trials were organised in the premises of Chalkis shipyards and the prototype was put in action. Two days were spent in a dry dock deploying the system. The empty dry dock could easily fit a car and the shipyard’s personnel allowed us to bring a car very close to the trial location. This fact eased logistics very much and all equipment was carried in the car. A rope was secured from the robot to the superstructure of the dry dock, although from all the previous tests we knew that the magnetic force of the robot’s caterpillars was more than adequate. A safety exclusion zone was used once the robot moved at a height above 1.90 meters from the dry dock’s surface. The zone was set at 1/3 of the maximum height, which is the suggested rule of thumb. The shipyard’s personnel also provided with a 220V power supply and cabling. Following these arrangements the robot was placed on the vertical wall of the dry dock and testing commenced. Tests were performed for over 3 hours, some issues were encountered and mitigated, but most importantly the crews from all RTDs became more accustomed to using the prototype in the field. Selected images of the demo are show in figures 22 to 24.
Figure 22: Tests on the 13th of November
Figure 23: Preparation on the 14th of November
Figure 24: 4 meters high and going
-Training-
Training material was developed and a dedicated session that included hands on experience with the final prototype was organised with all SMEs participating. Selected slides and photos from the training material are shown in the figures 25 to 28.
Figure 25: Explanation of the button functions of the robot control GUI, focus on the sensor arm control
Figure 26: Button functions of the joypad controlling the robot
Figure 27: Main program GUI on the mini PC and start data transmission of the laser system (actions are boxed in red)
Figure 28: Extract from ACFM probe configuration file, changes needed circled in red
All images can be found in the attachment : "Final report S&T images and tables.pdf"
Potential Impact:
-Impact-
X-Scan has reached both of its objectives, thin steel welds can be inspected with PAUT and ACFM methods and inaccessible weld can be inspected with a laser guided manipulator. The main result is the final prototype, but the results from the research and development performed to reach this result as well as the subsystems comprising are also exploitable. The exploitable results are analysed in deliverable 7.2 but SMEs are already discussing alternative uses of individual results like a handheld version of the laser profilometer.
The SMEs are receiving a prototype and subsystems at a high Technology Readiness Level and the core potential impacts come from profit from their sales and the provision of services using them. Plans to expand to markets apart from shipping have already been proposed by the SMEs. Apart from the remunerable results the project has the potential to impact the quality of life of a number of communities:
• Site radiography is unacceptably dangerous. X-scan aid the minimisation for the need for on-site radiography.
• Site radiography is conducted at night, forcing the operators to endure the hardship of long stretches of night shifts.
• The X-Scan project will eliminate the need for manual UT conducted at height, which is also dangerous.
• Safety: The occupation has high insurance rates and shipyards have a higher accident rate compared to other industries. Safety and health at work constitutes one of the European Union’s most important social policy sectors. Substantial legislation has aimed at raising standards of safety and health in the EU. The Commission is now looking to 2007 for improvements for a better strategy for Europe (Communication from the Commission- Adapting to change in work and society: a new Community strategy on health and safety at work 2002-2006. COM 118 final).
• The future NDT inspections that will result from this project will lessen the probability of further catastrophic structural failures that could result in a loss of life on oil and gas installations, as well as shipyards.
• Working Conditions: As a result of these advances they will give all workers a safer, healthier & better working conditions in European shipyard related inspection & maintenance activities.
X-Scan results can also potentially improve employment as the number of supplies of PAUT systems & ACFM systems is expected to increase. Also the need for more specialist NDT technicians working for NDT service inspection providers to the shipping industry can potentially increase employment prospects.
Finally the results will give a leading technological advantage to European SMEs giving them an edge in expanding their business activities internationally. The shipping market is world-wide with an ever-increasing number of installations. European SMEs will have the potential to become leading prime contractors, taking total responsibility for NDT inspection projects from design to through-life support.
-Dissemination Activities-
The dissemination plan dictated the use of specific media of dissemination throughout the project. These are described below; some points are featured in more detail in following sections.
Public website and X-Scan Extranet & Knowledge Management System:
Working documents & deliverables are available for partners to download & review in the member area of the X-Scan project website. Project partnership, technical objectives, news and contacts are available on the public domain of the website at http://www.x-scan.eu/. A gallery of pictures showing the integration and demonstration activities are also available along with X-scan’s official video. Moreover any external visitor can access the public deliverables. Currently only approved deliverables are available, once all have been approved they will be uploaded. The website’s URL has been purchased until a year after the project’s completion and its renewal cost is already covered. Google searches on the name “Xscan” or keywords such as “thin plate inspection ship” give links to the website within the first five hits. X-Scan also has a Google+ page and a youtube channel.
Magazine articles and Newsletter releases:
X-Scan has successfully drawn media’s attention. Lloyd’s List a highly reputable newspaper specialised in shipping news featured X-Scan in their June 4th 2013 issue. Lloyds Register also featured X-scan in the 38th issue of their Horizon magazine read by thousands of maritime professionals around the world. X-scan will also feature in the Maritime IT & Electronics magazine.
Technical leaflets & publications:
The X-Scan flyer has already been produced and has been used as promotional material for various events; an update is currently being prepared. Papers in scientific journals have been published while more are already under way (see Table A).
Events and conferences:
Attendance to major NDT conferences has already been undertaken while more conferences will be visited in the next year. Attendance at more maritime related fairs is being discussed with a chance of featuring at Posidonia 2014.
Links with past and current EU-funded projects:
Another project, MINOAS, with similar targets also funded under the FP7 programme was located and a number of dissemination routes followed by that project were used in X-Scan as well.
Network of Industries:
A network of Industries is gradually being established to ensure a wide spread of results outside of the Consortium. Chalkis Shipyards S.A. that kindly hosted the demonstration activities of the X-Scan already had the chance to see the prototype in action. The consortium is seeking are seeking to organise more demos in other potential customers as well.
TV / Radio news release:
The X-scan official video has just been released and the consortium is in the process of locating contacts in Euronews for potential broadcasting.
Future activities:
The first part of this is to successfully present the X-scan project in the already mentioned upcoming conferences and publications. The partners are also considering teaming up with an exhibitor so as to feature the X-scan prototype in the Posidonia 2014 exhibition one of the biggest international maritime fairs. A suggestion of SpectrumLabs, the consortium is in the process of organising a demo in a gas sphere storage facility. These structures give a possibility to expand X-scan in other markets and show great potential as they require inspection of 100% of their area.
-Exploitable Results-
Exploitable Result n° 1: X-Scan Inspection System
A previously unavailable autonomous system that can inspect thin steel gauge weld in the shipping industry The potential customers are maintenance shipping building companies and NDT service and welding companies, benefitting from conducting fast, reliable, multi-disciplinary NDT inspections
Approximate price range of this result / price of licences? €150,000
Exploitable Result n° 2: Weld laser tracking sub-system
A laser based system for weld tracking and flaw recognition. The potential customers are NDT service and welding companies, benefitting from automatic visual inspections, that previously needed physical proximity from a trained technician.
Approximate price range of this result / price of licences? €40,000
Exploitable Result n° 3: Manipulator system
An autonomous wall climbing crawler robot able to carry a number of platforms. The potential customers are NDT service and welding companies, benefitting from the ability to deploy autonomous inspection techniques.
Approximate price range of this result / price of licences? €70,000
Exploitable Result n° 4: PAUT sub-system
Advanced ultrasonic transducer and associated procedure for inspecting butt and fillet welds as thin as 6mm. The potential customers are NDT service and welding companies, benefitting from more reliable inspection of thin welds.
Approximate price range of this result / price of licences? €40,000
Exploitable Result n° 5: ACFM sub-system
Advanced electromagnetic sensor arrays and associated procedure for inspecting both butt and fillet welds. The potential customers are NDT service and welding companies, benefitting from, faster, more reliable inspection with wider coverage.
Approximate price range of this result / price of licences? €50,000
List of Websites:
www.x-scan.eu
Giorgos Asfis
TWI Ltd
Granta Park,
Great Abington
CAMBRIDGE
CB21 6AL
United Kingdom
00441223899000
giorgos.asfis@twi.co.uk
Ocean going ships are the most cost effective form of transporting bulk goods around the world. To date, Europe owns nearly 40% of the world’s fleet of ships, which account for 90% of its external trade and 40% of its internal trade. Moreover, in the supply of ship building components and services, the EU is a world leader. As a result, the maritime industry, which includes ship building and ship operation, are vital to Europe’s economy.
In this industry sector, structural failure is a major cause of the loss of ships, vessels and tankers resulting in loss of life and pollution of the world’s oceans, seas and coastal waters of Europe. Indeed, it has been reported in 2006, that each year over 400 ocean going ships sink, many as a result of weakened structures due to corrosion and inadequate/poor welding quality.
Most of the inspection techniques used to date proved to be disruptive to the manufacturing process and far from being cost effective. Additionally, as the current generation of ships are being built from thinner section steels (10mm or less) to lower the cost of build and ship operation, typical assessment methods are not as effective as for thicker sections. Therefore, there is a real need for more reliable, faster, cost effective and safer inspection techniques.
The X-Scan project aims to respond to this need by developing novel automated NDT techniques (ultrasonic and electromagnetic) for ship structures. The objective of the project is (1) to concentrate on solving the problem of inspecting thin steel welds using Phased Array Ultrasonic Testing (PAUT) and Alternating Current Field Measurement (ACFM) techniques and (2) tackle the automated inspection of inaccessible welds by means of a laser guided manipulator.
The X-scan project seeks to open up a new inspection market for the service inspection SMEs based in Europe, as it will allow end-users to further decrease the thickness of their steel structures without jeopardising quality or resorting to radiography. It also seeks to allow the SME proposers to tap into the niche market at a point where inspections are becoming ever more necessary but ever more difficult to achieve safely. Moreover by providing technological advancements it seeks to help European SMEs to increase their competitiveness and stave off the competitive threat from China and SE Asia, without jeopardising safety.
Project Context and Objectives:
The project concept originated with Tecnitest, the Spanish supplier of specialist, custom made NDT equipment and systems for the European inspection market. Their customers are small NDT inspection companies who provide inspection services to larger organisations. European shipyards typically sub-contract out the bulk of their inspection work to SMEs, and expect them to maintain their competitive costs while adapting to the customers changing needs, without compromising safety. These three driving forces have now created a clash that could see either European SME competiveness or safety being jeopardised. The worst situation would see the standard of weld inspection falling, resulting in an increase of hull failures. It was seen as an opportunity to increase sales of equipment for state-of-the-art ship weld inspection. In order to exploit this opportunity, the X-Scan consortium was formed, consisting of various European SMEs in the ship inspection supply chain.
The main objectives of the project are two:
1) to concentrate on solving the problem of inspecting thin steel welds using Phased Array Ultrasonic Testing (PAUT) and Alternating Current Field Measurement (ACFM) techniques
2) to tackle the automated inspection of inaccessible welds by means of a laser guided manipulator.
Splitting down in more targeted goals we have the following list of obectives:
a) To create a specification document on the end user requirements
b) To create a series of welded samples that accurately mirrors the end-users requirements
c) To develop PAUT technique and inspection methodology
d) To design and manufacture PAUT probes
e) To develop an ACFM technique and inspection methodology
f) To design and manufacture ACFM probes
g) To develop the laser seam tracker technique and weld visualistaion
h) To validate the ACFM and PAUT inspection methodologies
i) To compare the results with radiographic inspections
j) To design and manufacture the laser seam tracker subsystem and weld visualisation subsystem
k) To design the electronics, instrumentation and software
l) To design the mechanical components of the system
m) To create the obstacle detection and avoidance system
n) To manufacture and assemble the manipulator components
o) To design and manufacture the sensor holder
p) To integrate all the separate subsystems
q) To validate the integrated prototype’s functionality
r) To demonstrate the functionality of the system in lab and in the field
s) To transfer the foreground IP and technology created to the project partners by training
t) To disseminate and exploit the project results and update the project website
Project Results:
-Phased Array and ACFM techniques development for thin weld inspection-
Work was carried out by TWI on the development of the ultrasonic phased array and ACFM techniques that will be incorporated into the final X-Scan prototype for the weld inspection. A specification of the sensors was produced and their manufacturing commenced. Modelling was initially used to demonstrate the performance of the inspection technique and the sensors. Laboratory trials were performed on the use of the developed inspection techniques on the weld sample for both PAUT and ACFM. The results were compared with radiographic inspection and it was proven that the techniques could successfully substitute it.
Figure 1 shows some of the modelling results. Tables A to F show the inspection results from the mock-up plates’. Figure 2 shows the ACFM probe arrangement and Figures 3 to 5 show the inspection results from the mock-up plates’
Figure 1: sound beam profile generating by the array PA3, 7MHz, 32 elements, focussed at 9mm in depth a) Full sector b) along 45° c) along 60° d) along 70°
Table A PAUT results of 20mm butt weld testing.
Table B PAUT results of 10mm butt weld testing.
Table C PAUT results of 6mm butt weld testing
Table D PAUT results of 20mm fillet weld testing
Table E PAUT results of 10mm fillet weld testing
Table F PAUT results of 6mm fillet weld testing.
Figure 2: ACFM probes arrangement
Figure 3: Difference in position between the ACFM and the MPI/DPI testing.
Figure 4: Difference in length sizing between the ACFM and the MPI/DPI testing.
Figure 5: Difference in depth sizing between the ACFM and the MPI/DPI testing.
-Laser Weld tracking and visualisation-
In addition, the laser tracking technique, an essential part of the inspection robot, was developed by Brunel University. This system will be used to guide the robot and find surface flaws along welds or in their vicinity. The laser profile sensor for weld tracking was evaluated and a detection technique for surface flaws was tested. Initially a weld centre location algorithm was created based on wavelet transforms and experimental data showed that the sensor system was functioning optimally (Figures 6 and 7). Also flaws on the surface of a test work piece can be observed on the acquired weld profiles (Figure 9). Later during integration, the tracking algorithm was split for butt (bisection after thresholding, Figure 8) and fillet (low order polynomial) weld configurations to achieve better real time seam following.
Figure 6: User interface of offline profile analysis programme
Figure 7: Weld being scanned by the laser profile sensor
Figure 8: An example of butt weld tracking algorithm to find the error deviation from the current central weld seam position.
Figure 9: Visualisation software (GUI) for butt weld displayed on the visualisation inspection PC (ground station).
-Robot Development-
Moreover, the X-Scan robot’s systems and operations for the transportation and automated deployment of the NDT systems were developed by Innora. Preliminary design work defined initial design solutions, the optimal ones were chosen after many laboratory tests. These tests can be seen in Figures 10 to 14 and tables G and F. The design work finished and the mechanical parts of the robot were manufactured (Figure 15). Meantime the software to control the robot was developed and all electrical, electronics and pneumatic apparatus were assembled.
Figure 10: The magnets pulling force set-up.
Figure 11: Magnet pulling force.
Figure 12: Set-up for measurement of the friction between the belt and the magnet.
Figure 13: Motion recorded from encoder and acceleration part of the recorded data.
Figure 14: Acceleration part of the recorded data.
Table G: Static and kinetic friction coefficient between inner side of the belt and antifriction materials.
Table F: Kinetic friction coefficient between belt coating and painted plate.
Figure 15: The main manipulator.
-Integration-
All individual subsystems of the final prototype were brought together to create a meaningful whole. As all integration activities a lot of problems arose but they were successfully overcome with the combined effort of all RTDs and the extension of the project for two months. A number of integration meetings took place each one adding improvements on the previous one. The prototype was tested on a demo plate (Figure 16) that included the mock up plates created at the start of the project. Near the project’s end the plate was coated and a new set of tests was performed. Selected images from the test can be seen in Figures 17 and 18. Some results from the tests are show in Figures 19 to 21.
Figure 16: The demo plate uncoated and coated
Figure 17: Mounting points of the sensor holder on the robot
Figure 18: The integrated system automatically scanning the 20mm fillet weld
Figure 19: Visualisation on the ground station (inspector PC). Top: surface plot build up for the weld region. Bottom: time build up for the plates region. Right: current 2D profile.
Figure 20: Butt weld 10mm, 20mm/s speed (indication on weld side wall)
Figure 21: Butt weld 6mm, 20mm/s speed
-Demonstration-
Trials were organised in the premises of Chalkis shipyards and the prototype was put in action. Two days were spent in a dry dock deploying the system. The empty dry dock could easily fit a car and the shipyard’s personnel allowed us to bring a car very close to the trial location. This fact eased logistics very much and all equipment was carried in the car. A rope was secured from the robot to the superstructure of the dry dock, although from all the previous tests we knew that the magnetic force of the robot’s caterpillars was more than adequate. A safety exclusion zone was used once the robot moved at a height above 1.90 meters from the dry dock’s surface. The zone was set at 1/3 of the maximum height, which is the suggested rule of thumb. The shipyard’s personnel also provided with a 220V power supply and cabling. Following these arrangements the robot was placed on the vertical wall of the dry dock and testing commenced. Tests were performed for over 3 hours, some issues were encountered and mitigated, but most importantly the crews from all RTDs became more accustomed to using the prototype in the field. Selected images of the demo are show in figures 22 to 24.
Figure 22: Tests on the 13th of November
Figure 23: Preparation on the 14th of November
Figure 24: 4 meters high and going
-Training-
Training material was developed and a dedicated session that included hands on experience with the final prototype was organised with all SMEs participating. Selected slides and photos from the training material are shown in the figures 25 to 28.
Figure 25: Explanation of the button functions of the robot control GUI, focus on the sensor arm control
Figure 26: Button functions of the joypad controlling the robot
Figure 27: Main program GUI on the mini PC and start data transmission of the laser system (actions are boxed in red)
Figure 28: Extract from ACFM probe configuration file, changes needed circled in red
All images can be found in the attachment : "Final report S&T images and tables.pdf"
Potential Impact:
-Impact-
X-Scan has reached both of its objectives, thin steel welds can be inspected with PAUT and ACFM methods and inaccessible weld can be inspected with a laser guided manipulator. The main result is the final prototype, but the results from the research and development performed to reach this result as well as the subsystems comprising are also exploitable. The exploitable results are analysed in deliverable 7.2 but SMEs are already discussing alternative uses of individual results like a handheld version of the laser profilometer.
The SMEs are receiving a prototype and subsystems at a high Technology Readiness Level and the core potential impacts come from profit from their sales and the provision of services using them. Plans to expand to markets apart from shipping have already been proposed by the SMEs. Apart from the remunerable results the project has the potential to impact the quality of life of a number of communities:
• Site radiography is unacceptably dangerous. X-scan aid the minimisation for the need for on-site radiography.
• Site radiography is conducted at night, forcing the operators to endure the hardship of long stretches of night shifts.
• The X-Scan project will eliminate the need for manual UT conducted at height, which is also dangerous.
• Safety: The occupation has high insurance rates and shipyards have a higher accident rate compared to other industries. Safety and health at work constitutes one of the European Union’s most important social policy sectors. Substantial legislation has aimed at raising standards of safety and health in the EU. The Commission is now looking to 2007 for improvements for a better strategy for Europe (Communication from the Commission- Adapting to change in work and society: a new Community strategy on health and safety at work 2002-2006. COM 118 final).
• The future NDT inspections that will result from this project will lessen the probability of further catastrophic structural failures that could result in a loss of life on oil and gas installations, as well as shipyards.
• Working Conditions: As a result of these advances they will give all workers a safer, healthier & better working conditions in European shipyard related inspection & maintenance activities.
X-Scan results can also potentially improve employment as the number of supplies of PAUT systems & ACFM systems is expected to increase. Also the need for more specialist NDT technicians working for NDT service inspection providers to the shipping industry can potentially increase employment prospects.
Finally the results will give a leading technological advantage to European SMEs giving them an edge in expanding their business activities internationally. The shipping market is world-wide with an ever-increasing number of installations. European SMEs will have the potential to become leading prime contractors, taking total responsibility for NDT inspection projects from design to through-life support.
-Dissemination Activities-
The dissemination plan dictated the use of specific media of dissemination throughout the project. These are described below; some points are featured in more detail in following sections.
Public website and X-Scan Extranet & Knowledge Management System:
Working documents & deliverables are available for partners to download & review in the member area of the X-Scan project website. Project partnership, technical objectives, news and contacts are available on the public domain of the website at http://www.x-scan.eu/. A gallery of pictures showing the integration and demonstration activities are also available along with X-scan’s official video. Moreover any external visitor can access the public deliverables. Currently only approved deliverables are available, once all have been approved they will be uploaded. The website’s URL has been purchased until a year after the project’s completion and its renewal cost is already covered. Google searches on the name “Xscan” or keywords such as “thin plate inspection ship” give links to the website within the first five hits. X-Scan also has a Google+ page and a youtube channel.
Magazine articles and Newsletter releases:
X-Scan has successfully drawn media’s attention. Lloyd’s List a highly reputable newspaper specialised in shipping news featured X-Scan in their June 4th 2013 issue. Lloyds Register also featured X-scan in the 38th issue of their Horizon magazine read by thousands of maritime professionals around the world. X-scan will also feature in the Maritime IT & Electronics magazine.
Technical leaflets & publications:
The X-Scan flyer has already been produced and has been used as promotional material for various events; an update is currently being prepared. Papers in scientific journals have been published while more are already under way (see Table A).
Events and conferences:
Attendance to major NDT conferences has already been undertaken while more conferences will be visited in the next year. Attendance at more maritime related fairs is being discussed with a chance of featuring at Posidonia 2014.
Links with past and current EU-funded projects:
Another project, MINOAS, with similar targets also funded under the FP7 programme was located and a number of dissemination routes followed by that project were used in X-Scan as well.
Network of Industries:
A network of Industries is gradually being established to ensure a wide spread of results outside of the Consortium. Chalkis Shipyards S.A. that kindly hosted the demonstration activities of the X-Scan already had the chance to see the prototype in action. The consortium is seeking are seeking to organise more demos in other potential customers as well.
TV / Radio news release:
The X-scan official video has just been released and the consortium is in the process of locating contacts in Euronews for potential broadcasting.
Future activities:
The first part of this is to successfully present the X-scan project in the already mentioned upcoming conferences and publications. The partners are also considering teaming up with an exhibitor so as to feature the X-scan prototype in the Posidonia 2014 exhibition one of the biggest international maritime fairs. A suggestion of SpectrumLabs, the consortium is in the process of organising a demo in a gas sphere storage facility. These structures give a possibility to expand X-scan in other markets and show great potential as they require inspection of 100% of their area.
-Exploitable Results-
Exploitable Result n° 1: X-Scan Inspection System
A previously unavailable autonomous system that can inspect thin steel gauge weld in the shipping industry The potential customers are maintenance shipping building companies and NDT service and welding companies, benefitting from conducting fast, reliable, multi-disciplinary NDT inspections
Approximate price range of this result / price of licences? €150,000
Exploitable Result n° 2: Weld laser tracking sub-system
A laser based system for weld tracking and flaw recognition. The potential customers are NDT service and welding companies, benefitting from automatic visual inspections, that previously needed physical proximity from a trained technician.
Approximate price range of this result / price of licences? €40,000
Exploitable Result n° 3: Manipulator system
An autonomous wall climbing crawler robot able to carry a number of platforms. The potential customers are NDT service and welding companies, benefitting from the ability to deploy autonomous inspection techniques.
Approximate price range of this result / price of licences? €70,000
Exploitable Result n° 4: PAUT sub-system
Advanced ultrasonic transducer and associated procedure for inspecting butt and fillet welds as thin as 6mm. The potential customers are NDT service and welding companies, benefitting from more reliable inspection of thin welds.
Approximate price range of this result / price of licences? €40,000
Exploitable Result n° 5: ACFM sub-system
Advanced electromagnetic sensor arrays and associated procedure for inspecting both butt and fillet welds. The potential customers are NDT service and welding companies, benefitting from, faster, more reliable inspection with wider coverage.
Approximate price range of this result / price of licences? €50,000
List of Websites:
www.x-scan.eu
Giorgos Asfis
TWI Ltd
Granta Park,
Great Abington
CAMBRIDGE
CB21 6AL
United Kingdom
00441223899000
giorgos.asfis@twi.co.uk
