Final Report Summary - CORFAT (Cost effective corrosion and fatigue monitoring for transport products)
Project context and objectives:
The main objectives for the last (third) period of the project were:
- final prototype of monitoring equipment for transport products;
- generic survey and inspection procedure using acoustic emission monitoring technology;
- drafts for standardisation.
Thus, further validation tests and measurements (similar to those started in the second period) on transport products (ships, road trucks and railway tank cars) were performed and measuring data were analysed. Based on analysis of data and experiences gained during last and former tests and measurements, the final prototype for monitoring equipment was defined and last adaptations of the equipment were done.
A generic survey and inspection procedure was created combining state of the art knowledge with results, knowledge and experience from project works. Especially, the differences concerning diverse categories of transport products (ships, road trucks and railway tank cars) had to be taken into account. The new methodology is described including, pre-arrangements, specifications of transport products, application, instrumentation, equipment, inspection requirements, safety rules, monitoring procedure, data analysis and evaluation, source grading and identification, follow-up non-destructive testing (NDT) and implementation to maintenance programme.
Finally, drafts for standardisation organisations have been prepared, describing the new methodology, requirements for equipment and instrumentation, application at transport products (ships, trucks and railway cars), data analysis and evaluation, follow-up NDT and definition of related maintenance and/or repair activities.
Project results:
In a first step, requirements have been defined for adaptation and development of hardware and software of instrumentation for acoustic emission as well as for conventional non-destructive testing (e.g. ultrasonic testing, penetrant testing, magnetic particle testing) based on inspection rules and existing standards (e.g. ADR, RID, ABS rules, ATEX), the knowledge of the project partners and pre-tests results. In a further step, requirements for a monitoring system and for acoustic emission instrumentation have been defined, whereas also the usage in hazardous areas was taken into account. A feasibility and validation study of non destructive testing follow-up methods was carried out with respect to hazardous areas and, hence, requirements for these methods were evaluated and defined. NDT follow-up methods shall be used for evaluation of regions at transport products being indicated by acoustic emission monitoring as areas of degradation.
Laboratory tests related to corrosion and fatigue, respectively, were defined and carried out by different project partners. In parallel acoustic emission measurements were carried out and related acoustic emission data have been detected and stored in a prepared data base. Such a data base is essential for further data analysis and data discrimination. Acoustic waves caused by active corrosion and/or fatigue cracks can propagate either in the metal to an acoustic emission sensor being directly mounted on the surface or through the liquid cargo to an acoustic emission sensor immersed into the liquid. Acoustic emission measurements showed that it is possible to acquire acoustic waves for both types of wave propagation.
Taking into account background measurements at real structures (ships, railway cars and trucks) and test results from laboratory tests analysis (e.g. filtering, pattern recognition) of measuring data has been started regarding the data evaluation intended for later use in a detection and pre-warning system. By means of specific filtering, pattern recognition and data available in the data base analysis tool for data discrimination could be adapted. Thus, analysis tools were used for discriminating acoustic emission data caused by background noise from acoustic emission data related to corrosion and fatigue cracks.
With the experience and knowledge gained during the first part of the project a concept for integrating the acoustic emission measuring equipment at transport products was created. Also an overall strategy for complementing and/or replacing of recent time based repetition tests by risk based testing enabled by acoustic emission monitoring in combination with follow-up NDT (non-destructive testing), was formulated.
During the second part of the project, trail tests at real structures (ships, railway cars and trucks) according to the prepared test procedures for checking of the monitoring concept and measuring equipment were performed. Results from trial test were analysed and based on their evaluation, both monitoring concept and measuring equipment were adapted. Subsequently, validation tests at real structures have been started. Results from validation tests showed that the new methodology generally is working, but that as expected further adaptation with respect to the specific category of transport product is necessary. Furthermore, the data base has to be enlarged with data from further measurements so that analysis tools can be improved.
In parallel to the tests carried out at real structures, adaptations and development of measuring equipment have been continued, especially for use in hazardous areas. Technical needs and safety requirements have been included into the design and first prototypes were produced. For transport products carrying hazardous goods (e.g. fuel, oil) additionally have to be fulfilled the specific regulations for the respective category (ships: ABS-rules, trucks: ADR, railway cars: RID) referring to ATEX regulations. Hence, prototypes were designed and produced and after testing during monitoring the prototypes were finalised according ATEX and equipment was certified for use in hazardous areas and is now available.
Further, verification test at transport products were performed during the last (third) period of the project. The testing procedure, adaptations of measuring equipment and evaluation of indications from acoustic emission testing by follow-up NDT were finalised. Based on measuring results and testing experiences the final generic survey and inspection procedure as well as a draft for standardisation organisations were created regarding pre-arrangements, specifications of transport products, application, instrumentation, equipment, inspection requirements, safety rules, monitoring procedure, data evaluation, source grading and identification, follow-up NDT and related maintenance actions.
Additionally, dissemination materials (e.g. leaflet, slide presentation, video) were produced for use in seminars, workshops, meetings and conferences to inform about the new technology.
Potential impact:
Based on the results of validation tests, the applicability of the developed monitoring technology for ships, railway cars and trucks is demonstrated and described in technology guidelines. Furthermore, the requirements for measuring equipment and its implementation, the advantages and limitations of the monitoring technique, the applications for monitoring and all necessary and important matters to be taken into account for the monitoring procedure, data analysis and evaluation procedure are described in a generic test procedure. Additionally, drafts for standardisation have been created and draw attention to this new technology and its applications in inspection processes for increasing safety on transport products (ships, railway cars and trucks), especially on those carrying hazardous goods.
The implementation of the new monitoring methodology in inspection processes of transport products will reduce the downtime during inspection and survey. One of the main benefits of acoustic emission monitoring is the fact that allows monitoring of the whole structure or concentration on regions of interest (e.g. hot spots, where most of degradation takes place) using a few sensors.
Additionally, monitoring of transport products can be performed permanently during service time or during defined dwell times under service like conditions. Hence, follow-up NDT can be limited to indications from AT, what reduces costs and time for inspection. Validation of follow-up NDT will be based on defined acceptance criteria. Permanent monitoring by means of the new technology enables pre-warning in an earlier stage of degradation and, hence, will lead to notable safety increase and decrease of repairing costs.
Consequently not only safety will rise due to better condition of the structures but also repairing costs will decrease. As a consequence, the competitiveness of transport companies will be rise, mostly by enable costs savings due to diminished repair time and expenses. Also accidents, secondary damages and other negative impacts on the environment will be avoided. In addition, this will have a positive effect on building trust and confidence of population in transport products.
Project website: http://www.corfat.eu
The main objectives for the last (third) period of the project were:
- final prototype of monitoring equipment for transport products;
- generic survey and inspection procedure using acoustic emission monitoring technology;
- drafts for standardisation.
Thus, further validation tests and measurements (similar to those started in the second period) on transport products (ships, road trucks and railway tank cars) were performed and measuring data were analysed. Based on analysis of data and experiences gained during last and former tests and measurements, the final prototype for monitoring equipment was defined and last adaptations of the equipment were done.
A generic survey and inspection procedure was created combining state of the art knowledge with results, knowledge and experience from project works. Especially, the differences concerning diverse categories of transport products (ships, road trucks and railway tank cars) had to be taken into account. The new methodology is described including, pre-arrangements, specifications of transport products, application, instrumentation, equipment, inspection requirements, safety rules, monitoring procedure, data analysis and evaluation, source grading and identification, follow-up non-destructive testing (NDT) and implementation to maintenance programme.
Finally, drafts for standardisation organisations have been prepared, describing the new methodology, requirements for equipment and instrumentation, application at transport products (ships, trucks and railway cars), data analysis and evaluation, follow-up NDT and definition of related maintenance and/or repair activities.
Project results:
In a first step, requirements have been defined for adaptation and development of hardware and software of instrumentation for acoustic emission as well as for conventional non-destructive testing (e.g. ultrasonic testing, penetrant testing, magnetic particle testing) based on inspection rules and existing standards (e.g. ADR, RID, ABS rules, ATEX), the knowledge of the project partners and pre-tests results. In a further step, requirements for a monitoring system and for acoustic emission instrumentation have been defined, whereas also the usage in hazardous areas was taken into account. A feasibility and validation study of non destructive testing follow-up methods was carried out with respect to hazardous areas and, hence, requirements for these methods were evaluated and defined. NDT follow-up methods shall be used for evaluation of regions at transport products being indicated by acoustic emission monitoring as areas of degradation.
Laboratory tests related to corrosion and fatigue, respectively, were defined and carried out by different project partners. In parallel acoustic emission measurements were carried out and related acoustic emission data have been detected and stored in a prepared data base. Such a data base is essential for further data analysis and data discrimination. Acoustic waves caused by active corrosion and/or fatigue cracks can propagate either in the metal to an acoustic emission sensor being directly mounted on the surface or through the liquid cargo to an acoustic emission sensor immersed into the liquid. Acoustic emission measurements showed that it is possible to acquire acoustic waves for both types of wave propagation.
Taking into account background measurements at real structures (ships, railway cars and trucks) and test results from laboratory tests analysis (e.g. filtering, pattern recognition) of measuring data has been started regarding the data evaluation intended for later use in a detection and pre-warning system. By means of specific filtering, pattern recognition and data available in the data base analysis tool for data discrimination could be adapted. Thus, analysis tools were used for discriminating acoustic emission data caused by background noise from acoustic emission data related to corrosion and fatigue cracks.
With the experience and knowledge gained during the first part of the project a concept for integrating the acoustic emission measuring equipment at transport products was created. Also an overall strategy for complementing and/or replacing of recent time based repetition tests by risk based testing enabled by acoustic emission monitoring in combination with follow-up NDT (non-destructive testing), was formulated.
During the second part of the project, trail tests at real structures (ships, railway cars and trucks) according to the prepared test procedures for checking of the monitoring concept and measuring equipment were performed. Results from trial test were analysed and based on their evaluation, both monitoring concept and measuring equipment were adapted. Subsequently, validation tests at real structures have been started. Results from validation tests showed that the new methodology generally is working, but that as expected further adaptation with respect to the specific category of transport product is necessary. Furthermore, the data base has to be enlarged with data from further measurements so that analysis tools can be improved.
In parallel to the tests carried out at real structures, adaptations and development of measuring equipment have been continued, especially for use in hazardous areas. Technical needs and safety requirements have been included into the design and first prototypes were produced. For transport products carrying hazardous goods (e.g. fuel, oil) additionally have to be fulfilled the specific regulations for the respective category (ships: ABS-rules, trucks: ADR, railway cars: RID) referring to ATEX regulations. Hence, prototypes were designed and produced and after testing during monitoring the prototypes were finalised according ATEX and equipment was certified for use in hazardous areas and is now available.
Further, verification test at transport products were performed during the last (third) period of the project. The testing procedure, adaptations of measuring equipment and evaluation of indications from acoustic emission testing by follow-up NDT were finalised. Based on measuring results and testing experiences the final generic survey and inspection procedure as well as a draft for standardisation organisations were created regarding pre-arrangements, specifications of transport products, application, instrumentation, equipment, inspection requirements, safety rules, monitoring procedure, data evaluation, source grading and identification, follow-up NDT and related maintenance actions.
Additionally, dissemination materials (e.g. leaflet, slide presentation, video) were produced for use in seminars, workshops, meetings and conferences to inform about the new technology.
Potential impact:
Based on the results of validation tests, the applicability of the developed monitoring technology for ships, railway cars and trucks is demonstrated and described in technology guidelines. Furthermore, the requirements for measuring equipment and its implementation, the advantages and limitations of the monitoring technique, the applications for monitoring and all necessary and important matters to be taken into account for the monitoring procedure, data analysis and evaluation procedure are described in a generic test procedure. Additionally, drafts for standardisation have been created and draw attention to this new technology and its applications in inspection processes for increasing safety on transport products (ships, railway cars and trucks), especially on those carrying hazardous goods.
The implementation of the new monitoring methodology in inspection processes of transport products will reduce the downtime during inspection and survey. One of the main benefits of acoustic emission monitoring is the fact that allows monitoring of the whole structure or concentration on regions of interest (e.g. hot spots, where most of degradation takes place) using a few sensors.
Additionally, monitoring of transport products can be performed permanently during service time or during defined dwell times under service like conditions. Hence, follow-up NDT can be limited to indications from AT, what reduces costs and time for inspection. Validation of follow-up NDT will be based on defined acceptance criteria. Permanent monitoring by means of the new technology enables pre-warning in an earlier stage of degradation and, hence, will lead to notable safety increase and decrease of repairing costs.
Consequently not only safety will rise due to better condition of the structures but also repairing costs will decrease. As a consequence, the competitiveness of transport companies will be rise, mostly by enable costs savings due to diminished repair time and expenses. Also accidents, secondary damages and other negative impacts on the environment will be avoided. In addition, this will have a positive effect on building trust and confidence of population in transport products.
Project website: http://www.corfat.eu
