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AREVA NDE Solutions

ATHENA

Yannick CAULIER

AREVA NDE-Solutions

12th International Conference on NDE

Dubrovnik, Croatia

October the 4th 2016

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Contents

Context

Alternative to the DPI and the MPI

Existing (current) photothermal camera system

ATHENA project

Project objectives / Consortium

Technical and commercial aspects

Technical developments

Specifications: linking technical challenges vs. industrial requirements

Development: hardware and software of the prototype

Research: image processing and thermographic simulations

Conclusion / Next steps

Achieved results

What is planned (until and after the end of the project)

12th ICNDE (Dubrovnik, Croatia) – ATHENA – October the 4th 2016 - p.3

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ContextPT/MT historical techniques

Penetrant testing (DPI) and Particle magnetic testing (MPI)

Surface methods (since 1930 in the industry)

All industry sectors

Rules / standards (about 30 standards)

Existing certifications of the inspectors

Principe : excitation, perturbation, reveal

Main advantages

Sensitivity: 5 µm MPI, < 1 µm (DPI), subsurface (MPI)

Robust (usable in harsh environments)

‘Rapid’: huge pieces

Global: every dimensions and geometries, non-porous material (DPI)and ferromagnetic (MPI) (forged pieces, machined, swaging…)

Huge know-how (constant evolution of the market, competitive prices)

MPI

DPI

12th ICNDE (Dubrovnik, Croatia) – ATHENA – October the 4th 2016 - p.4

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ContextPT/MT: limitations / evolutions

Limitations concerning the NDE

Open discontinuities (DPI), ferromagnetic materials (MPI)

Long inspection time (standalone / complex pieces) ; sequential control

REACH (Registration, Evaluation, Authorization andRestriction of Chemicals) (GHS / CLP)

HSE factors (Health, Safety, Environment)

Operators: exposed to the solvents, organic products, EM fields

Environment: effluents and waste (solvent vapor, organic products)

Future evolutions

DPI/MPI: necessary adjustments (same performances / newrecommendations), see annex 14 of REACH (next update in 07/2017)

COFREND: WG “alternative methods to DPI/MPI” (AREVA lead)

Alternative NDE technique: sensitive, industrial, 100% automatic

12th ICNDE (Dubrovnik, Croatia) – ATHENA – October the 4th 2016 - p.5

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ContextThe current PTC

Main steps

1993-2000(1st demonstrator)

2001-2002 (2nd demonstrator)(AREVA / ONERAco-development)

2003-2007feasibilities(under water…)

2008-2011market / industrializationstudies

2012-2013collaborative projectsetup

Video

Main developments

Framatome / AREVA

• Tubes on plates (2002-PHENIX)

• CANOPY joint (2005-AREVA)

• Partition plate Chinon (2005-EDF)

• Internal weld (2005-CEA)

• Thermal crazing (2005-CEA)

• Vessel head adaptor (2005-AREVA)

• Vessel welds (2006-ITER)

• Thermal crazing (2007-EDF-R&D)

• Aluminum panel (2014-Dassault)

• …

AREVA / EDF Partnership(EDF R&D, CEIDRE, DTG)

(2008-09)

• Partition plate (SV2 Chinon)

• Influent parameters

12th ICNDE (Dubrovnik, Croatia) – ATHENA – October the 4th 2016 - p.6

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ATHENACollaborative project

ATHENA (09/2014 – 08/2017)

3 years collaborative project (labeled by thePôle de l’Industrie Nucléaire (PNB))

Financing FUI (Fonds Unique Interministériel)

8 partners (leaded by INTERCONTRÔLE)

Partners

4 industrials (final users): AREVA, EDF (DTGand CEIDRE), Aubert & Duval, AscotControls specifications (industrial constraints)

2 SMB (integrators):ARDPI, Imagine OpticDevelopment of the new PTC

2 academics (R&D):University of Burgundy, ARMINESSimulation tool and processing algorithms

12th ICNDE (Dubrovnik, Croatia) – ATHENA – October the 4th 2016 - p.7

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ATHENAProject objectives

Develop a new version of the photothermal camera (PTC)

Take into consideration the recommendations of the end-users(Aubert & Duval, Ascot, EDF and AREVA)

Be an alternative to the DPI and the MPI

Technically this means

Smaller (factor 3), faster (factor 2 to 4), lighter (factor 3)

Ergonomic system (simplified HMI)

Easier to use for onsite inspections (eye-safe)

Other objectives

Develop new type of competencies in software development androbotics (LabVIEW and CimStation for robot trajectories simulations)

Develop image processing algorithms (detection, segmentation) andsetup a simulation model (COMSOL + MATLAB)

12th ICNDE (Dubrovnik, Croatia) – ATHENA – October the 4th 2016 - p.8

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ATHENAEconomical model

Technologicalelements for currentand future products /

market outsideATHENA

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12th ICNDE (Dubrovnik, Croatia) – ATHENA – October the 4th 2016 - p.9

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ATHENAProject schedule

Achieved tasks

Specification of the mockups and associated inspections

Specification of the main components (infrared and visible cameras,heating laser, telemeter) and the software (HMI and architecture)

Upcoming tasks

PTC componentsintegration (10/16)

PTC and project robotvalidation (01/17)

Final validation trialsat EDF-DTGand Aubert & Duval(1st semester 2017)

End of project (08/17)

12th ICNDE (Dubrovnik, Croatia) – ATHENA – October the 4th 2016 - p.10

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Technical developmentsSpecifications: applications

12th ICNDE (Dubrovnik, Croatia) – ATHENA – October the 4th 2016 - p.11

Sub- / breaking flawsWelds of shells

(production)

Coating inspectionPelton wheels(maintenance)

Sub- / breaking flaws(scoured parts)

SG – partition plate(maintenance)

Surface breaking flawsTurbine blades

(production)

J-WeldsUnder the vessel(maintenance)

Surface breaking flawsGas turbine disk(production)

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Technical developmentsSpecifications: inspections

All 12 project mockups inspected with the current PTC

AREVA: weld inspection (J-weld, shell, partition plate)Subsurface detection up to 0,1 mm (and 1,0 mm) below the surface

Aubert & Duval: aluminum piece, turbine disk (UDIMET material)Very good detection of the cracks

EDF: mockups with HVOF-coating (300 µm) and 5 µm open cracksVery good detection of under coating defects and of small cracks

ASCOT: detection of porosities (≥ 0,5 mm)

Small cracks(≥ 5 µm width)

Small cracks(≥ 5 µm width)

Defects beneath the coating

12th ICNDE (Dubrovnik, Croatia) – ATHENA – October the 4th 2016 - p.12

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Technical developmentsDevelopment: hardware

Complete “box”

Smaller: 150x250x375 mm3

Lighter: maximum 11 kg

Laser line: adaptable /more homogeneous

Main components

Infrared sensor

Laser collimator

Visible sensor (with laser pointer)

Scanning galvanometers

Telemeter

Adjustments

Orientation of the laser of the camera done in the laboratory

Inspection on site (manual and/or robot)

12th ICNDE (Dubrovnik, Croatia) – ATHENA – October the 4th 2016 - p.13

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Technical developmentsDevelopment: hardware

Automatic inspection

First results of robot trajectories determination for the mainapplications: J-Weld, turbine blade, Pelton wheels

Turbineblades

Peltonwheels

J-Weldvideo

12th ICNDE (Dubrovnik, Croatia) – ATHENA – October the 4th 2016 - p.14

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Technical developmentsDevelopment: software

Software elements

New interface (“all in one”)

Integrated processing algorithms

Automatic (robot) inspections

Main modes

Configuration: characteristics of thecomponents to be inspected(type of material, working distance…)

Inspection: controls of the differenthardware components (galvanometer,laser, lenses…)

Processing: reconstruction of the final image,automatic preprocessing,visualization of the inspection resultsautomatic generation of an inspection report

12th ICNDE (Dubrovnik, Croatia) – ATHENA – October the 4th 2016 - p.15

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Technical developmentsDevelopment: research

Image processing

Detection and segmentationof critical defects(automatic generation ofinterpretable resultsfor the operator)

Works for 2 types of defects(cracks and delamination)

Processing algorithms(compiled in a DLL)

Few entrance parameters(defect size, type…)

12th ICNDE (Dubrovnik, Croatia) – ATHENA – October the 4th 2016 - p.16

Finalimage

Filteredimage

Detectionresult

Artefactssuppression

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Technical developmentsDevelopment: research

Thermographic simulation

Setup of the simulation modelsthermograms and synthetic images(for 18 MN D5, stainless steel 316Land Inconel 600)

Determination of the most influentparameters (parametric study)for the applications of the project

Aim of the simulation

To have a model for the project applications(simulation + synthetic images)

Help to the conception and validation(performances justification)

Prepare of exams (for known examinations)

New cases study (reduce the number of real tests)

12th ICNDE (Dubrovnik, Croatia) – ATHENA – October the 4th 2016 - p.17

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Conclusion

Current ongoing project results

Project developments ‘in time’ : specification done, ongoingdevelopments, validation in 2017

New technical add-ons: image processing, telemeter, visible camera

New functionalities: robot exams (trajectory determination)

More industrial: HMI, operator safety

Final validation of the industrial prototype (until 08/2017)13 mockups, 2 applicationsCriteria : detection results, examination time

Project management / planning

Good interaction of all project partners: regular exchanges / meetings

Annual meeting with all the technical / industrial partners and the financers

Major interests of a collaborative project: share of knowledge and material

12th ICNDE (Dubrovnik, Croatia) – ATHENA – October the 4th 2016 - p.18

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Next stepsMarket expectations

Key customers

Project consortium: EdF-nuclear -hydraulic, Aubert & Duval, Ascot Mistras

Others: aeronautic (Dassault, EADS, Snecma, Messier-Dowty, Boeing,Eurocopter), transport (DB, SNCF, Alstom), energy (EDF, GRT gas,Alstom), defense (DCNS), metallurgy (Sollac, Thyssen, Arcelor Mittal)

Market

Sales of systems (PTC alone or complete with robot)Aubert & Duval, Dassault and EDF-Nuclear are the most probable

Inspection: EDF-hydraulic is the most probable (we currently do severalinspection each year with the current PTC)

Aubert & Duval (turbine disk)

EDF-hydraulic(Pelton wheels)

Dassault (aluminumcomponents of the Falcon)

12th ICNDE (Dubrovnik, Croatia) – ATHENA – October the 4th 2016 - p.19

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This document contains elements protected by intellectual property rights as wellas confidential information.Any reproduction, alteration, transmission to any third party or publication in whole or in partof this document and/or its content is prohibited unless AREVA has provided its prior andwritten consent. This prohibition concerns notably any editorial elements, verbal and figurativemarks and images included herein.This document and any information it contains shall not be used for any other purpose thanthe one for which they were provided. In particular, no patent application and/or registereddesign may be applied for on the basis of the information contained herein.

Legal action may be taken against any infringer and/or any person breaching theaforementioned rules.No warranty what so ever, express or implied, is given as to the accuracy, completenessor fitness for a particular use of the information contained in this document. In no eventAREVA shall be liable for any damages what so ever including any special, indirect orconsequential damages arising from or in connection with access to, use or misuse of theinformation contained in this document.

Note

12th ICNDE (Dubrovnik, Croatia) – ATHENA – October the 4th 2016 - p.20