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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
Po
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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