Optimising non-destructive examination of newbuilding ship hull structures by developing a data-centric risk and reliability framework based on fracture mechanics

This thesis was previously held under moratorium from 18/11/19 to 18/11/21Ship structures are made of steel members that are joined with welds. Welded connections may contain various imperfections. These imperfections are inherent to this joining technology. Design rules and standards are based on the assumption that welds are made to good a workmanship level. Hence, a ship is inspected during construction to make sure it is reasonably defect-free. However, since 100% inspection coverage is not feasible, only partial inspection has been required by classification societies. Classification societies have developed rules, standards, and guidelines specifying the extent to which inspection should be performed. In this research, a review of rules and standards from classification bodies showed some limitations in current practices. One key limitation is that the rules favour a “one-size-fits-all” approach. In addition to that, a significant discrepancy exists between rules of different classification societies. In this thesis, an innovative framework is proposed, which combines a risk and reliability approach with a statistical sampling scheme achieving targeted and cost-effective inspections. The developed reliability model predicts the failure probability of the structure based on probabilistic fracture mechanics. Various uncertain variables influencing the predictive reliability model are identified, and their effects are considered. The data for two key variables, namely, defect statistics and material toughness are gathered and analysed using appropriate statistical analysis methods. A reliability code is developed based Convolution Integral (CI), which estimates the predictive reliability using the analysed data. Statistical sampling principles are then used to specify the number required NDT checkpoints to achieve a certain statistical confidence about the reliability of structure and the limits set by statistical process control (SPC). The framework allows for updating the predictive reliability estimation of the structure using the inspection findings by employing a Bayesian updating method. The applicability of the framework is clearly demonstrated in a case study structure.Ship structures are made of steel members that are joined with welds. Welded connections may contain various imperfections. These imperfections are inherent to this joining technology. Design rules and standards are based on the assumption that welds are made to good a workmanship level. Hence, a ship is inspected during construction to make sure it is reasonably defect-free. However, since 100% inspection coverage is not feasible, only partial inspection has been required by classification societies. Classification societies have developed rules, standards, and guidelines specifying the extent to which inspection should be performed. In this research, a review of rules and standards from classification bodies showed some limitations in current practices. One key limitation is that the rules favour a “one-size-fits-all” approach. In addition to that, a significant discrepancy exists between rules of different classification societies. In this thesis, an innovative framework is proposed, which combines a risk and reliability approach with a statistical sampling scheme achieving targeted and cost-effective inspections. The developed reliability model predicts the failure probability of the structure based on probabilistic fracture mechanics. Various uncertain variables influencing the predictive reliability model are identified, and their effects are considered. The data for two key variables, namely, defect statistics and material toughness are gathered and analysed using appropriate statistical analysis methods. A reliability code is developed based Convolution Integral (CI), which estimates the predictive reliability using the analysed data. Statistical sampling principles are then used to specify the number required NDT checkpoints to achieve a certain statistical confidence about the reliability of structure and the limits set by statistical process control (SPC). The framework allows for updating the predictive reliability estimation of the structure using the inspection findings by employing a Bayesian updating method. The applicability of the framework is clearly demonstrated in a case study structure

Machining-based coverage path planning for automated structural inspection

The automation of robotically delivered nondestructive evaluation inspection shares many aims with traditional manufacture machining. This paper presents a new hardware and software system for automated thickness mapping of large-scale areas, with multiple obstacles, by employing computer-aided drawing (CAD)/computer-aided manufacturing (CAM)-inspired path planning to implement control of a novel mobile robotic thickness mapping inspection vehicle. A custom postprocessor provides the necessary translation from CAM numeric code through robotic kinematic control to combine and automate the overall process. The generalized steps to implement this approach for any mobile robotic platform are presented herein and applied, in this instance, to a novel thickness mapping crawler. The inspection capabilities of the system were evaluated on an indoor mock-inspection scenario, within a motion tracking cell, to provide quantitative performance figures for positional accuracy. Multiple thickness defects simulating corrosion features on a steel sample plate were combined with obstacles to be avoided during the inspection. A minimum thickness mapping error of 0.21 mm and a mean path error of 4.41 mm were observed for a 2 m² carbon steel sample of 10-mm nominal thickness. The potential of this automated approach has benefits in terms of repeatability of area coverage, obstacle avoidance, and reduced path overlap, all of which directly lead to increased task efficiency and reduced inspection time of large structural assets

Quality management approach of product data models for shipbuilding

A quality management approach to manage the quality of ship product model data is discussed. It aims to improve and to automate product data model control to make the design and production processes more reliable. This approach is supporting an efficient correction of decient structural designs under visual guidance towards the identied problems. Two international standards ISO STEP-59 and ISO/PAS 26183:2006 are utilized in this thesis

NDE: An effective approach to improved reliability and safety. A technology survey

Technical abstracts are presented for about 100 significant documents relating to nondestructive testing of aircraft structures or related structural testing and the reliability of the more commonly used evaluation methods. Particular attention is directed toward acoustic emission; liquid penetrant; magnetic particle; ultrasonics; eddy current; and radiography. The introduction of the report includes an overview of the state-of-the-art represented in the documents that have been abstracted

A machine learning approach to pedestrian detection for autonomous vehicles using High-Definition 3D Range Data

This article describes an automated sensor-based system to detect pedestrians in an autonomous vehicle application. Although the vehicle is equipped with a broad set of sensors, the article focuses on the processing of the information generated by a Velodyne HDL-64E LIDAR sensor. The cloud of points generated by the sensor (more than 1 million points per revolution) is processed to detect pedestrians, by selecting cubic shapes and applying machine vision and machine learning algorithms to the XY, XZ, and YZ projections of the points contained in the cube. The work relates an exhaustive analysis of the performance of three different machine learning algorithms: k-Nearest Neighbours (kNN), Naïve Bayes classifier (NBC), and Support Vector Machine (SVM). These algorithms have been trained with 1931 samples. The final performance of the method, measured a real traffic scenery, which contained 16 pedestrians and 469 samples of non-pedestrians, shows sensitivity (81.2%), accuracy (96.2%) and specificity (96.8%).This work was partially supported by ViSelTR (ref. TIN2012-39279) and cDrone (ref. TIN2013-45920-R) projects of the Spanish Government, and the “Research Programme for Groups of Scientific Excellence at Region of Murcia” of the Seneca Foundation (Agency for Science and Technology of the Region of Murcia—19895/GERM/15). 3D LIDAR has been funded by UPCA13-3E-1929 infrastructure projects of the Spanish Government. Diego Alonso wishes to thank the Spanish Ministerio de Educación, Cultura y Deporte, Subprograma Estatal de Movilidad, Plan Estatal de Investigación Científica y Técnica y de Innovación 2013–2016 for grant CAS14/00238

Context-Enabled Visualization Strategies for Automation Enabled Human-in-the-loop Inspection Systems to Enhance the Situation Awareness of Windstorm Risk Engineers

Insurance loss prevention survey, specifically windstorm risk inspection survey is the process of investigating potential damages associated with a building or structure in the event of an extreme weather condition such as a hurricane or tornado. Traditionally, the risk inspection process is highly subjective and depends on the skills of the engineer performing it. This dissertation investigates the sensemaking process of risk engineers while performing risk inspection with special focus on various factors influencing it. This research then investigates how context-based visualizations strategies enhance the situation awareness and performance of windstorm risk engineers. An initial study investigated the sensemaking process and situation awareness requirements of the windstorm risk engineers. The data frame theory of sensemaking was used as the framework to carry out this study. Ten windstorm risk engineers were interviewed, and the data collected were analyzed following an inductive thematic approach. The themes emerged from the data explained the sensemaking process of risk engineers, the process of making sense of contradicting information, importance of their experience level, internal and external biases influencing the inspection process, difficulty developing mental models, and potential technology interventions. More recently human in the loop systems such as drones have been used to improve the efficiency of windstorm risk inspection. This study provides recommendations to guide the design of such systems to support the sensemaking process and situation awareness of windstorm visual risk inspection. The second study investigated the effect of context-based visualization strategies to enhance the situation awareness of the windstorm risk engineers. More specifically, the study investigated how different types of information contribute towards the three levels of situation awareness. Following a between subjects study design 65 civil/construction engineering students completed this study. A checklist based and predictive display based decision aids were tested and found to be effective in supporting the situation awareness requirements as well as performance of windstorm risk engineers. However, the predictive display only helped with certain tasks like understanding the interaction among different components on the rooftop. For remaining tasks, checklist alone was sufficient. Moreover, the decision aids did not place any additional cognitive demand on the participants. This study helped us understand the advantages and disadvantages of the decision aids tested. The final study evaluated the transfer of training effect of the checklist and predictive display based decision aids. After one week of the previous study, participants completed a follow-up study without any decision aids. The performance and situation awareness of participants in the checklist and predictive display group did not change significantly from first trial to second trial. However, the performance and situation awareness of participants in the control condition improved significantly in the second trial. They attributed this to their exposure to SAGAT questionnaire in the first study. They knew what issues to look for and what tasks need to be completed in the simulation. The confounding effect of SAGAT questionnaires needs to be studied in future research efforts

Coatings for Corrosion Protection: Offshore Oil and Gas Operation Facilities, Marine Pipeline and Ship Structures

This workshop on Coatings for Corrosion Protection: Offshore Oil and Gas Operation Facilities, Marine Pipelines, Ship Structures, and Port Facilities was held on April 14-16, 2004 in Biloxi, Mississippi. This workshop of 150 attendees drew participation by internationally recognized marine coating experts, material specialists, inspection specialists, coating manufacturers, maintenance engineers, and designers. The workshop was crafted to include multiple viewpoints: industrial, academic, environmental, regulatory, standardization, and certification. Keynote and topic papers were presented to establish a current information base for discussions. Six discussion groups addressed specific issues and identified, prioritized, and recommended specific research and development topics for the government and industries to undertake. The recommendations of this workshop offer a clear identification of research and development issues and create a roadmap for achieving them

Applications of Computer Vision Technologies of Automated Crack Detection and Quantification for the Inspection of Civil Infrastructure Systems

Many components of existing civil infrastructure systems, such as road pavement, bridges, and buildings, are suffered from rapid aging, which require enormous nation\u27s resources from federal and state agencies to inspect and maintain them. Crack is one of important material and structural defects, which must be inspected not only for good maintenance of civil infrastructure with a high quality of safety and serviceability, but also for the opportunity to provide early warning against failure. Conventional human visual inspection is still considered as the primary inspection method. However, it is well established that human visual inspection is subjective and often inaccurate. In order to improve current manual visual inspection for crack detection and evaluation of civil infrastructure, this study explores the application of computer vision techniques as a non-destructive evaluation and testing (NDE&T) method for automated crack detection and quantification for different civil infrastructures. In this study, computer vision-based algorithms were developed and evaluated to deal with different situations of field inspection that inspectors could face with in crack detection and quantification. The depth, the distance between camera and object, is a necessary extrinsic parameter that has to be measured to quantify crack size since other parameters, such as focal length, resolution, and camera sensor size are intrinsic, which are usually known by camera manufacturers. Thus, computer vision techniques were evaluated with different crack inspection applications with constant and variable depths. For the fixed-depth applications, computer vision techniques were applied to two field studies, including 1) automated crack detection and quantification for road pavement using the Laser Road Imaging System (LRIS), and 2) automated crack detection on bridge cables surfaces, using a cable inspection robot. For the various-depth applications, two field studies were conducted, including 3) automated crack recognition and width measurement of concrete bridges\u27 cracks using a high-magnification telescopic lens, and 4) automated crack quantification and depth estimation using wearable glasses with stereovision cameras. From the realistic field applications of computer vision techniques, a novel self-adaptive image-processing algorithm was developed using a series of morphological transformations to connect fragmented crack pixels in digital images. The crack-defragmentation algorithm was evaluated with road pavement images. The results showed that the accuracy of automated crack detection, associated with artificial neural network classifier, was significantly improved by reducing both false positive and false negative. Using up to six crack features, including area, length, orientation, texture, intensity, and wheel-path location, crack detection accuracy was evaluated to find the optimal sets of crack features. Lab and field test results of different inspection applications show that proposed compute vision-based crack detection and quantification algorithms can detect and quantify cracks from different structures\u27 surface and depth. Some guidelines of applying computer vision techniques are also suggested for each crack inspection application