R&D Projects

ONGOING PROJECTS:

 

Programme- call

Project

Horizon 2020
H2020-FTIPilot-2015-1
Polytest

Ultrasonic Phased Array Non-Destructive Testing and In-Service Inspection System for high integrity Polyethylene Pipe Welds with automated analysis software.

H2020-FTIPilot-2016-1 Ship Test

Fully automated laser guided inspection robot for weld defect detection on ship hulls

 

FINISHED PROJECTS:

 

Programme- call

Project

FP7-SME-2013 IndGEAR

On-line early damage diagnosis, prognosis and root cause analysis for Industrial multi-stage gearboxes used in the water industry

http://www.indgear.eu/

Eurostars – Interempresas Internacional LinkInspect Development of an advanced medium range ultrasonic technique for in-water inspection of mooring chains.
Financiación y Cooperación Nacional – CENIT AZIMUT AZIMUT: Energía Eólica Offshore 2020
FP7-SME-2012 WINTUR DEMO

In-situ wireless monitoring of on – and offshore WINd TURbine blades using energy harvesting technology – Demonstration.

http://www.winturdemo-project.com/

FP7-SME-2011 CRANESInspect

Continuous Reliable Advanced Novel Efficient Structural Health Monitoring system for crane inspection applications.

http://www.cranesinspect.eu/

FP7-SME-2011 INTRAPID

Innovative inspection techniques for laser powder deposition quality control.

http://www.intrapid.eu

FP7-SME-2011 SpotTrack

Development of an automated spot weld inspection device for safe vehicle repair.

http://www.spottrack.eu

FP7-SME-2011 X-Scan

Laser-guided inspection robot for the Non-Destructive Testing of thin steel gauge welds in the shipping industry.

http://www.x-scan.eu

FP7-SME-2010-1 UltraCleanPipe

Ultrasonic detection and removal of fouling inside industrial and domestic pipes.

http://ultracleanpipe.com

FP7-SME-2007-2 Ship Inspector

Detection of safety critical cracks and corrosion in ships using novel sensors and systems based on ultrasonic linear phased array technology.

http://www.shipinspector.eu

FP7-SME-2010-1 HOTSCAN

Long range ultrasonic system for continuous in service inspection and structural health monitoring of high temperature superheated steam pipes in power generation plant with 100% coverage.

http://www.hotscan.eu

FP7-SME-2007-1 QualiTi

Development of new and novel quality control system for the inspection of titanium components in safety critical applications in the aerospace Industry.

more information

FP6-2003-NMP-SME-3 FilmFree

Development of novel digital radiography technology; to facilitate the ‘traditionally less research intensive inspection industry sector’ change from manual film radiography to automated digital.

http://www.filmfree.eu.com/

FP6-2004-SME-COOP Oliwam

Development and validation of on-line monitoring and NDT inspection of laser welded thin sheet automotive components.

more information

FP6- SME-1Co-operative Research FPSO-Inspect

Non-intrusive in-service inspection robotic system for condition monitoring of welds inside floating production storage and offloading (FPSO). Vessels

more information

FP6-2002-SME-1 Hull Inspector

Development of an autonomous mobile inspection vehicle for detecting structural defects in ships hulls.

more information

FP6-SME-1Co-operative Research Pipescan

Development of inspection systems for the inspection of metal pipelines buried underground, in concrete in water or covered with coatings.

more information

FP6-2002-SME-1 Rimini

Development of new and novel low cost robot inspection methods for in-service inspection of nuclear installations.

more information

FP6- SMEHorizontal research activities involving SMEs Safe-ray

Development of digital radiography techniques, sensors and systems to replace film radiography for defect detection in safety critical welds and castings.

more information

FP6- SME-1Co-operative Research Tank-Inspect

Condition monitoring of large oil and chemical storage tanks using ultrasonic guided wave tomography without the need to empty and clean the tanks.

more information

FP6-2003-SME-1 Risertest

Development of a Guided Long Range Ultrasonic Inspection System for the examination of offshore subsea Risers, Steel Catenary Risers (SCRs) and Flowlines.

more information

FP6-2003-SME-2 LRUCM

Long range ultrasonic condition monitoring of engineering assets.

more information

FP5-GROWTH 1.1.3.-1. Robot Inspector

Development of a robotic system for the inspection of large steel/aluminium plates in industrial plants.

more information

FP5-GROWTH 1.1.3.-3. Rail Inspect

Train mounted sensors and systems for the inspection of rails (RAIL INSPECT).

more information

ERA-NET AirTN 18-WeLdt

Automatic thermography inspection of welded components with limited access.

FP7-SME-2013 HotPhasedArray

High Temperature Pipe Structural Health Monitoring System utilising Phased Array probes on TOFD configuration

http://www.hotphasedarray.eu/

FP7-SME-2013 SprinkTest

Medium range Ultrasonic inspection technique for detecting micro-biologically induced corrosion in automatic fire sprinkler systems

http://www.sprinktestproject.eu/

Programa Operativo FEDER de Madrid. PID SPOTCRAFT AUTO

Development of an automated ultrasonic inspection device for quality control of Spot Welds.

 

LinkInspect

For floating and semi-submersible platforms moored to the seabed via chains, the mooring lines are safety critical. Despite fatigue design recommendations, expect from a mooring system that has a duration of 20 years or more without an active inspection and maintenance program is unrealistic.

The costs of a line failure are very high, therefore it is important to carry out tests to detect the presence of defects before the failure occurs. However, when mooring lines aren’t inspected in-situ.

  • The lines may be damaged during recovery or re-installation and

  • The operation is expensive because anchor handling and heading control tugs will be required for a period of days.

For these reasons, there was a strong motivation to develop in water inspection methods which could be used without stopping production. So, LinkInspect project was defined with the main objective of developing an ultrasonic guided wave technique in order to detect fatigue damage in mooring chains.

Partners:

Tecnitest Ingenieros (coordinator); Vicinay Cadenas; Baugh & Weedon

Role in the project

Throughout the project’s development three main challenges were achieved

  • LinkInspect Model for a sensor at inner surface

    Regarding the probes: Electromagnetic acoustic transducers (EMAT) have been used. This type of probes generates the ultrasound directly, therefore it’s possible to adapt to the surface roughness.

  • Regarding the transducer collar: A marinised transducer collar suitable for inspecting typical size ranges of mooring chains was designed.

  • Regarding the remote manipulator: The inspection system has to be assembled on a remote manipulator, able to work in marine environments and to climb the chain

Dissemination activities

Tecnitest Ingenieros attended the Middle East Corrosion Conference (MECC) in Bahrain as exhibitors, where were presented the results of the Linkinspect project.

logo-ministerio

“The research in LinkInspect project has received funding from CDTI. Programme Eurostars-Interempresas Internacional. Project no. CIIP-20112026″

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AZIMUT

Eleven companies and 22 research centres specialising in offshore wind farm technologies have joined forces on the Azimut. Offshore Wind Energy 2020 project.

The initiative, was designed to establish the technological groundwork for the subsequent development, in around 2020, of a large-scale offshore wind turbine. The programme’s initial objectives call for developing a wind turbine with unit capacity of 15 MW that is capable of overcoming the technical and financial hurdles currently limiting the rollout of offshore wind energy. The most pressing of these obstacles are availability, wind turbine foundations and energy delivery to land, and the challenge consists in narrowing the gap between offshore energy’s cost and required investment and those of onshore wind energy sites.

Through this project, participating companies have reinforced their commitment to R&D in offshore wind energy as a vehicle for achieving global technological leadership and contributing to the generation of offshore wind energy in a reliable, economically sound manner with the utmost respect for the natural environment.

Partners:

Gamesa (coordinator); Tecnitest Ingenieros; Acciona WP; Alstom Wind; Acciona Energía; Iberdrola Renovables; IGETEAM; IMATIA; INGECIBER; DGSILENT; Técnicas Reunidas.

Role in the project

AZIMUT Inspection PA in wind turbine towers

Based on the need to develop new testing techniques that increase the availability of the wind turbine, Tecnitest has participated in the following activities:

  • “Inspection Methods and Non Destructive Testing” -Research of new technologies that allow testing turbine components, before being used in the marine environment, as well as subsequent maintenance.

  • “Nondestructive research of different turbine components” -Development of techniques to be used on the respective wind turbine components.

Dissemination activities

Tecnitest Ingenieros attended the following events where were presented the results of the AZIMUT project.

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The research in AZIMUT project has received funding from CDTI. Programme Financiación y Cooperación Nacional-CENIT. Project no. CEN-20101009″

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18-WeLdt

18-WeLdt-01 Areas of inspection

In fabricated components and structures, different inspection and non-destructive testing (NDT) methods are today being used for weld inspection and the reliable detection of defects (cracks, pores etc.). Current techniques such as Visual Inspection, Fluorescent Penetrant Inspection (FPI), Eddy current and Radiography have limitations in applicability and detectability, especially for inspection of parts with complex geometries and difficult to reach access and may thus reduce the design freedom which may result in a poorer and possibly heavier component.

Inspection of welds with limited access puts specific requirement on the NDT-method to be used. A non-contact method removing the requirement for special surface preparation that is both rapid and cost efficient, with the possibility of automation would be much preferred.

Infrared thermography is being used for today mainly for the for NDT inspection of composite structures. The technique is based on monitoring the heat conduction of the material of the surface of the structure. The method requires some kind of excitation resulting in a change of heat locally in the inspected area.

In this project, we will evaluate different excitation methods, such as continuous laser, flash lamp and induction, as well as the possibilities for miniaturization and automation of the selected inspection method.

18-WeLdt-2 Different excitation methods: induction and laser

Partners:

University West (coordinator); Tecnitest Ingenieros; IK4 Lortek; GKN Aerospace Engine Systems

Role in the project

Tecnitest is involved in all project activities and is responsible for Automation & Miniaturization tasks both with respect to the excitation and to the sensing unit as well as interpretation of results giving an industrial point of view in order to generate a competitive product. Dissemination activities 6th International Symposium on NDT in Aerospace. aeroNDT 2014

logo-ministerio

The research in 18-WeLdt project has received funding from Centro para el Desarrollo Tecnológico Industrial (CDTI). Programme AirTN. Project no. IDI-20130343″

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SprinkTest

SprinkTest-02 Corrosion products in a fire sprinkler pipe

The installation of sprinklers can result in substantial reductions in insurance premiums and so insurance companies are becoming increasingly interested in their proper installation and function.

The proper functioning of fire sprinkler systems can be catastrophically undermined by corrosion. The water in the system pipes is stagnant and, if inhibitors are inactive, then this can give rise to microbiological induced corrosion (MIC), which leads to leaks. This corrosion is localized and is not evident in close visual inspection until the leak starts. Moreover the pipes are often enclosed and difficult to access for close viewing. MIC may occur in both dry and wet sprinkler systems.

Long range ultrasonic testing (LRUT) has been developed for screening long lengths of pipe (up to 100m from one test location) for corrosion, especially in otherwise inaccessible areas. It has been used to a limited extent on the feeder pipes and risers in sprinkler systems.

However, the pipe lengths are too short (typically <5m) and the defects too small in comparison with the ultrasound wavelengths for current LRUT systems. Moreover the numerous features such as pipe elbows and branches, makes interpretation of ultrasound echo-signals difficult.

SprinkTest aims to inspect automatic fire sprinkler systems by developing a medium range ultrasonic test (MRUT) system, using higher frequency ultrasound (100KHz -500KHz), smaller flexible transducers to gain access to confined spaces, lower power electronics to allow hand-held portability and sophisticated software to process signals and extract information from the numerous guided ultrasonic waves present at the higher frequencies.

Partners:

Plant Integrity (coordinator); Tecnitest Ingenieros; WLB; Baugh & Weedon; DVC; Innora; Kaunas University of Technology; European Fire Sprinkler Network;

Role in the project

Tecnitest leads activities related to system specifications, field trials and the final system integration. Tecnitest will also assume the role of Exploitation and Dissemination Manager, responsible for the commercialisation of the project results.

With developing the project, Tecnitest will gain new scientific knowledge and experience on a validated Medium Range Guided Waves technique for automatic fire sprinkler testing.

europa-logo-certificado-europeo

“SprinkTest has received funding from the European Union’s Seventh Framework Programme for research, technological development and demonstration under grant agreement no 605050.”

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HotPhasedArray

HotPhasedArray Failed high temperature pipe, with disastrous outcomesFailed high temperature pipe, with disastrous outcomes

Uncertainties in the calculation of the lifetime of superheated steam pipes in power plants that contain a minor defect create situations with potentially catastrophic results, typically costing €120 million per event. Superheated steam pipes are periodically inspected and depending on their defects sizes they may be replaced after a lifetime assessment has been performed. Common errors in defect sizing create dangerous situations as size underestimation will result in a pipe prone to failure.

The final goal of the HotPhasedArray project is the development of a Structural Health Monitoring (SHM) system for superheated steam pipes. The expected benefits of the project are:

  • Increased safety in electrical production power plants

  • Elimination of catastrophic accidents from superheated steam pipe failures

  • Decrease of the required shut-down time for inspection purposes

  • Increase in confidence in the operational safety of thermal power and nuclear energy plants.

Partners:

Inetec (coordinator); Tecnitest Ingenieros; iKnowHow; CeramTec; InnoTecUK; Brunel University; Enkon; Vermon

Role in the project:

Tecnitest will support in sample specification alongside monitoring laboratory trials for relevance to field trial validation. Throughout field trial validation they will also be providing suggestions for data collection. Throughout the dissemination process Tecnitest will support the consortium by marketing and advertising project developments to the fossil fuel power industry.

europa-logo-certificado-europeo

“HotPhasedArray is a research project invested in by the European Union. Grant agreement number 605267″

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IndGEAR

IndGEAR Debris clinging to a mixer impeller, thus increasing gearbox loadDebris clinging to a mixer impeller, thus increasing gearbox load

The balance between water demand and availability has reached a critical level in many areas of Europe, according to the European Environment Agency and it is expected that the situation will be exacerbated in future by climate and social change.

The UN Environment Programme reports that trends indicate a 40% rise in average water consumption by Europeans over the next 20 years, while EC statistics show that total freshwater resources are at relatively low levels (below 3,000m³ per capita) in the six largest Member States (Germany, Spain, France, Italy, Poland and the UK), as well as in Belgium, Denmark and the Czech Republic. It is clear that the treatment of wastewater has a key and growing role to play in addressing this problem and will require an increase in the number of water treatment facilities available. European wastewater treatment plants delivering high-quality clean water from sewage face a number of unresolved problems related to gearbox operation. Because most gearboxes operate in outdoor conditions, they are one of the most vulnerable units at treatment plants. The following conditions can lead to extensive gearbox damage/failure:

  • The probabilistic nature of gearbox loads and essential load variation during gearbox operation.

  • High levels of humidity increases the possibility of water ingress into lubricant oil of the gearbox.

  • High temperature variations.

  • Most gearboxes operate in non-stationary start/stop conditions.

The lndGEAR project — through our consortium of SMEs, research and development partners, and major water industry end users — aims to introduce the radically novel triple technology for damage diagnosis, damage prognosis, and root cause analysis through radically novel signal processing of gear vibrations.

Partners:

Microsay (coordinator);Tecnitest Ingenieros; Bierens; LUKA; I & T Nardoni Institute; ERIKS; Northumbrian Water; Cranfield University; University of Modena; UK Intelligent Systems Research Institute

Role in the project:

Tecnitest will take the output from the research performers and produce the new IndGEAR technologies/system. To provide and facilitate dissemination and exploitation plans in Spain and Europe. Tecnitest will be able to supply experience on in-situ application issues to and help provide solutions to the logistics of on-site inspection at water plants.

This project will open up a new market opportunity for Tecnitest, enabling them to perform prognosis, diagnosis and root cause analysis on gearboxes/rotating equipment.

europa-logo-certificado-europeo

“The research in indGEAR project has received funding from the European Commission’s FP7 R4SME Programme under the Grant Agreement Number 605864″

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SPOTCRAFT AUTO

SPOTCRAFT-auto-Tecnitest NDT

Automated inspection of spot welds

Spot welding is one of the most widely used techniques for joining metal sheets. However, with these types of joint, the activities of inspection and quality control present different problems than in other cases. In fact, in these production processes, welding parameters are established through “test/error” systems. The cost associated with this type of inspection is high, is an extremely laborious method, produces a significant amount of waste, is unreliable and when the problem is identified have been manufactured several components that should be rejected. In this Project, a system of inspection is being developed in order to determine the quality of the joint minimizing human intervention in the evaluation of results.

The proposed system allows a new dry coupling technology (no messy membranes) and a new signal processing, that improves the reliability of the inspection and facilitates automatization, allowing the system to be used inline within the productive system. After each test, all inspection results are stored and readily available. Together with other data such as the part reference, spot and weld gun identification, welding parameters, etc. the results can then be processed for monitoring, traceability and further action.

SPOTCRAFT-auto tecnitest ndt

Automatic classification of a spot weld

 

logo-ministeriocertificado europeo

“The research in SPOTCRAFT AUTO project has received funding from Centro para el Desarrollo Tecnológico Industrial (CDTI). Programa Operativo FEDER de Madrid. Proyectos de Investigación y Desarrollo. Project no. IDI-20141053”

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POLYTEST

The overall key objective of the PolyTest action is to take recently developed FP7 inspection and Non Destructive Testing (NDT) technology for polyethylene (PE) pipe welds, from Technology Readiness Level TRL6 to a TRL9 commercial product that will be exploited globally by the consortium partner providers to the consortium end user, Tier1/Tier2 suppliers and other customers in the EU and globally. This will be achieved through direct sales, licensing and/or franchising of the product, services and technology support (i.e. technician training and internationally recognised certification, technique and product/system validation to industry [nuclear] standards, application specific [component/weld configurations] technique procedures).

This will be made possible through a process of product and software enhancements for the specific application of testing (at manufacture and in-service) polyethylene (PE) pipe welds in the range 100mm to 800 diameter and 10mm to 80mm wall thickness in the following energy (power), gas and water utilities, minerals/mining and process plant industry sectors:-

  • (a) Electrical Power Generation, Nuclear Power Plant (NPP) – Essential Water Systems (EWS), Emergency Cooling Water, Feed Water, Class 3 and Emergency Boration Systems (EBS).
  • (b) Gas Utility – offshore FPSO, distribution and flow PE pipeline welds.
  • (c) Water Utility – for industrial and domestic use through welded PE transmission and distribution pipelines.
  • (d) Mining Industry – PE pipe for water supply, chemicals and slurry (production, economic, safety critical issues)
  • (e) Petrochemical and Process Plant (chemical, food and pharmaceutical industry) distribution and flow PE pipeline welds.

The main business driver for each of the EU strategic energy (e.g. NPP) or utility industries (e.g. gas and water) is the need to increase efficiency and return on capital assets through improving pipeline reliability and therefore the availability to operate in a safe and cost effective manner throughout the life of the pipeline.

The lack of appropriate European and international standards and specifications for the automated NDT inspection and automated defect recognition (ADR), data analysis, evaluation and PE weld sentencing software is a serious restriction in the take-up of the technology in the strategic target energy, water utility and mineral mining industries. Furthermore the lack of trained and certificated NDT personnel is another limitation to be addressed as is the validation of appropriate ultrasonic testing techniques, procedures and personnel.

Polytest

A typical electrofusion (EF) welded joint – and a butt-fusion (BF) welded joint.

 

Partners:

TWI Ltd, UK (co-ordinator); M2M, France; Plasflow Ltd, UK: Tecnitest Ingenieros S.L., Spain.

Role in the project

Tecnitest will be involved in all the work packages giving opinion, advice and direction.  However their main objective in this project is to bring potential customers to the commercial demonstration and provide Ultrasonic Level 2 personnel for training in the use of the equipment.

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“This project has received funding from the European Union’s Horizon 2020 IA Innovation action  under Grant Agreement No 701194 “

 

SHIPTEST

ShipTest is a ground-breaking laser-guided robotic crawler with the capability to perform automated Nondestructive Testing (NDT) inspection of ship hull welds, while the vessel is in-service. This feature is crucial as current methods require the ship to be dry-docked incurring expenses and revenue loss amounting to more than €150k per ship inspection. ShipTest’s cutting edge NDT equipment, a combination of Phased Array Ultrasonic and Alternating Current Field Measurement devices, can reliably inspect metal plates of thickness less than 10mm; a feature currently exclusively achieved by slow and dangerous radiographic methods. The robot can be set-up and operated by non-specialized crew members so that there is no need for NDT experts on board. Instead, the data produced will be uploaded on an online cloud platform for remote analysis.

Partners:

I. DIMOULIS and Co (Spectrum); Tecnitest Ingenieros S.L. (Tecnitest); Lloyd’s Register EMEA (LR); TWI Limited (TWI); Innora Proigmena Technologika Systimata kai Ypiresies Anonumi Eteria (Innora).

Role in the project

Tecnitest will be involved in all the work packages giving opinion, advice and direction.  However their main objective in this project is to provide their experience in NDT and complement the consortium bringing in the knowledge of the market,

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This project has received funding from the European Union’s Horizon 2020 research and innovation programme under Grant Agreement No 730645” .

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