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As more offshore wind parks are commissioned, the focus will inevitably shift from a planning, construction, and warranty focus to an operation, maintenance, and investment payback focus. In this latter case, both short-term risks associated with wind turbine component assemblies, and long-term risks related to integrity of the support structure, are highly important. This research focuses on the role of condition monitoring to lower costs and risks associated with short-term reliability and long-term asset integrity. This enables comparative estimates of the life cycle costs and reduction in uncertainty, both of which are of value to investors.
Condition monitoring of industrial infrastructures using distributed fibre optic acoustic sensors
(2017)
Distributed fibre optic acoustic sensing (DAS) can serve as an excellent tool for real-time condition Monitoring of a variety of industrial and civil infrastructures. In this paper, we portray a subset of our current Research activities investigating the usability of DAS based on coherent optical time-domain reflectometry (C-OTDR) for innovative and demanding condition Monitoring applications. Specifically, our application-oriented Research presented here aims at acoustic and vibrational condition monitoring of pipelines and piping systems, of rollers in industrial heavy-duty conveyor belt systems and of extensive submarine power cable installations, respectively.
Condition monitoring of industrial infrastructures using distributed fibre optic acoustic sensors
(2017)
We report on BAM's current research activities targeting the usability of distributed fibre optic acoustic sensing (DAS)for monitoring applications of industrial and civil infrastructures. Specifically, we present investigations on the use of DAS for condition monitoring of pipelines, of rollers in industrial conveyor belt systems and of submarine power cables, respectively.
Distributed Fibre Optic Acoustic and Vibration Sensors for Industrial Monitoring Applications
(2017)
We investigate the usability of distributed fibre optic acoustic sensing (DAS) for innovative and advanced monitoring applications in industrial and civil infrastructure installations. In this paper, we report on our ongoing application-oriented research activities regarding the utilization of DAS based on coherent optical time-domain reflectometry (C-OTDR) for condition monitoring of a variety of infrastructures. Specifically, our research presented here aims at acoustic condition monitoring of and fault detection in pipelines and industrial piping systems, at acoustic condition monitoring of rollers in industrial conveyor belt installations, and at acoustic condition monitoring of and threat detection in extensive submarine power cables, respectively. Furthermore, we show a method to mitigate the effect of sensitivity fading of C-OTDR based DAS due to unstable environmental conditions via the modification of the sensor fibre. This can help to provide a continuous adequate sensor functionality for a number of different industrial monitoring applications.
Distributed fibre optic acoustic sensing for condition and structural health monitoring applications
(2017)
We present current and previous research projects and activities at BAM related to distributed fibre optic acoustic sensing (DAS) for condition monitoring purposes. Furthermore, we show the experimental capabilities of our DAS equipment and portray other BAM competences in fibre optic sensing that could be combined with DAS.
Distributed Fibre Optic Sensing for Monitoring and Testing of Industrial and Civil Infrastructures
(2018)
Fibre optic sensors enable the gathering of sensory information in environments where conventional sensors fail or simply can not be utilised. Their small size enables their use in confined spaces as well as their embedding or integration in components, structures or composite materials while offering, depending on the approach, high sensitivity, very high spatial resolution and, especially, the possibility to detect or measure physical quantities in a distributed way, meaning spatially continuous sensing over very long distances.
Those distributed fibre optic sensors (DFOS) provide access to sensing information from different locations along the sensing fibre without the need for technologically challenging multiplexing of many point sensors and the subsequent sensor data fusion. In this way, DFOS are excellently suited as smart sensors for monitoring or testing purposes as the spatially distributed sensing data make available spatially resolved measurand profiles without a gap. Furthermore, the possible embedding or integration of DFOS could facilitate the development of smart structures or smart components. In particular distributed vibration sensing (DVS) and distributed temperature sensing (DTS) are also ideally suited for condition monitoring of machinery, industrial installations or extensive infrastructure, also, on-line real-time assembly or component testing in production lines, e.g. for quality control, is possible.
In this talk, we will shortly outline the underlying principles of some fibre optic sensing approaches, explain their fundamental differences in mode of operation and performance, and discuss their applicability and limitations. Moreover, we will report on a subset of current and previous applied research projects at BAM, investigating different areas of use for distributed fibre optic sensors in particular.
The paper deals with the integration of a light emitting diode (LED) into an additive manufactured metal component. Selective laser melting (SLM) and laser metal deposition (LMD) are used. The material used is the chrome-nickel steel 316L. The basic component is manufactured by means of SLM and consists of a solid body and an area with grid structure. The solid body includes a duct in the shape of a groove with a recess for the positioning of the power cable. The LED is embedded in the grid structure via an inlet from the solid body. In further processing, the groove is filled with LMD. Two strategies with different parameter combinations were investigated. It shows that a high energy input near the power cable leads to its destruction. By using multiple parameter combinations during the manufacturing process, this destruction can be prevented. There was a comparison of both strategies with regard to the necessary number of tracks and duration of welding time.
The paper deals with the integration of a light emitting diode (LED) into an additive manufactured metal component. Selective laser melting (SLM) and laser metal deposition (LMD) are used. The material used is the chrome-nickel steel 316L. The basic component is manufactured by means of SLM and consists of a solid body and an area with grid structure. The solid body includes a duct in the shape of a groove with a recess for the positioning of the power cable. The LED is embedded in the grid structure via an inlet from the solid body. In further processing, the groove is filled with LMD. Two strategies with different parameter combinations were investigated. It shows that a high energy input near the power cable leads to its destruction. By using multiple parameter combinations during the manufacturing process, this destruction can be prevented. There was a comparison of both strategies with regard to the necessary number of tracks and duration of welding time.
Pipe integrity is a central concern regarding technical safety, availability, and environmental compliance of industrial plants and pipelines. A condition monitoring system that detects and localizes threats in pipes prior to occurrence of actual structural failure, e.g., leakages, especially needs to target transient events such as impacts on the pipe wall or pressure waves travelling through the medium. In the present work, it is shown that fiber-optic distributed acoustic sensing (DAS) in conjunction with a suitable application geometry of the optical fiber sensor allows to track propagating acoustic waves in the pipeline wall on a fast time-scale. Therefore, short impacts on the pipe may be localized with high fidelity. Moreover, different acoustic modes are identified, and their respective group velocities are in good agreement with theoretical predications. In another set of experiments modeling realistic damage scenarios, we demonstrate that pressure waves following explosions of different gas mixtures in pipes can be observed. Velocities are verified by local piezoelectric pressure transducers. Due to the fully distributed nature of the fiber-optic sensing system, it is possible to record accelerated motions in detail. Therefore, in addition to detection and localization of threatening events for infrastructure monitoring, DAS may provide a powerful tool to study the development of gas explosions in pipes, e.g., investigation of deflagration-to-detonation-transitions (DDT).
Comprehensive monitoring of pipelines over their full length is technically difficult and expensive. Considering a cost-benefit ratio it is reasonable to implement monitoring solutions in pipeline segments, which bear a high risk potential, like residential areas, construction sites, slopes, street or river crossings. Still such segments can measure up to several hundred meters in length, demanding for monitoring solutions that extend along such distances and enable fast response. Point wise sensing and periodical surveillance have clear drawbacks, particularly regarding early damage detection. Fibre optic sensors enable distributed sensing of temperature and strain, but they offer very limited possibilities for measuring gas concentrations. Linear membrane-based gas sensors enable the monitoring of gas concentrations alongside a pipeline. Such line-sensors are implemented in form of flexible tubes and can be arranged inside or outside the pipeline (also underwater or within the subsurface), corresponding to the technical requirements. The measuring method combines the gas specific diffusion rates through a membrane with Dalton’s law of partial pressures and enables the calculation of gas concentrations or the detection of a change of the gas composition. The objective is to detect gas leakages fast and with high reliability. Furthermore, the calibrated system enables to estimate the spatial extent of a leakage. So far the gas concentration measurement is tested for oxygen, carbon dioxide, methane; further gases should follow, e.g. hydrogen, carbon monoxide or mixtures like natural gas. The paper introduces in the different operating modes of line-sensors. A near real-time approach will be demonstrated to quantify the impact of a gas leak on the near environment. This approach is based on a critical length describing the expansion of the leaking gas.
Composite pressure vessels are important components in the storage of gases under high pressure. Among others, a common type of pressure vessel is made of a metal liner overwrapped with a fibre-reinforced plastic material. Conventional hydrostatic tests, used to assess the integrity of pressure vessels, may overstress the material and thus reduce the remaining lifetime of the tested component. Therefore, a truly non-destructive structural health monitoring (SHM) system would not only ensure a safer usage and extended lifetime, but also remove the necessity for periodic inspection and the testing of pressure vessels. The authors propose the use of guided ultrasonic waves, which have the potential to detect the main damage types, such as cracking in the metal liner, fibre breaks and composite matrix delamination. For the design of such an SHM system, multimodal ultrasonic wave propagation and defect-mode interaction must be fully understood. In this paper, simulation results obtained by means of finite element modelling (FEM) are presented. Based on the findings, suggestions are made regarding appropriate wave modes and their interaction with different flaw types, as well as the necessary excitation and suitable sensor configurations. Finally, a first approach for a reliable SHM system for composite pressure vessels is suggested.
Structural health monitoring of wind turbine blades by strain measurement and vibration analysis
(2011)
Wind turbine blades have to withstand a high number of load cycles in mostly hard weather conditions over 20 years. In a research project BAM and several partners have designed, evaluated and tested a condition monitoring system for all parts of a wind turbine. At a rotorblade with a length of 58 m fibre bragg grating sensors were applied for in-service strain measurement. Additionally a complex test rig was designed to enable real biaxial loading conditions at a representative test rotor blade to simulate the mechanical loading conditions in the lab. In this test blade with a length of 8 m also fibre bragg grating sensors were implemented to determine their influences for the structure and the condition monitoring system. Vibration measurements were carried out at different test phases. The results were compared with finite element strain and modal analysis.
This paper establishes the model basis regarding the ultimate limit state consisting of structural, loading, and probabilistic models of the support structure of offshore wind energy converters together with a sensitivity study. The model basis is part of a risk based assessment and monitoring framework and will be applied for establishing the 'as designed and constructed' reliability as prior information for the assessment and as a basis for designing a monitoring system. The model basis is derived considering the constitutive physical equations and the methodology of solving these which then in combination with the ultimate limit state requirements leads to the specific constitutive relations. As a result finite element models based on shell elements incorporating a structural and a loading model are introduced and described in detail. Applying these models the ultimate capacity of the support structure and the tripod structure are determined with a geometrically and materially nonlinear finite element analysis. The observed failure mechanisms are the basis for the definition of the ultimate limit state responses. A probabilistic model accounting for the uncertainties involved is derived on the basis of literature review and measurement data from a prototype Multibrid M5000 support structure. In combination with the developed structural and loading models, sensitivity analyses in regard to the responses are performed to enhance the understanding and to refine the developed models. To this end, as the developed models necessitate substantial numerical efforts for the probabilistic response analysis predetermined designs of numerical experiments are applied for the calculation of the sensitivities using the Spearman rank correlation coefficient. With this quantification of the sensitivity of the random variables on the responses including nonlinearity the refinement of the model is performed on a quantitative basis.