A Concept of Digital Platform for NDE4

International Virtual Conference on NDE 4.0 – 2021

1 License: https://creativecommons.org/licenses/by-nd/4.0/

A Concept of Digital Platform for NDE4.0

Makoto OCHIAI 1, Setsu YAMAMOTO 1 1 Toshiba Energy Systems and Solutions Corporation, Yokohama, Japan

Contact e-mail: [email protected]

Abstract

Toshiba is a plant manufacturer of energy and social infrastructure systems, as well

as a service vendor involved in the operation and maintenance of operating plants. Regarding

non-destructive testing (NDT), we not only provide inspection services for manufacturing

and maintenance but also have long been developing and applying lots of special inspection

systems in-house.

Recently, we are focusing on digitalization of NDT data and also increasing values

by linking and utilizing data using our digital platform. We consider NDT digitalization in 3

phases, those are: I. Fundamental digitization, II. Vertical integration of NDT data to improve

NDT performance and III. Horizontal integration to create new solutions. In Phase I, not only

digitization of flaw detection data but also NDT system information, inspector information

and document digitization are included. These are integrated with advanced digital

technologies such as local-5G communication and AR / VR. In Phase II, various NDT data

are linked and utilized. For example, by sharing NDT data across inspection personnel, NDT

systems, production lines and test subjects via the digital platform, it will enhance the

performances of AI and deep learning for NDT and improve the quality of NDT results. In

Phase III, data is linked through the supply chain, not limited to NDT field. By integrating

NDT data with a wide variety of data such as pre-manufacturing processes of test subjects or

operation history of the asset after in-service, new solutions for asset management such as

lifetime prediction, operation planning, inspection / renewal planning, etc. will be created.

In this presentation, we will introduce some practical examples of Toshiba's activities

on this fields and propose a concept for future international cooperation and discussion.

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A Concept of Digital Platform for NDE4.0

Makoto Ochiai and Setsu YamamotoEnergy Systems R&D CenterToshiba Energy Systems & Solutions CorporationYokohama, Japan 2021.04.15


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Takeaways

You will understand:

What we expect for NDE4.0.

How we deal with the NDT data and feed the data into various services.

Three types of data sources generating physical data (IoT), engineering data (IoS) and expertʼs concerns (IoP) accordingly.

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Toshiba’s Concept for NDE4.0

� World advanced techniques of plant and system control, AI and signal processing

� TOSHIBA SPINEX: Industrial digital service based on Toshiba IoT Reference Architecture (TIRA)

Long and rich experiences of design, manufacture, O&M of plants, systems and equipment.

×Advanced practical NDE techniques

Phased Array UT, Laser UT, Array ECT, Color I.I. etc...

Strength in CYBERStrength in PHYSICAL

Effectively use of NDT data for physical safety and security, Fedback valuable solutions using digital technologies to physical region

Robot UT for narrow partAuto positioning ECT

Solution

http://www.toshiba.co.jp/about/ir/en/pr/pdf/tpr20201203_2e.pdf?_ga=2.38421283.120314072.1615452436-953523302.1615452436


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Major Scope of Data Linkage and Usage

Asset Owner

Physical

ProcuremeProcuremeProcurementDesign/Engineering

ManufacturingLogistics/Construction

ProcurementProcurement

Cyber

Virtual ProductDigital Twin

Digital Platform

IoTIoT

IoTIoT

IoP

(O&M)(Asset Plan)

Digital Platform is a tool to make data- Accessable - Visualizable (Searchable)- Traceable - Available

＋Physical model

New/Additional Values

Owner/ VendorMulti Vendor

linkage

General Industry4.0

“Vendor in house”

Quality and EfficiencyImprovement

Other Companies,Systems and

Infrastructures

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NDE4.0・・・ Phase 0: IoT/ICT Aided NDE

� Inspection, Sensing

� Robotics

AcquisitionEdge Intelligence

� Local 5G

� QKD

� Cloud Comp.

� Mobile Devices

� AR/VR

DigitizationConnected Devices,Network & Storage

Big Data Analysis

Transformation

Automation & 5G Connection

5G Network

- Manufacturing Line- Remote Access

https://www.toshiba-clip.com/detail/p=272

Weld

Scan

Camera Probe UnitStereoScope

NDE data

AR / VR application for Enhancement ofInspector’s Skill

VirtualObjects

Check List


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NDE4.0・・・Phase I: Digitization of NDE

� HPC

� AI, ML, DL

� 1DCAE

� Simulation

� POD

EvaluationBig Data Analysis

UT Aided by Numerical Simulation Automated Defect Detection Using AI Algorithms

Training Data

OriginalPAUT Images

Defect

CNN

TrainingDefect


� Robotics

AcquisitionEdge Intelligence

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NDE4.0・・・Phase II: Vertical integration of NDE data

� Local 5G

� QKD

� Cloud Comp.

� Mobile Devices

� AR/VR

� HPC

� AI, ML, DL

� 1DCAE

� Simulation

� POD


� Robotics

Acquisition Evaluation

Digitization

Stand alone NDI (Digitization)

General IoT/ICT（Digitization）

Edge Intelligence Big Data Analysis

Connected Devices,Network & Storage

Acquisition

Digitization

� U/I

� Modeling

� Digital Twin

� CPS

TransformationPlatform


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NDE4.0・・・Phase II: Vertical Integration of NDE data

InspectionData

RevisedAlgorism

Before

InspectionData

InspectionData

RevisedAlgorism

RevisedAlgorism

AI/ML, DLAnalysis Engine




After

InspectionData

RevisedAlgorism

InspectionData

InspectionData

RevisedAlgorism

RevisedAlgorism

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Solution・Diagnosis & Lifetime prediction・Operation Optimization・Maintenance & Renewal Plan・Automation・OPEX/CAPEX Optimization・Resilience Evaluation

NDE4.0(Digitalization)

� Platform

� Modeling

� Digital Twin

� CPS

Transformation

NDE4.0・・・Phase III: Horizontal Integration of NDE data

� Local 5G

� QKD

� Cloud Comp.

� Mobile Devices

� AR/VR

� HPC

� AI, ML, DL

� 1DCAE

� Simulation

� POD


� Robotics

Acquisition Evaluation

Digitization

Conventional NDI（Digitization）

General IoT/ICT（Digitization）

Edge Intelligence Big Data Analysis

Connected Devices,Network & Storage

� U/I

� Modeling

� Digital Twin

� CPS

TransformationPlatform

・Material Data・Design Data・Manufacturing Data・Field Data・Operation Data

SoSsNon-NDE Data

（Expert Concern）


HN-2021-0873 Cyber Physical System (CPS) for NDE DigitalizationTOSHIBA SPINEX for Energy

Optimization, Planning

Analysis, Prediction

Recognition, Understanding

Sensing

Control

Physical Object

Cyber Platform

ObjectInformation

Model

モヤモヤ

Environment ?Operation History ?

Design, Material,Test data

KnowledgeExperience

Know-How

Human Concern

Visualize

Access

ConcernInformation

Model

AI Logic

Dashboard

Statistical Processing

DB DB

DB

Social SystemConnection

by SoS

IoT

IoP IoS

IoS

IoT

IoP

<Expert>

<Operator>

IoS

IoT

IoP

Diagnosis, Detection

Simulation

Data Search

Traceability

Security

Common SaaS Micro Services

Configuration Management, RDS-PP List…

Pump Operation Monitoring

Photo

Alarm

CharacteristicCurve

Graph

Pump Class

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HN-2021-0873 Practical Application of SPINEX to NDE:Piping Thinning Management System

Sensing

Control

Physical Object

Cyber PlatformHuman Concern

Visualize

Access

DB DB

DB

IoT

IoP IoS

IoS

IoT

IoP

Similar Part Search

Traceability

Security


モヤモヤ

Temperature︖Flow Rate ?

Layout︖

Weld, Treatment ?

Dashboard

<Expert>

<Operator>

Materials ?

EvaluationEvaluation

O&M PlanningO&M Planning

LifetimeLifetime

Leakage Risk Leakage Risk

Optimization

System Menu

Part Search

Piping Thickness (History)

Measurement Point Data

Piping & Instrumentation Design

Isometric Diagram

Thinning Prediction

AdvancedThinning PredictionModel

Piping


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Practical Application of SPINEX to NDE: Storage Drum Inspection System

Sensing

Control

Physical Object


Visualize

Access

DB DB

DB

IoT

IoP IoS

IoS

IoT

IoP

Similar Part Search

Traceability

Security


Optimization

モヤモヤ

Type, Kind?

Leakage ?Contamination ?

Defor-mation ?

Flaw ?Corrosion ?

<Expert>

<Operator>

Repair History ?

Dashboard

Storage Drums

Sensing Data・Camera Image, Spectral Image and Thermography...

Inspection DataFlaw, Corrosion, Leakage + History

Self-training predictive

model

Anomaly

Normal

Repair NecessityConfirmation Accordingto Internal Contents

Target Information・Manufacturing Date・Environment (Temperature, Humidity...)・Design Data (Thickness, Paint...)

Anomaly Judgment



LifetimeLifetime

Leakage Risk Leakage Risk https://www.photo-ac.com/main/search?q=%E3%83%89%E3%83%A9%E3%83%A0%E7%BC%B6&srt=dlrank&qt=&pp=70&p=1&pt=B

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HN-2021-0873 Practical Application of SPINEX to NDE: Structural Integrity Assessment System

Sensing

Control

Physical Object


Visualize

Access

DB DB

DB

IoT

IoP IoS

IoS

IoT

IoP

Similar Part Search

Traceability

Security




LifetimeLifetime

Availability FactorAvailability Factor

Optimization

モヤモヤ

Repair History ?

CorrosiveEnvironment ?

Design ?

Materials ?

<Expert>

<Operator>

DashboardWeld, Treatment ?

BWR Core Shroud

Crack Position

Cra

ck D

ep

th

Inspection DataDepth, Length, Position, Distribution + History

InspectionHistory

Crack Front

Material AMaterial B

MaterialC

Crack Growth Property: B > C > A

-Material DataReflection of Crack Growth Property

Conv.Analysis

FailureJudgement

Failure Criteria

Advanced FEA

Inspection + Advanced FEA

-Operation dataHistory, Environment

-Design DataActual Stress

Distribution Analysis


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Prerequisites of NDE4.0 Implementation – My Opinion –

A major premise : the data belongs to the owner.

Thorough “opt-in” (Only the owner should decide which service the data will be used for.).

Designing systems and rules based on win-win-win basis.

Building a new transparent (public) governance system.

Realize cooperation of various services including existing ones by external service bus and API instead of building a large and new integrated system.

Distributed data should be reconstructed with “Concern” and “Object”.

For these purposes, establish a minimum standard through international cooperation.

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Conclusion – My Opinion –

NDE is originally a data-oriented technology and has a high affinity with “Digitalization.”

One of the essence of “Digitalization” is the sharing and mutual-use of data. For this purpose, companies, industries and international cooperation are important.

A few people (but always a few) may argue that NDT is a “Non-Value Added (NVA)” process. The truly digitalized NDE should lead beneficial solutions and transform one from “NVA” process to “Value Added (VA)” process.

The win-win-win relationship between the three parties (asset owner, service provider and data supplier) is important. In order to realize the practical and realistic solution, it is also essential to involve three parties in the discussion and cooperation at a system design phase (NOW!).

On the other hand, NDE4.0 may change the conventional values on NDT we felt; that is, the recognition of the importance for a certified skilled inspector and standardized and authorized methods/equipment.


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Documents

A Concept of Digital Platform for NDE4