ABS Advisory On Structural Health Monitoring The Application of Sensor-Based Approaches
ABS Advisory On Structural Health Monitoring The Application of Sensor-Based Approaches
STRUCTURAL HEALTH
MONITORING: THE
APPLICATION OF
SENSOR-BASED
APPROACHES
INTRODUCTION ...........................................................................................................................................................................................................................................................................................1
SECTION 3 – COUPLING SENSOR DATA WITH ANALYSIS AND ANALYTICS MODELS .............................................................................9
APPENDIX D – COMMENTARY ON COUPLING SENSOR DATA WITH ANALYSIS AND ANALYTICS MODELS ...........17
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INTRODUCTION
Increasingly, modern marine vessels and offshore units are being equipped with various tools for structural
health monitoring, operational assistance, and maintenance optimization. These tools collect data through
sensors and onboard instrumentation and provide status of structural health for awareness of the crew and
owners and operational optimization or for carrying out repairs/modifications to prevent further deterioration
or future failures.
This document focuses on the collection of data using sensors for the purpose of structural health monitoring.
Specifically, it addresses the monitoring of structural loads and/or responses using sensors to infer current
structural health status, predict future health states, and inform maintenance activity.
The sensor data can be used either directly in the raw format or processed to represent physical parameters, such
as pressure, tensile and compressive stresses, bending moments and deformation. Trending and threshold-based
alarms, in addition to the parameter monitoring, are typically an integrated function of sensor-based structural
health monitoring.
This advisory provides guidance on sensor-based structural health monitoring implementation through four key
sections:
Section One: Structural Health Monitoring Principles
Section Two: Sensor-Based Monitoring Plans
Section Three: Coupling Sensor Data with Analytics and Analysis
Section Four: ABS Role
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SECTION 1: STRUCTURAL HEALTH MONITORING
PRINCIPLES
Structural health monitoring has been widely used for decades in various industries, such as aerospace, civil and
mechanical infrastructure, as well as early adoption in both the marine and offshore industries. Several industry
standards and publications discuss the application of sensor-based structural health monitoring for marine and
offshore assets.
IMO MSC/Circ.646 (June 1994), Recommendations for the fitting of hull stress monitoring systems requires that
the hardware and software of a hull stress monitoring system be type approved by an Administration, which in
practice is usually achieved via a certification of compliance issued by a recognized class society. Class societies
have also published technical standards and requirements for the use of various hull monitoring systems.
The Section sets out the key principles that need to be addressed when considering implementing a sensor-based
structural health monitoring program.
• What is the main purpose of the proposed structural health monitoring plan?
• What are the companies’ current practices on structural inspection, maintenance and integrity management?
Will the monitoring plan help support these aspects?
• What are the main concerns regarding the structural conditions, damages, and failure modes for the specific
vessel(s) being monitored given the historical issues with the vessel or vessel class?
• What are the anticipated operation and operational environment?
• What are the measurable physical variables reflecting the structural loads, capacity, and responses relevant to
the anticipated structural failure modes?
• What are the physical variable characteristics of the measured aspect of the structure, such as statics or
dynamics, range, the smallest meaningful change that needs to be captured, etc.?
• Will the sensor data be used/integrated with any engineering analysis and analytics models (e.g., finite element
analysis, operational modal analysis, machine learning algorithms, etc.) to derive structural health conditions
and assist in detecting anomalies?
• Does the sensor data need to be transferred on shore in real-time or near real-time for monitoring and further
analysis?
• Is there a need to retrieve or correlate data from other onboard systems to assist monitoring, analysis and
models? What data needs to be retrieved, and at what frequency?
• What are the tradeoffs between the investment and the added value of the structural health monitoring plan?
Will a techno-economic evaluation of the individual structural health monitoring plan be conducted?
• What sensor types are suitable for measuring the identified physical variables? Are the physical variables
directly measurable?
• What are the sensor specifications required for measuring the physical variables (e.g., range, sensitivity,
accuracy, response time, linearity, sensor-self noise, waterproof and environmental suitability, hazardous area
suitability, power supply, etc.)?
• Where should these sensors be installed? Are these installation locations accessible and feasible for the sensor
installation, inspection, and maintenance?
• How is the data transmitted and stored on board and/or on shore (wired or wireless, network topology)?
• What is the accuracy requirement for signal digitization (e.g. analog digital converter) to accurately reflecting
the physical variables?
• What are the compatibility requirements for the data acquisition devices (e.g., driver, bus, interface,
protocol, etc.)?
• What are the specification requirements for the data acquisition devices (e.g., electrical circuit design, noise
due to various sources, system accuracy, conversion time, waterproof and environmental suitability, hazardous
area suitability, power supply, and robustness)?
• How is the data from various sensors, data acquisition devices, and other data sources synchronized?
What is the synchronization requirement?
• What are the data quality requirements for the data to be suitable for analysis and models?
• What condition anomalies, such as overloading, excessive deformation, stress, and fracture, can be detected
directly from the data?
• What additional analysis and models are needed to extract more features and insights that cannot be derived
directly from the sensor data?
• How accurate and reliable are the analysis and models?
Questions – Set 6: Define Outcomes and Deliverables
• Who are the end users? Are they physically located on board, on shore, or both?
• What is the expected deliverable format and methods (reporting, visualization, dashboard, etc.)?
• What are key insights and information required to be included in the deliverables?
• What is the expected decision-making frequency? Is real-time needed?
• Is there any training required for the end users to interpret the deliverables?
It may not be practical to answer all the above questions during the initial planning and design stage, and the
answers may be refined as the project progresses. However, asking such questions up front can help stakeholders
better organize and manage the project and avoid costly rework.
• Accuracy (of Measurement): a qualitative concept describing the level of agreement between the result of a
measurement and the true value of the measurand, or quantity intended to be measured.
• Accuracy Class: the category of measuring instruments, all of which are intended to comply with a set of
specifications regarding uncertainty. Accuracy class is usually denoted by a number or symbol adopted by
convention. For example, accuracy classes of a thermometer are defined by IEC 60751:2008 Industrial platinum
resistance thermometers and platinum temperature sensors as Class AA; Class A, Class B and Class C.
• Error (of Measurement): the result of a measurement minus a true value of the measurand. Note that a true
value cannot be determined, so a unique “true” value is simply an idealized concept, and in practice a Reference
Quantity Value is used. ISO/IEC Guide 99:2007 may be referenced for calculating errors.
• Uncertainty (of Measurement): a non-negative quantitative parameter characterizing the dispersion of the
values attributed to a measurand, based on the information used. Two types of methods to evaluate uncertainty
are used: Type A evaluation by the statistical analysis of a series of observations, and Type B evaluation by
means other than the statistical analysis of a series of observations (for example, obtained from a calibration
certificate and/or the accuracy class of a verified measuring instrument).
• Relative Error: the ratio of the absolute error to a comparison value. This term can be seen in some product
specifications, conformity reports and verification certificates. In general, this “true value” approach concept is
used with a reference quantity value and/or a conventional true value together.
• Maximum Permissible Error (MPE): this represents extreme value of measurement error, with respect to
a known reference quantity value, permitted by specifications or regulations for a given measurement,
measuring instrument, or measuring system. MPE is usually given by the manufacturer in product
specification. For example, MPE = 0.05 mm for a caliper gauge specified based on absolute value and MPE = 0.1%
for a torque measurement based on relative error.
• (Measurement) Repeatability: the level of agreement among successive measurements of the same measurand,
carried out under the same conditions of measurement.
• (Measurement) Reproducibility: the level of agreement among measurements of the same value of a quantity,
when the individual measurements are made under different conditions of measurement.
• (Measurement) Precision: the level of agreement between indications or measured quantity values obtained
by replicate measurements on the same or similar objects under specified conditions. Precision is usually
expressed numerically by measures of imprecision, such as standard deviation, variance, or coefficient
of variation under the specified conditions of measurement. Precision is used to define repeatability and
reproducibility.
• Stability (of a Measuring Instrument): ability to keep its performance characteristics unchanged over time
when all other conditions remain the same. Stability may be quantified in several ways. For example, short-term
and long-term drifts can be used to quantify stability.
• Measurement Range (also called Measuring Range): a range defined by two values of the measurand, or
quantity to be supplied, within which the limits of uncertainty of the measuring instrument are specified.
• Sensitivity (of a Measuring System): the quotient of the change in an indication of a measuring system and the
corresponding change in a value of a quantity being measured. For example, gauge factor is the synonym of the
strain gauge sensitivity.
• Resolution: the smallest change in a quantity being measured that can be perceived.
• Discrimination Threshold: the largest change in a value of a quantity being measured that causes no detectable
change in the corresponding indication.
• Step Response Time: the duration between the instant when an input quantity value of a measuring
instrument or measuring system is subjected to an abrupt change between two specified constant quantity
values, and the instant when a corresponding indication settles within specified limits around its final steady
value.
• Sampling Rate: the number of analog-to-digital conversions per unit time; it is usually expressed in samples per
second.
• Drift: the change in the indication of a measuring instrument, generally slow, continuous, neither necessarily in
the same direction and nor related to a change in the measurand.
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SECTION 2: SENSOR-BASED MONITORING PLANS
Sensor packages and specifications should be developed according to the implementation goals, technology
readiness, and availability considering budget limitations. For a comprehensive sensor-based structural health
monitoring plan, the sensor data can be used to:
• Directly monitor the loads and structural responses, and alarm when overloading and other excessive measured
parameters or events are detected.
• Serve as a data source and input into the coupled analysis and models to derive structural health condition,
predict degradation and assist operational and asset integrity management decisions.
• Serve as high-fidelity data to validate and calibrate the analysis and analytics models in terms of model
parameters, analysis assumptions, and outcomes.
These sensors and their corresponding measured physical variables in Table 1 can also be applied to non-ship
shape structures (e.g., Column Stabilized Unit, Self-Elevating Unit, Tension Leg Platform, Spar). For example, sensors
for position, wave and wind are valid for both ship and non-ship structures. However, the direct measurand and
its required instrumentation plan typically need to be developed on a case-by-case basis for a non-ship shape
unit due to the diversity of its structural arrangement and configuration. Appendix B provides guidance on
the selection of sensor types based on the common physical variables to be measured on marine and offshore
structures.
System Components
Signal Conditioning Unit
Display Unit
UPS
Accelerometers
General High
Container Bulk Ore Ro–Ro LNG Chemical Passenger
Direct Measurand Oil Tanker Cargo Speed
Carrier Carrier Carrier Ship Carrier Carrier Ship
Ship Craft
Vertical accelerations
ACC ACC ACC ACC ACC ACC ACC ACC ACC
at bow
Vertical, transverse
and longitudinal ACC
acceleration at bow
Transverse acceleration
ACC ACC ACC ACC ACC ACC
amidships
Vertical, transverse
and longitudinal
acceleration at ACC
longitudinal center of
gravity
Vertical, transverse
and longitudinal ACC
acceleration at stern
Global longitudinal
stress amidships (port LBSG LBSG LBSG LBSG LBSG LBSG LBSG LBSG LBSG LBSG
and starboard side)
Global longitudinal
stress at quarter length
LBSG LBSG LBSG LBSG LBSG LBSG LBSG LBSG LBSG
fore and aft of midship
(port or starboard side)
Global longitudinal
stress below neutral axis
LBSG LBSG LBSG
amidships (port and
starboard)
Bending/shear stress in
SG
pillar bulkheads
Lateral loads at
bowflare or bottom near
PT/SG PT/SG PT/SG PT/SG PT/SG PT/SG PT/SG PT/SG PT/SG PT/SG
forward perpendicular
(slamming pressure)
Sloshing response of
liquid in tanks (sloshing PT/SG PT/SG PT/SG
pressure)
Wave condition/sea
WR WR WR WR WR WR WR WR WR WR
state
Wind condition WS WS WS WS WS WS WS WS WS WS
Some of the recommended sensor packages in Table 1 have been adopted in Hull Condition Monitoring Systems
on vessels. If they meet requirements of ABS Guide for Hull Condition Monitoring Systems, the vessels fitted
with such sensors may be eligible for three optional class notations (i.e., HM1 – Motion Monitoring, HM2 – Stress
Monitoring, and HM3 – Voyage Data Monitoring). For example, a vessel fitted with one accelerometer (ACC) at
the bow, one MRU, one wave radar, six LBSGs, ten strain gauges (SGs) at ten selected local critical structural areas,
one GNSS device and one wind sensor (WS) in Table 1 may consider class notation HM1 (Slam Warning: ACS1,
Ship Motion: MOT1, Sea State: ST1), HM2 (Hull Girder Stress: HS6, Local Load Monitoring: LS10), HM3 (Navigation,
Wind: WD1).
IEC 61757-1-1 provides more detailed requirements of strain sensors based on fiber Bragg gratings. There are many
FBG strain gauges and interrogators available in the market. Optical interrogators are typically more expensive
than the electrical ones, which may lead to the FBG solution being more costly than electrical.
ACCELEROMETERS
Various types of accelerometers are based on different physical principles and are suitable for different measuring
purposes. There are 2 types of accelerometers:
• AC-response accelerometer, which can only sense changes in acceleration (but not constant acceleration).
• DC-response accelerometer, which can sense both changes in acceleration, and constant acceleration.
Force-balanced accelerometers and servo-type accelerometers can measure DC components (i.e., constant
acceleration). Force-balanced accelerometers can be customized for low frequency and high sensitivity for high
precision measurements.
The target measurand and the potential usage of the measurement should be considered when choosing the
accelerometers to:
• Determine whether the DC-response (constant) is required for measurements
• Confirm the sensitivity, cross-axis sensitivity, and sensitivity temperature coefficient
• Confirm the measuring range
• Confirm the frequency response function / bandwidth
• Confirm the suitable temperature range
PRESSURE TRANSDUCER
Temperature and process medium of the measured fluid in contact with the sensing element must be considered
carefully when selecting pressure transducers. As pressure transducers must contact the process medium directly,
the mounting to the watertight members should be carefully planned and implemented. Watertight testing
is recommended after the installation. Alternatively, the pressure on watertight members can be measured
indirectly via strain gauges attached to the backing structures, which is a common practice for ice loading
monitoring.
Roll (ROLL) X X X X X
The accuracy and reliability of the analysis and analytics models reflect the uncertainties and assumptions of
the model inputs (e.g. loads, environments, structural gauging, etc.) as well as the analysis and model themselves
(e.g. model parameters, assumptions, approximation, etc.). Sensor-based full-scale measurements are typically
treated as high-fidelity data, which not only can be used for direct load and response monitoring and parameter
trending, but more importantly can be integrated with analysis and models through analysis/model calibration
and validation to enhance the analysis accuracy and reliability. The integration of sensor data with analysis and
models provides more accurate and reliable insights on the structural health and predicts potential damages for
both global hull and local critical areas. Table 3 lists recommendations on sensor packages for the calibration and
validation of global loads, analysis and model parameters. Furthermore, Appendix D provides considerations and
required effects on sensor data processing corresponding to specific application scenarios.
Note: Arrangement of sensors refers to both number and mounting position of sensors.
ABS has offered optional class notations to recognize that the structural health monitoring system is in
compliance with ABS standards and requirements. The ABS Guide for Hull Condition Monitoring Systems
presents the need for fitting sensor-based hull condition monitoring systems and lists safety and performance
specifications for various types of systems, such as slamming warning, hull girder stress monitoring, and green
seas warning. Optional class notations HM1, HM2, or HM3 can be awarded for monitoring systems that satisfy
the Guide’s requirements. With the advent of data analytics capabilities and the coupling of operational data
and sensor measurements with analytics and analytics models, structural health monitoring is evolving into the
concept of the structural digital twin. The ABS Guide for Smart Functions for Marine Vessels and Offshore Units
offers the optional class notation SMART (SHM) to vessels with structural health monitoring capabilities based
on the coupling of sensor-based monitoring with analysis and analytics models for structural health condition
diagnostics and prognostics.
For sensor-based structural monitoring, ABS can provide not only the requirements and independent verification
and validation on system capability, safety and integrity, but also give functional and implementation
recommendations to assist stakeholders to obtain more value out of the implementation. With the proven
accuracy and reliability of the structural monitoring system, informed, targeted, condition and risk-based
alternative means of crediting class survey requirements can be implemented to enhance the asset safety with
less intrusiveness and reduced cost.
Physical Variable
Physical Variable Recommended Sensor Types
Measurement
Rigid body motion (6 degrees of freedom) Direct Motion Reference Unit (MRU)
Accelerometers
Structural temperature Direct Temperature sensor e.g., thermal couple, fiber optic sensor)
Strain gauges
Structural modal shapes and natural
Indirect
frequency
Accelerometers
Crack initiation and propagation Direct Acoustic emission sensor, Electrochemical fatigue crack sensor
Still water bending moment (SWBM) Indirect LBSGs or from loading computer
Power output and revolutions of propulsor(s) Direct Shaft torque meter, Shaft revolution counter
Table 6 provides an overview and comparison of the different pressure transducer types in terms of different
sensing technology and design philosophy. Low and/or medium range strain gauge type pressure transducers
(either electrical or FBG strain gauge type) or variable capacitance transducers are recommended when measuring
pressure from sea/waves (such as slamming) and liquid pressure (such as sloshing in tanks). Variable reluctance
transducers may be considered when extreme overpressure may be experienced and high degrees of accuracy and
critical stability over extended periods are required.
Sensing Element
Design Category Sensing Element Remarks on Application
Configuration
Micromachined
Membrane/Diaphragm Membrane/Diaphragm
Deflection
Table 7 lists applicable sensors with popular vibration-based monitoring techniques and potential analysis and
models coupling. Table 8 lists the time series of vessel responses that can be obtained from structural sensors
and monitoring systems. Table 9 summarizes the application scenarios of the time series sensor data and the
corresponding required level of effort for signal processing.
Response
Sensor Package Option Application Example Use Case/Coupled Analysis and Model
Type
Rigid Body Use algorithm to calculate the real-time 6 degree of freedom motion
DC & AC
Motion based on kinetics principle and linear algebra
Notes:
[#1] Both displacement mode shapes and strain mode shapes are related to structural vibration natural frequencies. Using a modal
decomposition and a modal expansion technique, it is possible to obtain the time series of dynamic displacement and stress
based on identified mode shapes respectively. The total displacement and stress should consist of both static and dynamic parts,
which can be found by adding the static part to the inferred dynamic part as an offset properly. Such total displacement and
stress can be used for strength and buckling check or extreme value analysis.
[#2] Some finite element software can only output displacement mode shapes. If that is a case, the strain can be obtained by imposing
displacement on to the finite element model.
[#3] MEMS Capacitive Accelerometers and MEMS Piezoresistive Accelerometers are economic alternatives of force-balanced
accelerometers or servo-type accelerometers, when large numbers of sensors are required.
[#4] When harsh operational environments are to be encountered, MEMS Charge mode piezoelectric (PE) accelerometers are
substituted for MEMS Voltage mode Internal Electronic Piezoelectric (IEPE) accelerometers. A combination of IEPE or charge
mode PE accelerometers with a few force-balanced accelerometers or servo-type accelerometers could offer more flexibility and
a high quality of required time series that consists of both static and dynamic parts, when a proper algorithm (sensor fusion) is
adopted. This may benefit the hull monitoring system design.
Applicable Direct/
Pass-Band Stop-Band
Signal Type Indirect Basic Filter Applied Remarks
Frequency Frequency
Measurand
High-pass
0.4 Hz 0.3 Hz Hull global vibration components
filtering
Note: the pass-band and stop-band frequency are for typical ship applications, and are for reference purpose only.
High-pass Filter
Maximum value
Minimum value
Mean value
Standard deviation
1. Statistics of time series data
i. No filtering Skewedness
ii. Low-pass filtering
Kurtosis
iii. Dynamic high-pass filtering
iv. High-pass filtering Mean zero crossing period (or mean crossing up count)
4. Threshold values and alarms for Alarms triggered when the measured value exceeds the threshold (or a given percentage of the
each channel threshold).
6. Parametric roll Can be done by MRU directly, for roll and pitch specifically.
7. Trend predictions for each channel Calculations for each time interval of each sensor are adopted for trend prediction.
8. Hull strain/stress
Medium Option 2: dynamic strain after high-pass filter in order to remove low cycle temperature effects (only
ii. Dynamic strain
dynamic).
Option 3: compounded strain by adding a strain offset corresponding to the static strain retrieved
iii. Compounded strain by filtered
from the loading computer at sensor location to the filtered strain without low cycle temperature
dynamic strain and loading computer
effects via a high-pass filter.
Option 4: compounded strain by summing dynamic strain (only dynamic) and the mean of the
iv. Compounded strain by filtered dynamic
low pass filtered measured strain (only static; where the mean is taken over a day to remove the
and static strain
temperature effects).
9. Modal analysis Recommended 20-30 min time series with sampling rate 20 Hz.
11. Global sectional forces Recommended 20-30 min time series with sampling rate 20 Hz.
Refer to hull strain/stress Option 1 of Table 9 and Option 4 of Table 9 to estimate the bending moment
whose proper estimate could be the mean value of the time series. The SWBM’s estimates can be
i. Still water bending moment (SWBM)
assembled according to loading conditions, and the statistics of same loading condition may be
computed.
ii. Dynamic sectional forces (moment Refer to hull strain / stress Option 1, Option 3 and Option 4 which can be used to define the DLPs
and forces) (based on extreme value) for ships.
12. Loads due to liquid motions in tanks (sloshing) Event data trigger by predefined threshold as time series.
13. Response due to operation in ice Event data trigger by predefined threshold as time series.
TX 02/19 19016