Ultrasonic device and method for fuel channel inspection

Abstract

A device and method for ultrasonic inspection of a fuel channel. The ultrasonic inspection device includes multiple arrays of ultrasonic transducer (UT) elements arranged around its circumference. As the device is inserted into or withdrawn from a bore of a pressure tube of the fuel channel, the UT elements are actuated in an actuation pattern and data is collected from the UT elements in a collection pattern. The arrangement of the UT arrays and the actuation and collection patterns of the UT elements can be configured to generate overlapping circumferential UT scan coverage as the device is displaced axially within the pressure tube.

Description

[Technical Field]

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS This application claims priority to U.S. Provisional Application No. 63 / 415,617, filed October 12, 2022.

[0002] The present disclosure relates to devices and methods for non-destructive testing of conduits, and more particularly to devices and methods for non-destructive testing of nuclear fuel channels using ultrasonic sensors. [Background technology]

[0003] Non-destructive methods for inspecting solid materials are known in the art and are used for the inspection of pipes and other conduits, including fuel channels used in nuclear power plants. Ultrasonic sensors are one known technique for determining various properties of a conduit based on the shape and thickness of localized regions of the conduit wall.

[0004] In particular, an array of ultrasonic transducer elements (also called UT elements) can be used to capture data about physical objects, such as the inner or outer surface of a conduit and / or internal properties of the conduit wall (such as internal defects), using full matrix capture (FMC) techniques.

[0005] International Publication No. WO 2013 / 044350 discloses a manipulator for use in ultrasonic inspection of pipe surfaces. The manipulator includes a turntable that fits around the circumference of the pipe with an ultrasonic array attached to a shuttle. The shuttle moves around the turntable and scans around the pipe using the all-focus method, a version of the full-matrix capture technique for collecting and processing probe data. The reference describes methods for calibrating equipment and software, scanning the pipe surface, and collecting and analyzing probe data using the all-focus method to reconstruct a model of the pipe surface and / or the inside of the pipe wall. The present disclosure relies on the teachings of this prior publication, which are incorporated herein by reference.

[0006] In the context of nuclear fuel channel inspection, existing approaches to ultrasonic inspection use tools fitted with an array of ultrasonic transducers to inspect the inside of the fuel channels. Each fuel channel includes a pressure tube (PT) suspended inside a calandria tube (also called a sleeve) by end fittings and spacers. An ultrasonic inspection tool is inserted inside (i.e., bore of) the pressure tube to collect ultrasonic data around the inner circumference of the pressure tube while moving along the axial dimension of the pressure tube. Ultrasonic transducers positioned on the outer surface of the tool facing the inner surface of the pressure tube collect ultrasonic data (e.g., FMC data) as the tool is inserted or withdrawn axially.

[0007] However, physical constraints of the fuel channel and tool, as well as data communication constraints, typically limit the number and placement of UT elements on the tool, thereby limiting the spatial range and resolution of the ultrasonic inspection data. The UT elements used in existing approaches typically transmit ultrasound waves to a small number (e.g., 12) of specific locations on the inner surface of the conduit. In some approaches, the number of UT elements available for fuel channel scanning is even smaller because some spatial locations other than those used for the UT elements may need to be reserved for other sensors, such as a water temperature sensor. This can result in no signal if the conduit deforms or moves. In some applications, to perform a complete UT scan, the small number of UT elements may also require the tool to rotate within the fuel channel, which tends to introduce unwanted artifacts, such as fuel channel displacement due to vibration, that further reduce the accuracy of the scan. [Prior art documents] [Patent documents]

[0008] [Patent Document 1] International Publication No. WO2013 / 044350 Summary of the Invention [Problem to be solved by the invention]

[0009] Therefore, it would be desirable to provide a device for ultrasonic inspection of fuel channels that overcomes one or more of the limitations of existing techniques. [Means for solving the problem]

[0010] In various examples, the present disclosure describes devices and methods for ultrasonic inspection of fuel channels. In some embodiments, the ultrasonic inspection device includes multiple arrays of UT elements positioned around various portions of the circumference of an ultrasonic array. Each such array typically includes multiple UT elements configured to transmit and / or detect ultrasonic waves in a liquid medium. The device is inserted inside a pressure tube, and a subset of the UT elements is driven in an actuation pattern and data is collected from the subset of UT elements in a collection pattern. The relative placement of the arrays of UT elements, the relative placement of the individual UT elements in each array, the actuation pattern, and the collection pattern can be configured to optimize the spatial coverage, speed, accuracy, resolution, and / or reliability of the ultrasonic data collection.

[0011] As used herein, the terms "UT" and "UT element" refer to an ultrasonic transducer unless otherwise described. In some examples, a UT element may perform only a transmitting function or only a receiving function, in which case an ultrasonic transmitter or ultrasonic receiver, respectively, may be used instead of an ultrasonic transducer. In some examples, a single UT element may include a dedicated transmitter and a dedicated receiver.

[0012] As used herein, the terms "UT array" and "ultrasonic array" refer to an array of UT elements arranged side by side along a line, arc, or other linear curve.

[0013] In some exemplary aspects, the present disclosure describes a device for inspecting a conduit, the device including a body configured to be inserted into an interior cavity of the conduit along an axial dimension of the conduit such that a longitudinal axis of the body is substantially aligned with the axial dimension of the conduit. A plurality of ultrasonic transducer (UT) arrays are provided, each UT array disposed at a respective axial position along the longitudinal axis and defining an arc along a portion of the circumference of the body, each UT array comprising a plurality of UT elements, each respective UT element disposed at a respective circumferential position along the UT array arc, the circumferential positions corresponding to a circumferential portion of the conduit. A control circuit is configured to actuate the UT elements of the UT array according to an actuation pattern such that each UT element transmits ultrasound waves at each of a plurality of axial positions of the respective circumferential portion of the conduit. A data acquisition circuit is configured to acquire ultrasound data from the UT elements of the UT array according to the acquisition pattern such that ultrasound data is acquired from each respective UT element for each of a plurality of axial positions of the respective circumferential portion of the conduit.

[0014] In some embodiments, the actuation pattern and acquisition pattern are configured to perform a pitch-catch ultrasound scan such that one or more of the UT elements of the UT array acquire ultrasound data while one or more other UT elements of the UT array transmit ultrasound waves. In some embodiments, the actuation pattern and acquisition pattern are configured to perform a full-matrix capture ultrasound scan.

[0015] In some embodiments, the plurality of UT arrays includes a left UT array that subtends an arc of less than 180 degrees on a left portion of the body at a left-right array axial position, and a right UT array that subtends an arc of less than 180 degrees on a right portion of the body at a left-right array axial position. Optionally, the plurality of UT elements of the left UT array and the right UT array are oriented to transmit and receive ultrasound in a direction substantially perpendicular to the longitudinal axis of the body.

[0016] In some embodiments, the plurality of UT arrays include an upper UT array that subtends an arc of less than 180 degrees on an upper portion of the body at an upper-lower array axial position, and a lower UT array that subtends an arc of less than 180 degrees on a lower portion of the body at an upper-lower array axial position. Optionally, the plurality of UT elements of the upper UT array and the lower UT array are oriented to transmit and receive ultrasound in a direction substantially perpendicular to the longitudinal axis of the body.

[0017] In some embodiments, the plurality of UT arrays include a first conical UT array that defines an arc of less than 180 degrees around a first peripheral portion of the body at a first conical array axial position, wherein each UT element of the first UT array is oriented to transmit and receive ultrasound waves in a diagonal radially outward direction relative to a forward direction of the longitudinal axis of the body, and a second conical UT array that defines an arc of less than 180 degrees around a second peripheral portion of the body at a second conical array axial position, wherein each UT element of the second UT array is oriented to transmit and receive ultrasound waves in a diagonal radially outward direction relative to a reverse direction of the longitudinal axis of the body.

[0018] Optionally, the actuation pattern and collection pattern are configured to perform a pitch-and-catch ultrasound scan such that one or one UT element of one of the first and second cone arrays collects ultrasound data while one or one UT element of the other of the first and second cone arrays transmits ultrasound. In one embodiment, the plurality of UT elements of the at least one UT array includes at least 250 UT elements or at least 500 UT elements.

[0019] Optionally, the data acquisition circuitry is further configured to process the ultrasonic data collected from the UT element to identify localized irregularities in the inner surface of the conduit at one or more locations. In some embodiments, the data acquisition circuitry is further configured to process the ultrasonic data collected from the UT element to identify localized irregularities in the outer surface of the conduit at one or more locations. Optionally, the localized irregularities include at least one of thinning areas, bulges, and blemishes.

[0020] In some embodiments, the data acquisition circuitry is further configured to process the ultrasound data collected from the UT element to identify deformations in the conduit at one or more locations. Optionally, the deformations include at least one of a sagging deformation and an elliptical deformation.

[0021] Optionally, a tether is attached to the body, the tether comprising a communication link operably coupled to the control circuitry and the data acquisition circuitry, and a power link for providing power to the UT element. The communication link may be an optical communication link.

[0022] Optionally, the control circuitry is further configured to receive control data from the communication link and to actuate the UT element according to the actuation pattern based on the control data. In some embodiments, the data acquisition circuitry is configured to process the ultrasound data collected from the UT element to generate inspection data and to transmit the inspection data over the communication link.

[0023] The present invention also teaches a device for inspecting a conduit, the device including a body configured to be inserted into an interior cavity of the conduit along an axial dimension of the conduit such that a longitudinal axis of the body is substantially aligned with the axial dimension of the conduit. A plurality of UT arrays, each disposed at a respective axial position along the longitudinal axis and defining an arc along a portion of the circumference of the body, each UT array comprising a plurality of ultrasonic transducer (UT) elements, each respective UT element disposed at a respective circumferential position along the UT array arc, the circumferential positions corresponding to a circumferential portion of the conduit. A control circuit is configured to actuate the UT elements of the UT array according to an actuation pattern such that each UT element transmits ultrasound waves at each of a plurality of axial positions of the respective circumferential portion of the conduit. A data acquisition circuit is configured to acquire ultrasound data from the UT elements of the UT array according to the acquisition pattern such that ultrasound data is acquired from each respective UT element for each of a plurality of axial positions of the respective circumferential portion of the conduit. The plurality of UT arrays include a first pair of UT arrays each defining an arc of less than 180 degrees on a pair of substantially opposite circumferential portions of the body at a first axial location, and a second pair of UT arrays each defining an arc of less than 180 degrees on a pair of substantially opposite circumferential portions of the body at a second axial location, the areas covered by the first pair of arrays and the second pair of arrays collectively encompassing the entire longitudinal axis of the conduit.

[0024] Optionally, the first pair of UT arrays comprises a first pair of conical UT arrays, each UT element of the first pair of UT arrays oriented to transmit and receive ultrasound waves in a diagonal radial outward direction relative to a forward direction of the longitudinal axis of the body, and the second pair of UT arrays comprises a second pair of conical UT arrays, each UT element of the second pair of UT arrays oriented to transmit and receive ultrasound waves in a diagonal radial outward direction relative to a reverse direction of the longitudinal axis of the body.

[0025] Optionally, the conduit is a pressure tube of the fuel channel.Optionally, a device according to claims 1 to 23, wherein the device is tubular.

[0026] The present invention also provides a method for inspecting a conduit, comprising: inserting a device into an interior cavity of the conduit along an axial dimension of the conduit such that a longitudinal axis of the device is substantially aligned with the axial dimension of the conduit. The device includes a plurality of ultrasonic transducer (UT) elements, including a first plurality of UT elements at a first axial position along the longitudinal axis, defining a first partial circumferential portion of the device relative to the longitudinal axis, and a second plurality of UT elements at a second axial position along the longitudinal axis, defining a second partial circumferential portion of the device relative to the longitudinal axis. The first partial circumferential portion and the second partial circumferential portion have a non-zero circumferential overlap. The method includes moving the device in the axial dimension and, while moving the device in the axial dimension, actuating the UT elements according to an actuation pattern such that each UT element transmits ultrasound waves at each of a plurality of axial positions of the conduit; and collecting ultrasound data from the UT elements according to a collection pattern such that ultrasound data is collected from each respective UT element for each of a plurality of axial positions of the conduit.

[0027] Reference is now made to the accompanying drawings which illustrate, by way of example, exemplary embodiments of the present application. [Brief explanation of the drawings]

[0028] [Figure 1] FIG. 1 is a left front perspective view of an ultrasound inspection device according to an example of the present disclosure. [Figure 2] 2 is a right side elevational view of the ultrasound array portion of the ultrasound inspection device of FIG. 1. [Figure 3A] 3 is a front cross-sectional elevation view of the ultrasound array of FIG. 2 taken through line A. FIG. [Figure 3B] 3 is a front cross-sectional elevation view of the ultrasound array of FIG. 2 taken through line B. FIG. [Figure 4] 3 is a front cross-sectional elevation view of the calandria tube, pressure tube, and ultrasonic array of FIG. 2 inserted inside the pressure tube, showing a cross section of the ultrasonic array through line C of FIG. 2. [Figure 5] 1 is a flowchart illustrating steps of an exemplary method for ultrasonic inspection of fuel channels, according to an example of the present disclosure. [Figure 6] 10 is a graph of full matrix capture results based on ultrasound beam directionality. [Figure 7] 10 is a graph of full matrix capture results based on ultrasound beam directionality. [Figure 8] 10 is a graph of full matrix capture results based on ultrasound beam directionality. [Figure 9] 10 is a graph of full matrix capture results based on ultrasound beam directionality. DETAILED DESCRIPTION OF THE INVENTION

[0029] Similar reference numbers may be used in different drawings to indicate similar elements.

[0030] The present disclosure describes exemplary devices and methods for ultrasonic inspection of fuel channels using a device having multiple ultrasonic transducer (UT) elements arranged around the periphery of the ultrasonic array portion of the device to perform full matrix capture (FMC) ultrasonic data acquisition.

[0031] 1 shows an ultrasonic inspection device 100. The device 100 has a body including a front portion 106, an ultrasonic array portion 104, and a rear portion 102. The device 100 is elongated in shape and configured to be inserted, front portion 106 first, into the interior cavity (i.e., bore) of a fuel channel pressure tube, as defined by a longitudinal axis 140 shown pointing in a forward direction to indicate the direction of insertion. In one embodiment, the device is tubular in shape.

[0032] The illustrated device 100 includes a tether 114 extending from the rear opening of the pressure tube for communication with equipment outside the fuel channel. The tether 114 may include a communications link (such as an electrical or optical communications link) for two-way communication with external data processing equipment and / or a power link for providing power from an external power source.

[0033] The illustrated device 100 includes spacers 110 on the front 106 and rear 102. There may be multiple spacers 110 at each of one or more axial locations, for example, three spacers 110 at three equally spaced circumferential locations about a first axial location on the rear 102 and another three spacers 110 at three equally spaced circumferential locations about a second axial location on the front 106. The spacers 110 may be operable to radially center the device 100 within the circular interior cavity of the pressure tube, for example, by using an actuator to extend them radially outward from the device body or by being biased radially outward by a biasing means such as a spring. The spacers 110 may include rollers 112 to assist in axial displacement of the device 100 within the pressure tube. In some embodiments, the rollers 112 may be actuated (e.g., using an electric motor or hydraulic power) to actively displace the device 100 axially within the pressure tube. In some embodiments, the front portion 106 may not be present, and the ultrasonic array portion 104 may constitute the head (i.e., front-most portion) of the device 100. In some embodiments, a set of spacers 110 may be positioned at two or more axially spaced locations on the rear portion 102 to assist in centering and stabilizing the tool within the conduit.

[0034] The ultrasonic array portion 104 of the device 100 includes a plurality of UT elements grouped into a plurality of UT arrays, designated as upper UT array 122, lower UT array 124, left UT array 126, right UT array 128, left front cone UT array 130, right front cone UT array 131, left rear cone UT array 132, right rear cone UT array 133, upper front cone UT array 134, lower front cone UT array 135, upper rear cone UT array 136, and lower rear cone UT array 137. Each UT element is secured to the ultrasonic array portion 104 at a respective circumferential position about the body of the device 100, defined relative to a longitudinal axis 140. The arrangement of these UT elements enables each UT element to transmit and / or receive ultrasound at a corresponding circumferential portion within the pressure pipe or other conduit being inspected when the device 100 is inserted into the bore of the pressure pipe such that the longitudinal axis 140 is substantially aligned with the axial dimension of the pressure pipe. As device 100 is displaced axially within the conduit (i.e., along the length, i.e., axial dimension, of the pressure tube or conduit), each UT element travels an axial length of a respective circumferential location on the inner surface of the conduit, generating ultrasound data for an axial band or axial locations of a respective circumferential portion of the conduit. Collectively, the area covered by the first pair of arrays and the area covered by the second pair of arrays collectively encompass the entire longitudinal axis of the conduit.

[0035] FIG. 2 illustrates the right side of the ultrasonic array portion 104 of an exemplary ultrasonic inspection device. The ultrasonic array portion 104 includes a pair of upper and lower arrays, i.e., an upper UT array 122 and a lower UT array 124, at a first axial position. A cross-sectional view through line A at the first axial position is shown in FIG. 3A, described below. The ultrasonic array portion 104 includes a pair of left and right arrays, i.e., a left UT array 126 (not shown in FIG. 2) and a right UT array 128, at a second axial position. A cross-sectional view through line B at the second axial position is shown in FIG. 3B, described below. The individual UT elements 202 of the upper UT array 122, the lower UT array 124, the left UT array 126, and the right UT array 128 are oriented to transmit and receive ultrasound waves in a direction substantially perpendicular to the longitudinal axis 140.

[0036] The ultrasonic array portion 104 also includes two cone array subsections, a first cone array subsection 200 and a second cone array subsection 204. The first cone array subsection 200 includes a forward-facing cone surface on which the left front cone UT array 130 (not shown in FIG. 2 ) and the right front cone UT array 131 are disposed, and a rearward-facing cone surface on which the left rear cone UT array 132 (not shown in FIG. 2 ) and the right rear cone UT array 133 are disposed. The second cone array subsection 204 includes a forward-facing cone surface on which the upper front cone UT array 134 and the lower front cone UT array 135 are disposed, and a rearward-facing cone surface on which the upper rear cone UT array 136 and the lower rear cone UT array 137 are disposed. Each cone surface is disposed at a distinct axial position relative to the other cone surface.

[0037] In some embodiments, arrays on the forward-facing conical surfaces (e.g., left front conical UT array 130 and right front conical UT array 131) are oriented to transmit ultrasound waves axially outward at an angle forward (e.g., to operate as pitch UT elements in a pitch-and-catch ultrasound scanning operation), and corresponding arrays on the rearward-facing conical surfaces (e.g., left rear conical UT array 132 and right rear conical UT array 133) are configured to receive ultrasound waves axially outward at an angle backward (e.g., to operate as catch UT elements in a pitch-and-catch ultrasound scanning operation). These functions, i.e., rearward-facing array pitch and forward-facing array catch, can be reversed in some examples. In some embodiments, as described below, the UT elements 202 of each array are configured to both transmit / pitch and receive / catch in different operating modes, such as at different times in an actuation or acquisition pattern.

[0038] In some embodiments, each array 122, 124, 126, 128, 130, 131, 132, 133, 134, 135, 136, 137 defines an arc around an incomplete portion of the circumference of the body of the ultrasonic array 104. In some embodiments, the arcs are each less than 180 degrees. That is, each array covers less than half of the circumference of the ultrasonic array 104. This can allow for the placement of circuitry or other components in portions of the circumference of the ultrasonic array 104 that are not covered by the UT array. However, it can mean that the UT array at a given axial position does not affect 360-degree ultrasonic scan coverage of the interior surface of the conduit. Thus, in some embodiments, the UT arrays at the second axial position can be configured such that the circumferential positions of the ultrasonic array portion 104 occupied by the UT arrays at the first axial position (e.g., the upper UT array 122 and the lower UT array 124) overlap with the circumferential positions of the ultrasonic array portion 104 occupied by the UT arrays at the second axial position (e.g., the left UT array 126 and the right UT array 128).

[0039] FIG. 3A is a front cross-sectional view of the ultrasonic array portion 104 of FIG. 2 taken through line A at a first axial position, showing the upper UT array 122 and the lower UT array 124. FIG.

[0040] FIG. 3B is a front cross-sectional view of the ultrasound array portion 104 of FIG. 2 at a second axial position through line B, showing the left UT array 126 and the right UT array 128.

[0041] 3A-3B occupy less than 180 degrees around the ultrasonic array 104, it will be appreciated that the four arrays 122, 124, 126, 128 overlap together such that they cover a 360-degree circumference of the ultrasonic array 104. Thus, if all four arrays 122, 124, 126, 128 are used to perform an ultrasound scan of the interior surface of a conduit, while the device 100 is displaced axially (i.e., along axis 140 shown in FIG. 1), the entire circumference of the interior surface of the conduit will be scanned.

[0042] The ultrasonic array 104 includes an instrument core 300 that includes circuitry for controlling the UT elements 202 and collecting ultrasonic data from the UT elements 202. In the exemplary embodiment shown in Figure 2, the UT elements 202 are evenly spaced around the circumference of the ultrasonic array 104 such that each UT element 202 is positioned to inspect an equal-sized circumferential portion (i.e., a circumferential arc of equal length) of the conduit.

[0043] An electrical link 302 connects each UT element 202 to the instrument core 300. The instrument core 300 may include circuitry configured to send control signals to the UT elements 202 via the electrical link 302 according to an actuation pattern. Similarly, the instrument core 300 may include circuitry configured to acquire ultrasound data from the UT elements 202 via the electrical link 302 according to an acquisition pattern.

[0044] The instrument core 300 may include one or more circuit components, such as one or more printed circuit boards (PCBs) and / or application specific integrated circuits (ASICs). In some embodiments, the instrument core 300 includes an optical modulator and / or an optical demodulator, such as an electro-optical modulator (EOM) and / or a photodiode, for converting electrical signals to the optical domain. The communication link of the tether 114 (see FIG. 1 ) may be an optical link in some embodiments. In some embodiments, the instrument core 300 may include control circuitry configured to receive control data (e.g., multiplexed optical signal data) from the tether 114 and operate the UT element 202 according to an actuation pattern based on the received control data. In some embodiments, the instrument core 300 may include data acquisition circuitry configured to receive ultrasound data from the UT element 202 according to a collection pattern and transmit inspection data (e.g., multiplexed optical signal data) via the tether 114 based on the ultrasound data. The control data may be generated by a control device located outside the conduit and transmitted via the tether 114 to the device 100. The test data may be received via tether 114 by data processing equipment located outside the conduit and processed for analysis. In some embodiments, the control data and test data are multiplexed and bidirectionally communicated (i.e., control data to device 100, test data from device 100) via a multiplexed or bidirectional communication link, such as an optical or electrical communication link. In some embodiments, the test data is transmitted via an optical communication link, while the control data is received via an electrical communication link, as the control data is typically small in volume compared to the test data.

[0045] In some embodiments, the tether 114 may also include a power link for providing external power from an external power source to the UT element 202 and / or other electrically driven components of the device 100 (such as the actuation spacers 110 and / or rollers 112). In some embodiments, the device 100 may include an internal power source for powering one or more of its electrically driven components.

[0046] In some embodiments, one or more of the UT arrays of device 100 may include a large number of UT elements 202, such as 256 UT elements or 512 UT elements (i.e., 256 pairs of pitch-catch UT elements) for a total of 2048 elements. Including a large number of UT elements 202, such as 250 or more UT elements 202 or 500 or more UT elements 202, may enable device 100 to generate high-resolution, reliable, and accurate FMC ultrasound scan data for a given length of conduit in a relatively short period of time.

[0047] FIG. 4 illustrates a front cross-sectional view of the calandria tube 402, pressure tube 404, and ultrasonic array portion 104 of the ultrasonic inspection device 100 through a first forward-facing conical surface at line C in FIG. 2 , showing the ultrasonic inspection device 100 inserted inside the pressure tube 404. In operation, the spacers 110 (not shown) of the device 100 radially center the device 100 within the pressure tube 404 so that the UT elements 202 of the left front conical UT array 130 and the right front conical UT array 131 are directed radially outward at an angle forward toward the inner surface 408 of the pressure tube 404. As some subsets of the UT elements 202 are activated according to an activation pattern and ultrasonic data is collected by some other subsets of the UT elements 202, ultrasonic waves propagate through a medium (e.g., water) filling the space between the UT elements 202 and the inner surface 408 of the pressure tube 404. The ultrasonic data collected by the UT elements 202 represents ultrasonic waves present at the location of each respective UT element 202. The ultrasound data may be processed by the instrument cord 300 and / or external equipment to detect, based on the detected ultrasound pattern, multiple characteristics of the pressure tube 404 and / or its inner surface 408 and / or outer surface 410 and / or the inside of the pressure tube wall (between the inner surface 408 and outer surface 410). In some examples, localized irregularities in the pressure tube 404, such as thinning, bulges, and / or blemishes, may be detected at one or more locations. In some examples, deformations in the pressure tube 404, such as sagging and / or oval deformations, may be detected at one or more locations.

[0048] 5 illustrates steps of an exemplary method 500 for ultrasonic inspection of conduits, such as fuel channel pressure lines, etc. Method 500 will be described with reference to ultrasonic inspection device 100 (see FIG. 1). However, it will be appreciated that other means can be used to implement the steps of method 500.

[0049] At 502, the device 100 is inserted into the interior cavity of the conduit along the axial dimension of the conduit such that the longitudinal axis 140 of the device 100 is substantially aligned with the axial dimension of the conduit. The device includes a plurality of UT elements 202 including a first plurality of UT elements 202 at a first axial position along the longitudinal axis 140 (e.g., the top UT array 122 and the bottom UT array 124 at the first axial position) and a second plurality of UT elements 202 at a second axial position along the longitudinal axis 140 (e.g., the left UT array 126 and the right UT array 128 at the second axial position). The first plurality of UT elements 202 defines a first partial circumferential portion of the device about the longitudinal axis 140, and the second plurality of UT elements 202 defines a second partial circumferential portion of the device about the longitudinal axis 140. In some embodiments, the first partial circumferential portion and the second partial circumferential portion have a non-zero circumferential overlap, as described above.

[0050] At 504, the device is displaced (ie, withdrawn or inserted) relative to the axial dimension of the conduit.

[0051] At 506, a subset of the UT elements 202 is operated according to an actuation pattern.

[0052] At 508, ultrasound data is acquired from the UT element 202 according to an acquisition pattern.

[0053] Steps 504, 506, and 508 may be repeated sequentially or individually such that each UT element 202 transmits ultrasound waves at each of a plurality of axial positions of the conduit and ultrasound data is collected from each respective UT element 202 for each of a plurality of axial positions of the conduit.

[0054] Example results Figure 6 is a graph of the full matrix capture results based on ultrasound beam directionality showing the major diagonal lines of the FMC data set, based on data acquired on a new sample inside a defect-free calandria (pressure) tube.

[0055] Figure 7 is a graph of full matrix capture results showing a defect-free used calandria (pressure) tube sample. Note the increased noise level and degraded response.

[0056] Figure 8 is a graph of full matrix capture results showing a used calandria (pressure) tube sample with corroded internal surfaces. Note the increased noise level and degraded response.

[0057] Figure 9 is a color image based on full matrix capture results of a used calandria (pressure) tube sample showing visualization of dents and scratches that the sample endured during service.

[0058] Although this disclosure describes methods and processes having steps in a certain order, one or more steps of the methods and processes may be omitted or modified as appropriate. One or more steps may be performed in an order other than that in which they are described as appropriate.

[0059] While the present disclosure is described at least in part with respect to methods, those skilled in the art will understand that the present disclosure is also directed to various components for implementing at least some of the aspects and features of the described methods, whether through hardware components, software, or any combination of the two. Accordingly, the technical solutions of the present disclosure may be embodied in the form of a software product. Suitable software products may be stored on a pre-recorded storage device or other similar non-volatile or non-transitory computer-readable medium, including, for example, a DVD, CD-ROM, USB flash disk, removable hard disk, or other storage medium. The software product includes instructions tangibly stored thereon that can cause a processing device (e.g., a personal computer, a server, or a network device) to execute example methods described herein.

[0060] The present disclosure may be embodied in other specific forms without departing from the subject matter of the claims. The described exemplary embodiments are to be considered in all respects as illustrative only and not restrictive. Features selected from one or more of the above-described embodiments may be combined to create alternative embodiments not expressly described, and features suitable for such combinations are understood to be within the scope of the present disclosure.

[0061] All values ​​and subranges within the disclosed ranges are also disclosed. Also, while the systems, devices, and processes disclosed and illustrated herein may comprise a particular number of elements / components, the systems, devices, and assemblies can be modified to include additional or fewer such elements / components. For example, while any of the disclosed elements / components may be referred to in the singular, the embodiments disclosed herein can be modified to include a plurality of such elements / components. The subject matter described herein is intended to cover and encompass all suitable variations in the art. [Explanation of symbols]

[0062] 100 Ultrasonic Inspection Device 102 rear 104 Ultrasonic array section 106 Front 110 Spacer 112 Laura 114 Tether 122 Upper UT array 124 Lower UT array 126 Left UT arrangement 128 Right UT array 130 Left front cone UT arrangement 131 Right front cone UT arrangement 132 Left posterior cone UT arrangement 133 Right rear cone UT arrangement 134 Superior conus UT arrangement 135 Inferior anterior conus UT arrangement 136 Superior posterior cone UT arrangement 137 Inferior posterior cone UT arrangement 140 Longitudinal axis 200 First Conical Array Subsection 202 UT elements 204 Second Conical Array Subsection 300 Fixture Core, Fixture Code 302 Electrical Link 402 Calandria tube 404 Pressure Pipe 408 Interior 410 Exterior

Claims

1. a body configured to be inserted into an interior cavity of a conduit along an axial dimension of the conduit such that a longitudinal axis of the body is substantially aligned with the axial dimension of the conduit; a plurality of ultrasonic transducer (UT) arrays, each UT array disposed at a respective axial position along the longitudinal axis and defining an arc along a portion of the circumference of the body, each UT array comprising: a plurality of ultrasonic transducer (UT) arrays, each of the plurality of UT elements being disposed at a respective circumferential position along the arc of the UT array, the circumferential positions corresponding to a circumferential portion of the conduit; a control circuit configured to actuate the UT elements of the UT array according to an actuation pattern such that each UT element transmits ultrasound waves at each of a plurality of axial positions around the respective circumferential portion of the conduit; data acquisition circuitry configured to acquire ultrasound data from the UT elements of the UT array according to an acquisition pattern such that ultrasound data is acquired from each respective UT element for each of a plurality of axial positions around the respective circumferential portion of the conduit; 1. A device for inspecting a conduit, comprising:

2. 10. The device of claim 1, wherein the actuation pattern and the acquisition pattern are configured to perform a pitch-and-catch ultrasound scan such that one or more of the UT elements of the UT array acquire ultrasound data while one or more other UT elements of the UT array transmit ultrasound waves.

3. 3. The device of claim 1 or 2, wherein the actuation pattern and the acquisition pattern are configured to perform a full-matrix capture ultrasound scan.

4. the plurality of UT sequences a left UT array defining an arc of less than 180 degrees on a left portion of the body at a left-right array axial position; a right UT array defining an arc of less than 180 degrees on the right portion of the body at the left-right array axial position; 4. The device according to claim 1, comprising:

5. The device of claim 4 , wherein the plurality of UT elements of the left UT array and the right UT array are oriented to transmit and receive ultrasound in a direction substantially perpendicular to the longitudinal axis of the body.

6. the plurality of UT sequences an upper UT array defining an arc of less than 180 degrees on an upper portion of the body at an upper / lower array axial position; a lower UT array defining an arc of less than 180 degrees on a lower portion of the main body at the upper and lower array axial position; 6. The device of claim 1, comprising:

7. The device of claim 6 , wherein the plurality of UT elements of the upper and lower UT arrays are oriented to transmit and receive ultrasound in a direction substantially perpendicular to the longitudinal axis of the body.

8. the plurality of UT sequences a first conical UT array defining an arc of less than 180 degrees around a first circumferential portion of the body at a first conical array axial position, wherein each UT element of the first conical UT array is oriented to transmit and receive ultrasound waves in an oblique direction radially outward from and toward the forward direction of the longitudinal axis of the body; a second conical UT array defining an arc of less than 180 degrees around a second circumferential portion of the body at a second conical array axial location, wherein each UT element of the second conical UT array is oriented to transmit and receive ultrasound waves in an oblique direction radially outward from and toward the opposite direction of the longitudinal axis of the body; 8. The device of claim 1, comprising:

9. one or more UT elements of one of the first conical UT array and the second conical UT array collect ultrasound data, while One or more UT elements of the other of the first cone UT array and the second cone UT array transmit ultrasound.

9. The device of claim 8, wherein the actuation pattern and the acquisition pattern are configured to perform a pitch-and-catch ultrasound scan.

10. The device of claim 1 , wherein the plurality of UT elements of at least one UT array comprises at least 250 UT elements.

11. The device of claim 10 , wherein the plurality of UT elements of at least one UT array comprises at least 500 UT elements.

12. 12. The device of claim 1, wherein the data acquisition circuitry is further configured to process the ultrasound data collected from the UT element to identify local irregularities in an inner surface of the conduit at one or more locations.

13. 12. The device of claim 1, wherein the data acquisition circuitry is further configured to process the ultrasound data collected from the UT element to identify local irregularities in the outer surface of the conduit at one or more locations.

14. 14. The device of claim 12 or 13, wherein the localized irregularities include at least one of thinning areas, blisters, and blemishes.

15. 14. The device of claim 1, wherein the data acquisition circuitry is further configured to process the ultrasound data collected from the UT element to identify deformations in the conduit at one or more locations.

16. The device of claim 15 , wherein the deformation comprises at least one of a sagging deformation and an oval deformation.

17. The body further comprises a tether attached thereto, the tether comprising: a communication link operably coupled to the control circuitry and the data acquisition circuitry; a power link for providing power to the UT element; 17. The device of claim 1, comprising:

18. The device of claim 17 , wherein the communication link comprises an optical communication link.

19. The control circuit receiving control data from the communication link; activating the UT element according to the actuation pattern based on the control data; 19. The device of claim 17 or 18, further configured to:

20. the data acquisition circuitry processing the ultrasonic data collected from the UT elements to generate inspection data; Transmitting the test data over the communication link 20. The device of any one of claims 17 to 19, configured to:

21. a body configured to be inserted into an interior cavity of a conduit along an axial dimension of the conduit such that a longitudinal axis of the body is substantially aligned with the axial dimension of the conduit; a plurality of UT arrays, each UT array disposed at a respective axial position along the longitudinal axis and defining an arc along a portion of the circumference of the body, each UT array comprising: a plurality of UT arrays comprising a plurality of UT elements, each respective UT element disposed at a respective circumferential position along the arc of the UT array, the circumferential positions corresponding to a circumferential portion of the conduit; a control circuit configured to actuate the UT elements of the UT array according to an actuation pattern such that each UT element transmits ultrasound waves at each of a plurality of axial positions around the respective circumferential portion of the conduit; data acquisition circuitry configured to acquire ultrasound data from the UT elements of the UT array according to an acquisition pattern such that ultrasound data is acquired from each respective UT element for each of a plurality of axial positions around the respective circumferential portion of the conduit; Equipped with the plurality of UT sequences a first pair of UT arrays each defining an arc of less than 180 degrees on a pair of substantially opposite circumferential portions of said body at a first axial location; a second pair of UT arrays each defining an arc of less than 180 degrees on a pair of substantially opposite circumferential portions of said body at a second axial location; Including, A device for inspecting a conduit, wherein the area covered by the first pair of arrays and the area covered by the second pair of arrays collectively encompass an entire longitudinal axis of the conduit.

22. the first pair of UT arrays comprises a first pair of conical UT arrays, each UT element of the first pair of UT arrays oriented to transmit and receive ultrasound waves in a diagonal direction radially outward from and toward the longitudinal axis of the body; 22. The device of claim 21, wherein the second pair of UT arrays comprises a second pair of conical UT arrays, each UT element of the second pair of UT arrays oriented to transmit and receive ultrasound in an outward oblique direction from and toward opposite directions of the longitudinal axis of the body.

23. 23. The device of claim 1, wherein the conduit is a pressure tube for a fuel channel.

24. 24. The device of any one of claims 1 to 23, wherein the device is tubular.

25. such that the longitudinal axis of the device is substantially aligned with the axial dimension of the conduit. inserting the device into an interior cavity of the conduit along the axial dimension of the conduit; the device comprising a plurality of ultrasonic transducer (UT) elements; a first plurality of UT elements at a first axial position along the longitudinal axis and defining a first partial circumferential portion of the device relative to the longitudinal axis; a second plurality of UT elements at a second axial position along the longitudinal axis, defining a second partial circumferential portion of the device relative to the longitudinal axis; and Including, the first partial perimeter portion and the second partial perimeter portion including a plurality of ultrasound transducer (UT) elements having a non-zero perimeter overlap; displacing the device in the axial dimension; During the step of displacing the device in the axial dimension, actuating the UT elements according to an actuation pattern such that each UT element transmits ultrasound waves at each of a plurality of axial positions of the conduit; acquiring the ultrasonic data from the UT elements according to an acquisition pattern such that ultrasonic data is acquired from each respective UT element for each of a plurality of axial positions of the conduit; 11. A method for inspecting a conduit, comprising:

Images