Automated Ultrasonic Inspection of Nuclear Reactor Welds
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Solution Overview
Problem
The weld between the yoke section of the jet pump riser brace and the jet pump riser pipe in nuclear reactors is difficult to inspect accurately due to limited accessibility, leading to constraints in reactor operations and regulatory issues.
Innovation Solution
An automated, electro-mechanical inspection apparatus with a scan head and installation platform is used to perform remote ultrasonic testing, allowing for multi-axis motion and access to previously inaccessible areas, such as the welds on the jet pump riser pipe, using a phased array transducer to inspect the weld integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If visual inspection techniques are used to examine the weld, then the inspection method is simple, but the accuracy and accessibility are limited
Solution Approach 1:
The patent replaces manual visual inspection with an automated ultrasonic testing system that uses acoustic waves to detect weld defects. The mechanical system includes a robotic manipulator holding a phased array transducer that automatically scans the weld joint, substituting human operators with an automated mechanical inspection system that provides both simplicity of operation and high measurement precision
Solution Approach 2:
The patent changes the inspection parameter from visual observation to ultrasonic wave propagation characteristics. By using phased array technology, the system can vary the angle and position of ultrasonic beams to detect internal weld defects that are invisible to the naked eye, thereby improving measurement precision while maintaining ease of operation through automated parameter control
2Device complexity
If visual inspection techniques are used to examine the weld, then the equipment is simple, but the accessibility to difficult-to-reach areas is limited
Solution Approach 1:
The patent employs a dynamic robotic manipulator system that can move the ultrasonic transducer to various positions and orientations around the weld joint. The manipulator can navigate to difficult-to-reach areas and adjust its position dynamically, providing excellent accessibility while the entire system remains relatively simple in concept and operation
Solution Approach 2:
The patent introduces a robotic manipulator as an intermediary between the operator and the difficult-to-reach weld area. The manipulator serves as a mediator that extends the inspection capability into confined spaces and complex geometries that would be inaccessible to direct human observation, thereby improving accessibility without significantly increasing overall system complexity
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The inspection apparatus enables comprehensive characterization of weld integrity, improving accessibility and accuracy, thereby addressing the limitations of traditional inspection methods and enhancing reactor operations and regulatory compliance.
Implementation Method 1
perform remote ultrasonic testing, allowing for multi-axis motion and access to previously inaccessible areas
Data Source
AI summary
An inspection apparatus may include an installation platform and a scan head. The scan head may be configured to engage in an index movement, a theta movement, a wrist fold movement, and a scan movement. During the scan movement, a transducer of the scan head travels a circumferential path so as to allow an inspection of a surface that is opposite of a surface on which the installation platform is mounted. The inspection apparatus may be used to inspect a reactor component in a nuclear reactor.