Development of an automated scanner and phased array ultrasonic

testing technique for the inspection of nozzle welds in the nuclear

industry

Dimosthenis Liaptsis, Dawei Yan and Ian Cooper

TWI NDT Validation Centre (Wales)
Port Talbot, SA13 2EZ, UK
Tel: +44 (0)1639 873100
Fax: +44 (0)1639 864679
E-mail: [email protected]

Vasilios Papadimitriou, Ioannis Roditis and Panagiotis Chatzakos

Innora Ltd-Innovation Robotics Automation
59 Ioanni Metaxa Str., 19400, Koropi, Athens, Greece

Abstract

Regular in-service inspection is important to verify the integrity of welded nozzle

sections in the nuclear industry. Nozzle sections can be susceptible to crack growth due
to thermal fatigue and stress corrosion. Early detection of cracks is therefore essential to
ensure the continued safe operation of the facilities. In order to reduce the time and cost
of such inspections there is a need to develop a system capable of performing a full
inspection of nozzles without the need to change probes. The aim of this project was to
design an inspection system that is able to achieve the following: reduce the inspection
times, improve defect detectability and sizing, and reduce human intervention, which
will reduce workforce radiation uptake. The developed automated system reduces the
requirement for complex robotic manipulation and consequently reduces the size and
cost of robotic deployment systems. This paper will present the inspection technique
development and ultrasonic simulation using CIVA that was carried out to determine
the most appropriate phased array probe and its detection capabilities. The parameters
that are assessed are the beam propagation through the material, the beam coverage and
the focusing characteristics of the beam as well as the defect response at critical areas of
the nozzle. Furthermore, the developed automated inspection system and its
functionalities will be presented together with experimental results from nozzle mock
up samples with simulated defects at the nozzle to vessel weld.

1. Introduction

NozzleInspect(1) is a collaboration between EU companies and research organisations

supporting the effort of the nuclear industry in achieving better safety standards through
improved inspection of plant. The project aimed to develop a novel scanner and probe
manipulator combined with a phased array technique for the inspection of Boiling
Water Reactor (BWR) nozzles. The project focused on the development of a new
automatic NDT phased array ultrasonic system that can be deployed for the inspection
of nozzles in nuclear reactors.
Welded nozzles can be found in many sections in nuclear power plants and other critical
facilities. Cracking in BWR feedwater nozzless discovered during the 1970s led to a
change in both the design and the materials of the nozzle. Guidelines were established
for periodic ultrasonic testing with work undertaken since the early 1970s aimed at
specialising NDT testing methods for the application of in-service inspection of nozzles
in boiled water reactors(2). Early investigations serve to illustrate that complicated probe
configurations were required to provide the necessary beam angle within a tangent plane
of the target area(3). The requirement to manage defects in nozzles was addressed
through the investigation of the choice of optimal inspection parameters based on three
areas of inspection of the geometry of the nozzle(4).

Applications where the external geometry of the test specimen varies across the test area
require the control of the degradation of contact between the transducer and specimen(5).
Experimental techniques were developed to overcome variation through adaptability of
different control configurations(6)-(7). Physically flexible phased arrays overcome
irregularities in the test surface and improve the coupling between surface(8). These
arrays have been implemented in the interpretation of irregular shaped components of
BWRs including the nozzles and for more challenging inspection configurations in
nuclear and conventional power plant applications. Phased array techniques overcome
issues associated with complex geometries through adaptability based on a combination
of electronic commutation, beam-steering and focusing in complex geometries(9)-(10). In
such an approach, each element of the probe is controlled independently and can
therefore be delayed in responding to a signal. If all of the elements are activated
simultaneously, the probe behaves like a conventional device, but when a delay is
introduced, the resulting beam can be controlled and focussed as required.

2. Scanner mechanical design

2.1 Scanner base

The base of the robotic scanneris firmly clamped onto the nozzle feedwater pipe and
offers rigid support for accurate positioning of the manipulator that carries the phased
array probe. It consists of three main subsystems: the base frame, the clamping /
centering mechanism and the rotational degree of freedom.

The base frame is a lightweight and yet rigid structure that supports all components and
equipment. It is comprised of two segments, 180° each, that are possible to “open”, one
in relation to another, to mount the robotic scanner on the nozzle. Afterwards, the base
is easily and effectively secured using a latch mechanism (Figure 1a).

The clamping mechanism is located at the base frame and consists of four linear
actuators, two manually and two pneumatically actuated. The purpose of the clamping
mechanism is to stabilize the base on the nozzle offering as well, the required traction
during operation. The two manually adjustable actuators are coupled and this ensures
that the robotic scanner base remains concentric with the nozzle. They are mechanically
coupled through a system of two timing belts stages and two low backlash worm gears.
As a result the manual rotation, achieved by means of a hand knob, is transformed to an
accurately coordinated linear motion of each linear actuator, adjusting the “clamping”
diameter of the base on the specific nozzle. The adjustment of the manual actuators is

2
made prior to taking the robotic scanner on-site to avoid the calibration procedure near
the vessel. After the robotic scanner is placed on the nozzle and the base is “closed” and
secured using the latch, the base is forced to become concentric with the nozzle due to
the geometrical restriction of the manual actuators. The two other linear actuators are
pneumatically actuated and are activated to firmly clamp the robotic scanner on the
nozzle, through high friction yet low elasticity pads. To implement the peripheral
movement of the probe around the nozzle, the manipulator is mounted on a carriage that
rolls on a double V profiled precision stainless steel circular slide. The carriage
incorporates 8 rolling wheels that allow it to slide with precision and low friction. The
movement is actuated using a 60 Watt brushed DC motor and a timing belt stage
mounted on the carriage (Figure 1b).

(a) (b)
Figure 1. Design details of (a) base of the robotic scanner (b) peripheral degree of
freedom

2.2 Manipulator
The robotic manipulator (Figure 2) is mounted on a carriage that can rotate 360º around
the nozzle to fully cover the nozzle to vessel weld. Structurally, it is comprised of two
links and is able to accurately place the end-effector on the vessel in a workspace up to
820mm axially from the axis of the nozzle (400mm maximum axial distance from
nozzle-vessel weld). The power to both links is given by two 60 Watt brushed DC
motors accompanied with low backlash planetary gearheads. The payload of the
manipulator is estimated to 5Kg and it is able to apply 40N of force to the probe holder
to keep it against the surface of the vessel.

3
 Figure 2. The two degrees of freedom manipulator

2.3 End-Effector
The end-effector of the robotic scanner carries and deploys the probe holder that
encloses the 2D phased array UT probe. During inspection, in order for the probe holder
to comply with the varying surface of the vessel, two degrees of freedom are required.
A gimbal joint design was conceived for the purpose which allows two axes of rotation
perpendicular to each other (Figure 3).

In addition, during the inspection it is required that a vertical force of 30N is applied to
the probe holder to maintain sufficient ultrasonic coupling. Two springs mounted on
linear shafts provide the required force. The deflection of the springs is measured using
and absolute encoder (4096 ppr) and a two link mechanism, i.e., a “knee” mechanism,
for converting linear movement to rotational. The linear resolution achieved with this
mechanism is 0.03mm.

Figure 3. The end-effector

4
2.4 Control software
For the control of the robotic scanner, a Galil controller was programmed to execute the
low level functionalities using Galiltools software. The low level software includes the
sequence of functions for the motion and the synchronization of the axes movement so
that the scanner can move the probe smoothly on the curved surface of the vessel. The
software is stored in the memory of the controller and it is executed on a chip in real
time. A dedicated custom graphical user interface (GUI), shown in Figure 4, was
developed using the InspectionWare® (product of UTEX (13)) to combine the motion
control with the acquisition of the ultrasonic data.

Figure 4. The InspectionWare® (product of UTEX) GUI.

3. Modelling approach

This paper presents a series of modelling studies undertaken using CIVA 10(14)
ultrasonic modelling software developed by CEA. These models enable the simulation
of the wave propagation and interaction of ultrasound with simulated flaws in models of
the nozzle to vessel weld. The analysis of the beam propagation and interaction with the
defects was simulated in order to optimize and predict the performance of the phased
array technique in terms of critical area coverage and defect response. These
simulations included several different configurations of probes, defect parameters and
locations.

2.1 Defect parameters

The position, size and orientation of the defects were defined from the end user
requirements and ASME Code Case 235. The defects to be detected in the main weld
are planar (cracks) and parallel to the axis of the nozzle to vessel weld. The defects are
likely have an allowable tilt angle in the range 5-15° with respect to the normal of the
vessel wall. In addition, defects may be skewed with respect to the weld axis within the
range ±10°. The length of defects varies in the range of 5.8mm to 23.6mm while the
height is in the range of 2.9mm-11.8mm.

5
2.2 Ultrasonic modelling

2.2.1 Feedwater nozzle parameters

The nozzle under investigation is at the junction of the 300mm diameter feedwater pipe
with the cylindrical wall of the reactor vessel. The diameter of the nozzle to vessel weld
is 840mm. The wall thickness of the reactor vessel is 139mm and the material is low
alloy ferritic steel. 3D modelling and simulation of the inspection of the nozzle were
performed using CIVA 10 software. It can be observed that the weld volume can only
be inspected from the side of the vessel. Inspection from the side of the pipe is
problematic due to the curved surface of the nozzle and insufficient distance. The inner
surface of the vessel wall outside the weld is normally covered by cladding and in such
a case the use of the techniques based on the reflected from inner surface of the wall
signals (full skip) is not recommended.

2.2.2 Probe and probe holder design

Several configurations were evaluated to assess the most suitable, taking into account
the inspection requirements and the manufacturability of the probe. Among these
configurations were (see Figure 5):
 1D array (Figure 5a): standard phased array configuration ; only for comparison
purposes as this configuration does not allow the deflection of the ultrasound
beam in all directions
 2D array (Figure 5b): this configuration allows the deflection of the beam in all
directions
 2D annular segmented array (Figure 5c): this is the most complex configuration
that leads to differences in elementary areas.

Figure 5. Examples of phased array probe configurations evaluated during the

design phase
The modeling was performed on the YZ plane as defined in Figure 6(a) for the sectorial
scanning. The modeling was also performed in the plane that is perpendicular to YZ
plane and at an angle of 40° with respect to the Y axis (this plane is called XS as
described in the Figure 6(b) to assess the skewing abilities of the different probe
designs.

6
 (a) (b)
Figure 6. (a) position of the transducer when used for sectorial scanning (b)
beam steered at 40° and skewed at 10°
The modeling demonstrated that a 2D array configuration at 2MHz centre frequency
with 128 rectangular elements (3mm x 2mm) in water is the most suitable configuration
for this application. The resulting ultrasound beam presents some grating lobes but these
are low compared to the main beam and are not detrimental to the inspection (Figure
7).

For the different configurations, the beam amplitude, focal area and focal depth were
also modelled and confirmed the suitability of this 2D array configuration. It was
demonstrated that the selected configuration gives the highest amplitude of ultrasonic
beam when steering the beam at 40°, that the focal depths of -3dB and -6dB are the
largest and that the focal zone is able to reach the bottom of the inspected component.
The capability of this array on electronic beam skewing was also assessed and a
maximum skewing angle of ±20° can be achieved.

Figure 7. Modelling results of the beam profiles for the 2D array with the beam
steering at (a) 40° in the YZ plane, (b) 65° in the YZ plane, (c) 85° in the YZ plane,
(d) 40° in the YZ plane and the profile shown in the XS plane (e) 40° in the YZ
plane and 10° in the XS plane and the profile shown in the XS plane

7
The developed 2D matrix annular phased probe was fixed into a flexible probe holder
(designed by Phoenix ISL) filled with water as shown in Figure 8. A flexible membrane
was used to compensate for variations in the surface profile around the nozzle
circumference. The ultrasonic beam was transmitted from the probe into the water and
then passed through the flexible membrane.

Figure 8. Schematic drawing showing the designed probe holder and an actual
photo of the flexible membrane

4. Experimental set up and results

The probe holder assembly was placed on the nozzle reference samples as shown in
Figure 9. Gel coupling was used between the membrane and the sample in the
laboratory development work and water coupling will be applied to the inspection of the
real sample through the use of miniature spray nozzles. The profile of the nozzle to
vessel weld varies circumferentially and so three reference samples were designed and
manufactured to represent 0˚, 45˚ and 90˚ parts of the nozzle weld profile and surface
curvature profile. Figure 9 shows the 2D matrix annular phased array placed on the
sample representing 0˚ part of the vessel. The sizes, orientation and position of the
introduced defects into the reference samples were selected in accordance to ASME
Code Case 235.

Figure 9. Experimental set-up of the position of the probe holder on the

reference samples

8
Defects were introduced inot the samples using Electro Discharge Machining (EDM).
The skew angle of each defect ranges from 0˚ to 10˚, and the tilt angles are -5˚ and 5˚.
The defect sizes vary from 3.8mm x 1.9mm (L x H) for surface breaking defects to
14.6mm 7.3mm for postulated defects.

For the experimental work, a Micropulse 5PA (manufactured by PeakNDT) phased

array pulser-receiver was used to acquire the data. For the generation of the focal laws
and display of the data the ArrayGen software was used. The focal laws can also be
incorporated into the InspectionWare software which was used to drive the
scanner/manipulator, and to acquire and analyse the data.

A 2D matrix annular phased array was used to inspect three reference samples (0˚, 45˚
and 90˚ parts of the nozzle vessel). The inspection set up has been designed to generate
shear waves in the material. This paper presents some of experimental results obtained
from the 0˚ part of the nozzle vessel sample. Because of the presence of stainless steel
cladding in the inner surface of the vessel, full skip ultrasonic techniques cannot be
used. The direct response from the defects located in the middle of the vessel was
measured. Figure 10 shows that defect 3 positioned in the middle of the weld, size
5.8mm x 2.9mm, can be detected when the beam was electronically skewed at 5˚. Also
the vessel inner surface breaking defect 4, with a size of 3.8mm x 1.9mm, is shown in
the same phased array data display. The phased array data is displayed in corrected and
uncorrected sectorial scan and A-scan. Defects 3 and 5 are both tilted in the same
direction. Suitable electronic skewing was applied to improve the detectability and
increase the reflected amplitude response from the induced defects. There are some
other strong reflections that can be seen in the phased array data in Figure 10. The first
reflection that can be seen at approximately 70mm ultrasonic range is the reflection
from the interface between the flexible membrane and the top surface of the steel
sample. There are some other reflections noticeable that are due to internal ultrasonic
reflections and reverberations occurring inside the probe holder immersion bath. These
reflections are present in most of the acquired phased array data, but did not affect the
detection capabilities of the ultrasonic technique because they occur outside the region
of interest in which the defects are located. Furthermore, in the data set, a reflection
from the corner of the reference sample can be seen because of the small size of the
reference sample.

The use of the designed 2D array phased array probe on the reference samples
manufactured for the phased array technique development has shown that the
introduction of electronic skewing significantly improves the detection capabilities. The
electronic beam skewing is particularly important when the defect is mis-orientated with
respect to the incident ultrasonic beam. The technique developed on the reference
samples was used during the final integration trials on a full nozzle mock up with
induced cracks.

9
 Figure 10. Experimental results of the inspection of defect 3 (middle, 5.8 x
2.9mm, skew 5˚ and tilt 5˚) and defect 5 ((bottom, 3.8 x 1.9mm, skew 10˚
and tilt -5˚) in 0˚ sample

5. Testing and field trials

A mockup of a N5 feed water nozzle was manufactured (shown in Figure 11), in order
to test the functionalities and validate the performance of the prototype. This mockup
did not have the thickness of the actual nozzle, but the geometry of the nozzle where the
robotic scanner is mounted and the vessel curvature where the end effector is placed
were accurate.

Figure 11. The robotic scanner on the geometrical mockup

The robotic scanner was able to be managed by two persons and was successfully
clamped onto the nozzle in less than a minute. The base was very rigid and stable when
the pneumatic actuators clamped it onto the nozzle. No movement or wobbling occurred
during testing. The manipulator moved smoothly and the probe followed the curvature
of the vessel. The prototype of the robotic scanner and phased array probe was tested
on a full nozzle mock up with induced defects in the nozzle to vessel weld. The mockup
that was used is an exact replica of an actual N5 nozzle that is used for qualification of
scanning systems, ultrasonic techniques and inspection personnel. The system fitted in
the constrained environment that exists in nuclear facilities (Figure 12). The robotic
scanner was placed and clamped onto the nozzle without calibration or fine tuning. The

10
manipulator was able to move the ultrasonic phased array probe smoothly on the surface
of the vessel and all the defects in the nozzle to vessel weld of the mockup were
detected at the expected positions according to the defect plan. Furthermore, the
detected defects were accurately sized using the acquired phased array data.

Figure 12. The robotic scanner on the nozzle mockup

5. Conclusions

The developed automated robotic scanner/manipulator and phased array ultrasonic

testing technique is a working prototype that satisfies the requirements for nozzle
inspection in the harsh and challenging environment of the nuclear plant. It can be
mounted on a variety of nozzle diameters and nozzle-vessel configurations. The design
and control of the robotic scanner allows the operator to place and fasten the system on
the nozzle faster than any available equipment without the need of calibration and fine
tuning.

Furthermore, the developed scanner/manipulator provides the operator with the

flexibility of carrying out different scanning patterns, depending on the inspection
needs, by using a user-friendly interface. Additionally the manipulator maintains
sufficient force to the end effector to ensure constant ultrasonic coupling. As the
developed scanner/manipulator system is an integrated part, it is only required to be
transferred to the inspection area and clamped onto the nozzle pipe, using a quick latch
mechanism. All the initial system calibration and scanning set up can be completed
remotely away from the the high radiation area.

It was shown that the developed system is capable to detect all the defects with very
good sizing capabilities. The flexible probe holder was shown to run smoothly on the
mock up surface during scanning, and the water irrigation system provided good
ultrasonic coupling. The application of 2D steering capabilities enhanced the detection
capabilities of the phased array ultrasonic inspection technique when the defects were
misorientated with respect to the incident ultrasonic beam.

11
Acknowledgements

NozzleInspect is collaboration between the following organisations: Iberdrola

Generacion, Phoenix Inspection Systems Limited, PeakNDT Limited, Vermon, Innora,
Cereteth and Kaunas University of Technology. Furthermore, the authors would like to
thank the consortium collaborator for the access given to the full nozzle mock up that
allowed the final integration and testing of the complete automated inspection system.
The project was co-ordinated and managed by TWI Ltd and is partly funded by the EC.

References

1. www.nozzleinspect.eu
2. H Seiger and G Engl, ‘Ultrasonic inspection of the spherically shaped
perforated areas of light water reactor pressure vessels’, NDT International,
Volume 10, Issue 6, pp 293-296, 1997.
3. G. M. Van Dijk, ‘Special NDT systems applied to the in-service inspection of a
BWR nozzle and safe-end welds’, Nuclear Engineering and Design, Volume 81,
Issue 1, pp 77-84, 1984.
4. H. Wustenberg, H. Nimtz, G. Neiss, H. Berg, H.J. Maier, ‘Nondestructive
inspection of nozzle inner corner at boiling water reactor pressure vessels with
ultrasound-flaw detection and crack depth determination’, Nuclear Engineering
and Design, Volume 87, pp 175-184, 1985.
5. O. Roy and M. S. Chatillon, ‘Ultrasonic inspection of complex geometry
component specimen with a smart flexible contact phased array transducer:
modelling and application’, Ultrasonics Symposium, 2000 IEEE, Vol1, No 1,
pp763-766, 2000.
6. S. Mahaut, O. Roy, and M. Serre, ‘An adaptive system for advanced NDT
applications using phased arrays’, Ultrasonics, Vol 36, Issues 1-5, Ultrasonics
International 1997, pp 127-131, February 1998.
7. O. Roy, S. Mahaut and O. Casula, ‘Control of the ultrasonic beam transmitted
through an irregular profile using a smart flexible transducer: modelling and
application’, Ultrasonics, Vol 40, Issues 1-8, pp 243-246, 2002.
8. O. Casula, C. Poidevin, G. Cattiaux and P. Dumas, ‘Control of complex
components with Smart Flexible Phased Arrays’, Ultrasonics, Volume 44,
Supplement 1, Proceedings of Ultrasonics International (UI'05) and World
Congress on Ultrasonics (WCU), pp e647-e651, 2006.
9. L. Le Ber, O. Roy and N. Jazayeri, ‘Applications of Phased Array Techniques to
NDT of Industrial Structures’, 2nd International Conference on Technical
Inspection and NDT, 2008.
10. A. J. Hunter, B. W. Drinkwater and P C. Wilcox, ‘Autofocusing ultrasonic
imagery for non-destructive testing and evaluation of specimens with
complicated geometries’, NDT & E International, Vol 43, Issue 2, pp 78-85,
2010.
11. UTEX Scientific Instruments Inc., Mississauga, Ontario, Canada
http://www.utex.com
12. www-civa.cea.fr

12