Robert V. Harris

On-line ultrasonic density sensor for process control of liquids and slurries

Abstract An on-line ultrasonic density sensor is described in which six transducers are mounted upon a plastic wedge, the base of the wedge being in contact with a liquid or slurry. Ultrasonic beams striking the base at several angles are reflected. The amount of reflection at the plastic–liquid interface depends upon the density of the liquid ρ, the speed of sound c in the liquid, and wedge parameters. By determining the reflection coefficient at two angles, ρ and c can be determined. The sensor can be mounted in a pipeline configuration or submerged for tank applications.

Materials issues in high temperature ultrasonic transducers for under-sodium viewing

Liquid sodium is used as the coolant in some fast spectrum nuclear reactors. This material is optically opaque. To facilitate operations and maintenance activities, an ultrasonic under-sodium viewing system has been developed. In the USA, the technology was successfully demonstrated in the 1970s and, over the intervening 30+ years, the capability was lost. This paper reports materials challenges encountered in developing both single-element and linear phased-array 2-MHz transducers that must operate at temperatures up to 260°C. The critical issues are fundamentally material selection: the ability of a transducer to be immersed into liquid sodium and function at 260°C, to achieve wetting and transmission of ultrasound into the sodium, and to be able to be removed and re-used.

High temperature ultrasonic transducers for in-service inspection of liquid metal fast reactors

In-service inspection of liquid metal (sodium) fast reactors requires the use of ultrasonic transducers capable of operating at high temperatures (>;200°C), high gamma radiation fields, and the chemically reactive liquid sodium environment. In the early- to mid-1970s, the U.S. Atomic Energy Commission supported development of high-temperature, submersible single-element transducers, used for scanning and under-sodium imaging in the Fast Flux Test Facility and the Clinch River Breeder Reactor. Current work is building on this technology to develop the next generation of high-temperature linear ultrasonic transducer arrays for under-sodium viewing and in-service inspections.

Development of a Remotely Operated NDE System for Inspection of Hanford's Double Shell Waste Tank Knuckle Regions

This report documents work performed at the PNNL in FY01 to support development of a Remotely Operated NDE (RONDE) system capable of inspecting the knuckle region of Hanfords DSTs. The development effort utilized commercial off-the-shelf (COTS) technology wherever possible and provided a transport and scanning device for implementing the SAFT and T-SAFT techniques.

Passive fully polarimetric W-band millimeter-wave imaging

We present the theory, design, and experimental results obtained from a scanning passive W-band fully polarimetric imager. Passive millimeter-wave imaging offers persistent day/nighttime imaging and the ability to penetrate dust, clouds and other obscurants, including clothing and dry soil. The single-pixel scanning imager includes both far-field and near-field fore-optics for investigation of polarization phenomena. Using both fore-optics, a variety of scenes including natural and man-made objects was imaged and these results are presented showing the utility of polarimetric imaging for anomaly detection. Analysis includes conventional Stokes-parameter based approaches as well as multivariate image analysis methods.

METHODS FOR THE IN‐SITU CHARACTERIZATION OF CAST AUSTENITIC STAINLESS STEEL MICROSTRUCTURES

Cast austenitic stainless steel (CASS) that was commonly used in U.S. nuclear power plants is a coarse‐grained, elastically anisotropic material. Its engineering properties made it a material of choice for selected designs of nuclear power reactor systems. However, the material manufacturing and fabrication processes result in a variety of coarse‐grain microstructures that make current ultrasonic in‐service inspection of components quite challenging. To address inspection needs, new ultrasonic inspection approaches are being sought. However, overcoming the deleterious and variable effects of the microstructure on the interrogating ultrasonic beam may require knowledge of the microstructure, for potential optimization of inspection parameters to enhance the probability of detection (POD). The ability to classify microstructure type (e.g. polycrystalline or columnar) has the potential to guide selection of optimal NDE approaches. This paper discusses the application of ultrasonic and electromagnetic methods...

Evaluation of signal processing tools for improving phased array ultrasonic weld inspection

Cast austenitic stainless steel (CASS) that was commonly used in U.S. nuclear power plants is a coarse-grained, elastically anisotropic material. In recent years, low-frequency phased-array ultrasound has emerged as a leading candidate for the inspection of welds in CASS piping, due to the relatively lower interference in the measured signal from ultrasonic backscatter. However, adverse phenomena (such as scattering from the coarse-grained microstructure, and beam redirection and partitioning due to the elastically anisotropic nature of the material) result in measurements with a low signal-to-noise ratio (SNR), and increased difficulty in discriminating between signals from flaws and signals from benign geometric factors. There is therefore a need for advanced signal processing tools to improve the SNR and enable rapid analysis and classification of measurements. This paper discusses recent efforts at PNNL towards the development and evaluation of a number of signal processing algorithms for this purpose. Among the algorithms being evaluated for improving the SNR (and, consequently, the ability to discriminate between flaw signals and non-flaw signals) are wavelets and other time-frequency distributions, empirical mode decompositions, and split-spectrum processing techniques. A range of pattern-recognition algorithms, including neural networks, are also being evaluated for their ability to successfully classify measurements into two or more classes. Experimental data obtained from the inspection of a number of welds in CASS components are being used in this evaluation.

A Novel Passive Millimeter Imager for Broad-Area Search - Final Report on Project PL09-NPMI-PD07 (PNNL-55180)

This report describes research and development efforts toward a novel passive millimeter-wave (mm-wave) electromagnetic imaging device for broad-area search. It addresses the technical challenge of detecting anomalies that occupy a small fraction of a pixel. The purpose of the imager is to pinpoint suspicious locations for cuing subsequent higher-resolution imaging. The technical basis for the approach is to exploit thermal and polarization anomalies that distinguish man-made features from natural features.

Evaluation of Non-Nuclear Techniques for Well Logging: Final Report

The focus of this study is the understanding of the technical obstacles that hinder the replacement of and the disadvantages from the loss of extensive interpretation experience based on data accumulated with AmBe. Enhanced acoustic and electromagnetic sensing methods in combination with non-isotope-based well logging techniques have the potential to complement and/or replace existing isotope-based techniques, providing the opportunity to reduce oil industry dependence on isotopic sources such as AmBe.

NDE Assessment of PWSCC in Control Rod Drive Mechanism Housings

Studies being conducted at the Pacific Northwest National Laboratory (PNNL) in Richland, Washington are focused on assessing the effectiveness of nondestructive examination (NDE) techniques for inspecting control rod drive mechanism (CRDM) nozzles and J-groove weldments. The primary objective of this work is to provide information to the United States Nuclear Regulatory Commission (US NRC) on the effectiveness of NDE methods as related to the in-service inspection of CRDM nozzles and J-groove weldments, and to enhance the knowledge base of primary water stress corrosion cracking (PWSCC) through destructive characterization of the CRDM assemblies. In describing two CRDM assemblies removed from service, decontaminated, and then used in a series of NDE measurements, this paper will address the following questions: 1) What did each technique detect?, 2) What did each technique miss?, and 3) How accurately did each technique characterize the detected flaws? Two CRDM assemblies including the CRDM nozzle, the J-groove weld, buttering, and a portion of the ferritic head material were selected for this study. One contained suspected PWSCC, based on in-service inspection data and through-wall leakage; the other contained evidence suggesting through-wall leakage, but this was unconfirmed. The two CRDMs used in this study were cut from a pressure vessel head that has since been replaced. The selected NDE measurements follow standard industry techniques for conducting in-service inspections of CRDM nozzles and the crown of the J-groove welds and buttering. In addition, laboratory based NDE methods were employed to conduct inspections of the CRDM assemblies, with particular emphasis on inspecting the J-groove weld and buttering. This paper will also describe the NDE methods used and discuss the NDE results. Future work will involve using the results from these NDE studies to guide the development of a destructive characterization plan to reveal the crack morphology and a comparison of the degradation found by the destructive evaluation with the recorded NDE responses.© 2006 ASME