Patent Number: 
Section: description

Like reference numerals refer to corresponding parts throughout the drawings. FIG. 5 is a side view of an ultrasonic examination device 70 of the invention. The device 70 includes an elongated guide rod 72 and an ultrasonic transducer 74. The ultrasonic transducer 74 is positioned within a collapsible shoe 76. The collapsible shoe 76 includes a biasing mechanism (1) to allow the collapsible shoe to pass through pipe segments of different circumferences, and (2) to establish ultrasonic coupling for the ultrasonic transducer at a weld location in the pipe. As used herein, the term xe2x80x9cpipe segmentsxe2x80x9d refers to a single pipe with different circumferences or attached pipes with different circumferences. The elongated guide rod 72 is pushed through a pipe until the collapsible shoe 76 is at a weld location to be examined. Preferably, the elongated guide rod 72 includes measurement indicia to assess how far the elongated guide rod 72 has been pushed into a pipe. Once at the weld location, the ultrasonic transducer produces an ultrasonic signal indicative of the geometry of the remotely located weld. The signal is passed over line 75 and is then processed in a standard manner, as discussed below. As indicated above, the collapsible shoe 76 includes a biasing mechanism that may be implemented with a first shoe half 78 and a second shoe half 80. Preferably, each shoe half includes tapered ends 82. The shoe halves include aligned bias chambers 84. Springs 86 or other biasing elements are placed within the biasing chambers 84. Thus, the collapsible shoe 76, shown in an expanded state, can be collapsed into a collapsed state. A transducer well 88 accommodates the transducer 74 when the collapsible shoe 76 is in the collapsed state. The springs 86 operate to provide tight ultrasonic coupling during examinations. That is, the springs 86 force the collapsible shoe 76 against the pipe at the weld location. Typically, the collapsible shoe 76 will pass through a narrow circumference pipe segment (e.g., 1.3 inches) before reaching the weld location. The collapsible shoe 76 will be in a collapsed state in the narrow circumference pipe segment. When the collapsible shoe is at the weld location, it is typically at a wide circumference pipe segment (e.g., 1.5 inches). At this location, the biasing mechanism presses the collapsible shoe 76 into an expanded state such that it is forced against the pipe to insure ultrasonic coupling. The tapered ends 82 allow the collapsible shoe 76 to easily transition from pipe segments with different circumferences. The ultrasonic exam device 70 of FIG. 5 is used in connection with seal injection lines 46 and cooling lines 50 of a reactor coolant pump 30. By way of example, FIG. 6 illustrates the ultrasonic exam device 70 positioned in a seal injection line 46 of a reactor coolant pump 30. The figure illustrates the placement of the device 70 inside the seal injection line 46, with the ultrasonic beam 90 passing through the wall of the line 46, through the weld metal 60, and interacting with a flaw 62 in the thermal barrier 52. Observe that this ultrasonic examination technique is accomplished without passing through the complex grain structure of the cast stainless steel of the thermal barrier 52. The invention has been implemented to produce 45xc2x0 and 60xc2x0 longitudinal waves and a 45xc2x0 shear wave. The various angles and modes of propagation are achieved by altering the angle of the transducer 74 in the collapsible shoe 76. Snell""s Law is then applied using the acoustic velocity of the thermal barrier 52 and the acoustic velocity of the material of the shoe 76 to calculate the angles for each mode of propagation. The invention has been implemented with a xc2xc inch diameter transducer 74. Frequencies of 2.25 Mhz for shear and 3.5 Mhz for longitudinal waves have been successfully used. The guide rod preferably includes a scale or other measurement indicia to identify the distance to the beam exit point. The examination process preferably includes the following steps. First, the device 70 is calibrated such that the instrument screen display represents a linear metal path distance. The device 70 is then inserted through the line opening and is positioned at the start of the examination zone. The device 70 is then moved through the examination zone to evaluate the signal display. The device 70 is then withdrawn to the start of the examination zone, is rotated, and then the process is repeated. The extent of rotation is such that a minimum of 10% overlap is achieved within the examination volume. Signal characteristics and sound path distances are evaluated to determine whether the weld area contains flaws in the form of cracks or incomplete penetration. Standard ultrasound signal processing techniques may be used. However, the following factors should be considered when discriminating between cracks and incomplete penetrations. Only maximum amplitude signals obtained within the examination zone require evaluation. Only signals having sound paths of between 0.25xe2x80x3 and 0.65xe2x80x3 for the 45xc2x0 probes and 0.4xe2x80x3 to 0.95xe2x80x3 for the 60xc2x0 probe require evaluation. Signals outside of these sound path ranges are outside of the suspected crack area. A crack signal has a longer sound path distance than does the signal from an incomplete penetration, due to the location of the crack being on the far side of the weld as compared to the incomplete penetration being at the weld root. The change in metal path distance will decrease with decreasing crack depths. The crack signal contains more facets than the incomplete penetration signal. The signal amplitude will vary as a function of the size of the flaw and the orientation of the flaw with respect to the transducer. Once a flaw is identified, standard techniques are used to repair the flaw. For example, the flaw may be repaired by grinding it out and rewelding. While the invention has been disclosed in reference to the repair of seal injection lines and cooling lines in reactor coolant pumps, those skilled in the art will appreciate that the invention is also applicable to other remote geometries, especially those that have associated cast stainless steel components. The foregoing description, for purposes of explanation, used specific nomenclature to provide a thorough understanding of the invention. However, it will be apparent to one skilled in the art that the specific details are not required in order to practice the invention. Thus, the foregoing descriptions of specific embodiments of the present invention are presented for purposes of illustration and description. They are not intended to be exhaustive or to limit the invention to the precise forms disclosed, obviously many modifications and variations are possible in view of the above teachings. The embodiments were chosen and described in order to best explain the principles of the invention and its practical applications, to thereby enable others skilled in the art to best utilize the invention and various embodiments with various modifications as are suited to the particular use contemplated. It is intended that the scope of the invention be defined by the following claims and their equivalents.