M.M. Narayanan

Bio: M.M. Narayanan is an academic researcher from Indira Gandhi Centre for Atomic Research. The author has contributed to research in topics: Ultrasonic sensor & Transducer. The author has an hindex of 3, co-authored 6 publications receiving 26 citations.

Development of ultrasonic guided wave inspection methodology for steam generator tubes of prototype fast breeder reactor.

Abstract: An ultrasonic guided wave based methodology is developed for inspection of steam generator tubes of the prototype fast breeder reactor. To this aim, axisymmetric longitudinal mode (L(0,2)) at the frequency of 250 kHz is optimized using 3D-finite element simulation and experiments. The group velocity of mode L(0,2) at 250 kHz is found to be 5387 m/s. First, the long range propagation of the L(0,2) mode at 250 kHz is examined and the mode is found to propagate over a distance of 45.6 m with a sufficiently good SNR. Secondly, the detection of multiple defects such as circumferential, axial, partial-pinholes and tapered defects lying in the same line of sight is investigated using 3D-finite element simulation and the results obtained are validated experimentally for the first three cases. The sensitivities achieved are 0.23 mm depth (10%WT) for circumferential, axial and tapered defects and for partial-pinholes: 1 mm diameter and 1.38 mm depth (60%WT). Thirdly, 3D-FE simulations with ID and OD pinhole defects are performed which show that the ID and OD defects are detected by L(0,2) with a fairly similar sensitivity. Finally, study on the thermal expansion bend (with three successive bends) shows that the bend does not have much influence on the mode and the multiple circumferential defects considered in the bend are detected with good sensitivity.

Development of in-bore magnetostrictive transducer for ultrasonic guided wave based-inspection of steam generator tubes of PFBR.

Abstract: An in-bore magnetostrictive transducer is designed for the steam generator tubes of Prototype fast breeder reactor for the generation of L(0,2) modes of frequencies in the range of 250–350 kHz. Towards this, axi-symmetric finite element models are developed to optimize the coil parameters. The optimized length of the transmitter and the receiver coils turns out to be 10 mm (~half the wavelength) for the frequency of 300 kHz. The optimized width of the coils turns out to be 0.46 mm. FE models also show the generation, propagation and reception of L(0,2) modes in the frequency range of 250–350 kHz. The role of skin effect in the magnetostrictive based-generation of L(0,2) modes with frequency is also discussed. A transducer is designed based on the FE results. The transducer is tested for the generation of L(0,2) mode in the frequency range of 250–350 kHz in a 1 m long steam generator tube segment. A good agreement is observed between FE and experimental normalized amplitudes and the times of flight for different frequencies. L(0,2) modes are found to generate and propagate and received, as predicted by the finite element simulations. An excellent agreement is observed between the experimentally measured group velocities with those obtained from the dispersion curves in this frequency range. Experiments show the signal to noise ratio to be better than 15 dB. To ascertain the utility of the transducer in steam generator tubes for the long range testing, L(0,2) mode at 300 kHz frequency is propagated in a 1.5 m long tube. The resulted multiple end reflections amount to the propagation of 51 m distance. To check the capability of detection of defects, a short tube with a full circumferential defect of depth 0.46 mm (20%WT) and a short tube with a pin hole of 1.5 mm diameter are considered. Further, FE results for the case of the axi-symmetric circumferential defect are validated experimentally. For the case of the pinhole (non-axi-symmetric), the experimental signal to noise ratio turns out to be 6 dB, which is only 6 dB lower as compared to that obtained using a piezo based ultrasonic transducer of frequency 300 kHz coupled to the end of the tube.

An absolute method for determination of misalignment of an immersion ultrasonic transducer.

Abstract: An absolute methodology has been developed for quantification of misalignment of an ultrasonic transducer using a corner-cube retroreflector. The amplitude based and the time of flight (TOF) based C-scans of the reflector are obtained for various misalignments of the transducer. At zero degree orientation of the transducer, the vertical positions of the maximum amplitude and the minimum TOF in the C-scan coincide. At any other orientation of the transducer with the horizontal plane, there is a vertical shift in the position of the maximum amplitude with respect to the minimum TOF. The position of the minimum (TOF) remains the same irrespective of the orientation of the transducer and hence is used as a reference for any misalignment of the transducer. With the measurement of the vertical shift and the horizontal distance between the transducer and the vertex of the reflector, the misalignment of the transducer is quantified. Based on the methodology developed in the present study, retroreflectors are placed in the Indian 500 MWe Prototype Fast Breeder Reactor for assessment of the orientation of the ultrasonic transducer prior to the under-sodium ultrasonic scanning for detection of any protrusion of the subassemblies.

Influence of thermal expansion bend and tubesheet geometry on guided wave inspection of steam generator tubes of a fast breeder reactor

Abstract: Periodic assessment of steam generator tubes of a sodium-cooled nuclear reactor is very crucial for smooth operation of steam generators. To examine the integrity, an in-bore magnetostrictive trans...

Optimization of Geometrical Parameters of a Magnetostrictive Ultrasonic Guided Wave Probe for Tube Inspection

Abstract: Non-destructive examination of steam generator (SG) tubes of Fast Breeder Reactors is of paramount importance. The inspection needs to be carried out from the inner side of an SG tube due to the constraint in accessibility. Recently, the magnetostrictive ultrasonic guided wave (MUGW) technique has been proposed as an alternative for the inspection of SG tubes. As a commercial MUGW probe for small-diameter ferromagnetic tubes is not available, it needs to be designed and developed with optimum parameters. This paper proposes a three-step optimization approach for the development of a MUGW probe, namely optimization of the diameter and length of a permanent magnet (for bias) finite element modeling based, optimization of the width of the transmitter and receiver coils of the probe by empirical modeling and the optimization of the number of turns of the transmitter and receiver coils by equivalent circuit models. A MUGW probe is fabricated and tested experimentally to validate the optimized parameters. Experiments show the validity of the approach in terms of generation, long-range propagation (47.6 m) of L(0,2) mode at 300 kHz, and the required sensitivity (multiple 10% wall thickness deep uniform wall loss circumferential grooves) in SG tubes.

Development of in-bore magnetostrictive transducer for ultrasonic guided wave based-inspection of steam generator tubes of PFBR.

Abstract: An in-bore magnetostrictive transducer is designed for the steam generator tubes of Prototype fast breeder reactor for the generation of L(0,2) modes of frequencies in the range of 250–350 kHz. Towards this, axi-symmetric finite element models are developed to optimize the coil parameters. The optimized length of the transmitter and the receiver coils turns out to be 10 mm (~half the wavelength) for the frequency of 300 kHz. The optimized width of the coils turns out to be 0.46 mm. FE models also show the generation, propagation and reception of L(0,2) modes in the frequency range of 250–350 kHz. The role of skin effect in the magnetostrictive based-generation of L(0,2) modes with frequency is also discussed. A transducer is designed based on the FE results. The transducer is tested for the generation of L(0,2) mode in the frequency range of 250–350 kHz in a 1 m long steam generator tube segment. A good agreement is observed between FE and experimental normalized amplitudes and the times of flight for different frequencies. L(0,2) modes are found to generate and propagate and received, as predicted by the finite element simulations. An excellent agreement is observed between the experimentally measured group velocities with those obtained from the dispersion curves in this frequency range. Experiments show the signal to noise ratio to be better than 15 dB. To ascertain the utility of the transducer in steam generator tubes for the long range testing, L(0,2) mode at 300 kHz frequency is propagated in a 1.5 m long tube. The resulted multiple end reflections amount to the propagation of 51 m distance. To check the capability of detection of defects, a short tube with a full circumferential defect of depth 0.46 mm (20%WT) and a short tube with a pin hole of 1.5 mm diameter are considered. Further, FE results for the case of the axi-symmetric circumferential defect are validated experimentally. For the case of the pinhole (non-axi-symmetric), the experimental signal to noise ratio turns out to be 6 dB, which is only 6 dB lower as compared to that obtained using a piezo based ultrasonic transducer of frequency 300 kHz coupled to the end of the tube.

A modelling framework for simulation of ultrasonic guided wave-based inspection of welded rail tracks.

Abstract: A modelling framework for ultrasonic inspection of waveguides with arbitrary discontinuities, excited using piezoelectric transducers, is developed. The framework accounts for multi-modal, dispersive and damped one dimensional propagation over long distances. The proposed model is applied to simulate a realistic guided wave-based inspection of a welded rail. The framework models the excitation, propagation and scattering of guided waves from welds by respectively employing a hybrid model that couples a 3D FEM model of a piezoelectric transducer with a 2D SAFE model of the rail; a 2D SAFE model of the rail; and another hybrid method which couples a 3D FEM model of the arbitrary discontinuity (weld) with two SAFE models of the rail to represent the semi-infinite incoming and outgoing waveguides. Optimal damping parameters for hysteretic and viscous damping, respectively, are determined using a model updating procedure to approximate attenuation in the rail. Good agreement between the experimental measurement and simulation is demonstrated, even for weld reflections originating over 640 m from the transducer location. The proposed physics-based framework can be used to efficiently perform multiple analyses considering different numbers and locations of welds, different excitation signals or to investigate the effects of changes in parameters such as transducer geometry, or material property variations caused by temperature fluctuations. The framework could therefore be used in future to set up a digital twin of a section of rail track, or in the development of a rail monitoring system by predicting reflections from defects which cannot readily be measured, but which can be simulated.

Multi-objective optimization for joint actuator and sensor placement for guided waves based structural health monitoring using fibre Bragg grating sensors.

Abstract: Structural Health Monitoring (SHM) systems have a potential to reduce lifecycle costs of structures. As a result, there is a lot of active research in the area for SHM of civil and mechanical structures. Guided waves (GW) based SHM techniques allow monitoring of large plate-like structures with a few sensors and have been identified as the most promising of techniques for SHM. Fibre Bragg grating (FBG) sensors due to their low weight, and ability to be multiplexed have been long thought to be ideal sensors for SHM. The recent development of the edge filtering approach has increased their sensitivity to GW sensing and made them ideal sensors. Unfortunately the FBG sensors are passive sensors and show directional sensitivity. These operational constraints make extension of the earlier developed GW based SHM techniques for FBG sensors difficult. Recently the authors developed a technique for damage detection specifically designed for a network with FBG sensors. This paper builds on the past work by the authors and develops a methodology for a design of an actuator–sensor (AS) network for improving the damage assessment capability of the previously proposed method. The paper develops a multi objective optimization technique for the joint optimization of actuator and sensor placement for a network with FBG sensors. The joint optimization of the actuators and sensors is necessary due to the passive nature of the FBG sensors and also incorporates the directional nature of the FBG sensors. The paper develops an integer encoded NSGA-II for the optimization of the AS network. The objectives for the optimization are derived from the specific damage detection technique tailored for the use of FBG sensors. The objective are: coverage with at least 2 AS pairs, coverage with at least 1 edge reflected path and the cost of the deployed network. The results indicate that the encoding of the objectives of the optimization is valid and indeed the damage detection capabilities of the AS network are as predicted analytically. The paper for the first time develops a joint optimization of network for FBG sensors. It is also the first attempt at a truly multi-objective optimization of the AS network and promises to have applications on real structures.

Multi-objective optimization for joint actuator and sensor placement for guided waves based structural health monitoring using fibre Bragg grating sensors

Abstract: Structural Health Monitoring (SHM) systems have a potential to reduce lifecycle costs of structures. As a result, there is a lot of active research in the area for SHM of civil and mechanical structures. Guided waves (GW) based SHM techniques allow monitoring of large plate-like structures with a few sensors and have been identified as the most promising of techniques for SHM. Fibre Bragg grating (FBG) sensors due to their low weight, and ability to be multiplexed have been long thought to be ideal sensors for SHM. The recent development of the edge filtering approach has increased their sensitivity to GW sensing and made them ideal sensors. Unfortunately the FBG sensors are passive sensors and show directional sensitivity. These operational constraints make extension of the earlier developed GW based SHM techniques for FBG sensors difficult. Recently the authors developed a technique for damage detection specifically designed for a network with FBG sensors. This paper builds on the past work by the authors and develops a methodology for a design of an actuator-sensor (AS) network for improving the damage assessment capability of the previously proposed method. The paper develops a multi objective optimization technique for the joint optimization of actuator and sensor placement for a network with FBG sensors. The joint optimization of the actuators and sensors is necessary due to the passive nature of the FBG sensors and also incorporates the directional nature of the FBG sensors. The paper develops an integer encoded NSGA-II for the optimization of the AS network. The objectives for the optimization are derived from the specific damage detection technique tailored for the use of FBG sensors. The objective are: coverage with at least 2 AS pairs, coverage with at least 1 edge reflected path and the cost of the deployed network. The results indicate that the encoding of the objectives of the optimization is valid and indeed the damage detection capabilities of the AS network are as predicted analytically. The paper for the first time develops a joint optimization of network for FBG sensors. It is also the first attempt at a truly multi-objective optimization of the AS network and promises to have applications on real structures.

Demonstration of detection of the multiple pipe wall thinning defects using microwaves

Abstract: In this study, the applicability of a nondestructive method using microwaves to the detection of multiple pipe wall thinning defects was investigated. In numerical simulation, a single full circumferential defect was introduced into a straight pipe of 19 mm inner diameter, and the effect of the defect on transmitted waves was investigated. The transmitted energy ratio of the TM01 mode to the emitted wave was found to be 93% in average even in the presence of a 1-mm depth thinning. After that, experimental measurements were performed using a flanged brass tube with two artificial thinning defects. By applying signal processing to the measured S-parameters, clear reflections from the two defects were observed. By comparing the signals, we confirmed that the first full circumferential defect provides at most 12% amplitude attenuation of the reflected signal from the second defect, which should be related to the distance and size of the defects.