A Modular Ultrasonic System for Non-destructive Testing in Nuclear Power Plants

This paper presents a novel modular ultrasonic inspection system designed for non-destructive testing (NDT) applications in nuclear power plants. The proposed architecture addresses the limitations of conventional systems by integrating front-end electronics directly with ultrasonic transducer arrays, significantly reducing cable complexity and system deployment challenges. A module incorporated a 32 -element array with localized signal processing capabilities, enabling efficient inspection of reactor components while minimizing power consumption to 630 mW during operation and 2.4 mW in standby mode. The system’s performance was evaluated through the comprehensive characterization of a single module, demonstrating the ability to detect material flaws as small as 1 mm at depths ranging from 10 mm to 80 mm using both PlaneWave Imaging (PWI) and Full Matrix Capture (FMC) imaging acquisition methods. Experimental results showed that FMC provided superior image clarity, with signal-to-noise ratios approximately 4 dB higher than those of PWI. At the same time, PWI offered a more accurate representation of flaw size and faster acquisition times. Initial testing on steel blocks with artificial flaws validated the feasibility of this approach for practical NDT applications. The presented modular architecture offers a scalable solution for enhanced inspection capabilities while reducing system complexity and maintenance requirements in nuclear facilities. It also has further miniaturization potential through the application of an application-specific integrated circuit (ASIC).