The present disclosure relates generally to nuclear power plant maintenance procedures. In particular, methods for reducing outage time of nuclear power plants during routine maintenance and while a polar crane is maintained by continuing utilization of a bridge and supplemental crane are described.
Nuclear power plants play an essential role in the US power grid system. With nearly 20% of all power in the US coming from nuclear power, it is vital that these plants continue to operate safely and efficiently. To ensure that US nuclear power plants are safe and efficient, routine maintenance is performed on the plants, on average, every 18 or 24 months. This maintenance is called a refueling outage.
During a refueling outage, a specific reactor is shut down in order to replace spent or used fuel rods. In this process, a reactor head is removed, the fuel rods are removed from that reactor's core, and specific fuel rods are replaced and shuffled around to ensure an even distribution of heating. Also during an outage and while the reactor is shut down, other plant maintenance is performed. Valves are checked, lines are inspected, and facilities are maintained. Included in this maintenance is inspection, repair, and replacement of the plant's polar crane.
A polar crane is a large crane positioned in the top of a circular containment unit in nuclear power plants. A polar crane is used in typical plant maintenance and operational functions. The hoist is mounted on a trolley that is positioned between two bridge girders. Because it is on rails, the trolley and hoist are able to move horizontally back and forth along the rails. These rails and bridge girders are in turn supported by the walls of the containment unit itself and are positioned on a track that runs around the circumference of the circular containment unit. With the two bridge girders positioned on the circular track, the rails can rotate in a circular motion around the entire containment unit. Because the trolley and hoist are positioned on the girders, and the girders are positioned on a circular track, the crane is able to move and rotate to reach every part of the containment floor below it with a hook. The crane is operated by an operator from a cab that is positioned on the trolley or on the bridge girders above the crane hook.
Current methods for maintaining a nuclear power plant and a polar crane during a refueling outage are not entirely satisfactory for the range of applications in which they are employed. For example, existing methods for polar crane maintenance during a refueling outage extends the time of the refueling outage. If the polar crane or components of the polar crane need maintenance or replacing during a refueling outage, all lifting and other floor maintenance that depends on the use of the polar crane must cease. Without an operational polar crane, maintenance on the floor of the containment unit cannot be performed simultaneously with the polar crane maintenance. As a result, the total time of the refueling outage is extended based on the time the polar crane is not operational. This extension of refueling outage time costs the nuclear power plant millions in lost revenue and increased operational expenses.
Thus, there exists a need for nuclear power plant maintenance methods that improve upon and advance the current methods for nuclear power plant maintenance. Examples of new and useful methods relevant to the needs existing in the field are discussed below.
The present disclosure is directed to a method for nuclear power plant maintenance which reduces outage time while a polar crane is maintained. In some examples, the method includes the steps of placing an auxiliary crane on a set of rails of a polar crane, using the auxiliary crane to perform maintenance work while the polar crane is maintained, and removing the auxiliary crane after maintenance work on the polar crane is completed.
In other examples, the method for nuclear power plant maintenance includes the steps of lifting an auxiliary crane onto a set of rails of an operating polar crane, shutting down operations of the polar crane and maintaining the polar crane, using the auxiliary crane for floor maintenance operations in place of the polar crane, restarting operations of the polar crane after maintenance of the polar crane is complete, and removing and lowering the auxiliary crane from the set of rails of the operating polar crane.
In this example of the method, the step of lifting the auxiliary crane onto a set of rails of an operating polar crane may further include placing the auxiliary crane at an end of the rails opposite a cab of the polar crane. The auxiliary crane may then operate on at least one half of the set of rails opposite the cab of the polar crane. Further in this example of the method, the bridge motors may continue to operate the bridge and rotate the set of rails. Doing this allows the auxiliary crane to operate on the one half of the set of rails opposite the cab of the polar crane to reach an entire area of a floor of a nuclear power plant.
Further in this example of the method, the step of lifting an auxiliary crane onto a set of rails of an operating polar crane may include the step of lifting a second auxiliary crane onto the set of rails. When a second crane is lifted onto the rails, temporary controls may be connected to a bridge's bridge motors. Using the temporary controls, a user may operate the bridge motors to rotate the bridge and the set of rails. In these examples of the method, the auxiliary crane is a small, self-erecting boom crane.
In order to lift the auxiliary crane onto the set of rails of the operating polar crane, ropes or cables may be attached to a bridge of the polar crane. Then, the small, self-erecting boom crane is attached to the ropes or cables so that the small, self-erecting boom crane may climb the ropes or cables. Next, the small, self-erecting boom crane is placed on the set of rails.
In other examples of the method for nuclear power plant maintenance, the method may include the steps of disassembly, unload shuffle reload, and reassembly. The step of disassembly includes disassembling a core reactor using a polar crane, then attaching ropes or cables to a bridge of the polar crane. A small, self-erecting boom crane is then attached to the ropes or cables which then climbs the ropes or cables to the bridge. The self-erecting boom crane is then set on the bridge. Using the small, self-erecting boom crane, a larger knuckle boom crane is lifted and set on the bridge. Using the small, self-erecting boom crane again, a man basket and tooling and equipment is lifted.
Further included in this method, the step of unload shuffle reload includes shutting down the polar crane operations and connecting temporary controls to bridge motors. The temporary controls allow continued use of the bridge so that the small boom crane and larger knuckle boom crane can continue floor and polar crane maintenance operations. Further, half of the bridge motors are shut down for maintenance while the other half of the bridge motors control the bridge. After the first half of the bridge motors are maintained, they are returned to operation and the unmaintained motors are shut down for maintenance. After placing contaminated equipment in sealed containers, the polar crane and bridge motors are restarted and the temporary controls are disconnected.
Still further included in this method, the step of reassembly includes using the small, self-erecting boom crane to lower tooling and equipment and the man basket. Then the small, self-erecting boom crane lowers the larger knuckle boom crane. The small, self-erecting boom crane is next disconnected from the bridge and lowered down the ropes or cables. The ropes or cables are then removed from the bridge. Finally, the polar crane is returned to full operation and used to reassemble the core reactor.
The disclosed methods will become better understood through review of the following detailed description in conjunction with the figures. The detailed description and figures provide merely examples of the various inventions described herein. Those skilled in the art will understand that the disclosed examples may be varied, modified, and altered without departing from the scope of the inventions described herein. Many variations are contemplated for different applications and design considerations; however, for the sake of brevity, each and every contemplated variation is not individually described in the following detailed description.
Throughout the following detailed description, a variety of method examples are provided. Related features in the examples may be identical, similar, or dissimilar in different examples. For the sake of brevity, related features will not be redundantly explained in each example. Instead, the use of related feature names will cue the reader that the feature with a related feature name may be similar to the related feature in an example explained previously. Features specific to a given example will be described in that particular example. The reader should understand that a given feature need not be the same or similar to the specific portrayal of a related feature in any given figure or example.
With reference to
As shown in
Further shown, the first side 108 and second side 110 of bridge girders 106 have rail wheels, said rail wheels resting on a track 114. The rail wheels supported by track 114 is circular and sits atop the walls of the containment unit housing polar crane 100 and a nuclear core. The rail wheels allow bridge girders 106 to turn in a complete circle along the perimeter track 114 of the containment unit. The circular rotation of bridge girders 106, along with the horizontal movement of trolley 104 along rails 107, allow the hoist 102 to access every part of the containment unit on the floor within track 114.
Still further shown in
When it becomes necessary for polar crane 100 to undergo maintenance or replacement, polar crane 100 must be shut down, and any floor maintenance requiring the use of polar crane 100 is halted. Not until polar crane 100 is fully functional once again can floor maintenance continue. This stoppage of floor maintenance while polar crane 100 is maintained or replaced can take many days, and has the potential to cost the power plant millions in lost revenue and increased operating costs. The methods described below provide a way to continue floor maintenance using a crane while simultaneously performing polar crane 100 maintenance.
A first embodiment of the method is comprised of placing at least one auxiliary crane on the bridge girders 106 of polar crane 100 and using the auxiliary crane to continue lifting and floor maintenance while polar crane 100 is maintained or replaced. After maintenance is completed on polar crane 100, the auxiliary crane is removed from bridge girders 106, and polar crane 100 continues operations as normal.
With reference to
This embodiment of the method is beneficial because floor maintenance requiring use of a crane can continue while the main polar crane 100 is maintained or replaced. This allows for a shorter refueling outage than would normally be possible because there would be no time lost to maintaining polar crane 100. Simultaneous floor work requiring use of a crane could continue despite the polar crane 100 being inoperable during maintenance. In addition, through the use of the bridge motors, the auxiliary crane placed on bridge girders 106 is capable of reaching the entirety of the containment floor.
Despite polar crane 100 remaining on bridge girders 106 and utilizing up to half of the rails 107, the auxiliary crane is still capable of reaching the entire containment floor to perform any required or scheduled maintenance work. With the auxiliary crane placed opposite of cab 116, the auxiliary crane can use all of the second side 110 opposite cab 116 on first side 108, across center line 112. Because the auxiliary crane can utilize all of second side 110, and even some of the first side 108, and bridge girders 106 can rotate completely around, auxiliary crane can reach any part of the containment floor. Thus, the auxiliary crane can continue any necessary floor maintenance while polar crane 100 is simultaneously maintained.
With reference to
Still referring to
As seen in
As seen in
The power source operating the small self-erecting boom crane and the large knuckle boom crane is provided, in this embodiment, by one or more temporary power assemblies placed on polar crane 100, and more preferably, on bridge girders 106. The source of power for the one or more temporary power assemblies includes a polar crane power source, or a source on the containment unit floor, where a cord connects the cranes and the power source.
In this embodiment, method 300 utilizes more than one crane to perform maintenance work. In this embodiment, one crane can be used to perform necessary maintenance on polar crane 100, and the other crane can be used to continue floor operations and lifting. Alternatively, both cranes may be utilized for polar crane 100 maintenance or floor maintenance and lifting. In this embodiment, a small self-erecting boom crane and a large knuckle boom crane are used. However, any type and combination of crane can be used to perform the necessary maintenance.
With a small self-erecting boom crane and large knuckle boom crane on rails 107 and connected to a power source, step 304 is complete. Now turning to
As shown in
Shutting down only half of the motors at a time allows for floor maintenance work to continue. Through the use of the operational half of the bridge motors, the small self-erecting boom crane and the large knuckle boom crane placed on bridge girders 106 are capable of reaching the entirety of the containment floor while simultaneously maintaining or replacing polar crane 100. The small self-erecting boom crane and the large knuckle boom crane use all of the second side 110 opposite cab 116 on first side 108, across center line 112, and rotate around on bridge girders 106, to fully access the containment floor for continued maintenance.
Still referring to
In a similar fashion as previously described, shutting down only half of the motors at a time allows for floor maintenance work to continue. Through the use of the operational half of the bridge motors, the small self-erecting boom crane and the large knuckle boom crane placed on rails 107 are capable of reaching the entirety of the containment floor while simultaneously maintaining or replacing polar crane 100. The small self-erecting boom crane and the large knuckle boom crane use all of the second side 110 opposite cab 116 on first side 108, across center line 112, and rotate around on bridge girders 106, to fully access the containment floor for continued maintenance.
As shown in
Still referring to
After maintenance has been completed on the polar crane 100 and it is once again fully operational, step 330 is complete. Now turning to
As seen in
With polar crane 100 maintained and fully operational, it is ready to continue regular operations. Polar crane 100 can continue to lift and perform maintenance operations on the containment floor as normal. Polar crane 100 can also reassemble the core reactor.
The disclosure above encompasses multiple distinct inventions with independent utility. While each of these inventions has been disclosed in a particular form, the specific embodiments disclosed and illustrated above are not to be considered in a limiting sense as numerous variations are possible. The subject matter of the inventions includes all novel and non-obvious combinations and subcombinations of the various elements, features, functions and/or properties disclosed above and inherent to those skilled in the art pertaining to such inventions. Where the disclosure or subsequently filed claims recite “a” element, “a first” element, or any such equivalent term, the disclosure or claims should be understood to incorporate one or more such elements, neither requiring nor excluding two or more such elements.
Applicant(s) reserves the right to submit claims directed to combinations and subcombinations of the disclosed inventions that are believed to be novel and non-obvious. Inventions embodied in other combinations and subcombinations of features, functions, elements and/or properties may be claimed through amendment of those claims or presentation of new claims in the present application or in a related application. Such amended or new claims, whether they are directed to the same invention or a different invention and whether they are different, broader, narrower or equal in scope to the original claims, are to be considered within the subject matter of the inventions described herein.
This application claims priority to copending U.S. Provisional Application, Serial No. 62382135, filed on Aug. 31, 2016, which is hereby incorporated by reference for all purposes.
Number | Date | Country | |
---|---|---|---|
62382135 | Aug 2016 | US |