The present technology is related to steam generator systems including tubesheet assemblies for use in, for example, nuclear reactor power systems. More particularly, the present technology is related to stress-relieving attachments for attaching a tubesheet to a reactor vessel.
Nuclear reactor systems often include one or more steam generators positioned within a nuclear reactor vessel. The reactor vessel houses a reactor core and a primary coolant that absorbs heat produced from a nuclear reaction (e.g., a fission reaction) within the reactor core. Such a steam generator can include multiple tubes (e.g., helical tubes) within the reactor vessel that extend between a feedwater header and a steam header. Secondary coolant (e.g., water) enters the tubes at the feedwater header, rises through the tubes and converts to vapor (e.g., steam) as the secondary coolant absorbs heat from the primary coolant, and exits the tubes at the steam header for use in a power conversion system. The tubes can be connected to a tubesheet, such as a perforated plate, at and/or proximate to the feedwater header and/or the steam header (e.g., via tube-to-tubesheet (TTS) welds). The tubesheets can be integral with or attached to the reactor vessel.
Large stresses can develop locally in the tubesheets and/or in the tube-to-tubesheet (TTS) welds due to incompatible motion under pressure and thermal loading of the tubesheets and the reactor vessel caused by the differing geometries thereof. As the nuclear reactor system undergoes transients, including startups and shutdowns, the stresses in the tubesheets can be cyclic, which can lead to fatigue and premature decommissioning of the steam generator.
Many aspects of the present technology can be better understood with reference to the following drawings. The components in the drawings are not necessarily to scale. Instead, emphasis is placed on clearly illustrating the principles of the present technology.
Aspects of the present disclosure are directed generally toward steam generator systems including tubesheet assemblies, such as for use in nuclear reactor power systems, and associated devices and methods. More particularly, some aspects of the present disclosure are directed toward stress-relieving attachments for attaching a tubesheet to a reactor vessel within a nuclear reactor power system. In several of the embodiments described below, for example, a representative steam generator system can be installed in a nuclear reactor vessel (e.g., a reactor pressure vessel shell) positioned to house a primary coolant. The steam generator system can include a tubesheet assembly defining a plenum and comprising a tubesheet and a flexible connection portion coupling the tubesheet to the reactor vessel. The tubesheet can include a plurality of perforations fluidly coupled to the plenum. The steam generator system can further comprise a plurality of heat transfer tubes fluidly coupled to the perforations and configured to receive a flow of a secondary coolant. The connection portion can be more flexible than the tubesheet and the reactor vessel to reduce stresses on the tubesheet and the connections (e.g., tube-to-tubesheet (TTS) welds) between the heat transfer tubes and the tubesheet during operation of the nuclear reactor system. For example, the connection portion can be thinner than both the tubesheet and the adjoining reactor vessel.
Accordingly, in some aspects of the present technology, the connection portion can mitigate or reduce stresses (e.g., discontinuity stresses and/or fatigue) in the tubesheet and/or in the associated connections (e.g., tube-to-tubesheet (TTS) welds) between the tubesheet and the corresponding heat transfer tubes by functioning as a flexible connection between the reactor vessel and the tubesheet. Such a flexible connection can decouple the incompatible deformation between the differing geometries of the tubesheet (e.g., a perforated flat plate) and the reactor vessel (e.g., a cylindrical vessel) during cyclic loads. In some embodiments, the cyclic fatigue life of the tubesheet and associated TTS welds can be increased by one order of magnitude, two orders of magnitude, or more—increasing the lifespan of the steam generator system.
Certain details are set forth in the following description and in
The terminology used below is to be interpreted in its broadest reasonable manner, even though it is being used in conjunction with a detailed description of certain examples of embodiments of the technology. Indeed, certain terms may even be emphasized below; however, any terminology intended to be interpreted in any restricted manner will be overtly and specifically defined as such in this Detailed Description section.
The accompanying Figures depict embodiments of the present technology and are not intended to limit its scope unless expressly indicated. The sizes of various depicted elements are not necessarily drawn to scale, and these various elements may be enlarged to improve legibility. Component details may be abstracted in the Figures to exclude details such as position of components and certain precise connections between such components when such details are unnecessary for a complete understanding of how to make and use the present technology. Many of the details, dimensions, angles and other features shown in the Figures are merely illustrative of particular embodiments of the disclosure. Accordingly, other embodiments can have other details, dimensions, angles and features without departing from the present technology. In addition, those of ordinary skill in the art will appreciate that further embodiments of the present technology can be practiced without several of the details described below.
To the extent any materials incorporated herein by reference conflict with the present disclosure, the present disclosure controls. The headings provided herein are for convenience only and should not be construed as limiting the subject matter disclosed.
The power module 102 includes a containment vessel 110 (e.g., a radiation shield vessel, a radiation shield container, and/or the like) that houses/encloses a reactor vessel 120 (e.g., a reactor pressure vessel, a reactor pressure shell, a reactor pressure container and/or the like), which in turn houses the reactor core 104. The containment vessel 110 can be housed in a power module bay 156. The power module bay 156 can contain a cooling pool 103 filled with water and/or another suitable cooling liquid. The bulk of the power module 102 can be positioned below a surface 105 of the cooling pool 103. Accordingly, the cooling pool 103 can operate as a thermal sink, for example, in the event of a system malfunction.
A volume between the reactor vessel 120 and the containment vessel 110 can be partially or completely evacuated to reduce heat transfer from the reactor vessel 120 to the surrounding environment (e.g., to the cooling pool 103). However, in other embodiments the volume between the reactor vessel 120 and the containment vessel 110 can be at least partially filled with a gas and/or a liquid that increases heat transfer between the reactor vessel 120 and the containment vessel 110.
Within the reactor vessel 120, a primary coolant 107 conveys heat from the reactor core 104 to the steam generator system 130. For example, as illustrated by arrows located within the reactor vessel 120, the primary coolant 107 is heated at the reactor core 104 toward the bottom of the reactor vessel 120. The heated primary coolant 107 (e.g., water with or without additives) rises from the reactor core 104 through a core shroud 106 and to a riser tube 108. The hot, buoyant primary coolant 107 continues to rise through the riser tube 108, then exits the riser tube 108 and passes downwardly through the steam generator system 130. The steam generator system 130 includes a multitude of conduits 132 (e.g., tubes, heat transfer tubes) that are arranged circumferentially around the riser tube 108, for example, in a helical pattern, as is shown schematically in
The steam generator system 130 can include a lower header assembly 131 (e.g., a lower plena assembly, a lower tubesheet assembly, a feedwater header assembly, a first header assembly, a first tubesheet assembly, and/or the like) at which the incoming secondary coolant enters the steam generator conduits 132. The secondary coolant rises through the conduits 132, converts to vapor (e.g., steam), and is collected at an upper header assembly 133 (e.g., an upper plena assembly, an upper tubesheet assembly, a steam header assembly, a second header assembly, a second tubesheet assembly and/or the like). The vapor exits the upper header assembly 133 and is directed to the power conversion system 140.
The power conversion system 140 can include one or more steam valves 142 that regulate the passage of high pressure, high temperature steam from the steam generator system 130 to a steam turbine 143. The steam turbine 143 converts the thermal energy of the steam to electricity via a generator 144. The low-pressure steam exiting the steam turbine 143 is condensed at a condenser 145, and then directed (e.g., via a pump 146) to one or more feedwater valves 141. The feedwater valves 141 control the rate at which the feedwater re-enters the steam generator system 130 via the lower header assembly 131.
The power module 102 includes multiple control systems and associated sensors. For example, the power module 102 can include a hollow cylindrical reflector 109 that directs neutrons back into the reactor core 104 to further the nuclear reaction taking place therein. Control rods 113 are used to modulate the nuclear reaction, and are driven via fuel rod drivers 115. The pressure within the reactor vessel 120 can be controlled via a pressurizer plate 117 (which can also serve to direct the primary coolant 107 downwardly through the steam generator system 130) by controlling the pressure in a pressurizing volume 119 positioned above the pressurizer plate 117. In some embodiments, the upper header assembly 133 can be at least partially integrated into the pressurizer plate 117.
The sensor system 150 can include one or more sensors 151 positioned at a variety of locations within the power module 102 and/or elsewhere, for example, to identify operating parameter values and/or changes in parameter values. The data collected by the sensor system 150 can then be used to control the operation of the system 100, and/or to generate design changes for the system 100. For sensors positioned within the containment vessel 110, a sensor link 152 directs data from the sensors to a flange 153 (at which the sensor link 152 exits the containment vessel 110) and directs data to a sensor junction box 154. From there, the sensor data can be routed to one or more controllers and/or other data systems via a data bus 155.
In some embodiments, the steam generator system 230 includes multiple ones (e.g., four) of the lower tubesheet assemblies 231 and/or multiple ones (e.g., four) of the upper tubesheet assemblies 233 positioned circumferentially about the reactor vessel 220. Pairs of the lower and upper tubesheet assemblies 231, 233 can be fluidly coupled to a set of the tubes 232 to define an individual steam generator circuit. The lower and upper tubesheet assemblies 231, 233 can be coupled to or integral with the reactor vessel 220 and are positioned to provide a fluid flow path from the tubes 232 to/from the reactor vessel 220 to/from an external power conversion system (e.g., the power conversion system 140 of
In operation, the primary coolant within the reactor vessel 220 is heated and rises through the riser tube 208 past the tubes 232 before descending past the tubes 232 outside the riser tube 208. The tubes 232 receive a secondary coolant (e.g., water) via the lower tubesheet assemblies 231. The secondary coolant rises through the tubes 232 and heat is thermally transferred to the secondary coolant from the primary coolant such that the secondary coolant become super-heated vapor (e.g., steam). The secondary coolant in the steam generator system 230 can be isolated from the primary coolant in reactor vessel 220 such that they are not allowed to mix or come into direct contact with one another. The vaporized secondary coolant exits the tubes 232 into the upper tubesheet assemblies 233 for transfer to a power conversion system. After the heat from the secondary coolant is utilized by the power conversion system, the secondary coolant can be returned to the steam generator system 230 via the lower tubesheet assemblies 231.
The lower tubesheet assemblies 231 can be identical and can each include a body 234 (e.g., a wall, a body portion, a wall portion, and/or the like) integrally formed with or attached to the reactor vessel 220 and defining a plenum 235. The body 234 can include a tubesheet 236 (e.g., a perforated plate) and/or the tubesheet 236 can be a separate component attached to the body 234. The lower portions of the tubes 232 can be coupled (e.g., welded, affixed) to the tubesheet 236 which is positioned to route the secondary coolant from the plenum 235 to the tubes 232. In the illustrated embodiment, the tubesheet 236 is positioned within the annular region between the reactor vessel 220 and the riser tube 208 and is oriented in a horizontal or radial position. That is, the tubesheet 236 can extend along an axis X that extends orthogonal to a longitudinal axis Y of the reactor vessel 220. The body 234 can further include/define an inlet port 237 (e.g., a feed nozzle) that can be connected to a feed pipe for receiving the secondary coolant and that is positioned to direct the secondary coolant from the feed pipe into the plenum 235. In some embodiments, the lower tubesheet assembly 231 further includes a removable cover plate 238 that can be coupled (e.g., bolted) to the body 234 to enclose the plenum 235. The removable cover plate 238 can be removed from and/or installed on the body 234 during one or more operations such as maintenance, inspection, and/or installation.
In some embodiments, the lower tubesheet assemblies 231 and/or the upper tubesheet assemblies 233 can have different configurations. For example,
Referring to
In some aspects of the present technology, a tubesheet assembly (e.g., a header assembly) configured in accordance with the present technology can mitigate or reduce the stresses in a tubesheet and associated TTS welds by introducing a more flexible connection between the reactor vessel and the tubesheet. Such a flexible connection can decouple the incompatible deformation between the differing geometries of the tubesheet and the reactor vessel. For example, in some embodiments a tubesheet assembly can include a flexible section or portion between the reactor vessel and the tubesheet that is thinner than both the reactor vessel and the tubesheet. This can provide stress relief on the tubesheet by being more flexible than the parts it connects (e.g., the tubesheet and the reactor vessel).
For example,
In the illustrated embodiment, the tubesheet assembly 550 includes a body 534 defining or bounding (at least in part) a plenum 535 (obscured in
The body 534 can further include/define a port 537 (e.g., a nozzle) fluidly coupled to the plenum 535. In some embodiments, the tubesheet assembly 550 is a lower tubesheet assembly (e.g., a feed assembly) configured to (i) receive a secondary coolant through the port 537 and (ii) direct the secondary coolant through the plenum 535 and out of the perforations 539 into the corresponding heat transfer tubes (e.g., from lower portions of the heat transfer tubes) coupled to the tubesheet 536. In other embodiments, the tubesheet assembly 550 is an upper tubesheet assembly (e.g., a vapor assembly) configured to (i) receive the secondary coolant in vapor form through the perforations 539 from the heat transfer tubes (e.g., from upper portions of the heat transfer tubes) coupled to the tubesheet 536 and (ii) direct the secondary coolant in vapor form through the plenum 535 to the port 537 for outlet to a power conversion system.
Referring to
Referring to
In the illustrated embodiment, the groove 553 and the connection portion 554 extend entirely circumferentially about the tubesheet 536 and each have a circular shape with a constant width W (
In the illustrated embodiment, the inner and outer surfaces 555, 556 of the connection portion 554 are each planar/flat. In other embodiments, the inner and/or outer surfaces 555, 556 can have different profiles. For example,
Referring to
In some embodiments, individual ones of the perforations 539 can receive a corresponding one of the heat transfer tubes therein, and the heat transfer tube can be welded (e.g., via a TTS weld) or otherwise connected to the tubesheet 536 at and/or proximate to the outer surface 552 of the tubesheet 536. Accordingly, the connections between the heat transfer tubes and the tubesheet 536 can be positioned adjacent the groove 553 opposite the connection portion 554, which extends from proximate the inner surface 551 of the tubesheet 536. Because the connection portion 554 does not extend at or proximate to the outer surface 556 of the tubesheet 536, the tubesheet 536 can flex more readily near the outer surface 552. Accordingly, in some aspects of the present technology, spacing the connections between the heat transfer tubes and the tubesheet 536 away from the connection portion 554 in this manner can further decrease the stresses in the connections during operation of the nuclear reactor system 500.
In some embodiments, the connection portion 554 can be manufactured by milling the groove 553 via a tool inserted into the plenum 535 with the cover plate 538 removed. In some aspects of the present technology, forming the groove 553 to be circular and to have a constant width and depth can reduce the complexity of the manufacturing process used to form the groove 553.
As noted above, tubesheet assemblies in accordance with the present technology can have other configurations of groove(s) extending around a tubesheet that provide a flexible coupling between the tubesheet and an adjoining reactor vessel.
In the illustrated embodiment, the tubesheet assembly 550 includes an inner groove 757 and an outer groove 758 extending circumferentially about the tubesheet 536 and defining the connection portion 754 between the tubesheet 536 and the adjoining portions of the reactor vessel 520 and/or the body 534. Accordingly, the connection portion 754 can have a thickness T1 (
In the illustrated embodiment, the inner and outer grooves 757, 758 and the connection portion 754 extend entirely circumferentially about the tubesheet 536 and each have a lozenge-like or shield-like shape with a variable width W (
Accordingly, in some aspects of the present technology the connection portion 754 can be more flexible (e.g., less stiff) than the adjoining components it connects—e.g., the tubesheet 536, the body 534, and the reactor vessel 520—because it is thinner than the adjoining components. Accordingly, in some aspects of the present technology, the connection portion 754 can mitigate or reduce the stresses (e.g., discontinuity stresses and/or fatigue) in the tubesheet 536 and/or in the associated connections (e.g., tube-to-tubesheet (TTS) welds) between the tubesheet 536 and the corresponding heat transfer tubes by functioning as a flexible connection between the reactor vessel 520 and the tubesheet 536.
Although
The following examples are illustrative of several embodiments of the present technology:
1. A steam generator system for use in a nuclear reactor system including a reactor vessel positioned to house a primary coolant, the steam generator system comprising:
2. The steam generator system of example 1 wherein the tubesheet is a flat plate, and wherein the tubesheet assembly includes a groove extending circumferentially about the tubesheet and defining the connection portion.
3. The steam generator system of example 2 wherein the tubesheet includes an inner surface positioned to face an interior of the reactor vessel and an outer surface positioned to face the plenum, and wherein the groove extends partially from the outer surface toward the inner surface.
4. The steam generator system of example 2 or example 3 wherein the flat plate has a circular shape, and wherein the groove has a circular shape with a generally constant width and depth.
5. The steam generator system of example 2 or example 3 wherein the groove has a width that varies in a circumferential direction.
6. The steam generator system of any one of examples 1-5 wherein the tubesheet assembly is integrally formed with the reactor vessel.
7. The steam generator system of any one of examples 1-6 wherein the reactor vessel extends along a longitudinal axis, and wherein the tubesheet is positioned generally parallel to the longitudinal axis.
8. The steam generator system of any one of examples 1-6 wherein the reactor vessel extends along a longitudinal axis, and wherein the tubesheet is inclined relative to the longitudinal axis by an angle of between about 15°-45°.
9. The steam generator of any one of examples 1-6 wherein the reactor vessel extends along a longitudinal axis, and wherein the tubesheet is positioned generally perpendicular to the longitudinal axis.
10. The steam generator system of any one of examples 1-9 wherein the tubesheet is a flat plate having an inner surface positioned to face an interior of the reactor vessel and an outer surface positioned to face the plenum, wherein the tubesheet assembly includes a first groove extending circumferentially about the tubesheet from the inner surface partially toward the outer surface and a second groove extending circumferentially about the tubesheet from the outer surface partially toward the inner surface, and wherein the first groove and the second groove define the connection portion.
11. The steam generator system of any one of examples 1-10 wherein the tubesheet has a first thickness, and wherein the connection portion has a second thickness less than the first thickness.
12. The steam generator system of example 11 wherein the first thickness is less than half the second thickness.
13. The steam generator system of any one of examples 1-12 wherein the tubesheet assembly further comprises an inlet port fluidly coupled to the plenum, and wherein the tubesheet assembly is positioned to receive the secondary coolant in liquid form via the inlet port and route the secondary coolant in liquid form through the plenum into the perforations and into the heat transfer tubes.
14. The steam generator system of any one of examples 1-12 wherein the tubesheet assembly further comprises an outlet port fluidly coupled to the plenum, and wherein the tubesheet assembly is positioned to receive the secondary coolant in vapor form from the heat transfer tubes and route the secondary coolant in vapor form through the perforations into the plenum and into the outlet port.
15. A tubesheet assembly for use in a nuclear reactor system including a reactor vessel, the tubesheet assembly comprising:
16. The tubesheet assembly of example 15 wherein the tubesheet is a circular flat plate having an inner surface positioned to face an interior of the reactor vessel and an outer surface positioned to face the plenum, wherein the tubesheet assembly includes a circular groove extending circumferentially about the tubesheet and defining the connection portion, and wherein the circular groove extends from the outer surface partially toward the inner surface.
17. The tubesheet assembly of example 15 or example 16 wherein the tubesheet is a circular flat plate having an inner surface positioned to face an interior of the reactor vessel and an outer surface positioned to face the plenum, wherein the tubesheet has a first thickness in a direction between the inner surface and the outer surface, and wherein the connection portion has a second thickness, less than the first thickness, in the direction between the inner surface and the outer surface.
18. The tubesheet assembly of any one of examples 15-17 wherein the reactor vessel extends along a longitudinal axis, and wherein the tubesheet is inclined relative to the longitudinal axis by an angle of about 30°.
19. A nuclear reactor system, comprising:
20. The nuclear reactor system of example 19 wherein the first tubesheet assembly is positioned to receive the secondary coolant in liquid form and route the secondary coolant in liquid form to the heat transfer tubes via the first perforations, wherein the reactor vessel extends along a longitudinal axis, and wherein the first tubesheet is inclined relative to the longitudinal axis by an angle of between about 15°-45°.
All numeric values are herein assumed to be modified by the term about whether or not explicitly indicated. The term about, in the context of numeric values, generally refers to a range of numbers that one of skill in the art would consider equivalent to the recited value (e.g., having the same function and/or result). For example, the term about can refer to the stated value plus or minus ten percent. For example, the use of the term about 100 can refer to a range of from 90 to 110, inclusive. In instances in which the context requires otherwise and/or relative terminology is used in reference to something that does not include, or is not related to, a numerical value, the terms are given their ordinary meaning to one skilled in the art.
The above detailed description of embodiments of the present technology are not intended to be exhaustive or to limit the technology to the precise forms disclosed above. Although specific embodiments of, and examples for, the technology are described above for illustrative purposes, various equivalent modifications are possible within the scope of the technology, as those skilled in the relevant art will recognize. For example, although steps may be presented in a given order, in other embodiments, the steps may be performed in a different order. The various embodiments described herein may also be combined to provide further embodiments.
From the foregoing, it will be appreciated that specific embodiments of the technology have been described herein for purposes of illustration, but well-known structures and functions have not been shown or described in detail to avoid unnecessarily obscuring the description of the embodiments of the technology. Where the context permits, singular or plural terms may also include the plural or singular term, respectively.
As used herein, the phrase and/or as in A and/or B refers to A alone, B alone, and A and B. Additionally, the term comprising is used throughout to mean including at least the recited feature(s) such that any greater number of the same feature and/or additional types of other features are not precluded. It will also be appreciated that specific embodiments have been described herein for purposes of illustration, but that various modifications may be made without deviating from the technology. Further, while advantages associated with some embodiments of the technology have been described in the context of those embodiments, other embodiments may also exhibit such advantages, and not all embodiments need necessarily exhibit such advantages to fall within the scope of the technology. Accordingly, the disclosure and associated technology can encompass other embodiments not expressly shown or described herein.
This application claims the benefit of U.S. Provisional Patent Application No. 63/282,053, filed Nov. 22, 2021, and titled “STRESS RELIEVING ATTACHMENT OF TUBE TO TUBESHEET IN A PRESSURE VESSEL SHELL OF A NUCLEAR POWER SYSTEM,” which is incorporated herein by reference in its entirety.
This invention was made with government support under Contract #DE-NE-000-8928 awarded by the Department of Energy. The government has certain rights in the invention.
Number | Date | Country | |
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63282053 | Nov 2021 | US |