The subject invention relates to cleaning and inspection systems used within steam generators.
Steam generators convert heat from the primary side of a pressurized water reactor type nuclear power plant to steam on the secondary side so that the primary and secondary systems are kept separate. A typical generator is a vertical cylinder consisting of a larger number of U-shaped tubes which extend from the floor or “tube sheet” of the generator upwards. High temperature and pressure fluid from the reactor travels through the tubes giving up energy to a feed water blanket surrounding the tubes in the generator creating steam and ultimately power when later introduced to turbines.
Steam generators were designed to last upwards of forty years but in practice such reliability figures have proven not to be the case. The problem is that sludge from particulate impurities suspended in the feed-water forms on the tubes which greatly affects the efficiency of the generator and can even cause the tubes to degrade to the point of causing fissures in the tubes. If radioactive primary fluid within the tubes seeps into the secondary side, the result can be disastrous. Plugging or otherwise servicing such fissures is time consuming and results in expensive down time during which power must be purchased from other sources at a great expense.
There are known methods for cleaning the tubes. Chemical cleaning is very expensive (from $5,000,000 to $10,000,000 per application) and requires an extended outage. Also, some corrosion of steam generator internals by the solvents used will occur during the cleaning. In addition, large quantities of hazardous, possibly radioactive waste may be generated. Disposal of this waste is very expensive. For these reasons, few plants have actually implemented chemical cleaning. Alternative cleaning methods, such as inter-tube high pressure water system s can be advantageous.
On the other hand, there are severe technical challenges faced when considering such alternate cleaning methods. One typical steam generator has approximately 50,000 square fee of heat transfer area. The typical tube bundle is about 10 feet in diameter and 30 feet tall but the no tube lane in the middle of the tube bundle varies. In some models, the alley is more than four inches wide; in others it is as small as one inch. Access into steam generator internals is as much as eight inch diameter holes to as little as two inches. Finally, inter-tube gaps range from about 0.4 inches to about 0.11 inches wide.
U.S. Pat. No. 5,036,871, incorporated herein by this reference, discloses a system for cleaning tubes in such a steam generator. A transporter advances along the blow down lane in the steam generator between the tubes. A flexible lance extends outwardly at 90 degrees from the transporter and is able to maneuver between the tubes to clean and/or inspect them. See also U.S. Pat. Nos. 7,086,353; 6,820,575; RE 38,542; 6,543,392; 5,913,320; 5,695,003; and 4,456,068 all incorporated herein by this reference.
The system disclosed in U.S. Pat. No. 5,036,871, is typical of existing technology, and serves well steam generators with lange lanes (greater than 2.5 inches) and inter-tube gaps greater than 0.15 inches.
In some steam generators, however, such as the model CE-80 design, the blow down lane or “no-tube lane” along the tube sheet is very restrictive because a thick divider plate splits the hand hole opening, providing limited access (less than 1.35 inches) on either side and the inter-tube gap may not exceed 0.116 inches.
A typical flexible lance transporter is too large to enter such a blow down or no-tube lane in these steam generators and conventional lances are too thick to enter the small tube gaps and do any meaningful work.
Any device or system introduced into a steam generator must be highly reliable given the high cost of the steam generator.
It is therefore an object of this invention to provide a new cleaning and/or inspection lance.
It is a further object of this invention to provide a super-thin water jetting lance which makes it possible to access steam generator inter-tube gaps that conventional and commercially available lances cannot access because of geometrical limitations.
It is a further object of this invention to provide such a cleaning/inspection lance which is reliable, easy to operate, and efficient.
It is a further object of this invention to provide a steam generator cleaning system which maximizes hydraulic pressure for more effective cleaning.
It is a further object of this invention to provide such a system with fewer components for increased reliability.
The subject invention results from the realization that a new steam generator cleaning system lance able to proceed within a tube lane as narrow as 0.116 inches includes a stack of adjacent tubes secured together at least some locations wherein the tubes have a diameter less than the width of the tube lane and there is no lance structure wider than the tube lane or even the tubes themselves and deliver hydraulic cleaning power equal to that of conventional systems. An inspection lance, configured similarly to the cleaning lance, is also provided. Mechanisms are provided to drive and orient both lances. A bulk cleaning head is also provided to clean the steam generator from the no-tube lane.
The subject invention features a steam generator cleaning system comprising a cleaning lance comprising a stack of adjacent tubes in a single column. The tubes are secured together at least some locations. The lance includes a distal end with tube nozzles. A mechanism is provided for positioning the distal end of the lance in a no-tube lane of the steam generator at the entrance to a tube lane and for guiding the distal end of the lance into said tube lane. There are typically means for driving the lance so that the distal end thereof enters said tube lane.
In one example, the lance includes a thin drive strip on the top and bottom of the tube stack. Each drive strip may include spaced drive sprocket holes. The means for driving may then include an upper sprocket and a lower sprocket and a motor for rotating the upper and lower sprockets. Preferably the drive strip is made of a metal thinner than the diameter of the tubes. The tubes are preferably made of metal and are typically brazed together at least some locations.
In one embodiment, a sliding lance guide is received in a no-tube lane. The preferred sliding lance guide transporter includes rollers configured to reorient the lance at an angle for insertion into a tube lane. A rail is received in the no-tube lane and slidingly supporting the sliding lance guide. An inflatable bladder biases the rail against a steam generator divider plate in the no-tube lane. In this way, the sliding lance guide includes a lance guide break operable to engage the lance so the means for driving, when operated with the break engaging the lance, drives the sliding lance guide and the means for driving, when operating with the break disengaged, drives the lance. In one version, the sliding lance guide includes a lance guide tape extending therefore and further including a tape break, which, when operated to engage the tape, and with the lance break disengaged from the lance, fixes the sliding lance guide in a particular position so that the means for driving operates to drive the lance into a tube lane.
In one design, the tube nozzles comprise reduced diameter tubes. In another design, the tube nozzles comprise reduced diameter tube sections. In still another design, the tube nozzles comprise jet nozzles attached to the tubes. In another design, the tube nozzles include a lance head plenum.
There are typically N tubes, M of which carry a cleaning fluid, M/2 of which are angled upwardly at the distal end of the lance, and M/2 of which are angled downwardly at the distal end of the lance. M is usually less than N so select tubes can be used for inspection and the like. In one example, the system includes a high pressure cleaning fluid supply connected to a proximal end of the lance, a manifold for the upwardly angled tubes, and a manifold for the downwardly angled tubes. There may be means for sensing a differential pressure between both manifolds and processing electronics responsive to the means for sensing a differential pressure and configured to stop the supply of cleaning fluid to the tubes if a differential pressure greater than a preset threshold exists in the manifolds to prevent potential damage to the lance and/or steam generator. In the prototype design, the outer diameter of each tube was small and the maximum width of the lance was less than 0.086 inches. The system may further include an inspection lance configured with tubes secured together at least some locations.
The subject invention also features a steam generator cleaning system comprising a cleaning lance comprising a stack of adjacent tubes in a single column. The tubes are secured together at least some locations. The lance includes a distal end with tube nozzles. There are N tubes, M of which carry a cleaning fluid, M/2 of which are angled upwardly at the distal end of the lance, and M/2 of which are angled downwardly at the distal end of the lance. A mechanism is provided for positioning the distal end of the lance in a no-tube lane of the steam generator at the entrance to a tube lane and for guiding the distal end of the lance into said tube lane. There are means for driving the lance so that the distal end thereof enters said tube lane. A high pressure cleaning fluid supply is connected to a proximal end of the lance. There is a manifold for the upwardly angled tubes and a manifold for the downwardly angled tubes. There are means for sensing a differential pressure between both manifolds and processing electronics responsive to the means for sensing a differential pressure configured to stop the supply of cleaning fluid to the tubes if a differential pressure greater than a preset threshold exists in the manifolds to prevent potential damage to the lance and/or steam generator.
One steam generator lance in accordance with the subject invention includes a cleaning lance comprising a stack of adjacent tubes in a single column. The tubes secured together at least some locations. The lance includes a distal end with tube nozzles. A thin drive strip is secured on both the top and bottom of the tube stack.
A small tube gap steam generator can be cleaned and inspected via a stack of adjacent metallic tubes in a single column, the tubes secured together at least some locations; the tubes having a diameter less than the width of the tube lane; and no lance structure wider than the tube lane.
The subject invention also features a steam generator tube lane cleaning and/or inspection lance configured as a stack of adjacent metallic tubes in a single column secured together at least some locations, a thin drive strip on both the top and bottom of the tube stack, wherein the tubes have a diameter less than the width of the tube lane and no lance structure wider than the tube lane.
The subject invention, however, in other embodiments, need not achieve all these objectives and the claims hereof should not be limited to structures or methods capable of achieving these objectives.
Other objects, features and advantages will occur to those skilled in the art from the following description of a preferred embodiment and the accompanying drawings, in which:
Aside from the preferred embodiment or embodiments disclosed below, this invention is capable of other embodiments and of being practiced or being carried out in various ways. Thus, it is to be understood that the invention is not limited in its application to the details of construction and the arrangements of components set forth in the following description or illustrated in the drawings. If only one embodiment is described herein, the claims hereof are not to be limited to that embodiment. Moreover, the claims hereof are not to be read restrictively unless there is clear and convincing evidence manifesting a certain exclusion, restriction, or disclaimer.
A super-thin water jetting lance in accordance with the subject invention makes it possible to access steam generator inter-tube gaps where conventional or other commercially available lances cannot access because of geometrical limitations.
Commercially available equipment was designed to access steam generator inter-tube gaps by introducing a robotic device in the steam generator no-tube lane.
One problem with this existing technology is that lance 24 is too thick to enter the small tube gaps of a CE-80 steam generator and deliver meaningful hydraulic power necessary for removal of hard sludge deposits. In the existing technology, the lance body structure necessary for driving the lance into steam generator tube lanes is provided by its exoskeleton, and as a result, the hydraulic hoses, typically plastic hose encased in metallic weave material, further limit the hose internal diameter and, as a result, the amount of water (hydraulic power) that it can deliver. In addition, the type CE-80 steam generator no-tube lane geometry is such that none of the commercially available equipment can enter the no-tube lane and deliver a lance. The tube lanes are typically only 0.116 inches wide.
In one example of the subject invention, cleaning lance 50,
Tubes 56a-c are angled upwardly and tubes 56h-j are angled downwardly at the distal end 54 of the lance for a complete and balanced lance behavior. The downward tubs 56h-j impinge and clean the tube sheet, while tubes 56a-c provide counter balance. In this particular embodiment, the outer diameter of each tube is less than 0.116 inches and indeed the total width of lance 50 is typically less than 0.086 inches.
Thin metallic upper 60a and lower 60b lance drive strips are brazed/welded to tubes 52a and 52j, respectively, in this particular example. These strips, less than 0.086 inches in width and typically less than half the thickness of the tubes themselves, may include spaced-drive sprocket holes 62 as shown for engagement by a device which drives the lance. One such lance drive is discussed below in relation to
The proximal end 64 of lance 50 may include rear support block 66 where tubes 52a-j extend to connect, via high pressure fittings, to a high pressure supply of cleaning fluid, e.g., water and video control equipment. Typically, lance 50 is several feet long and the tubes are brazed together every half foot, approximately.
The subject invention also features, in one embodiment, a complete cleaning system including a lance drive and a mechanism configured to position the distal or head end of the lance in a no-tube lane of a steam generator at the entrance to a tube lane and for guiding the distal end of the lance into and along the tube lane for cleaning the tubes on either side of the tube lane. Lance drive 90,
In one embodiment, sliding lance guide 110,
Rollers 112a-112c,
The super-thin water jetting lance of the subject invention, in any embodiment, thus addresses several deficiencies of existing systems. The lance includes a plurality of metallic flexible tubes, with or without any metallic drive strips attached to it, capable of being driven from outside the steam generator, (thus eliminating the need for large no-tube lane access space) along the no-tube lane, and entering the 30 degree tube lanes for inspection and sludge deposits removal. The advantage of this lance over any known technology is that it does not require an additional exoskeleton for structure and driving. The metal tubes provide adequate structure necessary for driving the lance into and out of a steam generator inter-tube gap, yet flexible enough to bend 30° for entry into tube lanes.
Driving of the super-thin water jetting lance can be done either by friction, or positive engagement. When a friction drive is employed, the lance tubes are squeezed between two rubber rollers driven by a motor. When a positive drive is used, a motor driven sprocket, engages sprocket holes 62,
The result, in any embodiment, is a new cleaning and/or inspection lance with a configuration which is able to access steam generator inter-tube gaps that conventional and commercially available lances cannot access due to geometrical limitations. The cleaning/inspection lance system of the subject invention is reliable, easy to operate, and efficient. Hydraulic pressure is maximized for more effective cleaning.
Thus, although specific features of the invention are shown in some drawings and not in others, this is for convenience only as each feature may be combined with any or all of the other features in accordance with the invention. The words “including”, “comprising”, “having”, and “with” as used herein are to be interpreted broadly and comprehensively and are not limited to any physical interconnection. Moreover, any embodiments disclosed in the subject application are not to be taken as the only possible embodiments.
In addition, any amendment presented during the prosecution of the patent application for this patent is not a disclaimer of any claim element presented in the application as filed: those skilled in the art cannot reasonably be expected to draft a claim that would literally encompass all possible equivalents, many equivalents will be unforeseeable at the time of the amendment and are beyond a fair interpretation of what is to be surrendered (if anything), the rationale underlying the amendment may bear no more than a tangential relation to many equivalents, and/or there are many other reasons the applicant can not be expected to describe certain insubstantial substitutes for any claim element amended.
Other embodiments will occur to those skilled in the art and are within the following claims.
This application hereby claims the benefit of and priority to U.S. Provisional Application Ser. No. 61/010,340, filed on Jan. 8, 2008 under 35 U.S.C. §§119, 120, 363, 365, and 37 C.F.R. §1.55 and §1.78.
Number | Date | Country | |
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61010340 | Jan 2008 | US |