Patent Grant
8549748
The present invention relates generally to nuclear steam generators, and in particular to a new and useful tube support system and method for use in nuclear steam generators which employ tube support plates to retain the tube array spacing within the steam generator.
The pressurized steam generators, or heat exchangers, associated with nuclear power stations transfer the reactor-produced heat from the primary coolant to the secondary coolant, which in turn drives the plant turbines. These steam generators may be as long as 75 feet and have an outside diameter of about 12 feet. Within one of these steam generators, straight tubes, through which the primary coolant flows, may be ⅝ inch in outside diameter, but have an effective length of as long as 52 feet between the tube-end mountings and the opposing faces of the tube sheets. Typically, there may be a bundle of more than 15,000 tubes in one of these steam generators. It is clear that there is a need to provide structural support for these tubes, such as a tube support plate, in the span between the tube sheets to ensure tube separation, adequate rigidity, and the like.
U.S. Pat. No. 4,503,903 describes apparatus and a method for providing radial support of a tube support plate within a heat exchanger, such as a U-tube steam generator having an inner shell and an outer shell. The apparatus is rigidly attached to the inner shell, and is used to centrally locate the tube support plate within the inner shell.
U.S. Pat. No. 5,497,827 describes apparatus and method for radially holding a tube support within a U-tube steam generator. Abutments radially separate an inner bundle envelope, or inner shell, from an outer pressure envelope. Each abutment is fixed to the inner bundle envelope by welding, and contacts the inner face of the pressure envelope. The abutments maintain the different coaxial envelopes of the steam generator and the assembly of the bundle by spacer plates in the radial directions. This is done to avoid relative displacements and shocks between the envelopes and the bundle in the case of external stresses, such as those accompanying an earthquake. In one variant, elastic pressure used to make contact with a spacer plate is obtained by a spiral spring. The spring is located internal to the pressure envelope.
U.S. Pat. No. 4,204,305 describes a nuclear steam generator commonly referred to as a Once Through Steam Generator (OTSG), the text of which is hereby incorporated by reference as though fully set forth herein. An OTSG contains a tube bundle consisting of straight tubes. The tubes are laterally supported at several points along their lengths by tube support plates. The tubes pass through tube support plate holes having three bights or flow passages, and also having three tube contact surfaces for the purpose of laterally supporting the tubes. It is generally recognized that after a heat exchanger is assembled, the tubes will contact one or two of the inwardly protruding lands of the tube support plate holes. This contact provides lateral support to the tube bundle to sustain lateral forces such as seismic loads, as well as provides support to mitigate tube vibration during normal operation.
U.S. Pat. No. 6,914,955 B2 describes a tube support plate suitable for use in the aforementioned OTSG.
For a general description of the characteristics of nuclear steam generators, the reader is referred to Chapter 48 of Steam/Its Generation and Use, 41st Edition, The Babcock & Wilcox Company, Barberton, Ohio, U.S.A., © 2005, the text of which is hereby incorporated by reference as though fully set forth herein.
The present invention is drawn to an improved method and apparatus for supporting tubes in a steam generator.
According to the invention, there is provided a tube bundle support system and method which advantageously permits tube support plates to be installed in an aligned configuration that is compatible with normal fabrication processes. A controlled misalignment is then imposed on one or more tube support plates as the steam generator heats up, i.e. in the hot condition. The tube support plates are made from a material having a lower coefficient of thermal expansion than the shroud that surrounds the tubes. As a result, radial clearances open adjacent to the tube support plate as the steam generator heats up. These radial clearances provide space for lateral shifting or displacement of the individual tube support plates by an associated tube support plate displacement system.
Each tube support displacement system advantageously has only two parts located inside the steam generator shell, thereby minimizing the potential of loose parts.
The method and apparatus can be readily retrofit to existing steam generators, since few internal alterations are required. Conversely, the invention can be easily removed, restoring the steam generator to its original condition.
The normal load paths used for the transmission of seismic loads between tubes, supports, shroud and shell are advantageously unaltered.
Accordingly, one aspect of the invention is drawn to a method of assembling and operating a steam generator having a plurality of tubes in a spaced parallel relation for flow of a fluid there through and the tubes transfer heat with a fluid flowing over the tubes, and also having a plurality of tube support plates disposed transverse to the tubes. The method of assembling and operating the steam generator includes the steps of 1) aligning the tube support plates; 2) inserting the tubes through the aligned tube support plates; and 3) while heating up the steam generator, displacing at least one support plate out of alignment in a lateral direction transverse to the tubes, thereby increasing tube support effectiveness.
The method may include displacing adjacent support plates in the same lateral direction transverse to the tubes.
The method may include displacing only every other support plate in the same lateral direction transverse to the tubes.
The method may include displacing alternating support plates in a first lateral direction transverse to the tubes and displacing the remaining support plates in a lateral direction transverse to the tubes and opposite the first direction.
The method may include displacing a first plurality of support plates in a first lateral direction transverse to the tubes and a remaining plurality of support plates in a lateral direction transverse to the tubes and opposite the first direction.
The method may include displacing one or more tube support plates, in the same or varying amounts and directions, and providing one or more displacements for any individual tube support plate.
Another aspect of the invention is drawn to a tube support system for use in a heat exchanger having a plurality of tubes in spaced parallel relation for flow of fluid there through in indirect heat transfer relation with a fluid flowing there over, and also having a cylindrical shroud that is disposed within a cylindrical pressure shell and surrounds the tubes. The tube support system includes a tube support plate disposed transverse to the tubes that is made of a material having a lower coefficient of thermal expansion than the shroud. The tube support system also includes means for displacing the tube support plate in a lateral direction transverse to the tubes. The means for displacing the tube support plate includes a spring bar contacting the inner surface of the shell, and a push rod threaded through the spring bar which is sprung by continuing to thread the push rod after contact is made with an edge of the tube support plate, thereby displacing the tube support plate.
Yet another aspect of the invention is drawn to a tube support displacement system for use in a heat exchanger having a plurality of tubes in spaced parallel relation for flow of fluid there through in indirect heat transfer relation with a fluid flowing there over, the heat exchanger further having tube support plates arranged transverse to the tubes and a cylindrical shroud, the shroud disposed within a cylindrical pressure shell and surrounding the tubes. The tube support displacement system includes a push rod which has one end for contacting the outer edge of a tube support plate and a turning end opposite the contacting. A spring bar is threadably engaged with the push rod for applying a lateral displacement force to the tube support plate as it is screwed through the spring bar. The turning end has a drive head, accessible through a hand hole in the shell, for screwing the push rod through the spring bar and against the tube support plate while also reacting against the spring bar which is pushed toward the shell. The preload in the spring bar and the pushing force in the push rod are controlled by the distance that the push rod is screwed through the spring bar. The maximum lateral displacement of the push rod may be controlled by adjusting its length of the push rod or by pre-selecting the material of the tube support plate. The push rod and the spring bar are the only components of the tube support displacement system located within the shell.
The tube support plate displacement system can be used to provide controlled misalignments on one or more tube support plates, in the same or varying amounts and directions, and with one or more apparatus being provided for any individual tube support plate.
The various features of novelty which characterize the invention are pointed out with particularity in the claims annexed to and forming part of this disclosure. For a better understanding of the present invention, and the operating advantages attained by its use, reference is made to the accompanying drawings and descriptive matter, forming a part of this disclosure, in which a preferred embodiment of the invention is illustrated.
In the accompanying drawings, forming a part of this specification, and in which like reference numbers are used to refer to the same or functionally similar elements:
The upper head includes an upper tube sheet 14, a primary coolant inlet 15, a manway 16 and a hand hole 17. The manway 16 and the hand hole 17 are used for inspection and repair during times when the steam generator 10 is not in operation. The lower head 13 includes drain 18, a coolant outlet 20, a hand hole 21, a manway 22 and a lower tube sheet 23.
The steam generator 10 is supported on a conical or cylindrical skirt 24 which engages the outer surface of the lower head 13 in order to support the steam generator 10 above structural flooring 25.
The overall length of a typical steam generator of the sort under consideration is about 75 feet between the flooring 25 and the upper extreme end of the primary coolant inlet 15. The overall diameter of the unit 10 moreover, is in excess of 12 feet.
Within the shell 11, a lower cylindrical tube shroud, wrapper or baffle 26 encloses a bundle of heat exchanger tubes 27, a portion of which is illustrated in
The lower shroud 26 is aligned within the shell 11 by means of shroud alignment pins. The lower shroud 26 is secured by bolts to the lower tubesheet 23 or by welding to lugs projecting from the lower end of the shell 11. The lower edge of the shroud 26 has a group of rectangular water ports 30 or, alternatively, a single full circumferential opening (not shown) to accommodate the inlet feedwater flow to the riser chamber 19. The upper end of the shroud 26 also establishes fluid communication between the riser chamber 19 within the shroud 26 and annular downcomer space 31 that is formed between the outer surface of the lower shroud 26 and the inner surface of the cylindrical shell 11 through a gap or steam bleed port 32.
A support rod system 28 is secured at the uppermost support plate 45B, and consists of threaded segments spanning between the lower tubesheet 23 and the lowest support plate 45A and thereafter between all support plates 45 up to the uppermost support plate 45B.
A hollow, toroid shaped secondary coolant feedwater inlet header 34 circumscribes the outer surface of the shell 11. The header 34 is in fluid communication with the annular downcomer space 31 through an array of radially disposed feedwater inlet nozzles 35. As shown by the direction of the
The upper shroud 33, also aligned with the shell 11 by means of alignment pins (not shown in
An auxiliary feedwater header 41 is in fluid communication with the upper portion of the tube bundle through one or more nozzles 42 that penetrate the shell 11 and the upper shroud 33. This auxiliary feedwater system is used, for example, to fill the steam generator 10 in the unlikely event that there is an interruption in the feedwater flow from the header 34. As mentioned above, the feedwater, or secondary coolant that flows upwardly along the tubes 27 in the direction shown by the arrows rises into steam. In the illustrative embodiment, moreover, this steam is superheated before it reaches the top edge of the upper shroud 33. This superheated steam flows in the direction shown by the arrow, over the top of the shroud 33 and downwardly through an annular outlet passageway 43 that is formed between the outer surface of the upper cylindrical shroud 33 and the inner surface of the shell 11. The steam in the passageway 43 leaves the steam generator 10 through steam outlet nozzles 40 which are in communication with the passageway 43. In this foregoing manner, the secondary coolant is raised from the feed water inlet temperature through to a superheated steam temperature at the outlet nozzles 40. The annular plate 37 prevents the steam from mixing with the incoming feedwater in the downcomer 31. The primary coolant, in giving up this heat to the secondary coolant, flows from a nuclear reactor (not shown) to the primary coolant inlet 15 in the upper head 12, through individual tubes 27 in the heat exchanger tube bundle, into the lower head 13 and is discharged through the outlet 20 to complete a loop back to the nuclear reactor which generates the heat from which useful work is ultimately extracted.
To facilitate fabrication, and specifically the insertion of tubes 27 during the fabrication process, the tube support plates 45 are generally aligned with each other, and also with the upper and lower tube sheets. The alignment of the tube support plates 45 is maintained by tube support plate alignment blocks 104, shown in
Turning now to the present invention and referring to
Misalignment between the different elevations of tube support plates 45 is partially accomplished during heat up by making the tube support plates 45 from a material having a lower coefficient of thermal expansion than the shroud 26, 33. Radial clearances 102, shown in
As described in greater detail below, lateral shifting or displacement is achieved by means of a tube support plate displacement system 100 having spring bars 112 which, when loaded, push on the sides of respective tube support plates 45 by means of push rods 114. The difference in thermal expansion between the shroud 11, which is preferably made of carbon steel, and tube support plates 45, which are preferably made of 410S stainless steel, provides enough operational clearance to allow for effective lateral displacement of tube support plate 45, thereby mitigating flow induced vibration of tubes 27. Radial clearances 102 may be reduced to zero due to the push rod force.
Tube support plate alignment blocks 104 may be installed with an initial clearance to facilitate tube support plate motion in the hot condition.
As shown in
It may not be necessary to laterally misalign the tube support plates 45 at all elevations of the upright heat exchanger. It may, for example, be acceptable to shift every other tube support plate 45 in the same direction while restraining the remaining tube support plates 45 in their neutral positions to achieve the desired misalignment. Also, there may be more than one tube support displacement system 100 per tube support plate elevation. The tube support displacement system 100 can thus be used to variably displace the plurality of tube support plates, in one or more of a plurality of different directions, to provide controlled misalignments on one or more tube support plates, in the same or varying amounts and directions, and with one or more apparatus being provided for any individual tube support plate.
Referring now to
As shown in
The orientation of the push rod 114, in relation to the tube support plate 45, is shown in
When the shell/shroud/tube support plate assembly heats up, the higher coefficient of thermal expansion of the shell 11 and shroud 26, 33 material relative to the material of tube support plate 45 will cause a dilation of the shroud 26, 33 relative to the tube support plate 45. As shown in
Control of the tube-to-support plate contact forces in the hot condition is achieved by controlling the initial cold condition preload in the spring bar 112 and push rod 114. The load is adjustable through hand hole 132 which provides access to drive head 128 of the push rod 114. In the cold shutdown condition, the hand hole cover 132 can be removed to gain access to the push rod 114, and the spring bar 112 can be adjusted by turning the drive head 128 to obtain the desired load.
As shown in
Additionally, the contact forces between tubes 27 and tube support plates 45 may be controlled by limiting the lateral displacement, or stroke, of the push rod 114. This maximum stroke distance can be controlled by either selecting a material for the tube support plate 45 with a desired coefficient of thermal expansion, such that the stroke is limited by the maximum radial clearance in the hot condition between the tube support plate 45 and the tube support plate alignment blocks 104, or, alternatively, by adjusting the length of the push rod 114, thereby limiting the maximum range of motion between the push rod 114.
The material used to make push rod 114 may be selected to have a high thermal expansion coefficient to aid in its pushing function.
Advantages of the invention include:
The tube support plates 45 are installed in an aligned configuration that is compatible with normal fabrication processes. The desired misalignment occurs only when heating the heat exchanger.
The misaligned tube support plates 45 in the hot condition can mitigate tube vibration due to either cross flow or axial flow excitation mechanisms.
Tube to tube support plate contact loads in the hot condition are controlled by controlling the push rod force, the tube support plate displacement, the push rod displacement or a combination thereof.
The normal load paths used for the transmission of seismic loads between tubes 27, tube support plates 45, shroud 26, 33 and shell 11 are unaltered.
Tube support plate displacement system 110 has only two parts, spring bar 112 and push rod 114 which are threadably engaged, and are internal to the steam generator shell 11, thereby minimizing the potential of loose parts.
The hardware for spring bar preload adjustment or push rod stroke length adjustment is readily accessible.
The push rod contacting end 124 is situated within the shroud opening 130 and the push rod turning end 126 is situated within the hand hole 132. The push rod 114 is threadably engaged with the spring bar 112 thereby preventing each from becoming a loose part.
Push rod misalignment loads are reacted against the shell 11, which is a stiff anchor point, as opposed to a reaction against the shroud 26, 33 which is relatively flexible.
The subject invention pushes the tube support plates 45 to achieve misalignment, which is preferable to pulling tube support plates 45, since there is no need for a structural attachment to the tube support plate 45.
The design is capable of being retrofitted to existing designs, since few internal alterations are required. Conversely, the tube support plate displacement system 150 can be easily removed, restoring the support arrangement to its original condition.
The tube support plate alignment blocks 104 may be installed with an initial clearance to facilitate tube support plate displacement during heat up of the heat exchanger.
While specific embodiments and/or details of the invention have been shown and described above to illustrate the application of the principles of the invention, it is understood that this invention may be embodied as more fully described in the claims, or as otherwise known by those skilled in the art (including any and all equivalents), without departing from such principles.
| Number | Name | Date | Kind |
|---|---|---|---|
| 4204305 | Norton | May 1980 | A |
| 4336614 | Mitchell et al. | Jun 1982 | A |
| 4503903 | Kramer | Mar 1985 | A |
| 4690206 | Bein | Sep 1987 | A |
| 4768582 | Wepfer | Sep 1988 | A |
| 5492170 | Gil | Feb 1996 | A |
| 5497827 | Cornic | Mar 1996 | A |
| 6914955 | Klarner | Jul 2005 | B2 |
| 20100018688 | Klarner et al. | Jan 2010 | A1 |
| Number | Date | Country |
|---|---|---|
| 2003014391 | Jan 2003 | JP |
| Entry |
|---|
| The Babcock & Wilcox Company, Steam/its generation and use, 41st ed., Ch. 48, “Nuclear Steam Generators,” 2005, U.S.A. |
| English translation of Japanese Office mailed Mar. 19, 2013 for JP Patent Application No. 2009-174299. |
| Number | Date | Country | |
|---|---|---|---|
| 20100018689 A1 | Jan 2010 | US |
