A multi-station factory testing and debugging platform for PCS cooling systems

Abstract

This utility model relates to a multi-station factory testing and debugging platform for a PCS cooling system. It includes a debugging island and multiple debugging supports on both sides. The supports are equipped with mounting positions for equipment operating under real conditions, and the debugging island has multiple debugging stations, each equipped with a control console and test pipes. The test pipes have quick-connect clamps at both ends, allowing for flexible hose connection to the PCS cooling system piping. Exhaust valves and shut-off valves are sequentially installed on the pipes. The control console includes a main unit and a control circuit board. The main unit integrates a local PLC and a touchscreen for independent operation. The circuit board has terminal blocks for electrical connections to the PCS cooling system. This platform simulates real-world operating conditions, with pressure and flow data deviations of <3% and a confidence level increase of 40%. It supports parallel testing of multiple models with mixed wiring. The terminal blocks and quick-connect clamps ensure that the connection time between the piping and the circuit is ≤10 minutes. Each station has independent control and display, enabling real-time data visualization and precise anomaly location, preventing the spread of single-point anomalies.

Description

Technical Field

[0001] This utility model relates to the field of PCS cooling system technology, and is a multi-station factory testing and debugging platform for PCS cooling systems. Background Technology

[0002] PCS cooling systems, also known as passive containment cooling systems, are widely used in nuclear power plants. The factory testing of PCS cooling systems is crucial for their subsequent operational reliability, requiring verification of performance indicators against actual operating conditions using a specialized commissioning platform. However, several technical bottlenecks remain in the testing and commissioning process in this field.

[0003] 1. During the factory testing of the PCS cooling system, traditional commissioning platforms failed to simulate the actual installation layout (such as heat dissipation space and the distribution relationship between units), resulting in significant deviations between test data and actual operating conditions. 2. Currently, most mainstream commissioning platforms are single-station designs, requiring the installation of hardware such as water tanks at each station, leading to high equipment costs. 3. Although some multi-station commissioning equipment has emerged on the market, its multi-station operation relies heavily on centralized control. Failure at any node can cause a complete shutdown, and operators cannot obtain station-level temperature / pressure data in real time, resulting in low efficiency in anomaly diagnosis. Utility Model Content

[0004] The purpose of this invention is to overcome the above-mentioned technical problems and provide a multi-station factory testing and debugging platform for PCS cooling systems.

[0005] To achieve the above objectives, this utility model adopts the following technical solution: a multi-station factory testing and debugging platform for a PCS cooling system, comprising a debugging island and multiple debugging brackets arranged on both sides of the debugging island. The debugging brackets are equipped with equipment mounting positions set according to actual working conditions. The debugging island has multiple debugging stations corresponding to the debugging brackets. Each debugging station is equipped with an industrial control console and a set of test pipes. The test pipes have quick-connect clamps at both ends, and are connected to the PCS cooling system piping via flexible hoses. The industrial control console includes an industrial control host and a control circuit board. The industrial control host integrates a local PLC and a touch screen. It can be operated and controlled independently; the control circuit board is equipped with a terminal block, and the PCS cooling system is electrically connected to the control circuit board through the terminal block. The test pipeline is equipped with an exhaust valve, a shut-off valve, a water inlet, a flow meter, a drain valve, a pressure sensor, and a temperature sensor in sequence. The exhaust valve, shut-off valve, flow meter, drain valve, pressure sensor, and temperature sensor are connected to the control circuit board through the terminal block. The control circuit board includes a power switch module, a signal acquisition module, and a communication module for controlling the operation of each valve on the test pipeline and each electrical component in the PCS cooling system. The control circuit board is connected to the industrial control host through the communication module.

[0006] Furthermore, an electrical control box is provided at one end of the debugging island, and the electrical control box is wired to multiple industrial control consoles to provide power to the industrial control consoles.

[0007] Furthermore, a water tank is provided at the end of the debugging island away from the electrical control box, and a water supply pipe is provided above the debugging island. A self-priming pump is provided on one side of the water tank and is connected to the water supply pipe through the self-priming pump. A branch is provided on the water supply pipe corresponding to each debugging station and is connected to the water inlet on the test pipe.

[0008] Furthermore, the water inlet is equipped with a solenoid valve and a check valve.

[0009] Furthermore, a liquid collection tank is provided below the water tank, and a return water pipe is provided below the debugging island. Each debugging station has a branch on the return water pipe, which is connected to a drain valve on the test pipeline. A water replenishment pump assembly is provided on one side of the liquid collection tank, which connects the liquid collection tank and the water tank.

[0010] Furthermore, the water supply pipe is also equipped with a Y-type filter and a second pressure sensor at its head end, and the second pressure sensor is connected to the signal acquisition module on all industrial control consoles.

[0011] Furthermore, an air booster pump is provided at one end of the debugging island near the electrical control box, and an air supply pipe is provided above the debugging island. The first end of the air supply pipe is connected to the air booster pump, and a branch is provided on the air supply pipe corresponding to each debugging station, which is connected to the exhaust valve on the test pipe.

[0012] Furthermore, the PCS cooling system includes an external cooling unit, a cold air unit, and a pump cabinet unit. The equipment installation positions include placement positions for the external cooling unit, the cold air unit, and the pump cabinet unit, with the external cooling unit, the cold air unit, and the pump cabinet unit respectively placed in their corresponding placement positions.

[0013] The beneficial effects of this utility model are:

[0014] This invention simulates real-world working conditions using a test support system. Compared to the previous test platform used by our company, which employed a non-real-world working condition layout, the deviation in tested pressure and flow data is reduced to less than 3%, and the confidence level is increased by 40%. This invention employs parallel testing of multiple models in mixed lines, significantly improving production line utilization. Simultaneously, the use of terminal blocks and quick-connect clamps effectively saves time in wiring and piping connections; the time for piping and circuit connections can be controlled within 10 minutes, resulting in a significant improvement in testing speed compared to previous test platforms. Furthermore, each workstation in this invention is equipped with an individual control console for control and display, enabling real-time data visualization (temperature / pressure refresh in real time), accurate location of abnormal conditions, significantly improved diagnostic efficiency, and zero propagation of single-point anomalies. Attached Figure Description

[0015] Figure 1 This is a schematic diagram of the structure of a multi-station factory testing and debugging platform for a PCS cooling system according to this utility model;

[0016] Figure 2 This is a top view of a structural schematic diagram of a multi-station factory testing and debugging platform for a PCS cooling system according to this utility model;

[0017] Figure 3 This is a bottom view of the debugging island in this utility model;

[0018] Figure 4 This is a schematic diagram of the test pipe structure in this utility model;

[0019] Figure 5 This is a schematic diagram of the water supply pipeline in this utility model;

[0020] Figure 6 This is a top view of the quick-install clamp connector in this utility model;

[0021] Figure 7 This is a side view of the quick-install clamp connector in this utility model;

[0022] Figure 8 This is a structural block diagram of the industrial control host and control circuit board in this utility model;

[0023] Figure 9 This is a side view of the debugging bracket in this utility model;

[0024] Figure 10 This is a schematic diagram of the system for conducting experiments using the testing platform described in this utility model.

[0025] 1. Debugging island; 2. Debugging bracket; 3. Industrial control console; 4. Test pipeline; 5. Exhaust valve; 6. Shut-off valve; 7. Water inlet; 8. Flow meter; 9. Drain valve; 10. Pressure sensor 1; 11. Temperature sensor; 12. Electrical control box; 13. Water tank; 14. Water supply pipeline; 15. Self-priming pump 1; 16. Liquid collection tank; 17. Solenoid valve; 18. Check valve; 19. Return water pipe; 20. Water replenishment pump assembly; 21. Air booster pump; 22. Air supply pipeline; 23. Quick-connect clamp connector. Detailed Implementation

[0026] The technical solutions of the present utility model will be clearly and completely described below with reference to the accompanying drawings of the embodiments. Obviously, the described embodiments are only some embodiments of the present utility model, and not all embodiments. All other embodiments obtained by those skilled in the art based on the embodiments of the present utility model are within the protection scope of the present utility model.

[0027] Embodiments of this utility model: such as Figure 1-9 As shown, a multi-station factory testing and debugging platform for a PCS cooling system includes a testing island 1 and multiple testing brackets 2 arranged on both sides of the testing island 1. The testing brackets 2 are equipped with equipment mounting positions set according to actual working conditions. The testing island 1 has multiple testing stations corresponding to the testing brackets 2. Each testing station is equipped with a control console 3 and a set of test pipes 4. The test pipes 4 have quick-connect clamps 23 at both ends, and are connected to flexible hoses via the quick-connect clamps 23, thereby connecting to the PCS cooling system piping. The control console 3 includes a control host and a control circuit board. The control host integrates a local PLC and a touch screen, and can be operated and controlled independently. The control circuit board is equipped with a terminal block. The PCS cooling system is electrically connected to the control circuit board through the terminal block. The test pipe 4 is equipped with an exhaust valve 5, a shut-off valve 6, a water inlet 7, a flow meter 8, a drain valve 9, a pressure sensor 10, and a temperature sensor 11 in sequence. The exhaust valve 5, shut-off valve 6, flow meter 8, drain valve 9, pressure sensor 10, and temperature sensor 11 are connected to the control circuit board through the terminal block. The control circuit board includes a power switch module, a signal acquisition module, and a communication module for controlling the operation of each valve on the test pipe 4 and each electrical component in the PCS cooling system. The control circuit board is connected to the industrial control host through the communication module.

[0028] Through the above structure, the industrial control host controls the opening and closing status of each valve on the test pipeline 4. The flow meter 8, pressure sensor 10, temperature sensor 11, and valve opening and closing information on the test pipeline 4 are fed back to the display screen of the industrial control host. The industrial control host controls the main circulation pump, fan, electric heater, and valves in the PCS cooling system. The temperature sensor, pressure sensor, flow meter, and valve opening and closing information in the PCS cooling system are also fed back to the display screen of the industrial control host.

[0029] like Figure 9 As shown, the PCS cooling system includes an external cooling unit, a cold air unit, and a pump cabinet unit. The equipment installation positions include placement positions for the external cooling unit, the cold air unit, and the pump cabinet unit. During testing, the external cooling unit, the cold air unit, and the pump cabinet unit are respectively placed in their corresponding placement positions.

[0030] like Figure 1 As shown, one end of the debugging island 1 is equipped with an electrical control box 12, which is wired to multiple industrial control consoles 3 to provide power to the industrial control consoles 3.

[0031] The debugging island 1 is equipped with a water tank 13 at the end away from the electrical control box 12. A water supply pipe 14 is provided above the debugging island 1. A self-priming pump 15 is provided on one side of the water tank 13 and is connected to the water supply pipe 14 through the self-priming pump 15. A branch is provided on the water supply pipe 14 corresponding to each debugging station and is connected to the water inlet 7 on the test pipe 4 (a quick-connect coupling is used here).

[0032] With the above structure, during the water injection test, the self-priming pump 15 draws water from the water tank 13 and supplies water to the PCS cooling system.

[0033] like Figure 4 As shown, the water inlet 7 is equipped with a solenoid valve 17 and a check valve 18.

[0034] With the above structure, the water inlet to the test pipe 4 is controlled by controlling the opening and closing of the solenoid valve 17 in the water inlet 7, and the check valve 18 is directed from the water supply pipe 14 to the test pipe 4.

[0035] like Figure 3 As shown, a liquid collection tank 16 is provided below the water tank 13, and a return water pipe 19 is provided below the debugging island 1. Each debugging station has a branch on the return water pipe 19, which is connected to the drain valve 9 on the test pipe 4. A water replenishment pump assembly 20 is provided on one side of the liquid collection tank 16. The water replenishment pump assembly 20 connects the liquid collection tank 16 and the water tank 13 to realize wastewater recycling. A Y-type filter is provided on the pipeline of the water replenishment pump assembly 20.

[0036] With the above structure, after the test, the wastewater in the test pipe 4 is discharged into the return water pipe 19 through the drain valve, collected by the liquid collection tank 16, and pumped back into the water tank 13 through the water replenishment pump assembly 20 to replenish the water tank in time.

[0037] like Figure 5 As shown, the water supply pipe 14 is also equipped with a Y-type filter and a pressure sensor 2 at its head end. The pressure sensor 2 is connected to the signal acquisition module on all the industrial control consoles 3.

[0038] In the above structure, the data from pressure sensor 2 is fed back to all industrial control consoles for staff to view. The Y-type filter is used to filter impurities in the water to prevent them from entering the PCS cooling system and damaging the device.

[0039] like Figure 1 As shown, an air booster pump 21 is provided at one end of the debugging island 1 near the electrical control box 12. An air supply pipe 22 is provided above the debugging island 1. The first end of the air supply pipe 22 is connected to the air booster pump 21. A branch is provided on the air supply pipe 22 corresponding to each debugging station. The end of the branch is connected to the exhaust valve 5 on the test pipe 4.

[0040] Through the above structure, the air booster pump 21 provides gas pressure to provide pressurized gas for the air pressure test. The pressurized gas enters the test pipeline 4 through the gas supply pipeline 22 and supplies the PCS cooling system.

[0041] PCS cooling system testing steps: Figure 10 This is a schematic diagram of the PCS cooling system during testing. The PCS debugging fixture in the diagram represents the test piping section, and the remaining parts represent the PCS cooling system section.

[0042] It is worth noting that when testing the PCS cooling system: the first end of the test pipe is connected to the lower ball valve of the PCS pump cabinet unit via clamp connector 23 and hose, and the second end of the test pipe is connected to the upper ball valve of the PCS pump cabinet unit via clamp connector 23 and hose. The PCS cooling system is electrically connected to the industrial control console via terminal block. The industrial control console controls the start and stop of the PCS cooling system's circulating pump, fan, and heater, and can transmit the sensor information from the test pipe and the PCS cooling system to the industrial control console for display.

[0043] 1. Pressure test: to test the equipment's pressure resistance and sealing performance.

[0044] Step 1: Connect test pipe 4 to the PCS cooling system:

[0045] Step 2: Open the pressurized air source valve (i.e., the exhaust valve 5 on test pipe 4) to pressurize the system to 4 bar;

[0046] Step 3: After stopping pressurization, check the equipment for leaks, focusing on checking all instrument joints (PCS equipment body pressure / temperature sensor, test pipeline exhaust valve / drain valve, temperature / pressure sensor / flow meter) for leaks; the pressure may drop during the inspection, continue to pressurize the system to 8 bar, turn off the water pump, and maintain the pressure for 30 minutes.

[0047] Step 4: If there is no air leakage in the system after 30 minutes, and the pressure is not lower than 7.8 bar according to the pressure sensor, the pressure test is considered to be qualified at this stage.

[0048] During the pressure holding process, the output values ​​of the pressure sensors on the PCS cooling system and test pipeline 4 are compared to determine whether the accuracy of the pressure sensor in the PCS cooling system meets the requirements. The difference between the two displayed values ​​is within ±0.2 Bar, which is acceptable.

[0049] During the air pressure test, drain valve 9 remains closed.

[0050] 2. Water injection test: Verify whether the system's water injection and air venting functions are normal.

[0051] Step 1: Ensure that the water inlet of the water tank in the PCS cooling system is open and water can be added; ensure that there is water in water tank 13 of the test platform.

[0052] Step 2: Open the solenoid valve 17 at the inlet of test pipe 4 (the self-priming pump 15 is opened during normal testing). Water is drawn from water tank 13 and sent to test pipe 4 through water supply pipe 14 to inject water into the PCS cooling system. When the water level in the replenishment tank of the PCS cooling system reaches 90%, close the solenoid valve 17.

[0053] Step 3: Jog the main circulation pump in the PCS cooling system and observe the water level in the water tank. When the water level drops to 1 / 3, stop the circulation pump.

[0054] Step 4: Open solenoid valve 17 and continue to add water to the PCS cooling system. Stop adding water when the water level in the water tank reaches 90%.

[0055] Step 5: Repeat steps 3 and 4 until the water level in the replenishment tank remains stable. Open valve V202 in the PCS cooling system and record the actual water injection time.

[0056] During the water injection test, the air vent valve 5 was kept closed.

[0057] 3. System Functionality Test:

[0058] Functional testing of the main circulation pump and electric heater: Adjust the opening of the shut-off valve 6 on test pipe 4, monitor the inlet and outlet temperatures, pressures, and cooling water flow rates of the corresponding PCS cooling system's main circulation pump, and compare them with the rated design values ​​of the PCS cooling system to determine whether the main circulation pump and electric heater are functioning normally. Before turning on the electric heater, compare the temperature sensor values ​​in the PCS cooling system with those in test pipe 4 to determine whether the accuracy of the temperature sensor in the PCS cooling system meets the requirements; a difference between the two displayed values ​​within ±1℃ is acceptable.

[0059] Functional testing of other equipment (electric heating contactor): When the test water temperature is lower than the thermostat setting value, check whether the electric heating contactor in the PCS cooling system is engaged. Normal engagement is acceptable. When the test water temperature is higher than the thermostat setting value, check whether the electric heating contactor in the PCS cooling system is released. Normal release is acceptable.

[0060] 4. Continuous operation test: Before the PCS water cooling system is put into continuous operation, after the main circulation pump is turned on, it must be confirmed that the cooling water flow rate meets the rated inlet flow rate in the "Main Circulation Pump Function Test".

[0061] If the motor runs smoothly during the test and there are no abnormal phenomena such as overheating, and all valves are in normal operating condition, then the equipment is qualified.

[0062] The continuous operation test should, in principle, last for no less than 0.5 hours. During this 0.5-hour period, it should be monitored by professional personnel who must not leave the site. Operational data (such as supply water temperature, return water temperature, supply water pressure, return water pressure, test pipeline pressure, temperature, flow rate, and power supply voltage) should be recorded.

[0063] 5. Drainage:

[0064] 1) After the test is completed, open the drain valve 5 to allow the residual water in the test pipe 4 to flow into the return water pipe 19 for recycling.

[0065] 2) After commissioning, the PCS needs to be emptied. It is worth noting that: the gas supply pipe 22 and the water return pipe 19 are equipped with additional quick-connect fittings for each workstation to connect the compressed air pipe and the drain pipe, respectively. This part has been omitted in the figure.

[0066] External cooling unit evacuation: Connect the end of the drain pipe away from the return water pipe 19 to the fan outlet, insert the compressed air pipe into the fan inlet, and blow air for 2 minutes to force out the water inside until no liquid is discharged.

[0067] Pump cabinet evacuation: Insert the compressed air pipe into the V305 single-piece ball valve inside the pump cabinet, and insert the drain pipe into the bottom vent valve of the PCS water cooling system's water supply tank and the bottom vent valve of the water pump respectively. Slowly open the compressed air supply valve to blow air and drain the water until it is slowly dripping!

[0068] Evacuate the cold air unit: Connect the two ends of the included circulation hose to the drain pipe and the compressed air pipe respectively, and blow air through the compressed air pipe to force out the internal liquid until the liquid in the pipe is discharged.

[0069] It should be noted that, in this document, relational terms such as "first" and "second" are used only to distinguish one entity or operation from another, and do not necessarily require or imply any such actual relationship or order between these entities or operations. Furthermore, the terms "comprising," "including," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such process, method, article, or apparatus.

[0070] Although embodiments of the present invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and variations can be made to these embodiments without departing from the principles and spirit of the present invention, the scope of which is defined by the appended claims and their equivalents.

[0071] The present invention and its embodiments have been described above. This description is not restrictive, and the accompanying drawings are only one embodiment of the present invention; the actual structure is not limited thereto. In conclusion, if those skilled in the art are inspired by this description and design similar structures and embodiments without departing from the inventive spirit of the present invention, such designs should fall within the protection scope of the present invention.

Claims

1. A multi-station factory testing and debugging platform for a PCS cooling system, characterized in that: The system includes a test island (1) and multiple test brackets (2) set on both sides of the test island (1). The test brackets (2) are equipped with equipment installation positions set according to actual working conditions. The test island (1) is equipped with multiple test stations corresponding to the test brackets (2). Each test station is equipped with an industrial control console (3) and a set of test pipes (4). The test pipes (4) are equipped with quick-connect clamps (23) at both ends and are connected to the PCS cooling system pipeline by connecting hoses through the quick-connect clamps (23). The industrial control console (3) includes an industrial control host and a control circuit board. The industrial control host integrates a local PLC and a touch screen and can be operated and controlled independently. The control circuit board is equipped with a terminal block. The cooling system is electrically connected to the control circuit board via a terminal block. The test pipe (4) is sequentially equipped with an exhaust valve (5), a shut-off valve (6), a water inlet (7), a flow meter (8), a drain valve (9), a pressure sensor (10), and a temperature sensor (11). The exhaust valve (5), shut-off valve (6), flow meter (8), drain valve (9), pressure sensor (10), and temperature sensor (11) are connected to the control circuit board via a terminal block. The control circuit board includes a power switch module, a signal acquisition module, and a communication module for controlling the operation of each valve on the test pipe (4) and each electrical component in the PCS cooling system. The control circuit board is connected to the industrial control host via the communication module.

2. The PCS cooling system multi-station factory testing and debugging platform according to claim 1, characterized in that: The debugging island (1) is equipped with an electrical control box (12) at one end. The electrical control box (12) is wired to multiple industrial control consoles (3) to provide power to the industrial control consoles (3).

3. The PCS cooling system multi-station factory testing and debugging platform according to claim 2, characterized in that: The debugging island (1) is equipped with a water tank (13) at one end away from the electrical control box (12). A water supply pipe (14) is provided above the debugging island (1). A self-priming pump (15) is provided on one side of the water tank (13) and is connected to the water supply pipe (14) through the self-priming pump (15). A branch is provided on the water supply pipe (14) corresponding to each debugging station and is connected to the water inlet (7) on the test pipe (4).

4. The PCS cooling system multi-station factory testing and debugging platform according to claim 3, characterized in that: The inlet (7) is equipped with a solenoid valve (17) and a check valve (18).

5. The PCS cooling system multi-station factory testing and debugging platform according to claim 3, characterized in that: Below the water tank (13) is a liquid collection tank (16), and below the debugging island (1) is a return water pipe (19). Each debugging station has a branch on the return water pipe (19) and it is connected to the drain valve (9) on the test pipe (4). A water replenishment pump assembly (20) is provided on one side of the liquid collection tank (16), and the liquid collection tank (16) and the water tank (13) are connected through the water replenishment pump assembly (20).

6. The PCS cooling system multi-station factory testing and debugging platform according to claim 1, characterized in that: The water supply pipe (14) is also equipped with a Y-type filter and a pressure sensor II at its head end. The pressure sensor II is connected to the signal acquisition module on all industrial control consoles (3).

7. The PCS cooling system multi-station factory testing and debugging platform according to claim 2, characterized in that: An air booster pump (21) is provided at one end of the debugging island (1) near the electrical control box (12). An air supply pipe (22) is provided above the debugging island (1). The first end of the air supply pipe (22) is connected to the air booster pump (21). A branch is provided on the air supply pipe (22) corresponding to each debugging station and is connected to the exhaust valve (5) on the test pipe (4).

8. The PCS cooling system multi-station factory testing and debugging platform according to claim 1, characterized in that: The PCS cooling system includes an external cooling unit, a cold air unit, and a pump cabinet unit. The equipment installation positions include placement positions for the external cooling unit, the cold air unit, and the pump cabinet unit, with the external cooling unit, the cold air unit, and the pump cabinet unit respectively placed in their corresponding placement positions.

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