Nuclear Steam Generator Tube Inspection Automation
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Solution Overview
Problem
Current steam generator tube inspection processes in nuclear power plants are cumbersome and unreliable, requiring manual expertise and separate primary and secondary analysis processes, which are time-consuming and prone to errors, leading to potential failures and costly shutdowns.
Innovation Solution
The integration of Enhanced Automated Data Screening (EADS) and Real Time Automated Analysis (RTAA) processes into a single automated system, known as Total Integrated Tube Analysis (TITAN), which combines data and reports to provide a comprehensive, efficient, and reliable assessment of steam generator tube conditions, reducing the need for manual analysis and minimizing errors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If manual analysis of eddy current data is performed by expert analysts, then measurement precision and reliability are improved, but loss of time and productivity deteriorate significantly
Solution Approach 1:
The patent introduces an intermediary automated analysis system that acts as a bridge between raw eddy current data and expert analyst interpretation. The system processes signals through multiple automated algorithms (primary and secondary analysis) to generate pre-evaluated reports, reducing the time analysts need to spend on raw data review while maintaining assessment accuracy through layered automated filtering and identification of anomalies.
Solution Approach 2:
The patent replaces the manual mechanical process of expert analysts reviewing eddy current signals with an automated electronic analysis system. The system uses computer-based algorithms to automatically process, filter, and interpret eddy current data, substituting human manual analysis with automated computational methods that can process data faster while maintaining or improving measurement precision through consistent application of analysis criteria.
2Measurement precision
If separate primary and secondary analysis processes are used to ensure reliability, then measurement precision is improved, but device complexity and ease of operation worsen
Solution Approach 1:
The patent merges separate primary and secondary analysis processes into an integrated automated system where both analysis types are performed through a unified software platform. The system combines multiple analysis algorithms (including EADS and RTAA methods) into a single coordinated process that automatically performs both primary screening and secondary verification, reducing operational complexity while maintaining the reliability benefits of multi-layered analysis through automated workflow integration.
3Productivity
If automated analysis processes are implemented to reduce manual effort, then productivity is improved, but measurement precision and reliability may deteriorate
Solution Approach 1:
The patent uses automated analysis algorithms as intermediary processing layers that enhance rather than replace expert judgment. The system performs automated signal processing, noise filtering, and anomaly detection to prepare refined data for final interpretation, acting as an intermediary that improves both productivity through automation and measurement precision through sophisticated signal processing techniques that reduce false positives and enhance defect detection capability.
4Measurement precision
If comprehensive eddy current inspection of all tubes is performed, then measurement precision is improved, but loss of time and productivity worsen due to the large number of tubes
Solution Approach 1:
The patent extracts and prioritizes only the most significant signals and anomalies from the comprehensive eddy current data set. The automated analysis system processes all tube data but selectively identifies and flags only those signals that indicate potential tube degradation or defects, extracting critical information from the vast data set generated by inspecting thousands of tubes. This allows complete inspection coverage while focusing analyst attention only on relevant findings, significantly reducing the effective time required for meaningful assessment.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
TITAN enables faster, more accurate, and reliable detection of tube wear and degradation, reducing the likelihood of failures and unplanned shutdowns by providing a single, integrated report that identifies tube conditions and supports comprehensive repair solutions.
Implementation Method 1
an eddy current sensor is inserted into one or more of the tubes and a signal is extracted from the sensor
Data Source
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AI summary
The invention relates to improved systems and methods for inspecting the tubes of a steam generator of a nuclear reactor that involves modeling the steam generator, comparing signals of a tube from an eddy current sensor with aspects of the model to determine whether further analysis is required, employing primary and secondary analysis processes, and producing a combined report of the primary and secondary analyses results.