Remote Piping Weld Inspection System for Nuclear Reactors
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Solution Overview
Problem
Nuclear reactor components, such as jet pump riser pipe and elbow welds, are difficult to access for inspection due to their location in restricted spaces and the harsh, radioactive environment, leading to challenges in assessing structural integrity and increasing radiological exposure and costs.
Innovation Solution
An automated inspection assembly with subassemblies like a frame, positioning arm, kicker arm, and scanning subassembly, which can be remotely operated to wedge and position itself between pipes and surfaces, allowing for nondestructive scanning of hard-to-reach areas using ultrasonic, eddy current, and video sensors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual inspection methods are used in restricted spaces, then inspection can be performed, but radiological exposure increases and access difficulty worsens
Solution Approach 1:
A remotely operated robotic inspection system serves as an intermediary between the inspector and the radioactive environment. The system includes a robotic manipulator with sensors that can be inserted into restricted spaces through small openings, allowing inspection without direct human exposure to radiation. The robotic system transmits data back to operators who control it from a safe distance.
Solution Approach 2:
Manual mechanical inspection tools are replaced with an automated robotic system equipped with sensors and actuators. The robotic system uses computer-controlled mechanisms to navigate restricted spaces, position inspection tools, and collect data, eliminating the need for human operators to physically enter high-radiation zones.
2Adaptability or versatility
If multiple specialized inspection tools are used for different components, then inspection coverage improves, but device complexity and reconfiguration time increase
Solution Approach 1:
The robotic inspection system is designed as a universal platform capable of performing multiple inspection functions. It includes interchangeable sensor modules (ultrasonic, eddy current, visual) and adaptable end-effectors that can be configured for different component types. The system can inspect pipes, vessels, valves, and other nuclear reactor components using the same base platform, reducing the need for multiple specialized tools.
Solution Approach 2:
The robotic system features dynamic reconfiguration capabilities where sensor modules and inspection tools can be quickly swapped or adjusted during operations. The system includes programmable motion control that adapts to different geometries and inspection requirements, allowing rapid transition between different inspection tasks without complete system replacement.
3Ease of operation
If manual inspection procedures are used, then flexibility in handling different components is maintained, but inspection time and plant shutdown duration increase
Solution Approach 1:
The robotic inspection system performs autonomous navigation and inspection execution within programmed parameters. Once programmed with inspection paths and criteria, the system can operate semi-autonomously, reducing the need for continuous manual intervention while maintaining adaptability. The system automatically processes inspection data and generates reports, speeding up the overall inspection process.
Solution Approach 2:
The system uses programmable parameters to adapt to different inspection scenarios. Inspection speed, sensor sensitivity, path planning, and data analysis thresholds can be adjusted through software configuration rather than physical reconfiguration. This allows rapid adaptation to different components and inspection requirements while maintaining high-speed automated operation.
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
The automated inspection assembly minimizes the need for multiple tool reconfigurations and reduces radiological exposure by enabling efficient, remote inspection of inaccessible components, thereby reducing plant shutdown durations and costs.
Implementation Method 1
Ultrasonic inspection is a known technique for detecting cracks in nuclear reactor components
Implementation Method 2
eddy current, and video sensors
Data Source
AI summary
An apparatus and method to remotely perform automated piping and piping attachment weld inspections. The apparatus has two spaced positioning arms that rotate out from one side of a frame structure and a kicker arm that rotates out from an opposite side of the frame structure at a location between the two positioning arms. The positioning arms and the kicker arm wedge the frame structure between an object to be scanned and an opposing structure. A scanning subassembly supported on the frame structure is configured to pivot and move in an appropriate direction and to pilot a transducer around the surface of the object to be scanned.