Telescoping Boom Inspection System for Steam Generator Internals
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Solution Overview
Problem
Nuclear steam generators face challenges in inspecting the interior due to a highly corrosive environment, inaccessibility of steam generator tubes and support plates, and the complexity of maneuvering equipment within the generator, which limits effective detection of corrosion and leaks.
Innovation Solution
A vertical deployment system (VDS) with a telescoping boom and robotic inspection vehicles, including a magnetic inspection vehicle and an in-bundle robotic inspection vehicle, equipped with cameras, lighting, and cabling, allows for detailed inspection of steam generator internals, including support plates and tube bundles, by extending vertically through narrow flow slots and using magnetic tracks for movement along ferrous surfaces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If direct visual human inspection is used, then inspection time is limited to 3-5 minutes per man per six month period, but inspection completeness and detection precision are insufficient
Solution Approach 1:
The patent replaces human visual inspection with an automated robotic inspection system that uses cameras, lighting, and image processing to detect corrosion, holes, and leaks. The robotic vehicle navigates through the steam generator autonomously, capturing images of tubes and support plates without human intervention, thereby eliminating time constraints on inspectors while providing comprehensive and precise inspection coverage.
2Ease of operation
If inspection equipment is inserted through access ports, then equipment can access interior areas, but maneuvering is obstructed by flow distribution baffles and narrow spaces
Solution Approach 1:
The inspection system is divided into modular components: a robotic vehicle, camera systems, lighting arrays, and navigation equipment. This segmentation allows each component to be independently optimized for the constrained environment, with the robotic vehicle designed to navigate narrow lanes and maneuver around baffles while carrying the necessary inspection equipment.
Solution Approach 2:
The patent utilizes the vertical dimension by having the robotic vehicle travel along the inner surface of the steam generator wrapper from the access port at the bottom upward, rather than attempting to maneuver horizontally through the congested mid-section. This dimensional approach bypasses many of the obstructions caused by flow distribution baffles and tube bundles.
3Length of stationary object
If telescoping boom extends vertically through narrow flow slots, then access to high elevation areas is achieved, but device complexity and insertion difficulty increase
Solution Approach 1:
The boom system employs a nested telescoping structure where multiple boom sections are housed within one another, allowing the system to be compact enough to pass through narrow flow slots while extending to reach high elevation areas for inspection. The nested design reduces the overall footprint during insertion while providing extended reach when deployed.
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
Enables thorough and precise inspection of steam generator internals, overcoming the limitations of traditional inspection methods by providing enhanced visual feedback and access to previously inaccessible areas, improving the detection of corrosion and leaks while maintaining safety in a radioactive environment.
Implementation Method 1
magnetic inspection vehicle... utilizing magnets... to facilitate vertical movement of the magnetic inspection vehicle along a vertical surface comprising a ferrous metal
Data Source
Figure 1
Figure 2a~2b
Figure 3
AI summary
An inspection system for inspecting the interior of a steam generator includes, in one aspect, a first boom and a second, telescoping boom having a proximal end pivotally attached to the first boom and a distal end bearing a delivery capsule, the delivery capsule defining a storage bay. The inspection system includes a first robotic inspection vehicle dimensioned to fit in the delivery capsule storage bay and itself defines a storage bay. The first robotic inspection vehicle includes at least one inspection camera and at least one lighting system. The first robotic inspection vehicle further includes cabling connecting the first robotic inspection vehicle to the delivery capsule. The inspection system also includes a second robotic inspection vehicle dimensioned to fit in the first robotic inspection vehicle storage bay. The second robotic inspection vehicle includes at least one inspection camera and at least one lighting system and further includes cabling connecting the second robotic inspection vehicle to the first robotic inspection vehicle.