Westinghouse Electric Company LLC

Westinghouse Electric Corporation

Qui V Le

Craig Bowser

William K Cullen

Stephen J Beehner

Jeffrey E Hydeman

William G Cole

Thomas W Nenno

Jayne L Boynton

John C Lichauer

Kyle M Flanigan

Daniel C Wood

James M Gunsallus, Jr

Craig G Bowser

Stephen Beehner

The systems and methods of the invention pertain to analyzing steam generator tube data for the detection of wear. Further, the invention is capable of performing a comparison of current tube signal data to baseline or historic tube signal data, e.g., from previous and/or the first, in-service inspection of the steam generator. The systems and methods are automated and can generate results to show potential tube-to-tube contact wear areas as well as the progression of tube-to-tube gap reduction within a steam generator tube bundle. In certain embodiments, the invention is capable of comparing current and historical eddy current data to determine the difference that may be related to degradation or other interested phenomena, and of processing and trending historical comparison results to establish normal variance and detect abnormal variances.

Systems and methods for steam generator tube analysis for detection of tube degradation

A plurality of signal anomalies are identified in a number of tubes in a steam generator. Since the geometry of the steam generator is known, the location of each signal anomaly along each tube is converted into a location within the interior of the steam generator. If a plurality of signal anomalies are at locations within the steam generator that are within a predetermined proximity of one another, such a spatial confluence of signal anomalies is determined to correspond with a loose part situated within the steam generator. Additional methodologies can be employed to confirm the existence of the loose part. Historic tube sheet transition signal data can be retrieved and subtracted from present signals in order to enable the system to ignore the relatively strong eddy current sensor signal of a tube sheet which would mask the relatively weak signal from a loose part at the tube sheet transition.

Method of detecting an existence of a loose part in a steam generator of a nuclear power plant

A method of employing an eddy current sensor to perform an inspection of a tube of a steam generator involves accelerating and decelerating the eddy current sensor in a predetermined fashion that substantially reduces the likelihood of damage to the eddy current sensor. The reduction of probe stresses reduces radiological waste and reduces radiation exposure to workers involved in changing damaged probes The recording of an eddy current signal at each of a plurality of equally spaced apart locations along the tube permits the velocity of the eddy current sensor to be varied without compromising the validity of the data that has been recorded. The inspection system employs an encoder that outputs a series of signals as the probe is advanced incremental distances within the tube of the steam generator, and eddy current sensor signals are recorded responsive to at least some of the signals from the encoder.

Position-based sampling for eddy current inspection of steam generator tubes

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 analysis results.

Total integrated tube analysis

The invention relates to systems and methods for verifying complete analysis coverage in a steam generator tube inspection. The analysis is conducted by an automated analysis process. The process includes setup and analysis functions. Information is entered into the setup function to identify abnormalities to be inspected and to model the steam generator tubes. The verification includes employing a software verification program to detect and identify a gap within analysis coverage for a particular abnormality or set of abnormalities for which the steam generator tube is inspected, in a particular portion of the steam generator tube.

Automated analysis coverage verification (AACV)

An improved method of inspecting the tubes of a steam generator of a nuclear reactor involves collecting historic data regarding the tube sheet transition regions of each tube for use during a subsequent analysis to create a new simpler signal from which historic artifacts have been removed.

Method of processing steam generator tubes of nuclear power plant

An improved method for verifying a position of a sensor with respect to an object under test includes detecting a signal from the sensor that is positioned at a given location on an object under test and comparing the signal from the sensor with a historical signal that is associated with a Uniquely Identified Location (UIL) on the object under test. If the two signals are consistent, and if the position of the sensor at the given location on the object under test is the same as the UIL, it is concluded that the position of the sensor is correct.

Method for automated position verification

An improved method of inspecting the tubes of a steam generator of a nuclear reactor involves modeling the steam generator and comparing signals of a tube from an eddy current sensor with aspects of the model to determine whether further analysis is required. The model can advantageously include exception data with regard to particular regions of interest (ROIs) of particular tubes that is based upon historic data collected from the steam generator.

Method of modeling steam generator and processing steam generator tube data of nuclear power plant

A method of inspecting a heat exchanger including a plurality of tubes having ends fixed in a tubesheet includes the steps of: establishing a baseline for each tube of its location in the tubesheet and its unique eddy current pattern resulting, at least in part, from fixing the tube end in the tubesheet; inserting an eddy current probe into a first identified tube; obtaining eddy current data for the first identified tube in the region of the tubesheet; comparing the eddy current data obtained for the first identified tube with the baseline eddy current data for the tube, in order to verify the correctness of the tube identification; and accepting the obtained eddy current data if the correctness of the tube identification has been verified by the comparison. A computer program product for automatically carrying out the steps of the foregoing method is also disclosed.

Method of inspecting a heat exchanger and computer program product for facilitating same

Electric discharge machining apparatus and method. An electron discharge machining apparatus and method is provided for precisely machining a wall of a tubular member to form a wall portion thereof defined by a slot of predetermined configuration at a predetermined location in a wall of the tubular member. The tubular member may be a nuclear steam generator tube. The apparatus includes a housing sized to be disposed in the tube, the housing having an opening therethrough capable of being aligned with the predetermined location in the tube wall to be electro-machined. An electrode is housed in the housing for generating an electric discharge arc between the electrode and the wall of the tube in order to machine the slot at the predetermined location. A rotator is connected to the housing for precisely rotating the housing, so that the opening formed through the housing is rotated into registry with the predetermined location to be electro-machined. An extender mechanism housed in the housing is connected to the electrode for precisely extending the electrode through the opening of the housing as the electrode machines the tube wall. As the electrode forms the slot in the wall of the tube, the extender mechanism, which includes a worm gear, gear wheel and threaded axle combination connected to the electrode, precisely advances the electrode to precisely electro-machine the slot in the wall of the tube.

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Pittsburgh, PA, United States of America

Qui V Le