METHOD AND SYSTEM FOR MONITORING OPERATING CONDITIONS IN A STEAM GENERATOR

• US 20150330866A1
• Filed: 12/20/2013
• Published: 11/19/2015
• Est. Priority Date: 12/20/2012
• Status: Abandoned Application

• Current Assignee: BL Technologies Inc. (Ashland Global Holdings, Inc.)
• Original Assignee: General Electric Company
• Inventors: YANG, Xingwei, KUMAR, Aditya, CAN, Ali, WANG, Guanghua
• Application Number:
  US14/652,708
• Publication Number:
  US 20150330866A1
• Time in Patent Office: Days
• US Class Current: 1/1
• CPC Class Codes: F01D 25/285 Temporary support structures, e.g. for testing, assembling, installing, repairing; Assembly methods using such structures
• CPC Class Codes: F22B 37/002 specially adapted for nuclear steam generators, e.g. maintenance, repairing or inspecting equipment not otherwise provided for
• CPC Class Codes: F22B 37/10 Water tubes; Accessories therefor working of metal tubes B21D; pipes in general F16L; repairing leaks in water tubes F16L55/16; F28F11/00; baffles, screens, or deflectors formed of water tubes F23M9/10; cleaning internal or external surfaces of water tubes F28G
• CPC Class Codes: G01M 11/081 by using a contact-less detection method, i.e. with a camera
• CPC Class Codes: G01M 11/083 by using an optical fiber in contact with the device under test [DUT]
• CPC Class Codes: G01N 25/72 Investigating presence of flaws
• CPC Class Codes: G06T 2207/30108 Industrial image inspection
• CPC Class Codes: G06T 7/75 involving models
• CPC Class Codes: H04N 17/002 for television cameras
• CPC Class Codes: H04N 23/23 from thermal infrared radiation
• CPC Class Codes: H04N 23/661 Transmitting camera control signals through networks, e.g. control via the Internet
• CPC Class Codes: H04N 23/81 for suppressing or minimising disturbance in the image signal generation
• CPC Class Codes: H04N 25/61 the noise originating only from the lens unit, e.g. flare, shading, vignetting or "cos4"
• CPC Class Codes: H04N 5/33 Transforming infrared radiation cameras or camera modules for generating image signals from infrared radiation H04N23/20; circuitry of SSIS for transforming infrared radiation into image signals H04N25/20

Abstract

A system and method for monitoring operating conditions of tubes in a steam generator. The system comprises sensors, affixed to the tubes, for detecting one or more of mechanical strains, pressures, and temperatures in the tubes; or a camera positioned in the steam generator, the camera for capturing thermal images of the tubes; or both the sensors and the camera. The system also comprises one or more computers connected to the sensors, or the camera, or both the sensors and the camera, the computers for receiving one or more of the mechanical strains, pressures, temperatures, and thermal images, and monitoring the operating conditions of the tubes. The method comprises receiving, at one or more times, one or more of pressures, mechanical strains, temperatures, and infrared photon counts of the tubes; identifying segments of the tubes to which pertains the pressures, mechanical strains, temperatures, and infrared photon counts; and monitoring the operating conditions of the tubes.

Claims

1. A system for monitoring an operating condition of tubes in a steam generator, the system comprising:

fiber optic sensors affixed to the tubes, the sensors adapted for detecting one or more of mechanical strains, pressures, and temperatures in the tubes or sensors;

or a camera positioned in the steam generator, the camera adapted for capturing images of the tubes relatable to temperature;

or both the sensors and the camera; and

one or more computers connected to the sensors, or the camera, or both the sensors and the camera, the one or more computers adapted for receiving signals from the sensors or the camera or both, and monitoring the operating conditions of the tubes.

3. The system of claim 1 having fiber optic sensors and a camera, wherein the steam generator comprises a radiant section and a convention section, and wherein the sensors are affixed to tubes in the radiant section and the camera is positioned to capture thermal images of the tubes in the convention section.

4. The system of claim 1, wherein the one or more computers are configured to identify segments of the tubes to which pertain the one or more of mechanical strains, pressures and temperatures.

5. The system of claim 1, wherein the system comprises a camera and the one or more computers are configured to project a model of the tubes onto each image and locally fit a parametric template of the tubes in each image to identify segments of the tubes to which pertain infrared photon counts of the images.

6. The system of claim 5, wherein the one or more computers are configured to locally fit a parametric template to two or more tubes together in an image.

7. The system of claim 1, wherein the computer is configured to monitor one or more of the following operating conditions of the tubes:

a. temperatures;

b. pressures;

c. mechanical strain;

d. thermal trends;

e. mechanical degradation;

f. localized hot spots;

g. dynamic and transient events;

h. rupture events; and

i. fouled segments.

based on the one or more of the mechanical strains, pressures, and temperatures.

2. (canceled)

8-10. -10. (canceled)

11. A method for monitoring operating conditions of tubes in a steam generator, comprising:

receiving, at one or more times, one or more signals or images relatable to one or more of pressure, mechanical strain, and temperature of segments of the tubes;

identifying in a model of the steam generator the segments of the tubes which the signals or images related to; and

monitoring an operating condition of the tubes.

12. The method of claim 11, wherein monitoring an operating condition comprises detecting a difference between one or more of the pressure, mechanical strain, and temperature of one segment relative to another.

13. The method of claim 12, wherein a difference is detected by comparing one or more of the pressure, mechanical strain, and temperature of one or more of

a. a first segment of a first tube at a first time to the first segment of the first tube at a second time;

b. the first segment of the first tube to a second segment of the first tube; and

c. the first segment of the first tube to a second segment of a second tube.

14. The method of claim 11, further comprising steps of receiving infrared photon counts, which step further comprises receiving thermal images of the tubes, wherein the step of identifying segments comprises projecting a model of the tubes onto the image and locally fitting a parametric template to the image of the tubes to determine location data.

15. The method of claim 11, wherein the step of monitoring operation conditions comprises one or more of determining

a. tube temperatures,

b. thermal trends,

c. localized hot spots,

d. fouled segments, and

e. dynamic and transient events

16. The method of claim 14, further comprises a step of receiving a signal indicating a wavelength of light from a fiber optic sensor and converting the wavelength of the light into one or more of

a. temperatures of the tubes and the corresponding locations of the temperatures of the tubes;

and

b. pressures in the tubes and the corresponding locations of the pressures in the tubes.

17. The method of claim 11, wherein the step of monitoring operation conditions comprises one or more of determining

a. average temperature and pressure measurements in the tubes;

b. thermal trend of the tubes;

c. mechanical degradation trend of the tubes;

d. localized hot spots in the tubes;

e. averaged tube temperature trends;

f. dynamic thermal events in the tubes; and

g. transient thermal rupture events in the tubes.

18-19. -19. (canceled)

20. A method comprising:

receiving at least one image, from a camera, of one or more tubes for carrying water in a steam generator;

registering a model of the one or more tubes onto the image to generate a projection of the model;

determining location data for the one or more tubes from the projection.

21. The method according to claim 20, further comprising calibrating the camera to reduce a camera lens distortion characteristic in the at least one image.

22. The method according to claim 21, wherein the camera lens distortion characteristic comprises at least one of tangential distortion and radial distortion.

23. The method according to claim 20, further comprising:

calibrating the camera to adjust an extrinsic parameter of the camera, the extrinsic parameter comprising at least one of the angle of the camera to each part represented by a pixel of the image, and the distance of the camera to each part represented by a pixel of the image.

24. The method according to claim 20, wherein the registering comprises:

receiving an identification of landmarks on the image that correspond to known locations in the model; and

generating the projection from the landmarks, the projection comprising a projection matrix from the image to points on the model.

25. The method according to claim 20, further comprising:

adjusting the location data using a model based tube template.

26. The method according to claim 25, wherein the adjusting comprises:

constructing a plurality of parametric templates for each of the one or more tubes;

evaluating the plurality of parametric templates against the location data to generate a response; and

adjusting the location data when the parametric template has a local best fit response.

27. The method according to claim 26, wherein the parametric template comprises a rotation parameter and a shift parameter.

28. The method according to claim 26, wherein the adjusting is dependent on the local best fit response for at least one neighbor tube.

29. The method according to claim 20, wherein the image comprises a thermal image and the camera comprises an infrared camera.

30. The method according to claim 29, further comprising:

receiving a sequences of thermal images captured by the infrared camera;

monitoring the sequence of thermal images for a change of temperature affecting one or more of the tubes; and

when a temperature change is detected, determining location data for the affected tube.

31-37. -37. (canceled)

38. A system for monitoring operating conditions of the steam generator tubes in a steam generator, the system comprising a fiber optic sensing array;

a hermetical cable package disposed circumferentially around the fiber optic sensing array;

a light source in optical communication for emitting a light into the fiber optic sensors;

a detector optically connected to the fiber optic sensing array for receiving refracted wavelengths of the light;

a central processing unit in communication with the photodetector, the central processing unit configured to receive a signal from the photodetector corresponding to the refracted wavelengths of light and further configured to convert the signal into the operating conditions; and

a display device operatively connected to the central processing unit for displaying the operating conditions.

41. The system of claim 38, wherein the operating conditions comprise one or more of:

thermal strain and temperature measurements at multiple locations along a steam generator tube;

local and averaged temperature measurements and thermal strain measurement along a steam generator tube;

a thermal trend from a steam generator tube long-term operation performance;

mechanical degradation trend;

localized hot spot(s);

averaged steam generator tube temperature trend;

dynamic thermal event; and

transient thermal rupture event.

39-40. -40. (canceled)

42-49. -49. (canceled)

50. A system for monitoring the operating conditions of a steam generator, the system comprising:

a network in communication with a workstation;

a plurality of fiber optic sensors for sensing strain information of tubes in a steam generator;

instrumentation connected to the fiber optic sensors for obtaining the strain information therefrom and communicating the strain information to the workstation through the network; and

a camera for detecting the temperature in a plurality of tubes in a steam generator, and for communicating the temperatures to the workstation through the network;

wherein, the workstation is configured to determine the operating conditions of the steam generator.

51. The system of claim 50, wherein the strain information is temperature and location data.

52. The system of claim 50, wherein the strain information is pressure strain and location data.

54. The system of claim 50, wherein the fiber optic sensors sense the strain information of tubes in a convection section of the steam generator.

55. The system of claim 50, wherein the camera sense the temperature of tubes in a radiant section of the steam generator.

53. (canceled)