Abstract:
A system and method of detecting and monitoring flow conditions in the coolant of a nuclear reactor that relies upon acoustic or optical differences in the various flow conditions. The system uses a database of acoustic or optical characteristics of the various known flow conditions being monitored, and a processor that compares the detected acoustic signals with the known acoustic characteristics. The processor uses various methods of discrimination, such as altering or decaying the transmitted signal, to aid in the interpretation and comparison of the signals. The acoustic detection is provided by a pair of sensor assemblies positioned a distance from each other to detect variations in the acoustic patterns associated with the coolant flow. A transmitter and receiver of each sensor assembly can be positioned on opposite sides of the pipe in which the coolant is flowing, or on the same side of the pipe, depending upon which configuration provides the best discrimination between the flow conditions being monitored. The monitoring system is effective for determining, among other things, the existence of bubbles entrained in the coolant, the existence and level of a free surface, the existence of vortex or whirlpool formations, and the existence of entrained solid particulates.

Description:
BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     The present invention relates generally to flow condition monitoring systems and methods. In particular, the present invention relates to a system and method for monitoring flow conditions in the coolant and other fluids circulating through a nuclear power plant. 
     2. Description of the Related Art 
     In a nuclear plant of the pressurized water reactor (PWR) type, coolant fluid, which is basically boron and water, is continuously transferred through a closed circulation loop between a nuclear reactor and one or more steam generators. 
     During power production, the pressurized coolant absorbs heat released by the thermonuclear reaction occurring in the reactor. The heated coolant then flows through a main pipe which is appropriately known as the “hot leg” of the circulation loop. The hot leg delivers the hot coolant to a steam generator. 
     In the steam generator, the coolant fluid circulates through a heat exchanger. The heat exchanger cools the coolant fluid and uses the heat removed from the coolant to produce steam. This steam is eventually used to drive turbines and generate electricity. 
     After the circulating coolant is cooled by a heat exchanger, a circulation pump removes the coolant from the steam generator via a “suction leg” and returns it to the reactor via a “cold leg” and inlet. The coolant is then reheated in the reactor and the cycle repeats. 
     This circulation of coolant through one or more loops is critical for the operation of the power plant. Not only does it deliver heat energy to the steam generators where the energy is used to produce steam for driving the turbines, but the circulating coolant also prevents the reactor core in the reactor from overheating. 
     Nuclear power plant systems, including the steam generators, require periodic maintenance. In particular, the fluid circulation system must be inspected for potential degradation, and nozzle dams must be installed and removed from the steam generators to allow inspection and maintenance to be performed in a dry environment. 
     In order to install and remove nozzle dams, the coolant fluid must be drained from the steam generator. This requires lowering the fluid level in the main circulation loop and consequently the hot leg or main pipe. During such a maintenance period, which is termed a “shutdown,” the coolant continues to be heated by decay heat from the reactor core and is cooled by an alternate heat exchanger and auxiliary circulatory system known as the “shutdown cooling system.” 
     In order to lower the coolant or water level in the shutdown reactor system to permit refueling of the reactor core and to allow maintenance operations on portions of the system above the lowered water level, the water level must be controlled and maintained at a minimum level and flow rate to continuously provide adequate core cooling. This minimum level is about midway within the reactor coolant system main loop piping (the hot leg) and is commonly referred to as “midloop.” 
     During midloop operation, coolant water is circulated through the system to cool the core. Typically, there are a drain line or lines which communicate with the lower region of one or more of the main loop pipes or legs to draw the heated water from the core for cooling by the alternate heat exchanger in the shutdown cooling system and subsequent recirculation of cooled water to a reactor inlet and thus to the core. 
     It is possible to experience the formation of a Coriolis effect vortex in the drain line during midloop operation if the water level is lowered too far down or if the drain flow rate is too high. Such a vortex is undesirable because it limits the rate at which coolant flow can be drained from the system, and it can eventually lead to cavitations in the drain pump. Both results cause concern for continued cooling of the core. 
     The current methods to avoid vortex formation rely on keeping the water level as high as possible and/or reducing the flow rate, resulting in a conflict between the need to lower the water level for maintenance service, and the need to keep the water level high and at a sufficient rate for safe core cooling. Midloop measuring systems in use are related to a detection of the water elevation and inference of the status of the vortex therefrom. 
     In nuclear power plants much attention has been given to shutdown cooling system reliability, especially during reactor coolant system midloop water level operation. Midloop operation in a typical pressurized water reactor (PWR) nuclear steam supply system, for example, for the installation and removal of steam generator nozzle dams, can be a very difficult operational process. In fact, typically, the water level allowed tolerance is approximately plus or minus one inch (+/−1″). A vortex detection system has been disclosed in U.S. Pat. No. 5,861,560 by Robert P. Harvey to detect air vortexing and cavitation and thereby improve the shutdown cooling system reliability. However, the vortex detection system of Harvey is limited in its capability and usefulness because it relies only on the disruption of the signal of a conventional ultrasonic flowmeter to trigger an alarm indicating a vortex condition. The vortex detection system of Harvey is not capable or suitable for detecting various other fluid flow conditions throughout the nuclear reactor, such as fluid levels, entrained solid particulates caused by accident scenarios, condensible and noncondensible bubbles entrained in the fluid, and so forth. The vortex detection system of Harvey uses only one sensor and is looking only for the vortex condition in the drain pipe. 
     SUMMARY OF THE INVENTION 
     The present invention provides a flow condition monitor system and method for a nuclear reactor that rely upon acoustic detection of various flow conditions, including the existence of condensible or noncondensible bubbles entrained in the fluid, the existence and level of a free surface, the existence of vortex or whirlpool formations, the existence of entrained solid particulates, and various other flow conditions. The system uses a database of the acoustic characteristics of known flow conditions, and a processor that compares the detected acoustic signals with the known characteristics of the various flow conditions being monitored. The processor uses various means of discrimination, such as altering or decaying the transmitted signal, to aid in the interpretation, comparison and identification of the flow conditions. 
     The acoustic detection is provided by at least one sensor, and preferably a plurality of sensors, positioned to receive acoustic signals from the fluid flow being monitored. The sensor or sensors can be passive acoustic sensors, such as sensitive microphones or accelerometers attached to the pipe. Alternatively, the sensors can be ultrasonic devices that include ultrasonic transmitters and receivers positioned to capture variations associated with the coolant flow. In still another alternative, the sensors can be laser devices that include a laser source and a laser receiver diametrically opposed on a pipe structure whereby variations associated with the coolant flow cause unique disruptions in the laser signal. 
     In one embodiment, a first sensor is positioned upstream from a second sensor a sufficient distance that attenuations in the signal and noise detected by the first sensor can be detected by the second sensor. The signals can then be processed and compared with the acoustic characteristics of known flow conditions to determine the flow condition being detected. The transmitter and receiver of the sensors can be positioned on opposite sides of the pipe in which the coolant is flowing, or on the same side of the pipe, depending on the particular conditions and location of the fluid flow being monitored. An arrangement of the transmitter and receiver on opposite sides of the pipe will allow the compressibility difference of the water and air at the air/water interface to be taken into account, while an arrangement of the transmitter and receiver on the same side of the pipe will capture the variation associated with the reflection from the interface. Various arrangements of the sensors are described below and are shown in the accompanying drawings. 
     According to a broad aspect of the present invention, a flow condition monitoring system is provided for monitoring fluid flow conditions in a nuclear power plant. The system includes: a first sensor assembly positioned near a fluid flow to be monitored, said sensor assembly having an output signal; a database containing known characteristics of various fluid flow conditions being monitored; and a processor means connected to said first sensor assembly and to said database for receiving and comparing the signal from the sensor assembly with the known characteristics contained in the database to determine a condition of the fluid flow. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     The present invention will become more clearly appreciated as the disclosure of the invention is made with reference to the accompanying drawings. In the drawings: 
     FIG.1 is a schematic drawing of a nuclear power plant having two steam generators with a shutdown cooling system and drain illustrated in connection with one of the steam generators. 
     FIG. 2 is an enlarged, fragmented schematic view of the hot leg and drain pipe of FIG. 1 with a flow condition monitoring system according to an embodiment of the present invention attached. 
     Fig. 3 is an enlarged, fragmented schematic view of the hot leg and drain pipe of FIG. 1 with a flow condition monitoring system according to another embodiment of the present invention attached. 
     FIG. 4 is an enlarged, fragmented schematic view of the hot leg and drain pipe of FIG. 1 with a flow condition monitoring system according to another embodiment of the present invention attached. 
     FIG. 5 is an enlarged, fragmented schematic view of the hot leg and drain pipe of FIG. 1 with a flow condition monitoring system according to another embodiment of the present invention attached. 
     FIG. 6 is an enlarged, fragmented schematic view of the hot leg and drain pipe of FIG. 1 with a flow condition monitoring system according to another embodiment of the present invention attached. 
     FIG. 7 is an enlarged, fragmented schematic view of the hot leg and drain pipe of FIG. 1 with a flow condition monitoring system according to another embodiment of the present invention attached. 
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     FIG. 1 illustrates a nuclear power plant incorporating the present invention. The numeral  10  generally designates a pressurized water reactor type of plant in which water is continuously transferred through a closed circulation loop between a reactor  12  and each of two steam generators  14  and  16 , respectively. 
     The water coolant from the reactor  12  flows through main pipes or hot legs  18  to the respective steam generators  14  and  16 , each of which has similar piping. 
     In the case of the steam generator  16 , for illustration, a coolant system circulation pump  20  circulates water, which has been cooled in the steam generator, through a suction leg pipe  22 , and back to the reactor  12  via a cold leg  24  and an inlet  26 . The shutdown cooling system drain pipe  28  intersects the lower region of the substantially horizontal main pipe or hot leg  18 . Within the lower region of the main pipe  18  is a vortex  30 . 
     Flow from the main pipe  18  into the drain pipe  28  forms the vortex  30  which creates cavitations in a drain pump  33  which has direct fluid communication from the main pipe  18  where it intersects with the lower region of the main pipe  18 . This vortex  30  inhibits the flow rate in the drain pipe  28  and the drain pump  33  by creating voids and cavitation  32 . The drain pump  33  discharges through a conduit  28 ′ to an auxiliary heat exchanger  34  downstream from the drain pump  33  for performance of the shutdown cooling system water cooling function. 
     From the heat exchanger  34  the water is directed by a valve  36  in a drain pipe section  28 ″ to a drain  38  or to a section of pipe  40  which is connected to the main pipe cold leg  24  for recirculation through the inlet  26  of the reactor  12  to cool the core during the shutdown period or in an emergency when the auxiliary heat exchanger&#39;s capacity is needed for safety reasons. 
     In FIG. 2, the enlarged vortex  30  is illustrated at the junction of the main pipe  18  and the drain pipe  28 . A typical level of coolant in main pipe  18  for midloop operation is designated by the numeral  31 . Entrained air from the vortex  30  creates voids and cavitation  32  in the drain pipe  28  and the pump  33 . Also shown in the fluid flow in FIG. 2 are entrained solid particulates  42  and entrained bubbles  44 , both of which can provide important indications of the operating conditions of the nuclear power plant  10 . The solid particulates  42  may include, for example, sand, metal flakes, dust particles, crystalline particles, and so forth, each of which has different acoustic characteristics as they bounce off one another or off the pipe wall. The entrained bubbles  44  may include noncondensible bubbles, such as air, helium or hydrogen, or condensible bubbles, such as steam vapor bubbles, each of which has different frequency variations and acoustic characteristics. 
     The flow condition monitor of the present invention uses acoustic or optical/laser detection equipment to search for and monitor various conditions of the coolant flow, including the existence of condensible or noncondensible bubbles  44  entrained in the coolant, the existence and level of a free surface  31 , the existence of vortex or whirlpool formations  30 , the existence of entrained solid particulate  42 , and various other conditions that affect the nuclear reactor. 
     The flow condition monitor  46  according to one embodiment of the present invention is shown in FIG.  2 . The flow condition monitor  46  includes a database containing a library of the predetermined acoustic characteristics of the various conditions to be monitored. The library is developed by simulating the various flow conditions and combinations of flow conditions that may arise in the nuclear power plant  10 , and recording the acoustic patterns that emanate from such flow conditions. A main processor  50  compares and matches signals from the acoustic detection equipment with the acoustic patterns of the known possible flow conditions contained in the database  48 . When the detected acoustic characteristics are matched with a predetermined characteristic, the detected flow conditions are communicated to the nuclear plant operator using a video display  52 , an audio signal, or other suitable communication means. 
     The acoustic measurements in the monitor  46  shown in FIG. 2 are obtained by first and second acoustic sensor assemblies  53 ,  54  each having a respective transmitter T 1 , T 2  and receiver R 1 , R 2  positioned near the coolant flow. The first sensor assembly  53  includes an ultrasonic transmitter T 1  and receiver R 1  positioned near the main pipe  18  at a location upstream of the drain pipe  28 . The second sensor assembly  54  includes an ultrasonic transmitter T 2  and receiver R 2  positioned near the drain pipe  28  downstream of the top opening  28 ′ of the drain pipe  28 . The acoustic signals detected by the receivers R 1 , R 2  are filtered by suitable signal filters  55 ,  56  to remove unwanted noise, and are then inputted to the main processor  50 . 
     Although there is a possibility that many or all flow conditions being monitored in the nuclear power plant  10  could exist simultaneously, that possibility is remote. More likely is a combination of the flow conditions that can be anticipated in advance and simulated to provide a corresponding acoustic pattern to be stored in the database  48  for such combination of flow conditions. Since the acoustic signals from the various flow conditions are sometimes similar in amplitude and frequency, other means of discrimination, such as the alteration or decay of the transmitted signal, can be implemented by the processor  50  to aid in the interpretation. 
     Since sound is associated with density and pressure fluctuation, a steady, low Reynolds number flow, such as a laminar flow, may not generate sound. Turbulence or some other periodic or vibratory excitation, such as vortex shedding downstream of an obstacle in the example laminar flow field, might be necessary in some cases to generate acoustic patterns or signatures that may be detected. 
     Acoustic emission from noncondensible bubbles requires an excitation. This excitation may be a consequence of the generation of the bubbles or a pressure disturbance caused by an obstacle in the flow field or eddies or turbulence in the coolant flow. For the ideal case of a Rayleigh bubble, the frequency of the resulting oscillation, which may be perceived as an acoustic propagation through the fluid, may be expressed by a simple relationship of the undisturbed size of the bubble, the density and distant pressure of the coolant, the specific heats of the noncondensible gas, and the acceleration of gravity. For a condensible bubble, the frequency may not be so simply expressed, but the vapor bubble, if it persists, would exhibit a vibratory response that propagates through the coolant as an acoustic signal. Sensitive microphones have the capability to measure the frequency and pressure amplitude of condensible and noncondensible bubble oscillations. 
     The free surface of a confined flow does not generate noise unless the surface has been disturbed by turbulence, eddies, waves, or bubbles. The acoustic characterization of the confined free surface flow associated with the reactor coolant system hot leg piping  18  may be empirically determined from model or full scale testing. A sensitive microphone may be sufficient for this purpose. During shutdown cooling, the existence of a free surface flow in the hot leg piping  18  is expected, and knowledge of the level of the free surface  31  is essential to preventing generation of a gas core in the exit vortex  30  to the shutdown cooling system. Although empirically determined acoustic characteristics of the turbulent coolant flow may be sufficient to interpret the level, the acoustic alteration of a sonic signal by reflection or transmission through the free surface  31  provides more definitive information for measurement of the level. Thus, the sensor assemblies  53 ,  54  in the FIG. 2 embodiment each use a sonic pulse or ultrasonic transmitter T 1 , T 2  and a microphone receiver R 1 , R 2  as the source of information necessary to characterize the fluid flow conditions. 
     The frequency of the important physical phenomena is mostly in the audible range. The emission frequencies of the transmitters T 1 , T 2  are preferably selected to be most modified in frequency or phase by the physical phenomena. In the embodiment of FIG. 2, each sensor assembly  53 ,  54  has a single transmitter and receiver. However, it may be desirable to include a pair of transmitters and receivers for each sensor assembly to take advantage of the compressibility difference of the water and air at the air/water interface such that the level may be better interpreted. Furthermore, the orientations of the transmitters and receivers are shown in FIG. 2 to take advantage of the change in transmission through the interface at the free surface  31 . 
     During shutdown cooling, the coolant flow is drawn from the hot leg  18 . Since the hot leg pipe  18  is not completely filled with water, the air/water interface  31  forms, as shown in FIG.  2 . At high water levels, eddies, without the presence of a vortex, may form in the upper end  28 ′ of the drain pipe  28 . These eddies have periodic shedding from the edge of the opening, which is an audible phenomena with a different frequency than the turbulent eddies  57  formed at low water levels which have a smaller length scale. Another flow possibility is the formation of a filled central vortex in the drain pipe  28 . This causes an acceleration of the flow which will likely increase fluid shear with an accompanying increase in eddying and turbulence. This flow condition will have a different and unique acoustic signature. At reduced water levels, an air core will be present in the inlet vortex. This core may extend deep into the drain pipe  28  and break up with the resulting entrainment of air into the flow to the drain pump  33 . Detection of these latter conditions is possible through the monitoring of bubble oscillations, the increase in turbulence activity, and/or the sensing of the core air/water interface as mentioned above. 
     Under extreme conditions, solid particulates  42  may enter the flow stream. Solid particles  42  in the flow will have still a different acoustic signature as a consequence of eddies occurring in front of the particles, particle-to-particle contact, and particle-to-metal contact. 
     An alternative embodiment of the flow condition monitor  60  of the present invention is shown in FIG.  3 . The arrangement shown in FIG. 3 is similar to that shown in FIG. 2, except that the two sensor assemblies  61 ,  62  are both positioned upstream of the drain pipe opening  28 ′. This arrangement of sensor assemblies  61 ,  62  will detect somewhat different acoustic patterns than the arrangement shown in FIG. 2, but will otherwise operate in substantially the same manner. The arrangement shown in FIG. 3 can also be used to monitor flow conditions in a straight section of pipe remote from the drain pipe opening  28 ′. 
     Another alternative embodiment of the flow condition monitor  65  of the present invention is shown in FIG.  4 . The arrangement shown in FIG. 4 is similar to that shown in FIG. 3, except that a single transmitter T 1  provides an acoustic disturbance which is detected by both of the receivers R 1 , R 2 . The upstream receiver R 1  provides information about the magnitude and frequency of the original disturbance, while the downstream receiver R 2  determines how the disturbance attenuates with distance, thereby allowing the system to better determine where the acoustic disturbance is coming from. 
     Another alternative embodiment of the flow condition monitor  70  of the present invention is shown in FIG.  5 . The arrangement shown in FIG. 5 is similar to that shown in FIG. 3, except that the transmitter T 2  of the second sensor assembly  72  is placed on an opposite side of the pipe  18  from the transmitter T 1  of the first sensor assembly  71 . This arrangement will detect somewhat different acoustic patterns than the arrangement shown in FIG. 3, but will otherwise operate in substantially the same manner. The arrangement shown in FIG. 5 can also be used to monitor flow conditions in a straight section of pipe remote from the drain pipe opening  28 ′. 
     Another alternative embodiment of the flow condition monitor  80  of the present invention is shown in FIG.  6 . The arrangement shown in FIG. 6 is similar to that shown in FIG. 3, except that the transmitters T 1 , T 2  of each sensor assembly  81 ,  82  are placed on the same side of the pipe  18  as the receivers R 1 , R 2  of each sensor assembly  81 ,  82 . This arrangement will provide better information in some circumstances by capturing the variation associated with reflection from the air/water interface at the free surface  31 . 
     The acoustic sensor technology for the embodiments of the present invention described above is available commercially. So-called loose part monitors, which are typically located on the reactor vessel and steam generators, have sufficient sensitivity to listen to acoustic emissions from a reactor coolant pump. In addition, ultrasonic cross flow monitors apply the delay of the modification of an ultrasonic signal by turbulent eddies using pairs of transmitters/receivers mounted some distance apart to interpret the coolant flow rate. 
     Another alternative embodiment of the flow condition monitor  85  of the present invention is shown in FIG.  7 . The arrangement shown in FIG. 7 is similar to that shown in FIG. 2, except that the sensor assemblies  86 ,  87  are laser/optical sensor assemblies. Each sensor assembly includes a laser beam source L 1 , L 2  and a laser beam detector D 1 , D 2 . The laser beam source L 1 , L 2  and detector D 1 , D 2  components penetrate the main pipe  18  and the drain pipe  28  and cause respective laser beams  88 ,  89  to pass through the fluid flowing within the pipes  18 ,  28 . The optical disruption patterns in the laser beam signals are filtered by signal filters  90 ,  91  and processed in much the same way as the acoustic patterns of the other types of sensor assemblies described above. The optical disruption patterns are processed by the processor  92  to compare and match the detected patterns with the predetermined patterns contained in the database  93  corresponding to known flow conditions. The determined flow conditions are then communicated to the nuclear plant operator using a video display  94  or other suitable communication means. 
     The flow condition monitor of the present invention has applications other than monitoring the coolant flow conditions in the drain pipe of a pressurized water reactor. For example, the sensor assemblies can be attached to the main pipe immediately downstream of the reactor to provide useful information about the condition of the reactor coolant flow following an accident situation. The flow condition monitor may also provide useful information in connection with the chemical volume control systems, the steam components on the secondary side of PWR reactors, and various fluid flow systems in boiling water reactors. 
     It will be appreciated that the present invention is not limited to the exact constructions that have been described above and illustrated in the accompanying drawings, and that various modifications and changes can be made without departing from the scope and spirit of the invention. It is intended that the scope of the invention only be limited by the appended claims.