APPARATUS AND METHOD FOR CUSTOMIZING REPLACEMENT UPPER CORE PLATE INSERTS OF A NUCLEAR REACTOR

Abstract: The apparatus comprises a circular gauge plate (51) which has: (a) a diameter corresponding substantially to the diameter of the upper core plate of the reactor to be gauged; (b) U-shaped peripheral gauging slots (55) of known size for receiving, with clearance, the guide pins (33) for the lower internals of the reactor; (c) means (57) for positioning the gauge plate within the core barrel (11) at the normal elevation of the upper-core-plate inserts and the guide pins; (d) means (59, 63) for positioning the gauge plate relative to the reactor baffle-plate arrange­ ment (25); and, (e) means (63) for determining the actual positior of the gauge plate relative to the baffle plates (27). Utilizing the means (c) and (d) above, the gauge plate is accurately positioned in a core barrel (without the upper internals therein) such that it rests upon the upper ends of the baffle plates and the guide pins extend into the respective gauging slots, whereupon the clearances between the gauge plate and the core barrel, and between the sides of each gauging slot and the adjacent sides of the guide pin therein, are measured (85, 87, 89) and the actual position of the gauge plate relative to the baffle plates is determined (means e ), the measurements and actual-position data being made available for use in customizing the replacement upper-core-plate inserts.

Description: The present invention relates to an apparatus for determining and measuring the actual locations of the guide pins for the lower internal structure in a nuclear reactor vessel for use in customizing a replacement upper internals structural package, and to a method of using this apparatus. More particularly, the invention relates to an apparatus, and a method of using same, whereby the actual position and dimensions of the existing guide pins in the barrel of a nuclear reactor vessel for the lower internal structure can be determined so that the conventional inserts for the upper core plate which mate with these guide pins can be customized to the required close tolerances when the upper internals structural package for an existing nuclear reactor is replaced. In a liquid cooled nuclear reactor, the internal structure of the core barrel generally includes, in addition to the core itself, an upper internals structural package which is installed and can be removed as a unit, and a lower internals structure which is axially aligned with the upper internals structural package. To ensure that the upper and lower internals structures are correctly oriented and aligned with one another, the inner surface of the core barrel is provided with a plurality, usually four, symmetrically disposed guide pins which are fixedly aligned with the lower internal structure, and which extend radially inward from the inner wall of the core barrel and engage in respective slots formed in the peripheral surface of the upper core plate which, in turn, forms the lowermost portion of the upper internals structural package. In view of the relatively close tolerances required for the orientation of the upper and lower internal structures, it is customary to machine the surfaces of the peripheral slots in the upper core plate to general, relatively large tolerances relative to the guide pins, and then to customize the upper core plate to the actual position and size of the guide pins by providing each of the peripheral slots of the upper core plate with an insert which has been finely machined to provide the desired small clearances, e.g. 0.13 mm, based on actual clearance measurements. In order to take these measurements when the reactor is initially being built at the factory, the upper internals structural package or unit, or at least the portion of same which is necessary to properly position the upper core plate, is placed in the core barrel and properly aligned with the lower internal structure including the baffle plate arrangement which surrounds the area in which the core is located. Thereafter, the various clearances between the surfaces of the peripheral slots in the upper core plate and the adjacent surfaces of the respective guide pins are actually measured by an individual, and then the upper internals structural package is removed from the core barrel. Thereafter, the actual measurements taken are used to machine the relatively small inserts which are then positioned and fastened in the respective peripheral slots of the upper core plate so as to customize the core plate to the actual positions of the lower internal structure. Although the above technique is satisfactory when building a new reactor, a number of significant problems are encountered when it is necessary to replace the upper internals structural package of a reactor which has been in use for some time. First of all, since the reactor vessel, including the core barrel with its guide pins and the fixed portions of the lower internal structure, e.g., the baffle plate arrangement, is no longer located at the factory, it would be extremely difficult, time-consuming and expensive (particularly in view of the large size and weight of even the upper core plate which, for example, weighs in the order of 13-1400kg for a typical reactor) to ship the upper core plate, or a sufficient portion of the upper internals structural package, to the situs of the reactor, to take the necessary measurements, return the upper core plate to the factory for customizing, and then return the completed package to the reactor for ultimate installation. Moreover, since the reactor vessel of a previously operating reactor is somewhat radioactive wherefore it is customary to flood it with water during the replacement or refitting period, it would be very difficult and extremely dangerous for an individual to take the measurements needed to customize the new upper core plate to the existing guide pins in the core barrel. It is the object of the invention to provide ways and means for taking the measurements necessary for the customization of a replacement upper core plate, and in particular the upper core plate inserts for the peripheral guide slots, without requiring the use of the actual upper core plate for such measurements. The invention achieves this object by providing a gauge plate for use in customizing replacement upper core plate inserts of a nuclear reactor of the type including a pressure vessel, a core barrel disposed within the pressure vessel, a lower internal structure disposed in the core barrel and including a baffle plate arrangement, and an upper internals structural package having an upper core plate at its lower end, with the upper core plate being provided with a plurality of peripheral grooves, each including an insert machined to close tolerances, for engaging respective approximately rectangular shaped guide pins extending radially inwardly from the inner surface of the core barrel for aligning the upper internal structural package relative to the lower internal structure; wherein the gauge plate comprises a circular metal plate of a known diameter corresponding substantially to that of the upper core plate of the nuclear reactor to be gauged; a plurality of U-shaped gauging slots formed in the peripheral surface of the gauge plate and extending between its major surfaces, the gauging slots being formed at locations corresponding to the respective locations of the guide pins of the reactor vessel to be gauged and being of a known size sufficient to receive the respective guide pins with clearance on all sides; first means for positioning the gauge plate within the core barrel of the nuclear reactor vessel to be gauged, and while the latter contains the baffle plate arrangement but not the upper internals structural package, at the normal elevation of the upper core plate inserts and the guide pins; second means, disposed on the gauge plate, for positioning the gauge plate relative to the baffle plate arrangement of the reactor to be gauged; gauge means for the gauge plate for determining the actual position of the gauge plate relative to the baffle plate arrangement; and remotely controlled measuring means disposed on the gauge plate for measuring the respective clearances between each of the U-shaped gauging slots and the adjacent surfaces of a respective guide pin and the clearance between the peripheral surface of the gauge plate and the inner surface of the core barrel adjacent each gauging slot, and for providing an indication of the measured clearances at a remote location. Preferably, the gauge plate has a thickness substantially less than that of the upper core plate of the reactor, and is provided with cutouts in its inner portion in order to reduce its weight and to permit it to be more easily lowered through water. According to the preferred embodiment of the invention, the first means comprises a plurality of support pads disposed on one major surface of the gauge plate and positioned so as to be able to rest on the upper end of the baffle plates of the baffle plate arrangement of the reactor in which said gauge plate is to be used, the support pads being of the thickness so as to position the gauge plate at the elevation of the interface of the upper core plate inserts and the guide pins when the pads are resting on the upper ends of the baffle plates, and the second means comprises a plurality of positioning pins extending from the above-mentioned major surface of the gauge plate, the positioning pins being located on the gauge plate at respective positions corresponding to the outermost positions of the fuel assembly top nozzles of the reactor, and with each positioning pin being of a length such that it can extend into the area enclosed by the baffle plate arrangement when the gauge plate is resting on the upper ends of the baffle plates. Moreover, the gauging means preferably include a plurality of gauging holes extending through the gauge plate for receiving gauge pins, the gauging holes being located at positions corresponding to the expected positions of respective baffle plates of the reactor in which the gauge plate is to be used. According to the method of the invention, the actual dimensions of the lower internals guide pin locations of a nuclear reactor vessel are measured by positioning the gauge plate embodying the invention in a nuclear reactor vessel core barrel containing a baffle plate arrangement, but with the upper internals structural package removed, such that the gauge plate rests on the upper end of the baffle plate arrangement, with the lower internal structure guide pins of the reactor vessel extending into the gauging slots of the gauge plate, and with the positioning pins of the gauge plate properly positioned relative to the baffle plate arrangement; and then, at each of the gauging slots and with the gauge plate in the same position, (a) measuring the difference between the peripheral surface of the gauging plate and the inner surface of the reactor barrel, and (b) measuring the clearance between each of the three sides of the U-shaped gauging slot and the adjacent side of the associated guide pin; and, with said gauge plate in the same position, determining the actual position of the gauge plate relative to the existing baffle plates by inserting gauging means into each of the gauging holes. According to the preferred embodiment of the method, wherein the gauging plate includes at least three gauging holes two of which are located at positions corresponding to the positions of two adjacent baffle plates and the third one of which is located at a position corresponding to a baffle plate diametrically opposite one of the two adjacent baffle plates, and wherein the center line of each of the gauging holes is displaced by a common given dimension from the expected position of the upper edge of the respective baffle plate in a direction perpendicular to the inner surface of the respective baffle plate, the actual position of the gauge plate relative to the baffle plates is determined by inserting gauge pins of known size into the gauging holes until the inner surface of the respective baffle plate is located. Preferably, gauge pins of known different sizes are successively inserted into one of the gauge holes to determine the largest diameter gauge pin which can be inserted, and then, with this largest diameter gauge pin inserted in its respective gauge hole, the sequence of successively inserting gauge pins is carried out for each of the other gauge holes. The step of determining the actual position of the gauge plate relative to the baffle plates is carried out before the measurements are taken at the respective gauging slots. A preferred embodiment of the invention will now be described, by way of example, with reference to the accompanying drawings, in which: Figure 1 is a simplified cross-sectional schematic of a nuclear reactor vessel with the top closure or head assembly removed and showing the positioning of the gauge plate according to the invention; Figure 2 is a schematic plan view of the gauge plate which shows the relationship of the latter with respect to the lower internals guide pins and to the underlying baffle plates; Figure 3 is a partial plan view showing one peripheral groove in an upper core plate together with an upper core plate insert the dimensions of which are to be customized by using the gauge plate according to the invention; Figure 4 is a schematic partial side view illustrating the use of gauge pins to determine the position of the baffle plate relative to the gauge plate; and Figure 5 is an enlarged schematic view illustrating the measurements to be taken adjacent each peripheral groove of the gauge plate. Referring now to the drawings, and in particular Figure 1, there is shown an elongate, generally cylindrical nuclear reactor vessel 1 of conventional design for use in a pressurized-water nuclear reactor system. The vessel 1 has the usual hemispherical bottom 3, at least one cooling water inlet nozzle 5, and at least one cooling water outlet nozzle 7. The vessel 1 forms a pressurized container when sealed at its open end 9 by means of a head assembly (not shown). Disposed within the vessel 1 is a cylindrical core barrel 11 which is suspended from an inwardly extending flange 13 of the vessel 1. The core barrel 11 includes a bottom forging 15 having a plurality of projections 17 disposed thereon about its circumference and which cooperate with a corresponding number of key members 19 on the vessel 1 to stabilize the core barrel 11 in the circumferential and radial directions. Mounted within the core barrel 11 near its lower end, and supported therein by means of connecting elements 21 on the inner wall of the core barrel 11, is a lower core plate 23 on which rest the nuclear reactor core (not shown) and the lower internals structure of the reactor. Of the lower internals structure, the only element shown in Figure 1 is the baffle plate arrangement or baffle structure 25 formed of a plurality of individual interconnected baffle plates 27. The baffle plate structure 25 is connected to the core barrel 11 by spacer plates 29, and it normally contains and surrounds the nuclear reactor core. As shown more clearly in Figure 2, the baffle plate structure 25 has a cross-sectional configuration corresponding to that of the reactor core made up of the various fuel assemblies each of which is generally rectangular in cross-section. Normally, the space within the core barrel 11 above the baffle plate arrangement 25 contains the upper internals structural unit which is simply suspended within the core barrel 11 in a conventional manner by having its upper end, which is constituted by an upper support plate (not shown), supported from the upper flange 31 of the core barrel 11. In order to accurately align the upper internals structural unit with the lower internals in both the circumferential and radial directions, the upper core plate (not shown in Figure 1), which forms the lower end or bottom of the upper internals structural unit, is provided with a plurality of symmetrically disposed peripheral grooves which are engaged with a like plurality of guide pins 33 extending from the inner wall of the core barrel 11 radially inward at the normal elevation of the upper core plate. The guide pins 33 are fixed to the inner wall of the core barrel 11 so that they have a defined relationship with respect to the lower internals structure of the reactor vessel and, in particular, with respect to the baffle structure 25. As indicated above, in order to provide compensation for the various possible machining and positioning tolerance values and in order to ensure accurate alignment between the upper internals structural unit and the lower internals structure, each of the peripheral guide or alignment grooves in the large upper core plate, which are machined to relatively large tolerance values, has associated therewith a relatively small insert, such as the insert 39 shown in Fig. 3, which is machined to the actual required tolerance values on the basis of actual measurements, and provides the actual bearing or guide surfaces between the associated guide pin 33 and the upper core plate. As seen from Figure 3 showing a portion of the upper core plate 35 with one of its peripheral guide grooves 37, each of which extends between the two major surfaces of the core plate 35 and has substantially larger dimensions, in both the circumferential and the radial directions, than the dimensions of the associated guide pin 33 (Fig. 1), the core plate insert 39 for the groove 37 has a flange portion 41 which extends from the groove 37 laterally along the bottom surface of the upper core plate 35 and is secured to the latter by means of screws 43, and an insert portion which is actually disposed within the groove 37 in that it extends upwards from the flange portion 41 and between the two major surfaces of the upper core plate 35. The insert portion is provided with a generally U-shaped groove defined by two accurately machined guide surfaces 45 and 49, the spacing between which is determined on the basis of actual measurements of a corresponding guide pin 33 relative to a corresponding slot 37 and is such that the two surfaces 45 and 49 bear against the lateral surfaces of the generally rectangular guide pin 33 so as to accurately position the core plate 35 in the circumferential direction while similar surfaces oriented at 90° relative to the surfaces 45 and 49 serve to accurately position the upper core plate 35 in the radial direction. Of course, although only one peripheral guide groove 37 and its insert 39 are shown, it should be understood that the upper core plate 35 has several such grooves 37 with inserts 39 symmetrically disposed about is circumference. In the particular embodiment illustrated, there are four guide grooves 37 and inserts 39 disposed on the orthogonal or cardinal axes of the upper core plate 35; i.e., each groove 37 is displaced from the two adjacent grooves by 90° relative the center of the plate 35. For taking the measurements necessary to customize the inserts 39 for use thereof with a replacement upper core plate, the invention provides a gauge plate 51, as shown in section in Figure 1 and in plan view in Figure 2, which is formed of metal, such as 304 stainless steel, for example. The gauge plate 51 has an outer diameter corresponding to that of the upper core plate to be replaced, but is of much less thickness and therefore of much less weight than the upper core plate. For example, whereas the upper core plate typically may have a thickness of 7.62 cm, the gauge plate 51 may have a thickness in the order of only 1.9 cm. In order to reduce the weight of the gauge plate 51 still further, and also to facilitate lowering of the gauge plate through the body of water in which the reactor vessel is normally submerged during the replacement or refitting period, the inner portion of the circular gauge plate 51 is provided with cut-out sections 53. As shown in Figure 2, the gauge plate 51 has in its periphery four U-shaped gauging slots 55 which are located on the cardinal axes of the gauge plate 51 and positioned to coincide with the locations of the guide pins 33 for the lower internal structure. The gauging slots 55 are of a known size and location relative to one another, and they are wide enough to receive the guide pins 33 with sufficient clearance therebetween. For example, the slots 55 may be approximately 7.16 cm wide which, in a typical installation, would allow for an approximately 0.15 cm gap between their walls and the respective guide pins 33 received in the gauging slots 51. Since, as indicated above, the gauge plate 51 is substantially thinner than the upper core plate, it is necessary to provide some means for positioning the gauge plate 51 at the elevation of the guide pins 33 within the core barrel 11. According to the preferred embodiment of the invention as illustrated, the vertical positioning means used for this purpose are several, and preferably at least three, pads 57 of metal, for example, stainless steel, which are disposed on the lower surface of the gauge plate 51 and so positioned thereon as to rest on the upper ends of the baffle plates 27 when the gauge plate 51 is inserted into the core barrel 11. The pads 57 have a thickness, e.g., 2.86 cm, such as to place the gauge plate 51, hence its gauging slots 55, at the elevation of the guide pins 33 when the pads 57 are resting upon the upper of the baffle plate structure 25, as shown in Figure 1. In addition to positioning the gauge plate 51 relative to the guide pins 33, it is also necessary to accurately position it relative to the baffle plate arrangement 25. For this purpose, the gauge plate 51 is provided with a plurality of positioning pins 59 which project from the lower major surface of the gauge plate 51, i.e. from the same major surface having thereon the pads 57, in a direction perpendicular thereto. The positioning pins 59 on the plate 51 are at locations corresponding to the outboard or outermost positions of the fuel-assembly top nozzle locations in the upper core plate so as to simulate such positions, and they are of sufficient length, e.g., 10.16 cm, to extend into the area delimited by the baffle plate arrangement 25 when the gauge plate 51 is resting upon the upper end surfaces of the baffle plates 25. As shown, there are eight such positioning pins 59 arranged in four pairs, with two pairs of positioning pins 59 diametrically opposed to one another along each of the two cardinal or orthogonal axes of the gauge plate 51, and with the positioning pins 59 of each pair symmetrically disposed with respect to the associated cardinal axis. As seen from Figure 2, the eight positioning pins 59 are in fact disposed in the respective outermost corners 61 formed between adjacent baffle plates 27, the individual positioning pins 59 being located on the gauge plate 51 such that they will, based upon the original drawings of the particular nuclear reactor being gauged, provide an expected, very small nominal clearance, for example in the order of 0.028 to 0.03 cm, with each of the baffle plates 27 forming the respective corners 61. Finally, in order to permit determining the actual position of the existing baffle plate arrangement 25 relative to the gauge plate 51, the gauge plate is provided with a plurality of gauging holes 63, which are located at positions corresponding to the expected actual as-built locations of respective baffle plates 27. The gauging holes 63 extend completely through the gauge plate 51, and they are of a sufficient diameter for a gauging device to be inserted through each of them in order to accurately locate the actual position of the inner surface of the associated baffle plate 27. Although it is possible to provide such gauging holes 63 for a substantial plurality of the baffle plates 27, preferably at least three such gauging holes 63, distributed as shown in Figure 2, are provided. As seen from Figure 2, two of the gauging holes, designated 63′ and 63′′, are associated with the baffle plates 27 forming one outermost corner 61, and the third gauging hole 63 is associated with the baffle plate 27 diametrically opposed to one of the two baffle plates 27 associated with the pair of gauging holes 63′ and 63′′, the single gauging hole 63 preferably being associated, as shown, with a baffle plate 27 which extends generally radially. According to the preferred embodiment of the invention, the gauging device used with the gauging holes 63 in order to determine the actual position of the inner surface of the respective baffle plates 27 is a step gauge pin 65 (Figure 4) which includes a cap 67, a collar 69 of the same diameter as the gauging hole 63, and a lower pin portion 70 of a known gauging diameter. To take the measurements, a plurality of pins 65 with different known diameter portions 70 are provided. Alternatively, a single step gauge pin 65 with a plurality of successive different diameter portions 70 may be utilized. In any case, in order to utilize the step gauge pin 65 as a "go no-go" type gauge, each of the gauging holes 63 is positioned relative to its associated baffle plate 27 so that the center line of the gauging hole 63 is displaced or offset, by a given known amount, from the expected location of the inner surface of the associated baffle plate 27 in a direction perpendicular to this inner surface. More particularly, the center line of each gauging hole 63 is offset by a distance equal to the radius of a desired-size step gauge pin portion 70 so that if, for example, the center line of the gauging hole 63 is offset by 1.27 cm, the gauge plate 51 will be in the optimum or best position relative to the associated baffle plate 27 if a gauge pin with a portion 70 having a diameter of 2.54 cm can be inserted into a gauging hole 63, but a gauge pin with a diameter of 2.67 cm cannot be inserted. To utilize the above-described gauge plate 51 for its intended purpose, the gauge plate 51 is lowered into the core barrel 11, for example, by means of an overhead crane, until its pads 57 rest on the upper end surfaces of the baffle plate arrangement 25. During the lowering procedure, the gauge plate 51 is oriented so that, when it is at rest, the guide pins 33 extend into the respective gauging slots 55 and the positioning pins 59 extend into the respective corners 61 formed by adjacent baffle plates 27. Thereafter, the desired measurements at each of the gauging slots 55 and at each of the gauging holes 63 is carried out with the gauge plate 51 remaining in the same position. Preferably, in order to clearly establish a reference position for the gauge plate 51 relative to the baffle plate arrangement 25, the measurements at the respective gauging holes 63 are carried out before the measurements at the respective gauging slots 55. More specifically, at each of the gauging holes 53, a step gauge pin 65 with the standard or desired diameter portion 71 is inserted into a respective gauging hole 63, and if it can be inserted, an attempt is made to insert the next larger diameter step gauge pin 65, and so forth, until the step gauge pin with the largest diameter which can be inserted into the gauging hole 67 is determined and noted. This procedure is repeated for each of the gauging holes 63, the largest diameter step gauge pin 65 which can be inserted preferably being allowed to remain in the respective gauging hole 63 so as to firmly fix the position of the gauging plate 51 relative to the baffle plate arrangement 25. Thereafter, the desired measurements are taken at each of the gauging slots 55. As illustrated in Figure 5, four measurements are taken at each of the gauging slots 55. More specifically, using the known outer diameter of the gauge plate 51 as a reference, the inner diameter of the core barrel 11 at the elevation where it interfaces with the upper core plate is determined by measuring the gap or distance 71 between the periphery of the gauge plate 51 and the inner surface of the core barrel 11. Additionally, the two radial gaps 73 and 75 between the respective radially extending surfaces 77 and 79 of the generally U-shaped gauging slot 55 and the respective adjacent lateral surfaces of the guide pin 33 are measured and recorded. Finally, the circumferential gap 81 between the circumferential gauging surface 83 of the gauging slot 55 and the end surface of the guide pin 33 is measured and recorded. The measurements of the gaps 71, 73, 75 and 81 are carried out at each of the four gauging slots 55 of the gauge place 51. Since all of the dimensions of the gauge plate 51 are accurately known, the measured data, as indicated above, can be used to customize the inserts for the replacement upper core plate so that the replacement upper internals structural unit will be compatible with the existing lower internals structure in an operating nuclear reactor plant. Moreover, as can easily be appreciated, since all of the dimensions of the gauge plate 51 are accurately known prior to the measurements, the gauge plate 51 itself need not even be returned to the factory where the replacement parts are being manufactured. That is, all that need be sent to the factory is the results of the various measurements. As indicated above, during the replacement or refitting period of the nuclear reactor, as well as during the measuring process with the gauge plate 51, the reactor vessel 1 is normally submerged in water in order to provide protection against radioactivity. Accordingly, it is desirable for all of the measurements indicated above to be controlled and/or read out from a remote location. This can be accomplished, for example, by means of remotely controlled robot arms (not shown), such as well known in this art, and/or by means of conventional remotely controlled linear measuring instruments disposed on the gauge plate 51 or on a remotely controlled robot arm. According to the preferred mode of carrying out the method according to the invention, the insertion of the step gauge pins 65 is carried out by a remotely controlled robot arm, while the measurements of the gaps 71, 73, 75 and 81 at each gauging slot 55 are carried out by respective sets of four measuring devices which are appropriately mounted at known positions on a major surface of the gauge plate 51. More particularly, and as shown in Figures 1 and 2, respective sets of measuring devices 85, 87, 89 and 91 are mounted at known positions on the upper surface of the gauge plate 51 adjacent each of the gauging slots 55. Each of the measuring devices 85, 87 and 89 is disposed adjacent, and has its longitudinal axis perpendicular to, a respective one of the surfaces 77, 83 and 79 of the associated slot 55 so as to measure the respective gaps 73, 81 and 75 between the respective slot surfaces and the adjacent surfaces of the guide pin 33. The remaining measuring device 91 of each set is disposed adjacent the peripheral surface of the gauge plate 51 and has its longitudinal axis extending in a radial direction so as to measure the gap 71 between the peripheral surface of the gauge plate 51 and the adjacent inner surface of the core barrel 11. The measuring devices 85, 87, 89 and 91 may, for example, each simply be a spring loaded plunger which, when released from a remote location, will move forward until it rests against a respective one of the three measuring surfaces of the associated guide pin 33 (devices 85, 87, 89) and against the inner surface of the core barrel 11 (device 91) and remains locked in that position. The actual dimensions of the various gaps are then determined by manually measuring the positions of sixteen plungers, for example, by means of a micrometer, after the gauging plate 51 has been removed from the reactor vessel 1. Preferably, however, measuring devices 85, 87, 89, 91 are provided which can be remotely controlled and will additionally produce a direct remote readout of the measured clearances. For example, each of the measuring devices 85, 87, 89 and 91 can be a spring loaded plunger provided with an electrical position sensor which produces an electrical signal proportional to the distance moved by the respective plunger and which is individually connected to a remotely located control and indicator circuit 93 via respective wires of a multi-conductor cable 95, such as shown schematically in Figure 1. It is of course understood that the position of the circuit 93 in Figure 1 is schematic only and in reality would be located outside the reactor vessel 1 and at a safe distance therefrom.

Claims: Apparatus for use in customizing replacement upper core plate inserts of a nuclear reactor of the type including a pressure vessel (1), a core barrel (11) disposed within the pressure vessel, a lower internal structure disposed in the core barrel and including a baffle plate arrangement (25), and an upper internals structural package having, at its lower end, an upper core plate (35) provided with a plurality of peripheral grooves (37) each containing an insert (39) machined to close tolerances for engaging a respective one of a plurality of substantially rectangular guide pins (33) which extend from the inner surface of the core barrel radially inward for cooperation with said grooves in aligning the upper internals structural package relative to the lower internal structure, characterized in that said apparatus is a gauge plate comprising a circular metal plate (51) of a diameter corresponding substantially to the diameter of the upper core plate of the nuclear reactor to be gauged; a plurality of U-shaped gauging slots (55) formed in the peripheral surface of said gauge plate and extending between the major surfaces thereof, said gauging slots being formed at locations corresponding to the respective locations of the guide pins (33) of the reactor to be gauged and being of a size sufficient to receive the respective guide pins with clearance on all sides; first means (57) for positioning said gauge plate within the nuclear-reactor vessel to be gauged, while the latter contains the baffle plate arrangement (25) but not the upper internals structural package, at the normal elevation of the upper core plate inserts and the guide pins; second means (59), disposed on said gauge plate, for positioning said gauge plate relative to the baffle plate arrangement (25) of the reactor to be gauged; and gauge means (63) in said gauge plate for determining the actual position of the gauge plate relative to the baffle plate arrangement. Apparatus according to claim 1, characterized in that said gauge plate (51) has a thickness substantially less than the thickness of the upper core plate (35) of the reactor. Apparatus according to claim 1 or 2, characterized in that said first means comprises a plurality of support pads (57) disposed on one major surface of said gauge plate (51) and positioned so as to be able to rest on the upper end of the baffle plates (27) of the baffle plate arrangement (25) of the reactor in which the gauge plate (51) is to be used, said support pads having a thickness such as to position the gauge plate at the elevation of the interface of the upper core plate inserts and the guide pins when said pads are resting on the upper ends of the baffle plates. Apparatus according to claim 3, characterized in that said second means comprises a plurality of positioning pins (59) extending from said one major surface of the gauge plate (51) and located thereon at positions corresponding to the outermost positions of fuel-assembly top nozzles of the reactor, each of said positioning pins having a length such as to extend into the area enclosed by the baffle plate arrangement (25) when the gauge plate is resting on the upper ends of the baffle plates (27). Apparatus according to claim 4, characterized in that said positioning pins (59) are arranged in four pairs, two of said pairs being located along each of the cardinal axes of the gauge plate (51) so as to be diametrically opposed to each other, and the positioning pins of each pair being symmetrically disposed with respect to the associated cardinal axis. Apparatus according to claim 4 or 5, characterized in that said gauge means includes a plurality of gauging holes (63) extending through said gauge plate (51) and adapted to receive gauge pins (65), said gauging holes being located at positions corresponding to the expected positions of respective baffle plates (27) of the reactor in which the gauge plate is to be used. Apparatus according to claim 6, characterized in that said gauging holes (63) are located at positions corresponding to the expected positions of respective baffle plates (27) which cooperate with said positioning pins (59) to position said gauge plate (51). Apparatus according to claim 6 or 7, characterized in that there are three of said gauging holes (63, 63′, 63′′) two (63, 63′′) of which are located at positions corresponding to the positions of two adjacent baffle plates (27), and the third one (63) of which is located at a position corresponding to a baffle plate (27) diametrically opposite one of said two adjacent baffle plates. Apparatus according to claim 8, characterized in that the center line of each of said gauging holes (63) is displaced by a common given dimension from the expected position of the upper edge of the respective baffle plate in a direction perpendicular to the inner surface of the respective baffle plate (27). Apparatus according to any one of the preceding claims, characterized in that said metal plate (51) has a plurality of relatively large-area openings (53) formed in the interior portion thereof. Apparatus according to any one of the preceding claims, characterized in that there provided four of said gauging slots (55), said four gauging slots being symmetrically disposed about the circumference of said gauge plate (51). Apparatus according to any one of the preceding claims, characterized in that said gauge plate (51) has disposed thereon means (85, 87, 89, 91) for measuring the clearances (73, 75, 81) between each of said U-shaped gauging slots (55) and the adjacent surfaces of the respective guide pin (53), and the clearance between the peripheral surface of said gauge plate (51) and the inner surface of the core barrel (11) adjacent each gauging slot (55). Apparatus according to claim 12, characterized in that the measuring means (85, 87, 89, 91) adapted to be connected to means (93) for remotely controlling said measuring means and for providing an indication of the measured clearances at a remote location. Apparatus according to claim 12 or 13, characterized in that the measuring means comprise a respective set of four linear measurement devices (85, 87, 89, 91) mounted on the upper major surface of said gauge plate (51) adjacent each U-shaped gauging slot (55), three of said measurement devices (85, 87, 89) being disposed each adjacent and perpendicular to one of the three surfaces (77, 83, 79) defining the associated U-shaped gauging slot (55), and the fourth of said measuring devices (91) being disposed adjacent the periphery of said gauge plat (51) and oriented in a radial direction. A method of using the apparatus according to any one of claims 1 to 6 for measuring and providing actual dimensions of the lower internals guide pin locations in a nuclear reactor vessel for use in customizing a replacement upper internals structural package so that it will mate with existing lower internal structure, characterized by the steps of positioning said gauge plate (51) into the core barrel of a nuclear reactor vessel containing a baffle plate arrangement, but with the upper internals structural package removed, such that the gauge plate rests on the upper end of the baffle plate arrangement (25), the guide pins (33) of the reactor vessel extend into the respective gauging slots (55) of the gauge plate, and the positioning pins (59) of the gauge plate are properly positioned relative to the baffle plate arrangement (25); measuring, at each of said gauging slots (55) and with the gauge plate (51) in the same position, the difference (71) between the peripheral surface of the gauging plate and the inner surface of the reactor core barrel (11), and the clearance (73, 75, 79) between each of the three sides of the U-shaped gauging slot (55) and the respective adjacent side of the associated guide pin; and determining, with the gauge plate (51) in the same position, the actual position of the gauge plate (51) in relation to the baffle plates (27) by inserting gauging means (65) into each of the gauging holes. A method according to claim 13, wherein the gauge plate (51) has at least three of said gauging holes (63, 63′, 63′′), two (63′, 63′′) of which are located at positions corresponding to the positions of two adjacent baffle plates (61, 27), and the third one (63) of which is located at a position corresponding to a baffle plate (27) diametrically opposite one of the two adjacent baffle plates, the center line of each of the gauging holes (63, 63′, 63′′) being displaced by a common given dimension from the expected position of the upper edge of the respective baffle plate (27) in a direction perpendicular to the inner surface of the respective baffle plate, characterized in that the step of determining the actual position of the gauge plate relative to the baffle plates comprises inserting gauge pins (65) of known size into the gauging holes (63, 63′, 63′′) until the inner surface of the respective baffle plate (27) is located. A method according to claim 16, characterized in that the step of inserting gauge pins comprises successively inserting gauge pins (65) of known different size into one of the gauging holes (63) to determine the largest diameter gauge pin which can be inserted, and then, with this largest diameter gauge pin inserted in its respective gauging hole, repeating said step of successively inserting for each of the other gauging holes. A method according to claim 17, characterized in that the step of determining the actual position of the gauge plate relative to the baffle plates is carried out before the two measuring steps. A method according to claim 15, 16, 17 or 18, characterized in that the measuring steps and said step of determining are controlled and carried out from a remote location.

Inventors: HOPKINS, RONALD JACOBS
Applicants: WESTINGHOUSE ELECTRIC CORPORATION
Application year: 1987
Main classification: G21C5
IPC codes: G21C17, G21C5