Large riser extended reach sluicer and tool changer

Abstract

Extended reach sluicer systems, devices, and methods for breaking up and retrieving chemical, radioactive, hazardous materials and/or other waste and/or other material from storage tanks with mechanical arms and nozzles to break up and transfer tank material. And this invention can work with tanks having high temperature or low temperature conditions.

Claims

1. A large riser extended reach sluicer and tool changer comprising: a vertically adjustable upper mast section that mounts to existing riser structures of a waste tank approximately 34 inches in diameter; a movable cleaning boom arm having one end attached to the mast section and an opposite end with a changeable end effector; a nuclear waste pump system on a distal end of the upper mast section, comprising: a submersible pump assembly that fits through an upper mast; and a hydraulically driven pump motor for high power density and for safe operation in areas in the waste tank with hazardous/explosive vapors; a level indicator; wetted parts constructed of stainless steel to allow for decontamination; a hydraulic power unit with displacement limiting features to keep system pressures in a safe operating range; one or more seals that prevent a waste stream from contaminating a hydraulic fluid; one or more seals with recirculating barrier fluid that is cooled through a heat exchanger comprised of a helical path traversing the outside diameter of a discharge piping; an accumulator to compensate for changes in barrier fluid pressure and temperature; and a sump tank housing a pump mounted at a distal end of a telescoping mast.

2. The large riser extended reach sluicer and tool changer of claim 1, further comprising: a plurality of hose management systems that accommodate axial and radial motion of the movable cleaning boom arm.

3. The large riser extended reach sluicer and tool changer of claim 1, wherein the upper mast section includes: a plurality of hydraulically actuated cylinders and motors allowing operation in hazardous and explosive environments.

4. The large riser extended reach sluicer and tool changer of claim 1, wherein the upper mast section includes: a mast assembly attached to a turntable that rotates the movable cleaning boom arm +/− approximately 180 degrees.

5. The large riser extended reach sluicer and tool changer of claim 1, wherein the moveable boom cleaning arm includes: a telescoping boom that pivots approximately 180 degrees from vertical to horizontal and extends beyond approximately 37 and ½ feet.

6. The large riser extended reach sluicer and tool changer of claim 1, wherein the moveable cleaning boom arm includes: a telescoping boom that when in an approximate 12 o'clock position is extendable up through the riser and stow the changeable end effector in a storage container.

7. The large riser extended reach sluicer and tool changer of claim 1, wherein the moveable cleaning boom arm includes: a telescoping boom that when in an approximate 12 o'clock position is extendable up through the riser and pick the changeable end effector from a storage container to be commissioned in the waste tank.

8. The large riser extended reach sluicer and tool changer of claim 1, further comprising: one or more sliding gates at a containment interface of the changeable end effector to shield the environment from radiation.

9. The large riser extended reach sluicer and tool changer of claim 8, further comprising: a wash station prior to the sliding gates at the containment area interface.

10. The large riser extended reach sluicer and tool changer of claim 1, further comprising: a quick disconnect plate mounted at a distal end of the movable cleaning boom arm with the ability to mate with and support varying end effectors for use in the waste tank.

11. The large riser extended reach sluicer and tool changer of claim 1, further comprising: a quick disconnect plate with circuits for hydraulics, high pressure and low flow water, low pressure and high flow water, supernate, and a suction line for waste conveyance as needed by varying end effectors.

12. The large riser extended reach sluicer and tool changer of claim 1, further comprising: a failsafe that includes a quick disconnect plate with hydraulically actuated clamps where pressure applied disengages the clamps so that if pressure is lost, or a hose is damaged, the changeable end effector remains secured to the quick disconnect plate such that the changeable end effector cannot become separated from the movable cleaning boom arm and dropped into the waste tank.

13. The large riser extended reach sluicer and tool changer of claim 1, further comprising: a container for housing radioactive end effectors and which prevents radiation from leaking into the environment.

14. The large riser extended reach sluicer and tool changer of claim 1, further comprising: nickel plating on wetted mechanical structures in the tool changer to counteract corrosive environments.

15. The large riser extended reach sluicer and tool changer of claim 1, further comprising: a total service weight that is able to be supported by a tank dome and riser structure; a capability to clean inside, behind, on top, below and around obstructions in tanks; a number of degrees of freedom up to 5 or more; operable capability during the course of a tank cleaning campaign without the need for service; and an extended reach to allow the changeable end effector to get closer to a work surface over a larger area.

16. The large riser extended reach sluicer and tool changer of claim 1, further comprising: a manifold system for a supply/return of working hydraulic fluid utilizing adjustable electro-hydraulic valves allowing control of the manifold system from up to approximately 1000 feet away.

17. The large riser extended reach sluicer and tool changer of claim 1, wherein the sump tank housing includes one of: a conical seat to allow self-alignment of the pump during installation through the mast, and a conical pump seat that creates a seal to prevent waste material from overfilling into and through the mast.

18. The large riser extended reach Sluicer and tool changer of claim 1, wherein the sump tank housing includes one of: a sump tank with a tangential inlet to allow for air separation, and a sump tank with an outlet port to allow for mist recirculation such that no mist is discharged into the waste tank that would compromise visibility.

19. The large riser extended reach sluicer and tool changer of claim 1, wherein the sump tank housing includes: a sump tank with a hydraulically actuated door at the bottom to clear debris and allow back flushing of the pump.

Description

BRIEF DESCRIPTION OF THE FIGURES

(1) The drawing figures depict one or more implementations in accord with the present concepts, by way of example only, not by way of limitations. In the figures, like reference numerals refer to the same or similar elements.

(2) FIG. 1 illustrates a large riser extended reach sluicer and tool changer mounted in a nuclear storage tank with optional auxiliary tool in a possible off-center location.

(3) FIG. 2A illustrates a left side view of large riser extended reach sluicer and tool changer of FIG. 1 with the boom horizontal and retracted and the mast fully retracted.

(4) FIG. 2B shows a cross-sectional view of the upper assembly of the large riser extended reach sluicer and tool changer of FIG. 2A.

(5) FIG. 2C is a close-up view of the process hose and hose reel of FIG. 2B.

(6) FIG. 2D is a close-up view of the outer and inner mast tube of FIG. 2B

(7) FIG. 2E is an alternative cross-sectional view of the upper assembly of the large riser extended reach sluicer and tool changer of FIG. 2A.

(8) FIG. 2F is an enlarged view of the quick disconnect plate on the distal end of the boom of FIG. 2A.

(9) FIG. 2G is a perspective view of the large riser extended reach sluicer and tool changer of FIG. 2A illustrating the ranges of motion.

(10) FIG. 2H illustrates the large riser extended reach sluicer and tool changer of FIG. 2A, with the boom in the 12 o'clock position.

(11) FIG. 3 is a cross-sectional view of the pump assembly of FIG. 2A.

(12) FIG. 4 is diagrammatical view of the level indicator apparatus which is used in FIG. 3.

(13) FIG. 5 is a schematic of the barrier fluid recirculation, cooling circuit used in FIG. 2A.

(14) FIG. 6 is a diagram illustrating the tangential inlet at the sump tank of FIG. 2A.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

(15) Before explaining the disclosed embodiments of the present invention in detail it is to be understood that the invention is not limited in its applications to the details of the particular arrangements shown since the invention is capable of other embodiments. Also, the terminology used herein is for the purpose of description and not of limitation.

(16) In the Summary above and in the Detailed Description of Preferred Embodiments and in the accompanying drawings, reference is made to particular features (including method steps) of the invention. It is to be understood that the disclosure of the invention in this specification does not include all possible combinations of such particular features. For example, where a particular feature is disclosed in the context of a particular aspect or embodiment of the invention, that feature can also be used, to the extent possible, in combination with and/or in the context of other particular aspects and embodiments of the invention, and in the invention generally.

(17) In this section, some embodiments of the invention will be described more fully with reference to the accompanying drawings, in which preferred embodiments of the invention are shown. This invention may, however, be embodied in many different forms and should not be construed as limited to the embodiments set forth herein. Rather, these embodiments are provided so that this disclosure will be thorough and complete, and will convey the scope of the invention to those skilled in the art. Like numbers refer to like elements throughout, and prime notation is used to indicate similar elements in alternative embodiments.

(18) Other technical advantages may become readily apparent to one of ordinary skill in the art after review of the following figures and description.

(19) It should be understood at the outset that, although exemplary embodiments are illustrated in the figures and described below, the principles of the present disclosure may be implemented using any number of techniques, whether currently known or not. The present disclosure should in no way be limited to the exemplary implementations and techniques illustrated in the drawings and described below.

(20) Unless otherwise specifically noted, articles depicted in the drawings are not necessarily drawn to scale.

(21) A list of components will now be described. 1 Large riser extended reach sluicer and tool changer 2 Adapter spool 3 Nuclear waste storage tanks 4 End effector 5 Pump assembly 6 Boom 7 Mast 8 Upper assembly 9 Pivot point 10 Hydraulic cylinders 11 Hose management system 12 Hydraulic cylinders 13 Hydraulic cylinders 14 Hydraulic motor and gearbox arrangement 15 Pinion 16 Turntable 17 Turntable 18 Outer mast tube section 19 Inner mast tube section 20 Slide pads 21 Primary enclosure 22 Quick disconnect plate 23 Locating pins 24 Container 25 Sliding gates 26 Hydraulic cylinder 27 Hose management system 28 Hose reel 23 Process hose 31 Hydraulic motor 32 Float 33 Seal housing 34 Conical interface 35 Sump tank 36 Tangential inlet 37 Inner mast tube section 39 Door 40 hydraulic cylinder 41 slide pads 42 submersible pump 44 drive shaft 45 cable 46 flexible couplings 47 encoder 48 pump shaft 49 discharge piping 51 seals 52 heat exchanger 53 suction hose 54 accumulator 57 outlet

(22) FIG. 1 illustrates a large riser extended reach sluicer and tool changer 1 mounted in a nuclear storage tank 3 with optional auxiliary tool in a possible off-center location.

(23) In reference to FIG. 1, the large riser extended reach sluicer and tool changer 1 cleaning system can be mounted in nuclear waste storage tanks through existing pipe tank risers and holes as small as approximately 34-inches in diameter. The large riser extended reach sluicer and tool changer can be constructed to be lightweight, and as such, it can be fully supported by the adapter spool 2 at the tank interface.

(24) The boom can extend in and out and the mast 7 can travel up and down to allow full reach in an approximately 75 foot diameter tank with a waste depth of up to approximately 10 feet. Waste material can be delivered from the end effector 4 located at the end of the boom 6 to a pump assembly 5 situated at the distal end of the mast 7. The pump assembly 5 can then transfer the waste out of the tank. The use of hydraulic power removes any potential ignition sources from electrical components and allows operation in tanks with explosive vapors.

(25) FIG. 2A illustrates a left side view of large riser extended reach sluicer and tool changer 1 of FIG. 1 with the boom 6 horizontal and retracted and the mast 7 fully retracted. FIG. 2B shows a cross-sectional view of the upper assembly 8 of the large riser extended reach sluicer and tool changer 1 of FIG. 2A. FIG. 2C is a close-up view of the process hose 29 and hose reel 28 of FIG. 2B. FIG. 2D is a close-up view of the outer mast tube 18 and inner mast tube 19 of FIG. 2B.

(26) FIG. 2E is an alternate cross-sectional view of the upper assembly of the large riser extended reach sluicer and tool changer 1 of FIG. 2A.

(27) FIG. 2F is an enlarged view of the quick disconnect plate 22 on the distal end of the boom 6 of FIG. 2A.

(28) In reference to FIGS. 2A, 2B, 2C, 2E and 2F the large riser extended reach sluicer and tool changer cleaning system 1 can comprise an upper assembly 8 that contains a turntable 17 and hose management system 11 comprised of one or more articulating tracks to guide and accommodate the hydraulic hoses through the various stages as they rotate, extend or retract.

(29) A similar hose management system 27 can be used to control the additional length of hydraulic hose running down the mast 7. Running along the inside of the inner most tube can be the process hose 29 that leads to a hose reel 28 in the primary enclosure 21 of the upper assembly 8.

(30) Extending down from the turntable 16, a rectangular mast 7 can be rotated approximately +/−180 degrees about the longitudinal axis through a slew ring 17 driven by a pinion 15 coupled to a hydraulic motor and gearbox arrangement 14.

(31) FIG. 2D depicts an embodiment utilizing a rectangular telescopic mast assembly comprised of an outer mast tube section 18 and an inner mast tube section 19 that can slide past each other lengthwise with slide pads 20 between. Hydraulic cylinders 12 provide the extension and retraction.

(32) Elevation of the boom 6 can be about the pivot point (9) with up to approximately 180 degrees of rotation from the approximate 12 o'clock to the approximate 6 o'clock position. The boom is telescopic and allows extension and retraction to reach radially out over approximately 37 and approximately ½ feet within the perimeter of the tank. Hydraulic cylinders (10) can be used to provide the force for extending and retracting as well as for elevation. The overall range of motion and degrees of freedom can be further extended with the addition of varying end effectors.

(33) In reference to FIG. 2,/ a quick disconnect plate 22 on the distal end of the boom 6 can be comprised of a plurality of circuits for hydraulics, high pressure/low flow water, low pressure/high flow water, supernate, and a suction line for waste conveyance. Locating pins 23 ensure proper alignment between the quick disconnect plate 22 and applicable end effector. Built in compliance allows for minor misalignment during initial engagement. Hydraulically actuated clamps secure the plate where pressure applied disengages the clamps. If pressure is lost, or a hose is damaged, this failsafe mechanism prevents accidental separation of the end effect or from the arm.

(34) FIG. 2E shows the boom 4 at the approximate 12 o'clock position and a hydraulic cylinder 26 extending it up through the adapter spool 2 and into the end effector storage container 24. To reduce environmental exposure, a wash station can rinse the radioactive waste from the end effector prior to entering the containment area.

(35) Once the fouled end effector is secured in the container, the boom 6 lowers, sliding gates 25 separating the containment area from the tank close, and the container 24 can be lifted by hoist and taken away for further processing. A new end effector storage container 24 can then be lowered into place, the sliding gates 25 opened, the boom 6 extended, and a new end effector 4 is engaged and commissioned. The container remains can place for the duration of the operation.

(36) FIG. 2G is a perspective view of the large riser extended reach sluicer and tool changer 1 of FIG. 2A illustrating the ranges of motion.

(37) FIG. 2H illustrates the large riser extended reach sluicer and tool changer 1 of FIG. 2A, with the boom 6 in the 12 o'clock position. Waste can be transferred through a suction hose 53 running from the end effector 4 to the pump assembly 5.

(38) FIG. 3 is a cross-sectional view of the pump assembly 5 of FIG. 2A.

(39) In reference to FIG. 3, the pump assembly 5 can raise and lower independently of the upper mast section 7 to control the relative height between the end effector and the pump inlet, and therefore, reduce the required pressure head required from the end effector. This embodiment can utilize a telescopic mast assembly comprised of an outer mast tube section 7 and an inner mast tube section 37 that can slide past each other lengthwise with slide pads 41 between. Referring back to FIG. 2A, hydraulic cylinders 13 can provide the extension and retraction.

(40) In reference to FIG. 3, the pump assembly 5 can be comprised of a submersible pump 42 driven by a hydraulic motor 31 and is stacked vertically to fit through the mast 7. The pump 42 can be enclosed by a sump tank 35. The conical interface 34 between the pump 42 and the tank 35 allow the pump 42 to be lowered into position and self-align.

(41) Seals can prevent liquid from rising past the interface, into the mast 7, and spilling out into the environment. The wetted components of the pump assembly 5 can be constructed from stainless steel to prevent corrosion and allow for decontamination. Where feasible, 12 point bolts are used to prevent the buildup of hazardous waste.

(42) FIG. 4 is diagrammatical view of the level indicator apparatus 32 which is used in FIG. 3.

(43) In reference to FIG. 4, a level indicator can monitor the fluid level in the sump tank 35. The level indicator can be a float 32 attached to the first end of a cable 45 that travels longitudinally through the pump assembly, through the upper mast 7, and out of the waste tank 3, in order to keep any electronics outside the highly radioactive environment. The second end of the cable attaches to a mechanical device that can rotate an encoder 47. As the level in the sump 35 goes down, gravity will cause the float to travel down, rotating the encoder 47 in one direction. As the level in the sump 35 goes up, the float 32 will travel up, rotating the encoder 47 in the counter direction. The positional information from the encoder 47 can then feedback to a controller as a fluid level.

(44) In an alternate embodiment, the float 32 could be attached to a strain gauge that detects change in force as a float travels up or down. In further embodiments, the level could be measured through pressure transducers or capacitance transducers. The sensors could also be non-contact sensors such as laser, ultrasonic, LED, radar, or any other non-contact sensor that can output an analog signal to a controller. The sensors could be rated for use in hazardous and radioactive environments.

(45) The hydraulic motor 31 can be located above the pump, mounted to the seal housing 33 such that it is separated from the waste stream through seals, thereby eliminating the possibility of nuclear waste contaminating the hydraulic system and reaching outside of the waste tank. In case of a leak at the seals, the seal housing has ports to allow any waste to drain back into the waste tank.

(46) The hydraulic motor 31 and the pump 42 can be coupled through drive shaft 44 and one or more flexible couplings 46.

(47) A door 39 coupled to a hydraulic cylinder 40 on the bottom of the sump tank 35 can swing open to clear debris and allow back flushing of the pump 42.

(48) FIG. 5 is a schematic of the barrier fluid recirculation, cooling circuit used in FIG. 2A.

(49) In reference to FIG. 5, the seals 51 coupled to the pump shaft 49 can contain a barrier fluid at the seal faces to reduce heat from friction and reduce wear on the seals. The barrier fluid can be circulated around the seals 51 and cooled through a barrier fluid heat exchanger 52 to improve the performance and increase the life of the seals. The heat exchanger 52 can be comprised of a helical path traversing the outside diameter of the discharge piping 49. An accumulator 54 self-compensates for changes in the barrier fluid due to temperature and/or pressure.

(50) FIG. 6 is a diagram illustrating the tangential inlet at the sump tank of FIG. 2A.

(51) As shown in FIG. 6, a tangential inlet 36 to the sump tank 35 can promote the separation of entrained air from the liquid. This process can also generate mist that would render visibility impossible if vented back into the tank, so a hose connection between an outlet 57 at the top of the sump tank and the suction inlet at the end effector allows for recirculation of the mist.

(52) The large riser extended reach sluicer and tool changer hydraulic power unit can be comprised of a skid mounted pumping system that delivers hydraulic fluid to a manifold system utilizing adjustable electro-hydraulic valves. From up to approximately 1000 feet away, operation of the system is achieved through a remote control station containing pushbuttons, switches, and joysticks.

(53) The pump hydraulic power unit can be comprised of a skid mounted pumping system that delivers hydraulic fluid to the pump hydraulic motor 31 of FIG. 3. The hydraulic supply pump can be displacement limited by a mechanical stop so that the nuclear waste pump hydraulic motor cannot over pressurize the discharge piping, thus keeping the system within safe operating conditions and preventing environmental contamination from piping failures.

(54) The terms “approximately”/“approximate” can be +/−10% of the amount referenced. Additionally, preferred amounts and ranges can include the amounts and ranges referenced without the prefix of being approximately.

(55) Although specific advantages have been enumerated above, various embodiments may include some, none, or all of the enumerated advantages.

(56) Modifications, additions, or omissions may be made to the systems, apparatuses, and methods described herein without departing from the scope of the disclosure. For example, the components of the systems and apparatuses may be integrated or separated. Moreover, the operations of the systems and apparatuses disclosed herein may be performed by more, fewer, or other components and the methods described may include more, fewer, or other steps. Additionally, steps may be performed in any suitable order. As used in this document, “each” refers to each member of a set or each member of a subset of a set.

(57) To aid the Patent Office and any readers of any patent issued on this application in interpreting the claims appended hereto, applicants wish to note that they do not intend any of the appended claims or claim elements to invoke 35 U.S.C. 112(f) unless the words “means for” or “step for” are explicitly used in the particular claim.

(58) While the invention has been described, disclosed, illustrated and shown in various terms of certain embodiments or modifications which it has presumed in practice, the scope of the invention is not intended to be, nor should it be deemed to be, limited thereby and such other modifications or embodiments as may be suggested by the teachings herein are particularly reserved especially as they fall within the breadth and scope of the claims here appended.