Note : Les descriptions sont présentées dans la langue officielle dans laquelle elles ont été soumises.
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NUCLEAR REACTOR FEEDER REMOVAL PROCESS
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] The present application claims priority to U. S. Provisional Patent
Application No.
61/433,058, filed January 14, 2011.
BACKGROUND
[0002] The present invention relates to refurbishment of nuclear reactor
systems.
[0003] More specifically, the invention relates to removal of feeder
components from the
primary heat transport system of a CANDUTm-type nuclear reactor. The CANDUTM
(''CANada
Deuterium Uranium") reactor is a pressurized heavy-water moderated, fission
reactor capable of
using fuels composed of natural uranium, other low-enrichment uranium,
recycled uranium,
mixed oxides, fissile and fertile actinides, and combinations thereof.
However, it will be
appreciated that invention is not limited in its applicability to CANDU'-type
nuclear reactors,
and that the invention can be practiced in connection with any other nuclear
reactor having the
same or similar reactor structures disclosed herein.
SUMMARY
[0004] In some embodiments, the invention provides a method of removing
feeders from a
CANDUTm-type nuclear reactor plant, including removing at least a portion of a
first feeder
cabinet, at least a portion of a first feeder cabinet soffit, and at least a
portion of a second feeder
cabinet soffit, disconnecting at least one feeder coupling, and cutting and
removing the
corresponding feeder of the coupling.
[0005] In other embodiments, the invention provides a method of removing
feeders from a
CANDU'-type nuclear reactor plant, wherein the method includes installing a
first feeder
platform, installing a second feeder platform, and installing a retubing
platform.
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BRIEF DESCRIPTION OF THE DRAWINGS
[0006] FIG. 1 is a perspective view of a reactor core of a CANDU'-type
nuclear reactor.
[0007] FIG. 2 is a cutaway view of a CANDU'-type nuclear reactor fuel
channel.
[0008] FIG. 3 is a flow chart illustrating a process for feeder and feeder
cabinet removal
according to some embodiments of the present invention.
[0009] FIG. 4 is a front view of a CANDUTM feeder cabinet.
[0010] FIG. 5 is a side view of the CANDUTM feeder cabinet illustrated in
FIG. 4.
[0011] FIG. 6 is a perspective view of a hoist well, crane and upper feeder
monorail disposed
adjacent the feeder cabinet shown in FIGs 4 and 5.
[0012] FIG. 7 is a perspective view of the upper feeder monorail of FIG. 6.
[0013] FIG. 8 is a perspective view of portions of a first feeder cabinet
being removed with
the assistance of scissor lifts.
100141 FIG. 9 is a perspective view of a first feeder platform in place to
remove the first
soffit of the feeder cabinet
[0015] FIG. 10 is a side view of a second feeder platform in place to
remove a second upper
feeder cabinet and soffit.
[0016] FIG. 11 is a perspective view illustrating lower feeder removal
cutting with from
scissor lifts, along with work from a retubing-platform (RIP).
DETAILED DESCRIPTION
[0017] Before any embodiments of the invention are explained in detail, it
is to be
understood that the invention is not limited in its application to the details
of construction and the
arrangement of components set forth in the following description or
illustrated in the
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accompanying drawings. The invention is capable of other embodiments and of
being practiced
or of being carried out in various ways.
[0018] FIG. 1 is a perspective of a reactor core of a CANDU'-type reactor
6. The reactor
core is typically contained within a vault that is sealed with an air lock for
radiation control and
shielding. A generally cylindrical vessel, known as a calandria 10, contains a
heavy-water
moderator. The calandria 10 has an annular shell 14 and a tube sheet 18 at a
first end 22 and a
second end 24. The tube sheets 18 each include a plurality of bores that each
accept a fuel
channel assembly 28. As shown in FIG. 1, a number of fuel channel assemblies
28 pass through
the tube sheets 18 of the calandria 10 from the first end 22 to the second end
24 of the calandria
10.
[0019] As in the illustrated embodiment, in some embodiments the reactor
core is provided
with two walls at each end 22, 24 of the reactor core: an inner wall defined
by the tube sheet 18
at each end 22, 24 of the reactor core, and an outer wall 64 (often referred
to as a "end shield")
located a distance outboard from the tube sheet 18 at each end 22, 24 of the
reactor core. A
lattice tube 65 spans the distance between the tube sheet 18 and the end
shield 64 at each pair of
apertures (i.e., in the tube sheet 18 and the end shield 64, respectively).
[0020] FIG. 2 is a cut away view of the fuel channel assembly 28. As
illustrated in FIG. 2,
each fuel channel assembly 28 includes a calandria tube ("CT") 32 surrounding
other
components of the fuel channel assembly 28. The CTs 32 each span the distance
between the
tube sheets 18. Also, the opposite ends of each CT 32 are received within and
sealed to
respective apertures in the tube sheets 18. In some embodiments, a CT rolled
joint insert 34 is
used to secure the CT 32 to the tube sheet 18 within the bores, although other
tube-to-sheet
joining structures and methods can instead be used. In this manner, the CTs 32
each form a first
boundary between the heavy water moderator of the calandria 10 and the
interior of the fuel
channels assemblies 28.
[0021] A pressure tube ("PT") 36 forms an inner wall of the fuel channel
assembly 28. The
PT 36 provides a conduit for reactor coolant and fuel bundles or assemblies
40. The PT 36, for
example, generally holds two or more fuel assemblies 40 and acts as a conduit
for reactor coolant
that passes through each fuel assembly 40. An annulus space 44 is defined by a
gap between
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each PT 36 and its corresponding CT 32. The annulus space 44 is normally
filled with a
circulating gas, such as dry carbon dioxide, helium, nitrogen, air, or
mixtures thereof. The
annulus space 44 and gas are part of an annulus gas system typically having at
least one of two
primary functions. First, a gas boundary between the CT 32 and PT 36 provides
thermal
insulation between hot reactor coolant and fuel within the PTs 36 and the
relatively cool CTs 32.
Second, the annulus gas system provides indication of a leaking calandria tube
32 or pressure
tube 36 via the presence of moisture, deuterium, or both detected in the
annulus gas.
[0022] An annulus spacer or garter spring 48 is disposed between the CT 32
and PT 36. The
annulus spacer 48 maintains the gap between the PT 36 and the corresponding CT
32, while
allowing passage of the annulus gas through and around the annulus spacer 48.
Maintaining the
gap helps ensure safe and efficient, long-term operation of the reactor 6.
[0023] As also shown in FIG. 2, each end of each fuel channel assembly 28
is provided with
an end fitting 50 located outside of the corresponding tube sheet 18. At the
terminal end of each
end fitting 50 is a closure plug 52. Each end fitting 50 also includes a
feeder assembly 54. The
feeder assemblies 54 feed reactor coolant into or remove reactor coolant from
the PTs 36. In
particular, for a single fuel channel assembly 28, the feeder assembly 54 on
one end of the fuel
channel assembly 28 acts as an inlet feeder, and the feeder assembly 54 on the
opposite end of
the fuel channel assembly 28 acts as an outlet feeder. As shown in FIG. 2, the
feeder assemblies
54 can be attached to the end fittings 50 using a coupling assembly 56
including a number of
screws, washers, seals, and/or other types of connectors.
[0024] The lattice tube 65 (described above) encases the connection between
the end fitting
50 and the PT 36 containing the fuel assemblies 40. Shielding ball bearings 66
and cooling
water surround the exterior the lattice tubes 65, which provides additional
radiation shielding.
[0025] With continued reference to FIG. 2, coolant from the inlet feeder
assembly 54 flows
along a perimeter channel of the end fitting 50 until it reaches a shield plug
58. The shield plug
58 is contained within the PT 36 and the lattice tube 65, and includes a
number of openings that
allow the coolant provided by the inlet feeder assembly to enter the end of
the PT 36. Another
shield plug 58 is located within the PT 36 and the lattice tube 65 at the
other end of the fuel
channel assembly 28, and includes similar openings that allow coolant passing
through the PT 36
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to exit the PT 36 and flow to the outlet feeder assembly 54 through a
perimeter channel of
another end fitting 50 at the opposite face of the reactor 6. As shown in FIG.
1, feeder tubes 59
are connected to the feeder assemblies 54 that carry coolant to or away from
the reactor 6.
[0026] Returning to FIG. 2, a positioning hardware assembly 60 and bellows
62 are also
coupled to each end fitting 50. The bellows 62 allows the fuel channel
assemblies 28 to move
axially ¨ a capability that can be important where fuel channel assemblies 28
experience changes
in length over time, which is common in many reactors. The positioning
hardware assemblies 60
can be used to set an end of a fuel channel assembly 28 in either a locked or
an unlocked
position. In the locked position, the end of the fuel channel assembly 28 is
fixed in an axial
position. In the unlocked position, the end of the fuel channel assembly 28 is
allowed to move
axially. A tool can be used with the positioning hardware assemblies 60 to
switch the position of
a particular fuel channel assembly 28.
[0027] The positioning hardware assemblies 60 are also coupled to the end
shield 64. The
positioning hardware assemblies 60 each include a rod having an end that is
received in a bore of
the respective end shield 64. In some embodiments, the rod end and the bore in
the end shield 64
are threaded.
100281 A number of preliminary steps must often be taken to perform
refurbishment and
retubing operations of a CANDUTm-type heavy water fission reactor (or more
broadly, for many
other types of nuclear reactors). In the context of CANDUTm-type reactors,
retubing is the
process of removing calandria tubes, pressure tubes, and associated feeder
piping from a
CANDU'-type nuclear reactor, and replacing them with new or refurbished
components. Some
of the preliminary steps in re-tubing operations involve important and
innovative manners of
preparing a reactor for such re-tubing operations, many of which can enable a
re-tubing team
significant time and costs over the course of such operations.
[0029] FIG. 3 is a flowchart illustrating an overview of a feeder and
feeder cabinet removal
method according to some embodiments of the present invention. The feeder and
feeder cabinet
removal method may be generally described with reference to FIG. 3 as follows,
with many of
the steps in the process described in greater detail below.
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[0030] A first (e.g., front) feeder cabinet wall is removed using, for
example, a scissor lift.
An example of a first feeder cabinet wall is indicated with reference numeral
70 in FIG. 5. Next,
a first (e.g. front) feeder platform is installed, an example of which is
indicated at 81 in FIGs. 9
and 10. From the first feeder platform, a first (e.g., front) feeder cabinet
soffit is removed, an
example of which is the approximate right half of the soffit 72 shown in FIG.
5. Next, the first
feeder platform is raised above a vault crane 83 and a second (e.g., rear)
feeder platform is
installed, an example of which is indicated at 82 in FIG. 10. From the second
feeder platform, a
second (e.g. rear) feeder cabinet soffit is removed, an example of which is
the approximate left
half of the soffit 72 shown in FIG. 5. Next, the second feeder platform is
raised above the vault
crane 83, and a retubing platform (RTP) is assembled by first installing RTP
columns and then
installing a vertically-adjustable platform thereon. An example of an RTP is
shown in FIGs. 4
and 11 at 98 (not shown in FIGs. 8-10). From the RTP, positioning hardware
assemblies 60 and
closure plugs 52 are removed from each of the fuel channel assemblies 28 (see
FIG. 2), and the
couplings connecting the feeder assemblies 54 to the fuel channel assemblies
28 are
disconnected. The first feeder platform is then lowered to a position at which
lower feeders
(i.e., connecting to lower fuel channel assemblies 28 on the reactor face) are
cut and removed
from the RTP, the first feeder platform, and scissor lifts. Examples of lower
feeders to be cut are
shown at 90 in FIG. 9. Using the RTP and scissor lifts, back wall insulation
and cantilever
supports are then removed. An example of a back wall of the cabinet is
indicated at 78 in FIG. 5,
whereas an example of a cantilevered support (extending away from the
calandria 10 and used
for supporting the lower feeders 90 described in greater detail below) is
shown at 94 in FIG. 9.
The first feeder platform is then raised and secured to the second feeder
platform, and redundant
supports of the first and second feeder platforms are removed. To complete the
feeder and
feeder cabinet removal process, upper feeders (i.e., connecting upper fuel
channel assemblies 28
on the reactor face) are then removed from the joined first and second feeder
platforms.
Examples of upper feeders to be cut are shown at 88 in FIG. 9.
[0031] FIGS. 4 and 5 illustrate an example of a feeder cabinet 68 to which
the process of the
present invention can be applied. The illustrated feeder cabinet 68 includes a
front face 70, a
soffit 72, and an upper feeder cabinet rear wall 74. Each of these components
70, 72, and 74 is
removed during feeder cabinet removal. Side walls 76 and a lower back wall 78
of the cabinet
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68 can remain in place. In some embodiments, scissor lifts 80 (see FIGs. 8 and
11) may be used
to remove the front face 70 of the feeder cabinet 68.
[0032] A feeder platform, including the front feeder platform 81 (FIG. 9)
and rear feeder
platform 82 (see FIG. 10) will be used for the removal of the soffit 72 and
upper cabinet rear
wall 74. As illustrated in Fig. 10, the feeder platforms 81, 82 may be
suspended from support
members coupled to support framework above the soffit, or from the soffit
itself. The support
members may includes cables, ropes, chains or other suitable support devices
and systems for
platforms. A vertical position of the feeder platforms 81, 82 may be adjusted
by known vertical
control means including pulleys, strand jacks, chain hoists, etc.
[0033] In some embodiments, the feeder cabinet 68 is disassembled and
removed by
detaching panels 84 and frame members 86. FIG. 8 illustrates a feeder cabinet
68 in the process
of being disassembled. The feeders 59 are visible behind portions of the front
face 70 that have
been removed. FIG. 9 illustrates an exposed calandria end shield 64, as well
as feeders 59
associated with one side of the reactor 6, each of which extends and is
connected in fluid
communication with a respective fuel channel assembly 28.
[0034] Once the feeder cabinet 68 has been removed as just described, the
process of
removing the feeders 59 can commence. However, it should be noted that in some
embodiments
of the present invention, the process of feeder cabinet removal overlaps to
some extent with the
process of feeder removal.
[0035] With reference now to FIG. 11, the feeders 59 include upper
feeders 88 and lower
feeders 90, each of which extends to and is connected to a respective fuel
channel assembly 28 at
the upper portion and lower portion of the calandria, respectively. As best
shown in FIG. 11, the
feeders 59 are removed by cutting and disconnecting each feeder 59 at
particular locations along
the length of each feeder 59 in a particular sequence of steps, thereby not
only resulting in a
highly efficient feeder removal process, but also reducing the opportunities
for removal error,
operator injury due to falling reactor components and tooling, and
contamination of the area in
front of the reactor face with debris (some of which can be radioactive) from
disconnected and/or
severed feeders 59.
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[0036] Once the feeder cabinet removal steps have been completed, and the
front and rear
feeder platforms 81, 82 have been elevated to their respective positions above
the vault crane 83,
(see FIG. 3), the Retubing platform 98 (RTP) can be installed in front of the
reactor face (and
below the front and rear feeder platforms 81 and 82) in preparation for
removing the upper and
lower feeders 88, 90. The RTP 98, in combination with the front feeder
platform 81 and rear
feeder platform 82, provide for a worksite that has at least three work
platforms that can be
moved in space substantially independently. This allows for parallel series of
work to occur on
the reactor face, hence reducing the worker radiation dose, production costs,
and schedule.
[0037] While an exemplary RTP 98 is illustrated in FIGs. 4 and 11, it
should be understood
that a substantially similar RTP can be provided on either end of the reactor
core. Therefore, it
will be understood that the description of the RTP herein relates to the
illustrated RTP 98, but
that multiple RTPs 98 having the same features and capabilities can be
provided to enable
servicing both end faces of the reactor core simultaneously.
[0038] In some embodiments, the RTP 98 is a stand-alone powered elevating
platform that
provides access to the reactor face for retube work. Referring to FIG. 11, the
RTP 98 includes a
plurality of columns 104 (e.g., four vertical columns from the a reactor vault
floor, in the
illustrated embodiment), a platform 106 movably supported by the columns 104,
and an elevator
system 108 for moving the platform 106 vertically relative to the columns 104.
[0039] The illustrated RTP platform 106 includes a structural (e.g., steel)
frame 110 and a
decking surface 112 coupled to the frame 110. The platform 106 can be sized
(spatially and
structurally) to accommodate all of the required tooling for retubing removal
and installation
processes, including support and movement of heavy shielded flasks used to
transport
radioactive reactor components removed from the reactor during retubing
operations. By way of
example, the platform 106 can provide a working surface of about 500 square
feet or more (e.g.,
the width can be about 29-31 feet, and the length can be about 17-24 feet),
and can provide a
working surface nearly filling the plan view area that the fueling machine and
gantry of the
reactor normally occupy. To maximize working space, the RTP platform 106 can
provide small
clearances with respect to surrounding structures, including the underside of
the RTP platform
106 when the RTP platform 106 is at its lowest elevation. Also, in some
embodiments the
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platform 106 can be movable via the elevator system 108 to have a vertical
stroke that is at least
equal to the height of the calandria 10 (about 22 feet, in some cases), so
that all of the fuel
channel assemblies 28 across the entire reactor end face are accessible from
the RTP platform
106. In the illustrated embodiment, the vertical stroke is about 27 feet, or
about 5 feet more than
the height of the illustrated calandria 10. Also, the elevator system 108 can
position the RTP
platform 106 at any desired height within the vertical stroke. Although the
RTP 98 may be
configured to lower the platform 106 into a pit or recess in the vault floor,
this is dependent upon
the vault design at a particular reactor site, and is not required.
[0040] The platform 106 provides a base upon which precision tooling can be
supported at
different elevations of the platform 106, as well as a personnel work platform
onto which tooling
required for reactor disassembly and reassembly can be mounted. The
significant accuracy with
which the RTP 98 moves to position tooling with respect to the fuel channel
assemblies 28 on
the reactor face is achieved by providing the RTP platform 106 with high
relative rigidity and
stability. The RTP 98 can also serve as the primary elevating device for
movement of the heavy
shielded flasks from a lower elevation (e.g., vault floor) to the target
lattice site, and back down
to the lower elevation. In this regard, the use of the RTP 98 provides a more
efficient method of
vertical movement than individually craning each of the large flasks down to a
lower elevation.
[0041] As indicated in FIG. 3, in some embodiments prior to the steps of
feeder removal,
positioning hardware assemblies 60 and closure plugs 52 are removed from each
of the fuel
channel assemblies 28 (see FIG. 2) by personnel on the RTP platform 106, and
the couplings
connecting the feeder assemblies 54 to the fuel channel assemblies 28 are also
disconnected by
personnel on the RTP platform 106. When this process is completed, and in an
effort to assist in
the process of feeder removal, the front feeder platform 81 (FIGs. 9 and 10)
is lowered to a
position in which personnel have easy access to the lower feeders 90 from both
the front feeder
platform 81 and the RTP platform 106.
[0042] With reference now to FIG. 9, a lower horizontal portion 92 of each
lower feeder 90
is removed first. For this purpose, a first cut is made from scissor lifts to
each lower feeder 90 at
its 45-degree bend 96 located beyond a respective cantilever support 94
supporting the lower
feeder 90. A cantilever support 94 is a supporting structure used to restrain
displacement of
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select feeders 59 in the CANDUTM reactor. The lower feeders 90 are cut and
removed in this
manner from outboard-most lower feeder 90 to inboard-most lower feeder 90, top
to bottom.
Each cut feeder section can be capped from the RTP platform 106, whereas the
other cut ends of
the lower feeders 90 can be capped from scissor lifts 30 just after cutting to
contain any loose
contamination. Referring to FIG. 11, as the lower feeders 90 are cut, the
lower feeders 90 can be
moved onto the RTP 98 and placed at the rear of the RTP platform 106. For long
feeder
sections, an additional cut can be made from the RTP 98 as needed.
[0043] As shown in FIG. 6, an overhead crane 114, located above a catwalk
116 (see FIG.
11), can be used to remove bulk feeder sections from the RTP 98 and to place
them on carts at
one end of the RTP 98. The loaded carts can then be rolled around the vault
and out of an air
lock for further processing. The cantilever supports 94 (FIG. 9) that each
supported at least one
respective lower feeder 90 can also be removed along with the first cut and
removed section of
each lower feeder 90. Although the hardware used to secure the cantilevered
supports 94 in
place may not be reused, the cantilever supports 94 may be refurbished as
desired.
[0044] To complete removal of the lower feeders 90 a second cut can be made
to each lower
feeder at an existing field weld location 117 (FIG. 11). The front feeder
platform 81 (see FIG.
10) can be lowered to the elevation of the floor of the reactor vault in order
for workers to reach
the existing field weld location for each lower feeder 90. Feeder hanger
supports 119 (FIG. 11)
may be inspected ahead of time to ensure they can be used as lifting points to
lower the feeders
59 onto the RTP 98 or to the vault floor. To facilitate movement of the cut
feeders 59, the
feeders 59 can he rigged with slings prior to cutting. For longer cut feeder
sections, an additional
cut may be done on the RTP 98 or on the vault floor as needed. The sections
can then be loaded
onto carts and rolled out a first air lock for further processing. Various
lower feeder spacer
hardware can be removed during removal of the second sections of the lower
feeders 90, and
may not be used in some embodiments to allow for quick removal and clean
installation.
[0045] With reference again to FIG. 3, after the lower feeders 90 have been
removed,
removal of the upper feeders 88 can begin. To commence upper feeder removal,
the front feeder
platform 81 can be raised above the vault crane 83 and can be secured in
placed (e.g., bolted) to
the rear feeder platform 82 (FIG. 10), with a falling-object barrier (e.g., a
net or other obstacle)
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put in place therebetween so that other retubing operations can begin on the
reactor face while
the upper feeders 88 are still being removed. A decision to allow upper
feeders 88 to be
removed while other reactor retubing processes are taking place can be made
following
appropriate radiation protection assessments.
[0046] As shown in FIG. 6 and 7, in some embodiments a monorail 118 is
installed above
the catwalk 116 (FIGs. 6 and 11), between inlet and outlet headers 115 (FIGs.
6 and 10). The
monorail 118 helps support the upper feeders 88 during upper feeder removal
and installation,
and may be used as a means to support the upper feeders 88 during their
transport to a hoist well
120 defined in the catwalk 116 (FIG. 6). The hoist well 120 allows for
lowering and raising the
upper feeders 88 via the crane 114. Once feeders 59 are lowered, the feeders
59 can be loaded
onto carts or waste containers and rolled around the sides of the vault, and
out of an air lock.
[0047] Removal of upper feeders 88 is performed from a first end to a
second end across the
reactor face. Accordingly, sections of the catwalk 116 will be removed as the
upper feeders 88
are removed. This catwalk 116 may be retained, refurbished and re-installed.
[0048] The upper feeders 88 may be slung from the monorail 118 and cut
several inches
from the headers 115, more specifically, the nozzles of each header 115. Each
upper feeder may
then be transferred to a location with a hoist well (e.g. hoist well 120).
[0049] In some embodiments, upper feeder spacers are removed at the same
time as the
upper feeders 88 are removed. Other tubing and components may be removed as
well.
Resistance temperature detector (RTD) lines may cut at an accessible area
where welding can
take place for re-installation as needed.
[0050] Understanding that both sides of the reactor have similar
components that are likely
to be removed and/or refurbished at the same time, it will be appreciated that
lower feeder
cabinet removal may be done with two crews per face of the reactor, working in
parallel.
Another crew may be on the vault floor transferring material from the removal
crew to waste
bins. Also, upper feeder cabinet removal may be done with, for example, a
large crew of eight
individuals per reactor face, which includes a crew of two individuals per
face standing on the
vault floor for material handling. Due to space constraints, upper feeder
removal may be done
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with one crew per reactor face, but upper feeder removal can be performed in
parallel to other
activities on the RTP 98 as discussed above.
[0051] A number of commercial production tools may be employed in the
feeder cabinet and
feeder removal processes described herein. By way of example only, a
reciprocating saw can be
used for cutting feeders, and can also be used for feeder waste processing,
whereas a portable
band saw can be used to process feeders into pieces small enough to fit into
waste containers. As
another example, manual bolt cutters can be used to cut small diameter piping
and components
such as RTDs, orifice and tube cutting, cantilever beam support hardware
cutting, and spacer
removal. As yet another example, battery-powered bolt cutters can also be used
for RTD and
tube cutting, cantilever beam support hardware cutting, and spacer removal. A
portable grinder
can be used for hanger rods and cantilever beam hardware.
[0052] The embodiments described above and illustrated in the figures are
presented by way
of example only and are not intended as a limitation upon the concepts and
principles of the
present invention. As such, it will be appreciated by one having ordinary
skill in the art that
various changes in the elements and their configuration and arrangement are
possible without
departing from the spirit and scope of the present invention as set forth in
the appended claims.
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