Automatic machining system for the refurbishment of degraded welds in piping systems

Abstract

Degradation of dissimilar metal welds in the piping systems of power plants is recognized as a significant ageing factor. Hence, close scientific attention is paid to various degradation mechanisms concerned with dissimilar metal welds, as well as to welding metallurgy. However, the process of dissimilar metal weld refurbishment consisting of the weld groove machining and subsequent repair welding is based on obsolete methods. Particularly, the machining stage has to rely on conventional portable machining or, more often, on manual grinding. Neither of these methods is adequate, especially when it comes to the special environment of the nuclear power plants. In this article, a novel design of an automatic orbital milling system intended for machining degraded welds in piping systems is presented. The system incorporates an orbital milling head designed to enable machining within the limited space, combined with a microcontroller-based control system providing full control over the geometry of the weld groove. Thus, the degraded dissimilar metal weld is removed, and simultaneously, the weld groove of desired geometry is prepared rapidly and flexibly, without the need for customized profile cutters, being the main contribution of the proposed design. The system prototype was verified by implementation in the Bohunice V2 nuclear power plant.