CA3213584A1

CA3213584A1 - Apparatus and method for segmentation of large workpieces

Info

Publication number: CA3213584A1
Application number: CA3213584A
Authority: CA
Inventors: David Taro Morikawa
Original assignee: ATS Automation Tooling Systems Inc
Current assignee: ATS Corp
Priority date: 2021-03-26
Filing date: 2022-03-23
Publication date: 2022-09-29
Also published as: KR20240007746A; WO2022198320A1; EP4313483A1

Abstract

A segmentation assembly, including a support framework; a cutting apparatus mounted to the support framework and operable to cut a large workpiece into a plurality of axial segments; and a welding apparatus mounted to the support framework and operable to weld a first plate to a first segment of the plurality of axial segments and a second plate to a second segment of the plurality of axial segments. A method of segmenting a large workpiece, including positioning the large workpiece adjacent a segmentation assembly, the large workpiece including an outer shell elongated along a longitudinal axis of the large workpiece; cutting the large workpiece into a plurality of axial segments along the longitudinal axis; and welding a first plate to a first segment of the plurality of axial segments; and welding a second plate to a second segment of the plurality of axial segments.

Description

TITLE: Apparatus and Method for Segmentation of Large Workpieces CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. Provisional Patent Application No. 63/166,853, filed March 26, 2021. The entire contents of U.S. Provisional Patent Application No. 63/166,853 is hereby incorporated by reference for all purposes.
FIELD
10 [0002] The specification relates generally to decommissioning, and more specifically to apparatus and methods for segmenting large workpieces such as steam generators and heat exchangers.
BACKGROUND
[0003] Korean Patent No. 101721937 purports to disclose a cutting apparatus for cutting a bundle of tubes of a heat transfer tube, wherein the cutting apparatus is arranged in a direction perpendicular to the longitudinal direction of the bundle of tubes at the upper side of the bundle of tubes.
[0004] Korean Patent No. 101164520 purports to disclose a cutting system capable of effectively dismantling large metal waste such as a steam generator, greatly shortening the dismantling period and minimizing the generation of secondary waste. Korean Patent No. 101164520 purports to provide a device for preventing the spread of pollution to the surrounding area by allowing the recovery of chips or dust generated during the cutting process as the dismantling operation is performed in the cutting system.
SUMMARY
[0005] The following summary is intended to introduce the reader to various aspects of the applicant's teaching, but not to define any invention.
[0006] According to some aspects, there is provided a segmentation assembly, comprising a support framework; a cutting apparatus mounted to the support framework and operable to cut a large workpiece into a plurality of axial segments;
and a welding apparatus mounted to the support framework and operable to weld a first plate to a first segment of the plurality of axial segments and a second plate to a second segment of the plurality of axial segments.
[0007] In some examples, the support framework includes a gantry, and the cutting apparatus is mounted to the gantry.
[0008] In some examples, the cutting apparatus is operable, when cutting the large workpiece into the plurality of axial segments, to cut into the large workpiece from a top surface of the large workpiece.
[0009] In some examples, the cutting apparatus includes an elongated cutting member operable to bisect the large workpiece into the plurality of axial segments in a single pass.
[0010] In some examples, the elongated cutting member is a diamond wire saw.
15 [0011] In some examples, the segmentation assembly further comprises a containment assembly mounted to the support framework and operable to contain debris from the large workpiece while the at least one cutting apparatus cuts the large workpiece.
[0012] In some examples, the cutting apparatus is operable to cut the large workpiece at a cutting location on the large workpiece when cutting the large workpiece into the plurality of axial segments, and the containment apparatus is operable to enclose the cutting location when the cutting apparatus is cutting the large workpiece at the cutting location.
[0013] .. In some examples, the containment apparatus includes a plurality of wall portions operable to close against the large workpiece when the large workpiece is in arranged adjacent the cutting apparatus, the plurality of wall portions forming an enclosure around the cutting location when closed against the large workpiece.
[0014] In some examples, the welding apparatus is operable to weld the first plate to the first segment, reorient after welding the first plate to the first segment

2 to face in an opposite direction, and weld the second plate to the second segment after reorienting.
[0015] In some examples, the welding apparatus is rotationally mounted to the support framework to rotate about a reorientation rotational axis, and reorienting after welding the first plate to the first segment to face in an opposite direction includes being rotated about the reorientation rotational axis.
[0016] In some examples, the welding apparatus includes a welding head mounted on a rotatable arm operable to rotate about a welding rotational axis perpendicular to the reorientation rotational axis, such that the welding apparatus is operable to create a first circular weld when welding the first plate to the first segment and a second circular weld when welding the second plate to the second segment.
[0017] In some examples, the large workpiece is a steam generator of a nuclear facility or a heat exchanger of the nuclear facility.
[0018] According to some aspects, there is provided a method of segmenting a large workpiece, comprising: positioning the large workpiece adjacent a segmentation assembly, the large workpiece including an outer shell elongated along a longitudinal axis of the large workpiece; cutting, following (a), the large workpiece into a plurality of axial segments along the longitudinal axis using a cutting apparatus of the segmentation assembly; welding a first plate to a first segment of the plurality of axial segments using a welding apparatus of the segmentation assembly, including welding the first plate to a first portion of the outer shell, the first segment including the first portion of the outer shell;
and welding a second plate to a second segment of the plurality of axial segments using the welding apparatus, including welding the second plate to a second portion of the outer shell, the second segment including the second portion of the outer shell.
[0019] In some examples, the segmentation assembly includes a gantry and the cutting apparatus is mounted to the gantry to cut into a top surface of an object that is positioned under the gantry, and positioning the large workpiece adjacent

3 the segmentation assembly includes positioning the large workpiece under the gantry.
[0020] In some examples, the method further comprises containing debris from the large workpiece while cutting the large workpiece into a plurality of axial segments using the cutting apparatus of the segmentation assembly.
[0021] In some examples, containing the debris includes containing the debris using a containment assembly of the segmentation assembly.
[0022] In some examples, the containment assembly includes a plurality of wall portions, and wherein containing the debris includes, prior to (b), closing the plurality of wall portions against the large workpiece around a cutting location on the large workpiece at which the cutting apparatus is cutting in (b) to enclose the cutting location.
[0023] In some examples, the welding apparatus is not enclosed within an enclosure formed around the cutting location when the plurality of wall portions are closed against the large workpiece, the method further comprising opening the plurality of wall portions prior to (c).
[0024] In some examples, an enclosure formed around the cutting location when the plurality of wall portions are closed against the large workspace is fully enclosed [0025] In some examples, the large workpiece is a steam generator of a nuclear facility or a heat exchanger of the nuclear facility.
BRIEF DESCRIPTION OF THE DRAWINGS
[0026] The drawings included herewith are for illustrating various examples of articles, methods, and apparatuses of the present specification and are not intended to limit the scope of what is taught in any way. In the drawings:
[0027] Figure 1 is a front perspective view of a segmentation assembly;

4 [0028] Figure 2 is a partially transparent front perspective view of a portion of the segmentation assembly of Figure 1;
[0029] Figure 3 is a rear perspective view of a portion of the segmentation assembly of Figure 1;
[0030] Figure 4 is a front perspective view of the segmentation assembly of Figure 1 in a first position;
[0031] Figure 5 is a front perspective view of the segmentation assembly of Figure 1 in a second position;
[0032] Figure 6 is a front perspective view of the segmentation assembly of Figure 1 in a third position;
[0033] Figure 7 is a front perspective view of the segmentation assembly of Figure 1 in a fourth position;
[0034] Figure 8 is a front perspective view of the segmentation assembly of Figure 1 in a fifth position;
[0035] Figure 9 is a front perspective view of the segmentation assembly of Figure 1 in a sixth position;
[0036] Figure 10 is a front perspective view of the segmentation assembly of Figure 1 in a seventh position;
[0037] Figure 11 is a front perspective view of the segmentation assembly of Figure 1 in an eighth position;
[0038] Figure 12 is a front perspective view of the segmentation assembly of Figure 1 in a ninth position;
[0039] Figure 13 is a front perspective view of the segmentation assembly of Figure 1 in a tenth position;

5 [0040] Figure 14 is a front perspective view of the segmentation assembly of Figure 1 in an eleventh position;
[0041] Figure 15 is a front perspective view of the segmentation assembly of Figure 1 in a twelfth position;
[0042] Figure 16 is a front perspective view of the segmentation assembly of Figure 1 in a thirteenth position;
[0043] Figure 17 is a front perspective view of the segmentation assembly of Figure 1 in a fourteenth position;
[0044] Figure 18 is a front perspective view of the segmentation assembly of Figure 1 in a fifteenth position;
[0045] Figure 19 is a front perspective view of the segmentation assembly of Figure 1 in a sixteenth position;
[0046] Figure 20 is a front perspective view of the segmentation assembly of Figure 1 in a seventeenth position;
[0047] Figure 21 is a front perspective view of the segmentation assembly of Figure 1 in an eighteenth position;
[0048] Figure 22 is a front perspective view of the segmentation assembly of Figure 1 in a nineteenth position;
[0049] Figure 23 is a front perspective view of the segmentation assembly of Figure 1 in a twentieth position; and [0050] Figure 24 is a flow chart of a method of segmenting a large workpiece.
DETAILED DESCRIPTION
[0051] Various apparatuses or processes will be described below to provide an example of an embodiment of each claimed invention. No embodiment described below limits any claimed invention and any claimed invention may cover processes

6 or apparatuses that differ from those described below. The claimed inventions are not limited to apparatuses or processes having all of the features of any one apparatus or process described below or to features common to multiple or all of the apparatuses or process described below. It is possible that an apparatus or process described below is not an embodiment of any claimed invention. Any invention disclosed in an apparatus or process described below that is not claimed in this document may be the subject matter of another protective instrument, for example, a continuing patent application, and the applicants, inventors or owners do not intend to abandon, disclaim, or dedicate to the public any such invention by its disclosure in this document.
[0052] Although method steps may be described (in the disclosure and/or in the claims) in a sequential order, such methods may be configured to work in alternate orders. In other words, any sequence or order of steps that may be described does not necessarily indicate a requirement that the steps be performed in that order.
The steps of methods described herein may be performed in any order that is practical. Further, some steps may be performed simultaneously.
[0053] Furthermore, it will be appreciated that for simplicity and clarity of illustration, where considered appropriate, reference numerals may be repeated among the figures to indicate corresponding or analogous elements. In addition, numerous specific details are set forth in order to provide a thorough understanding of the example embodiments described herein. However, it will be understood by those of ordinary skill in the art that the examples described herein may be practiced without these specific details. In other instances, well-known methods, procedures, and components have not been described in detail so as not to obscure the examples described herein.
[0054] As used herein, the wording "and/or" is intended to represent an inclusive - or. That is, "X and/or Y" is intended to mean X or Y or both, for example.
As a further example, "X, Y, and/or Z" is intended to mean X or Y or Z or any combination thereof.

7 [0055] Referring to Figure 1, illustrated is an example of a segmentation assembly 100 for segmenting a large workpiece 106. The assembly 100 includes a frame 110 with a first or front end 112 an opposite second or rear end 114, a first side 116 and a second side 118. The assembly 100 and/or frame 110 also includes a longitudinal axis 120.
[0056] The segmentation assembly 100 includes a cutting apparatus 126 and a welding apparatus 130 (Figure 3) each mounted on the support frame 110. In some examples, the segmentation assembly 100 also includes a containment assembly 134 mounted to the support frame 110 to contain debris (e.g., chips and/or dust released by operation of the cutting apparatus 126) and/or to contain the cutting apparatus 126 (e.g., a saw containment box including two laterally translatable doors).
[0057] The segmentation assembly 100 may be partially or fully automated.
One or more device of the assembly 100 is operable automatically in response to a command from a human user and/or a predetermined condition. For example, the cutting apparatus 126 may be operable to automatically cut through the workpiece 106 in response to a command and/or a condition such as the closing of the containment assembly 134 against the workpiece 106. In another example, the containment assembly 134 is operable to close and/or open automatically in response to a command and/or a condition such as a workpiece 106 positioned adjacent the containment assembly (e.g., between the doors). In some examples, the segmentation assembly 100 is operable to perform a segmentation operation automatically in response to a command or a condition, the segmentation operation including a plurality of automated steps including cutting the workpiece 106 and welding on end caps, discussed further elsewhere herein.
[0058] The large workpiece 106 is at least 5 meters long, and may be at least 7, at least 10, or at least 15 meters long. A large workpiece may be difficult to work with. For example, a large workpiece may be difficult to move, contain, and/or store. Segmenting the large workpiece may make it easier to work with (e.g., after the large workpiece is no longer needed and can be decommissioned).

8 [0059] In some examples, the large workpiece 106 is an elongated workpiece with a length 138 along a longitudinal axis 140 that is greater than a maximum width 142 and/or a height 144 of the workpiece 106. The large workpiece 106 may be segmented into a plurality of axial segments by cutting the large workpiece using the segmentation assembly 100.
[0060] In some examples, the support frame 110 includes a workpiece mount 148 to hold the large workpiece. The workpiece mount 148 may include a base 150 (e.g., a plurality of bases 150) and a removeable fastener 152 (e.g., a plurality of straps 152) such that the large workpiece 106 may be rested on the base 150 and secured to the base 150 using the removeable fastener 152. For example, a separate crane may be used to hoist the large workpiece 106 (e.g., a workpiece with a weight of at least 100 metric tons, 200 metric tons, 300 metric tons, metric tons, or 500 metric tons) onto the base 150 of the segmentation assembly 100.
15 [0061] Referring now to Figure 2, the cutting apparatus 126 may include a cutting member 154 and may include a carrier body 156 to which the cutting member 154 is mounted. The carrier body 156 may be translatable, e.g., vertically translatable to carry the cutting member 154 vertically. The cutting apparatus is operable (i.e., automatically in response to a condition and/or a command) to cut the large workpiece 106 into the plurality of axial segments (e.g., while the large workpiece 106 is mounted on the workpiece mount, such as resting on and/or secured to the base 150).
[0062] In some examples, the frame 110 includes a gantry 160. The cutting apparatus 126 may be mounted to the gantry 160. The cutting apparatus 126 may be operable, when cutting the large workpiece 106 into the plurality of axial segments, to cut into the large workpiece 106 from a top surface of the large workpiece 106. For example, the cutting apparatus 126 may be positioned above the workpiece 106 prior to a cutting operation, and then applied to cut into the top surface of the workpiece 106 and then cut down through the workpiece 106 (e.g.,

9 generally vertically). The workpiece may be orientated with the axis 140 generally parallel to the axis 120 when in a position to be cut.
[0063] In some examples, the cutting apparatus 126 includes an elongated cutting member 154. The elongated cutting member 154 may be operable to bisect the large workpiece into the plurality of axial segments in a single pass. For example, the elongated cutting member 154 may be a band saw or a diamond wire saw. A diamond wire saw may enable the cutting apparatus 126 to more easily cut into the workpiece 106, particularly if the workpiece 106 includes a material that is difficult to cut (e.g., InconelTm). For example, a diamond wire saw may be used when the workpiece is a steam generator or heat exchanger.
[0064] The segmentation assembly 100 may also include a manipulator arm 162. The manipulator arm 162 may be used to apply a tool to the workpiece 106.

The tool may be, e.g., selected from the group including a gripper, an oxy torch, a drill, a laser decontamination device, a grinder, a wire brush, a camera, and a gamma probe.
[0065] Referring now to Figure 3, the welding apparatus 130 is operable to weld plates onto exposed ends of the workpiece and/or segments. In some examples, the welding apparatus is operable to reorient after welding a first plate and then weld a second. The welding apparatus 130 may be operable to rotate between a first orientation in which it faces a first direction to weld against a surface perpendicular to the first direction and a second orientation in which it faces a second direction to weld against a surface perpendicular to the second direction.
The second direction may be at least 45 degrees, at least 90 degrees, or about 180 degrees from the first direction. In some examples, the welding apparatus is operable to be flipped around between welding operations. In some examples, the welding apparatus 130 is rotationally mounted to the frame 110 to be rotated between welding operations. For example, the welding apparatus 130 may be mounted to a rotatable bar 166 to be rotated about a reorientation axis 168 between welds.

[0066] .. The welding apparatus 130 may be a rotary welding device, and may include a welding head 170 mounted on a rotatable arm 172 operable to rotate about a welding rotational axis 174. Accordingly, the welding apparatus 130 may be operable to create a circular weld on a work piece by rotating the arm 172 about the welding rotational axis 174 during a welding operation. The welding rotational arm 172 may be perpendicular to the reorientation rotational axis 168. The welding apparatus 130 may be operable to create a first circular weld when welding the first plate to the first segment and a second circular weld when welding the second plate to the second segment.
[0067] The segmentation assembly 100 may also include a crane 178 to, e.g., lift the workpiece 106. For example, the crane may be used to lift the workpiece 106 onto the base 150.
[0068] The large workpiece 106 may be a component of a nuclear facility (e.g., a component of a nuclear reactor). For example, the large workpiece may be a steam generator (e.g., as in the illustrated example) or a heat exchanger of a nuclear facility. Accordingly, the large workpiece may be contaminated (e.g., radioactive and/or contaminated with radioactive particles).
[0069] The large workpiece 106 may include an outer shell 180. The outer shell 180 may hold contamination within the large workpiece 106 while the outer shell 180 is intact. Cutting the large workpiece 106 into the plurality of axial segments may include cutting into the outer shell 180. The welding apparatus 130 is operable to weld a first plate to a first segment of the plurality of axial segments and a second plate to a second segment of the plurality of axial segments, which may facilitate containing radiation and/or radioactive particles within the segment(s).
25 [0070] Referring now to Figures 4 and 5, the segmentation assembly 100 includes a motive system 186. The workpiece mount 148 and/or the portion of the frame 110 on which the cutting apparatus 126 is mounted (e.g., the gantry 160) is operable to be moved along the frame 110 and/or the rest of the frame by the motive system 186 (e.g., the workpiece mount 148 moved relative to the cutting apparatus 126 or vice versa). The motive system 186 may be operable to move the cutting apparatus 126 relative to the workpiece 126. In some examples, as illustrated, the motive system 186 includes a first track 188 (e.g., a pair of rails) along which the portion of the frame 110 on which the cutting apparatus 126 is mounted (e.g., the gantry 160) is moveable and a second track 190 along which the workpiece mount 148 is moveable.
[0071] Referring now to Figure 6, in some examples, the containment assembly 134 is operable to contain debris from the large workpiece 106 while the cutting apparatus 126 cuts the large workpiece 106 and/or operable to contain the cutting apparatus 126 (e.g., a saw containment box). In some examples, the cutting apparatus 126 is operable to cut the large workpiece at a cutting location 192 on the large workpiece 106 when cutting the large workpiece 106 into the plurality of axial segments, and the containment apparatus 134 is operable to enclose the cutting location 192 when the cutting apparatus 126 is cutting the large workpiece 106 at the cutting location 192.
[0072] The containment assembly 134 may include a plurality of wall portions 198 (e.g., two, as in the illustrated example). The plurality of wall portions 198 are each moveably mounted to the support frame 110 (e.g., to the gantry 160) and moveable between a rest position in which one or more of the wall portions 198 is spaced from the workpiece 106 (e.g., as shown in Figure 5) and a closed position in which they enclose a cutting location 192 on the workpiece 106 (e.g., as shown in Figure 6). The wall portions 198 may be laterally translatable. The wall portions 198 may close against the workpiece 106 from directions perpendicular to the axis 140.
[0073] In the closed position, the wall portions 198 may each abut the workpiece 106, as shown. In some examples, the containment assembly 134 is operable to be closed against the workpiece 106 to enclose the cutting location 192. In some examples, the containment assembly 134 is operable to close against the workpiece 106 without enclosing either axial end of the workpiece 106.
The containment assembly 134 may close against lateral sides of the workpiece 106.

[0074] Referring to Figures 5 and 6, in some examples, the plurality of wall portions 198 include a first wall portion 200 and a second wall portion 202 each having an internal cavity 206 and operable to close against each other around an axial portion of the workpiece 106 (e.g., around a cylindrical workpiece) to form a joined internal cavity 210 with the workpiece 106 extending through the joined internal cavity 210.
[0075] Referring now to Figure 7, the cutting apparatus 126 (e.g., including a diamond wire saw) may be received in the joined internal cavity 210 to cut through (e.g., down through) the axial portion of the workpiece 106 against which the walls 198 have closed. In some examples, as illustrated, the walls are generally horizontal and/or generally perpendicular to the longitudinal axis 140 of the workpiece 106. The cut made by the cutting apparatus 126 may be generally horizontal and/or generally perpendicular to the longitudinal axis 140 of the workpiece 106.
[0076] The containment assembly 134 may be a cutter box shaped to enclose the cutting device 126 (e.g., a saw containment box for a diamond wire saw, as illustrated). The cutter box may be sized to allow the cutting apparatus 126 to move within the joined internal cavity 210. The cutter box may exclude one or more other tools or apparatus of the assembly 100, such as the welding apparatus 130, the motive system 186, the reorientation apparatus 220 (described elsewhere herein) and/or the manipulator arm 162.
[0077] Referring now to Figure 8, the containment assembly 134 may open following a cutting operation of the cutting apparatus 126. In some examples, the segmentation assembly 100 includes a debris removal tool such as a vacuum that may remove debris from the cutting cavity 210 prior to the containment assembly 134 opening.
[0078] Referring now to Figure 9, the segments 216 may be separated (e.g., one or both carried along the second track 190 by the base 150). The segments 216 may be separated by being moved parallel to the longitudinal axis 120. The segments 216 may be moved after the containment assembly 134 has been opened following the cutting operation.
[0079] Referring now to Figures 10 and 11, the welding apparatus 130 is operable to weld end caps 224 on one or each of the now-exposed ends 226 (e.g., newly-exposed) of the segments 216 that are separated by the cutting apparatus 126. For example, the welding apparatus is operable to weld a first end cap on a first segment 232 and a second end cap 234 on a second segment 236. The end caps 224 may each close off the now-exposed end 226 of the segment 216 (e.g., abutting all now-exposed surfaces cut by the cutting apparatus).
[0080] Where the workpiece has an outer shell 180 (e.g., a shell of a steam generator or a heat exchanger) the plates 224 may be welded to the portions of the outer shell 180 of each segment 216 (e.g., only welded to the portion 240 of the outer shell 180 or welded to both the portion of the outer shell 180 and one or more other parts of the segment 216). The welding apparatus 130 may be operable to weld the plate 224 to the outer shell portion 240 along the entire perimeter and/or exposed end of the outer shell portion 240 to close off the now-exposed end of the outer shell portion 240. Welding the plate on the now-exposed end may close off the outer shell portion 240 of the segment (e.g., if the opposite end is already closed off) to turn the segment 216 into a closed container to contain any contaminants in the segment 216.
[0081] The welding apparatus 130 may be operable to create a circular weld on a segment 216. Where the outer shell portion 240 is cylindrical, a circular weld may be helpful in welding the plate to the outer shell portion along the circumference of the outer shell portion. In some examples, the plate 224 is circular in cross section to conform to the shape of the outer shell portion 240.
[0082] The welding apparatus 130 may be repositioned between welding one plate to one segment and another plate to another segment. For example, the welding apparatus 130 may be rotated about a repositioning axis 168 as described elsewhere herein.

[0083] Referring now to Figure 12, the segmentation assembly 100 may be operable to segment the large workpiece 106 into three or more axial segments 216. For example, the segmentation assembly 100 may be operable to segment the large workpiece 106 into five axial segments 216. Each segment may be closed off with an end cap 224. Some segments 216may be closed off with a plurality (e.g., two) of end caps 224 (e.g., where the segment was cut on each end). The segments 216 may be easier to work with than the full-sized workpiece 106.
[0084] Referring now to Figure 13, in some examples the segmentation assembly 100 includes a workpiece reorientation apparatus 246 to reorient the workpiece 106 (e.g., the full workpiece or a part thereof) relative to the cutting apparatus 126 (with may be a main cutting apparatus) and/or a longitudinal axis 120 of the frame 110. The workpiece reorientation apparatus 246 is mounted to the support frame 110. The workpiece reorientation apparatus includes a mount 248 to which the workpiece (the full workpiece or a portion of the workpiece) can be secured, and an actuator 250 operable to reorient the mount to which the workpiece is secured (i.e., rotate the mount relative to the cutting apparatus).
[0085] The workpiece reorientation apparatus 246 may include a tilt table. For example, as illustrated, the mount 248 may include a planar table top against which the workpiece can be secured (e.g., via fastener 252) and the actuator 250 may include a hydraulic cylinder operable to raise and/or lower one side of the table top. The workpiece reorientation apparatus 246 may be operable to reorient the workpiece (i.e., all or a portion thereof) from between horizonal and vertical orientations.
[0086] Referring still to Figure 13, the workpiece 106 may be positioned against the workpiece reorientation apparatus 246 (e.g., against the planar table top).
[0087] Referring now to Figure 14, the workpiece 106 positioned against the workpiece reorientation apparatus 246 may be secured to the workpiece reorientation apparatus 246. For example, the fastener 252 (e.g., one or more straps, clamps, and/or screws) may secure the workpiece against the apparatus 246 (e.g., against the table top). The fastener 252 may hold the workpiece at a location on the workpiece 106 that is adjacent to the apparatus 246 (e.g., within 1 meter, 0.5 meters or 0.1 meter of the surface of the apparatus 246 against which it is held) such that the portion 260 of the workpiece 106 that is secured to the apparatus 246 (e.g., a portion with a length of less than 5 meters, less than meters, or less than 3 meters parallel to the longitudinal axis 140) can be cut free of the rest of the workpiece and remain secured to the apparatus 246.
[0088] Referring now to Figure 15, in some examples the portion 260 is cut free from the rest of the workpiece 106. A cutting apparatus (e.g., cutting apparatus 126) may be used to cut the portion 260 free of the rest of the workpiece 106.
For example, as shown in Figure 15, the cutting apparatus 126 may be positioned adjacent (e.g., above) a cutting location between the portion 260 and the rest of the workpiece 106. The portion 260 may then be severed from the rest of the workpiece 106 as shown in Figure 16.
15 [0089] Referring now to Figure 17, the portion 260 remains secured to the apparatus 246 and may be spaced from the rest of the workpiece 106 (e.g., by moving the rest of the workpiece 106 and/or the reorientation apparatus 246 along the second track 190).
[0090] Referring now to Figure 18, the reorientation apparatus 246 is operable to reorient the portion 260 relative to the first cutting apparatus 246 and/or the longitudinal axis 120 of the frame 110. The reorientation apparatus 246 may be operable to reorient the portion 260 from a horizontal position (i.e., with a longitudinal axis 140 of the portion 260 extending horizontally and/or parallel to the longitudinal axis 120 of the frame110; Figure 17) to a vertical position (Figure 18).
The reorientation apparatus 246 may be operable to lower the portion 260 and/or rotate the portion 260 by at least 45 degrees at least 80 degrees or about 90 degrees. As in the illustrated example, the reorientation apparatus 246 may reorientate the portion 260 by retracting a hydraulic cylinder to rotate the table top about a pivot axis.

[0091] Referring now to Figures 19 to 21, one or more cutting apparatus of the segmentation assembly 100 may be used to cut the portion 260 into disposal pieces. Accordingly, the segmentation apparatus 100 may include one or more cutters in addition to the cutting apparatus 126. For example, a band saw 262 (e.g., a BehringerTM band saw; may be mounted on a second gantry 264) secured to the frame 110 may be used (see, e.g., Figure 19), the cutting apparatus 126 may be used (see, e.g., Figure 20), and/or a cutter 266 (e.g., an oxy torch) mounted to a manipulator arm 162 may be used (see, e.g., Figure 21).
[0092] Referring now to Figure 22, a cleaning device 270 mounted to the manipulator arm 162 may be used to reduce the amount of contamination adjacent the portion 260 (e.g., on the table top and/or on the frame). For example, the cleaning device 270 may be a vacuum to vacuum up debris (e.g., chips and/or dust) that may be and/or include radioactive contamination.
[0093] Referring now to Figure 23, the manipulator arm 162 mounted to the frame 110 (e.g., to the gantry 160) may be used to load the disposal parts into a disposal container 272 (e.g., a free container not mounted to the frame).
[0094] Referring now to Figure 24, illustrated is a method 280 of segmenting a large workpiece (e.g., a steam generator or a heat exchanger). The method 280 includes, at step 282, positioning the large workpiece (e.g., workpiece 106) adjacent a segmentation assembly (e.g., segmentation assembly 100). The large workpiece may include an outer shell elongated along a longitudinal axis of the large workpiece.
[0095] The method 280 also includes, at step 284 following step 282, cutting the large workpiece into a plurality of axial segments along the longitudinal axis using a cutting apparatus of the segmentation assembly (e.g., cutting apparatus 126). The method 280 may include, at step 286, containing debris from the large workpiece while cutting the large workpiece into a plurality of axial segments using the cutting apparatus of the segmentation assembly 100.
[0096] The method 280 also includes, at step 288, welding a first plate to a first segment of the plurality of axial segments using a welding apparatus of the segmentation assembly (e.g., welding apparatus 130), including welding the first plate to a first portion of the outer shell, the first segment including the first portion of the outer shell. At step 290 the method 280 includes welding a second plate to a second segment of the plurality of axial segments using the welding apparatus, including welding the second plate to a second portion of the outer shell, the second segment including the second portion of the outer shell.
[0097] The present invention has been described here by way of example only.
Various modification and variations may be made to these exemplary embodiments without departing from the scope of the invention, which is limited only by the appended claims.

Claims

CLAIMS:

1. A segmentation assembly, comprising:
a. a support framework;
b. a cutting apparatus mounted to the support framework and operable to cut a large workpiece into a plurality of axial segments; and c. a welding apparatus mounted to the support framework and operable to weld a first plate to a first segment of the plurality of axial segments and a second plate to a second segment of the plurality of axial segments.

2. The segmentation assembly of claim 1, wherein the support framework includes a gantry, and the cutting apparatus is mounted to the gantry.

3. The segmentation assembly of claim 2, wherein the cutting apparatus is operable, when cutting the large workpiece into the plurality of axial segments, to cut into the large workpiece from a top surface of the large workpiece.

4. The segmentation assembly of claim 3, wherein the cutting apparatus includes an elongated cutting member operable to bisect the large workpiece into the plurality of axial segments in a single pass.

5. The segmentation assembly of claim 4, wherein the elongated cutting member is a diamond wire saw.

6. The segmentation assembly of claim 1, further comprising a containment assembly mounted to the support framework and operable to contain debris from the large workpiece while the at least one cutting apparatus cuts the large workpiece.

7. The segmentation assembly of claim 6, wherein the cutting apparatus is operable to cut the large workpiece at a cutting location on the large workpiece when cutting the large workpiece into the plurality of axial segments, and the containment apparatus is operable to enclose the cutting location when the cutting apparatus is cutting the large workpiece at the cutting location.

8. The segmentation assembly of claim 7, wherein the containment apparatus includes a plurality of wall portions operable to close against the large workpiece when the large workpiece is in arranged adjacent the cutting apparatus, the plurality of wall portions forming an enclosure around the cutting location when closed against the large workpiece.

9. The segmentation assembly of claim 1, wherein the welding apparatus is operable to weld the first plate to the first segment, reorient after welding the first plate to the first segment to face in an opposite direction, and weld the second plate to the second segment after reorienting.

10. The segmentation assembly of claim 9, wherein the welding apparatus is rotationally mounted to the support framework to rotate about a reorientation rotational axis, and reorienting after welding the first plate to the first segment to face in an opposite direction includes being rotated about the reorientation rotational axis.

11. The segmentation assembly of claim 10, wherein the welding apparatus includes a welding head mounted on a rotatable arm operable to rotate about a welding rotational axis perpendicular to the reorientation rotational axis, such that the welding apparatus is operable to create a first circular weld when welding the first plate to the first segment and a second circular weld when welding the second plate to the second segment.

12. The segmentation assembly of claim 1, wherein the large workpiece is a steam generator of a nuclear facility or a heat exchanger of the nuclear facility.

13.A method of segmenting a large workpiece, comprising:
a. positioning the large workpiece adjacent a segmentation assembly, the large workpiece including an outer shell elongated along a longitudinal axis of the large workpiece;

b. cutting, following (a), the large workpiece into a plurality of axial segments along the longitudinal axis using a cutting apparatus of the segmentation assembly;
c. welding a first plate to a first segment of the plurality of axial segments using a welding apparatus of the segmentation assembly, including welding the first plate to a first portion of the outer shell, the first segment including the first portion of the outer shell; and d. welding a second plate to a second segment of the plurality of axial segments using the welding apparatus, including welding the second plate to a second portion of the outer shell, the second segment including the second portion of the outer shell.

14. The method of claim 13, wherein the segmentation assembly includes a gantry and the cutting apparatus is mounted to the gantry to cut into a top surface of an object that is positioned under the gantry, and positioning the large workpiece adjacent the segmentation assembly includes positioning the large workpiece under the gantry.

15. The method of claim 13, further comprising containing debris from the large workpiece while cutting the large workpiece into a plurality of axial segments using the cutting apparatus of the segmentation assembly.

16. The method of claim 15, wherein containing the debris includes containing the debris using a containment assembly of the segmentation assembly.

17. The method of claim 16, wherein the containment assembly includes a plurality of wall portions, and wherein containing the debris includes, prior to (b), closing the plurality of wall portions against the large workpiece around a cutting location on the large workpiece at which the cutting apparatus is cutting in (b) to enclose the cutting location.

18. The method of claim 17, wherein the welding apparatus is not enclosed within an enclosure formed around the cutting location when the plurality of wall portions are closed against the large workpiece, the method further comprising opening the plurality of wall portions prior to (c).

19. The method of claim 17, wherein an enclosure formed around the cutting location when the plurality of wall portions are closed against the large workspace is fully enclosed.

20. The method of claim 13, wherein the large workpiece is a steam generator of a nuclear facility or a heat exchanger of the nuclear facility.