15. The UK’s ambitions for new build
AREVA EPR
Westinghouse AP1000
Hitachi ABWR
16. Small Modular Reactors
• Now seen by some as very attractive
• Economics more favourable with 21Century manufacturing
technology
• Better from a grid management perspective
• May be possible to re-examine some of the UK’s smaller old
Magnox sites
• Export potential to areas with no large scale grid
• UK assessing prospects for development and deployment
17. Full Fuel Cycle Industrial Experience
Springfields
Fuel Manufacture
Sellafield
Reprocessing , Waste management
And decommissioning
Capenhurst
Enrichment
19. Academic Nuclear R&D in the UK
•
Numbers of people in UK academic nuclear
R&D:
– Academics:
– PDRAs:
– PhDs:
– TOTAL:
•
230 (FTE)
134
627
991
To put these numbers into context, there are
around 1250 nuclear R&D staff in UK
National Laboratories and around 400 in
industry
Source: Dalton Nuclear Institute
26. ONR: The UK’s Nuclear Regulator:
Over 60 years of Experience
Nuclear Installations
Act, 1959
Health and Safety
Executive 1974
Office of Nuclear Regulation
ONR 2011
35. Decommissioning and Reuse of an
ALPHA Facility
Before:
Fast Reactor Fuel Facility
After:
Store for Pu contaminated waste
36.
37. The UK’s Rich History and Experience
in Nuclear Systems
• A wealth of talent, capability and modern facilities in UK Industry,
National Lab and Academia
• All being applied to the new build, operations, fuel cycle, waste
management and decommissioning challenges of the 21st Century
38
Presentation title - edit in the Master slide
51. Orgreave Restoration Scheme - 1994
■ Cleaned up
extensive
contamination and
dereliction from
200 years of
mining
■ Recovered four
million tonnes of
shallow coal
reserves
Coking works – 1990 before demolition
52. Nuclear AMRC Key Objectives
■ To raise the quality, capability and cost-competitiveness of the UK civil
nuclear manufacturing supply chain, to a level of “best global practice”
■ To work with UK Manufacturers and develop world-leading manufacturing
processes and technologies
60. High Value Manufacturing Catapult
The High-Value
Manufacturing Catapult
(HVMC) is a consortium of 7
world-leading research
centres with £350m public &
private investment and
working with over 160
industrial partners. It
receives grant funding of
around £30m per annum
66. Sales Mix
Historical sales mix at the
Management Buyout
Current sales mix
10% value added
services
100% manufacturing
90% manufacturing
Highly cash generative
service offering
British Nuclear Forgings
85. Key industry and regulatory accreditations
ISO 9001:2008
ISO 14001:2004
ISO 18001:2007
Lloyds Register:
Steelmaking
Forging
Casting
British Nuclear Forgings
ASME:
NCA3800
86. Key industry and regulatory accreditations
ASME NPT Accreditation
British Nuclear Forgings
87. Conclusions
• The nuclear industry is about Quality first
• It demands a combination of both resources and technologies to
meet the most demanding challenges.
• Sheffield Forgemasters combines experience with advanced
manufacturing techniques to support the nuclear industry
British Nuclear Forgings
89. UKTI Nuclear Conference 27th – 28th – 29th January
2014
Bespoke Engineering Solutions
Andrea Basso
Head of Engineering
Nuclear Engineering Services (NES)
90. Why bespoke engineering solutions?
Wastes – 1 April 2010 and estimated for future arising volume and masses in UK
NDA – The 2010 UK Radioactive Waste Inventory: Main Report
93
91. Nuclear Waste in the UK
Majority of the Nuclear wastes in the UK are stored at Sellafield in four main storage facilities.
These facilities contain waste such as: irradiated and non-irradiated steel, activated stainless steel, reactive metals, organic /
cellulosic material, graphite, cans and drums etc.
94
92. Why we need Bespoke Solutions
We need unique bespoke solutions to
retrieve, size reduce and encapsulate
waste
• Two mechanical rotating, extending arms with and
end effector which is able to pick-up a rope and crab
in-cell from a crane or other device and manage the
deployment of the crab to cover the full silo surface.
• The arms are extendable to 4 metre length and
designed and manufactured with tolerances at full
extension +/- 50mm and +/- 0.1 degree on rotation.
• To drive the arms a chain driven system was
developed.
• SSD could be fully software integrated with the crane
or other rope and crab deployment.
NES Solution - Second Stage Deployment
(SSD) system
93. NES Solution - Waste levelling Silo Rake
• The rake ensures waste is levelled for flat retrieval
to avoid loading the civil structure of the silo with
forces derived from the collapsing of unlevelled
waste.
• Silo rake fits inside a standard 3m3 skid for input
and export into and from the silo.
• Deployed attached by rope.
• Fully extended up to 6m length.
• Chain driven system, not hydraulic cylinders.
• Collapses vertically in failure mode allowing the
rake to exit from the silo
• Raking does not apply forces to the
civil structure
95. UKTI Nuclear Conference 27th – 28th – 29th January
2014
Range of available Heavy
Transportation
& Heavy Lifting Techniques
Gerrit Zenner
Global Area Sales Manager
Sarens Group Nuclear & Thermal Plants
96. Modular or Stick Built Solutions
•
Partially or entirely constructed in factory
•
Transport to site for assembly and installation
•
Needs depend of technology provider
•
There are some copy / paste systems (e.g. AP1000)
•
Equipment build on frames (skid) or tailor made
97. Modular or Stick Built Solutions
•
Primary circuit equipment is tested prior to
arrival – in one piece – example reactor &
steam generators
•
Need for good supply chain
•
Plenty of modular yards on
West coast of UK & Scotland
98. Options for Transportation
•
Moorside Sellafield & Wylfa : will have interface
between Sea & Land
•
Inventive solutions:
River transport
Beach landing
99. Building a Jetty (temporary)
• Building jetty (for maintenance afterwards)
• Port facilities
• Semi Submersible ships
• Geared ships
• Barges (different sizes) – draft - roro
101. Super Heavy Lifting Equipment
•
Up to 200,000 M/T is available
•
Capacity up to
5.000 ton @ 40m radius
•
Global experience:
ALE – Mammoet – Sarens
•
OPEN TOP for installations of equipment or …..
102. Availability of Techniques
•
•
early engineering & involvement
Why :
Different concepts with feasibility study
Bringing in equipment after Polar Crane &
Dome is installed
•
Our advise :
Skidding & Jacking in via Hatch
Reactor & Steam generators
106. What do we do in the UK….
We build reactors
We support operations
We decommission reactors and nuclear facilities
109
107. Applications Supported by UK
Equipment Suppliers
RC & I
Process Control
Security and Area/Environmental Monitoring
Health Physics
High Energy Physics
110
108. Examples of UK Specialist Instrumentation Suppliers
Canberra
Cavendish Nuclear
Mirion Technologies
Rolls-Royce Nuclear
Ultra Electronics
ANTECH
Centronic
Cooknell Electronics
Delta Controls
Hybrid Instruments
Labimpex Systems
Southern Scientific
Tracerco
109. Supplying International Markets
ANTECH
Delta Controls
Canada
Canada
Canada
USA
USA
USA
South Korea
South Korea
South Korea
Japan
Japan
China
China
China
India
Finland
India
Middle East
Australia
Middle East
Sweden
Europe
112
Centronic
Spain
110. Delta Controls
Delta Controls have been
manufacturing process control
Instrumentation for the nuclear
industry for over 40 years
The Delta range of products
have been designed and tested to
meet the requirements of todays
NPP and are used extensively in
critical areas of process control
111. ANTECH
ANTECH designs and manufactures
equipment for waste measurement,
nuclear safeguards and radiation
detection
Founded in 1987 ANTECH has a
broad international customer base
including government laboratories,
power stations and nuclear industry
operators and contractors
112. Centronic
Centronic was formed in 1945 and has
been supplying the world nuclear
industry for over 68 years
Centronic designs and manufactures
radiation detectors for reactor control,
health physics, environmental
monitoring and security applications as
well as radiation tolerant cameras
and systems
114. Summary
The UK has a vibrant and internationally active supply chain that supplies
specialist RC&I and process control instrumentation around the world
The UK has a supply chain that can support a wide range of nuclear
applications, across different reactor technologies
UK suppliers are used to working on overseas projects and supporting
overseas customers and partners for the long term
The wide range of skills and exceptional breadth of experience in the UK
supply chain is adding value to the nuclear industry both in the UK market as
well as internationally - and is ready to do more…..
117
115. Specialist Control and
Instrumentation Equipment
Thanks for listening!
Neil Foreman, Chairman
Centronic Ltd
118
Presentation title - edit in the Master slide
117. UKTI Nuclear Conference 27th – 28th – 29th January
2014
High Integrity Inspection Technology
Colin Bird
Business Development Manager
Doosan Babcock
Doosan Babcock
118. High Integrity Inspection Design, Consultancy and
Application
UK NDT (Inspection) industry cooperates to
provide integrated inspection solutions
throughout the world.
Reliable procedure development
Qualification
Training
Implementation
Technology transfer
Underpinned by basic research
122
Doosan Babcock
119. France
NDT Experience Outside of UK
Argentina
Lithuania
Russia
Sweden
Lithuania
Ukraine
China
Bulgaria
Finland
Hungary
South Africa
Doosan Babcock
123
Czech Republic
120. UK Investment in NDT Technology
40 year investment in Inspection (NDT) for the Civil Nuclear Industry
in the UK.
People: UK Industry invests heavily in graduate and technician
training schemes.
Techniques: Company & Government support for technique and
equipment development.
Research - RCNDE formed in 2003 through collaboration of
government, industry and universities.
Implementation – Investment in Inspection Qualification & Human
Factors
This investment enables UK to be a world leader in nuclear
inspection technology.
124
Doosan Babcock
121. Complex Nozzle and Pipe Inspection
Primary circuit nozzle
inspection for EDF
France.
Doosan Babcock provides inspection
service to 28 French nuclear power
units.
All inspections are qualified to the
highest level RSE-M Code.
This qualification follows the guidelines
of ENIQ.
125
Doosan Babcock
123. In service Monitoring of Plant
In line crack monitoring on operating plant
Advanced defect analysis methods
127
Doosan Babcock
124. Confidence through ENIQ
European Network For
Inspection Qualification
Appropriate assessment of an NDT
system giving reliable confirmation it is
capable of achieving the required
performance under real conditions.
Our inspection qualification
commences with agreement of the
required defect detection and sizing
targets with the client and regulator.
128
Doosan Babcock
125. Inspection Qualification
Qualification of manufacturing, pre-service
and in-service inspections
Inspection design underpinned with
mathematical modelling
Construction of test pieces
Training of personnel
Trials
Open – procedure
Blind – personnel
Technical Justification
Certificates Issued
AMEC’s IVC is the UK Independent
Qualification Body
129
Doosan Babcock
126. Testing on Mock Ups
Our inspection systems are tested on test
pieces containing realistic defects and
representing access.
Test pieces designed to provide validation of
inspection system.
Ensures effective preparation before application
on site.
Testing includes training on these test pieces.
Enabling young engineers to train in a safe
environment.
e.g. Inspection systems for Atucha Argentina.
130
Doosan Babcock
127. Compliance with National Regulators
All countries have different regulatory
requirements.
ENIQ is a framework which can be adapted
to meet local needs.
AMEC and Doosan Babcock have 25
years of experience using ENIQ which has
enabled to them to provide Qualification
and Inspection support throughout the
world under different regulatory regimes.
131
Doosan Babcock
128. Offered Inspection Services & Technology
Research – Advanced techniques
Phased Array: FMC – TFM imaging
Inspection Design - Complex Geometry, Modelling of Ultrasonics,
Electromagnetic, Radiography
Consultancy
Inspection Qualification
In Manufacture Inspection
Pre-Service Inspection
In Service Inspection
Plant Monitoring
132
Doosan Babcock
131. UKTI Nuclear Conference 27th – 28th – 29th January
2014
Supplying Specialist Valves
Delivering highly engineered valves to the global nuclear industry
from a UK base
Ian Tough
Nuclear Sales & Product Manager
UK Valves, Weir Group PLC
133. Modern Valve Design & Manufacture
•Heath & Safety as the #1 priority
•World class manufacturing methods
•Advanced Computer Aided Design
•Internationally recognised standards
•Strong nuclear culture
•Global sourcing & representation
137
Hopkinsons, Britannia Works Site, Birkby, Huddersfield, Circa. 1915
Weir Valves & Controls UK, Britannia House, Elland, 2013
134. MSIV Case Study
•
Main Steam Isolation Valve for Changjiang Nuclear
Power Plant, Hainan Island, China.
•
Manufactured by Weir Valves & Controls UK Ltd,
Elland, West Yorkshire, UK.
•
Rotork-Hiller Gas charged hydraulic actuator, with
fast closure of 5 seconds.
•
Key benefits of UK manufacture were strong
experience base, qualified product and an
established supply chain
•
Over 80% of finished components are UK
manufactured.
138
Changjiang NPP, Under Construction in China
Image from inventorspot.com
Assembling the disc into the body of the MSIV at
the WVC UK facility in Elland, West Yorkshire UK
135. MSIV Case Study
Shipped to Changjiang site in 2013 after successful
performance testing at the Elland Factory.
The final valve stood almost 5 metres tall, weighed
over 13 tonnes and was shipped with over 100
binders of documentation.
An apprentice engineer preparing valve for shipment from WVC UK, 2013
139
MSIV Awaiting Shipment from WVC UK, 2013
136. Why choose the UK for specialist valves?
Global Reach &
International
Partnerships
Advanced R&D
Programme
140
Quality, Heritage
and Experience
Excellent Safety
Performance
Stable Aftersales
Support
Industry &
Government
Partnership on UK
Nuclear Strategy
138. Innovation
Developing new tools and techniques for the nuclear
decommissioning industry
Richard Smith
Technical Director
Reaching the unreachable
cheaper, faster, safer
143
Presentation title - edit in the Master slide
139. Sources of innovation in industry
•
•
Universities
Traditional approach
•
144
Large company R&D Departments
First to be cut in times of austerity
SME’s
Untapped resource – Strength of British industry
148. 2013 NDA Awards
“I was extremely surprised yet
delighted to receive this award; it is an
acknowledgement of our efforts and
shows what collaborative working can
achieve. I’ve been working with
WallRover for two years to give us this
unique and versatile tool. It has been a
combination of a novel idea, belief and
an appreciation of its potential at an
early stage that enthuses all to see it
Highly Commended award for championing Small succeed.”
to Medium sized Enterprises (SME) innovation
Alex Jenkins
Sellafield Ltd
153
This presentation will attempt to give a flavour of what specialist equipment is available from the UK supply chain and also to demonstrate how the UK is supporting the industry around the world.
I will give a bit of a flavour of the supply chain from a UK perspective, describe some of the equipment that is on offer and use some examples of suppliers to demonstrate capability.
I am sure you will understand that I can only talk with any degree of authority on my own company so will use Centronic as one of the examples.
I think its worth noting what we have in the UK. As we’ve heard already during the course of the showcase, the UK has been building reactors since the industry started with Calder Hall being one of the earliest civil reactors.
From then the supply chain grew up and built all the civil fleet in the UK as well as diversifying in to other sectors. Over the years we have continued to support reactor operations, innovating in support of plant life extension and indeed continuing to build reactors for the naval fleet.
That same industry has continued to respond to the demand for new solutions and techniques as we decommission reactors and facilities.
An extremely high percentage of all the specialist equipment for process control and instrumentation is sourced from UK companies.
These are just some of the applications that are supported by UK companies that design and manufacture equipment and electronics for the industry.
Many of these are safety critical applications and it is essential that the suppliers are suitably skilled and experienced.
Many of them specialise in specific aspects of the applications with multiple tiers completing the solution.
I should state for the record that all these company's have been listed alphabetically, selected at random and I apologise if anyone feels they should also have been listed!
I am sure everyone here will recognise the company names in the list on the left of this slide. If have listed them as examples of more recognisable business that are either British or have significant activities in the UK. They all supply equipment for the industry and represent some of the excellence that can be found here, particularly at the tier 2 and 3 level.
The list on the right is made up of smaller company's that supply a variety of products for different specialist applications.
I will use ANTECH, Centronic and Delta as examples in a moment but the other companies listed are generally suppliers of radiation protection instruments, electronics or systems.
The three companies I have sampled are ANTECH, Centronic and delta controls. ANTECH supplies measurement and monitoring instruments and systems, Centronic detectors and cameras for RC&I and process control and Delta Controls supplies pressure switches, transmitters and temperature switches.
I wanted to show this slide in order to demonstrate that we in the UK are used to supplying the industry worldwide.
In fact both Centronic and ANTCH also have facilities in the US and Delta have offices in China in order to support their clients.
Delta controls is a company not unlike Centronic in as much as it also has products that it supplies across the energy and other sectors and so is not totally reliant on nuclear.
This is an example example of a differential pressure switch manufactured from Radiation resistant materials and qualified for nuclear applications
ANTECH are a comp[any that specialises in measuring radiation. They have a highly skilled team that design instruments and have nearly thirty years of experience.
This photo shows a wide range segmented gamma ray scanning assay instrument installed in the waste measurement room at Loviisa.
This clearly shows that in addition to designing the electronics and integrating the sensors needed to measure the radioactivity they also incorporate the mechanical handling required.
These photographs are of a camera typically used for process control monitoring such as in a vitrification plant and a selection of detectors.
The company has a multi-disciplined team that understands all that it takes to design and manufacture products for these safety critical applications.
The product demands expertise in physics, materials, electronics (analogue and digital), chemistry and mechanical engineering as well as project management skills for delivering major contracts. Centronic has installed bases in most countries that have nuclear plant.
They supply the worlds leading brand of GM tube and have manufacturing facilities in the UK and the US.
This slide demonstrates that although the UK is not a supplier of any particular reactor technology its supply chain supports all types.
I have included the first two as an indication of our ‘heritage’ but they do of course also still require support through their plant life extension.
Delta Controls can produce a similar list and at lot of UK companies are supplying to multiple projects around the world. Indeed it is looking increasingly likely that the UK will be build EPR, ABWR and PWR reactors in the next ten years. Not only does that make it one of the most exciting markets in the world but it will also enable a diverse ‘technology agnostic’ supply chain.
I stated at the start of the presentation that I spend a proportion of my time supporting UK industry from an export perspective.
I believe passionately that our nuclear industry supply chain is in rude health and that the standard and quality of our components, electronics and instruments are outstanding.
They have been developed over many years to meet a wide variety of applications and are in use all over the world.
If anyone seeks more information on any of the companies I have mentioned then please do not hesitate to contact me after the session.