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Nuclear Showcase 29th January - Manufacturing and the Supply Chain
- 4. The UK’s Rich History and Experience in Nuclear Systems Dame Sue Ion FREng Chairman Nuclear Innovation Research Advisory Board
- 5. Civil Nuclear Export Showcase Dame Sue Ion FREng Chairman Nuclear Innovation Research Advisory Board
- 6. Civil nuclear power: UK 1950 1960 1970 1980 1990 Present Gas-cooled reactors Magnox 1956 Sodium-cooled fast reactors 1959 DFR Water-cooled reactors HTR 1965-1976 1967 SGHWR AGR 1977 PFR 1976 1990 1974 1995 1994 Sizewell B PWR
- 7. Windscale Air Cooled Piles
- 8. UK Nuclear Generation Magnox - Calder Hall AGR -Heysham PWR - Sizewell ‘B’
- 9. Opening of Calder Hall 1954
- 10. UK’s Early Magnox Power Stations
- 11. Last two UK Magnox Stations Oldbury Magnox Technology Exported Latina Italy Tokai Mura Japan Wylfa
- 12. UK: a first mover in fast reactor technology at Dounreay With Demonstration and Prototype Reactor Systems
- 13. UK AGR Sites Hartlepool Heysham1 Dungeness Hinkley B Hunterston B Heysham 2 Torness
- 14. Sizewell B PWR
- 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
- 18. Advanced Manufacturing Research and Innovation
- 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
- 20. Dalton Cumbrian Facility Academic gateway to NNL Engineering decommissioning Radiation Science
- 23. JET Europe’s Flagship Research Facility MAST the UK’s Fusion Experiment
- 24. ITER : the next step towards Fusion Power
- 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
- 27. Legacy Ponds and Silos now being decommissioned
- 28. New Stores constructed at UK reactor sites to hold waste Hunterston Trawsfynydd
- 29. New ventilation and extract systems constructed to enable work to proceed on old facilities
- 31. Change is already a Reality Before After
- 32. Old facilities cleared Early 1960’s to September 2002 December 2002
- 33. Clear out of beta/gamma facilities
- 34. Pile Chimney Demolition at Sellafield Before After
- 35. Decommissioning and Reuse of an ALPHA Facility Before: Fast Reactor Fuel Facility After: Store for Pu contaminated waste
- 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
- 41. UKTI Nuclear Conference 27th – 28th – 29th January 2014 The Essential Guide’ for the New Nuclear Build Supply Chain Dr Glen Little Director Nuclear New Build Doosan Babcock
- 46. UK Imperatives Civil Nuclear Diverse Technology
- 47. UK Imperatives Civil Nuclear Economic Strike Price
- 48. UK Imperatives Civil Nuclear Develop UK Advanced Manufacturing Capability and Capacity
- 49. UK Imperatives Civil Nuclear Creating long term, high value jobs
- 50. Nuclear AMRC Purpose To help UK manufacturers win work
- 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
- 54. We Operate in the UK Civil Nuclear Market Place Nuclear New Build Existing Nuclear Fleet Nuclear Decommissioning
- 55. Nuclear AMRC Work Programmes
- 59. Nuclear AMRC Technology Themes Welding & Cladding Materials Development Advanced Machining Structural Integrity Inspection & NDE Thermal & Surface Treatment Mechanisation & Automation Design & Quality Hot Isostatic Pressing (HIPing) Additive Layer Processes Modeling, Simulation & Visualisation Productivity & Manufacturing Optimisation Assembly Applied Metrology
- 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
- 61. www.namrc.co.uk
- 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
- 70. Civil Nuclear Nuclear Cask Seal Housings Rotor Forging Steam Generator Shell Tubesheet Transition Cone British Nuclear Forgings
- 75. Nuclear Castings Westinghouse AP1000 Pump Casing Stainless Steel for Safety Critical Application British Nuclear Forgings
- 76. Nuclear Ingot Development British Nuclear Forgings
- 77. Hollow and Conventional Ingots British Nuclear Forgings
- 78. Hollow Ingots British Nuclear Forgings
- 79. Section Through Forging Generator Shape Steam British Nuclear Forgings
- 80. Transition Cone Shape Forging British Nuclear Forgings
- 81. Forming a Spherical dome British Nuclear Forgings
- 82. Extruded Nozzles British Nuclear Forgings
- 83. Quench Optimisation Pump Casing Shell Forging Water Immersion Quench British Nuclear Forgings
- 84. Collaborators Research Partners 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
- 88. UKTI Nuclear Conference 27th – 28th – 29th January 2014 Manufacturing and The supply Chain
- 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
- 94. UKTI Nuclear Conference 27th – 28th – 29th January 2014 Manufacturing and The supply Chain
- 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
- 100. Internal Transportation on Site Companies with available equipment in UK : •ALE •Mammoet •Sarens
- 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
- 103. UKTI Nuclear Conference 27th – 28th – 29th January 2014 Manufacturing and The supply Chain
- 104. UKTI Nuclear Conference 27th – 28th – 29th January 2014 Specialist Control and Instrumentation Equipment Neil Foreman Chairman Centronic Ltd
- 105. Content General UK Sector Overview What type of Equipment is Available Examples of Suppliers 108
- 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
- 113. Reactor Technologies Supplied by Centronic MAGNOX AGR BWR CANDU PHWR PWR VVER
- 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
- 116. UKTI Nuclear Conference 27th – 28th – 29th January 2014 Manufacturing and The supply Chain
- 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
- 122. Complex Robotic Manipulators Inspection deploys complex manipulators which are tested in a realistic environment and conditions 126 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
- 129. Thank you - Questions Please 133
- 130. UKTI Nuclear Conference 27th – 28th – 29th January 2014 Manufacturing and The supply Chain
- 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
- 132. The UK Nuclear Valve Industry UK Heritage Brands
- 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
- 137. UKTI Nuclear Conference 27th – 28th – 29th January 2014 Manufacturing and The supply Chain
- 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
- 140. Innovation key ingredients • • Painful, expensive. • Share responsibilities. • Commitment. • Communication. • 145 No blame. Brutally honest communication.
- 142. WallRover A 2nd Generation Concept 147 1st Generation
- 143. WallRover B – Heavy lift vehicle WallRover B – Drill Payload 148
- 144. WallRover Box Project – 1st Generation 149
- 145. WallRover Box Project 2 Generation nd 150
- 146. WallRover Box Project – 3rd Generation 151
- 147. 152
- 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
- 149. UKTI Nuclear Conference 27th – 28th – 29th January 2014 Manufacturing and The supply Chain
- 150. UKTI Nuclear Conference 27th – 28th – 29th January 2014 Summary & Close Terry Gilbert Conference Chair
- 151. UKTI Nuclear Conference 27th – 28th – 29th January 2014 Manufacturing and The supply Chain
Hinweis der Redaktion
- SFRs: 1958-1969 - Dounreay MTR 1959-1977 – DFR (14 MWe) 1974-1994 – PFR (250 MWe, 600 MWt) Magnox: 1956-71 HTR: 1966 - 1976 AGRs: 1976 - 1990 SGHWR: 1967 - 1990 SXB: 1995 - ?
- 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.