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UKTI Nuclear Conference  
27th – 28th – 29th January 2014
 

Manufacturing and The supply Chain
UKTI Nuclear Conference  27th – 28th – 29th January 
2014

Welcome 
 

Keith Parker
CEO
Nuclear Industry Association 
UKTI Nuclear Conference  
27th – 28th – 29th January 2014
 

Manufacturing and The supply Chain
The UK’s Rich History and Experience
in Nuclear Systems
Dame Sue Ion FREng
Chairman
Nuclear Innovation Research Advisory B...
Civil Nuclear Export Showcase
Dame Sue Ion FREng
Chairman
Nuclear Innovation Research Advisory Board
Civil nuclear power: UK
1950
1960
1970
1980
1990
Present

Gas-cooled
reactors
Magnox
1956

Sodium-cooled fast
reactors
195...
Windscale Air Cooled Piles
UK Nuclear Generation

Magnox
- Calder Hall

AGR
-Heysham
PWR
- Sizewell ‘B’
Opening of
Calder Hall 1954
UK’s Early Magnox Power Stations
Last two UK Magnox Stations

Oldbury

Magnox Technology Exported

Latina Italy

Tokai Mura Japan

Wylfa
UK: a first mover in fast reactor technology at Dounreay
With Demonstration and Prototype Reactor Systems
UK AGR Sites
Hartlepool

Heysham1

Dungeness

Hinkley B

Hunterston B

Heysham 2
Torness
Sizewell B PWR
The UK’s ambitions for new build
AREVA EPR
Westinghouse AP1000

Hitachi ABWR
Small Modular Reactors
• Now seen by some as very attractive
• Economics more favourable with 21Century manufacturing
tech...
Full Fuel Cycle Industrial Experience

Springfields

Fuel Manufacture

Sellafield

Reprocessing , Waste management
And dec...
Advanced Manufacturing Research and Innovation
Academic Nuclear R&D in the UK
•

Numbers of people in UK academic nuclear
R&D:
– Academics:
– PDRAs:
– PhDs:
– TOTAL:

•
...
Dalton Cumbrian Facility

Academic gateway
to NNL

Engineering
decommissioning

Radiation Science
NNL Central Laboratory
JET Europe’s
Flagship Research Facility

MAST the UK’s
Fusion Experiment
ITER : the next step towards Fusion Power
ONR: The UK’s Nuclear Regulator:
Over 60 years of Experience
Nuclear Installations
Act, 1959
Health and Safety
Executive 1...
Legacy Ponds and Silos now being decommissioned
New Stores constructed at UK
reactor sites to hold waste
Hunterston

Trawsfynydd
New ventilation
and extract systems
constructed to
enable work to
proceed on old
facilities
New
Facilities
at Dounreay
Change is already a Reality

Before

After
Old facilities cleared

Early 1960’s to September 2002

December 2002
Clear out of beta/gamma facilities
Pile Chimney Demolition at Sellafield

Before

After
Decommissioning and Reuse of an
ALPHA Facility

Before: 
Fast Reactor Fuel Facility

After:
 Store for Pu contaminated was...
The UK’s Rich History and Experience
in Nuclear Systems
• A wealth of talent, capability and modern facilities in UK Indus...
UKTI Nuclear Conference  
27th – 28th – 29th January 2014
 

Manufacturing and The supply Chain
UKTI Nuclear Conference  27th – 28th – 29th January 
2014

Manufacturing and The supply Chain
Moderator
 

Jason Smith
Pre...
UKTI Nuclear Conference  
27th – 28th – 29th January 2014
 

Manufacturing and The supply Chain
UKTI Nuclear Conference  27th – 28th – 29th January 
2014

The Essential Guide’ for the New 
Nuclear Build Supply Chain
 
...
UKTI Nuclear Conference  
27th – 28th – 29th January 2014
 

Manufacturing and The supply Chain
UKTI Nuclear Conference  27th – 28th – 29th January 
2014

The Decommissioning and Waste Management 
Supply Chain 1947 to ...
UKTI Nuclear Conference  
27th – 28th – 29th January 2014
 

Manufacturing and The supply Chain
UKTI Nuclear Conference  27th – 28th – 29th January 
2014

Nuclear Supply Chain
 

Mike Tynan
CEO
The Nuclear Advanced Man...
UK Imperatives Civil Nuclear
Diverse Technology
UK Imperatives Civil Nuclear
Economic Strike Price
UK Imperatives Civil Nuclear
Develop UK Advanced Manufacturing Capability and Capacity
UK Imperatives Civil Nuclear
Creating long term, high value jobs
Nuclear AMRC Purpose
To help UK manufacturers win work
Orgreave Restoration Scheme - 1994
■ Cleaned up
extensive
contamination and
dereliction from
200 years of
mining
■ Recover...
Nuclear AMRC Key Objectives

■ To raise the quality, capability and cost-competitiveness of the UK civil
nuclear manufactu...
Industry-led Partnership:
We Operate in the UK Civil Nuclear
Market Place
Nuclear New Build

Existing Nuclear Fleet
Nuclear Decommissioning
Nuclear AMRC Work Programmes
Supplier Development
Programme
Supporting Programmes
Innovative Manufacturing
Nuclear AMRC Technology Themes
Welding & Cladding

Materials
Development

Advanced Machining

Structural
Integrity

Inspec...
High Value Manufacturing Catapult
The High-Value
Manufacturing Catapult
(HVMC) is a consortium of 7
world-leading research...
www.namrc.co.uk
UKTI Nuclear Conference  
27th – 28th – 29th January 2014
 

Manufacturing and The supply Chain
UKTI Nuclear Conference  27th – 28th – 29th January 
2014

Nuclear Supply Chain
 

Brian McConnell
Chairman
NIA New Build ...
UKTI Nuclear Conference  
27th – 28th – 29th January 2014
 

Manufacturing and The supply Chain
UKTI Nuclear Conference  27th – 28th – 29th January 
2014

British Nuclear Forgings
 

Graham Honeyman
CEO
Sheffield Forge...
Sales Mix
Historical sales mix at the
Management Buyout

Current sales mix
10% value added
services

100% manufacturing

9...
Company Structure

British Nuclear Forgings
2008-2009 Product Mix

British Nuclear Forgings
2011-2012 Product Mix

British Nuclear Forgings
Civil Nuclear

Nuclear Cask

Seal Housings

Rotor Forging

Steam Generator Shell

Tubesheet

Transition Cone

British Nucl...
Geographic External Turnover – FY2013

British Nuclear Forgings
Nuclear Development Focus
•
•
•
•
•

Predictive capabilities through computer modelling
Conventional & Hollow ingot Techno...
Schematic of Nuclear Power Generation

British Nuclear Forgings
Reactor Coolant Pump Casings

British Nuclear Forgings
Nuclear Castings

Westinghouse AP1000 Pump Casing
Stainless Steel for Safety Critical Application
British Nuclear Forgings
Nuclear Ingot Development

British Nuclear Forgings
Hollow and Conventional Ingots

British Nuclear Forgings
Hollow Ingots

British Nuclear Forgings
Section Through Forging Generator
Shape Steam

British Nuclear Forgings
Transition Cone
Shape Forging

British Nuclear Forgings
Forming a Spherical dome

British Nuclear Forgings
Extruded Nozzles

British Nuclear Forgings
Quench Optimisation

Pump Casing

Shell Forging

Water Immersion Quench
British Nuclear Forgings
Collaborators
Research Partners

British Nuclear Forgings
Key industry and regulatory accreditations
ISO 9001:2008
ISO 14001:2004
ISO 18001:2007

Lloyds Register:
Steelmaking
Forgi...
Key industry and regulatory accreditations

ASME NPT Accreditation

British Nuclear Forgings
Conclusions
• The nuclear industry is about Quality first
• It demands a combination of both resources and technologies to...
UKTI Nuclear Conference
27th – 28th – 29th January 2014

Manufacturing and The supply Chain
UKTI Nuclear Conference 27th – 28th – 29th January
2014

Bespoke Engineering Solutions
Andrea Basso
Head of Engineering
Nu...
Why bespoke engineering solutions?
Wastes – 1 April 2010 and estimated for future arising volume and masses in UK
NDA – Th...
Nuclear Waste in the UK
Majority of the Nuclear wastes in the UK are stored at Sellafield in four main storage facilities....
Why we need Bespoke Solutions
We need unique bespoke solutions to
retrieve, size reduce and encapsulate
waste
• Two mechan...
NES Solution - Waste levelling Silo Rake
• The rake ensures waste is levelled for flat retrieval
to avoid loading the civi...
UKTI Nuclear Conference
27th – 28th – 29th January 2014

Manufacturing and The supply Chain
UKTI Nuclear Conference 27th – 28th – 29th January
2014

Range of available Heavy
Transportation
& Heavy Lifting Technique...
Modular or Stick Built Solutions

•

Partially or entirely constructed in factory

•

Transport to site for assembly and i...
Modular or Stick Built Solutions
•

Primary circuit equipment is tested prior to
arrival – in one piece – example reactor ...
Options for Transportation
•

Moorside Sellafield & Wylfa : will have interface
between Sea & Land

•

Inventive solutions...
Building a Jetty (temporary)
• Building jetty (for maintenance afterwards)
• Port facilities
• Semi Submersible ships
• Ge...
Internal Transportation on Site
Companies with
available equipment in UK :
•ALE
•Mammoet
•Sarens
Super Heavy Lifting Equipment
•

Up to 200,000 M/T is available

•

Capacity up to
5.000 ton @ 40m radius

•

Global exper...
Availability of Techniques
•
•

early engineering & involvement

Why :

Different concepts with feasibility study

Bringin...
UKTI Nuclear Conference
27th – 28th – 29th January 2014

Manufacturing and The supply Chain
UKTI Nuclear Conference 27th – 28th – 29th January
2014

Specialist Control and
Instrumentation Equipment
Neil Foreman
Cha...
Content
General UK Sector Overview

What type of Equipment is Available

Examples of Suppliers

108
What do we do in the UK….
We build reactors

We support operations

We decommission reactors and nuclear facilities

109
Applications Supported by UK
Equipment Suppliers
RC & I
Process Control
Security and Area/Environmental Monitoring
Health ...
Examples of UK Specialist Instrumentation Suppliers
Canberra
Cavendish Nuclear
Mirion Technologies
Rolls-Royce Nuclear
Ult...
Supplying International Markets
ANTECH

Delta Controls

Canada

Canada

Canada

USA

USA

USA

South Korea

South Korea

S...
Delta Controls
Delta Controls have been
manufacturing process control
Instrumentation for the nuclear
industry for over 40...
ANTECH
ANTECH designs and manufactures
equipment for waste measurement,
nuclear safeguards and radiation
detection
Founded...
Centronic
Centronic was formed in 1945 and has
been supplying the world nuclear
industry for over 68 years
Centronic desig...
Reactor Technologies Supplied by Centronic
MAGNOX
AGR
BWR
CANDU
PHWR
PWR
VVER
Summary
The UK has a vibrant and internationally active supply chain that supplies
specialist RC&I and process control ins...
Specialist Control and
Instrumentation Equipment
Thanks for listening!
Neil Foreman, Chairman
Centronic Ltd
118

Presentat...
UKTI Nuclear Conference
27th – 28th – 29th January 2014

Manufacturing and The supply Chain
UKTI Nuclear Conference 27th – 28th – 29th January
2014

High Integrity Inspection Technology
Colin Bird
Business Developm...
High Integrity Inspection Design, Consultancy and
Application
UK NDT (Inspection) industry cooperates to
provide integrate...
France

NDT Experience Outside of UK

Argentina
Lithuania
Russia
Sweden
Lithuania
Ukraine
China
Bulgaria
Finland
Hungary
S...
UK Investment in NDT Technology
40 year investment in Inspection (NDT) for the Civil Nuclear Industry
in the UK.
People: U...
Complex Nozzle and Pipe Inspection
Primary circuit nozzle
inspection for EDF
France.
Doosan Babcock provides inspection
se...
Complex Robotic Manipulators
Inspection deploys complex
manipulators which are tested in a
realistic environment and condi...
In service Monitoring of Plant
In line crack monitoring on operating plant
Advanced defect analysis methods

127

Doosan B...
Confidence through ENIQ
European Network For
Inspection Qualification
Appropriate assessment of an NDT
system giving relia...
Inspection Qualification
Qualification of manufacturing, pre-service
and in-service inspections
Inspection design underpin...
Testing on Mock Ups
Our inspection systems are tested on test
pieces containing realistic defects and
representing access....
Compliance with National Regulators
All countries have different regulatory
requirements.
ENIQ is a framework which can be...
Offered Inspection Services & Technology
Research – Advanced techniques
Phased Array: FMC – TFM imaging

Inspection Design...
Thank you - Questions Please

133
UKTI Nuclear Conference
27th – 28th – 29th January 2014

Manufacturing and The supply Chain
UKTI Nuclear Conference 27th – 28th – 29th January
2014

Supplying Specialist Valves

Delivering highly engineered valves ...
The UK Nuclear Valve Industry
UK Heritage Brands
Modern Valve Design & Manufacture
•Heath & Safety as the #1 priority
•World class manufacturing methods
•Advanced Computer...
MSIV Case Study
•

Main Steam Isolation Valve for Changjiang Nuclear
Power Plant, Hainan Island, China.

•

Manufactured b...
MSIV Case Study
Shipped to Changjiang site in 2013 after successful
performance testing at the Elland Factory.
The final v...
Why choose the UK for specialist valves?
Global Reach &
International
Partnerships

Advanced R&D
Programme
140

Quality, H...
UKTI Nuclear Conference
27th – 28th – 29th January 2014

Manufacturing and The supply Chain
Innovation
Developing new tools and techniques for the nuclear
decommissioning industry

Richard Smith
Technical Director
...
Sources of innovation in industry
•
•

Universities
Traditional approach

•

144

Large company R&D Departments
First to b...
Innovation key ingredients
•
•

Painful, expensive.

•

Share responsibilities.

•

Commitment.

•

Communication.

•

145...
Innovation process

146
WallRover A

2nd Generation
Concept
147

1st Generation
WallRover B – Heavy lift vehicle

WallRover B – Drill Payload
148
WallRover Box Project – 1st Generation

149
WallRover Box Project
2 Generation
nd

150
WallRover Box Project – 3rd Generation

151
152
2013 NDA Awards
“I was extremely surprised yet
delighted to receive this award; it is an
acknowledgement of our efforts an...
UKTI Nuclear Conference
27th – 28th – 29th January 2014

Manufacturing and The supply Chain
UKTI Nuclear Conference 27th – 28th – 29th January
2014

Summary & Close
Terry Gilbert
Conference Chair
UKTI Nuclear Conference
27th – 28th – 29th January 2014

Manufacturing and The supply Chain
Nuclear Showcase 29th January - Manufacturing and the Supply Chain
Nuclear Showcase 29th January - Manufacturing and the Supply Chain
Nuclear Showcase 29th January - Manufacturing and the Supply Chain
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Nuclear Showcase 29th January - Manufacturing and the Supply Chain

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  • 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.
  • Transcript of "Nuclear Showcase 29th January - Manufacturing and the Supply Chain"

    1. 1. UKTI Nuclear Conference   27th – 28th – 29th January 2014   Manufacturing and The supply Chain
    2. 2. UKTI Nuclear Conference  27th – 28th – 29th January  2014 Welcome    Keith Parker CEO Nuclear Industry Association 
    3. 3. UKTI Nuclear Conference   27th – 28th – 29th January 2014   Manufacturing and The supply Chain
    4. 4. The UK’s Rich History and Experience in Nuclear Systems Dame Sue Ion FREng Chairman Nuclear Innovation Research Advisory Board
    5. 5. Civil Nuclear Export Showcase Dame Sue Ion FREng Chairman Nuclear Innovation Research Advisory Board
    6. 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. 7. Windscale Air Cooled Piles
    8. 8. UK Nuclear Generation Magnox - Calder Hall AGR -Heysham PWR - Sizewell ‘B’
    9. 9. Opening of Calder Hall 1954
    10. 10. UK’s Early Magnox Power Stations
    11. 11. Last two UK Magnox Stations Oldbury Magnox Technology Exported Latina Italy Tokai Mura Japan Wylfa
    12. 12. UK: a first mover in fast reactor technology at Dounreay With Demonstration and Prototype Reactor Systems
    13. 13. UK AGR Sites Hartlepool Heysham1 Dungeness Hinkley B Hunterston B Heysham 2 Torness
    14. 14. Sizewell B PWR
    15. 15. The UK’s ambitions for new build AREVA EPR Westinghouse AP1000 Hitachi ABWR
    16. 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. 17. Full Fuel Cycle Industrial Experience Springfields Fuel Manufacture Sellafield Reprocessing , Waste management And decommissioning Capenhurst Enrichment
    18. 18. Advanced Manufacturing Research and Innovation
    19. 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. 20. Dalton Cumbrian Facility Academic gateway to NNL Engineering decommissioning Radiation Science
    21. 21. NNL Central Laboratory
    22. 22. JET Europe’s Flagship Research Facility MAST the UK’s Fusion Experiment
    23. 23. ITER : the next step towards Fusion Power
    24. 24. 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
    25. 25. Legacy Ponds and Silos now being decommissioned
    26. 26. New Stores constructed at UK reactor sites to hold waste Hunterston Trawsfynydd
    27. 27. New ventilation and extract systems constructed to enable work to proceed on old facilities
    28. 28. New Facilities at Dounreay
    29. 29. Change is already a Reality Before After
    30. 30. Old facilities cleared Early 1960’s to September 2002 December 2002
    31. 31. Clear out of beta/gamma facilities
    32. 32. Pile Chimney Demolition at Sellafield Before After
    33. 33. Decommissioning and Reuse of an ALPHA Facility Before:  Fast Reactor Fuel Facility After:  Store for Pu contaminated waste
    34. 34. 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
    35. 35. UKTI Nuclear Conference   27th – 28th – 29th January 2014   Manufacturing and The supply Chain
    36. 36. UKTI Nuclear Conference  27th – 28th – 29th January  2014 Manufacturing and The supply Chain Moderator   Jason Smith President Rolls Royce Nuclear
    37. 37. UKTI Nuclear Conference   27th – 28th – 29th January 2014   Manufacturing and The supply Chain
    38. 38. 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
    39. 39. UKTI Nuclear Conference   27th – 28th – 29th January 2014   Manufacturing and The supply Chain
    40. 40. UKTI Nuclear Conference  27th – 28th – 29th January  2014 The Decommissioning and Waste Management  Supply Chain 1947 to 2014   Ron Gorham NDA’s Head of Supply Chain Optimisation and Small and Medium  Enterprise  (SME) Champion 
    41. 41. UKTI Nuclear Conference   27th – 28th – 29th January 2014   Manufacturing and The supply Chain
    42. 42. UKTI Nuclear Conference  27th – 28th – 29th January  2014 Nuclear Supply Chain   Mike Tynan CEO The Nuclear Advanced Manufacturing Research Centre (NAMRC)
    43. 43. UK Imperatives Civil Nuclear Diverse Technology
    44. 44. UK Imperatives Civil Nuclear Economic Strike Price
    45. 45. UK Imperatives Civil Nuclear Develop UK Advanced Manufacturing Capability and Capacity
    46. 46. UK Imperatives Civil Nuclear Creating long term, high value jobs
    47. 47. Nuclear AMRC Purpose To help UK manufacturers win work
    48. 48. 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
    49. 49. 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
    50. 50. Industry-led Partnership:
    51. 51. We Operate in the UK Civil Nuclear Market Place Nuclear New Build Existing Nuclear Fleet Nuclear Decommissioning
    52. 52. Nuclear AMRC Work Programmes
    53. 53. Supplier Development Programme
    54. 54. Supporting Programmes
    55. 55. Innovative Manufacturing
    56. 56. 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
    57. 57. 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
    58. 58. www.namrc.co.uk
    59. 59. UKTI Nuclear Conference   27th – 28th – 29th January 2014   Manufacturing and The supply Chain
    60. 60. UKTI Nuclear Conference  27th – 28th – 29th January  2014 Nuclear Supply Chain   Brian McConnell Chairman NIA New Build Group
    61. 61. UKTI Nuclear Conference   27th – 28th – 29th January 2014   Manufacturing and The supply Chain
    62. 62. UKTI Nuclear Conference  27th – 28th – 29th January  2014 British Nuclear Forgings   Graham Honeyman CEO Sheffield ForgeMasters 
    63. 63. 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
    64. 64. Company Structure British Nuclear Forgings
    65. 65. 2008-2009 Product Mix British Nuclear Forgings
    66. 66. 2011-2012 Product Mix British Nuclear Forgings
    67. 67. Civil Nuclear Nuclear Cask Seal Housings Rotor Forging Steam Generator Shell Tubesheet Transition Cone British Nuclear Forgings
    68. 68. Geographic External Turnover – FY2013 British Nuclear Forgings
    69. 69. Nuclear Development Focus • • • • • Predictive capabilities through computer modelling Conventional & Hollow ingot Technologies Innovative Forging and Forming Processes Bespoke novel forging processes Material Development British Nuclear Forgings
    70. 70. Schematic of Nuclear Power Generation British Nuclear Forgings
    71. 71. Reactor Coolant Pump Casings British Nuclear Forgings
    72. 72. Nuclear Castings Westinghouse AP1000 Pump Casing Stainless Steel for Safety Critical Application British Nuclear Forgings
    73. 73. Nuclear Ingot Development British Nuclear Forgings
    74. 74. Hollow and Conventional Ingots British Nuclear Forgings
    75. 75. Hollow Ingots British Nuclear Forgings
    76. 76. Section Through Forging Generator Shape Steam British Nuclear Forgings
    77. 77. Transition Cone Shape Forging British Nuclear Forgings
    78. 78. Forming a Spherical dome British Nuclear Forgings
    79. 79. Extruded Nozzles British Nuclear Forgings
    80. 80. Quench Optimisation Pump Casing Shell Forging Water Immersion Quench British Nuclear Forgings
    81. 81. Collaborators Research Partners British Nuclear Forgings
    82. 82. Key industry and regulatory accreditations ISO 9001:2008 ISO 14001:2004 ISO 18001:2007 Lloyds Register: Steelmaking Forging Casting British Nuclear Forgings ASME: NCA3800
    83. 83. Key industry and regulatory accreditations ASME NPT Accreditation British Nuclear Forgings
    84. 84. 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
    85. 85. UKTI Nuclear Conference 27th – 28th – 29th January 2014 Manufacturing and The supply Chain
    86. 86. UKTI Nuclear Conference 27th – 28th – 29th January 2014 Bespoke Engineering Solutions Andrea Basso Head of Engineering Nuclear Engineering Services (NES)
    87. 87. 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
    88. 88. 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
    89. 89. 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
    90. 90. 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
    91. 91. UKTI Nuclear Conference 27th – 28th – 29th January 2014 Manufacturing and The supply Chain
    92. 92. 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
    93. 93. 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
    94. 94. 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
    95. 95. Options for Transportation • Moorside Sellafield & Wylfa : will have interface between Sea & Land • Inventive solutions: River transport Beach landing
    96. 96. Building a Jetty (temporary) • Building jetty (for maintenance afterwards) • Port facilities • Semi Submersible ships • Geared ships • Barges (different sizes) – draft - roro
    97. 97. Internal Transportation on Site Companies with available equipment in UK : •ALE •Mammoet •Sarens
    98. 98. 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 …..
    99. 99. 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
    100. 100. UKTI Nuclear Conference 27th – 28th – 29th January 2014 Manufacturing and The supply Chain
    101. 101. UKTI Nuclear Conference 27th – 28th – 29th January 2014 Specialist Control and Instrumentation Equipment Neil Foreman Chairman Centronic Ltd
    102. 102. Content General UK Sector Overview What type of Equipment is Available Examples of Suppliers 108
    103. 103. What do we do in the UK…. We build reactors We support operations We decommission reactors and nuclear facilities 109
    104. 104. Applications Supported by UK Equipment Suppliers RC & I Process Control Security and Area/Environmental Monitoring Health Physics High Energy Physics 110
    105. 105. 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
    106. 106. 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
    107. 107. 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
    108. 108. 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
    109. 109. 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
    110. 110. Reactor Technologies Supplied by Centronic MAGNOX AGR BWR CANDU PHWR PWR VVER
    111. 111. 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
    112. 112. Specialist Control and Instrumentation Equipment Thanks for listening! Neil Foreman, Chairman Centronic Ltd 118 Presentation title - edit in the Master slide
    113. 113. UKTI Nuclear Conference 27th – 28th – 29th January 2014 Manufacturing and The supply Chain
    114. 114. UKTI Nuclear Conference 27th – 28th – 29th January 2014 High Integrity Inspection Technology Colin Bird Business Development Manager Doosan Babcock Doosan Babcock
    115. 115. 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
    116. 116. France NDT Experience Outside of UK Argentina Lithuania Russia Sweden Lithuania Ukraine China Bulgaria Finland Hungary South Africa Doosan Babcock 123 Czech Republic
    117. 117. 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
    118. 118. 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
    119. 119. Complex Robotic Manipulators Inspection deploys complex manipulators which are tested in a realistic environment and conditions 126 Doosan Babcock
    120. 120. In service Monitoring of Plant In line crack monitoring on operating plant Advanced defect analysis methods 127 Doosan Babcock
    121. 121. 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
    122. 122. 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
    123. 123. 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
    124. 124. 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
    125. 125. 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
    126. 126. Thank you - Questions Please 133
    127. 127. UKTI Nuclear Conference 27th – 28th – 29th January 2014 Manufacturing and The supply Chain
    128. 128. 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
    129. 129. The UK Nuclear Valve Industry UK Heritage Brands
    130. 130. 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
    131. 131. 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
    132. 132. 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
    133. 133. 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
    134. 134. UKTI Nuclear Conference 27th – 28th – 29th January 2014 Manufacturing and The supply Chain
    135. 135. 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
    136. 136. 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
    137. 137. Innovation key ingredients • • Painful, expensive. • Share responsibilities. • Commitment. • Communication. • 145 No blame. Brutally honest communication.
    138. 138. Innovation process 146
    139. 139. WallRover A 2nd Generation Concept 147 1st Generation
    140. 140. WallRover B – Heavy lift vehicle WallRover B – Drill Payload 148
    141. 141. WallRover Box Project – 1st Generation 149
    142. 142. WallRover Box Project 2 Generation nd 150
    143. 143. WallRover Box Project – 3rd Generation 151
    144. 144. 152
    145. 145. 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
    146. 146. UKTI Nuclear Conference 27th – 28th – 29th January 2014 Manufacturing and The supply Chain
    147. 147. UKTI Nuclear Conference 27th – 28th – 29th January 2014 Summary & Close Terry Gilbert Conference Chair
    148. 148. UKTI Nuclear Conference 27th – 28th – 29th January 2014 Manufacturing and The supply Chain
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