Nuclear Showcase 29th January - Manufacturing and the Supply Chain

Manufacturing and The supply Chain

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


Keith Parker

CEONuclear Industry Association

Welcome

The UK’s Rich History and Experience in Nuclear Systems

Dame Sue Ion FREngChairman

Nuclear Innovation Research Advisory Board

Civil Nuclear Export Showcase

Dame Sue Ion FREng

Chairman

Nuclear Innovation Research Advisory Board

Sodium-cooled fast Sodium-cooled fast reactorsreactors

DFRDFR

PFRPFR

19501950

19601960

19701970

19801980

19901990

PresentPresent

Gas-cooled Gas-cooled reactorsreactors

MagnoxMagnox

AGRAGR

Water-cooled Water-cooled reactorsreactors

SGHWRSGHWR

Sizewell B PWRSizewell B PWR

HTR HTR 1965-1976

Civil nuclear power: UK

1959

1977

1974

1994

1967

1990

1995

1976

1956

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

Oldbury Wylfa

Latina Italy Tokai Mura Japan

Magnox Technology Exported

Last two UK Magnox Stations

UK: a first mover in fast reactor technology at DounreayWith Demonstration and Prototype Reactor Systems

Hartlepool Hinkley B

Heysham1 Heysham 2

DungenessTorness

Hunterston B

UK AGR Sites

Sizewell B PWR

AREVA EPR

Westinghouse AP1000

Hitachi ABWR

The UK’s ambitions for new build

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

SellafieldReprocessing , Waste management

And decommissioning

SpringfieldsFuel Manufacture

CapenhurstEnrichment

Full Fuel Cycle Industrial Experience

Advanced Manufacturing Research and Innovation

• Numbers of people in UK academic nuclear R&D:

– Academics: 230 (FTE) – PDRAs: 134 – PhDs: 627 – TOTAL: 991

• To put these numbers into context, there are around 1250 nuclear R&D staff in UK National Laboratories and around 400 in industry

Academic Nuclear R&D in the UK

Source: Dalton Nuclear Institute

Dalton Cumbrian Facility

Radiation Science

Academic gatewayto NNL

Engineeringdecommissioning

NNL Central Laboratory

JET Europe’s Flagship Research Facility

MAST the UK’sFusion Experiment

ITER : the next step towards Fusion Power

Nuclear Installations Act, 1959

Office of Nuclear RegulationONR 2011

Health and SafetyExecutive 1974

ONR: The UK’s Nuclear Regulator: Over 60 years of Experience

Legacy Ponds and Silos now being decommissioned

New Stores constructed at UK reactor sites to hold waste

Hunterston

Trawsfynydd

New ventilationand 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

December 2002Early 1960’s to September 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 waste

38 Presentation title - edit in the Master slide

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


Jason Smith

PresidentRolls Royce Nuclear

Manufacturing and The supply ChainModerator


Dr Glen Little

DirectorNuclear New Build Doosan Babcock

The Essential Guide’ for the New Nuclear Build Supply Chain


Ron Gorham

NDA’s Head of Supply Chain Optimisation and Small and Medium Enterprise (SME) Champion

The Decommissioning and Waste Management Supply Chain 1947 to 2014


Mike Tynan

CEOThe Nuclear Advanced Manufacturing Research Centre (NAMRC)

Nuclear Supply Chain

Diverse Technology

UK Imperatives Civil Nuclear

Economic Strike Price


Develop UK Advanced Manufacturing Capability and Capacity


Creating long term, high value jobs


Nuclear AMRC Purpose

To help UK manufacturers win work

Orgreave Restoration Scheme - 1994

Coking works – 1990 before demolition

■ Cleaned up extensive contamination and dereliction from 200 years of mining

■ Recovered four million tonnes of shallow coal reserves

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

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 ThemesWelding & Cladding

StructuralIntegrity

Advanced Machining

Inspection & NDE

AppliedMetrology

Mechanisation& Automation

Thermal &Surface Treatment

Modeling, Simulation & Visualisation

MaterialsDevelopment

AssemblyProductivity & Manufacturing Optimisation

Design &Quality

Additive Layer Processes

Hot Isostatic Pressing (HIPing)

High Value Manufacturing CatapultThe 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

www.namrc.co.uk


Brian McConnell

ChairmanNIA New Build Group

Nuclear Supply Chain


Graham Honeyman

CEOSheffield ForgeMasters

British Nuclear Forgings


Historical sales mix at the Management Buyout

Current sales mix

10% value added services

Highly cash generative service offering

100% manufacturing 90% manufacturing

Sales Mix


Company Structure


2008-2009 Product Mix


2011-2012 Product Mix


Civil Nuclear

Nuclear Cask

Transition ConeTubesheetSteam Generator Shell

Seal Housings Rotor Forging


Geographic External Turnover – FY2013


Nuclear Development Focus

• Predictive capabilities through computer modelling• Conventional & Hollow ingot Technologies• Innovative Forging and Forming Processes• Bespoke novel forging processes• Material Development


Schematic of Nuclear Power Generation


Reactor Coolant Pump Casings


Westinghouse AP1000 Pump Casing

Stainless Steel for Safety Critical Application

Nuclear Castings


Nuclear Ingot Development


Hollow and Conventional Ingots


Hollow Ingots


Shape ForgingSection Through Steam Generator


Shape ForgingTransition Cone


Forming a Spherical dome


Extruded Nozzles


Quench Optimisation

Pump Casing Shell Forging

Water Immersion Quench


Research PartnersCollaborators


Key industry and regulatory accreditations

ISO 9001:2008ISO 14001:2004ISO 18001:2007

Lloyds Register:SteelmakingForgingCasting

ASME:NCA3800


Key industry and regulatory accreditations

ASME NPT Accreditation


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


Andrea Basso

Head of EngineeringNuclear Engineering Services (NES)

Bespoke Engineering Solutions

93

Why bespoke engineering solutions?Wastes – 1 April 2010 and estimated for future arising volume and masses in UKNDA – The 2010 UK Radioactive Waste Inventory: Main Report

94

Nuclear Waste in the UKMajority 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.

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

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


Gerrit Zenner

Global Area Sales ManagerSarens Group Nuclear & Thermal Plants

Range of available Heavy Transportation & Heavy Lifting Techniques

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

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

Options for Transportation• Moorside Sellafield & Wylfa : will have interface

between Sea & Land

• Inventive solutions:River transportBeach landing

Building a Jetty (temporary)• Building jetty (for maintenance afterwards)

• Port facilities

• Semi Submersible ships

• Geared ships

• Barges (different sizes) – draft - roro

Internal Transportation on SiteCompanies 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 experience:ALE – Mammoet – Sarens

• OPEN TOP for installations of equipment or …..

Availability of Techniques

• Skidding & Jacking in via Hatch

• Bringing in equipment after Polar Crane & Dome is installed

• Reactor & Steam generators

Our advise : early engineering & involvement

Why : Different concepts with feasibility study


Neil Foreman

ChairmanCentronic Ltd

Specialist Control andInstrumentation Equipment

108

Content

General UK Sector Overview

What type of Equipment is Available

Examples of Suppliers

109

What do we do in the UK….

We build reactors

We support operations

We decommission reactors and nuclear facilities

110

Applications Supported by UKEquipment Suppliers

RC & I

Process Control

Security and Area/Environmental Monitoring

Health Physics

High Energy Physics

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

112

Supplying International MarketsANTECH

Canada

USA

South Korea

Japan

China

Finland

Australia

Centronic

Canada

USA

South Korea

Japan

China

India

Middle East

Europe

Delta Controls

Canada

USA

South Korea

China

India

Middle East

Sweden

Spain

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

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

CentronicCentronic 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

Reactor Technologies Supplied by Centronic

MAGNOX

AGR

BWR

CANDU

PHWR

PWR

VVER

117

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…..


Specialist Control and Instrumentation Equipment

Thanks for listening!

Neil Foreman, ChairmanCentronic Ltd


Colin Bird

Business Development ManagerDoosan Babcock

High Integrity Inspection Technology

Doosan Babcock

122

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

Doosan Babcock

123

NDT Experience Outside of UKFrance

Argentina

Lithuania

Russia

Sweden

Lithuania

Ukraine

China

Bulgaria

Finland

Hungary

South Africa

Czech RepublicDoosan Babcock

124

UK Investment in NDT Technology40 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.

Doosan Babcock

125

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.

Doosan Babcock

126

Complex Robotic ManipulatorsInspection deploys complex manipulators which are tested in a realistic environment and conditions

Doosan Babcock

127

In service Monitoring of Plant

In line crack monitoring on operating plant

Advanced defect analysis methods

Doosan Babcock

128

Confidence through ENIQ

European Network For Inspection QualificationAppropriate 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.

Doosan Babcock

129

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

Doosan Babcock

130

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.

Doosan Babcock

131

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.

Doosan Babcock

132

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

Doosan Babcock

133

Thank you - Questions Please


Ian Tough

Nuclear Sales & Product ManagerUK Valves, Weir Group PLC

Supplying Specialist ValvesDelivering highly engineered valves to the global nuclear industry from a UK base

The UK Nuclear Valve IndustryUK Heritage Brands

Ian Tough

Will note where this supply was and that towards the end of the period it was mainly a support role to the installed base.

Ian Tough

mention s.korea

137

Modern Valve Design & Manufacture

Hopkinsons, Britannia Works Site, Birkby, Huddersfield, Circa. 1915 Weir Valves & Controls UK, Britannia House, Elland, 2013

•Heath & Safety as the #1 priority

•World class manufacturing methods

•Advanced Computer Aided Design

•Internationally recognised standards

•Strong nuclear culture

•Global sourcing & representation

138

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.

Changjiang NPP, Under Construction in ChinaImage from inventorspot.com

Assembling the disc into the body of the MSIV atthe WVC UK facility in Elland, West Yorkshire UK

139

MSIV Case StudyShipped 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 MSIV Awaiting Shipment from WVC UK, 2013

140

Why choose the UK for specialist valves?

Global Reach & International Partnerships

Quality, Heritage and Experience

Advanced R&D Programme

Stable Aftersales Support

Excellent Safety Performance

Industry & Government

Partnership on UK Nuclear Strategy


Innovation Developing new tools and techniques for the nuclear

decommissioning industry

Reaching the unreachable cheaper, faster, safer

Richard SmithTechnical Director

144

Sources of innovation in industry• Large company R&D Departments

First to be cut in times of austerity

• UniversitiesTraditional approach

• SME’sUntapped resource – Strength of British industry

145

Innovation key ingredients• No blame.

• Painful, expensive.

• Share responsibilities.

• Commitment.

• Communication.

• Brutally honest communication.

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Innovation process

147

WallRover A

2nd Generation

Concept

1st Generation

148

WallRover B – Heavy lift vehicle

WallRover B – Drill Payload

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WallRover Box Project – 1st Generation

150

WallRover Box Project

2nd Generation

151

WallRover Box Project – 3rd Generation

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2013 NDA Awards

Highly Commended award for championing Small to Medium sized Enterprises (SME) innovation

“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 succeed.”

Alex JenkinsSellafield Ltd


Terry Gilbert

Conference Chair

Summary & Close

Nuclear Showcase 29th January - Manufacturing and the Supply Chain

Technology

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