Real-time innovation

New techniques for weld evaluation

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European Regional Development Fund 2007-13

Investing in Your FutureEUROPEAN UNION

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Fit For Nuclear

Robotic machining

New welding capabilities

Civil nuclear Sharing in Growth

Stuart Harrison Q&A

Apprentice support

The largest electron beam welding chamber in the UK, and one of the most powerful diode laser cladding facilities, are now available for collaborative research and development.

The Nuclear AMRC took possession of its Pro-Beam K2000 electron beam welding chamber in March, following a 10 month installation and commissioning process. With a vacuum chamber volume of 208m3, over 80 times the volume of the centre’s established K25 chamber, the K2000 is believed to be the largest e-beam chamber available for research anywhere in the world.

Engineers and executives from Pro-Beam and UK agents Vacuum Furnace Engineering joined welding specialists from Rolls-Royce and the Nuclear AMRC to toast the handover.

“It’s a fantastic, unique piece of equipment, not only in terms of its size, but also its capabilities,” Keith Bridger, Nuclear AMRC head of welding and materials engineering, told guests. “The design team at Pro-Beam must be congratulated because they faced some really big challenges.”

The Pro-Beam K2000 can complete very intricate joins on large components using nine axes of movement – four for the component and five

for the electron gun. It can be used to weld gas turbine parts up to three metres in diameter, with fully automatic joint following and variable thickness programming – capabilities found in only a handful of machines worldwide.

Electron beam welding can join very thick metal sections with a single weld, potentially cutting the time required to join nuclear pressure vessels from weeks to hours. The Nuclear AMRC team has already demonstrated a 100mm thick weld on the smaller K25 chamber (see last issue).

Another major new welding facility, a diode laser cladding cell, was in the final stages of commissioning as this newsletter went to press. It will be available to develop new techniques for large-scale surface treatment from mid-May.

Diode laser cladding uses a powerful laser to rapidly coat large areas of metal with a high quality layer of speciality alloy. Currently used in the aerospace, automotive and offshore industries, it can potentially revolutionise the production of pressure vessels for civil nuclear. Compared with current methods used to clad vessel interiors, such as conventional wire or strip cladding, diode laser cladding can cut production time from weeks to hours.

The Nuclear AMRC facility features a 15kW Laserline fibre-coupled diode laser, one of the most powerful available on the market. The laser is controlled by a gantry-mounted robot arm, capable of working on pieces of up to three metres diameter. The cell will be capable of depositing stainless steel, nickel alloys, wear-resistant alloys and other specialist cladding material at up to 10kg per hour.

Research will initially focus on proving the viability of diode laser cladding for civil nuclear pressure vessels. The cell will also be available for collaborative research and development for other industries requiring large-scale surface enhancement.

• To find out more about the Nuclear AMRC’s welding and cladding capabilities, contact Keith Bridger: keith.bridger@namrc.co.uk

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Giant e-beam chamber opens for R&D

Nuclear AMRC news Q2 2014

Chamber concert: Nuclear AMRC staff and partners examine the Pro-Beam K2000 electron beam welding cell.

A new continuous evaluation technique for high-temperature welds promises to slash production and inspection time for pressure vessels.

The Nuclear AMRC’s welding and non-destructive testing specialists are working with member companies Tata Steel and TÜV Rheinland Sonovation to develop new ways of identifying defects during the welding of thick sections. The research is part-funded by the Technology Strategy Board.

Thick sections are typically made by welding the root, allowing the assembly to cool before testing for defects, then laying down more weld – and repeating until the joint is the required thickness.

“For a weld of 200mm thickness, which can be pre-heated to 150°C depending on the weld procedure, the time you’re taking out can add up to days,” says John Crossley, non-destructive testing technology lead at the Nuclear AMRC. “Continual monitoring during the weld process can give you big time savings.”

The project is investigating an adaptation of the established time-of-flight diffraction technique, which uses an ultrasonic transmitter and receiver to identify material flaws in a weld at temperatures of up to 450°C. The probes bounce soundwaves across the weld, with any defects showing up in the reflected waveform.

“The beauty of this is that anything it detects will show up immediately in the image,” says Crossley. “You can tell the length and height of the flaw very accurately, and you can calculate the depth. There are some potential flaws that you’re not going to detect during the weld process, such as hydrogen cracking which can happen up to 48 hours later, but it gives you the confidence to carry on with your weld all the way through.”

Initial trials at the Nuclear AMRC in April tested the technology on a submerged arc weld around a representative-sized cylinder, with the probes providing a real-time display of the weld’s internal structure.

“The trials performed well, and we successfully detected some artificial defects in the weld,” Crossley says. “We’re working on a full evaluation, but the next step will be to create an automated system.”

The technique can be used on a variety of automated welding processes. As well as civil nuclear pressure vessels, it can potentially provide significant time savings in the welding of other safety-critical assemblies such as subsea pipelines and wind turbine towers.

• To find out more about the Nuclear AMRC’s NDT programme, contact John Crossley: john.crossley@namrc.co.uk

The Nuclear AMRC has launched an up-to-date equipment and capability directory to help companies understand its world-leading resources and expertise in manufacturing innovation.

The illustrated directory is freely available online, and details the centre’s capabilities in machining, welding and cladding, metrology and inspection, and visualisation.

The directory showcases the facilities of the Nuclear AMRC’s research factory – all of which are available to help manufacturers develop innovative and optimised manufacturing techniques – and aims to give companies the information they need to scope out potential collaborative research projects.

The centre’s resources and expertise are described in an easy-to-understand style for managers and engineers with varying levels of knowledge, from simple descriptions of core capabilities through to detailed technical information. The guide describes key machining centres and welding cells in terms of their features, applications and applied research areas, and gives full specifications.

• To download the directory and find out more about the Nuclear AMRC’s R&D capabilities, visit: namrc.co.uk/work/research

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Real-time weld inspection could save days

New guide to centre’s capabilities

Safe and sound: ultrasonic probes used in the trial.

Nuclear AMRC news Q2 2014 4

Nuclear AMRC researchers are addressing one of the biggest challenges in robotic machining – how a flexible robot platform can provide the rigidity needed to cut metal accurately.

The Nuclear AMRC is using a machining spindle mounted on a Fanuc F200i hexapod robot to investigate how such tools can carry out a range of operations on large and unwieldy components and assemblies for the nuclear industry. Initial studies by the Nuclear AMRC showed that the lower capital cost of portable robotic systems, compared with gantry machines, can potentially reduce the cost of machining work on pressure vessels by 80 per cent (see Nuclear AMRC News issue 13).

One of the biggest challenges, thanks to the lack of structural stiffness in such robots, is making sure that the system can work to the required precision. To solve that problem, it’s vital to understand exactly how the robot’s stiffness changes as it moves and how that affects the machining parameters.

Taner Tunc, research associate at the Nuclear AMRC, has carried out extensive tap testing of the hexapod robot system to study its dynamic response, and identified optimum spindle speeds and depths of cut for vibration-free cutting with a range of cutting tools. Tunc also used tap testing and dynamic analysis to investigate how the hexapod’s

stiffness changes in different position within its working envelope, and is now studying the effects of changes in the robot’s dynamics during machining.

“Preliminary studies showed that the hexapod has an asymmetrical dynamic response in different directions, which means the preferred cutting parameters change when you cut in different directions,” says Tunc. “That makes it even more important to apply the correct machining strategy to increase stability.”

Tunc also found that the natural frequency at the tool tip varies significantly as the robot changes position.

“The next stages of research will include developing cutting strategies for different industrial cases, determining positions with similar dynamic response, applying variable spindle speed to compensate for the change in natural frequency, and designing special cutters,” he says.

Accuracy can also be improved by integrating an inspection system with the machining head, and using the data to automatically correct the machining program. Postgraduate researcher Josh Barnfather is leading trials using the Nuclear AMRC’s Cognitens photogrammetry system, and is also investigating the development of a dedicated low-cost system.

The Nuclear AMRC robotics team is also working with the Culham Centre for Fusion Energy (CCFE) and other nuclear research leaders to develop new capabilities in remote and automated handling. CCFE, home to the UK’s nuclear fusion research programme, secured £7.8 million government funding to create a major remote applications facility at its Oxfordshire campus. The National Nuclear Laboratory, National Physical Laboratory and The Welding Institute Technical Centre are also bringing their expertise in remote interventions and autonomous systems to the new centre.

• To find out more about the Nuclear AMRC’s robotic machining research, contact Dr Taner Tunc: taner.tunc@namrc.co.uk

Installation of the Nuclear AMRC’s biggest machining centres is now underway, following over 20 weeks of preparatory foundation work.

When commissioned by late summer, the machines will be the largest of their kind available for collaborative research anywhere in the world.

Leeds-based Richlea Developments led the foundation work, which involved breaking up the existing 800mm steel-reinforced concrete floor, excavating to five metres depth, driving in 72 piles to 20 metres depth, and installing 120 tonnes of rebar and 1,200m3 of concrete.

The first sections of the Dörries Scharmann vertical turning lathe (VTL), which will be capable of working on parts of up to five metres diameter and three metres height, were delivered to the Nuclear AMRC at the end of April.

The VTL will take around 14 weeks to install. Once commissioned, it will offer full turning, milling and deep drilling capabilities for the largest high-value components for the nuclear industry, including full-scale reactor internal parts. The VTL is funded by the High Value Manufacturing Catapult.

A second very large machine, a Soraluce FX12000 floor-type milling and boring centre, will be installed alongside the VTL. The Soraluce will be capable

of working on parts up to 12 metres in length and five metres diameter, and can complete five-sided machining of complex parts in a single set-up. Installation begins in mid-May and will take around 12 weeks.

Work is also underway to create a new metrology extension to the main Nuclear AMRC workshop. The temperature-controlled extension will house one of the largest gantry-type coordinate measuring machines available, a Hexagon DEA Delta capable of measuring parts of six metres length and three metres width to accuracies of around 25 microns.

• To find out more about the Nuclear AMRC’s machining capabilities, contact Jay Shaw: jay.shaw@namrc.co.uk

Stiff challenge for robotic machining

Foundations for the future

Flexible friend: the Nuclear AMRC’s hexapod machining robot.

Base for growth: beginning installation of the Dörries VTL.

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A brief history of Sellafield

The

Tynan View

As we at the Nuclear AMRC become more involved with Sellafield Limited and the Nuclear Decommissioning Authority, I thought it would be worthwhile describing the Sellafield site and its history. The challenges of decommissioning the UK’s nuclear legacy sites present significant opportunities for companies along the supply chain, and it’s important for manufacturers to understand why these challenges exist.

The Sellafield complex is Europe’s largest nuclear facility. It sits two miles north of the village of Seascale on the West Cumbrian coast, on the site of the hamlets of High and Low Sellafield. The site covers approximately four square miles and employs over 10,000 people.

Sellafield’s industrial heritage stretches back to 1942 when the site was developed as a Royal Ordnance factory producing TNT. After the war, the site was acquired by the Ministry of Supply to produce weapons-grade nuclear material. The construction of two nuclear reactors to produce plutonium began in 1947, and the reactors – or piles – became operational in 1950 and 1951.

The site was renamed Windscale, after a local landmark, to avoid any confusion with the newly-opened Springfields nuclear fuel manufacturing facility, 120 miles to the south. The first two plutonium-producing reactors became known as Windscale Piles 1 and 2.

In 1954, ownership passed to the new United Kingdom Atomic Energy Authority (UKAEA). At this time, four new nuclear reactors were under construction a half-mile to the south of the Windscale Piles on land that was formerly part of Calder Hall farm. The combined site became known as the UKAEA’s Windscale and Calder Works.

The nuclear power station at Calder Hall was the world’s first nuclear facility to export electricity to a grid on a commercial basis. It began operations on 27 August 1956, and was officially opened by the young Queen Elizabeth II in October.

The nuclear reactors were gas-cooled, fuelled by metre-long elements consisting of a solid uranium bar encased in a magnesium oxide cladding – the reactors were named Magnox reactors after this fuel type. Calder Hall became the first of a fleet of 11 Magnox power stations in the UK, with a total of 26 nuclear reactors between them. Calder Hall finally ceased operations on 31st March 2003, after 47 years of service.

Windscale and Calder Works was the site of many pioneering developments in the nuclear industry. The Magnox gas-cooled reactor was further developed, and a prototype advanced gas-cooled reactor (AGR) was built at Windscale. This first AGR, known locally as “the golf ball”, and the Windscale Piles became familiar landmarks.

In 1971, the UKAEA was restructured into two divisions, focusing on research and production. The production division was named British Nuclear Fuels Limited (BNFL) and, in 1981, the factory complex was renamed Sellafield.

The Sellafield site continued to develop as a leader in nuclear reprocessing and technology for the storage, treatment and conditioning of wastes. The most modern of the reprocessing plants at Sellafield, commissioned in the mid-1990s, is the Thermal Oxide Reprocessing Plant (Thorp). Many ancillary plants have been built to support operations – fuel storage ponds, waste storage silos and tanks, effluent treatment plants, waste stores and waste conditioning facilities, including waste vitrification and waste encapsulation plants.

The early days of the nuclear industry have left a legacy of old plant that needs to be safely decommissioned and dismantled. There are also a variety of nuclear materials and wastes from early operations at Sellafield, stored in both solid and liquid form. These legacy nuclear plants and materials require innovative solutions for their treatment and conditioning into a safe, passive form.

The responsibility for the clean-up of legacy plants, and for the operation of current plants at Sellafield, lies with the Nuclear Decommissioning Authority (NDA). Formed on 1 April 2005, the NDA owns 19 nuclear sites across the UK.

Following the break-up of BNFL in 2006, the NDA contracts out the operation of the Sellafield site to Nuclear Management Partners Ltd (NMP), a joint venture of Amec, URS and Areva. For the duration of its contract, NMP owns Sellafield Limited, the site licence company (SLC) which holds the nuclear site licence for the site.

The NDA is actively seeking to develop the decommissioning supply chain to deliver further value for money, identify risks, and eliminate duplication of costs across its six SLCs. The UK’s decommissioning programme is worth around £1.5 billion a year to the supply chain, with Sellafield estimated to need around two thirds of the total investment required.

At the Nuclear AMRC, we are now working to develop the UK supply chain to support the NDA, NMP and Sellafield Ltd in their mission to decommission and dismantle Sellafield – and to provide innovative advanced manufacturing solutions for the Sellafield site.

• For more information about opportunities at Sellafield and the other NDA sites, see: namrc.co.uk/intelligence/decommissioning

Tynan appointed visiting professorMike Tynan has been appointed visiting professor of nuclear manufacturing at the University of Sheffield’s Department of Materials Science and Engineering.

Alongside his role as chief executive of the Nuclear AMRC, Tynan will support the development of nuclear research, training and education strategy across the engineering faculty. The materials department includes the Immobilisation Science Laboratory, a world leader in developing new technologies for treating radioactive waste.

• www.sheffield.ac.uk/materials

Nuclear AMRC news Q2 2014 6

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The nuts and bolts of nuclear fitness

Specialist fastener manufacturer Hydrobolt has driven significant improvements to its business after taking part in the Fit For Nuclear programme.

Wolverhampton-based Hydrobolt produces a wide range of special fasteners and threaded components for demanding applications, from standard precision bolts to high-integrity components in exotic materials. It employs over 260 people and is well established in the energy markets. Around 40 per cent of its business is in power generation, for stations operated by EDF and others, and top-tier manufacturers including Alstom, Siemens, Doosan Babcock, Cavendish Nuclear and Toshiba.

“There are a variety of applications within the power generation and nuclear environments where our products are used,” says Richard Barnes, business development director for Hydrobolt. “These range

from flask lid bolts for Magnox, to reactor coolant pump and ASME III bolts for Sizewell, and turbine bolts for EDF nuclear stations.

“None of our products are standard off-the-shelf nuts and bolts – our products are becoming more specialist, more technical and undergoing stricter testing as we expand more and more into markets such as nuclear and subsea. The integrity of our supply, flexibility, customer focus and our fully-equipped machine shop are our key strengths. We are able to machine pretty much any size of threaded fastener in-house.”

Hydrobolt started to talk to the Nuclear AMRC in the early days of the centre. The company had experienced sustained growth over the past decade, and was keen to maintain that momentum as the energy market underwent significant change. “We knew that a lot of the power stations we were dealing with would eventually close, and we saw the UK’s new nuclear build programme as an opportunity to fill the gap,” Barnes says.

Barnes and his team completed the online Fit For Nuclear questionnaire in late 2011. Fit For Nuclear (F4N) is a unique diagnostic tool to help manufacturing companies test whether they are ready to enter the nuclear supply chain. Managed by the Nuclear AMRC, F4N lets companies measure their operations against the standards required to supply the nuclear industry, and take the necessary steps to close any gaps.

The initial F4N assessment rated Hydrobolt as being of a high standard, but identified a number of opportunities for improvement. The biggest was in manufacturing process management, as the company

was then working to integrate an enterprise resource planning (ERP) system across the business.

“Before ERP, the company operated on a series of stand-alone systems. Jobs had to be pushed through the system,” Barnes recalls.

Now, every job is planned up front, and the ERP pulls it through production. “To make our fasteners, we produce a bill of materials specifying where the steel comes from, who’s machining it and how, heat treat details and so on. Once that information is in the system, ERP pulls the job through,” Barnes explains. “ERP gives us full traceability, visibility and real-time planning and stock management – and the massive win is that when we have a repeat job, the manufacturing route is already in place as it has previously been engineered and is in the system.”

The Nuclear AMRC’s F4N team also encouraged Hydrobolt to improve its health, safety and environmental management systems and move to ISO 14001 and 18001 standards.

“HSE is very important, and we invested a lot of time and resource in these areas following our initial F4N audit,” says Barnes. “A big part of the improvement plan was ISO 18001 integration – it ticks so many boxes and has driven so many improvements across the company.”

As well as mandatory personal protection equipment in the workshop, the team has revamped the company reception, introduced health and safety inductions for all visitors and contractors, and instigated a health and safety training programme for all employees.

Driving improvements: Richard Barnes and Michael Lloyd of Hydrobolt.

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‘Meaningful benefits’ from F4NThree quarters of companies which have completed Fit For Nuclear say they are experiencing meaningful business benefits as a result – and all would recommend the programme to other manufacturers.

In a survey of companies which have completed the F4N programme, 100 per cent of respondents said they would recommend participation in F4N to other companies.

The survey found that 96 per cent said that the final report was a fair assessment of their business, and the same number said the recommendations for further action were appropriate – 87 per cent said the recommendations had been incorporated into the company’s improvement plan.

Most importantly, 74 per cent said they had experienced or were expecting meaningful business benefits as a result of participating in F4N.

Over 140 companies have now completed the online F4N assessment, with most receiving ongoing support and development from the Nuclear AMRC team – as of April, 46 had completed their action plan, with 38 still in the process. Of the companies approached for feedback, 79 per cent responded.

Over 50 companies have been referred to other organisations for business development, after the initial F4N assessment found they were some way from meeting the stringent demands of the nuclear industry.

The Fit ListIntroducing some of the manufacturers which have developed their businesses through the F4N programme.

CPE Pressure Vessels is a manufacturer of bespoke pressure vessels, pipework and pressure systems in stainless steels, carbon steels, duplex and alloy materials. www.pressure-vessels.co.uk

Delta Controls has over 40 years’ experience of manufacturing high-performance process control instrumentation for the nuclear industry in the UK and overseas. www.delta-controls.com

Metalflex is a specialist designer and manufacturer of high quality bespoke stainless steel and PTFE hoses. www.metalflex.co.uk

Newburgh Engineering is a hi-tech precision engineering company, manufacturing bespoke engineering components and assemblies in a competitive environment. www.newburgh.co.uk

SPX Flow Technology designs, manufactures, services and repairs process control valves, desuperheaters and turbine bypass systems. www.spxft.com

TTI Group Ltd is a specialist provider of surface engineering and heat treatment services and solutions to all major industries. www.ttigroup.co.uk

Valve Components Ltd is a global supplier of precision machined components, with over 75 CNC machine tools and bases in the UK and Malaysia. www.vcl.uk.com

F4NFit For Nuclear

“We made a lot of what you would class as non-profit investments,” says Michael Lloyd, power division sales manager for Hydrobolt. “It’s about looking at different areas within the business to give our customers confidence – we’ve always had the capabilities and procedures, but we needed to move ourselves up the corporate ladder.”

Nuclear AMRC supply chain consultant Martin Ride says that Hydrobolt is an example for others to follow.

“Hydrobolt made tremendous use of the F4N programme, quickly consolidating our findings into their wider business-led continuing improvement planning process,” Ride says. “Over a two-year period, Hydrobolt has remained focused on its plan, steadily and sensibly taking the entire business on an impressive change and development journey.

“This is evident from the moment anyone arrives at their Wolverhampton site, with a welcome and safety briefings approach that has clearly raised the bar. Walking through the facility bays, it is clear that Hydrobolt is continuing to drive its standards controls and process adherence, which its workforce team has fully embraced.”

For Hydrobolt, F4N gave a valuable independent insight into the business and the specific demands of

the nuclear new build industry. “One of the biggest things they gave us was a greater awareness of the industry,” says Lloyd. “They said this is what you’re doing in existing plant but, if you want to progress and work towards new build, this is what’s expected. That was the big difference – it’s where we are and where the industry is going in new build.”

Hydrobolt is now targeting continued growth and investment, concentrating on more specialised markets including nuclear and subsea operations. “We’re looking at new products in flanges and fittings, which we can cross-sell to our existing customer base,” says Barnes. “We want to be the supplier of choice for special fasteners for the new nuclear programme, as well as the decommissioning market – we hadn’t realised that decommissioning was such a big opportunity until Martin explained it to us.”

Hydrobolt is also working with the Nuclear AMRC team to better understand international nuclear standards and requirements. “We’re not limiting ourselves to the UK,” says Barnes. “Over 70 per cent of our products are exported, and we really want to attack the global nuclear markets.”

• Hydrobolt Group: www.hydroboltgroup.com

• Fit For Nuclear: namrc.co.uk/work-with-us/f4n

Nuclear AMRC news Q2 2014 8

Four companies are beginning intensive business improvement programmes under the civil nuclear Sharing in Growth (CNSIG) programme.

The companies successfully applied to join CNSIG in summer 2013. Following a detailed three-month assessment, they are now beginning a three-year programme of business development and training worth £1 million, tailored to the specific needs of their business. This includes shopfloor manufacturing improvement, process improvement, leadership development and specific nuclear sector knowledge.

The CNSIG programme aims to develop the UK manufacturing supply chain for civil nuclear – in new build, operations and decommissioning – and help UK companies win work in the nuclear industry at home and overseas. CNSIG is part-funded by government through the Regional Growth Fund, and supported by industry leaders including Rolls-Royce.

Participating companies include Stainless Metalcraft, the Cambridgeshire-based designer and manufacturer of pressure vessels, tanks and other systems for the energy and metal sectors.

“The initial assessment identified a number of areas of strength across the business, and we are already taking steps to maximise these, as well as working to strengthen areas of our business where there is potential for real improvements,” says Austen Adams, managing director of Metalcraft.

“What is particularly pleasing is that, by approving this investment, the CNSIG board has not only actively recognised our potential to become a significant player in the UK’s nuclear industry, but

has also demonstrated its confidence in our team to deliver results.”

Another participant is Nuclear Engineering Services (NES), the Wolverhampton-based provider of design, manufacture, test, commissioning, installation and training services for the nuclear decommissioning, defence and new build markets.

NES is using CNSIG support to build on strategic improvements being made as part of an internal programme dubbed the Continuous Sustainable Improvement Plan. Over 100 NES personnel took part in diagnostic workshops and information gathering and analysis sessions during the assessment.

“Being part of this programme will allow NES to evolve into a more efficient and competitive supplier, underpinning our ambitious plans for growth and allowing the company to compete more effectively in the global marketplace,” says Mark Kelly, head of business improvements at NES.

The other companies to enter the improvement phase are specialist heavy precision engineer Goodwin International, based in Stoke-on-Trent; and Therco, the Sheffield-based manufacturer of air-cooled and tubular heat exchangers. The final company from the first round, Tata Steel Projects, is still in the assessment phase.

Five companies which successfully applied to join CNSIG in its second phase in late 2013 are now in the assessment phase – see box for details.

• For more information about CNSIG and the participating companies, visit: namrc.co.uk/work-with-us/sig

Sharing in Growth: the second waveGraham Engineering – an established supplier to the nuclear industry since 1985, Graham Engineering produces a wide range of intermediate waste containers. Based in Nelson, Lancashire, its manufacturing capabilities include advanced laser welding, deep drawing and press tooling. www.graham-eng.co.uk

Hayward Tyler – one of the world’s leading suppliers of electric motors and pumps. Based in Luton with offices worldwide, Hayward Tyler has over 1000 pumps in active service in nuclear plants across the globe.www.haywardtyler.com

James Fisher Nuclear – an established supplier of specialist engineering, manufacturing and technical services for high-integrity applications. Based in Leyland, Lancashire, James Fisher Nuclear designs, produces and tests components for the nuclear fuels, operations, decommissioning and new build markets. www.jfnl.co.uk

NIS Ltd – a specialist integrated engineering company, providing bespoke design and manufacture of plant and equipment for a wide range of markets. Based in Chorley, Lancashire, NIS has over 25 years’ experience in nuclear, including automation, mechanical handling equipment, waste treatment systems and fuel transport. www.nisltd.com

Truflo Marine – a specialist producer of high-integrity valves and actuators for critical applications, primarily for the naval marine sector, Birmingham-based Truflo has provided valves for nuclear power plant since 1975. Customers include Rolls-Royce, EDF, Rosatom and Forsmark Vattenfall. www.truflo.co.uk

The next step to share in growth

Ambitious plans: engineers at NES.

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Stuart Harrison joined the Nuclear AMRC as business development director in March. Nuclear AMRC News asked him for his thoughts on the industry.

Could you introduce yourself and your experience in the nuclear sector?My career in the nuclear industry started in the late 1980s when I was sponsored by BNFL through my degree, and ultimately into employment at Sellafield. In the 13 years I was with BNFL, I undertook many different roles starting with technical support in the legacy ponds and silos area, through a communications role to support the licence-to-operate application for Thorp, divisional training manager with responsibility for over £2 billion worth of assets and 1500 people, and finally operational training manager for the Sellafield site.

This led to my next move to the UKAEA to implement a company-wide competence management system. From here I moved into the supply chain, and for the past seven years have held business development director positions at two SMEs, Gen2 Training and GSE Systems Ltd – both had major nuclear clients including site owners and their supply chain, and both successfully grew in turnover and profitability. But when the opportunity came to join the Nuclear AMRC team, it was an easy decision to make.

What is your role at the Nuclear AMRC?In March, I started with the Nuclear AMRC as business development director. This means leading our commercial operations, customer acquisition and retention, and the development of the Nuclear AMRC’s products and services to ensure we deliver our purpose: to help UK manufacturers win work.

What are the opportunities for UK manufacturers?Within the civil nuclear market, there are three distinct sectors: decommissioning and waste management, existing fleet support, and nuclear new build. The total spend into the supply chain runs to billions of pounds per year.

There are existing supply chains within these markets, so the challenge for the Nuclear AMRC is to assist UK manufacturers by ensuring they are as competitive as possible on cost, quality and capability, and to help them identify their potential role within these markets. These opportunities can present themselves as complete solutions, systems to be delivered, sub-systems development, or individual component supply.

And what are the challenges?

The supply chains are complex and, in many cases, initial contracts placed by the main site operators can run to many millions of pounds. This can potentially exclude the smaller specialist manufacturers.

There’s also the need to constantly strive for improvements in quality, capability and cost competitiveness.

This is where the Nuclear AMRC’s in-depth knowledge of the market and access to the major players in the industry, combined with our expertise and facilities, allows us to help manufacturers innovate and improve.

How can the Nuclear AMRC make an impact in UK industry?

We are already making in an impact. Through our intensive supplier development programme, we are working with ten UK companies to transform their manufacturing businesses. This is an investment of approximately £2 million per company over four years.

With our Fit For Nuclear programme, we are assisting manufacturers to assess themselves as a company that is both suitable and serious about working in nuclear. We can then produce and support a focused development programme to enable them to become more effective in the nuclear industry. So far we have engaged with over 140 companies.

Finally, our multi-million pound factory facility is allowing us to work directly with UK companies to solve their manufacturing challenges or improve their capabilities. This includes prototyping, applying different machining and welding techniques to their specific production challenges, process optimisation, and developing new intellectual property.

If you look next door at the AMRC with Boeing, which has been operational for over a decade, it’s much easier to see what can be achieved. That facility has transformed UK manufacturers and manufacturing in the Boeing supply chain, and itself received the accolade of Supplier of the Year to Boeing. Across the AMRC group, we have access to over 1000 man-years of manufacturing expertise – and being part of the High Value Manufacturing Catapult gives us access to even more specialist resources and capabilities.

Finally, what’s your main message for manufacturers interested in the nuclear sector?

The Nuclear AMRC can assist you in supplier development, raising your quality, capability and cost competitiveness; and in manufacturing innovation, developing world-leading manufacturing technologies and processes. Please call us to find out more.

• To find out more about how the Nuclear AMRC can help your business, contact Stuart Harrison at stuart.harrison@namrc.co.uk or call 0114 222 9900.

New directorsThe Nuclear AMRC has made another two director-level appointments to drive the centre’s mission of helping manufacturers win work.

Stuart Dawson, head of machining at the Nuclear AMRC since 2010, becomes operations director. Dawson will be responsible for managing the operation of the Nuclear AMRC’s research factory, ensuring that it has the capabilities and capacity to help manufacturers develop innovative and optimised manufacturing techniques.

Jay Shaw, previously deputy head of machining, steps up to take overall responsibility for the machining group.

Dr Alan McLelland has been appointed projects director, with responsibility for managing the Nuclear AMRC’s portfolio of R&D projects. McLelland was previously chief executive of the National Metals Technology Centre (Namtec), which became part of the University of Sheffield AMRC in 2012. He has worked closely with the Nuclear AMRC on key programmes, including the civil nuclear Sharing in Growth programme.

Helping manufacturers win work: Stuart Harrison Q&A

Nuclear AMRC news Q2 2014 10

Sheffield Forgemasters is set to become one of the few UK companies able to fabricate safety-critical cast components for nuclear power stations, after passing a final audit for ASME NPT (nuclear partials) status.

As a result of the audit, Sheffield Forgemasters will receive an accreditation certificate which will allow it to take on a whole new strand of civil nuclear manufacture, complementing its status as an ASME-certified nuclear materials organisation. Forgemasters is an established supplier of civil nuclear castings and forgings, and a founding member of the Nuclear AMRC.

Forgemasters’ NPT status will allow the company to weld-fabricate the components it currently supplies – a part of the nuclear assembly process that few organisations can undertake, and one with significant challenges posed by weld-joining different materials.

The ASME code is the most comprehensive series of guidelines for civil nuclear manufacture in the world – other standards, including the French RCC-M code, operate to similar compliance requirements.

“Forgemasters currently enjoys ASME status as a materials organisation, an accreditation for which we have had to pass a similar audit and a full quality systems survey every three years,” said Forgemasters group quality director David Street.

“The audit to gain NPT status is a significant landmark for the company, which is the culmination of several years of work to establish enhanced requirements and disciplines embracing

all our processes, employees and sub-suppliers. This is to ensure we meet the exacting construction requirements of the ASME code, which are some of the most stringent demands in modern engineering.”

Forgemasters claims an unparalleled understanding of the ASME code within the UK and, as a tier one member of the Nuclear AMRC, is poised to play a crucial part in establishing quality assurance requirements for businesses aiming to enter the UK civil nuclear supply chain.

“The code is an absolute requirement with no scope for concessions,” Street said. “Manufacture must be ASME code compliant to avoid non-acceptance and rejection. That’s where our involvement with the Nuclear AMRC should enable our expertise in this field to reach a much broader market.”

Forgemasters has also announced that it has realised a £300,000 annual saving by adopting lean manufacturing policies across the business. Initiatives included rigorous recycling of scrap and excess steel, bringing outsourced operations such as tool grinding in-house, and recycling water from the company’s own reservoir. Operations director Mick Dickson says the firm aims to double that saving within 12 months.

• www.sheffieldforgemasters.com

An updated agreement between the Nuclear Decommissioning Authority (NDA) and new build group NuGen has been hailed as a milestone for new nuclear power in West Cumbria.

The NDA, which owns the Moorside site close to current facilities at Sellafield, has agreed terms with NuGen owners Toshiba and GDF Suez to update and extend the land option agreement.

“This is a significant step forward for the plan to establish new nuclear in West Cumbria,” said John Clarke, NDA chief executive officer.

“Together with our nuclear partners, we are seeing the emergence of West Cumbria as a centre of nuclear excellence across the whole span of the industry from new build to decommissioning and waste management.”

NuGen plans to build three Westinghouse AP1000 reactors at Moorside, with the first online in 2024.

The NDA announcement came as the UK and Japanese prime ministers released a joint statement highlighting nuclear energy as a key area for cooperation between the two countries.

Sheffield Forgemasters approved for new nuclear work

Significant step for Moorside new build

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Nuclear AMRC secures ISO14001The Nuclear AMRC has been awarded the industry benchmark certificate for its environmental management systems.

The ISO 14001 standard sets out the criteria for an environmental management system. It provides assurance to company management, employees and external stakeholders that environmental impact is being measured and improved.

“Registration to ISO 14001 gives our partners confidence that we are maintaining a recognisable standard,” says environmental manager Kristina Parry. “Our environmental management system helps us to manage our impacts appropriately, maintain legal compliance, and make improvements to our environmental performance.”

The civil nuclear top tier often looks for ISO 14001 and other quality management certificates in potential suppliers. As part of the Fit For Nuclear programme, the Nuclear AMRC’s supply chain specialists regularly recommend that companies secure certification to help win business (see p6).

The Nuclear AMRC also has ISO 9001 certification for its quality management systems, while the shared AMRC laboratories are certified to ISO 17025 for structural testing and microscopic analysis.

Look on the Brightside: Forgemasters’ Sheffield base.

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Small and medium-sized manufacturers working in the nuclear sector can now access up to £5,000 funding to support the cost of employing apprentices.

The Supply Chain Apprentices for Nuclear Manufacturing programme is a collaboration between reactor provider Areva and the National Skills Academy for Nuclear Manufacturing. The Academy aims to attract 150 new apprentices to nuclear manufacturing by 2017.

“Supply chain companies need support to enable them to employ apprentices, and this investment provides a clear message that the nuclear industry is starting to take an active leadership role,” said Jean Llewellyn, chief executive of the National Skills

Academy for Nuclear. “To enable UK manufacturers to maximise the opportunities that new build presents, it is paramount that the UK retains the skills it already has and develops the skills it needs.”

Areva is committing £100,000 to the programme, which will also support apprentices through vocational or academic courses.

• For more information about the programme, contact Dawn Vinall at the National Skills Academy for Nuclear Manufacturing: d.vinall@nuclear.nsacademy.co.uk

• To find out about the apprentice training available at the University of Sheffield AMRC, visit: www.amrctraining.co.uk

New support for nuclear manufacturing apprentices

Siemens and Associated British Ports are to invest £310 million in new wind turbine manufacturing facilities in East Yorkshire, in a move likely to create hundreds of jobs along the supply chain.

Siemens will build a new factory in Paull to manufacture rotor blades for its 6MW turbines, and create a logistics and service centre as part of the Green Port Hull development.

“We invest in markets with reliable conditions that can ensure that factories can work to capacity,” said Michael Suess, energy sector chief executive for Siemens. “The British energy policy creates a favourable framework for the expansion of offshore wind energy. In particular, it recognises the potential

of offshore wind energy within the overall portfolio of energy production.”

Offshore wind projects with over 40GWe capacity are currently in planning around the UK, with 14GWe due to be installed by 2020. As with the nuclear new build programme, there will be significant opportunities for manufacturers of engineered products which can meet the top tier’s requirements.

The Nuclear AMRC is supporting process innovation in the sector through a government-backed programme called Grow:OffshoreWind which offers technical, market and funding support to manufacturers.

Companies looking to expand their manufacturing capabilities for this market can receive up to 50 per cent funding for process technology innovation projects. Qualifying projects can access the large-scale technology demonstration facilities at the Nuclear AMRC, as well as the resources of the other centres in the High Value Manufacturing Catapult.

Matthew Chinn, managing director of Siemens Energy UK, will discuss plans for the East Yorkshire investment at the Global Manufacturing Festival conference, held at the University of Sheffield AMRC on 25 June.

• www.growoffshorewind.com

Investment boost for offshore wind

Diary

Some of the events that the Nuclear AMRC will be attending in the coming months – see us to find out more about how we can help your business.

Triple Bar Nuclear Manufacturing 4-5 June, 3-4 September, Sheffield

An introduction to the nuclear industry for manufacturers, developed by the National Skills Academy for Nuclear Manufacturing and delivered by the AMRC Training Centre. www.nuclear.nsacademy.co.uk/course/ triple-bar-nuclear-manufacturing

Sellafield Supplier Forum 12 June, Cumbria

Sellafield’s annual supplier forum provides the opportunity for businesses at all tiers to network and share learning, and discover new commercial opportunities in the decommissioning market. suppliers.sellafieldsites.com/supplier-events

Nuclear Industry Forum 18-19 June, London

Marketforce’s Nuclear Industry Forum features government decision-makers and industry leaders, including the Nuclear AMRC’s Mike Tynan, discussing major strategic issues covering supply chain, investment, skills, and global partnerships. www.marketforce.eu.com/events/nuclear/ nuclear-industry-forum

Global Manufacturing Festival 24-25 June, Sheffield

The University of Sheffield AMRC hosts the conference and trade show for the Global Manufacturing Festival, part of the International Festival for Business. The GMF aims to help SMEs understand the supply chains for a range of high-growth sectors. www.globalmanufacturingfestival.com

Nuclear UK 25 June, Warrington

Part of the International Festival for Business, Nuclear UK will feature high-calibre speakers from the new build and decommissioning sectors and the science, technology and skills arenas. Confirmed speakers include John Hutton of the NIA, John Clarke of the Nuclear Decommissioning Authority, Mike Tynan of the Nuclear AMRC, and key figures from EDF Energy, NuGen and Westinghouse. nuclearukevent.com

Look on the Brightside: Forgemasters’ Sheffield base.

Hull and high water: concept design for the Green Port development.

Contact us:

Tel: +44 (0)114 222 9900 Email: enquiries@namrc.co.uk Online: namrc.co.uk Twitter: @NuclearAMRC

Nuclear AMRC The University of Sheffield, Advanced Manufacturing Park, Brunel Way, Rotherham S60 5WG

Manufacturing Technology Research Laboratory The University of Manchester, Sackville Street, Manchester M13 9PL

Technology Strategy BoardDriving Innovation

Supported by:

Tier 1 members:

Tier 2 members:

Nuclear AMRC news Q2 2014

Work with usThe Nuclear AMRC is here to support manufacturing companies, from SMEs to global giants, which are seriously interested in winning business in the nuclear sector. If we can help your company, we want to hear from you.

We help manufacturers through supplier development and innovation.

We can work with you to raise your quality, capability and cost competitiveness to meet the needs of the global nuclear industry.

And we can develop world-leading manufacturing processes and technologies. We have the production-scale facilities and the manufacturing expertise to help you improve cycle time, reduce lead time, improve quality and reduce costs.

Our capabilities and services are open to all UK manufacturers. We provide a responsive service to help you solve your manufacturing challenges and win new work.

We also offer full membership, giving you access to our generic projects and the opportunity to determine our core research.

To find out more about how we can help your business, contact Stuart Harrison, Nuclear AMRC business development director: stuart.harrison@namrc.co.uk

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