sustainable growth Nuclear innovation to drive for recovery Powering up

No.39 Autumn 2020

New members Fit For Nuclear Advanced modularreactors Midlands investment Safe working Nuclear AMRC News Autumn 2020

Welcome back to Nuclear AMRC News

We suspended the usual quarterly We now bring you this bumper issue to very much open for business. cover all the developments since our last schedule for this newsletter at the We are aiming to resume our normal edition in January. Like many of you, we’ve start of the Covid-19 lockdown schedule for the newsletter in the new year. had to change the way we work to manage in the spring, to concentrate on If you have any suggestions for the kind of the risks of Covid, and to respond to the our online channels. Our priority story or information you’d like to see, to impact of the pandemic on our customers was sharing timely news and inform and inspire you to further success and partners. We’ve continued to support information which our network in the nuclear supply chain, please do get manufacturers of all sizes across the UK, could easily access wherever in touch. and have secured new funding and started they were – working from some major new research projects to help Tim Chapman, home, carrying on with essential drive our nation's economic recovery. communications manager: manufacturing, or contributing [email protected] to the national effort on PPE and Things are still a long way from normality ventilator production. for many of us, but the Nuclear AMRC is

Science minister visits to map the future of research

Science minister Amanda Solloway visited the Nuclear AMRC in August to discuss how applied innovation in low- carbon nuclear power and advanced manufacturing can help power an economic recovery across the UK.

During her tour of the Nuclear AMRC workshop in Rotherham, CEO Andrew Storer highlighted the potential of electron beam welding and other techniques for the cost-effective production of small modular reactors, and work to support manufacturers nationwide through the Fit For Nuclear programme.

Solloway and her BEIS colleagues were the first visitors to the Nuclear AMRC since Covid-19 restrictions were introduced in March. The visit was carefully managed to Inside innovation: Andrew Storer and Koen Lamberts welcome Amanda Solloway minimise any health risk to the visitors or to the Nuclear AMRC. staff, in line with the centre's painstaking approach to safeguarding staff health (see new R&D roadmap with industry come, and to build the foundations for p16). leaders, senior researchers and regional the new industries of tomorrow. The The minister also met Professor Koen stakeholders. government plans to increase public investment in R&D to £22 billion by Lamberts, University of Sheffield Vice- Published in July, the roadmap sets out 2024–25. Chancellor, and apprentices at the AMRC proposals to invest in science and research Training Centre, and took part in a virtual to deliver economic growth and societal www.gov.uk/government/publications/ roundtable to discuss the government's benefits across the UK for decades to uk-research-and-development-roadmap

2 namrc.co.uk Funding secured for Nuclear AMRC Midlands The Nuclear AMRC’s proposal to establish a new advanced manufacturing research centre in Derby has secured government funding.

Infinity and beyond: design for the new facility in Derby.

The proposal, supported by Derby City The team have developed new capabilities and smart materials. Council and the D2N2 Local Enterprise in technology areas including controls IISE includes a Rail Research and Partnership, was awarded £6.85 million and instrumentation, digital engineering Innovation Centre to support collaborative in August by the Ministry of Housing, and additive manufacturing, and worked research and innovation projects with local Communities & Local Government. with companies of all sizes to help them rail supply chains. It also leads the DE- innovate and win work. Local partners will also invest in the £20 Carbonise project, offering comprehensive million project to create a new permanent The new facility, with around 5,000m2 of support to SMEs which want to reduce home on Derby’s Infinity Park for Nuclear floorspace, will further extend the Nuclear carbon emissions in their operations, AMRC Midlands, creating 70 jobs and AMRC’s ability to help manufacturers production and supply chain. helping to reboot the local economy after develop and adopt innovative technologies The project is viewed as a key part of the Covid-19 crisis. which will deliver the maximum impact for Derby’s post-Covid economic recovery the UK’s nuclear supply chain. “We’re delighted to have received strategy, and will provide local businesses government support for our manufacturing “Nuclear generation is a vital part of with access to cutting-edge R&D facilities research centre on Infinity Park, and look the energy mix for clean electricity and to help them diversify, grow and create forward to continuing our work with Derby meeting the UK’s net zero commitment,” new jobs. City Council, regional universities and Kelly said. “We will work alongside The government funding comes from the businesses to deliver jobs and support the regional industrial partners to ensure Getting Building Fund, which is investing economic recovery of the region,” said a suitably qualified supply chain that is £900 million in shovel-ready infrastructure Dr Emma Kelly, Nuclear AMRC strategy able to capitalise on advanced nuclear and housing projects across England. The director. technologies within the clean energy D2N2 region, which covers Derbyshire and sector.” The investment follows a successful pilot Nottinghamshire, secured a total of £44.4 project over the past 18 months, with the The facility will also be a base for million for projects including a high-tech growing Nuclear AMRC Midlands team the University of Derby’s Institute for food manufacturing campus in Derby, a 5G operating from workshops and offices Innovation in Sustainable Engineering innovation hub in Worksop, and a digital within the iHub facility on Infinity Park, (IISE), which has developed an advanced manufacturing and engineering creating the first High Value Manufacturing international reputation for innovation in centre in Chesterfield. Catapult centre in the East Midlands design, manufacturing, product lifecycle region. management and the application of new

3 Nuclear AMRC News Autumn 2020 New projects to drive nuclear innovation

The Nuclear AMRC is part of four new manufacturing R&D collaborations supported by the Nuclear Innovation Programme, and is working with advanced modular reactor developers to progress their technologies with UK government support.

The projects are part of a £40 million funding package to kickstart the development of next-generation nuclear technologies and unlock thousands of jobs in the low-carbon energy sector.

Around £5 million total has been awarded The other new funded projects are led “Advanced modular reactors are the to seven new R&D projects through the by U-Battery, to design and build key next step in nuclear energy and have the advanced manufacturing and materials components for its compact reactor; potential to be a crucial part of tackling competition (phase 2B), part of the Rolls-Royce, to develop novel sensor carbon emissions and climate change,” Nuclear Innovation Programme. All the technologies; and Jacobs, to develop said business minister Nadhim Zahawi. collaborative projects are led by UK enhanced evaluation technologies for “Today’s investment will immediately create companies, including several SMEs. future reactor plant. new jobs in Oxfordshire, Cumbria and Lancashire. But through this vital research, The Nuclear AMRC is part of four projects: The £180 million Nuclear Innovation the technology could also create thousands Programme is part of BEIS’s wider £505 • Awesim, led by Cavendish Nuclear, more green-collar jobs for decades to million Energy Innovation Programme, to develop automated inspection and come.” which includes investment in industrial monitoring techniques for high-quality decarbonisation, carbon capture, The government is also investing £5 million welding. energy efficiency and other low-carbon to strengthen the UK’s nuclear regulatory • Research with Createc and TSP technologies. regime for advanced reactors, and has Engineering to improve the safety and released a report from the Nuclear AMRC The programme also includes support for performance of radiographic weld and NNL on the readiness of the UK’s generation IV advanced modular reactors inspection. supply chain and research base to develop (AMRs), through an AMR feasibility and and produce AMRs (see p12). • SonicSMR, led by Laser Additive development competition. Solutions, to develop high-quality The funding is part of the Nuclear Sector In 2018, eight organisations won an initial additive manufacturing techniques for Deal launched in 2018. grant to produce feasibility studies on their small modular reactor components. reactor designs. Now, in the competition’s • PITCO2C, led by Nuclear Energy second phase, Westinghouse, U-Battery Components, to develop supercritical and Tokamak Energy have each been carbon dioxide coolant for nuclear awarded £10 million to bring their AMRs machining. closer to market (see opposite).

See the following pages for more information on these projects.

4 namrc.co.uk

Advanced modular reactors

Westinghouse – lead-cooled fast reactor

Westinghouse, a founding member technologies and modular construction of the Nuclear AMRC, is developing a strategies. high-temperature fission reactor which Industry partners include Frazer-Nash will allow flexible generation to balance Consultancy, Jacobs, Ansaldo Nucleare and intermittent renewable sources. Vacuum Process Engineering. Research Westinghouse’s 450MWe lead-cooled partners include the Nuclear AMRC, NNL fast reactor (LFR) features a simplified and Italy’s ENEA, with academic support design, flexible operations and fuel cycle from Bangor University, the University capabilities, walk-away safety features and of Cambridge and The University of modular assembly. Using molten lead as Manchester.

primary coolant allows for efficient high- Electric Company Image: Westinghouse “This is the perfect combination of reducing temperature operation at atmospheric the cost of electricity and maintaining in February and supported by the Nuclear pressure, without any risk of the coolant a leading edge of science, research AMRC, the CETP aims to support innovation boiling off or reacting with other materials. and innovation for the UK,” said Patrick and collaborative partnerships, and bring Westinghouse UK will work with industry, Fragman, Westinghouse president and CEO. highly-skilled jobs to the north-west of research and academic partners to England. Westinghouse proposes to build advance the LFR design, demonstrating development facilities for the LFR at the www.westinghousenuclear.com/new- key components and accelerating the Clean Energy Technology Park (CETP) at plants/lead-cooled-fast-reactor development of high-temperature its Springfields site in Lancashire. Launched cetpspringfields.com materials, advanced manufacturing

U-Battery – industrial power and heat

U-Battery, a subsidiary of Urenco, is “U-Battery has been identified as an developing a small high-temperature excellent potential solution for the supply gas-cooled fission reactor for industrial of low-carbon industrial heat, which will applications including hydrogen support the decarbonisation of a number of production. heavy and energy intensive industries here in the UK, and enable them to continue to The government funding allows U-Battery operate as we decarbonise the economy and partners to initiate design and and strive towards delivering net zero by development work this year, and work 2050,” said general manager Steve Threlfall. towards first deployment by 2028. Image: U-Battery Urenco will also look to form new U-Battery is designed to be deployed at commercial partnerships to support U-Battery has also received funding from energy-intensive industrial sites and remote development. U-Battery is already BEIS to design and build mock-ups of the off-grid locations. It uses the proven Triso supported by Jacobs, Kinectrics, Cavendish two main vessels for the reactor and the fuel, based on spherical pellets of triple- Nuclear, Rolls-Royce, BWXT, Mammoet, connecting duct. coated uranium. The reactor design also NNL and the Nuclear AMRC. uses modular and off-site construction to www.u-battery.com reduce construction cost and risk.

Tokamak Energy – compact fusion power

Tokamak Energy is developing the ST40 technologies to extract waste material. support from the University of Oxford, spherical tokamak fusion reactor, with the University of Illinois and Oak Ridge National “I am pleased that our hard work to aim of building a first commercial plant by Laboratory. demonstrate that fusion energy can be 2030. delivered at scale in a cost-effective The funding was welcomed by UKAEA, the Oxfordshire-based Tokamak was founded and regulatory-compliant way has been publicly-owned fusion developer. “This is in 2009 by former staff at UKAEA’s Culham recognised by BEIS,” commented Jonathan really good news – not just for Tokamak Centre for Fusion Energy. The new funding Carling, CEO of Tokamak Energy. Energy, but also for the wider fusion will contribute to the development of high- community,” said CTO Tim Bestwick. The government-funded development temperature superconducting magnets will see Tokamak work alongside Cern www.tokamakenergy.co.uk to control the plasma, as well as divertor and Qdot Technology Ltd, with research

5 Nuclear AMRC News Autumn 2020 Nuclear Innovation Programme

Automated weld inspection and monitoring

The Awesim project builds on previous The Nuclear AMRC will build a factory-scale “We’ve initially developed Awesim for the Nuclear AMRC research to develop demonstrator of the Awesim technology at nuclear sector, but any industry developing automated inspection and monitoring its Rotherham facility later this year. large-scale critical assets involving high- techniques for high-quality welding. integrity welding processes will benefit The Awesim collaboration also includes from what it will deliver,” noted Tony Cavendish Nuclear, part of Babcock the University of Strathclyde’s Advanced Burnett, head of innovation and technology International and a member of the Nuclear Nuclear Research Centre and Derbyshire- for Cavendish Nuclear. AMRC, is leading the £2.1 million project based Peak NDT. which combines machine learning, sensor www.cavendishnuclear.com Cavendish Nuclear will work in development and advanced remote collaboration with its sister company manufacturing processes to deliver welding Doosan Babcock to ensure the technology and inspection – and potentially weld is industry-ready. certification – in close to real time.

The proposed technology will enable early detection of flaws as they occur, reducing rework, repair and mid-stage weld inspections, and delivering significant cost and time savings.

Awesim (Automated Welding Equipment System Inspection and Monitoring) will build on research led by the Nuclear AMRC in the Simple project funded by an earlier round of the Nuclear Innovation Programme. Inspection innovation: Simple (Single Manufacturing Platform concept design for the Awesim Environment) developed a range of weld monitoring technology. digital manufacturing techniques, which the Nuclear AMRC team successfully demonstrated on a prototype integrated welding and monitoring tool.

Robotic weld radiography

Cumbrian technology development obstructive and dangerous, and it does independent robotic systems on either company Createc is working with partners not reliably detect certain types of defect,” side of the weld,” said Clark. “This would on a robotic system to inspect the most commented David Clark, operations allow the system to be used in a wide challenging welds. director for Createc. range of applications, not limited by having to physically co-locate the two robotic The project focuses on improving the safety Createc’s concept combines autonomous systems.” and performance of weld radiography, robotics with 3D position-sensing an essential stage of inspection for many techniques for computed tomography (CT) The Nuclear AMRC and TSP Engineering are welds in safety-critical assemblies for the weld inspection. The technology promises working with Createc to provide technical nuclear, aerospace and marine industries. to be safer and less obstructive, and offer and market expertise in CT, radiography higher performance than other established and ultrasonic capability, and to quantify “Weld radiography is a mainstay of weld techniques. and compare inspection performance. inspection but has two considerable drawbacks when deployed in situ: it is “One of the key innovations is the ability to www.createc.co.uk potentially hazardous, making its use achieve the accuracy required for CT with

6 namrc.co.uk

Sound benefits: welding engineer Xiaoying Honey trials the SonicSMR technology in the Nuclear AMRC’s disk laser cell.

Additive manufacturing for SMRs

The SonicSMR project aims to develop for product customisation and design against the current state of the art. The next a high-quality additive manufacturing development. stage is to integrate all sub-components process for small modular reactor into the disk laser cell, and start optimising The key to the project is using high-power components. the process.” ultrasonic technology to improve the Metal additive manufacturing has become a components’ material properties. Creating The project draws on the Nuclear AMRC’s standard tool in sectors such as aerospace and collapsing minuscule bubbles in the previous research in power beam additive and automotive, and is seeing increasing molten metal – a technique known as manufacturing, as well as the Simple interest from the nuclear sector for new acoustic cavitation – can reduce the risk of project to develop automated weld reactor designs and to replace legacy parts residual stresses forming as the metal cools monitoring techniques. in operating plant. and solidifies. The project is led by Laser Additive Concerns over material quality and process The Nuclear AMRC is working with Brunel Solutions Ltd (LAS), a Doncaster-based SME control have meant that adoption has been Innovation Centre to develop the ultrasonic specialising in additive manufacturing and slow, however. Current techniques can technology. repair for aerospace and other industries. result in porosities or poor fusion between Other research partners include Derby- “We are conducting controlled experiments layers which can increase the risk of based Ivy-Tech Ltd, and University of using our disk laser cell to manufacture cracking. Nottingham spin-out Taraz Metrology. scaled representative metal additive SonicSMR aims to overcome these components, with positive results from Following initial trials on the Nuclear problems by using power ultrasonics to the proof-of-concept trials,” explained Dr AMRC’s disk laser cell, LAS will create a fully improve material properties, with real-time Shehan Lowe, technical manager for the operational additive cell at its own facility to process monitoring and AI-based defect project at the Nuclear AMRC. test and demonstrate the technology. recognition to ensure quality. The research “All components manufactured in the trials www.laseradditivesolutions.co.uk will improve the quality and efficiency have undergone thorough inspection to of additive manufacturing for a range assess the built quality and benchmark of metals, and open up new capabilities

7 Nuclear AMRC News Autumn 2020 Nuclear Innovation Programme

Supercritical CO2 coolant for high-performance machining

Nuclear Energy Components (NEC) is working with the Nuclear AMRC to develop environmentally-friendly machining techniques which will reduce the cost, lead time and risk of high-value nuclear components.

Derbyshire-based NEC specialises in metal components for the nuclear industry, including stainless steel parts for the fuel assemblies used in the UK’s fleet of advanced gas-cooled reactors. These intricate components are machined using traditional emulsion-based coolants, resulting in large volumes of liquid waste and contaminated metal chips.

Over the past few years, the Nuclear AMRC’s machining researchers have investigated supercritical carbon dioxide Process improvements: the prototype system will be retrofitted to NEC’s existing machine tools. as an alternative coolant, alone or in combination with a minimum quantity of lubricant (MQL). “Using supercritical CO2 as a cutting cooling methods such as liquid nitrogen, lubricant offers us the opportunity A supercritical fluid combines the physical the technology is relatively easy to retrofit to increase productivity while greatly properties of both a liquid and a gas. That on the machine tools which manufacturers reducing the environmental impact of makes it extremely efficient for carrying are already using.” our manufacturing process. Not using a away heat from the cutting zone, and also NEC will work with the Nuclear AMRC traditional flood coolant also means the dense enough to carry away swarf in deep- to develop a rotary gas connector for products we produce need less cleaning, hole drilling. retrofitting a CO coolant unit to legacy and reduces any potential detrimental 2 machine tools, removing barriers to Minimising oil-based coolant also improves health impacts on our staff.” component cleanliness, an important adoption for the supply chain. The The project builds on previous projects consideration for safety-critical nuclear prototype connector will be tested on one led by the Nuclear AMRC, with early components, while reducing health risks to of NEC’s large-scale milling machines, and research funded by the High Value machine operators and environmental risks at TSP Engineering in Cumbria. Manufacturing Catapult. The technology from used oil. The Nuclear AMRC team will also work was further developed as part of the Inform with NEC to model the financial impact The new year-long project, called Process project funded by the first phase of the of adopting supercritical CO2 in place Improvement Through CO2 Cooling Nuclear Innovation Programme, which of traditional coolants. By optimising (PITCO2C), will develop the technology demonstrated that supercritical CO2 and the cutting parameters for tool life and to take it closer to production for 316L MQL can significantly improve machining productivity, machining costs could stainless steel, and demonstrate its benefits performance and increase tool life, with no potentially be cut by half. for the production of fuel assembly detriment to the material properties of the components. machined alloy. “It is vitally important, not just for us but also for UK manufacturing as a whole, that “As a key supplier to the UK fleet of “Each R&D project get us one step closer we increase our competitiveness in a global advanced gas-cooled reactors, and with to providing the UK with a competitive marketplace,” Greenan said. “If we can over 50 years experience manufacturing advantage in the nuclear industry,” achieve this alongside reducing health risks for the nuclear sector, we are committed to commented Dr Krystian Wika, technical and minimising our environmental impact, remaining at the forefront of manufacturing fellow at the Nuclear AMRC. “One of the then the benefits would be huge.” technology,” said David Greenan, sales major benefits for industry of supercritical director for NEC. CO2 is that, compared with other advanced www.nec-ltd.co.uk

8 namrc.co.uk Clean future for coolants Carl Hitchens and Dr Krystian Wika of the Nuclear AMRC machining technologies group take a closer look at the benefits of alternative coolants such as supercritical carbon dioxide.

A few years ago, we were investigating operations. Advances the post-manufacture cleaning processes in soluble oil coolants used to prepare components for nuclear have delivered applications, and noted the significant some major leaps added cost of meeting the stringent in performance, but standards. cutting fluids can now account for 15 per cent For components which need a very high or more of total machining level of surface cleanliness, the additional costs. And with the trend costs of removing residual oils can be as to higher coolant pressures – high as 20 per cent of the total component with 120 bar or higher becoming cost. increasingly common – the pumps We started to think – why post-clean? often use more energy than the spindle Can we not improve the cleanliness of the motor doing the actual cutting. manufacturing process? Cool benefits: milling Exposure to these oils and the mist trials with supercritical Most surface contamination is due to resulting from high pressure delivery CO2 coolant. the cutting fluids used in machining. present health risks to the workforce, These fluids are an expensive part of the including skin disorders such as dermatitis, machining process. You pay for the fluids and respiratory diseases due to inhalation. We have investigated the total and management, including biocide to Some additives are considered to be environmental impact of CO2 coolant, and prevent bacterial growth; pay to dispose carcinogenic. If properly calculated, these it does provide a significant net benefit of the used coolant; and pay to clean their health risks would further increase the over traditional techniques. residue off the surface of the component. financial cost of coolants. We're also exploring alternatives to At the same time, we were starting to Our research into gas coolants has conventional oil for MQL. We expect to see investigate the use of supercritical and focused on CO2 because, although other increasing use of biodegradable vegetable near-cryogenic carbon dioxide (CO2) as a gases such as nitrogen can provide lower oil, either by dispersing a small amount in machining coolant. Although our primary temperatures, the heat transfer properties pressurised air, or using supercritical CO2 aim was to improve cleanliness, we also of CO2 are significantly greater. as a solvent. achieved significant increases in tool life It is also technically easier to retrofit CO Creating a clean machining environment compared with conventional oil coolant. 2 delivery systems to standard machine can reduce costs by avoiding This can reduce tooling costs, giving you tools, as the coolant is transferred through environmentally harmful cleaning, and greater scope to increase removal rates the machine tool as a liquid at ambient can increase quality and reduce risk to and productivity at an optimised cost. temperatures. This reduces barriers to subsequent processes, such as welding This is a fantastic opportunity for large entry for the supply chain, which is a major where surface contamination is a frequent machine tools, where dry cutting is often driver for our current collaboration with root cause of failure. used because oil coolants can't be easily Nuclear Energy Components (see previous The clean environment will also support contained. Gas coolants and minimum page). digital manufacturing, by making it easier quantity lubrication (MQL) could be a People often ask about the environmental to use sensors for collecting real-time real productivity boost, increasing cost costs of using CO , which is of course a production, cost, and quality data. As well efficiency, reducing waste, and making 2 greenhouse gas. The gas used has been as improving productivity, this can provide machining processes more future-friendly. captured as a by-product of some other data for digital twins to support through- The same technique can also enable industrial process, and the coolant system life servicing and life extension. portable robotic machining, avoiding the uses a fairly small amount – typically a For more information about advanced hazards of uncontained liquid coolants and few hundred grams per minute during coolant research, contact Dr Krystian providing a clean working environment. machining, similar to a car's emissions, but Wika: [email protected] that's in place of tens of litres of oil per Alternative coolant technologies can minute used in conventional systems. benefit many traditional machining

9 Nuclear AMRC News Autumn 2020 Research office to tackle challenges of geological disposal The Nuclear AMRC is part of a new research venture to support the long-term disposal of nuclear waste.

The new Radioactive Waste Management “Advanced manufacturing research is key the knowledge and understanding required Research Support Office (RWM RSO) is a to building sustainable waste management to underpin the safety case to deliver a £2.5 million collaboration between the systems,” said Jones. “Manufacturing GDF that deals permanently with the UK’s University of Sheffield and The University research supported by the RSO will focus higher-activity waste,” said Lucy Bailey, of Manchester. It is funded by RWM Ltd, on developing cost-effective fabrication who is heading the collaboration for RWM. part of the Nuclear Decommissioning and construction techniques, as well University researchers from across the UK Authority (NDA). as product standardisation and process will be invited to bid to undertake research automation to enhance product integrity The RSO will support the delivery of within the nine themes. RWM expects to and performance.” independent evidence-based research provide around £20 million of funding to underpin the development of a UK Research will be driven by RWM’s needs over the next decade, with potential for Geological Disposal Facility (GDF). It will as it develops its plans for the GDF, the additional funding from relevant research form the hub of an academic community location of which is still to be decided. councils. across the UK, and focus on developing Copeland Council in Cumbria voted in July The RSO will also look to extend the research to underpin the safe geological to open up discussions about hosting the core team by appointing discipline leads disposal of the UK’s higher activity facility, but identifying a suitable location in applied mathematics, environmental radioactive wastes. with a supportive community is likely to be science and public communication of a long process. Research will cover nine themes: advanced science, and add additional representatives manufacturing, applied mathematics, The RSO will cover applied social science from other UK universities through applied social science, environmental research to explore the societal and socio- dedicated calls over the coming months. science, geoscience, materials science, economic aspects of geological disposal, www.research-support-office-gdf.ac.uk public communication of science, including how public trust and confidence radiochemistry, and training. can be developed and sustained with potential host communities. The advanced manufacturing programme is led by Professor Steve Jones, CTO of the “Through the RSO, we will harness the best Nuclear AMRC. research expertise across the UK to build

£25m for decommissioning R&D

The NDA has announced The Direct Research Portfolio (DRP) and site decommissioning led by DBD, contracts are shared by a series of Galson Sciences and NSG Environmental; £25 million worth of consortiums involving companies, as well as three covering spent fuels and framework contracts universities and national laboratories, and nuclear materials led by DBD, Jacobs and will cover projects over four years. The Orano. to develop innovative winning groups will bid for projects as the The NDA and its site licence companies NDA and its site licence companies identify approaches for tackling typically invest more than £85 million in the need for targeted research. the challenges of R&D every year. The University of Sheffield, including the nda.gov.uk decommissioning. Nuclear AMRC, is part of three consortiums covering integrated waste management

10 namrc.co.uk Smart sensors for long-term waste storage

The Nuclear AMRC has led a project for Sellafield Ltd to develop new smart technologies to monitor the condition of waste containers in long-term storage.

The research focused on innovative sensors which can help ensure the long- term safety of waste from the earliest years of the UK nuclear programme. The proposed sensor system will provide data on the condition of the waste over decades of storage.

Sellafield Ltd produces many thousands of containers of nuclear packages which require interim storage on the Sellafield site until a Geological Disposal Facility (GDF) is available. Throughout this storage period, Sellafield must demonstrate that the waste, the container and the store are evolving as expected, ideally with in situ monitoring over decades of storage.

Different kinds of waste require different kinds of container, with each type requiring a different set of key parameters to be Box store: waste containers need to be monitored over decades of storage. monitored. In all cases, the sensors and any other electronic devices will need to of no main power or battery supply, and for Sellafield Ltd. “We are continually operate for decades within a hazardous no communication cables,” said Dr Li Li, seeking better ways to undertake our environment. They need a power supply head of the Nuclear AMRC's C&I team. business through the novel application which can also last for decades without “With a combination of in-house hardware of technology. This project was designed human intervention. And they need to be development and commercial off-the-shelf to challenge our baseline approach and able to securely transmit their data. electronics, we were able to down-select to demonstrate an early-stage concept. To tackle the challenges, Sellafield brought the best techniques to meet the customer's The impact has been to waken interest in the Nuclear AMRC's digital controls requirements and expectations for this first across the Sellafield business, and to turn a and instrumentation (C&I) group based at stage of research.” concept in a real business proposition.” Nuclear AMRC Midlands in Derby. To bring a full range of expertise to bear Proposed future work will involve In the first phase, the team reviewed and on the challenge, the Nuclear AMRC called producing a full prototype for further tested a variety of commercially available on the specialist capabilities of other High testing and validation, with protective low-power components to identify which Value Manufacturing Catapult centres and shielding and miniaturisation of the whole could best meet the requirements, then academic researchers. integrated system. The prototypes will be used these off-the-shelf components to tested in a simulated radiation environment The Centre for Process Innovation (CPI) build and test initial prototype systems. at a UK test facility, to understand the studied potential solutions for the energy mechanistic effects of gamma radiation on The team also identified several energy harvesting system, and developed a the electronics. harvesting techniques which can be prototype to demonstrate the technology. integrated with conventional power The University of Bristol also contributed to “Although we have validated the sources. Initial proof-of-concept tests the energy harvesting research. technologies developed in the lab showed that the proposed method is environment, we need to go through the Digital engineering specialists from the capable of harvesting enough ambient irradiation test and hardness design in the University of Sheffield AMRC developed radiation to power a sensor over several next stage to ensure the robustness of wireless transmission and communication weeks of operation. the prototypes,” Li said. “These sensors techniques which can securely carry data. need to survive the extreme conditions “The challenge was to develop “This is an ambitious project,” commented of radioactive material storage for the technologies to monitor asset health in a Stephen Hepworth, technical lead long term.” hazardous environment, on the assumption

11 Nuclear AMRC News Autumn 2020 Research highlights Recent publications by Nuclear AMRC researchers.

Supply chain capabilities for AMRs Government-sponsored research has assessment, which identified a range of and modular assembly. identified opportunities to develop the development needs which must be filled The team identified opportunities to UK's nuclear supply chain to make sure before the UK can deploy domestically- develop the supply chain's capabilities it has the capabilities to manufacture produced AMRs. in areas including advanced digital new designs of advanced modular Based on analysis of the requirements of instrumentation and control systems, fuels, reactor (AMR). different classes of AMR, the team found advanced manufacturing and materials. Following a techno-economic assessment that the UK's current supply chain could Creating a modular assembly facility of small modular reactors published in produce only a minority of components. could benefit all AMR designs and give 2017, BEIS commissioned NNL and the The capability gaps varied between the UK supply chain a global competitive Nuclear AMRC to assess the strengths of between reactor types, but common gaps advantage. the UK’s supply chain and R&D capabilities included large pressure vessel fabrication, for design, manufacture and deployment of the different families of AMR technologies. www.gov.uk/government/publications/uk-rd-and-supply-chain- The Nuclear AMRC’s Tauseef Syed and capability-for-advanced-modular-reactors Matthew Wilkinson led the supply chain

Ultrasonic inspection for safety-critical pipes An ultrasonic inspection technique used Ultrasonic guided waves are an accepted on HDPE pipes. for metal pipework can also be a low-cost inspection tool for metallic structures, but In research published in the journal Sensors, way to continually monitor the health are relatively untested in other materials. the team successfully proved the concept, of thermoplastic pipes in safety-critical The technique uses an array of flexible and identified an optimal frequency range applications. piezoelectric transducers to capture real- and other key parameters. Further research time data from induced ultrasonic waves, High density polyethylene (HDPE) pipes are will focus on characterising specific defects, with any defects in the structure showing used to transport gas, water and chemicals, and miniaturising the prototype system for up as a distinct signal. and could replace steel pipes for some industrial use. applications in nuclear power stations and The Nuclear AMRC’s ultrasonic inspection other safety-critical plant. Unfortunately the specialist Shehan Lowe worked with doi:10.3390/s20113184 pipes can degrade over time, particularly researchers from Brunel Innovation in hot environments, potentially leading to Centre and the University of Surrey to catastrophic failure. investigate whether the technique works

Sizing up SMR modules Prize-winning research for the UK SMR site location. consortium will help to ensure that all As the UK SMR design is still being parts of the modular power plant can be developed, the researchers scaled safely transported to site by road. down equipment data from a larger The project was led by Rolls-Royce Westinghouse design which uses similar rapidly assess millions of potential layouts research engineer Paul Wrigley, as part of PWR technology. They found that all for a module, and produce a digital his doctoral studies jointly supervised by scaled-down components could fit within model for further development by design the Nuclear AMRC’s Professor Richard Hall. the maximum road transport envelope, engineers. and identified several vessels which Modular manufacturing involves the off-site were close to the limit and would need Wrigley presented the research at the assembly of large-scale complex systems, to be redesigned to fit a smaller module 28th International Conference on Nuclear which are then transported to site for envelope. Engineering in August, where it was final installation. It can deliver significant awarded the prize for best European improvements in cost and schedule, but The research will inform the final design student paper. The full paper will be poses extra design challenges. of the UK SMR, with the team developing published in the conference proceedings. a preliminary layout optimisation model To be transported by road without to ensure all modules fit within a standard special permits, modules must fit within a envelope. The optimisation model will event.asme.org/ICONE maximum size envelope which depends on

12 namrc.co.uk New capabilities in plasma welding A new robotic cell gives the Nuclear AMRC new capabilities in automated plasma welding for challenging fabrications.

Plasma welding is similar to the well- established gas tungsten arc welding (GTAW) process used for many applications in the nuclear sector. The difference is that plasma welding uses a cooled gas nozzle to produce a concentrated high-energy arc which can create a much deeper weld without the risk of part distortion.

The technique offers welding speeds up to 20 per cent faster than conventional GTAW, with up to 30 per cent less filler material and no weld-seam preparation.

The new cell is based around a Fronius Joined-up research: the Nuclear AMRC’s first Fronius robotic cell. MagicWave and PlasmaModule system linked to a choice of specialised welding After the cell is commissioned in The cell sits alongside another robotic torches mounted on a 1.85 metre robot September, the Nuclear AMRC arc welding welding cell installed in 2019 which uses arm. It is also capable of high-quality team will put the equipment through its Fronius’s cold metal transfer technology. conventional GTAW work. paces to better understand its capabilities This is an advanced form of gas metal arc The securely shielded cell also includes for applications such as waste container welding (GMAW) which can join and clad a a twin-axis positioning table capable fabrication and additive manufacturing. range of steels with much lower heat input of holding parts up to 750kg, and other Ongoing research will establish key than conventional methods. process variables for high-quality joins in advanced features including calibration www.fronius.com/en and alignment tools. carbon steel.

Successful finish for flawed welds The Nuclear AMRC arc welding team are celebrating the successful completion of the most challenging fabrications in an ongoing collaboration with NDT specialist Sonaspection.

The centre has worked with Sonaspection components of increasing complexity. The two test pieces but had no luck at all," says and Jacobs to produce a series of largest piece was a large ring assembly Max Yates, group operations manager for intentionally flawed test pieces which representing a section of a pressuriser for Sonaspection. will help ensure the quality of welded the UK-EPR reactor. Around four metres "Thanks to the outside-of-the-box thinking components for Hinkley Point C. in diameter, the assembly includes two to get around the issue of them being internal structures featuring nozzle-to- Sonaspection, part of the Institution of part sections and the skilled welding shell welds with implanted flaws. Mechanical Engineers, is the UK's longest- workforce at Nuclear AMRC, we have established manufacturer of flawed test The Nuclear AMRC team clad the achieved fantastic results. Without the pieces in the non-destructive testing (NDT) structures using two mechanised ongoing working relationship between industry. The company was contracted to techniques, submerged arc strip Sonaspection and Nuclear AMRC, these produce a series of test pieces by Jacobs, cladding and gas tungsten arc cladding, blocks would never have happened." whose Inspection Validation Centre (IVC) is using equipment provided by member The test pieces will be used as part of the the independent qualification body for EDF companies WB Alloys and Polysoude. overall assessment of the NDT system for Energy's Hinkley Point C project. "We searched all over UK and Europe to Hinkley Point C in practical procedure and The Nuclear AMRC has now helped try and find a supplier who would be able personnel qualification trials. complete a series of test pieces and to perform the cladding welds on these sonaspection.com

13 Nuclear AMRC News Autumn 2020 New collaboration to boost clean energy in North Wales A new partnership between the Nuclear AMRC and M-SParc will help support clean energy innovation in North Wales.

Low-carbon hub: Menai Science Park.

The Menai Science Park (M-SParc) on and so this collaboration is beneficial not R&D capabilities for nuclear, and we’re the Isle of Anglesey is part of Bangor only from an engineering perspective already collaborating on a number of major University, with the mission of developing but on other aspects such as digital projects to support clean energy in North the region’s knowledge-based economy. technology into the future. This enhances Wales.” Bangor University is also home to the the collaboration further, bringing new The Nuclear Future Institute focuses Nuclear Futures Institute (NFI), which opportunities for current and potential on materials for nuclear and extreme aims to help North Wales become a global future tenants of M-SParc, and SMEs in the environments, thermal hydraulics and centre in nuclear technology. region, to benefit from the nuclear cluster.” reactor design. By joining the Nuclear AMRC as a tier two As part of its membership, M-SParc is “Working with the Nuclear AMRC gives member, M-SParc will foster collaboration providing office space for the Nuclear the NFI instant links with many companies between the centre and researchers AMRC, giving the centre a regional base to and institutions working in the nuclear at Bangor, covering commercial and engage with businesses in North Wales and sector,” said Professor Bill Lee, NFI director. collaborative R&D projects into nuclear support future development on the region’s “In particular, there are opportunities to materials, controls and instrumentation, licenced nuclear sites. The Nuclear AMRC collaborate with world-leading researchers digital technology and modularisation. has already worked with dozens of Welsh on new reactors such as small modular manufacturers through its Fit For Nuclear Pryderi ap Rhisiart, M-SParc’s managing reactors, advanced modular reactors, supplier development programme, with director, sees the collaboration as a step and small spherical tokamaks, and the support from the Welsh government. forward for SMEs in the region. “This new application of new thermal hydraulic, collaboration should yield opportunities for “This helps cement the relationship digital, AI and robotic technologies to these our eco-system of innovative businesses between the Nuclear AMRC and the reactors.” in the nuclear sector and I look forward nuclear cluster around Bangor, in one Menai Science Park: www.m-sparc.com to seeing them engage with the Nuclear of the UK’s most strategically important AMRC,” he said. nuclear regions,” said Professor Richard Nuclear Futures Institute: nubu.nu Hall, regional director for the Nuclear “M-SParc’s focus is on low carbon energy, AMRC. “Bangor University has growing the environment, ICT and natural products,

14 namrc.co.uk

Executive view

Why we need whole system thinking

This year has been an education in crisis report* on how government could use We believe the best way of reducing management. We've all had to change "a disciplined and rigorous whole systems emissions before 2050 is with a mix the way we live our lives at home and at approach" to achieve net zero. of gigawatt-scale reactors and small/ work. The response to the coronavirus advanced modular reactors. Our centre is A whole systems approach is based on has shown us the dedication of frontline part of the UK SMR consortium, and we are a managed process to understand the workers, and the ingenuity of those who working with other developers to turn their complex challenges posed by the net-zero stepped forward to help close the gaps in designs into engineered reality. commitment, and to devise and deploy the PPE and medical equipment, bringing the solutions and innovations that are most We’re also working with the developers work of medical research and science to likely to succeed. of a host of advanced reactors, including the forefront of our minds. compact flexible fission reactors and the The Council argues that investment in R&D However, Covid-19 isn't the only crisis first commercial fusion reactors. Whether will be an essential part of this. Investment we need to deal with. The battle against these are producing power before 2050 needs to tackle three tracks – discovery, climate change still needs to be addressed, will again depend on UK strategy and the development and deployment – with and the UK committing to net zero maturity of technology. the greatest emphasis on removing the emissions by 2050 is not going to deliver a barriers to deployment for market-ready We're working closely with UKAEA on change: that simply sets a goal. technologies, and accelerating those at an materials and manufacturing for fusion Net zero is a massive challenge, and advanced stage of development. power, and looking forward to the opening there's been a lot of talk but little of their Yorkshire facility this winter In energy, that has to mean investment in meaningful action since it was made (see p26). The success of the Advanced new nuclear – the only proven low-carbon a legal commitment in 2019. Action is Manufacturing Park has shown the impact generation capable of providing always-on needed to decide which technologies we of clustering innovative R&D capabilities baseload power to balance the variability develop and deploy to create the power with industrial knowhow – a model for of wind and other renewables. Nuclear we need to survive and thrive. This requires local regeneration and economic recovery currently makes up 40 per cent of our low- us to consider the entire complex system which we're now replicating with our new carbon generation, and keeping that share of energy and the economy, and apply centre in Derby. makes engineering and economic sense. innovation in every area. We recognise that Nuclear AMRC is a very As the Council noted, achieving net zero In recent months, reports from the Energy small part of the machinery needed to will require very strong and effective Systems Catapult, Atkins, the government's tackle the fight against climate change but, leadership from government, as well as Committee on Climate Change and others if all the small parts are brought together innovative approaches to policy making have all plotted potential pathways to net around an agreed plan of attack, I remain and delivery in all regions of the UK. zero. Crucially, all highlight the opportunity confident that the UK can deliver its net to drive a national economic renewal by Boris Johnson has signalled his backing for zero commitment and be a leader for the investing in new low-carbon technologies, a whole systems approach, and hopefully rest of the world. produced by UK manufacturers and this will be articulated in the long-overdue I hope we can establish a plan soon and backed by world-leading R&D. Energy White Paper. put all our efforts to this, which will also Industry and the research base are ready to Thinking about the whole system also go a long way to address the Covid-19 act, but we need government to take the shows how nuclear power can play a recovery and stimulate economic growth. lead in deciding the path the UK takes. much more varied role in the low-carbon Andrew Storer, CEO, Nuclear AMRC economy, with opportunities in industrial At the start of the year, the Prime cogeneration, municipal district heating Minister's advisory Council for Science * www.gov.uk/government/publications/ and hydrogen production. and Technology submitted a detailed achieving-net-zero-carbon-emissions-through- a-whole-systems-approach

15 Nuclear AMRC News Autumn 2020

Managing a safe return to work

Every organisation has faced a host of challenges since the Covid-19 pandemic hit the UK in early spring. For the Nuclear AMRC, it meant taking swift action to protect staff, then managing a careful return to operations to meet the needs of its customers – while continuing to support the supply chain and playing a role in vital national initiatives.

The centre suspended all workshop “As we continue to successfully move specifications for ventilator and PPE operations to protect staff health, through the phases of our plan, we are supplies, connecting businesses with local following the national lockdown in late able to safely bring more shopfloor-based NHS trusts and national programmes March. All 145 members of staff continued projects back online,” Shaw noted. “This is where they can contribute their skills and to work safely from home while a core testament to the hard work, diligence and capabilities. team led by programme director Jay Shaw professionalism of everyone involved.” In early June, Shaw led a webinar for carried out risk assessments and drew up All Nuclear AMRC staff worked from members and Fit For Nuclear (F4N) a five-phase plan for returning to work home throughout early summer, focusing companies to discuss best practice in while keeping staff safety as the number on desk-based research and business managing a safe return to work. The F4N one priority. support initiatives, and supporting team also produced a widely-shared guide In the fourth phase, beginning in late national initiatives including the to how the nuclear industry’s established June, the Nuclear AMRC returned its VentilatorChallengeUK consortium led by safety culture could provide a model for research factory in Rotherham to full the High Value Manufacturing Catapult businesses in other sectors (see over). capacity. Work resumed on all the R&D (see p26). “Many of our stakeholders have said how projects suspended in March to meet the The team advised more than 130 impressed they are with the professional requirements of its industrial customers companies from the nuclear supply approach of our centre, and it has been and stakeholders. Staff continued to work chain and local networks on design, held up as an example of best practice for from home where possible. manufacturing techniques and industry and the rest of the University of

16 namrc.co.uk

Sheffield,” Shaw said. All staff were issued with the overarching and staff. Science minister Amanda risk assessment, training and details of Solloway was the first to visit (see p2). The phased return to work was based on work practices to maintain distancing, rigorous risk assessments, drawing on From September, all staff will be invited to cleaning and personal hygiene. For best practice from the centre’s network return to the centre on a rota basis, with a each project, the team reviewed risk of manufacturers and other nuclear different group of people allowed in each assessments and methods statements organisations. week to gradually resume regular working to make sure that safe distancing and patterns. In the first phase, beginning in May, hygiene can be maintained. If distancing a skeleton team implemented new is impracticable, a full range of control “This will help safeguard the mental health safeguards to allow work to resume a small measures were put in place to minimise of our colleagues as they return to normal number of key research projects in the risk to staff. work after months of home working, and second phase. allow us to increase productivity across The Nuclear AMRC regional teams in our operations,” Shaw noted. Measures included markings to help Derby and Birkenhead followed the people maintain safe distancing from same process, with support from local The final phase, with all staff returning full- the car park to the shopfloor, a one-way stakeholders. time to the facilities, will be implemented flow system around the building, hands- only when the government lifts all work The centre started to admit visitors in free door openers, protective shields in and travel restrictions. August, with additional risk assessments reception, and hand-sanitising stations and precautions to protect both visitors throughout the facility.

17 The daily grind: safety measures are part of everyday life in nuclear manufacturing.

Safety culture doesn’t happen by accident

The Covid pandemic turned every workplace into a hazardous Nuclear AMRC industrial advisor environment. As more businesses adapt to operating under very Huw Jenkins different working conditions, the nuclear industry’s established introduces the essential attitudes safety culture could provide a model for other sectors. and behaviours for safe working

The VE day anniversary in May reminded So you’d expect British workers to embrace Nuclear safety culture has eight us how the British can be at their best in a culture that works by consent – a culture internationally recognised characteristics, adversity, working together to defeat a that is characterised by leaders setting an which I’ve listed below, along with some common foe. In the continuing Covid-19 example, and individuals accepting personal questions to ask about how they can be crisis, we can be proud of the selflessness responsibility. applied within a business. Not all will be of our health and care workers, and the applicable to every sector, but the essential That is the basis of nuclear safety culture. kind acts of volunteers helping out those attitudes and behaviours can help save lives less fortunate. This safety culture applies to every business in manufacturing, construction and beyond. working in the nuclear supply chain, not The British instinctively dislike being Ultimately, the key to safety culture is just those managing radioactive or fissile told what to do, being generally more shared responsibility. While it’s always materials. Any seemingly minor quality issue amenable to reasoned polite request. the legal responsibility of the employer in the supply chain has the potential to “Policing by consent” has been the basis of to provide a safe working environment, become a safety problem for an operating our approach since the 19th century, and including all necessary PPE, everyone from reactor or waste store, maybe decades into there’s been widespread opprobrium for the boardroom to the shopfloor needs to the future. heavy-handed applications of lockdown take personal responsibility for protecting law by some officers. Many of the companies we help through the health and safety of themselves and the Fit For Nuclear programme say that their colleagues. The public also gives short shrift to figures upgrading their safety culture is one of the of authority setting a “do as I say, not as How well does your company culture most valuable improvements they make, I do” example, as several politicians and match up? bringing business benefits that go well advisors have been reminded. beyond their work for the nuclear sector.

18 1 Everyone is personally responsible 5 Nuclear technology is recognised for safety. as special and unique. • Do all individual employees actively participate in pre- (This one is really only for companies in the nuclear job briefings? Do they understand the objective of the supply chain, although every business should understand work they do, and their role in achieving it safely? the specific requirements of the industry they work in.)

• Are staff open to performance feedback? • Are the special characteristics of nuclear technology understood and taken into account? • Do they observe and coach colleagues, especially when behaviours fall short of expected standards? • Is work on safety-critical equipment or components for nuclear plant identified as such? • Is everyone committed to improving themselves, the way they work and the working environment? 6 A questioning attitude is cultivated. 2 Leaders demonstrate their • Do leaders question assumptions, decisions and commitment to safety. risk assessments that don’t appear to be sufficiently rigorous? • Do the senior leadership team communicate • Do they ensure specific contingency actions are frequently, through a variety of channels, to reinforce discussed and understood during pre-job briefings? the understanding that safety is the business’s overriding priority? • Do individual employees challenge assumptions and guidance, and offer opposing views when they think • Are senior managers leading advocates of safety, something isn’t correct? demonstrating commitment in both word and action? Do they walk the talk when resolving safety or • Do they have the integrity and confidence of quality issues that appear in conflict with production leadership support to stop work when assumptions requirements? and guidance cannot be validated?

• Do they encourage individual employees to challenge unsafe behaviour and conditions? 7 Organisational learning is embraced. • Do they support those who stop operational activities for safety reasons? • Are opportunities to learn sought out and implemented? Do these routinely include ways of ensuring safety? 3 Trust permeates the organisation. • Do you conduct objective, self-critical reviews and assessments of your work processes and procedures? • Does the business regard its employees, and their professional capability and experience, as its most • Are there processes in place to learn from other valuable asset? organisations, and so continuously improve knowledge, skills and safety performance? • Is everyone treated with dignity and respect?

• Do leaders respond to questions openly, sharing important information in an open, honest and timely 8 Safety undergoes constant manner? examination. • Does everyone treat decision-makers with respect, • Does the senior leadership team use a variety of even if they might disagree? monitoring tools to regularly monitor the business’s safety culture? 4 Decision-making reflects the • Do these include feedback from employee surveys, safety-first approach. external independent assessment/audits or internal review/audits? • Is safety-related decision-making systematic, rigorous and thorough? Is it delegated to the correct individual at the lowest appropriate level?

• Do individuals understand expectations to place plant, equipment and work in a safe condition, when faced with unplanned or uncertain conditions?

19 Fibre protection: Heatsense’s cables are made for extreme environments.

Fit For Nuclear helps Heatsense hurdle barriers to entry

Heatsense Cables is winning new customers after becoming the first specialist cable manufacturer to be granted Fit For Nuclear status.

Based in Rochdale, Greater Manchester, recalls. “A clear objective from day one Heatsense is the UK’s leading was to ensure that there were no barriers manufacturer of high-performance to doing business with Heatsense. Step thermocouple and signal cables for one was to ensure that the company had Adopting lean: extreme environments. all the relevant quality and environmental inside Heatsense’s Rochdale factory. accreditations that are now considered The firm specialises in cables which are essential by corporates.” resistant to flame, oils and chemicals, and The assessment highlighted the importance operate in ultra-high vacuum, cryogenic The new team quickly achieved the of health and safety culture to nuclear and high radiation environments for latest ISO9001 quality management and customer expectations. “Part of the journey customers in nuclear, aerospace, medical ISO14001 environmental management involved sending key staff members on and other sectors. Products range from certification, and looked for other ways to a nuclear awareness course, and this single wires to multicore cables, braided reduce barriers to new markets. knowledge, awareness and understanding in glass or ceramic fibres, other specialist “At the time, there was a great deal of talk was embedded back into the business,” yarns or metals. regarding developments and opportunities Kemsley-Pein says. “Another key factor was Founded in 1984, the business was acquired in the nuclear industry,” says Kemsley-Pein. the importance of regular communication in 2014 by a new management team led by “We took the view that there would be with all staff members. It is easy to assume director Jeremy Kemsley-Pein. opportunities, and that F4N approval would that all staff know what is going in an SME, reduce barriers to entering the industry. No but that is not necessarily the case.” “We saw an opportunity to build other cable company had been awarded the company into a specialist high- Lean manufacturing was another area for F4N status, as is still the case today.” performance cable business,” Kemsley-Pein development, with Nuclear AMRC industrial

20 advisor John Olver helping the firm adopt “We understood the critical nature of contractors, and be regarded as having Kaizen and 5S techniques to continually the production and were happy to go outstanding knowledge and design improve systems and procedures. Kemsley- the extra mile,” says Kemsley-Pein. “Over capabilities for cables that operate in Pein points to the visual presentation of key time, we would like to establish strong extreme environments.” performance indicators and analysis posted business relationships with all key nuclear www.heatsensecables.co.uk on the factory walls and meeting rooms as evidence of the encouragement and guidance of the F4N team. The F4N journey also helped Heatsense Congratulations to the develop its digital strategy to embrace Industry 4.0 technologies, with digital latest companies to be processes on individual production lines allowing further improvements to efficiency, quality and throughput rates. granted Fit For Nuclear “The F4N journey has significantly These companies have benchmarked improved the company on all fronts, and we encourage customers, prospective their performance against the customers and auditors to visit as we are standards demanded by the nuclear extremely proud of what our team has industry’s top tiers, and driven achieved over the last five years,” Kemsley- Pein says. business improvements.

Heatsense has continued to develop since Bendalls Engineering is a world-class manufacturer operating in the nuclear, being awarded F4N status at the start oil & gas, process, pharmaceutical and petrochemical industries with of the year, remaining fully operational capabilities to design, fabricate, machine, inspect and test in-house. throughout the Covid-19 lockdown. The bendalls.co.uk firm has taken on more space, purchased additional plant and equipment, expanded LTi Metaltech specialises in precision fabrication and welding for highly- its manufacturing capabilities, employed regulated industries including nuclear, fusion, healthcare, renewables, more staff, and won a number of new high- transport and rail. end customers. www.lti-metaltech.com

The changes made through F4N have Site Heat-Treatment Services has 40 years’ experience of specialist service undoubtedly assisted in securing additional in thermal engineering, covering all types of on-site electrical and gas heat business in a range of sectors, Kemsley- treatment, as well as furnace heat treatment. Pein notes, but progress in the nuclear www.shs-group.com sphere has been slow.

“Ideally, we would work in conjunction with major contractors serving the Congratulations also to the F4N companies which have nuclear industry and act as a tier two supplier addressing their specific cable renewed their status three years after initial granting. requirements,” he says. “We have found it difficult to get access to large nuclear • AM Sensors • Nuclear Energy Components contractors and consultants, but we hope • Cam Machine Components • Pipex that higher visibility through the F4N • NIS • Teddington Engineering Solutions community will assist.” • NTR Heatsense’s capabilities for the nuclear sector were vividly illustrated during its F4N For details of all F4N-granted companies: journey, when the firm received an enquiry namrc.co.uk/services/f4n/companies from a nuclear plant operator. The request was for bespoke temperature monitoring cables to operate within the extremely hazardous environment of its spent fuel storage system – a job that would usually take at least four weeks to deliver. The team agreed a technical specification within four days, and delivered the cables to site one week after the initial enquiry.

21 Hardstaff aims to be supplier of choice

Site protection specialist Hardstaff Barriers is aiming to become the nuclear sector’s supplier of choice. Service manager Kathryn Cooper explains how support from the Fit For Nuclear programme helped the company get ready for the opportunities.

Hardstaff Barriers is a multi award- monitored them to ensure that these were same time. We have also recently acquired winning manufacturer and supplier of achieved within 12 months. Fleet Operator Recognition Scheme (FORS) protective barriers and perimeter security Gold, which we are extremely proud We introduced a staff forum, which really systems. Available as both temporary of. This demonstrates the company’s helped to improve communication and and permanent solutions, our roadside commitment to fleet safety, efficiency and employee engagement. This was very hostile vehicle mitigation (HVM) systems, environmental protection. helpful to the business overall. perimeter fencing, concrete security We would like to be the supplier of choice barriers and access gates are designed The increased communication and for temporary and permanent perimeter for one reason: to keep people and employee engagement has already security, barrier and gate systems for the property safe. improved staff morale. All members of nuclear industry in the UK and abroad. the team are excited to have achieved this Our products are designed to offer the status and are excited for what the future Hardstaff is proud to be working in the highest levels of protection and are holds in the nuclear sector. nuclear industry, which is ultimately making delivered with expertise and excellence. a major contribution to the UK’s move to As trusted experts in the industry, we also We are keen to improve security by reduce carbon emissions. deliver the National Barrier Asset for the providing a range of HVM solutions that are UK government. Our product approvals specific to the threat and are flexible at the www.hardstaffbarriers.com include EN 1317, IWA 14-1 and PAS68, giving protection in all transport and construction sectors including highways, aviation, nuclear and ports for protection and delineation.

Hardstaff took part in the F4N programme in an effort to become leaders in the sector of supplying and installing HVM and perimeter security solutions. Our barrier products have already provided edge protection and delineation for nuclear construction projects including Hinkley Point C.

Hardstaff has also provided HVM protection at major existing nuclear infrastructure sites, such as Sellafield. The company is passionate about safety and protecting people and property through its variety of products. We would like to be the supplier of choice in the nuclear sector.

The assessment highlighted a few ways that we can improve our processes and systems. With the help of F4N consultant Kevin Ross, we created targets and actions and closely Edge protection: Hardstaff is helping keep workers safe at Hinkley Point C.

22 The next phase begins: Hinkley Point C in summer 2020. F4N manufacturers win work at Hinkley Point Two Fit For Nuclear companies have secured major contracts as Hinkley Point C moves into the next phase of construction.

Ventilation specialist Exyte Hargreaves the way for our sister project at Sizewell C,” in project delivery, off-site assembly and control system group Capula are now said Glenn Lee, electrical project manager and site-based roles. The project will beginning work to deliver key parts of for Hinkley Point C. also provide new roles for apprentices mechanical, electrical and HVAC (heating, in the South West, and new training and Capula was granted F4N status in summer ventilation and air conditioning) systems development opportunities for apprentices 2019, after entering the programme to across the Hinkley Point C site. The overall on the Exyte Hargreaves Engineering Young support its ambition of being the supplier of work programme is being delivered by Talent Scheme. choice to the nuclear industry. the MEH Alliance joint venture headed by “In this next major chapter for our project, Altrad, Balfour Beatty Bailey, Cavendish It will now create up to 50 new engineering the MEH phase will join together hundreds Nuclear and Doosan Babcock. roles to fulfil the contract, enhancing its of small and large companies from across design and manufacturing capabilities and Staffordshire-based Capula was awarded Britain, creating 1,200 new jobs and 300 investing to upgrade existing facilities. The a multi-million-pound contract to apprenticeships,” said Simon Parsons, MEH company is also implementing a rigorous design and manufacture safety-classified programme director for Hinkley Point C. training programme to support the next instrumentation and control marshalling generation of skilled workers to support “Together we are delivering on our promise cabinets to house electronic circuitry for projects across the UK and beyond. to build Britain’s industrial capability by Hinkley Point C. The cabinets are a first creating new jobs and skills. Development of their kind to be designed and made in Bury-based Exyte Hargreaves, which was of a near-identical power station at the UK. first granted F4N in 2013, will design, Sizewell C will bring further opportunities manufacture, assemble and commission “Capula brings a wealth of skills and for our extensive and experienced British HVAC systems across the conventional experience in automation and system supply chain.” non-reactor areas of Hinkley Point C. integration, which will allow our team www.capula.co.uk to deliver a high-quality right-first-time At least a third of the plant and equipment system, and ensure that HPC can be safely will be manufactured in the UK, with 30 www.exyte-hargreaves.net brought online as planned in 2025, paving new jobs to be created at Exyte Hargreaves

23 Nuclear AMRC News Autumn 2020 TSP Engineering wins £30m Sellafield contract TSP Engineering has won a £30 million contract to manufacture nuclear waste containers for Sellafield Ltd.

The West Cumbrian company will produce complex solutions within budget and for Sellafield, previously completing 50-tonne lead-lined containers for the programme plan. one new and nine refurbished packages transfer of nuclear waste from the legacy for the Magnox Swarf Storage Silo. The “It is a significant step towards our Magnox Swarf Storage Silo to new storage new contract will complete the fleet ambition to further grow in the nuclear facilities on the Sellafield site. of packages needed to empty the silo, industry, and highlights the calibre and skill which is one of the NDA’s highest priority The work is expected to run over several of our award-winning workforce.” programmes. years, creating or sustaining around 200 TSP Engineering is a tier one member jobs at TSP Engineering. Alongside other “I was delighted to see a local business of the Nuclear AMRC, and is currently recent orders, the work will bring the firm’s win this contract, which will lead to job collaborating with the centre on projects workforce to more than 250 people. creation and opportunities for West funded by the Nuclear Innovation Cumbria,” said Martin Chown, CEO of “This is great news for TSP Engineering, Programme. TSP has also worked with the Sellafield Ltd. “TSP Engineering is a world- our workforce, supply chain and the local centre through the Fit For Nuclear and class company. Its success in winning this economy,” said John Coughlan, CEO Civil Nuclear Sharing in Growth supplier contract proves our nuclear supply chain at TSP Engineering. “Sellafield placing development programmes. can compete with the best in the world.” this order highlights the confidence our The company has a long history of nuclear customers have in our proven www.tsp-engineering.co.uk manufacturing high-integrity products ability to deliver the most technical and

First companies granted Fit 4 Offshore Renewables

Three Scottish manufacturers are the first to be granted F4OR status under a new supply Congratulations to the chain programme based on the proven Fit For first F4OR companies: Nuclear model. Balmoral provides high-tech buoyancy, protection and insulation products for Fit 4 Offshore Renewables (F4OR) is a collaboration between the offshore wind installations, as well as Offshore Renewable Energy Catapult and the Nuclear AMRC, specialist products for the defence and with the pilot programme supported by the Scottish government. oil & gas sectors. www.balmoraloffshore.com Like F4N, F4OR was designed to provide targeted support for suppliers wanting to develop their capabilities and competitiveness, and win Leask Marine provides vessel charter, work in a fast-growing low-carbon energy sector. commercial diving and international marine construction services, and has Following the successful pilot in Scotland, F4OR is now completed projects for leading marine launching in other key regions for the offshore wind energy converters. industry, starting in Norfolk and Suffolk with support www.leaskmarine.com from the New Anglia Local Enterprise Partnership. Peritus International provides subsea ore.catapult.org.uk/f4or system and offshore pipeline engineering services to the offshore energy industry. www.peritusint.com

24 namrc.co.uk Codra signs up for digital innovation

Industrial software specialist Codra has joined the Nuclear AMRC to help develop new digital engineering tools for manufacturers and operators of critical national infrastructure.

Manchester-based Codra Software Ltd, design, analysis, training, validation and or factories. the UK division of the Paris-based Codra production scheduling. The team draw on The Nuclear AMRC team will explore group, has joined the Nuclear AMRC as a a wide range of software and hardware innovative ways of integrating these tier two member. technologies, developing new applications models with virtual and augmented reality to meet industry needs. Codra specialises in industrial supervisory technologies to develop new ways of control and data acquisition (SCADA) “We’re delighted to welcome Codra visualising and understanding information software, which collects, models and as a member of the Nuclear AMRC,” from sensors across complex installations. analyses operational data from plant said Dr Stephen Marr, head of the The team will also create technology and facilities to support continuous digital environment group. “Codra demonstrators for companies of all sizes, improvement. Codra’s Panorama suite is offers a powerful software platform for to explore new applications such as used by more than 1,000 blue-chip clients management functions such as production condition monitoring and inspection for worldwide, with several major customers control and facilities management, which waste management sites, and improved in the UK nuclear sector including EDF is scalable from small applications with data collection and analysis for predictive Energy. around 100 variables, to much larger and maintenance. more complex requirements with millions Codra is working closely with the Nuclear of variables.” “Technology demonstrators can help AMRC’s digital engineering team to help manufacturers to understand how they can smaller businesses integrate systems and As part of its tier two membership, Codra benefit from industrial digital technologies, data in innovative ways, and to develop will provide its Panorama suite platform and serve as a testbed for integrating new applications based on the Panorama to the Nuclear AMRC, along with support, different software and hardware solutions platform. training and innovative design ideas. into systems that meet their requirements,” Based at the Nuclear AMRC Midlands This collaboration will focus on using Marr said. facility in Derby, the digital environment Panorama to develop data pathways for codra.net/en group work with manufacturers of all sizes digital twins, detailed real-time replicas of to improve performance through digitalised operational facilities such as power plants

Jobs map shows nuclear resilience The number of people working in the UK nuclear sector has remained steady despite the Covid-19 pandemic, according to the latest survey by the Nuclear Industry Association (NIA).

The NIA's annual jobs map shows that power because of the pandemic, and emissions free, reliable and secure nuclear 59,584 people are employed in the civil Hunterston B has been able to restart power can cut emissions and create the nuclear sector across the UK, a slight generation. skilled, long-term jobs we need for a green increase on 2019. recovery.” “The nuclear industry has shown All parts of the industry, including extraordinary resilience in sustaining New build projects have played a key role generation, new build, decommissioning high-skilled, well-paid jobs and keeping in sustaining employment and improving and R&D, have sustained operations the lights on throughout this pandemic," the UK’s construction skills base. Hinkley throughout the disruptions of Covid-19. commented NIA chief executive Tom Point C employs around 4,500 people on Thousands of workers in the existing fleet Greatrex. "The growth in employment on site, and more than 600 apprentices have across Scotland and England have ensured new build projects and advanced research been trained on the project. that no station has had to stop producing and development shows how investing in www.niauk.org/resources/jobs-map-2020

25 Nuclear AMRC News Autumn 2020

Future fusion: UKAEA’s new facility on the Advanced Manufacturing Park.

UKAEA Yorkshire prepares to open UKAEA is fitting out its new fusion technology facility in South Yorkshire, ahead of an official opening this winter.

Construction completed in August, with “There are exciting times ahead – the “The Sheffield City Region is a growing hub the £22 million building handed over to fusion technology facility in Rotherham of innovation, expertise, and knowledge,” UKAEA in September. will be unique in the world and, as well as commented Dan Jarvis, Mayor of the delivering cutting-edge R&D, it will help to Sheffield City Region. “Building a low- The 2,500m2 facility will develop and seed the development of a UK supply chain carbon future is one of the most important test technologies for fusion materials for fusion. goals we can use those strengths to and components, including novel metals achieve. As we look to rebuild and renew and ceramics. These will be tested and “We can’t wait to get going and have following the pandemic, this facility will evaluated under conditions simulating the no doubt the hub of manufacturing create new skilled jobs and opportunities inside of a fusion reactor, including high excellence being created in the area will for collaboration with nearby research heat flux, vacuum and extreme magnetic prove to be of great importance to the centres and other businesses as specialist fields. commercialisation of fusion power.” suppliers, boosting the region’s economy The facility will also help UK companies The facility is strategically placed to and highlighting our world-leading win contracts for Iter, the international engage industry in commercial fusion specialisms in advanced manufacturing.” fusion project being built in the south development, and to work with the The Nuclear AMRC’s Professor Steve Jones of France. Further ahead, it will enable established engineering research joined Johnstone and other key partners technology development for the first cluster on and around the Advanced for a webinar on the new centre, hosted by commercial fusion power plants. Manufacturing Park (AMP). the Nuclear Industry Association in early “We are delivering the new facility at It will bring 40 initial jobs to the area, September. pace, with major milestones on building and foster increased collaboration with ccfe.ukaea.uk/technology/fusion- mobilisation and recruitment for the new research organisations based on AMP technology facility proceeding to plan,” said Damon including the Nuclear AMRC, University of Johnstone, head of UKAEA Yorkshire. Sheffield AMRC and TWI.

26 namrc.co.uk NIA calls for 40 by ‘50 The UK needs to commit to new nuclear power stations to make a clean economic recovery and meet net-zero commitments, according to a report from the Nuclear Industry Association (NIA).

The NIA produced the report, Forty by ‘50: “Nuclear needs to be part of the energy mix cheaply by building on repeat and tried and The Nuclear Roadmap, for the industry/ for net zero and, as this report shows, it’s a tested designs, capturing learnings from government Nuclear Industry Council technology that can maximise the benefits our new build programme, and making (NIC) in June. for the UK economy,” Storer commented. important changes to the way projects are “British companies can lead the financed. The NIC-endorsed report says that, in development of new technologies such as addition to helping meet long-term goals, “We’re confident the price of nuclear power small and advanced modular reactors and prompt decisions on a new nuclear power will fall from the £92.50 per megawatt hour fusion power, using their manufacturing programme could unlock mega-projects for the first plant, closer to £60/MWh for expertise and innovation to reduce the cost and deliver immediate benefits to help the next wave of power stations reducing of the low-carbon transition while driving tackle the economic impact of Covid-19. to around £40/MWh for further reactors. economic growth and creating jobs in the According to the report, an ambitious North of England and across our industrial “Greenlighting new projects already in programme based on existing and new heartlands. We really need to push forward the pipeline would trigger a ramp-up technologies could provide up to 40 per now to grasp the opportunity and deliver in investment and job creation in parts cent of clean power by 2050, and drive on our clean energy commitment.” of the UK facing the biggest economic deeper decarbonisation. It could eventually challenges, and clear the way for long term Earlier in June, the International Energy bring as many as 300,000 jobs and £33 decarbonisation through the hydrogen Agency urged policy-makers to focus on billion of annual economic value. economy, helping establish the UK nuclear sustainable recovery. At the same time, the sector as global leader in the field. Nuclear currently contributes 40 per cent Energy Systems Catapult published detailed of the UK’s clean electricity, but total analysis calling for at least 10GW of new “Commitment to the roll-out of smaller demand is expected to quadruple from the nuclear capacity beyond the current new- and advanced reactors would build on that replacement of fossil fuels and a boom in build at Hinkley Point. momentum. Conversely, if we do nothing, the electric vehicles and heating sectors. we are effectively sitting on a winning hand “Net zero needs nuclear, and the sector is for a greener future.” The report was welcomed by Nuclear developing fast,” said NIA chief executive AMRC CEO Andrew Storer, a member of Tom Greatrex. “The next large-scale www.niauk.org/the-nuclear-roadmap the NIC. projects are now deliverable much more

Six-point plan

The Forty by ‘50 report sets out six important short-term steps to turn aspiration into reality:

1. The nuclear industry must continue to 4. A national policy statement and 6. Industry and government should drive down costs of new build projects facilitative programme, including siting agree a framework and commitments, and establish delivery excellence. and licensing proposals, should be focused on cross-sector collaboration developed for small reactors. outside traditional electricity 2. The government should articulate a production including the production clear long-term commitment to new 5. The 2030 targets of the Nuclear of medical isotopes, hydrogen, and nuclear power. Sector Deal (which marked its second synthetic fuels for transport, along anniversary in late June) should be 3. Progress must be made on an with heat applications including maintained, including cost reduction appropriate funding model for nuclear district heating, agriculture and targets for 30 per cent for new build new build to stimulate investment in storage technologies. and 20 per cent for decommissioning, new capacity and reduce the cost a 40 per cent female workforce, and of capital. £2 billion of domestic and international contracts for the UK supply chain.

27 Nuclear AMRC News Autumn 2020 HVM Catapult leading the green manufacturing revolution The High Value Manufacturing Catapult has published its annual review, capturing the impact of its work to lead a green manufacturing revolution and support the national response to the Covid pandemic.

The report highlights the HVM Catapult’s capacity to respond to a crisis, as demonstrated by its leading role in the VentilatorChallengeUK consortium. CEO Dick Elsy co-ordinated the industrial consortium which successfully delivered around 13,400 ventilators, more than doubling the stock available to the NHS.

The report also illustrates how the HVM Catapult is responding to other challenges facing the UK. Last year, the UK committed to achieving net zero greenhouse gas emissions by 2050. The report shows how the HVM Catapult is already supporting this ambition, enabling innovation in transport, energy generation and manufacturing processes to drive down emissions and deliver economic impact. Meeting the challenge: Dick Elsy (right) with Penlon CEO Guru Krishnamoorthy. “As the most significant advanced • Demonstrating single-platform manufacturing research body in Europe, High Value Manufacturing Catapult will manufacturing techniques for large we are determined to use our position to step forward to play a full part in the UK’s nuclear components. help industry to get back on its feet after economic resurgence.” the Covid-19 crisis and, importantly, keep The annual report includes summaries • Supporting regional manufacturers from the torch lit for innovation,” said Elsy. “This of dozens of projects from across the Nuclear AMRC Midlands in Derby. will be crucial to our competitiveness as all Catapult’s network of seven specialist • Anchoring the innovation cluster at nations fight to return to a new normal. centres. Success stories from the Nuclear the Advanced Manufacturing Park in Rotherham. “We will also use this opportunity to show AMRC include: leadership in driving progress towards • Developing new low-carbon reactors as • Helping companies enter new markets achieving net zero by 2050. I know that part of the UK SMR consortium. with Fit For Nuclear and Fit 4 Offshore the manufacturing community can deliver • Working with UKAEA on materials Renewables. for the planet in a similar way it delivered and modular construction for fusion Download the full review: for the country in its time of need. The reactors. hvm.catapult.org.uk/annual-review-2020

Dr Rahul Mandal, Nuclear AMRC researcher and star baker, cooked up a mouthwatering thank-you for the VentilatorChallengeUK team. The cake replicating the Penlon ES02 ventilator was delivered to Penlon’s Oxfordshire factory in early July as the last ventilator was dispatched to the NHS.

Large enough for more than 100 helpings, the cake was based on one of Rahul’s winning recipes from Great British Bake-Off in 2018, and the largest he has yet made. It involved 12 chocolate tray bakes and two orange-flavoured cakes, held together with 4kg of chocolate fudge and 5kg of white chocolate ganache, and intricately decorated with over 6kg of fondant.

28 namrc.co.uk Working life at the Nuclear AMRC During lockdown, members of the Nuclear AMRC team were invited to share their expertise and experiences on the centre’s website. Here’s insight from one of our most experienced colleagues, and a young engineer at the start of her career.

For more insight and comment from the team: namrc.co.uk/news/comment

Over the past four decades, Beatriz Acevedo Gonzalez, a James Turner – known to all as mechanical engineering student Jimmy – has worked his way at Loughborough University, from machining apprentice completed a year’s placement at with the National Coal Board the Nuclear AMRC as an assistant to shopfloor supervisor at the research engineer. Nuclear AMRC in Rotherham. I wanted to work at Nuclear AMRC I started my apprenticeship in because it is at the forefront of the late ’70s, when this area was manufacturing technologies, and this predominantly coal and steel. My excited me. It is a great place to work for father insisted if I was going into coalmining, problem-solving and investigation-based work, and I knew I I did a recognised proper apprenticeship. would be working on essential skills that would benefit me in my later career. I did a four-year machining apprenticeship, and worked as a machinist all the way through until they started closing During my time at the centre, I have learnt a lot of practical the mines. My engineer then got me a job at an oil and gas engineering knowledge. I have learnt about organisation in order to company, and that was the first time I’d ever clocked eyes complete projects as planned, and to work effectively within a team. on a CNC machine. I had to go to night school, and I did I put myself forward for presenting virtual reality demonstrations to three years on CNCs. external visitors, which meant that I have continuously improved my I then did five years in Germany, working with exotic skills with the equipment while also helping my presentation and materials, and after I came back, I got a job in aerospace at confidence. Doncasters Bramah. That set me on the route to working As the technical secretary to the research board, I also had the with complex parts, which I found really interesting. opportunity to learn a lot about the world-leading ideas discussed I got into this role because I knew that there were jobs within the nuclear industry, and all the different organisations it coming through the university, and I knew that they did takes to drive the sector. This knowledge and information was aerospace down in the AMRC. I really enjoy my job as a extremely valuable in helping me understand the industry in more shopfloor supervisor, but I do miss being on machines detail. because it’s something that I’ve done all of my life. One of my highlights at the centre was submitting an idea to the The changes to machining practices over the years have Spark! Contest, which is a British–French competition to produce been absolutely phenomenal, and what our machinists can innovative thinking. My team and I made it to the second round, do with the machines today is just sheer brilliance. which was supposed to be in Paris – but due to the pandemic, this was moved to a virtual platform. The advice I’d give to young engineers is to go as far as you can. The education system now is a lot better than when I The challenges I faced were when I didn’t have the background started, and it’s a great time to come in to be a machinist. knowledge I needed when starting particular projects and topics. This is why I decided to undertake a placement year, as it helped me If you’ve got the opportunity, grab it with both hands. Learn expand my skills and knowledge. as much as you can, because that period between being 17 and retiring might seem a long way, but I could tell you I will take a great deal of skills back to my final year of university. it’s not. In particular, I have noticed that I am a lot more organised with my time and have become a self-motivated individual. Some of the guys on the shopfloor will tell you, you never ever stop learning. There’s always something else to learn. My experience at Nuclear AMRC was extremely rewarding, and I enjoyed the working atmosphere and the people that I have met at the centre.

29 Nuclear AMRC News Autumn 2020

Things to come: Professor Keith Ridgway, one of the founding directors of the Nuclear AMRC, presents the vision for the new centre. 10 years ago: a royal visit remembered On 18 November 2010, royal visitors came to the Advanced Manufacturing Park in Rotherham to launch construction of the new Nuclear AMRC.

Her Majesty The Queen, accompanied by cover of the Sunday Times Magazine and HRH The Duke of Edinburgh, donned a Private Eye, and the BBC’s Have I Got set of virtual reality glasses to remotely News For You – the Nuclear AMRC gained activate a digger from within the AMRC unexpected publicity in the US, Canada, Mantra vehicle, a customised lorry South Africa and beyond. designed to give young people a taste of During their visit, the Royals met with modern manufacturing technologies. Royal approval: photos of the Queen wearing apprentices and representatives from the VR glasses were a global media success. As a signal went out to the real digger on Nuclear AMRC’s key partner companies, the site, the Royals saw a three-dimensional and viewed plans for the new building and Funding for the development included animation of the new building rising from other developments. £15 million from the Department of the virtual ground. Construction of the 8,000m2 building was Business, Industry and Skills as part of Images of Her Majesty in VR glasses proved completed to schedule by autumn 2011, 2009’s Low-Carbon Industrial Strategy, plus a hit with the world’s media. As well as with the initial Nuclear AMRC team working £10 million from the regional development being featured in national newspapers, from temporary offices and workshops agency Yorkshire Forward. TV and industry press – including the elsewhere on the park.

30 namrc.co.uk Events in the time of Covid Industry events have long been seen as an essential way of making new contacts and sharing knowledge, but the Covid lockdown put a sudden halt to face-to-face meetings. Nuclear AMRC events manager Jo Byron explains how the centre adapted to online events, and looks forward to a hybrid future with the best of the virtual and real worlds.

Since joining the Nuclear AMRC in early providing support and sharing information 2017, I have played a key role in launching on new opportunities. In early June, we our new facilities and delivering our first reached out to our members and the F4N major conference, as well as managing our community with our first webinar, sharing hybrid platforms. Many key industry events regular calendar of visits, seminars and our lessons learnt on managing a safe are being considered as hybrid in 2021, but partner events. return to work. This was a huge success, for now we continue to support and attend and we are now planning a variety of That now seems like a different world. With virtual activity. webinars over the coming months. the start of the Covid pandemic, events I do think virtual events have a lot going came to an almost complete standstill. I was part of a small organising group for for them, and I do feel they will continue We decided to cancel and postpone any the first UK World Nuclear Exhibition (WNE) to play a big part in the events industry events, visits and tours with immediate networking event, in place of the full- even when live events return. They do offer effect. scale WNE which has been postponed to some positive impacts, by avoiding carbon- December. This was attended by more than Over the past few months, I have seen intensive travel, saving delegates’ time and 150 people, with very positive feedback the events industry emphasise the need expense, and offering more accessibility. despite some technical problems on the to diversify into the virtual sphere. With so day. On reflection, our committee agreed Virtual events are cost-effective for many webinars and virtual events filling the that there will be a continuing need for organisers, and because attendees can view diary to replace in-person events, my initial virtual events, but it’s yet to be proven the event from anywhere, we can offer challenge was to carefully consider the whether they can ever really replace the much more flexibility to attendees and gain objectives and practicalities of launching buzz, creativity and sheer vibrancy of a live far larger audiences. our own webinars. event. But you can never replace the networking Our key focus is always on engaging our Like many other organisations and value of face-to-face interaction, which customers in the nuclear supply chain, businesses, we need to adapt to virtual and inevitably has more impact.

Diary namrc.co.uk/news/events

Some of the events that the Nuclear AMRC will be attending or supporting in the coming months. Please be aware than plans may change in response to the developing pandemic situation and local restrictions.

Nuclear 2020: Roadmap to World Nuclear Exhibition Net Zero 8–10 December, Paris 3 December, London The leading marketplace dedicated to the The Nuclear Industry Association presents global civil nuclear community, bringing its 20th annual conference, covering together around 730 organisations from nuclear new build, decommissioning, around the world. export opportunities, skills and more. www.world-nuclear-exhibition.com www.niauk.org/event-listing/ nuclear-2020

31 Work with us The 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 supply chain development and innovation. We can work with you to raise your quality, capability and cost Contact us: competitiveness to meet the needs of the global nuclear industry. Nuclear AMRC And we can develop world-leading manufacturing processes and The University of Sheffield technologies. We have the production-scale facilities and the manufacturing Advanced Manufacturing Park Brunel Way, Rotherham, S60 5WG expertise to help you improve cycle time, reduce lead time, improve quality and reduce costs. tel: +44 (0)114 222 9900 email: [email protected] Our capabilities and services are open to all UK manufacturers. We provide a online: namrc.co.uk twitter: @NuclearAMRC responsive service to help you solve your manufacturing challenges and win new work. Nuclear AMRC Midlands iHub, Infinity Park, Derby, DE24 9FU We also offer full membership, giving you access to our generic projects and the opportunity to determine our core research. Nuclear AMRC Birkenhead facility Cammell Laird, Campbeltown Road To find out more about how we can help you win work, Birkenhead, Merseyside, CH41 9BP contact the Nuclear AMRC business development team: [email protected] Manufacturing Technology Research Laboratory The University of Manchester Sackville Street, Manchester, M13 9PL Tier 1 members:

Tier 2 members:

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