Nuclear Plant in Microcosm

Brief

In keeping with their objective of ‘harnessing the latest technology to improve delivery of training skills’, the National College for Nuclear (NCfN) at Bridgwater & Taunton College wanted to develop a learning environment that could replicate a nuclear plant in microcosm.

This would need to allow students to experience the demands of the nuclear workplace, enabling them to practise industry operations & behaviours away from the ‘Licensed Environment’.

Design of this Practical Reactor Activity Centre was to be based on a twin flow loop of hot & cold water. It would demonstrate thermodynamic principles on a closed loop system (similar to a nuclear power station) and incorporate the appropriate functional controls and instrumentation.

To underpin ‘real life’ context, the final design would also need to present students with the realities of ongoing system maintenance and equipment replacement scenarios.

Berry & Escott tendered the design of a representative system that would simulate these principles. The installed Flow Rig system would be realistic to the types of equipment students could ultimately be exposed to at nuclear facilities such as Hinkley.

Outcome

“Berry & Escott have been pro-active in engaging with nuclear opportunities for a number of years. They have been involved in 2 consortium groups; APEC for precision machining, and the Nucleus fabrication consortium. It is great to see the hard work they have put in starting to come through in terms of recognition, and ultimately contracts.”

Nick Golding, Hinkley Supply Chain DirectorFit 4 Nuclear

As a recognized Fit 4 Nuclear (F4N) company, Berry & Escott were introduced to NCfN and supported by the Hinkley Supply Chain Team.

With a track record within the nuclear industry and some innovative thinking, Berry & Escott successfully beat competitor submissions, securing the contract to design, manufacture & install the NCfN Flow Rig.

In the process the company addressed, and put forward solutions to overcome historical design concerns & project specific challenges, including: historical commissioned design, limited budget, restricted timeframe, space limitations, ground floor loading, existing pipework infrastructure, and rebar identification.

On review of the originally commissioned design and budget, Berry & Escott undertook an options analysis to evaluate system functionality requirements. This was followed by an outline project plan to prioritise the mechanical elements of the system as Phase 1 of the project.

Utilising cutting edge 3D scanning equipment in conjunction with nuclear infrastructure design expertise, the project team could identify & put forward solutions to site specific structural challenges within the budgetary requirements.

Based on these findings a redefined functional specification was agreed with NCfN and the system was manufactured in line with this specification.

NCfN Flow Rig Tank Support Assembly DrawingSupporting structure for system platform needed to be notched around existing pipework, potentially weakening the efficiency of the structure.

The Berry & Escott team carried out FEA and structural analysis on supporting structure and gathered dimensional data to create installation drawings that ensured correct alignment of base to support the structure.

NCfN Flow Rig Platform UDL AnalysisOriginal commissioned design incorporating a suspended floor design had underestimated the floor loading to support the structure.

Berry & Escott design engineers undertook a comprehensive review of the uniformly distributed load (UDL) and implemented design revisions to ensure an even floor loading weight distribution across the structure.

NCfN now have a state-of-the-art Flow Rig training system that will be used to hone the skills of many future nuclear engineers.

“Our collaboration with local business has been a critical factor in the success of the NCfN, and specifically this project. Funding from UFI and EDGE made this project possible which has resulted in Berry & Escott realising our vision, and exceeded our expectations.”

Paul Goss, Head of National College for Nuclear (southern hub)

If you require a similar project or to discuss your own requirements, please email: enquiries@berryescott.co.uk