Inspection, NDT & replication tooling
The Rolls-Royce engineering team pulls from an elite pool of experts from around the globe with experience from facilities in many different countries. We are dedicated to providing customized, long term, advanced technical solutions to our global customer base. Leveraging decades of specialty nuclear engineering, project management and hands on field experience, we work hand in hand with our customers from conception to implementation to deliver one of a kind solutions to the most challenging technical issues facing the nuclear industry today.
From small projects ranging only a few weeks or months in length to major developmental challenges spanning years, Rolls-Royce can create a custom engineered solution to suit your needs. Our rigorous engineering, qualification and testing processes coupled with our in house manufacturing capabilities and unmatched knowledge of nuclear generation systems continue to deliver nothing short of excellence time after time.
Our inspection, NDT & replication tooling solution capabilities include :
- Design, qualification and deployment of remote NDT, Visual, sampling and repair solutions
- Custom engineered robotic solutions
- Feasibility studies
- Maintenance tooling and programs
Reactor pressure vessel Well Inspection Tool "WIT" - Case study
Rolls-Royce instrumentation and control (I&C) teams required a dedicated equipment to inspect the wells of neutronic measurement instrumentation installed around the bottom of the Reactor Pressure Vessel. The teams desired capabilities included the ability to inspect 900 and 1300 MW reactors with 8 meter deep wells from the ground at the bottom of the reactor pool, The tool must also be able to produce high quality and high resolution images at no less than a 2 meter distance from the selected object for inspection. The teams main objectives were to inspect the equipment before servicing for defects and cleanliness, monitor the entirety of maintenance or any replacement operations as well as perform final checks of the equipment after maintenance or replacement operations were complete. Specific areas of interest were the area under the detector carriage, system cables and the fixing screw.
The Rolls-Royce solution
To answer this challenge, Rolls-Royce has developed the exclusive Well Inspection Tool also known as "WIT". This dedicated technology is designed specifically for the inspection of the wells of neutronic measurement instrumentation around the Reactor Pressure Vessel at the bottom of the reactor. As a remotely operated solution, the tool supports maintenance operations conducted by instrumentation and control (I&C) teams on neutronic measurement instrumentation. The systems pan, tilt, zoom (PTZ) inspection camera is capable of capturing high resolution video and images from the 8 meter (26 feet) deep well within the radioactive environment . The robust tool is designed to support initial inspections before maintenance activities and perform final checks for successful instrumentation replacement.
- High performances PTZ and lighting
- Detailed views and general environment images
- Allow to detect, diagnosis and record any disorder and therefore secure maintenance service operations
- Easy set-up at the bottom of the pool
Wing & cage remote NDT delivery - Case study
A leak was identified in a header tube at a nuclear power station that required multiple types of non-destructive testing to determine the source of the leak. The primary concern of the utility was stress corrosion cracking. The 3 feet diameter header was constructed of multiple types of metal welded together and was mounted in a 12 foot thick wall of the reactor. The access gap to the header was less than 3 feet and had a diameter change 3 feet inside the concrete, thus the majority of the header did not have line of site access.
The inspection of the welds required various forms of NDT including, weld profiling, surface preparation, surface finish testing, and visual inspection and surface salinity tests. As an added challenge, in order to access the area to be examined,it was also required that a stainless steel spacer bar be remotely ground from 1/4 inch to 1/8 inch thickness to allow the passage of tooling through the area.
The Rolls-Royce solution
To overcome this challenge, Rolls-Royce designed, built a qualified a “Wing & Cage” remote delivery system with a total of six different tooling attachments within 3 months. This was done using a rigorous engineering process that allows the team to leverage many years of experience. A high level of coordination was required between the Rolls-Royce team, the NDT equipment vendors and the customer to meet the difficult requirements. A Field Service team was trained and deployed along with the equipment to perform the service on site.
The “Wing & Cage” system could be inserted into the header opening one piece at a time and fully assembled once inside the inspection area. Modular assembly of the inspection system was necessary to overcome the change in pipe diameter while entering the inspection area. Once inserted, one of the six custom tooling options were used to complete the inspection for each different phase of the project.
To make the project even more challenging, the station realized the need for surface replication testing just weeks before the projects scheduled end date. Determined to help our customer meet their scheduled project close out, Rolls-Royce designed,tested and qualified a remote surface replication tooling attachment within a week. The project schedule was successfully met.
A true analysis of header condition for better risk management and maintenance planning on other headers within the facility.