A wealth of experience in nuclear process and equipment Process equipment

Reducing risk, raising efficiency

During reactor operation radioactive impurities can become trapped in the thin oxide layer of inner piping surfaces and process components of a nuclear reactor. The presence of these impurities can create a radiation hazard for operators or maintenance personnel. Chemical decontamination can be used to dissolve this oxide layer, free up the active impurities, and concentrate them outside of the process system. This is done by means of filtration and ion exchange.

Rolls-Royce has the capability to design, manufacture and supply integrated decontamination process systems. They reduce active liquid wastes and decontaminate aging nuclear reactor pipework and process components. Our decontamination systems are designed to operate in situ, without costly dissassembly or drainage of the system.

High-integrity engineering for safety-critical systems

Rolls-Royce has the capability to design and build bespoke valve stations for use during on-line fuelling of CANDU reactors. These remotely-controlled fuelling machines use D2O as their hydraulic medium. This is in an intricate system of process control in which D2O-operated actuators are packaged in complex valve stations. These stations are designed to extremely fine tolerances for reliable and effective operation.

The complex structure of piping and components that controls the flow and pressure of D2O has both hydraulic and pneumatic systems. All piping and instrumentation systems in the valve stations are built to a suit a range of different ASME code sections and classes. They each have their own differing procurement, manufacturing, testing and inspection demands.

Through supply chain management and continuous development of in-house manufacturing capabilities, we are able to design and build D2O valve stations. These stations meet the most stringent customer, plant and legislative requirements.

Supporting capabilities include:

  • Fabrication of valve station support structure, brackets and clamps, piping subassemblies and components
  • Installation of D2O and pneumatic tubing and equipment
  • Installation of wiring, junction boxes and interconnecting cables
  • Hydrostatic and air leak testing and liquid penetrant inspection
  • Flushing and flow testing of completed panels
  • Drying and packaging for overseas shipment
  • Extensive performance testing

Customised, high integrity heat exchangers for the nuclear industry

Rolls-Royce specialises in the design, specification and manufacture of customised heat exchangers for a range of nuclear applications. Rolls-Royce has the capability to deliver on time and budget. Whether you require an off the shelf design or a unique component, where pre-existing infrastructure dictates the size and shape of heat exchangers.

Rolls-Royce heat exchangers are in use in nuclear generating stations in Korea and China. They feature ten coils of tubing with UHMW polyethylene baffles, separating the coils and directing the shell side flow from one coil loop to another. The centre pipe doubles as both a structural support for the tube-sheets and a return passage for the shell side flow. The tube side flow originates and terminates in manifolds built into the upper head. This design produces a very high rate of heat transfer within an unusually small volume.

We provide these heat exchangers in all-welded and bolted construction and in horizontal and vertical configurations. The design can be adapted to suit a broad range of service requirements simply by adding or removing cooling coils.

Supporting capabilities:

  • ASME accredited design and manufacture
  • Nozzle loading, pressure drop, heat transfer calculations
  • Registration with regulatory authority
  • Final testing including air leak, hydrostatic and helium leak tests
  • Seismic analysis 

Safe removal of radioactive isotopes.

Rolls-Royce ion exchange capabilities extend across a broad range of specialised equipment for nuclear and defence applications. The ion exchange columns Rolls-Royce designs and manufactures ensure ions are removed efficiently from process streams. This is through ion exchange in a resin bed while water is directed uniformly through the resin.

To minimise the likelihood of flow channelling and subsequent loss of resin efficiency, Rolls-Royce provides custom-built manifold systems. They distribute the downward flow over the entire cross-section of the column.

Rolls-Royce has supplied hundreds of ion exchange vessels to the nuclear industry. We are capable of supplying diameters ranging from between 25cm (10 inches) and 184cm (72 inches). Applications include the removal of cobalt 60 from the process piping of CANDU reactors. This reduces employee exposure in radiation fields for maintenance workers during reactor refurbishment.

Supporting capabilities:

  • ASME Pressure vessel design and registration
  • Custom flow manifold design
  • Flow calculation and testing

Tritium handling, transportation and storage

Tritium is a natural by-product of CANDU reactors and has a variety of commercial and industrial uses. For almost three decades Rolls-Royce has designed, fabricated and tested a comprehensive range of tritium vessels. These vessels are for the handling, transportation and storage of tritium within. Also for the safe transport between nuclear facilities and industrial users.

The design and fabrication of vessels for the safe containment of tritium is complex. It requires specialist engineering and quality assurance capabilities. It also requires the facility to manufacture and test to extremely fine tolerances. Rolls-Royce has the complete range of capabilities in-house, from high integrity welding to helium leak testing and radiographic non destructive examination.

Rolls-Royce’s standard Immobilized Tritium Containers (ITC’s) contain a titanium sponge type product for tritium storage in the form of titanium tritide. The ITC’s are stainless steel vessels with embedded leak tight valves designed to withstand extremes of pressure and elevated temperatures. They are of welded construction and meet extremely strict helium leak tightness requirements.