Wed, 05 March, 2025
Concerns over energy security, affordability and the environmental impact of global warming has seen a shift in electricity generation, with nuclear energy deemed as a solution for low carbon base load electricity and competitive prices.
Some 65 countries are currently implementing or planning new nuclear power programmes as projections state that nuclear will account for between 24% and 38% of global electricity production by 2050, which opens up avenues for support from organisations like TWI.
While nuclear energy provides a number of benefits, there are also challenges around the public perception of the nuclear industry, particularly in relation to safety, security and waste management. In addition, nuclear assets require large initial investment and those nations who are building a new nuclear capacity also require institutional and regulatory frameworks.
TWI Support
TWI has been involved in over 800 separate nuclear and fusion industry projects, with our experience in the nuclear industry crossing everything from new builds and life extension to waste disposal and decommissioning. We have been involved in the build of new power stations, offering expert advice and support with regard to welding and joining processes, the use of the correct codes and standards, and more. Extending the lifecycle of existing nuclear power stations has seen assets that were originally designed to last 30-40 years undergo extensive structural integrity assessments and refurbishment to maintain the long-term safety of the plants.
TWI also helps with nuclear waste management and decommissioning to ensure the safe and efficient methods of packing, storing and disposing of different waste streams from the nuclear industry. Our expertise in laser cutting technology has informed a range of decommissioning projects, delivering novel techniques for cutting up reactor components ahead of disposal. In addition, we have worked on projects to safely handle nuclear waste that can remain active for thousands of years. Our work in this area includes the US Department of Energy’s Yucca Mountain project for the safe storage of high level nuclear reactor waste, while we have also been involved in projects in France, Japan, Sweden, Switzerland and the UK. TWI’s welding expertise has been called upon to assist in the selection of welding processes and procedures for the deep geological disposal of nuclear waste storage canisters.
As an independent and impartial organisation, TWI is also able to deliver expert witness and peer review services in support of submissions to regulatory bodies, as well as failure investigation support and safety case reviews.
Our range of expertise allows us to provide materials and non-destructive testing, structural integrity modelling, and asset management and business support, including asset management surveys, plant assessments, risk analysis and supply chain development.
Example Projects
For over 75 years, our Members have trusted us to deliver Technical Excellence, which has included within the nuclear and fusion industries. This work has covered everything from remote in-bore cutting and welding for nuclear fusion reactors, nuclear decommissioning at Sellafield using LaserSnake, training on asset management at decommissioning sites, electron beam welding and friction stir welding of nuclear storage containers, the advancement of fusion power, and the creation of small modular nuclear reactors.
TWI joined a consortium led by Rolls-Royce alongside Assystem, BAM Nuttall, Laing O’Rourke, National Nuclear Laboratory (NNL), Atkins, Wood and the Nuclear AMRC to develop domestic small modular nuclear reactors (SMRs). The consortium received matching funding from UK Research and Innovation (UKRI) to create a new solution for affordable energy production with a low carbon footprint that can be recreated anywhere in the world. SMRs provide a fast and flexible solution with lower input costs and a smaller environmental impact.
- Remote In-Bore Cutting and Welding for Nuclear Fusion Reactors
TWI worked with RACE (Remote Applications in Challenging Environments), part of UKAEA (the UK Atomic Energy Authority), to develop remote, in-bore, laser-based cutting and welding maintenance technologies for future nuclear fusion reactors. RACE worked with TWI to create miniaturised laser welding and cutting tools for the future needs of in-bore pipe cut-and-replace operations.
- Nuclear Decommissioning at Sellafield using LaserSnake
TWI has successfully completed the size reduction of an active dissolver cell from the First Generation Reprocessing Plant at Sellafield using laser cutting - transforming the approach to dismantling redundant nuclear equipment, leading to significant cost and time savings. The LaserSnake, which was used for the operation, combines TWI’s high powered laser cutting technology with an OC Robotics snake-arm robot, giving a decommissioning tool with the dexterity required to work in high-hazard confined nuclear environments and the safe, precise size reduction process. It also meets the rigorous safety requirements of both Sellafield Ltd and the Nuclear Decommissioning Authority. The rapid laser size reduction process produces minimal fume with a low dispersion of fume particles, and reduces the production of other secondary waste streams as no operator suits or contaminated hand equipment are put into the waste chain. Operator exposure to contamination is eliminated through remote operation, and economic savings can be made due to its high productivity, reliability, and reduced secondary waste.
- Training on Asset Management at Decommissioning Sites
The nuclear decommissioning company, Magnox Limited asked TWI to develop a training course on asset management for System Engineers at its various sites. The course was based on HSE Research Report RR912 ‘Management of Ageing: A framework for nuclear chemical facilities’ of which TWI was the principal author. The report applied specifically to the nuclear industry and described the System Engineering approach for managing ageing of nuclear chemical facilities. By proactively managing the ageing of assets entering stage 3 of the bathtub curve, inspection and maintenance can be made more effective and cost efficient, while also avoiding unexpected failures and costly remedial work. The interactive course was delivered to over 50 System Engineers at four different venues around the UK in a one day format.
- Electron Beam Welding of Spent Nuclear Storage Containers
Safe and effective long-term storage of nuclear waste is critical to eliminate risks of potential radioactive leakage and pollution, which could have major implications for the surrounding environment and population. TWI has provided expertise and process guidance for nuclear waste management programmes across the world and, as a reliable process for the manufacture of spent fuel containers, EB welding meets the challenge both structurally and hermetically. Work carried out at TWI in the late 1980s and early 1990s with the Swedish Nuclear Fuel and Waste Management Co (SKB) was the first to identify reduced pressure electron beam (EB) welding as a solution for sealing and encapsulating spent nuclear fuel canisters. Since this time, research and development of EB processing for nuclear waste control at TWI has established best practice for materials selection, and set out a series of manufacturing and high integrity welding methods and parameters for fabricating and sealing containers. TWI has provided services to the Office of Civilian Radioactive waste management in the USA, the Swedish Nuclear Fuel and Waste Management Co (SKB), Nagra in Switzerland and the French National Radioactive Waste Management Agency (ANDRA).
- Supporting the ITER Project
TWI completed a project providing design and engineering support to part of the ITER fusion project in Cadarache, France. Working closely with the ITER team, engineers at TWI provided advice and support with respect to the manufacturing, welding, joining and NDT inspection of parts for a Tokamak assembly. As part of the project a number of key technical challenges were assessed, including:
- Ability to machine parts, including alternative manufacturing options and suppliers
- Assessment of welding and fabrication requirements
- Ability to apply non-destructive testing
- Relevant codes and standards
Through an iterative development process, the overall design concept was finalised, allowing the team at ITER to identify critical components and manufacturing activities that will be progressed to testing via mock ups.
TWI Technology Fellows' Day
We are holding an in-person seminar at our headquarters near Cambridge 15 May 2025. This is the first event its type ever to be held by TWI, bringing together the world-leading expertise of our Technology Fellows to focus on challenges and solutions for nuclear and fusion with crossover to other industries.
You can find out more and register, here: https://www.twi-global.com/media-and-events/events-diary/twi-technology-fellows-day