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GAME CHANGERS UPDATE September 2017
Smart Tech and Digital Solutions: event review and outcomesOxford Technologies: meet DexterTM
Rawwater: tech transfer from oil and gas helping plug the gaps
The Game Changers programme is entering its second year and continues to discover and embrace new and innovative technologies which have the potential to help meet the decommissioning challenges faced at Sellafield.
Through identifying and publishing specific 'challenge statements' Game Changers has grown a network across diverse industries and academia resulting in 125 applications to the initiative, with 5 of these progressing to further proof of concept funding, each showing great potential for future deployment at the Sellafield site.
The Game Changers team have hosted two events in 2017: Waste Container Challenge at Nuclear AMRC in Rotherham, and Smart Technology and Digital Solutions in Manchester.
Each event was focused on specific decommissioning ‘challenges’, authored and presented by Sellafield Ltd and NNL personnel, and designed to illustrate key areas of interest to the decommissioning programme.
Both events were very well attended by pre-qualified delegates and facilitated high levels of engagement with Sellafield Ltd personnel, something which has continued post-event.
The following pages of this document contain applications from the Manchester event which have been awarded initial £5k funding to present the business case for their technologies.
Their full 'poster presentations' are available from Andrew Cooney ([email protected])
What next for Game Changers?
The progamme is currently planning next suite of challenge statements, with the focus being on supporting the Analytical Services teams led by Dr Mike Edmondson.
Supporting this, a challenge event is scheduled for November 2017 with collaboration between the National Physical Laboratory and the University of Southampton.
Further challenges will follow in early 2018 with the attention being on Condition Monitoring and Alpha Glovebox Decommissioning.
For further updates, please visit: www.gamechangers.technology
Newsletter September 2017
The event welcomed any organisations, academia or individuals with the knowledge, experience, ideas, solutions or early stage technologies which might help accelerate the decommissioning programme.
There was no requirement for previous experience of working within nuclear or decommissioning, and the Game Changers Team positively encouraged those who may bring technologies and solutions from other sectors and industries. THE CHALLENGES. Presenting the specifics of a number of decommissioning challenges were:
Mark Dowson and Charlie Scales Real time monitoring of waste treatment and clean up; thermal treatment.
Dr Mike Edmondson Knowledge rich decommissioning - characterisation, data management and optimised planning.
Tom Robinson Industry 4.0’s role in decommissioning - communication with remote devices, plus tools and sensors that can be deployed in harsh environments.
Andrew Cooney Surveillance and maintenance - monitoring of buildings; interconnected array to provide real-time monitoring and surveillance of buildings.
WHO ATTENDED? Companies who are focused in smart technologies and digital solutions, typically: • Real time radiometric measurement of gaseous effluent
• Detectors, sensor networks and aerial gas sensor specialists
• Big data, analytics, data mining
• Legacy dataset conversion
• Augmented Reality / Virtual Reality
• Imaging and modelling
• Automated monitoring and testing
• Robotics
• Remote asset care and monitoring
• Reducing energy / raw material consumption
THE EVENT IN NUMBERS. pre-qualified delegates registered for the event in Manchester
different UK companies or academic institutions represented applications received in the two weeks after the event different organisations submitting applications to the programme applicant organisations who had attended the event
Feedback from delegates illustrated that engagement between the event’s presenters, Sellafield Ltd and NNL personnel and the delegates was high, with many appreciating the opportunity for open and informal discussions at the challenge sessions.
The Museum of Science & Industry in Manchester was the venue in April 2017 for Smart Technology & Digital Solutions, a one day event hosted by Game Changers, Sellafield Ltd and the University of Manchester Knowledge Exchange Team.
The event introduced specific decommissioning challenges to SMEs, corporations and academia with delegates intoducing their innovative ideas, engaging in discussion and potential for collaboration.
8540351811
ALTRAN UK LTD - APPLETON PARK SERVICES - AVA TECHNOLOGIES - BARRNON - COJAC LTD COSTAIN - GROUND STIFFNESS SURVEYS - I44I - MISSION CX - MONITION - OMNIFLEX SABISU - SERIOUS GAMES INTERNATIONAL - SHAW ENGINEERING SOFTWARE & ROBOTICS
SPOT SENSORS TECHNOLOGIES - STAFFORDSHIRE UNIVERSITY - TETHERED DRONE SYSTEMS - WYG
What next?Opposite are brief overviews of the applicantions which were appraised by a review panel and considered worthy for consideration by Sellafield personnel.Should you wish to find out more about any of the applications, or any aspect of the Game Changers programme, contact:
Adrian Davis-Johnston, NNL [email protected]
Paul Knight, NNL [email protected]
Frank Allison, FIS360 [email protected]
APPLICATION REF. TITLE DESCRIPTION
GC-090 Aether The Aether Tethered UAV is the only CAA licensed drone of its type in the UK. Built as a TETHERED DRONE SYSTEMS - Sustained Flight UAV consultation project by the University of Southampton, the UAV has flown in demonstration many times including in central London. The powered tether ensures the drone can stay in flight indefinitely and can carry 'pods' up to 7kg to fulfil multiple tasks. CCTV, IR spectrum, thermal imaging, radio re-broadcast antenna, radiation survey meters, matrix cameras.
GC-092 / 094 / 100 / 112 / 113 Visual monitoring; Quiescent To take some of the technology which has been developed for the drone market, particularly SHAW ENGINEERING building monitoring and control; the flying drones such as multi-rotors, and to use it to build smart devices for use in the SOFTWARE & ROBOTICS Smart tools; Real-time dose Sellafield environments. The main advantage of this approach is that a lot of sophisticated and position monitoring; technology has been developed and is already being mass produced, so is lightweight, low power Innovation ideas and lower cost, allowing for rapid development of ideas.
GC-101 Sellafield data digest Consolidation and ordering of data sets on asset conditioning and monitoring for nuclear SPOT SENSORS TECHNOLOGIES installations and waste to help with decommissioning planning, management and operations. An innovative approach for data ingestion, storage, analytics, reporting and management using contemporary data tools and techniques.
GC-102 Connected sensing systems A system of environmental monitoring and asset condition monitoring that can be used as a SPOT SENSORS TECHNOLOGIES for nuclear waste sensor network array across Sellafield Sites. This system is designed to pro-actively monitor and Conditioning and Management manage assets prior to decommissioning via innovative sensor network design, lower cost hardware development, new approaches to sensor node to gateway communication, active monitoring and survey, predictive tools for asset management and further monitoring of waste movement and storage status.
GC-107 3D navigation of radioactive Remotely operated 3D navigation of complex structures at Sellafield site is well met by use of COSTAIN buildings for long term UAVs. Potential restrictions for their practical use, e.g. large amounts of shielding may interfere monitoring and surveillance with communications between operator and UAV. The anticipated need to introduce and retrieve the UAV with each operation reduces their long term monitoring effectiveness, where operators may be repeatedly exposed to radiation. Costain propose remote permanent multi-sensor 'hubs' where operators can navigate in 3D through a simple, lightweight and low cost infrastructure.
GC-108 In-situ embrittlement A process steel cutting using in-situ embrittlement and subsequent brittle fracture intended to COSTAIN of in-cell furniture eliminate fumes, dust and debris, and reduce the spread of contamination and generation of secondary waste. Improved management of hazards during dismantling and size reduction in space constrained areas.
GC-109 2D to 3D enabling smarter A toolset for fast and cost effective conversion of 2D drawings into 3D, enabling companies to i44i decommissioning work in virtual environments. For Sellafield Ltd, this will help with effective planning in decommissioning and tangible use of virtual and augmented reality.
GC-115 Site monitoring: detection, Novel machine vision software to detect change between images which can be used for real-time AVA TECHNOLOGIES classification and behavioural processing of image sequences. These could be CCTV video or sequential images taken over a analysis using intelligent video longer period of time (e.g. time lapse). The software can be applied in a variety of applications analytics such as video surveillance, object classification (by shape) and behaviour analysis. The technology can detect and track: moving objects; count the number of moving objects in or out of a reference perimeter; unauthorised removal of objects; unattended objects or objects stopped in restricted zones; automated or semi-automated access control for buildings and other facilities or resources. The software can also detect changes in sequential static images - possible detection of corrosion, changes in position of objects etc.
GC-121 / GC-122 / GC-123 Advanced project analytics This technology ensures project teams deliver on their commitments (time and budget) through SABISU for plant construction the combination of project data and modern analysis techniques. The proposed approach ensures teams stay ahead of the project by extracting more information from project data using advanced mathematical techniques. An ‘early warning system’ keeps teams ahead of the project to ensure efficient delivery from concept through to commissioning and into operations. Use of machine learning for It is important to ensure that a process is performing correctly and that the outputs the assurance of successful conform to the specification. Time and cost make it often infeasible to test every output ILW treatment manually. This technology ensures the quality of process outputs by analysing the data that is recorded by the system whilst the process is underway. Common architecture for In industrial sites in use for a number of decades it is common for IT infrastructure and systems data aggregation to be upgraded several times. On large sites it is also common to find a heterogeneous infrastructure where there are several different solutions in use across a site. These data ‘silos’ pose a challenge when it comes to viewing, interrogating or making use of the data (modern analysis approaches such as machine learning become impossible). This project aims to aggregate data from every site system into one place including structured process data and unstructured data such as reports and designs.
Below are 9 applications which were submitted after the Smart Technology and Digital Solutions event in Manchester in April 2017, and which have been award £5k funding for the production of business case and presentation poster. For further information on any of these submissions, please contact [email protected] stating the application reference number.
From design and consultancy to specification and planning, Abingdon-based Oxford Technologies Limited (OTL)have lengthy track record of solving engineering problems, specifically in the areas of complex remote handling operations.Well versed in the sector, the OTL team delivered the world’s first remote handling equipment to operate inside a nuclear fusion reactor.OTL's application to the Game Changers programme has progressed to proof of concept stage with a live demonstration now planned at NNL's facility in Workington.The technology being presented is designed to replace current glove boxes and would remove operators to a remote location away from any radiation dose. This would essentially allow operations to be performed on much higher activity systems which otherwise would be challenging (or even impossible) to be performed manually. The technology brings together two well-developed systems to a new area of application to form a new disruptive technology. These sub-technologies are the remote Dexter™ Telemanipulator System that is a proven
technology based upon the Mascot telemanipulator that has been used for many years at the JET fusion site in Culham. The other technology is the Glovebox which, again, is well-developed but would have to be developed further to allow it to be used in a remote handling manner. The Dexter™ slave arm would be located within a glovebox on a base rail that would allow it to be positioned as required within the glovebox. The slave arm would be controlled by a kinematically identical master that could be situated well away from any dose (up to 8km if required) in a control room environment. By moving the master arms, the operator is able to interact with and feel the forces exerted upon objects. Moreover, using a range of cameras, the operator can see the operations taking place and gains a sense of telepresence similar to actually performing the operations at the work site itself. By removing the need for sealed gauntlets and viewing windows, the gloveboxes are simplified and only require ports for entry and removal of equipment. This will reduce the costs associated with the gloveboxes. Additional cost savings are made due to removal of requirement for
operator barrier change facilities and PPE contaminated waste and the potential longer shift patterns both due to the time saving and no restrictions due to operator dose. OTL's current proposal is a proof of concept which would use an existing Dexter™ master-slave system at the NNL Workington site where the slave would be inserted into a simplified glove-box mock-up. The trials will run for a period of up to 2 weeks to allow demonstration and operator testing of many operations. During a visit by NNL and Sellafield to OTL in November 2016, it was indicated that sensitivity adjustment would be a useful development to the Dexter™ control system when manipulating low masses (e.g. spatulas) as well as devices with low mechanical compliance (e.g. fixed volume pipette plungers) that result in low contact forces. This would allow sensitivity trials to investigate the adjustment to gripper closure and end-effector sensitivity and its effect on the force output and operator perceived haptic feedback.
Development concept for a versatile Dexterous Remote Handling Cell (DRHcell) replacing the glovebox for higher activity operations.
www.oxfordtechnologies.co.uk
Hoist rail
Tool-rack
Dexter rail
Force interaction is fed back to operator
Work-items rail Worktable
Dexter™ Demonstration (early October 2017 at NNL Workington)Groups of NNL, Sellafield and other NDA staff will be invited to witness demonstrations of the Dexter™ system at NNL's Havelock Road facility in Workington during October 2017. These demonstrations will be constructed to be as relevant as possible to those witnessing the demonstrations and, where appropriate, guests will be able to use the Dexter™ system following instructions from OTL staff. When the Dexter™ master is being used by a guest an OTL staff member will supervise and will have to hand an emergency brake and emergency stop so that they can intervene to stop Dexter™ motion.
Dexter™ is proven technology in nuclear fusion• Operator is removed from
hazardous environment• No operator dose• No PPE Requirement• Up-skilling of workforce• Elimination of windows and
glove-ports• Simplification of glovebox and
protection systems• Reduced shielding requirement
Modified Standard CellOperator can be based up to 8km away with telepresence via ‘hands on’ operation and camera viewing
An established business with a global customer base in the oil and gas sector, Rawwater Engineering Company Limited (RECL) provides materials science and engineering solutions to oil and gas operators and service companies. An innovative technology, the Bismuth Plug, was developed by RECL as a superior option to cement for sealing onshore and offshore oil and gas wells during decommissioning. The Bismuth Plug is a metal alloy with a composition that can be tailored to expand when it solidifies, according to need. It can seal large openings, or fill small cracks or pores, preventing leakage of fluids in a wide range of applications.RECL identified a potential opportunity for this same molten metal alloy technology to be deployed in nuclear decommissioning as a novel system for containment and potential decontamination of radioactive surfaces.After initial discussions with Sellafield Ltd and Game Changers delivery partners National Nuclear Laboratory (NNL) and FIS360, an application was made to the Game Changers initiative for funding to assess the feasibility of transferring the technology from the oil and
gas industry by implementing the molten metal alloy product and deployment system for sealing cracked walls underwater. A successful application to Game Changers in October 2016 led to a £5k Game Changers award to cover RECL's time and effort to prepare a poster, detailed proof of concept business case and project plan.RECL went on to present their project idea to relevant technical teams from Sellafield Ltd and NNL and gained feedback that the technology could potentially tackle one of their key challenges in decontamination and decommissioning of porous materials. RECL prepared a business case expounding their proposal and the technological and commercial benefits. Support and feedback from Sellafield Ltd and NNL technical experts and FIS360 commercialisation specialists was provided throughout this process, to ensure that the business case and project plan addressed Sellafield’s needs. This engagement with the end user helped RECL understand the industry pull for the technology and gave them the confidence that this was a viable commercial
opportunity in a new market area for the company.In January 2017 RECL pitched to the Game Changers Investment Panel with RECL making a strong technical and commercial case, matched to the needs of Sellafield. RECL was successful in securing £46k of proof-of-concept funding from the Game Changers Technology Innovation Fund towards their £65k project, with RECL investing the remaining £19k. The funding awarded is being used to support technology development at RECL, leading to demonstrator trials that are scheduled for late 2017. If successful this could open up a significant new market for RECL and provide substantial cost savings for the UK’s nuclear decommissioning programme. “It was encouraging to find that our Bismuth Plug technology was exactly the type of innovation that Sellafield was looking for through the Game Changers initiative.With our experience in the oil and gas industry, we were able to give Sellafield confidence that the technology had been proven in another field with similarly high standards of health and safety and quality."
Novel application of oil and gas technology to solve nuclear decommissioning challenge.
Plugging a gap.
www.rawwater.com/engineering
"Engaging with the Game Changers initiative has enabled our innovative technology to gain an accelerated level of interest across the Sellafield site and the funding awarded has given us confidence that there is a potential significant new market for our technology.”Bob Eden, MD of Rawwater Engineering Company Ltd.
In 2010 the Bismuth Plug was a world first for metal-to-metal plugging technology, and underpinned the launch of Rawwater's Joint Industry Project to develop offshore plugging and well abandonment tools.Rawwater are currently designing and qualifying large diameter offshore plugs deployable using electric as well as pyrotechnic heaters. As if the rigours of new technology qualification are not enough, their project partners have set a target life expectancy of 'in perpetuity'.
The next challenge: Analytical Services
Sellafield Ltd Analytical Services currently operates with 175 analysts and 125 support staff to analyse approximately 60,000 samples each year for more than 100 customers across the Sellafield Site and regulatory bodies. An essential service to the Sellafield site operations, Analytical Services is considered to be one of the site’s highest operational risks (ARM ID 58083, the current analytical services facility) due to its 60 year age and degradation. Samples being analysed include solids, liquids, gases and mixtures for chemical, physical and radiological properties so site can comply with regulations with respect to management of nuclear materials and waste disposal. This activity informs decision making on how to optimise and manage plants and processes, and plan for decommissioning.The existing laboratory facility is not configured to support the changing business needs of Sellafield site as it moves from routine analysis (supporting reprocessing operations) to the more challenging requirements of decommissioning. This introduces considerable uncertainty in the ability to reliably provide future services to the Sellafield site.It has been identified that an alternate facility is required in order to mitigate this significant business capability gap. Following a review of options, a decision was made for NNL to provide the future Analytical Services in NNL Central Laboratory. A joint Sellafield/NNL programme and a replacement analytical project were established to relocate the analytical provision. This is currently at the concept stage, with the functional specification being developed. There are opportunities to optimise the operations in the new facility which will:• improve operator and environmental safety;• increase precision in activities undertaken;• reduce waste generation;• and create a world leading nuclear analytical capability
through introduction of new technologies and innovative ideas.
The next Game Changers challenge statements are currently being produced to support these challenges and aspirations, along with an engagement event in October at the University of Southampton and hosted in collabroration with the National Physical Laboratory. Visit www.gamechangers.technology for the latest updates.
Future Game Changer Challenges: Q4 2017: Condition Monitoring and InspectionQ1 2018: Alpha Glovebox Decommissioning
GAME CHANGERS ACHIEVEMENTS TO DATE
Marketing Activity
DEDICATED WEBSITE + E-MARKETING
SOCIAL MEDIATWITTER + LINKEDIN
REFINED APPLICATION PROCESS MESSAGING
STAKEHOLDER ‘SHOW + TELL’ EVENTS
STRONG BUY-IN WITH SELLAFIELD IIT / IPT
125 52APPLICATIONS ASSESSED APPLICATIONS AWARDED £5K GRANT+
FURTHER 20 ALREADY IN PIPELINE
End-user Engagement
5PROOF OF CONCEPT GRANTS
AWARDED
Process / Applications
Events : Hosted, Planned + Attended
230+CROSS-SECTOR DELEGATES ATTEND CHALLENGE
EVENTS IN ROTHERHAM (NUCLEAR AMRC) AND MANCHESTER
UNIVERSITIES ENGAGED: MANCHESTER, EDINBURGH, DURHAM, NEWCASTLE, LANCASTER, KEELE, ASTON,
GLASGOW AND STRATHCLYDE
2POC PROJECTS PROGRESSING
TO INVESTMENT PANEL
15+
All proof of concepts generating strong Sellafield buy-in and
demonstrating a clear ‘use case’:
• Aligned to user need
• Projects that will hit the ground running
• Mentoring / business / commercialisation
support provided
SUPPLY CHAIN + HACKATHON EVENTS ATTENDED
ENGAGEMENT WITH INNOVATIVE COMPANIES +
DIVERSE INDUSTRY SECTORS
SMART TECHNOLOGY EVENT AT MoSI, MANCHESTER
ATTRACTING HIGH CALIBRE DELEGATES
www.gamechangers.technology
