Enhancing NDE training in the North American nuclear industry 

Approached by a prominent player in the North American nuclear industry, our team took on the challenge of creating a bespoke solution to help address specific challenges in Non-Destructive Evaluation (NDE) training and performance validation of operators within the sector. The result? Three custom-engineered nozzle specimens. 

Facing unique challenges related to in-service flaw identification, particularly cracks, the client sought a solution to aid operator accuracy in flaw detection and sizing. Our team came up with the solution of three stainless steel nozzle specimens. 

Two nozzles, each measuring 1.3 meters in length with a thickness of 63.5 mm, weighed approximately 1.4 tons. In contrast, the third nozzle measured 1.5 meters, had a thickness of 89 mm, and weighed 1.7 tons, presenting a significant engineering challenge. Overcoming this challenge required a combination of internal planning expertise and knowledge, ensuring the availability of the right assets for flaw implantation and welding. 

This intricate process emphasised the importance of communication among the planning team, QA office, inspectors and welders. Coordination across four different departments was vital to successfully navigate and resolve the complexities associated with these nozzles. 

These nozzles simulate realistic scenarios for NDE training, enhancing operator accuracy in detecting and sizing flaws in nuclear facilities to minimize the risk of catastrophic failure.  

What we delivered  

Expert Sonaspection team member working on the nozzle project at the UK site 

Why operator validation and performance demonstration matter  

In the intricacies of the nuclear industry, where the consequences of failure are exceptionally high, operator validation and performance demonstration are critical aspects of ensuring operational excellence and safety. Here’s why: 

• Safety Assurance: Operator validation ensures that personnel responsible for NDE procedures possess the necessary skills and competence to identify and address potential flaws within the nuclear infrastructure. Demonstrating performance underlines their ability to execute these tasks safely. 

• Regulatory Compliance: The nuclear industry is subject to stringent regulations to ensure the safety of operations. Operator validation and performance demonstration are integral components of complying with these regulations, providing evidence of a skilled and qualified workforce. 

• Risk Mitigation: Identifying and addressing flaws in the nuclear infrastructure is a proactive measure to mitigate potential risks. Operator validation through realistic NDE training and performance demonstration assures that operators are well-equipped to handle real-world scenarios, reducing the risk of failures. 

• Enhanced Operational Efficiency: Skilled and validated operators contribute to enhanced operational efficiency. By accurately identifying and addressing flaws during routine inspections, nuclear facilities can minimize downtime, optimize maintenance efforts, and ensure continuous, reliable operations. 

• Continual Improvement: Operator validation and performance demonstration provide a feedback loop for continual improvement. Insights gained from these processes can be used to refine training programs, update procedures, and adapt to evolving challenges in the nuclear industry. 

How we can help you 

We support organisations in the nuclear industry and other sectors, providing precision-engineered solutions to address unique challenges and enhance training programs. Contact us to discuss your specific needs and elevate your training effectiveness