Engineering Laboratory and Rig Design - Rolls-Royce

SERVICE OFFERING
Engineering Laboratory and Rig Design
COMMISSIONING AND IN-SERVICE SUPPORT
Rolls-Royce is a world leader in engineering
and component testing.
Our dedicated nuclear rig development and test laboratory facilities
are specifically designed and utilised in support of our civil nuclear and
nuclear submarines programmes.
The department has the following facilities and expertise at its disposal:
Mechanical maintenance
Our dedicated workshops are equipped to perform fitting, welding and
various machining functions including turning, milling, grinding and a
large sawing capability. This enables the laboratory to develop bespoke
test rigs and processes in support of component development activities.
Standards laboratory
An in-house Instrumentation calibration authority is delegated to support
the nuclear submarines programme including calibration services for
naval submarines and dockyards.
Instrumentation laboratory
Calibration and Electrical maintenance support to existing and new test
rigs. Activities include specialist build and repair of all types of electrical
equipment, and test and inspection of electrical installations including
portable appliance testing (PAT).
Main coolant pump test facility
The main coolant pump test facility is used for production and prototype
testing of Mk7 main coolant pumps. The tests are conducted at full
operating temperature and pressures. The rig is used to measure head
pressure, pump run-down times, operating current, loss of phase tests,
noise and vibration tests and endurance tests. The rig can also be isolated
from vibration by lifting the rig raft
on pneumatic bladders. Rolls-Royce
has been testing main coolant
pumps since 1967 and has been
involved in the testing of Mk12
pumps, and was instrumental in
the prototype and development
testing of the hard-on-hard bearing
technology, now used on all main
coolant pumps.
Main coolant pump test rig
Flexible coupling rigs
The flexible coupling test facility has been used for carrying out prototype
and development testing of Trafalgar, Vanguard and Astute class
secondary system flexible couplings. Prototype testing involved pressure
testing, noise testing and articulation. The facility is now used to build and
pressure test production components, main circulating flexible coupling,
seawater services and feed water couplings, for fleet spares and on Astute
class submarines.
www.rolls-royce.com
NUCLEAR INNOVATION & TECHNOLOGY

Primary circuit relief valves rig
Valve test facility
The valve test facility (VTF) works in the development and production
testing of valves for use on the nuclear reactor plant using high temperature
high pressure water. The rig is capable of performing functionality tests on
the following valves: hydraulically operated, pneumatically operated, oil
operated, electrically operated and manual valves.
Control rod test facility
The control rod test facility comprises 3 rigs:
Hot CRTF rig – This rig is used to test control rod drive mechanisms
(stators, upper drive mechanisms and position indicators) in a pressurised
heated vessel. The rig is capable of testing at NSRP conditions, ie high
temperature and pressure. The rig is mainly used to perform development
and prototype testing and was used for the new generation of upper
mechanism containing out-motion and rebound latches.
In air CRTF rig – This rig is used to perform the same functionality tests of
CRDMs as the hot CRTF rig without the need to immerse the components
in a pressurised vessel. This rig is used to carry out production testing of all
CRDMs that are fitted to the nuclear submarine fleet.
Position indicator rig – This rig is used to carry out electrical calibration
of production position indicators. These components are used on the
submarine to indicate the position of all the fuel rod in the reactor
pressure vessel during operation.
Heat transfer rig
The heat transfer rig is used to provide experimental data to validate the
thermal and hydraulic mathematical models used for the design and
safety justifications of pressurised water reactor (PWR) cores. To date,
the rig has been used to develop PWR1, SWR and PWR2. A test section,
representing a reactor core cooling channel, is fitted between insulating
flanges. Heated, pressurised water is passed through 6”, 2”, or ½” lines
into the test cell. A series of tests is carried out where the parameters of
fluid flow rate, temperature and pressure drop are measured as power
is increased via a 2MW DC power supply through the test section. The
aim is to find an operating envelope within which the heat transfer
mechanism remains intact, and the structural integrity of the test section
is maintained. The rig has also been adapted to test compact heat
exchanger units for the oil industry and perform tests on stator can units
for the Ministry of Defence.
Primary circuit relief valves (PCRV)
Installed, upgraded and commissioned in Sept 2006. The PCRV rig tests
relief valves at high temperature and pressures. The test rig mainly
comprises a steam generator (boiler), 3 large accumulator vessels, stainless
steel pipework and valves, a discharge tank and a modern control room. To
supplement the rig pressure once temperature has been attained, a high
pressure nitrogen system is incorporated which provides the necessary
surge to lift the valve at test.
Rigs team
The team provide complete solutions for the design, implementation
and testing of rigs. In addition, we also have the capability to
design mechanical handling systems, jigs and tools, and automated
inspection systems.
Test rigs
Rolls-Royce has considerable experience in the design and
implementation of mechanical test rigs (used for testing components) and
fluid flow rigs (used to understanding of flow regimes within components
and systems).
The Rolls-Royce engineering laboratory and test rig team, has the
capability and experience to produce bespoke test rigs to operate at both
ambient conditions and high pressure and temperature environments.
Working closely with the customer at all times, our specialist team design
specific test requirements and then develop solutions to meet customer
expectations.
The team offers full rigs service from conception to final handover to the
customer. Additionally, we provide full support after delivery including
upgrades and modifications where necessary to maintain standards and
support ongoing test development.
7406/SO.24/Nov10
Rolls-Royce Power Engineering plc
PO Box 2000, Derby DE21 7BD, England
Tel: +44 (0)1332 632688
Fax: +44 (0)1332 622936
Email: nuclearsolutions@rolls-royce.com
www.rolls-royce.com
© 2010 Rolls-Royce plc
Whilst this information is given in good faith, no
warranty or representation is given concerning such
information, which must not be taken as establishing
any contractual or other commitment binding upon
Rolls-Royce plc or any of its subsidiary companies.