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There is a prevailing view that decommissioning within the nuclear industry is a fairly mature business, with little scope for significant innovation. However that view does not prevail within BD Nuclear Limited, a company which specialises in development and deployment of diamond wire cutting technology. The approach adopted by this company is to provide innovative and practical solutions to many challenging tasks hitherto considered to be too difficult to be undertaken with diamond wire cutting techniques.


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hese redundant objects tend to be heavily contaminated/ irradiated or both and require major size reduction with volumes strictly minimised to assist with their ultimate disposal. It is to this objective that BD Nuclear has already applied its innovative skills to good effect and working forwards from this platform has now developed a unique piece of equipment that the industry so urgently needs.


The machine, labelled ‘STEALTH’, is a fully remotely operable diamond wire sawing rig capable of cutting through the hardest of metallic materials without the need for lubrication. The design features allow cutting to be undertaken within both vertical and horizontal planes with good precision and control. This in itself is a major advance and is not usually available without rotation of the object or readjustment of the cutting head. The machine comprises four major components, a sturdy bridge supported on two steel columns within which is mounted the diamond wire drives and cooling system. The diamond wire spans the space between the two vertical columns and can be raised or lowered under controlled conditions. Beneath the main structure the fourth item comprises a sturdy support bed mounted upon rails to allow any object to be moved under close control between the vertical columns when required to undertake the horizontal cutting. This carriage will be provided with bespoke clamping features to remotely secure items for cutting and attached to the carriage there is a steel beam that is used to support the sections as they are being cut away. It is envisaged that this carriage will be moved away from the main machine to enable the items to be loaded onto its base and to unload cut sections when appropriate. Hydraulically powered arms can be used for this purpose, designed as necessary for the duty required. This machine incorporates the latest


developments in wire technology such that the nature and specification of the diamond cutting beads are matched to the demands emanating from the object to be cut such that maximum cutting efficiency is delivered. The scale of the machine as currently configured - ~4.7m high, 4.5m wide and with a horizontal bed movement of up to 20m - will allow it to undertake sectioning of items of substantial size. It should also be emphasised that these main dimensions are flexible and can be adjusted to suit a client’s specific requirements. The whole ethos of this machine lies in the very high quality of the components utilised, the skill in developing diamond wires to


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‘STEALTH’, is a fully remotely operable diamond wire sawing rig


suit a range of duties and the bespoke software that enables the operator to undertake specific actions under very closely controlled conditions. Throughout the cutting process the machine monitors key functions such as the wire velocity, the wire tension, the main carriage and support carriage velocities and the power amperage in the main wire drive motor. This is dry, cold cutting and one vital feature of the machine is the presence of a bespoke module in the main head to cool the wire continuously during operations. The software is also capable of undertaking repetitive operations of a batch nature with minimal supervision. This machine is an exciting prospect since it will take difficult areas of nuclear decommissioning to a new plane, where highly active and contaminated items can be remotely size reduced under closely controlled conditions. The control and ability


to cut in different planes without recourse to material realignment is a major step forward and has the potential to significantly reduce the volume of many decommissioned items ahead of their disposal.


As well as investing heavily in research and development of diamond wire cutting technology, BD Nuclear also provide at their Portsmouth facilities a detailed training base for operators of their equipment. There they have the ability to mock up cutting applications and to test and commission equipment set up especially for the client. This facility provides the client with an ideal opportunity to ‘fine tune’ their requirements and at the same time train their operators in a ‘real’ situation such that their decommissioning needs are met first time.


BD Nuclear will be pleased to demonstrate the capabilities of the STEALTH machine to potential clients and to discuss their practical needs which may be met by use of a bespoke machine designed around their specific requirements.


For further information please contact: Dave Dougan on 0845 5210004 or visit www.bdnuclear.co.uk


Consultancy • Design and Build • Feasibility Studies • Diamond Wire Sawing • Multi Skilled Classified Labour • Health Physics • Hot Cutting • Brokk Operations • Diamond Drilling • Bespoke Lifting Solutions


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