Brooks Forgings Ltd has been awarded a contract by EDF energy to manufacture and supply a range of foundation bolting assemblies for critical groundworks. This is in preparation for the installation of various critical infrastructure systems for two new nuclear reactors at Hinkley Point C in Somerset, UK.
The two new nuclear reactors are the first in a new generation of nuclear power stations that will provide low carbon electricity for up to six million homes. The new reactors will also make a significant contribution to the UK’s initiative to reduce carbon emissions.
Brooks Forgings will supply bolting assemblies that utilise the removable DIN 7992 hammerhead T bolt design. Ranging from M24 up to M48 in varying lengths, the bolts will be used in a fabricated tube assembly that is welded to BS EN 1090 execution Class 2.
Nuclear safety is a priority, which is why extensive quality certification and documentation was required before Brooks Forgings was awarded the contract. This included, but was not limited to, positive material identification (PMI), ultrasonic testing (UT), magnetic particle inspection (MPI), as well as full mechanicals including tensile and charpy impact tests. This was backed up by an on-site audit that required all documentation and finished components to be made available for inspection.
A total of five quality reports were compiled, one for each size/type of foundation bolt assembly. Totalling over 200 pages each, a physical copy was supplied along with fully searchable and bookmarked PDF files to assist in locating critical information swiftly if required.
Another unique aspect of the supply was the stringent packaging requirements. Supplied in FSC and ISPM15 compliant wooden packing crates, the components were not allowed to make physical contact with the wood during transit. To prevent this, and minimise rust generation during storage, special Vapour Corrosion Inhibitor (VCI) bags were used to line the interior of the wooden boxes. A full packing procedure, 3D rendered component layout, and packing list for each box, was designed by Brooks Forgings and supplied for approval.
“The advantages of dealing with one manufacturer are evident throughout this project. By having in-house forging, machining, and fabrication capability – approved to EN15048 and EN1090 execution Class 3 – we were able to have complete control of production and ensure all components met the strict quality, testing and traceability requirements specified,” commented Brooks Forgings.
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