Delivering Safety-Critical Control & Instrumentation Solutions Under Demanding Nuclear Timescales

Project Overview

Client: AMCO

Location: Dungeness A

Delivering safety-classified Control & Instrumentation systems to compressed nuclear project timescales requires more than accelerating manufacture; the challenge is maintaining technical rigour, quality assurance and regulatory compliance while keeping the wider programme moving. AMS Nuclear delivers complete C&I solutions from manufacture and assembly through testing, installation support and commissioning, supported by robust documentation and traceability throughout.

At Dungeness A, AMS Nuclear delivered the C&I systems for the Wet Waste Transfer Facility (WWTF), supporting the retrieval and transfer of legacy intermediate level waste (ILW) into disposal-compliant packages. Working to a demanding 6–8 week programme, AMS Nuclear delivered a fully verified Plant Class 2, QA Grade 3 solution to specification and within budget, incorporating control panels, junction boxes, cabling, emergency stops and safety interlocks, together with Factory Acceptance Testing and comprehensive lifetime quality records.

Supporting Safe Waste Retrieval During Nuclear Decommissioning

As part of the ongoing decommissioning programme at Dungeness A, legacy intermediate level waste (ILW) sludges and resins required retrieval from historic storage packages before being transferred into modern disposal-compliant containers for interim storage.

The Wet Waste Transfer Facility was developed to provide a controlled environment where this process could be undertaken safely and efficiently, protecting both personnel and waste packages while integrating seamlessly with existing site infrastructure. Achieving this required a robust Electrical Control & Instrumentation solution capable of meeting stringent nuclear safety requirements, British Standards and NRS Management Control Procedures throughout every stage of the project.

Engineering a Solution That Balanced Compliance, Quality and Programme Certainty

The project presented a significant delivery challenge. Alongside the technical complexity of designing and manufacturing safety-classified EC&I equipment, AMS Nuclear was required to complete the work within an exceptionally compressed delivery programme.

Rather than treating the programme as a constraint, the engineering team developed a coordinated delivery strategy that combined close client collaboration, proactive planning and disciplined quality assurance. Weekly progress reviews ensured technical queries and design decisions were resolved quickly, allowing engineering, manufacturing and testing activities to progress in parallel without compromising compliance or quality.

AMS Nuclear was contracted to design, manufacture and assemble the complete Electrical Control & Instrumentation package, including the main CP201 control panel, junction boxes, cabling, containment systems, emergency stop circuits, safety interlocks and all associated electrical infrastructure. Every component was produced in accordance with QA Grade 3 requirements with Plant Class 2 safety categorisation and designed to satisfy the applicable regulatory framework governing nuclear installations.

"Delivering nuclear-grade systems under significant programme pressure demands more than technical capability, it requires disciplined planning, collaboration and an unwavering commitment to quality at every stage."

Project Lead, AMS Nuclear

From Design Through Commissioning - Delivering Confidence at Every Stage

AMS Nuclear managed the project through the complete engineering lifecycle, ensuring consistency, traceability and quality from manufacture through to final commissioning.

Control panels and junction boxes were manufactured in accordance with approved NRS drawings using fully compliant components and industry-standard identification systems. Factory Acceptance Testing (FAT) validated continuity, polarity, alarms and safety interlocks before equipment left the workshop, providing confidence that every system met its functional requirements prior to installation.

During site delivery, AMS Nuclear supported installation activities through cable management, integration with existing containment systems and compliance with BS7671 wiring requirements. Specialist electrical SQEP personnel also supported commissioning activities, while comprehensive lifetime quality records, material certification, CE documentation and fully updated “As Built” drawings were produced to complete the project dossier.

A Proven Delivery Model for Future Nuclear Programmes

Successfully delivering the Wet Waste Transfer Facility demonstrated far more than the ability to complete a single project on time. It reinforced AMS Nuclear’s capability to mobilise experienced engineering teams quickly, maintain rigorous quality assurance under programme pressure and deliver fully compliant safety-classified systems without compromise.

The modular approach adopted for panel manufacture, combined with structured Factory Acceptance Testing and collaborative project governance, has created a repeatable delivery model that can be applied across future waste retrieval and decommissioning programmes throughout the UK nuclear sector.

As operators continue to manage ageing facilities, evolving regulatory expectations and ambitious decommissioning schedules, the principles demonstrated on this project – technical excellence, programme agility and collaborative delivery – remain directly relevant to the industry’s future needs.