Boiler Safety Control System Engineering For Dungeness B

Project Overview

Client: EDF Energy Nuclear Generation Ltd

Location: Dungeness B

Extending Reactor Integrity Through Smart Engineering

EDF Energy’s Dungeness B Power Station required a series of critical system upgrades as part of its Boiler Lifetime Modifications Programme – a strategic initiative to ensure long-term plant reliability and compliance with the station’s safety case.

With a proven track record in safety-classified EC&I design and build, AMS Nuclear was selected to deliver two key systems: the Automatic Boiler Depressurisation System (ABDS) and the Safety Relief Valve Isolation (SRVI). Our end-to-end capability, from concept development to manufacturing, testing and commissioning support, made us uniquely placed to deliver these high-integrity systems within demanding timescales. Combining technical rigour, proactive delivery and a collaborative approach with EDF’s engineering and operations teams, AMS Nuclear provided a dependable solution that strengthened plant resilience for years to come.

Both systems play a vital role in maintaining boiler integrity and managing reactor pressure safely and effectively. The project demanded precision engineering, strict adherence to safety classification standards and full compliance with EDF’s regulatory and quality expectations.

Meeting a Safety-Critical Challenge Under Tight Timescales

The Dungeness B modifications programme focused on delivering tangible risk reduction within challenging outage schedules. The ABDS was designed to automate the depressurisation process following a reactor trip, preventing overpressure events and reducing the potential for water ingress. The SRVI, meanwhile, enabled remote operation of critical isolation valves to reduce operator workload and improve response time.

AMS Nuclear faced the challenge of developing fully compliant, nuclear-qualified control panels that could integrate with EDF’s complex existing infrastructure, all within immovable statutory outage deadlines. The design also needed to consider seismic robustness, environmental resilience and long-term maintainability through 2028 and beyond.

We knew the solution had to be more than functional; it had to deliver confidence. Our approach focused on precision, substantiation and absolute traceability from design through to commissioning.

Project Engineer, AMS Nuclear

Designing and Delivering Confidence in Control

AMS Nuclear delivered a complete design-and-build service covering the ABDS and SRVI control panel suites for Reactors 21 and 22. Each system was engineered to Class 2, Safety Function Category B standards in full compliance with BS EN 61508 and EDF’s internal specifications.

The project was delivered in three clear stages:

Detailed Design – AMS Nuclear developed EDF’s concept designs into fully substantiated, build-ready engineering solutions. All layouts and logic were reviewed and approved through EDF’s technical review process, with human factors input ensuring operator usability.
Manufacture and Test – The control panels were fabricated in mild steel to IP55 protection standards, incorporating proven Commercial-Off-The-Shelf (COTS) components. Each panel underwent rigorous type testing and Factory Acceptance Testing (FAT) witnessed by EDF engineers.
Installation and Commissioning Support – AMS Nuclear installed the control suites within the new Boiler Protection Control Building (BPCB) and supported EDF’s site testing and commissioning phases, ensuring the systems met all functional, environmental and EMC performance criteria.

A key element of the design was the 2-out-of-3 (2oo3) logic voting system applied to the ABDS initiation sequence. This configuration provides reliability, redundancy and resilience against false trips, essential for nuclear safety systems.

Delivering Proven Performance and Long-Term Value

The ABDS and SRVI systems were successfully delivered ahead of the 2021 operational deadline, supporting EDF’s commitment to safe and continuous generation.

Key outcomes included:

Enhanced reactor safety: automatic pressure control and remote isolation significantly reduced risk of overpressure or radiological release.
Improved operator efficiency: remote operation and fault indication reduced manual intervention and improved response times.
Sustained lifecycle assurance: each panel was designed for maintainability and future support, with full traceability and obsolescence planning.
Regulatory compliance achieved: the project supported EDF’s Nuclear Safety Case requirements under Licence Condition 22.

This project demonstrates what AMS Nuclear does best: delivering high-integrity, safety-critical systems that perform flawlessly in demanding environments.

Project Manager, AMS Nuclear

The Result: Lasting Impact

Through precise engineering, accountable project management and clear communication, AMS Nuclear helped EDF Energy safeguard one of the UK’s key generation assets.

Result: a modernised, compliant and dependable control system that underpins the continued safe operation of Dungeness B, delivering safety and reliability where it matters most.

Engineering Control Systems That Protect and Perform