Modernising Safety-Critical Pneumatic Control Systems to Enhance Operational Reliability

Project Overview

Client: EDF Energy Nuclear Generation Ltd

Location: Torness

Ageing pneumatic control equipment presents an increasing lifecycle challenge as nuclear stations extend their operating lives. The difficulty is not simply replacing components, but ensuring new equipment performs the required functions while integrating with established plant systems and meeting stringent nuclear quality requirements.

AMS Nuclear delivers engineered pneumatic system upgrades that combine technical equivalency, modern replacement components, comprehensive lifetime records and commissioning support, helping operators maintain reliable performance while managing ageing assets and future maintenance requirements. At Torness Power Station (EDF Energy), operational experience had identified pressure losses affecting the performance of pneumatic equipment supporting the Control Actuator (CA) and Flux Measuring Assembly (FMA) teletubes.

AMS Nuclear delivered a QA Grade 3 replacement solution from site survey and detailed design through manufacture, Factory Acceptance Testing and commissioning support, incorporating non-lubricated pneumatic cylinders and fully traceable components to restore reliable pneumatic performance and strengthen long-term lifecycle support.

Supporting Reliable Plant Performance Through Planned System Modernisation

Within Torness Power Station’s fuel route, the pneumatic systems controlling the Control Actuator (CA) and Flux Measuring Assembly (FMA) teletubes perform an important role in supporting plant operations. Powered by station general service air, these systems are relied upon to deliver consistent pneumatic performance.

Operational experience identified that the original pneumatic equipment was no longer performing as intended due to pressure losses developing over time. Rather than reacting to equipment failure, EDF Energy initiated a planned programme of improvements in accordance with BEG/SPEC/FENG/019, ensuring the systems continued to meet modern expectations for reliability, maintainability and lifecycle support.

The challenge extended beyond replacing components. Any new solution needed to demonstrate technical equivalence, maintain compliance with stringent nuclear quality standards and integrate seamlessly into existing plant operations without introducing unnecessary risk or disruption.

Engineering a Fully Integrated Replacement Solution

AMS Nuclear provided a complete engineering service from initial survey through to commissioning support, working collaboratively with EDF throughout the project.

The programme began with a comprehensive site survey to understand the existing installations, identify routing requirements and capture all interface details. Using this information, AMS Nuclear designed replacement pneumatic control panels and instrument plates incorporating modern flow regulators, non-return valves and flow direction control valves while maintaining functional equivalence with the existing system.

Where appropriate, non-lubricated pneumatic cylinders were introduced to reduce future maintenance requirements and improve long-term reliability. Alongside the physical design work, AMS Nuclear produced a full system description and engineering equivalency assessment to demonstrate compliance with EDF’s technical requirements and provide the justification necessary for replacement within a regulated nuclear environment.

Every stage of the design process was supported by detailed engineering drawings, operating procedures, conformity certification and lifetime quality records, ensuring complete traceability throughout the project.

"Projects like this demonstrate the value of combining practical engineering knowledge with rigorous nuclear quality assurance. Our objective wasn't simply to replace equipment, but to provide EDF with a solution that will remain reliable and fully supportable for years to come."

Design Engineer, AMS Nuclear

Delivering Confidence Through Quality, Testing and Collaboration

To minimise risk during installation, AMS Nuclear adopted a structured delivery methodology that provided assurance at every stage.

Following detailed design approval, new pneumatic panels and associated pipework were manufactured and subjected to comprehensive leak and functional testing during Factory Acceptance Testing (FAT). EDF representatives were invited to witness testing, providing independent verification that every assembly met performance expectations before delivery to site.

All fittings, flexible hoses and stainless steel compression components were fully traceable and supplied in accordance with QA Grade 3 requirements. Comprehensive technical documentation accompanied every deliverable, including certificates of conformity, risk assessments, manufacturing records and installation procedures.

During site implementation, AMS Nuclear engineers provided technical oversight to support installation and commissioning activities, helping ensure the transition to the new equipment was completed efficiently and with minimal operational disruption.

Applying Engineering Excellence That Benefits the Wider Nuclear Industry

This project highlights how proactive engineering can extend the operational life of critical plant systems while maintaining compliance with modern nuclear standards.

By restoring reliable pneumatic performance, introducing lower-maintenance components and providing comprehensive engineering justification and lifetime records, AMS Nuclear delivered a solution that supports both immediate operational performance and future lifecycle management.

The methodologies developed throughout this project – including equivalency-based engineering assessments, end-to-end quality assurance and collaborative commissioning support – provide a proven framework for similar pneumatic and control system upgrades across the UK nuclear sector. As operators continue to modernise ageing infrastructure, this approach enables critical assets to remain safe, reliable and supportable throughout extended operational lifetimes.