Bespoke Test Rigs for Nuclear Instrumentation and Control Training

Effective training equipment starts with understanding what learners need to do. From fitting and replacing components to calibrating transmitters, configuring controls and interpreting engineering drawings, practical tasks should shape the design.

AMS Nuclear can translate these requirements into bespoke equipment that supports instructor demonstrations and hands-on exercises. By considering instrument selection, component access and supporting documentation together, we help you create a training environment where learners can explore how systems work and practise the activities their roles require.

For HPC, the brief covered level, flow, pressure, temperature and information and communication technology, supporting instrumentation and control maintenance personnel and selected commissioning roles. Our previous design and manufacture of mobile test rigs for the National College for Nuclear, covering water analysis, pressure and temperature instrumentation, provided a practical foundation for the proposal.

Test rigs need to offer realistic learning opportunities while remaining practical to operate, maintain and store. Industrial instruments must be accessible for repeated removal and replacement, with suitable test connections and clear identification of components, cables and signals.

We can design around these requirements alongside the constraints of your teaching space. The HPC proposal brings five training areas together on three mobile frames:

• level and flow share a frame, along with the reservoir and pump;
• pressure and temperature occupy opposite sides of a second frame; and
• networking equipment has a dedicated third frame.

This arrangement makes use of shared equipment while retaining access for practical exercises. Braked castors and dimensions selected to pass through a standard doorway support movement between teaching and storage locations, helping the equipment fit into the day-to-day use of a workshop.

By bringing different technologies together, we can help your learners compare measurement methods, investigate instrument behaviour and understand the relationship between an individual device and the wider system.

The proposed HPC equipment illustrates how this can work across five training areas.

Level measurement and control: Radar, ultrasonic, capacitance, hydrostatic and differential pressure instruments would allow learners to compare responses to the same changing water level. A configurable proportional–integral–derivative controller and variable speed drive would extend exercises into control behaviour, connecting measurement principles with system response.

Flow measurement: Sharing the level rig’s water circuit, the proposed flow equipment combines venturi and orifice plate measurement with alternative flowmeter technologies. This provides opportunities to compare readings and explore how different measurement principles apply within a common process.

Pressure instrumentation: Accessible gauges, switches and transmitters, including a differential pressure transmitter with HART communication, support calibration and maintenance exercises. Isolation manifolds and test connections give learners access to practise the associated tasks.

Temperature instrumentation: A PT100 resistance temperature sensor, thermocouple and temperature switch bring different sensing methods into one training arrangement. External terminals and transmitters support connection and testing activities, while a cooling rack provides a designated location for hot instruments.

Networking: Managed and unmanaged switches, Ethernet and fibre connections, computers, a firewall and network attached storage would form a functional network. This extends practical training into network testing, maintenance and component replacement.

Together, these arrangements show how AMS Nuclear can turn a broad training brief into equipment that supports both understanding and practical application.

The details of a rig’s construction influence how effectively it can be used throughout its working life. Access, protection, labelling and component replacement all need to be considered alongside the learning objectives.

For HPC, our proposal includes lockable electrical panels, suitable isolation and protection and 24 V DC instrument supplies. Provision for emergency stops on the level and flow rigs, pressure relief where required and a drip tray for the water system addresses the practical demands of the workshop environment.

Clear labelling and test disconnect terminals would help learners identify equipment and access signals during exercises. Commercially available components support future replacement and ongoing maintenance.

We bring these considerations into the design so that your training equipment can support repeated practical use and remain maintainable over time.

Engineering drawings and manuals can play an active role in training. Alongside operating the equipment, learners need opportunities to trace signals, identify test points and relate physical components to the documents used to describe them.

AMS Nuclear can develop supporting documentation around both equipment operation and these learning activities. The proposed HPC package includes electrical schematics, general arrangements, labelling schedules, operating and maintenance manuals, risk assessments and method statements. Process and loop drawings for the four instrumentation rigs would support exercises in interpreting drawings and investigating instrument connections.

Bringing the equipment and documentation together helps instructors connect explanation, demonstration and practical investigation.

Whether your focus is measurement, control or networking, AMS Nuclear can help translate the tasks your people need to perform into a bespoke training solution. Our approach combines instrumentation expertise with experience of designing and manufacturing training equipment, considering learning objectives, workshop requirements and ongoing maintenance together.

The HPC proposal demonstrates this approach across five training areas within three mobile frames. If you are developing or expanding your practical training provision, we can work with you to define the equipment, interfaces and documentation needed to bring your training objectives to life.