Brokk: Transforming Nuclear Decommissioning Through Innovation

Brokk: Transforming Nuclear Decommissioning Through Innovation

When faced with the daunting task of dismantling and decommissioning a nuclear power plant, safety, efficiency, and precision are paramount. Decommissioning the Ågesta plant in Sweden required Vattenfall to utilize innovation, meticulous planning, and the right tools to achieve these objectives.

Enter Brokk, a world leader in remote-controlled demolition robots. With nearly five decades of experience and a strong commitment to safety and efficiency, Brokk delivered a custom robotic solution that transformed the Ågesta decommissioning project.

A Custom Solution for a Unique Challenge

Brokk’s legacy of innovation dates back to 1976, and its robotic systems have evolved to address increasingly demanding environments. The Ågesta project marked another milestone.

Drawing on years of experience with Brokk robots in industries ranging from construction to decommissioning, the team at Ågesta knew they needed a tailored approach. A partnership with Brokk was a natural fit. The result? A remote-controlled Brokk demolition robot outfitted with tools designed for decommissioning and a customized, innovative BGS65 Grapple Saw.

Nicklas Tjernlund, Senior Specialist in dismantling and decommissioning at Vattenfall, described the innovation:

It is the combination of safety for the operator when controlling the Brokk from a distance and the power and capability of the robot and the tools it can carry. The developed BGS65 is a perfect example of efficiency and safety combined.

The Scope of Decommissioning: Challenges and Objectives

Decommissioning a nuclear facility is a complex and time-intensive process. It involves the removal of activated and contaminated components, pipes, and structures, all while adhering to stringent national regulations to free-release the plant from regulatory control.

At Ågesta, the challenges were manifold: robust, radiation-exposed infrastructure, extensive pipe networks at elevated heights, and the overarching need to minimize risks to personnel.

‘’If we have kilometers of pipes at a plant, and many of them are at a height of 3-5,5 meters, and you also have high dose rates and hotspots in some pipes,’’ explained Tjernlund, ‘’then you need a machine that is reliable, capable but also agile enough to handle the worst-case scenarios that can come up during decommissioning.’’

The custom BGS65 Grapple Saw addressed this need by not only cutting but also securely grabbing pipes, offering a safer and more efficient solution that transformed the decommissioning process, and in turn, reduced the risks associated with manual dismantling.

Redefining Safety and Efficiency

The Brokk robot’s ability to remotely handle hazardous materials significantly reduced radiation exposure for personnel.

“The fewer people we have in the plant, the lower the overall dose,” said Tjernlund. This capability, combined with the BGS65’s unique precision cutting and handling, eliminated many risks associated with manual dismantling methods.

Tjernlund also highlighted the significant efficiency gains:

“We found that cutting pipes with the BGS65 Grapple Saw was, on average, between three to six times faster than handheld tools, depending on the diameter and thickness of the pipe” explained Tjernlund. Indeed, traditional methods involving handheld tools or clamshell cutters often require scaffolding and prolonged manual intervention, increasing risk and extending decommissioning timelines.

A Collaboration Built on Expertise and Innovation

The success of this project hinged not only on the unique capabilities of Brokk’s customized robotic solution but also on the close collaboration between Brokk and Vattenfall when developing the tool.

Tjernlund emphasized the strength of the partnership:

I would say that the technical expertise and the know-how that Brokk as a company provided was necessary for the success of this project. The special projects department really understood our needs and really went above and beyond when solving the initial problems with the design and challenges with it.

 

The collaboration between Ågesta’s team and Brokk resulted in a tailored robotic solution. The BGS65 Grapple Saw combined precision cutting with enhanced safety, allowing operators to dismantle high-risk components while minimizing exposure to hazardous conditions.

Setting New Standards in Nuclear Decommissioning

With its success at Ågesta, the Brokk robot has set a new benchmark for the nuclear decommissioning industry. By combining safety, efficiency, and innovation, the technology has proven its potential for broader applications.

Tjernlund added:

My hope is that when we prove the usefulness of the robots during dismantling, hopefully we can start using them in the yearly outages the plants have. And there I see a potential use in support of the dismantling tasks done when performing the services during the outage.

Pushing the Envelope in Nuclear Decommissioning

Vattenfall’s Ågesta decommissioning project is yet another example of the transformative potential of robotic solutions in nuclear decommissioning. Brokk’s BGS65 custom robotic solution not only met the project’s safety and efficiency goals but also set a new benchmark for overcoming complex challenges in the nuclear sector. As the industry continues to evolve, Brokk solutions like these pave the way for safer, more efficient decommissioning worldwide.