S.A.Robotics

Reactor Waterjet Cutting Arm Completes Initial Cut

October 6, 2006

(Herald, CA) Sacramento Municipal Utility District (SMUD) completed the cutting and removal of the first section of the Rancho Seco Nuclear Plant reactor vessel using the waterjet cutting system designed and fabricated by S.A.Robotics. The project required the supply of a remotely operated waterjet cutting manipulator to section the reactor vessel as manual cutting was not permitted due to high radiation levels. The waterjet head cuts the reactor vessel from the inside using a 38’ (11.6 m) rotary mast and carbon fiber manipulator arm. The reactor was fabricated from nuclear grade carbon steel with thicknesses up to 17” (43 cm) which are cut using the waterjet system.

Additionally, S.A.Robotics provided a water and garnet collection system which follows the cut on the exterior of the reactor vessel. The collection system dewaters and collects the garnet and cutting fines for processing and disposal.

S.A.Robotics initiated the design effort in December of 2005 and delivered the equipment in July of 2006, following extensive testing at S.A.Robotics facility in Loveland, Colorado. SMUD employees were trained in the operation and maintenance of the waterjet cutting arm and began cutting operations in August. Cutting operations are scheduled to be completed in early 2007.

Tank Camera Arm Ordered by CH2MHill for Hanford Tank Farms

September 19, 2006

S.A.Robotics has received an order for an arm-deployed video system for the Hanford Tank Farms through CH2M Hill Hanford Group, Inc. The 4 degree of freedom arm and camera assembly provides self cleaning camera lenses and onboard lighting. The camera arm is completely sealed to prevent any contamination breach and is retractable into an included housing for maintenance. CH2M Hill will deploy the arm in 2006 at the Hanford Tank Farm.

National INC. 500 List for 2006

September 5, 2006

S.A.Robotics’ sustained growth has earned a repeat placement on the INC. magazine’s national INC. 500 list as one of America’s fastest growing private companies. S.A.Robotics was also listed on the INC 500 fastest growing private companies list in 2005. A company profile is included in the Environmental Services section of the September 2006 25th Anniversary Edition of Inc. Magazine.

New Contract Award at Idaho National Laboratory

August 9, 2006

S.A.Robotics recently won a 3 year Blanket Master Contract with CH2M-WG Idaho, LLC (CWI) to provide A&E services for the Idaho Closure Project. S.A.Robotics is teamed with URS Corporation, Idaho State University, Hughes Associates, Inc, ANTECH Corporation and Alpha Group & Associates, Inc. to provide the A&E Services.

British Nuclear Group In-Tank Pipe Cropping a Great Success

July 11, 2006

The novel use of a light-weight, long reach robotic manipulator by nuclear engineering specialists, INS (previously RTS Innovation), has helped British Nuclear Group (BNG) maximise the capacity of two Bulk Storage Tanks (BST) in the Site Ion Exchange Effluent Plant (SIXEP) at Sellafield.

Magnox head of projects at BNG, Simon Wittridge, described the project as “an excellent example of innovative working between the teams,” adding, “such good collaborative working between ourselves, INS and S.A.Robotics, has resulted in a very challenging project being delivered early, under budget and, most importantly, with no accidents or events at all.”

The tanks receive effluents from Magnox reprocessing activities and separation area ponds and act as buffer storage. They allow the liquor and sludge in the effluent to settle out before the liquor is transferred through SIXEP for treatment prior to release. Having been in operation for over 20 years, levels of sludge in the tanks had built up to such a level that they were close to their original maximum capacity of 450m3. Vital to maintaining reprocessing operations at Sellafield, installing new tanks would have cost many millions of pounds, so various methods of expanding their capacity were investigated by BNG. By cropping the decant pipes, it was calculated that an additional 200m3 could be accessed. The outcome of this technically challenging project was that five stainless steel pipes were cut in each of two BST, without damaging the existing tank furniture, tank walls or disturbing the ongoing operations of SIXEP.

INS and S.A.Robotics undertook the execution of the project, on a ‘fixed’ price basis, from design through equipment delivery, installation, active commissioning, operation and final removal of the equipment from the SIXEP facility.

Doug Kirk, the engineering director at INS, BNG’s subcontactors on this project, felt at the outset that a traditional, heavy, sectional mast construction manipulator might not be the best solution given the tight time frame. The deadline of September 2006 was part of the larger Magnox Operating Plan, meaning that the project could not be allowed to overrun. When faced with the tender for this project, Mr. Kirk initiated talks with S.A.Robotics in the US, convinced that their technology could hold the key to not only the technical challenge of the project, but also the crucial timetable as well.

INS engaged S.A.Robotics to provide a light-weight, long reach robotic manipulator to undertake the cutting operations. VP of projects, Brian Dyck explained: “We used 3D computer modeling to ensure the Pipe Cropping Manipulator (PCM) would both fit and have access to all the necessary pipes. In addition, we designed the PCM for remote panel operation thus minimising the worker’s radiation exposure. While our work is recognised in the US nuclear industry, this is the first time we have ever taken part on a UK fabrication project. We are therefore grateful to INS for taking the lead to ensure the equipment was compliant to the relevant UK legislation and for CE Marking the system prior to use. As the prime contractor, INS provided the health and safety audit trail and their involvement was key at every stage of the project.”

With its carbon fibre mast capable of both a vertical extension of 11 metres and boasting a five metre horizontal reach, the PCM had five degrees of freedom and weighed 3.5 tons, approximately half the weight of an equivalent steel manipulator. At floor level, two offset slewing rings maneuvered the PCM around the multiple obstructions present in each BST. The outer ring provided 180 degrees of rotation and the inner provided 350 degrees, with both being controlled electrically. The inner ring provided support for the mast which comprised three carbon fibre sections, individually hydraulically actuated. At the base of the mast was the shoulder pivot which enabled the mast to be retracted for both penetration and recovery. At the end of the PCM, a water jet cutting end effector was mounted. This consisted of two abrasive waterjet cutting heads as well as a hydraulic gripper to attach the PCM to the pipes. The system deployed a two camera system to give a “bird’s eye view” of both the tank and the manipulator.

While the PCM was being built, S.A.Robotics at the request of INS, simultaneously designed and built a full size test facility topped by a five ton crane 55 feet in the air. The Sellafield tanks, pipes and all other obstructions were slavishly recreated at S.A.Robotics HQ in Colorado. Phil Hodgson, INS site commissioning manager, then flew out with his team for several weeks, helping SA Robotics to achieve the necessary repeatability and quality required for successful deployment and operation on site. Modifications were made; the cutting head jewel was changed and the mixing tube rebored to reduce turbulant flow. Phil said: “The manipulator functioned correctly from day one, but with the nuclear industry you are looking for exceptional robustness. By the end of the works testing phase we were confident we could do all five cuts in eight hours and mitigate the known risks.”

This attention to detail by all three teams involved paid off when the chimney into the tank was found not to be perpendicular and the plant configurations “as built” were not quite what had been anticipated. The extra redundancy designed into the robot coupled with the engineering expertise on the PCM enabled small modifications to be made. These were passed by the Nuclear Inspectorate and Environmental Agency and the pipe cutting took place successfully during the planned seven day shutdown. The PCM was then safely dismantled exactly as planned in the 3D ‘fly through’.

BNG project manager, Paul Halligan, commented: “The team had to cope with a number of challenges, and at times worked under the extremes of pressure in order to complete the project within nine months – a tremendous achievement.”

Tony Moore, CEO of INS, concluded: “We considered every aspect of the project lifecycle with specific emphasis on safety and fulfilling the overall success criteria. This focus, which began right at the start of the tender phase of the project, enabled INS to provide an innovative solution whilst improving delivery, reducing costs and, most importantly, reducing the risk to personnel. The number of movements and handling operations at the site were significantly reduced as a result of our innovative approach. The shared focus and involvement of both the engineering and the site commissioning teams through all phases of the project, was not only instrumental in winning this project for INS under a competitive tendering process, but also helped to exceed the clients’ delivery expectations for an extremely challenging project.”

Notes

International Nuclear Solutions’ areas of expertise include waste and nuclear materials handling, processing and storage, including new build facilities in support of clean-up and decommissioning of the nuclear legacy plants. In addition, the Company provides support for plant asset care and maintenance of redundant facilities.

The INS Cumbrian office provides engineering support directly to the commercial operating facilities associated with fuel fabrication and spent fuel-reprocessing activities at Sellafield and on clean-up and decommissioning projects. There are almost fifty people working at both the INS Cumbrian Office and at the associated client site.

New Contract Award

September 1, 2005

S.A.Robotics recently won a Basic Ordering Agreement (BOA) with Duke Cogema Stone & Webster to provide budgetary cost estimates for the design/construction of the Mixed Oxide Fuel Fabrication Facility Project. The term of the BOA is for one year. Duke Cogema Stone & Webster enters into this agreement in furtherance of its Prime Contract with the United States Department of Energy.

National INC. 500 List for 2005

S.A.Robotics explosive growth has earned a place on the national INC. 500 list as one of the fastest growing companies in the U.S. This prestigious award provides S.A.Robotics with national/worldwide recognition of it’s successful growth.

Ernst & Young Entrepreneur of the Year Nomination for S.A.Robotics CEO

S.A.Robotics CEO Michael W. Cappello was chosen as a finalist for the 2005 Rocky Mountain Ernst & Young Entrepreneur of the Year Award. This is the world’s most prestigious awards program for business innovation, recognizing outstanding entrepreneurs who inspire others with vision and leadership, establish a track record of achievement, and continue to build and lead growing and dynamic businesses. The award was established in 1986 and has recognized more than 7,000 entrepreneurs within 36 U.S. regions and in over 35 countries. Since Cappello joined S.A. Robotics in 2003, the company has established itself as an industry leader in applying advanced material sciences and technologies to high hazard facilities and operations. The company’s revenues have grown over 850% since 2003.

Senator Wayne Allard tours S.A.Robotics

Senator Wayne Allard and staff member Anne Brewster toured S.A. Robotics with Owners Dan Johnson and Michael Cappello. Senator Allard sits on the Senate Appropriations Committee and was very familiar with many of the projects S.A. Robotics is supplying technology to. The scheduled 1 hour tour turned into a 3 hour briefing addressing the role technology will continue to play in DOE and DOD projects and the challenges that small business is faced with.

S.A. Robotics makes Mercury 100 list:

April 22, 2005

The Northern Colorado Business Report names S.A. Robotics as #2 Fastest Growing Private Company on the Mercury 100 list. This highly prestigious Mercury 100 ranking honors those companies based in Northern Colorado that enjoyed the most rapid growth in revenues from 2003-2004.

S.A. Robotics Patents

S.A.Robotics is a leader in deploying innovative technology into the nuclear, utility, chemical and commercial industries. Throughout the company’s history, the technologies that have been developed to solve project specific challenges as well as independent products created by the ingenious staff at S.A.Robotics have been filed for patent with the United States Patent Office. S.A.Robotics currently owns IP rights on six technologies with many more soon to be introduced.

The patents filed by S.A.Robotics range from the fabrication of the carbon fiber cylinders to cleaning methods of coal-fired boilers. S.A.Robotics is currently performing cyclic endurance testing, static load testing, and product specific function tests on these products for preparation for market deployment.