2013

James Fisher Nuclear Capability Statement

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1. Introduction Page 2 2. Business approach Page 3 3. Locations Page 3 4. Facilities Page 4 5. Divisions Page 8 6. Capability Page 9

6.1. Design Page 9 6.2. Manufacturing Page 11 6.3. Project Management Page 12 6.4. Radiological Calibration Services Page 12 6.5. RPI Calibration Page 13 6.6. Site Services Page 13 6.7. Research & Development Page 14 6.8. Non-Destructive Testing Page 14 6.9. Digital Radiography Page 14

7. Harsh Environment Products Page 15 7.1. Power Manipulators Page 15 7.2. Power Manipulator Accessories Page 17 7.3. Heavy Duty Master Slave Manipulator Page 18 7.4. Bespoke Solutions Page 18 7.5 Electrical Distribution Equipment Page 21 7.6 Miscellaneous Products Page 23 7.7 Remote Handling Concepts Page 24 7.8 Commercial ROV Platforms Page 26

8. High Integrity Products Page 30 9. EC&I Equipment & Systems Page 32

9.1 Programmable Logic Control (PLC) Programming Experience Page 33 9.2 SCADA Systems Page 34 9.3 Data Acquisition Systems Page 35 9.4 Control Desks Page 36 9.5 Motor Control Centres Page 37 9.6 Power Distribution Boards Page 37 9.7 Distributed Control Systems Page 38

10. Analysis Page 39 11. Control Systems Page 42

11.1 Configuration Management Page 42 11.2 Software Lifecycle Processes Page 44 11.3 Programming Page 45

12. Environment, Health, Safety & Quality Page 48 12.1 Environment Page 48 12.2 Health & Safety Page 49 12.3 Quality Assurance Page 50

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1. Introduction James Fisher Nuclear Limited (JFN) is a wholly owned subsidiary of James Fisher and Sons PLC (FTSE 250 Company) and is an established supplier of high integrity services and equipment for operation in adverse environmental conditions, comprising the following:

• Design and supply of high integrity electro mechanical handling and measurement equipment

• Operation of Test, Trials and Simulation facilities • Design and supply of instrumented test rigs, fixtures and mechanical handling systems • Design and supply of facility EC&I and infrastructure control systems • Radiological Instrumentation Design, Supply and Maintenance • Non Destructive Testing Services - In house / On Site • Accredited Laboratory based Instrument Calibration Services • On Site Instrument Maintenance and Calibration Services

From within the company portfolio JFN is able to provide the majority of the skills and disciplines required to deliver its products and services; comprising:

• Project Management • Design (mechanical / CE&I /

software) • Procurement • Manufacture • Assembly

• Works Test • Installation and Commissioning • In Service Support • NDT • Trials, Training and Simulation

JFN is a highly regarded equipment supplier to high integrity industries; the company is able to provide a comprehensive range of services to its clients as discrete, standalone packages, or combinations comprising of:

• Consultancy • Design • Analytical analysis (stress / mechanisms / thermal etc) • Peer review • Build to print manufacture • Equipment refurbishment and upgrade

JFN’s customers are typically engaged in operations to support highly regulated industries comprising the following:

• Nuclear • Aerospace • Industrial Process

• Ministry of Defence

• Oil and Gas

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JFN is therefore fully conversant with the requirement to deliver in a highly regulated market sector to both customer specific standards and procedures as well as statutory legislation.

2. Business approach

The JFN company approach to business is flexible in that the company response may be structured to meet specific customer expectations. In instances where discrete specialist knowledge and experience is required then delivery may be effected from one of the divisions directly, however in instances where a higher value, more comprehensive offering is required, then delivery will be effected from the top tier company (JFN). 3. Locations James Fisher Nuclear operates from six locations ideally placing us to serve our clients nationwide. Company operations are headed from our headquarters in Leyland.

1. Egremont 2. Leyland 3. Malton 4. Queensferry/Deeside 5. Worcester 6. Sittingbourne

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4. Facilities Manufacturing: The JFN manufacturing site is located in Malton, North Yorkshire. With a range of modern computer controlled machine tools, Malton produces high precision machined and fabricated components used in diverse applications from nuclear to sub-sea. The machine shop works closely with around thirty engineering and project staff to design and manufacture highly specialised equipment for the group. Malton’s design specialty lies in bespoke solutions for the nuclear industry. The team has a long history of tackling high-risk design-and-build projects that solve problems in radioactive or other hazardous environments. There is deep expertise in all aspects of machine development including mechanical, hydraulic, electrical and systems engineering.

Rig Halls: JFN has extensive rig hall facilities at its Egremont site each with its own supporting offices ideally placed 6 miles south of the port of Whitehaven and 6 miles north of the Sellafield site. The rig halls host a collaborative development team incorporating the technology supplier, JFN and the end-user. JFN also has the skills and resources for modifications to be rapidly implemented and tested with minimal impact on the programme. JFN has extensive design and fabrication capabilities which are backed up by in-house manufacturing with support services as well as a responsive local supply chain for additional plant, scaffolding and other engineering materials and supplies.

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Unit 7 Rig Hall

• Test Area: 265 m2 • Internal height: 7m • Floor Capacity: 20KN/m2 • Lifting Capability: 10 Tonne EOTC • Hook height: 6.4m • Access: 1 x Roller Shutter Door 4m

wide x 5m high • Services: 110V, 240V, 415V,

Compressed air, Mains Water • Additional Plant: 2T Fork Lift Truck

• Technical Support: Mechanical, EC&I, Safety Related Systems, Safety Management

• Workstations: 24 • Meeting/Training Facilities: Meeting

Room - 12 people supported with video link

• Workshop Facilities: Mechanical and Electrical workshop

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Unit 10 Rig Hall

• Test Area: 280m2 • Internal height: 5.5m • Floor Capacity: 25KN/m2 • Lifting Capability: 5 Tonne EOTC • Hook height: 3.8m • Access: 1 x Roller Shutter Door 4.5m

wide x 4.0m high • Services: 110V, 240V, 415V, Mains

Water (additional services can be provided on a project basis)

• Additional Plant: 2T Fork Lift Truck • Technical Support: Mechanical,

EC&I, Safety Related Systems, Safety Management

• Workshop Facilities: Supported by the Unit 7 facility (Mechanical and Electrical)

• Workstations: 11 • Meeting/Training Facilities:

Meeting/Training Room – 10 people

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Unit 14 Rig Hall

• Test Area: 900 m2 • Internal Height: 18.5m • Floor Capacity: 60KN/m2 • Lifting Capability: 20 Tonne EOTC • Hook Height: 14.6m • Access: 2 x Roller Shutter Door 8.4m

wide x 6.5m high • Services: 110V, 240V, 415V, Mains

Water (additional services provided on a project basis)

• Additional Plant: 2T Fork Lift Truck

• Technical Support: Mechanical, EC&I, Safety Related Systems, Safety Management

• Workshop facilities: Supported by the Unit 7 facility (Mechanical and Electrical)

• Workstations: 48 • Meeting Facilities: • Meeting/Training Room 1 – 12

people • Meeting Room 2 – 6 people • Meeting Room 3 – 6 people

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Inspection, Measurement and Calibration: The JFN measurement and inspection division operates from three strategically placed locations in Queensferry, Sittingbourne and Worcester. JFN offers a comprehensive range of services that covers the full spectrum of conventional NDT inspections and many Hi-End specialist techniques. Maintained by experienced staff and a well-equipped repair workshop backed up with manuals, and stock of key spares from all major UK suppliers of Radiation Protection Equipment to minimise turn-round times for faulty or damaged instruments.

The companies RPI calibration and RCS services are operated from our Deeside facility. Managing calibrations and repairs for customers nationwide. The service offers a prompt and reliable service with a rapid turn-round to all customers and compliments our on-site calibration service. The service is backed up by a solid quality management system and uses sources traceable to UK national standards. JFN can arrange the transport of RPI to and from the RCS facility.

5. Divisions Nuclear provides design and build solutions to the Nuclear and Process Industries. The company has a comprehensive mechanical, CE&I and analysis capability with an ever growing resource of engineers complemented by manufacturing facilities in Malton, Rigs halls in Cumbria all supported by a high quality international manufacturing supply chain. Our Cumbrian workforce of nuclear engineers together with local design offices, service facilities and rig halls, ideally place us to support Sellafield. JFN also has extensive practical experience in trialling and perfecting equipment in a rig-hall environment, rehearsing and training operatives for work in a hostile environment, practical development of innovative solutions. Aerospace provides design and build solutions to the Aerospace Industry. The company has a comprehensive mechanical, tooling, analysis and CE&I capability with an ever growing number of engineers again complemented by an international manufacturing supply chain.

IMS provides inspection and measurement capabilities for the nuclear, defence, homeland security, aerospace, offshore as well as many other industries. In partnership with international market leaders the company offers a range of products and services addressing radiation measurement, radiological protection, non-destructive testing and non-destructive examination requirements.

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Defence provides design and supply solutions to the Defence Industry. The company has a comprehensive mechanical, analysis and CE&I capability complemented by an international manufacturing supply chain. 6. Capability JFN fully appreciates the importance of having the correct suitably qualified and experienced persons (SQEP’ed) working not only in our organisation but on our clients projects. We ensure that all our engineers and managers are adequately trained and continually provide training as part of their Professional Career Development Plan. We have our own SQEP’ing and grading process internally to ensure compliance with today’s demands on engineering accuracy, safety and ever changing standards. In addition this also alleviates any pressure for external auditors by providing a fit for purpose structure for third party assessments on competence and internal reassurance. The standards listed below address the need to utilise a structured approach to software design and system development to achieve a verifiable design which includes requirements tractability and is able to be modified by suitably qualified systems engineers without requiring interaction with the original designers. Any solution generated is deterministic and permits changes to be assessed against the original design intent prior to modification of the system. This allows the end user greater confidence in the lifetime support options available. Additionally systems developed in line with the standards mentioned can be interrogated as part of a structure design, code and test lifecycle. This ensures a greater certainty that the code meets the requirements and does not contain hidden components which would otherwise cause apparently random failures during operation.

• BS ISO/IEC 12207:2008 Systems and software engineering – Software life cycle processes • BS EN ISO 10007:2003 Quality management systems – Guidelines for configuration

management • BS EN IEC 61131-3:2003 Programmable controllers – Part 3: Programming languages.

6.1 Design Design costs are a significant element of the total cost of a one off part. It is therefore important to use systems that are efficient and concentrate the designer’s time on quality. The 3D design software packages used within JFN comprise the following:

• Autodesk Inventor: 22 licenses • Unigraphics NX: 10 licenses • Catia: 18 licensees

These software packages provide good visualisation of components and assemblies and also provide full bidirectional associativity between part model, assembly model, detail manufacturing and/or assembly drawing(s), and simulation/analysis models for mechanisms and structure. Creation of the

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3D model in one of the above packages has now become the normal starting point for the design process and the further development of the initial design may be undertaken at the model level. These packages will also import solid models from other modelling packages, such as PTC’s Pro/ENGINEER, thereby allowing further development of existing design models where practicable. The design packages also maintain strict version control and facilitate collaborative working, even between different sites, on the same assemblies. The design control features of the Vault system ensure that only a single designer can make changes to items when “checked out” to them and any changes they make that affect other designers’ work are automatically notified. These measures ensure that all the subsequent design, analysis and even manufacture information is derived from the same source part model. From the design point of view there is no longer a technical requirement to produce 2D drawings until the detail design has been completed and final manufacturing drawings are required. The production of 2D General Arrangement drawings is now only undertaken generally to service customer requirements. All 2D drawings are automatically generated from the 3D solid models and can be provided in a variety of formats including an SL approved AutoCAD format suitable for upload into SL’s drawing registry system.

The 3D software packages identified above have been found to cater for the majority of the industry requirements which JFN has been required to service. However where customer specific requirements are demanded JFN is willing to work with the customer to satisfy such requirements.

Although the 3D modelling packages themselves incorporate a limited analysis capability, external packages are employed to deliver further capability.

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6.2 Manufacturing

JFN manufactures, assembles and tests the equipment and systems it supplies either in-house or with the support of an international chain of qualified suppliers. The manufacturing strategy is selected for each individual project as part of the project delivery planning process to ensure that the cost and quality required by the customer is delivered. Extensive use is made of carefully selected standard components which support the reliability and maintainability of JFN’s finished products. Where a specialist capability is required, off-the-shelf subsystems will be integrated to deliver a complete system that meets specifications. The JFN manufacturing facility comprises a range of CNC machines which are ideally suited to the production of 1 offs and small scale batch components as required by the UK nuclear industry. The facility utilises “Alphacam” Computer Aided Machining (CAM) software for machine tool programming. The manufacturing interface with the design is from the same part file that the supporting design substantiation data is derived from. This ensures that no manual input of dimensional data is required thereby eliminating the potential for data input error. • There is a direct transmission of machine code to

the machines. • Machining cycle times are calculated as an output

of the programming process. • Tools are automatically selected from a pre-loaded

turret. • Tool tip setting via electronic probes. • Automatic tool setting routines. • Tool settings automatically compensate for tool

and machine wear. • No operator input required • Automatic datum acquisition via electronic probe

provides fast and accurate setup for machining operations.

• Electronic probes also offer the option of on machine inspection where applicable.

• Compensation for progressive tool wear. • Reduced component lead times. Final post machining inspection will be undertaken using a coordinate measuring machine. JFN are currently assessing the requirements for this machine and are intending to incorporate software that can

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directly compare the measured features of the manufactured component with the actual original 3D design model data. This facility will provide a clear demonstration that the component is in line with the design intent and the output reports will be included in the LTQR package. JFN relies on a production planning package to ensure the efficient planning of manufacturing and assembly operations through the manufacturing facilities. 6.3 Project Management

Whatever the size of project or industry of operation, all JFN projects are run under a consistent project management framework. This delivers efficient initiation, execution and close-out of projects whilst enabling controlled identification and management of both risk and change. This structured approach also ensures that the project delivery is to the correct quality standards and attention to health and safety, and the environment is built into the project delivery from the outset. JFN project managers will work closely with customers to ensure both parties understand clearly the project scope, deliverables and timescale from the outset. Engineers and designers can also be drawn from all divisions within the company, if appropriate - to provide multi-disciplinary capability.

6.4 Radiological Calibration Services Radiological Calibration Service calibrates and repairs portable RPI for customers across the UK. The service offers a prompt and reliable response with a rapid turn-round to all customers and complements our on-site calibration service. The service is backed up by a solid quality management system and uses sources traceable to UK national standards. The Radiological Calibration Service is based at Deeside in Cheshire, with good links to the UK national road network. We can manage the transport of RPI to and from the RCS.

We can measure air kerma rate, ambient dose equivalent (H*(10)) and personal dose equivalent (Hp(10)) for the assessment of the radiometric performance of a wide range of gamma monitors, dose rate meters and personal alarming dosimeters and other RPI in our purpose-built gamma cell.

We have experienced staff and a well-equipped repair workshop backed up with manuals and stock of key spares from all major UK suppliers of RPI to minimise turn-round times for faulty or damaged instruments. Repair work is only undertaken after you have accepted our written quotation. The instrument is then fully checked and calibrated prior to being returned for use.

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We have a range of large-area alpha and beta sources for the calibration of surface contamination monitors providing alpha and beta radiation of both low and medium energies. The surface emission rates are traceable to national standards. 6.5 RPI Calibration JFN can offer calibration services for installed and portable radiation protection equipment on customer sites. Test work carried out can include full checks, performance checks and plateau plots on all types of detectors. All work is carried out to a comprehensive set of maintenance and test procedures approved by an experienced senior qualified person, and can be scheduled to coincide with routine preventative maintenance visits to deliver a cost-effective total care service. Repair work is only undertaken after the customer has accepted our written quotation. The instrument is then fully checked and calibrated prior to being returned for use. 6.6 Site Services Support from JFN does not naturally cease following the acceptance of equipment and handover to the customer. JFN is able to offer a comprehensive range of post-handover support services in support of ongoing customer operations, typically comprising the following:

• Operator training • Scheduled maintenance • Breakdown maintenance

• Supply of spares • Equipment upgrades • Decommissioning support

Such support may be made available in the form of engineering support, delivered from a remote location, or the provision of suitably qualified and experienced radiation classified workers, who are fully conversant with the requirements of delivering implementation works on a nuclear licensed site. JFN currently operates a team of mobile service engineers who are engaged to deliver such services in support of JFN supplied radiological instrumentation across the Magnox and British Energy fleet of nuclear licensed facilities. Although JFN does not actively market a ‘hands on’ decommissioning service, the company recognises that an in depth knowledge of the equipment design and assembly process may be of value when it comes to the delivery of ALARP decommissioning operations. These services help to ensure that the plant is operating correctly and meets the owner’s legal obligations to protect the workforce and environment. JFN can deliver comprehensive service and support, with packages configured to ensure safe and cost-effective operations which are combined with full regulatory compliance.

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6.7 Research and Development JFN boasts an impressive track-record of delivering development projects and innovation to its customers. JFN employs new technologies and can identify technology which has been applied in a different domains, and focuses on integrating it into a delivery system or adapting it for operation within specific challenging environments. JFN has extensive experience of designing, building and test proofing of principal prototypes and completed products. Our extensive rig hall facilities allow for the fabrication of specialist test rigs, plant mock-ups or simulated environments to be constructed to thoroughly trial and qualify equipment prior to its operational deployment. 6.8 Non-Destructive Testing The JFN NDT division serves a broad range of industries including nuclear, aerospace, automotive, chemical process industries, oil and gas, water and power generation, offering component testing and plant inspection services either in-house or at customer's premises. Offering a comprehensive range of services that covers the full spectrum of conventional NDT inspections as well as many Hi-End specialist techniques developed by JFN.

The company routinely deploys inspection techniques based upon visual, radiographic, ultrasonic, eddy current, dye penetrant and magnetic particle inspection, taking care to ensure that the correct inspection approach is deployed for each application. Specialist equipment is used to access challenging

locations, such as boiler tubes or storage tanks and to carry out advanced techniques which deliver better and quicker results to customers. 6.9 Digital Radiography Part of the NDT services JFN offers is digital radiography where we perform inspection on a wide variety of components and welded assemblies. The manipulator and x-ray set are fully programmable, allowing a series of shots in a technique to be run automatically from a single placement of the inspection piece on the turntable. Each item to be inspected can therefore have its own specific routines with all of the data normally stored on a technique sheet stored as a programme file ready to be called up as required.

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The advantages of this approach are that the programme can be run reproducibly each time it is required for that component. Once the images have been captured they are viewed on a high resolution monitor. Viewing is assisted by a number of digital manipulation tools including defect enhancement algorithms and electronic mark-ups of defects identified. The manipulator does not corrupt the raw data and is carried out when required using reproducible algorithms.

The image can always be viewed without the electronic mark-ups. For customers requiring pinpoint location of defect, a LASER marking system can be used to identify the defect location at the surface. We can then provide an accurate calculation of the defect depth. Once the images have been viewed, reporting can either be in paper or electronic form. Electronic reporting has the benefit of low cost and rapidity. In addition the archiving and storage of films can be a significant issues for customers with a requirement to retain records for the life of the component, whilst advances in digital storage media has reduced the cost, volume and the retrieval time of the archive. 7. Harsh environment products Over the last 20 years JFN has acquired a demonstrable track record for the supply of robust and reliable equipment suitable for remote operations in harsh environments. Such equipment enables access to man inaccessible locations, the processing of hazardous materials and negates the requirement to locate operators in hazardous environments. Although primarily developed in support of the nuclear industry JFN has the engineering expertise to readily adapt or develop equipment for use in similarly hostile environments or high integrity industries. All engineering services required to deliver JFN supplied remote handling systems are provided from within the company. Turnkey solutions to meet customer expectations may therefore be delivered on a ‘fast track’ basis at commercially competitive prices. Customers are able to select from a range of standard manipulator products and accessories or to work in collaboration with JFN to develop bespoke solutions to address discrete technical requirements.

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7.1 Power Manipulators Moduman 100: A heavy duty modular power manipulator, constructed from commercially available actuators, resolvers and sensors. Suitable for horizontal or vertical mounting applications with a high degree of dexterity. Design parameters: (6 degrees of freedom / 2.5m envelope / 100Kg payload)

ModuMan Link: A mast mounted, medium duty, multi-link manipulator designed for vertical deployment into tanks, vaults etc. Design parameters: (3 degrees of freedom / 5.0m vertical reach / 4.0m horizontal reach / 360 deg rotation / 60Kg payload)

ModuMan Cave: A rugged, heavy duty, power manipulator, incorporating a telescopic boom. Ideally suited to deliver reliable operation under extremely arduous physical conditions. Design parameters: (6 degrees of freedom / 2.0m envelope / 200Kg payload)

ModuMan Inspector: A light duty, highly dexterous, power manipulator. Designed to enable the deployment of remote sensing and measurement equipment. Design parameters: (7 degrees of freedom / 2.0m envelope / 25Kg payload)

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All of the JFN power manipulators are available with the following options:

• On arm instrumentation (CCTV / radiation / microphone) • Remote tool change facility (Arterial connection system) • Hydraulic fluid options (non-mineral oil) • Enhanced control system (Resolved tip motion / Teach and repeat / Collision avoidance etc) • Data logging • Self-contained deployment system

7.2 Power Manipulator Accessories Remote Tool Change Carousel: An in cell facility to permit the remote storage and exchange of powered end effectors via multiple Portable Arterial Connection System (PACS) stations.

Mounting Table: Multiple manipulators may be remotely mounted and serviced via a common, adjustable in cell support platform.

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Decontamination Booth: A self-contained, remotely controlled facility to enable the decontamination of equipment prior to manual intervention operations.

7.3 Heavy Duty Master Slave Manipulator (HDMSM)

JFN has developed a heavy duty variant of the commonly used VNE80 machine, incorporating a complete replacement shaft / gear driven slave arm and a power assistance system enhancement to the existing master arm. The new system interfaces with the existing through wall tube assembly. Design parameters: Retracted length: 1.4m Extended length: 3.5m Translation load: 75Kg Wrist load: 20Kg 7.4 Bespoke Solutions In the event that company ‘products’ may not be readily adapted to address customer requirements, JFN is always prepared to work in collaboration with customers to develop tailor made solutions via a QA accredited design and manufacture process. Examples of such solutions are included below: De-fuelling Verification Machine: A diverse system to confirm that the removal of all reactor fuel elements has been successfully completed in line with regulatory requirements.

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Re-heater Tube Welding Manipulator: Failed steam tubes in the boilers are required to be mechanically isolated. The machine identifies the location of the failure, prepares the repair area and undertakes the repair by the insertion and welding of a pre-manufactured plug.

Modular Effluent Treatment Plant: Liquid effluent waste streams require effective management prior to disposal from Nuclear Licensed Sites.

Typically this requires the construction of fixed facilities and infrastructure for through life support however such systems are often inadequate to manage decommissioning phase waste arising. JFN has designed and manufactured equipment to remediate such streams (Active Effluent & Dissolved Fuel Effluent) in a contained processing facility delivering a flexible and versatile solution to suit the capacity needs of the decommissioning phase.

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Modular Sludge Recovery Plant: First Generation Nuclear Power Stations generated large volumes of waste which was accumulated on site in sludge storage tanks. As the sites are decommissioned there is a requirement to recover sludges and resins for onward treatment and long term storage. JFN design, manufacture, test and support the installation and commissioning of such facilities for the UK decommissioning programme.

Modular Waste Processing Facility: JFN designed equipment to enable the remote processing and packaging of drummed hazardous materials is incorporated into a suite of modular enclosures to deliver a turnkey, self-contained processing facility delivering a flexible and versatile solution for increase capacity whilst minimizing installation and commissioning time and cost.

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Reactor Cartridge Removal System: A manually powered system to enable the location, retrieval, transfer and packaging of high dose rate cobalt cartridges from a graphite reactor core.

Reactor Endoscope Deployment System: During extended operations the condition of reactor gamble joints has given cause for concern. This mechanism enables the deployment of a high resolution camera system from the pile cap to undertake visual inspections of the gamble joints in order to gain confidence as to the integrity of the joints.

Disc Saw: A 1.0m diameter, ‘intelligent’ disc saw to enable the size reduction of redundant crucibles.

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7.5 Electrical Distribution Equipment In support of its remote handling equipment, JFN has developed a suite of electrical distribution equipment, suitable for remote deployment in high dose radiation environments.

Bulkhead Connector

Junction Box

Instrument Connector

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Compliant Connector

Floor Coupler

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7.6 Miscellaneous Products By way of supplementing its remote handling equipment, JFN has developed a suite of complimentary equipment, suitable for deployment in harsh environments.

Resolver Interface Unit

In Cell Light

Valve Angle Sensor

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Powered Vice

Proximity Sensor

7.7 Remote Handling Concepts 3D concepts are produced in support of HAZOP and optioneering studies.

Sludge Retrieval Scheme

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Swabbing Manipulator

Sludge Retrieval Head

Bolting Manipulator

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7.8 Commercial ROV Platforms

BROKK: 180 Nuclear High Power Tooling: Concrete Crusher Re Bar Cutter Remote Tool Change

BROKK: 250 (Concrete Breaker) Project: Platform Deflection Tests

Customer: BNFL Sellafield Project: B38 Silos BROKK: 250 Tooling: Jaws / Reciprocating Saw

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Customer: BNFL Sellafield

Project: B229 Lab 190 BROKK: 40

Tooling: Mechanical Shear

Customer: UKAEA Windscale Project: Reactor Piles Decommissioning BROKK: 150 Tooling: Graphite Handling Tool

Remote Decommissioning Machine Customer: Sellafield Ltd

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Glove Box Facility

Customer: Sellafield Ltd

Skip Tipping Machine

Customer: Sellafield Ltd

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Concrete Crushing Trials Customer: Sellafield Ltd

Sludge Pumping Test Rig Customer: AKER Solutions

8. High Integrity Products

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Aero Engine Transfer Rig Customer: Rolls Royce

Aero Wing Manufacture Jig Customer: Airbus UK

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Undercarriage Test Rig Customer: Airbus UK

Aero Wing Support Jig Customer: BAE Systems

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Fuel Vent Test Rig Customer: Airbus 9. EC&I Equipment and Systems The ‘Control and Automation Division’ of JFN is a market Leader in the industrial automation world. Experience established over two decades of interpreting and pursuing clients aims have made this division one of the most experienced companies in the process control and electrical systems industries. JFN has a client profile as diverse as the range of industries for which it has provided working systems and provides: -

• A comprehensive electrical design service including calculation support. • Technical ability and awareness • Hardware configuration • Networking • Service support • Application support • Qualified engineering and consultancy • Software writing (PLC based) • Software writing (SCADA based) • Software writing (bespoke) • Commissioning and site acceptance testing.

Our in house facilities include a comprehensive design office with CAD facilities. The company has also been successful in the design and commissioning of control systems in the export market and is currently undertaking design services for the Norwegian Oil Fields.

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9.1 Programmable Logic Control (PLC) Programming Experience The company has proven experience in using PLC’s and MMI’s from the following manufacturers:

• Allen Bradley (all ranges) • Siemens • Schneider – Telemacanique and

Modicon • Omron • Other Specialist Manufacturers

• Alstom – GEM Range • Fanuc • Toshiba and re-badged equivalents • Mitsubishi • Square D

9.2 SCADA Systems In addition to software development of PLC equipment, we are fully conversant with all leading SCADA (Supervisory Computer and Data Acquisition) packages, including;

• Intellution FIX DMACS • Intellution iFIX • Mitsubishi MX • Siemens Win CC

• Wonderware Intouch (Solution PT) • Allen Bradley RS View • Other Specialist Manufacturers

Again, engineers who are dedicated and committed, and who have many years of experience at their disposal, develop the software to the highest standards, against in house Quality Assurance Procedures. (A typical SCADA screen can be seen overleaf)

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Typical SCADA Screens:

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9.3 Data Acquisition Systems JFN has developed and commissioned data acquisition systems, as standalone systems or as part of larger SCADA packages. Standalone systems have been utilised on multiple test rigs to determine performance prior to releasing the equipment into production facilities, or for type destructive testing of components to meet worldwide certification requirements In its simplest form, technical logging of an oven temperature through LabView software on a basic Laptop PC has been developed, followed by multiple logging of the whole oven, to determine specific temperature requirements to enable correct colour control of baked products. These logged parameters were transferred to Microsoft Excel Recipe Menu’s to enable different product runs. In its most complex form, complete plant input / output devices have been logged (approx 6500 tags) for operation over a period of twelve months and data historically recorded and displayed to evaluate potential plant failures. These systems have further been developed to include digitally recorded video on specific items allowing slow speed viewing of the video at a later date in conjunction with logged parameters on a single VDU. Any logging of data in today’s production environment plays a critical role in ensuring component / production success to increase efficiency, streamline operations and improve competitive advantages Types of logging:

• Wireless Data Acquisition Systems • Serial Communication Data Acquisition Systems • USB Data Acquisition Systems • Data Acquisition Plug-in Boards • Ethernet based complete SCADA package long term Logging and data Acquisition Systems

Typical Trend Logging:

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9.4 Control Desks During the configuration of various control systems, bespoke and standard control desks have been designed and supplied to meet customer requirements. These have included, full sweeping floor standing arc’s, comprising all necessary control actuation and indication, Hardwired mimics, in-built CCTV/ SCADA displays and keyboards, etc. Fabrication design has also been undertaken to meet limited space applications and customer specification where applicable.

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9.5 Motor Control Centres MCC (Motor Control Centre) systems have been designed utilising proprietary fully fault rated cubicles of various manufacture, including removable compartments for ease of maintenance, and bespoke design and build.

9.6 Power Distribution Boards Power distribution boards have also been designed for green field and refurbished buildings where applicable.

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9.7 Distributed Control Systems The majority of systems completed to date include the integration into existing Distributed Control Systems (DCS) or complete new systems. Successful integration of these systems relies significantly on interpreting customer immediate and expansion requirements. Expansion has included review of ongoing Management Data Display/Reporting and plant modelling Through initial site surveys and subsequent definition of requirements, JFN has supplied detailed Functional Design Specifications outlining network configuration, communication protocols and control systems. Network Configuration and Communication Protocol Database definition is given the highest priority to ensure that data transfer and plant operation is optimised. Recent projects have utilised dual fibre Ethernet based network systems. This type of network benefits from dual redundancy, self-hunting of communication pathways in the event of failure, minimum electrical noise interference from high power sources, universal standards, ever increasing speed and easily managed expansion. A number of these projects have additionally been fitted with IP Addressed CCTV type camera’s (plug and play) rather than install a dedicated CCTV network, thus resulting in significant project cost savings.

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10. Analysis

Working closely with the various specialist engineering design teams within our group, we have provided software based static, dynamic and thermal analysis support to many high profile projects, including test rig and component design in relation to a large number of prestigious Nuclear, Civil and Military projects. Our innovative, yet highly practical approach to problem solving, coupled with our extremely wide range of in-house skills and experience, places us well to meet the current and future demands of the fast changing markets we currently operate in. The range of services currently available within the team comprise the following:

• Finite element modelling (Static/dynamic/thermal) • Classical methods • Metallic’s/Non Metallic’s/Composites analysis • Structural test design and analysis • Investigation of mechanical failures or the characterisation of machine performance

The mechanism simulation and analysis package allows mechanisms to be driven to see that there are no geometrical clashes and also allows inputs of pressure, force, and speed etc. The outputs can be selected for any part of the mechanism. In the illustration below the input is hydraulic pressure in the cylinder and the output is shoulder torque. This example is a modification to a Schilling RigMaster manipulator to allow 180 degree shoulder motion in place of 105 degrees for the standard unit.

In addition to the analysis packages incorporated within the 3D software design packages, JFN also operates the following dedicated analysis packages:

• Nx Nastran • Ansys • MathCAD • PVE lite

• CAESAR ii • STAAD Pro • ALGOR • MatLAB

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It is a given that safety and quality are at the forefront of everything that we do. The ongoing quality of our systems and delivery is ensured by multiple accreditations including AS9100 and ISO 9001 with scopes regarding Project Management, Design and Supply of Mechanical and Electrical Hardware. Our strong team of engineers is fully supported with the latest software and hardware systems within an environment of continuous improvement. Manipulator devices are inherently complex machines, incorporating multiple degrees of freedom, which require detailed and thorough underpinning analysis to ensure the suitability of the design. By virtue of their location and function, significant emphasis is placed on reliability, maintainability and system integrity; the latter criteria being of particular significance in the case of hydraulically powered machines. Maximum benefit is derived from the software design packages and the dedicated analysis packages to ensure that the design is robust prior to the commencement of manufacture. The analysis process starts at the Concept Design stage where scoping calculations are produced to demonstrate that the concept is credible and not just a picture drawn on a 3D design package. As the design progresses through Scheme and Detail Design, the scope and intensity of the analysis is progressively increased to a stage where on the completion of Detail Design, sufficient analysis exists to enable the production of the technical construction file, used to underpin the CE marking of the manipulator. In the case of a hydraulic manipulator the key areas of analysis required to underpin the design comprise the following:

• Overall machine strength and rigidity (static and dynamic) • Load path components (machined and procured) • Actuators (rotary and linear) • Drive mechanisms (mechanical linkages, sprockets, chains etc) • Hydraulic system (capacity, power, response, damping, feedback etc) • Routing of services (hydraulics, electrics etc) • Mechanical handling (installation and retrieval) • Failure mode response (loss of hydraulic power) • Weight assessment

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Loop Gain K:

-K G

Feedback Loop:

0.2 s2 + 0.3 s + 1

s3 + 0.2 s2 + s = G(s)

-60

-40

-20

0

20

40

60Open Loop G⋅K

Mag

nitu

de (

dB)

10-1

100

101

-225

-180

-135

-90

-45

Frequency (rad/sec)

Pha

se (

deg)

0 5 10 15 200

0.5

1

1.5Closed-Loop Step Response

Time (sec)

Am

plitu

de

0.05 100

Of particular concern in the case of hydraulically powered manipulators is the potential for system instability (arm bounce), due to the capacity of the hydraulic system existing between the servo valves and the actuator. In this instance there is a trade-off between the positioning of the valves and the potential magnitude of the problem. Valves located on the manipulator arm reduce the ‘latent’ system capacity and hence the magnitude of the problem; however their location makes them un-maintainable. Valves located off the arm serve to emphasise the problem, but the valves are in a location where maintenance is possible. In the latter case control system damping is incorporated to manage the symptom. JFN will always seek to maximize the use of commercially available equipment and technology to reduce the technical risk associated with complex system designs. The analysis forms an integral part of the overall design process and like the design it is subject to formal checking and review, both internal and external to the company.

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11. Control Systems

Structured software design is understood to be critical to the success of projects where Programmable Electronic Systems are a critical component of the overall scope of works. The development and evaluation of such systems requires the use of a broad tool kit of tools notably with respect to requirements capture, configuration control and change management. The use of BS ISO/IEC 12207:2008 compliant lifecycle processes, BS EN ISO 10007:2003 compliant configuration management systems and a BS EN IEC 61131-3:2003 coding environment allied to engineering competence and structured development training demonstrates JFN competence and commitment to providing the customer with a robust fit for purpose design which enables confidence that today’s product is certifiable and maintainable throughout the products life. 11.1 Configuration Management JFN’s main objectives relating to Configuration Management is to identify and record the functional and physical characteristics of all our electronic, electrical and programmable electronic system components covering all aspects hardware, software, documentation throughout the development lifecycle. Having this approach ensures we maintain the integrity and identification of E/E/PE systems components as they evolve through the design and manufacture phases. In doing we ensure we are compliant to ISO 10007:2003 (Quality Management Systems — Guidelines for Configuration Management) which has been utilised in the development of our internal configuration management system. JFN realises the vital component of configuration management throughout the lifecycle phases of system development is change control management. To support the change management process the majority of our project managers are APMP trained and SQEP’ed to identify change, and once actioned the importance of monitoring the status of any changes. Changes to E/E/PE system components are controlled ensuring that continuity and traceability are maintained throughout the lifecycle. Our implementation of configuration management provides the following:

• A unique identification of each configuration item and its revision history • That correct and accurate data is captured • The identification, tracking and control of modifications and changes • Visibility of the current and previous configuration baselines allowing the status of achievement

of the E/E/PE system’s physical and functional requirements to be identified throughout the systems lifecycle.

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As part of our ISO 9001:2008 QMS technical and administrative processes are utilised throughout the E/E/PE system lifecycle. JFN‘s PES Configuration Management System assesses the following as a minimum:

• Project Management • Quality Assurance • PES Cubicle Equipment • PES Hardware • Operator Interface Equipment • PES Communications • PES Software

• Testing Requirements • Documentation • Installation and Commissioning • Maintenance • Training • Reliability • Deliverables

Typically ES79 and EG90 standard compliant documentation is utilised. JFN has an exemplary track record of configuration status accounting and reporting built into our QMS assured JFN Information Management System (JIMS) and Design Document Register (DDR). This allows our clients to have further benefits of the configuration status accounting including information regarding the configuration documentation (including document identifiers and effective dates); information about the software configuration (such as code, algorithm definitions and links; information with respect to the software’s operational and maintenance documentation and information about the configuration management process (such as the status of change requests). As a minimum JFN assesses and controls all essential documentation including but not limited to:

• Software Requirement Specification • System Definition Documents • Software System Specifications • Engineering Drawings • Functional and Non- Functional User

Requirements Specification • Operational and Maintenance

Documentation • Technical Files • Source Codes Files and Link Libraries • Programme Development Software

• Validation and Verification Tools and Certification

• Competence Levels and Assessment Records

• Application Code • Modulated Code • Code Test Scripts • System Architecture • Block Test Documents • Module Test Documents • Integration Test Documents • Acceptance Test Documents

JFN systems ensure that project delivery is a continuous reiteration and monitoring process to provide coherency, accuracy and clarity at all times to the client, external verifier or internal member of the project team. This structured approach allows JFN to conduct SIL 4 external assessments of developed code and products. JFN (Safety Related Systems) is setup to provide external peer review assessments of

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products and code and is structurally segregated from JFFaber and JFRH projects providing complete independency. In this regard JFN as a whole can be compliant with the requirements of ISO 10007:2003 configuration auditing. Additionally this independence allows us to minimise third party costs to the client. Configuration auditing is essential to ensure compliance with the project specifications and ensure all deliverables align. It ensures that all relevant quality assurance procedures have been implemented and that there is consistency throughout the project documentation. JFN SRS appoints a configuration manager for each specific project thereby ensuring coherency between ISO 9001:2008, IEC 10007:2003 and IEC 12207:2008. 11.2 Software Lifecycle Processes ISO/IEC 12207 is designed to be integrated into an organisations QMS when software development is required. It is designed to be utilised at all stages in the software lifecycle providing a unique set of processes, activities and tasks for software that is part of a larger system or a standalone product or services. That the tender requires a demonstrated understanding of IEC 12207:1995 is appreciated although JFN would recommend compliance to IEC 12207: 2008. The latest revision of this standard includes new additional and revised processes that ensure project execution is more structured. The latest amendment applies new SC7 guidance, with the new additional definitions and guidelines to provide further support of consistency and improved usability. JFN appreciate the importance of a holistic approach early in the project lifecycle and defining the software requirements in Functional Design Specification (FDS) and the Software Design Specification (SDS) mitigates against hazards and enforces the processes of IEC 12207. These documents integrate into the following systems:

• Decision Management Processes • Risk Management Processes • Configuration Management Processes

• Information Management Processes • Measurement Processes

In addition the FDS and SDS cover the following aspects of the standard to ensure consistency throughout the organisational level and project specific QMS:

• Stakeholder requirements • Technical requirements • System Requirement Assessments • System Architecture Design • Implementation • Systems Integration

• Systems Qualification Testing – Verification

• Software Installation – Transition • Software Acceptance – Validation • Software Operation • Software Maintenance • Software Disposal

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At all stages both hazard identification and risk mitigation are carried out as an ongoing process. Additional key requirements are also assessed during the early stages of any software development including ergonomics and environmental requirements. Assessments are typically conducted by a team selected for a diversity of expertise and SQEP’ing capabilities. Depending on project size team members include:

• Quality Manager • Systems Development • Verification

• Validation • Project Manager

11.3 Programming It is fully appreciated that compliance with EN 61131-3:2003 is based upon the selection of a compliant software environment. JFN has a broad spectrum of experience in a variety of programming language and is able to select the most appropriate for the application. This experience includes the following languages and environments: • PLC/PAC Systems:

• Mitsubishi – PLC • Omron – Trajexia Basic and CXOne • Siemens – SIMATIC Step 7 • Allen Bradley – RSLogix 500 / 5000 • National Instruments

• High Level Languages: • BASIC • Visual Basic • C • C++ • C# • JAVA • PASCAL • HTML

• Bus Architectures: • CANBUS • MODBUS • ProfiBUS • Compobus S • DeviceNet • RS232, 485 et al. • TCP/IP

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With respect to EN 61131-3:2003 we have significant experience with respect to Instruction List, Structured Text, Graphical (Ladder Diagrams), Block Function Diagrams and Sequential Function Charts. Enterprise Resource Planning (ERP) Data for every part used in any product or project, whether it be a manufactured or proprietary part and its version, is stored and linked by a bill of materials for each assembly. The production resources required for the manufacture of parts and the routing of those parts to each resource is also entered. The benefit of this system for one off jobs is it provides the base data for the allocation of stock material, material ordering, material traceability, engineering change control, capacity planning and the reporting of shortage lists. For repeat orders, the data can then be used to automatically generate material orders and works orders on individual bills of material, or through MRP, if there are many of the same parts being used by a number of orders. Significant savings in product management time result from this capability. Time sheets are entered by all personnel into the system on a daily basis. All material purchases and stock allocations are entered into the system and so all factors affecting cost can be recorded and reported. Reports are available for each contract showing purchase costs, stock material costs and labour cost. These costs can be for orders placed and for orders invoiced. The difference being a time delay and sometimes delivery costs are not accurately recorded at the time of order placement. When there are many orders for assemblies having some common parts, the MRP system enables works orders to be grouped so that all common parts can be put onto the same works orders and so minimise CNC set up operations. All works orders can be loaded onto the appropriate resources and the effect can be assessed using infinite and finite capacity planning. The former gives the loading set against required by dates and the latter shows dates that can be achieved with the available capacity. The two approaches give a good visual indication of the effect of subcontracting some of the workload.

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12. Environment, Health, Safety and Quality 12.1 Environment JFN operates an Environmental Management System compliant with the requirements of BS EN ISO 14001; the company has an Environmental Policy Statement. • Environmental Policy Statement (SM01) is available by request JFN is committed to the protection of the environment and we are all responsible for minimising the impact we have on it. This commitment extends to all JFN activities, wherever they take place, which have the potential to adversely affect the environment. JFN aims to reduce environmental harm, minimise the use of energy and other resources and ensure that the principles of sustainable development are operated throughout the range of activities in which the company is engaged. JFN is currently working towards ISO 14001 certification – target date Jan 2013. • A copy of the Environment Manual is available by request. JFN undertakes ‘Environmental Impact Assessments’ which require that project related environmental impacts are considered, in order to determine their significance and establish appropriate controls for reducing or preventing pollution of the environment. The following is a schedule of relevant EU and UK legislation which is typically applicable to JFN equipment : • Radioactive Material (Road Transport) Act 1991 • Radioactive Substances Act 1993 • Noise Emissions In the Environment By Equipment For Use Outdoors Regulations 2001 • Radioactive Contaminated Land Regulations 2008 • Environmental Protection Act 1990 • Environmental Protection (Ozone Depleting Substances) Regulations 2002 • Ozone depleting Substances Regulations 2009 • Control of Asbestos Regulations 2006 • Control of Substances Hazardous to Health Regulations 2003 Generically JFN will avoid the incorporation of environmentally harmful substances into the design of its products. For the purposes of this document, environmentally harmful substances shall include substances covered under the EC Dangerous Substance Directive (76/464/EEC) and the Ground Water Directive 80/68/EEC together with any substances classified as toxic or harmful to man or the environment

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12.2 Health and Safety JFN’s commitment to health and safety is reflected in the company’s H&S Policy Statement and Safety Management System. Specifically JFN expects that all business operations to ensure that:

• Health and safety management systems including, where appropriate, specific individual policy statements and workplace procedures safeguard the health and safety of our employees, business partners and the general public.

• Health and safety risks have been identified, are periodically reviewed and assessed, with prioritised action plans and work instructions in place for risk and impact elimination and reduction.

• Incidents are reported, causes identified, actions implemented to prevent the incident

happening again and clearly documented.

• Health surveillance programmes monitor and record employees where the health risk assessment has identified a need and to comply with legal or regulatory requirements.

• Occupational health programmes are in place to support the well-being of employees and

measure and report on health in the workplace.

• Where the workplace, work activities or work planning are shared with any other employer, occupier or relevant person, there is demonstrable evidence of cooperation and coordination of health and safety and environmental management.

Ultimate responsibility for H&S issues rests with the directors of JFN, who set policy. The EHS&Q manager is responsible for ensuring policy is implemented and that the Board is kept informed of its effective application. H&S is an agenda item at the monthly management meetings, comprising representatives from all operating divisions and is an agenda item at quarterly PlC Board meetings. H&S performance is reviewed with the aim of improving the effectiveness of the processes. It is the ultimate ambition of JFN to be trusted by staff, customers and stakeholders as a safe organisation with a record for health, safety and staff welfare that exceeds internal and external market expectations. JFN operates a Safety Management System (SMS) which is compliant with the requirements of both BS OHSAS 18001: 2007 and HSG 065.

• Health and Safety Policy Statement (SM01) is available by request The scope of the safety management system is defined in the following documents:

• Health and Safety Arrangements (SM02) is available by request

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• Health and Safety Management Responsibilities (SM03) is available by request

• Health and Safety Handbook (SM04) available by request

A comprehensive suite of discipline specific Safety Procedures (SPs) is in place below the above high level documents, the schedule for which is included in the JFN Management Systems Index.

• Management System Index is available by request

The JFN Safety Management System is subject to external independent audit. The accreditation authority is National Quality Assurance Ltd (NQA).

• BS OHSAS 18001 certificate available by request

• BS OHSAS 18001 audit report available by request 12.3 Quality Assurance JFN operates in a range of market sectors, nuclear included, where the quality of products and services is considered to be crucially important. However within the nuclear decommissioning industry it is important to recognize that the level of quality demanded should be proportionate to the application; much of the equipment supplied is required to service a short term application and then become redundant as opposed to supporting power station or fuel processing operations over an extended (circa 30 years) duration. The overall quality objective is to ensure that JFN delivers a consistently high level of service throughout its extensive and diverse business. JFN is committed to implementing appropriate quality management systems and processes to enable the delivery of the highest practicable quality products and services. JFN will therefore:

• Clearly understand the current and potential future requirements and expectations of its customers.

• Work closely with customers, suppliers and partners to achieve business and quality

objectives. • Deliver products and services of the highest practicable quality, reliability and consistency

that meet customer requirements.

• Implement quality management in a systematic and planned way through the application of management systems that support the delivery of the business plan.

• Educate and train the people to support the delivery of high quality work.

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• Establish and measure performance and customer satisfaction against appropriate quality objectives and/or targets.

• Measure at an appropriate level service performance and customer satisfaction.

• Continually review and improve our processes and levels of service.

Ultimate responsibility for Quality issues rests with the directors of JFN, who set policy. The EHS&Q manager is responsible for ensuring policy is implemented and that the Board is kept informed of its effective application. Quality is an agenda item at the monthly management meetings, comprising representatives from all operating divisions; Quality performance is reviewed with the aim of improving the effectiveness of the processes. JFN operates a Quality Management System (QMS) in compliance with the requirements of BS EN ISO 9001:2008. The accreditation authority is National Quality Assurance Ltd (NQA).

• A copy of the current QA Certificate is available by request • A copy of the recent NQA Audit Report is available by request

• A copy of the JFN Quality Policy Statement is available by request

The JFN Quality Management System comprises:

• Quality Manual [Available on Request]

• Quality Management Procedures [Available on Request] The Index of the JFN Management / Quality Procedures is included in: [Available on Request] Copies of Quality Management Procedures made available on request.