Sponsored Content

For nuclear power operators, the challenge is no longer simply running a reliable plant. Today’s utilities must optimize fuel investments, manage evolving reactor designs, meet regulatory requirements, and respond quickly to changing operating conditions.

More than two-thirds of the U.S. nuclear fleet has now been operating for over 40 years, and many plants are pursuing subsequent license renewal to continue generating carbon-free electricity well into the 2050s. As facilities age, maintaining components affected by corrosion/erosion mechanisms, including flow accelerated corrosion (FAC) in particular, has become an increasingly important part of long-term operation.

Cross-under piping, feedwater systems and steam turbine components are particularly vulnerable. High-velocity wet steam gradually removes the protective oxide layer from carbon steel, leading to wall thinning, erosion and reduced structural margin. Left unmanaged, these degradation mechanisms can result in costly repairs, extended outages and, ultimately, replacement of major components.

In power generation facilities, scale is more than a maintenance issue. It is an efficiency issue, a reliability issue, and ultimately a profitability issue.

Mineral deposits such as calcium carbonate create an insulating barrier on heat transfer surfaces. As scale accumulates inside condensers, feedwater heaters, boilers, cooling systems, and auxiliary heat exchangers, thermal efficiency declines. The result can be higher operating costs, increased condenser backpressure, greater energy requirements, reduced generating capacity, and longer maintenance outages.

Removing these deposits is critical, but traditional chemical descaling has often required facilities to balance cleaning performance against worker safety, environmental impact, and operational complexity.

Goodway® ScaleBreak®-000 changes that equation.

It’s no secret America’s energy demand is entering a new era. Growth in artificial intelligence, advanced manufacturing, electrification and national security infrastructure is creating unprecedented demand for reliable, affordable and secure power. Nuclear energy – particularly small modular reactors (SMRs) – has been identified as a critical part of that solution.

However, deploying new nuclear capacity fast enough to meet demand will require more than innovative reactor designs. It will require experienced partners who understand licensing, environmental permitting, engineering, project delivery and long-term operations.

The nuclear industry is entering a new chapter.

Existing plants are extending operating lives beyond their original design expectations. New reactor technologies are moving from concept to construction. Investment in domestic manufacturing and fuel production is accelerating, and utilities are strengthening supply chains to support decades of future operation.

At the same time, another transition is taking place.

In an era where clean, reliable energy is more critical than ever, nuclear operators are under increasing pressure to optimize performance, reduce operational risk, and streamline complex workflows. Studsvik Scandpower, the leading independent provider of state-of-the-art nuclear fuel management software and world-class engineering services, is helping utilities meet these challenges head-on.

At the center of this innovation is MARLA, an advanced solution designed to simplify and optimize shuffle design, pool management, cask loading, and nuclear material tracking.

The United States and Canada are preparing to build and renew nuclear capacity at a scale not seen in decades. New construction, refurbishments, reactor restarts, license renewals, and a pipeline of small modular reactors and microreactors are advancing at once, driven by increasing power demands.

For more than seven decades, Leonardo DRS has supported some of the world’s most demanding nuclear applications. That legacy began with Consolidated Controls Corporation (CCC), founded in 1958, and evolved through decades of innovation supporting U.S. naval nuclear propulsion and commercial nuclear power generation. Today, as the nuclear industry enters a new era driven by plant modernization, advanced reactors, energy security, and maritime nuclear innovation, Leonardo DRS is uniquely positioned to help customers navigate the future with proven technology, nuclear-grade quality, and operationally grounded expertise.

GETTING STARTED

At the outset, the project looked solid.

The schedule was well defined. Cost projections were within expectations. Engineering milestones were aligned with procurement and construction plans. On paper, everything pointed toward success. But as construction progressed, challenges began to emerge.

To meet current and future power capacity needs, nearly all utilities with nuclear generation assets are looking at the feasibility of extended power uprates (EPU) for their facilities. Much of the engineering efforts of the plants and their engineering partners is focused to how the affected systems need to be modified to accommodate increases in steam and water flow.

Motor Generator (MG) sets and the associated Control Power Cabinets provide critical control power for rod drive systems in pressurized water reactor (PWR) plants. As these systems age, many utilities face growing challenges related to component obsolescence, limited supplier support, and legacy cabinet designs that introduce maintenance risk and single‑point vulnerabilities (SPV).

System modifications are often treated as the default solution. But in many cases, the problem can be addressed more directly, avoiding unnecessary engineering effort, extended timelines, and significant cost.

Curtiss-Wright has successfully tested several full prototypes of a new high temperature neutron flux detector that we have developed to operate at up to 800°C, a necessary feature for many new reactor types. The new detectors are fission ionization chambers and the prototypes were constructed in our own facilities, which we use to manufacture our mature detector designs that operate at up to 600°C in the UK’s AGR fleet. Curtiss-Wright has a comprehensive suite of reactor protection electronics and the new detector is designed to complement our Guardline™ reactor protection system.

In today’s rapidly evolving threat environment, nuclear facilities must prioritize speed and precision in their security responses—because in critical moments, every second counts. An early warning system serves as a vital layer of defense, enabling real-time detection of potential intrusions or anomalies before they escalate into full-blown incidents. By providing immediate alerts and actionable intelligence, these systems empower security personnel to respond decisively, minimizing risk to infrastructure, personnel, and the public. The ability to anticipate and intercept threats at the earliest possible stage not only enhances operational resilience but also reinforces public trust in the safety of nuclear operations. Investing in such proactive technologies is no longer optional—it’s essential for modern nuclear security.

The Westinghouse Parts Business plays a vital role in maintaining the critical assets of customers and ensuring safety and reliability through high-quality spare parts, component repairs, and equipment upgrades. Obsolescence and sourcing qualified replacements remain major challenges in the nuclear industry. To address these, Westinghouse provides targeted solutions for obsolete parts and manages comprehensive obsolescence programs.

Power generation has many factors and key indicators to identify the “health” of a plant. Some macro-level indicators are vital to help identify challenges before they become problems; others are less sensitive yet just as important. Micro indicators such as condenser return temps or changes in pump pressures can be critical indicators of a problem that few understand, yet which results in enormous loss of efficiency. That problem is deposits on critical system tubing and piping caused by calcium carbonate or other mineral buildups. The bottom line? Scaling is a significant issue in power plants that can considerably impact efficiency and profitability.

As many Pressurized Water Reactors (PWRs) approach or exceed 40 years of operation, maintaining asset integrity under aging infrastructure, tight outage schedules, and strict ALARA (As Low As Reasonably Achievable) mandates is a real challenge.

Introduction

The nuclear energy industry is critical not only for meeting the world’s growing demand for electricity but also for advancing global decarbonization goals. As the sector evolves—through life extensions of existing plants, decommissioning, innovations like small modular reactors (SMRs) and microreactors, and new facility construction—the need for safe, efficient, and environmentally responsible maintenance and decommissioning continues to grow. Whether a plant is coming online, operating beyond its original design life, or entering decommissioning, cleanliness and operational integrity remain non-negotiable. That’s where dry ice blasting stands out—a powerful, safe cleaning method ideally suited for the high-stakes demands of nuclear environments.

PacTec's Legacy of Engineering Excellence

For over 35 years, PacTec, Inc. has been at the forefront of innovation in waste packaging, continuing to develop new packaging solutions for Class 7 radioactive waste. From humble beginnings in Clinton, Louisiana, to a global presence in the nuclear industry, PacTec's commitment to innovation and excellence continues to drive the development of more efficient and cost-effective waste packaging solutions. Our in-house engineering, production, and testing capabilities—combined with over a century of collective expertise—ensure we can quickly design, test, and deliver groundbreaking solutions to meet the ever-evolving needs of nuclear waste packaging.

Demand is increasing dramatically for carbon-free reliable power to support data center growth and ensure energy security. This creates a clear opportunity to accelerate new nuclear plant builds as well as optimize and extend plant life.

That’s where AI can help.