As a world-class Tier‑2 supplier of specialized fabricated nuclear components, tanks, vessels, custom tooling, and mock-ups required for reactor refurbishment activities, Arrow Engineered Products (AEP) is a premier choice that supports Tier‑1 contractors.
In this month’s blog, we present an AEP case study in which we delivered a custom-engineered solution for a CANDU reactor refurbishment project.
The Customer’s Profile And Project Requirements
Our customer was a Tier‑1 CANDU refurbishment contractor hired to engineer and manage a portion of the refurbishment and life‑extension of a CANDU nuclear reactor. A critical part of this project was the development of a detailed, highly accurate calandria tube mock-up and specialized tooling to support two key objectives:
- Training refurbishment crews before entering the reactor vault, and
- Testing and validating tooling and procedures used for calandria tube removal and installation
Access to the reactor vault is very limited, and refurbishment schedules are tightly controlled, leaving little tolerance for error during the project’s execution. Any unforeseen issues with tooling or procedures could delay the overall refurbishment program.
Additionally, their selected Tier-2 supplier would be required to fabricate tooling and precision components that support the refurbishment work itself, further validating the mock-ups as an essential step in ensuring a successful project completion.
To achieve these outcomes, the contractor needed to partner with a respected CSA N299.2 and N299.3-compliant Tier-2 supplier who understood the complex and critical nature of calandria tubes and pressure tube replacement. Their supplier of choice must also carry out the work with extremely high precision, under strict safety protocols, and within tight outage schedules.
Why Our Customer Chose AEP
We’re extremely proud and excited when a contractor turns to our team to collaborate on highly complex nuclear projects. Our proven track record of successfully completing supplier audits and qualifying for the Tier‑1 contractor Approved Vendor Lists (AVLs) has helped us build strong relationships among the top nuclear contractors, giving AEP an edge as a preferred nuclear refurbishment vendor.
Nuclear projects, such as calandria tube mock-ups and refurbishment tooling, are typically awarded through a competitive bidding process in which suppliers are evaluated on technical capability, nuclear quality systems, manufacturing capacity, and experience with complex custom fabrication.
Thanks to AEP ticking all of those boxes, we were awarded the contract and got right to work on fulfillment.
Read More: How AEP Is Prepared To Support Ontario’s Growing Nuclear Industry
Our Collaborative Customer Discovery Session
The first step to any successful project is to conduct a comprehensive discovery session between AEP’s engineering and manufacturing teams and the contractor’s engineering and quality teams. During our initial discussions, we reviewed the engineering package and assessed the manufacturing feasibility of the calandria tube mock-ups and associated tooling.
We worked closely with the customer’s teams to review tolerances and fabrication methods and identify potential manufacturing challenges. Where appropriate, we recommended adjustments that would ensure the design could be manufactured efficiently while still meeting strict functional and quality requirements. Our specialized experience producing similar mock-ups also enabled AEP engineers to propose improved manufacturing processes that helped optimize fabrication, maintain required tolerances, and solve design challenges.
For example, AEP’s team identified a challenge involving maintaining dimensional stability in a long, narrow tubular structure, where bowing or distortion could occur during fabrication. Our solution was to refine the manufacturing process and implement corrective techniques that brought the component within the required tolerances.
AEP’s collaborative approach to this project ensured the mock-ups would accurately replicate the reactor environment.
The AEP Solution
AEP fabricated full-scale calandria tube mock-ups designed to replicate the exact geometry and configuration of the reactor environment. These deliverables provided the end-users with a full-scale rehearsal environment, allowing their teams to simulate the calandria tube removal and installation process, train operators, validate procedures, and test tooling before performing the work inside the reactor.
Alongside this work, our team manufactured a range of specialized tooling for the removal and installation of calandria tubes. This scope included both complete tools and individual sub-assemblies required for refurbishment activities.
Following the successful deployment of the project, the contractor issued an additional order for a similar reactor refurbishment program, located internationally, reaffirming AEP’s position as a trusted Tier-2 supplier within the global nuclear supply chain.
Beyond This Project: AEP’s Broader Nuclear Capabilities
While this case study highlights one custom-engineered solution, it represents only a portion of the work AEP delivers across the nuclear supply chain. Our refurbishment and outage experience spans a wide range of components and tooling, including:
• Code-compliant components for inside the CANDU reactor and steam generator
• Fuel channel and feeder tooling
• Reactor vault equipment and handling tools
• Custom precision fabrications for other reactor systems
• SMR development components and next-generation nuclear programs
Whether the requirement is a single specialized component or a fully integrated package of tooling and fabricated assemblies, AEP brings the same engineering rigour, code compliance, and collaborative approach to every nuclear program we support.
Read More: Our Capabilities
Partner With Arrow Engineered Products On Your Next Nuclear Refurbishment And Outage Program
For over 25 years, Arrow Engineered Products (AEP) has been a trusted partner supporting the nuclear supply chain with high‑precision solutions for critical reactor systems that meet the stringent quality, documentation, and traceability requirements of nuclear projects.
We specialize in the fabrication of tanks, vessels, and pressure-related components manufactured under the CSA N285 nuclear quality program. Our wide range of capabilities enables us to contribute across multiple stages of the nuclear lifecycle, including refurbishment support, outage components, and next-generation nuclear development programs, such as Small Modular Reactors (SMRs).
Get A Project Quote From Arrow Engineered Products For Your Next Industrial Processing Or Nuclear Design And Fabrication Project
Partner with Arrow Engineered Products for high-value design, engineering, and fabrication solutions to suit almost any application. Visit www.arrowmfgep.com/contact to experience the Arrow difference in quality, precision, and service for yourself today!