The construction and decommissioning of hundreds of new nuclear power and research reactors necessitate substantial resources for material handling and logistics within the nuclear power sector. Decommissioning a nuclear power plant is a lengthy and costly process that requires exceptionally high levels of security, adhering to strict rules and standards for cleaning up radioactively contaminated infrastructure and safely removing radioactive fuel.
Since its founding, Morello has developed numerous projects utilizing customized heavy-duty industrial carts for nuclear energy decommissioning in various European countries. Given that stringent requirements and standards dictate that every aspect and detail of the equipment must be checked and documented, Morello is well-equipped to provide all necessary supporting services and documentation. Our structured project management goes beyond equipment design and construction.
Safety and security are paramount in the nuclear industry, a principle exemplified by our work on the decommissioning of the nuclear power plant in Latina, located in the Lazio region, in Italy. This plant, which operated from 1963 until 1987, is currently in the first phase of its decommissioning process, scheduled for completion in 2027. Morello submitted detailed proposals to Sogin, the company responsible for the decommissioning project, addressing two operational requirements for handling heavy materials.
The first requirement involves moving shell casings weighing 120 tons and measuring 5.6 x 3.4 meters from an external location to a purpose-built warehouse, where they will be cut and sectioned into smaller pieces for disposal. The second requirement concerns the movement of containers holding contaminated waste, weighing up to 20 tons, which need to be transported within the plant and lifted to higher floor levels.
The nuclear site in Latina is situated in a seismic zone, and Morello had to ensure that the heavy transportation equipment for nuclear energy could withstand potential earthquake tremors of varying intensities. To meet these stringent requirements, Morello proposed and constructed three heavy-duty industrial transfer carts.
For the transportation of shell casings, we designed a customized battery-powered transport cart on wheels, model SGAI-E VSP3. This cart features a unique configuration with 32 super-elastic wheels and equalizing mechanisms to ensure that all wheels maintain contact with the floor. This solution provides optimal weight distribution, supported by 4 electric traction motors that require no maintenance, along with a wheel steering mechanism designed to prevent wheel grinding during turns using Ackermann steering. This self-loading platform has a capacity of 130 tons and utilizes 8 cylinders integrated into the loading platform.
The SGAI model is equipped with laser scanners that ensure secure stopping when obstacles are detected in the cart’s path. Additionally, it features a steel chassis frame supported by four 10-ton weight supports, designed to lift and move once the shell casings are positioned on top.
Shell casing handling is accomplished using the battery-powered Rail Guided Transport Cart, model SBA, which has a load capacity of 130 tons and is supported by 8 double-edged rail wheels for precise positioning. A special rotating platform facilitates accurate positioning of the shell casings for cutting and sectioning.
Morello’s heavy-duty industrial transfer cart, model SBA-E, is specifically designed for handling contaminated materials in the nuclear energy sector. This customized rail cart is equipped with numerous sensors and safety controls to ensure maximum operational safety. It features a liftable platform that raises the containers using 4 cylinders equipped with position and pressure sensors.
The design of these 3 heavy-duty industrial transfer carts is engineered to withstand seismic shocks, as detailed in comprehensive supporting documentation and technical documents from Morello that exceed the general requirements for heavy industry operations within a nuclear energy setting.
Advanced diagnostics are available on the HMI (human-machine interface), and the integrated IoT capabilities allow Morello to provide ongoing remote assistance as needed. We ensure a high level of performance, security, and precision, which are crucial for material handling in the nuclear energy sector and power plants. Our experience and expertise equip multinational corporations in the energy sector with the support and solutions necessary for efficient and safe material handling.