Prototype to nuclear approved: a robotic decommissioning technology
Context
An entrepreneurial SME developed a virtual reality-enabled robotic platform for nuclear decommissioning. The system enabled operators to remotely control a mobile robot capable of entering hazardous legacy facilities at Sellafield Limited. Using laser cutting technology, it could safely dismantle contaminated equipment and prepare waste for disposal—significantly reducing operator exposure to radiation.
The solution had successfully progressed through an Innovate UK programme and had been prototyped and tested.
The next challenge was to deploy the technology within a live nuclear environment.
Problem
Despite technical success, the company faced significant barriers to deployment within the Sellafield environment.
The platform combined multiple advanced technologies—robotics, laser cutting, and virtual reality—making it highly innovative, but difficult to assure within a nuclear context. The system needed to be demonstrated as not only safe and effective, but compliant with Best Available Technology expectations. Sellafield required a rigorous, standards-based approach aligned with ISO 12100 and IEC 60825-1, supported by comprehensive, audit-ready documentation meeting stringent internal quality requirements.
While the company had strong technical and manufacturing capability, they underestimated the complexity, cost, and organisational impact of nuclear compliance.
This created significant risk:
Without structured evidence and documentation, the technology would not be approved
Failure to meet compliance expectations could lead to delays, costly rework, or rejection
The company risked breach of contract despite having a technically successful solution
Critically, the challenge extended beyond the product. The organisation itself was not yet equipped to operate within the nuclear supply chain. This required:
Development of formal quality assurance capability
Transformation of management systems and working practices
Adoption of nuclear-grade traceability, supplier assurance, and documentation standards
Without this transformation, the technology—despite being world-class—could not be deployed.
Approach
Moongate Consultancy was engaged to bridge the gap between innovation and nuclear compliance. The engagement began with a detailed contract review, identifying critical compliance obligations and the implications of specific clauses. This was followed by a comprehensive gap analysis of the company’s policies, procedures, and management systems.
A structured compliance framework was then implemented, integrating missing elements into a fully aligned Quality, Health, Safety and Environmental (QHSE) management system. Delivery was managed through formal change control aligned with the Association for Project Management framework, providing a clear and controlled pathway from prototype to deployment readiness.
Key elements included:
Development of technical files to support CE marking, aligned with ISO 12100
Creation of structured, audit-ready documentation compliant with ISO 9001:2015
Alignment with the Sellafield Limited Approved Supplier and audit processes
Beyond documentation, Moongate led a full organisational transformation.
This included redefining quality systems to meet nuclear expectations, implementing material traceability, strengthening supplier assurance, and embedding controlled processes across the business.
The transformation required:
Engagement from board level through to shop floor
Introduction of new working practices and management controls
Training, consultation, and ongoing support to embed change
Establishment of a culture of compliance and continuous improvement
Moongate also acted as the primary interface with the nuclear client, interpreting complex requirements, structuring all submissions, and leading technical, managerial, and commercial communications.
Result
The technology was successfully progressed to deployment readiness within a regulated nuclear environment at Sellafield Limited. A structured, standards-based approach ensured the system was:
Developed and justified in line with ISO 12100 design risk assessment requirements
Supported by complete, audit-ready technical and quality documentation
Aligned with nuclear expectations for safety, assurance, and Best Available Technology
All required quality, technical, and organisational assurance activities were completed, enabling the technology to successfully pass the necessary stages of review and acceptance.
Impact
This engagement transformed the company from an innovative technology developer into a fully qualified nuclear supply chain partner.
As a result, the company:
Was accepted onto the Sellafield Limited Approved Supplier List
Gained access to the Sellafield Dynamic Purchasing System, enabling participation in tenders typically ranging from £100k to £2.5m
Achieved compliance with ISO 9001, ISO 14001, ISO 45001, and ASME NQA-1
Established capability to operate within both UK and US nuclear markets