X-energy
Custom Control Consoles Empower Plant Support Center for Advanced Nuclear Training
A Hub for Next-Generation Nuclear Operations
X-energy is a pioneering company in small modular nuclear reactor (SMR) technology, with a mission to transform the nuclear energy landscape through innovative reactor designs and comprehensive operator support.
In 2024, X-energy opened its first Plant Support Center (PSC) in Frederick, Maryland — a 10,000-square-foot facility designed to support the deployment, operation, and training of operators for its Xe-100 advanced SMR. The PSC is a critical investment in X-energy’s broader strategy to train the next generation of nuclear plant operators and to centralize fleet-wide diagnostics, plant monitoring, and operational support.
The center houses a full-scale nuclear plant control room simulator, a reactor protection system prototype, a digital-twin maintenance lab, and a state-of-the-art virtual reality environment. By integrating high-fidelity simulations with real-time instrumentation, artificial intelligence-based tools, and advanced training methodologies, the PSC provides hands-on learning opportunities that mirror the realities of live plant operations.
With capacity for up to 52 operators training simultaneously, the facility supports everything from initial deployment training to continuing education and business services such as maintenance planning and regulatory compliance. This center not only accelerates operator readiness but also serves as a showcase to industry stakeholders, investors, and potential customers eager to see X-energy’s innovative technology and operational vision.
"The furniture in this simulator control room would need to allow us to optimize the workspace design for the operator, enabling them to focus primarily on their work while minimizing distractions."
Bridging the Gap Between Simulation and Live Operations
To succeed as a realistic training environment, the PSC faced a complex set of requirements centered on authenticity, functionality, and regulatory compliance. As an entirely new build, the center wasn’t constrained by past designs from existing power plants or preconceived notions about nuclear power control rooms. This presented an opportunity to develop an entirely new concept that future control room renovations could follow.
The core challenge was to build a simulator space that would accurately replicate the operator experience within a live nuclear power plant control room. This meant every console and piece of furniture needed to reflect the operational realities — from the feel of embedded analog switch panels required by Nuclear Regulatory Commission (NRC) standards to specialized electrical and power connectors supporting advanced plant control systems.
“My team’s primary job is to build anything and everything related to human interaction, and in this case, that pertains to the control room operators,” said James Park, Human Factors Engineering Manager at X-energy. “The furniture in this simulator control room would need to allow us to optimize the workspace design for the operator, enabling them to focus primarily on their work while minimizing distractions. Overall, these consoles would need to help us design an environment optimized for the human element, where control room operators could achieve their best work performance and safely and efficiently operate the Xe-100.”
Since the PSC is envisioned not only as a training facility but also as a model for future live production sites, the consoles had to be designed with seismic certification standards in mind — a necessity for operational nuclear power plants in earthquake-prone regions. The consoles also needed to enable 24/7 operational readiness and maintenance, with modular designs that supported multiple users working independently or collaboratively.
Front and rear IT serviceability was another crucial design consideration, which was necessary for reducing downtime and ensuring the technology infrastructure could be easily maintained. The integration of advanced audiovisual systems, including a Barco video wall for content management, required precise attention to room layout and sightlines to ensure visual acuity and operator comfort. Ultimately, the furniture and consoles had to do more than “look the part”: they needed to perform flawlessly in a high-pressure, high-stakes training environment.
“Having this setup saves significant time and money in the long run because this serves as our initial control room console prototype, allowing us to test and identify what works well and what we need to refine with Winstead later on to continuously improve the operator experience across X-energy’s many facilities."
Custom Consoles Tailored to a Digital-First Control Room
With over three decades of experience in the nuclear power industry, Winsted’s entrance into the project came through a prior collaboration with Tecnatom, a subsidiary of Westinghouse Electric Company and a respected Madrid-based nuclear design and consulting firm. Over the course of approximately 18 months, Winsted worked closely with Tecnatom, Barco, and systems integrator CTI to deliver a tailored control console solution that met the demanding PSC specifications.
Using the Sightline series as its foundation for cable management and frame structure, Winsted developed fully customized consoles with solid surface Compact Laminate worktops featuring flame-retardant properties, embedded analog switch panels for NRC compliance, and automated pop-up computer stations that deploy and retract as needed. The consoles also incorporated modular, multi-user operator station designs to facilitate both individual focus and group collaboration. Every aspect was engineered with ease of IT servicing in mind, allowing access from both the front and rear of the consoles without disrupting ongoing operations.
“The technology within this control room involves a distributed control system integrated into these workstations. Each operator has three fully redundant workstations,” said Paul Hippely, Director for Simulation & Human Factors Engineering at X-energy. “This gives us the capability to operate from a single workstation, what existing plants would manage with hundreds of switches spread across the entire footprint of a control room. Now, we can achieve the same level of control from just one workstation."
A key part of the project was collaboration on the integration of the Barco video wall system. Through multiple joint design reviews, site visits to Winsted’s custom manufacturing facility and Barco’s U.S. headquarters, and coordinated planning meetings with general contractors and architects, Winsted ensured that the console placements, operator sightlines, and technology interfaces were optimized. This ongoing partnership was essential for aligning the physical console design with the broader room technology strategy, guaranteeing that operators could view and interact with real-time data intuitively and efficiently.
“Our early introduction to the Tecnatom team, who were responsible for the overall design encompassing far more than just the control room — including all electronics, components, and wiring — was key,” said Lee Schalk, Sr. Strategic Market Manager, Federal Civilian Agencies & Public Safety at Winsted. “This early involvement allowed us to understand their vision and design our solution accordingly. This was particularly important because numerous changes and adjustments occurred along the way, and we were able to address their concerns and modify our design to accommodate their unique requirements. Therefore, early and collaborative engagement with architects, engineers, integration specialists, and other vendors like Barco was vital throughout the process.”
“X-energy's work has the potential to revolutionize the nuclear power industry globally.”
A Springboard for Excellence
Since its unveiling, the Plant Support Center has successfully delivered X-energy’s vision for a realistic, immersive, and highly functional training environment. Operator trainees and experienced staff alike have praised the authenticity and responsiveness of the simulation space, with the Winsted consoles playing a central role in creating an environment that feels indistinguishable from a real nuclear plant control room. The facility has also welcomed numerous industry stakeholders, investors, media, and potential customers, all of whom have noted the high quality and thoughtful design of the control room, including the seamless integration of Winsted consoles and the Barco video wall.
The success of this installation has positioned the Winsted consoles and associated workstations as a recommended standard for X-energy’s future production sites, where seismic-rated, NRC-compliant equipment is essential. Through the combined efforts of Winsted, Tecnatom, Barco, CTI, and X-energy, the team was able to deliver a modern training and operational facility finely tuned to the specialized demands of nuclear plant simulation.
“Using the control rooms right now has allowed us to not only confirm the comfort and functionality of our current designs but also identify potential small improvements for future consoles,” said Meghan Fickett, Human Factors Engineer at X-energy. “Having this setup saves significant time and money in the long run because this serves as our initial control room console prototype, allowing us to test and identify what works well and what we need to refine with Winstead later on to continuously improve the operator experience across X-energy’s many facilities."
More broadly, the PSC and its control consoles contribute meaningfully to X-energy’s goals of advancing operator training, optimizing operational costs, and supporting sustainable growth. The facility provides operators with a thoughtfully designed environment that helps prepare them to manage the complex challenges of tomorrow’s power plants with confidence and precision.
“X-energy's work has the potential to revolutionize the nuclear power industry globally,” said Schalk. “Partnering with such an innovative company was very exciting for Winstead. Furthermore, witnessing the initial vision come to life after months of dedicated effort was rewarding. After considerable time and energy, we have finally seen their aspirations materialize.”