Weapons Complex Vol. 26 No. 20
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Weapons Complex Monitor

Article 7 of 9

May 15, 2015

UK Cleanup Focus

By Kenny Fletcher

Sellafield Awards £50 Million Canister Contract to Metalcraft

Kenneth Fletcher
WC Monitor
5/15/2015

Sellafield Limited has awarded a contract worth up to £50 million ($78 million) to Metalcraft for providing high integrity stainless steel nuclear waste storage containers for material stored at the Pile Fuel Cladding Silo, the company announced this week. The contract covers the procurement of 2,200 three cubic meter boxes needed to store the waste before demolition work can begin on the silo. Sellafield Ltd. plans to soon announce the award of a second contract for another container supplier.

In a statement, Sellafield Ltd. Managing Director Paul Foster said, “This announcement demonstrates our total commitment to ensuring value for money for the UK taxpayer and securing a package of benefits to the communities in which we operate, from the annual £1.95 billion ($3 billion) annual expenditure on Sellafield.” He went on to say, “We recognize that how we work with our supply chain can and should play a fundamental part in supporting socio-economic growth and ensuring that we remain the backbone of the community. Our investment in education, skills and infrastructure must be felt in West Cumbria and the wider UK economy.”

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Weapons Complex Vol. 26 No. 10
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Weapons Complex Monitor

Article 12 of 16

March 06, 2015

UK Cleanup Focus

By Kenny Fletcher

Sellafield Cleanup Cost Increases by £5 Billion

Kenneth Fletcher
WC Monitor
3/6/2015

The estimated total cost of cleaning up Sellafield has increased £5 billion ($7.6 billion), while the early termination of the Nuclear Management Partners contract will cost the government £430,000 ($656,000), according to a U.K. National Audit Office report released this week. Following the January decision to cancel the contract and this week’s release of the NAO report, the U.K. Parliament’s Public Accounts Committee will hold a hearing next week to examine the government’s management decisions at the Sellafield site. PAC Chair Margaret Hodge said in a statement this week: “Despite my Committee’s calls in February 2014 for the Nuclear Decommissioning Authority to make big improvements, the cost of cleaning up the nuclear waste at Sellafield continues to soar and has risen by an astonishing £5 billion to £53 billion ($80.8 billion) in February 2015, from £48 billion ($73.2 billion) on 31 March 2014.”

The PAC plans to hold a hearing March 11 with officials from the NDA, NMP and the U.K. Department of Energy and Climate Change. “It has taken far too long for the Authority to deal with management incompetence at Sellafield,” Hodge said. “My Committee concluded in February 2014 that the Authority had not demonstrated why Nuclear Management Partners’ ownership of Sellafield provides value for money. Yet the Authority only took the decision in January 2015 to terminate this contract with Nuclear Management Partners, which is almost a year after my Committee told it to do so if performance did not improve.”

NMP, composed of URS (now owned by AECOM), Amec and AREVA, has managed Sellafield since 2008 as owner of Sellafield, Ltd. under a contract worth up to £9 billion ($13.6 billion) for up to 17 years. However, site management has received strong criticism in recent years due to cost overruns and schedule delays. In October 2013, the NDA decided on a five-year extension to NMP’s contract to manage Sellafield, a decision met with opposition by some lawmakers and other stakeholders. Then in January, the Nuclear Decommissioning Authority announced plans to cancel NMP’s contract and revert to government management, citing issues with the parent body organization model used to run the site.

NAO Report Finds Improved Performance

In response to Hodge’s comments, the NDA this week pointed to the NAO report, which states that “during 2014-15 performance has improved, with in-year costs being slightly less than planned, and progress against schedule being closer to, though still behind, plan.” The NDA said in a statement: “The primary reason for increases in costs and schedule is because we now have a better understanding of the technical approach necessary to tackle these unique facilities that date back to the 1940s and 50s”

Magnox and Research Reactor Companies to Merge, Address Scope Changes

Kenneth Fletcher
WC Monitor
3/6/2015

Parent body organization Cavendish Fluor has announced plans to merge U.K. site license companies Magnox Ltd and Research Sites Restoration Ltd this spring to manage the sites under one leadership team, and will also continue efforts to address changes in scope. The Cavendish Fluor team took over management of the U.K.’s 10 Magnox reactor sites and two research reactor sites after winning the contract in spring 2014 from the U.K.’s Nuclear Decommissioning Authority. It aims to combine the two site license companies in order to simplify the structure and management of the sites.

Additionally, over the next 12 months the team will continue to work through differences in scope that were discovered after the team submitted its bid. That includes the decision to extend power generation at the Wylfa station, and “ambitious” programs to accelerate closure dates at Bradwell and Trawsfynydd, according to the NDA. A new budget is expected by the end of this calendar year. “As part of the contract won by CFP, a period of consolidation and reconciliation was built into the process for the winning bidder to consider the financial bid they made in 2013 and to test that against the situation they actually inherited in September 2014,” NDA Chief Financial Officer David Batters said in a statement. “The new plan emerging from that process is not due to be presented to the NDA until later this year, but we remain confident that the final plan agreed with CFP at that time will see substantial savings and represent excellent value for money to the taxpayer.”

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Weapons Complex Vol. 25 No. 29
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Weapons Complex Monitor

Article 10 of 15

July 18, 2014

UK Cleanup Focus

By Mike Nartker

Sellafield Making Headway on Sludge Plants

Kenneth Fletcher
WC Monitor
7/18/2014

After decades of having radioactive sludge sitting in unlined open air ponds at Sellafield, the site is commissioning two new plants aimed at removing and processing the material. Site license company Sellafield Ltd. recently completed construction of the £240 million ($412 million) Sludge Packaging Plant to remove material from the highly radioactive First Generation Magnox Storage Pond. Sellafield hopes to begin test retrievals at the end of this year. “The idea of the SPP facility, which is a new building with giant tanks in it, is that the most important safety consideration is to get the fuel … out because that’s where the risk is,” Sellafield Ltd. Chief Decommissioning Officer Jack DeVine said in an interview with WC Monitor this month. “That concrete pool has a significant number of cracks and it certainly has potential for leakage over time. It is certainly vulnerable to external events. We want to get it in a secure place. So the plan is to get the fuel out and get the sludge out.”

Spent fuel has been stored since the 1950s at the Magnox Storage Pond and the Windscale Pile Fuel Storage Pond. Over the decades, corroded fuel and equipment, along with organic material blown into the open-air pools, accumulated to form a heavy sludge in the ponds, which is estimated to total 1,500 cubic meters in the Magnox pond and lay up to one meter deep. In order to take out the spent fuel in the ponds and eventually drain them, the sludge must first be removed, which has proven challenging in the past.

‘We Are Essentially Attacking the Risk First’

The new Sludge Packing Plant essentially vacuums up the sludge and transfers it from the Magnox pond to the plant through a 31-meter-long pipe bridge. In the plant, the material ends up in three large tanks equipped with 11 pulse jet mixers, which prevent the sludge from settling and forming a crust within the vessels. It will be stored there in the interim until it can be prepared for storage. “It is going from a facility of unknown design to one that is very well designed, very firm, properly shielded, properly instrumented and properly isolated from the environment. You are taking that material and putting it in a much safer place where you can deal with it later,” DeVine said. “We are essentially attacking the risk first and then we will attack the disposal as a second bite for the whole approach.”

Sellafield has an “aggressive program” to begin test retrievals at the end of this year using portable equipment, with a full-bore start scheduled for 2016, DeVine said. “We want to test drive this whole system and be able to move material out of the pond, through the transport system into the SPP-1 tanks and really validate and verify that whole process and learn from it,” he said, adding later, “I think we are going to learn a lot. One of the big philosophical things we are trying to do here is as much as possible move fast and learn by doing and not spend years analyzing things.”

Efficiencies Added to Pile Fuel Storage Pond Drum Filling Plant

Meanwhile, to address sludge in the Windscale Pile Fuel Storage Pond, design efficiencies are being incorporated into a planned Drum Filling Plant, which is expected to be operational by mid-2015. The site says that the new design will save more than £50 million ($88 million) from the original cost estimate. The pond is estimated to have more than 300 cubic meters of sludge. The Drum Filling Plant will accept waste from the pond that has been processed at the Local Sludge Treatment plant, which was completed in 2012. It will then be sent to the Waste Encapsulation Plant, a treatment facility.

The material will be transferred between the plants using a “petrol-pump style design,” according to a Sellafield release. “The original planned encapsulation export facility was estimated to cost well over £70 million ($120 million), but we’ve come up with some innovative ideas using technology borrowed from other industries and will build a fit-for-purpose plant which is simpler and will instead cost in the region of £20 million ($34 million),” Project Manager Chris Plane said in a statement, adding, “We’ve thrown out the original idea of a high capacity nuclear crane, shielded concrete operating cells and substantially reinforced foundations. Instead we have designed a building skeleton containing what is effectively a large-scale petrol filling pump which we’ve proved using a test rig and it does what it says on the tin—it fills drums.”

Fuel Retrievals Restart

Meanwhile, retrievals of canned fuel has resumed at the Pile Fuel Storage Pond after a two-year pause. “In 2012 we accelerated the retrieval of the first sixteen cans of fuel to allow us to prove our retrieval techniques and underpin the treatment route; while this work was successful we had to pause the retrieval programme while a scheduled upgrade of the Windscale Laboratory was carried out,” Dorothy Gradden, Head of PFSP said in a statement. “This is now complete and we are very pleased to be able to start moving canned fuel from the pond and reducing the hazard associated with the facility.”

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Weapons Complex Vol. 25 No. 26
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Weapons Complex Monitor

Article 6 of 19

June 27, 2014

UK Cleanup Focus

By Kenny Fletcher

NDA Tells Lawmakers Sellafield Lifecycle Cost to Increase by £6 Billion

Kenneth Fletcher

WC Monitor

6/27/2014

Lifecycle cleanup costs at the U.K.’s Sellafield site have risen by more than £6 billion ($10.2 billion) from last year’s estimate, according to an annual financial report the Nuclear Decommissioning Authority submitted to Parliament this week. The current undiscounted cost left to complete Sellafield stands at £79.1 billion, but is expected to rise by £5.4 billion under a new performance plan and £0.7 billion due to accounting changes. “At Sellafield the Performance Plan 2014 has been submitted by Sellafield but is still being scrutinised by NDA so whilst the provision has increased due to known project costs it is anticipated that the provision will increase significantly next year once the impact of the Performance Plan 2014 is known,” the report states. “This is not a surprise to the NDA and whilst in many ways it is disappointing it is to be expected due to the nature of the projects at Sellafield.”

The NDA said it is currently reviewing the new plan for Sellafield, “which will reflect a greater emphasis on assessing uncertainties surrounding the complex work required on the site’s ageing high-hazard facilities.” It has also reviewed a number of scenarios for outcomes at Sellafield and has put the total estimated cost at a range from £88 billion to £218 billion. After recent scrutiny by Parliament regarding rising costs and the management at Sellafield, the NDA is striving for improved performance. “We have noted the Public Accounts Committee’s concern about the importance of providing transparency to the taxpayer over the full range of possible costs of the NDA’s mission and have been working to provide a better estimate of the range which we are publishing in our Accounts,” NDA CEO John Clarke said in a statement.

Other Lifecycle Costs for NDA Sites Remain ‘Relatively Stable’

The lifecycle cost for the rest of the NDA’s portfolio of site has “remained relatively stable over the past couple of years,” the report states, and now stands at about £31.2 billion. That includes £15.4 billion for the Magnox estate, as well as work at Dounreay, the Research Reactor sites, the Low Level Waste Repository and others.

The NDA reported a commercial income of £935 million in the year covered by the report, from April 2013 to March 2014. That comes through “exceeding targets through sustained performance from the last remaining Magnox power station at Wylfa, the conclusion of commercial deals in respect of nuclear materials in the UK and through continued progress in the reprocessing and management of spent fuels,” states an NDA release. “In addition, tight control of spending has seen the support and overhead costs in the estate reduce by more than the 25 percent target over four years which has meant more expenditure committed to front-line decommissioning activity.”

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Weapons Complex Vol 25 No 19
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Weapons Complex Monitor

Article 12 of 16

May 09, 2014

UK Cleanup Focus

By Mike Nartker

Kenneth Fletcher
WC Monitor
5/9/2014

Regulator Issues ‘Formal Cautions’ after Sellafield Contamination Incident

The U.K.’s Office for Nuclear Regulation last week issued “formal cautions” to two Sellafield workers after a contamination incident in December at the Highly Active Liquor Evaporation and Storage facility (HALES). The event occurred when the workers removed without permission a contaminated thermometer from a tank pocket in an attempt to repair it, according to ONR. The individuals were exposed to radiation below prescribed limits and released contamination into part of the facility. The investigation found that the event “was caused solely by the acts and omissions of the individuals, in full knowledge of what was required by the company to safely control and carry out the work.”

ONR issued the formal caution as a result of an investigation, which applies when there is “evidence of a criminal offense” but prosecution is not found to be appropriate. “This is the first time that ONR, as the independent regulator for nuclear safety and security, has issued cautions to individual employees,” ONR Inspector Steve Vinton said in a May 1 statement. “This should send out a clear signal that ONR takes a serious view of offences of this nature, and underlines the importance of the need for employees to comply and cooperate with their employer’s arrangements for health and safety.”

Individuals Still Facing Discipline

Site license company Sellafield Limited said that it has informed the public of the event. “All relevant stakeholders were informed of this event at the time, and it was proactively reported in the Sellafield Newsletter, with further updates provided publicly at the Risk and Hazard Reduction and Waste Management working groups of the West Cumbria Site Stakeholder Group,” spokesman Karl Connor said in a statement. “As the disciplinary process concerning the individuals involved is still active it would be inappropriate for Sellafield Ltd to comment any further.”

Sellafield first reported the event in an incident report released in its Feb. 6 newsletter. “A number of contaminated items of works clothing were found outside of the appropriate disposal route in the High Level Waste Plant change room on the Sellafield site,” according to the incident report, which adds that “an assessment of the release of radioactive material has been undertaken and the result exceeds the level that requires a Sellafield Incident Report (SIR) to be raised and is above the ministerial reporting level.”

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Weapons Complex Vol 25 No 18
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Weapons Complex Monitor

Article 10 of 14

May 02, 2014

UK Cleanup Focus

By Mike Nartker

Kenneth Fletcher
WC Monitor
5/2/2014

EnergySolutions Sues NDA for Damages in Magnox Award

Incumbent contractor EnergySolutions this week filed a claim for damages against the Nuclear Decommissioning Authority in a challenge to the recent award of the Magnox/RSRL contract to the Cavendish Fluor Partnership. Bechtel, EnergySolutions’ teaming partner in the Reactor Site Solutions bid for the contract, did not join in the legal challenge. EnergySolutions contends that the NDA “has inconsistently and in breach of equal treatment applied the evaluation criteria (including the scoring criteria),” and “committed manifest errors of assessment in scorings of both” the Reactor Site Solutions and Cavendish Fluor bids, according to a filing by the company in the High Court of Justice Queen’s Bench Division Technology and Construction Court.

The claim states that the NDA did not evaluate some material in the Reactor Site Solutions bid, and evaluated it against requirements that weren’t specified beforehand, and did not fully apply scoring criteria to Cavendish Fluor. “As a result of the Defendant’s breaches (or any of them), the Claimant has suffered and/or risks suffering loss and damage,” the filing states. The challenge comes after last May 2, 2014 month the NDA began transition to Cavendish Fluor, which is scheduled to end in December. However, if the legal challenge drags out beyond the scheduled transition, as incumbent, EnergySolutions could potentially continue to earn fee for Magnox work.

Bechtel Doesn’t Join In

For its part, team member Bechtel decided not to participate in the suit. “As we are in different commercial circumstances, Bechtel has not joined EnergySolutions in its legal challenge. Bechtel stands fully behind the thorough and realistic tender from Reactor Site Solutions for Magnox/RSRL, and we respect EnergySolutions’ right to independently seek legal redress,” Bechtel spokesman Fred Desousa said in a written response.

AMEC Team Leaves Open Option for Challenge

It’s still undecided as to whether the other two unsuccessful bidders for management of the 10 Magnox sites and two research reactor sites will file challenges of their own. UK Nuclear Restoration Ltd., comprised of AMEC, Atkins and Rolls Royce,is still considering options. “We have not mounted a challenge, but that doesn’t preclude us from doing so in the future,” AMEC spokesman Harold Ashurst said this week. The third unsuccessful team, CAS Restoration Partnership made up of CH2M Hill, AREVA and Serco, has declined to comment.

The NDA so far has remained confident of its process. “The NDA understands that legal action is being commenced by one of the unsuccessful participants in the Magnox/RSRL competition. The NDA remains confident that the competition process was carried out in a robust manner in compliance with EU guidelines. The standstill period following the announcement of the preferred bidder has closed and the transition programme leading to the preferred bidder taking over the 12 nuclear sites in September is now underway. The new contract looks set to deliver savings in excess of 1 billion pounds against previous plans,” spokesman Bill Hamilton said in a statement.

No Word Yet on Key Personnel

While Cavendish Fluor has identified key personnel for the Magnox work, the names of the personnel have not yet been made public. “The preferred bidder has identified key personnel and a final list will be agreed within the next two weeks. Those individuals will then go through checks to ensure they are suitably qualified and experienced before taking up shadow roles in the SLCs in readiness to take over in September,” Hamilton said. Fluor declined to comment on who key personnel may be, and Cavendish did not respond to request for comment.

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Weapons Complex Vol 25 No 16
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Weapons Complex Monitor

Article 7 of 11

April 18, 2014

UK Cleanup Focus

By Mike Nartker

Kenneth Fletcher
WC Monitor
4/18/2014

NDA Launches Magnox Transition, No Challenges So Far

The Nuclear Decommissioning Authority has launched a five-month transition period for Cavendish Fluor Partnership to take over management of 10 Magnox power plants and two research reactor sites after no legal challenges to the contract award were filed during a recent 10-day standstill period. The NDA and the winning team inked the transition agreement this week after the required standstill period following the March 31 award. “We have run a rigorous competition process, which has been the subject of considerable scrutiny by the Major Projects Authority, and we remain on track to award a contract that will deliver over £1 billion of savings to the taxpayer,” NDA CEO John Clarke said in a statement. “We look forward to continuing to work with the incumbent Parent Body Organisations, Energy Solutions for Magnox and Cavendish Nuclear for RSRL, over the next five months to deliver a smooth handover.”

Any challenge or protest to the award would have to go through the U.K. court system. While so far none of the three unsuccessful bidders have filed challenges to the Magnox award, it is still possible that they could be filed in the early weeks of transition. The Bechtel-EnergySolutions team and the Amec-led team are both still evaluating their options, though those teams declined to comment this week on the possibility. In an April 1 Securities and Exchange Commission filing, EnergySolutions said it had not decided whether to protest the results, but the loss would have a “significant impact on our results of operations.” UK Nuclear Restoration Ltd., comprised of AMEC, Atkins and Rolls Royce, also said earlier this month it was considering its options. The third unsuccessful team, CAS Restoration Partnership made up of CH2M Hill, AREVA and Serco, has not weighed in publicly.

The standstill period gave the unsuccessful teams a chance to request additional information from the NDA. Completion of transition and contract award is now expected for September 2014. “We are grateful to all the companies involved in the four consortia for their contribution to the competitive process and for the quality of their bids, and we look forward to their future participation in the UK’s £3 billion a year nuclear clean-up programme,” Clarke said.

Sellafield Awards Large Contract to AREVA Team for Silos Project

Sellafield Limited this week awarded a massive £1.4 billion contract to a team comprised of AREVA, Mace and Atkins for the Silos Direct Encapsulation project at Sellafield. The project aims to design and build a facility to treat legacy waste from the Magnox Swarf Storage Silo for long-term storage. The preferred bidder clarification process is underway as the contract is being finalized. “The contract is estimated to be worth £1.4 billion … although the final details will be confirmed during the next phase of agreeing the contract,” Sellafield spokesman Karl Connor said in a written response. “The final contract award will be subject to approval from Britain’s Nuclear Decommissioning Authority.”

The project will employ “several hundred” workers and rely on the local supply chain as much as possible, according to AREVA. “AREVA was able to demonstrate the value of its experience in managing end of nuclear fuel cycle activities, especially in Europe and the United States. We are committed to providing the best value to the UK nuclear industry while ensuring that these projects maintain the highest levels of safety, security and environmental performance,” AREVA Senior Executive Vice President Back End Business Group Dominique Mockly said in a statement.

Sellafield noted that the award was part of a new acquisition strategy that focuses on “performance based contracting” with the supply chain. “The market recognised the challenges presented by this important and complex project and two strong joint venture organisations emerged to tender for the contract. Sellafield Ltd was very pleased with the quality, capability and commitment offered by each of these organisations,” Sellafield Ltd. Chief Projects Officer Scott Reeder said in a statement.

Sellafield Marks Progress on Windscale Chimney D&D

An effort to demolish a 530-ton filter gallery on top of a massive chimney at Sellafield has passed the halfway point, site license company Sellafield Limited announced this week. The large filter gallery must be addressed at the last remaining Windscale chimney before it can be brought down. The 110-meter chimney was a ventilation shaft for a reactor which suffered a core fire in 1957, increasing contamination. “The contaminated filters themselves were removed not long after the fire and the chimney was then sealed up to allow the radiation to decay. We’re now working to dismantle the filter gallery itself, which provided access to change and clean the filters,” Pile Chimney Demolition Project Manager Chris Wilson said in a statement. “The filter gallery is a large, robust structure built of steel, brick and concrete at the top of the chimney. We’re using conventional demolition techniques common in other industries but in an unconventional environment at the top of a nuclear chimney.”

About half of the filter gallery has been brought down, including 150 tons of concrete, 175 tons of steel and 66 tons of brick. The current schedule calls for completion of the gallery by October, followed by the demolition of the 1,400 ton diffuser box in 2017 to 2018. “The decommissioning challenges posed by the Pile chimney are unique and no other structure in the world provides the same complexity in terms of both radiological and conventional decommissioning constraints,” Head of Decommissioning Projects Jeremy Hunt said in a statement. “There’s no instruction manual for the job and we have to prove the decommissioning techniques chosen can be used 100 percent safely on the congested Sellafield site.”

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Weapons Complex Vol 25 No 15
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Weapons Complex Monitor

Article 5 of 13

April 11, 2014

UK Cleanup Focus

By Martin Schneider

Dounreay Costs May Go up £200 Million

Kenneth Fletcher
WC Monitor
4/11/2014

The last eight double-shell waste tanks built at Hanford had only minor construction issues, according to the final construction review report released by the Department of Energy this week. The review concluded that double-shell tanks in the AP Tank Farm were in better condition overall following construction than Tank AY-102, which is leaking waste between its shells. It was the first tank to be built. The interior leak is suspected to be due in part to difficulties with the tank’s construction, prompting a look at the construction history of the other double-shell tanks. The AP Tank Farm was the sixth group of tanks and was built from 1982-86. Some 5 to 12 percent of welds in those tanks required rework during construction, compared to 34 percent in the bottom of the inner shell of Tank AY-102, according to the review done by Washington River Protection Solutions.

The construction reviews became an issue when Sen. Ron Wyden (D-Ore.) obtained the reviews that had been finished by early March and said they contradicted DOE’s statements that construction difficulties on Tank AY-102 were an isolated problem. He concluded that six tanks in addition to Tank AY-102 have construction problems that could increase the risk of leaks and 13 more tanks may have construction problems that will shorten their life span. He has asked Energy Secretary Ernest Moniz to provide a plan to address tank construction issues, including considering building more waste storage tanks. DOE said the interior leak in Tank AY-102 likely was the result of construction difficulties and a combination of high heat waste that is sitting above waste without an added corrosion inhibitor at the bottom of the tank. None of the other double-shell tanks have that combination of waste, according to DOE.

The construction review on Tank AY-102 concluded that “construction difficulties and trial-and-error repairs left the primary tank bottom with residual stresses that could not be foreseen by the designers. These provided a fertile incubator for sustained corrosion to take place.” The Washington State Department of Ecology has ordered DOE to start removing waste from the tank by Sept. 1. Other construction reviews concluded that enhanced inspection was needed on the next three tanks built after Tank AY-102, which included the second tank in the AY Tank Farm and the two tanks in the AZ Tank Farm. Some problems also were found that were similar to those in Tank AY-102 in the next three tanks constructed, those in the SY Tank Farm built from 1974-77. The 13 tanks in the AW and AN Tank Farms, built from 1976-80, also had some issues that leave room for uncertainty in long-term tank integrity, the reviews said.

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