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Building the Sellafield Plan - Sellafield Ltd

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<strong>Sellafield</strong> <strong>Plan</strong>www.nda.gov.uk | www.sellafieldsites.com | www.nuclearmanagementpartners.com


Issue 1 August 2011<strong>Sellafield</strong> <strong>Plan</strong> 1<strong>Sellafield</strong> <strong>Plan</strong>ContentsOverviewForeword by NDA and NMP<strong>Building</strong> <strong>the</strong> <strong>Sellafield</strong> <strong>Plan</strong>Map of supporting documentsHow to use <strong>the</strong> <strong>Sellafield</strong> <strong>Plan</strong><strong>Sellafield</strong> site activitiesKey plants and projects<strong>Sellafield</strong> <strong>Plan</strong> Summary Costs2011/12-2025/26GlossaryRisk & Hazard ReductionRisk & Hazard Reduction IntroductionFloc Storage TanksFirst Generation Reprocessing <strong>Plan</strong>tsPile Fuel Storage PondFirst Generation Magnox Storage PondMagnox Swarf Storage SilosPile Fuel Cladding SiloHAL WorkstreamPCM Treatment and StorageWindscaleSpent Fuel ManagementMagnox ReprocessingOngoing Receipt of AGR FuelThorp ReprocessingWet Inlet Facility (WIF)Decommissioning<strong>Sellafield</strong> Site DecommissioningNuclear MaterialsOverseas Pu ReturnSafe Storage of PuWaste ManagementEffluent ManagementILW Treatment and StorageLLW and Sub LLW TreatmentInfrastructureInfrastructureFunctionsFunctionsEnd StatesLand and Groundwater RemediationSocio-economicSocio-economicAppendix


<strong>Sellafield</strong> <strong>Plan</strong> – Issue 1 August 2011OverviewIntroduction to <strong>the</strong><strong>Sellafield</strong> <strong>Plan</strong>The <strong>Sellafield</strong> <strong>Plan</strong> is an underpinned anddeliverable plan for <strong>the</strong> <strong>Sellafield</strong> nuclearsite. This section explains <strong>the</strong> backgroundto <strong>the</strong> document and how to use it.


Issue 1 August 2011<strong>Sellafield</strong> <strong>Plan</strong> 3Overview: ForewordWe have applied world leading expertise, to produce <strong>the</strong> firstcredible and underpinned lifetime plan for <strong>the</strong> <strong>Sellafield</strong> site.Nuclear Management Partners and its Parent Companies arenow fully committed to applying our full corporate strengthto delivering <strong>the</strong> plan and accelerating <strong>the</strong> clean-up of <strong>the</strong>high hazard facilities.Tom Zarges, Nuclear Management PartnersWhen Nuclear Management Partners (NMP)arrived at <strong>Sellafield</strong> in 2008 our immediatetask was to evaluate and absorb <strong>the</strong> fullextent of <strong>Sellafield</strong>’s issues, operationalconcerns and condition of <strong>the</strong> site’sinfrastructure. With this understanding asa solid foundation we now have a credibleplan for accelerated delivery at <strong>Sellafield</strong>. Weare absolutely committed to achieving – infact improving upon – this plan. No doubt<strong>the</strong> plan will be dynamic and require activeresponse and leadership from us all as it isundertaken. But <strong>the</strong> pace and objectives areclear – and <strong>the</strong> commitment to it unwavering.<strong>Sellafield</strong>’s greatest resource is its people.The men and women who operate <strong>the</strong><strong>Sellafield</strong> site are, collectively, <strong>the</strong> greatestconcentration of nuclear expertise in Europe.I am pleased that this year has seen uscontinue to supplement and complement<strong>the</strong> <strong>Sellafield</strong> <strong>Ltd</strong> team with experts from<strong>the</strong> parent organisations – URS, AMEC andAREVA. There are currently over 80 keypersonnel from <strong>the</strong>se global organisationswho are on <strong>the</strong> ground, working with <strong>the</strong>ircolleagues from <strong>Sellafield</strong> <strong>Ltd</strong>.The dedication and initiative of thiscollaborative team are fundamental tostepping up our performance.By working much moreefficiently and effectively thanhas historically been <strong>the</strong> normat <strong>Sellafield</strong>, we will achievetrue value for money for ourcustomer, <strong>the</strong> NDA; deliveringaccelerated clean-up andgreatly improved operationalperformance.Delivery of this plan also requires significantfunding from NDA and Government; we donot underestimate <strong>the</strong> expectations and levelof responsibility this puts upon us to deliver.We are very aware of <strong>the</strong> importance of oursuccess to <strong>the</strong> local community of WestCumbria. It is vitally important for <strong>the</strong> future of<strong>Sellafield</strong>, <strong>the</strong> local West Cumbria economyand <strong>the</strong> future of <strong>the</strong> UK nuclear industrythat <strong>Sellafield</strong> is operated safely, moreproductively and more efficiently than before.To achieve this, we will have to change<strong>the</strong> way we go about our business. Thedriving force behind cultural change anddelivering efficiencies is <strong>the</strong> IntegratedChange Programme, which is a wide rangingprogramme of carefully conceived andexpected change initiatives. This is beingmanaged comprehensively with clearlyidentified scope, milestones and benefittargets. It is by driving through <strong>the</strong> IntegratedChange Programme that we will deliver thisPerformance <strong>Plan</strong>.Our overriding business priorities remain; <strong>the</strong>safety of our workforce, <strong>the</strong> public and <strong>the</strong>environment; and our relentless pursuit ofexcellence in <strong>the</strong>se areas.We believe that <strong>the</strong> best years are to come.We are working in partnership with <strong>the</strong> siteowners, <strong>the</strong> Nuclear DecommissioningAuthority, to make <strong>Sellafield</strong> and its workforce<strong>the</strong> obvious choice for potential new missions.This is a team that can rise to <strong>the</strong> challenge.URS manages more US governmentnuclear clean-up projects and sites thanany o<strong>the</strong>r companyAMEC is <strong>the</strong> leading UK nuclear engineeringand project management companyAREVA operates <strong>the</strong> French fuel cycleprogramme – <strong>the</strong> industry’s model


Issue 1 August 2011<strong>Sellafield</strong> <strong>Plan</strong> 5Overview: IntroductionWhat Nuclear Management Partners brings to <strong>Sellafield</strong> is a globalnetwork of nuclear experts who can, and have, complemented <strong>the</strong>highly skilled and experienced <strong>Sellafield</strong> <strong>Ltd</strong> workforce. Toge<strong>the</strong>rwe are challenging <strong>the</strong> norm, exploring new solutions andapproaches to work and safely accelerating <strong>the</strong> rate at which wedeliver for our customer. As a result of this, we have delivered <strong>the</strong>first underpinned plan for <strong>the</strong> <strong>Sellafield</strong> site and we will continueto deliver on <strong>the</strong> commitments it contains.Dr Todd Wright, Managing Director, <strong>Sellafield</strong> <strong>Ltd</strong>The Contract BaselineLike all Site Licence Companies, <strong>Sellafield</strong><strong>Ltd</strong> is required to set out Lifetime <strong>Plan</strong>sfor <strong>the</strong> sites under its control so whilst aninherited plan was in place when NMP tookownership of <strong>Sellafield</strong> <strong>Ltd</strong> in November 2008it was collectively agreed that <strong>the</strong> plan wasnot realistic and could not be delivered.It had been built upon a significant numberof key assumptions such as <strong>the</strong> availabilityof downstream plants for decommissioning,<strong>the</strong> rates at which waste can be retrievedand treated and estimates for <strong>the</strong> duration ofconstruction of new plants at <strong>Sellafield</strong>.Consideration was given to simply updatingthis plan but it was agreed <strong>the</strong> best approachwas to completely rebuild that plan, based onhistoric delivery levels and updated priorities.This is known as <strong>the</strong> Contract Baseline, as itgives us a solid base against which we canjudge how much improvement is being madeacross <strong>the</strong> site.The Contract Baseline was subjected tothorough assurance reviews by both NDAand NMP.The Performance <strong>Plan</strong>NMP were <strong>the</strong>n tasked with building a newplan that would capture what <strong>the</strong>y believedcould be delivered across <strong>the</strong> site by applying<strong>the</strong>ir expertise, innovation and leadershipwhilst retaining <strong>the</strong> key safety and economicfactors referred to earlier.Indeed it is against this Performance <strong>Plan</strong>,accepted by <strong>the</strong> NDA in April this year,that performance across <strong>the</strong> site can betruly judged, and it is <strong>the</strong> milestones andobjectives of that plan that are highlighted inthis document.The Performance <strong>Plan</strong> reflects <strong>the</strong> currentand expected availability of resources andpolicy priorities, and takes account of <strong>the</strong>improvements NMP can bring. It has aparticular focus to 2025/26, <strong>the</strong> maximumduration, following potential extensions, of<strong>the</strong> current contract between <strong>the</strong> NDA andNMP as <strong>the</strong> Parent Body Organisation for<strong>Sellafield</strong> <strong>Ltd</strong>.Reviewing performanceAt regular intervals throughout <strong>the</strong> financialyear, <strong>the</strong> NDA will review <strong>Sellafield</strong> <strong>Ltd</strong>’sperformance against this plan. Indeed <strong>the</strong>NDA will only pay <strong>Sellafield</strong> <strong>Ltd</strong> fee if it meets<strong>the</strong> targets in <strong>the</strong> performance plan, not <strong>the</strong>contract baseline. So, in order to earn fee,<strong>Sellafield</strong> <strong>Ltd</strong> needs to consistently improve<strong>the</strong> way it operates, under <strong>the</strong> strategicguidance of NMP.Those performance targets are also capturedin this document so we can report against<strong>the</strong>m both at <strong>the</strong> end of each financialyear but also in-year so stakeholders canassess progress across <strong>the</strong> site. It must beremembered of course, that this plan canonly reflect what we know now. It will by itsvery nature be subject to change in responseto different circumstances that may ariseresulting from Government policy, resourceavailability or o<strong>the</strong>r significant factors.NMP and <strong>Sellafield</strong> <strong>Ltd</strong> don’t just hope tosuccessfully deliver <strong>the</strong> new Performance<strong>Plan</strong>, we will also challenge performance sowe will be able in some areas to beat it andfur<strong>the</strong>r accelerate progress and deliver fur<strong>the</strong>rvalue for money. You can be reassured thatwe will keep you informed of progress.Early reviews brought subject matterexperts from <strong>Sellafield</strong> <strong>Ltd</strong> and URS, AMECand Areva toge<strong>the</strong>rThe Integrated Change Programme launchedin 2009 to coordinate <strong>the</strong> implementation ofimprovements across <strong>Sellafield</strong> <strong>Ltd</strong>Key:Laurem ipsomerVienam fuller estronaSafety underpins all of <strong>the</strong> work that we doNamque institue einsTemporid aurteme


6 <strong>Sellafield</strong> <strong>Plan</strong>Issue 1 August 2011Overview: Roles and ResponsibilitiesNDA Core ProcessesKey Factors in <strong>Building</strong> <strong>the</strong><strong>Sellafield</strong> <strong>Plan</strong>The key task for NMP in establishing <strong>the</strong>Contract Baseline was to quickly understand<strong>the</strong> existing performance of <strong>the</strong> <strong>Sellafield</strong> site.<strong>Sellafield</strong> is <strong>the</strong> most complex nuclear site inEurope. NMP has taken <strong>the</strong> time to properlyunderstand <strong>the</strong> operations and issues on <strong>the</strong>site in order to build a deliverable plan.A programme of intensive reviews – calledPartner, Assess, Innovate and Sustain(PAIS) – was carried out within <strong>the</strong> first12 months of <strong>the</strong> NMP contract. The PAISreviews partnered subject matter experts from<strong>Sellafield</strong> <strong>Ltd</strong> with those from <strong>the</strong> Parent BodyOrganisations. Toge<strong>the</strong>r, <strong>the</strong>y assessed <strong>the</strong>processes and procedures across <strong>Sellafield</strong><strong>Ltd</strong> against industry best practice. They <strong>the</strong>nbrought innovations in order to close anyidentified gaps.<strong>Sellafield</strong>’s proven performanceNMP and <strong>Sellafield</strong> <strong>Ltd</strong> also undertook anintensive review into what <strong>the</strong> <strong>Sellafield</strong> sitecould achieve, based on historic performance,if everything stayed <strong>the</strong> same and noimprovements were made. A number ofareas were looked at including <strong>the</strong> normalproduction rates of our operational facilitiesand how long it traditionally takes to constructa new building at <strong>Sellafield</strong>. This provided asound baseline performance that was realistic,not aspirational.Integrated Change ProgrammeTo make sure that any changes made at<strong>Sellafield</strong> are made in a coordinated way, <strong>the</strong>Integrated Change Programme was launched.This centralised programme monitors <strong>the</strong>changes that need to be made and how<strong>the</strong>y are implemented across <strong>the</strong> site. Theimprovements that are being delivered through<strong>the</strong> Integrated Change Programme provideconfidence that <strong>the</strong> accelerated delivery datesin <strong>the</strong> Performance <strong>Plan</strong> are underpinned and<strong>the</strong> required efficiencies are being delivered.The Integrated Change Programme provides agreat opportunity to deliver a site that reflects<strong>the</strong> best practices from across <strong>the</strong> worldand one which its workforce and <strong>the</strong> widerCumbrian community can be justly proud of.Underpinned by performanceNMP is fully committed to applying its fullcorporate strength to delivering <strong>the</strong> planand accelerating <strong>the</strong> clean-up of <strong>the</strong> highNuclear DecommissioningAuthorityOwns <strong>the</strong> sites and competescontract – strategic directionhazard facilities as our priority. By workingmuch more efficiently and effectively thanhas historically been <strong>the</strong> norm at <strong>Sellafield</strong>,we are bringing true value for money to <strong>the</strong>UK Government and taxpayer, deliveringaccelerated clean-up and greatly improvedoperational performance.Working toge<strong>the</strong>r, we are planning significantschedule acceleration in most areas, butespecially focused on Legacy Ponds andSilos, where we are already moving legacyfuel skips for <strong>the</strong> first time in decades andretrieving active liquors and sludges.We will achieve sustained higher throughputsin production facilities, we will maintaininvestment in asset care for ageing facilitiesand infrastructure and we are targeting£1.2bn of cost-efficiencies against <strong>the</strong>contract baseline over <strong>the</strong> first five years ofour contract.Parent Body Organisation:Nuclear Management Partners <strong>Ltd</strong>which is a consortium comprising…<strong>Sellafield</strong> <strong>Ltd</strong> (SLC)Holds SLC shares and provides reachback &management expertise and appropriate governanceHolds and is responsible forsite licences – <strong>Sellafield</strong> andCapenhurst – tactical deliveryRegulatory bodies inc <strong>the</strong> Office for Nuclear Regulation,Health and Safety Executive, Environment AgencyRelationship diagram


Issue 1 August 2011 <strong>Sellafield</strong> <strong>Plan</strong> 7Working toge<strong>the</strong>r NDA, NMP and<strong>Sellafield</strong> <strong>Ltd</strong> are making <strong>Sellafield</strong>cleaner, safer, more productive anda better neighbour


8 <strong>Sellafield</strong> <strong>Plan</strong>Issue 1 August 2011Overview: Supporting documentsMap of supportingdocumentsThe <strong>Sellafield</strong> <strong>Plan</strong> sets out in detail <strong>the</strong> work that will be completed over<strong>the</strong> coming years, when it will be completed and how much that work willcost. Although comprehensive in its own right, it is only part of a wholesuite of documents which are produced by <strong>the</strong> Nuclear DecommissioningAuthority (NDA) and <strong>Sellafield</strong> <strong>Ltd</strong> to set out what currently happens andwhat will happen at <strong>Sellafield</strong>.Supporting documentsThe table on <strong>the</strong> right sets out how <strong>the</strong><strong>Sellafield</strong> <strong>Plan</strong> fits into a wider range ofdocuments. This ensures that <strong>the</strong>re is a directlink from <strong>the</strong> Strategy set by <strong>the</strong> NDA through<strong>the</strong>ir annual Business <strong>Plan</strong> and into <strong>the</strong><strong>Sellafield</strong> <strong>Plan</strong>.Members of <strong>the</strong> publicare invited to take part inconsultations on <strong>the</strong> NDAStrategy and <strong>the</strong> Business <strong>Plan</strong>as well as a range of subjectspecific consultations to do withoperations on <strong>the</strong> <strong>Sellafield</strong> site.Relationship diagramNDA StrategyIndividual TopicStrategiesExternal Influences(eg. Radwaste Inventory,Discharges Strategy,OSPAR, new build<strong>Sellafield</strong> <strong>Plan</strong>Client SpecificationNDA Internal Business<strong>Plan</strong>ning ProcessesBusiness <strong>Plan</strong>The Nuclear Decommissioning Authority’sStrategy document is made available forcomment prior to publicationThe Nuclear Decommissioning Authority’sBusiness <strong>Plan</strong> is also made available forconsultation and sets out priorities


Issue 1 August 2011<strong>Sellafield</strong> <strong>Plan</strong> 9Overview: Supporting documents<strong>Sellafield</strong> <strong>Ltd</strong> undertakes a formal consultation process on specificissues as <strong>the</strong>y arise and members of <strong>the</strong> public and interestedparties are encouraged to take part. Consultations have alreadybeen completed on a number of key <strong>Sellafield</strong> areas: Document descriptionsThe <strong>Sellafield</strong> <strong>Plan</strong> is just one of a series ofdocuments which are in place as part of <strong>the</strong>contractual relationship between <strong>the</strong> NDA,<strong>Sellafield</strong> <strong>Ltd</strong> and NMP.This page sets out <strong>the</strong> o<strong>the</strong>r primarydocuments which are produced by <strong>the</strong>NDA, some of which are open to publicconsultation prior to publication. Throughout<strong>the</strong> <strong>Sellafield</strong> <strong>Plan</strong> we have indicated whereour individual programme plans deliveragainst <strong>the</strong> objectives outlined in <strong>the</strong> NDA’sBusiness <strong>Plan</strong>.NDA StrategyThe Energy Act 2004 requires <strong>the</strong> NDA toreview and publish its Strategy at least everyfive years. It undergoes a formal consultationprocess and sets <strong>the</strong> strategic direction for <strong>the</strong>NDA for <strong>the</strong> duration of its mission.NDA Business <strong>Plan</strong>The Business <strong>Plan</strong> supplements <strong>the</strong> NDAStrategy which sets out near term objectivesand plans for delivering our priorities over <strong>the</strong>following three year period.Individual Topic StrategiesThe underpinning detail behind <strong>the</strong> NDAStrategy is shown in <strong>the</strong> individual topicstrategy documents. These documents give<strong>the</strong> technical information on <strong>the</strong> developmentand implementation of <strong>the</strong> individualstrategies.NDA Internal Business <strong>Plan</strong>ningprocessesInternally, <strong>the</strong> NDA has processes for <strong>the</strong>consideration of <strong>the</strong> short, medium and longterm plans for its sites. The information from<strong>the</strong>se plans supports <strong>the</strong> development of <strong>the</strong>annual Business <strong>Plan</strong>, and <strong>the</strong> revision of <strong>the</strong>Strategy document (when required).Client SpecificationsThe NDA issues <strong>the</strong> SLCs with a specificationthat describes <strong>the</strong> strategic requirements of<strong>the</strong> contract, and has introduced <strong>the</strong> conceptof strategic tolerance reporting as a way tomonitor <strong>the</strong> health of strategies.<strong>Sellafield</strong> <strong>Plan</strong>The <strong>Sellafield</strong> <strong>Plan</strong> is produced by <strong>Sellafield</strong><strong>Ltd</strong> to meet a contractual requirement of <strong>the</strong>NDA, and is revised annually. It gives detailsof <strong>the</strong> planned activities and costs of <strong>the</strong> workrequired to fully decommission <strong>the</strong> site to anagreed end-state.www.sellafieldsites.com | www.nda.gov.uk | www.nuclearmanagementpartners.com


10 <strong>Sellafield</strong> <strong>Plan</strong>Issue 1 August 2011Overview: Document guideHow to use <strong>the</strong><strong>Sellafield</strong> <strong>Plan</strong>The <strong>Sellafield</strong> <strong>Plan</strong> sets out <strong>the</strong> work that will be completed at <strong>Sellafield</strong>over <strong>the</strong> coming years. The information is set out firstly in sections– such as ‘risk and hazard reduction’ and ‘spent fuel management’.Within <strong>the</strong>se sections are individual work programmes – such as‘Pile Fuel Storage Pond’ and ‘First Generation Magnox Storage Pond’.The following pages will help you to find <strong>the</strong> information that you arelooking for at individual work programme level.Milestone timeline example:Milestones:Key activity/programmeThis part of <strong>the</strong> table identifies <strong>the</strong>different financial year periodsInitial contract term5 year extended contract term2011/12 2012/13 2013/14 2014/15 2015/16 2016/17Design, Install and Inactive CommissionRetrieval EquipmentRetrievals Operations and MaintenancePreparation for DecommissioningThis part of <strong>the</strong> tablelists <strong>the</strong> key activitiesto be completedThe grey line represents<strong>the</strong> ‘contract baseline’schedule for <strong>the</strong> workThe purple line represents <strong>the</strong>‘performance plan’ schedulefor <strong>the</strong> same workSummary of costs example:Summary of costs:Initial contract term2011/12 2012/13 2013/14Total (£k)2011/12-2013/14Total (£k)2014/15-2025/26Total (£k)2011/12-2025/2641,658.5 43,322.5 73,052.0 158,033.0 457,554.8 615,587.9You will find cost summaryinformation for each individualwork programme. This informationis split between <strong>the</strong> initial contractterm and future contract terms.This section details <strong>the</strong>investment in <strong>the</strong> project for <strong>the</strong>remainder of <strong>the</strong> initial contractterm (ie <strong>the</strong> first five years of <strong>the</strong>NMP contract, starting in year 3)This section sets out <strong>the</strong> total cost of<strong>the</strong> remainder of <strong>the</strong> initial contractterm (years 3, 4 and 5), <strong>the</strong> total cost of<strong>the</strong> remaining potential contract term(12 years), and <strong>the</strong> total investmentover <strong>the</strong> maximum contract term.


Issue 1 August 2011<strong>Sellafield</strong> <strong>Plan</strong> 11Overview: Document guideABCThe front page of each work programme section sets outsome ‘at a glance’ information. From this page you can seeA. Section titleDB. Picture of plant or key activityC. Programme titleD. Overview of current status, key activities and processesfrom <strong>the</strong> past or present dayThe red dashed line and arrows highlights <strong>the</strong>improvement from <strong>the</strong> ‘contract baseline’ to<strong>the</strong> ‘performance plan’ scheduleKey:Contract BaselinePerformance planMaximum contract term5 year extended contract term 2 year extended contract term2017/18 2018/19 2019/20 2020/21 2021/22 2022/23 2023/24 2024/25 2025/26Completion of Preparation for RetrievalsStart of Bulk RetrievalsThe red diamond represents<strong>the</strong> ‘performance plan’completion date for workThe grey diamond represents<strong>the</strong> ‘contract baseline’completion date for work<strong>Plan</strong>t programme diagram example:The majority of plants and processesat <strong>Sellafield</strong> rely in some way on <strong>the</strong>availability of o<strong>the</strong>r plants and processes.Each section features flow diagrams likethis which highlight <strong>the</strong> work programmein relation to o<strong>the</strong>rs.Pile FuelCladding SiloWaste Retrieval<strong>Plan</strong>tInterim Storage ofUntreated WasteWaste Treatment<strong>Plan</strong>tThe Pile Fuel Cladding Silo ProgrammeOn Site Storage ofTreated Waste


12 <strong>Sellafield</strong> <strong>Plan</strong>Issue 1 August 2011Overview: <strong>Sellafield</strong> site activities<strong>Sellafield</strong> siteactivitiesThe <strong>Sellafield</strong> site is home to a wide range of interdependent nuclear facilitiesand operations. These range from hazard and risk reduction, decommissioning,reprocessing, fuel manufacturing and nuclear waste management.Calder HallSite ion exchange plantWAGRSegregated effluent treatment plantSeparation areaEvaporators A, B, C, with D under constructionWaste monitoring & compaction plantLegacypondsLegacysilosPrimarySeparationareaSPP1 – Sludge packaging plantWaste treatment complexMagnox reprocessingVitrification plantThorpEffluent and encapsulation facilitiesUranium exportsto customers<strong>Sellafield</strong> MOXplantNew fuel exportedto customersMagnoxencapsulationplantSolventtreatmentplantEnhancedactinideremoval plantWasteencapsulationplantWaste packaging& encapsulationplantLLW disposedof to <strong>the</strong> LLWRIn order to decommission <strong>the</strong> <strong>Sellafield</strong> site itis necessary to first build some new facilitiesthat will treat and store <strong>the</strong> waste generatedThe safe management of nuclear waste is aspecialist area for <strong>the</strong> <strong>Sellafield</strong> workforceThe <strong>Sellafield</strong> site is home to two reprocessingplants – <strong>the</strong> Thermal Oxide Reprocessing <strong>Plan</strong>tand <strong>the</strong> Magnox Reprocessing <strong>Plan</strong>t


Issue 1 August 2011<strong>Sellafield</strong> <strong>Plan</strong> 13Overview: <strong>Sellafield</strong> site activitiesMeasuring 2 square miles, <strong>the</strong> <strong>Sellafield</strong>site is home to over two hundred nuclearfacilities and over one thousand buildings.The primary mission on <strong>the</strong> site is <strong>the</strong> safeacceleration of risk and hazard reduction.O<strong>the</strong>r operations on <strong>the</strong> <strong>Sellafield</strong> siteinclude nuclear waste management,reprocessing and fuel manufacturing.This is all carried out by a 10,000 strongworkforce.Vitrifiedproduct storeResidue exportfacility<strong>Sellafield</strong>product &residue storeEncapsulatedproduct stores1, 2, 3Eventualdisposal atUK repositoryReturned tooverseascustomersPrimary operations: Legacy Ponds and Silos buildings which are among <strong>the</strong>oldest facilities on <strong>the</strong> <strong>Sellafield</strong> site management and associated operations with UK andforeign customers high level waste. Low level waste is compacted andsent to <strong>the</strong> Low Level Waste Repository for storage.Intermediate level waste is mixed with grout and storedin drums inside engineered stores. High level wasteis mixed with molten glass to create a stable solidsubstance suitable for long term storage facilities at <strong>Sellafield</strong> are over 60 years old so asignificant investment is required to ensure that<strong>the</strong>y remain operational and in a safe state prior todecommissioningWhere possible to treat very low level waste,removing <strong>the</strong> surface contamination andallowing <strong>the</strong> remaining material to be recycledThe final stage of <strong>the</strong> decommissioningprogramme is <strong>the</strong> demolition of <strong>the</strong> emptyfacilities


14 <strong>Sellafield</strong> <strong>Plan</strong>Issue 1 August 2011Overview: Key plants and projectsKey plants and projects2010 2020 2030 2040 2050 2060SeparationAreaVentilationSAVDemolish Reprocessing <strong>Plan</strong>t Vent Stack1st Generation Reprocessing <strong>Plan</strong>t Decommissioning / DemolitionSludgeBuffer Care & MaintenanceLSTP(B)Pile Fuel Pond RetrievalsTreatment <strong>Plan</strong>t OpsPile Fuel Pond – POCO / Decommissioning / DemolitionLSTP(E) <strong>Plan</strong>t (Build)Magnox Pond Retrievals / TreatmentSPP1(B)SPP1(P&E)BEPSeparation MachinerySDEP / SMF /+ 3m 3 BoxMagnox Swarf Silos – Sludge Retrievals / TreatmentPile Fuel Cladding Silo RetrievalsMagnox Pond – POCO / Decommissioning / DemolitionMagnox Swarf Silos POCO / Decommissioning / DemolitionCladding Silo PrepsCladding Silo – POCO / Decommissioning / DemolitionBEPPS 1LP&S ILW StorageDILWEPBEPPS 2ILW Final Treatment and StorageBEPPS 3BEPPS 4ILW GDF AvailableWPEP / MBGWSEPS1, 2, & 3ILW Store ExportsCommercial Ops ILW StorageMagnox OpsThorp OpsMagnox <strong>Plan</strong>ts – POCO / Decommissioning / Demolitioncontinued long term on site product storageThorp HE & CSP Decommissioning & Thorp HE & CSP DemolitionHALES / WVP OpsVPS StorageEvap DReplacement HASTsAGR ReceiptsAGR Fuel Conditioning <strong>Plan</strong>tAGR StorageCustomer Fuel StorageSMP OpsSMP – POCO / Decommissioning / DemolitionD&B New PCM Treatment <strong>Plan</strong>tsWTC3 ConstructionWTC Ops No PCM Treatment 2026 – 2036 New PCM Treatment OpsWTC POCO / Decom / DecommissioningEDS ExportsPCM Treatment <strong>Plan</strong>tPOCO / DecommissioningEDS StorageCalder Final DefuelCalder Reactors into SafestoreCalder Reactors in Safestore (Care & Maintenance Equivalent)Land & Groundwater MonitoringLand & Groundwater RemediationLLWR Receives final Low Level Waste Receipts


Issue 1 August 2011<strong>Sellafield</strong> <strong>Plan</strong> 15Overview: Key plants and projectsThe chart below provides a very high level overview of <strong>the</strong><strong>Sellafield</strong> <strong>Plan</strong> in its entirety. Fur<strong>the</strong>r detail on this scope canbe found in <strong>the</strong> relevant section of this document.2070 2080 2090 2100 2110 2120KeyDecomm Directorate / LP&SLonger Term <strong>Building</strong> Decommissioning PhasesInterim ILW / Fuel StorageRepro / HA / SNM / Offsite Customer FuelPCM <strong>Plan</strong>ts & OpsCalder HallBEPPSCritical PathMilestonesFILWEPILW StoreBEPPS StoreDemolitionFHP Final DecommissioningHLW GDF AvailableVPS ExportsVPS2 DemolitionAGR Fuel Condition & ExportsThorp R&S POCO / Decommissioning / Demolition (& Condition <strong>Plan</strong>t)Customer Fuel ExportsConstruct Customer FuelConditioning <strong>Plan</strong>tPOCO / Decommissioning / DemolitionIn-grout CapabilityWTC3 – POCO / Decommissioning / DemolitionCalder Site CloseoutCalder Hall Final Decommissioning<strong>Sellafield</strong> Site CloseoutCritical SL Land & Groundwater Remediation


16 <strong>Sellafield</strong> <strong>Plan</strong>Issue 1 August 2011Overview: <strong>Sellafield</strong> <strong>Plan</strong> Summary Costs<strong>Sellafield</strong> <strong>Plan</strong>Summary Costs2011/12-2025/26CategoryInitial contract term2011/12 2012/13 2013/14Transition – – –New Construction Projects 554,879.1 601,369.4 655,001.6Commercial Operations 264,136.0 264,584.4 257,551.3Decommissioning & Termination 44,492.8 44,253.5 39,367.6Waste & Nuclear Materials Management 324,702.5 335,994.1 331,465.1Site Support and Services 455,185.7 440,638.2 413,824.3Total 1,643,395.9 1,686,839.5 1,697,209.9Escalated value 1,643,395.9 1,739,131.5 1,804,068.0Discounted value 1,643,395.9 1,650,527.9 1,624,926.7Revenue Income 13,742.9 13,635.0 13,748.4The four year spending settlement from Government implies an annual site funding for<strong>Sellafield</strong> <strong>Ltd</strong> around £1.5bn, as reflected in <strong>the</strong> illustrations above. The costs shown in <strong>the</strong>tables included in <strong>the</strong> separate sections of <strong>the</strong> plan are based on a set of assumptions on <strong>the</strong>level of efficiencies and acceleration for completing <strong>the</strong> overall work programme. Actual levelsof efficiencies achieved will determine how much work can be delivered within <strong>the</strong> spendingsettlement. For that reason costs shown in those separate sections are indicative and are notdirectly comparable with those shown above. Some sections do not contain detailed financialinformation, where commercial confidentiality prevents publication.


Issue 1 August 2011<strong>Sellafield</strong> <strong>Plan</strong> 17Overview: <strong>Sellafield</strong> <strong>Plan</strong> Summary CostsKey:TransitionNew Construction ProjectsCommercial OperationsDecommissioning & TerminationWaste & Nuclear MaterialsManagementSite Support and ServicesRevenue Income1,309,648.31,811,250.14,358,078.65,064,998.55,667,726.96,876,248.6992,161.61,732,019.13,917,681.64,909,843.2786,271.6128,113.81,060,434.0Costs 2011/12-2013/14 Costs 2014/15-2025/26 Costs 2011/12-2025/261,188,547.82,518,290.7CategoryTotal (£k)2011/12-2013/14Total (£k)2014/15-2025/26Total (£k)2011/12-2025/26Transition – – –New Construction Projects 1,811,250.1 5,064,998.5 6,876,248.6Commercial Operations 786,271.6 1,732,019.1 2,518,290.7Decommissioning & Termination 128,113.8 1,060,434.0 1,188,547.8Waste & Nuclear Materials Management 992,161.6 3,917,681.6 4,909,843.2Site Support and Services 1,309,648.3 4,358,078.6 5,667,726.9Total 5,027,445.4 16,133,211.8 21,160,657.2Escalated value 5,186,595.5 20,770,204.3 25,956,799.8Discounted value 4,918,850.5 13,564,331.4 18,483,182.0Revenue Income 41,126.2 154,589.5 195,715.8


18 <strong>Sellafield</strong> <strong>Plan</strong>Issue 1 August 2011Overview: GlossaryGlossaryAdvanced Gas-cooled ReactorAn Advanced Gas-cooled Reactor (AGR) is atype of nuclear reactor. These are <strong>the</strong> secondgeneration of British gas-cooled reactors,using graphite as <strong>the</strong> neutron moderator andcarbon dioxide as coolant.Analytical Services LabsProvides two main functions: Facilities forundertaking scientific research and facilities forundertaking analytical work.Box Encapsulation <strong>Plan</strong>tDesigned to sort and encapsulate in cementa wide range of solid radioactive intermediatelevel waste and export boxes of encapsulatedproduct to a purpose-built store for interimstorage pending <strong>the</strong> availability of a GeologicalDisposal Facility.Box Transfer FacilityWill provide export routes for waste retrievedfrom <strong>the</strong> Magnox Swarf Storage Silos andprocessed in <strong>the</strong> Silos Direct Encapsulation<strong>Plan</strong>t. Currently under construction.Calder HallThe world’s first commercial nuclear powerstation and part of <strong>the</strong> UK’s fleet of Magnoxnuclear power stations. Calder Hall ceasedoperations in March 2003.ClinoptiloliteA sand material which is used in <strong>the</strong> Site IonExchange <strong>Plan</strong>t.Comprehensive Import/Export Facilityand Box Encapsulation <strong>Plan</strong>t ProductStore 1Will incorporate <strong>the</strong> completion and expansionof a purpose-built above ground nuclear wastestore and an import/export facility to handle<strong>the</strong> waste. Currently under construction.DecommissioningWithdraw a facility from service and make itinoperative, dismantling and decontaminatingit ready for demolition.Engineered Drum StoresProvide modern fit-for-purpose storage forintermediate level waste.Engineered Product StoreIntermediate level waste store at <strong>Sellafield</strong>.Enhanced Actinide Removal <strong>Plan</strong>tSupports both Magnox and Thorpreprocessing and removes radioactivecomponents from waste liquid effluentstreams.Evaporator DThis new highly active evaporator iscurrently under construction and will supportreprocessing operations.First Generation Magnox Storage PondConstructed in <strong>the</strong> 1950s and 1960s, <strong>the</strong>facility was used to store, cool and prepareMagnox fuel for reprocessing.First Generation Reprocessing <strong>Plan</strong>tsConstructed during <strong>the</strong> late 1940s and early1950s, <strong>the</strong> facility carried out <strong>the</strong> first stageof reprocessing fuel from <strong>the</strong> Windscale Pilereactors.Floc Storage TanksA series of ten concrete storage tankswhich were built in <strong>the</strong> 1950s. They wereused to store liquid effluents produced fromreprocessing operations. Overlying liquid wasdischarged from <strong>the</strong> tanks leaving a sludgelike substance which is now being retrievedfor processing.Fuel Fabrication FacilitiesRedundant fuel fabrication facilities.Fuel Handling <strong>Plan</strong>tResponsible for receiving, storing andmechanically processing spent nuclear fuelfrom Magnox and Advanced Gas-cooledReactor stations from across <strong>the</strong> UK.Highly Active Liquor TankCommissioned to generate radio<strong>the</strong>rapysources for commercial and medical use.Highly Active LiquorHighly Active Liquor is classed as high levelwaste and is a by-product of reprocessingspent nuclear fuel. It contains 99% of <strong>the</strong>radioactivity from spent nuclear fuel.Highly Active Liquid Effluent Storage<strong>Plan</strong>tThe plant stores, concentrates and conditionsHighly Active Liquor (HAL) in evaporators forbuffer storage in Highly Active Storage Tanks(HAST).Highly Active EvaporatorsThe highly active evaporators at <strong>Sellafield</strong> playa pivotal role in <strong>the</strong> delivery of reprocessing,historic clean-up and hazard reductionmissions across <strong>the</strong> site. They reduce <strong>the</strong>volume of highly active liquors which are <strong>the</strong>nfed to <strong>the</strong> Vitrification <strong>Plan</strong>t.Inactive commissionWork done to prepare <strong>the</strong> facility foroperations before radioactive material isintroduced. Once radioactive material isintroduced to <strong>the</strong> facility a period of activecommissioning is undertaken before <strong>the</strong>facility goes into full operations.International Nuclear ServicesInternational Nuclear Services a wholly ownedsubsidiary of <strong>the</strong> NDA, is <strong>the</strong> commercialagency for spent fuel management services in<strong>the</strong> UK and is <strong>the</strong> world’s most experiencedglobal shipper of nuclear materials.Low Active Effluent Treatment TankSludge storage tanks which are being emptiedas part of <strong>the</strong> Floc Retrieval Project (see FlocStorage Tanks section of <strong>the</strong> plan).Low Level Waste RepositoryThe UK’s national low level waste repository issituated approximately seven miles south of<strong>the</strong> <strong>Sellafield</strong> site.Magnox Encapsulation <strong>Plan</strong>tDesigned to process solid intermediate levelwaste, packaging it into drums which aregrouted to create a waste which is suitablefor handling, transport, storing and eventualdisposal.Magnox Reprocessing <strong>Plan</strong>tMagnox reprocessing operations began in1964. The plant is used for <strong>the</strong> decanning,dissolution and retrieval of uranium andplutonium components of spent Magnox fuelfrom throughout <strong>the</strong> UK.Magnox Swarf Storage SilosConstructed in <strong>the</strong> 1960s and extendedduring <strong>the</strong> 1970s and 1980s, <strong>the</strong> facilitywas built to hold irradiated decanningwastes (Magnox swarf and miscellaneousintermediate level waste).


Issue 1 August 2011<strong>Sellafield</strong> <strong>Plan</strong> 19Overview: GlossaryMedium Active Liquor Tank FarmProvides buffer capacity for day-to-dayplant operations in both Thorp and Magnoxreprocessing plants, whilst also providing aninterim storage facility for solvent and aqueousliquors before <strong>the</strong>y are processed in <strong>the</strong>Enhanced Actinide Removal <strong>Plan</strong>t and <strong>the</strong>Solvent Treatment <strong>Plan</strong>t.Metal Decontamination FacilityUsed to mechanically remove <strong>the</strong> outersurface of contaminated steel to clean metalfor recycling.Miscellaneous Beta Gamma Waste StoreThe facility packs different types, sizes andshapes of waste materials and equipment,minimising <strong>the</strong> volume for storage. The wastepackages are <strong>the</strong>n placed into a temperatureand humidity-controlled store.Multi-element BottlesMulti-element bottles are used to store LightWater Reactor spent fuel assemblies in Thorpstorage ponds.North Group CompoundHistoric contaminated waste stores.Pile ChimneyOriginally <strong>the</strong>re were two pile chimneys builtbetween 1947 and 1950. The chimneys (orventilation shafts) discharged cooling air from<strong>the</strong> two Pile Reactors.Pile Fuel Cladding SiloBuilt in <strong>the</strong> 1950s, <strong>the</strong> building was <strong>the</strong> firststorage facility for intermediate level wasteto be constructed at <strong>Sellafield</strong>. It is one of<strong>Sellafield</strong>’s Legacy Pond and Silo facilities.Pile Fuel Cladding Silo Retrievals <strong>Building</strong>The building which will house <strong>the</strong> remoteequipment needed to empty <strong>the</strong> Pile FuelCladding Silo.Pile Fuel Storage PondConstructed between 1948 and 1952, <strong>the</strong>facility was used to store, cool and prepareWindscale Pile fuel for reprocessing.Plutonium Contaminated MaterialsTools and equipment that come into contactwith plutonium during operations. These itemsare treated as intermediate level waste.POCOThe actions taken by <strong>the</strong> plant operatorsat <strong>the</strong> end of <strong>the</strong> plant’s operational life toallow <strong>the</strong> structured and recorded removalof residual plant process inventory or storedwastes, utilising existing plant facilities andprocesses.Residue Export FacilityA key facility in <strong>the</strong> programme of returningvitrified waste to its country of origin.Salt Evaporator <strong>Plan</strong>tSupports <strong>the</strong> operation of <strong>the</strong> Thorpand Magnox reprocessing operations. Itevaporates high ‘salt’ liquors that wouldo<strong>the</strong>rwise limit <strong>the</strong> evaporation factorsachieved in o<strong>the</strong>r on-site evaporators.<strong>Sellafield</strong> MOX <strong>Plan</strong>tManufactures mixed oxide fuel.Segregated Effluent Treatment <strong>Plan</strong>tReceives, neutralises and buffer-stores lowactive effluents to facilitate sampling andanalysis prior to discharge.Separation AreaThe Separation Area at <strong>Sellafield</strong> is hometo some of <strong>the</strong> oldest buildings on <strong>the</strong> site,including <strong>the</strong> Legacy Pond and Silo facilities.Separation Area LagoonThis lagoon provides a collection anddischarge facility for surface water drainageand pumped groundwater from <strong>the</strong>Separation Area.Separation Area Ventilation <strong>Plan</strong>tComprises a new ventilation plant room and<strong>the</strong> equipment needed to carry ventilationductwork from <strong>the</strong> existing donor plantsthrough to <strong>the</strong> monitoring plant room and upto <strong>the</strong> new discharge stack. Currently underconstruction.SEP Product Finishing and StorageFacilityProvides interim storage capacity forplutonium products from MagnoxReprocessing.SEP Purification <strong>Plan</strong>tConstructed to purify plutonium nitrate fromfission products.Silos Direct Encapsulation <strong>Plan</strong>tWill be used to immobilise waste exportedfrom <strong>the</strong> Magnox Swarf Storage Silos.Site Ion Exchange <strong>Plan</strong>tUsed to treat pond storage water fromacross <strong>the</strong> <strong>Sellafield</strong> site by removing<strong>the</strong> radio nuclides before <strong>the</strong> effluent isdischarged to sea, within <strong>the</strong> appropriatedischarge limits set by our regulators.Sludge Packaging <strong>Plan</strong>t 1Will hydraulically receive sludge from <strong>the</strong> FistGeneration Magnox Storage Pond. Currentlyunder construction.Solid Waste Storage CellsUsed as a store for Medium Beta GammaWaste arising from Magnox reprocessing.Solvent Treatment <strong>Plan</strong>tUsed for <strong>the</strong> treatment of waste solvent fromThorp, Magnox and historic solvent in storage.It is <strong>the</strong> only UK facility which can processradioactive solvent.ThorpThe Thermal Oxide Reprocessing <strong>Plan</strong>t(Thorp) combines all of <strong>the</strong> facilities needed toreprocess spent oxide fuel under one roof. Itreprocesses both UK and foreign spent fuel.VitrificationInvolves drying high level liquid waste to apowder, mixing it with glass and heating it to atemperature of around 1,200 degrees Celsius.Molten mixture is poured into stainless steelcontainers and allowed to solidify. The processreduces <strong>the</strong> liquid waste volume to about athird of its original liquid size.Vitrified Product StoreOnce high level waste has been vitrified <strong>the</strong>full stainless steel containers are stored in <strong>the</strong>Vitrified Product Store.Waste – low level wasteMakes up <strong>the</strong> largest physical volumeof radioactive waste and is only slightlyradioactive. Includes things like protectiveclothing, paper towels, gloves and buildingfabric.


20 <strong>Sellafield</strong> <strong>Plan</strong>Issue 1 August 2011Overview: GlossaryGlossary cont.Waste – intermediate level wasteIncludes materials such as fuel elementcladding, contaminated equipment, radioactivesludge and plutonium contaminated material(PCM) that arises from both historic and currentoperations. The waste is put into stainlesssteel drums, which are <strong>the</strong>n filled withcement grouting before being placed into aspecial above-ground storage facility.Waste – high level wasteHigh level waste is produced when spent fuelhas been reprocessed through <strong>the</strong> Magnoxand Thorp facilities. At <strong>Sellafield</strong>, this waste istreated through a process called vitrification.This involves converting <strong>the</strong> high-level liquidwaste into a solid form, reducing <strong>the</strong> volumeof <strong>the</strong> liquid waste to one third of its originalsize. Vitrifying <strong>the</strong> waste enables <strong>the</strong> materialto be stored safely and in preparation foreventual transport and disposal.Waste Monitoring and Compaction <strong>Plan</strong>tLow level waste is monitored and compactedin this facility. The compaction processreduces <strong>the</strong> low level waste to a quarter of itsoriginal size before it is exported to <strong>the</strong> LowLevel Waste Repository.Waste Packaging and Encapsulation<strong>Plan</strong>tTreats waste which arises from <strong>the</strong> Low ActiveEffluent Treatment facilities (including <strong>the</strong>Enhanced Actinide Removal <strong>Plan</strong>t).Waste Treatment ComplexProvides for <strong>the</strong> supercompaction of plutoniumcontaminated material in 200 litre drums.Waste Treatment FacilityWill condition intermediate level waste intoa format for long term storage and eventualdisposal when a Geological DisposalFacility becomes available. Currently underconstruction.Wet Inlet FacilitySafely manages used nuclear fuel on behalf ofcustomers.WindscaleWindscale was historically a separate licensedsite located on <strong>the</strong> <strong>Sellafield</strong> site. On 1 April2008 <strong>the</strong> site licence for Windscale wastransferred to <strong>Sellafield</strong> <strong>Ltd</strong>, integrating <strong>the</strong>two sites. Windscale is home to <strong>the</strong> iconicWindscale Advanced Gas-cooled Reactor.


<strong>Sellafield</strong> <strong>Plan</strong>Risk & Hazard Reduction<strong>Sellafield</strong>’s Top PriorityThe Nuclear Decommissioning Authority’s Strategy, approved by <strong>the</strong> Secretary ofState for Energy and Scottish Ministers in March 2011 has at its heart <strong>the</strong> priorityof reducing risk and hazard and to deliver <strong>the</strong> clean-up mission cost-effectively.This is particularly relevant at <strong>Sellafield</strong>where <strong>the</strong> Legacy Ponds and Silos pose<strong>the</strong> most significant challenges, and whereit is essential that tangible, demonstrableprogress is made.The Legacy Ponds and Silos comprise offour main plants on <strong>the</strong> site which were usedhistorically to prepare fuel for reprocessing orstore waste.They are: Radioactive materials have accumulated and decades plant conditions have deterioratedand <strong>the</strong>re is now an increased urgency toreduce <strong>the</strong> risk <strong>the</strong>y pose. The facilities werenot designed with decommissioning in mindso innovative technology is being used toretrieve <strong>the</strong> radioactive material for storagein modern containment facilities, ahead ofits subsequent treatment, packaging andstorage.Aerial view of Pile Fuel Storage PondElevated view of First Generation MagnoxStorage PondThe importance placed onmaking real progress in thisarea has driven <strong>the</strong> increaseof resources <strong>the</strong> Governmentand NDA have made availableat <strong>Sellafield</strong>, as referred to in<strong>the</strong> Overview section of thisdocument.The work programmes to deliver risk andhazard reduction in <strong>the</strong> Legacy Ponds andSilos are detailed in this section of <strong>the</strong> planand are a national priority.External view of Magnox Swarf Storage SiloExternal view of Pile Fuel Cladding Silo


<strong>Sellafield</strong> <strong>Plan</strong> – Issue 1 August 2011Risk & Hazard ReductionFloc StorageTanks <strong>the</strong> 1950s


2<strong>Sellafield</strong> <strong>Plan</strong>Issue 1 August 2011 Floc Storage Tanks The Floc Storage Tanks at <strong>Sellafield</strong> area series of ten concrete tanks built in <strong>the</strong>1950s. Liquid effluents produced as aresult of reprocessing operations werehistorically held in <strong>the</strong>se large concretetanks.Although <strong>the</strong> overlying layer of liquid wasdischarged to <strong>the</strong> sea as liquid waste,<strong>the</strong> remaining floc stayed in <strong>the</strong> tanks.More than 99% of <strong>the</strong> radioactivity wascontained in this floc – which remainedin <strong>the</strong> tanks. The tanks operated until <strong>the</strong>mid-1990s when <strong>the</strong> Low Active EffluentTreatment plants came on stream.The tanks are now over fifty years oldand are unsuitable for indefinite storageof <strong>the</strong> waste.Arrangements have been made to treatthis intermediate level radioactive wasteand encapsulate it in cement. In order todo this <strong>the</strong> sludges from <strong>the</strong> tanks mustfirst be resuspended with water and <strong>the</strong>ntransferred into a buffer store from which<strong>the</strong>y will be fed into <strong>the</strong> Low ActiveEffluent Treatment plants for processingand encapsulation.Although emptying a tank takes a matterof weeks, processing <strong>the</strong> material fromeach tank will take approximately twoyears.Once treated in <strong>the</strong> Enhanced ActinideRemoval <strong>Plan</strong>t at <strong>Sellafield</strong>, <strong>the</strong> materialwill be fur<strong>the</strong>r processed through an ultrafiltration system, before being sent to<strong>the</strong> Waste Packaging and Encapsulation<strong>Plan</strong>t as intermediate level waste forstorage.Floc is contained within a series of storagetanks at <strong>Sellafield</strong> which are now over fiftyyears oldA project was completed in <strong>the</strong> 1990s toinstall an overbuilding above <strong>the</strong> storagetanks and to refurbish <strong>the</strong> tanks <strong>the</strong>mselves


Issue 1 August 2011<strong>Sellafield</strong> <strong>Plan</strong> 3 Floc Storage Tanks The floc is being treated as intermediatelevel waste and encapsulated into steeldrums for long term storageThe forward programme for <strong>the</strong>clean-up and decommissioning of <strong>the</strong>Floc Storage tanks is to:


4<strong>Sellafield</strong> <strong>Plan</strong>Issue 1 August 2011 Floc Storage TanksThe <strong>Plan</strong>Floc Storage Floc Retrieval OperationsSludge Storage Tanks POCOSludge Storage Tanks DecommissioningSludge Storage Tanks ID2 –Local Encapsulation <strong>Plan</strong>t ConstructionTechnical & Development work commencesCapital Project CommencesThe Floc Storage Tanks programmeretrieves floc created from <strong>the</strong> firstGeneration Reprocessing programmeand stored in <strong>the</strong> floc tanks to a buffertank. This floc is immobilised and sent tointermediate level waste storage.The programme to complete <strong>the</strong> retrievalof <strong>the</strong> floc material is scheduled forcompletion during <strong>the</strong> 2020/21 financialyear. Following a Post Operational CleanOut (POCO) phase, <strong>the</strong> sludge storagetanks will begin <strong>the</strong>ir decommissioningprogramme in 2022/23. This programmewill include <strong>the</strong> retrieval of <strong>the</strong> heels andclinker.In parallel, a programme to design andconstruct a local encapsulation plantis being undertaken with constructionscheduled for completion during <strong>the</strong>2024/25 financial year.In 1998 a containment building was constructedand slid into position over <strong>the</strong> storage tanksSuccessful transfers of <strong>the</strong> floc material to <strong>the</strong>Enhanced Actinide Removal <strong>Plan</strong>t have alreadytaken place


Issue 1 August 2011<strong>Sellafield</strong> <strong>Plan</strong> 5 Floc Storage Tanks Volume Reduction from Storage Tanks – Operations CompletePOCO CompleteConstruction Completed 3,206.4 4,448.2 3,393.7 11,048.2 58,998.6 70,046.8For more information please see pages 16 and 17 of <strong>the</strong> overview section


<strong>Sellafield</strong> <strong>Plan</strong>Issue 1 August 2011 Floc Storage Tanks The Enhanced Actinide Removal <strong>Plan</strong>tsupports both Magnox and Thorpreprocessing operations as well asprocessing material that has beenretrieved from <strong>the</strong> floc storage tanks, and<strong>the</strong> historic backlog and future arisings ofmedium active liquor at <strong>Sellafield</strong>. The Waste Packaging and Encapsulation<strong>Plan</strong>t at <strong>Sellafield</strong> is a facility for <strong>the</strong>treatment of wastes arising from <strong>the</strong>Low Active Effluent Treatment facilities(including <strong>the</strong> Enhanced ActinideRemoval <strong>Plan</strong>t).It provides <strong>the</strong> means for <strong>the</strong> removalof radioactive components from wasteliquid effluent streams.The Enhanced Actinide Removal <strong>Plan</strong>t(above) is a key enabler to this programmeas it processes <strong>the</strong> retrieved flocThe Waste Packaging and Encapsulationplant – encapsulation lineProgramme ScopeFloc StorageTanksResuspension,Mobilise FlocTransfer Floc fromHolding Tank toBuffer TankRetrieve Floc fromBuffer & VolumeReductionFlocDecommissioningActivities includingConstruction of LocalEncapsulation <strong>Plan</strong>tILW StorageSolid LLWMisc.BetaGammaWasteEnhanced ActinideRemoval <strong>Plan</strong>tLow Active EffluentAerialSegregated EffluentTreatment <strong>Plan</strong>tLLW ManagementMiscellaneous BetaGamma Waste StoreStacks


<strong>Sellafield</strong> <strong>Plan</strong> – Issue 1 August 2011Risk & Hazard ReductionFirst GenerationReprocessing <strong>Plan</strong>ts


2<strong>Sellafield</strong> <strong>Plan</strong>Issue 1 August 2011 First Generation Reprocessing <strong>Plan</strong>tsOverview LegacyThe First Generation Reprocessing<strong>Plan</strong>ts were constructed in <strong>the</strong> early1950s to carry out <strong>the</strong> first stage ofreprocessing fuel from <strong>the</strong> WindscalePile Reactors. It was later modified foroxide fuels following <strong>the</strong> opening of <strong>the</strong>Magnox Reprocessing <strong>Plan</strong>t, beforeceasing operations in <strong>the</strong> 1970s.The plant was used to reprocess earlyreactor fuel before being converted to ahead-end treatment plant where fuel wassheared.The plant contains four highly activecells, each containing redundantradioactive material and two mediumactive cells. The Highly Active NorthOuter cell was also used as a shieldedventilation route from 1966 to 1988.The building also has a 61m stackwhich is housed on <strong>the</strong> building roof.The primary decommissioning challengeassociated with <strong>the</strong> First GenerationReprocessing <strong>Plan</strong>ts is <strong>the</strong> safe removalof this stack.The location of <strong>the</strong> stack on <strong>the</strong> roof of<strong>the</strong> building presents a unique demolitionchallenge.Physical demolition of <strong>the</strong> plantcan not be completed until a newventilation plant – <strong>the</strong> Separation AreaVentilation <strong>Plan</strong>t – is constructed andcommissioned.The First Generation Reprocessing<strong>Plan</strong>ts programme of work also includes<strong>the</strong> decommissioning of <strong>the</strong> ThorpMiniature Pilot <strong>Plan</strong>t.Historic image of <strong>the</strong> First GenerationReprocessing <strong>Plan</strong>tsA laser image of <strong>the</strong> inside of <strong>the</strong> FirstGeneration Reprocessing <strong>Plan</strong>ts


Issue 1 August 2011<strong>Sellafield</strong> <strong>Plan</strong> 3 First Generation Reprocessing <strong>Plan</strong>ts The construction of <strong>the</strong> new SeparationArea Ventilation <strong>Plan</strong>t is a key step in <strong>the</strong>programme. The construction of <strong>the</strong> stack isalready completeThe forward programme for <strong>the</strong>First Generation Reprocessing<strong>Plan</strong>ts is to: project Historic aerial view of <strong>Sellafield</strong> with <strong>the</strong>First Generation Reprocessing <strong>Plan</strong>ts in <strong>the</strong>foreground


<strong>Sellafield</strong> <strong>Plan</strong>Issue 1 August 2011 First Generation Reprocessing <strong>Plan</strong>ts First GenerationReprocessing <strong>Plan</strong>ts New Build Separation Area Ventilation SAV Available to StartFull OperationsSeparation Area Ventilation Operationsand MaintenanceSEP Head End <strong>Plan</strong>t – West End StaircaseRefurb & Stabilise HANO CellWest StaircaseRefurbishment CompleteSep Head End Stack DecommissioningStackDemolishedThorp Mini Pilot <strong>Plan</strong>t DecommissioningVent DisconnectThe First Generation Reprocessing<strong>Plan</strong>ts programme scope is <strong>the</strong>decommissioning of <strong>the</strong> PrimarySeparation Head End <strong>Plan</strong>t, <strong>the</strong> ThorpMiniature Pilot <strong>Plan</strong>t housed in legacybuildings and <strong>the</strong>ir associated secondarybuildings.The construction and subsequentoperation of <strong>the</strong> Separation AreaVentilation <strong>Plan</strong>t along with removal of<strong>the</strong> separation area ductwork maderedundant by <strong>the</strong> Separation AreaVentilation project are also covered inthis programme.The short term priority is <strong>the</strong> demolitionof <strong>the</strong> Separation Head End <strong>Plan</strong>t Stackwhich cannot be completed until <strong>the</strong>new Separation Area Ventilation <strong>Plan</strong>t isconstructed and commissioned with allassociated pipework in place.The Separation Area Ventilation Stackwill be available to start full operationsin 2014.The Separation Area Ventilation project isa key deliverable in this work programmeThe decommissioning of <strong>the</strong> FirstGeneration Reprocessing <strong>Plan</strong>ts isalready under way


Issue 1 August 2011<strong>Sellafield</strong> <strong>Plan</strong> First Generation Reprocessing <strong>Plan</strong>ts 41,344.0 22,966.2 10,476.2 74,786.4 82,458.9 157,245.3For more information please see pages 16 and 17 of <strong>the</strong> overview section


<strong>Sellafield</strong> <strong>Plan</strong>Issue 1 August 2011 First Generation Reprocessing <strong>Plan</strong>ts The Separation Area Ventilation project– a major design and build – comprisesa new two-storey ventilation plant roomhousing <strong>the</strong> ventilation equipment, aventilation discharge monitoring plantroom and a series of new steel supportstructures.These carry ventilation ductwork fromexisting donor plants through to <strong>the</strong>monitoring plant room and up to <strong>the</strong> newdischarge stack. Thorp Miniature Pilot <strong>Plan</strong>t’s ventilationdischarge is to be disconnected fromPrimary Separation <strong>Plan</strong>t ventilationstack, as an enabler to <strong>the</strong> stackdemolition. This work will also allow <strong>the</strong>ventilation duct and supporting bridgebetween Thorp Miniature Pilot <strong>Plan</strong>tand <strong>the</strong> Primary Separation <strong>Plan</strong>t to beremoved, thus avoiding <strong>the</strong> costs offur<strong>the</strong>r repair and maintenance of <strong>the</strong>corroding structure.First Generation Reprocessing The SEP Head End <strong>Plan</strong>t external weststaircase is being subject to extensiverenovation in order to ensure that <strong>the</strong>building meets statutory fire escaperegulations to allow decommissioningwork to continue unhindered throughout<strong>the</strong> facility. The 6th to 10th floors willbe enclosed with cladding to allow<strong>the</strong> refurbished staircase to meet <strong>the</strong>requirements of decommissioning whichis scheduled to run until 2077.The Separation Area Ventilation projectdischarge stack has been constructed on<strong>the</strong> <strong>Sellafield</strong> siteFirst GenerationReprocessing <strong>Plan</strong>tsDemolition of <strong>the</strong> stackEnablersSeparation AreaVentilation (SAV)ProjectThorp Miniature Pilot<strong>Plan</strong>t Pipebridge andvent disconnectionGeneral Operations, Maintenanceand Asset Care of SEPHead End <strong>Plan</strong>t & <strong>the</strong> ThorpMiniature Pilot <strong>Plan</strong>t to maintainlegality/asset integrityFirst GenerationReprocessing <strong>Plan</strong>t Weststaircase project toallow decommissioningactivities to continue safely


<strong>Sellafield</strong> <strong>Plan</strong> – Issue 1 August 2011Risk & Hazard ReductionPile Fuel StoragePond


<strong>Sellafield</strong> <strong>Plan</strong>Issue 1 August 2011 Pile Fuel Storage PondThe Pile Fuel Storage Pond at The construction of <strong>the</strong> First GenerationMagnox Fuel Storage Pond at <strong>Sellafield</strong>started in 1948 and <strong>the</strong> facilitywas commissioned in 1952. It wasconstructed to receive, cool and decanfuel from <strong>the</strong> Windscale Piles, prior toreprocessing.The facility was modified in <strong>the</strong> mid-1950sto allow <strong>the</strong> receipt of spent Magnox fuelfrom <strong>the</strong> Calder Hall reactors.The pond and adjoining decanningbuilding provided <strong>the</strong> storage and coolingfacility for used fuel and isotopes from <strong>the</strong>two Windscale reactors.The pond is a sub-divided outdoorstorage pond containing skips ofirradiated fuel. The building contains aseries of sub-ponds, o<strong>the</strong>rwise knownas bays, connected underwater to <strong>the</strong>main pond.Following <strong>the</strong> closure of <strong>the</strong> WindscalePile reactors and <strong>the</strong> commissioning of<strong>the</strong> First Generation Magnox Fuel StoragePond, plant operations were scaleddown, although <strong>the</strong> facility was still usedas a cooling and decanning facility forsome materials.When decanning in <strong>the</strong> plant stopped in1962 <strong>the</strong> pond continued to be used asstorage for fuel, contaminated items, andoperational waste.During its working life <strong>the</strong> pond processed2,100te of pile fuel and 300te of Magnoxfuel. All operations in <strong>the</strong> pond ceased in<strong>the</strong> 1970s.The Pile Fuel Storage Pond combinesused nuclear fuel, sludge, intermediatelevel waste and pond water, each ofwhich needs to be safely removed andprocessed through separate routes.Historic view of <strong>the</strong> Pile Fuel StoragePond at <strong>Sellafield</strong>Historic aerial view of <strong>the</strong> Pile FuelStorage PondThe Pile Fuel Storage Pond in operation


Issue 1 August 2011<strong>Sellafield</strong> <strong>Plan</strong> 3 Pile Fuel Storage PondSolution The ultimate aim for <strong>the</strong> programme is toempty <strong>the</strong> Pile Fuel Storage PondIn order to safely empty anddecommission <strong>the</strong> Pile Fuel StoragePond <strong>the</strong> solution is to:


<strong>Sellafield</strong> <strong>Plan</strong>Issue 1 August 2011 Pile Fuel Storage PondThe <strong>Plan</strong>Pile Fuel Storage Storage Pond No 1 LSTP Storage LSTP Sludge BufferProject CompleteStorage Pond No 1 LSTP ExportStorage Pond No 1 Operations and MaintenanceBulk Desludging CompleteThe Pile Fuel Storage Pond programmescope is to progressively remove <strong>the</strong>radiological inventory, reducing <strong>the</strong> riskand hazard posed by <strong>the</strong> storage ofwastes within <strong>the</strong> legacy facility.The sludge is currently being transferredinto an in-pond Sludge Corral, where itwill be stored pending treatment through<strong>the</strong> Local Sludge Treatment <strong>Plan</strong>t.The first major milestone will be tocomplete <strong>the</strong> Local Sludge Treatment<strong>Plan</strong>t Sludge Buffer project whichinvolves <strong>the</strong> transfer of sludge from <strong>the</strong>in-pond corral to <strong>the</strong> Local SludgeStorage Tanks.Bulk desludging will be completedduring <strong>the</strong> 2015/16 financial year and<strong>the</strong> completion of <strong>the</strong> Local SludgeTreatment <strong>Plan</strong>t Export Project isplanned for <strong>the</strong> 2017/18 financial year.The final phase of <strong>the</strong> programme willsee <strong>the</strong> dewatering and dismantling of<strong>the</strong> remaining structure to base slab.A Local Effluent Treatment <strong>Plan</strong>t has beeninstalled to control <strong>the</strong> activity of <strong>the</strong> pond liquorusing an ion exchange processIn-pond sludge corral installed to provideinterim storage for sludge prior to finaltreatment24 fuel skips have already been retrieved from<strong>the</strong> pond, creating more room for desludgingoperations


Issue 1 August 2011<strong>Sellafield</strong> <strong>Plan</strong> Pile Fuel Storage Pond LSTP Export Project CompleteMetal Fuel Export Complete 23,573.9 38,110.5 38,102.5 99,786.9 228,918.0 328,704.9For more information please see pages 16 and 17 of <strong>the</strong> overview sectionA sludge retrieval hood has been installed into<strong>the</strong> pond. Toge<strong>the</strong>r with o<strong>the</strong>r equipment <strong>the</strong>hood will help with sludge retrieval operationsA skip tip and wash mechanism has beeninstalled in <strong>the</strong> building to assist with <strong>the</strong>recovery of in-pond skips


<strong>Sellafield</strong> <strong>Plan</strong>Issue 1 August 2011 Pile Fuel Storage Pond The Local Sludge Treatment <strong>Plan</strong>t(LSTP) project will provide <strong>the</strong> plant andequipment for <strong>the</strong> safe interim storageof <strong>the</strong> radioactive sludge once retrievedfrom <strong>the</strong> Pile Fuel Storage Pond. Theproject involves <strong>the</strong> construction of anew plant located to <strong>the</strong> north side of<strong>the</strong> existing pond.The facility has been designed to provide<strong>the</strong> equipment to receive <strong>the</strong> sludgefrom an in-pond corral <strong>the</strong>n thicken andstore <strong>the</strong> sludge in buffer storage tanks.The project also includes provision of<strong>the</strong> services, sentencing and samplingequipment required to export <strong>the</strong> sludgeto a future treatment process. The BEPPS1 and CIEF project willincorporate <strong>the</strong> completion andexpansion of a purpose built aboveground nuclear waste store and <strong>the</strong>construction of a new import/exportfacility to handle radioactive waste,arising from <strong>the</strong> ongoing nucleardecommissioning and high hazardreduction operations at <strong>Sellafield</strong>.A Local Sludge Treatment <strong>Plan</strong>t has beenconstructed near to <strong>the</strong> Pile Fuel Storage PondThe Local Sludge Treatment <strong>Plan</strong>t (seenbehind <strong>the</strong> pond) will receive sludge whichhas been retrieved from <strong>the</strong> pondLocal Sludge Treatment <strong>Plan</strong>tPile FuelStorage PondSludge & SolidsPhase 1 bufferstorage of sludgePhase 2 treat sludgefor long term storageLow ActiveAqueous WasteEffluentManagementRemainingSolidsMetal fuelConditionedMetal fuelCanned fuelElementExamination CavesMetal fuelFuel Handling<strong>Plan</strong>tCarbide andOxide FuelOxide FuelStorage PondOn site storage oftreated sludgeKeyPile Fuel Storage Pond ProgrammeTreatment in BoxEncapsulation <strong>Plan</strong>tOn site storage oftreated solids/fuelO<strong>the</strong>r Programmes


<strong>Sellafield</strong> <strong>Plan</strong> – Issue 1 August 2011Risk & Hazard ReductionFirst GenerationMagnox Storage Pond


2 <strong>Sellafield</strong> <strong>Plan</strong>Issue 1 August 2011 First Generation Magnox Storage Pond The Magnox Storage and DecanningFacility was constructed during <strong>the</strong>1950s and 1960s as part of <strong>the</strong> UK’sexpanding nuclear programme. Its rolewas to receive and store irradiated fuelfrom Magnox reactors, and to remove<strong>the</strong> fuel cladding prior to <strong>the</strong> fuel beingprocessed.In 1974, a long reprocessing shutdownat <strong>Sellafield</strong> caused fuel to be storedunderwater in <strong>the</strong> storage pond for longerperiods than normal. This resulted in <strong>the</strong>Magnox fuel corroding in <strong>the</strong> pond, whichin turn gave rise to increased radiationlevels and poor underwater viewing.This slowed <strong>the</strong> rate of decanning leadingto increased residence times and fur<strong>the</strong>rfuel corrosion. The plant continuedto operate until its replacement, <strong>the</strong>Fuel Handling <strong>Plan</strong>t at <strong>Sellafield</strong>, wascommissioned in 1986. The final fuel wasreceived into <strong>the</strong> First Generation MagnoxStorage Pond in 1992.The First Generation Magnox StoragePond was constructed as an open-airpond. Over <strong>the</strong> years <strong>the</strong> pond hasaccumulated significant quantities ofwaste materials, sludges from corrosionof fuel cladding, fuel fragments and o<strong>the</strong>rdebris which has blown into <strong>the</strong> pond,and skips of fuel.The First Generation Magnox StoragePond combines used nuclear fuel,sludge, intermediate level waste andpond water, each of which needs to besafely removed and processed throughseparate routes.Historical aerial view of <strong>the</strong> First GenerationMagnox Storage Pond during constructionHistorical internal view of <strong>the</strong> FirstGeneration Magnox Storage Pond beforeoperationsHistorical aerial view of <strong>the</strong> First GenerationMagnox Storage Pond


Issue 1 August 2011<strong>Sellafield</strong> <strong>Plan</strong> 3 First Generation Magnox Storage Pond Sludge will be removed from <strong>the</strong> pond andtransferred to new facilities at <strong>Sellafield</strong>In order to safely empty anddecommission <strong>the</strong> First GenerationMagnox Storage Pond <strong>the</strong>solution is to:


4<strong>Sellafield</strong> <strong>Plan</strong>Issue 1 August 2011 First Generation Magnox Storage Pond First GenerationMagnox Storage New Build Export/Inlet <strong>Building</strong> (Combined)Sludge Retrievals Project: SEP Storage Pond 2& Decanner LP&SERPReady to Pump SludgeMajor Asset Care: SEP Storage Pond 2 &Decanner– Sludge Packing <strong>Plan</strong>t 1 BufferReady forActive Tie InsRetrievals Operations & MaintenanceThe First Generation MagnoxStorage Pond programme scope isto progressively retrieve and treat <strong>the</strong>radiological inventory residing within <strong>the</strong>facility, reducing initially <strong>the</strong> risk posed byits ongoing storage and <strong>the</strong>n reducing<strong>the</strong> inherent hazard of <strong>the</strong> materials.A new facility – <strong>the</strong> Sludge Packaging<strong>Plan</strong>t 1 – is currently under constructionand will temporarily store <strong>the</strong> sludgeretrieved from <strong>the</strong> pond. Active tie-ins to<strong>the</strong> Sludge Packaging <strong>Plan</strong>t are expectedto begin during <strong>the</strong> 2013/14 financial year.Operations and maintenance work willcontinue throughout this period.The plants will be ready to retrievesludge during 2014/15.The export of fuel and skips is scheduledto begin during <strong>the</strong> 2015/16 financialyear with bulk desludging complete(2018/19).Completion of retrieval operationswill <strong>the</strong>n enable <strong>the</strong> dewatering andsubsequent dismantling of <strong>the</strong> remainingstructure to its base slab.The First Generation Magnox Storage PondGantry Refurbishment System has successfullycompleted a key risk reduction enabler forrecovery of <strong>the</strong> pond inventoryWe have completed a project to install <strong>the</strong> firstof a series of hammock restraints which willsupport and capture <strong>the</strong> High Level ServiceLines pipework in <strong>the</strong> event of a failureA new pond purge unit will treat <strong>the</strong> radioactivityin <strong>the</strong> pond water and is expected to reduceradioactive dose rates for people workingaround <strong>the</strong> pond, reduce aerial discharges andreduce operator doses during fuel retrievals


Issue 1 August 2011<strong>Sellafield</strong> <strong>Plan</strong> First Generation Magnox Storage Pond The Skip Handler steelwork, which supports<strong>the</strong> return to work of <strong>the</strong> Skip HandlingMachine within <strong>the</strong> First Generation MagnoxStorage Pond, has been extensively refurbishedbringing it back into service for use inremoving hazardous bulk sludge and solidwaste inventory from <strong>the</strong> pond. Ready to ExportFuel & SkipsPond Desludging CompleteBays Desludging Complete Financial information withheld due to commercial confidentialityFor more information please see pages 16 and 17 of <strong>the</strong> overview sectionRedundant pipework which used to link <strong>the</strong>bays within <strong>the</strong> pond are being isolated anddecommissioned. A new emergency pumpingsystem has already been successfully installed


<strong>Sellafield</strong> <strong>Plan</strong>Issue 1 August 2011 First Generation Magnox Storage Pond The Sludge Packaging <strong>Plan</strong>t 1 (SPP1) isbeing built to hydraulically receive over1,350m 3 – that’s equivalent to a halffull Olympic sized swimming pool – ofsludge from <strong>the</strong> First Generation MagnoxStorage Pond.The plant is a key risk reduction projectfor <strong>the</strong> First Generation Magnox StoragePond. It comprises three stainless steelbuffer storage vessels to contain <strong>the</strong>sludge, to allow it to decant and settle.The Sludge Packaging <strong>Plan</strong>t 1, which willreceive sludge from <strong>the</strong> First GenerationMagnox Storage Pond is being constructed andcommissionedSite clearance for <strong>the</strong> plant began inNovember 2005 and required <strong>the</strong> removalof a number of redundant facilities. In2007 a perimeter fence was erectedaround <strong>the</strong> site to move it out of <strong>the</strong>Separation Area and improve accessibilityfor construction. In 2008 <strong>the</strong> first concretepour took place and <strong>the</strong> main civil buildhas now been completed.First Generation MagnoxStorage PondSludge Packaging <strong>Plan</strong>t 1RedundantSettling TankSludgeBuffer Storageof SludgeProcessing andExport of SludgeAqueouswasteEffluentDistribution<strong>Plan</strong>tSIXEPKeyIn ProgrammeLaterretrievalof pondsolids ando<strong>the</strong>r fuelEarly retrieval of fueland isotopesStorage in FuelHandling <strong>Plan</strong>t (FHP)Treatment in BoxEncapsulation <strong>Plan</strong>tILWILWTreatment ofILW SolidsWasteEncapsulation<strong>Plan</strong>tMiscellaneousBeta GammaWaste StoreTreatedsludgeOn Site Storage ofTreated SludgeOn Site Storage ofTreated Solids/FuelSIXEPSludgeEffluentDistribution<strong>Plan</strong>tOutside ProgrammeFirst Generation Magnox Storage Pond


<strong>Sellafield</strong> <strong>Plan</strong> – Issue 1 August 2011Risk & Hazard ReductionMagnox SwarfStorage Silos


<strong>Sellafield</strong> <strong>Plan</strong>Issue 1 August 2011 Magnox Swarf Storage Silos The Magnox type nuclear reactorwas <strong>the</strong> first type to generate nuclearelectricity in <strong>the</strong> UK. Including CalderHall at <strong>Sellafield</strong> a total of eleven Magnoxpower stations were commissionedduring <strong>the</strong> 1950s, 60s and early 70s.In support of <strong>the</strong> growing contributionof electricity generated by <strong>the</strong> Magnoxpower stations, <strong>the</strong> Magnox SwarfStorage Silos Facility was built at<strong>Sellafield</strong> to accommodate <strong>the</strong> swarfwaste produced by <strong>the</strong> Magnox fueldecanning operations. The claddingswarf was removed from <strong>the</strong> fuel prior toreprocessing.The facility became operational in 1964for <strong>the</strong> underwater storage of swarfwaste.Following its inception in 1964 with sixwet silos, <strong>the</strong> facility was extended onthree fur<strong>the</strong>r occasions to cater for <strong>the</strong>increased storage demands; by 1983,a complement of 22 silos had beenestablished.By <strong>the</strong> early 1990s, technologicaldevelopments meant that ‘wet storage’of Magnox swarf was no longer seen as<strong>the</strong> best solution. Dry waste, immobilisedin discrete containers offered positiveadvantages: it becomes more passiveand much more practical to manage.Therefore <strong>the</strong> Magnox Encapsulation<strong>Plan</strong>t was constructed at <strong>Sellafield</strong> toreceive dry Magnox swarf, encapsulateit in cement and seal it in stainless steeldrums.The Magnox Swarf Storage Silosreceived Magnox fuel cladding from <strong>the</strong>First Generation Magnox Storage Pondand <strong>the</strong> Fuel Handling <strong>Plan</strong>t along with arange of o<strong>the</strong>r items of intermediate levelwaste. The swarf was transported inpurpose built flasks and tipped into <strong>the</strong>silo compartments.In 1992, swarf received from <strong>the</strong> FuelHandling <strong>Plan</strong>t was routed to <strong>the</strong>Magnox Encapsulation <strong>Plan</strong>t. Variousfacilities continued to use <strong>the</strong> MagnoxSwarf Storage Silos to aid <strong>the</strong>ir ownPost Operational Clean Out (POCO).The final receipts were tipped into <strong>the</strong>compartments in June 2000.The Magnox swarf, which is almost100% magnesium, is stored underwater.The swarf <strong>the</strong>n undergoes a processwhich results in <strong>the</strong> release of gaseoushydrogen. The plant design andoperations ensure that <strong>the</strong> heat andhydrogen cannot build up and riskexceeding safe levels within <strong>the</strong> plant.Between 1994 and 1999, a significantquantity of metal swarf was retrievedfrom <strong>the</strong> facility, by use of <strong>the</strong> SwarfRetrieval Facility. The waste wasexported to <strong>the</strong> Magnox Encapsulation<strong>Plan</strong>t for encapsulation and storage.Historical view of <strong>the</strong> inside of <strong>the</strong> MagnoxSwarf Storage Silos during constructionHistorical external view of <strong>the</strong> Magnox SwarfStorage Silos during construction


Issue 1 August 2011<strong>Sellafield</strong> <strong>Plan</strong> 3 Magnox Swarf Storage Silos Waste from <strong>the</strong> Magnox Swarf Storage Silos willbe exported from <strong>the</strong> building in 3m 3 boxesIn order to safely empty anddecommission <strong>the</strong> Magnox SwarfStorage Silos <strong>the</strong> solution is to: The Magnox Swarf Storage Silos duringconstruction


4<strong>Sellafield</strong> <strong>Plan</strong>Issue 1 August 2011 Magnox Swarf Storage Silos Magnox SwarfStorage Silos SEP Solid Waste Storage Prepare for RetrievalsDesign and Construct Retrievals& Treatment FacilitiesNuclear Safety Surveillance Operations& MaintenanceRetrieve and Treat Silo WasteThe Magnox Swarf Storage Silosprogramme scope is to retrieve <strong>the</strong>waste from compartments within <strong>the</strong>silos and treat to form an interim storageproduct. The product will be storedabove ground pending availability of <strong>the</strong>Intermediate Level Waste ConditioningFacility and consignment to <strong>the</strong>Geological Disposal Facility.A major milestone for <strong>the</strong> facility will comewith <strong>the</strong> completion of a project to designand construct retrieval and treatmentfacilities. The first silo emptying plant willbe ready to retrieve during <strong>the</strong> 2016/17financial year with preparation forretrievals complete in <strong>the</strong> same period.The start of active retrievals will beginduring 2017/18 financial year when <strong>the</strong>Treatment Facility is available.Over nine liquid activity reduction (LAR)transfers have already taken place with <strong>the</strong>liquid transferred to <strong>the</strong> Site Ion Exchange<strong>Plan</strong>t (SIXEP) at <strong>Sellafield</strong>After each transfer, <strong>the</strong> silos are toppedup with clean water to maintain shieldingof <strong>the</strong> solid waste


Issue 1 August 2011<strong>Sellafield</strong> <strong>Plan</strong> 5 Magnox Swarf Storage Silos Initial Preparation forRetrievals CompleteFirst Machine Ready for RetrievalsThird Machine Readyfor RetrievalsSustained RetrievalsStart of Active Commissioning Financial information withheld due to commercial confidentialityFor more information please see pages 16 and 17 of <strong>the</strong> overview section


<strong>Sellafield</strong> <strong>Plan</strong>Issue 1 August 2011 Magnox Swarf Storage Silos The original Silos Direct Encapsulation<strong>Plan</strong>t was constructed between 1995 and2001, however work was halted whennew information on <strong>the</strong> waste streams tobe processed meant that a decision hadto be taken to put <strong>the</strong> project on hold.The building was <strong>the</strong>n placed in a careand maintenance regime.In 2004 work was carried out on <strong>the</strong> newprocess options for <strong>the</strong> plant and in 2005significant elements of <strong>the</strong> redundantplant and equipment were stripped out, inpreparation for <strong>the</strong> new plant.Construction of <strong>the</strong> plant is programmedto be completed in 2018, howeveraccelerated programmes are looking tobring this forward. The Box Transfer Facility will provideexport routes for waste retrieved from<strong>the</strong> Magnox Swarf Storage Silos andprocessed in Silos Direct Encapsulation<strong>Plan</strong>t (SDP). The waste will be in <strong>the</strong>form of 3m 3 product boxes which will beexported via <strong>the</strong> Box Transfer Facility to<strong>the</strong> Encapsulation Product Store 3 andeventually <strong>the</strong> Box Encapsulation <strong>Plan</strong>tProduct Store via <strong>the</strong> ComprehensiveImport/Export Facility when it has beencompleted.Construction of <strong>the</strong> Box Transfer Facilityat <strong>Sellafield</strong> is under wayTransportPackages &MaintenanceItemsSilos MaintenanceFacilityLLWMaintenanceWasteTreatment through<strong>the</strong> LLW ProgrammeMagnox SwarfStorage SiloEffluentDistribution <strong>Plan</strong>tAqueous wasteSludgeand solidsSludge &Spent IronExchangeSilo Direct Encapsulation <strong>Plan</strong>tTreatment of Sludge and SolidsEffluent Transfer FacilitySIXEPSIXEPWaste RetrievalOn Site Storage of TreatedSludge and SolidsKeyIn ProgrammeOutside Programme


<strong>Sellafield</strong> <strong>Plan</strong> – Issue 1 August 2011Risk & Hazard ReductionPile FuelCladding Silo


<strong>Sellafield</strong> <strong>Plan</strong>Issue 1 August 2011 Pile Fuel Cladding Silo Built between 1950 and 1951 <strong>the</strong> PileFuel Cladding Silo is 21m high and,inside, houses six extremely tall wastecontainers known as ‘silos’.Commissioned for use in 1952 <strong>the</strong>facility’s primary role was to receive andsafely store radioactive fuel claddingfrom <strong>the</strong> military project at Windscale.As Magnox power stations started togenerate electricity for domestic use,it also received fuel cladding from <strong>the</strong>Calder Hall and Chapelcross powerstations.Between 1952 and 1965, flasks ofdecanning waste (aluminium, graphite,and later on Magnox) were sent to<strong>the</strong> Pile Fuel Cladding Silo on a roadtransporter. The flasks were lifted to <strong>the</strong>east end tower and placed onto atrolley. The trolley took <strong>the</strong> flask into ashielded antechamber where <strong>the</strong> lid wasremoved and <strong>the</strong> flask transferred to asecond trolley.The second trolley carried <strong>the</strong> lidlessflask into <strong>the</strong> transfer tunnel where <strong>the</strong>flask was turned upside down. Thewaste dropped out of <strong>the</strong> flask and into<strong>the</strong> compartment. The flask was <strong>the</strong>nremoved, its lid replaced and <strong>the</strong> flaskreturned to <strong>the</strong> Pile Fuel Storage Pond.The Pile Fuel Cladding Silo has sixcompartments and now holds over 3,200cubic metres of intermediate level waste.By <strong>the</strong> mid 1990s, <strong>the</strong> silo was nearing<strong>the</strong> end of its intended life. And, like anybuilding exposed to <strong>the</strong> wea<strong>the</strong>r for 50years, it required care and maintenance.A programme of upgrade work wascompleted to enable <strong>the</strong> building tocontinue to store waste safely, priorto <strong>the</strong> next task in <strong>the</strong> programme: tosafely retrieve <strong>the</strong> waste and store it incompact concealed units.Historical aerial view of <strong>the</strong> Pile FuelCladding SiloThe Pile Fuel Cladding Silo with <strong>the</strong> CalderHall Cooling Towers in <strong>the</strong> distanceAerial view of <strong>the</strong> Pile Fuel Cladding Siloduring <strong>the</strong> 1970s


Issue 1 August 2011<strong>Sellafield</strong> <strong>Plan</strong> 3 Pile Fuel Cladding Silo A ‘superstructure’ is being constructedopposite <strong>the</strong> Silo which will be used toretrieve <strong>the</strong> wasteIn order to safely empty anddecommission <strong>the</strong> Pile Fuel CladdingSilo <strong>the</strong> solution is to: The Pile Fuel Cladding Silo followingexternal refurbishment work


<strong>Sellafield</strong> <strong>Plan</strong>Issue 1 August 2011 Pile Fuel Cladding Silo Pile Fuel Cladding Design, Install and Inactive CommissionRetrieval EquipmentRetrievals Operations and MaintenancePreparation for DecommissioningThe first major milestone will be todesign, install and inactive commission<strong>the</strong> retrieval equipment which includes<strong>the</strong> construction of a waste retrievalsbuilding adjacent to <strong>the</strong> silo (see enablerson <strong>the</strong> following page). Completion ofpreparation for retrievals is planned for<strong>the</strong> 2017/18 financial year.Once retrievals begin within <strong>the</strong> facility,<strong>the</strong> programme moves to its retrievalsoperations and maintenance phase. Thestart of bulk retrievals is planned for <strong>the</strong>2017/18 financial year.The final phase of <strong>the</strong> programme for<strong>the</strong> Pile Fuel Cladding Silo will be <strong>the</strong>preparation for decommissioning of both<strong>the</strong> silo and <strong>the</strong> retrievals building.The transfer tunnel on <strong>the</strong> roof of <strong>the</strong> buildingwas emptied and removedA passive off gas system has been installedStorage of <strong>the</strong> intermediate level waste hasbeen significantly improved following anextensive programme of streng<strong>the</strong>ning,re-pointing and rendering


Issue 1 August 2011<strong>Sellafield</strong> <strong>Plan</strong> Pile Fuel Cladding Silo Completion of Preparation for RetrievalsStart of Bulk RetrievalsPreparations Begin for Residuals Removal 41,658.5 43,322.5 73,052.0 158,033.0 457,554.8 615,587.9For more information please see pages 16 and 17 of <strong>the</strong> overview sectionThe storage environment within <strong>the</strong> silo has beenchanged from air to inert gas, vastly reducing <strong>the</strong>potential risk of fire. New argon plants provide acontinuous supply of argon to <strong>the</strong> siloWork is under way to construct <strong>the</strong>‘superstructure’ which will house <strong>the</strong> equipmentneeded to retrieve waste from <strong>the</strong> siloA Silo Retrieval Facility is being constructedopposite <strong>the</strong> silo which will be used toretrieve <strong>the</strong> waste


<strong>Sellafield</strong> <strong>Plan</strong>Issue 1 August 2011 Pile Fuel Cladding Silo The waste retrieval facility will consist ofa reinforced concrete support skeletonstructurally independent from <strong>the</strong> silo,but adjoining it. A number of moduleswill be bolted on: retrieval modules;waste loading modules and wastecontainer modules.Holes will be cut into <strong>the</strong> northside of <strong>the</strong> silo so that each of <strong>the</strong>compartments can be accessed in turn.Access doors will be made for eachcompartment, which will be bolted to <strong>the</strong>silo structure and sealed against <strong>the</strong> faceof <strong>the</strong> silo. The retrieval module will dockagainst each compartment.A telescopic boom and grab will bedeployed through <strong>the</strong> new holes in <strong>the</strong>side of <strong>the</strong> silo. This grab will pick up<strong>the</strong> waste from within <strong>the</strong> silo, retract,rotate through 180 degrees and lower<strong>the</strong> grab full of waste into <strong>the</strong> wastecharacterisation module. A robotic armwill spread <strong>the</strong> waste out within <strong>the</strong>module where photographic and videofootage of <strong>the</strong> waste will be taken alongwith basic radiological measures to aidcharacterisation and treatment. Whencharacterisation is completed <strong>the</strong> wastewill be transferred into 3m 3 storageboxes which will be raised up to <strong>the</strong>lidding station, swabbed and exportedfor storage prior to treatment and finalstorage. The BEPPS1 and CIEF project willincorporate <strong>the</strong> completion andexpansion of a purpose built aboveground nuclear waste store and <strong>the</strong>construction of a new import/exportfacility to handle radioactive waste,arising from <strong>the</strong> ongoing nucleardecommissioning and high hazardreduction operations at <strong>Sellafield</strong>. The retrieved waste will be characterisedin <strong>the</strong> retrievals facility prior to packagingin 3m 3 boxes. Characterisation dataga<strong>the</strong>red will be used as a basis to designa new Waste Treatment Facility. The WTFwill condition <strong>the</strong> waste into a format forlong term storage and eventual disposalwhen a geological disposal facility (GDF)becomes available.The ‘superstructure’ used to empty <strong>the</strong> silo willconsist of a reinforced concrete skeletonHoles will be cut into <strong>the</strong> side of <strong>the</strong> silo sothat <strong>the</strong> compartments can be accessed inturn. Trials of this work are under wayA telescopic boom and grab will bedeployed through <strong>the</strong> new holes in <strong>the</strong>side of <strong>the</strong> silo to retrieve <strong>the</strong> wastePile FuelCladding SiloWaste Retrieval<strong>Plan</strong>tInterim Storage ofUntreated WasteWaste Treatment<strong>Plan</strong>tOn Site Storage ofTreated Waste


<strong>Sellafield</strong> <strong>Plan</strong> – Issue 1 August 2011Risk & Hazard ReductionHALWorkstream


Issue 1 August 2011<strong>Sellafield</strong> <strong>Plan</strong> 3 HAL Workstream Highly active liquors are processed in <strong>the</strong>Vitrification <strong>Plan</strong>t where <strong>the</strong>y are turnedinto a stable form in vitrified productcontainers (above)The forward programme for <strong>the</strong>highly active liquor (HAL)workstream is to:


<strong>Sellafield</strong> <strong>Plan</strong>Issue 1 August 2011 HAL Workstream HAL Workstream HALES Operations & Maintenance(Including preparations for POCO)Final HALES POCO Evaporator D OnlineEvaporator D Full OperationsActive Safety CommissioningHA Liquor Tanks – preparationfor DecommissioningWVP Lines 1 & 2 Operations & MaintenanceWVP Lines 1 & 2 POCOWVP Line 3 OperationsVPS/REF Operations & MaintenanceThe Highly Active Liquor (HAL)programme scope is to receive highlyactive raffinate from Thorp and Magnoxreprocessing plants. The raffinate isevaporated and stored in Highly ActiveStorage Tanks. The concentrated HALis <strong>the</strong>n vitrified in <strong>the</strong> Waste Vitrification<strong>Plan</strong>t. The resultant vitrified productcontainers are stored in <strong>the</strong> VitrifiedProduct Store.HAL evaporation and storage also takesmedium active effluents and concentratearisings. All of <strong>the</strong>se arisings requireevaporation and storage via <strong>the</strong> HALEvaporation and Storage facilities.Additional evaporative capacity will beprovided by a new evaporator (EvaporatorD – see enablers) which is due to comeonline during <strong>the</strong> 2014/15 financial yearand will be fully operational during <strong>the</strong>2016/17 financial year. ReplacementHighly Active Storage Tanks are dueto become available for use during <strong>the</strong>2017/18 financial year.In <strong>the</strong> Vitrification <strong>Plan</strong>t, lines 1 and 2are due to cease operations during <strong>the</strong>2017/18 financial year.The Residue Export Facility which isused to facilitate <strong>the</strong> return of vitrifiedwaste to its country of origin is currentlyoperational. Operations in this facility aretargeted for completion in 2018.The first high level waste return was safelycompleted in January 2010The construction of a new evaporator on<strong>the</strong> <strong>Sellafield</strong> site, Evaporator D, is wellunder way and will support <strong>the</strong> ongoingsafe management of HAL


Issue 1 August 2011<strong>Sellafield</strong> <strong>Plan</strong> 5 HAL Workstream Replacement HASTs onlineComplete OperationsCompletion of Thorp POCO Operations (excluding MASFE)Completion ofMASFE POCOOperationsFinal HALES POCOOperations CeasedPOCO CompleteVPS New BuildREF Operations End Financial information withheld due to commercial confidentialityFor more information please see pages 16 and 17 of <strong>the</strong> overview section


<strong>Sellafield</strong> <strong>Plan</strong>Issue 1 August 2011 HAL Workstream One of <strong>the</strong> largest projects under wayat <strong>Sellafield</strong> is <strong>the</strong> construction of anew evaporator to support continuedreprocessing operations. Until thisproject is complete, reprocessingthroughput will be limited by <strong>the</strong> capacityof existing evaporators. One of <strong>the</strong> key waste streams fromreprocessing is <strong>the</strong> liquid high levelwaste. This waste is separatedout from <strong>the</strong> reusable uranium andplutonium during reprocessing. Thefirst part of treating this waste is toconcentrate it down in evaporators toreduce its volume in preparation for itsincorporation into glass – a processknown as vitrification, which takes placein <strong>the</strong> Waste Vitrification <strong>Plan</strong>t. The Residue Export Facility hasstate-of-<strong>the</strong>-art safety systemswith practical, fit-for-purpose plantand equipment designed to delivercustomers’ requirements.It consists of a series of heavily shieldedcells containing equipment thatprepares, checks and confirms that <strong>the</strong>product canisters meet <strong>the</strong> requirementsof <strong>the</strong> customers.With <strong>the</strong> customer present <strong>the</strong> canistersare accepted, and <strong>the</strong>n safely loadedinto a shielded flask. The first stage inthis process is for <strong>the</strong> canisters to beretrieved from Vitrified Product Storeand placed in <strong>the</strong> Residue Export Facilitywhere <strong>the</strong>re are three main process cells,<strong>the</strong> cleaning cell (prepares <strong>the</strong> canisters),<strong>the</strong> inspection cell and <strong>the</strong> flasking cell.Two more cells – <strong>the</strong> buffer and transfercells – are required to assist with <strong>the</strong>logistics of loading <strong>the</strong> flask. Beforetransporting <strong>the</strong> flask with its loadedcontents of solid waste, it is checkedto confirm it meets <strong>the</strong> regulatoryrequirements for transport.Historic internal view of a highly activestorage tank at <strong>Sellafield</strong>A new evaporator is currently underconstruction. The first two modules of <strong>the</strong>new evaporator were safely delivered to<strong>Sellafield</strong> by sea in June 2011ThorpReprocessingHA RaffinateMagnoxReprocessingMAEvaporationMA ConcentrateHA BufferTanksHAEvaporatorsA, B, C,HAEvaporator D(New Build)EffluentHALHALHA StorageTanksReplacementHA StorageTanks(New Build)HALHALVitfrified ProductContainersWasteVitrification<strong>Plan</strong>t (WVP)Long TermStorageUK BasedContainersUK GeologicalDisposalFacilityVitrified ProductStore (VPS)Residue ExportFacility (REF)Replacement VPSProduct Store(New Build)Flasks MaintenanceTransport & RailOverseasReturnsFlasks/ContainersKeyNot in HAL Programme of WorkEffluentManagementInternational NuclearServices (INS)Within <strong>the</strong> HAL ProgrammeOverseas Customers


<strong>Sellafield</strong> <strong>Plan</strong> – Issue 1 August 2011Risk & Hazard ReductionPCM Treatment& Storage


2<strong>Sellafield</strong> <strong>Plan</strong>Issue 1 August 2011 PCM Treatment & Storage During spent fuel reprocessing,fuel fabrication, maintenance,decommissioning, refurbishmentand o<strong>the</strong>r site operations, toolsand equipment come into contactwith plutonium and thus becomecontaminated.These wastes are classified as‘plutonium contaminated materials’.Due to <strong>the</strong> toxicity of plutonium, <strong>the</strong>seplutonium contaminated materialsare subject to a higher level of controlthan o<strong>the</strong>r radioactive wastes such asthose disposed at <strong>the</strong> Low Level WasteRepository.Plutonium contaminated material at<strong>Sellafield</strong> is classified into several genericgroups, according to <strong>the</strong>ir type and how<strong>the</strong>y are packaged for storage prior totreatment.Mixed plutonium contaminated materialpredominantly consists of a combinationof items such as PVC gloves, PVCprotective suits, small items of plant,hand tools and laboratory equipment.These wastes are double-bagged inheat-sealed PVC linings within mild steel200 litre drums.Whole equipment and dismantled itemsconsist of such things as contaminatedgloveboxes and machinery. These itemsare packaged in crates.Filters are used throughout <strong>Sellafield</strong> toremove particulate material, includingplutonium containing dust, from air inbuilding ventilation systems. Older filtersare double-wrapped in heat-sealed PVCsheeting. The filters from newer <strong>Sellafield</strong>buildings are cylindrical and designed tofit directly into a 200 litre drum.Plutonium contaminated material istreated at <strong>the</strong> waste treatment complexon <strong>the</strong> <strong>Sellafield</strong> site. The wastetreatment complex provides for <strong>the</strong>supercompaction of mixed plutoniumcontaminated material in 200 litre drums.The resulting compacted pucks arestacked in larger 500 litre drums whichare <strong>the</strong>n backfilled with a cement grout.Some of <strong>the</strong> plutonium contaminated material was retrieved from <strong>the</strong>Low Level Waste Repository site and returned to <strong>Sellafield</strong>


Issue 1 August 2011<strong>Sellafield</strong> <strong>Plan</strong> 3 PCM Treatment & Storage The forward programme forPCM Treatment and Storage at<strong>Sellafield</strong> is to: Receipt Airlocks Breakdown Cell &Glovebox FacilityStoresReceiptStoreOutline process ofwaste management in<strong>the</strong> Waste TreatmentComplexAssay Compaction Grout Cure & Export


4<strong>Sellafield</strong> <strong>Plan</strong>Issue 1 August 2011 PCM Treatment & Storage PCM Treatment & Waste Treatment Complex TreatmentOperations & MaintenanceEngineered Drum Stores – Storage Operations& MaintenanceEngineered Drum Store 4 – New Build/ConstructionThe plutonium contaminated materialtreatment and storage programme scopetreats and stores plutonium contaminatedmaterial arising from routine operations on<strong>the</strong> site or during decommissioning.A plutonium contaminated material wastedrum being loaded into an assay monitorPlutonium contaminated material drumsbeing transported by railPreparing drums of plutoniumcontaminated material for transport


Issue 1 August 2011<strong>Sellafield</strong> <strong>Plan</strong> 5 PCM Treatment & Storage 20,574.0 25,072.0 21,931.4 67,577.4 253,354.7 320,932.1For more information please see pages 16 and 17 of <strong>the</strong> overview sectionNupak container inners were developed for<strong>the</strong> transport of plutonium contaminatedmaterial from <strong>the</strong> Low Level WasteRepository to <strong>Sellafield</strong>


<strong>Sellafield</strong> <strong>Plan</strong>Issue 1 August 2011 PCM Treatment & Storage Engineered Drum Stores have beenconstructed at <strong>Sellafield</strong> in order toprovide modern fit-for-purpose storagefor intermediate level waste, includingplutonium contaminated material, whichhas been compacted and placed in steeldrums. Plutonium contaminated material istreated at <strong>the</strong> Waste Treatment Complexon <strong>the</strong> <strong>Sellafield</strong> site. The wastetreatment complex provides for <strong>the</strong>supercompaction of mixed plutoniumcontaminated material in 200 litre drums.The resulting compacted pucks arestacked in larger 500 litre drums whichare <strong>the</strong>n backfilled with a cement grout. The Engineered Drum Store Assay Suitewill improve <strong>the</strong> throughput of <strong>the</strong> WasteTreatment Complex by reclassifyingplutonium contaminated waste belowaccountancy level to <strong>the</strong> Low LevelWaste Repository. We are developing a business case fora new type of treatment plant which willreplace <strong>the</strong> Waste Treatment Complex at<strong>the</strong> end of its operational lifetime.One of <strong>the</strong> engineered drum stores whichhave been constructed at <strong>Sellafield</strong> toprovide modern fit-for-purpose storagefor intermediate level wasteSite ConsignorsThorp, Magnox, Mox, DecommissioningFirst Generation Reprocessing <strong>Plan</strong>ts,SEP Conversion, Analytical ServicesPCM Storage EngineeredDrum StoresProduct DrumsUK GeologicalDisposal FacilityHistoric Plutonium ContaminatedMaterial (PCM) Waste Storage FacilitiesFuture PCM EDS <strong>Building</strong>sFuture PCM Treatment andProcessing <strong>Plan</strong>tsKeyWithin <strong>the</strong> PCM ProgrammeFuture <strong>Plan</strong>tsWaste Treatment ComplexThe Facility will only be available until 2025/26This facility will treat PCM that would previously havebeen treated via WTC, and PCM that is unsuitable fortreatment through WTC (Crates and filters for example)Crate Breakdown Facility


<strong>Sellafield</strong> <strong>Plan</strong> – Issue 1 August 2011Risk & Hazard ReductionWindscale


2<strong>Sellafield</strong> <strong>Plan</strong>Issue 1 August 2011 Windscale The Windscale Pile reactors wereconstructed to support <strong>the</strong> BritishAtomic programme. The Piles were<strong>the</strong> country’s first large scale nuclearreactors producing plutonium for <strong>the</strong>UK’s nuclear deterrent. Following afire in Pile one in October 1957, bothreactors were shut down. Phase 1decommissioning started in <strong>the</strong> early1980s and recent work has focused oncarrying out intrusive survey work of <strong>the</strong>Pile 1 core and developing approachesto remove <strong>the</strong> fuel and isotopes from <strong>the</strong>fire damaged reactor.In <strong>the</strong> late 1950s, Windscale waschosen as <strong>the</strong> setting for a new reactorwhich was to explore <strong>the</strong> potential ofhigh pressure and temperature gascooledreactor fuel and components.The Windscale Advanced Gas-cooledReactor (WAGR) was constructedbetween 1957 and 1961 and operatedsuccessfully. WAGR was built to studyand prove in service <strong>the</strong> performanceof gas-cooled fuel elements suitablefor a commercial reactor. It also servedas a test bed for <strong>the</strong> development ofadvanced fuel and o<strong>the</strong>r componentsand provided operational experienceof power production. WAGR was <strong>the</strong>forerunner of a family of 14 reactors onseven sites built to generate cheaperand more efficient electricity in <strong>the</strong> UK.WAGR has been a decommissioningdemonstration project, showingthat a full sized reactor can bedecommissioned safely, cost-effectivelyand in an environmentally acceptablemanner. The decommissioning of<strong>the</strong> reactor within WAGR was safelycompleted in May 2011, significantlyreducing <strong>the</strong> hazard associated with <strong>the</strong>iconic ‘golf ball’ structure.The iconic Windscale Advanced GascooledReactor under construction at<strong>Sellafield</strong>The giant reactor vessel was loweredinto <strong>the</strong> Windscale Advanced Gas-cooledReactor through <strong>the</strong> roofThe completed Windscale AdvancedGas-cooled Reactor became known as‘<strong>the</strong> golf ball’


Issue 1 August 2011<strong>Sellafield</strong> <strong>Plan</strong> 3 Windscale The Windscale programme is subject to anumber of deferrals which will allow us tomove resources to complete higher hazardwork at <strong>Sellafield</strong>The forward programme for <strong>the</strong>clean-up and decommissioning of<strong>the</strong> Windscale site: Decommissioning operations under wayat Windscale


<strong>Sellafield</strong> <strong>Plan</strong>Issue 1 August 2011 Windscale Active Handling Facility – Tenant OperationsDecommissioning Western AreaDecommissioning Redundant ActiveHandling FacilityThe Windscale programme constitutesan area which is presently subject to aseparate Nuclear Site Licence, within <strong>the</strong><strong>Sellafield</strong> <strong>Ltd</strong> boundary. The scope of <strong>the</strong>programme is to reduce hazards through<strong>the</strong> decommissioning and demolitionprogrammes of legacy nuclear facilitiesand <strong>the</strong> environmental restoration of<strong>the</strong> site.Due to <strong>the</strong> fact that <strong>the</strong> Windscaleprogramme is not on <strong>the</strong> critical path,<strong>the</strong> programme has been subject to anumber of deferrals, this has allowedtime and funding to be transferred tohigher hazard work.In <strong>the</strong> Active Handling Facility <strong>the</strong>cave refurbishment project is due forcompletion during <strong>the</strong> 2025/26financial year.The Pile 1 Fuel and Isotope RemovalCapital Phase is scheduled to startin <strong>the</strong> 2017/18 financial year. Forfur<strong>the</strong>r details on <strong>the</strong> decommissioningof <strong>the</strong> Pile Chimney please see <strong>the</strong>Decommissioning section of <strong>the</strong><strong>Sellafield</strong> <strong>Plan</strong>.The giant reactor vessel was removedfrom <strong>the</strong> Windscale Advanced Gas-cooledReactor <strong>the</strong> same way it went in –through <strong>the</strong> roofThere were originally two pile reactorsand associated chimneysOne of <strong>the</strong> pile chimneys has been safelydecommissioned and dismantled


Issue 1 August 2011<strong>Sellafield</strong> <strong>Plan</strong> Windscale Cave Refurbishment Complete 21,152.3 18,388.7 18,016.5 57,557.5 178,142.7 235,700.2For more information please see pages 16 and 17 of <strong>the</strong> overview sectionThe view of <strong>the</strong> pile chimney cappedafter being dismantledDecommissioning under way inside <strong>the</strong>Windscale Advanced Gas-cooled Reactor


<strong>Sellafield</strong> <strong>Plan</strong>Issue 1 August 2011 WindscaleThe decommissioning of <strong>the</strong>remaining Pile Chimney willcontinue throughout thisperiod. Fur<strong>the</strong>r information on<strong>the</strong> project can be found in <strong>the</strong>Decommissioning section of<strong>the</strong> <strong>Sellafield</strong> <strong>Plan</strong>.Active Handling Facility (AHF)Integrated SafetyImprovementProgrammeRedundant Active Handling Facility (RAHF)Preparations for RetrievalsPiles 1 & 2RAHF ILW Removedto WEP & MBGWSRAHF ILW RetrievalsAHF Tenant Operations supporting Windscalecommercial operations and potentially <strong>Sellafield</strong> HighHazard Programmes.AHF Tenant OperationsSupporting <strong>Sellafield</strong> HighHazard Programmes &UK Nuclear IndustryLong Term Asset CareImprovementsEnvironmental PermissionsObstruction RemovalFuel & Isotope (F&I)Removal Design andConstructionWestern AreaWAGR Reactor Core RetrievalsWAGR ILW Conditionedin WAGR StoreF&I Retrievalsand EncapsulationWAGR Sphere & Bioshield C&MWAGR ILW Conditionedin WAGR StorePiles 1 & 2 Care &Maintenance (C&M)WAGR PIE Facility RetrievalsWAGR ILW Storage & SurveillanceAcronymsMBGWS: Miscellaneous Beta Gamma Waste StoreWAGR: Windscale Advanced Gas-cooled ReactorPIE: Post Irradiation ExaminationWEP: Waste Encapsulation <strong>Plan</strong>t


<strong>Sellafield</strong> <strong>Plan</strong> – Issue 1 August 2011Spent Fuel ManagementMagnoxReprocessing


2<strong>Sellafield</strong> <strong>Plan</strong>Issue 1 August 2011 Magnox Reprocessing There are two nuclear fuel reprocessingplants at <strong>Sellafield</strong>. The Thermal OxideReprocessing <strong>Plan</strong>t (Thorp) dealswith fuel from British Advanced GascooledReactors (AGR) and Light WaterReactors (LWR) from around <strong>the</strong> world.For more information please see <strong>the</strong>Thorp section of <strong>the</strong> <strong>Sellafield</strong> <strong>Plan</strong>.The second deals with Magnox fuel fromBritain’s early nuclear reactors, like <strong>the</strong>ones which were used at Calder Hallpower station at <strong>Sellafield</strong> which ceasedgeneration in March 2003.Before it can be reprocessed, irradiatedMagnox fuel must be stored for at least180 days in ponds to allow short livedfission products to decay. Followingtransport to <strong>Sellafield</strong> and a period offur<strong>the</strong>r storage <strong>the</strong> cladding (magnesiumalloy) is removed from <strong>the</strong> uranium bar.This all happens in <strong>the</strong> Fuel Handling<strong>Plan</strong>t. The fuel is <strong>the</strong>n transferred to <strong>the</strong>Magnox Reprocessing <strong>Plan</strong>t.The main Magnox Reprocessing plantbegan operations in 1964.The reprocessing operation withinMagnox Reprocessing entails <strong>the</strong>dissolution of <strong>the</strong> irradiated uraniumrods in nitric acid. The solution is <strong>the</strong>nsubject to a series of solvent extractionprocesses in which <strong>the</strong> uranium,plutonium and fission products areseparated into three different streams.These streams are directed to o<strong>the</strong>rplants at <strong>Sellafield</strong> where <strong>the</strong> uranium, in<strong>the</strong> form of uranium nitrate, is convertedto solid uranium trioxide; <strong>the</strong> plutonium,in <strong>the</strong> form of plutonium nitrate, isconverted to plutonium oxide, and <strong>the</strong>fission products, in <strong>the</strong> form of nitricliquor, are stored in Highly Active StorageTanks before being vitrified. For moreinformation on <strong>the</strong> vitrification processplease see <strong>the</strong> HAL Workstream sectionof <strong>the</strong> <strong>Sellafield</strong> <strong>Plan</strong>.The Magnox Reprocessing <strong>Plan</strong>t at<strong>Sellafield</strong> is <strong>the</strong> only one of its kind in<strong>the</strong> UK. As such <strong>the</strong> plant has a vitalrole in supporting risk and hazardreduction operations across <strong>the</strong> NuclearDecommissioning Authority’s estateby reprocessing fuel which is beingretrieved from operating and closedMagnox power stations. This work is coordinatedthrough <strong>the</strong> Magnox OperatingProgramme.It will also support risk and hazardreduction at <strong>Sellafield</strong> by reprocessing<strong>the</strong> fuel which will be retrieved from <strong>the</strong>Calder Hall station on site.Historic photograph showing <strong>the</strong> MagnoxReprocessing <strong>Plan</strong>t under constructionHistoric external view of <strong>the</strong> MagnoxReprocessing <strong>Plan</strong>tSpent Magnox Fuel arrives at <strong>Sellafield</strong>as Magnox Fuel Elements


Issue 1 August 2011<strong>Sellafield</strong> <strong>Plan</strong> 3 Magnox Reprocessing We will safely reprocess spent Magnox fuel,supporting <strong>the</strong> defuelling of <strong>the</strong> Magnoxpower stations. We will also safely manage<strong>the</strong> waste generated (above)In order to safely operate and eventually decommission<strong>the</strong> Magnox Reprocessing facilities <strong>the</strong> solution is to: The outside of <strong>the</strong> fuel element – <strong>the</strong> swarf– is stripped off during reprocessing. Thisswarf is encapsulated in grout filled drumsat <strong>Sellafield</strong>


<strong>Sellafield</strong> <strong>Plan</strong>Issue 1 August 2011 Magnox Reprocessing MagnoxReprocessing Calder Hall DefuellingCalder Hall – Handover to DecommissioningDefuelling CompleteFuel Handling <strong>Plan</strong>t Magnox Flask HandlingMagnox ReprocessingCompletion of Magnox ReprocessingMagnox Encapsulation <strong>Plan</strong>t OperationsUO 3 transfers to Capenhurst StorageUO 3 Transfers CompleteThe Magnox Reprocessing Programmeconstitutes <strong>the</strong> facilities to maintain <strong>the</strong>receipt of and to reprocess Magnox fuelto support <strong>the</strong> operation and end-oflifedefuelling programmes of <strong>the</strong> UKMagnox Reactors.The Magnox Reprocessing <strong>Plan</strong>t willsupport <strong>the</strong> defuelling of <strong>the</strong> CalderHall station at <strong>Sellafield</strong> which ceasedgeneration in 2003. The Calder Halldefuelling programme is expected tobegin during 2012/13 and is due to becompleted at <strong>the</strong> end of <strong>the</strong> 2015/16financial year.Magnox Reprocessing operations at<strong>Sellafield</strong> are scheduled for completionin 2017 with operations in <strong>the</strong> MagnoxEncapsulation <strong>Plan</strong>t expected to endduring 2021.UO 3 transfers to Capenhurst for storagewill continue until <strong>the</strong> end of 2016/17financial year.The defuelling of Calder Hall is part of<strong>the</strong> Magnox Reprocessing Programmeand is due to be completed during <strong>the</strong>2015/16 financial year. Once defuellinghas been completed Calder Hall willtransfer to <strong>the</strong> DecommissioningProgramme.Over forty years of operations withinMagnox ReprocessingRemoval of ducts from <strong>the</strong> Calder Hallreactors at <strong>Sellafield</strong>Magnox Reprocessing will support <strong>the</strong>defuelling operations at <strong>the</strong> Calder Hallstation at <strong>Sellafield</strong>


Issue 1 August 2011<strong>Sellafield</strong> <strong>Plan</strong> 5 Magnox Reprocessing Start of Safestore PreparationsMEP Operations Cease 85,361.1 85,806.9 80,187.7 251,355.8 619,742.8 871,098.6For more information please see pages 16 and 17 of <strong>the</strong> overview section


<strong>Sellafield</strong> <strong>Plan</strong>Issue 1 August 2011 Magnox Reprocessing Covering over 5.3 acres on <strong>the</strong> <strong>Sellafield</strong>site, <strong>the</strong> Fuel Handling <strong>Plan</strong>t (FHP) isresponsible for receiving, storing andmechanically processing spent nuclearfuel from Magnox and Advanced GascooledReactor (AGR) stations fromacross <strong>the</strong> UK.Having undergone a preliminaryinspection, Magnox and AGR flasksare transferred to FHP using <strong>the</strong> site railsystem.The fuel is removed from <strong>the</strong> transportflask and <strong>the</strong>n transferred into <strong>the</strong>storage pond where it remains for apredetermined period of time to allow <strong>the</strong>short lived fission products to decay.After <strong>the</strong> storage period is over, <strong>the</strong> fuel is<strong>the</strong>n transferred into <strong>the</strong> decanner facility(for Magnox fuel) or alternatively <strong>the</strong> AGRdismantler for AGR fuel.In order to be able to reprocess <strong>the</strong>Magnox fuel rod, its outer cladding mustfirst be stripped off. By using speciallydesigned remote control equipment, <strong>the</strong>cladding is peeled off into small pieces afew centimetres in length.The waste itself is made up primarily of<strong>the</strong> cladding or ‘swarf’ from fuel elementsthat have been used in Magnox nuclearpower stations.The Magnox fuel cladding is removed and<strong>the</strong> uranium metal bar is loaded into amagazine and transferred into a shieldedtransport flask. It is <strong>the</strong>n taken across <strong>the</strong>site to <strong>the</strong> Magnox reprocessing plant. The Magnox Encapsulation <strong>Plan</strong>t at<strong>Sellafield</strong> was designed to process solid,intermediate-level radioactive waste,packaging it into a convenient form whichprovides for efficient and simple handling,transport and storage.The encapsulation process takes placeinside heavily shielded concrete cellswhich ensures maximum operatorprotection from <strong>the</strong> radioactive swarf.The Fuel Handling <strong>Plan</strong>t receives spentMagnox fuel and stores it before it is sentacross site to <strong>the</strong> Magnox Reprocessing <strong>Plan</strong>tIntermediate level waste, in <strong>the</strong> formof swarf, is processed in <strong>the</strong> MagnoxEncapsulation <strong>Plan</strong>tSIXEPCalder HallSpent Fuel fromMagnox Stations(External to site)Magnox FuelMagnox FuelInletPond waterfor coolingFuel Handling<strong>Plan</strong>tPond EffluentSludgesMagnoxSwarfMagnoxEncapsulation<strong>Plan</strong>tOn Site Storageof Treated WasteDecanned FuelVitrificationConditioning andTreatment EARPHighly ActiveEvaporatorsILWStreamsHALMagnoxReprocessingUraniumNitratePlutoniumNitrateUraniumFinishingPlutoniumFinishingUO3PuO2Uranium OxideProduct (drums)Plutonium OxideProduct (cans)KeyWithin Magnox ProgrammeOutside Magnox ProgrammeLow ActiveEffluentSegregatedEffluentTreatment <strong>Plan</strong>t


<strong>Sellafield</strong> <strong>Plan</strong> – Issue 1 August 2011Spent Fuel ManagementOngoing Receiptof AGR Fuel


2<strong>Sellafield</strong> <strong>Plan</strong>Issue 1 August 2011 Ongoing Receipt of AGR Fuel Advanced Gas-cooled Reactor (AGR)fuel is received into <strong>the</strong> Fuel Handling<strong>Plan</strong>t at <strong>Sellafield</strong>.Within <strong>the</strong> Fuel Handling <strong>Plan</strong>t <strong>the</strong>fuel is dismantled using <strong>the</strong> AGR fueldismantler.Thorp Receipt and Storage willprovide interim storage for fuel thatis not reprocessed through Thorp,pending packaging and disposal to <strong>the</strong>Geological Disposal Facility.The programme scope includes all of<strong>the</strong> oxide fuel storage facilities on <strong>the</strong><strong>Sellafield</strong> site: storage (shared with <strong>the</strong> MagnoxReprocessing Programme) pond The programme also includes: handling plant be built) for <strong>the</strong> export of AGR fueland Wet Inlet Facility fuel to <strong>the</strong> UKGeological Disposal Facility Fuel Management (FHP, AGR Pond and TR&S) Review of Oxide Fuel StrategyOngoing Receipts of AGR FuelProject Work CompleteLWR Pond Operations & MaintenanceExport Fuel from <strong>the</strong> LWR PondExport of Fuel CompleteExport Incompatible MEBs from TR&SOngoing receipts of AGR fuel and LWRpond operations and maintenance willcontinue throughout this period.Multi-element bottles (MEBs) incompatiblewith future closed storage pondconditions will be exported from ThorpReceipt and Storage. This work will becompleted during 2018/19 financial year.Spent nuclear fuel is kept in storageponds on <strong>the</strong> <strong>Sellafield</strong> site for a periodof coolingFlasks are maintained on behalf of<strong>the</strong> customer in <strong>the</strong> Cuboid FlaskMaintenance Facility


Issue 1 August 2011<strong>Sellafield</strong> <strong>Plan</strong> Ongoing Receipt of AGR Fuel When delivered to <strong>the</strong> <strong>Sellafield</strong> site,spent AGR fuel is dismantled in <strong>the</strong> fuelhandling plant Export of Incompatible MEBs Complete Financial information withheld due to commercial confidentialityFor more information please see pages 16 and 17 of <strong>the</strong> overview section


<strong>Sellafield</strong> <strong>Plan</strong>Issue 1 August 2011 Ongoing Receipt of AGR Fuel cont.Ongoing Receipt of AGR Fuel An internal view of <strong>the</strong> AGR fuel dismantler AGR fuel Inside Thorp receipt and storage ThorpShearLLW MEBsMulti Element BottleInterim StorageILW MEBsFuelMEB DisposalLight WaterReactor PondEngineered ProductStoreAGR DismantlerWaste StoreILWFuelAssembliesAGR FuelFuelRacks toWheelabratorFacilityThorp Receiptand StorageAGRFuel1st Generation AGRPond Buffer StorageAGRFuelFuel that is not reprocessed in Thorp will be interim stored in TR&S pendingconditioning and disposal to <strong>the</strong> GDFAGR DismantlerFuel Handling <strong>Plan</strong>tStoreEmpty Skips


<strong>Sellafield</strong> <strong>Plan</strong> – Issue 1 August 2011Spent Fuel ManagementThorp Reprocessing


<strong>Sellafield</strong> <strong>Plan</strong>Issue 1 August 2011 Thorp Reprocessing The Thorp reprocessing plant at <strong>Sellafield</strong>combines all <strong>the</strong> facilities necessary forreprocessing spent oxide fuel under oneroof.The construction of Thorp was oneof <strong>the</strong> world’s most complex civilengineering projects employing up to5,000 contractors on site and supportinga fur<strong>the</strong>r 10,000 with suppliers andsubcontractors. Construction beganon <strong>the</strong> Thorp Head End and ChemicalSeparation plants in 1985 and <strong>the</strong> firstfuel was sheared in 1994.Thorp’s operations are divided into threemain areas: spent fuel is chopped up anddissolved in nitric acid plutonium and waste products areseparated outAfter 3 to 4 years in a reactor nuclear fuelbecomes less efficient so is removed.97% of <strong>the</strong> spent fuel can be recycledto produce new fuel (96% uranium, 1%plutonium). The rest is nuclear waste.Transport flasks containing spent fuelfrom <strong>the</strong> power stations are delivered byrail to <strong>the</strong> <strong>Sellafield</strong> site.On arrival at <strong>Sellafield</strong> <strong>the</strong> fuel is removedfrom <strong>the</strong> transport flasks underwater andstored in storage ponds to allow <strong>the</strong> fuelto cool fur<strong>the</strong>r before reprocessing.The empty flasks are sent for cleaningand quality checks before beingreturned to <strong>the</strong> power station forano<strong>the</strong>r consignment.Once <strong>the</strong> fuel has cooled sufficiently itis monitored and transferred from <strong>the</strong>storage pond to <strong>the</strong> Head End <strong>Plan</strong>tshear cave where <strong>the</strong> fuel is chopped intosections. The fuel drops into a basketin a dissolver vessel where <strong>the</strong> fuel isdissolved in nitric acid. The fuel claddingremains in <strong>the</strong> basket.The dissolved fuel liquor is forwardedto <strong>the</strong> chemical separation plant withinThorp, where solvent extraction takesplace to separate <strong>the</strong> 3% wastes from <strong>the</strong>96% uranium and 1% plutonium.The wastes from this process are sentto <strong>the</strong> High Level Waste plants forconcentration, storage and eventualconversion to glass. The uraniumand plutonium are converted to oxidepowders and stored. Both <strong>the</strong> uraniumand <strong>the</strong> plutonium can be recycled andmanufactured into new uranium oxide orMixed Oxide (MOX) fuels.Thorp has dispatched over 1,200 tonnesof uranium for customers to recycleback into new fuel, this will save morethan 14 million tonnes of CO 2 from fossilfuel generation.Spent oxide nuclear fuel is sent to<strong>Sellafield</strong> by rail and is delivered to <strong>the</strong>receipt and storage part of ThorpOnce inside Thorp Receipt and Storage <strong>the</strong>fuel is removed from its transport flask


Issue 1 August 2011<strong>Sellafield</strong> <strong>Plan</strong> 3 Thorp Reprocessing Our commitment is to safely reprocess fuelthrough <strong>the</strong> Thorp facility in line with ourcontractual arrangementsIn order to safely fulfil Thorp Reprocessing Contracts<strong>the</strong> solution is to: The fuel is placed into cooling ponds withinThorp for a period of cooling


<strong>Sellafield</strong> <strong>Plan</strong>Issue 1 August 2011 Thorp Reprocessing Thorp Reprocessing THORP Head End and Chemical<strong>Plan</strong>t ReprocessingTHORP Feed Pond Long Term OperationsTHORP Uranium Product Storage OpsTHORP LETP New BuildWaste Encapsulation <strong>Plan</strong>t (WEP)Treatment OperationsTHORP Preparation for Decommissioning(Including Assessment & Implementation Phase)THORP POCOOxide fuel is reprocessed in <strong>the</strong> Thermal as Thorp. The products are storedin <strong>the</strong> plutonium and uranium stores. as intermediate level waste in <strong>the</strong> WasteEncapsulation <strong>Plan</strong>t and exported to <strong>the</strong>Encapsulated Product Stores. scheduled to end in 2018, althoughpreparation for <strong>the</strong> decommissioning ofThorp will begin before this date.Operations in <strong>the</strong> associated WasteEncapsulation <strong>Plan</strong>t are expected to endin 2022/23.The Post Operational Clean Out (POCO)operations in Thorp are scheduled tobegin in 2018 once reprocessing hasstopped and is scheduled for completionin 2021.Thorp will continue to shear sufficient fuel to maintain capacity to always placeinto storage fuel that is despatched reactor operator lives <strong>the</strong> precise finallifetime tonnage is variable. <strong>Sellafield</strong> its plans to be able to maintain ongoingoperational storage capacity for routine receipts can be found in <strong>the</strong> Ongoing <strong>Sellafield</strong> <strong>Plan</strong>.The construction of Thorp was <strong>the</strong> singlelargest construction project of its kindin <strong>the</strong> UKThorp received its first fuel into <strong>the</strong>building in 1994 for shearingA £20m project was completed to installa replacement Medium Active Salt FreeEvaporator (MASFE) into Thorp. This was apredicted activity in <strong>the</strong> plant design


Issue 1 August 2011<strong>Sellafield</strong> <strong>Plan</strong> 5 Thorp Reprocessing Cessation of ReprocessingCompletion of WEP OperationsCompletion of Thorp POCO Operations (excluding MASFE)Completion of MASFE POCO Operations Financial information withheld due to commercial confidentiality Thorp recently reprocessed its 6,600thtonne of fuelMulti-element bottles (MEBs), used to storeLight Water Reactor fuel in Thorp, are beingremoved, creating more room in <strong>the</strong> pond


<strong>Sellafield</strong> <strong>Plan</strong>Issue 1 August 2011 Thorp ReprocessingThe Performance <strong>Plan</strong> shows that Thorpwill complete its contractual reprocessingcommitments in 2018. However, we areactively pursuing options to meet <strong>the</strong>serequirements as early as possible.This work includes: The Waste Encapsulation <strong>Plan</strong>t is agroup of buildings which consists of<strong>the</strong> Main Process <strong>Building</strong>, <strong>the</strong> Services<strong>Building</strong> and <strong>the</strong> Silo and Grout Washings<strong>Building</strong>. The plant encapsulatesintermediate level waste and its primarypurpose is to support Thorp, howeverit can also treat o<strong>the</strong>r intermediate levelwaste streams. One of <strong>the</strong> key waste streams fromreprocessing is <strong>the</strong> liquid high levelwaste. This waste is separatedout from <strong>the</strong> reusable uranium andplutonium during reprocessing. Thefirst part of treating this waste is toconcentrate it down in evaporators toreduce its volume in preparation for its known as vitrification, which takes placein <strong>the</strong> Waste Vitrification <strong>Plan</strong>t. One of <strong>the</strong> largest projects under wayat <strong>Sellafield</strong> is <strong>the</strong> construction of anew evaporator to support continuedreprocessing operations and <strong>the</strong> PostOperational Clean Out (POCO) of <strong>the</strong>highly active waste treatment plants. Untilthis project is complete, reprocessingthroughput will be limited by <strong>the</strong> capacityof existing evaporators. All overseas reprocessing contractssigned since 1976 contain a return ofwaste clause. This means that <strong>the</strong> wasteassociated with reprocessing overseascustomers’ spent fuel belongs to <strong>the</strong>customers and will be returned to <strong>the</strong>m.In 2010 we started returning vitrified highlevel waste to customers in both Japanand Europe. UO 3 product from processing overseascustomer fuels will be despatched forrecycle or storage by <strong>the</strong> customers. This UK owned UO 3 product will be retainedat <strong>Sellafield</strong> until a decision on its futuremanagement has been made. overseas came in multi-element bottles(MEBs). These MEBs must be removedfrom <strong>the</strong> Thorp pond to prepare it for There are various options that we areexploring which could enable accelerationof <strong>the</strong> removal of MEBs to prepare <strong>the</strong> early as possible. These include: waste despatch to storage facility capacity by building a fur<strong>the</strong>r storagefacilityFuel is taken to <strong>the</strong> Fuel Handling <strong>Plan</strong>tfor cooling before being transferred toThorp for reprocessingThe programme of returning vitrified highlevel waste started in 2010The construction of a new evaporator, whichis being delivered to <strong>Sellafield</strong> in modularform by sea, will support reprocessingoperations in Thorp


Issue 1 August 2011<strong>Sellafield</strong> <strong>Plan</strong> Thorp ReprocessingThorp PondsReprocessing Buffer1st Generation OxidePond Historic LWRProgramme ScopeIn CleanFuelMEBs OutILWLLWInterim Store (MEBs)Feed PondFuelWaste Encapsulation<strong>Plan</strong>tILWReprocessingHighly Active RaffinateHigh LevelWaste <strong>Plan</strong>tUranium ProductStoreUO3LLW/ILW/PCM/MBGWPuPu Finishing Lineand Store<strong>Sellafield</strong> Mox <strong>Plan</strong>tLiquid EffluentSolid WasteAerial/Effluent The vitrification plant at <strong>Sellafield</strong> processes<strong>the</strong> high level waste produced in Thorp andturns it into a solid stable form


<strong>Sellafield</strong> <strong>Plan</strong> – Issue 1 August 2011Spent Fuel ManagementThe Wet InletFacility (WIF)


2<strong>Sellafield</strong> <strong>Plan</strong>Issue 1 August 2011 WIFThe <strong>Plan</strong> 2011/12 2012/13 2013/14 2014/15 2015/16 2016/17WIF Ops & MaintenanceLWR Pond (Old Side) POCOThe Wet Inlet Facility (WIF) Programmeincludes <strong>the</strong> short to mediumterm storage of customer fuel andcomponents in <strong>the</strong> ‘old’ side of <strong>the</strong> FirstGeneration Oxide Fuel Storage Pond.It also includes <strong>the</strong> transfer of fuel andcomponents from <strong>the</strong> First GenerationOxide Fuel Storage Pond to <strong>the</strong> WIF, <strong>the</strong>receipt of fuel from off site to <strong>the</strong> WIFand <strong>the</strong> long term storage of fuel within<strong>the</strong> WIF.WIF operations and maintenance willcontinue throughout <strong>the</strong> reportingperiod. Post Operational Clean Out(POCO) work on <strong>the</strong> ‘old’ side of <strong>the</strong>First Generation Oxide Fuel StoragePond will begin after 2022.Receipts of fuel from customers’ facilitiesare accepted directly into <strong>the</strong> WIF. Flasksand flasking infrastructure (lifting beamsetc) that support customers’ flasks aremaintained on behalf of our customers in<strong>the</strong> Flask Maintenance Facility which isoperated as an external facility.An elevated view of <strong>the</strong> WIFThe WIF storage pond is used to storecustomer fuelFlask Maintenance Facility


Issue 1 August 2011<strong>Sellafield</strong> <strong>Plan</strong> 3 WIF 2017/18 2018/19 2019/20 2020/21 2021/22 2022/23 2023/24 2024/25 2025/26 2011/12 2012/13 2013/14 2011/12 2014/15 2011/12Financial information withheld due to commercial confidentialityFor more information please see pages 16 and 17 of <strong>the</strong> overview sectionWIF ProgrammeUsed Fuel FlasksOff SiteCustomer FuelSite CaveFacilityPIEFuelOld SideLWR PondFuel &ComponentsWet Inlet Facility(WIF) & WIFConditioning <strong>Plan</strong>tExportUK GeologicalDisposal FacilityClassified itemsfor destructionand disposal


<strong>Sellafield</strong> <strong>Plan</strong> – Issue 1 August 2011Decommissioning<strong>Sellafield</strong> SiteDecommissioning


2<strong>Sellafield</strong> <strong>Plan</strong>Issue 1 August 2011 <strong>Sellafield</strong> Site Decommissioning FacilitiesThe Decommissioning Programmeat <strong>Sellafield</strong> includes <strong>the</strong> strategy andpreparation for decommissioning andfuture decommissioning. It excludes <strong>the</strong>specific decommissioning of facilitieswhich are currently operational orsubject to retrieval operations, <strong>the</strong>se arecovered within <strong>the</strong> scope of <strong>the</strong> relevantprogramme area.The programme lists <strong>the</strong> physicaldecommissioning of: analytical services, remainder is done in <strong>the</strong>ir homeprogrammes once operations and Post Operational A range of decommissioning activitiesneed to be carried out in redundantbuildings before <strong>the</strong>y can be demolishedA number of redundant facilities at <strong>Sellafield</strong>have already been decommissioned anddemolished, making room for new facilitieswhich will support risk and hazard reduction


Issue 1 August 2011<strong>Sellafield</strong> <strong>Plan</strong> 3 <strong>Sellafield</strong> Site Decommissioning The Windscale pile chimneys will be fullydecommissioned and demolished as part of thisprogramme. The associated pile reactors sit in<strong>the</strong> Windscale Programme.The strategic objectives are: segregation of waste into intermediate waste will be returned to <strong>the</strong> cell until be decommissioned and demolished. decommissioned and demolisheddown to approximately 35m level. Theremaining structure will <strong>the</strong>n be placedunder care and maintenance along with final decommissioning of <strong>the</strong> pile reactors remaining pile chimney structures will bedemolished. phase, focus is on removing <strong>the</strong>ventilation system, followed bydecommissioning and demolition of <strong>the</strong>building. operations have finished, followed by aprogramme of decommissioning anddemolition of <strong>the</strong> building. Once <strong>the</strong> compound is no longeroperational we will continue tomonitor it before completing interimdecommissioning and demolition. Theresultant land will be <strong>the</strong> first to be decommissioning of specific laboratories.The long term decommissioning anddemolition sits as part of <strong>the</strong> InfrastructureProgramme. specific zones within <strong>the</strong> facility. Theremaining decommissioning and Safe Storage of Plutonium Programme. decontamination and demolition can becompleted. The final decommissioning Management Programme. waste inventory is under way, <strong>the</strong>n <strong>the</strong>wall will be resealed and <strong>the</strong> moduledecontaminated. The remaining Programme.A number of buildings have already beensafely decommissioned and demolished


4<strong>Sellafield</strong> <strong>Plan</strong>Issue 1 August 2011 <strong>Sellafield</strong> Site Decommissioning <strong>Sellafield</strong> SiteDecommissioning Pile 1 Chimney Dismantle Phase 2FSEP Purification <strong>Plan</strong>t Phase 3A(Including Operations)Solid Waste Storage Cells OperationsWaste & Effluent Drum Store PCM Storage,Drum Store DemolitionDemolition CompleteNorth Group Compound DemolitionHA Liquor Tank Phase 6 RemainingMOX Demonstration FacilityALPHA DecommissioningCompletion of Caesium <strong>Plan</strong>t DecommissioningLA Effluent Treatment <strong>Plan</strong>tLA Effluent Treatment <strong>Plan</strong>t OverbuildingSEP Research Development – LabLab 188, 194 and 195 Decommissioning CompleteZones 2&3 Decommissioning MaintenanceAlpha Decommissioning <strong>Plan</strong>t OperationsTargeted R&T for DecommissioningDemolishing redundant buildings frees upvital space on <strong>the</strong> <strong>Sellafield</strong> site for newfacilities to support our risk and hazardreduction workThe separation area research laboratoryforms part of <strong>the</strong> DecommissioningProgrammeThe demolition of redundant plutoniumcontaminated material drum stores (above)will be completed during 2016/17


Issue 1 August 2011<strong>Sellafield</strong> <strong>Plan</strong> 5 <strong>Sellafield</strong> Site Decommissioning Decontamination CompleteOverbuilding Complete


<strong>Sellafield</strong> <strong>Plan</strong>Issue 1 August 2011 <strong>Sellafield</strong> Site Decommissioning cont.The <strong>Sellafield</strong> DecommissioningProgramme is a group of projectscovering facilities across <strong>the</strong> <strong>Sellafield</strong>site, where decommissioning is currentlybeing carried out.The programme includes <strong>the</strong>strategy and preparation for futuredecommissioning but excludes <strong>the</strong>specific decommissioning of all futurefacilities and all facilities which arecurrently operational or subject toretrievals operations.Key highlights of <strong>the</strong> decommissioningprogramme include <strong>the</strong> following: financial year. Drum Store was completed in <strong>the</strong> early <strong>the</strong> electrical substation which is still demolished releasing <strong>the</strong> whole of <strong>the</strong>footprint for alternative use. decommissioning is scheduled for <strong>the</strong> The construction of an overbuilding is scheduled for completion during Treatment <strong>Plan</strong>t will begin. 31,719.8 31,183.0 28,896.2 91,799.0 410,323.3 502,122.3 The dismantling of <strong>the</strong> pile chimney willcontinue during this periodThe decommissioning of <strong>the</strong> Caesiumplant is scheduled for completion in2012/13


Issue 1 August 2011<strong>Sellafield</strong> <strong>Plan</strong> <strong>Sellafield</strong> Site Decommissioning This Programme includes <strong>the</strong> strategyand preparation for decommissioningand future decommissioning, it excludes<strong>the</strong> specific decommissioning of facilitieswhich are currently operational orsubject to retrieval operations, <strong>the</strong>seare within <strong>the</strong> scope of <strong>the</strong> specific Safety is central to allof our decommissioningactivities including <strong>the</strong> careof our employees and <strong>the</strong>environment<strong>Sellafield</strong> DecommissioningSolid WasteStorage CellsPile ChimneySEP Purification<strong>Plan</strong>tCarry out characterisation and segregation of waste into ILW and LLW. LLW will be consigned to <strong>the</strong>LLWR and ILW will be returned to <strong>the</strong> cell until <strong>the</strong> Box Encapsulation <strong>Plan</strong>t is available. When <strong>the</strong> cellsare empty, <strong>the</strong> facility will be decommissioned and demolished.Following <strong>the</strong> demolition of Pile 1 chimney to approximately 35m level <strong>the</strong> remaining structure will beplaced under care and maintenance along with <strong>the</strong> Pile 2 remaining structure. Following finaldecommissioning of <strong>the</strong> pile reactors under <strong>the</strong> Windscale programme, <strong>the</strong> remaining pile chimneystructures will be demolished.Currently in <strong>the</strong> interim decommissioning phase, focus is on removing <strong>the</strong> ventilation system, followedby decommissioning and demolition of <strong>the</strong> building.Fuel FabricationFacilitiesMonitor facilities in a quiescent state, followed by decommissioning and demolition of <strong>the</strong> building.North GroupCompoundAnalyticalServices LabsMonitor compound in a quiescent state, followed by completion of interim decommissioning anddemolition. The zone will <strong>the</strong>n be one of <strong>the</strong> first areas to be transferred to <strong>the</strong> Land andGroundwater Remediation Programme.Continue with interim decommissioning of specific laboratories only. The long term decommissioningand demolition is within <strong>the</strong> Infrastructure Programme.SEP ProductFinishing &Storage facilityDecommissioning and demolition of specific zones, <strong>the</strong> remaining decommissioning anddecontamination is within <strong>the</strong> Safe Storage of Plutonium Programme.LA EffluentTreatment TankHA Liquor TankFunctionsFollowing recovery of effluent from <strong>the</strong> identified tanks, decontamination and decommissioning can becompleted. The final decommissioning is within <strong>the</strong> Effluent Management Programme.Removing <strong>the</strong> ILW inventory is under way, <strong>the</strong>n <strong>the</strong> wall will be resealed and <strong>the</strong> module decontaminated.The remaining decommissioning is within <strong>the</strong> HAL Programme, dismantling of <strong>the</strong> module will be alignedto this.The <strong>Sellafield</strong> Decommissioning Programme carries a provision for functional support for futuredecommissioning strategy to <strong>the</strong> wider <strong>Sellafield</strong> Site; support to both <strong>the</strong> Programme and widerdecommissioning directorate.


<strong>Sellafield</strong> <strong>Plan</strong> – Issue 1 August 2011Nuclear MaterialsOverseasPu Return


2<strong>Sellafield</strong> <strong>Plan</strong>Issue 1 August 2011 Overseas Pu Return MOX Operations End of MOXOperationsMOX Post-Operative Clean-OutMOX Surveillance and Maintenance The overseas return of plutonium scopecomprises <strong>the</strong> <strong>Sellafield</strong> MOX <strong>Plan</strong>twhich converts overseas plutoniumderived from reprocessing into new fuelfor export to customers.Current contracted business in <strong>the</strong><strong>Sellafield</strong> MOX <strong>Plan</strong>t is due to becompleted in 2016 after which time<strong>the</strong> plant will go into a phase of PostOperational Clean Out (POCO), unlessfur<strong>the</strong>r contracts are agreed.International Nuclear Services is indiscussions with all customers abouthow <strong>the</strong>y wish to have <strong>the</strong>ir plutoniummanaged.The <strong>Sellafield</strong> MOX plant converts overseasplutonium derived from reprocessing intonew fuel for export to customersThe control room inside <strong>the</strong> <strong>Sellafield</strong>MOX plantA dry laboratory inside <strong>the</strong> <strong>Sellafield</strong>MOX plant


Issue 1 August 2011<strong>Sellafield</strong> <strong>Plan</strong> Overseas Pu ReturnOverseas Pu Return Financial information withheld due to commercial confidentialityFor more information please see pages 16 and 17 of <strong>the</strong> overview sectionA powder blender inside <strong>the</strong> <strong>Sellafield</strong>MOX <strong>Plan</strong>tDry lab pellet end inspection equipmentinside <strong>the</strong> <strong>Sellafield</strong> MOX <strong>Plan</strong>tPellet press inside <strong>the</strong> <strong>Sellafield</strong> MOX plant


<strong>Sellafield</strong> <strong>Plan</strong>Issue 1 August 2011 Overseas Pu ReturnThe <strong>Sellafield</strong> MOX <strong>Plan</strong>t (SMP) usesplutonium separated from used nuclearfuel during reprocessing and recyclesit into new MOX fuel. MOX fuel is avaluable source of energy and one tonneof plutonium, when recycled as MOX,can generate <strong>the</strong> same energy as wellover 2 million tonnes of coal.Customers send <strong>the</strong>ir used nuclearfuel to <strong>Sellafield</strong> to be reprocessed.Reprocessing involves <strong>the</strong> chemicalseparation of <strong>the</strong> 1% plutonium and96% uranium, from <strong>the</strong> 3% wasteproducts. Reprocessing customersretain ownership of <strong>the</strong>se materials andrecycling <strong>the</strong> plutonium into MOX fuelallows customers to unlock <strong>the</strong> energyby making new fuel from old fuel.MOX fuel contains uranium andplutonium oxide powders which aremilled and mixed toge<strong>the</strong>r in <strong>the</strong> correctproportions for <strong>the</strong> particular MOX fueldesign required. The MOX powder is<strong>the</strong>n pressed into MOX fuel pellets whichrange in size and contain approximately5% plutonium.These pellets are sintered in hightemperature furnaces which turns <strong>the</strong>MOX into a hard ceramic material.Following grinding to <strong>the</strong> exact size andnumerous inspections, MOX pelletsare <strong>the</strong>n loaded into MOX fuel rods.Finally, fuel rods are built into MOX fuelassemblies or bundles in <strong>the</strong> correct arrayto fit <strong>the</strong> particular customer’s reactor.The whole process requires a hugeamount of precision and quality controlinspections to ensure a high qualityproduct that performs optimally in <strong>the</strong>customers’ reactors. Typically, reactoroperators load up to one third areactor core with MOX fuel in place ofuranium fuel.A large amount of work in <strong>the</strong> <strong>Sellafield</strong>MOX plant is done using gloveboxesOnce manufactured <strong>the</strong> mixed-oxide fuelis transported to customersUranium(UO 2 )MOX PLANTUO 2 PlutoniumOxide(PuO 2 )PuO 2 Blending Rod Fill and <strong>Sellafield</strong> MOX <strong>Plan</strong>t Scope: MOX Fuel


<strong>Sellafield</strong> <strong>Plan</strong> – Issue 1 August 2011Nuclear MaterialsSafe Storageof Pu


2 <strong>Sellafield</strong> <strong>Plan</strong>Issue 1 August 2011 Safe Storage of PuThe safe storage of plutoniumprogramme consists of <strong>the</strong> facilities andactivities that produce plutonium dioxideand all of <strong>the</strong> associated facilities. It alsoincludes those facilities and activitiesthat are and will be required to treat and/or repackage plutonium product andresidues to facilitate <strong>the</strong> safe ongoingstorage of <strong>the</strong> stock of civil plutoniumat <strong>Sellafield</strong>.We are safely storing over 100 tonnesof material at <strong>Sellafield</strong>.The <strong>Sellafield</strong> Product and ResidueStore (SPRS) is now operational andwill remain so for <strong>the</strong> duration of thisreporting period. Work on <strong>the</strong> SPRSretreatment construction project willbe complete during <strong>the</strong> 2023/24financial year.Plutonium containers 2011/12 2012/13 2013/14 2011/12-2013/14 2014/15-2025/26 2011/12-2025/26Financial information withheld due to commercial confidentialityFor more information please see pages 16 and 17 of <strong>the</strong> overview sectionOur primary strategic objective for thisprogramme is <strong>the</strong> continued safe andsecure storage of <strong>the</strong> inventory


Issue 1 August 2011<strong>Sellafield</strong> <strong>Plan</strong> 3 Safe Storage of Pu Safe Storage of Pu


4 <strong>Sellafield</strong> <strong>Plan</strong>Issue 1 August 2011 Safe Storage of Pu 2011/12 2012/13 2013/14 2014/15 2015/16 2016/17Magnox Pu Storage OperationsStore 9 Export Facility ConstructionPu Residue Conditioning & StorageStart of Active CommissioningPu Residue Conditioning & Storage OperationSEP Prod Finishing & Storage OperationsTHORP HE&CP Oxide Pu <strong>Plan</strong>t FinishingLine (TPFL) OpsTHORP HE&CP Oxide Pu <strong>Plan</strong>t FinishingLine (TPFL) POCO<strong>Sellafield</strong> Product & Residues Store (SPRS)SPRS Operational<strong>Sellafield</strong> Product & Residues Store – OperationsSPRS Retreatment Construction ProjectSEP Prod Finishing & Storage Replacementof CIDAS SystemPF+S POCO Projects


Issue 1 August 2011<strong>Sellafield</strong> <strong>Plan</strong> 5 Safe Storage of Pu 2017/18 2018/19 2019/20 2020/21 2021/22 2022/23 2023/24 2024/25 2025/26ConstructionCompletePU Residue Conditioning & Storage Operation CommencesThorp Finishing Line CompleteConstruction Project CompletePOCO Complete


6 <strong>Sellafield</strong> <strong>Plan</strong>Issue 1 August 2011 Safe Storage of Pu PuO2<strong>Sellafield</strong> MOX<strong>Plan</strong>tThorp HE&CS<strong>Plan</strong>tDecommissioningProjectsMagnoxSeparationProgramme ScopePuNitratePuNitrateThorpConversion <strong>Plan</strong>tPu ResiduesPu ResiduesSEP Conversion(Finishing)PuO2Thorp PuProduct StoreSEP StoragePuO2 andPu ResiduesPuO2 andPu ResiduesPu ResiduesPuO2 and Pu ResiduesImmobilisationFacilityRetreatment<strong>Plan</strong>tPu Residues<strong>Sellafield</strong> Product& Residue Store(SPRS)Extensions toSPRSLong Termstorage of Puand residuesin SPRSKeyPotential future streamHistorical Pu Arisings and associatedHazard Reduction activitiesAerial Effluent


<strong>Sellafield</strong> <strong>Plan</strong> – Issue 1 August 2011Waste ManagementEffluentManagement


2<strong>Sellafield</strong> <strong>Plan</strong>Issue 1 August 2011 Effluent Management Effluent management at <strong>Sellafield</strong> iscarried out in two groups of plants.The first is <strong>the</strong> low active effluentplants and includes; <strong>the</strong> EnhancedActinide Removal <strong>Plan</strong>t (EARP), <strong>the</strong>Solvent Treatment <strong>Plan</strong>t (STP), <strong>the</strong> SaltEvaporator <strong>Plan</strong>t (SEP), <strong>the</strong> SeparationArea Lagoon, <strong>the</strong> Medium Active LiquorTank Farm and <strong>the</strong> Segregated EffluentTreatment <strong>Plan</strong>t.The second is <strong>the</strong> Site Ion Exchange<strong>Plan</strong>t, also known as SIXEP. This facility was designed to removesolids and soluble radioactive caesiumand strontium from pond water purgesprior to discharge, store waste solidsfrom this process and to help maintain<strong>the</strong> <strong>the</strong>rmal conditions of <strong>the</strong> pond waterin <strong>the</strong> Fuel Handling <strong>Plan</strong>t. This facility provides buffer capacityfor day-to-day plant operations in bothThorp and Magnox reprocessing plants.It also provides an interim storage facilityfor solvent and aqueous liquors before<strong>the</strong>y are processed in <strong>the</strong> EnhancedActinide Removal <strong>Plan</strong>t and <strong>the</strong> SolventTreatment <strong>Plan</strong>t. This facility supports plants associatedwith both Thorp and Magnoxreprocessing. It provides <strong>the</strong> means for<strong>the</strong> removal of radioactive componentsfrom liquid waste streams. This building supports <strong>the</strong> operation of<strong>the</strong> Thorp and Magnox reprocessingplants. Its function is to evaporate high‘salt’ liquors that would o<strong>the</strong>rwise limit<strong>the</strong> evaporation factors achieved in o<strong>the</strong>ron-site evaporators. This facility is used for <strong>the</strong> treatment ofwaste solvent from Thorp, Magnox andhistoric solvent in storage. It is <strong>the</strong> onlyUK facility which can processradioactive solvent. The Segregated Effluent Treatment <strong>Plan</strong>treceives, neutralises and buffer-storeslow active effluents to facilitate samplingand analysis prior to discharge to <strong>the</strong>Break Pressure Tank and to sea. This lagoon provides a collection anddischarge facility for surface waterdrainage and pumped groundwater from<strong>the</strong> Separation Area – which is hometo some of <strong>the</strong> oldest buildings on <strong>the</strong><strong>Sellafield</strong> site.The Enhanced Actinide Removal <strong>Plan</strong>tremoves radioactive components fromradioactive waste streamsThe lagoon provides a collection anddischarge facility for surface water drainageand pumped groundwater from <strong>the</strong>separation area of siteThe Site Ion Exchange <strong>Plan</strong>t helps tomaintain <strong>the</strong>rmal conditions of <strong>the</strong> fuelhandling plant (above)


Issue 1 August 2011<strong>Sellafield</strong> <strong>Plan</strong> 3 Effluent Management Effluent will continue to be safely managed intwo groups of plants; <strong>the</strong> low active effluentplants and <strong>the</strong> Site Ion Exchange <strong>Plan</strong>t


4<strong>Sellafield</strong> <strong>Plan</strong>Issue 1 August 2011 Effluent Management SIXEP OperationsSIXEP Waste Retrievals Project & FSTR ProjectSIXEP Waste Retrievals OperationsSIXEP Contingency <strong>Plan</strong>t ConstructionMA Liquor Tank Farm Storage OperationsMA Tanks Local Treatment <strong>Plan</strong>t – ConstructionOverbuildings for MA Liquor Tank Farmand Active Tank FarmActive Tank Farm OpsEARP and EPMF OperationsSalt Evaporation <strong>Plan</strong>t Treatment OperationsSalt Evaporation <strong>Plan</strong>t POCOSolvent Treatment <strong>Plan</strong>t Treatment OperationsSolvent Treatment <strong>Plan</strong>t POCOSegregated Effluent Treatment <strong>Plan</strong>tLow Active Effluent <strong>Plan</strong>t POCOPreparation for POCO Commences<strong>Sellafield</strong> Active Discharge Management ProjectEffluent <strong>Plan</strong>ts Decommissioning


Issue 1 August 2011<strong>Sellafield</strong> <strong>Plan</strong> 5 Effluent Management Waste Retrievals Operations CommenceSIXEP Contingency<strong>Plan</strong>t CompletedOperationsCompleteConstructionCompleteActive Liquor OverbuildingConstructionOperations CompletePOCO CompletePreparation for POCO CommencesOperations CompletePOCO CompletePOCO CompleteCommissioning Complete


<strong>Sellafield</strong> <strong>Plan</strong>Issue 1 August 2011 Effluent Management Effluent Management


Issue 1 August 2011<strong>Sellafield</strong> <strong>Plan</strong> Effluent ManagementThe Effluent Management programmeconsists of two distinct groups of plants;<strong>the</strong> Low Active Effluent <strong>Plan</strong>ts and <strong>the</strong>Site Ion Exchange <strong>Plan</strong>t.The primary objective of <strong>the</strong> Site IonExchange <strong>Plan</strong>t at this time is to support<strong>the</strong> Fuel Handling <strong>Plan</strong>t in <strong>the</strong> deliveryof <strong>the</strong> Magnox Operating Programme.In <strong>the</strong> future, <strong>the</strong> Site Ion Exchange<strong>Plan</strong>t will play a key role in <strong>the</strong> LegacyPonds and Silos remediation strategy.Consequently <strong>the</strong> plant is beingenhanced by a number of improvementsincluding a waste retrievals project whichwill retrieve sludge and spent sand/clinoptilolite for encapsulation in <strong>the</strong><strong>Sellafield</strong> Direct Encapsulation <strong>Plan</strong>t.These sludge and clinoptilolite retrievalsare scheduled to begin in 2023/24.Storage of medium active (MA) liquideffluent in <strong>the</strong> Medium Active EffluentTank Farm was originally scheduled tobe completed at <strong>the</strong> end of <strong>the</strong> 2023/24financial year. The performance plancompletion date shows an accelerationof twelve months with an improvedcompletion date of <strong>the</strong> end of <strong>the</strong>2022/23 financial year. Active Tank Farmoperations will also end at this time.Post Operational Clean Out (POCO)operations will be completed in <strong>the</strong>Salt Evaporation <strong>Plan</strong>t and <strong>the</strong> SolventTreatment <strong>Plan</strong>t in 2023/24; and in<strong>the</strong> Low Active Effluent <strong>Plan</strong>t during2018/19. 37,648.3 39,763.8 48,761.0 126,173.1 1,242,912.1 1,369,085.2For more information please see pages 16 and 17 of <strong>the</strong> overview sectionClinoptilolite is a sand product used in <strong>the</strong>Site Ion Exchange <strong>Plan</strong>t. In <strong>the</strong> coming yearsthis material will be retrieved from <strong>the</strong> plantand transferred to bulk storage tanksThe Solvent Treatment <strong>Plan</strong>t at <strong>Sellafield</strong>is <strong>the</strong> only UK facility which can processradioactive solvent


<strong>Sellafield</strong> <strong>Plan</strong>Issue 1 August 2011 Effluent ManagementThe Effluent Management programmeas a whole is an essential enablingprogramme. The diagram belowillustrates its relationship with o<strong>the</strong>roperational and decommissioningfacilities.The Site Ion Exchange <strong>Plan</strong>t will continue toplay a role in supporting <strong>the</strong> safe managementof effluent at <strong>Sellafield</strong>Low Active Effluent <strong>Plan</strong>tsSea Discharge viaBreak PressureTankSegregated EffluentTreatment <strong>Plan</strong>tEnhanced ActinideRemoval <strong>Plan</strong>tWaste Packagingand Encapsulation<strong>Plan</strong>tDrum StoresLow Risk LADrain LiquorsSolvent Treatment<strong>Plan</strong>t LiquorsSalt EvaporatorConcentrateMA/LA Liquors inc.Magnox and ThorpFloc RetrievalSite Ion Exchange<strong>Plan</strong>t (SIXEP)Sand/Clino & SludgeSIXEP WasteRetrieval (SWR)Silos DirectEncapsulation<strong>Plan</strong>tDrum StoresSIXEP or SIXEPContingency <strong>Plan</strong>tSea Discharge viaBreak PressureTankFHP Purge FlowEncapsulation<strong>Plan</strong>t EffluentsSettling TanksKeyIn ProgrammeOutside ProgrammeSludge Packaging<strong>Plan</strong>t (SPP1)First GenerationMagnox StoragePondSolid Waste StorageSilo LiquorsFirst GenerationAGR StoragePond Purge


<strong>Sellafield</strong> <strong>Plan</strong> – Issue 1 August 2011Waste ManagementILW Treatmentand Storage


2<strong>Sellafield</strong> <strong>Plan</strong>Issue 1 August 2011 ILW Treatment and Storage An integrated nuclear wastemanagement programme is in placeat <strong>Sellafield</strong> which seeks to reducewaste volumes arising as part of currentcommercial activities as well as historicaloperations, ensuring that waste is storedsafely, minimising <strong>the</strong> risk to <strong>the</strong> publicand environment.Early waste management activitiesinvolved <strong>the</strong> storage of untreated wastefrom <strong>the</strong> first generation reprocessingoperations associated with <strong>the</strong> militaryprogramme which took place at <strong>Sellafield</strong>during <strong>the</strong> 1950s. Waste arising from<strong>the</strong> programme was historically held inponds and silos with no plans for futuretreatment and disposal.Intermediate level waste (ILW) includesmaterials such as fuel element cladding,contaminated equipment, radioactivesludge and plutonium contaminatedmaterial that arises from both historicaland current operations.At <strong>Sellafield</strong>, ILW is put into stainlesssteel drums, which are <strong>the</strong>n filled withcement grouting before being placedinto a special above-ground storagefacility on <strong>the</strong> site.The task today is to retrieve andprocess this material as well as manage<strong>the</strong> arisings produced as part of <strong>the</strong>ongoing decommissioning of historicaland redundant plants at <strong>Sellafield</strong> andCapenhurst alongside waste producedfrom current reprocessing activities.Waste management at <strong>Sellafield</strong> startedin <strong>the</strong> 1950s in support of <strong>the</strong> militaryprogramme at <strong>the</strong> timeILW includes <strong>the</strong> cladding which is removedfrom <strong>the</strong> outside of spent fuel elements as partof our reprocessing


Issue 1 August 2011<strong>Sellafield</strong> <strong>Plan</strong> 3 ILW Treatment and Storage An artist’s impression of <strong>the</strong> plannedComprehensive Import/Export Facility and BoxEncapsulation <strong>Plan</strong>t Product Store 1In order to continue to safelymanage intermediate level waste(ILW) at <strong>Sellafield</strong>, <strong>the</strong> solution is to: 3 ILW is grouted in steel drums making itsuitable for long term storage


4<strong>Sellafield</strong> <strong>Plan</strong>Issue 1 August 2011 ILW Treatment and Storage ILW Treatment and Design, Prototype Manufacture & Developmentof 3m³ ILW ContainerBEPPS & CIEF ConstructionBEPPS 1 & CIEF Storage Operations CommenceConstruction of Class II Decommissioning StoreOperation of Class II Decommissioning StoreEncapsulated Product Store 3EPS 3 ConstructionCompleteEncapsulated Product Store Storage OperationsWaste Packaging & Encapsulation <strong>Plan</strong>tStorage and Treatment OperationsMiscellaneous Beta Gamma Waste StoreStorage OperationsDecomm ILW Encap <strong>Plan</strong>t (DILWEP)New ConstructionDecom ILW Encap <strong>Plan</strong>t (DILWEP) OperationsThe contract for <strong>the</strong> Early Contractor EngagementPhase of <strong>the</strong> Box Encapsulation <strong>Plan</strong>t ProductStore (BEPPS) and Comprehensive Import/ExportFacility (CIEF) Project has been awardedThe team working on <strong>the</strong> Encapsulated ProductStore 3 project has safely conducted threemajor lifts, one of which involved <strong>the</strong> lifting ofa huge 102-tonne shield door into <strong>the</strong> plantInside a store at <strong>Sellafield</strong>


Issue 1 August 2011<strong>Sellafield</strong> <strong>Plan</strong> 5 ILW Treatment and Storage 3 BEPPS 1 & CIEF Construction CompleteBEPPS 3 Construction Project CommencesBEPPS 2 Construction Project CommencesDecommissioning StoreConstruction CompleteEncapsulation Construction CompleteExternal view of Encapsulated ProductStore 3 during constructionOperations under way inside <strong>the</strong> WasteEncapsulation <strong>Plan</strong>t


<strong>Sellafield</strong> <strong>Plan</strong>Issue 1 August 2011 ILW Treatment and Storage The intermediate level waste (ILW)programme is an essential enablingprogramme for <strong>Sellafield</strong>. It immobilisesILW streams and puts MiscellaneousBeta Gamma Waste into interim safestorage.One of <strong>the</strong> largest construction projectswithin <strong>the</strong> ILW programme is <strong>the</strong> BoxEncapsulation <strong>Plan</strong>t Product Store 1 andComprehensive Import/Export Facility.Construction is scheduled for completionduring <strong>the</strong> 2018 financial year which willbe immediately followed by <strong>the</strong> start ofoperations in that facility.Ano<strong>the</strong>r construction project,Encapsulated Product Store 3, is duefor completion during <strong>the</strong> 2012/13financial year. The operations of all of <strong>the</strong>encapsulated product stores at <strong>Sellafield</strong>will continue throughout this reportingperiod.The construction of a new facility, <strong>the</strong>Decommissioning Intermediate LevelWaste Encapsulation <strong>Plan</strong>t, which willsupport hazard and risk reduction workat <strong>Sellafield</strong>, is due to start in 2015. It isscheduled for completion in 2025.A key project within this programme willbe <strong>the</strong> design, prototype manufactureand development of 3m 3 ILW containers.These containers are an essentialpart of much of <strong>the</strong> work that we areplanning in <strong>the</strong> risk and hazard reductionprogramme. Financial information withheld due to commercial confidentialityFor more information please see pages 16 and 17 of <strong>the</strong> overview sectionA cross section view of ILW which hasbeen grouted in cement for long termstorage


Issue 1 August 2011<strong>Sellafield</strong> <strong>Plan</strong> ILW Treatment and Storage The BEPPS1 and CIEF project willincorporate <strong>the</strong> completion andexpansion of a purpose built aboveground nuclear waste store and <strong>the</strong>construction of a new import/exportfacility to handle radioactive waste,arising from <strong>the</strong> ongoing nucleardecommissioning and high hazardreduction operations at <strong>Sellafield</strong>. When completed in late 2012 <strong>the</strong>Encapsulated Product Store 3 will be <strong>the</strong>new intermediate level waste (ILW) storefor <strong>the</strong> <strong>Sellafield</strong> site, providing additionalcapacity to support <strong>the</strong> two existingstores.The store will receive ILW arising from<strong>the</strong> sites reprocessing operations andILW from <strong>the</strong> work being undertakento maximize <strong>the</strong> reduction of risk to <strong>the</strong>public and <strong>the</strong> environment as part of <strong>the</strong>site’s high hazard clean-up operations.3m 3 A key project within <strong>the</strong> ILW treatmentand storage programme is <strong>the</strong> design,prototype and development of 3m 3 ILWcontainers. These containers are anessential part of <strong>the</strong> work that we areplanning in <strong>the</strong> risk and hazard reductionprogramme.When completed in 2012 <strong>the</strong> EncapsulatedProduct Store 3 will provide storage for ILWMagnox & ThorpEncapsulation<strong>Plan</strong>tsDismantlingAGR FuelILWWaste Packaging& Encapsulation<strong>Plan</strong>tEncapsulatedILWWaste Packaging& Encapsulation<strong>Plan</strong>t StoreEncapsulatedILWEncapsulatedProductStore 1-2EncapsulatedProductStore 3EPS ExportFacilitySupporting Project:3m 3 Box Project includes <strong>the</strong> design,prototype, manufacture and testing ofwaste containers for ILW arisings fromLP&S and decommissioning.This will hold <strong>the</strong> processed outputfrom decommissioning retrievals andtreatment facilities.Pre-packagedILWContainersComprehensiveImport/ExportFacilityImport route for LP&S anddecommissioning ILWstainless steel boxes to a suiteof product stores BEPPS andexport route to <strong>the</strong> GDF.Box Encapsulation<strong>Plan</strong>t ProductStores 1-4Final Conditioningfor DisposalUK GeologicalDisposal FacilityKeyCurrent facility<strong>Sellafield</strong> andExternalConsignorsMiscellaneousBeta GammaWaste StoreFacility yet to be built


<strong>Sellafield</strong> <strong>Plan</strong> – Issue 1 August 2011Waste ManagementLLW and SubLLW Treatment


2<strong>Sellafield</strong> <strong>Plan</strong>Issue 1 August 2011 LLW and Sub LLW Treatment At <strong>Sellafield</strong> an integrated nuclear wastemanagement programme is in placewhich seeks to reduce waste volumesarising as part of current activities aswell as historic operations, ensuring thatwaste is stored safely, minimising <strong>the</strong> riskto <strong>the</strong> public and <strong>the</strong> environment.LLW, which forms 80% of all nuclearwaste, is only slightly radioactive andincludes things like protective clothing,laboratory equipment, paper towels andgloves etc, items that have been used in<strong>the</strong> controlled areas of a nuclear site, or inhospitals and nuclear research centres.The waste is treated at <strong>Sellafield</strong> at <strong>the</strong>Waste Monitoring and Compaction <strong>Plan</strong>t.At <strong>the</strong> Waste Monitoring and Compaction<strong>Plan</strong>t <strong>the</strong> waste is placed inside boxeswhich are monitored and <strong>the</strong>n compacteddown to a quarter of <strong>the</strong>ir original sizeusing a high force compactor.The facility also processes waste fromo<strong>the</strong>r waste producers. The material isreceived in drums which are monitoredand compacted.These drums and boxes are <strong>the</strong>n placedinside an ISO freight container andtransported mainly by rail to <strong>the</strong> LowLevel Waste Repository in West Cumbria.Non compactable waste is placed in ISOcontainers and sent to <strong>the</strong> Low LevelWaste Repository by rail.Only 50% of <strong>the</strong> solid low level radioactivewaste disposed of at LLWR is from<strong>Sellafield</strong>. The rest comes from hospitals,universities, research establishments andindustries, including <strong>the</strong> nuclear industry,around <strong>the</strong> UK.Wherever possible, work will beundertaken to minimise <strong>the</strong> futuregeneration of all nuclear waste. At<strong>Sellafield</strong> today <strong>the</strong>re are a number ofworkstreams under way concernedwith <strong>the</strong> treatment and storage of LLW,including waste sorting, segregation andsize reduction techniques and using <strong>the</strong>supply chain for optimum disposal routes.Metallic waste is treated via <strong>the</strong> MetalsRecycling Facility and where possibleexempted for re-use, volume reduced tominimise <strong>the</strong> volume of waste sent to <strong>the</strong>Low Level Waste Repository or sent to<strong>the</strong> supply chain for treatment.Low level waste is made up of things likepaper towels and laboratory equipmentwhich has been used in <strong>the</strong> controlledareas of a nuclear site or in hospitalsLow level waste at <strong>Sellafield</strong> also includespersonal protective clothing which hasbeen used in controlled areas of <strong>the</strong> siteWaste sorting operations inside <strong>the</strong> WasteMonitoring and Compaction <strong>Plan</strong>t at<strong>Sellafield</strong>


Issue 1 August 2011<strong>Sellafield</strong> <strong>Plan</strong> 3 LLW and Sub LLW Treatment Our focus is on safely managing low levelnuclear waste while implementing newtechnology (such as <strong>the</strong> wheelabrator seenhere) to reduce <strong>the</strong> volumes of waste whichneeds to be disposed of


4<strong>Sellafield</strong> <strong>Plan</strong>Issue 1 August 2011 LLW and Sub LLW Treatment LLW and Sub LLW Waste Monitoring & Compaction (WAMAC)<strong>Plan</strong>t Treatment OperationsWAMAC – POCOWAMAC – DecommissioningMetals Recycling Treatment OperationsNew LLW Metals Recycling & Treatment FacilityCurrent Metals Recycling Facility – POCOLLW Sort/Segregate/Size Reduction FacilityLLW/Sort/Segregate/Size Reduction Facility– OperationsCLESA OperationsOff Site Disposal LLWR – WasteOperations TasksLLW is placed into containers which are<strong>the</strong>n compacted to reduce <strong>the</strong>ir sizeThe site’s wheelabrator facilities removesurface contaminationElevated view of CLESA Disposal Facility


Issue 1 August 2011<strong>Sellafield</strong> <strong>Plan</strong> 5 LLW and Sub LLW Treatment WAMAC OperationsCompletePOCOCompleteConstruction of TreatmentFacility CompleteCurrent Metals RecyclingFacility POCO CompleteConstructionCompleteLow level waste is sent to <strong>the</strong> Low LevelWaste Repository for disposal


<strong>Sellafield</strong> <strong>Plan</strong>Issue 1 August 2011 LLW and Sub LLW Treatment The low level waste (LLW) and sub-lowlevel waste programme is a key enablerin supporting ongoing hazard reductionand decommissioning activities.It includes <strong>the</strong> facilities to process andexport LLW to <strong>the</strong> Low Level WasteRepository or to an alternative futuredisposal facility.The schedule will see <strong>the</strong> completion ofactivities at <strong>the</strong> Waste Monitoring andCompaction Facility at <strong>Sellafield</strong> in 2020.The Waste Monitoring and CompactionFacility will <strong>the</strong>n go through a twelvemonth Post Operational Clean Out(POCO) period before decommissioningwork starts in 2021.Metals Recycling Treatment operationswill continue throughout this reportingperiod. A new LLW metals recyclingfacility to support <strong>the</strong>se operations isdue for completion in 2018. The originaltreatment facility will undergo POCOwork during <strong>the</strong> 2019/20 financial year.Construction of a new LLW sort/segregate/size reduction facility willbegin in 2012 and will start its operationsduring 2018/19.The programme will aim to identifycombustible materials and metallicmaterial suitable for treatment via <strong>the</strong>supply chain to minimise volumes ofwaste being disposed of at <strong>the</strong> LowLevel Waste Repository. 23,790.1 29,874.9 28,909.5 79,735.7 405,599.2 485,334.9For more information please see pages 16 and 17 of <strong>the</strong> overview section


Issue 1 August 2011<strong>Sellafield</strong> <strong>Plan</strong> LLW and Sub LLW Treatment Low level waste (LLW) at <strong>Sellafield</strong>is treated at <strong>the</strong> Waste Monitoringand Compaction <strong>Plan</strong>t. At <strong>the</strong> WasteMonitoring and Compaction <strong>Plan</strong>t <strong>the</strong>waste is monitored and <strong>the</strong>n compacteddown to a quarter of its original sizeusing a high force compactor.These drums are <strong>the</strong>n placed inside anISO freight container and transportedmainly by rail to <strong>the</strong> Low Level WasteRepository in West Cumbria. Noncompactable waste is packaged asefficiently as possible and sent to <strong>the</strong>Low Level Waste Repository. We have a metal decontamination facilityon <strong>the</strong> <strong>Sellafield</strong> site which is used tomechanically remove <strong>the</strong> outer surfaceof contaminated steel to clean metal forrecycling. Once LLW has been compacted at<strong>Sellafield</strong> it is transported for disposalat <strong>the</strong> UK’s national Low Level WasteRepository, approximately seven milessouth of <strong>the</strong> <strong>Sellafield</strong> site. We will continue to work with <strong>the</strong> LowLevel Waste Repository to identifysuitable supply chain options for <strong>the</strong>treatment of waste.ExternallyGenerated LLWCompactable Waste<strong>Sellafield</strong>Generated LowActivity Wastem 3WAMAC LLWR m 3WAMACLLWR Metal WastetonneWheelabrator, Waste Tanks anddecontamination facility LLWR VLLWm 3Calder Landfill ExtensionSegregated Area (CLESA)Key New Generations of Waste Treatment <strong>Plan</strong>ts: Acronyms


<strong>Sellafield</strong> <strong>Plan</strong> – Issue 1 August 2011InfrastructureInfrastructure


2 <strong>Sellafield</strong> <strong>Plan</strong>Issue 1 August 2011Infrastructure Site Maintenance& EngineeringProgrammeSupport RolesOperationsSecurity, Safeguards,Emergency ManagementInfrastructure ProjectsInformation Services& Technology


Issue 1 August 2011<strong>Sellafield</strong> <strong>Plan</strong> 3Infrastructure Key Infrastructure Objectives Meeting Customer Requirements The infrastructure programme manages<strong>the</strong> rail service provision at <strong>Sellafield</strong> – avital service that supports a number ofoperating plantsThere are thousands of metres of pipeworkacross <strong>the</strong> <strong>Sellafield</strong> site which providesessential services to our buildings, all ofwhich must be maintainedThe <strong>Sellafield</strong> site has its own fire andrescue service which includes fire response,ambulance and paramedics and search andrescue teams


4<strong>Sellafield</strong> <strong>Plan</strong>Issue 1 August 2011Infrastructure Analytical Services Operations & Maintenance Replacement Analytical ServicesFacility – New BuildFlask Maintenance Service (Cuboid and Oxide)Transport Services (Road and Rail)Replacement Flask Maintenance FacilityFacilities Management (Accommodation etc)Active Area Support (Laundry, Changeroomand Decontamination)Replacement Decontamination CentreOperation of Combined Heat and Power <strong>Plan</strong>tCombined Heat and Power – Fellside Boiler ParkReplacement of Combined Heat and Power <strong>Plan</strong>tConstructionCompleteProvision of Utilities Services (Steam, Electricity,Water, Compressed Air) and Bulk ChemicalsRefurbishment and Replacement of UtilityServices (Substation, Grid Transformers,Chemical Storage and Distribution, SteamLine and Water Systems)Roads InfrastructureSubstation 6 & 7 CompleteCivil InfrastructureSafeguards, Security and EmergencyManagementLaundry Replacement and Refurbishment


Issue 1 August 2011<strong>Sellafield</strong> <strong>Plan</strong> 5Infrastructure ConstructionCompleteConstructionCompleteConstruction CompleteConstruction CompleteConstruction Complete


<strong>Sellafield</strong> <strong>Plan</strong>Issue 1 August 2011Infrastructure 300,855.6 303,087.4 269,467.2 873,410.2 2,968,125.0 3,841,535.2 Maintenance work being carried out atCalder Hall.Our employees use changerooms toaccess radiological areas. The provision of<strong>the</strong>se services is essential in getting ouremployees to <strong>the</strong>ir plant


Issue 1 August 2011<strong>Sellafield</strong> <strong>Plan</strong>Infrastructure Flask maintenance is an essential part of <strong>the</strong>infrastructure programme and supports bothMagnox and Thorp reprocessing as well as<strong>the</strong> defuelling of Magnox stationsSteamline maintenance work under wayat <strong>Sellafield</strong>. Steam is provided to <strong>the</strong> siteby <strong>the</strong> Combined Heat and Power <strong>Plan</strong>tA number of employees at <strong>Sellafield</strong> arerequired to wear personal protective clothingwhen carrying out <strong>the</strong>ir work. The on sitelaundry ensures that this clothing is availablewhen needed


<strong>Sellafield</strong> <strong>Plan</strong>Issue 1 August 2011Infrastructure


<strong>Sellafield</strong> <strong>Plan</strong> – Issue 1 August 2011Functions


2<strong>Sellafield</strong> <strong>Plan</strong>Issue 1 August 2011 Functional SupportCorporate ResponsibilityStakeholder RelationsThe portfolio includes functional areasthat support <strong>the</strong> operation of <strong>Sellafield</strong><strong>Ltd</strong>. Services within <strong>the</strong> portfolio suchas Finance, Engineering and DesignCapability, are also provided to o<strong>the</strong>rNDA sites. The key strategic objectivefor Functions is to provide effectivefunctional support to <strong>Sellafield</strong> <strong>Ltd</strong>operations in <strong>the</strong> most cost-efficientmanner.General scope of workEngineering& DesignCapabilitySiteManagementProcurementCommercial& ContractBusinessSupportProductionOperationsSupportStrategy &ProgrammesEnvironmentalHealth & SafetyQuality Programme Finance HumanManagementResourcesRegulatoryLiaison<strong>Sellafield</strong>CommunicationINS Relations


Issue 1 August 2011<strong>Sellafield</strong> <strong>Plan</strong>Safe working in our functional areasis as important as safe working in ouroperational areasThe functional programme includes ourwork with <strong>the</strong> supply chainThe functional areas of <strong>Sellafield</strong> providesupport to <strong>the</strong> operational areas includingservices such as employee training anddevelopment 185,805.9 175,474.9 167,433.0 528,713.8 1,856,077.8 2,384,791.5For more information please see pages 16 and 17 of <strong>the</strong> overview sectionSafe management of <strong>the</strong> environmentis a vital role within <strong>the</strong> functionalprogrammeOur occupational health departmentprovides 24/7 health care to ouremployees while working on siteOur engagement with <strong>the</strong> local communityincludes an extensive educational programmewhich takes science and engineeringambassadors into local schools


<strong>Sellafield</strong> <strong>Plan</strong> – Issue 1 August 2011End StatesLand and GroundwaterRemediation


2<strong>Sellafield</strong> <strong>Plan</strong>Issue 1 August 2011 Land and Groundwater RemediationRainfall/RechargeRainfall/RechargeSurfaceRunoffMade GroundIrishSeaBeachEhenSpitRiverUnsaturatedZoneAnthropogenicRecharge BeachSpringsPercolationExchange with RiversDrift Groundwater FlowSaline InterfaceBoreholesDisposalTrenchPerched GroundwaterRegional Groundwater FlowContaminantPlumeBuriedChannelUpper GroundwaterWater TableDriftSandstoneThe objectives of <strong>the</strong> Land QualityProgramme are to understand, control,manage and remediate <strong>the</strong> legacy ofcontaminated land and groundwater at<strong>Sellafield</strong> in order to ensure protectionof <strong>the</strong> work force, <strong>the</strong> public and <strong>the</strong>environment.To meet <strong>the</strong>se objectives <strong>the</strong> LandQuality Programme integratesprogramme management,characterisation, assessment andremediation management, groundwatermanagement, and data management.During <strong>the</strong> short to medium term <strong>the</strong>main objectives of <strong>the</strong> Land QualityProgramme are to minimise any increasein contaminated land inventory andto limit expansion of <strong>the</strong> volume ofcontaminated land.The longer term objective for <strong>the</strong> LandQuality Programme is to work towards<strong>the</strong> Nuclear Decommissioning Authority’s(NDA) agreed end-state as stated in <strong>the</strong>NDA strategy.The Land and Groundwater Programmeincludes a groundwater monitoringprogramme which characterises,assesses and monitors <strong>the</strong> groundwaterquality underlying <strong>the</strong> <strong>Sellafield</strong> sitethrough groundwater sample acquisitionand analysis.Sampling <strong>the</strong> groundwater monitoringwells and evaluating <strong>the</strong> sample analysisdata provides an understanding of<strong>the</strong> nature and extent of groundwatercontamination beneath <strong>the</strong> <strong>Sellafield</strong> site.Sampling boreholes at <strong>Sellafield</strong> helpus to understand, control, manage andremediate <strong>the</strong> legacy of contaminatedland and groundwaterThere are more than 140 boreholesacross <strong>the</strong> <strong>Sellafield</strong> siteManaging land contamination in siturequires a comprehensive understandingof <strong>the</strong> groundwater under <strong>the</strong> site


Issue 1 August 2011<strong>Sellafield</strong> <strong>Plan</strong> 3 Land and Groundwater Remediation Borehole drilling operations on <strong>the</strong> site The groundwater sample schedule providestime-series data to track <strong>the</strong> movement ofcontaminants


4<strong>Sellafield</strong> <strong>Plan</strong>Issue 1 August 2011 Land and Groundwater Remediation Land andGroundwaterRemediation Land Quality DeliveryProduction of an Annual EnvironmentAgency ReportThe objective of <strong>the</strong> land andgroundwater remediation programmeis to deliver clean-up of <strong>the</strong> <strong>Sellafield</strong>site to <strong>the</strong> agreed end-state of partialremediation, followed by indefiniteinstitutional control.This is an extensive piece of work whichstretches out over <strong>the</strong> next 110 years.Land and groundwater monitoring isdone on and off <strong>the</strong> <strong>Sellafield</strong> siteMonitoring activities under way outsideof <strong>the</strong> <strong>Sellafield</strong> siteEvery year we publish a groundwatermonitoring report which is available on<strong>the</strong> <strong>Sellafield</strong> <strong>Ltd</strong> website


Issue 1 August 2011<strong>Sellafield</strong> <strong>Plan</strong> 5 Land and Groundwater Remediation 3,302.9 3,254.2 3,266.0 9,823.1 38,954.2 48,777.3For more information please see pages 16 and 17 of <strong>the</strong> overview section


<strong>Sellafield</strong> <strong>Plan</strong>Issue 1 August 2011 Land and Groundwater Remediation Managing <strong>the</strong> contamination in siturequires a comprehensive understandingof <strong>the</strong> groundwater under <strong>the</strong> siteincluding estimates of <strong>the</strong> extent ofcontamination and how it moveswith time. A way to achieve thisunderstanding is through <strong>the</strong> collection,analysis and evaluation of groundwatersamples from an appropriate network ofmonitoring wells.In 2010 <strong>the</strong> groundwater monitoringnetwork increased to 142 individualmonitoring wells and 208 piezometers.Piezometers are individual pipes thataccess a screened interval in <strong>the</strong> pipethat allows sampling of groundwaterfrom a selected depth interval within <strong>the</strong>monitoring well.Implementation of <strong>the</strong> Land QualityProgramme also requires an integratedapproach that combines <strong>the</strong> followingactivities: regulations and site-specificregulatory requirements of physical, chemical, andradiochemical trends in <strong>the</strong> groundand groundwater contaminant distribution in <strong>the</strong>ground and groundwater bymaintenance and optimisation of <strong>the</strong>monitoring well programme contaminant transport attenuationand provide time series datamonitoring well maintenance,redevelopment and decommissioning in groundwater and risks to relevantreceptors information including: databases,reports, numerical models andparameters implementation of contaminated landmanagement, remediation optionsand clean-up activities in line with<strong>the</strong> <strong>Sellafield</strong> waste managementhierarchy to human health (both <strong>the</strong> workforceand <strong>the</strong> public) and environmentalreceptors (including groundwater)are as low as reasonably practicable(ALARP) Programme to prevent, as far asreasonably practicable, fur<strong>the</strong>r leaksto ground from <strong>the</strong> <strong>Sellafield</strong> Site inorder to ensure a minimal increase in<strong>the</strong> subsurface inventory Programme infrastructure (build andmaintain a suitably qualified andexperienced staff; maintenance of <strong>the</strong>intelligent customer base; acquisitionand utilisation of hydrogeologicdata analysis tools such as GIS andnumerical models; and data/recordsmanagement including environmentaldata management) internal and external stakeholderengagement plansThe safety of our employees and <strong>the</strong>environment remains our number one priorityContinualBoreholeSamplesBorehole Sampling Operations and ModellingWork scope will include generating an updated conceptual modeland delivery of a suite of technical reports. This will includefactual and interpretative findings from this project.Long Term Modelling/SamplingThis scope includes: decision making, sampling, analysis,data assessment, modelling, risk assessment work, assetcare and maintenance along with reporting requirementsto <strong>the</strong> Environment Agency on an annual basis.Land RemediationThis work scope involves <strong>the</strong> planning and implementation, and remediation ofhistoric subsurface disposal facilities, contaminated soils and groundwater within andoutside <strong>the</strong> <strong>Sellafield</strong> Site boundary in conformance with regulations, regulatoryagreements and ‘as low as reasonably practicable’ (ALARP) principles.


<strong>Sellafield</strong> <strong>Plan</strong> – Issue 1 August 2011Socio-economicSocio-economic


2 <strong>Sellafield</strong> <strong>Plan</strong>Issue 1 August 2011Socio-economic Over <strong>the</strong> years <strong>the</strong> site has supportedthousands of well-paid jobs. But as <strong>the</strong>main focus of activity began to changefrom reprocessing to decommissioning, itwas feared that thousands of jobs wouldbe lost in <strong>the</strong> West Cumbrian economy.However, <strong>the</strong> 2011 Performance <strong>Plan</strong>provides crucial new information to <strong>the</strong>economic development of West Cumbria.Acceleration of <strong>the</strong> decommissioningprogramme at <strong>Sellafield</strong> provides higheremployment levels for a longer periodof time than would o<strong>the</strong>rwise have been<strong>the</strong> case. This allows us to invest timeand resource to retraining and reskillingour workforce to adapt to <strong>the</strong> futurechallenges on <strong>the</strong> site.Today, <strong>the</strong> site employs over 10,000people and offers opportunities for<strong>the</strong> local supply chain and increasedprospects of inward investment.However, we recognise that, despite<strong>the</strong> prosperity offered to West Cumbriathrough employment in <strong>the</strong> nuclearindustry, some sections of <strong>the</strong> communitystill suffer from high levels of worklessnessand deprivation. We will continue tosupport <strong>the</strong> organisations and agenciesthat are addressing this issue.Toge<strong>the</strong>r with Nuclear ManagementPartners and <strong>the</strong> NuclearDecommissioning Authority, <strong>Sellafield</strong>is funding Britain’s Energy Coast WestCumbria (BECWC), <strong>the</strong> body chargedwith delivering economic developmentfor <strong>the</strong> area.Successful delivery of <strong>the</strong> Performance<strong>Plan</strong>, combined with <strong>the</strong> work of oureconomic development partners, providesa win-win outcome for all involved – valuefor money for Government and <strong>the</strong>taxpayer, accelerated progress in <strong>the</strong>NDA’s mission, a positive future for ourworkforce and <strong>the</strong> prospects of economicdevelopment for <strong>the</strong> local community.Understanding <strong>the</strong> meaning of successis an important part of our socioeconomicprogramme. We will workwith our Local Authority partners usingindependent advice to develop anobjective perspective of how successwill be defined, measured and tracked.A detailed, agreed set of relevantperformance indicators will provide aneffective process against which socioeconomicperformance can be measured. Our employees are very much part of <strong>the</strong>community, undertaking key roles suchas councillors, school governors andrescue volunteersThe large work programme at <strong>Sellafield</strong>will continue to provide opportunities for<strong>the</strong> supply chainThe West Cumbria Development Agencyis supported solely by nuclear investment


Issue 1 August 2011<strong>Sellafield</strong> <strong>Plan</strong> 3Socio-economic Long term manpower profile12,000KeyStaffing Level FTEs - High RangeStaffing Level FTEs - Low RangeFTE / Head Count Nos10,0008,0006,0004,0002,000PotentialEmploymentRangeThe manpower profile curve ismade up of 85% <strong>Sellafield</strong> and15% Risley employees02011201420172020202320262029203220352038204120442047205020532056205920622065206820712074207720802083208620892092209520982101210421072110211321162119Short term manpower profile12,000KeyStaffing Level FTEs - High RangeStaffing Level FTEs - Low RangeFTE / Head Count Nos10,0008,0006,0004,000PotentialEmploymentRange2,00002011 2012 2013 2014 2015 2016 2017 2018 2019 2020 2021The manpower profile above is shown asa range, due to <strong>the</strong> complexities inherentin such long term planning. The upperboundary assumes acceleration of ourworkscope and increased efficienciesin how we deliver our work. The lowerboundary represents increased efficiencywith limited acceleration. In reality, fundinglevels will determine where within thisrange our employment levels will be.The information provided here allowsfor an update of <strong>the</strong> West Cumbriasocio-economic study undertaken byconsultants ERM in 2001. This work iscurrently being undertaken funded byBritain’s Energy Coast and is due toreport in late 2011.The manpower profile shown above isof course based on our current plansand forecasts and is obviously subjectto change, whe<strong>the</strong>r that be changes inpolicy, resource allocation or o<strong>the</strong>r eventsthat could impinge on our industry.Breakdown of <strong>Sellafield</strong> <strong>Ltd</strong>employment by area:LocationProportion of <strong>Sellafield</strong><strong>Ltd</strong> workforce:Allerdale 21.5%Copeland 58.4%Carlisle (Area) 0.6%Barrow (Area) 3.7%Risley 7%Risley (Area) 1.3%O<strong>the</strong>r 7.5%Source: <strong>Sellafield</strong> <strong>Ltd</strong>The work within <strong>the</strong> <strong>Sellafield</strong> <strong>Plan</strong> willbe delivered using a combination of<strong>Sellafield</strong> <strong>Ltd</strong>, reachback and supplychain employeesOur employees have <strong>the</strong> skills andexperience to safely manage allcategories of nuclear waste


4 <strong>Sellafield</strong> <strong>Plan</strong>Issue 1 August 2011Socio-economic Supply chain spend1,200KeyHigh rangeLow range1,0008006004002000201120142017202020232026202920322035Spend in millions2038204120442047205020532056205920622065206820712074207720802083208620892092209520982101210421072110211321162119At <strong>Sellafield</strong> more than £800 million ayear is spent in <strong>the</strong> supply chain. Thisin itself is a significant benefit to <strong>the</strong> UKeconomy, and, with almost 30% of thisexpenditure being retained within WestCumbrian business, a vital part of <strong>the</strong>local economy.Historically <strong>Sellafield</strong> <strong>Ltd</strong> procurementactivities were seen as operating atarms length, on a short term contractingbasis which detracted from adding valueand building relationships. This type ofarrangement produced little gain forei<strong>the</strong>r <strong>Sellafield</strong> <strong>Ltd</strong> or <strong>the</strong> supply chain,both being in a constant state of fluxdue to <strong>the</strong> short term nature of <strong>the</strong>contracts awarded.The external environment is alsochanging and is increasingly presentingreal threats to <strong>Sellafield</strong> <strong>Ltd</strong> access toskills and resources. We are looking toalign procurement activities to industrybest practice and follow <strong>the</strong> exampleset by international and national leadingcompanies.The new Acquisition Strategy isunderpinned and focused on long termcollaborative relationships with <strong>the</strong> supplychain organisations. The awarding oflonger term contracts, so called ‘AnchorTenants’, provides better security for <strong>the</strong>supply chain which drives knowledgeforward and provides incentives forinvestment in education, skills, technologyand infrastructure.Collaborative working using this ‘AnchorTenants’ approach is a way to build anuclear knowledge economy in WestCumbria, which aligns with <strong>the</strong> visionfor <strong>the</strong> area to become Britain’s EnergyCoast. It is expected that a moreintegrated supply base associated with<strong>Sellafield</strong> <strong>Ltd</strong> would provide enhancedopportunities and attract o<strong>the</strong>r servicecompanies to West Cumbria.Long term contracts allow for long termleases and make local infrastructuredevelopment more economically viable.They also help employment in WestCumbria to become more diverse androbust, encouraging fur<strong>the</strong>r participationand opportunity.<strong>Sellafield</strong> <strong>Ltd</strong> is working with <strong>the</strong> NDAand major Tier 2 suppliers to helpimprove <strong>the</strong> visibility of opportunities forsmaller suppliers.Our supply chain supports ourcommercial operations as well asconstruction and risk and hazardreduction workWe are committed to regular engagementwith our supply chainWe have <strong>the</strong> greatest concentration ofnuclear workers in Europe at <strong>Sellafield</strong>supporting risk and hazard reduction


Issue 1 August 2011<strong>Sellafield</strong> <strong>Plan</strong> 5Socio-economic The Nuclear Partners are funders ofBritain’s Energy Coast to a sum ofapproximately £10m per annumToge<strong>the</strong>r with Nuclear ManagementPartners and <strong>the</strong> NuclearDecommissioning Authority, <strong>Sellafield</strong> <strong>Ltd</strong>is supporting Britain’s Energy Coast WestCumbria (BECWC), <strong>the</strong> body chargedwith delivering economic development for<strong>the</strong> area.BECWC is made up of Local Authorityand public and private sector partners,toge<strong>the</strong>r with <strong>the</strong> nuclear partners’financial and human resource input. Thecombined expertise of <strong>the</strong>se partners willdeliver real transformational change inWest Cumbria.<strong>Sellafield</strong>’s socio-economic commitmentalso includes support for skillsdevelopment and charitable projects.<strong>Sellafield</strong> <strong>Ltd</strong>Nuclear FundingPartnership<strong>Sellafield</strong> <strong>Ltd</strong>NDANMP£10m per annumBritain’s EnergyCoast WestCumbriaWCDA– supportingbusiness start-upSupply chainspendEducationprogrammein schoolsDirect andindirectemploymentGraduateand apprenticerecruitmentCommunityvolunteering£100k p/acharitabledonationsBEC Campus– improving skillsat all levelsBEC Cluster– creating and growinglocal businessesWest Cumbria Tourism– attracting visitorsto <strong>the</strong> area Whitehaven FestivalThrough our involvement with Britain’s EnergyCoast we have provided significant investmentto <strong>the</strong> regeneration of <strong>the</strong> port of Workington


6<strong>Sellafield</strong> <strong>Plan</strong>Issue 1 August 2011Socio-economic Socio-economic investment – <strong>Sellafield</strong> <strong>Ltd</strong>£3.1 million annuallySocio-economic investment – NMP Our work with local schools will continueto focus on <strong>the</strong> provision of teachingmaterials aimed at achieving an earlyinterest in science and engineeringrelated topics and involving teachersthroughout <strong>the</strong> production of teachingmaterials and in researching what isrequired in schools. This ensures that ourmaterial meets <strong>the</strong> national curriculum.<strong>Sellafield</strong> <strong>Ltd</strong>’s dedicated team ofScience, Technology, Engineeringand Maths (STEM) ambassadors willcontinue to provide an ongoing variedprogramme of educational events tothose schools in our travel to work area.There are around 200 ambassadors at<strong>Sellafield</strong> and Risley. They are employeesfrom STEM backgrounds who volunteeras inspiring role models for young people.Skills at <strong>Sellafield</strong> – Schemes Intake TrendNew recruits180160140120100806040200251941251446Key2529622005 2006 2007 2008 2009 2010 2011STEM ambassadors enable teachers tomake links from <strong>the</strong> curriculum to howscience, technology, engineering andmaths is practised in <strong>the</strong> world of work.Community App Graduates Trainee Scheme Apprentice25391270254212852532158725341287Numberspredicted to holdat current levelsfor 5 yearsWe will continue to work with localschools to support science andengineering related topicsOur work with local schools includes avaried programme of educational eventssuch as robotics daysOur STEM ambassadors are inspiring rolemodels for school children


Issue 1 August 2011<strong>Sellafield</strong> <strong>Plan</strong>Socio-economic Since Nuclear Management Partnerstook over at <strong>Sellafield</strong> in 2008, <strong>the</strong>number of graduates, apprentices andtechnical trainees recruited directly into<strong>the</strong> company has increased significantly.The total intake for 2011 is almostdouble that for 2005 and <strong>the</strong> plan is tocontinue to recruit at this level for <strong>the</strong>foreseeable future.In addition to training apprentices fordirect recruitment to <strong>Sellafield</strong>, wealso fund <strong>the</strong> training of CommunityApprentices through GEN II. Since thisscheme began in 2004, over 165 youngmen and women have successfullycompleted <strong>the</strong>ir apprenticeships andhave attained full time employment withbusinesses across Cumbria and <strong>the</strong>supply chain. As a result of fundingreceived from <strong>Sellafield</strong> <strong>Ltd</strong>, GEN II hasmanaged to leverage in a fur<strong>the</strong>r £1.3mof government funding to support <strong>the</strong>programme. As part of <strong>Sellafield</strong> <strong>Ltd</strong>’s CommunityInvolvement Policy, we will supportExecutives and employees whovolunteer to support a range of localcommunity activities, which help toleverage sustainable benefits.These activities range from communitysecondments, school activities, suchas mock interviews, industry days,STEM Ambassador activities, electedGovernment duties, school governors,Justice of <strong>the</strong> Peace, Territorial Army,Mountain Rescue, RNLI, etc. As in previous years a budget of£100k will be retained for making smallcharitable donations and to providematch funding for staff charitableactivities. <strong>Sellafield</strong> <strong>Ltd</strong> aims to provideincentives that encourage communitygroups and staff to engage in activitiesthat align with <strong>the</strong> West CumbriaCommunities that Work Strategy.Our employees complete a number ofcommunity regeneration events every yearincluding <strong>the</strong> refurbishment and decorationof community buildingsWe invest a significant amount of moneyon <strong>the</strong> training and development of ouremployeesOur employees undertake a wide rangeof events in order to raise money for localcharities and we are proud to support <strong>the</strong>irachievements through match funding


<strong>Sellafield</strong> <strong>Plan</strong>Issue 1 August 2011Socio-economic with NDA and Nuclear ManagementPartners operational executive impact assessment giving LocalAuthorities information to supporteconomic development and servicedelivery planning Community Foundation match funding in West Cumbria to maximise <strong>the</strong>ir ability to benefitfrom contracts development organisationsresponsible for optimising <strong>the</strong> localsupply chain (via WCSSG, Local Authority nuclearissues groups and on website) to develop and agree partnershipperformance measures and reportingprocesses economic performance indicatorswill be published identifying targetsand measures against partnerorganisation accountabilities annual review of supply chain spendin West CumbriaPort of WorkingtonArtist impression of Albion Square

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