Springfields

Site Stakeholder Group

Site Reports – November 2015

Contents

Business Report 2

Environment, Health & Safety Report 7

Socio-Economic Report 9

Glossary and Abbreviations 11

Springfields Fuels Limited

Springfields, , Preston, PR4 OXJ

T+44 (0) 1772 762000 www.westinghousenuclear.com/springfields 2

Business Report

Mick Gornall Managing Director

1 Environmental, Health, Safety & Quality – Highlights

1.1 As of 16 October 2015, Springfields employees have worked 188 days without an industrial safety accident that resulted in a days-away case.

1.2 A RIDDOR Reportable accident (absence >7 days) took place in April 2015. The injured party was working in the Oxide Fuels Complex when they trapped the second finger of their right hand on final assembly carriage whilst moving a fuel assembly. This caused a deep cut at the nail bed and displacement of the finger. The injury required surgery (wiring) to rectify.

1.3 Westinghouse Springfields has been recognised with the President’s Award for its outstanding approach to occupational safety and health by the Royal Society for the Prevention of Accidents (RoSPA). Success in the RoSPA Occupational Health and Safety Awards in the last 14 consecutive years, in which Springfields has gained a Gold Award each year, has resulted in the manufacturing site receiving a President’s Award in this year’s awards – the second time the site has received such an award.

1.4 Springfields provided its Annual Review of Safety to the Office for Nuclear Regulation (ONR), the Environment Agency (EA) and the Hazardous Installations Directorate (HID) in July 2015. The review considers the performance over the previous financial year as well as looking forward at upcoming challenges and is an important aspect of the site demonstrating suitable oversight and control of the hazards on site. The review was well received by the regulators with acknowledgement of the positive safety and environmental performance of the site. A number of recommendations were also made regarding subsequent Annual Review submissions and these will be embedded into the review for 2015/16.

1.5 On 27 July 2015, a Part A notification was sent to the EA concerning a battery fire in some waste from SFL that was about to be off-loaded at Clifton Marsh.

1.6 On 2 September 2015 a Part A notification was sent to the EA concerning the non- representative sampling of the Site Trade Effluent discharge.

1.7 On behalf of the Office of Nuclear Regulation (ONR), Public Health (PHE) has carried out a number of confirmatory perimeter monitoring surveys at the Springfields Site. The scope of work, on the inside of the perimeter fence, included:

• Walking the perimeter of the site with a sensitive gamma monitor linked to GPS. • Neutron dose rate measurements around the site perimeter. • Placement of dose measuring devices at various locations along the fence. • Background measurements at 2km from the site. PHE’s measurements are used to confirm the accuracy of the data provided to the ONR by SFL.

1.8 Springfields has been recognised by Westinghouse for the excellence it displayed during last year’s Hermes Project which oversaw the closure of the Hex Plants. President and CEO of Westinghouse, Danny Roderick, hosted the recent annual WEC Awards in Pittsburgh, at which he presented the Westinghouse award to Jenny Leybourne, Director, EMEA Human

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Resources, who collected the award on Springfields’ behalf.

1.9 On 20 May 2015 the annual Security Emergency Exercise took place. The incident centred on intruders (anti-nuclear) getting onto site and locking themselves into a fuel store building and fuel transport trailer. The exercise involved the site warning sirens being activated, full muster, roll call, lockdown procedures, activation of blue phones, RapidReach (emergency call out system) and full deployment of the on-site emergency teams supported by Constabulary. Our Regulators declared an adequate demonstration of our emergency arrangements. Learning points were identified and these will be dealt with over the coming months.

1.10 On 7 October 2015 the annual Emergency Exercise took place. It is important to note that this exercise was a joint Level 1 and 2 Exercise – including live play at the site (which tested both the on and off-site emergency plans). This was the first time in the country that an emergency scenario involving a criticality event has been tested in an off-site nuclear exercise. The incident centered on a criticality event occurring in A26, though the cause of the incident was deliberately not an obvious one. The exercise involved the site warning sirens being activated, full muster, roll call, activation of blue phones, Rapid Reach emergency call out system and full deployment of the on-site emergency teams supported by , Lancashire Fire and Rescue, North West Ambulance Service, Lancashire County Council and many other external agencies. Our Regulators declared an adequate demonstration of our emergency arrangements for both the Level 1 and Level 2 aspects of the exercise. Learning points were identified and these will be dealt with over the coming months. It also demonstrated many good interoperability practices between all agencies.

1.11 Between 22 September and 1 October Euratom Inspectors carried out a Physical Inventory Verification (PIV) of all the civil nuclear material stored on the Springfields Site. During the inventory over 110,000 items were verified and accepted. The ‘Material Unaccounted For’ figures were some of the lowest ever recorded on site and the whole exercise was accepted by the regulator as satisfactory. Personnel across site were thanked by the Lead Euratom Inspector for their support, cooperation and professionalism in helping deliver a first class PIV; the inspection team included three inspectors who were unfamiliar with the Site, yet the exercise ran very smoothly. Many areas were highlighted as best practice and certain individuals were singled out for their personal contribution. Only nine minor comments for improvement were raised and there were no significant issues.

2 Operational

2.1 The 30 September brought to a close the first half of the 2015/16 financial year, during which the production of Advanced Gas-Cooled Reactor (AGR) fuel was completed as planned, and all deliveries to EDF Energy’s stations successfully achieved. Intermediate

products (UO2 powder and granules) have also been manufactured to time and delivered in line with our customers’ requirements.

LWR (Light Water Reactor) fuel manufacturing has now been operating for over two and a half years at Springfields, successfully achieving all deliveries to EDF SA in France. In order to meet the growing demand for the RFA1300 fuel variant (a physically longer fuel assembly than the RFA900 currently being manufactured) the LWR production facility is currently being modified to accommodate this requirement. The programme of work is progressing to schedule with several areas of the plant already qualified for the longer fuel type.

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2.2 Following Toshiba’s acquisition of a controlling stake in NuGen, Springfields is looking forward to manufacturing the AP1000 fuel for the initial cores and the subsequent re-loads of the three stations planned for the Moorside site in Cumbria. The introduction of the LWR fuel manufacturing capability has been a crucial step in positioning Springfields to produce fuel for both the current and next generation of reactors planned for construction in the UK and across the rest of Europe, Middle East and Africa. This objective is further supported by the ongoing modifications of the facility to accommodate the longer RFA1300 fuel variant, as the AP1000 fuel is of a similar geometry.

2.3 The installation of the HT-IDR (High Throughput – Integrated Dry Route) technology for UF6 re-conversion has been completed on two out of the three process streams. Both streams are continuing to perform extremely well. During the recent planned production outage, the modifications to the third stream were completed and commissioning work is underway.

This project is vital to ensure we have the necessary UF6 to UO2 re-conversion capacity to meet future fuel demand.

2.4 Significant progress has been made this year with the new UO2 powder export facility within the Oxide Fuels Complex. All installation work has been successfully completed and the final testing and commissioning work is well underway. Full operations on the new line will commence in early December. The new facility is key to supporting our contract with Korean Nuclear Fuel (KNF).

3 Uranium Recovery

3.1 We are looking on track to achieve all Authority (NDA) and Ministry of Defence (MOD) contractual targets this year. This is despite the fact that uranium recovery processes are becoming increasingly high complexity and lower volume.

3.2 Work is continuing with the NDA to identify material at other NDA owned sites which are suitable for the liability to be discharged or the material processed into a stable form for long term storage. Material from RSRL has been delivered to site whilst other material at DSRL is identified as potentially being transferred this financial year. Similarly, international opportunities for Uranium Recovery continue to be explored to off-set any decline in UK business.

3.3 Characterisation and Route Development continues for Ministry of Defence (MOD) owned material. Processing routes have been identified for a large proportion of the complex residues, whilst development work on the remaining material is showing promising results.

3.4 As noted in previous reports, obsolete cylinders have been brought into an internal store. A project is now underway to enable the final population of the cylinders to be processed. It is estimated that the work should be complete early next year.

4 Decommissioning

4.1 A284 Line 1 (Hex) Decommissioning This project has continued to progress well with demolition of the building superstructure completed in early May. Excavation of the building slab then commenced and progressed on schedule with 100% of the in-ground substructures and material subsequently removed and sentenced for disposal. Site re-instatement with imported clean sub/topsoil is nearing completion.

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4.2 A331 ( Assembly) Decommissioning De-planting of the A331 Magnox Assembly plant continues to progress to schedule. Milestones successfully achieved to date include final decommissioning of the Active Waste Monitoring Facility, the Magnox Canning Bays 6 and 7 and the Line 4 Assembly Bay including End Cap Welders, Mass Spectrometry Rigs and Fuel X-Ray. Asbestos remediation work throughout the plant has also continued without issue.

4.3 A326 (Archive and Criticality Assembly Point) Decommissioning Detailed design and planning for final decommissioning and demolition of this facility have now been completed. Tender activities are currently in progress, with the overall project anticipated to be completed in early FY2016/17.

4.4 Contaminated Land Management No issues – the 2015/16 programme of sampling and monitoring has now been implemented. The 2014/15 annual review completed by the specialist contractor did recommend some additional sampling at specific locations where data anomalies had been identified, and these are being progressed during 2015.

5 Employees

5.1 Over the last 6 months we have recruited 14 new employees, these were 5 Advanced Apprentices and 4 Higher Apprentices who have been recruited at A Level and will progress onto degree studies as part of their training period. A further degree 6 degree qualified graduates have been recruited and they will participate in a formal 2 year training programme.

The site hosted 11 interns from various universities across the country and from varying disciplines which included, for example, engineering and business.

5.2 To date 11 employees have left the company through either ill health, retirement or resignation. There is a voluntary severance programme currently running on the site with a plan to allow some employees to leave this financial year from areas that are reducing due to the closure of the Hex and Kiln Plants last year.

5.3 On 27 November 2015 the annual Reward and Recognition event will be held at the Gibbon Bridge where around 70 employees and contractors have been invited in recognition of winning company awards on key improvement projects, safety and environmental awards.

5.4 On 15 October the annual Skills Awards day was held at Springfields to recognise the annual apprentice awards, including the Apprentice of the Year, as well as recognising those employees who had gained qualifications during the year.

5.5 Our annual safety awards event will be held on 6 November and will recognise significant work achieved by our employees in the area of safety improvements and also use of Human Performance tools. The site continues to look for opportunities to improve on its safety performance with work currently being done on “In the moment” which raises people’s situational awareness to help prevent accidents/near misses.

5.6 The site transformation teams continue to work with the local union representatives on making changes across the site. The marketing and business development areas continue to look for opportunities globally to bring new business to Westinghouse UK which includes new external

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business as well as other opportunities that exist from within Westinghouse itself. Some of our employees are also supporting a number of bids being made by Westinghouse for new contracts in the areas of services and decommissioning work.

5.7 Representatives from the Human Resources and Stakeholder Relations teams are attending a number of working groups and committees in West Cumbria to contribute to discussions on the skills and stakeholder needs associated with existing businesses alongside the needs of the new build programme as this develops into the future.

6 Commercial

6.1 The Hex Plant remains in a care and maintenance regime pending any final decisions on the ultimate future for the facility. Westinghouse is continuing to pursue opportunities to restart the plant in the coming years.

6.2 The first deliveries of UO2 powder under a new contract were completed in the summer and the Oxide Fuels Complex is performing modifications and qualification work in support of a new type of PWR fuel to be delivered in 2016.

6.3 Westinghouse is relocating some of its staff from its office to Manchester to work closely with the NuGen customer who has opened offices in the city. NuGen is planning to construct three new Westinghouse designed AP1000 reactors at the Moorside site near . Westinghouse intends to utilise its Springfields facility to manufacture the fuel for AP1000 reactors built in the UK, thereby securing indigenous fuel supply.

6.4 Westinghouse has signed a contract to process uranium bearing residues at Springfields. Processing of the material will take approximately 10 years to complete and any recovered uranium will be added back into the . Other opportunities are continuing to be pursued.

6.5 Westinghouse has presented the government with a proposal to partner in the deployment of small modular reactor (SMR) technology, a move that would advance the UK from being a buyer to a global provider of the latest nuclear energy technology. The Springfields Site would be the location for the manufacture of nuclear fuel for any such reactors built in the UK and across Europe.

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Environment, Health & Safety Report

Dave Peacock EHS&Q Director

1. Industrial Safety / Process Safety 1.1 The graph below shows the Site accident performance up to 16 October 2015, together with previous years’ performance for reference.

Springfields Combined Accident Performance (SFL/WEC/Contractors)

100 Minors OSHA DAC Other OSHA Recordable RIDDOR Reportable

90

80

70

60 To 16/10/15 50

40

30

20

10

0 2009/10 2010/11 2011/12 2012/13 2013/14 2014/15 2015/16 2016/17 2017/18 2018/19 2019/20

2 Radiological / Nuclear Safety

2.1 The dose received by both SFL personnel and contractors for the first 6 months of 2015 indicate that dose uptake for the whole year should be less than in 2014.

Average Dose (mSv) 0.90 Contractors Springfields Fuels Ltd

0.80

0.70

0.60

0.50

0.40

0.30

0.20

0.10

0.00 2006 2007 2008 2009 2010 2011 2012 2013 2014 2015 2016

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2.2 Regulator Visits & Inspections

There have been a number of ONR, EA and HID visits to the Site since the last report. These include:

• ONR (RMT) – Radioactive Materials Data Review and SFL management system overview. No issues were raised. • ONR (CNS) – Counter Terrorism Arrangements review and exercise. • ONR Nuclear Safety – review of new Criticality Assembly Point. Some minor improvements were identified. • ONR Nuclear Safety & Fire - Fire & Rescue Service Arrangements Review. • ONR Nuclear Safety - Systems Intervention. Some minor opportunities for the enhancement of nuclear safety were identified. • ONR Nuclear Safety – Exercise involving new Criticality Assembly Point. Some minor suggestions for improvement were provided. • ONR Conventional Health and Safety –Although fundamental requirements of asbestos management were met, ONR raised issues which require their follow-up. An improvement plan has been submitted. • ONR Fire Safety – XJPC Fire Strategy Review. No significant issues were raised. • ONR (CNS) Counter Terrorism Arrangements and Contingency Plan. • HID/EA – Competency management. SFL systems considered exemplary. • HID/EA – Electrical Control & Instrumentation. Report awaited but no adverse feedback following inspection. • HID/EA – Containment. Deemed fully compliant.

3 Environmental Safety

There have been a number of EA visits to the Site since the last report. These include:

• Discussions on new Site Environmental Permit and the High Throughput Kiln in Oxide Fuels Complex. • Discussions covering the battery fire at Clifton Marsh, shutdown of the Hex Plant ventilation and the SFL application for Corporate Radioactive Waste Advisor. • Further discussions on the SFL application for Corporate Radioactive Waste Advisor and non-representative sampling of the Trade Effluent stream.

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Socio-Economic Report Alan Beauchamp Communications and Media Relations Manager, Westinghouse Springfields

1 Visits to Springfields

1.1 Community Relations Department has organised the following Socio-Economic activities to Springfields over the last six months:

• 18 Educational visits (554 students/teachers /Uniform Groups) • 5 Adults Groups, including Sellafield Graduates, Helicopter Club of Great Britain, National Grid, Council (106 visitors) • 8 work experience placements for local students

1.2 The site’s nature trail has now closed for the winter after another successful summer season. In total there were 16 nature trail visits (515 students/teachers/uniform groups). New signage was designed and positioned around the nature trail providing more information and talking points for visitors.

2 Stakeholder Relations

2.1 Over the last 6 months we have had two complaints from members of the public:-

• A complaint regarding speeding and driving along Vicarage Lane and Moor Hall Lane. A note was issued to employees reminding them to drive with due care and attention on the country roads adjacent to site. • A complaint was received regarding the overgrown hedges along the perimeter of site along Deepdale Lane. For environmental reasons it is illegal to trim hedgerows before 1 August (due to the effect on nesting birds), unless there is a safety issue. On this occasion, because the extent of the overgrowth meant pedestrians had to walk in the road in parts, it was deemed a safety issue. As a goodwill gesture the site arranged for the hedgerows to be trimmed, although this is actually the responsibility of the local council.

2.2 Sponsorships and Donations: • Over the last 6 months the main sponsorships have been: - Education Awards in both Preston and - Young Enterprise Strategic Area Final - Newton and Clifton Field Day

2.3 The Springfields Employees’ Medical Research & Charity Trust Fund has supported the following charities since the beginning of the year:

Date Description £ Jan-15 Cauldwell Children 1,084.00 Jan-15 British Red Cross 1,500.00 Jul-15 Hutton Grammar School 1,846.38 Jul-15 Medequip4Kids 7,566.00 Aug-15 Brian House (Lifelites) 2,501.00 Aug-15 Rosemere 2,953.00 Aug-15 Asthma Relief 1,190.25 Sep-15 L’Arche Trust, Preston 324.80 Sep-15 Physio-Control UK (Little Hoole Primary PTA) 1,000.00 19,948.90

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The Trust Fund does not make monetary donations, but buys items of equipment for medical and charitable organisations. In June this year the Fund celebrated its 30th anniversary. Since 1985, equipment to the value of over £1million has been purchased by the Fund and donated to organisations within the Lancashire area.

3 Community and Employee Involvement

The site charity for 2014-2017 is the local heart charity, Heartbeat.

Heartbeat supports people who have been affected by heart disease or those who are at high risk of developing it. They are committed to the fight to reduce the impact of heart disease throughout the North West through rehabilitation, information and advice, education and lifestyle support

Heartbeat provide these services from 11 local locations, including Preston, Blackpool, Chorley, and Kirkham.

To date Springfields employees have raised over £11,000 for Heartbeat.

The charity has recently moved into new, larger premises at Preston North End’s football ground at Deepdale and Springfields purchased medical monitoring equipment and gym equipment to the value of £2,700 to help furnish and equip their new headquarters.

4. Skills Training

4.1 17 August saw the start of the 2015 intake of 20 apprentices who are now making progress through the initial stages of the foundation programme. Springfields have 9 new starters, four Higher apprentices and five Craft apprentices in a variety of disciplines. The other apprentices come from a number of local manufacturing companies, Victrex, Vinnolit, Tangerine Confectionary, Lyndhurst Precision Engineering and AGCCE.

4.2 Springfields continues to invest in engineering resources to support the training activities and capital purchases of a milling machine, two lathes, an instrument pressure training rig and a mechanical belts and drives rig have been made.

4.3 The recruitment season is starting for next year with Springfields instructors and volunteer apprentices attending school careers events to promote what Springfields has to offer in engineering apprenticeships. These are usually focused on Year 11 pupils.

4.4 The Association of Springfields Apprentices has been active in their fundraising events using a bicycle race challenge to raise over £650 from site collections and family and friends sponsorship.

4.5 Deed signing and skills awards event was held on 15 October. This is a significant date in the apprentice calendar and we look forward to recognizing apprentice achievements. Brian Nixon, Head of Oxide Operations was the guest presenter and spoke highly of achieving an apprenticeship as a foundation for an engineering career and opening up opportunities for future progression. A total of 13 different awards were presented and the top award, the coveted Westinghouse Guild Trophy for the Apprentice of the Year, went to 19-year old Connor Bligh.

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Glossary and Abbreviations

AHF Anhydrous hydrofluoric Acid ALARA As Low As reasonably Achievable ALARP As Low As Reasonably Practicable AGR Advanced Gas-cooled Reactor Cogent The sector Skills Council for the Chemicals, Pharmaceuticals, Nuclear, Polymers, Petroleum and Oil & Gas industries COSHH Control of Substances Hazardous to Health Regulations Customer 1st A Westinghouse internal company initiative intended to improve all-round company performance. CR Community Relations OSHA Occupational Safety & Health Administration (USA) DAC OSHA Days Away Case (time off due to injury that is certified by a medical practitioner). LWR Light Water Reactor Hex Uranium Hexafluoride (UF6) HR Human Resources

Milli Sievert These are units of measurement for radiation dose to individuals. & microSievert 1 Sievert (Sv ) = 1000 Millisievert (mSv) 1 Millisievert (mSv) = 1000 Microsievert (µSv)

NDA Nuclear Decommissioning Authority NNL National Nuclear Laboratory NSAN National Skills Academy Nuclear NSG National Stakeholder Group (Facilitated by the NDA, as an interface between local, national and international stakeholders) PWR Pressurised Water Reactor (type of LWR reactor) RIDDOR Reporting of Injuries, Diseases & Dangerous Occurrences Regulations RoSPA Royal Society for the Prevention of Accidents SFL Springfields Fuels Ltd TRIR Total Recordable Incidence Rate UAM Uranium Asset Management UO2 Uranium Dioxide, both powder and granules WEC UK Westinghouse Electric Company UK Ltd