Decommissioning Capability Development

END OF YEAR REPORT 2016-17 Future Decommissioning Project

Decommissioning Decommissioning • Collaborative working nuclear site is a significant Capability Development within undertaking, expecting has established the Future to communicate the to take over 100 years Decommissioning project decommissioning and cost an estimated which is responsible for challenges and ‘pipeline’ £85billion – a large cost to delivering Research and lower TRL technologies the UK taxpayer. Through Development activities to through to active challenging current enable decommissioning deployment assumptions and delivering to be safer, faster, and • Active demonstration and improved capabilities, there cheaper. integration of technologies is an opportunity to make Focussing primarily on to prove capability in an substantial savings to these near-term (up to 5 years) active environment and long-term predictions. development, the project determine benefits

“This year the Future addresses challenges • Industrialise technologies Decommissioning Decommissioning Project spanning the full lifecycle and techniques Supporting the of decommissioning; The assessment of Team has strengthened where appropriate and supply chain Commercially-off- and made a step change in from characterisation and communicate the learning development by the-shelf tools to providing end performance and delivery. Post-Operational Clean to enable the greatest provide business user or intelligent Out (POCO), through to benefit The Team have increased potential for the business customer guidance dismantling and waste both the number and to realise the benefits assay. complexity of active (facilitate business as demonstrators performed, Future Decommissioning’s usual). COLLABORATIVE including the award activities fall into five key This 2016/17 report WORKING TO areas: PROGRESS LOW winning LaserSnake2. The details the key activities Capability Development team are also working • Assessment of COTS and successes this year, TECHNOLOGY READINESS LEVEL in collaboration with the equipment for suitability to identifying the progress SYSTEMS NDA and Innovate UK to provide benefit towards improving deliver a major innovation • Support development of capabilities for the competition with the decommissioning of fit for purpose Active Enable transition aim of encouraging Sellafield site. Demonstration technologies in the supply of suitable and Integration of organisations (both technologies to chain by providing end technologies to Business-as-usual nuclear and non- prove capability user or intelligent operation nuclear) to innovatively customer guidance and benefits solve a significant (market pull) Remediation decommissioning challenge.”

End of Year Report 2016-17 / [email protected] 02 Key Achievements

Major Awards Won: Gamma Imaging Capability Delivered - NDA Supply Chain Award - Business Excellence Award

11 Active Unmanned Aerial 20 Products progressed Demonstrations Vehicles Industrialised towards industrialisation of Technology

2 World First of their 24 R&D Projects Kind Deployments

End of Year Report 2016-17 / [email protected] 03 • Legacy Ponds In the next four years, To best align with this current and future activities Sellafield Limited will transition, the business has are aligned to bring real & Silos undergo a historic introduced the Value Stream benefit to Sellafield Limited • Spent Fuel change. The reprocessing model. long-term mission. operations at THORP and The four streams identified Decommissioning Capability Management Reprocessing are: Legacy Ponds Development, and Future Plants will cease, and and Silos, Spent Fuel Decommissioning, is aligned • Special Nuclear the site will transition to Management, Special primarily to the Remediation Materials a business focussed on Nuclear Materials, and value stream. decommissioning and long- Remediation. The purpose • Remediation term remediation of the of this model is to ensure Sellafield site.

Alpha Capability Integration Inactive Alpha Decommissioning Key - Evolving Characterisation Capability Demonstrator - Evolving Decontamination Capability

2017 2018

Remote Glovebox Alpha Manipulator Strippable GeGi Vacuum Camera Coatings Capability Capability Decision

Beta-Gamma Capability Integration Collaborative Innovation Competition Key - Evolving Characterisation Capability - Evolving Decontamination Capability Phase 1 Phase 2

2017 2018

Remote Gamma DEMplus Depth Strippable Imaging Capability Profiling Coatings Capability Embedded Deplyment

End of Year Report 2016-17 / [email protected] 04 Value Streams & Capability Development

Remediation Value The vision of this value Alpha and Beta- This year’s key development Stream stream is to “remediate Gamma projects are on the timelines Sellafield with commercial below – showing the likely From active Within the Remediation efficiency”, delivering date each technology will decommissioning through portfolio, there is a best value while reducing be mature for business to ground remediation whole range of different intolerable risks. use, compared with the key and possible delicencing challenges, and the milestones for both areas. of the Sellafield site, the business has sub-divided Remediation value stream them into two areas; alpha, covers the whole range of and beta-gamma, depending activities that will take place on the predominant over the next 100+ years. radiological challenge present.

Optimise Active Deployment - Cutting Capability

Avoid additional store builds

Decommissioning 2019 2020 & process 5000 drums per year

Manage asset care Portable Drumscan Laser at best value Alpha Decontamination Detectors

Optimise Active Demonstration - Competition Outputs Collaborative Phase 2 beta-gamma value stream 2019 2020 Manage asset care at best value

Process wastes Non- Measuring Real-Time Destructive Heels in Laser Monitoring Nitrocision at best value Depth Vessels Non- Decontamination during Profiling Destructively POCO

End of Year Report 2016-17 / [email protected] 05 Decommissioning Challenges

Decommissioning The challenges faced These 37 challenges, along Theme: with decommissioning with further descriptions 7.01 Plant Dismantling / a complex nuclear site and information have Decommissioning such as Sellafield site been collated into a single are many and varied. In document – for sharing to Plant Characterisation Tank, Vessel, Pipework & order to aid development, enable innovation. Copies Decommissioning Capability of this Challenge Statement Steelwork Decommissioning Development broke this document are available on overall task down into request, and have been Modelling, Knowledge Management & Procedures ten Decommissioning handed out at various Themes (left) which can conferences and events – be seen throughout this including the NDA Supply report. These themes Chain Event in November Post-Operational Clean Out (POCO) cover the whole lifecycle 2016. of decommissioning, front In addition, this year a upfront characterisation benefits assessment and POCO, through to final has been made for each Surveillance & Maintenance demolition and waste assay. Decommissioning Challenge Within each Theme, one to estimate the possible or more Decommissioning savings achievable from Challenges have been innovation in each area. Decommissioning Infrastructure & Enablers identified. These Challenges address specific needs where targeted development could bring significant Decontamination improvements to current capabilities. Creating these decommissioning challenges began in 2015/16, with Plant Dismantling / Decommissioning this year seeing updates and additional challenges added. The total number of individual Decommissioning Waste Characterisation & Conditioning Challenges identified is currently 37. However, as decommissioning 1.02 Plant Characterisation progresses, this list may Waste Handling & Storage evolve. Waste Estimation

End of Year Report 2016-17 / [email protected] 06 Projects this Year

Waste Estimation S F C 08

DEMplus S F C 09

Lasersnake 2 S F C 10-11

Gamma Imaging S F C 12

UAVs S F C 13

Alpha Cameras S F C 14

Strippable Coatings S F C 15 & Fixings

Depth ProfilingS F C 16

ViridiScope S F C 17

Challenge the Baseline 18-19

MASSIVE Results >50% faster than the Savings >£200million over Collaborative Inovation Competition 20 S F C benefit to worker safety current baseline the current baseline SIGNIFICANT Results up to 25% faster than Savings up to £100million S F C benefit to worker safety the current baseline over the current baseline Other Achievements 21-22 MARGINAL (or no) Results <10% faster than the Savings <£1million over the S F C benefit to worker safety current baseline current baseline Meet the Team 23

End of Year Report 2016-17 / [email protected] 07 Waste Estimation

Plant Characterisation

Understanding the volume A number of gamma on future applicability of and expected classification imaging systems have these detectors. of waste that may arise is the capability to estimate a key requirement when activity in an object non- CHALLENGE planning decommissioning destructively. However, there Determine the relative operations at Sellafield Site. have not been any tests quantities of ILW and LLW Intermediate Level Waste to confirm the accuracy of in-situ (ILW) vs Low Level Waste these quoted values. Without SOLUTION (LLW) can vary in treatment this information, assessing Benchmark gamma imaging and disposal costs by a the suitability of these systems in a known factor of 30. Also, as ILW is systems for the purpose environment to increase kept in interim storage on of waste classification stakeholder confidence in site, an estimation of ILW estimation is a challenge. the approaches arisings determines the This year, the First BENEFITS number and size of storage Reprocessing Some current expected facilities required. Plant (FGRP) hosted ILW volumes may be five times higher than reality. Currently, estimations an active demonstration This has a significant cost / COMPANIES INVOLVED: for these waste volumes intended to address this timescale impact are based off operational issue. An area of the CURRENT STATUS experience / provenance Medium Active South Five technologies deployed often with a pessimistic (MAS) cell was made in MAS cell used to approach. In some cases, available for gamma imaging underpin vessel activities limited characterisation may technologies, with six FUTURE ACTIVITIES be performed – this consists vessels identified as being Active Demonstrator of taking core samples from of known activity / waste Report, business-as- items of interest and sending classification. usual use of technologies, Benefit Realised from 2017 S F C for laboratory analysis. In collaboration with increased characterisation This destructive process is capability and programme Sellafield’s Radiometric of characterisation unfeasible in many cases Systems Group (RSG) five and introduces significant systems were deployed. pessimisms. The results from these KEY MILESTONE ACHIEVED “Waste volume estimates deployments will form an form a critical part of Active Demonstrator Report with the aim of better March 2017 the Sellafield Ltd. future - All active deployments complete strategy.” informing decision making

End of Year Report 2016-17 / [email protected] 08 DEMplus® for Nuclear

Modelling, Knowledge Management, & Procedures

Decisions made during the • Reduction in cost through strategies, potentially decommissioning planning more efficient planning improving: conventional stage of projects have and scenario modelling and radiological safety, significant impact in terms of software. waste management, timescales and costs. That’s In 2015/16, this software and a cost saving for why the current planning was first demonstrated at decommissioning operations involve large Sellafield, taking real data operations.” numbers of stakeholders, from three cells on site to processing vast amounts determine the impact of CHALLENGE of information, in order different decommissioning Determining optimal to determine the most strategies. decommissioning appropriate approach for the This year, those models approaches specific challenge. have been completed and a SOLUTION DEMplus is a software tool number of other tasks have 3D visualisation of which is intended to aid begun, utilising this software. decommissioning schemes this process. By combining These other tasks include with quantified benefits over alternative approaches operational data (working the first use of DEMplus at COMPANIES INVOLVED: times, waste routes etc.), Sellafield in a study phase of BENEFITS with a geometric and a decommissioning project. Most appropriate radiological 3D model, decommissioning strategy In addition, Sellafield Ltd alternative approaches chose enabling best use of has taken the decision resources with balancing can be visualised and to procure DEMplus and time, cost and dose quantitatively compared. embed it within the business. CURRENT STATUS The benefits from improved Utilising the Sellafield Multiple Sellafield Site scenario planning include: Operational Research Group environments modelled, Benefit Realised from 2017 S F C • Improved (SORG) as the Intelligent alternative schemes decommissioning & Customer, a set of licences developed and compared and the supply chain dismantling strategies has been purchased to capability developed • Ability to see the effects enable some support in- house. FUTURE ACTIVITIES KEY MILESTONES ACHIEVED of in-situ decontamination Decommissioning study • Optimised working and “DEMplus gives Sellafield using DEMplus due to dose reduction Ltd the capability for complete in 2018/19 - Make/ buy decision resulting in purchase of DEMplus licences and completion of operator training • Waste forecasting (future easier optimisation - Supply chain capability delivered store needs) of decommissioning

End of Year Report 2016-17 / [email protected] 09 Lasersnake 2

Plant Dismantling / Decommissioning CHALLENGE Dismantling / size reduction Decommissioning Sellafield Increasing productivity in Engineering (LOE), ULO of pipes, vessels, and site will involve a large remote decommissioning Optics, and the National steelwork with limited number of operations in is estimated to save up to Nuclear Laboratory. access in a hazardous hazardous and restricted £2billion over the lifetime Sellafield Ltd provided end environment environments. A significant of the site. In addition, user support and delivered SOLUTION number of these operations there are potentially further an active and inactive A robotic ‘snake arm’ will be cutting / size savings from utilising remote demonstration opportunity. manipulator with a high reduction tasks- either to solutions to do activities powered laser for remote / The environment chosen semi-remote cutting free an object for handling previously thought of as for the active demonstration and removal, or to fit into a manual operations. was a redundant dissolver BENEFITS waste container. Lasersnake 2 is an NDA/ in the West Dissolver cell Flexible remote approach, reducing risk and increased Previous decommissioning Innovate UK/BEIS-funded in the First Generation cutting rates for higher work has relied on human project which combines Reprocessing Plant. This productivity intervention to perform the two relatively mature vessel presented multiple CURRENT STATUS majority of activities. Only technologies high power challenges: Lasersnake system actively where human access is laser cutting, and a • Double skinned demonstrated on Sellafield prohibited (e.g. radiation, multi-jointed “snake arm” • site with new opportunities physical access, high levels manipulator. The resultant for future decommissioning thicknesses from 9mm to of contamination, etc.) have system is a remotely & demonstration identified 50mm remote approaches been operated device capable of FUTURE ACTIVITIES • Access possible through taken. Historic experience reaching awkward locations Laser cutting in alpha with using robotics for and performing size- only one port into cell decommissioning & decommissioning has shown reduction activities. vitrification cell, depth profiling tools deployed large uncertainties in costs As the majority of the OTHER APPLICATIONS from a snake arm and productivity. electronics / high value In addition to the success tool in an inactive pond on equipment are situated of the Lasersnake 2 active Sellafield site (January 16) demonstration, Sellafield – performing pick-and-place outside of the area, it is Ltd recognises the benefits activities underwater. ideally suited to working in from both the snake arm Work is currently ongoing areas of high dose rates and manipulator and from laser to set up a demonstration of high contamination. cutting. the snake arm robot remotely Prior to the active deploying novel depth The Innovate UK project is demonstration of Lasersnake, profiling technologies (page Benefit Realised from 2019 S F C a collaboration of several the snake arm robot was 16) in an active redundant industrial partners: OC deployed with a gripping water duct. Robotics, The Welding Institute (TWI), Laser Optical

End of Year Report 2016-17 / [email protected] 10 Lasersnake 2

Plant Dismantling / Decommissioning

Preparations for this The success of the trial demonstration, required has been recognised by input from a large number of across the industry with WINNER Sellafield Ltd stakeholders the receipt of both the including: operations team, NDA Supply Chain Award safety case, health physics, (Technology / Innovation system engineering, and Implementation) and the Business Excellence Award others. Some of the required Sellafield Ltd Business preparations included: Excellence Award (People’s • Creating a light-safe cell Choice). This work has – with access hole for the also opened opportunities snake arm for the technologies WINNER involved as well, with future • Infrastructure installation deployments planned for (ventilation, compressed, both laser cutting and snake electrical supply, CCTV, NDA Supply Chain arm-deployed tooling. Award lighting, etc.) • Plant Modification Proposals, Risk Assessments, and World First Operator Instructions Deployment • Training and site access for suppliers The demonstration began COMPANIES INVOLVED: in June 2016, and so successful was the trial that the time on site was extended to complete more KEY MILESTONES ACHIEVED size reduction. In total, over 10 weeks were spent on site, cutting over 200m April 2016 (42 hours of cutting) and - Underwater demonstration of snake arm on site completely size reducing the September 2016 dissolver vessel for future - Active Demonstration finishes disposal.

End of Year Report 2016-17 / [email protected] 11 Gamma Imaging

Plant Characterisation KEY MILESTONES ACHIEVED CHALLENGE Measuring the dose environment and the Understanding the varied from small handheld systems, the coming - Active demonstration of two location of radioactive radiation environments is systems, to large, remotely months will see multiple gamma imaging systems sources important in order to best operable, collimated devices. deployments of the new - Internal evaluation report endorsed by SOLUTION determine if any remediation The purpose of these devices. The report the Remediation technical committee A range of Fit-For-Purpose (decontamination, shielding demonstrations was to also enabling other - N-Visage and GeGi gamma imagers purchased gamma imaging systems etc.) or controls need to understand the performance Sellafield teams to further be put in place to protect of each system, and which make vs buy decisions. BENEFITS people. were most appropriate for These systems will be COMPANIES INVOLVED: Faster acquisition of results and improved Current methods to do this Sellafield’s challenges. This demonstrated all across deployment options could involve simple, manually is shown in a report in which Sellafield site enabling save >£100million over the deployed probes which gives future decisions can be benefit realisation, with lifetime of the site limited information about made. a potential saving of CURRENT STATUS the location and type of any The Decommissioning £50k a task with the new Nine systems tested and sources. Capability Development technologies. evaluated, with two devices purchased Advancements in detector team purchased two technology indicate that systems following this report. FUTURE ACTIVITIES new systems may be able to This included the N-Visage Utilising Sellafield’s new measure not only the dose gamma imager and GeGI internal capability and Gamma-ray imaging a “watching brief” for rate, but also the location, additional systems of quantity and key sources spectrometer. interest and a program of contributing to the overall The N-Visage gamma characterisation so a state of business a usual can be dose environment. imager, this detector reached “The ability to effectively is utilised in high dose characterise environments environments where there is is becoming increasingly restricted access and can fit important, as the through access holes. business transitions The second system towards decommissioning purchased is the GeGI operations” Gamma-ray imaging Over the past 2-3 years, spectrometer – better suited Sellafield Ltd has facilitated to fast results in low dose the demonstration of nine rate areas. Benefit Realised from 2018 S F C different gamma imaging With projects lining up to systems. These technologies make use of these new

End of Year Report 2016-17 / [email protected] 12 UAVs

Decommissioning Infrastructure & Enablers KEY MILESTONES ACHIEVED

Accessing areas of interest As a result of these novel UAV platforms to April 2016 on site, both indoors and activities, the supply chain increase the possible - Underwater demonstration of snake arm on site outside, can be a real has built up a UAV capability applications for these September 2016 challenge. Especially in to meet Sellafield’s Ltd systems. - Active Demonstration finishes high dose or contaminated needs. This project has now “Sellafield now has the environments, constructing reached sufficient maturity appropriate procedures in scaffolding to perform to begin realising benefit for COMPANIES INVOLVED: place to enable the use of simple monitoring tasks is a Sellafield Ltd. small unmanned aircraft lengthy and costly process. This year, decommissioning on site, paving the way for Often the balance of cost capability development has the future” / practicality vs benefit produced the Sellafield Ltd means that inspections do Procedure – standardising not take place and instead the use of UAVs on site. CHALLENGE pessimistic assumptions Viewing structures without Following this, a key have to be made. the need for scaffolding / Benefit Realised from 2017 S F C objective this year was infrastructure With the emergence of to deliver this capability SOLUTION small Unmanned Aerial for Business-As-Usual Vehicles (UAVs) for low- operation by the rest of site. Unmanned Aerial Vehicles cost visual and radiometric with tools for visual / In this way technical support radiometric monitoring monitoring, these has been provided for BENEFITS pessimistic assumptions can several flights in Sellafield be challenged with minimally Ltd airspace. Including: Reduced time, cost, and intrusive activities. dose for inspections monitoring the local beaches (indoors and outdoors) Over the past 4 years, (The first business as usual CURRENT STATUS the decommissioning flight off site), Calder Hall’s Active demonstrations capability development turbine hall roof (The first and the first Business-As- team has overseen the business as usual flight on Usual activities carried out implementation of UAVs site) and the civil inspections through engagement with on the Sellafield site. The of FGRP chimney (The first the supply chain first flight at Sellafield site business as usual flight in FUTURE ACTIVITIES was carried out in April separation). UAV capability delivered to 2014, with subsequent Now that the use of drones the business active demonstrations in the is a standard practice on Solvent Recovery Plant and site, future development the Windscale Chimney. work may include more

End of Year Report 2016-17 / [email protected] 13 Alpha Cameras

Plant Characterisation KEY MILESTONE ACHIEVED

There are over 350 alpha be put in place during The trials have July 2016 gloveboxes on Sellafield operations, and upfront demonstrated that further - Active Demonstration of second system site. Each box has its decommissioning planning development/ deployment own operational history, activities can be better work is required to enable COMPANIES INVOLVED: and the levels of alpha informed. a usable system to realise contamination within will be A potential solution identified business benefits, with similarly varied. Identifying is “Alpha Cameras”. this being reviewed in this contamination is These devices measure 2017/18”. a particular challenge the ultraviolet radiation in these environments produced when alpha CHALLENGE as alpha particles are particles collide with typically shielded by thin Identifying alpha nitrogen in the air. As these contamination without layers of material, or a few collisions take place within intrusive measurement, or centimetres of air. the first few centimetres, significant pessimism As the site comes to the source of this UV light SOLUTION decommission these closely matches the source “Alpha cameras” that detect gloveboxes, understanding of alpha contamination. UV light produced by alpha the contamination present Sellafield Ltd is aware particles in air before opening the glovebox of a number of different BENEFITS (and breaking containment) alpha camera systems. Ability to visualise and is important. The risks In 2015, the first alpha target clean out and carry present will define the camera system was active out large area assessment contamination control without the need for demonstrated in the Mixed extensive surveys requirements and any Oxide Fuel Demonstration additional safety measures Facility (MDF). This year, a CURRENT STATUS that need to be in place. second system was trialled Two alpha camera systems demonstrated on site Current techniques in the same facility. FUTURE ACTIVITIES for assessing alpha Learning and comparisons contamination involve between the two systems Define future development worst-case neutron requirements and other will now be collated suitable technologies measurements, and visual This will better inform the inspections. Through more future requirement for Benefit Realised from 2019 S F C accurately understanding alpha cameras and future the environment, fit-for- developments to be shared purpose controls can with companies involved.

End of Year Report 2016-17 / [email protected] 14 Strippable Coatings & Fixings

Decontamination CHALLENGE The need to create a set standard for the use of In support of current understanding of which Active trials have also taken Strippable coatings and operations and product is acceptable for place in the First Generation Fixings across site to fix decommissioning of every scenario. Magnox Storage Pond and remove contamination the Sellafield site, Fixatives and strippable area to look into: ease SOLUTION fully understanding coatings are chemicals of application, coverage, A prescribed list of decontamination methods in the form of a liquid or adhesion, ease to peel, approved products that and products is essential. a gel that can be either and resistance to tearing, have been formally alongside the ability to assessed for the use across Historic plants were not painted, rolled or sprayed Sellafield Site and the NDA built with decommissioning onto a substrate (, pick up contamination, and estate the retention of the loose in mind, and the brickwork, metals etc.), and BENEFITS risk of making loose left to cure over a period of contamination within the products. Correct use of strippable contamination airborne time (nominally 24hours). coatings and fixings delays advancements in The fixatives remain in place The goal is to get a can lead to possible Post Operational Clean Out on the substrate; in contrast, prescribed list of approved reclassification of C5 areas, (POCO). the strippable coatings can products that have been with Reductions in cross contamination, easier clean There is current work be peeled off once cured formally assessed for use up and faster recovery after looking at base lining and disposed of as a solid across the Sellafield site operations fixatives and strippable waste form. and the NDA estate, with CURRENT STATUS an agreed list of approved coatings. The applicability This financial year various Trials completed, with of the coating and fixings stakeholders were engaged products that, in their rawest a review of the findings is plant specific, as some from several waste form, are accepted by a COMPANIES INVOLVED: underway chemical coatings may management streams with number of waste routes. FUTURE ACTIVITIES react differently in varying question sets taken to build “Assessing and Formal assessment and environments. up a baseline of acceptable benchmarking a variety approved list of products chemicals. completed. Assessment of To counteract this issue, a of strippable coatings & any gaps in trials i.e. Alpha set list of approved products Following this, products fixings to fully understand specific environments so it is needed. Various waste were irradiated in their cured their performance and becomes normal practice management routes can state are being tested at the disposability.” then plug-and-play with University of Manchester’s a specific coating to suit Dalton Facility; a particular environment. to determine the products KEY MILESTONE ACHIEVED This will allow for smart tolerability to high radiation deployment of coatings fields and how they Benefit Realised from 2018 S F C March 2017 which will lead to increased potentially degrade. - Active Demonstration efficiency and a thorough

End of Year Report 2016-17 / [email protected] 15 Depth Profiling

Plant Characterisation KEY MILESTONE ACHIEVED CHALLENGE Determine the activity profile in porous At Sellafield Site, there are “Removing the active This year, the results from Analytical results analysed and substances as a function of a number of areas where surfaces of concrete both active demonstrations recommendations for future use identified depth concrete surfaces have structures can lower have been analysed, with SOLUTION become contaminated. the overall waste recommendations for future COMPANIES INVOLVED: Non-destructive techniques Due to concrete’s porous classification; huge development / use identified which can produce accurate nature, this contamination savings in cost and waste for each system. In tandem depth profiles of activity, can permeate beneath the volumes can be realised.” with this, the first “real” without the need for core samples surface. A consequence Through faster and less use of the systems has of this is that activity dose intensive techniques taken place in the Pile Fuel BENEFITS contained within the first few to acquire this activity Storage Pond. Faster analysis & more millimetres of the surface depth profiling could lead to effective segregation of may impact the waste Intermediate Level Waste significant schedule and cost and Low Level Waste classification of the entire savings across site of up to bulk material. To reduce £30million. Additionally, more CURRENT STATUS the over-classification of an accurate measurement of Active demonstrations in entire structure, the depth FGRP and in Pile 1 water these profiles may enable duct complete with first of this contaminated layer more effective segregation deployment in the Pile Fuel needs to be understood. of Low Level Waste and Storage Pond The current procedure Intermediate Level Waste. FUTURE ACTIVITIES for measuring the activity As ILW costs approximately Transition to Business- profile in a material involves 30 times more than LLW as-Usual with several extracting core samples to dispose, this is a key deployment opportunities and off-site laboratory opportunity. under consideration including remote analysis. This destructive Sellafield Ltd has become deployment analysis process has several aware of several potential limitations: non-destructive solutions • Coring is time consuming for measuring activity depth and involves operators profiles – at varying stages of working in potentially high development. Previous years dose environments have seen several supply • Laboratory analysis can chain technologies tested in take several months before two active environments on Benefit Realised from 2019 S F C receiving results site, with core samples also taken to provide a known result for comparison.

End of Year Report 2016-17 / [email protected] 16 ViridiScope®

Plant Characterisation CHALLENGE To enable the sampling of a wide range of decommissioning wastes Waste Characterisation & Conditioning for characterisation SOLUTION Surface sampling is The samples required by “This was the first Easily deployable technique a common activity on ViridiScan® may be as deployment of ViridiScope which can produce results Sellafield site. Swabs and much as 1000 times smaller in an active environment; in-situ scrapings of concrete walls, than needed for laboratory the learning gained will be BENEFITS ceilings, and floors are taken analysis. This could also invaluable for this project.” Potential to reduce in order to understand any reduce the risk associated The output from this active timescales for contamination that may be with generating airborne demonstration will help characterisation results by present. This information contamination during quantify the benefits the months forms part of the process for sample operations. ViridiScope®/ViridiScan® CURRENT STATUS characterising and disposing Throughout this project, tool will bring Sellafield Ltd. Active and inactive of concrete wastes. Sellafield Ltd has been demonstrations carried out Current processes involve offering end-user support. this year on Sellafield site collecting samples for off- In April 2016, the sampling- FUTURE ACTIVITIES site analysis, which can end of the ViridiScan was Possible further take weeks or even months demonstrated in an inactive deployments of ViridiScan to receive results from. area at Sellafield Site. This in 2017/18 COMPANIES INVOLVED: Reducing these timescales front end, ViridiScope®, can improve the efficiency of extracts the sample and this waste assay process. collects it on a filter paper for ViridiScan® is an analysis. Innovate UK project, Following this Benefit Realised from 2019 S F C sponsored by the Nuclear demonstration, an active trial World First Decommissioning Authority. of ViridiScope was setup in Deployment The project uses a laser to November 2016 to directly ablate a small sample off compare the ViridiScope® the surface, for collection sampling process with KEY MILESTONES ACHIEVED on a filter paper and in-situ current baseline techniques. analysis. The sampling The generated samples April 2016 head would be small, either were sent for off-site - Inactive Demonstration handheld, or deployed analysis and the results will from a Remotely Operated provide valuable learning for November 2016 Vehicle (ROV). the ViridiScan development. - Active Demonstration

End of Year Report 2016-17 / [email protected] 17 Challenge the Baseline

The greatest improvements from the expected lifetime Beta-Gamma Manual to time, cost, and safety costs. Decommissioning BASELINE APPROACH Decommissioning for decommissioning Capability Development A pre-existing plan for operations on Sellafield has termed this process decommissioning is identified. Initiated in 2015/16, this This is naturally conservative project considered the site will come from step- “Challenging the Baseline” and does not account changes in how we tackle and has begun projects in for potential technology challenge of a beta-gamma our challenges. With the three distinct environments: developments. cell, where man access is decommissioning mission alpha-contaminated achievable. The cells chosen ASSESS ALTERNATIVE at Sellafield site expected gloveboxes, beta-gamma were the Medium Active SOLUTIONS to take over a 100 years decommissioning in a South (MAS) and Medium Using DEMPlus, the baseline Active North (MAN) cells to complete, by identifying man-access cell, and beta- approach is compared against these step-changes now, gamma decommissioning in alternative solutions to identify in FGRP. These big cells, £billions can be saved a remote-access cell. the significant factors future spanning several floors, R&D should be targeting. contain large volumes of steel vessels and pipework Challenge the R&D ROADMAP – accessible by a single Baseline Approach These identified opportunities Waste Dose form a roadmap that is then walkway on each floor. used to inform the sites The baseline scheme for Research and development these cells consists of size- plan. reducing these vessels using Integration into the Business ACTIVE DEMONSTRATIONS manually deployed power Baseline Appropriate technologies can tools from a scaffold platform Scheme 1 then be demonstrated in this erected from the ground representative environment Cost Time Scheme 2 Active Demonstrations to assess suitability against floor. Due to the protective decommissioning challenges. equipment required, operator Scheme 3 INTEGRATION INTO THE working conditions are harsh BUSINESS and limit productivity. R&D Roadmap Tools and techniques: In 2015/16 three alternative underpinned with clear schemes were identified: benefits to the business, tested in active environments, 1. Manual approach using Assess Alternative Solutions and ready for industrialisation dancefloor scaffolding / business-as-usual use. 2. Semi-remote tooling, PROGRESS THIS YEAR HAS INCLUDED decommissioning top- Baseline Approach down in MAS and bottom- • Quantifying the relevant benefits between schemes • Characterise area (if necessary) up in MAN and sensitivities within schemes • Update Baseline 3. Fully remote deployment • Final report and R&D roadmap issued using a high power laser • Outputs feeding into MAN/MAN decommissioning study cutting system

End of Year Report 2016-17 / [email protected] 18 Challenge the Baseline

Beta-Gamma Remote Alpha-Contaminated Decommissioning Gloveboxes In some of the highest There are over 350 alpha- hazard environments at contaminated gloveboxes Sellafield Site, all access on Sellafield site. These has to be carried out boxes (which vary in size, remotely. This may be shape, and contents) act due to high activities and as the primary containment radiation posing a risk for the various powders and to human operators, or residues left behind from because physical access their operational use. is too restrictive. With These aged units now remote decommissioning at Due to the variety of require a considered Sellafield Site estimated to HASI Cell Baseline challenges the HASI approach to safely cost £3 billion, highlighting Decommissioning cell poses, the solutions decommission, containing relevant development Scheme generated through this any contamination and opportunities could result in project will be applicable reducing the site’s overall significant cost savings. Work undertaken next 7 YEAR to other remote access hazard. It is estimated that PROGRESS year looks to establish The High Active South Inner OPERATION environments. In particular, the decommissioning of THIS YEAR: cell in the First Generation the reprocessing facilities alpha-contaminated facilities an inactive demonstrator Reprocessing Plant was OVER £30 THORP (Thermal Oxide will cost £billions. • Two case study area for alpha chosen as a case study Reprocessing Plant) and This project identified two gloveboxes chosen and decommissioning which MILLION 3D models produced for this project. This large, Magnox Reprocessing gloveboxes which, together, will serve as a route open cell poses challenges • Six alternative schemes for future technology >170 Plant, which are due to demonstrate a range of generated with limited access and finish operations in 2018 characteristics associated • Alternative schemes integration. potentially high dose rates. OF ILW and 2020 respectively. with different boxes. In and baseline modelled in DEMplus As the current baseline addition, a mapping exercise approach is based off very PROGRESS carried out identified the FUTURE WORK: limited knowledge of the THIS YEAR: various different schemes cell’s status, one of the key that might be required, given FUTURE WORK: stages in this project is to • Produced 3D Cell • Characterisation of different glovebox properties. better understand this cell Environment HASI cell Although the two case • Review the surveillance and maintenance benefits for plants environment. • Modelled Baseline • Update of DEMPlus entering into POCO to realise significant cost savings Scheme in DEMplus Baseline study boxes may not be the • Develop a system for laser cutting on a robotic arm to offer • DQO Workshop to • Generate Alternative next to decommission, the Remediation projects more efficient methods of glovebox define characterisation Schemes learning from this project dismantling requirements • Assess Potential Benefits is being utilised in current • Demonstration of alpha - contaminated re-cleanable filter • Characterisation plan • Produce R&D Roadmap systems on site to lessen the burden of hands-on filter changes developed decommissioning projects. and to minimise the amount of PCM waste produced

End of Year Report 2016-17 / [email protected] 19 Collaborative Innovation Competition

VISION: The following step change is being driven by: Due to the complexity of “A transferable These solutions need to the challenge posed. It is integrated • Safer - provide safer, faster, and expected that submissions cheaper approaches across to the competition will be decommissioning minimise human the full decommissioning made by collaborations of toolkit which lifecycle, including: companies. To aid the forming of consortia, Innovate UK, intervention • Characterisation minimises the NDA, and Sellafield Ltd interface between the • Faster - increase • Planning have worked with KTN (the • Decontamination Knowledge Transfer Network), decommissioning productivity • Contamination to host a series of events: operator and the Management • BRIEFING EVENT, hazard, whilst • Cheaper - waste • Cutting , 14TH FEB • BROKERAGE EVENTS AT achieving a optimisation • Holding • Moving Aberdeen - 28th February significant increase Decommissioning Capability Birmingham - 2nd March in productivity and a Development has been Penrith - 7th March reduction in lifecycle acting on Sellafield Ltd’s Bristol - 9th March cost”. behalf as the end user for In total, around 300 people this competition, providing from within the nuclear In January 2017, the key scope definition and a industry and external to it integrated innovation for route to market for suitable have been engaged. The deadline for submissions was outputs. The final stage of April 2017 with successful competition opened. This £3 the competition is inactive applications beginning in July million call (funded by the demonstration at an offsite 2017. Nuclear Decommissioning location around September Authority and Innovate 2019. Successes at this UK) is seeking, integrated point will likely lead to solutions for tackling active demonstration on decommissioning of Sellafield site, with a suitable reprocessing cells with cell environment already limited man access. Any identified. developed system will need to be transferable and scalable to address the range of process cells on site.

End of Year Report 2016-17 / [email protected] 20 Other Achievements

Plant Characterisation

In-Situ Capabilities for Hazardous & Chemotoxic Assessment Plant Status Monitoring for Neutron Detectors

In order to dispose of potentially hazardous / chemotoxic wastes, the Current detection of in-situ involves the deployment of bulky concentration of various compounds needs to be measured. Currently, each neutron detectors. These systems need to completely surround the object of sample collected is transported for laboratory analysis; this can be a significant interest in order to reduce uncertainty in the results gained. task when hundreds of samples may be required to cover a representative area. This feasibility study investigated the suitability of a new detector which would A market review was conducted to identify any potential systems that can work reduce these limitations, allowing for neutron survey of a large area with greater in-situ and provide analysis of the compounds of interest. Future development / ease. Following this initial success, further development is to take place to bring active demonstration work will then follow this project. the system to be demonstrated on site.

Benefit Realised from 2020 S F C Benefit Realised from 2020 S F C

Surveillance & Maintenance Measuring Heels in Vessels

The decommissioning of reprocessing cells on Sellafield site will commonly include size reduction of inter-connected pipes and vessels. Due to the Optimisation of Facility Surveillance and Maintenance harsh chemicals involved during reprocessing operations, appropriate safety When a facility finished operations on Sellafield site, it typically goes through a phase of Post- precautions need to be in place to prevent any unintended releases. Operational Clean Out (POCO). Following this depending on resource / site priorities, the building The focus of this project was to assess what options are available to detect the may be left in a state of Surveillance and Maintenance for several years. Keeping facilities in this presence of liquor heels without intrusive operations. The results from this work state for extended periods of time is expected to cost £billions over the site’s lifetime. will identify any potential active demonstration opportunities. This project set out to underpin the possible lifetime savings by performing more hazard reduction before entering S&M. Recommendations from this work will go towards the site strategy and identify any R&D activities that could be beneficial.

Benefit Realised from 2019 S F C Benefit Realised from 2020 S F

End of Year Report 2016-17 / [email protected] 21 Other Achievements

Plant Dismantling / Decommissioning Post-Operational Clean Out (POCO)

Remote Glovebox Manipulator Real Time Plant Monitoring POCO involves washing out plant and equipment in order to reduce the hazard prior to Characterising and cleaning out historic gloveboxes is a challenging task. Over decommissioning. This project investigates the possibility of monitoring the effectiveness of POCO time, glovebox windows become opaque; this makes operator intervention in real-time. through gloveports undesirable and less effective. Through real-time monitoring, a specified end state for the system can reached efficiently – saving time and money, and potentially reducing volumes of waste generated. The Remote Glovebox Manipulator is a small robotic arm for deployment through a gloveport, capable of carrying out characterisation and clean out operations. This concept, developed by Sellafield Ltd graduates, is maturing with a first active demonstration planned for 2017/18. Benefit Realised from 2020 S F C

Benefit Realised from 2019 S F C Waste Characterisation & Conditioning

Characterisation of Dense Improvements to Fissile Waste Materials Segregation & Sentencing Generic Vent Duct Cutting Tool Radiological characterisation of dense Decommissioning operations in alpha- The technology currently available for removing and decommissioning materials (such as lead) is a significant contaminated environments is likely to redundant ductwork are either bespoke, or requires intensive manual challenge at Sellafield Site. Self-shielding generate large volumes of combined with the limitations of current Contaminated Material (PCM). operations. Given that across Sellafield site, there are kilometres of ductwork tools produce large uncertainties which limit that will need to be decommissioned; a generic tool capable of size reducing This project looked to understand if available waste routes. improving on current pessimisms and clean and contaminated ductwork could bring significant benefit. This project investigated what commercially technology developments could increase The purpose of this project was to understand how a more generic vent duct available techniques could be used in the segregation of PCM and Low Level Waste. future. The final report will inform future active cutting tool might look like, and what benefits it may offer over the current demonstration activities and any broader baseline approaches. challenges need to be addressed (e.g. culture change).

Watching Brief S F C Watching Brief S F C Benefit Realised from 2020 S F C

End of Year Report 2016-17 / [email protected] 22 Meet the Team

MIKE GUY CHRIS HOPE GRAEME ASKEW

Technical Capability Decommissioning Decommissioning Capability Development Manager Capability Dev Lead Dev Team Member

What I have been involved in: ‘By 2020 we will have What I have been involved in: ‘As well as the team What I have been involved in: ‘Main project focus this year demonstrated a set of tooling that can meet the majority achieving some fantastic ‘world’s first’ demonstrations of was the DEMplus capability and its implementation within the of challenges to deliver ‘General Decommissioning’. new technology, I have had the great pleasure of providing SORG. The DEMplus software has a number of applications Beyond 2020, as plans mature and decommissioning gets ‘end-user’ input and steering the exciting new collaborative which greatly enhance the way we currently carry out started, we will continue to develop this capability to make innovation competition - Integrated Innovation for Nuclear Studies and Scenario planning for decommissioning our delivery safer, faster, cheaper and look to address Decommissioning. Working with the NDA and Innovate UK operations. Ensuring that DEMplus is widely available within specific challenges aligned to decommissioning and waste has been very rewarding and the supply chain response the supply chain will ensure the software is used to its best management projects.’ has exceeded all our expectations.’ advantage.’

BILL JOHNSON DAVID PROCTER ALAN CARDWELL

Decommissioning Capability Decommissioning Capability Decommissioning Capability Dev Team Member Dev Team Member Dev Team Member

What I have been involved in: ‘I have been involved with What I have been involved in: ‘During my previous role What I have been involved in: ‘The challenge set was the team since I joined the nucleargraduates graduate in Alpha Decommissioning Projects I had the opportunity to remotely decommission complex environments with scheme back in 2013. Since starting at Sellafield Ltd. full- to work alongside the Future Decommissioning Team on a access being restricted to existing penetrations. This was time, the majority of my work has been focussed around number of projects and challenges. Since transferring into successfully achieved with the deployment of Lasersnake, the development of new tools for our characterisation the team earlier this year I have had the opportunity to be the technology was proven with the dismantling of the challenges.’ involved in a number of exciting new technologies that with dissolver vessel and will now be used to springboard future further development will enable value for money for the developments.’ taxpayer.’

OTHER PROJECT LEADS JAMES MOORE JAMES SANT Liz Ostle - Decontamination Technical Decommissioning Capability Technical Specialist Dev Team Member Trainee Jen Rochford - Facility Characterisation Technical Delivery Team

What I have been involved in: ‘Getting the small What I have been involved in: ‘I joined the team in January Alex Jenkins - Decontamination Centre of Expertise unmanned aircraft (drone) procedure launched within the 2017, as part of the TST Degree apprentice scheme. Myself company now means that Sellafield is in a position to really and Bill have created this document to highlight some of make this technology take off.’ the exemplary work that goes on in our team. Next year I am looking forward to getting stuck in to some projects of Xavier Poteau - Technical Manager my own.’

Tom Robinson - Research Technologist

End of Year Report 2016-17 / [email protected] 23 Useful Documents More Information about https://www.gov.uk/ the Lasersnake 2 Project government/publications/ http://www.sellafieldsites. nuclear-decommissioning- com/2016/11/arm-in-arm- research-and-development- approach-wins-awards-for- brochures nuclear-companies/ http://www.sellafieldsites. http://www.ocrobotics.com/ com/wp-content/ lasersnake2--news--a- uploads/2017/03/ world-first--laser-cutting-for- Technology-Development- nuclear-decommissioning- and-Delivery- at-sellafield/ Summary_2015-16_LoRes. pdf Special Mentions Simon Candy - Head of Technical Sue Brown - Future Characterisation Development Lead Stephen Balmforth - Studies & IT Capability Dev Lead

For more information email us at: [email protected] or visit the Sellafield Ltd website: www.sellafieldsites.com 0304 Indd