Major Achievements of the Springfields Decommissioning Program - 16512
Since the 1940's, Springfields has manufactured fuel products for the UK's nuclear power stations and for international customers. The early operations were in support of the atomic weapons program, closely followed by fuel manufacture for electricity generation via the Magnox power stations commencing in the late 1950's. In 2005, responsibility for the assets and liabilities of Springfields was transferred to the Nuclear Decommissioning Authority (NDA). A new company, Springfields Fuels Limited, was created to run the site, which was managed and operated by Westinghouse Electric UK Ltd on the NDA's behalf. On April 1, 2010, Westinghouse entered into an agreement with the NDA for a long-term lease of the Springfields site, which transferred responsibility for the commercial fuel manufacturing business and Springfields Fuels Limited to Westinghouse. Today, the main Springfields activities include: - Oxide fuels for Advanced Gas-cooled and Light Water Reactors, as well as intermediate fuel products, such as powders, granules and pellets, - Manufacture of Uranium Hexafluoride (now in Care and Maintenance), - Processing and recovery of Uranium residues, - Decommissioning and demolition of redundant plants and buildings. Some 120 plant buildings and support facilities have been successfully decommissioned and demolished in the period 1996 to date. These range from 1940's buildings, subsequently converted for nuclear fuel manufacture, together with some of the formerly sealed chemical agent manufacture and storage facilities. Decommissioning of the now redundant Magnox manufacturing facilities is ongoing at Springfields without compromising the other site operations. Westinghouse is managing all activities related to the whole lifecycle, planning, design, safety case, radiation protection, Post Operational Clean Out (POCO), service diversions, characterization, decommissioning all phases through to ground remediation, waste disposal and agreed end states. Decommissioning of process plants starts with the removal of the majority of radiological activity or hazard contained within the plant. This is known as Post Operational Clean Out. Once this is complete, the plant may be dismantled. Work is scoped and defined within packages (at plant or cell level) to aid control and commercial monitoring as the decommissioning is progressed. This package approach also enables clean or lightly contaminated items to be removed separately to aid potential re-cycling and minimize decontamination and waste disposal costs. Westinghouse is further optimising work package delivery by planning parallel POCO and Decommissioning work phases within plant at a cell level to systematically remove redundant plant and reduce hazard earlier, whilst optimising use of both internal and external resources to reduce total project cost. Waste and Residues from all phases are disposed of via authorized disposal routes and in accordance with our environmental authorizations. On completion of decommissioning and removal of plant and equipment the building is re-assessed radiologically, categorized and appropriate remediation work progressed to render it safe for conventional demolition. The major elements of the success achieved to date can be attributed to the following elements: - Overall programme management with extensive experience of planning, cost, and risk management. Integration of the programme within a major commercial site without compromising safety or operations. - Complete site EHS management working within a complex regulatory framework including the Nuclear Site Licenses, Environmental Authorisations and Security requirements. - Avoiding safety complacency by use of rigorous and systematic process to emphasise safety over competing goals. Including structured use of Human Performance and Corrective Action and Learning processes. - Unique safety experiences attained through complex hazard reduction across a broad range of uranium manufacturing and chemical hazard/agent facilities. - Project leadership and excellence utilizing a core site team to deploy repeatable processes and safe practices to deliver complex scope within budget and schedule. - Optimised use of internal and external resources, with extensive use of Operating Experience to drive continuous improvement and problem resolution. - Management of Contractors from initial selection, pre-qualification, tender assessment and Performance using varied contract forms across delivery phases. - Use of Westinghouse expertise for safety case, waste management, uranium recovery, health physics and design. - Implementation of a work package to ensure gated discreet manageable packages. Underpinned by package specific method statements, with appropriate hold points to maintain management and control of the works. - Continuous local safety focus via safety planning, induction, plant specific training, proactive risk assessment, and a defined approach to decoupling operating plant safety cases enabling focussed and usable documentation. This paper will provide an overview of the latest decommissioning activities achieved on the Springfields site and will focus on best practices that allowed Westinghouse to maintain the program on time and on budget. (authors)