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British Nuclear Group maximises storage tank capacity
The innovative use of a robotic device has helped British Nuclear Group maximise the capacity of the buffer storage tanks in the Site Ion Exchange Effluent Plant (SIXEP) at Sellafield, increasing the amount of sludge storage space.
The tanks, which receive effluents from Magnox reprocessing activities and separation area ponds, act as buffer storage, allowing the liquor and sludge in the effluent to settle out before the liquor is transferred through SIXEP for treatment prior to release.
Having been in operation for over 20 years, levels of sludge in the tanks had built up to such a level that they were close to their maximum capacity. Vital to maintaining reprocessing operations at Sellafield, installing new tanks would have cost many millions of pounds, so instead the team rose to the challenge of increasing storage space in the current tanks.
This was done by developing a specially designed robotic cutter to alter the level of the ejector pipes inside the tanks, increasing sludge capacity sufficiently to cover operations to 2012 and beyond. Working together with specialist contractors, RTS and SA Robotics, the team were able to overcome the challenges posed by cropping pipework inside an operational active tank with very limited access by manufacturing a carbon fibre manipulator capable of both a vertical extension of over 11 metres and a five metre horizontal reach.
With development work and testing taking place in America, the team had no opportunity for a dry run in the UK prior to installing the equipment on plant after its ten thousand mile journey. However, the preparation and effort put in by the teams paid off in style and the project was successfully completed in just 15 days and nights.
Magnox head of projects, Simon Wittridge, described the project as “an excellent example of innovative working between the teams.” He went on to add: “Such good collaborative working has resulted in a very challenging project being delivered early, under budget and, most importantly, with no accidents or events at all.”
Project manager, Paul Halligan, added to this: “The team had to cope with a number of challenges, and at times worked under the extremes of pressure in order to complete the project within 9 months of sanction – a tremendous achievement.”
John Storer, Director of Production Operations commented: “I have personally spent time with the project team at Risley, and visited the plant where the work has been completed. I am tremendously impressed by the application of innovation, and the close attention to safety during the delivery of the project. It is another demonstration that attention to detail and the right quality of planning delivers a successful project, and a safe project.”
