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Babcock Nuclear Division has completed the inactive commissioning phase of the Sellafield Product and Residue Store (SPRS).

The SPRS project is more than a month ahead of schedule and has been delivered below target cost, according to the company.

Babcock has been involved with Sellafield’s biggest new build since the design phase began in 2003.

The company was responsible for the design, supply and testing of all SPRS’s mechanical handling equipment.

SL appointed Babcock to supply the detailed design of all the mechanical handling plant and building control system in 2004.

Carillion was later appointed as the main contractor for the build.

Babcock was awarded the contract for the supply and integrated works testing (IWT) and commissioning of the mechanical handling plant.

Jordan Nuclear carried out mechanical plant installation, Edmund Nuttall constructed the building, Balfour Kilpatrick was responsible for the electrical installation, and Capula supported Babcock on the plant control system.

During SPRS’s HAZOPs and early design reviews, Babcock used facilities at its Technical Development Centre to carry out vital trials that were used by the Sellafield design team as part of the design justification process.

The detail design contract brought together the equipment designer, services designer and civil designer in key performance indicators incentivised contracts formulated to encourage collaborative working to deliver a co-ordinated design.

Babcock delivered the equipment detail design in advance of the construction contract being awarded.

The control system specification required a demanding delivery programme from Babcock in order that the implementation contractor’s engagement date could be met.

The Babcock team jointly developed SPRS’s IWT methodology with SL’s design team.

Essentially, the SPRS facility and control system was assembled and tested at Babcock’s Manchester site.

This involved the complete assembly of an inspection line from point of entry into the building to the final storage location with its associated control system.

The IWT strategy verified the plant’s functionality by demonstrating its sequential control, mechanical handling and proved safety mechanisms, as well as demonstrating the control system operation.

The IWT documentation was extensive and the team was able to ‘roll it through’ to the commissioning stage at Sellafield.

Babcock’s knowledge of the SPRS system enabled it to carry out all the modifications to the control system software, including coding, validation, installation, and commissioning of software changes to both the process equipment PLCs and the process management systems.

Babcock Nuclear Division

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