Dounreay’s Nuclear Flask Loading Facility Project – A New Delivery Strategy, Liverpool John Moores University - 30 Jan 17

Flask Loading Facility (FLF)

Flask Loading Facility (FLF) ProjectA new delivery strategy

FLF Project Overview

Irradiated Exotic Fuel is currently stored at Dounreay. As part of the Dounreay decommissioning and restoration scheme, this fuel is to be relocated to the Sellafield site in Cumbria.

To support this operation, the requirement was identified for a new Flask Loading Facility (FLF) to enable the handling of transport flasks to be loaded with Irradiated Fuel (IF) Containers for both road and rail transfer.

Client: Dounreay Sites Restoration Limited

Location: Dounreay and Warrington

Contractor: Nuvia Limited

Nuclear Technology and Innovation

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Project OutlineThe Project was to complete a concept and scheme design for a new Flask Loading Facility at Dounreay.

The function of the facility is to transfer fuel in Irradiated Fuel Containers from site flasks to road/rail transport flasks for onward transfer.

Contract stages

Phase 1 ConceptPhase 2 Preliminary Safety Case (PSR and Planning App support)Phase 3 Scheme Design


association for project managementAs part of the Irradiated Exotic Fuels programme, Nuvia were awarded a contract to complete concept and scheme design for a new Flask Loading Facility at Dounreay. The function of the facility will be to transfer fuel in Irradiated Fuel Containers from site flasks to road/rail transport flasks for onward transfer to Sellafield site3

Scope of WorkThe Project scope included the following:

Concept Design - a fully functional plant proposal was produced with fuel storage, fuel preparation, and onsite flask unloading and offsite road/rail flask loading capability.

Development of the Preliminary Safety Case (PSR) and Environmental documentation.

Scheme Design Developing the approved concept to enable a technical specification to be produced for Detailed Design and Build Contract.

Performance of the CDM 2015 roles of Designer and Principal Designer.


association for project managementThe client outlined a preferred approach to roll back major elements of the FLF functionality into the Donor Plants resulting in a much reduced specification.

Project timescales were vital as the Clients overall site decommissioning programme required, by a specific date (Jan 2016), the ability to place a contract for detailed design and build. Therefore delays at the front end of the project could not be allowed to impact the overall completion date.

The resulting challenge for the FLF team was that a new Scheme Design including PSR was required in six months instead of the planned 10 month schedule for the scheme design without the benefit of a proven concept.

This presented a challenge as key elements of the design specification were yet to be decided

The Challenge



Options DevelopedMain project driver - to decommission PFR at the earliest possible dateBaseline OptionFLF with 30 IF Container Storage

Option 1FLF with 300 IF Container StorageOption 2PFR Re-Use of Pond - FLF with 300 IF Container StorageOption 3Phased Build FLF with 300 IF Container StorageBuilding Information Modelling (BIM) with a Nuclear Project


BIM - The project was delivered using a BIM (Building Information Modelling) Level 2 process whereby the majority of plant design definition was incorporated into one 3D model. Supporting drawings were reduced to a minimum.

BIM Level 2 is all about Collaboration.

Minimise dumb information, Maximise centralised information.

Building Information Modelling (BIM) with a Nuclear Project



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Planning is key.

Getting the right systemisation in place early makes proper collaboration much easier.

Each discipline has its own centralised model which is incorporated into a federated model for reviews and clash detection.

Building Information Modelling (BIM) with a Nuclear Project



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Component Parts

FLFFlask Loading Facility - 36 Flask StorageIF ContainerIrradiated Fuels Container 2700mm x 195mmInter site Flask (Existing)MEBMulti Element Bottle - IF ContainersFlaskTransport Flask - 50 Tonne and 4000mm highWhat is a Flask?


association for project managementAs part of the Irradiated Exotic Fuels programme, Nuvia were awarded a contract to complete concept and scheme design for a new Flask Loading Facility at Dounreay. The function of the facility will be to transfer fuel in Irradiated Fuel Containers from site flasks to road/rail transport flasks for onward transfer to Sellafield site9

MEB lidding equipmentPlatform & stairsto in-cell Crane Maintenance AreaIF container swab monitoringglove boxMSM & shieldedviewing windowMSM extractionhoist & beamStairwell to-3m levelShielded cell wall1.350m thkOriginal Concept Design


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Original Concept DesignOriginal Storage for 300 IF containers

association for project management Flask Handling Area

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Z6022 Transfer Hall


Plant Rooms


BIM - The project was delivered using a BIM (Building Information Modelling) Level 2 process whereby the majority of plant design definition was incorporated into one 3D model. Supporting drawings were reduced to a minimum.

The team developed new processes for checking/approving designs and working with the 3D model and managed the records electronically which streamlined the process significantly reducing timescales.

Making it Happen

Nuvia demonstrated their ability to truly integrate with the client team to deliver the scheme design scope. To collaborate, be flexible in meeting our moving requirements, and yet be robust in applying the processes and procedures that ensured the delivery of a substantiated scope of work when it was required. Many a time I challenged Nuvia personnel to 'make it happen', and they delivered.DSRL Engineering Manager, FLF Project



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Throughput video


Stage 3 Scheme Design

The Concept and PSR were completed on schedule and within budget when a significant change in approach was initiated by an emerging opportunity which required the design to be reworked.

Project ChangeChange entailed the de-scoping of many of the original functional processes as they were rolled back into their own donor plants.Typically the project completion date remained fixed as it formed part of the site wide decommissioning programme.



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In delivering the Project with a such a significant change we formed an integrated team with the Client and jointly developed a set of revised baseline design parameters at the outset against which we delivered the design.

The scope of work was developed in stages as we moved forward re-setting objectives around decision points which acted as gateways. This approach provided focus in short term whilst working toward an agreed goal.

Weekly internal technical reviews based around the model were held agreeing approaches and resolving issues as they were encountered.

Managing the ChangeThe approach undertaken mitigated potential conflict situations arising.



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Delivery Team

The team demographic in which the relationship between the discipline leads and the 3D modellers meant that the engineering seniors could be centred on developing engineering solutions in an emerging scope while the modellers were able to focus on producing the designs and integrating the requirements of the engineering teams.


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Collaboration and Conflict ManagementLogistics

Separated by a distance of 550+ miles the integrated team needed to work closely and efficiently as we effectively restarted the team building process.

Management of potential conflict situations was vital during the forming and storming process as we were redefining the project scope whilst delivering on a fast track basis.

The new requirements brought many new stakeholders into the project including donor plant Operations, safety and security teams.Rules of engagement were agreed at the outset to promote an open culture and trust.


Logistics Design Reviews, HAZOPs etc.24 people at Thurso plus Client team8 people at Risley

Stakeholder ManagementUse of communications technology such as remote desktop and video conferencing enabling key team members top work collaboratively even when separated by significant distances. This proved a major advantage as it negated the impact of travelling logistics and reduced the time in meetings to a minimum.


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Stakeholder Management

Stakeholder Engagement - Access to Information The 3D model data was presented through Navisworks, a freeware platform available to all parties without licensing issues. This has the added benefit of reducing demand on PC specification greatly increasing the accessibility of the model data to all stakeholders.

Design Reviews - We implemented a fast track review process in which the MDDR and constructability reviews were held using on screen 3D model walk through's. 2D documentation was reduced to a minimum.

Thanks for all that you and others are doing. I understand that we are pushing hard with it but be assured we appreciate all that you've done and are doing to get us over the line. DSRL Project Manager, FLF ProjectAs the change introduced many stakeholders new to the project, bringing them up to speed as quickly as possible was essential.



Stakeholder ManagementValue engineering studies were undertaken to identify innovative or even novel solutions to functional requirements, simplifying plant maintenance and identify cost saving initiatives.

In-cell equipment was minimised to meet the requirements of the process and reduce the decommissioning challenges at the end of plant life. Other stakeholders who were engaged from the outset included operations, RPA and SHE representatives throughout the design process to ensure buy-in and produce a proposal capable of meeting all operational and legislative requirements. Along with the change of scope we needed to ensure that the Project Benefits were maintained and where required re-defined.


Benefit RealisationFocus on use of existing Plant Functionality - The use of existing DSRL equipment withinthe donor plants was exploited where possible and newly specified equipment was aligned with the existing site maintenance capability.

Economic materials such as aluminium cladding were selected to maximise the opportunities offered by a short plant life.

Plant infrastructure was reduced to a minimum, full advantage being taken of opportunities such as natural ventilation where plant operating conditions permitted.

Space envelopes have been claimed to give the design the flexibility to incorporate additional capabilities should the need arise as the unknowns in the baseline data reach maturity.

Along with the change of scope we needed to ensure that the Project Benefits were maintained and where required re-defined.


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Outcomes

Smaller Facility FootprintFinal Facility DesignOriginal Concept Design


Outcomes

11.47m8.98m8.85m20.07m3.00mSimplification of In-cell OperationOriginal Concept DesignFinal Cell Design

association for project managementClient FeedbackDSRL was able to meet the requirements of the overall decommissioning programme and successfully navigate the ONR milestone for completion.

The project is considered by DSRL to be a major success.

We are now in receipt of the scheme design for the flask loading facility Can I take this opportunity in offering my congratulations to all of you and your teams in achieving this. The journey to get to this point has at moments been difficult but there is no doubt when everyone pushes in the same direction with the same aim that significant things are achieved.DSRL Project Manager, FLF Project


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Sharing LFE from the Project

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COSTSA 55% DD&B cost reduction was achievedDELIVERYWe delivered a PSR in an accelerated timeframe from Hazop to Safe Working Party Review in 7 weeksMILESTONESEvery project milestone was successfully achievedREVIEWDesigns were subject to independent PBO review and declared to be of a high standard.1234COMMUNICATIONEffective communication is vital to collaboration and ultimately project success. APPROACHBIM Model approach is foundation for Detailed Design and Construction Information (A process therefore following straight through). INNOVATIONBIM encourages innovation and streamlining review processesEFFICIENCYSignificant use of BIM, as trialled on this project, has indicated improvements in efficiencies, potentially providing competitive advantage. 5678


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Dounreay’s Nuclear Flask Loading Facility Project – A New Delivery Strategy, Liverpool John Moores University - 30 Jan 17

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