Sellafield Evaporator D
Sellafield, Cumbria, UK · 2006 (decision to build)–2017 (operational) · £750 million (2017 prices, outturn cost, escalated from £297 million)
The judgement call
Account-gated at launchThe decision to build Evaporator D was made in 2006 due to technical problems and aging of existing evaporators, highlighting the need for continuous investment in nuclear waste management infrastructure. - The project experienced substantial delays (operational 6 years late) and significant cost overruns (from an initial £297M contract to an outturn of £750M+), underscoring the complexities and risks of nuclear projects. - The use of prefabricated modules aimed to improve efficiency and quality but presented its own set of integration and logistical challenges. - Evaporator D is a critical component of Sellafield’s mission to safely manage and reduce the volume of the UK’s most hazardous nuclear waste.
Key engineering challenges
Designing and constructing a facility to reduce the volume of highly active legacy waste, requiring specialized materials and construction techniques. - Managing the integration of prefabricated modules into the building shell, ensuring precise fit and functionality in a nuclear environment. - Ensuring the integrity of extensive pipework (over 21 km) and welds (10,000+) for highly active liquor containment. - Working within a highly regulated nuclear environment with stringent safety and security requirements. - Overcoming significant technical challenges and managing project delays and cost escalations inherent in complex nuclear infrastructure.
Project facts
- Client / owner
- Sellafield Ltd
- Lead contractor
- Costain (EPC contract); Shepley Engineers (fabrication); West Cumberland Engineering (fabrication); Bowercross Construction (civil works); Robert Wynn & Sons (transportation)
- Lead designers
- Sanderson Watts (design and analysis of RCCV)
- Project type
- new build
- Scale
- Building shell with 11 primary cells; over 21 km of pipework; over 10,000 welds; 300 tonnes of specialist steel; steel-lined reinforced concrete containment vessel (RCCV).
- Disciplines
- Nuclear engineering; chemical engineering; civil; structural; mechanical; electrical; process engineering; decommissioning
- Standards & frameworks
- Nuclear Site License Conditions; Office for Nuclear Regulation (ONR) regulations; relevant British Standards for nuclear facilities
Sources: West Cumberland Engineering: Evaporator D (https://westcumberlandengineering.co.uk/case-studies/evaporator-d/) - World Nuclear News: Evaporator D modules arrive at Sellafield (https://world-nuclear-news.org/Articles/Evaporator-D-modules-arrive-at-Sellafield) - NEI Magazine: Costain wins entire Sellafield EVAP D project (https://www.neimagazine.com/news/costain-wins-entire-sellafield-evap-d-project/) - Core Cumbria: Sellafield’s delayed Evaporator D now operating (http://corecumbria.co.uk/briefings/sellafields-delayed-evaporator-d-now-operating-and-gift-wrapped-for-christmas/) - Sanderson Watts: Project Overview: Sellafield Evaporator D Facility (https://sandersonwatts.com/projects/sellafield-evaporator-d-facility/)