Alternative skip handler for nuclear storage ponds

Sellafield Ltd is seeking an alternative to the Skip Handling Machine (SHM) used in the First Generation Magnox Storage Pond (FGMSP). The FGMSP is an ageing and degrading facility and a high Hazard and Risk Reduction priority. Reliance on a single crane limits throughput, particularly during planned maintenance or unplanned outages. The challenge is to identify a solution that can safely operate underwater to move and position skips, work alongside or independently of the SHM, and potentially deploy sludge retrieval tools. Applicability to the Pile Fuel Storage Pond (PFSP) and other sites would be beneficial.

An alternative skip handling solution would increase operational resilience by allowing skip movements and exports to continue when the SHM is unavailable, while also accelerating exports when used in parallel.

CHALLENGE AIMS

Sellafield Ltd is seeking solutions that can effectively interface with skips, move and reposition them within the ponds, and allow recovery of those skips into safer storage.

The main aim is to allow movement of skips within the FGMSP without reliance on the SHM (i.e. so skips can still be moved when the SHM is in outage). Any solution must be able to work under the pond water conditions and accurately move the skips from stacks to the export cell and bay bogies around the pond.

Additionally, the solution should be able to deploy with the sludge retrieval tools to enable the removal of radioactive sludge from the ponds.

Within the stacks, it is acknowledged that some solutions may not be able to access skips adjacent to the pond walls or in the corners, and, whilst this would be preferrable, Sellafield Ltd still would be open to solutions that can only manage a limited number of skips.

Whilst the FGMSP is the main focus, solutions that can be applied to the PFSP would also be desirable.

The Legacy Ponds Programme is currently considering short-term solutions to enable skip movements for export from FGMSP due to the SHM repair outage, with the focus on short time to implementation. This Game Changers challenge is intended to address the longer-term need for performance and reliability as well as the ability to undertake all functions required of the current SHM.

As Sellafield Ltd’s legacy ponds retrievals programme is currently ongoing, solutions that can be implemented within a 1–2 year timeframe would be advantageous. Full solutions or partial solutions that can enable a suite of different technologies in a retrievals toolkit are welcomed.

FIND OUT MORE

Please download the challenge statement for full details of this opportunity.

You can watch a webinar and Q&A session with the challenge owners for more information and details of how to apply.

The deadline for applications for this challenge is 3pm on Friday 30th January 2026.

ADDITIONAL INFORMATION FOR THIS CHALLENGE

What are the safety case requirements for the lift process, e.g. redundant load paths or seismic assessment?

The current safety case has been assessed against the current system without wider consideration; hence new solutions would require an update to the safety case assessment and possibly subject to HAZOP review. However, this should not rule out innovation of new ideas. There may be some elements that are covered by the existing safety case, e.g. dropped loads for SHM will have been assessed based on skip remaining underwater.

Ultimately, solutions will require more general balance of ALARP arguments based various parameters, e.g. dose, failure and recovery, space constraints, performance and reliability. For example, in comparison to a small floating platform, a 600t crawler crane lifting skips out of the pond would need a fairly compelling argument to justify.

Is chemical analysis/composition of pond water available for material selection?

The pond water is caustic dosed to pH 11.6 and contains various particulates from spent Magnox fuel corrosion. Various radiological species and competing ions are monitored, such as total beta, total alpha, Cs-137, Sr-90, Mg (total and soluble), Na, K, Ca. More detailed chemical analysis can be made available to successful applicants.

If we're successful in the second phase and provide a viable solution, what's the estimated potential value?

In terms of the value of an alternative to the SHM, we generally assess the number of years off programme as a measure of reduction in hazard and risk. In terms of monetary value, an order of magnitude estimate is available on the gov website (Quality and Continuous Improvement - First Generation Magnox Storage Pond (FGMSP) - Case study - GOV.UK) outlining "each year the project is extended an additional sum of approximately £60 million would be needed".

ASSESSMENT OF APPLICATIONS

Applications are reviewed against set criteria by a panel of challenge owners, prospective end‐users from our partner organisations, and Game Changers project staff. Brief summary feedback will be provided if your project is not awarded feasibility funding.

Application forms and posters will be assessed consistently and transparently using the following criteria:

1. How well does the application align with the challenge aims?
2. Is the proposed solution credible from the perspective of deployment?
3. What potential does the proposed solution have to transform practice in your area?
4. Do you feel the applicant is well placed to deliver a feasibility project?
5. Would the solution proposed in the application benefit from feasibility funding?
6. Does the application meet the scope of the challenge?