Y-12 Blog

Posted: Thursday, March 24, 2016 - 9:39am

Y-12 is developing an Extended Life Program, or ELP, for Buildings 9215 and 9204-2E, two key processing facilities at the site. These two facilities will house all material processing activities not incorporated into the Uranium Processing Facility design.

To better understand what it takes to keep an older, large facility going, a team at Y-12 has conducted two workshops. The invitees included other DOE/NNSA sites and outside experts to share knowledge and experience dealing with aging infrastructure.

The first workshop, conducted in February 2015, provided a forum for exchanges on management challenges, initiatives and processes used to resolve enterprise-wide aging infrastructure issues. Y-12 identified several best practices during the workshop and integrated these concepts into the development of the ELP.

Internal expert-based teams gathered information on material condition, codes, standards, nuclear requirements and operational/maintenance cycles, that was reviewed by workshop attendees so they could provide recommended actions to establish a life-extension program.

The Y-12 team took that data and compiled it for a forum to evaluate and integrate into a recommended Extended Life Program plan. The forum was conducted in November with representatives of NNSA, the Defense Nuclear Facilities Safety Board, and several outside aging management program experts from the Institute of Nuclear Power Operations, Savannah River, the United Kingdom’s Atomic Weapons Establishment and the American Nuclear Society attending.

Workshop presentations noted that the Y-12 infrastructure supporting 9215 and 9204-2E is generally beyond design life, with a significant portion of electrical equipment obsolete and process equipment, in many cases, beyond design life and in need of upgrade/refurbishment.

To address these aging concerns, Y-12 presented a three-prong approach to aging management:

  1. reduce the material at risk in these facilities so the consequences of any accidents is significantly reduced;
  2. replace or refurbish key facility infrastructure and process equipment and
  3. address and update regulatory requirements for extending life (versus a soon-to-be-abandoned/replaced mode).

Workshop attendees’ consensus was that the current program provided a comprehensive appraisal of infrastructure and process material condition and basis for risk identification, risk mitigation and risk acceptance.

In addition, several good practices were identified, including incorporating system outages for replacements, refurbishments and preventative maintenance. There was general consensus that an outage program made up of routine short equipment/system outages and longer periodic outages was required to support the program.

The workshop attendees concluded that current elements of the proposed Y-12 ELP, with improvements to the aging management program and outage program, addressed the essential elements of a workable management program. However, sustained investment will be needed to restore key facility processes and supporting infrastructure, along with an increase in maintenance resources.

With a solid program plan established, the next steps for Y-12 involve determining budget layouts.

Posted: Thursday, March 24, 2016 - 9:35am

NPO Program Manager David Wall points out infrastructure upgrades to NNSA Uranium Program Manager Tim Driscoll, front, during a recent tour of Y‑12’s Building 9995.NPO Program Manager David Wall points out infrastructure upgrades to NNSA Uranium Program Manager Tim Driscoll, front, during a recent tour of Y‑12’s Building 9995.

Y-12’s Analytical Chemistry Operations provides comprehensive analytical services in support of the site’s core missions, environmental compliance and overall worker health and safety. ACO scientists, for example, analyze impurity levels to ensure the materials destined for nuclear weapons or naval reactor fuel are of suitably high quality. They also analyze soil and groundwater samples for hazardous contaminants and characterize the site’s waste output to ensure regulatory compliance.

Much of this crucial work, however, is done in a degrading laboratory using equipment well beyond its intended life cycle. A 2014 baseline assessment of the facility outlined the most significant issues and identified numerous single-point failures and associated risks. To address the risks, of course, ACO would need money.

In late August of that year, NNSA Uranium Program Manager Tim Driscoll toured Y-12’s primary lab facility, Building 9995, and saw firsthand the need for infrastructure investments. Four days later, he committed $5 million toward improvements, but with one caveat: CNS must match the funds.

“Our senior managers made a commitment to DOE that we could do this,” David Maguire, Maintenance Program manager, said. “We were able to come up with the money by deferring some planned scope into later fiscal years and utilizing underruns from other areas within maintenance programs.”

Driscoll’s contingent offer, unique among project funding, proved successful. “This allowed us to obtain $5 million of additional funding to address serious infrastructure needs in one of our mission critical facilities,” Maguire said.

The funding was secured relatively quickly, and, over the course of the year, that $10 million was used for a number of equipment and facility upgrades. One major beneficiary was 9995’s radiochemistry laboratory, which separates isotopes from uranium using concentrated levels of
specific acids. The use of those acids necessitates ventilation hoods capable of meeting certain safety requirements. Until recently, only five of the lab’s nine hoods met those requirements, leaving the other four out of commission.

“Since each hood is ten feet long, the lab effectively lost forty feet of work area,” said Darrin Mann, manager of the radiochemistry labs. “This forced the lab to double and triple up in the remaining hoods to meet the site’s analytical needs, resulting in very crowded work areas.”

A portion of the $10 million funding source went toward replacing all nine hoods with lighter, shatter-proof windows, giving each technician their own hood to safely and efficiently handle hazardous chemicals.

“The hood flow has been greatly increased as well, reducing any potential fume exposure in the lab,” Mann noted. “And there were other modern updates such as better placement of electrical connections and an integrated lighting system to improve working visibility.”

In addition to the hood replacement and improvements, the funding helped upgrade electrical panels, install a new transformer, and improve the HVAC system in Building 9995. ACO Manager Jim Placke noticed immediate benefits.

“We now have much better control of temperatures in the labs, which is critical for some of our sensitive analytical equipment,” Placke said. “Overall, we have a better work environment, and we’ve reduced future risks to operations.”

Once funding was received, all the planning, procurement and installation activities for the various improvements were planned and executed expeditiously.

Posted: Wednesday, March 9, 2016 - 7:06pm

A Missile Combat Crew commander from Malmstrom Air Force Base, Mont., practices procedures at Vandenberg AFB, Calif., in preparation for the launch of an unarmed Minuteman III intercontinental ballistic missile. Photo: U.S. Air Force photo, Michael PetersonA Missile Combat Crew commander from Malmstrom Air Force Base, Mont., practices procedures at Vandenberg AFB, Calif., in preparation for the launch of an unarmed Minuteman III intercontinental ballistic missile. Photo: U.S. Air Force photo, Michael Peterson

Standing 30 feet below the cold, snow-covered Montana earth, looking at a live, 60-foot-tall Minuteman III missile that he could reach out and touch (if that were allowed), Alan Armentrout found himself speechless.

“I’ve tried, but I can’t even come up with a word to describe it,” Armentrout, a machinist in Special Materials Operations, said. “You could say ‘powerful’ or ‘amazing’ or something, but none of those are strong enough.”

Armentrout and five other Y-12 Production employees — Dwayne Beaty, Aaron Burlingame, Marty Fritts, Jim Hackworth and Carl Hill — spent a week last month at Malmstrom Air Force Base near Great Falls, Montana, witnessing firsthand the active missiles whose nuclear payloads begin as materials and shapes in Y-12’s production facilities.

The group climbed down into a Minuteman III missile silo; toured the associated launch capsule where, behind 10-ton blast doors, Air Force operators sit strapped into chairs at their workstations; and witnessed a warhead changeout from both the silo and the payload transporter situated above the silo’s opening.

“You’re standing in that silo, looking up at the tip of that missile near the surface and just thinking about what it can do,” said Burlingame, a 9212 supervisor. “It was an eye opener.”

Throughout their time in — and under — Montana, the men couldn’t help but think of Y-12, nearly 2,000 miles away, and its role in the massive display of force in front of them.

“At Y-12, we get entangled in schedules and the minutiae of running a shop daily,” noted Hackworth, Special Materials Operations production manager. “But all the work we do has converged to this one point. These nuclear weapons are there, and they need to be able to go off at any point. All the work we’re doing really counts.”

On the first day back at Y-12, Fritts, a supervisor at the Highly Enriched Uranium Materials Facility, took that message to his crew. “I told them that they do have a bigger purpose,” he said. “We might think that moving a can here or there seems tedious, but it’s the beginning of this whole process. I’ve seen that end product now, and it wouldn’t get done without us.”

Armentrout has already noticed that perspective affecting the way he approaches his work. “I think I pay attention more to all the little details that protect what we’re doing,” he said. “I appreciate even more what we do and feel an immense amount of pride.”

As a bonus, the group was able to sit in on an intelligence briefing. For most, it was their first time hearing a detailed assessment of foreign relations and threats. “The world is a dangerous place,” Burlingame said. “There’s a real threat out there and a real need for these weapons.”

That need, Fritts thinks, is ultimately about peace. “These things are there to guarantee peace,” Fritts said. “We certainly hope they’re never used, and so does everyone else — that’s why they are so absolutely essential to our defense.”

For Burlingame, the trip is still largely indescribable. “It was something visceral,” he said of his experience. “We play a major role in national security. That’s clear to me now, and those words have taken on a whole different meaning.”

Posted: Wednesday, March 9, 2016 - 7:02pm

UPF employees collected donations to determine who would take the Polar Plunge, a leap into the University of Tennessee’s outdoor swimming pool.UPF employees collected donations to determine who would take the Polar Plunge, a leap into the University of Tennessee’s outdoor swimming pool.

Managers from the Uranium Processing Facility raised nearly $9,000 for Special Olympics Tennessee by leaping into ice cold water on Feb. 27 as part of the Polar Plunge, an annual fundraising effort.

UPF was the top fundraising team in Knoxville, contributing 45 percent of the total amount raised in the city, and four UPF managers — Aaron Love, Tony Giordano, Matt Nuckols and Jim Sowers — were the top individual fundraisers. Other UPF participants were Bob Bentley, Mark Braccia, Joe Brown, Jesse Jones, Mike Pratt and Bryan Roberts.

Nominees collect donations to determine who will take the Polar Plunge, a leap into the University of Tennessee’s outdoor swimming pool. At UPF, it was a hotly contested race until the polls closed on Feb. 25. Ultimately, Deputy Engineering Manager Aaron Love edged out Deputy Project Manager Tony Giordano for the top spot by a mere two votes, raising $1,857.

“Thanks to good-natured competition and the generosity of UPF personnel, we led the city in fundraising for this great cause,” said NextGen president Amit Patel.

NextGen is an employee resource group focused on supporting the orientation, development, retention and empowerment of employees as they begin and build their careers.

Posted: Thursday, February 25, 2016 - 3:57pm

Students from Farragut High School work on their entry for the FIRST (For Inspiration & Recognition of Science & Technology) robotics competition. Students from Farragut High School work on their entry for the FIRST (For Inspiration & Recognition of Science & Technology) robotics competition.

Consolidated Nuclear Security, LLC plays an active role in strengthening the quality of FIRST (For Inspiration & Recognition of Science & Technology) robotics competitions for individual high school–aged teams in Tennessee and Texas that compete head to head on a special playing field with robots they have designed, built and programmed. FIRST was founded in 1989 to inspire students’ interest and participation in science and technology.

CNS sponsors the Smoky Mountain Regional competition as well as individual teams at: Robertsville Middle; L & N STEM; and Austin East, Bearden, Bushland, Caprock, Farragut, Hardin Valley, Oak Ridge, Roane and Webb high schools.

In addition to the company’s support, CNS engineers work as volunteer mentors on local teams to educate and support tomorrow’s scientists, engineers and mathematicians. “This is exactly the type of activity CNS wants to support,” said Keith Kitzke, a CNS engineer. “This is one of the best activities I have seen for developing team-building and problem-solving skills in high school students.”

On January 8 inventor and FIRST founder Dean Kamen launched the 2016 season with the release of the FIRSTSTRONGHOLD competition. The game changes yearly, keeping the excitement fresh and giving each team a more level playing field. More than 75,000 high-school students representing more than 3,100 teams at 114 venues around the globe joined the FIRST Robotics 2016 Kickoff via live broadcast hosted by Comcast NBCUniversal. This season’s FIRST competition involves alliances (with other schools) of robots on a quest to breach their opponents’ fortifications, weaken towers and capture the opposing tower. “This competition will test the effectiveness of each robot, the power of collaboration and the determination of the students,” said Jane Skinner, Farragut High School coach. “This program is important to our students and impacts each of them in valuable ways.”

Marvin J., a student on the team, validated Skinner’s statement. He said, “For me, FIRST has helped improve my knowledge all around. It has helped me better understand the influence of technology and engineering in everyday life.” He also noted that participating in the competition expanded his knowledge regarding everyday tools and the importance of teamwork, which enhanced his collaborative skills.

FIRST robotics teams are in phase one, which is the six-week design and build phase of their team robot. Phase two of the robotics season involves seven weeks of competition in districts or regions. The Smoky Mountain Regional competition will take place at Knoxville’s Thompson-Boling Arena March 30–April 2, 2016. The championships will take place in April.

For more information about the competition visit TNFIRST or firstinspires.org.