EM Manager Discusses WIPP Recovery, Photos of WIPP Reopening Event, 25 Years of Successful Idaho Cleanup, Contractor Award Fee Scorecards, and Much More!
DOE Office of Environmental Management sent this bulletin at 01/17/2017 11:26 AM EST
EM’s Carlsbad Field Office Manager Todd Shrader, left, and Energy Secretary Ernest Moniz, following the ribbon-cutting ceremony for the Waste Isolation Pilot Plant reopening.
CARLSBAD, N.M. – Todd Shrader is the manager of EM’s Carlsbad Field Office (CBFO), which oversees the Waste Isolation Pilot Plant (WIPP). Shrader is an accomplished leader and engineer with experience in transuranic (TRU) waste packaging and disposal, engineering for underground repository environments, project management and safe conduct of operations. He has more than 26 years of DOE headquarters and field experience. Below, he discusses the recent reopening of WIPP. The event marked the end of recovery operations and resumption of waste emplacement activities, which had been halted in February 2014 following a waste drum rupture in an underground storage panel and a separate underground fire.
1. How can you be sure all the requirements to restart WIPP have been adequately addressed, so that WIPP is safe to operate?
In order to ensure WIPP is safe to operate, many improvements at WIPP have been implemented in response to the February 2014 incidents — in the safety management programs such as ground control, work controls, radiological controls, and others. Areas of weakness were identified as Judgments of Need in the DOE Accident Investigation Board Reports. Each Judgment of Need required for resumption of operations has been fully addressed by appropriate corrective actions that were documented in formal, approved Corrective Action Plans. These improvements have been successfully implemented and validated. Additionally, the New Mexico Environment Department (NMED) has provided detailed oversight and, as have the Defense Nuclear Facility Safety Board, DOE Office of Enterprise Assessments, Environmental Protection Agency and the Mine Safety and Health Administration. We have reviewed and overseen WIPP recovery activities to ensure that all findings and recommendations from the reviews have been properly addressed and the corrective actions validated.
Beginning in the fall of 2016, WIPP underwent a series of readiness assessments that included an internal management self-assessment and a contractor operational readiness review (ORR), which was performed by subject-matter experts from across the DOE complex. In late November, DOE conducted the final operational readiness review necessary for restart of operations. Corrective actions were developed for all pre-start findings, and were implemented and validated by CBFO and the DOE ORR team. Corrective action plans were reviewed and approved for all post-start findings and we continue working to close out all actions.
In December, representatives from NMED conducted their annual inspection for compliance with the hazardous waste facility permit and approved WIPP’s return to normal operations.
2. Why did it take so long to resume operations?
We took the time we needed to do things safely and to do them right. It has been roughly 35 months since the fire and radiological release incidents at WIPP in 2014. The recovery process was a first-time experience for everyone involved. The initial reentries into the underground and investigations were done slowly and methodically, to ensure worker safety and to avoid altering the environment that was important to understanding the cause of the incidents.
Recovery activities were complex and required detailed planning and training: cleaning and restoring electrical services impacted by the fire, improvement to safety basis and safety management programs, upgrades to equipment, infrastructure and facilities, ground control (rock bolting, mine stability), characterization and decontamination, etc…The safety of the workers, members of the public, and the environment has always been our priority. I’m very proud of the progress we’ve made to get where we are today.
3. Looking back over the 35 months it took, what was the most challenging part of resuming operations?
Each aspect of recovery presented its own set of challenges and it would be difficult to identify one specific area as most challenging. Moving from working in a clean (uncontaminated) environment, to an environment with potential airborne radioactive contamination was a significant departure from what the workforce had previously experienced. Another challenge was catching up and maintaining ground control after the nine-month hiatus following the events. Ground control, including roof bolting, side bolting and floor leveling, is paramount to worker safety and was necessary to ensure the future stability of the WIPP underground. Catch-up bolting was particularly challenging in the contaminated areas where ground-control teams had to operate bolters in personal protective clothing and respirators. What I’m most proud of is that, at every step of the way, safety has driven our decisions and our workforce has risen to the challenges.
4. How long will WIPP have to operate in a contaminated environment?
With the decision to withdraw from the far south end of the mine, the area of the WIPP underground still considered contaminated was reduced by approximately 60 percent. In addition, due to the hygroscopic (recrystallization of salt brine) nature of the salt, surface contamination levels continue to decrease over time as the radioactive particles are absorbed into the surface of the salt. Therefore, the overall footprint of the contaminated area will continue to decrease, creating an opportunity for some areas to be available for down posting, but in all likelihood some portion of the underground will remain designated as a contaminated area until Panel 7 has been filled and associated closure bulkheads have been installed.
5. When will “normal” operations resume?
We have a new “normal” at WIPP now, based on the program changes and safety enhancements, as well as the reality of operating in a contaminated underground area. When we begin receiving shipments, we will start slowly and ramp up to about five shipments per week. This rate may be slightly increased as we identify efficiencies. These rates are based on the 110,000-cubic-feet-per-minute (cfm) level of underground ventilation that is currently available. We cannot return to higher shipping rates until the new exhaust shaft and filter building projects are completed sometime after 2021, which will provide underground ventilation rates at about 450,000 cfm.
6. When will transuranic waste shipments from off-site resume? How will DOE determine the order of waste shipments from generator sites?
Shipments are expected to resume sometime in the spring of 2017, at the rate of up to five shipments per week. The shipping schedule and queue is under development. Considerations in determining priorities will include: the WIPP emplacement rate; waste available for shipping; generator site regulatory commitments and agreements; WIPP transportation/waste acceptance capabilities; programmatic, logistical, and TRU waste storage capacity factors at the generator sites; and operational needs at WIPP and TRU waste generator sites.
7. What are you most proud of today?
I’m most proud of our workforce here at WIPP. Much of the work that was a priority for recovery was in underground areas that had surface contamination or the potential for airborne contamination. Many of the workers have been operating in personal protective equipment and respirators, which made work conditions difficult. In fact these conditions can reduce work efficiency by as much as 75 percent. However, our workforce stepped up and continued to work through the adversity to get us where we are today. I’d like to especially mention the ground-control crews who nearly doubled production over the last few months to help ensure we had safe access to Panel 7 for waste emplacement.
CARLSBAD, N.M. – Energy Secretary Ernest Moniz and EM Assistant Secretary Monica Regalbuto joined members of the New Mexico delegation, including Gov. Susana Martinez, U.S. Sen. Martin Heinrich, U.S. Reps. Steve Pearce and Michelle Lujan Grisham, and Carlsbad Mayor Dale Janway for a celebration this month marking the reopening and resumption of waste operations at EM’s Waste Isolation Pilot Plant (WIPP) near Carlsbad, N.M. Waste emplacement activities were halted in February 2014 following a waste drum rupture in an underground storage panel and a separate underground fire. “The tireless efforts by the workforce, the contractor and federal management and the community to make WIPP a safer place to fulfill its critical mission is a remarkable feat,” Moniz said. Here, Moniz, Martinez and members of the N.M. congressional delegation cut a ceremonial ribbon in WIPP's Waste Handling Building on Jan. 9.
National Champion Mine Rescue Team Captain Heath Fowler, center, shared information about WIPP's mine rescue team members, who secured the 2016 national championship, with Energy Secretary Ernest Moniz and EM Assistant Secretary Monica Regalbuto during an underground tour Jan. 9.
Nuclear Waste Partnership Deputy Manager of Underground Operations Mark Pearcy describes airflow in the WIPP underground to Sen. Martin Heinrich, from left, Rep. Michelle Lujan Grisham, Energy Secretary Ernest Moniz and EM Assistant Secretary Monica Regalbuto. The underground tour was part of a Jan. 9 event for WIPP's reopening.
N.M. Gov. Susana Martinez leads a round of applause for the resumption of waste emplacement at WIPP during the reopening ceremony Jan. 9. Energy Secretary Ernest Moniz, Sen. Martin Heinrich, Reps. Steve Pearce and Michelle Lujan Grisham, and Carlsbad Mayor Dale Janway also spoke at the event.
Workers underground at WIPP celebrate the completion of the first waste emplacement since 2014. On Jan. 4, 2017, they emplaced waste from the Savannah River Site that had been recertified and stored in the Waste Handling Building (WHB). All recertified waste from the WHB will be emplaced prior to accepting new waste shipments from generator sites to WIPP. EM expects to resume shipments to WIPP in spring 2017.
Workers move waste for emplacement underground at WIPP on Jan. 4.
Using an onsite lined landfill to dispose of cleanup debris at the Idaho Site has saved taxpayers hundreds of millions of dollars over the cost of shipping the material offsite for disposal.
IDAHO FALLS, Idaho – DOE has successfully cleaned up the Idaho Site’s legacy waste for the last 25 years, protecting the primary drinking and irrigation water source for more than 300,000 Idahoans in compliance with an agreement with the state.
DOE, Idaho and the state’s Environmental Protection Agency (EPA) signed the Federal Facility Agreement and Consent Order in 1991. It outlines a plan to investigate and clean up to 500 waste areas within the 890-square-mile site, most of which is complete. The waste came from nuclear reactor research and decades-old waste disposal and defense missions. The sites consist of unlined wastewater disposal ponds; debris piles; radioactive groundwater plumes; buried barrels and boxes of radioactive waste; and unexploded ordnance.
DOE’s Idaho Site cleanup contractors have met 981 milestones in the agreement on or ahead of schedule. Crews are two years ahead of schedule in a project that has removed more than 7,700 cubic meters (or nearly 37,000 drums) of waste from an unlined Cold War landfill. High-pressure pumps are removing solvent vapors beneath it. Workers removed and destroyed nearly 246,000 pounds (equivalent to 336 55-gallon drums) of solvent vapors through catalytic oxidation units.
Workers exhume buried transuranic waste from Pit 9.
Fifteen of the milestones have proven more challenging than the others, resulting in delays. EM completed, renegotiated or rescheduled 14 of those. The remaining outstanding milestone deals with treating 900,000 gallons of radioactive liquid waste in three underground storage tanks. The site’s current cleanup contractor, Fluor Idaho, LLC, has a four-phase approach to safely and efficiently start up the Integrated Waste Treatment Unit, a facility to treat the waste. The contractor is redesigning equipment and resolving a chemistry challenge in the facility’s primary reaction vessel.
Longtime cleanup employee Kirk Dooley, far right.
Kirk Dooley, a remediation manager and engineer, has seen significant progress in his 26 years working with the cleanup program.
“The biggest change that I have seen over the years is the cultural change,” he said. “It’s no longer just a job but employees take pride in doing their job well and doing it safe.”
Dooley said many innovations have made the cleanup safer and more efficient.
“Several patents were awarded for treating and monitoring contaminants, and treating sodium and groundwater,” he said. “We’ve also developed better methods for retrieving buried contaminated waste, treating the material, and then repackaging it. All of these things have contributed greatly to the successful cleanup of the site.”
EM is treating an aquifer at the site’s north end. Workers have treated more than 600 million gallons of water there. They’ve used a pump-and-treat system and bioremediation, in which a food-grade whey is injected into the aquifer near a contaminant plume to encourage microorganisms to feed on waste.
Construction of a 510,000-cubic-foot landfill in the early 2000s allowed DOE to consolidate waste from many areas of the site into a single, managed location with impermeable liners, a leachate collection system and lined disposal ponds. Disposing of the waste onsite saves hundreds of millions of dollars over the cost of disposing of the material out of state.
CH2M HILL BWXT West Valley workers place a vertical storage cask liner on a construction pad.
WEST VALLEY, N.Y.– CH2M HILL BWXT West Valley (CHBWV), the cleanup contractor for the West Valley Demonstration Project (WVDP), earned $360,000 of a possible $450,694 award fee for the March to August 2016 performance period, according to a recently released scorecard.
CHBWV received a “very good” rating for safety, health, and quality management; business and project management; and environmental and regulatory strategy.
“The team made remarkable progress in accomplishing the cleanup mission in 2016,” EM Federal Project Director Bryan Bower said.
Contractor award fee evaluations determine what will be paid based on performance against stated objectives in accordance with annual award fee plans. EM releases information relating to contractor fee payments to further transparency.
According to EM’s final performance evaluation for CHBWV:
With more than 2.1 million safe work hours, the contractor continued its commitment to safety excellence. CHBWV received DOE’s Voluntary Protection Program Star of Excellence for a second consecutive year, conducted excellent coordination with off-site emergency responders, implemented a first-rate radiological controls program and continued efforts to enhance the emergency management program.
CHBWV submitted quality and timely contract deliverables, and continued its commitment to improve cybersecurity. The contractor exceeded the DOE strategic sourcing goals for fiscal year 2016, saving money in procurements through e-sourcing, a procurement tool.
The contractor’s partnering efforts were “excellent,” its problem solving and work planning and control were “very good” and its risk management was “good.”
EM attributed the “very good” environmental and regulatory strategy rating to CHBWV’s regulatory work activities relative to project implementation, “good” coordination with DOE staff, and “very strong” liaison work with regulators and stakeholders.
EM noted that CHBWV met a majority of performance goals and objectives for the evaluation period.
Bower cited several CHBWV accomplishments over the past year, including:
Completing a high-level waste relocation project, including construction of the storage pad and haul road;
Constructing 56 vertical concrete storage casks lined with carbon-steel containers, each for holding five canisters of vitrified high-level waste, welded closed and transported to an onsite interim storage pad;
Loading and transport of three large, low-level waste packages mostly by rail to a permanent disposal site in Andrews, Texas;
Deactivating 97 percent of the Vitrification Facility to prepare for demolition in 2017; and
Deactivating 58 percent of the Main Plant Process Building to prepare for eventual demolition.
“I am very proud of their accomplishments and look forward to working together in 2017 to safely begin demolition of the Vitrification Facility,” Bower said.
Once the site of the first and only commercial nuclear fuel reprocessing plant in the U.S., WVDP is now an environmental cleanup and waste management project located about 35 miles south of Buffalo. The cleanup is conducted by EM in cooperation with the New York State Energy Research and Development Authority.
“Demolition is progressing safely, deliberately and well,” said Tom Teynor, project director of EM’s PFP Closure Division. “Starting demolition of the Americium Recovery Facility brings another chapter of Hanford history to an end and represents a significant hazard reduction on the site.”
One of PFP’s four large buildings, the Americium Recovery Facility operated during the site’s plutonium production days, separating radioactive americium. It ceased operations in 1976 following an explosion that severely injured Harold McCluskey, an employee who was working inside. He survived, and the room became known as the McCluskey Room. In 2014, CH2M began final cleanout and demolition preparations, including removal of the glove box that burst and contaminated McCluskey.
Employees continue preparing PFP’s main production building and a ventilation fan house and stack for demolition, which is expected to begin in late April after the teardown of the other PFP facilities. Workers are removing highly contaminated ventilation ductwork and process piping, and installing temporary power. Demolition of the entire PFP complex is scheduled for completion by September 2017.
“The PFP team has done a tremendous job safely performing this hazardous work, whether it’s cleaning out the buildings or demolishing them,” said Tom Bratvold, vice president of CH2M’s PFP closure project. “We are making steady progress, and we will continue to do so safely.”
AIKEN, S.C. – In a first for EM, the Savannah River Site (SRS) has partnered with DOE’s Office of Science to host emergency data recovery capabilities at the Oak Ridge Site.
SRS management and operations contractor Savannah River Nuclear Solutions (SRNS) is responsible for the SRS information technology mission, overseeing primary and backup data centers within the site. DOE and SRNS recently decided that off-site backup is preferred to a prior policy calling for no data to leave the site.
“There was a concern that with our primary and backup data centers located on site about eight miles apart, a natural disaster or other catastrophic event could in fact impact both data centers,” SRNS Chief Information Officer Jeff Krohn said. “We worked with the Department to identify a couple of locations in Oak Ridge. It’s an optimal location because it’s far enough away from SRS to meet our needs but it’s also drivable from the site.”
The DOE Savannah River Operations Office signed a memorandum of understanding with the Office of Science to enable the partnership. The data center managed by the Office of Science and Technical Information (OSTI) in Oak Ridge hosts copies of the applications for disaster recovery at SRS.
“We were very impressed with the OSTI facility,” Krohn said. “They were a good fit because they have had more experience with multiple tenants, could provide the physical separation we needed for our dedicated servers and were ready to go from a bandwidth perspective. It was a great match for our needs.”
Employees moved the data to the OSTI center over eight months in 2016. SRNS then tested the system and reported a successful transition.
“We are proud of this partnership with the Office of Science to make our data more secure and provide further protection against unforeseen events,” Krohn said.
WAI’s obtained nearly $126,000 for the evaluation period of Nov. 21, 2015 to Sept. 30, 2016. ORP recognized the contractor for establishing positive relationships with its customers, adapting to shifting customer priorities and skillfully managing a changing workforce.
“Wastren Advantage made a near seamless transition from the previous contractor,” ORP Manager Kevin Smith said. “It’s never easy transitioning work scope between different contractors, and to do it without any mission impact reflects well on WAI.”
Contractor award fee evaluations determine what will be paid based on performance against stated objectives in accordance with annual award fee plans. EM releases information relating to contractor fee payments to further transparency.
According to ORP, WAI:
Delivered high-quality data to customers in a timely manner;
Reduced the quantity of hazardous chemicals in the lab by 11 percent through vigorous inventory standards and a new Environmental Management System procedure.
The scorecard lists seven performance incentive areas. Three are performance-based, focusing on delivery, evaluations and proficiency tests, and maintaining holding times. The others are special emphasis areas, including business interfaces and efficiency; analytical reporting and data quality; environmental stewardship and compliance; and worker safety, health and safety culture.
WAI provides analytical services at the laboratory in Hanford’s 200 West Area. Its employees receive, handle, prepare, analyze and store samples from projects on the site. They have expertise in nuclear engineering and physics, organic chemistry, waste management, biology and ecology.
Workers install a booster pump for sludge removal.
RICHLAND, Wash. – EM’s Richland Operations Office (RL) and contractor CH2M HILL Plateau Remediation Company (CH2M) are preparing to move highly radioactive sludge away from the Columbia River.
Hanford Site workers shipped equipment and tools from a mock-up facility to the 100 K Reactor Area. The equipment is being installed in the K West Reactor’s former spent fuel basin, where 35 cubic yards of sludge is stored in containers, and in a nearby annex.
Employees prepared for this first-of-a-kind work in the mock-up building inside the site’s Maintenance and Storage Facility. They developed and tested technology and tools in the non-radioactive environment. The testing was integral to resolving issues in the project.
“This equipment system testing at the mock-up and in the K Area will ensure we can have a high level of confidence that the system will work as designed,” RL Project Director Mark French said.
Workers deliver sludge removal equipment.
Workers plan to ship and install sludge removal and handling equipment this month. They are scheduled to complete tests by mid-March to ensure the system performs as expected.
“It’s a great feeling to see all of this coming together so well,” said Andre LaBonty, a CH2M construction project lead. “There are many layers of teams coordinating to make this possible: operations, construction, engineering, the group at the mock-up facility and others.”
The sludge is stored in six stainless steel containers under 16 feet of water that provides shielding. The basin is 400 yards from the river.
Workers install a second extraction well for EM’s chromium project.
LOS ALAMOS, N.M. – The cleanup contractor for Los Alamos National Laboratory (LANL) earned approximately 90 percent of the available fee for fiscal year (FY) 2016, according to a recently released award fee scorecard from the EMLos Alamos Field Office (EM-LA).
Los Alamos National Security (LANS) received $9,133,211 of an available $10,095,919 fee. In its scorecard, EM-LA noted the contractor’s strong performance in several areas, including:
Safely managing and storing nitrate salts as part of legacy waste management;
Preparing to treat the nitrate salts;
Addressing chromium contamination in the regional aquifer, and associated schedule recovery;
Partnering to establish effective relationships to efficiently complete work.
Contractor award fee evaluations determine what will be paid based on performance against stated objectives in accordance with annual award fee plans. EM releases information relating to contractor fee payments to further transparency.
The LANS scorecard summarizes objective award fee and performance-based incentives earned by the contractor for the Los Alamos Legacy Cleanup Bridge Contract. Its FY 2016 milestones include installing an extraction well for the chromium project and modifying the Waste Characterization Remediation and Repackaging Facility, where remaining containers of remediated nitrate salts will be treated beginning in spring 2017.
Areas to improve include project controls, cost estimating, and contract management; emergency and issues management; procedural compliance; and quality assurance, according to the scorecard.
The EM-LA mission is to safely and efficiently complete the cleanup of legacy contamination and waste resulting from nuclear weapons development and government-sponsored nuclear research at LANL.
Noteworthy accomplishments by Savannah River Remediation (SRR) in this period include:
Maintaining salt and sludge processing by effectively operating the liquid waste system without storage volume reduction capability from the 25H evaporator due to unanticipated pot failure;
Operational closure of Tank 12 ahead of the commitment date in the Federal Facilities Agreement, which was established to remove 24 old-style tanks without full secondary containment from operational service and address cleanup decisions for soil and groundwater;
Successfully completing a demonstration project that safely increased the salt waste processing rate;
Supporting startup and integration of the Salt Waste Processing Facility into the site’s liquid waste program; and
Initiating and awarding a contract for the tank closure cesium removal demonstration project to supplement current salt processing throughput rates.
Contractor award fee evaluations determine what will be paid based on performance against stated objectives in accordance with annual award fee plans. EM releases information relating to contractor fee payments to further transparency.
DOE Savannah River Operations Office (DOE-SR) Manager Jack Craig recognized SRR management in the evaluation for doing the “right thing” in addressing uncertain and emergent issues.
“Management remains actively engaged in maintaining operational excellence and is quick to address issues as they emerge,” Craig said. “These philosophies to stop, evaluate and proceed when appropriate are clearly evident of a management team dedicated to safe operations of SRS liquid waste facilities.”
Craig noted that although some performance objectives, such as the storage reduction target, were not achieved due to emergent technical issues, such as the 25H evaporator pot failure, the award fee recognizes and reinforces SRR management’s performance regarding these issues.
SRR President and Project Manager Tom Foster credits his employees with the accomplishments.
“Our success is the result of our employees, who not only work safely but take pride in their work. They also understand that innovation continues to play a key role in how we disposition waste and operationally close waste tanks to meet the expectations of DOE, regulators, stakeholders, and the public,” said Foster.
DOE-SR noted that improvements are needed in conduct of operations in the liquid waste facilities and management of corrective actions.