EM Update | Vol. 10, Issue 5 | Feb. 6, 2018

• Energy Secretary Rick Perry Breaks Ground on SRS Waste Facility
• SRS Employees Gather With Energy Secretary Rick Perry at All-Hands Meeting
• EM's Lab Highlights Innovations for Energy Secretary Rick Perry
• Oak Ridge Begins Demolition of Central Neutralization Facility
• Employees Complete Major IWTU Redesign Safely, Ahead of Schedule
• Kentucky Middle School Advances to DOE’s National Science Bowl
• EM Contractor Preserves Hanford’s History Through Lens of Old Photos
• Early Career Engineers Grow Professionally, Support SRS Liquid Waste Mission

Energy Secretary Rick Perry Breaks Ground on SRS Waste Facility

Energy Secretary Rick Perry (center) breaks ground at the site where Saltstone Disposal Unit (SDU) 7 will stand. From left are SDU 7 Project Manager Craig Carlisle; Savannah River Remediation President and Project Manager Tom Foster; Secretary Perry; DOE-Savannah River Manager Jack Craig; and SDU 7 Federal Project Director Shayne Farrell. In the background is SDU 6, which was completed last year.

AIKEN, S.C. – Energy Secretary Rick Perry joined Savannah River Site (SRS) officials Feb. 1 to break ground on EM’s second 32.8-million-gallon liquid waste disposal unit during his first visit to the site.

   “We are pleased that Secretary Perry could be here to commemorate this occasion with us today,” DOE-Savannah River Manager Jack Craig said. “The Saltstone Disposal Units (SDU) are an important part of our cleanup mission and underscore the Department of Energy's continued commitment to furthering progress on the closure of the high-level waste tanks at SRS.”

   SDUs are permanent disposal units for low-activity waste grout produced from the solidification of decontaminated non-hazardous salt waste at SRS. The groundbreaking was for SDU 7, the second of seven mega units planned to store the remaining tank waste. EM approved the concept of replicating the mega-volume design for all remaining SDUs at SRS.

Energy Secretary Rick Perry joined about 100 Savannah River Site employees for the groundbreaking of Saltstone Disposal Unit 7.

Energy Secretary Rick Perry (left) shakes hands with Saltstone Disposal Unit (SDU) 7 Project Manager Craig Carlisle at the SDU 7 groundbreaking.

   Tom Foster, president and project manager of Savannah River Remediation (SRR), the SRS liquid waste contractor, noted that SDU 7 site preparation began just three months after SRR completed construction on SDU 6. Workers completed SDU 6 $25 million under budget and 16 months ahead of schedule last year. EM recognized the successful project by naming it the 2017 EM Project of the Year.

   “The template created by the liquid waste team from safely completing Saltstone Disposal Unit 6 will continue as we begin construction on Saltstone Disposal Unit 7,” Foster said. 

   Workers removed structures as part of the SDU 7 site preparation that began in October 2017. They are rerouting above- and below-ground utilities within the SDU 7 footprint to allow for excavation of more than 170,000 cubic yards of soil for the structural base slab.

Energy Secretary Rick Perry signs a groundbreaking shovel with SDU 7 Federal Project Director Shayne Farrell.

   The mega-volume SDUs will accommodate the larger stream of decontaminated salt solution from the Salt Waste Processing Facility (SWPF), which is scheduled to begin operating in December.

   The seven larger units will result in more than $500 million in cost savings over the life of the low-level saltstone waste storage program because less infrastructure and materials are required to design and build the larger SDUs. SRS will need only seven of the larger units to meet mission needs — equivalent to 80 small SDUs, each holding roughly 3 million gallons. 

   SWPF is key to the SRS liquid waste program and will process the majority of the site’s salt waste inventory. Removing salt waste, which fills over 90 percent of tank space in the SRS tank farms, is a major step toward emptying and closing the site’s remaining 43 high-level waste tanks.

-Contributor: Maddie Blair

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SRS Employees Gather With Energy Secretary Rick Perry at All-Hands Meeting

Energy Secretary Rick Perry responds to questions from employees at an all-hands meeting at the Savannah River Site.

AIKEN, S.C. – Energy Secretary Rick Perry conducted an all-hands meeting with Savannah River Site (SRS) employees at the conclusion of his first visit to the site last week.

   During his SRS visit on Feb. 1 and 2, Secretary Perry toured EM cleanup projects, the Savannah River National Laboratory (SRNL), and other operations. He also broke ground for construction of the Saltstone Disposal Unit 7. Read about those events in this issue of the EM Update newsletter.

   “It is a privilege for me to be here today and to share what we have going on together,” Secretary Perry told approximately 150 employees at a gathering simulcast to workers at other site facilities. “The DOE’s mission here is incredibly important, and I come today to salute you.”

   Secretary Perry noted the important roles SRS and other EM sites played in World War II and the Cold War. 

   “I am honored to be your partner and part of one of the most extraordinary teams in America,” he said.

Energy Secretary Rick Perry addresses employees of the Savannah River Site in an all-hands meeting.

Energy Secretary Rick Perry participates in a demonstration of crane equipment at the H Canyon Chemical Separations Facility. 

Energy Secretary Rick Perry observes a demonstration of equipment and training at the Plutonium Blend Down Mock Up Training Facility.

Dan Iverson (right), melter engineer with Savannah River Remediation, the Savannah River Site's liquid waste contractor, explains melter operations to Energy Secretary Rick Perry at the Defense Waste Processing Facility. 

   U.S. Sen. Lindsey Graham (S.C.) and Reps. Joe Wilson (S.C.) and Rick Allen (Ga.) joined Secretary Perry for portions of his visit, including the all-hands meeting. 

   Secretary Perry toured the K Area Plutonium Blend-Down, H Canyon Separations Facility, Saltstone Facility, and Defense Waste Processing Facility.

   Reflecting on the innovations that he saw during his SRNL tour, Secretary Perry noted that the potential for growth for the EM national laboratory is substantial.

   Secretary Perry also shared that he met with representatives from the site's surrounding communities.

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EM's Lab Highlights Innovations for Energy Secretary Rick Perry

Energy Secretary Rick Perry examines an item in the FBI’s Radiological Evidence Examination Facility (REEF) as Savannah River National Laboratory Program Manager Todd Coleman explains the lab’s capabilities. Run by SRNL for the FBI, the REEF is the world’s first crime lab capable of examining radiological and radiologically contaminated evidence.

AIKEN, S.C. – Energy Secretary Rick Perry toured EM’s Savannah River National Laboratory (SRNL) last week to learn more about research underway in environmental stewardship, nuclear security, energy, and advanced manufacturing.

   Secretary Perry toured the materials science laboratories at SRNL’s Applied Research Center (ARC) and the unique facilities at the lab’s main campus. Among the highlights of the visit were a stop at the world’s first radiological crime lab, a demonstration of a nanomaterial developed at SRNL that is being commercialized, a briefing on how SRNL secures and disposes of weaponizable nuclear materials globally, and a discussion about advanced manufacturing.

   The lab tour was part of Secretary Perry’s first visit to the Savannah River Site. During the Feb. 1 and 2 visit, he also broke ground for construction of the Saltstone Disposal Unit 7 and conducted an all-hands meeting with about 150 employees at the site. Read about those events in this EM Update newsletter issue.

   Joining Secretary Perry for the lab tour were U.S. Sen. Lindsey Graham (S.C.) and Reps. Joe Wilson (S.C.) and Rick Allen (Ga.). In addition to overviews and demonstrations, the group had the opportunity to talk with staff scientists and researchers about their work.

Savannah River National Laboratory (SRNL) Director of Defense Programs Science and Technology David Babineau explains the Thermal Cycling Absorption Process (TCAP) to Energy Secretary Rick Perry. Invented by SRNL, TCAP has reduced the footprint needed to separate hydrogen isotopes by up to 10 times while saving operational costs and improving performance.

Energy Secretary Rick Perry tests the dexterity of glovebox gloves made with a Savannah River National Laboratory (SRNL)-developed nanomaterial by signing his autograph while SRNL Senior Scientist Dr. Jay Gaillard watches.

   “It was very exciting to have the opportunity to speak with Secretary Perry and to share some of the laboratory’s research programs,” SRNL Senior Engineer Kallie Metzger said. “He spoke passionately about his visits to the national laboratories and was engaged during our lunch discussion about the advancement of commercial technologies in support of DOE missions. It is evident that he understands the importance of the national laboratories and is very supportive of our efforts.”

   At ARC, the group learned more about SRNL’s hydrogen research, including tritium, the radioactive isotope of hydrogen that is essential to the U.S. nuclear deterrent. SRNL’s research in this area has led to commercial partnerships for solar energy systems and the creation of a domestic supply of medical isotopes. 

   The visit to ARC also included a demonstration of glovebox gloves made of graphene nanomaterials being commercialized with a private company. Secretary Perry learned that the graphene prevents hydrogen from penetrating the glove and gives users more dexterity.

   At SRNL’s main campus, the group toured the FBI’s Radiological Evidence Examination Facility, the only dedicated forensic examination facility in the U.S. for handling radiological and radiologically contaminated evidence. 

Energy Secretary Rick Perry learns more about the Mark-18a program from Bill Bates, Savannah River National Laboratory Deputy Associate Lab Director for Nuclear Materials Management Programs.

Savannah River National Laboratory (SRNL) Director of Wasteform Processing Technology Connie Herman shares more about the cleanup work SRNL is doing across the entire EM complex with Energy Secretary Rick Perry, SRNL Associate Lab Director of Environmental Stewardship Dr. Jeff Griffin (center) and U.S. Rep. Rick Allen (Ga.) (back). 

   The group stopped at SRNL’s Shielded Cells Facility, a specialized work area providing shielding for the safe analysis of highly radioactive materials, and received an overview of the lab’s work to secure and dispose of weaponizable nuclear material around the world. They learned about SRNL’s unique nuclear materials management capabilities that allow the recovery of rare and valuable isotopes for space, medical, and scientific applications.

   Lab staff also provided Secretary Perry with a briefing on its innovations in vitrification, the process used to turn highly radioactive liquid waste into a stable glass form for long-term disposal. Through strategic advances in glass science and new manufacturing technologies, SRNL has been able to save DOE $1.5 billion in cleanup costs and reduce the liquid waste mission by five years.

   The tour concluded with a working lunch to discuss the lab’s effort to accelerate the use of advanced manufacturing technologies and methods to transform a range of DOE and National Nuclear Security Administration missions. A focus of discussion was SRNL’s Advanced Manufacturing Collaborative, a collaboration among national laboratories, industry, and education to innovate and accelerate new technology adoption in process intensification, additive manufacturing, virtual reality, and other areas.

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Oak Ridge Begins Demolition of Central Neutralization Facility

Equipment dismantles piping from the neutralization tanks. 

OAK RIDGE, Tenn. – Oak Ridge’s EM program and cleanup contractor URS | CH2M Oak Ridge (UCOR) have begun demolishing the Central Neutralization Facility at the East Tennessee Technology Park (ETTP).

   Constructed in the mid-1980s to treat wastewater from operations at the former uranium enrichment complex, the facility consists of tanks, trailers, and other treatment systems used to filter and remove radioactive materials, metals, and suspended solids from wastewater at the site. 

   All operations at the facility ceased in 2013, and a new wastewater treatment facility, the Chromium Waste Treatment System, began operating on the same footprint.  

   UCOR deactivated the facility by disabling utilities and cutting tie lines, which are the pipes that transported enriched uranium between the site’s facilities. During previous closure activities, crews removed materials containing radiological, metal, and organic contamination. Workers thoroughly rinsed and sampled remaining process tanks, pipes, and equipment.

Crews deactivate the Central Neutralization Facility by disabling utilities and cutting tie lines.

   “Demolishing the Central Neutralization Facility removes old infrastructure that no longer serves a mission at ETTP, and it greatly improves the aesthetic in the back of the site that reflects our ultimate vision for the site,” said James Daffron, federal project manager for the Oak Ridge of Environmental Management.

   Demolition is expected to be completed this spring as workers transform the former uranium enrichment complex into a private sector industrial park. To date, EM has torn down more than 400 facilities and transferred more than 1,000 acres. 

   EM is working to complete major cleanup and building and land transfers at ETTP by 2020, providing the community an asset to attract major industry and enable economic development for the region.

-Contributors: Wayne McKinney, Ben Williams

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Employees Complete Major IWTU Redesign Safely, Ahead of Schedule

Tyson Pincock assists Ben Hobley in the welding of ½-inch-thick plates outside the Integrated Waste Treatment Unit’s Denitration Mineralization Reformer. 

IDAHO FALLS, Idaho – EM's Idaho Site workers recently completed improvements to the Integrated Waste Treatment Unit (IWTU), including the challenging task of welding a stainless steel alloy designed to withstand high temperatures. 

   Welders and pipefitters with EM cleanup contractor Fluor Idaho successfully finished initial welds and other modifications to the waste treatment facility’s primary reaction vessel known as the Denitration Mineralization Reformer (DMR). They modified the vessel from a hemispherical bottom to a conical shape, and installed directional nozzles, or gas distributors, to improve the movement of billions of tiny beads inside the vessel needed for efficient waste treatment.

   “Haynes 556 is extremely challenging to weld,” Fluor Idaho Project Manager Scott Shurtliff said of the alloy. “It’s a material that’s widely unknown to most other welders in the world.” 

   A carbon steel DMR mockup allowed the workers to practice their tasks before entering the vessel’s confined space. Welders brought ½-inch-thick curved plates into the 48-inch vessel through a tight 18-inch manway, or portal. They tacked the plates into place before following up with subsequent welds.

   “Getting the individual pieces to fit into the out-of-round vessel was one of our biggest challenges,” said welder Ben Hobley. “Some of those cone sections took us over two days to get their shape right before we could start welding on them.”

   Noting the uncomfortable working conditions, Hobley said much of the welding required him to bend down to weld at the level of his ankles and knees.

   “It was difficult to make things ergonomically comfortable,” he said. “Welding out of position for days on end can be exhausting, but we know how important this project is and we are proud to be a part of it.”

   Welder Tyson Pincock echoed Hobley’s comments. 

   “This was a mentally and physically challenging project considering we had to work in such a tight space,” Pincock said. “We always take pride in our work, but this required the most meticulous attention to detail. We had to be very strategic in how we applied each weld.”

A mockup of the Denitration Mineralization Reformer was invaluable in helping welders prepare for days of work inside the cramped quarters of the Integrated Waste Treatment Unit’s primary reaction vessel.

Workers tacked ½-inch-thick plates in place and followed up with welds.

   Shurtliff praised the crew headed by lead pipefitter Eric Lewis.

   “I was very impressed with everyone,” he said. “They’ve been a very good team.”

   Fluor Idaho Program Manager Fred Hughes said the welders and pipefitters completed their work safely and ahead of schedule.

   “I want to thank them for their get-it-done attitude as well as their professionalism during the entire effort. They are clearly leaders in their fields.” Hughes said.

   All welds will be inspected before the next IWTU demonstration planned for March. Following treatment of a simulant demonstrating proper operation of the facility, crews will inspect the DMR and welds to ensure the facility is ready for operations. 

   The IWTU will use a fluidized bed steam-reforming process to treat the remaining 900,000 gallons of liquid radioactive waste from the Idaho Site’s underground tank farm. The beads in the DMR are kept in a fluidized state with the help of superheated gases. Liquid waste enters the fluidized bed, coating the beads like the formation of pearls. The waste product is transferred to stainless steel canisters and ultimately concrete vaults.

-Contributor: Erik Simpson

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Kentucky Middle School Advances to DOE’s National Science Bowl

The Lone Oak Middle School winning team (left to right): Jack Perriello, Reese Bell, EM Paducah Site Lead Jennifer Woodard of EM’s Portsmouth/Paducah Project Office, Isaac Reynolds, Avery Miller, Cameron Willis, and coach Daniel Rushing.

PADUCAH, Ky. – Lone Oak Middle School won DOE’s West Kentucky Regional Science Bowl Feb. 2 during competition among 20 middle school teams. 

Lone Oak advances to represent western Kentucky, southern Illinois, and western Tennessee in the middle school competition at DOE’s National Science Bowl (NSB) April 26-30 in Washington, D.C.

“Lone Oak Middle School is thankful for this incredible opportunity sponsored by DOE,” said Daniel Rushing, the team’s coach. 

“First of all, we thank the Lord for blessing us with our knowledge. We’d also like to thank our educators,” said Isaac Reynolds, 8th grade student and Lone Oak team captain. “Science Bowl was a great experience for us.”

The Lone Oak Middle School team deliberates during the finals of the DOE West Kentucky Regional Middle School Science Bowl.

   The event was held on the University of Kentucky College of Engineering—Paducah Campus at West Kentucky Community and Technical College. It was organized by employees and contractors from EM’s Portsmouth/Paducah Project Office. More than 100 volunteers serve as moderators, judges, technical advisors, and scorekeepers.

   DOE’s Office of Science manages the NSB finals competition. More information is available on the NSB website.

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EM Contractor Preserves Hanford’s History Through Lens of Old Photos

Dan Ostergaard (left) and Nolan McCants with Mission Support Alliance look through historical photos in EM’s Hanford Site collection. Old photos are critical to current cleanup planning.

RICHLAND, Wash. – Seventy-five years ago in January, U.S. Army Corps of Engineers Lt. Gen. Leslie Groves, director of the Manhattan Project, selected the Hanford Site in Washington state as a plutonium production site. Since the site’s inception, activities at Hanford have often had historical significance, including in this era of environmental cleanup. 

   EM Richland Operations Office contractor Mission Support Alliance (MSA) manages a collection of historical photos for EM. It contains hundreds of thousands of photographs dating back to the pre-Hanford Site days, which includes the Hanford Township and the town of White Bluffs. MSA catalogs and organizes this information for future use.  

   “Making sure we preserve these historical photographs is not only key to understanding Hanford’s past, but also helps in cleanup. Often they are used for determining and examining how certain structures were built,” said Ladd Allison with MSA’s Content and Records Management.

   After the partial collapse of the Plutonium Uranium Extraction (PUREX) Plant tunnel last May, EM asked MSA for photographs related to the tunnel’s construction. MSA provided those historical photos, as well as images of an adjacent PUREX tunnel, which gave EM a better understanding of the collapse and helped identify steps to stabilize both tunnels. 

   “The photos not only helped us understand why there was a partial collapse, but they were very important in defining a near-term response,” said Al Farabee, federal project director. “The use of experienced personnel with a knowledge of the Hanford photographic history, categorization, and storage protocols was extremely valuable.” 

   To help with cataloging, MSA brought in a former long-time Hanford photographer to help identify relevant photos and to ensure accurate photo labeling.

-Contributor: Patrick Conrad

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Early Career Engineers Grow Professionally, Support SRS Liquid Waste Mission

Savannah River Remediation’s Carl Scherman gives a tour of the Salt Waste Processing Facility to Reaching Engineers at the Development Years participants. 

AIKEN, S.C. – The Reaching Engineers at the Development Years (READY) program provides an avenue for personal and professional growth at the Savannah River Site (SRS) while supporting the liquid waste cleanup mission. 

   Early career engineers can join the five-year career development program when they begin working for SRS liquid waste contractor Savannah River Remediation (SRR). The program stands on six foundational pillars — job rotation, training and development, mentoring/coaching, professional development, site visibility, and social networking.

   SRR Salt Waste Processing Facility Senior Project Advisor Carl Scherman chairs READY. Scherman recognizes the challenges newly graduated engineers face when considering their careers. He said allowing participants to spend their first year rotating through three assignments gives them exposure to the many ways legacy liquid waste is remediated at SRS.

   “Choosing an industry can be a daunting task, and many times newly graduated engineers are unsure about the trajectory of their careers,” Scherman said. “Participation in the program helps SRR meet their business needs by developing its engineer workforce through a structured experience where employees obtain a broader knowledge of the liquid waste process.”  

   The employees’ educational background sets the path for customized progression, allowing the engineers to find niches in the liquid waste system. They build knowledge and skills, increasing their advancement opportunities, while helping SRR retain its employees. 

   DOE-Savannah River Facility Engineer/Safety System Oversight Engineer Tom Temple said READY supports the long-term liquid waste mission by developing the contractor’s early career workforce.

   “We are always trying to develop and implement new technology to better achieve our goal of safely receiving, storing, processing, and ultimately dispositioning the waste,” Temple said. “This approach makes the work interesting, and keeps engineers engaged.”

-Contributor: Ashley Dernberger

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