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UPF construction could cost more, take longer

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The entrance sign at Y-12 National Security Complex at Bear Creek Road and Scarboro Road is pictured above on Wednesday, Jan. 25, 2023. (Photo by John Huotari/Oak Ridge Today)

The Uranium Processing Facility at Y-12 National Security Complex was supposed to be completed by 2025 for no more than $6.5 billion, but that might no longer be the case.

In the past week, federal officials said construction projects across the country, including UPF, have been affected by the COVID-19 pandemic, supply chain delays, inflation, labor shortages, and increased labor costs. Those factors have led to higher construction costs and longer project timelines, the federal officials said.

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For members: CNS violated nuclear safety requirements at Y-12, NNSA says

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Y-12 Building 9212
A low-level aerial shot of Building 9212 at the Y-12 National Security Complex.

A federal contractor violated nuclear safety requirements at the Y-12 National Security Complex, according to the National Nuclear Security Administration.

The violations are associated with the accumulations of uranium-235 in a glovebox, furnace, and casting line in Building 9212 at Y-12. The equipment is used to recover and process uranium-235, a fissile material that can be used in nuclear weapons and reactors.

Y-12 Building 9212

A low-level aerial shot of Building 9212 at the Y-12 National Security Complex.

 

A federal contractor violated nuclear safety requirements at the Y-12 National Security Complex, according to the National Nuclear Security Administration.

The violations are associated with the accumulations of uranium-235 in a glovebox, furnace, and casting line in Building 9212 at Y-12. The equipment is used to recover and process uranium-235, a fissile material that can be used in nuclear weapons and reactors.

The buildup of enriched uranium, discovered after hydraulic lines leaked in a glovebox, exceeded limits established by a safety program meant to help prevent a nuclear chain reaction.

An investigation of the uranium accumulations found weaknesses in five areas, according to the NNSA, which is part of the U.S. Department of Energy and overseas nuclear weapons work at sites like Y-12. Among the deficiencies were procedural compliances, evaluations of process changes, the analyses of causes, the establishment of roles and responsibilities, and the implementation of a program meant to prevent inadvertent accumulations.

“The National Nuclear Security Administration considers these deficiencies to be of high safety significance,” Administrator Lisa Gordon-Hagerty wrote in an April 6 letter. “Although there were no actual consequences to the public, workers, or the environment, these deficiencies eroded the barriers preventing a nuclear criticality and could, if left uncorrected, adversely impact nuclear and worker safety at the Y-12 National Security Complex.”

The letter was sent to Morgan Smith, president and chief executive officer of Consolidated Nuclear Security. CNS manages and operates Y-12, as well as the Pantex Plant near Amarillo, Texas, for the NNSA.

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For members: After leak, hydrogen fluoride operations resume at Y-12

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Y-12 Building 9212
A low-level aerial shot of Building 9212 at the Y-12 National Security Complex.

After a leak in April, hydrogen fluoride operations have resumed at the Y-12 National Security Complex.

The leak in a cylinder enclosure in Building 9212 in the production area on the west side of Y-12 was reported Thursday morning, April 4. An operational emergency was declared, and employees in the buildings in and around the 9212 processing complex were evacuated to other buildings in the production area.

Y-12 Building 9212

A low-level aerial shot of Building 9212 at the Y-12 National Security Complex.

 

After a leak in April, hydrogen fluoride operations have resumed at the Y-12 National Security Complex.

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For members: Likely cause of Y-12 gas leak has been identified

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Y-12 Building 9212
A low-level aerial shot of Building 9212 at the Y-12 National Security Complex.

An inspection has determined the likely cause of the hydrogen fluoride gas leak in the main processing building at the Y-12 National Security Complex in April.

A visual inspection found a hole in a calibration valve in a cylinder enclosure in Building 9212 on the west side of Y-12, the Defense Nuclear Facilities Safety Board said in an April 12 report. The hole is the likely source of the leak of anhydrous hydrogen fluoride, the DNFSB said.

Y-12 Building 9212

An inspection has determined the likely cause of the hydrogen fluoride gas leak in the main processing building at the Y-12 National Security Complex in April.

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DOE, NNSA deny alleged risk of ‘catastrophic collapse’ of old Y-12 buildings

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Y-12 Building 9212

A low-level aerial shot of Building 9212 at the Y-12 National Security Complex, one of the buildings mentioned in a federal lawsuit filed in July over the proposed Uranium Processing Facility.

 

Note: This story was updated at 8:30 a.m.

The plaintiffs in a civil lawsuit filed in federal court in July alleged that there is a risk of a catastrophic collapse of old buildings containing nuclear weapon components at the Y-12 National Security Complex, possibly due to a large earthquake. A catastrophic collapse “would likely” result in the release of nuclear or toxic materials and place the environment and local residents in “extreme peril,” the plaintiffs said.

But federal officials denied that allegation and others in a response filed in late September.

The 44-page civil complaint, which is related to the planned Uranium Processing Facility at Y-12, was filed July 20 in U.S. District Court in Washington, D.C. The seven plaintiffs include three public interest organizations—Oak Ridge Environmental Peace Alliance, Nuclear Watch of New Mexico, and Natural Resources Defense Council of Washington, D.C.—and four people who live in Oak Ridge and Knoxville.

The federal lawsuit asked for an environmental review of the new design for the UPF, where design plans have changed from one building to three. The lawsuit alleged that the U.S. Department of Energy and the National Nuclear Security Administration have violated a federal environmental law, the National Environmental Policy Act, or NEPA, as they implement the major design change.

Specifically, the plaintiffs have requested a new supplemental environmental impact statement or a new site-wide environmental impact statement for the revised UPF design. They cited the decision to build several new buildings and the plan to continue using existing buildings that the plaintiffs say have significant structural defects. They want the U.S. District Court to vacate, or void, a supplement analysis and an amended record of decision prepared by the NNSA in 2016. [Read more…]

Officials celebrate new bridge, road relocation, haul road for UPF at Y-12

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Bear Creek Road Extension and Bridge

Pictured above is the new Bear Creek Road extension and bridge on the west side of the Y-12 National Security Complex.

 

They called it their first major milestone: the completion of site readiness work, delivered on time and under budget. The work included the relocation of Bear Creek Road, a new bridge, and construction of a haul road.

It’s part of the project to build a Uranium Processing Facility at the Y-12 National Security Complex. UPF could replace World War II-era buildings at Y-12. The project has been capped at $6.5 billion, and it’s expected to be completed by 2025.

Federal officials and contractors celebrated the completion of the site readiness subproject in a Friday morning ceremony at Y-12. [Read more…]

NNSA finishes upgrades at Y-12 enriched uranium buildings ahead of schedule, under budget

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Y-12 Building 9212 Stack 110

At Building 9212, Stacks 110 and 43 were combined, which eliminated use of one exhaust stack. Further improvements on the project at the Y-12 National Security Complex included the old bag filtration system being replaced with a new cartridge dust collector, shown here. (Photos courtesy NNSA)

 

Project provides critical infrastructure upgrades in Building 9212

The National Nuclear Security Administration has completed a major capital improvement project that has resulted in critical infrastructure upgrades to two key production buildings at the Y-12 National Security Complex. The $75.7 million project was completed nearly 11 months ahead of the construction completion schedule and approximately $5.6 million under budget.

The Nuclear Facilities Risk Reduction, or NFRR, project included upgrades to mechanical, electrical, ventilation, and heating/cooling systems for enriched uranium operations in Buildings 9212 and 9204-2E. The project began in 2008, when 10 tasks were identified and undertaken to make those facilities safer for operations. The project was originally scheduled for completion in 2016.

Improvements include major portions of a 40‑year‑old ventilation system being replaced, and 11 steam stations being consolidated into seven with improved function and maintainability. Several upgrades, replacements, and modifications have been made to electrical switchgear and motor control center systems, and a Kathabar system was replaced with a more environmentally friendly brine chiller. [Read more…]

Uranium Processing Facility team signs partnering agreement

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UPF Partnering Agreement

The Uranium Processing Facility Project Office and Consolidated Nuclear Security LLC signed a partnering agreement to move forward on delivering the UPF mission. Shown in the photo are, front row, left to right: Bill Priest, CNS; John Eschenberg, UPO; Brian Reilly, CNS; and Dale Christenson, UPO; and back row, left to right: Joe Brown, CNS; Brant Morowski, CNS; Mike Pratt, CNS; Jim Sowers, CNS; Matt Crookshanks, CNS; John Clayton, UPO; Art Haugh, UPO; Laurie Folden, UPO; and Steve Wellbaum, UPO. (Submitted photo)

 

Officials from the National Nuclear Security Administration’s Uranium Processing Facility Project Office and Consolidated Nuclear Security LLC recently signed a partnering agreement to create a cohesive and effective team united in accomplishment of the Uranium Processing Facility mission.

“The UPF partnering agreement is an important step to ensure our team carries out its mission to deliver a new UPF, a key infrastructure investment for our country, with Building 9212 capabilities, for not more than $6.5 billion by 2025,” said UPF Federal Project Director John Eschenberg.

The agreement also emphasizes a collaborative approach to problem-solving and issue resolution focused on early identification and rapid communication. [Read more…]

Mason to brief feds on UPF alternatives report today

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Ernest Moniz, Lamar Alexander, Thom Mason, Joe DiPietro, Jimmy Cheek at University of Tennessee

From left are UT President Joe DiPietro, Chancellor Jimmy Cheek, Energy Secretary Ernest Moniz, U.S. Sen. Lamar Alexander, and ORNL Director Thom Mason.

Note: This story was last updated at 2:30 p.m.

KNOXVILLE—Federal officials have expressed concerns about increasing cost projections and delayed construction dates for a new Uranium Processing Facility at the Y-12 National Security Complex, and a so-called Red Team has drafted an alternative approach that could keep the project at $6.5 billion or less—and help workers get out of the aging Building 9212 at Y-12 by 2025.

Thom Mason, the director of Oak Ridge National Laboratory, chaired the Red Team, and he is expected to brief federal officials in Washington, D.C., today (Monday) on the team’s report. The report will then go to Congress, Energy Secretary Ernest Moniz said in a media briefing at the Howard H. Baker Jr. Center at the University of Tennessee on Friday.

Among the questions that could be answered are which old production buildings at Y-12 should be replaced and which can be refurbished. Y-12 was built to enrich uranium as part of the top-secret Manhattan Project during World War II as the United States raced to beat Germany to build the world’s first atomic weapons. [Read more…]

Review team develops UPF alternative, sends report to NNSA

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Thom Mason

Thom Mason

The projected cost had passed $10 billion and the completion date pushed back to 2038, so federal officials were looking for an alternative approach for the proposed Uranium Processing Facility at the Y-12 National Security Complex.

Earlier this year, the National Nuclear Security Administration asked Thom Mason, Oak Ridge National Laboratory director, to lead a team—a so-called “Red Team”—that would develop an alternative approach.

The team’s task was to find a faster, more efficient solution, NNSA Acting Administrator Bruce Held told a House subcommittee on April 3.

On Tuesday, the deadline for submitting a report, Mason said the team has identified a possible alternative and provided information on how the proposal could be implemented if the NNSA adopts it. The next step will be up to the NNSA. Y-12 is an NNSA site.

The goal is to still allow workers to get out of Y-12’s aging Building 9212 by 2025 and keep the cost within an approved range of $4.2 billion to $6.5 billion, Mason said late Tuesday afternoon, when the report was being polished before transmittal. [Read more…]

NNSA budget request includes slight spending increase for UPF

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Uranium Processing Facility

Pictured above is the proposed Uranium Processing Facility at the Y-12 National Security Complex, with the administrative area in the front and the fortified section of the building in the rear. (Submitted image)

The budget request announced this week for the National Nuclear Security Administration includes a slight increase in spending for the proposed multi-billion-dollar Uranium Processing Facility at the Y-12 National Security Complex.

The $335 million request for UPF in Fiscal Year 2015, which starts Oct. 1, is up slightly from $326 million in FY14. That’s roughly a 2.8 percent increase.

The UPF project, which has an official cost estimate of up to $6.5 billion, is part of a broader effort to modernize Y-12, including its production facilities. The 811-acre plant was built during World War II to help enrich uranium for the world’s first atomic weapons.

But questions have been raised about rising cost projections and a redesign of the UPF. In February 2013, the NNSA said the redesign could add $539 million to the project cost and extend its schedule.

During a conference call with reporters on Tuesday, NNSA Acting Administrator Bruce Held said the agency wants to get workers out of Building 9212 at Y-12 by 2025. [Read more…]

Equipment used in uranium casting falls from Y-12 furnace

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Equipment and materials used in uranium casting operations at the Y-12 National Security Complex fell several feet from a furnace in Building 9212 last month after someone accidentally bumped a control lever, a federal safety board said in a recently released report.

The lever controls the movement of what is known as the stack assembly, which includes a crucible, mold, and uranium “charge.”

The loaded stack assembly had recently been cast, and it fell several feet from the body of an induction furnace to the base of the furnace, where loading and unloading occur, the Defense Nuclear Facilities Safety Board said in a report for the week ending April 19. [Read more…]