News

Ability to course correct at design sets new enterprise standard

Operations at half a dozen aging Pantex buildings will come together under one roof at the High Explosives Pressing Facility (HEPF), which is expected to be complete in November 2013. The new facility will greatly reduce the movement of high explosives at Pantex, increasing safety and aiding production, as high explosives moves can restrict other Plant operations.

What sets HEPF apart from other facilities constructed at Pantex is the technological advances in design on which engineers have capitalized. The 3D Building Information Model (BIM) approach, provided by B&W Pantex and CH2M Hill, was employed to ensure all aspects of the facility were captured in the design. The design tool optimizes coordination in systems-intensive facilities
and allows the team to “see” critical interfaces between structure, systems, and operating equipment.

“It enables us to derive material quantities both as total and installed counts, compare against the contractor’s invoices and review proposed design changes as well as field deviances to keep control of the overall and detailed design,” said Steve Forman, project engineer. “This is
groundbreaking for maintaining construction progress.”

The HEPF 3D BIM was so successful during the design phase of the project that DOE supported funding to maintain the 3D BIM throughout the four-year construction period. This allows for the model to be updated daily, weekly or monthly, as needed, to keep it an ongoing “as-built” that reflects real-time changes in the field. On project completion, Pantex Maintenance will use the BIM to enhance maintenance capabilities throughout the life of the facility, which should result
in significant cost savings, according to David McCown, maintenance manager.

“The 3D BIM made it possible to correct utility and system conflicts during the design phase of the project and eliminated 500 Requests for Information during construction that the contractor would have submitted, which would have impacted cost and schedule of the project and ultimately startup of the facility. An independent government estimate determined that these
cost savings were between $7 and $10 million dollars,” said Rodney Whisenhunt, project manager.

According to Fabian Thomas, NNSA Production Office federal project director, the 3D design has pioneered a new approach to the design and construction of future industrial facilities. “The HEPF 3D BIM is the new standard and has changed the method that Line Item Projects, those greater than $20 million, will be planned and executed at Pantex as well as throughout the NNSA,” he said.

HEPF 3D BIM was selected as a finalist within the category “Innovation in Industrial Facilities” in the Bentley BE Awards, ranking it one of the top three design projects in the competition for Best Practices for Sustaining Infrastructure, according to Robert Cole, program manager.

The HEPF project, constructed by Kiewit, managed by the U.S. Army Corps of Engineers and supported by the B&W Pantex project management team, is on budget and on schedule. Startup and commissioning are projected to finish ahead of schedule in April 2016.

When completed, the HEPF will provide increased levels of protection for workers, improve pressing operation efficiencies, eliminate single points of failure for the pressing process and support the U.S. Department of Energy’s High Explosives Center of Excellence for manufacturing at Pantex.

by Paul Lamonica, 2012 Summer Intern

This year, the B&W Pantex Plastics Shop began formulating a new method of mixing polyurethane molded parts for explosives, coatings, seals, cushions, tool covers and more. The old method consisted of mixing the components in a generic “ice cream bucket.” After the correct amounts of materials were mixed together, the mixture would be carefully injected into the mold to form the needed part.

At first glance, this process appears simple, but it took approximately two to three hours to make one mold. In addition, the cleaning process could expose people to hazardous chemicals. Some of the molds formed bubbles and voids after the mixture was injected. After rising concerns about the old mixing method, the Plastics Shop knew that it was time to start researching better
alternatives.

Months were spent researching solutions, and the group discovered a revolutionary type of mixer. This eco-friendly system, known as the dynamic mixer, resolved all of the previous problems with the ice-cream-bucket method.

When the dynamic mixer arrived in February, the Plastics Shop teamed with West Texas A&M University (WTAMU) to give students the opportunity to be engaged with this research. The mixer is residing at the university for research purposes, and Stephanie Steelman, a polymer chemist in the Explosives Technology Division, is the project manager and principal investigator for the
WTAMU collaboration.

Devin Cook and Matt Dolezal, both mechanical engineering majors at WTAMU, have been working on this project since the beginning of this year.

Cook, a senior, has been working on the mold designs and optimizing software specifically for the dynamic mixer. “Engineering today is mainly done on computer, and having knowledge of all this software and technology will benefit me in the future,” said Cook.

Dolezal, who graduated from WTAMU in May, has been working with the mechanical engineering and chemistry research of the project, although both work together on all areas of the project. “I really enjoy how much I’ve learned from this experience; I think the knowledge and
skill sets I’ve gained will help me greatly starting my career,” said Dolezal.

Using the dynamic mixer, it now takes only a few minutes to produce each mold. There is minimal cleanup with no exposure to chemicals and there are no bubbles within the mold. The largest mold, which takes about five pounds of material, requires only three to four minutes to fill.

The project will be finished later this year, and the mixer will reside at Pantex starting sometime in March. “The new mixer will save the Plant money in the form of time, raw materials and personnel resources,” Steelman said.

Each year, the old method cost to the Plant is approximately $100,000 just in packaging and weighing materials for the Plastics Shop to use. The dynamic mixer will allow the Plastics Shop to decrease raw material and rejected parts by at least 80 percent and reduce employee hours and resources repackaging raw materials, said Steelman.

by Lauren O'Brien, 2012 Summer Intern

The summer intern program is one of three student work programs B&W Pantex offers. It has been implemented nine out of the 11 years since B&W Pantex took over the management and operation of the Plant in 2001, and the Explosives Technology Division has had at least one intern each year.

Mike Whitley, program manager in the High Explosives Engineering and Physics Department, said several summer interns have come back multiple times, and some, like Amanda Wiggins, who is now a section manager, have returned as full-time employees. Whitley believes this program is “definitely” beneficial to the organization.

“It gives interns exposure to what we do out here at Pantex,” he said.

One such intern, Charmaine Gobert, a first-time intern for Explosives Technology, is attending McNeese University with a major in chemical engineering. During her internship, she worked on developing piping and instrumentation diagrams for formulation processes. She also has been researching cost and design aspects for future synthesis operations. Through this experience, she enjoyed “being able to see [her] books come to life” as she worked.

“This internship has allowed me to make more sense of the principles, equipment and techniques I’ve only been able to see on paper,” Gobert said.

Another intern, Edward Flores, is majoring in mechanical engineering at Texas Tech University. This summer, his second at Pantex, he worked on a project involving a rigid-arm pendulum.

“The [apparatus] is used for skid testing of high explosives (HE). A piece of HE that’s placed in the pendulum arm is dropped at different angles and tested to see the ignition point and the ignition size of the HE after the rubbing of the two surfaces,” Flores said.

He enjoys working on Professional Engineer (Pro-E), which is a program that allows him to create two-dimensional drawings, three-dimensional images and complete virtual assemblies.

“My favorite part of the internship is getting to see several different explosions at the Firing Sites,” he said.

Both Gobert and Flores would like to return as full-time employees after they graduate this year.
“I have really grown to enjoy the environment Pantex offers,” Gobert said. “The work performed here is very interesting, and the people are genuinely quite friendly and helpful.”

John Woolery, B&W Pantex President and General Manager, believes the internship program is “super valuable” to the organization as it looks for prospective employees.

“We get a chance to check students out… and make sure we get the best and brightest,” he said.

Work with migratory birds nets U.S. Fish and Wildlife Service award nomination

For the second year in a row, the Pantex Plant was nominated by the Department of Energy and the National Nuclear Security Administration for an award in recognition of its efforts to research and protect migratory birds.

Pantex will represent the DOE/NNSA in the competition for the 2013 Presidential Migratory Bird Federal Stewardship Award, which has been administered by the U.S. Fish and Wildlife Service since 2011. Each federal agency is eligible to nominate one project or action conducted by or in partnership with a federal agency that meets the intent and spirit of Executive Order 13186 by focusing on migratory bird conservation.

“We were honored to be selected last year, but to be picked two years in a row is very gratifying,” said Kenneth A. Hoar, assistant manager for Environment, Safety and Health with the NNSA Production Office (NPO). “We are proud to represent the DOE and NNSA in this competition and proud that our migratory bird conservation efforts have been recognized through this nomination.”

The site’s work to research and protect migratory birds began to evolve in 2002, and over the years has included efforts involving Western Burrowing Owls, Purple Martins and migratory birds that may be affected by wind energy development. Work is proposed and coordinated by James D. Ray, Pantex Plant wildlife biologist, with support from NPO.

Since 2002, more than 8,500 nestling martins have been banded throughout northwest Texas and western Oklahoma under the program. In 2008, protective devices were installed on 500 new utility poles at Pantex to help protect raptors from electrocution.

Much of the research was performed through contracted collaboration with Texas Tech University, the United States Geological Survey’s Texas Cooperative Fish and Wildlife Research Unit and West Texas A&M University (WTAMU).

Currently, a multifaceted project is evaluating the effects of wind energy development on migratory birds. This program includes a contract with WTAMU and has resulted in the development of a comprehensive literature review on the impacts of wind energy on wildlife, and the initiation of pre- and post-turbine monitoring of migratory birds. This project also involves surveys of plots for wintering and migrating raptors, surveys of plots in different habitat types during the breeding season for birds and nests, along with radio and satellite tracking of Swainson’s hawks.

Taken together, the different actions involved in the Migratory Bird Program present a picture of a site that is dedicated to going beyond the minimum federal mandates of migratory birds.

“At Pantex, we have an abiding respect for the environment and recognize our obligation to protect it,” said Jim Stevens, division manager for the Environment, Safety, Health & Quality Division at B&W Pantex.
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CONTACT
Greg Cunningham
Public Affairs
Office (806) 477-5140
Pager (806) 345-1560

NNSA NEWS

U.S. Department of Energy
National Nuclear Security Administration
Production Office News Release

AMARILLO, Texas - The National Nuclear Security Administration (NNSA) has awarded a contract to Siemens Government Technologies, Inc. (Siemens) to construct and operate the Federal government’s largest wind farm. The Pantex wind farm, a first in the NNSA enterprise, will consist of five 2.3 megawatt turbines located on 1,500 acres of government-owned property east of the Pantex Plant.

Energy savings from the wind farm average $2.9 million annually over a 20-year contract term and the project will enable Pantex to meet the President’s energy initiatives for green energy. In fact, the wind farm at Pantex will allow NNSA to meet almost all of its renewable energy goals while also offering unique research opportunities to longtime partner in education, Texas Tech University and its research collaborators. The farm will generate approximately 45 million kilowatt-hours of electricity annually which is greater than 60% of Pantex’s annual electricity needs.

Steve Erhart, Manager, NNSA Production Office said, “Three years of hard work, dedication and determination have paid off. The NNSA’s goal was to turn Texas wind into energy, and we have overcome numerous hurdles in implementing the contracting strategy.”

Using an Energy Savings Performance Contract, Siemens will provide a turn-key wind farm system for 20 years that includes a five-year service, maintenance, and warranty agreement with operating and maintenance options from years six through ten. Siemens will also provide an annual energy production guarantee. The government payment to them will come directly from the value of guaranteed energy savings generated from the Pantex wind farm.

Established by Congress in 2000, NNSA is a semi-autonomous agency within the U.S. Department of Energy responsible for enhancing national security through the military application of nuclear science. NNSA maintains and enhances the safety, security, reliability and performance of the U.S. nuclear weapons stockpile without nuclear testing; works to reduce global danger from weapons of mass destruction; provides the U.S. Navy with safe and effective nuclear propulsion; and responds to nuclear and radiological emergencies in the U.S. and abroad.
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CONTACT
Brenda Finley
NNSA Production Office Public Affairs
Office (806) 477-3120

Pantex Engineers Host Workshop for Girl Scouts

Don’t tell the young women engineers at Pantex that engineering is a career for men only. They just spent their Saturday making sure that old-fashioned notion winds up in the dustbin of history.

The half dozen young Pantexans, all around their mid-20s, put on a workshop called “Smart Cookies” to show more than 40 Girl Scouts that engineering is a great career for everyone, especially young women.

“There is no doubt that engineering has traditionally been viewed as a man’s career field, but that is changing,” said Savannah Gates, a process engineer at Pantex. “We want to continue that transformation by encouraging these young women to join us in the engineering field.”

Gates was joined by her fellow engineers Ashley Latta, Brandy Ramirez, Sarah Cox, Jessie Phifer, Raquel Barrera and Halianne Crawford in organizing the workshop. The Pantex engineers demonstrated the principles of a variety of types of engineering, including electrical, mechanical, civil and chemical.

The activities ranged from making a homemade battery from foil, pennies and paper towels soaked in a vinegar-salt solution to building cars powered by the kinetic energy of a mousetrap. The mousetrap cars proved so entertaining for the Girl Scouts, and took up so much of the day, that the women engineers were forced to postpone several other engineering activities that will be used as the basis of a second workshop later this year.

“It was amazing to see how excited these young ladies were to learn about engineering,” Phifer said. “You could tell our message really resonated with them, so I’m hopeful that some of these girls might be working with us as engineers at Pantex one day.”

On the storm-wracked plains of the Texas Panhandle, it pays to be ready for severe weather. The Pantex Plant has risen to that challenge, once again earning recognition from the National Weather Service (NWS) as a StormReady site.

“Pantex was one of the first entities of its kind to become StormReady,” said Jose Garcia, meteorologist in charge of the NWS’s Amarillo office. “Pantex is a special facility, and it is important the public knows it is prepared for severe weather.”

Garcia and other NWS officials were at the plant Wednesday to present Pantex officials with the recertification. He said StormReady status indicates Pantex has the weather sirens, shelters, notification technology and emergency response infrastructure to respond effectively to severe weather.

The StormReady program started in 1999 in Tulsa, Okla., and has since grown to encompass more than 2,000 sites. Pantex was the first nuclear site to earn the designation and remains one of only a handful that has achieved StormReady status.

Alonza Campbell, manager of the Emergency Management Department at Pantex, said the Plant has a long history of working hand-in-hand with the community. Pantex maintains contact with the NWS to anticipate storms and other inclement weather conditions. Pantex even uses and the National Oceanic and Atmospheric Administration (NOAA) weather radios to alert residents living near the plant of emergency conditions.

“We recognize that we have a responsibility to our neighbors to be prepared for all types of emergency situations,” Campbell said. “In this part of the country, severe weather is a fact of life and it is one of the potential risks we have to be ready for at all times.”

Pantexans again hit the road Friday, December 7, to raise awareness about hunger in the Texas Panhandle during the second Pantex Run Against Hunger. Byron Logan, an officer from the Pantex Safeguards and Security Division, escorted by four coworkers and a Bearcat armored vehicle, made a 40-mile bicycle ride from Pantex to Panhandle schools and then to Highland Park schools. While at the schools, the Pantexans encouraged the students to support their schools’ food drives and the importance of giving to those who are in need. The students then had an opportunity to explore the Bearcat.

At Highland Park schools, four Pantexans took to the road for a 20-mile run to the High Plains Food Bank’s food drive collection center in Amarillo. Other Pantexans and family members joined them along the route. A group of Pantexans meet the runners at the food drive finish line, where they presented a $4,300 check to the food bank. The donation was from Pantex employees to support the runners.

The Pantex runners were Logan, Randy Stokes, Cliff Cawthon and Sherry Philyaw. Darla Fish joined them for the last five miles of the run.

“We wanted to do something to help people in our community who are struggling,” Logan said. “We run long distances, and we wanted to use that skill to raise awareness about hunger in our area.”

Plant Partners with Panhandle and Highland Park Schools

Pantexans will be hitting the road Friday in an effort to raise awareness about hunger in the Texas Panhandle in the second Pantex Run Against Hunger. Pantex also invited Highland Park and Panhandle schools to join them in a food drive to benefit the High Plains Food Bank.

Byron Logan and Randy Stokes, officers in the Safeguards & Security Division at Pantex, will again embark on a long-distance trek through parts of the Panhandle ending at the High Plains Food Bank’s food drive, which is being hosted at United Market Street.

The Run Against Hunger began in 2011 with a 30 mile run from Pantex to United Market Street. This year, the pair wanted to expand the event to allow others to participate and to grow awareness about the need for food in the area. The pair has added a 40-mile bicycle ride from Pantex Plant to Panhandle High School and then Highland Park High School. They will begin the approximately 20-mile run to United Market Street at Highland Park Schools. Other Pantexans will join them along the route, some during the bike ride and others during the run. They will be followed by a Bearcat, which is an armored vehicle used by Security Police Officers at Pantex.

“Randy and I wanted to do something to help people in our community who are struggling,” Logan said. “We run long distances, and we wanted to use that skill to raise awareness about hunger in our area.”

The food bank is conducting its annual food drive this week. They can take a donation of $5 and stretch it into $50 of food. The top needs this year are green beans, canned soups, canned mixed vegetables, bagged rice and sweet peas.

Any media outlet wishing to cover this effort is welcome to film along the route of the run. They plan to begin the running portion at approximately 11 a.m. running west on U.S. Highway 60, south on Lakeside Drive and west on the Interstate 40 access road into Amarillo. For safety purposes, they will leave I-40 at Ross Osage and run several smaller roads to Georgia Street. They expect to arrive at Market Street at approximately 2 p.m., where they will be available for interviews. For updates on where the run is along the route, please contact Laura Bailey at 223-8211.

B&W Pantex manages and operates the Pantex Plant near Amarillo, Texas, for the U.S. Department of Energy’s National Nuclear Security Administration. B&W Pantex is also the proud recipient of the DOE’s Voluntary Protection Program Superior STAR status for safety excellence. The company was also named one of America’s safest companies by Occupational Hazards magazine and has received numerous awards from the National Safety Council.

CONTACT
Laura Bailey
Public Affairs
Office (806) 573.0502
Pager (806) 345-6604
laura.bailey1@pantex.doe.gov

The public face of Pantex on the Internet has a new look following a project to redesign the Website.

Pantex unveiled the new Website Monday. The site features updated information, easier navigation and new search tools. The site was created over the past several months in a joint effort between the Chief Information Officer (CIO) Division, the Public Affairs Department and an external Web development contractor.

“Completely redesigning the Pantex internet presence was a large undertaking,” said Pantex CIO Kent Gross. “The new site reflects our modernization movement and establishes a framework that we can easily build on.”

A prime objective of the redesign was to create a Website that would provide up-to-date information to the public and stakeholders in an efficient manner. The site features a new section on doing business with Pantex that will be beneficial to subcontractors and others who work with the site. Plant status and emergency information is also more easily accessed.

New content will continue to roll out on the site over the coming months as more features are added to increase functionality.

“The Website is a critical facet of our outreach to stakeholders and the general public,” said Public Affairs Department Manager Ed Veiga. “We continue to strive to provide the most useful information possible to our audiences, and this new Website will aid in that effort.”

B&W Pantex manages and operates the Pantex Plant near Amarillo, Texas, for the U.S. Department of Energy’s National Nuclear Security Administration. B&W Pantex is also the proud recipient of the DOE’s Voluntary Protection Program STAR status for safety excellence. The company was also named one of America’s safest companies by Occupational Hazards magazine and has received numerous awards from the National Safety Council.
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CONTACT
Greg Cunningham
Public Affairs
Office (806) 477-5140
Pager (806) 345-1560