October 2003 Vision BWXT will continue to be the premier manager of complex, high-consequence nuclear and national security operations and will expand its position in defense nuclear production and nuclear remediation markets.

Core Values At BWXT, we embrace Commitment & Integrity, Quality & Safety, and Value & Stewardship as our Core Values.

Commitment & Integrity - At BWXT, we are committed to the relentless pursuit of our cusotmers’ needs. While meeting those needs, we are dedicated to the highest technical standards that allow an environment for our employees to make the right decision when confronted by difficult situations.

Quality & Safety - At BWXT, we deliver the highest level of quality products and services to our customers. In developing our products and providing our services, we strive to maintain a safe work- place with an ongoing goal of zero accidents.

Value & Stewardship - At BWXT, we place the utmost importance on being the best stewards - dedicated to preserving the long-term well being of our customers, our employees, our neighbors, and the environment we share. We value the trust others have placed in us.

BWX Technologies, Inc., a McDermott company BWX Technologies, Inc.

Employees: 10,940 Manufacturing Site Budgets Managed: $520 Million DOE Site Budgets Managed: $1.053 Billion Nuclear Facilities Under Management: 12 Million ft.2 Site Record For Safe Operations w/o Lost Work Days: 8 Million Man-Hours

BWXT Facilities

BWXT Corporate Headquarters - Lynchburg, VA Lynchburg Technology Center - Lynchburg, VA Nuclear Equipment Division - Barberton, OH Nuclear Equipment Division - Mt. Vernon, IN Nuclear Products Division - Lynchburg, VA Solid Oxide Fuel Cell Co. - Alliance, OH

NNSA Sites

Bettis Atomic Power Laboratory - West Mifflin, PA Los Alamos National Laboratory - Los Alamos, NM Pantex Plant - Amarillo, TX Savannah River Site - Aiken, SC Y-12 National Security Complex - Oak Ridge, TN

DOE Sites

Idaho National Engineering and Environmental Laboratory - Idaho Falls, ID Miamisburg Closure Project - Miamisburg, OH Oak Ridge National Laboratory - Oak Ridge, TN Rocky Flats Environmental Technology Site - Golden, CO Savannah River Site - Aiken, SC Strategic Petroleum Reserve Operations - LA, TX By Craig S. Hansen

On the high desert plains of Northern Texas, amid the evening primrose and fringed sagebrush, a silent revolution in operational performance is taking place in a sprawling but secure, high-conse- quence nuclear weapons facility called Pantex - our Nation's only nuclear weapons assembly and disas- sembly facility. Nearly 1,200 miles due east, nestled at the western edge of the great valley in the farmlands and woodlots east of the Cumberland Plateau, lies the Y-12 National Security Complex. It too is under- going an operational revolution - its 600 structures being refur- bished or torn down as part of the United States Government's effort to modernize its nuclear weapons industrial complex and ensure the continuing viability of a significantly downsized, and aging nuclear deterrent.

EXPLORE BWXT / October 2003 5 The two sites have a storied but secretive history. dle of the east-west corridor of Interstate 40. By its As essential components of the Nation's nuclear own right, Amarillo, spurred on by ranching and oil weapon's race with the Soviet Union they played a money, has become a regional center - a gathering key role in the Nation's security, but as the Cold War place in the country's southern heartland, where waned, and the Government implemented the pre- hungry visitors and locals can still try to polish off cepts of the START I and II Treaties, the sites’ mate- 72-ounce steaks, and receive some of the best rial readiness deteriorated, and healthcare in the country. But the missions significantly Pantex and its complex nuclear changed. Pantex’s operations gives Amarillo much In the year 2000, the Panel to Primary Missions higher visibility in the Nation's Assess the Reliability, Safety, capital than other cities with its and Security of the United States Nuclear Weapons Assembly size and location. Mac Nuclear Stockpile (the Foster and Disassembly Thornberry, 13th District Panel) reported to Senator John Representative, chaired a Warner, Chairman of the Senate Evaluate Nuclear Weapons special Congressional panel Committee on Armed Services, to Maintain Reliability of overseeing the startup of the of "…growing deficiencies…deep the Nation’s Weapons newly established NNSA. His morale and personnel prob- Stockpile efforts, combined with the lems…continued slippage of pro- leadership of NNSA, including gram milestones…and unaccept- Research and Development Ambassador Linton Brooks and ably high risks to the completion High-Explosive Capabilities Dr. Everet Beckner, and its of needed weapons refurbish- field offices, have created the ments." Warning of a potential Maintain Interim Plutonium environment necessary to start crisis the panel recommended Pit Storage revitalizing the nuclear steps for the newly created weapons complex. National Nuclear Security Administration (NNSA) to take. Both Congress and John Gordon, the newly appointed Administrator for NNSA, began to take corrective actions. BWXT began operational changes at Pantex and Y-12 after it was awarded new manage- ment and operations contracts in 2000. Compared to 2000, Pantex operations achieved an port functions. DOE owns about 9,100 acres at the Drawing on its strength as an owner/oper- 81 percent increase in productive output in 2002. Pantex site, of which about 2,000 acres are used for ater of large nuclear manufacturing oper- BWXT Pantex, a limited liability corporation running the industrial operations. Mike Mallory, BWXT Pantex ations, and a history of commercial Pantex site for the DOE, trained hundreds of employees President and General Manager, characterizes the suc- practice and disciplined conduct of in quality improvement and cost savings - training, cess at Pantex as the result of, "attention to detail, operations, BWXT and its partner which combined with other quality initiatives, has strong conduct of operations, excellent personnel effec- companies, Bechtel and Honeywell, reduced the number of tively used, and an began the process of working with product defects by more BWXT’s approach to revitalizing Pantex emphasis on process, NNSA, and a highly talented than half since BWXT took knowledge, and but often underutilized over operations. And the is attention to detail, strong conduct improvement." workforce, to transform the increased productivity isn't of operations, excellent personnel Cleanup work at the troubled sites. coming at the expense of plant is also reducing safe operations: in roughly effectively used, and an emphasis on employee health risks. the same period accident process, knowledge, and improvement. Testing and cleanup of Amarillo, TX: and lost- time injury rates Pantex facilities to Cattle, black gold, the were cut in half. eliminate additional per- eastern hognose snake, BWXT brought in a new team of managers, steeped sonnel exposure to beryllium, a substance that can in commercial practices, program management and cause respiratory problems in personnel with certain and the heart of the production, to create a new management structure to sensitivities, was finished 18 months ahead of Nation's nuclear deterrent upgrade its operations. The managers oversee an array schedule. of buildings for assembly/disassembly of nuclear (Continued on page 8.) Founded in 1887, the city of weapons and for storage, administrative and other sup- Amarillo lies almost exactly in the mid- EXPLORE BWXT / October 2003 7 Oak Ridge, TN: BWXT recently sent Dennis Ruddy to head the Lakes, Mountains, Y-12 Primary Missions storage of nuclear material, and pre- operation and to ensure the turnaround produces vention of the spread of weapons of long-term sustainable results. "We are making the and Yellow Cake's Produce and Refurbish Nuclear mass destruction. Its storage func- Y-12 complex more able, agile and affordable," says Fort Knox Weapon Components tion alone makes it the Nation's Fort Ruddy, President and General Manager of BWXT Knox of highly enriched uranium. Y-12. The statement belies Ruddy's reputation as Oak Ridge, originally known Safeguard Special Nuclear Material It is also the Nation's premier a turnaround agent, and his long years of technical as “Clinton Engineer Works,” location for uranium and lithium and program management experience with the was World War II's secret Prevent the Proliferation of Weapons materials research. In addition, Y-12 Naval Nuclear Propulsion Program and Tenneco. city. Created in 1942 as one of Mass Destruction conducts assesment and certifica- of the major sites of the tion of certain nuclear weapons "Manhattan Project," the Provide Support For Other National components. These assessments of Restart of Y-12’s wet chemistry 60,000-acre tract where the Security Needs stockpiled nuclear weapons compo- operations is the critical milestone town and its plants were built nents allowed the Nation to forego would become the lynchpin underground weapon tests. in a phased plan to resume full in a massive effort to shorten Unlike Amarillo, Oak Ridge grew operation. the war, and its burgeoning impact up as a nuclear town, and its leadership in Congress, on the Nation, through the use of nuclear weapons. Representative Zack Wamp, of the 3rd District, appreci- Deliberately placed "off the main path" in a location ates that history. As Vice-Chairman of the Energy and northwest of the Great Smoky Mountains, the Y-12 Water Appropriations Subcommittee, and recently named Working with NNSA leadership, BWXT Y-12 National Security Complex is the NNSA's part of Oak to the Homeland Security Appropriations Subcommittee, recently received design approval for a new storage Ridge's Operation. Y-12 focuses on production and refur- the 45-year-old Chattanoogan has consistently played a facility for highly enriched uranium, and has started bishment of components for nuclear weapons, production key role in defending the site, promoting modernization, construction on a purification facility to handle spe- of components for Navy nuclear propulsion systems, and in securing new missions. cial materials. At the same time, it has reduced the site’s "footprint" by more than 500,000 square feet through removal of about 65 structures. Modern- ization and infrastructure revitalization is no longer a concept at Y-12. Improved capabilities include the restart of opera- “We are making the Y-12 tions that had been halted because of safety concerns for over nine years in certain cases. complex more able, Recently NNSA approved the plan of Y-12 wet agile and affordable.” chemistry operations, which were shut down in 1994. Wet chemistry involves six processes that are Dennis Ruddy BWXT Y-12 essential for extracting and purifying usable quanti- President & General Manager ties of uranium-235 from scrap metal and other waste streams. The work is important because it enables Y-12 to recapture virtually all of the enriched uranium used in plant operations. Restart of those wet chemistry operations was to be done gradually, over a six-month period. The authorization for the restart was one of a series of milestones in Y-12's phased plan to resume full operations. In 2000, NNSA approved a resumption of handling and storage of fissile mate- rials. In 2001, NNSA authorized restart of what are called "reduction and pour-up" operations. The final step to full operations will be the return to action of a hydrogen fluoride system, currently expected to be complete in July 2004. "An indica- tion," Ruddy says, "that through aggressive man- agement planning, Y-12 will return to its full produc- tion capabilities." E

EXPLORE BWXT / October 2003 9 By Craig S. Hansen BWXT played an important role in The "Idaho Settlement Agreement" supplies. And, in July 2002, the DOE the early years of INEEL, providing as it came to be known, is unique in designated INEEL as the depart- daho's Snake River Plain, a desolate high components, fuel, and specialty prod- its scope and detail, and it laid out the ment's nuclear energy laboratory. II desert basalt plateau, stretches from near ucts for what was originally a rapidly path forward for INEEL. Without it and INEEL was to be "the central com- the southern edges of the Washburn Caldera growing industry. But use of nuclear without the relationships forged during mand for the federal government's in Yellowstone National Park, to the interior power for commercial purposes dimin- the years it was negotiated and imple- Generation IV nuclear systems ished with growing public concern over mented, it is unlikely that INEEL would research." It will also be the focal badlands of Oregon and Idaho. Surrounded by waste streams, and with the accidents be where it is today - poised to lead point for developing and demon- towering mountains, and borne of violent vol- at Three Mile Island and Chernobyl. the country in developing the next strating the Advanced Fuel Cycle canic explosions, the plain presented a formi- Orders for new nuclear power plants generation of nuclear reactors - reac- Technology Initiative that would treat dable barrier to early American settlers travel- were cancelled, and INEEL's mission tors that will help meet world energy and reduce SNF and high-level ing west on the Oregon Trail. But to the changed - focusing more on repro- needs for the next 50 years, and waste. Shoshone Bannock tribe who live on its edges, cessing spent nuclear fuel, and power a new generation of space and to the farmers who carved miles of canals environmental cleanup then on probes that will explore the outer solar new nuclear power research and system. Lost Rivers, Obsidian, a to bring water to fertile ground, it is a vibrant development. Generation IV reactors, the latest Legendary Leader, and a ecosystem, teeming with the animals, plants, For nearly 10 years INEEL was des- generation of commercial power reac- Submarine on Dry Land and nutrients necessary to build a good life - ignated the Department of Energy's tors, will be more economical to build, provided one has the perseverance and skills (DOE) lead lab for Environmental safer to operate, produce less waste On June 25, 1953, on the northern to do so in the isolation, dryness, and altitude. Management. As the Department's for disposal, and reduce the danger of half of the INEEL reservation, where lead for spent nuclear fuel (SNF), nuclear materials falling into the hands the Big Lost River finally disappears INEEL managers and engineers tack- of hostile organizations. They will help The Idaho National Engineering and into the sand, at a facility built for the led one of the hardest problems in the meet projected world energy demands Navy to test the use of a reactor to Environmental Laboratory (INEEL), established nuclear power industry. Their program- that are expected to more than double power a radically different type of in 1949 on a former naval artillery range on the matic, nationwide, dual agency today's needs by 2050, contribute to submarine, Captain Hyman Rickover, northern half of the Snake River Plain, brought Environmental Impact Statement (EIS) improved environmental quality and was overseeing a series of power its own breed of pioneers: men and women on SNF was unparalleled in scope, support this country's energy security. increases on the Mark I prototype as dedicated to developing nuclear energy for and completed in an unprecedented The DOE placed INEEL and ANL in it ramped up to its first full-power run. two years. The document laid the foun- the forefront to lead this national effort. power and propulsion and who would harness Rickover, a legendary pioneer of dation needed to implement an SNF In 1999, the DOE named INEEL and nuclear power, wasn't satisfied with the untamed atom and eke out, kilowatt by solution, including a permanent geo- ANL as lead laboratories for nuclear the achievement. In a series of kilowatt, the power to turn on light bulbs, sub- logical repository. It was also the basis reactor technology. In 2001, the United controversial decisions, he extended marines, and cities. Over its 54-year history, for a profound long-term agreement States National Energy Policy the full power-run, first from 24 hours the laboratory has been the site of 52 test between the State of Idaho, the Navy, endorsed nuclear energy as a major to 48 hours, and then to 100 hours. reactors, many first-of-a-kind, and its scientific and the DOE. component of future U.S. energy Rickover's goal - to simulate a sub- research and testing have contributed immea- merged full-power run across the surably to the development, safety, and suc- Atlantic Ocean. At 96 hours, mock charts showed landfall at Fastnet, cess of commercial and naval nuclear power in Ireland - there was now, no longer, the United States and worldwide. any doubt: nuclear power had been INEEL and Argonne National Laboratory successfully demonstrated and the (ANL) first produced electricity by nuclear strategies used by the Navy to power, first lit a city - Arco - using nuclear project power and to control seas, energy, developed the reactor technology that had been forever changed. powers the U.S. nuclear navy, built the first light water and pressurized water reactors, and INEEL's Strategic Plan is to be the developed many of the computer codes still leading contributor to our Nation's energy security and environmental used by the Nuclear Regulatory Commission in quality by developing advanced, licensing, re-licensing, and evaluating the safe- sustainable, safe, and economic ty of commercial nuclear power plants. The nuclear energy and fuel cycle tech- testing, done at INEEL's Materials Test nologies. BWXT, its management Reactor in the 1950s and ‘60s, influenced the team, and its production plants, will design of every nuclear reactor built and be an important part of achieving that plan. operated in this country. (Continued on page 24.)

Test reactor area workers load a BWXT fuel element into the Nation’s Kevan Weaver (l) and Denis Clark inspect the Gleeble machine used for welding and EXPLORE BWXT / October 2003 premier test reactor, ATR. joining special materials slated for Generation IV nuclear reactor service. 11 N uclear technology is opening new F or nearly three decades, BWXT has been active in space technology. As early frontiers for space exploration, as as the 1960s, BWXT participated as a subcontractor in the U.S. Space Nuclear planning proceeds with NASA's Jupiter Program. It was during the 1980s and '90s that BWXT assumed a more expanded Icy Moons Orbiter (JIMO) project sched- role, providing detailed design of reactor subsystems, and the fabrication and uled for launch not earlier than 2011. assembly of reactor technology, including fuel particles. JIMO's mission? Take the first steps Project Rover - In an effort to look for a less-costly, reliable alternative to chemical toward searching for life in the subsurface rocket engines, Los Alamos National Laboratory developed a series of reactor oceans of Jupiter's three ice-covered designs, known as Project Rover, which took advantage of fissionable materials to moons. heat high-temperature fuels. JIMO is part of NASA's Project The basic concept was simple - take a solid-core, hydrogen-cooled reactor in Prometheus, an initiative to develop new which the exiting gas expanded through a rocket nozzle to discharge in space, space nuclear power and electric propul- producing thrust. This design could produce twice the thrust per unit flow rate of sion technologies that will revolutionize propellant of the best chemical rockets. space exploration. NASA's Jet Propulsion BWXT served as a subcontractor to Westinghouse Electrical Corp. and Aerojet Laboratory recently awarded a $6 million General Corp. Jointly, the companies tested the NERVA program NRX series contract to a Boeing-led team, which prototype reactors based on the Los Alamos designs. Although the project was includes BWXT, to study technology terminated in January 1973, it was praised as a technical success. options for the JIMO project. Ball Aerospace and Technologies Corp. is also NASA Space Exploration Initiative (SEI) - BWXT and Brookhaven National participating on the team. Laboratory were leading proponents of the Particle Bed Reactor, which has been Nuclear is identified as the energy evaluated for the Space Exploration Initiative (SEI) applications. The concept was source capable of providing enough developed in 1981 on the basis of the Rotating Bed Reactor and other nuclear power for JIMO to reach and travel propulsion work performed by BWXT, including the SP-100. between the remote moons. Fueled by nuclear energy, Project Prometheus will Timberwind - From 1987 to 1991 during the Reagan Administration's Strategic provide more than 100 times more usable Defense Initiative, commonly referred to as Star Wars, BWXT supplied compact onboard power than previous science nuclear reactors for space and defense applications. The workscope included By Regina W. Carter developing and manufacturing high-temperature fuel for nuclear rocket applications, probes. This power boost opens new pos- and the design, construction, and operation of the related critical experiment facility. sibilities for space exploration, and allows for the collection and return of a signifi- Radioisotope Thermoelectric Generators (RTG) - Since 1961, the DOE has cant amount of imagery and scientific provided RTGs for space applications, which provide electrical power for spacecraft data. by directly converting the heat generated by the decay of plutonium-238 oxide to "We have to step away from traditional, electrical energy. Between 1997 and 2003, BWXT provided power systems and the conventional ways that we do propulsion manufacturing capability for the DOE, including the Cassini Probe. and power generation," says NASA Administrator Sean O'Keefe. Once serv- Space Nuclear Thermal Propulsion (SNTP) - In the late 1980s, the DOD/SNTP ing as the Secretary of the Navy, O'Keefe program undertook developing a much smaller and lighter second-generation recently praised the U.S. Navy's safety nuclear rocket based on the Particle Bed Reactor (PBR). When the SNTP program record in its use of nuclear propulsion. stopped in 1993 at the end of the Cold War, the PBR component had been exten- During the course of more than 40 years, sively tested and validated, with high power nuclear testing of PBR fuel elements the nuclear Navy has traveled approxi- assemblies as the planned next step. The PBR was a major step forward in reduc- mately 124 million miles without incident. ing the size and weight of nuclear thermal propulsion engines. "If we can do that successfully here on our planet, certainly between here and Integrated Solar Upper Stage (ISUS) - Spearheaded by the U.S. Air Force, ISUS any other destination you can imagine, was designed to provide a high specific impulse propulsion system for orbital transfer and electrical power for a satellite system once in final orbit. BWXT was

Artist rendering of the Jupiter Icy Moons Orbiter. Courtesy of NASA/Caltech. of Courtesy Orbiter. Moons Icy Jupiter the of rendering Artist using a reactor significantly smaller than what they [U.S. Navy] use every single responsible for the design, manufacture, and assembly of the ISUS energy systems. BWXT successfully manufactured the Receiver-Absorber-Converter day and operate very effectively and very (RAC) as well as tested it in Tank 6 at the NASA-Lewis Research Center. This safely, we can achieve some tremendous program ultimately led to the Solar Orbital Transfer Vehicle (SOTV) program. things." Utilizing a similar concept, BWXT was responsible for design, development, and Providing proficient deliverables for the manufacture of the next generation RAC system. nuclear technology demonstration mis- sion, BWXT's Nuclear Products Division’s (NPD) objective would be to design and manufacture the nuclear technology and reactor components that can be launched safely in space. (Continued on page 24.) EXPLORE BWXT / October 2003 13 By Laura P. Ellis Ultimately, the Institute of Nuclear Power Operations Star Wars program, the initiative was terminated as SDI (INPO) was formed, a premier group for promoting shifted its focus on laser-based technologies. "Even safety and reliability in the operation of nuclear power though the program ended, the effort demonstrated it is generating plants. Roy was later appointed Chief possible to put nuclear in space," says Roy. Dr.Don Roy Technical Witness to the Emergency Core Cooling Roy states he is supportive of NASA's new initiative System Rulemaking hearings, spending 14 months in to improve the radioisotope thermal generators that are Washington, DC, promoting new rules and defending already in use and to develop fission energy systems. Keeping in Step With the Changes of Time the nuclear industry. "In the end, we were able to According to the scientist, "A fission space reactor is demonstrate that ultimately we designed safe, quality the only way to get the power needed for detailed reactor systems," says Roy. mapping, deep space probes, and data streams when we want them and not just when the planets "You had to have the confidence to make the change." A New Direction are favorably aligned." Roy's career later journeyed to a new horizon - Beginning in 1991, Roy would make the first of some space technology. At BWXT's Nuclear Products 20 trips to Russia to work with various Russian ince the development of nuclear plants dropped off. With the last reac- Division (NPD), Roy began working on a compact institutes and ministries during a technology exchange power in the 1940s, the nuclear tor order placed in the late 1970s, reactor for space power and propulsion that would program. He and an associate were reportedly the first S industry has evolved at a rapid Roy said the company strategically produce large amounts of power in a small volume. foreigners to ever be allowed into Russia's underground pace. From the first experimental assessed the industry's direction and In this endeavor, BWXT teamed with Brookhaven testing facilities for its space reactors. The technology reactor to full-scale nuclear power ultimately refocused its efforts on National Laboratories, Aerojet Nuclear Company, exchange included information on space power, fuel plants and space nuclear power and servicing the existing nuclear plants, Grumman, and Sandia National Laboratories to cells, and gas turbine plant design. propulsion systems, starting with steam design the reactor. the industry has generator inspec- The DOE later awarded NPD a contract to build Global Change experienced a vast tions. "You had to Particle Bed Reactor fuel elements, which according The 1990s marked a significant period in world history of change. A have the confidence to Roy was an innovative project because the elements history that would have far-reaching implications for key participant in to make the change," used small kernels of uranium. "In working with Oak the nuclear industry. With the ending of the Cold War, many of the mile- says Roy. "It proved Ridge National Laboratories to develop the manufactur- nuclear disarmament began to take political center stones that helped a successful transi- ing technology, we found ourselves in the compact stage. As the world became more global, new business define and redefine tion from building space reactor business." ventures began to emerge. In response, NPD expanded the nuclear industry plants to servicing BWXT's space nuclear workscope expanded when its capabilities to include downblending - the conversion is Dr. Don Roy, a them." it won a contract to design a compact Particle Bed of high-enriched uranium into low-enriched uranium for recent retiree of It was March 28, Reactor for the Star Wars project, which was part of commercial use. To assist with the company's position- BWXT who served 1979, that the the Strategic Defense Initiative (SDI) created under the ing efforts, Roy was tapped as a lead expert. the company for 41 nuclear industry Reagan Administration. The contract included develop- Tasked with developing a Uranium Processing years. would find itself ing and manufacturing high-temperature coated particle Services department (UrPS), Roy worked to help enveloped in a crisis fuel for nuclear rocket applications, and designing, design the layout of NPD's facilities, assess its needs, The Early Years when an accident constructing, and operating a related critical experiment and to pursue and win downblending work. The UrPS occurred at the Roy began his pro- facility. Following five years as Program Director for the business got under way with Project Sapphire whereby Three Mile Island fessional engineer- weapons-grade material was converted to commercial Unit 2 (TMI-2) ing career by joining nuclear fuel as part of the Non-Proliferation Treaty nuclear power plant the company's initiatives under the Clinton Administration. The success in Pennsylvania. Lynchburg opera- of Project Sapphire resulted in a 50-metric ton contract The event had an immediate impact tions in 1959, working in the commer- with the US Enrichment Corporation (USEC) - a on the world's perspective of nuclear cial nuclear power plant business. It contract that NPD is still working today. power as a safe energy source - a proved an exciting time for the young Though retired, Roy remains active in the nuclear change in perception that would take engineer as the construction of new industry serving as a consultant to BWXT. Having years to overcome. Following the inci- domestic nuclear power generating witnessed the many evolutions of nuclear power he dent, Roy spent much time and effort plants surged. "The company had just acknowledges that the industry is still progressively before investigative committees, pro- won a contract to build the first developing. And with those evolutions, BWXT has viding depositions supporting the nuclear commercial units for Duke successfully proven it can keep in step with the engineering integrity of the reactor. Power Company's Oconee site in changes of time. South Carolina." Oconee was among Among others, Roy worked closely the first nuclear power plants to be with Duke Power President Bill Lee, E built out of more than 100 construct- a renowned figure in the nuclear ed in the U.S. business, in assisting the industry As his Russian counterparts look on, Dr. Roy (left) signs a contract to The economic tide would eventual- in responding to the TMI-2 incident. exchange information on nuclear fuel development for thermoelectric ly turn and orders for building new conversion. EXPLORE BWXT / October 2003 15 Over the next 40 years, numerous nuclear production facilities labeled secretively in an alphabet soup of names - “BWXT Savannah River Company - M, F, H, Z Areas to name a few - and employing thou- refocused the program to increase risk Race to Cleanup sands of people, were constructed on the massive site: five reduction efforts combined with building nuclear reactors lining the Savannah River, two chemical separation plants, a heavy water extraction plant, nuclear demolition to reduce overall infrastructure Savannah River’s “Six Pack” fuel and target fabrication facilities, and waste manage- ment facilities. With the abrupt end of the Cold War costs....” By Jeffrey C. Crater and much of the nuclear weapons production - Larry Davis mission halted by President George H.W. Bush President, BWXT Savannah River Company in the early ‘90s, the Nation embarked on an ambitious, multi-billion dollar project to cleanup highly contaminated nuclear Finally, BWXT Savannah River Company has introduced The Savannah weapons plants in nearly every state in an innovative financial approach to the Six Pack project - the union. River, which flows along its entire budget is coming from site cost savings and At the Savannah River Site, vast, highly contaminated productivity improvement initiatives, including a reduction the border of South Carolina nuclear facilities needed to be safely shutdown, cleaned up in annual surveillance and maintenance costs. and demolished, and the nuclear materials safely pack- and Georgia, is formed at Furthermore, under the innovative Assets for Services aged and isolated to prevent environmental harm. In 1996, Hartwell Reservoir by the con- concept, subcontractors are performing decommissioning BWXT, bringing its cleanup expertise from the remediation work and receiving excess materials from the old facilities fluence of the Seneca and and demolition of its own plutonium and highly enriched as payment. uranium fuel fabrication facilities in Parks and Apollo, PA, Tugaloo Rivers. Draining a "We are driving the Six Pack project and others like it was tapped to begin nuclear facility decontamination and to meet Assistant Secretary Roberson's goals for greater 10,000 square-mile watershed, decommissioning as a part of the new Savannah River Site risk reduction in the Department's accelerated cleanup contractor team. it flows down from the Blue program," Davis concluded. "When I arrived at Savannah River from our Parks As the site accelerates to complete the cleanup, Ridge Mountains onto the cleanup, the work here was focused primarily on deconta- BWXT Savannah River Company is developing cleanup Piedmont Plateau and minating buildings with some risk reduction," said Larry approaches such as reducing the site footprint by 2.5 mil- Davis, President, BWXT Savannah River Company. "BWXT then past the "fall line" into lion square feet and removing an additional 167 facilities - Savannah River Company refocused the program to to continue reducing risk to workers, the public, and the the low country, the increase risk-reduction efforts combined with building dem- environment. swamps, and eventually the olition to reduce overall infrastructure costs, lessening the E burden on the taxpayer," he added. Atlantic Ocean. At the edge of In the race to accelerate the cleanup of the nuclear the fall line, where the rugged hills are eroding into gentler plains, is the city of Aiken, SC, weapons complex, BWXT led the biggest decommissioning project ever undertaken at Savannah River, a project recognized for great race horses and the late Strom Thurmond. known as the "Six Pack," which is now underway led by In the early 1900s, Aiken, known for its temperate climate, became a winter retreat for BWXT Savannah River Company. The project will demolish horse breeders from the north. Thoroughbred horse farms, polo fields, and sprawling six buildings, with more than 150,000 square feet of con- taminated facilities, in less than 18 months. The overall site estates sprouted in this beautiful southern town whose entire city area is classified as an goal is to reduce the industrial and nuclear facility "foot- arboretum. Business slowed in the thirties during the Great Depression and later during the print" by over 1.2 million square feet by 2006. And BWXT is doing the job safely. Even with the huge amount of Second World War, but reinvigorated in 1950 the beginning of the nuclear arms race. At decommissioning work being performed at an accelerated that time, the U.S. Atomic Energy Commission needed a remote location to produce strate- pace, there has not been a single accident resulting in time gic materials, plutonium, and tritium, for the Nation's nuclear arsenal. lost from work since the project began. While only 10 percent was developed for nuclear weapons production, approximately 310 square miles of rural farmland near Aiken was enveloped in In the T-Area, 22 buildings have been removed, reducing the what is known today as the footprint by 112,000 square feet. Savannah River Site.

EXPLORE BWXT / October 2003 17 afety is one of BWXT’s top priori- S ties - a practice embraced by the BWXT workforce in all of its opera- tions. Promoting the message of safety, BWXT Y-12 hosted its annual Safety Expo in July that was open to the Oak Ridge, TN, S community. An estimated 9,000 people attended the Top: Rex Renfro, right, event, which featured more than 160 gets a hand from Tom Altum, in donning exhibitors, activities, and demonstrations of a level “A” chemical health and safety practices and products. protection suit. The daylong safety experience, coordinated Middle: Laura Bailey Spreading and Eddie Magness by a committee of Y-12 employees, was of BWXT Pantex held at the local mall and was kicked off by discuss safety topics at the Expo. Oak Ridge Mayor David Bradshaw. Bottom: Joe Childs, a A The Message Bradshaw proclaimed it Safety Day in Oak BWXT Y-12 electrician, Ridge, referring to the event as a terrific demonstrates a protec- tive suit at the PPE way “to spread a health and safety mes- fashion show. sage to the community.” “We are thrilled by the support we receive from Oak Ridge,” said Dennis Ruddy, President and General Manager of BWXT Y-12. “This Safety Expo is one of the ways we can show by example that we are a part F of this community. It’s a great way to bring the important message of safety to our employees, their families, their friends, and neighbors.” At the Expo, employees tested their safe- ty knowledge with Safety Jeopardy and demonstrated their forklift driving skills in a rodeo. There were programs on boating safety, firearms safety, hiking safety, and stress avoidance and relaxation techniques. E In addition, a local hospital provided free health screenings for health issues such as cholesterol, stroke, and vascular disease. Activities were available for both adults and children, including Chemical Hazard Awareness Golf, Spin and Win On the Safety Wheel, a climbing wall, and glovebox basketball. Some Y-12 employees even proved T they’re not shy as they modeled safety attire in a crowd-pleasing fashion show. Dancing to disco music, the employees modeled an array of personal protective equipment (PPE) - from safety shoes to hard hats. This marked the third year that BWXT Y-12 has sponsored the Safety Expo and each year, it has successfully grown. The Y 2003 program drew participation from other federal sites, including BWXT Pantex and Ethan Kitchens participates in a the Savannah River site as well as atten- climbing wall exercise. dance from NASA and BNFL. E Is Your School Connected? Y-112 Turns A Triple Play In Safety The National Safety Council presented three awards to BWXT Y-12 for its achievements in worker safety. The School Connection is a service - sponsored by The Green Cross for Safety Excellence Achievement was BWXT Savannah River Company and provided by The awarded Y-12 for outstanding effort in occupational safety per- From The Field Augusta Chronicle - to inform parents of their children's formance and the Certificate of Merit for Outstanding Safety homework and assignments through a telephone hot- Practices for its 2002 Safety Exposition to promote the health line. Participating teachers have four-digit extensions to and safety of employees both at home and at work. Y-12 also Nuclear Products Division Passes BWXT’s record daily assignments and important class informa- received the 2003 Significant Improvement in Safety IAEA Safeguards For 2002 tion. In the first year of operation, The School Performance Award. Nuclear Products Division Connection received more than 100,000 telephone calls. Receives Highest The Nuclear Products Division (NPD) to remotely and to continuously col- Coupled with the hotline, participating schools receive reached a significant milestone, hav- lect material transfer and blending Rating From NRC 4,000 copies of The Augusta Chronicle each month for ing received word that its Uranium data. In addition, the IAEA has been classroom use. The newspapers serve as a current event tool in the classroom. Processing Services (UrPS) passed conducting monthly on-site inspec- The Nuclear Regulatory Commission the International Atomic Energy tions and comparing NPD's declared The School Connection and BWXT Savannah River (NRC) gave the highest rating possible Company were recognized by South Carolina Governor Agency (IAEA) Safeguard Standards transfers against the IAEA collected to the Nuclear Products Division (NPD) for 2002. At the invitation of the U.S. data. Mark Sanford and staff in a ceremony at the state capi- during its annual Licensee Performance tal in Columbia. Government in 1999, the IAEA began The IAEA reported it could confirm Review. Each year, the NRC conducts independently verifying that high- that NPD had downblended the quan- "The School Connection is a great program that an assessment, addressing safety, safe- deserves recognition for connecting parents, teachers enriched uranium (HEU) was being tity of HEU it declared into low- guards, radiological controls, facility downblended by NPD into a low- enriched uranium. This is a significant and students, and allowing them all to play a vital part support, and special topics such as in the educational process," said Governor Sanford. enriched form not usable for nuclear accomplishment as the facility went licensing. A letter from the Region II weapons. To accomplish this mission, from having no safeguard standards office of the NRC stated, "Our review the IAEA set up unattended monitors relative to the downblending process determined that BWXT continued to Y-12 National Security Complex around the blending system to having a successful safeguards conduct its activities safely and secure- program implemented in a short, Dennis Ruddy, President and General Manager of BWXT ly, thereby protecting public health and Y-12, said, "These national awards recognize the improvements three-year time frame. Furthermore, safety, protecting the environment, and to date, no other manufacturing oper- that Y-12 has made in its worker safety programs, as well as the assuring control and security of licensed commitment of both BWXT Y-12's management team and the ation that processes HEU in the material." U.S. has ever passed these National Nuclear Security Administration's Y-12 Site Office to In an announcement to NPD continued improvements in safety." inspections. employees, Winfred Nash, NPD Vice The National Safety Council noted that Y-12 had significantly President and General Manager, wrote, reduced its total accident rate to less than 20 percent of the "It is important that we pass "Each of us plays an important role in industry's average and had significantly reduced the number of these safeguards," said Jim helping ensure we operate the facility injuries and illnesses that resulted in days away from work in Creasey, Manager, UrPS. safely and securely by complying with 2002. "The safeguards system pro- procedures and requirements. I ask In 2001 there were 43 injuries or illnesses that resulted in vides assurance that declared that we assess and challenge ourselves days away from work; in 2002, that number was reduced by nuclear materials are not daily so that we may continuously BWXT Savannah River Company is recognized for its participation in The nearly half - from 43 to 23. diverted into undeclared improve in all aspects of our School Connection. Pictured, left to right, are South Carolina Governor nuclear activities." Mark Sanford; Larry Davis, President, BWXT Savannah River Company; operations." and Don Smith, South Carolina State House Representative. EXPLORE BWXT / October 2003 21 From The Field Pantex Team Winsins NED Receives National Securityity ComCompetition Safety Awards

The BWXT Pantex Security Competition Team The Nuclear Equipment Division's won first place at the Department of Energy's (NED) Barberton Works recently 2002 Security Police Officer Training Competition (SPOTC), beating out more than 20 teams to take received four safety awards from home the Secretary's Trophy for the sixth time in the Ohio Bureau of Workers' the last 10 years. Compensation and the Summit Held at the Nonproliferation and National County Safety Council. These Security Institute's Safeguards and Security awards recognized NED for its Central Training Academy in Albuquerque, NM, outstanding safety performance for the annual competition attracted some of the best 2002 in the following safety-related security teams in the nation. The individual and categories: team firearms and tactical exercise required vari- Group Award for the lowest injury ous shooting, running, climbing and rescue tasks frequency rate in the Summit simulating situations security personnel may potentially encounter. County Council's Standard BWXT Pantex Security Competition Industry Group Team wins Secretary & Trophy. Members of this year's team were Captains Gene Ferris and Clay Stephens, Team Leader Special Award for working more Joe Hardin, Joe Martinez, Steven Zuniga, Jeremy than 500,000 hours without a lost- McCoid, Chris Jenkins and David Aud. In the indi- time injury vidual competition, McCoid, Martinez, and Hardin placed in the top 10 among all com- Achievement Award for having a petitors, and Aud and Jenkins placed in the top 20. 25 percent reduction in total injury “The competition was tough, making the team’s success even more impressive. Their frequency victory was a direct result of highly skilled personnel working effectively as a single 100% Award for completing team, a capability exhibited by the entire security force,” said Pantex Site Office Manager Dan Glenn. “I am also proud to recognize that Pantex's Federal Agent Central CY2002 with no lost-time injuries. Command won their division. Congratulations to all involved!” Collectively, these awards reflect Larry Spaulding, Protective Force Chief, conveyed the same sentiments stating, “It is NED's commitment to Safety an honor to bring the first-place trophy back home to Pantex. The six individuals are Excellence and the overall goal of excellent representatives of the entire security force at Pantex.” an injury-free workplace.

Commissioning ceremony of the USS Ronald Reagan gets underway. From The Field The ship's four catapults and three arresting gear engines enable A Naval Milestone rapid and simultaneous launch and recovery of aircraft. Catapults thrust 60,000-pound aircraft 300 feet, from zero to 165 miles per hour in two Small Business Administration Recognizes BWXT Y-112 For more than two decades, BWXT's Nuclear Equipment Division and seconds. Arresting cables are able to bring planes traveling in at 150 Nuclear Products Division have provided the design and manufacturing miles per hour to a complete stop in approximately 320 feet. services for heavy equipment and nuclear The USS Ronald Reagan is scheduled for its first deployment in BWXT has again been recognized for its active support of components for the Nimitz-class aircraft 2005 from her San Diego, CA, homeport. small businesses. BWXT Y-12 in Oak Ridge, TN, has been carriers. July 12, 2003, marked the com- named the recipient of the Small Business Administration's missioning of the U.S. Navy's ninth and (SBA) Award of Distinction, honoring federal contractors that newest nuclear-powered aircraft carrier Admiral Vern Clark, Chief of Naval Operations, with his wife; Vice President have exceptional small business subcontracting programs. USS Ronald Reagan (CVN 76). The cer- Dick Cheney with Mrs. Cheney; and Mrs. Nancy Reagan sit together during emony occurred at the Norfolk Naval the ceremony. Less than two percent of the SBA's large contractors are Station, VA. recipients of the award. Towering 20 stories above the "BWXT-12 is pleased to receive this distinction for waterline, the USS Ronald encouraging the growth of small business and our Reagan is nearly as long as community," stated Dennis Ruddy, BWXT-12 President the Empire State Building is and General Manager, in response to the award. tall, with a flight deck that cov- Mitchell Morand, SBA's area director for government ers 4.5 acres. The carrier will contracting, commented, "BWXT Y-12 has continued to serve as home to approxi- demonstrate outstanding accomplishments in assisting small mately 6,000 sailors and more than 80 combat aircraft. business concerns through its mentoring programs and other Bob Waters (center) and Dennis Ruddy (right) accept the The nuclear propulsion sys- contracting vehicles." Award of Distinction from SBA’s Mitchell Morand. tem will power the ship for A year ago the SBA named BWXT of Ohio the DOE M&O more than 20 years without Contractor of the Year for outstanding achievement in award- refueling. Senator John Warner of Virginia ing subcontracts to small businesses. addresses the audience at the commissioning ceremony. EXPLORE BWXT / October 2003 23 (INEEL, continued from page 11.) BWX Technologies, Inc. 2016 Mt. Athos Rd. In 1991, BWXT increased its pres- is the Very High Temperature Reactor a quarter of the U.S. transportation fuel EXPLORE BWXT Lynchburg, VA 24504 Volume 1 Number 1 ence on the INEEL site by assuming (VHTR). The VHTR's mission is to production should be produced by 434.522.6000 the management and operation of the demonstrate high-efficiency electricity nuclear energy (fuel production coming www.bwxt.com Published for BWX Technologies, Inc. Army's "Specific Manufacturing and hydrogen production. INEEL's goal from nuclear-produced hydrogen), and and its subsidiaries. Capability," at that time a highly is to demonstrate improved economics that by 2020 a closed fuel cycle system John A. Fees President & COO secretive operation that manufactured through reduced capital costs and should be demonstrated. depleted uranium armor for U.S. mili- expanded product markets. Other With the Idaho Congressional dele- Richard W. Loving tary vehicles. BWXT's management goals include demonstration of natural- gation and DOE leadership strongly Director of Administration Editorial Staff role continued to grow at INEEL ly safe, high-temperature capabilities, supporting INEEL's nuclear mission; 434.522.5076 through the 1990s to the present, zero emissions and energy security, with the increased focus on nuclear Executive Editor where they are now responsible for all plutonium burn-up capability, deep- propulsion for space missions; with the BWXT Services, Inc. Lynchburg, VA Richard W. Loving nuclear operations as part of Bechtel burn or closed fuel cycle technology, dedicated and high-caliber efforts of its Rhonnie L. Smith BWXT of Idaho, a limited liability and facility security. talented workforce; and with the sup- President Associate Editors corporation. Advanced fuel cycle research will be port Congressional committees are Regina W. Carter INEEL represents DOE in coordinat- another major INEEL nuclear energy showing in proposed legislation for BWXT Pantex, LLC Amarillo, TX Craig S. Hansen ing the Generation IV International initiative. Researchers will explore 2004, INEEL's reputation as a Michael B. Mallory Richard J. Rademacher Forum (GIF). This group of 10 nations technologies for recycling spent fuel pioneering institution is poised to President & General Manager Contributors is working together to develop future- to reduce the volume (by up to 96 continue. BWXT will be there to Jud Simmons Bill Baker, PCG, Inc. generation nuclear energy systems that percent) and lifetime (to a few help lead the way. Manager, Public Communications Ellen F. Boatner can be licensed, constructed, and hundred years) of disposable waste, 806.477.3773 Jeff C. Crater operated to produce competitively and to reduce nuclear materials INEEL is an applied engineering Laura P. Ellis priced and reliable energy while proliferation concern. national laboratory dedicated to BWXT Y-12, LLC Oak Ridge, TN Teri L. Ehresman addressing safety, waste, and prolifera- Directors of six of DOE's premier supporting the U.S. Department of Dennis R. Ruddy Adam Findeisen, PCG, Inc. tion issues. Its objective is to deploy national laboratories have endorsed a Energy's missions in national President & General Manager Melissa K. Leinart multiple energy systems worldwide comprehensive and integrated plan to security, energy security, environment, Mimi H. Limbach, PCG, Inc. before 2030. The GIF has identified six further the development and deploy- and science. INEEL is operated for the Mark D. Neuhart Mark D. Neuhart Manager, Public Communications Elizabeth M. Shine reactor technologies to be investigated. ment of nuclear energy and the man- Department of Energy by Bechtel 865.574.1612 Jud Simmons Of these proposed technologies, the agement of nuclear materials. Their BWXT Idaho, LLC. W. Glenn Smith concept selected by the U.S. for joint endorsement stressed that by Nuclear Equipment Division Barberton, OH Helen P. Villasor research and demonstration at INEEL 2050, half of the U.S. electricity and E Sandy M. Wessel Douglas L. Garlock William R. Wilburn Vice President & General Manager

(SPACE, continued from page 13.) Terry R. Albright Graphic Designer Manager, Employee & Kerri E. Douthat BWXT is a leader in nuclear technology. The company brings exten- Community Relations sive experience in designing and fabricating research and test reactors 330.860.6389 and commercial pressurized water reactors. During its 50-year history, BWXT has manufactured heavy nuclear equipment and fuel needed for Nuclear Products Division Lynchburg, VA nuclear power particularly those used in special purpose and high-conse- Winfred D. Nash quence operations. The NPD has demonstrated success in previous Vice President & General Manager space Regina W. Carter programs, serving as the lead design organization for developing the Manager, Communications & Space Nuclear Thermal Propulsion System under contract with the U.S. Employee Activities Air Force. 434.522.5158 "BWXT's exceptional nuclear capabilities and unparalleled safety record are essential components for successful exploration of space Washington Operations Arlington, VA through nuclear energy," said BWXT President and COO John Fees. Roland B. Knapp "Our role in the JIMO project will enable NASA to design new space Vice President missions and conduct more in-depth investigations, while providing Billy Bingham (seated), Jeff Halfinger, and Gary Neeley greater flexibility in reaching and exploring distant areas of space." from NPD evaluate reactor neutronics model for space Jeffrey C. Crater applications in support of the JIMO Phase A trade studies. Manager, Government Programs According to O'Keefe, "to achieve the mission of exploring the universe 703.351.6305 and searching for life, there is much we must still learn and many technical challenges that must be conquered." As NASA's visionary, O'Keefe is looking to nuclear power to overcome the time and dis- Craig S. Hansen tance challenge of space exploration. "Its application to space travel has great potential." JIMO will ultimately demonstrate Manager, Government Programs O'Keefe's belief in nuclear power as the emerging technology for space exploration. E 703.351.6307 October 2003