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1 LA-UR Approved for public release; distribution is unlimited. Title: Los Alamos National Laboratory, Kansas City Plant, and Lawrence Livermore National Laboratory Plutonium Sustainment Monthly Program Report January 2013 Author(s): Robertson, William G. Storey, Bradford G. Bowidowicz, Martin McLaughlin, Anastasia Dawn Hobson, Beverly F. Moreno, Louis Zagar, Mark H. Intended for: Report Disclaimer: Los Alamos National Laboratory, an affirmative action/equal opportunity employer,is operated by the Los Alamos National Security, LLC for the National NuclearSecurity Administration of the U.S. Department of Energy under contract DE-AC52-06NA By approving this article, the publisher recognizes that the U.S. Government retains nonexclusive, royalty-free license to publish or reproduce the published form of this contribution, or to allow others to do so, for U.S. Government purposes. Los Alamos National Laboratory requests that the publisher identify this article as work performed under the auspices of the U.S. Departmentof Energy. Los Alamos National Laboratory strongly supports academic freedom and a researcher's right to publish; as an institution, however, the Laboratory does not endorse the viewpoint of a publication or guarantee its technical correctness.

2 UNCLASSIFIED LosAlamosNationalLaboratory,KansasCityPlant,andLawrence LivermoreNationalLaboratory PlutoniumSustainmentMonthlyProgramReport January2013 Page1of30

3 UNCLASSIFIED Page2of30

4 UNCLASSIFIED LANL Executive Summary... 5 Table1:JanuaryBaselineChangeRequests LANL Pit Development Technical Progress Equipment Issues Variance Analysis and Recovery Plan BCRs Risk Table Earned Value Metrics LANL Power Supply Technical Progress Equipment Issues Variance Analysis and Recovery Plan BCRs Risk Table Earned Value Metrics Program Management and Support Program Management Support Issues Variance Analysis and Recovery Plan BCRs Earned Value Metrics Facilities, Waste and Institutional Support Technical Progress Equipment Issues Variance Analysis and Recovery Plan BCRs Earned Value Metrics KCP Technical Progress Equipment Issues Variance Analysis and Recovery Plan BCRs Risk Table Earned Value Metrics (January data is for December and January combined) Page3of30

5 UNCLASSIFIED 6.0 LLNL Technical Progress Equipment Issues Variance Analysis and Recovery Plan BCRs Risk Table Earned Value Metrics Page4of30

6 UNCLASSIFIED LANL Executive Summary InJanuaryof2013thePlutoniumSustainmentprogramatLANLcompletedoraddressedthefollowinghigh level activities: 1) CompletedmajorproductionactivitiesfortheLANLproducedEDUW87 legacypitonthefirstbuildattempt. 2) Attendedthe1 st QuarterPuSustainmentProgramReviewinAlbuquerque,NMonJanuary30, ) SupportedthePowerSupplyPRTMeetinginAlbuquerque,NMonJanuary8, ) SupportedaSystemReviewmeetingforPowerSupplyinAlbuquerque,NMonJanuary22, ) HostedthePitManufacturingDevelopmentIPTMeetingatLANLonJanuary23,2013. AllfourMRTL2Milestones( )associatedwithPlutoniumSustainmentareontrackforsuccessinFY13. TheearnedvaluemetricsoverallforLANLarewithinacceptablethresholds,sonohigh levelrecoveryplanisrequired. LANLcostsinJanuaryaccountfor5.8weeksinaplanned4 weekmonthduetoapayrollaccountingproblemin December(only3.2weeksofcostswerecapturedinaplanned5 weekmonthindecember).thishasnoeffecton earnedvalue(s.p.i.)butitdoeshaveaneffectonactualcosts(negativec.p.i.varianceforjanuarytooffsetthepositive variancefromdecember). EachofthefourmajorLANLWBSelementsarediscussedindetailbelowwithtwosectionsattheendthatareprovided bykcpandllnl. Page5of30

7 Table1:JanuaryBaselineChangeRequests UNCLASSIFIED WBS BCR # BCR Description Date Assigned Date Approved Impact Cost Impact Change Level PowerSupply Pit Equipment PowerSupply PowerSupply Pit Equipment Program Support Pit Development Pit Development Pit Development PowerSupply PowerSupply Program Support PSM PSM PSM PSM PSM PSM PSM PSM PSM PSM PSM PSM Adjustment to MR & TCP Due to Overhead Rate Increases 12/5/12 1/16/13 TPC $673k 1 CMM Replacement 12/5/12 1/24/13 Cost/Schedule $300k 3 PSAA: Engineering changes 12/5/12 1/14/13 Cost/Schedule $63k 3 PSAA: MSA 12/5/12 Working Cost/Schedule $92k 3 High Voltage EBW Replacement Plus up to University of Texas at Austin WP Product Realization Process Integration Welding & Joining New Hires Dimensional Inspection New Hires PSAA: Construction Elevator Control Relocation & Roll-up Door Installation PSAA: Construction Mechanical Relocations due to Design Changes Dri-Train Replacements - Preventive & Corrective Maintenance 12/18/12 1/14/13 Cost/Schedule $300k 3 1/7/13 1/28/13 Cost/Schedule $109k 3 1/22/13 1/29/13 Cost/Schedule $100k 3 1/22/13 1/29/13 Cost/Schedule $500k 3 1/22/13 1/29/13 Cost/Schedule $200k 3 1/24/13 1/28/13 Cost/Schedule $29k 3 1/24/13 1/28/13 Cost/Schedule $95k 3 1/25/13 1/29/13 Cost/Schedule $500k 3 Page6of30

8 Earned Value Metrics UNCLASSIFIED Page7of30

9 UNCLASSIFIED Page8of30

10 1.0 LANL Pit Development UNCLASSIFIED MRT 4622 GREEN Perform Activities to Sustain Base Pit Material Processing and Fabrication Capability 1. ContinueW87legacypitIPTactivities. 2. Maintainpitmanufacturingcapabilitybyproducing4pit likebuildsand/orexercisingthepitfabricationflowsheet. 3. ContinuetomakeprogressontheElectro Refiningline,PlutoniumFoundry,andLaserBeamwelderprojects. Builds Baseline Date Status/Comments Completion Date RGYB BuiltAttempt#1 Start October4,2012 October4,2012 BLUE Complete January24,2013 January30,2013 BLUE BuiltAttempt#2 Start December3,2012 Girthlaserweldcompleted. November14,2012 BLUE Complete March28,2013 GREEN TubeDrill&Pressandlaser March3,2013 BuiltAttempt#3 Start weldingcompleted January7,2013 BLUE Complete June27,2013 GREEN BuiltAttempt#4 Start June3,2013 Waitingforfinaldesigndrawings GREEN Complete September30,2013 GREEN Equipment ERLineStartConstruction November1,2012 October 17, 2012 BLUE ERElectrical/MechanicalComplete forgloveboxesi,ii,iii,&iv March13,2013 Ontracktomeetmilestone GREEN CompletePhaseIIIFoundryCold Testing March21,2013 Ontracktomeetmilestone GREEN CompleteLaserWeldersystem testinginthesm 66coldlaboratory April19,2013 Ontracktomeetmilestone GREEN ERElectrical/MechanicalComplete fortrunklinesii,iii,andiv June27,2013 GREEN FoundryDCP Approvedfor Construction June30,2013 GREEN CompleteLaserWelderTestingin thepf 4 cold glovebox July19,2013 GREEN ERElectrical/MechanicalComplete formts July26,2013 GREEN Conveyor,Dri train,trunklinesi&v FoundryCoolingSystemUpgrade IntegratedWorkDocument July30,2013 GREEN Complete ERElectrical/MechanicalComplete forbrakingpress,hpu,&primary August29,2013 GREEN StagingCarousel StartconstructionofFoundryGB1 September20,2013 GREEN ERLineUpgradesComplete September30,2013 GREEN CompleteLaserWeldertestingin thepf 4 hot Glovebox September30,2013 GREEN MRT 4623 GREEN Progress towards competency to build W87 pits by achieving W87 EDU by September 30, CompleteW87legacyEDUbuild jointlyreviewedbyw87legacypitiptbyseptember30,2013. EDUBuild September30,2013 EDUbuildiscomplete.Data reviewwilltakeplaceatthenext IPTandclosethismilestone. GREEN Page9of30

11 1.1 Technical Progress UNCLASSIFIED CompletedmajorproductionactivitiesfortheLANLproducedEDUW87 legacypitonthefirstbuildattempt. o CompletedthefirstdowndraftassemblyoperationofaW87 legacypitsuccessfully. o CompletedthefirstelectronbeamgirthweldingoperationofaW87 legacypitsuccessfully. o CompletedthefirstbasementoperationofaW87 legacypitsuccessfully. CompletedthegirthlaserweldingoperationsuccessfullyonW87Dev 1. Performedtwodowndraftassemblies,twoelectronbeamgirthwelds,andonelaserbeamgirthweldofthe W87 legacypitdesigninoneweek. Thethirdlasertubeweldwassuccessfullyperformedandpassedleakchecking. o Sinceallthreeattemptedlasertubeweldsweresuccessful,wehaveeliminatedfromourrisktableoneof thehighesttechnicalrisks,namely,thelasertubeweldingoperation. CompletedmachiningoperationsontwoFY13shapecastings.Thiscompletestheshapecastingmachining plannedforaprilputtingthemachiningoperations3monthsaheadofschedule. 1.2 Equipment Theplantomeetthegradingcriterion#3forL2milestoneMRT4622includesthefollowing: 1. TheLaserWelderUpgrade completeallplannedlaserweldingsystemupgradesandreleaseboththe cold and hot gloveboxforweldingoperationsbyseptember30, ThePlutoniumFoundryUpgrades completecoldtesting,issueanapproveddesignforconstruction,and startconstructiononthefirstofthreefoundrygloveboxesbyseptember30, TheElectro RefiningLineUpgrade completeallmechanicalandelectricalconstructionactivityassociated withtheelevenelectro refiningboxesandsystemsbyseptember30,2013. LaserWelderUpgrade o Installationoftheinfrastructuretosupportthenewmotioncontrolandlaserintegratingsystemsisnearing completion. o Acceptablesurrogateweldshavebeencompletedwiththecoldtestsystem. o TheColdSkidhascompetentfunctionalcontrolofall5axesandisreceivingsignalinputsfortheinterlock safetysystemsandthelaser. o TheHotSkidhasbeenbuiltandisundergoingpreliminarychecks. o PlanningthePF 4workscopecontinueswiththegenerationofIWD/DOPworkdocumentsandother preparationtostartpf 4activities. FoundryUpgrade o SubmittedreadinessdeterminationtotheOperationalSafetyBoard(OSB). o Completed30%GB2vacuum/coolinginstallationengineeringdesignreview. o GB1coolingIWD80%complete. o GB1vacuuminstallation75%complete. o Processequipmentdesigndrawings85%complete. o VacuumsystemHMIsoftware85%complete. o CoolingsystemHMIsoftware75%complete. Electro RefiningLineUpgrade o EndpanelforstaginggloveboxandtrolleyconveyorinspectedandacceptedfromIPSystems. o ProcurementoftheConstructionBillofMaterialsprogressing. o ServiceManifolds(3)alignedonTrunklineandsoldered. o ALARAreportcompleted. o PreparationofCriticalitySafetyEvaluationDocuments(CSEDs)isinprocess. Page10of30

12 1.3 Issues UNCLASSIFIED None 1.4 Variance Analysis and Recovery Plan None 1.5 BCRs PSM for$300K:ThisBCRincludesfundstobegintheCMMreplacementproject PSM for$300K:ThisBCRincludesfundstobegintheElectronBeamWelderreplacementproject PSM for$100K:ThisBCRfundsaSeniorEngineer sexpandedroleinsupportofpitdevelopment PSM for$500K:ThisBCRfundsweldingengineer(3)andtechnician(2)newhires. PSM for$200K:ThisBCRfundsdimensionalinspectornewhires oneengineerandonetechnician. Page11of30

13 UNCLASSIFIED Page12of Risk Table Work Description Handling Strategy Status Laserweldingupgradeswillconflict withthe4thpitbuildattempt(dev 3) infy13. Thelaserbeamwelderupgradesareexpectedtooccurinthe summerof2013andtakethesystemoutofoperational status.thepitmanufacturingflowsheetcannotproceed withoutthiscapability.thiscoulddelaydev 3(plannedin FY13)untilearlyFY14.Dev 3isplannedtobetheW87 like build. IfpossiblethesubassemblyforDev 3willbebuiltahead ofschedule.ifthiscannotbeaccomplished,thebuild mightoccurinfy14orbereplacedwithalegacyw87pit design(sameasthefirstthreebuildsinfy13). LLNLdesignfortheW87 likeisstillnotfinalized. Withthedelaysinreceivingthefinaldesign drawingsforthew87 likebuild,wehavedecided toproceedwithaw87 legacybuildasdev 2. Thisbuildisrunningaheadofschedule.Weplan tohavealllaserweldingoperationscompleted bymid maytoallowcwlaserupgradesto proceedwithminimalscheduleconflicts. Maintenanceisinsufficientto maintainreliablesystemsfor scheduledwork. Preventivemaintenancesupportedbyalargeinfrastructure hasbeenreplacedwithamodifiedcorrectivemaintenance approach.preventativemaintenancewillbeperformedonly onsafetysignificantsystemsrequiredtomeetdsa based TSRs.Mostequipmentwillberununtilcorrective maintenanceisrequired.sparepartswouldbereplacedas limitedfundspermit.currentstockswillbedrawndown. Giventheageofmanymissioncriticalsystems,thetimeto repairandreturntoserviceisnotpredictable.duetothe sequentialandinterrelatedprocessesinvolvedin manufacturing,longlapsesinfabricationarepossible. Theriskhandlingstrategyforlimitedmaintenanceis basicallytoaccepttheriskofequipmentfailureandthe correspondingdelayinw87pitdevelopment. Maintenanceonmissioncriticalsystemshasbeen prioritized.ifunrecoverable(within3weeks)events occur,scopeandfundingwillberevisedviaabcrto reducedeliverablesandrepairorreplaceequipment. Anadditional$500khasbeenmadeavailablefor Dri Trainreplacementsandpreventativeand correctivemaintenance(seebcr ). Criticalpiecesofequipmentare knownsingle pointfailures.ifanyof theequipmentfailscatastrophically, pitdevelopmentwillstopuntila replacementisinstalled.thiswould mostlikelydelaythefpu. Giventheageofmissioncriticalequipment,unrecoverable failureisprobable.equipmentinstallationinpf 4takesyears tocomplete.areplacementtimeof1 4yearswouldbe expected,whichinturnwilldelaythew87pitfpu. Threeelements,ERLine,PuFoundry,andLaserBeam Welder,ofthepitproductionlinealreadyhave installationandupgradesunderway.thesethreeprojects arefullyfunded.otherareasofconcernininspection, welding,andmachiningwillhaveplanningcompletedfor requirementsanalysis,costestimate,andoptions.this willpermittheseprojectstobeavailabletostartshould fundingbecomeavailableorintheeventofequipment failure,fundscanbemovedfromotherpartsofthe programtostartthereplacement. $300khasbeenmadeavailablefora replacementcmmwithanadditional$1.5m plannedinlatefy13(fundingpermitted)to procurethereplacementcmm(seebcr ). Anadditional$300khasbeenmadeavailablefor ahighenergyelectronbeamwelderwithan additional$2.5mplannedinlatefy13(funding permitted)toprocurethereplacementelectron beamwelder(seebcr ). Analyticalactinidechemistrymay losethesupportfromother programsatlanl. TheNA 26fundedARIESprogramisconsideringtheoptionto transferchemistryoutoflanl.currentlytheprogramand ARIESaretheprimaryfundingsourcesforthiscapability.The Programhasalreadyreducedthenumberofsamplesfor chemistryanalysis.thispotentialforanarieselimination andprogramreductioninfundingcouldresultinlossofthe chemistrycapabilityaltogetherforactinidesamplesatlanl. 1)SeniormanagersatLANLandLASOareworkingto resolvethisissue. 2)TheProgramcouldincreasetheamountofchemistry workbeyondtheminimumrequiredtoexploreissuesof lowerimportanceinordertomaintainthiscompetency. DiscussionscontinuewithChemistryDivision managerswithmeetingsplannedinfebruaryto establishmaintenanceofcorecompetencies duringthenextfewtransitionalyears.

14 1.7 Earned Value Metrics UNCLASSIFIED Page13of30

15 2.0 LANL Power Supply UNCLASSIFIED Complete FY 2013 RTG material recovery activities MRT 4624 GREEN 1. Dismantle95%ofthePantexitemsreceivedbyJune30,2013(upto450items) 2. RecoverandstoretheoxidebySeptember30,2013. L3 Milestone Baseline Date Status/Comments Completion Date RGYB FuelRecovered&Stored July 2012Shipment FuelRecovered&Stored August 2012Shipment FuelRecovered&Stored November2012Shipment FuelRecovered&Stored January 2013Shipment FuelRecovered&Stored March 2013Shipment FuelRecovered&Stored May 2013Shipment FuelRecovered&Stored June 2013Shipment October16,2012 CompletethroughFSOwelding. September12,2012 BLUE November8,2012 CompletethroughFSOwelding. December11,2012 BLUE February6,2013 CompletethroughFSOwelding. January3,2013 BLUE April17,2013 Shipmentreceivedandrecovery isinprogress. GREEN June11,2013 GREEN August13,2013 September3,2013 Expecttonotreceivethis shipment. Expecttonotreceivethis shipment. GREEN GREEN Install the RTG ATF equipment and upgrades MRT 4625 GREEN 1. CompleteconstructionoftheRTG ATFbySeptember30, TurnoverRTG ATFfacilitytoOperationsbySeptember30,2013 L3/L4 Milestone Baseline Date Status/Comments Completion Date RGYB DuctbankInstallationComplete October12,2012 Asphaltinstallationtiedto milestone. October18,2012 BLUE ProcessEquipmentReadyfor November19,2012 DeliverytoPF 5Basement January15,2013 BLUE HVACInstallationComplete November21,2012 January18,2013 BLUE InstallationofProcessEquipment December13,2012 Complete January29,2013 BLUE Expectedtobecompleteinlate ConstructionComplete February19,2013 FebruarytoearlyMarch dependinguponfinaldeliveryof YELLOW equipmentandhardware. ReleasetoOperations June3,2013 GREEN 2.1 Technical Progress MaterialRecovery o ReceivedFY13Shipment#1,#2,#3and#4(receivedinJuly,August,October,andJanuary). Allunitsfromshipments1,2,and3aredismantled.Currentlyinprocessofdismantlingshipment4 units. Completedfuelrecoveryandstoragefromshipments1,2,and3inFSOs. FSOradiographydelayedduetoequipmentfailure.TheservicevendorisonsitetheweekofFebruary 11todetermineexactcauseofequipmentfailure. Page14of30

16 UNCLASSIFIED ProcessDevelopment o OnMonday,January21,2013,thePowerSupplyDesignAgencycontacted LANLandrequestedaquickturnaroundonproducingfourPowerSupply MassMocks.ThemassmockswerenecessaryforthenextDesignAgency assemblytestingscheduledforjanuary30,2013.lanlpersonnelfrom acrossthelaboratorydiligentlyworkedtoprocuretheneededmaterials, machinealloftheparts,laseretcheachsothattheycouldbeindividually identifiedduringexperiments,andweldedallofthecomponents.on Tuesday,January29thLANLdeliveredallfourofthecompletedmass mocks. 2.2 Equipment RadioisotopeThermoelectricGenerator Assembly&TestingFacility(RTG ATF) o Startedinstallofacousticalceiling. o ContinuedinstallofHVACcontrols. o Continuedinstallofdevicesforthefirealarmsystem. o ContinuedinstallofracewaysfortheYellowNetsystem. o Completeinstallofoneofthetwonewfiredampersrequired. o CompletedinstallationofHVACexteriorfreshairintakeductwork. o Argontankandvaporizerwhereshipped,willarrivetheweekofFeb11,2013. o CompletedACBsinstallandboltingtogethercompleted,utilityconnectionsstarted. TheLowVoltageElectronBeam(LVEB)Welder o CompletedtheTechnicalAssistTeamreview.TheAssistTeamidentified30itemstoberesolvedpriortothe ManagementSelf Assessment(MSA).Theprojectteamiscurrentlyworkingonresolvingthoseitemsin preparationofthemarchmsa. o Initiatedthereviewandapprovalprocessfortheoperationsandmaintenanceprocedures. AnalyticalChemistrygloveboxes(PuAssayandRadiochemistry) o CompletedtheZone2ductwork. o Completedinstallationofmechanicalwork. o InitiatedZone1ductwork. SM 39DevelopmentLaboratory o GTAwelderoperationalandhasweldedlinersforestablishingweldparameters o E beamwelderisoperationalandcompletedcorrectingbeamprofileissue. 2.3 Issues None 2.4 Variance Analysis and Recovery Plan None 2.5 BCRs BCP for$29K:ThisBCRincludesfundsspecifiedforinstallationofafireratedrollupdoorandthe relocationoftheelevatorcontrolsduetotheinstallationoftherollupdoor.thesechangeswererequiredto meetthefacilitytwo hourfirerating. Page15of30

17 UNCLASSIFIED BCP for$94.5K:ChangesinthisBCPincorporatedtherelocationandinstallationoftheshakertable vacuumblower,re routingthechilledwaterpiping,andfabricationandinstallationofthea/cunitstand.allof thesechangeswereduetodesignchangesnecessarytoaccountforfacilityinterferences. Page16of30

18 UNCLASSIFIED 2.6 Risk Table Work Description Handling Strategy Status Workforcedevelopmentand recruiting Harvesting 238 Pu Dedicatedstaffinganddepthoftrainedoperatorsarebothat risktosupportthedevelopment,ppi,andqualseriesforrtg manufacturingdevelopment.theplantostarthiringinfy13 fordedicatedstaffingwillnotoccur.staffingissharedwith otherprogramsandmaynotalwaysbeavailableas scheduled.notethattheincreaseinstaffalsowasplannedto maintainlowerdoseratesinthestaffaspartoflanlalara goals. PantexmaynotbeallowedorabletoshiptheexpiredRTGs tolanlatarateof80everytwomonths.thiswouldprevent LANLfromharvestinginFY13the 238 Purequiredforthe productionrun. 1)CommunicateandintegratefrequentlywithRTG surveillance,ne 75,andotherprogramstomakethe bestuseofavailablestaff. 2)RequestLANLandLAFieldOfficemanagementto allowforincreasedoseinstaffassignedtothiswork. 3)Delaynon criticalpathactivitiesuntiltheybecome criticalpathforfpu. 1)HarvestinFY14andFY15butatagreaterexpenseto theprogram. 2)Useexisting 238 PualreadyatLANLtobackfillwhat Pantexdoesnotship. 3)Startproductionwithlessfuelandcompromisethe plannedscraprateallowance.thisputstheabilityto meetproductionratesatrisk. Dailyworkplanningmeetingscontinuetoensure availabilityofstaffingresources.startedworking withlinemanagementtoidentifyfuture strategichiresthroughout yearschedule planning. Currentlyperformingareviewofmaterial presentatlanlthatcouldbeusedtomeet missionneeds.workingwiththesurveillance Communitytoidentifymaterialforprogram transfer. Page17of30

19 2.7 Earned Value Metrics UNCLASSIFIED Page18of30

20 3.0 Program Management and Support UNCLASSIFIED 3.1 Program Management SupportedthePowerSupplyPRTMeetinginAlbuquerque,NMonJanuary8,2013. SupportedaSystemReviewmeetingforPowerSupplyinAlbuquerque,NMonJanuary22,2013. HostedthePitManufacturingDevelopmentIPTMeetingatLANLonJanuary23,2013. Supportedthe1 st QuarterPuSustainmentProgramReviewinAlbuquerque,NMonJanuary30,2013. Initiatedout yearfynspplanningforallpusustainmentprogramelements. 3.2 Support DocumentControl,RecordsManagement,andTraining o Atotalof167documentrequestswerereceivedinJanuary o Atotalof72documentactionrequestswerecompletedinJanuary o TheTA 55/PF 28facilityisnowfullyturnedovertooperationsforaclassified/NQA 1/QC 1compliant temporaryrecordsassemblylocation o FormalOntheJobTrainingdocumentsforpyrochemicaloperationsarenearlycomplete. Calibration o PerformedMonthlyCalibrations:TheLANLStandards&CalibrationLaboratory(S&CL)hascalibrated approximately92pusustainmentitemsthroughjanuary23,2013 o QualityEngineering/ContinuousImprovement:Withthehelpofengineeringsupportmadeavailablewith thes&cl spusustainmentworkpackage,thes&clcontinuestodevelopspecificationsheetsand automatedproceduresusingspectrackandcalibrationprocessmanagermodulesofitsnewmudcats metrologydatabase.specsheetshavebeendevelopedforareassuchaspressuregages,pressure transducers,andthermocouples.theseimprovementsareexpectedtoreduceturnaroundtimeforpu Sustainmentequipmentandimprovetheoverallqualityofthecalibrationprocess. WarehousingandProcurement o ContinuetoeffectivelyprocureandmanagematerialformultiplePuSustainmentprojects(ER,PUASSAY, FoundrycoldtestingandFoundryVacuumupgrades,andIPGlaserupgrades.) o Theprocurementteamsuccessfullyprocessedover235procurementrequestsforTA55inJanuaryandwas abletoworkthroughtheperiodwithoutthedevelopmentofasubstantial(>1week)andpermanent backlog. o TheConsolidatedBillofMaterialsDatabaseVersion3wasreleased.Itincludesamaterialrequestpicklistto beusedbyconstructiontorequestmaterialfromthewarehouseteam.italsoincludesthecapabilityto receiveandissueitemsintothedatabase. 3.3 Issues None 3.4 Variance Analysis and Recovery Plan None 3.5 BCRs PSM for$108.9K:ThisBCRaddsadditionalfundingtoourstudentpipelineworkpackage.Thespecific scopefundedislevelofeffortfundingtosupportstudentresearchofcurrent torquemappingandhigh bandwidthcontrol.thisbcrwillallowlanltheopportunitytointegratetheperformanceofindustrial Page19of30

21 UNCLASSIFIED manipulatorswithadvancedcompliantcontrolandothertechniqueswhilemeetingthedemanding manufacturingrequirementsforsafety,payload,reliability,etc. PSM for$500K:AmendscopewithintheMaintenanceWorkPackagetoincludetheremovaloftwo existingairpurificationsystems(dri Train)supportingcomponentweldingoperationsandtoprovidean estimateandproposeddesignforreplacementofthesetwosystems.toachievetherequiredproductionrate overthenext~10years,areliablepurificationsystemisnecessarytopreventunwantedoxidationofthepu parts,weldjointcontamination,andinextremecasespufires. Page20of30

22 3.6 Earned Value Metrics UNCLASSIFIED Page21of30

23 UNCLASSIFIED 4.0 Facilities, Waste and Institutional Support 4.1 Technical Progress AD NHHO:13 026January2013ProgressReportonPF 4Seismic/StructuralAnalysesandFacilityUpgrades transmittedtolosalamosfieldoffice. Rad ConandLASOTrainingAssessmentandOperationsCenterCertifications 4.2 Equipment TA 55ReinvestmentProject TRPhasclosedPOST116(mainentrytoPF 4)fromJanuary25forapproximately3 weekswhiletheyreplacetheconfinementdoor.duringthisperiod,accesstopf 4willbethroughPOST Issues None 4.4 Variance Analysis and Recovery Plan None 4.5 BCRs RTBFallocationofanadditional2%totheBaseFacilityOperationsfortheMasterResourceDictionaryimpacts: RLW,RLUOB,andTA 55non distributedworkpackagebaselinechangerequestscomplete Page22of30

24 UNCLASSIFIED 4.6 Earned Value Metrics Page23of30

25 5.0 KCP UNCLASSIFIED MRT 4750 GREEN Begin Development of Non Nuclear Component Manufacturing capability 1.Purchaseandinstallnewprecisionlathesby9/30/13 2.Procuredevelopmentmaterialby7/31/13 3.Startfabricationofoneofthreedevelopmentshellsetsby8/31/13 L2 Milestone 4750 Baseline Date Status/Comments Completion Date RGYB Purchaseandinstallnewprecision lathes 9/30/2013 Procuredevelopmentmaterial 7/31/2013 Startfabricationofoneofthree developmentshellsets 5.1 Technical Progress Quotesreceivedfromtwo vendors.p.o.tobeplacedend offeb2013 Surrogatedevelopmentmaterial procured GREEN GREEN 8/31/2013 4thquarterFY13 GREEN KCPfinalizedthespecificationandrequestedaquoteforcross rolled21 6 9fromMSCandMetalwerkstoroll andcutblanksfromkcpsuppliedmaterial. KCPfinalizedthespecificationandrequestedaquotefromWahChangtocrossrollmaterialsuppliedbyKCP. TubingfromKCPstoreswasidentifiedandpulledtosupporttheprocurementoftheunclassifiedcomponents. Surrogatematerialcutintoblanksofvarioussizestodeterminethestartingblanksizerequiredforthehydro formprocess.asecurityplanisinworktoallowtheclassifiedpartstobeprocessedonthehydroformmachine. ThisisexpectedtobeapprovedandreadybytheendofFebruary.Hydroformtoolingwascompletedin January. Drawingsfortheunclassifiedpartsreviewedandchangesidentified.AVTCisplannedinFebruarytoreviewand implementthechanges.kcphasrequestedllnldterthedrawingstokcptoexpediteandsimplifythedrawing changeprocess. AstereolythefixturewasmadetoholdthetwosamplepartsfromLLNLforCMMinspectiondevelopment. 5.2 Equipment InitialquotesreceivedonthetwoT baselathesandwerewithinbudget.additionalfollowupwiththevendors isneededtoensureallaspectsofthecontractaremetandincludedinthequote.itisexpectedtheorderwill beplacedbytheendoffebruary. 5.3 Issues None 5.4 Variance Analysis and Recovery Plan None 5.5 BCRs None Page24of30

26 UNCLASSIFIED Page25of Risk Table Work Description Handling Strategy Status Developmentmaterialavailability Ifsuitablematerialinappropriatequantitiesisnotreadily available,thenadditionalleadtimewillberequiredtoobtain rawmaterial,possiblydelayingkcpsupportofppischedules. Mitigate.Inordertostarthydroformingdevelopment, surrogatematerialisbeingpurchasedtodevelopinitial formingandmachiningparameters.lanlhasoffered approximately10platesofoneofthematerialsthatwill beusedtosupport5ofthedevelopmentlot.additional plateswillberolledfromexistingmaterialatkcp. Thesurrogatematerialwasreceivedinearly January.LANLrespondedonthematerialrequest theycouldsupply50plates.kcpisevaluating theprocesstodetermineifthesmallersizeof theplateswillworkwithourequipment,tooling andprocess.kcphasrequestforquotesoutto obtaindevelopmentmaterial.expecteddelivery willsupportdevelopmentschedule. PPIandQualmaterialavailability IfexistingmaterialatKCPisrestrictedfromusethennew materialwillberequired.theprocurementtimeonnew materialis(6to18months)beforetheystartmakingand rollingthematerial.thematerialmaynotbeavailableto supportppiandqualschedules. Mitigate.Effortsareunderwaytoupdatethematerial specificationandworkwiththesuppliertoreducecost andtimetodelivery.alternatesuppliersarealsobeing consideredprovidedthematerialcanmeetthe specification. TheWahChangvisitprovidedapathforward thatwillmeetscheduleandlevel2milestones. WahChangisquotingrollingKCPmaterialand providingnewmaterialthatwillmeetthe developmentscheduleandlevel2milestones. Fundsavailability ThetimingoffundingbecomingavailabletoKCPiscriticalto enablingkcp ssupportofthisnewmission. Mitigate.KCPisworkingwithLLNLtoredefinethe specificationandmaterialprocessingrequirements, whichwillreducecost.multi yearprocurementand timedprocurementcanspreadthecostoverdifferent fundingyears.combiningprocurementneedsbetween sites(llnl,lanlandkcp)canincreasequantitiesand reducecost. TheWahChangvisitprovidedinsighttonew materialprocurementandexistingmaterial processinganddeliverytimesthatcansupport programneeds.kcpandllnlagreedonthe materialspecificationthatshouldbereleasedin springof2013.kcpiswaitingonquotesforall materialprocurementsthatwilldefinecost impact.thequotesareexpectedtobelessthan originallyfigured. T baselatheavailabilityatbannister Facility TheT baselathecurrentlyinstalledinthe coldroom atthe Bannisterfacilityistheonlymachinecurrentlyavailableupon whichtobeginprocessdevelopment.ithasmarginal capabilitytoholdtherequiredtolerancesinproduction.its availabilityiscriticaltobeginprocessdevelopmentwhilenew equipmentisbeingprocured&installed. Mitigate.Thefirstphaseofprocessdevelopmentwould havetobeeliminatedinordertousethet baselathe, whichismovingduringthattimeperiod.this compressionmaynotallowenoughtimetodevelop adequatewrprocesses. Procurementactivitiesareinfinalapprovaland expectedtohaveanorderplacedbymarch1st. Duetosubstitutingthestrongerspindlerequired tosupportthepartsthedeliveryandsetupof themachinesmayincurdelay.atthistimethe equipmentisnotexpectedtomissthelevel2 milestone,butthisisanelevatedrisk. Hydroformingequipment Hydroformingequipmentisrequiredforthisprojectandthe currentequipmentisnotplannedtobemovedtobotts. Mitigate.Procurementcost($1M)ofrequiredequipment hasbeenincludedincontingencyinfy13. Procurementactivitiescontinueandareontrack tomitigatetherisk. CMMPartAcceptance ThecurrentinspectionmethodutilizestheSheffieldanda fixture($250k)whichbothareunavailableatkcp.ifan alternatemethodtoverifypartacceptanceisapproveditwill takeateamtodeterminetheprobingdensityandfixturing requirementswhichmayexceedthefundingallocatedtothis activity. Mitigate.LLNLisgoingtosendtworepresentativeparts tokcpforfixturingdesignandpracticecmmprobing. TheteamingactivitieswillbeincludedaroundIPT meetingstominimizetravel.datasetswillbe transmittedelectronicallyforteammemberreview. TwopartsfromLLNLwerereceivedbyKCPin January.LLNLisworkingonprovidingthe modelsfortheparts.kcpisproceedingwith buildingafixtureandperforminginitialcmm scanningtechniques.

27 UNCLASSIFIED 5.7 Earned Value Metrics (January data is for December and January combined) Page26of30

28 6.0 LLNL MRT 4749 GREEN UNCLASSIFIED 1. ContinuetosupportandleadtheW87legacypitIPTastheDA 2. IncoordinationwithLANLPA,maintainSheffieldmeasuringdeviceforprocessqualification 3. DocumentandprovidedesignforW87 likebuildnolaterthandecember31st, InconjunctionwithLANLPA,completeW87 likebuild 5. Receiveandprocessspecialitems Perform Activities to Enable Plutonium Sustainment Goals L2/L3 Milestone Baseline Date Status/Comments Completion Date RGYB SupportcompletionofW87EDUbuild 9/30/2013 UpdateW87metalspecification 7/30/2013 Completeweldcertificationtests 3/31/2013 Initiatereadinessreviewforcompatibility tests ReceiveshipmentfromSRSandbegin processing Completeprocessingfirstsetofspecial itemsfromsrsand/orreceiveshipmentof specialitemsfromnnss Completeinitialdemonstrationof purificationandrecoveryofdesired materials 9/30/2013 1/1/2013 9/30/2013 6/30/2013 DocumentandprovidedesignforW87 like 12/31/2012 InconjunctionwithLANLPA,complete W87 likebuild 6.1 Technical Progress 9/30/2013 ContinuedtoprovideEDU developmentsupport ReceivedmetalfromLANL fornextsetofcoupon studies Partsarebeingmachinedfor weldtests IdentifiedLANLworkscope andequipmentneeds Shipmentreceivedand processingstarted ProcessingcontinuedforSRS specialitems DevelopingMD 2procedures AwaitingNNSAapprovalfor equipmentinstallation DesignprovidedtoNNSA andlanl. Currentlyscheduledasthird orfourthbuild GREEN GREEN GREEN GREEN 11/30/12 BLUE GREEN GREEN 11/30/12 BLUE GREEN TheW87 likedrawingrevisionsareexpectedtobeprovidedtolanlinearlyfebruary. DraftworkcontroldocumentsarebeingpreparedforpackagingandshippingspecialitemsfromNevada.The MD 2sarenowprojectedtobeavailableinlateMay/earlyJuneperY 12.NSTecisreviewingauthorizationbasis issuestodetermineifoverpackingcanoccurwithinanarea5facility. TheprocessingoftheSpecialItemsfromSavannahRiverSitecontinued. LANLreviewofthecompatibilitytestwasheld.LANLcontactsandfundingsourcehavechanged,sothecost estimatetolanlforsupportwascancelled. MaterialsampleswereshippedandreceivedfromLANLfortesting. FurnaceprocessparametersforfabricationofsamplesthatwillbeusedforW87metalspecification determinationwereestablished. 6.2 Equipment None 6.3 Issues None Page27of30

29 6.4 Variance Analysis and Recovery Plan UNCLASSIFIED None 6.5 BCRs None Page28of30

30 UNCLASSIFIED 6.6 Risk Table Work Description Handling Strategy Status Allworkpackages AvailabilityofrequiredunitoperationsatLANLorLLNL Worktointegratedscheduleandadjustsasneeded Notrealized SpecialItemsShipmentfromNNSS AvailabilityofMD 2andassociatedcomponents Earlyidentificationofissuesandalternatemethods MD 2availabilityinJune2013 W87 LikefabricationatLANL DesignincompatiblewithLANLweldingandassembly hardware Adjustdesignorprovideequipmentfixturesasneeded Revisiontodesigninprogress;expectrevisionin February ModernFoundryColdTesting Lossofkeypersonnelduetomedicalissuesorretirement Adjustscheduleiflossistemporaryoradjuststaffto criticalneedsiflossispermanent Notrealized Page29of30

31 6.7 Earned Value Metrics UNCLASSIFIED Page30of30