Maintenance Technology August 2017 - 11

PLANT PROFILE
SPANNING 2.5 MILES between its east and west boundaries,
the 74-yr.-old Y-12 National Security Complex is a "mini city"
inside the city of Oak Ridge, TN. Within its secure borders, are
379 buildings of manufacturing, production, laboratory, support,
and research and development areas managed by Consolidated
Nuclear Security LLC (CNS) under contract for the National
Nuclear Security Administration (NNSA).
Y-12 also includes its own armed security force, fire department, steam plant, medical facility, cafeteria, and electricaldistribution center, all of which accommodate the nearly 8,000
people who work within the "city" borders each day.
Led by director of enterprise reliability and maintainability
Joe Boudreaux, a 45-member reliability team is responsible for
the proactive maintenance strategies of the buildings on the
811-acre campus. Deep into the second of a five-year reliabilityimprovement program, the team has built a firm foundation and
is now strategically navigating its road map with the ultimate
destination of establishing a sustainable, proactive maintenance
program.
"Within the building site there are mini-plants within the city,"
reliability and maintainability manager Paul Durko explained.
"And within each of those mini-plants, certain processes,
systems, and cultures that exist. Our goal is to secure a sustainable system of processes that work across the board, promoting
an increase in overall reliability for this aging site. But it also has
to be a system that will translate to a new facility-a $6.5-billion
Uranium Processing Facility (UPF) that will be built and in
operation by 2025."

Y-12 history
Since 1943, Y-12 has played a key role in strengthening the
United States' national security and reducing the global threat
from weapons of mass destruction.
The Y-12 National Security Complex is one of eight sites
in NNSA's Nuclear Security Enterprise (NSE). Y-12's unique
emphasis is in the processing and storage of uranium and the
development of technologies that are associated with those
activities. CNS also manages the 18,000-acre Pantex plant
in Amarillo, TX, which is the primary U.S. nuclear weapons
assembly, dismantlement, and maintenance facility. A majority of
the weapons-related operations at Pantex are conducted on 2,000
acres of the site.
Constructed as part of the World War II Manhattan Project,
Y-12 provided the enriched uranium for Little Boy, the atomic
bomb dropped on Hiroshima, Japan to help the U.S. and its
allies end a war that had taken 63 million lives worldwide.
Afterward, Y-12 provided lithium-separation functions and key
components for thermonuclear weapons. Y-12's expertise in
machining, handling, and protecting radiological materials has
made the Oak Ridge site central to the nation's nuclear security.
Y-12 is the only site in the Nuclear Security Enterprise that can
produce lithium materials. Replacement of the lithium operations is anticipated in the mid- to late-2020s.

AUGUST 2017

Y-12 has developed state-of-the-art capabilities in three core
areas: nuclear technology and materials, security and consequence management, and manufacturing and technical services.
Y-12 lends its specialized expertise to other federal agencies, such
as the U.S. Departments of Defense and Homeland Security,
state governments, and private-sector companies.
Projects at Y-12 include providing protective equipment to
soldiers in combat, training National Guard units for radiological
emergencies, and creating machining platforms that improve
production and efficiency.
More than 9,200 Tennessee citizens work at Y-12, including
federal and contractor staff.
"Our primary responsibility is to make sure the nuclear
weapon is reliable," Boudreaux said. "We do all of the testing and
checking to make sure that if there is ever a need to use a nuclear
weapon, that that weapon will work. The whole goal of the plant
is global threat reduction, and when you think about all of the
components that go into that, there are a lot of different things

Y-12 by the numbers
Y-12 today:

■ 811 acres, including 150 that are
high security

■ 7.3 million sq. ft. of laboratory, machining,
■
■
■
■
■
■

dismantlement, research and development,
and office areas
343 buildings, 13 mission-critical facilities
48% of all Y-12 facilities are more than
60 years old
~9,300 personnel at Y-12
~4,700 CNS employees; remainder are
subcontractor and federal employees
Deferred maintenance of $354 million
Contracts with more than 770 small businesses, totaling $177 million in FY 2016.

Y-12 site includes:

■ 550,000-sq.-ft. on-site leased facilities
(Jack Case and New Hope Centers)

■
■
■
■
■

24 mi. of paved roads
10 mi. of overhead steam lines
3 mi. of natural-gas-distribution lines
55 mi. of aerial electrical-distribution lines
10 mi. of underground
electrical-distribution lines

■ 19 mi. of main water piping
■ 50 mi. of storm drain lines
■ 15 cooling towers.

MAINTENANCETECHNOLOGY.COM | 11


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Table of Contents for the Digital Edition of Maintenance Technology August 2017

Editorial
Uptime
On The Floor
Reliable Security, Reliable Operations
Highly Charged Reliability
Drowning in Data? Look to the 'Stars'
Reliable Pumping Supplement
SAP: Tips and Tricks
Steam-Trap Inspections
Saving Tribal Knowledge
Seats for Butterfly Valves
IIoT
ISO 55000
Understand Lube ID Systems
Tomato Processor Boosts Steam Output, Cuts Emissions
Products
Ad Index
Showcase
Final Thought
Maintenance Technology August 2017 - 1
Maintenance Technology August 2017 - Cover1
Maintenance Technology August 2017 - Cover2
Maintenance Technology August 2017 - 1
Maintenance Technology August 2017 - 2
Maintenance Technology August 2017 - 3
Maintenance Technology August 2017 - Editorial
Maintenance Technology August 2017 - 5
Maintenance Technology August 2017 - Uptime
Maintenance Technology August 2017 - 7
Maintenance Technology August 2017 - On The Floor
Maintenance Technology August 2017 - 9
Maintenance Technology August 2017 - Reliable Security, Reliable Operations
Maintenance Technology August 2017 - 11
Maintenance Technology August 2017 - 12
Maintenance Technology August 2017 - 13
Maintenance Technology August 2017 - 14
Maintenance Technology August 2017 - 15
Maintenance Technology August 2017 - Highly Charged Reliability
Maintenance Technology August 2017 - 17
Maintenance Technology August 2017 - 18
Maintenance Technology August 2017 - Drowning in Data? Look to the 'Stars'
Maintenance Technology August 2017 - 20
Maintenance Technology August 2017 - 21
Maintenance Technology August 2017 - 22
Maintenance Technology August 2017 - Reliable Pumping Supplement
Maintenance Technology August 2017 - 24
Maintenance Technology August 2017 - 25
Maintenance Technology August 2017 - 26
Maintenance Technology August 2017 - 27
Maintenance Technology August 2017 - 28
Maintenance Technology August 2017 - 29
Maintenance Technology August 2017 - 30
Maintenance Technology August 2017 - SAP: Tips and Tricks
Maintenance Technology August 2017 - Steam-Trap Inspections
Maintenance Technology August 2017 - Saving Tribal Knowledge
Maintenance Technology August 2017 - Seats for Butterfly Valves
Maintenance Technology August 2017 - IIoT
Maintenance Technology August 2017 - ISO 55000
Maintenance Technology August 2017 - Understand Lube ID Systems
Maintenance Technology August 2017 - 38
Maintenance Technology August 2017 - 39
Maintenance Technology August 2017 - Tomato Processor Boosts Steam Output, Cuts Emissions
Maintenance Technology August 2017 - 41
Maintenance Technology August 2017 - 42
Maintenance Technology August 2017 - Products
Maintenance Technology August 2017 - 44
Maintenance Technology August 2017 - 45
Maintenance Technology August 2017 - Ad Index
Maintenance Technology August 2017 - Showcase
Maintenance Technology August 2017 - Final Thought
Maintenance Technology August 2017 - Cover3
Maintenance Technology August 2017 - Cover4
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