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Global Management & Operations Services 2010 Annual Review Table of Contents Introduction3 Waste Management & Disposition Savannah River Site Liquid Waste 4 Hanford Tank Operations 5 Hanford Waste Treatment & Immobilization Plant 6 Waste Isolation Pilot Plant 7 Cleanup & Closure Services Hanford River Corridor Closure Project 8 Idaho Cleanup Project 9 West Valley Demonstration Project 10 Safety, Consulting & Engineering URS Safety Management Solutions 11 Yucca Mountain Repository 12 Laboratory Services National Energy Technology Laboratory 13 Idaho National Laboratory 14 Lawrence Livermore National Laboratory 14 Los Alamos National Laboratory 14 United Kingdom Sellafield 15 Low Level Waste Repository 16 Talent Development17 Community Support18 Looking Ahead to 201119 2 Introduction U RS Global Management & Operations Services (GMOS) continued its high level of safety performance in 2010, with all six of its major projects placing above the U.S. Department of Energy (DOE) Environmental Management (EM) average in safety for the fiscal year – including the top spot in the complex and six of the top seven (see chart below). Our two United Kingdom projects also performed well, receiving accolades and racking up record numbers of safe work hours. Six of our sites were recognized by the DOE Voluntary Protection Program (VPP) with Star of Excellence Awards, and two sites received the Legacy of Stars – DOE’s highest safety award. Safety goes hand in hand with disciplined work performance. Our combined workforce of nearly 20,000 uses decades of experience in the government nuclear industry to ensure our contract scope is accomplished safely. Operational accomplishments in 2010 included: ► Led demolition of the graphite core of the Brookhaven National Laboratory’s (BNL) Graphite Research Reactor, a first-of-a-kind accomplishment that is key in completion of Recovery Act (RA) work at BNL ► Made significant upgrades to the Savannah River Site’s Defense Waste Processing Facility, currently the nation’s largest radioactive waste glassification plant, that will result in a substantial increase in throughput ► Made the most single-year retrieval progress in tank farm history at the Hanford tank farms ► Safely shipped and disposed a record-breaking 1,194 transuranic waste shipments at the Waste Isolation Pilot Plant ► Operated the River Corridor Closure Project under budget and ahead of schedule, and reinvested $202 million back into the project due to savings gained through efficiency ► Completed installation of a treatment wall at West Valley that will contain and treat a decades-old waste plume from the Main Plant Process Building We understand that with our work at DOE and UK Nuclear Decommissioning Authority sites comes responsibility to our communities. Collectively, our companies have donated hundreds of thousands of dollars and spent countless hours on community causes. DOE-EM Prime Production Contractor Safety Ranking, FY 2010 Contractor/Contract TRC 1 DART 2 Savannah River Remediation (Savannah River Site Liquid Waste) 0.25 0.10 Savannah River Site Management & Operations 0.27 0.05 Washington TRU Solutions (Waste Isolation Pilot Plant) 0.28 0.00 West Valley Environmental Services (West Valley Demonstration Project) 0.34 0.17 CH2M-WG Idaho (Idaho Cleanup Project) 0.41 0.12 Washington Closure Hanford (River Corridor Closure Project) 0.47 0.07 Washington River Protection Solutions (Hanford Tank Operations) 0.77 0.44 3 DOE-EM average 0.82 0.40 East Tennessee Technology Park (Oak Ridge) 0.91 0.43 Paducah Remediation 0.93 0.84 Hanford Mission Support 0.94 0.30 Hanford Plateau Remediation 1.01 0.63 LATA/Parallax/Portsmouth 1.38 0.86 Uranium Disposition Services 1.45 0.29 Moab Uranium Mill Tailings Remedial Action Project 1.51 1.21 Advanced Mixed Waste Treatment Plant 1.80 1.08 Orange shading indicates a URS team 1 TRC: Total Recordable Case 2 3 DART: Days Away, Restricted Job or on Transfer Includes 2 reclassified DART cases 3 Savannah River Site Liquid Waste 2010 Safety Highlights ► ► ► ► ► DOE-EM’s safest contractor in FY 2010 Nearly 3 million hours without a lost workday case in 2010 23 million safe hours and counting by construction workforce 1 million safe hours by Recovery Act employees Integrated Safety Management verification, VPP Star of Excellence, and third VPP Legacy of Stars Award P erhaps 2010 will be remembered as the year that the Defense Waste Processing Facility (DWPF) received an extreme makeover. DWPF, the largest radioactive waste glassification plant in the nation, converts liquid nuclear waste into a solid glass form suitable for long-term storage and disposal. In October, DWPF produced its 3,000th canister of vitrified waste since operations began in 1996. Developed for use at DWPF by the Vitreous State Laboratory of Catholic University of America and Energy Solutions, the four bubbler devices in the melter will increase the annual average production rate of waste canisters from Recovery Act the current ► Installed bubblers at the Defense Waste level of 215 Processing Facility, significantly increasing canisters per throughput year to 325. ► Supported development and deployment of When all facility robot devices to sample tank waste enhancements ► Upgraded aging infrastructure, which are complete, will avoid delays and prepare SRS liquid the annual waste operations for integration with the production rate Salt Waste Processing Facility, now under is projected construction to reach 400 canisters. The bubblers, 6-ft-long, tube-like structures, were installed in the melter in September 2010 during a planned outage. The bubblers inject argon gas into a molten glass and waste mixture inside the melter and significantly increase the capability of the 15-year-old waste processing facility to process radioactive waste. Significant strides in salt removal Improving and deploying a technology developed by EM-30 and the Savannah River National Laboratory to accelerate salt waste processing was a major highlight during 2010. Savannah River Remediation (SRR) also processed over one million gallons of hazardous waste, mostly from underground storage tanks. Since beginning operations in 1990, the Saltstone Production Facility has processed over 7.8 million gallons and continues to safely stabilize and dispose of low-activity salt and incidental process waste at record numbers. SRR engineers are working to deploy and apply Small Column Ion Exchange (SCIX) technology as a means of speeding processing and expediting closure of the site’s 49 underground waste storage tanks. SCIX is a chemical process that removes specific constituents from salt waste, allowing the remaining waste to be processed more quickly. The Actinide Removal Process and Modular Caustic Side Solvent Extraction units also had an outstanding year of processing salt waste materials. With current technology, about 1 million gallons of salt waste can be removed from tanks each year. SCIX technology can increase that rate to 2.5 million gallons annually, The $130 million program is projected to result in $3 billion in life cycle cost savings. 4 SRS is the only site in the DOE complex that processes and permanently disposes of salt waste from waste tanks. Removing salt waste, which constitutes 90 percent of the volume of waste in SRR’s two tank farms, is a major step toward closing the site’s waste tanks. Was te M an age me n t & D is po s i ti o n Hanford Tank Operations Safety. In its first two years as the tank operations contractor at Hanford, Washington River Protection Solutions has achieved a dramatic reduction in the number of worker injuries. In 2010, WRPS employees logged more than 3 million hours worked without a workday lost to injury, setting a new tank farm safety record. W ashington River Protection Solutions (WRPS) is eliminating the risk posed by 53 million gallons of radioactive and chemical waste stored in 177 underground tanks at the Hanford Site. The waste is the lasting legacy of more than 45 years of plutonium production for nuclear weapons. A major focus is to move waste out of aging, leak-prone single-shell tanks and store it in newer, safer double-shell tanks until it can be prepared for disposal. The world’s largest vitrification plant is being built at Hanford, and WRPS is preparing for its commissioning. Work is under way to upgrade and install systems needed to feed the Waste Treatment Plant (WTP) a continual flow of waste. The waste will be turned into a stable glass so it can be safely stored and disposed. 2010 Accomplishments Recovery Act Recovery Act (RA) work is more than twothirds complete, with over $200 million of $323 million spent through December 2010 to complete 74 projects on time and under budget. These projects included important upgrades to critical operating facilities, systems, and equipment needed to successfully complete the long-term mission of tank waste retrieval and delivery. ► Made the most single-year retrieval progress in tank farm history. Workers began removing waste from two aging single-shell tanks, the 12th and 13th such tanks to undergo waste retrieval. WRPS has initiated or completed waste retrievals to the limits of technology in nine single-shell waste tanks. Through December, 430 full-time equivalent ► Safely cut a 55-inch diameter hole in the top of single-shell tank C-107, the positions were created with RA funding. largest cut ever made into an active DOE radioactive waste storage tank. The hole was cut through 15 inches of concrete and steel rebar and creates access for a new robotic arm developed and tested on the project to more effectively remove radioactive and chemical waste. ► Improved integration between WRPS and WTP by putting in place systems necessary to help transition WTP from design, construction, and commissioning to operations. Creating a barrier between the waste and the water table In September 2010, WRPS finished placing a 4-inch-thick layer of high-density asphalt over one of Hanford’s single-shell tank farms, marking the completion of a Recovery Actfunded interim barrier that provides additional environmental protection. For the next three months, nearly 20 inches of snow, ice, and rain soaked the area. The 80,500-square-foot barrier kept more than 215,000 gallons of runoff from seeping into the soil and pushing contaminants from leak-prone tanks down towards the water table. Precipitation flows to an evaporation basin just outside the tank farm. The basin is lined with material to prevent it from leaking and is covered with soil, native plants and grasses to help drink up the moisture. Was te Managemen t & Dispo s itio n 5 Hanford Waste Treatment & Immobilization Plant H anford’s Waste Treatment and Immobilization Plant (WTP) project is now 58 percent complete. Led by our partner, Bechtel, the workforce of about 3,000 includes nearly 300 highly skilled URS professionals. This group is responsible for vitrification research and technology, process development, startup, commissioning, permitting, and operations planning. By the Numbers ► $12.2 billion project ► 257,000 tons of concrete ► 1,000,000 linear feet of piping ► 4.28 million feet of electrical cable ► 35,000 tons of structural steel WTP is the largest nuclear construction project in the United States today. When construction is complete in 2016, it will be the world’s largest radiochemical vitrification plant. It will treat 53 million gallons of radioactive waste now stored in Hanford’s 177 waste tanks. The waste was created during World War II and Cold War production of plutonium for the nation’s nuclear weapons program. URS has the unique distinction of being the sole company involved with the United States’ only three vitrification facilities -- at West Valley, SRS, and now at Hanford. 2010 Significant Accomplishments ► Advanced the total project to 58 percent complete with engineering at 83 percent, procurement 57 percent, and construction at 54 percent ► Earned high marks from large teams of outside experts who looked at every facet of WTP during extensive Construction Project Reviews in May and November ► Adeptly handled project commitments and technical challenges while also responding to high-profile, often concurrent, external reviews and technical requests from the Defense Nuclear Facilities Safety Board, Office of Health, Safety and Security, Environmental Management Advisory Board, and others ► Closed the last and final of 28 technical issues identified by an external review team in 2005 ► Moved forward on two major technical approaches that will enhance WTP’s cost and schedule: sequential Operational Readiness Reviews and integrating the missions of WTP and Hanford’s tank operations ► Supported construction site employees as they earned VPP Star recognition in July, the culmination of a two-year effort Superb safety performance The scope of WTP’s design and construction is roughly equivalent to the building and permitting of two commercial nuclear power plants at the same time. The WTP campus covers about 65 acres, although the entire construction site is much larger. It includes four major nuclear facilities for pretreatment, low-activity and high-activity waste vitrification, and an analytical laboratory. These buildings, plus 25 more, are under construction. 6 By the end of 2010, the 290 URS employees on the WTP project had achieved more than 556,000 safe working hours, bringing their total to more than 2.8 million hours accumulated over nearly six years. The URS workforce at WTP has not had a lost workday case since Jan. 17, 2005. Employees have earned three President’s Awards for safety and hope to earn another later this spring for reaching their fourth mark of 1 million safe working hours. Was te M an age me n t & D is po s i ti o n Waste Isolation Pilot Plant U RS subsidiary Washington TRU Solutions (WTS) manages and operates the Waste Isolation Pilot Plant (WIPP) in southeast New Mexico for the U.S. Department of Energy. WIPP is the nation’s first deep-geologic repository for the safe disposal of long-lived transuranic (TRU) waste left from nuclear defense programs. Making room for TRU waste. URS mining crews at WIPP carve out waste disposal rooms, 2,150 feet underground in an ancient salt formation. WTS received the 2010 Safety and Health Innovator of the Year Award from the New Mexico Mining Association and Bureau of Mine Safety. In 2010, URS employees handled a record-breaking 1,194 TRU waste shipments, which included direct shipments to WIPP and intersite shipments. WIPP received 36 shipments in a single week, the highest number of shipments in the facility’s 11- year operating history. Environment Significant WTS permitting efforts paid off in 2010. The WIPP received full authorization to continue operations from its two prime regulators. The U.S. Environmental Protection Agency recertified that WIPP’s underground repository would continue to safely contain TRU waste for the project’s 10,000-year regulatory period. WTS permit experts worked tirelessly to renew WIPP’s 10-year Hazardous Waste Facility Permit, based on the facility’s 11-year record of safe, compliant operations. WTS received DOE’s “Best in Class” award for fuel conservation efforts in support of a construction project at the WIPP site in 2010. Banner year in safety ► WTS ranked as the third safest contractor in the DOE-EM complex in FY 2010. ► Washington TRU Solutions was presented the 2010 Safety and Health Innovator of the Year award from the New Mexico Mining Association and New Mexico Bureau of Mine Safety. ► URS mine rescue teams finished 5th and 6th in the nation in First Aid competition and 2nd in the field competition from a field of 38 teams at the 2010 National Mine Rescue Competition in Reno, Nev. URS’ Joe Baca was inducted into the National Mine Rescue Hall of Fame. ► WTS received DOE Voluntary Protection Program “Star” Status for the 16th consecutive year. WTS employees accrued 1.4 million safe work hours while safely disposing of 13,718 containers of radioactive waste. 2010 1999-2010 7,919 72,422 Cubic meters of TRU waste disposed At year end 2010, approximately 64 percent of WIPP’s allotted $150 million had been spent and 591 jobs had been created or retained. Waste cleanup activities at three small sites were completed, bringing the total number of sites cleaned up to 17. 13,718 139,545 TRU waste containers disposed 1,194 9,207 Total TRU waste shipments, including 66 intersite shipments 985 8,761 Contact-handled TRU waste shipments received A $4.4 million reconstruction project for the South Access Road and a $2.2 million storm water evaporation pond construction project were completed. 143 446 Remote-handled TRU waste shipments received 1.4M 11M Loaded miles traveled 5% 65% Lifecycle TRU waste inventory disposed Recovery Act Was te Managemen t & Dispo s itio n WIPP Key Metrics 7 Hanford River Corridor Closure Project Safety. In August 2010, Washington Closure Hanford was awarded the DOE Voluntary Protection Program (VPP) Star of Excellence, DOE’s highest safety award. The award recognizes outstanding mentoring, innovation, and continuous improvement in the field of safety with rates at least 75 percent below the industry average. S ince 2005, Washington Closure Hanford has managed the River Corridor Closure Project at the U.S. Department of Energy’s (DOE) Hanford Site in Washington state. The $2.4 billion, 10-year project is responsible for protecting the Columbia River by cleaning up defense wastes from nuclear reactors and support facilities from World War II and the Cold War, dating back to the early l940s. The mission is challenging and hazardous and involves cleaning up some of the nation’s most contaminated and radioactive defense legacy waste. The project, currently DOE’s largest environmental cleanup closure project, is 60 percent complete. When finished, the River Corridor Closure Project will have successfully reduced the Hanford site active footprint by 220 square miles, a major cornerstone of DOE’s 2015 Vision. 2010 Accomplishments Significant accomplishments in 2010 included: ► Remediated 149 hazardous waste sites and burial grounds from a projected total of 386; decontaminated and removed 142 facilities out of a projected total of 490; and transported 5 million tons of contaminated debris away from the Columbia River for disposal at the Environmental Restoration Disposal Facility, the largest in the DOE complex ► Operated under budget, ahead or on schedule, and reinvested $202 million back into the project due to savings gained through efficiency ► Met all regulatory milestones (28) on or ahead of schedule ► Maintained an excellent safety record Recovery Act WCH has spent $133.5 million of its $233.6 million in allocated Recovery Act funds, creating or retaining 106 jobs. Recovery Act scope at the Hanford River Corridor includes: ► Characterization of the 618-10 burial ground, one of Hanford’s most complex waste sites, to determine cleanup methods and protective measures An explosive accomplishment After months of preparation, WCH workers used explosive demolition to destroy three structures in the 300 Area, known as the center for Hanford’s radiological research and nuclear fuel fabrication. These facilities were located along the Columbia River Corridor just a mile north of Richland, Wash. Safety in demolishing the concrete facilities was the deciding factor in selecting explosives over conventional demolition. The tallest structure was the three-story 337 building. 8 ► Expansion and operational enhancements at the Environmental Restoration Disposal Facility by constructing two new super cells, which will increase the disposal facility’s capacity by 50 percent and help accelerate Hanford cleanup ► Cleanup of 19 buried waste sites in the 100-F Area, one of Hanford’s nine production reactor sites, and determine if an additional 67 sites discovered along the Columbia River require cleanup ► Cleanup of six waste sites discovered in a 28-mile section in the northwestern part of the Hanford Site C le an up & C lo s ure S e r v i c e s Idaho Cleanup Project Safety. CWI reduced recordable injuries by 20 percent at the end of calendar year 2010 and achieved one million hours worked without a recordable injury on Aug. 12, 2010. CWI received the “Voluntary Protection Program STAR of Excellence” and the VPP Legacy of Stars -- the highest safety award the DOE presents to a VPP site. T he Idaho Cleanup Project (ICP), operated by the integrated CH2M HILL/URS team of CH2M-WG Idaho (CWI), conducts environmental cleanup work at the Idaho National Laboratory site. The seven-year, $2.9 billion project focuses on reducing risks to workers, the public, and the environment, and protecting the Snake River Plain Aquifer. 2010 Accomplishments Recovery Act ICP is making significant progress on Recovery Act scope. Thus far, $268.3 million of $422.8 million dollars have been spent, and 692 positions have been created or retained. Work progress includes: ► Retrieval of 0.97 acres of buried waste completed ► 464,652 of 812,815 square feet of footprint reduced ► 69 of 89 facilities demolished ► 149 of 160 remote-handled TRU containers received ► 105 of 150 remote-handled TRU containers processed ► Disposition of 47.41 cubic meters of low-level waste and mixed low-level waste from the Advanced Mixed Waste Treatment Plant completed ► C ompleted wet to dry transfer of 3,186 fuel units ahead of schedule, shipped three of 15 Navy large cell cask shipments, and prepped 144 of 714 Navy Fuel Handling Units for shipment ► 92 percent complete with physical construction, 60 of 73 systems complete at the Integrated Waste Treatment Unit facility, which will treat 900,000 gallons of sodium bearing liquid waste stored in three underground storage tanks ► Completed over 200 remote-handled transuranic (TRU) waste shipments and shipped 3,637 of 5,108 cubic meters of contact-handled TRU to WIPP on schedule ► Completed waste exhumation of 2.0 of 2.55 acres ahead of schedule and on budget, exhumed 45,800 cubic yards of waste zone materials, packaged 21,027 drums of targeted waste ► Demolished 200 of 220 facilities and structures. The 20 remaining structures are expected to be demolished by March 2012. Key milestone met In 2010, CWI reached a key cleanup milestone three weeks ahead of schedule by completing the transfer of nearly 6.6 metric tons of spent nuclear fuel from wet to dry storage. While pools serve as an effective shield for radiation, dry storage prevents the fuel from degrading as quickly and is recognized as the preferred method of safely storing spent nuclear fuel long term. The fuel transfer is a key milestone in the 1995 Settlement Agreement between the Navy, the DOE, and the State of Idaho. C leanup & Closur e Ser vice s 9 West Valley Demonstration Project 2 010 was a year of significant accomplishments at the West Valley Demonstration Project (WVDP). Tremendous progress was made at the radioactive waste management and environmental cleanup project, both in terms of physical deactivation and decontamination as well as programmatic decisions that will define cleanup at the site for the next 7-10 years. Funding provided under the American Recovery and Reinvestment Act (ARRA) was put to good use in furthering these cleanup goals. Facility Deactivation and Decontamination In the Main Plant Process Building (MPPB), West Valley Environmental Services (WVES) deployed a technology called Nitrocision® using this new remote application to decontaminate 3,200 square feet in two of WVDP’s most radiologically contaminated rooms. WVES also remotely removed 3,000 feet of piping and all three large tanks from another extremely contaminated cell and removed 2,893 linear feet of asbestos-containing materials from the MPPB. Waste Processing 2010 Safety Highlights ► Achieved 3.5 million consecutive hours (3.8 years) without a lost-time work injury ► Named URS Safe Project of the Year for 2009 ► Received the URS President’s Award for Safety in recognition of achieving 1 million hours and 1 year without a lost-time work injury -- the third time WVES received the President’s Award ► Received DOE-VPP Star recertification Significant efforts to improve radioactive waste processing productivity rates were successful. Existing facilities were upgraded and new equipment such as plasma-cutting technology was procured and placed in service. ISOCS™ (In Situ Object Counting Scan) technology was used to isolate and remove transuranic (TRU) components within a waste box, which has led to a reduction in the volume of TRU waste by 85 percent. By the end of 2010, WVES had processed 83 percent of legacy low-level waste, 83 percent of contact-handled TRU waste, and 70 percent of remote-handled TRU waste. Underground High-Level Waste Tank Management This project was initiated with base funds and completed with ARRA funds. By the end of December, WVES replaced the aging underground ventilation piping with new stainless steel piping and installed a system to dry the underground waste tanks and the vaults in which they are contained. Recovery Act WVES has spent approximately 78 percent of its nearly $63 million in Recovery Act funds. Thus far, 102 jobs have been created or retained due to Recovery Act work at West Valley. As of Dec. 31, 2010, WVES employees and subcontractors have worked 355,099 safe hours on ARRA-related projects. Mitigating contaminated groundwater During fuel reprocessing operations in the 70s, a leak occurred at the Main Plant, creating a plume of contaminated groundwater that has slowly been migrating. The primary constituent of the plume is radioactive strontium-90. Using base funds, WVES analyzed and characterized the plume and provided DOE with a recommendation. With funding made available under ARRA, WVES installed a permeable treatment wall (PTW) to capture the Sr-90. The PTW is approximately 860 feet long, three feet wide, and up to 30 feet deep. A piece of equipment called a one-pass trencher simultaneously excavated the soil from the trench and placed more than 2,000 tons of sorbent material, called Zeolite, into the trench. Installation of the trench and 60 monitoring wells was completed by the end of 2010. 10 C le an up & C lo s ure S e r v i c e s URS Safety Management Solutions I n 2010, URS Safety Management Solutions (SMS) continued its drive to provide technical support for GMOS’ overall success. Our complement of over 800 professionals applied their talent and energy to exceed our customers’ requirements. In 2010, we performed more high-hazard work than ever before. SMS continued to deliver value to our customers at a reasonable cost, utilize core capabiliti es to assist GMOS M&Os, and assist URS efforts in adjacent markets to leverage SMS capabilities and tools. The Waste Transportation Project received the President’s Award for Safety in 2010 for reaching six years without a Days Away, Restricted, or Transferred injury and almost six million miles driven without a DOT violation. And the Consulting Services organization hit a significant milestone by reaching eight million hours since its last lost workday case. Safety. SMS’s Waste Transportation Project received the President’s Award for Safety in 2010 for reaching six years without a lost time injury and almost six million miles driven without a Department of Transportation violation. Consulting Services employees reached eight million hours without a lost workday case. The Potable Water Upgrade Project at Oak Ridge’s Y-12 was completed this year, exceeding customer expectations by meeting very aggressive milestones and significantly improving the Y-12 infrastructure. The Pit Disassembly and Conversion (PDC) engineering team achieved an outstanding performance rating from DOE-NNSA while completing an accelerated Conceptual Design that combines two previous projects in the Savannah River Site’s K Reactor building. SMS is involved in all Uranium Processing Facility (UPF) engineering projects and in 2010 completed the UPF preliminary design, while receiving good to outstanding performance ratings. URS SMS provided on-going support to all four National Energy Technology Laboratory contracts, assisting in the development of nonnuclear capabilities while exceeding our client’s expectations. At Fermilab, our engineers developed the first full quality assurance program for the lab, receiving endorsement from the DOE site director. Recovery Act In 2010 SMS obtained a key role in two new Recovery Act projects, both at the Oak Ridge National Laboratory. Miscellaneous Facilities D&D ► Demolition of 34 facilities covering 115,902 facilities at the ORNL Central Campus ► Removing material and miscellaneous legacy materials from six facilities and six Radiological Test Generators in the ORNL Central Campus Hot Cells D&D ► Complete deactivation, demolition, and disposition of one building’s hot cells, once used to handle highly radioactive materials ► Remove and disposition legacy material from two other buildings New work SMS won several major contracts in 2010, including: ► Engineering, Procurement and Construction Management for the Spent Fuel URS SMS delivered its nuclear safety and risk Handling Facility in Idaho management technical support to all GMOS ► National Institute of Occupational Safety and Health technical support affiliates in 2010. At Sellafield, LANL, SRR, ► Sandia National Laboratory Safety Basis integration LLNL, TOC, WIPP, WCH, West Valley, SPRU, WTP, ► Nuclear Regulatory Commission Research Test Reactor license application and CWI, SMS experts helped affiliates meet reviews commitments and customer expectations. Additionally, SMS consultants satisfied clients such as Sandia, ETTP, SRNS, USEC, Chalk River, NTS, Y-12, and ORNL, while gaining intelligence to support future GMOS business prospects. And, a team of URS SMS personnel led a successful, first-of-a-king effort to decommission the Brookhaven National Laboratory’s Graphite Research Reactor and place the High Flux Beam Reactor in long-term layup. S afe ty, C onsultin g & Engin e e rin g 11 Yucca Mountain Repository T he URS-led USA Repository Services (USA RS) continued as the management and operating contractor for the Yucca Mountain Repository, supporting the Department of Energy’s (DOE) Office of Civilian Radioactive Waste Management (OCRWM) on the deep geologic repository program and most recently supporting its shutdown as directed by DOE. USA RS supported License Application (LA) review by the U.S. Nuclear Regulatory Commission (NRC) staff. The last eight responses to NRC Requests for Additional Information (RAIs) were submitted to the NRC in January 2010, supporting completion of NRC’s Safety Evaluation Report (SER). In all, 303 RAIs required USA RS response. USA RS worked with DOE, legal counsel, and national laboratory scientists to prepare 13 integrated plans for defending the LA and SER in public hearings. Hearings were slated to begin in late 2010 but are on hold, pending the outcome of decisions by the NRC Commissioners and the US Court of Appeals, D.C. Circuit. As the RAI effort ramped down at the end of 2010, engineering documents and drawings were updated in a new “Reachback Center” at URS’ Nuclear Center in Fort Mill, SC. The Reachback Center featured direct computer ties to the Las Vegas computer network. In addition, the project began transition of engineering automation to the SmartPlant® suite -- increasingly the industry standard for design and construction of complex industrial facilities. Project Shutdown Safety and quality. USA RS had zero recordable injuries, first aid cases, or security infractions in 2010, which brought the record to 350,000 safe hours before the end of the Project. During the last four months of Project efforts, USA RS earned a Quality Performance Index of 100%, successfully completing the climb to the highest level of quality performance just 10 months after start of the contract. Key events in 2010 ► February: DOE announces that “Yucca Mountain is no longer an option,” and the License Application will be withdrawn. President’s Budget zeros the OCRWM budget. ► Spring: Four varied parties petition the US Court of Appeals to reverse DOE’s decision to terminate the project. ► July: NRC’s Atomic Safety and Licensing Board finds that withdrawing the License Application would violate the Nuclear Waste Policy Act. NRC Commissioners move toward undertaking a review of the Board’s order. ► Fall: Congress maintains funding for OCRWM through continuing resolutions. ► December: Court of Appeals established expedited schedule to reach a decision on petitions to reverse DOE’s decision to end OCRWM’s Project. Oral arguments are to be held in March 2011. At the end of May 2010, DOE directed USA RS to shut down the project and close offices in Las Vegas. USA RS created electronic archives; shut down computer systems; and transferred all records, data, and property to other parties. All but essential USA RS employees were terminated from USA RS employment, subcontracts were closed out, and offices were vacated. The entire shutdown effort was completed ahead of schedule and under budget. URS corporate staffing personnel and project management teams across the U.S. recognized the high level of expertise of USA RS personnel and worked in a deliberate and timely manner to extend offers of alternate employment to a large majority of USA RS employees. USA RS “alumni” are now working at other URS projects stretching from England to the Pacific Coast of the US. At the end of 2010, USA RS had just 10 employees, most working in Aiken, SC, closing out subcontracts and administering benefits to retirees and displaced project workers. Ready for Future Decisions USA RS recognizes that national disposal policies for spent nuclear fuel and high-level waste are being reviewed in several federal government venues. With decisions anticipated in 2011, URS, through its subsidiary USA Repository Services, is prepared to be the implementer of choice in the chosen path forward for the nation’s high-level waste program. 12 S afe ty, C o n s ultin g & E n gi n e e r i n g National Energy Technology Laboratory T he National Energy Technology Laboratory (NETL) is the lead research and development laboratory under the DOE Office of Fossil Energy (FE). Research and Engineering Services (RES), a team led by URS, provides technical, operational, and administrative support to NETL’s Office of Research and Development. Activities are focused on accelerating the development of energy-related technologies to meet the nation’s needs for reliable, clean, and efficient energy systems with a minimal environmental footprint. Safety. URS-RES had zero recordable injuries and zero days away or restricted. URS also implemented and funded a “Partner-Assess-Improve-Sustain” process for evaluating and making recommendations for improving SARS and engineering processes at all of the NETL sites. URS also provides primary support in the following areas: ► P roject execution and integration. URS provides scientific and engineering, project management, and information/data management expertise appropriate for the range of projects in each of NETL’s program areas. ► S ite operations services. URS provides comprehensive life-cycle asset, engineering and technical management, property management, ES&H maintenance and infrastructure services, and consultation services for NETL. Recent highlights include the startup of the new Compressed Air System, which is vital to achieve NETL’s mission. ► E nergy Sector planning and analysis. The objective of this contract is to provide Energy Sector planning and analysis services for NETL, including expert services that will complement and support the efforts of federal staff in strategic energy sector analysis and planning, engineering analysis using state of the art simulation and modeling tools, R&D benefit analyses, life-cycle analysis, natural resource development impact assessment (e.g., water resources, and energy infrastructure analyses). Recovery Act URS supported NETL in obtaining $60 million in ARRA funding for the research and development focused on carbon capture and storage technologies, including new facilities. The money is planned for the installation of the SimulationBased Engineering User Center, the Carbon Capture Storage Initiative, the Integrated Carbon Management Simulation and Testing Facility, and the National Risk Assessment Partnership. NETL Regional University Alliance URS played a strategic role in the formation and implementation of the NETL Regional University Alliance (NETL RUA) and strongly supports its mission of collaborating fossil energy expertise and research efforts between NETL and five nationally recognized regional universities: Carnegie Mellon University, Penn State, the University of Pittsburgh, Virginia Tech, and West Virginia University. In support of NETL, URS is contractually managing and overseeing a large body of research work performed by these five major universities for NETL. The collaborative efforts of the Alliance produce greater results than what could be achieved by any of the individual organizations acting alone. Extreme Drilling Laboratory URS also played a key role in the startup of the Extreme Drilling Laboratory, Ultradeep Drilling Simulator (UDS) in Morgantown, WV. The Extreme Drilling Laboratory is an international signature research facility for NETL. There are at least two other high-pressure drilling simulators in the United States, but neither are designed for the range of pressures and temperatures of the NETL UDS. None in the world are designed with the ability for visible light and X-ray videography in both clear and opaque drilling fluids. Laborator y Ser vices 13 DOE’s Nuclear Laboratories A s a member of the operational teams at the Idaho, Lawrence Livermore, and Los Alamos national laboratories, URS has a strong foundation in laboratory services. All three labs had strong performances in 2010, helping position URS for an increased presence in laboratory operations. Idaho National Laboratory The Idaho National Laboratory, where URS is a principal teaming subcontractor, achieved significant success during 2010 in carrying out its DOE-assigned mission to “ensure the nation’s energy security with safe, competitive, and sustainable energy systems.” Significant accomplishments include: ► In partnership with the leading Washington, D.C. think tank Third Way, the lab staged the New Millennium Nuclear Energy Summit, a bipartisan forum on the future of nuclear energy. ► One of INL’s newest assets for advancing nuclear and other energy systems research was fully brought on line in 2010. The new 3-D computer-assisted virtual environment — or CAVE — allows researchers to literally walk into their data and examine it. Lawrence Livermore National Laboratory URS is a key member of Lawrence Livermore National Security, LLC, which operates the Lawrence Livermore National Laboratory (LLNL) to meet its mission to “ensure the safety and security of the nation through applied science and technology in the key areas of nuclear security, international and domestic security, and energy and environmental security.” Significant URS accomplishments in 2010 included: ► The 15 Megawatt Terascale Simulation Facility Project Power Supply project was completed on schedule and under budget. This project helps extend LLNL’s leadership in high-performance computing and scientific simulation by allowing co-location of multiple, world-class computers. ► The B419 building, initially built in the 1940s for airplane maintenance and later used as a hazardous waste treatment facility, was demolished under the Recovery Act. The demolition was completed on schedule and under budget with no injuries or contamination issues. Los Alamos National Laboratory URS is a member of Los Alamos National Security, LLC, a team led by the University of California and Bechtel. It was formed in 2005 to manage the NNSA management and operations contract for Los Alamos National Laboratory (LANL). In 2010, significant success was achieved in implementation of Conduct of Operations, Conduct of Maintenance, and Conduct of Engineering with customer acceptance of formal declarations of implementation. Specific accomplishments include: ► ► ► ► ► Documented Safety Analyses were completed to close out legacy deficiencies. The plutonium facility safely containerized and disposed of significant quantities of legacy weapons grade plutonium materials. The Radiological Liquid Waste facility was restarted after an extended shutdown and disposition of legacy inventories. Various facilities resumed operations and conducted critical tests for national security missions. Transuranic waste remediation and disposition to WIPP were the highest ever, due to improved operations, and new glovebox operations, which were initiated and expanded. ► The excavation of the World War II disposal area is more than 50 percent complete, and most of the buildings in the original plutonium area have been removed. 14 L abo rato r y S e r v i c e s Sellafield S ellafield Ltd, under the management of URS-led Nuclear Management Partners (NMP), has made real progress in 2010 toward its mission of high hazard risk reduction and safe commercial operations, on behalf of the UK Nuclear Decommissioning Authority (NDA). Safety. Sellafield workers reached 6 million safe hours and also launched a Peer to Peer safety observation program, providing each other with feedback on how we work. More than 10,600 observations have been conducted by almost 4,000 observers in the first four months of its launch. There have been more one-toone discussions on safety and standards since the launch of Peer to Peer than in any 12 months over the previous five years. Together, Sellafield Ltd, NMP, and the NDA are using their combined global excellence to help tackle some of the UK’s most important decommissioning challenges. 2010 Accomplishments ► Work to decommission Sellafield’s Primary Separation Plant took a major step forward with the removal of the entire redundant inventory in the top section of one of its process cells. ► Sellafield Ltd safely completed one of the largest asbestos removal projects in Europe in 2010. In all, 2,300 tons of asbestos cladding were removed from the station’s heat exchangers, turbine halls, and associated plant at a cost of £26 million. ► High hazard risk reduction of the historic Pile Fuel Storage Pond reached two significant milestones in 2010. Six of the facility’s 12 decanning bays were desludged and 16 fuel skips were retrieved from the pond, creating additional room on the pond floor to enable further desludging operations to take place. ► The decommissioning of another of Sellafield’s Legacy Pond and Silo facilities took a step forward, with the successful transfer of 14,800 liters of historic radioactive liquid waste from the 50-year-old Magnox Swarf Storage Silo for safe treatment. ► The first major project to be completed by Sellafield Ltd under NMP, the Sellafield Product and Residue Store, was delivered ahead of schedule and under budget. The store incorporates some of the most advanced nuclear security features ever used in a building of its type and will provide safe and secure storage of nuclear materials on the Sellafield site. NMP -- making Sellafield safer, cleaner, more productive, more cost effective, and a better neighbor each and every day. U n ited K i ngdom Europe’s largest nuclear project Construction of Evaporator D is the largest nuclear project in Europe and will provide additional capacity to support the Sellafield site’s existing evaporators, which play a pivotal role in the delivery of reprocessing, historic clean up and high hazard reduction. Large scale modules are being fabricated off site and transported to Sellafield by sea, to be installed into the building’s concrete shell using a gantry system. This is the first time in the history of the Sellafield site that large scale modular construction will be used. The project’s main construction phase continued in 2010, with civil construction and mechanical, electrical, and instrumentation work. Modules are being constructed off site, and delivery logistics and infrastructure are being planned, implemented, and installed. In 2011: ► The main Evaporator D building will reach the necessary height to install the gantry system. ► The gantry, which will be used to lift the completed modules into the facility, will be installed. ► The first modules will be delivered to Sellafield via barge and will be installed, followed by other modules throughout the year. 15 Low Level Waste Repository The new Vault 9 will serve LLWR’s needs for the next 10-15 years. Vault 8 at capacity L ess than halfway through its first five-year contract with the Nuclear Decommissioning Authority (NDA), LLW Repository Ltd (LLWR) has made good progress toward its mission to integrate the Low Level Waste (LLW) program throughout the United Kingdom (UK). 2010 accomplishments ► Integrating LLW solutions in waste treatment, packaging and disposal. LLWR is a leader on the delivery of the UK Nuclear Industry LLW Strategy. Contracts are being executed to provide waste services for nuclear and non-nuclear industries throughout the UK. ► Delivery of Vault 9. On July 29, LLWR marked the opening of Vault 9, a new vault that has a capacity of 110,000 cubic meters and will serve LLWR’s needs for 10-15 years. ► Delivery of the Environmental Safety Case (ESC). The ESC is on course for delivery to the UK Environment Agency by May 1, 2011. The past two years has witnessed the submission of high quality interim deliverables on time to the UK Environment Agency. ► Right-sizing the organization for implementation of UK LLW Strategy. Strengthening the organizational structure of the LLW Repository Ltd was vital to successful implementation of our Life Time Plan. NDA Launches Final UK LLW Strategy The NDA issued the UK Strategy for the Management of Solid Low Level Radioactive Waste from the Nuclear Industry in August 2010. In partnership with the NDA, the LLWR National Strategy Team developed numerous strategic technical documents, option studies and reviews, and plans to inform the emerging LLW strategy and underpin the potential benefits of waste management options to the NDA for strategy development and implementation. LLW Repository Ltd is in an excellent position to address challenges and determine appropriate and cost-effective solutions. Legacy projects, such as decommissioning storage magazines containing plutonium-contaminated materials and remediating past waste disposal trench covers, will require substantial project planning and implementation during the next phases of our contract. Elite in safety LLW Repository Ltd was proud to receive the RoSPA Award in 2010, which reflects five consecutive years of Gold Awards for safety excellence. Our mission for integrating the LLW Program throughout the NDA estate will also require unprecedented teamwork with other Site License Companies. 16 U n ite d K i n g do m The Talent Pipeline Hanford Tank Hanford River Operations Corridor Hanford Waste Treatment & Immobilization Plant National Energy Technology Laboratory Idaho Cleanup West Valley Demonstration Project Project Separations Process Research Unit National Energy Idaho National Laboratory Technology Laboratory Livermore Lawrence National Laboratory National Energy Technology Laboratory Yucca Mountain Repository Oak Ridge Los Alamos National Laboratory Savannah River Site Liquid Waste URS Safety Management Solutions Waste Isolation Pilot Plant ► Sellafield Sites ► Low-Level Waste Repository A s our company continues to grow – through new work and added scope of current projects – URS is ensuring that we have the right resources to execute our work with seamless performance excellence. The Talent Solution program was created to identify, evaluate, and track the development of the URS talent pool to put the right people in the right jobs at the right time, to do the best job possible for our customers. Participants in the Talent Solution are individuals who are either currently in key/essential positions or who have the potential to move into key/essential positions across URS or into positions of higher responsibility within their current project. We also continually recruit the best and brightest young talent from top college and universities across the nation, to ensure our pipeline remains filled. Program Elements Our program is driven by succession planning and placement process. Early identification of individuals who could, with some development, move into various key/essential positions is critical to sustaining our critical mass of talent. All participants complete a skills and career interest survey to identify technical skills, competencies, and career interest and readiness. The data is used for development discussions, career placement and business development endeavors. Development Courses We offer various development courses to Talent Solution participants. Many of these have senior management engagement and in some cases are taught by senior staff. Talent D eve lop ment Communication We use a seamless knowledge management system designed to ensure all our employees are linked. A common web site centralizes and synergizes information to enhance collaboration. We are thus able to place the best talent in the company where it will be most effective and efficient. Cascade URS is made up of various diverse projects and sites. Talent management works with each project to develop and establish customized talent programs that meet the needs of the project and will serve as a feeder into the Talent Solution pool. 17 Giving Back to Our Communities U RS companies and employees responded to continued economic difficulties with their usual community spirit in 2010, donating millions of dollars and giving of their personal time, talent, and energy to benefit their communities. The URS GMOS corporate office set the pace by participating in such events as Dollars for Scholars and the Children’s Place annual Christmas shopping spree. GMOS also placed 13 summer interns at URS sites across the complex, provided $25,000 to the City of Aiken Festival Center, and presided at the National Environmental Justice Conference in Washington, D.C. The Morgantown URS site was selected as one of the elite pacesetter organizations to set the tone for this year’s United Way campaign. Between the Morgantown and Pittsburgh sites, URS raised $16,100, an office record, helping the United Way of Monongalia and Preston Counties exceed their goal of $1,444,000. One agency supported through the United Way is the Shack Neighborhood House, which offers before and after school care, Happy School, and Teen Time for children; skating, basketball, swimming, and literacy classes; and summer programs for all ages. URS Safety Management Solutions (SMS) employees participated in the 2010 United Way Campaign. Donations were raised through employee pledges as well as fundraising activities. SMS raised $66,261 in employee pledges alone. Savannah River Remediation (SRR) employees continued to respond to opportunities to reach out in 2010 through our Habitat House work and the United Way days set aside to perform jobs at area agencies. SRR has given away hundreds of thousands of dollars for education, health and welfare, civic and social work, and cultural performances and programs. The company also funded flu shots for low income senior citizens in Allendale and Barnwell counties; rang Red Kettle bells for the Salvation Army; and provided economic development incentive and seed money to area groups whose mission is to bring more jobs to our area. CH2M-WG Idaho and its employees sponsored or supported 82 events/organizations and supported another 15-20 events/ organizations with time or supplies; raised nearly $176,000 for the United Ways of Bonneville County and Southeastern Idaho with employee support and corporate funds; was a major sponsor of the Diamonds in the Rough Charity Golf Tournament, helping to raise 18 over $16,000 for the organization that pairs “Big Brothers” and “Big Sisters” with disadvantaged children; and donated more than $4,500 in corporate funds along with employee contributions – both time and money -- to Christmas for Families, which helps families with food, household items and gifts during the holiday season. Washington Closure Hanford (WCH) is a sponsor for the Tri-Cities Second Harvest food drive. For the 2010 drive, WCH employees raised over $12,000 along with 700 pounds of food donations. Washington River Protection Solutions (WRPS) provided a jump start for a local educational organization in 2010 by donating $50,000 to the Dream Builder’s Educational Foundation, a nonprofit group encompassing 23 Washington school districts. The donation is one of several handed out by WRPS in 2010. In August, the company pledged $450,000 to Washington State University’s Tri-Cities campus to help build and maintain science and engineering programs. URS employees on Hanford’s Waste Treatment Plant project (WTP) rallied with others in support of the annual Family Food Drive held in April. The equivalent of more than 107 tons of food was collected for some 27 food banks and missions. Also joining in this community effort were employees of other URS affiliates at Hanford, as well as Bechtel National employees on the WTP project. Washington TRU Solutions (WTS) received the Carlsbad Chamber of Commerce Business of the Year award for 2010. WTS also celebrated eight years of Blanket Brigade sponsorship, in which WTS employees hand out blankets to Carlsbad visitors for a nighttime river boat ride down the Pecos River. Proceeds benefit the Carlsbad Chamber of Commerce. The company and its employees were also generous contributors to the local United Way Campaign, and 140 WTS employees participated in the annual local “Relay for Life” event to fight cancer. West Valley Environmental Services (WVES) actively participated in the West Valley and Springville Chambers of Commerce, with a WVES employee serving as the Springville Chamber vice president and working on development of Chamber’s four-year strategic plan. United Way support remained strong, with more than $55,000 in donations. Employees collected 77,000 pounds of food for eight area food pantries and URS made a $10,000 corporate donation to a local food bank. C o mmun ity S upp o r t Supporting Our Customers in 2011 S uccess in 2011 means continuing to deliver for our customers while reducing risk to our employees, our communities, and the environment. Although our 2010 safety records were outstanding, we must continue our improvement towards a goal of zero days away and recordable injuries. Among our anticipated accomplishments in 2011 are: Reducing Lifecycle Costs At Savannah River, significant progress will be made toward tank closure and achieving $3 billion in lifecycle cost savings. The following will be completed in 2011: ► ► ► ► ► ► Bulk waste in three high level waste tanks Final residual waste sampling in two tanks Heel removal in one tank Annulus waste sampling and cleaning in one tank Grout addition preparations for two tanks Incorporate scope changes to maintain Fluidized Bed Steam Reformer fabrication and module delivery schedule in Tank 48 ► Finalize detailed Small Column Ion Exchange equipment and installation design and initiate procurements of all major equipment At Hanford, we will make major strides toward achieving the Department’s goal of $16 billion in lifecycle cost savings, including: ► Deploy the revolutionary new technology known as Mobile Arm Retrieval, which will speed the removal of waste from underground tanks and reduce lifecycle costs ► All tank waste treatment systems constructed and operating by 2019 ► Advance the Waste Treatment Plant project to more than 60 percent completion, including another successful Construction Project Review ► Increase the disposal rates at the Environmental Restoration Disposal Facility (ERDF) by 500,000 tons to a record 2.3 million tons of waste ► Complete construction of super cells 9 and 10 at ERDF as a part of the $100 million facility expansion funded by the Recovery Act Innovation Our position as a member of the operating teams at three national laboratories and lead at the National Energy Technology Laboratory (NETL) puts us into an excellent position to drive and lead innovative change for the Department. Among our anticipated 2011 accomplishments: Looki ng A head to 201 1 ► Start up a chemical loop reactor for the Recovery Act-funded Industrial Carbon Management Initiative and formalization of the NETL Regional Commercialization Initiative TRU Waste Disposition At the Waste Isolation Pilot Plant, we will: ► Target cleanup of five smallquantity TRU waste sites to reduce the DOE Environmental Management (EM) footprint ► Through use of Recovery Act funds, accelerate waste characterization at all DOE sites to reduce TRU waste inventories, to meet the EM goal of cleanup of 90 percent of legacy TRU waste by 2015 ► Fabricate the first of six TRUPACT III packages to accommodate large boxed waste United Kingdom For the UK Nuclear Decommissioning Authority, we will accomplish the following at Sellafield: ► Process 400 metric tons of fuel at the Thorp facility ► Process 800 metric tons of fuel at the Magnox facility ► First removal of spent fuel from the Pile Fuel Storage Pond At the Low Level Waste Repository, LLWR will continue our role as the UK integrator in LLW management, through partnership with the NDA by leveraging our knowledge and technical reachback capabilities within URS and consortium companies. In 2011, we will complete the following key activities: ► Submit a robust Environmental Safety Case and application for planning approval in Site Optimization and Closure ► Continue plutonium contaminated materials decommissioning ► Deploy new reusable waste packages and expand our waste service contracts for metallic and combustible waste treatment Summary To be successful in 2011, URS will continue to lead the way with partnering with our customers. To win the future, we must leverage our knowledge, communicate our lessons learned, and reach out to all within the industry for mutual success. 19 Corporate Headquarters 600 Montgomery Street, 26th floor San Francisco, California 94111 Global Management & Operations Services Group 106 Newberry Street Southwest Aiken, South Carolina 29801 www.urscorp.com