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2003 Kansas City Plant Annual Illness and Injury Surveillance Report, Revised September 2007

Description: Annual Illness and Injury Surveillance Program report for 2003 for the Kansas City Plant. The U.S. Department of Energy’s (DOE) commitment to assuring the health and safety of its workers includes the conduct of epidemiologic surveillance activities that provide an early warning system for health problems among workers. The IISP monitors illnesses and health conditions that result in an absence of workdays, occupational injuries and illnesses, and disabilities and deaths among current workers.
Date: October 4, 2007
Creator: U.S. Department of Energy, Office of Health, Safety and Security, Office of Illness and Injury Prevention Programs
Partner: UNT Libraries Government Documents Department

ALT-GTS-Stem Fabrication

Description: In 2007, a study investigated options to manufacture stems utilizing methods that would replace crush form grinding while maintaining or improving quality at a comparative cost. Crush form grinding is a special process used at the Kansas City Plant to finish stem sections of reservoir products. However, crush form grinding is a complex process with many variables affecting the final product. This study identified two potential methods that can be applied to stems. Profile grinding was investigated in 2007. This project continued in 2008 proving that single point turning on a multi-turret is an option with additional benefits. It is an economical way to meet floor space limitations for our KCRIMS mission.
Date: September 25, 2008
Creator: Nguyen, Thuan
Partner: UNT Libraries Government Documents Department

FILL STEM MANUFACTURING CHANGES AND PINCH WELD QUALIFICATIONS

Description: In March of 2007 a document was issued, see attachment I, that defined the test protocol and required welding for the Kansas City Plant to change cutting oils from the recently approved 50:50 oil to an oil with similar characteristics but with different chemistry, additives, and possibly a different vendor due to plans by the current vendor to stop preparing the oils that are used in the KCP 50:50 mix. The KCP manufactured stems with the existing 50:50 oil blend in late FY07 and SRNL welded the stems and evaluated them in agreement with the test plan. This report provides all the data from these set-up and test welds. Set-up welds were shot and low and high voltages (currents) to ensure the window limits were applicable and then additional welds were made to validate the window. The purpose of this report is to ensure that the agreed upon path forward is still applicable.
Date: February 22, 2008
Creator: Korinko, P & David Maxwell, D
Partner: UNT Libraries Government Documents Department

Crush Grinding

Description: Crush Grinding is a special process used at the Kansas City Plant to finish stem sections of reservoir products. In this process, a precise profile of the desired product is formed on a tungsten carbide roll. This roll slowly transfers a mirror image of the profile onto the grinding surface of a wheel. The transfer rate of the profile is between 0.001 and 0.010 inches per minute. Crush grinding is desirable since it provides consistent surface finishes and thin walls at a high production rate. In addition, it generates very sharp fillet radii. However, crush grinding is a complex process since many variables affect the final product. Therefore, the process requires more attention and knowledge beyond basic metal removal practices. While the Kansas City Plant began using these machines in 1995, a formal study regarding crush grinding has not been conducted there. In addition, very little literature is available in the grinding industry regarding this process. As a result, new engineers at the Kansas City Plant must learn the process through trial and error. The purpose of this document is to address this literature deficit while specifically promoting a better understanding of the stem crush grinding process at the Kansas City Plant.
Date: April 1, 2005
Creator: Nguyen, T. Q.
Partner: UNT Libraries Government Documents Department

Adjustable Shock Test Sled for Haversine Pulses at 250 fps

Description: New test requirements were developed by Sandia National Laboratory to simulate a regime of shock testing not previously performed at the Kansas City Plant operated by Honeywell Federal Manufacturing & Technologies. These environments were unique in that they involved amplitude of shock >1000g with relatively long pulse durations (greater 5 ms but less than 10 ms) and involved velocity changes up to 235 ft/sec. Ten months were available to develop, design, manufacture and prove-in this new capability. We designed a new shock sled to deliver this new family of shock environments in a laboratory test. The performance range of the new sled includes five specific shocks (1000 g – 8 ms, 1300 - 6 ms, 1500 g – 5.4 ms, 1950 g – 6 ms, 2250 g – 5.4 ms; all haversine shaped), and it also incorporates adjustability to accommodate new shocks within this range. These shock environments result in velocity changes ranging from 160 fps to 250 fps. The test sled accommodates test articles weighing up to 20 lbs and measuring up to 10” along any axis.
Date: May 5, 2008
Creator: Hartwig, Troy; Hower, Brent & Seaholm, Aaron
Partner: UNT Libraries Government Documents Department

Business process mapping techniques for ISO 9001 and 14001 certifications

Description: AlliedSignal Federal Manufacturing and Technologies/Kansas City (FM and T/KC) produces nonnuclear components for nuclear weapons. The company has operated the plant for the US Department of Energy (DOE) since 1949. Throughout the history of the plant, procedures have been written to reflect the nuclear weapons industry best practices, and the facility has built a reputation for producing high quality products. The purpose of this presentation is to demonstrate how Total Quality principles were used at FM and T/KC to document processes for ISO 9001 and 14001 certifications. The information presented to the reader will lead to a better understanding of business administration by aligning procedures to key business processes within a business model; converting functional-based procedures to process-based procedures for total integrated resource management; and assigning ownership, validation, and metrics to procedures/processes, adding value to a company`s profitability.
Date: November 1, 1997
Creator: Klement, R.E. & Richardson, G.D.
Partner: UNT Libraries Government Documents Department

Routine environment audit of the Kansas City Plant, Kansas City, Missouri

Description: This report documents the results of the routine environmental audit of the Kansas City Plant, Kansas City, Missouri. During this audit the activities the audit team conducted included reviews of internal documents and reports from previous audits and assessments; interviews with U.S. Department of Energy (DOE) and contractor personnel; and inspections and observations of selected facilities and operations. The onsite portion of the audit was conducted October 24-November 4, 1994, by the DOE Office of Environmental Audit (EH-24), located within the Office of Environment, Safety, and Health (EH). DOE 5482.1 B, {open_quotes}Environment, Safety, and Health Appraisal Program,{close_quotes} establishes the mission of EH-24, which is to provide comprehensive, independent oversight of Department-wide environmental programs on behalf of the Secretary of Energy. The ultimate goal of EH-24 is enhancement of environmental protection and minimization of risk to public health and the environment. EH-24 accomplishes its mission by conducting systematic and periodic evaluations of the Department`s environmental programs within line organizations and by using supplemental activities that strengthen self-assessment and oversight functions within program, field, and contractor organizations. The audit evaluated the status of programs to ensure compliance with Federal, state, and local environmental laws and regulations; compliance with DOE Orders, guidance, and directives; and conformance with accepted industry practices and standards of performance. The audit also evaluated the status and adequacy of the management systems developed to address environmental requirements.
Date: November 1, 1994
Partner: UNT Libraries Government Documents Department

Evaluation of micropurging versus traditional groundwater sampling at the Department of Energy`s Kansas City Plant

Description: A field trial comparing the micropurge and the traditional purge and sample method of groundwater sampling was conducted at the U.S. Department of Energy (DOE), Kansas City Plant (KCP) in 1993 and 1994. Duplicate groundwater samples were collected using traditional and micropurge methods, analyzed for selected organic and inorganic constituents, and the results compared statistically. Evaluation of the data using the Wilcoxon Sign Rank test indicates that within a 95% confidence interval, there was no significant difference between the two methods for the site contaminants and the majority of naturally occurring analytes. These analytical results were supported by visual observations with the colloidal borescope, which demonstrated impacts on the flow system in the well when using traditional sampling methods. Under selected circumstances, the results suggest replacing traditional sampling with micropurging based on reliability, cost, and waste minimization.
Date: August 1, 1995
Creator: Stites, M.E.; Baker, J.L. & Kearl, P.M.
Partner: UNT Libraries Government Documents Department

Procedure preparation for ISO 9000 certification

Description: The Kansas City Division (KCD) produces nonnuclear components for nuclear weapons. The company has operated the plant for the US Department of Energy since 1949. Throughout the history of the plant, procedures were written to reflect the nuclear weapons industry best practices, and the facility built a reputation for producing high quality products. In 1991 a critical process team was asked to use Just In Time principles to determine a better way to administrate procedures. By 1992 the team was successful in implementing a full-time centralized procedure group to handle the creation, coordination, review, resolution, and publication of plant-wide administrative and operating procedures. In 1993 AlliedSignal was commissioned by its President and CEO Larry Bossidy to register all of the world-wide sites under the ISO 9000 quality standard. This presented a formidable challenge for the Kansas City Division. Though the independent third-party auditors conceded during a preassessment that the company did in fact build high quality products, the procedures and procedure system did not accurately reflect the current business practices. The purpose of this paper is to share information about the successful implementation of centralized procedure administration and the re-engineering of the procedure system, leading to successful ISO 9001 certification at AlliedSignal Inc., Kansas City Division.
Date: November 1, 1995
Creator: Klement, R.E.
Partner: UNT Libraries Government Documents Department

Flood protection for the Kansas City bannister federal complex

Description: The Bannister Federal Complex is bordered on the east by the Blue River and on the south by Indian Creek. After a flood in 1961 and several near-miss floods, flood protection has been installed. The protection consists of 2,916 feet of concrete flood walls, 8,769 feet of levee, five rolling gates, four stoplog gaps, one hinged pedestrian gate, and one sandbag gap. The flood walls are over 14 feet tall. Construction was started on August 3, 1992 and was completed in early 1995. Architectural treatment was incorporated in the flood walls as well as landscaping to enhance the appearance of the flood protection.
Date: August 1, 1995
Creator: Nolan, J.J.; Williams, R.H. & Betzen, G.A.
Partner: UNT Libraries Government Documents Department

Technical Assistance to Kansas City Plant: Mitigation of Polychlorinated Biphenyl Discharges

Description: Soil and storm water discharges from the Department of Energy Kansas City Plant (KCP) contain polychlorinated biphenyls (PCBs) resulting from past spills and discharges. KCP has implemented a range of actions to mitigate the soil contamination and to reduce the measured PCB releases.
Date: April 21, 2003
Creator: Looney, B.B.
Partner: UNT Libraries Government Documents Department

Biotelemetry system for Epilepsy Seizure Control

Description: The Biotelemetry System for Epilepsy Seizure Control Project developed and tested an automated telemetry system for use in an epileptic seizure prevention device that precisely controls localized brain temperature. This project was a result of a Department of Energy (DOE) Global Initiatives for Proliferation Prevention (GIPP) grant to the Kansas City Plant (KCP), Argonne National Laboratory (ANL), and Pacific Northwest National Laboratory (PNNL) to partner with Flint Hills Scientific, LLC, Lawrence, KS and Biophysical Laboratory Ltd (BIOFIL), Sarov, Russia to develop a method to help control epileptic seizures.
Date: July 2, 2009
Creator: Smith, LaCurtise & Bohnert, George W.
Partner: UNT Libraries Government Documents Department

Topical Report Tantalum – 2.5% Tungsten Machinability Testing

Description: Protection Association (NFPA). NFPA 484, Standard for Combustible Metals, Chapter 9 Tantalum and Annex E, supplemental Information on Tantalum require cutting oil be used when machining tantalum because it burns at such a high temperature that it breaks down the water in a water-based metalworking fluid (MWF). The NFPA guide devotes approximately 20 pages to this material. The Kansas City Plant (KCP) uses Fuchs Lubricants Ecocut Base 44 LVC as a MWF. This is a highly chlorinated oil with a high flash point (above 200° F). The chlorine is very helpful in preventing BUE (Built Up Edge) that occurs frequently with this very gummy material. The Ecocut is really a MWF additive that Fuchs uses to add chlorinated fats to other non-chlorinated MWF.
Date: September 2, 2009
Creator: Lazarus, L. J.
Partner: UNT Libraries Government Documents Department

Geometric Qualification of Production Parts

Description: Computer Aided Design (CAD) is a commonly utilized software tool to conceptualize and create the part designs that are then used as input for product definition, or for the manufacture of production parts within commercial industry and, more specifically, at the Kansas City Plant (KCP). However, data created on CAD systems is, at times, unable to regenerate within the originating CAD system or be shared or translated for use by a dissimilar CAD system. Commercial software has been developed to help identify or qualify these difficulties that occur in the usage of this data. This project reviewed the different commercial software packages available for the activity of qualification and made recommendations for availability and use in the design processes at the KCP prior to the release of the product definition.
Date: September 30, 2005
Creator: Bradley, J. A.
Partner: UNT Libraries Government Documents Department

An Assessment of the Bioaccumulation of PCBs and Chloridane Near the U.S. Department of Energy's Kansas City Plant

Description: Studies conducted by the Missouri Department of Conservation in the late 1980s found high levels of PCBs and chlordane in fish from the Blue River near the Kansas City Plant (KCP). Follow-on biomonitoring studies by Oak Ridge National Laboratory (ORNL) staff from 1991-1993 (Southworth et al. 1992, Ashwood et al. 1993, Ashwood and Peterson 1994), and again on a more limited basis in 1998 (Ashwood 1998), were conducted for the KCP. The studies in the early 1990s characterized concentrations of PCBs and chlordane in fish from Indian Creek, Boone Creek, and the Blue River. These studies concluded that the KCP appears to be one of multiple sources of PCBs to both Indian Creek and the Blue River. There continues to be interest in the potential role of KCP discharges on PCB concentrations in local fish. Elevated PCB concentrations in Indian Creek fish have consistently been found at the location downstream of the NPDES-permitted 002 discharge, which drains a section of the KCP complex. A risk evaluation conducted during 2001 found that some local fish exceeded risk-based guidelines for PCBs. It has been nearly a decade since intensive sampling of fish was conducted within all waters near the KCP (the 1998 study included Indian Creek only); therefore, an update study was warranted. The purpose of the present study is to provide PCB and chlordane concentrations in fish useful in determining the potential human health risks associated with fish in waters near the KCP, to evaluate the relative significance of KCP discharges relative to other inputs on fish levels, and to determine if levels have changed in the years since fish were last analyzed. Fish were collected near the KCP for PCB and chlordane analyses in October and November of 2002. Although chlordane does not appear to be associated with the KCP ...
Date: December 30, 2003
Creator: Peterson, M.J.
Partner: UNT Libraries Government Documents Department

Oil Mist Compliance

Description: This report summarizes activities at the KCP related to evaluating and modifying machine tools in order to be in compliance with Section 23 of DOE 10 CFR 851, Worker Safety and Health Program. Section 851.23 (a) states that “Contractors must comply with the following safety and health standards that are applicable to the hazards in their covered workplace”, and subsection 9 contains the following applicable standard: “American Congress of Governmental Industrial Hygienists (ACGIH), ‘Threshold Limit Values for Chemical Substances and Physical Agents and Biological Exposure Indices,’ (2005) (incorporated by reference, see §851.27) when the ACGIH Threshold Limit Values are lower (more protective) than permissible exposure limits in 29 CFR 1910.” In the 2005 ACGIH – Threshold Limit Value book a Notice of Change was issued for exposure to mineral oil mist used in metalworking fluids (MWFs). The effects of planning for the new facility and which machine tools would be making the transition to the new facility affected which machine tools were modified.
Date: February 2, 2009
Creator: Lazarus, Lloyd
Partner: UNT Libraries Government Documents Department

CMM Technology

Description: This project addressed coordinate measuring machine (CMM) technology and model-based engineering. CMM data analysis and delivery were enhanced through the addition of several machine types to the inspection summary program. CMM hardware and software improvements were made with the purchases of calibration and setup equipment and new model-based software for the creation of inspection programs. Kansas City Plant (KCP) personnel contributed to and influenced the development of dimensional metrology standards. Model-based engineering capabilities were expanded through the development of software for the tolerance analysis of piece parts and for the creation of model-based CMM inspection programs and inspection plans and through the purchase of off-the-shelf software for the tolerance analysis of mechanical assemblies. An obsolete database application used to track jobs in Precision Measurement was replaced by a web-based application with improved query and reporting capabilities. A potential project to address the transformation of the dimensional metrology enterprise at the Kansas City Plant was identified.
Date: October 20, 2008
Creator: Ward, Robert C.
Partner: UNT Libraries Government Documents Department

2006 Kansas City Plant Annual Illness and Injury Surveillance Report

Description: The U.S. Department of Energy’s (DOE) commitment to assuring the health and safety of its workers includes the conduct of illness and injury surveillance activities that provide an early warning system to detect health problems among workers. The Illness and Injury Surveillance Program monitors illnesses and health conditions that result in an absence, occupational injuries and illnesses, and disabilities and deaths among current workers.
Date: June 13, 2008
Creator: United States. Department of Energy. Office of Health, Safety, and Security.
Partner: UNT Libraries Government Documents Department

Implementation of passive samplers for monitoring volatile organic compounds in ground water at the Kansas City Plant

Description: Passive sampling for monitoring volatile organic compounds (VOCs) has been suggested as a possible replacement to the traditional bailer method used at the Department of Energy Kansas City Plant (KCP) for routine groundwater monitoring. To compare methods, groundwater samples were collected from 19 KCP wells with VOC concentrations ranging from non-detectable to > 100,000 {micro}g/L. Analysis of the data was conducted using means and medians of multiple measurements of TCE, 1,2-DCE, 1,1-DCE and VC. All 95% confidence intervals of these VOCs overlap, providing evidence that the two methods are similar. The study also suggests that elimination of purging and decontamination of sampling equipment reduces the labor required to sample by approximately 32%. Also, because the passive method generates no waste water, there are no associated disposal costs. The results suggest evidence to continue studies and efforts to replace traditional bailer methods with passive sampling at KCP based on cost and the similarity of the methods.
Date: June 1, 1998
Creator: Gardner, F.G.; Korte, N.E.; Wilson-Nichols, M.J.; Baker, J.L. & Ramm, S.G.
Partner: UNT Libraries Government Documents Department

Pollution prevention opportunity assessment approach, training, and technical assistance for DOE contractors

Description: One of the tools used in a successful pollution prevention program is a pollution prevention opportunity assessment (PPOA). PPOAs can be used to identify the nature and amounts of waste and energy usage from processes and projects within a site`s operations, identify the opportunities that exist for pollution prevention and energy conservation, and then evaluate those opportunities for feasible implementation. The purpose of this project is to share the Kansas City Plant`s (KCP`s) PPOA methodology and experience with other DOE personnel and DOE contractors. This consisted of three major activities in FY96: (1) completing the PPOA training module specific to Environmental Restoration activities; (2) providing PPOA training and technical assistance to interested DOE personnel and DOE contractors, and (3) implementing and maintaining the DOE-wide PPOA database. This report documents the FY96 efforts, lessons learned, and future plans for all of the PPOA-related activities.
Date: March 1, 1997
Creator: Pemberton, S.
Partner: UNT Libraries Government Documents Department

Prevention of Reservoir Interior Discoloration

Description: Contamination is anathema in reservoir production. Some of the contamination is a result of welding and some appears after welding but existed before. Oxygen was documented to be a major contributor to discoloration in welding. This study demonstrates that it can be controlled and that some of the informal cleaning processes contribute to contamination.
Date: April 3, 2001
Creator: Arnold, K.F.
Partner: UNT Libraries Government Documents Department

Advanced Telemetry Data Capturing

Description: This project developed a new generation or advanced data capturing process specifically designed for use in future telemetry test systems at the Kansas City Plant (KCP). Although similar data capturing processes are performed both commercially and at other DOE weapon facilities, the equipment used is not specifically designed to perform acceptance testing requirements unique to the KCP. Commercially available equipment, despite very high cost (up to $125,000), is deficient in reliability and long-term maintainability necessary in test systems at this facility. There are no commercial sources for some requirements, specifically Terminal Data Analyzer (TDA) data processing. Although other custom processes have been developed to satisfy these test requirements, these designs have become difficult to maintain and upgrade.
Date: May 16, 2000
Creator: Paschke, G.A.
Partner: UNT Libraries Government Documents Department