Department of Energy: Accelerated Closure of Rocky Flats: Status and Obstacles (Chapter Report, 04/30/99, GAO/RCED-99-100). Pursuant to a congressional request, GAO reviewed the Department of Energy's (DOE) ability to close the Rocky Flats Environmental Technology Site by the end of 2006, focusing on: (1) DOE's plans for accelerating the site's closure and challenges that could impede closure; (2) the condition of the site at closure and the activities that will remain after closure; and (3) the costs of closing the site and the savings expected from accelerating its closure. GAO noted that: (1) while DOE and the Kaiser-Hill Company have had some success in accelerating cleanup activities, it is questionable whether they can meet DOE's target date of 2006 for cleaning up and closing Rocky Flats at the costs and savings originally projected; (2) they face numerous challenges, significant compression of scheduled activities, and unresolved issues relating to the disposal of certain wastes and the site's condition at closure; (3) Kaiser-Hill has encountered delays in implementing its plan to close the site in 2010 and expects to have a detailed plan and schedule for closing the site by the end of 2006 in May 1999; (4) DOE and Kaiser-Hill believe that the contractor can take advantage of learning curves and efficiencies gained through early efforts to expedite cleanup and closure activities; (5) DOE and Kaiser-Hill must overcome various challenges to accelerate key activities to close the site by the end of 2006; (6) while plans for closing the site depend on other organizations within and outside DOE to take the site's materials and wastes for storage or disposal, several types of materials and wastes have no sites available to take them; (7) DOE and Kaiser-Hill officially maintain that the contractor can close the site by the end of 2006; (8) DOE, the Environmental Protection Agency (EPA), and Colorado have agreed on the condition of the site when it is closed; (9) nevertheless, many specific decisions still must be made; (10) if a more stringent cleanup level will be required than the interim level agreed to by DOE, EPA, and Colorado, the site's closure could be delayed; (11) developing plans and cost estimates for the site after closure will be difficult until agreement has been reached on all aspects of the site's closure and on future uses of the site; (12) the costs of cleaning up and closing Rocky Flats could be higher than DOE's official estimate; (13) although DOE has not validated the accuracy of the estimate, DOE and contractor site managers maintain that the site can be closed for $7.3 billion; (14) the contractor's 1998 detailed cost estimate, based on the costs of specific projects needed to close the site, totalled $8.4 billion; (15) these estimates do not include the costs that will be incurred after the site is closed; (16) the savings estimate for accelerating the site's closure from 2010 to 2006 was based on avoiding the costs of operating and maintaining the site for 4 years; and (17) if the cleanup and closure can be accelerated, health and safety risks may be reduced and financial benefits may be achieved. --------------------------- Indexing Terms ----------------------------- REPORTNUM: RCED-99-100 TITLE: Department of Energy: Accelerated Closure of Rocky Flats: Status and Obstacles DATE: 04/30/99 SUBJECT: Nuclear waste management Cost control Nuclear waste disposal GOCO Nuclear facilities Strategic planning Cost analysis Obsolete facilities Cost overruns IDENTIFIER: Colorado New Mexico DOE Long-Term Surveillance and Maintenance Program DOE Rocky Flats Cleanup Agreement ****************************************************************** ** This file contains an ASCII representation of the text of a ** ** GAO report. This text was extracted from a PDF file. ** ** Delineations within the text indicating chapter titles, ** ** headings, and bullets have not been preserved, and in some ** ** cases heading text has been incorrectly merged into ** ** body text in the adjacent column. Graphic images have ** ** not been reproduced, but figure captions are included. ** ** Tables are included, but column deliniations have not been ** ** preserved. ** ** ** ** Please see the PDF (Portable Document Format) file, when ** ** available, for a complete electronic file of the printed ** ** document's contents. ** ** ** ** A printed copy of this report may be obtained from the GAO ** ** Document Distribution Center. For further details, please ** ** send an e-mail message to: ** ** ** **** ** ** ** with the message 'info' in the body. ** ****************************************************************** rc99100.book GAO United States General Accounting Office Report to the Chairman, Committee on Armed Services, U. S. Senate April 1999 DEPARTMENT OF ENERGY Accelerated Closure of Rocky Flats: Status and Obstacles GAO/RCED-99-100 GAO/RCED-99-100 GAO United States General Accounting Office Washington, D. C. 20548 Lett er Resources, Community and Economic Development Division B-282092 Letter April 30, 1999 The Honorable John W. Warner Chairman, Committee on Armed Services United States Senate Dear Mr. Chairman: In response to your request, this report reviews the Department of Energy's ability to close the Rocky Flats Environmental Technology Site by the end of 2006. Specifically, it examines (1) DOE's plans for accelerating the site's closure and challenges that could impede closure; (2) the condition of the site at closure and the activities that will remain after closure; and (3) the costs of closing the site and the savings expected from accelerating its closure. As arranged with your office, unless you publicly announce its contents earlier, we plan no further distribution of this report until 15 days after the date of this letter. At that time, we will send copies of this report to the Honorable Bill Richardson, Secretary of Energy; the Honorable Jacob Lew, Director, Office of Management and Budget; and other interested parties. Copies will also be made available to others upon request. Please call me at (202) 512- 3841 if you or your staff have any questions. Major contributors to this report are listed in appendix II. Sincerely yours, (Ms.) Gary L. Jones Associate Director, Energy, Resources, and Science Issues Page 2 GAO/RCED-99-100 Accelerated Closure of Rocky Flats Executive Summary Purpose In 1989, the Rocky Flats Environmental Technology Site stopped making plutonium components for nuclear weapons, leaving the Department of Energy (DOE) with the challenge of managing and cleaning up nearly 40 years' worth of contamination at the site. Compared with the other sites in DOE's former nuclear weapons production complex, Rocky Flats has some of the most dangerous and highest- risk materials and facilities. Currently, DOE is spending approximately two- thirds of the site's annual budget of nearly $700 million to maintain the site in a relatively safe and secure state, with the remaining one- third going to cleanup. Partly because of these high maintenance costs, the Department developed plans in fiscal year 1994 to clean up and close the site. Subsequently, DOE advanced the site's goal for closure several times, from the original date of 2070 to the current date of 2006. Concerned about the Department's ability to meet its current goal to close Rocky Flats by the end of 2006, the Chairman of the Senate Committee on Armed Services asked GAO to review (1) DOE's plans for accelerating the site's closure and challenges that could impede closure; (2) the condition of the site at closure and the activities that will remain after closure; and (3) the costs of closing the site and the savings expected from accelerating its closure. Background The Rocky Flats site, located at the base of Colorado's Rocky Mountains, lies about 16 miles northwest of Denver. More than 2.5 million people live within a 50- mile radius of the site. Of particular concern are the site's special nuclear materials-- such as plutonium and uranium-- and radioactive wastes, which pose substantial risks to workers, the public, and the environment. In 1995, after entering into a 5- year contract with DOE to manage Rocky Flats, Kaiser- Hill Company, L. L. C., began to stabilize and consolidate these materials for safe storage until they could be removed from the site. Kaiser- Hill and DOE also began to arrange for other DOE and commercial facilities to receive the various radioactive and hazardous materials and wastes that had accumulated at the site or were by- products of cleanup activities. Some wastes will be generated in large quantities throughout the site's cleanup. In 1996, DOE signed the Rocky Flats Cleanup Agreement with the U. S. Environmental Protection Agency (EPA) and the state of Colorado, the primary regulators of cleanup activities at Rocky Flats. Under the cleanup agreement, special nuclear materials will be removed by 2015; other Executive Summary Page 3 GAO/RCED-99-100 Accelerated Closure of Rocky Flats radioactive and hazardous wastes will be removed; and all buildings will be decontaminated, decommissioned, and demolished. DOE plans to close the site when those tasks are complete. Also in 1996, DOE's Office of Environmental Management revamped its plans for cleaning up the Department's contaminated sites, attempting to accelerate the closure of sites and coordinate cleanup activities across the DOE complex. In response, in 1997, Kaiser- Hill proposed advancing Rocky Flats' closure to 2010. 1 This plan remains in effect today, even though DOE has since accelerated the target date for closing the site to the end of 2006. The cleanup and closure of Rocky Flats involves not only DOE and the site's contractor and subcontractors but also regulatory and oversight agencies and others with an interest in the site's cleanup and closure. In addition to EPA and Colorado, the site's regulatory and oversight bodies include the Department of the Interior's Fish and Wildlife Service and the Defense Nuclear Facilities Safety Board. Other interested parties- - or stakeholders-- include local governments; citizen, community, business, and environmental groups; and individuals. Results in Brief While DOE and Kaiser- Hill have had some success in accelerating cleanup activities, it is questionable whether they can meet the Department's target date of 2006 for cleaning up and closing Rocky Flats at the costs and savings originally projected. They face numerous challenges, significant compression of scheduled activities, and unresolved issues relating to the disposal of certain wastes and the site's condition at closure. Kaiser- Hill has encountered delays in implementing its plan to close the site in 2010 and expects to have a detailed plan and schedule for closing the site by the end of 2006 in May 1999. DOE and Kaiser- Hill believe that the contractor can take advantage of learning curves and efficiencies gained through early efforts to expedite cleanup and closure activities. However, DOE and Kaiser- Hill must overcome various challenges to accelerate key activities to close the site by the end of 2006. For example, they have to compress the 2010 schedule, which calls for decontaminating and decommissioning the majority of the site's buildings from 2005 through 2007 and demolishing over two- thirds of the buildings in 2006 or later. However, the contractor has not determined how to compress these 1 The 2010 plan is based on closing the site by the end of fiscal year 2010. Executive Summary Page 4 GAO/RCED-99-100 Accelerated Closure of Rocky Flats activities enough to close the site by the end of 2006, and some site officials question both the feasibility of compressing the schedule and the availability of resources, especially of qualified workers. Furthermore, while the plans for closing the site depend on other organizations within and outside the Department to take the site's materials and wastes for storage or disposal, several types of materials and wastes-- including some low- level radioactive waste and some uranium-- have no sites available to take them. Nevertheless, DOE and Kaiser- Hill officially maintain that the contractor can close the site by the end of 2006, primarily by taking advantage of lessons learned and efficiencies gained through experience. DOE, EPA, and Colorado have agreed, in general, on the condition of the site when it is closed. Nevertheless, many specific decisions still must be made. Issues remaining to be resolved include how the site will be used in the future and what level of cleanup will be required. If a more stringent cleanup level will be required than the interim level agreed to by DOE, EPA, and Colorado, the site's closure could be delayed. In addition, DOE is just starting to consider issues that will be important after the site is closed, such as who will own, monitor, and maintain the site and what barriers will be used to prevent exposure to residual contamination. Developing plans and cost estimates for the site after closure will be difficult until agreement has been reached on all aspects of the site's closure and on future uses of the site. The costs of cleaning up and closing Rocky Flats could be higher than DOE's official estimate of $7. 3 billion 2 for fiscal year 1997 through fiscal year 2010. Although DOE has not validated the accuracy of this estimate, DOE and contractor site managers maintain that the site can be closed for $7. 3 billion. However, the contractor's 1998 detailed cost estimate, based on the costs of specific projects needed to close the site, totaled $8.4 billion. Assumptions underlying both estimates have changed or have the potential to change, generally indicating higher costs. In addition, these estimates do not include the costs that will be incurred after the site is closed, which could range from hundreds of millions to billions of dollars over a period of the first 30 to 40 years. Finally, the savings estimate for accelerating the site's closure from 2010 to 2006 was based on avoiding the costs of operating and maintaining the site for 4 years. Therefore, if closure occurs after 2006, the savings could be less than DOE's $1.3 billion 2 Unless otherwise noted, dollar values represent the sum of annual expenditures and incorporate an annual 2.7- percent increase for expected inflation. Executive Summary Page 5 GAO/RCED-99-100 Accelerated Closure of Rocky Flats estimate. A preliminary estimate presented by the contractor in February 1999 indicates that the savings from closing the site by the end of 2006 could be lower. DOE's decision to accelerate the closure of Rocky Flats to 2006 is laudable. If the cleanup and closure can be accelerated, health and safety risks may be reduced and financial benefits may be achieved. With the May 1999 issuance of Kaiser- Hill's detailed plan for closing the site by the end of 2006, the likelihood of this effort's success and the accompanying potential benefits will become clearer. Principal Findings DOE Faces Many Challenges in Accelerating the Site's Closure Although Kaiser- Hill does not expect to have detailed plans for closing the site by the end of 2006 until May 1999, both DOE and the contractor believe that the accelerated closure date is feasible. While developing detailed plans, the contractor is attempting to advance scheduled activities, especially those viewed as critical to closing the site by the end of 2006. However, some of the work completed to date has fallen behind the existing schedule for closing the site in 2010. For example, the contractor has encountered delays in preparing several types of nuclear wastes for removal, as well as delays in shipping special nuclear materials from the site-- both considered key to closing the site in 2010. The contractor has identified four key activities that must be accelerated to close the site by the end of 2006. These include (1) removing about 106 metric tons of plutonium- contaminated residues left over from nuclear weapons production; (2) shipping approximately 16. 5 metric tons of special nuclear materials off- site; (3) decontaminating and decommissioning the site's 691 buildings and facilities; and (4) constructing barriers to prevent exposure to residual contamination. The contractor has had some successes in accelerating some of these activities. However, challenges in implementing each of these activities could hinder acceleration. For example, the site has had difficulty readying the residues and special nuclear materials for removal from the site; decontamination and decommissioning are costing more and taking longer than anticipated; and DOE and the contractor have not reached agreement with the site's regulators or stakeholders on the use of protective barriers over portions of the industrial area. Executive Summary Page 6 GAO/RCED-99-100 Accelerated Closure of Rocky Flats Other challenges within and outside the Department could also hinder closure. For example, the operation of DOE's Waste Isolation Pilot Plant in New Mexico was delayed because of regulatory issues and litigation. 3 Consequently, Rocky Flats could not dispose of radioactive waste there. In addition, several types of orphan materials and wastes-- including some low- level radioactive and hazardous wastes and some uranium contaminated with plutonium or hazardous materials-- have no site available to take them. To overcome these challenges, DOE is working with the site's regulators and stakeholders to coordinate Rocky Flats' cleanup and closure activities with other organizations within and outside the Department. However, DOE's progress in accelerating the site's closure will depend, in part, on the priority given to Rocky Flats' activities by other DOE sites and organizations; the availability of transportation resources; and litigation, which is largely outside DOE's control. Status of the Site at Closure and Activities Required After Closure Have Not Been Defined Although there is general consensus that Rocky Flats should be closed, DOE has not reached agreement with regulators or other stakeholders on specifics of the condition of the site at closure or on its future uses. According to DOE, it is moving forward on decisions concerning the closure of the site and activities after closure in accordance with the regulatory requirements governing the site's cleanup. In the meantime, DOE and the contractor are basing their closure plans and estimates on broad goals and objectives addressed in the Rocky Flats Cleanup Agreement. These include removing the site's special nuclear materials, radioactive and hazardous wastes, and buildings, as well as cleaning up the site's 6,000- acre buffer zone for use as open space and its 385- acre former production area for potential industrial use or for use as restricted open space. Decisions or changes to assumptions about the status of Rocky Flats at closure could affect current and future cleanup requirements and, therefore, the feasibility of closing the site by the end of 2006. For example, the specifics of the future uses of the site are still undecided. Similarly, the interim soil cleanup level agreed to by DOE and the regulators has been questioned by local governments and by citizen and environmental groups. A change to a more stringent cleanup level could 3 The Waste Isolation Pilot Plant is DOE's deep geologic repository for transuranic and transuranic mixed waste, located in an underground salt formation near Carlsbad, New Mexico. On Mar. 26, 1999, DOE made its first shipment to the facility from Los Alamos. DOE anticipates beginning shipments from Rocky Flats over the next several months. Executive Summary Page 7 GAO/RCED-99-100 Accelerated Closure of Rocky Flats entail more cleanup work and could ultimately affect the site's closure date. DOE is just beginning to consider how Rocky Flats will be used after it is closed. No decisions have been made about whether additional cleanup or the removal of roads and other remaining infrastructure will be required; who will own, monitor and maintain the site; or what kinds of barriers (physical or legal) will be used to prevent exposure to residual contamination at the site. Although DOE is developing draft guidance for all of its sites on activities and responsibilities after closure, this guidance will take several years to develop. In any event, until DOE and the regulators have agreed on the condition of the site at closure and its future uses, DOE may not be able to plan effectively for activities after closure. Costs of Closing Rocky Flats May Be Higher Than Estimated DOE's official estimate of the costs to clean up and close Rocky Flats is $7. 3 billion. This estimate is based on a 1997 proposal by Kaiser- Hill to close the site in 2010. Both DOE and the contractor maintain that the site can be closed in 2010 for $7.3 billion; however, several factors suggest that the costs could be substantially higher. First, Kaiser- Hill's mid- level managers responsible for specific projects necessary for closure recently estimated that it would cost $8.4 billion to close the site. This estimate was based on the same major assumptions and schedule that Kaiser- Hill used for the $7. 3 billion estimate. Finally, a number of assumptions underlying the $7. 3 billion estimate have changed or have the potential to change in ways that would generally increase costs. For example, the contractor's assumptions about the costs of decontaminating and decommissioning the site's facilities changed with experience, causing the contractor to nearly triple the cost estimate for these activities. DOE's costs to manage Rocky Flats will not end when the site is closed. Because DOE and the regulators have not yet defined DOE's responsibilities after closure, DOE has not developed detailed cost estimates. However, according to DOE site officials, DOE could incur costs of as much as $100 million 4 for additional cleanup; $20 million to $50 million per year for monitoring and maintenance, 5 and at least $50 million 4 Unless otherwise noted, the cost estimates for activities after closure are in fiscal year 1998 constant dollars and are net of inflation. 5 Site officials estimate that the total cost of monitoring and maintaining the site through 2040, including adjustments for expected inflation, will be nearly $1.5 billion. Executive Summary Page 8 GAO/RCED-99-100 Accelerated Closure of Rocky Flats per year for workers' pensions and benefits. In addition, DOE could be exposed to litigation seeking compensation for damages resulting from the effects of the site's activities on workers, nearby residents, or natural resources. DOE originally estimated that it would save $1.3 billion by closing the site by the end of 2006 instead of in 2010. This estimate represented the basic costs of operating and maintaining the site for 4 years-- costs that DOE would avoid by closing the site 4 years earlier. However, given the progress to date and the challenges that remain, several site officials questioned the feasibility of closing the site by the end of 2006. As long as the site remains open, DOE will continue to incur operations and maintenance costs, thereby reducing the savings. In addition, the contractor's February 1999 preliminary cost estimate for closing the site by the end of 2006 indicated that the savings from closing the site 4 years earlier may be only $700 million. Recommendations This report makes no recommendations. Agency Comments GAO provided a draft of this report to DOE for its review and comment. The Department generally concurred with the facts of the report, stating that GAO had done a thorough job of documenting the complexity, uncertainties, and challenges the Department is facing in accelerating the closure of Rocky Flats. However, the Department commented that while the report does note some of the site's accomplishments, it does not adequately recognize the progress already made or the obstacles already overcome. GAO added material to the report to more thoroughly discuss the actions that DOE has taken. In addition, the Department raised a concern that the report identifies uncertainties facing the site's closure that (1) are subject to the regulations governing the cleanup, (2) are not at a point where resolution is necessary, or (3) are not obstacles to closure because the resolution of some uncertainties falls under the Rocky Flats Cleanup Agreement. On the basis of DOE's comments, GAO added information to the report, such as statements about the Department's actions under the regulations governing the site's cleanup, including the Comprehensive Environmental Response, Compensation, and Liability Act. While DOE does not view the issues discussed as obstacles to closure, GAO believes that the issues could affect the site's closure because they are Executive Summary Page 9 GAO/RCED-99-100 Accelerated Closure of Rocky Flats subject to a number of decisions and changes; as a result, GAO did not revise this part of the report. More detailed discussions of the Department's comments are included at the end of chapters 2 and 3. The full text of DOE's comments is presented in appendix I. The Department separately provided a number of technical comments, and GAO revised the report, where appropriate, to reflect them. Page 10 GAO/RCED-99-100 Accelerated Closure of Rocky Flats Contents Executive Summary 2 Chapter 1 Introduction History of Rocky Flats 12 Magnitude of the Cleanup and Closure Effort 13 Parties Involved in Rocky Flats' Cleanup and Closure 22 Objectives, Scope, and Methodology 25 Chapter 2 Challenges to Accelerating the Site's Closure Detailed Plan Assumes That the Site Will Be Closed in 2010 28 Numerous Challenges Could Hinder Efforts to Accelerate Closure 30 Coordination of Closure Activities Could Affect Acceleration 37 Challenges Outside DOE's Control Could Affect Closure 44 Observations 45 Agency Comments and Our Evaluation 46 Chapter 3 Status of the Site at Closure and Activities After Closure Have Not Been Defined Full Agreement on the Status of the Site at Closure Has Not Been Reached 47 Decisions on the Status of the Site at Closure May Affect Accelerated Cleanup 48 DOE's Activities and Responsibilities After Closure Have Not Been Defined 53 Observations 55 Agency Comments and Our Evaluation 56 Chapter 4 Costs of Closing Rocky Flats May Be Higher Than Estimated Closure Costs May Be Higher Than Estimated 57 Costs After Rocky Flats Is Closed Could Be Substantial 61 Estimated Savings May Be Reduced 64 Appendixes Appendix I: Comments From the Department of Energy 66 Appendix II: Major Contributors to This Report 70 Related GAO Products 72 Figures Figure 1.1: Rocky Flats Environmental Technology Site 12 Figure 1.2: Cutaway View of Transuranic Waste Drums 17 Figure 1.3: Sample Pipe and Go Container for Residues to Be Disposed of at the Waste Isolation Pilot Plant 18 Page 11 GAO/RCED-99-100 Accelerated Closure of Rocky Flats Figure 1.4: Remediation Activities at One of Rocky Flats' Contaminated Environmental Sites 21 Figure 2.1: A Rocky Flats Worker Handling Plutonium Residues in a Glovebox 31 Figure 2.2: Diagram of the Layers of a Closure Cap 36 Figure 2.3: Sites That Have Accepted and Expect to Receive Rocky Flats' Nuclear Materials and Wastes 39 Abbreviations DOE Department of Energy CERCLA Comprehensive Environmental Response, Compensation, and Liability Act EPA Environmental Protection Agency GAO General Accounting Office PCB polychlorinated biphenyl RCRA Resource Conservation and Recovery Act TRUPACT Transuranic Package Transporter WIPP Waste Isolation Pilot Plant Page 12 GAO/RCED-99-100 Accelerated Closure of Rocky Flats Chapter 1 Introduction Chapt er 1 History of Rocky Flats Rocky Flats Environmental Technology Site, shown in figure 1.1, occupies about 6,300 acres at the base of the foothills of the Rocky Mountains, about 16 miles northwest of Denver, Colorado. The site began operations in 1952 and, at the height of the Cold War, was 1 of 16 major U. S. defense nuclear facilities. Rocky Flats received plutonium that was manufactured elsewhere and produced plutonium triggers, or pits, for nuclear weapons. Most nuclear materials and other hazardous substances used in the production of plutonium pits were employed in the site's industrial area- about 385 acres in the center of the site, where most of the 691 buildings and facilities were located. The remaining nearly 6, 000 acres served as a buffer zone to help ensure the security of the nuclear material and of the site's operations, as well as the safety of nearby residents. Figure 1. 1: Rocky Flats Environmental Technology Site Source: Kaiser- Hill. For years, the site's principal regulators-- the Environmental Protection Agency (EPA) and the state of Colorado-- expressed concerns about potential threats to the environment and human health and safety at Rocky Flats. In 1986, the Department of Energy (DOE) signed an agreement with EPA and Colorado to ensure compliance with certain environmental regulatory requirements and to establish milestones for major cleanup operations. However, in 1989, Federal Bureau of Investigation agents and Chapter 1 Introduction Page 13 GAO/RCED-99-100 Accelerated Closure of Rocky Flats EPA officials raided Rocky Flats, responding to alleged violations of federal environmental laws and regulations. After the raid, DOE stopped production at the site. Environmental studies revealed that, over time, radioactive and hazardous substances had been released into the environment, contaminating the groundwater, soil, and surface water at the site. In 1991, DOE signed a new agreement with EPA and Colorado to ensure compliance with environmental laws and regulations and to set milestones for certain cleanup activities. However, DOE fell behind these milestones and, in 1994, agreed to regulatory penalties and supplemental environmental projects costing an additional $2. 8 million. In fiscal year 1994, the Department developed plans to close Rocky Flats. In 1996, DOE signed another agreement with EPA and Colorado, called the Rocky Flats Cleanup Agreement, which allowed DOE and the regulators to set priorities, make decisions on cleanup and closure, and establish decision- making processes. Of particular concern to the regulators were the weapons- grade special nuclear materials (plutonium and enriched uranium) and other radioactive and hazardous materials left at the site when production ceased. These materials pose substantial threats to the environment and could jeopardize human health and safety. An estimated 2.5 million persons live within 50 miles of Rocky Flats, and recent growth around the site, including residential and industrial construction adjacent to the buffer zone, has raised concerns for DOE and the regulators about possible future uses of the site. Magnitude of the Cleanup and Closure Effort When Rocky Flats was shut down in 1989, DOE assumed that the site would resume production and left much of its 16. 5 metric tons 1 of special nuclear materials in processing systems or short- term storage. But the site did not resume operations, and the short- term storage proved inadequate for the longer term, especially for plutonium, plutonium- contaminated residues, and plutonium- and uranium- bearing solutions. In 1994, DOE's Plutonium Working Group identified numerous problems with Rocky Flats' storage of plutonium and contaminated residues, including containers that had ruptured because the materials were improperly packaged and stored. 2 The group also reported that many of the site's buildings and much of the equipment, some dating back to the 1950s and 1960s, had deteriorated with 1 A metric ton is equal to 1 million grams, or 1.1 tons. 2 Plutonium Working Group Report on Environmental, Safety and Health Vulnerabilities Associated with the Department's Plutonium Storage (DOE/ EH- 0415, Nov. 1994). Chapter 1 Introduction Page 14 GAO/RCED-99-100 Accelerated Closure of Rocky Flats age. Furthermore, some of the safety systems for these buildings and equipment had become unreliable. Today, DOE and its contractor, KaiserHill, face massive challenges in cleaning up the results of nearly 40 years' worth of nuclear weapons production-- removing the site's materials and waste, cleaning up and demolishing the site's structures, and reducing the contamination at the site to agreed upon levels. The Site's Nuclear Materials and Wastes To close the site, Kaiser- Hill must prepare and ship huge quantities of materials and wastes from the site, many of them radioactive. These activities must be largely completed before the contractor can remove the site's structures and perform further cleanup activities. Each type of material and waste presents its own challenges. The type of processing and packaging required for each type of nuclear material and waste varies in complexity. Descriptions of the primary types of nuclear materials and wastes follow. Chapter 1 Introduction Page 15 GAO/RCED-99-100 Accelerated Closure of Rocky Flats Special nuclear materials. When the decision was made to close Rocky Flats, there were approximately 16. 5 metric tons of special nuclear materials on the site about 6. 7 metric tons of enriched uranium and about 9. 8 metric tons of plutonium metals and oxides and plutonium pits-- to prepare and ship off- site. Uranium is a naturally occurring radioactive element that can be enriched to increase the percentage of a particular uranium isotope for use in nuclear weapons or as reactor fuel. Some of the site's enriched uranium must be processed to remove plutonium contamination before it can be packaged and shipped to a site designated to receive the material. The contractor recently started shipping enriched uranium to DOE's Oak Ridge Reservation and expects to complete its shipments of uranium to this facility by September 1999. The contractor reports that as of January 1999, it had shipped 40 percent of the enriched uranium off- site. Plutonium, a man- made radioactive element produced by irradiating uranium in nuclear reactors, is primarily in the form of metals, oxides (fine powders), and pits. The plutonium metals and oxides must be stabilized before they can be shipped. Stabilization includes brushing the metals to remove loose oxides and heating the oxides to a high temperature to remove moisture and other impurities, and reduce the potential for dispersal. Both the metals and the oxides must then be packaged in long- term storage containers, which are packed into containers certified by the regulators as safe for transporting special nuclear materials. 3 The contractor has not yet started shipping plutonium metals and oxides. A plutonium pit is the central core of a nuclear weapon, which can be compressed with high explosives to create a nuclear explosion. 4 To be shipped from Rocky Flats, the plutonium pits must be packaged in certified transportation containers. As of January 1999, the contractor had shipped about 80 percent of the plutonium pits off- site. Both the plutonium and the enriched uranium must be shipped in specially designed trucks and trailers. Residues. Residues are plutonium- contaminated materials left over from nuclear weapons production, such as plutonium- contaminated ash; combustibles (including paper, rags, cloth, and gloves that can ignite easily); fluorides (compounds containing fluorine); salts (chloride 3 For additional information on the Department's management of its plutonium, see Department of Energy: Plutonium Needs, Costs, and Management Programs (GAO/RCED-97-98, Apr. 17, 1997) and Department of Energy: Problems and Progress in Managing Plutonium (GAO/RCED- 98-68, Apr. 17, 1998). 4 In a thermonuclear weapon, the pit is the primary device that is imploded to cause a fission reaction to generate heat and energy to create a fusion reaction in the secondary part of the weapon. Chapter 1 Introduction Page 16 GAO/RCED-99-100 Accelerated Closure of Rocky Flats salts); sand, slag, and crucibles (from plutonium metal production); and scrub alloy (a plutonium and aluminum alloy from plutonium recovery operations). The plutonium content of these residues ranges from onetenth of a percent to 80 percent. During production, Rocky Flats retained its residues to recycle the plutonium from them. When the site was shut down, it was left with about 106 metric tons of residues, contaminated with about 3.1 metric tons of plutonium. Each type of residue may require a different method of preparation for shipment; some residues must be stabilized, while others can be processed and packaged in their current form. The variety of residues, and the mixture of other materials with them, makes their management difficult. 5 The contractor is making progress in processing and repackaging residues and recently shipped a small quantity of more highly contaminated and higher- risk residues to DOE's Savannah River site for processing. Transuranic and transuranic mixed waste. Transuranic waste is radioactive waste contaminated with elements heavier than uranium, such as plutonium, in concentrations above 100 nanocuries per gram of waste. 6 This waste includes materials ranging from clothing and gloves to pieces of equipment or other materials that are contaminated with radioactivity. Figure 1.2 shows examples of typical transuranic waste drums. 5 For additional information on Rocky Flats' residues, see Nuclear Materials: Removing Plutonium Residues From Rocky Flats Will Be Difficult and Costly (GAO/RCED-92-219, Sept. 4, 1992), Nuclear Materials: Plutonium Storage at DOE's Rocky Flats Plant (GAO/RCED- 95-49, Dec. 29, 1994), and Department of Energy: Problems and Progress in Managing Plutonium (GAO/RCED-98-68, Apr. 17, 1998). 6 A nanocurie is one- billionth of a curie, which is the amount of radioactivity in 1 gram of radium. Chapter 1 Introduction Page 17 GAO/RCED-99-100 Accelerated Closure of Rocky Flats Figure 1. 2: Cutaway View of Transuranic Waste Drums Source: Kaiser- Hill. Transuranic mixed waste contains hazardous as well as radioactive materials. The contractor at Rocky Flats plans to dispose of approximately 14, 500 cubic meters of transuranic and transuranic mixed waste generated through former production activities or anticipated from the decontamination, decommissioning, and demolition of the site's buildings. In addition, the site plans to dispose of most of its residues as transuranic waste after they are processed and packaged in robust storage containers, called "pipe and go" containers, that are then packed into 55- gallon drums (see fig. 1.3). In total, site officials expect the site could generate up to 80, 000 drums of transuranic and transuranic mixed waste, which must be shipped in specially designed transportation casks. The contractor has not Chapter 1 Introduction Page 18 GAO/RCED-99-100 Accelerated Closure of Rocky Flats started shipping its transuranic wastes because the facility designated to receive these wastes, the Waste Isolation Pilot Plant (WIPP) in New Mexico, has not been available to receive these wastes. 7 The contractor is in the process of implementing additional storage for the site's transuranic wastes to allow processing and packaging and cleanup activities to continue while the site awaits the ability of WIPP to take Rocky Flats' transuranic wastes. Figure 1. 3: Sample Pipe and Go Container for Residues to Be Disposed of at the Waste Isolation Pilot Plant Source: Kaiser- Hill. Low- level and low- level mixed waste. Low- level waste has less radioactive content than transuranic waste-- 100 or fewer nanocuries per gram of waste. Low- level mixed waste is low- level waste that contains hazardous materials. At Rocky Flats, these two types of waste consist 7 WIPP is DOE's deep geologic repository for transuranic and transuranic mixed waste, located in an underground salt formation near Carlsbad, New Mexico. On Mar. 26, 1999, DOE made its first shipment to the facility from Los Alamos. DOE anticipates beginning shipments from Rocky Flats over the next several months. Chapter 1 Introduction Page 19 GAO/RCED-99-100 Accelerated Closure of Rocky Flats mainly of rags, paper, plastic, glassware, filters, soil, and building rubble with low levels of contamination. Through cleanup and closure, the site expects to ship over 180, 000 cubic meters of low- level and low- level mixed waste. Because this waste is less radioactive than transuranic waste, it does not require the same degree of special handling. After being packaged, it can be shipped by standard semitrailer trucks and trailers. Site officials reported that, in fiscal year 1998, the contractor shipped about 2,600 cubic meters of the site's projected 143,000 cubic meters of low- level waste to a disposal facility on DOE's Nevada Test Site and about 6, 500 cubic meters of the site's projected 60, 000 cubic meters of low- level mixed waste to a commercial disposal facility in Utah. According to DOE, the site has met its 1999 targets for shipments of low- level and low- level mixed waste. Cleanup and Closure of the Site In addition to preparing and shipping the site's nuclear materials and waste, DOE and the contractor are cleaning up and demolishing the site's structures and cleaning up the site for closure. Decontamination and decommissioning of the site's 691 buildings and facilities. This work involves removing or reducing radioactive and/ or hazardous contamination to stabilize the environment and to prepare the buildings and facilities for demolition. Decontamination and decommissioning may include dismantling equipment or scrubbing down portions of buildings. One hundred thirty- one of the site's 691 buildings and facilities have some radiological contamination, and 6 have significant radiological contamination. Others may be contaminated with hazardous materials. As of March 1999, decontamination and decommissioning had been completed for 48 buildings, 3 of which had some radiological contamination. In addition, the contractor reported that as of March 1999, 7 additional buildings were being decontaminated and decommissioned- - 3 with some radiological contamination and 4 with significant radiological contamination. Buildings and facilities on the site range from small tanks to massive processing buildings, including tents, trailers, towers, slabs, pads, stacks, and pipelines. Demolition of nearly 3.5 million square feet of buildings and facilities. After being decontaminated and decommissioned, the site's 691 buildings and facilities will be demolished. As of January 1999, the contractor had demolished 48 buildings and facilities comprising 109,266 square feet, or about 3 percent of the total square footage. According to contractor officials, this is consistent with the site's Chapter 1 Introduction Page 20 GAO/RCED-99-100 Accelerated Closure of Rocky Flats decontamination and decommissioning strategy, in which the majority of facilities are demolished later in the closure project. Remediation of 116 designated contaminated environmental sites. According to DOE, 116 of an estimated 367 environmental sites are expected to require soil remediation. The 367 environmental sites are locations on Rocky Flats where DOE and the regulators believed there could be radioactive or hazardous contamination. A DOE official reported that of 367 sites identified, 25 have been remediated, 116 may still require remediation, and the remainder may require no further action, because further examination revealed or may reveal that contamination levels are less than expected or nonexistent. The 116 environmental sites that may still require remediation include areas where radioactive or hazardous materials were buried or leaked. Remediation could include removing contaminated soil or water or employing other treatment options. In addition, surface water leaving the site must be safe for all uses, including drinking. Some of these contaminated sites are beneath existing structures, and their cleanup will not begin until after the structures have been demolished. Some environmental sites may be very complex and expensive to clean up, while others may be less so. Other contaminated environmental sites may be identified in the future, especially because the amount and level of contamination in the industrial area-- especially under the buildings- has not yet been determined. Contractor officials expect that many of the remaining environmental sites may not require further cleanup. Figure 1.4 shows workers in protective clothing conducting remediation activities at one of Rocky Flats' contaminated environmental sites. Chapter 1 Introduction Page 21 GAO/RCED-99-100 Accelerated Closure of Rocky Flats Figure 1. 4: Remediation Activities at One of Rocky Flats' Contaminated Environmental Sites Source: Kaiser- Hill. Disposal of up to 1 million items of personal property. Estimates of the site's personal property (including computers, chairs, and desks) vary- from approximately 600,000 to 1 million items-- because a complete inventory has not been done. 8 DOE officials said that much of the personal property is old and may be more of a liability than an asset. Therefore, in May 1998, the site was authorized to use expedited disposal methods, which allow the site to bypass certain federal disposal requirements, including those for screenings to determine whether other federal agencies can use the property before disposing of it. However, before releasing property to the public, the contractor must follow specific procedures to ensure that items are not contaminated with radiological or hazardous substances. According to the contractor, from fiscal year 1996-- when the site started disposing of its personal 8 For more information on Rocky Flats' property management, see Department of Energy: The Property Management System at the Rocky Flats Plant Is Inadequate (GAO/RCED-94-77, Mar. 1, 1994), Department of Energy: Property Management Has Improved at DOE's Rocky Flats Site (GAO/RCED-96-39, Dec. 28, 1995), and Department of Energy: Management of Excess Property (GAO/RCED-99-3, Nov. 4, 1998). Chapter 1 Introduction Page 22 GAO/RCED-99-100 Accelerated Closure of Rocky Flats property in preparation for closure-- through mid- February 1999, Rocky Flats disposed of almost 100,000 items of personal property. About onefourth of these items were disposed of using the expedited procedures, which were implemented near the end of fiscal year 1998. Parties Involved in Rocky Flats' Cleanup and Closure The cleanup and closure of Rocky Flats is a complex undertaking, involving not only DOE; the site's primary contractor, Kaiser- Hill; and subcontractors but also regulatory and oversight agencies and others with an interest in the site's cleanup and closure. The regulatory and oversight bodies include the EPA, the state of Colorado, the Department of the Interior's Fish and Wildlife Service, and the Defense Nuclear Facilities Safety Board. Other stakeholders include local governments; citizen, community, business, and environmental groups; and individuals. DOE DOE's Office of Environmental Management, a headquarters organization, is responsible for cleaning up the Department's nuclear weapons complex and closing down facilities, including Rocky Flats, that are no longer needed for producing nuclear weapons. In June 1998, Environmental Management released Accelerating Cleanup: Paths to Closure, 9 which projects the technical scope, cost, and schedule required to clean up and/ or close these facilities. At the Rocky Flats Field Office, approximately 230 DOE employees manage and oversee the site's cleanup. Other DOE headquarters organizations also play a role in the site's cleanup and closure, including the Office of Defense Programs, the Office of Fissile Materials Disposition, and the Office of Worker and Community Transition. In addition, other DOE sites play a significant role in Rocky Flats' cleanup and closure, especially those that are scheduled to receive materials or wastes from Rocky Flats. Contractor and Subcontractors In 1995, through a competitive procurement process, Kaiser- Hill Company, L. L. C. (Kaiser- Hill), 10 was awarded the contract to manage Rocky Flats through June 2000. Kaiser- Hill proposed managing the site's work through four principal subcontractors, which now include Rocky Mountain Remediation Services, L. L. C.; Safe Sites of Colorado, L. L. C.; Rocky Flats 9 Accelerating Cleanup: Paths to Closure (DOE/ EM- 0362, June 1998). 10 A company formed through a joint venture by IFC Kaiser International, Inc. and CH 2 M Hill. Chapter 1 Introduction Page 23 GAO/RCED-99-100 Accelerated Closure of Rocky Flats Closure Site Services, L. L. C.; 11 and Wackenhut Services, L. L. C. The first two companies perform most cleanup activities, the third handles support services, and the last provides security. Kaiser- Hill and the four principal subcontractors enter into contracts with other subcontractors to perform various site operations and cleanup activities. Regulatory and Oversight Agencies EPA and the Colorado Department of Public Health and Environment are the primary regulators for Rocky Flats. EPA derives its regulatory authority primarily from the Comprehensive Environmental Response, Compensation, and Liability Act of 1980, as amended (CERCLA) 12 and the Resource Conservation and Recovery Act of 1976, as amended (RCRA). 13 Colorado exercises regulatory authority over hazardous wastes under RCRA and the Colorado Hazardous Waste Act 14 and other legislative and regulatory requirements. Both regulatory agencies have field staff at Rocky Flats to oversee cleanup and closure activities. These federal and state laws cover hazardous wastes, but not special nuclear materials. 15 Under the Rocky Flats Cleanup Agreement, DOE, EPA, and Colorado annually establish or update regulatory milestones for the site for the next 2 fiscal years. If these milestones are not met, the regulators can fine DOE according to a penalty schedule included in the agreement. 16 In general, EPA has primary authority over the site's buffer zone, while Colorado has primary authority over the site's industrial area. The Department of the Interior's Fish and Wildlife Service has had a regulatory presence at Rocky Flats for many years. The Fish and Wildlife Service derives its regulatory authority from the Endangered Species Act. 17 11 Rocky Flats Closure Site Services, L. L. C., replaced DynCorp of Colorado as a top- level subcontractor in 1998. DynCorp continues to provide some services at Rocky Flats as a lower- tier subcontractor. 12 42 U. S. C. section 9601 et seq. 13 42 U. S. C. section 6901 et seq. 14 Colorado Revised Statutes 25- 15- 301 et seq. 15 These federal and state laws do not cover special nuclear materials or source or by- product materials as defined in the Atomic Energy Act of 1954, 42 U. S. C. 2014. However, the Rocky Flats Cleanup Agreement defines plutonium as a hazardous material under CERCLA. 16 According to DOE, to date, the site has not missed a regulatory milestone without an excusable delay (such as delays in WIPP's opening). 17 16 U. S. C. section 1531 et seq. Chapter 1 Introduction Page 24 GAO/RCED-99-100 Accelerated Closure of Rocky Flats The Endangered Species Act prohibits DOE from taking any actions that would jeopardize the existence of species listed as threatened or endangered. The Fish and Wildlife Service, through a consultative process, may require mitigation efforts to ensure the protection and recovery of listed species. The Congress created the Defense Nuclear Facilities Safety Board in 1988 to oversee DOE's defense nuclear facilities and to ensure the protection of public health and safety. The Board is charged with identifying safety problems at DOE's nuclear facilities and recommending corrective actions to the Secretary of Energy. If the Secretary accepts a recommendation, DOE develops an implementation plan. The Board has issued several recommendations pertaining to Rocky Flats, including recommendations about the safety of the site's plutonium and residues, and the site is implementing corrective actions to address these recommendations. Although the Board does not have regulatory authority over DOE, a memorandum of understanding attached to the Rocky Flats Cleanup Agreement recognizes the Board as the primary oversight entity for Rocky Flats' special nuclear materials and activities relating to them. Other Stakeholders The site's other stakeholders include local governments; community, business, and citizen groups; and individuals. The Rocky Flats Cleanup Agreement requires that these stakeholders be consulted during the development of cleanup plans. The stakeholders may also provide input to and exert influence on the regulatory and oversight agencies, as well as their local, state, and federal elected representatives. The stakeholders' level of involvement varies. Some of the stakeholders and their roles are listed below. Rocky Flats Citizens Advisory Board. The Citizens Advisory Board was formed in 1993 to provide informed, community- based recommendations to EPA, the state, and DOE on the cleanup of Rocky Flats. The board consists of up to 30 volunteers, including local citizens; businesspersons; Rocky Flats employees; and representatives of local governments, academia, and public interest and environmental organizations. Local communities. Because they are located near Rocky Flats and could be affected by its cleanup and closure activities, cities such as Arvada, Broomfield, and Westminster provide input to DOE and the contractor on cleanup and closure issues. Partly because the communities surrounding Rocky Flats do not depend for their economic Chapter 1 Introduction Page 25 GAO/RCED-99-100 Accelerated Closure of Rocky Flats vitality on jobs related directly or indirectly to the site, the cities generally agree on the need to close it. However, they do not agree on how the site should be used in the future. For example, Arvada wants to see part of the site used as an industrial area, while Broomfield and Westminster would like to have all of it converted to open space, with little or no development. County governments. Rocky Flats is located almost entirely within Jefferson County, along the foothills of the Rocky Mountains. Although the county government has only recently become involved in the site's cleanup and closure, DOE officials expect it to become a major stakeholder as the cleanup progresses and the site nears closure. About 35 acres of the site lie within Boulder County, which also borders the site on the north. Boulder County has also begun to take an interest in the site's cleanup and closure. Rocky Flats Local Impacts Initiative. Formed in 1991 and funded by DOE, this organization represents and serves as a focal point for the views and concerns of about 60 organizations, including businesses and environmental, academic, and citizen groups. It also advises DOE on the impact of workforce restructuring on local communities and manages several DOE- funded programs to help mitigate the impact of downsizing on these communities. Outside this organization, according to site officials, business groups such as the Denver and Northwest Metro Chambers of Commerce, the Colorado Forum, and various other groups also provide input to the site on issues concerning the cleanup and closure of Rocky Flats. The Rocky Flats Local Impacts Initiative will be disbanded in early 1999, and in April 1999, a new organization, the Rocky Flats Coalition of Local Governments, will begin operations. The coalition's mission will be to "provide an effective mechanism for local governments in the vicinity of Rocky Flats and their citizens to work together on issues of mutual concern relating to the safe, prompt and effective cleanup and closure of Rocky Flats, its future use and long term protection. . . ." Environmental/ activist groups. These types of groups have been involved in issues at Rocky Flats for many years. The groups' activities have ranged from conducting antinuclear protests during the site's production years to taking stands on current cleanup and closure issues. Objectives, Scope, and Methodology Concerned about the Department's ability to meet its current goal to close Rocky Flats by the end of 2006, the Chairman of the Senate Committee on Armed Services asked us to review (1) DOE's plans for accelerating the site's closure and challenges that could impede closure; (2) the condition of Chapter 1 Introduction Page 26 GAO/RCED-99-100 Accelerated Closure of Rocky Flats the site at closure and the activities that will remain after closure; and (3) the costs of closing the site and the savings expected from accelerating its closure. We performed our work at DOE headquarters in Washington, D. C.; DOE's Inspector General Denver Audit Group in Golden, Colorado; and the Rocky Flats Field Office, located on the Rocky Flats site, near Golden, Colorado. We also performed work at the primary contractor's and some of the subcontractors' locations on the site. We contacted other DOE sites and headquarters organizations whose activities either affect or are affected by Rocky Flats' closure. In addition, we performed work at EPA's Region VIII in Denver, Colorado, and at two Colorado offices the Office of Policy and Initiatives, within the Office of the Governor, and the Department of Public Health and Environment, both in Denver. We also obtained information from stakeholders in communities surrounding the site. To examine DOE's plans for accelerating the site's closure and challenges that could impede closure, we reviewed many complexwide and sitespecific planning documents, including Accelerating Cleanup: Path to Closure: Rocky Flats Environmental Technology Site and Closure 2006- Rocky Flats Closure Project: Management Plan, both dated June 1998, as well as plans and schedules from the Rocky Flats Field Office and KaiserHill. We also obtained and analyzed other documents. In addition, we interviewed DOE officials from the Office of Environmental Management, the Rocky Flats Field Office, and other DOE sites with activities related to Rocky Flats' closure. We also interviewed representatives of Kaiser- Hill and some of its subcontractors, as well as officials from EPA, Colorado's Office of the Governor and the Department of Public Health and Environment, and the Defense Nuclear Facilities Safety Board's Rocky Flats office. We obtained documents from and interviewed representatives of numerous stakeholder groups, including the Rocky Flats Citizens Advisory Board; the Rocky Flats Local Impacts Initiative; the Rocky Mountain Peace and Justice Center; and local city governments, including those of Broomfield and Westminster, Colorado. To determine the condition of the site at closure and the activities that will remain after closure, we obtained and analyzed the Rocky Flats Cleanup Agreement and interviewed officials from the three organizations that developed it: DOE (headquarters and Rocky Flats Field Office), EPA, and Colorado (the Office of the Governor and the Department of Public Health and Environment). In addition, we obtained and analyzed documents and interviewed officials from DOE's Office of Inspector General, Kaiser- Hill, Chapter 1 Introduction Page 27 GAO/RCED-99-100 Accelerated Closure of Rocky Flats some of the subcontractors, and the Defense Nuclear Facilities Safety Board. We also toured various facilities and cleanup projects at the site. Finally, we obtained documents and interviewed representatives from several local stakeholder groups, including the Rocky Flats Citizens Advisory Board, the Rocky Flats Local Impacts Initiative, the Rocky Mountain Peace and Justice Center, and local city governments. To determine the costs of closing the site and the savings expected from accelerating closure, we obtained and analyzed documents and interviewed officials from DOE's Office of Environmental Management and Rocky Flats Field Office and from Kaiser- Hill. Specifically, we reviewed cost and savings estimates in closure planning documents, including Closure 2006-- Rocky Flats Closure Project: Management Plan; cost estimates prepared by Kaiser- Hill and the Rocky Flats Field Office, including project baseline descriptions and project baseline summaries; and other reports by DOE and the contractor on the site's cost and savings estimates. We also interviewed regulatory officials and representatives of local stakeholder groups to obtain their views on the Department's cost and savings estimates for Rocky Flats. We provided DOE with a copy of a draft of this report for its review and comment. DOE's comments are discussed and evaluated at the ends of chapters 2 and 3. The full text of DOE's comments appears in appendix I. We conducted our review from May 1998 through March 1999 in accordance with generally accepted government auditing standards. Page 28 GAO/RCED-99-100 Accelerated Closure of Rocky Flats Chapter 2 Challenges to Accelerating the Site's Closure Chapt er 2 DOE and the primary contractor, Kaiser- Hill, are attempting to accelerate the closure of Rocky Flats to meet the Department's new target date of 2006. The contractor has not yet developed a detailed plan and schedule for closure by the end of that year and has encountered some delays in implementing the earlier plan for closing the site in 2010. 1 The contractor is developing a plan for closing the site by the end of 2006 and believes that it can take advantage of learning curves and efficiencies gained through early efforts to expedite required cleanup and closure activities. However, although DOE and the contractor have made progress in some areas, they face challenges that could hinder efforts to accelerate the site's closure. In addition, extensive requirements for coordinating the work at Rocky Flats with work at other DOE sites and challenges outside of DOE's control could further hinder efforts to close Rocky Flats by the end of 2006. Detailed Plan Assumes That the Site Will Be Closed in 2010 In fiscal year 1994, when the Department developed plans to close Rocky Flats, DOE estimated that the site could be closed as late as 2070. In 1995, DOE selected Kaiser- Hill to manage and operate Rocky Flats. At that time, Kaiser- Hill proposed closing the site in 2015. Then, in 1996, DOE's Office of Environmental Management announced efforts to accelerate the cleanup of contaminated sites throughout DOE's nuclear complex. In 1997, Kaiser- Hill proposed closing the site in 2010 and developed a detailed plan and schedule to support its proposal. This plan remains in effect today, even though DOE has advanced the date for closure to the end of 2006. To meet the 2006 target, the contractor must complete the tasks set forth in the 2010 plan in about 30 percent less time. Kaiser- Hill has started developing a detailed plan to close the site by the end of 2006. According to contractor officials, this plan will be submitted to DOE by the end of May 1999. In the meantime, both contractor and DOE officials are attempting to get ahead of the 2010 plan by accelerating activities they view as critical to closing the site by the end of 2006. While making progress in some areas, the contractor has incurred delays in some activities considered important to closing the site. These delays could affect the schedule for accomplishing other cleanup activities. For example, the contractor fell behind the 2010 schedule in preparing three types of plutonium- contaminated residues for removal from the site, as well as in shipping plutonium pits to DOE's Pantex Plant, the site designated to receive and store most of DOE's nuclear weapons 1 The 2010 plan is based on closing the site by the end of fiscal year 2010. Chapter 2 Challenges to Accelerating the Site's Closure Page 29 GAO/RCED-99-100 Accelerated Closure of Rocky Flats components. Such delays can have a cumulative impact because many of the site's cleanup and closure activities must be completed in sequence. For example, delays in removing residues and special nuclear materials from the buildings where they are now stored can delay efforts to decontaminate, decommission, and demolish these buildings. Site officials maintain that the contractor can make up for the delays experienced thus far and accelerate activities to close the site by the end of 2006. According to many site officials, the contractor is climbing a learning curve in many of the activities, and once it has gained experience, it will be able to accelerate activities and achieve efficiencies. However, the officials have not yet clearly indicated how learning curves and efficiencies will accelerate later activities in time to meet the 2006 target. Furthermore, subsequent cleanup tasks may present different problems. Despite DOE's and Kaiser- Hill's position that they can close the site by the end of 2006, several DOE and contractor personnel told us that although they think some acceleration of the 2010 plan is possible, they are not sure that closure by the end of 2006 is feasible. Some of these personnel believe that a date between 2006 and 2010 may be more realistic, while others characterize even the 2010 date as ambitious. Many of the site's regulators and stakeholders said they support efforts to accelerate Rocky Flats' closure but are more concerned that it be done right than that it be done by the end of 2006. The contractor's recent risk analysis of the 2010 closure plan identified uncertainties and technical problems that the contractor must overcome to close the site. The uncertainties and problems include such key areas as preparing the site's nuclear materials and wastes for shipment, establishing sites to take Rocky Flats' materials, and decontaminating and decommissioning the site's buildings and facilities. The risk analysis determined that unless the contractor resolves these existing uncertainties and technical problems, it has a 1- percent chance of closing the site by the end of fiscal year 2010. 2 Kaiser- Hill management stated that this risk analysis is a tool to identify and focus management's attention and planning efforts on cost and schedule uncertainties and problems that could affect the site's closure. Whether and when these uncertainties and technical problems are resolved will also affect the prospects for closing the site by the end of 2006. Both DOE and Kaiser- Hill 2 According to Kaiser- Hill, a schedule risk analysis process was initiated in 1998 to periodically identify and prioritize uncertainties that must be overcome to close the site by 2006. An initial analysis identified uncertainties associated with several technically complicated activities scheduled to occur in the later stages of closure; consequently, a 1- percent chance of overall success resulted. Chapter 2 Challenges to Accelerating the Site's Closure Page 30 GAO/RCED-99-100 Accelerated Closure of Rocky Flats officials emphasized that the site has been able to resolve or overcome uncertainties and problems in the past. Numerous Challenges Could Hinder Efforts to Accelerate Closure DOE and the contractor have identified four primary activities that will need to be accelerated in order to close the site by the end of 2006: (1) processing and removing plutonium- contaminated residues; (2) shipping special nuclear materials off- site; (3) decontaminating and decommissioning buildings; and (4) constructing closure caps-- man- made protective barriers between contamination that remains on the site and the public or the environment. According to DOE and contractor officials, the contractor may be able to accelerate the removal of special nuclear materials and residues by 2 years, allowing for closure in 2008, largely by identifying and implementing more expeditious ways of processing and shipping the residues and special nuclear materials. However, the officials are less confident that they can gain 2 more years by compressing the schedule for decontaminating and decommissioning buildings and constructing closure caps. These activities are scheduled for later years and largely require the completion of other activities first. We found challenges in each of the four areas that could hinder efforts to close the site by the end of 2006. Challenges in the Residues Program Recently, as well as historically, Rocky Flats has faced problems and delays in managing its plutonium- contaminated residues. According to DOE officials, to close the site by the end of 2006, the contractor needs, by 2003, to treat, package, and ship approximately 106 metric tons of residues to sites designated to receive them. However, DOE, the Defense Nuclear Facilities Safety Board, and we have reported that Rocky Flats has had problems managing its residues in the past. 3 To accelerate the removal of residues from the site, Rocky Flats is no longer planning to extract the plutonium from them. The site is now planning to send most of the residues that are high in plutonium content or categorized as high risk to DOE's Savannah River Site in South Carolina for processing. It is also planning to prepare the bulk of the residues-- sometimes by blending them with less contaminated or clean material to lower the percentage of 3 See Plutonium Working Group Report on Environmental, Safety and Health Vulnerabilities Associated with the Department's Plutonium Storage (DOE/ EH- 0415, Nov. 1994), Recommendation 94- 1, Improved Schedule for Remediation in the Defense Nuclear Facilities Complex, Defense Nuclear Facilities Safety Board (59 FR 28848, May 1994), and Department of Energy: Problems and Progress in Managing Plutonium (GAO/RCED-98-68, Apr. 17, 1998). Chapter 2 Challenges to Accelerating the Site's Closure Page 31 GAO/RCED-99-100 Accelerated Closure of Rocky Flats plutonium and sometimes by just repackaging the materials-- for disposal as transuranic wastes at the Waste Isolation Pilot Plant (WIPP) in New Mexico. A DOE official estimates that this change will shave at least 1 year from the residues program and save at least $50 million. Figure 2.1 shows a Rocky Flats worker handling plutonium residues in a glovebox. 4 Figure 2. 1: A Rocky Flats Worker Handling Plutonium Residues in a Glovebox Source: Kaiser- Hill. However, even under this revised approach to managing the site's residues, the contractor has recently experienced additional delays in processing and repackaging some of the site's residues. According to a DOE official overseeing the processing, repackaging, and removal of residues, some repackaging efforts have fallen behind schedule and some processes have been temporarily shut down. According to Kaiser- Hill officials, they are 4 A glovebox is a sealed glass, metal, or plastic chamber designed to protect a worker handling radioactive or hazardous materials from exposure to contamination. The worker, who remains outside the box, uses gloves attached to the wall of the chamber to handle the contaminated materials. Chapter 2 Challenges to Accelerating the Site's Closure Page 32 GAO/RCED-99-100 Accelerated Closure of Rocky Flats adding funding and other resources primarily additional workers and equipment to make up for these problems, catch up to the 2010 schedule, and accelerate future processing and repackaging efforts. According to contractor officials, despite some of the earlier delays, progress is being made in processing and repackaging residues. 5 The contractor told us that it has already made up for some of the delays and is working to overcome the others. According to DOE, as of April 1999, the site had caught up to the 2010 processing schedules for four of the five major residue types. In addition to the contractor's efforts, DOE redirected an additional $2 million to $3 million in fiscal year 1999 funding to residue repackaging activities, according to site officials. The recent delays have nevertheless prompted regulatory and DOE officials to question whether the contractor will meet its fiscal year 1999 and 2000 goals for processing and repackaging the site's residues. In addition, the site has had problems obtaining the certification, or approval, it will need from DOE's Carlsbad Area Office to ship its processed and packaged residues to WIPP for disposal. In August and September 1998, auditors from the Carlsbad Area Office found adverse conditions, such as inadequate record- keeping and verification procedures, that required correction before the residues could be certified for eventual disposal at WIPP. A DOE site official told us that the audit results indicated a serious cultural problem-- a failure by subcontractor engineers and managers to understand DOE's requirements and make a commitment to meeting them. The residues will not require further processing, and after the site takes the required corrective actions, the auditors will return to certify the residues. Their return visit was scheduled for March 1999. According to Kaiser- Hill officials, the contractor has completed correcting the findings from the 1998 audit. An audit of the site's transuranic waste characterization and certification processes in March 1999 resulted in no major audit issues. Challenges to Accelerating the Shipment of Special Nuclear Materials Off- Site Rocky Flats has shipped about 80 percent of its plutonium pits off- site, and the remainder are expected to be shipped to the Pantex Plant near 5 In Mar. 1999, Kaiser- Hill officials said that the contractor is approaching the production rates needed to finish reprocessing all of the residues by fiscal year 2002, a date the officials view as critical to closing the site by 2006. Chapter 2 Challenges to Accelerating the Site's Closure Page 33 GAO/RCED-99-100 Accelerated Closure of Rocky Flats Amarillo, Texas, or to the national laboratories by September 1999. 6 However, most of the site's plutonium metals and oxides must still be stabilized, packaged in long- term storage containers, 7 and then shipped to DOE's Savannah River Site for storage until they can be processed for ultimate disposal at DOE's high- level waste repository. The Savannah River Site is modifying an existing structure to accommodate the accelerated shipment of Rocky Flats' plutonium metals and oxides. The site is now planning to accelerate the stabilization, packaging, and shipment of its plutonium metals and oxides by 2 years. The 2010 closure schedule called for this plutonium to be stabilized, packaged, and shipped to Savannah River by the end of fiscal year 2004. The site now expects to complete these tasks by May 30, 2002. However, as we reported in April 1998, the site has encountered problems-- including difficulties in procuring an automated plutonium stabilization and packaging system-- that have delayed its progress and increased its costs. 8 Recently, because of reliability and technical difficulties, the site decided to use manually operated furnaces to stabilize the plutonium oxides instead of the stabilization portion of the automated system. Site officials estimate that these furnaces should be ready to stabilize the plutonium oxides in April 2000. The packaging portion of the automated system, turned over-- a year late-- to the contractor in September 1998, must be operational by December 1999 to meet the accelerated shipping schedule. However, as of February 1999, the complex automated plutonium packaging system was still in a warehouse in a community near the site. The automated packaging system proved very sensitive and performed below expectations during off- site testing and required unanticipated modifications. The contractor must still move the system to the site, install it in a building within the site's protected area, test it, and bring it up to operational capability-- tasks that may require months' worth of adjustments to the equipment, given its complexity and sensitivity. While the contractor has developed and is implementing a schedule to install the equipment to enable the stabilization and accelerated shipment of the plutonium metals 6 DOE anticipates that the pits that can be shipped to the Pantex Plant will be shipped by the end of May 1999. 7 Some plutonium metals are classified because of their shape or constituents and will require additional processing at another site to make them unclassified before they can be stored. These metals will be shipped to the site designated to receive them, where they will be processed and then packaged into long- term storage containers. 8 Department of Energy: Problems and Progress in Managing Plutonium (GAO/RCED-98-68, Apr. 17, 1998). Chapter 2 Challenges to Accelerating the Site's Closure Page 34 GAO/RCED-99-100 Accelerated Closure of Rocky Flats and oxides, some site officials note the challenges ahead and question the contractor's ability to meet the required time frames. Challenges in Decontaminating and Decommissioning Buildings Of the 691 buildings or facilities at Rocky Flats, as of March 1999, 48 had been decontaminated, decommissioned, and demolished. Three of these buildings had some radiological contamination. In addition, the contractor reported that as of March 1999, seven additional buildings were being decontaminated and decommissioned-- three with some radiological contamination and four with significant radiological contamination. According to the 2010 closure plan, the majority of the remaining buildings, including some of the most difficult radiologically contaminated buildings, are now scheduled for decontamination and decommissioning from 2005 through 2007, and over two- thirds of the demolition is scheduled from 2006 through 2009. Contractor officials have not yet determined how the schedule for decontamination, decommissioning, and demolition can be compressed enough to close the site by the end of 2006. The contractor is developing a detailed decontamination and decommissioning schedule as part of its detailed plan for closing the site by the end of 2006. According to the contractor, its senior management recognizes that the site faces a daunting task in achieving the accelerated decontamination and decommissioning of the site's nuclear facilities; nevertheless, the managers remain convinced that the earlier closure can be accomplished. However, some DOE and contractor officials have questioned both the feasibility of completing the work under the compressed schedule and the availability of resources-- especially of qualified workers-- to carry out the work on time. The contractor has successfully conducted some of the more complex early decontamination and decommissioning work nearly on schedule, but at double the anticipated cost. In decontaminating and decommissioning two of the first major buildings at the site a health science building and a plutonium processing building-- the contractor found that the work on these radiologically contaminated buildings took longer and cost more than planned. The tasks proved to be more complex and generated more waste than expected, and unanticipated radiological or hazardous contamination was found. The contractor offset delays of several months through the use of overtime work and the application of lessons learned, especially in reducing the time for packaging waste materials. As a result, the contractor finished decontaminating and decommissioning one building only about a month behind schedule and expects to do the same for the second building. However, overcoming these problems and delays had a significant cost. The contractor more than doubled the cost estimate for Chapter 2 Challenges to Accelerating the Site's Closure Page 35 GAO/RCED-99-100 Accelerated Closure of Rocky Flats decontaminating and decommissioning the plutonium processing building, from $21. 1 million in November 1997 to $55.4 million in October 1998. 9 Contractor officials said they expect to learn from their early efforts and develop efficiencies that will enable them to make up for lost time, reduce costs, and accelerate the decontamination and decommissioning of the remaining buildings. For example, according to Kaiser- Hill officials, the subcontractor was able to remove gloveboxes five times faster from the plutonium processing building by applying lessons learned-- using better tools and learning to cut the gloveboxes to better fit into the disposal containers-- and by funding overtime work. According to contractor officials, as of March 1999, over 120 gloveboxes had been removed from this building. However, earlier efforts may not always be applicable because each building-- especially each radiologically contaminated building-- may present unique problems. Because different types of activities took place in the buildings where nuclear weapons were produced, the buildings contain widely different levels and types of contamination, requiring different cleanup activities. Adding to the challenges involved in decontaminating, decommissioning, and demolishing the site's buildings and facilities, the contractor increased its estimates of the wastes expected from these efforts. These wastes will ultimately have to be packaged and removed from the site. Primarily on the basis of its experience with decontaminating and decommissioning the first major buildings and some subsequent changes in approach, in July 1998, the contractor increased its estimates of transuranic waste from about 9, 500 cubic meters to over 14,500 cubic meters and of low- level waste from about 66, 000 cubic meters to nearly 143, 000 cubic meters. It also decreased its estimate of low- level mixed waste by over 20,000 cubic meters. Contractor officials stated that they believe they will be able to ship these wastes off- site at the rate they are generated by decontamination, decommissioning, and demolition activities. Contractor and DOE officials told us that decontamination and decommissioning activities tend to be labor intensive, especially for former nuclear weapons production buildings in the site's protected area. 10 9 These cost estimates are for decontaminating, decommissioning, and demolishing the building cluster, which consists of the primary plutonium processing building and its support buildings and facilities. 10 The protected area is a safeguarded zone within the site's industrial area where activities that involve special nuclear materials are conducted. Access requires special authorization, and a protective force of guards and physical barriers provide security for the nuclear materials. Chapter 2 Challenges to Accelerating the Site's Closure Page 36 GAO/RCED-99-100 Accelerated Closure of Rocky Flats Workers, who require special training and security clearances, must go through time- consuming procedures to dress in required protective gear and enter contaminated buildings. Site officials said they plan to create special decontamination and decommissioning teams to work simultaneously on different radioactively contaminated buildings. They noted that using teams should create efficiencies, allowing them to compress the schedule for decontamination and decommissioning. According to contractor officials, the majority of the site's buildings are not contaminated and their decontamination and decommissioning will not require special training, security clearances, or protective equipment. Challenges With the Use of Closure Caps The contractor is planning to use closure caps to isolate residual contaminants in four areas, but the site's regulators have agreed to the use of these caps for only two of the areas. Closure caps are man- made barriers designed to isolate contaminants from the surrounding environment or the public. Descending layers are made of increasingly finer materials to restrict the infiltration of water to contamination below (see fig. 2.2). Figure 2. 2: Diagram of the Layers of a Closure Cap Source: GAO's presentation of data provided by Kaiser- Hill and DOE. 24 12 24 Top Soil and Vegetation Gravelly Sand - Coarser Material Sandy Gravel - Finer Material Membrane- Man- Made Material Clay Layer Gravel or Rock - Structural Backfill Chapter 2 Challenges to Accelerating the Site's Closure Page 37 GAO/RCED-99-100 Accelerated Closure of Rocky Flats As allowed under the Rocky Flats Cleanup Agreement, the contractor plans to construct closure caps over the site's landfills and solar evaporation ponds 11 (about 33 acres of caps). However, the contractor also plans to construct closure caps over two portions of the industrial area (an additional 31 acres) after the contaminated buildings have been demolished. DOE and the contractor are just starting to discuss the use of these additional caps with the regulators and stakeholders, and no agreements have been reached. Contractor officials told us they need a final decision on the use of closure caps for the two portions of the industrial area by 2004 if they are to finish constructing the caps by the end of 2006. If the contractor is not allowed to use caps in these areas, site officials said, the costs of closure could be higher and the site's closure could be delayed. Many of the site's stakeholders oppose the use of additional closure caps because they are concerned that the caps will not provide an adequate barrier for the industrial area for as long as necessary. Given current technology, they expect the caps to fail long before the radiological contamination ceases to pose a threat to human health and the environment-- many thousands of years in the future. A DOE official said that closure caps have failed in the past, primarily because the construction was not adequate for the conditions or the caps were not properly maintained. Coordination of Closure Activities Could Affect Acceleration Closing Rocky Flats depends on coordinating activities across the DOE complex, as well as outside the complex. Virtually everything at the site must go somewhere else for storage or disposal. 12 Currently, DOE does not have sites to receive all of the materials and wastes that must be removed from Rocky Flats. Furthermore, other DOE facilities will need sites to receive their materials and wastes, and Rocky Flats will be competing with these other facilities for storage and processing services, as well as for vehicles and containers to transport materials and wastes. The Department has made some efforts to coordinate activities across the DOE complex to support Rocky Flats' accelerated closure, including 11 According to documentation from the site, these ponds were used to store and evaporate radiological and hazardous wastes. 12 Exceptions include some uncontaminated or slightly contaminated materials that may be disposed of on- site. Chapter 2 Challenges to Accelerating the Site's Closure Page 38 GAO/RCED-99-100 Accelerated Closure of Rocky Flats establishing a headquarters office, a senior management team, and a management plan. Rocky Flats Does Not Have Facilities to Take Some of Its Materials and Wastes Rocky Flats has shipped some of its nuclear materials and wastes to other DOE sites and commercial facilities. It has also designated other sites to receive additional types of materials, but these sites have not yet been able to receive the materials from Rocky Flats. However, no sites are available to take several orphan materials and wastes, including some low- level mixed wastes and uranium contaminated with plutonium or hazardous materials. No sites are available to take these materials because existing facilities are not licensed to accept them. Rocky Flats has already shipped plutonium pits to the Pantex Plant near Amarillo, Texas; low- level waste to a disposal site on the Nevada Test Site; and enriched uranium to the Oak Ridge Reservation in Tennessee. In addition, some materials have been sent to commercial facilities. For example, some low- level mixed waste has gone to the Envirocare disposal facility in Utah, and some sanitary waste (nonradioactive and nonhazardous waste) has gone to a landfill near Erie, Colorado. Other types of materials and wastes have been designated to go to other DOE sites. As noted, the Savannah River Site in South Carolina is designated to receive the site's plutonium metals and oxides, and the WIPP facility near Carlsbad, New Mexico, is designated to receive transuranic and transuranic mixed waste. (Fig. 2.3 shows the location of the sites that have accepted or expect to receive Rocky Flats' nuclear materials and wastes.) Chapter 2 Challenges to Accelerating the Site's Closure Page 39 GAO/RCED-99-100 Accelerated Closure of Rocky Flats Figure 2.3: Sites That Have Accepted and Expect to Receive Rocky Flats' Nuclear Materials and Wastes Key: Solid lines indicate that shipments have occurred; broken lines indicate that no such shipments have taken place. Note: The map shows the sites that are receiving or are designated to receive the majority of these types of materials. Small amounts of the materials may be sent to other sites. Source: GAO's presentation of data provided by DOE. Envirocare Low- Level Waste/ Some Low- Level Mixed Waste Disposal Oak Ridge Reservation Highly Enriched Uranium Storage Savannah River Site Residue Processing and Plutonium Storage Pantex Plant Plutonium Pit Storage Waste Isolation Pilot Plant Transuranic/ Transuranic Mixed Waste Disposal Nevada Test Site Low- Level Waste Disposal Rocky Flats Enviornmental Technology Site Current receiver sites Future receiver sites Plutonium Metals and Oxides Some Residues Chapter 2 Challenges to Accelerating the Site's Closure Page 40 GAO/RCED-99-100 Accelerated Closure of Rocky Flats Rocky Flats currently has nowhere to send low- level mixed waste with higher plutonium contamination (10 to 100 nanocuries per gram of material). Rocky Flats expects to generate about 10,000 cubic meters of this kind of waste, but no commercial or DOE facility has the RCRA permits required to accept it. 13 According to site officials, the most promising option for disposing of the site's orphan low- level mixed waste is to enter into a contract with a waste management company that is interested in operating a low- level mixed waste disposal facility in eastern Colorado. The company is currently operating a hazardous waste disposal facility at this location but does not have the authority to accept low- level mixed waste. However, according to DOE officials, the Department is required under a DOE order to use DOE facilities for radioactive waste disposal and can use commercial facilities only on an exception basis. 14 DOE recently analyzed this waste disposal policy to determine if it needed to be changed. DOE headquarters put the proposal for the Colorado waste disposal facility on hold during this study. On March 11, 1999, the Department announced that the policy analysis had concluded that DOE should continue its preference for using DOE disposal facilities for DOE wastes and should use commercial facilities under an exemption process when disposal at DOE facilities is not practical. DOE has delegated the exemption authority to the managers of its field offices- in consultation with its Office of Environment, Safety and Health-- to facilitate the process when the use of commercial facilities is necessary and in DOE's best interest. According to site officials, if the Colorado disposal facility is not established, Rocky Flats may have to store its orphan low- level mixed waste on- site, greatly diminishing the likelihood of closing the site by the end of 2006. Alternatively, site officials say, the site could send this orphan waste to existing disposal facilities at another DOE site (if the site could obtain a state permit to dispose of hazardous waste) or to a commercial facility (if the facility could obtain a license to dispose of low- level radioactive waste). However, according to the site officials, these alternatives appear unlikely. 13 Low- level mixed waste includes hazardous wastes and therefore is subject to regulation under RCRA. Authorized state hazardous waste programs issue permits for hazardous waste treatment, storage, and disposal within their borders. 14 Department of Energy Order on Radioactive Waste Management (DOE 5820.2A, Sept. 26, 1988). Chapter 2 Challenges to Accelerating the Site's Closure Page 41 GAO/RCED-99-100 Accelerated Closure of Rocky Flats Rocky Flats also needs a site to receive about one- fourth of its enriched uranium that is contaminated with plutonium. The site is sending most of its enriched uranium to the Oak Ridge Reservation. However, Oak Ridge is unable to take uranium that is contaminated with plutonium, and Rocky Flats cannot remove enough of the plutonium contamination to send all of its uranium to Oak Ridge. Rocky Flats may be able to send this plutoniumcontaminated uranium to Savannah River, which can process the material. However, DOE is evaluating other technical options and is attempting to determine where existing environmental impact statements allow for the disposition of the remaining uranium. 15 Still another orphan material at the site is depleted uranium contaminated with polychlorinated biphenyls (PCB), a toxic substance. 16 A few drums of this material were unearthed during a recent environmental cleanup project at the site. The one DOE facility that can process depleted uranium with PCBs is the Oak Ridge Reservation. However, Tennessee is not allowing the site to accept this waste. DOE is currently exploring potential commercial disposal options for this material. Other Coordination Issues Could Affect the Site's Closure To close by the end of 2006, Rocky Flats will need adequate numbers of specialized transportation vehicles to ship large amounts of special nuclear materials and nuclear wastes in the near future. However, contractor officials regard the coordination of shipping schedules as a "key challenge," given projected generation rates, volumes, and storage capacity. For example, plutonium and enriched uranium must be shipped in specially equipped trucks and trailers called Safe Secure Transports, managed by DOE's Albuquerque Operations Office. Some Rocky Flats officials have questioned whether enough of these transports will be available when the site needs them, especially when shipping schedules change and other sites are competing for their use. The site's transuranic wastes must be shipped in another type of truck and trailer with specialized transportation casks called Transuranic Package Transporters (TRUPACT), managed by DOE's Carlsbad Area Office, where WIPP is located. DOE has only 15 TRUPACTs available, and, according to site officials, Rocky Flats will need two to three 15 Environmental impact statements are prepared to accompany major federal actions under the National Environmental Policy Act, 42 U. S. C. 4321 et seq. 16 Depleted uranium is natural uranium that has had most of its fissionable isotope, uranium 235, stripped out for use in weapons or nuclear fuel production. PCBs are regulated by EPA under the Toxic Substances Control Act, 15 U. S. C. 2601 et seq. Chapter 2 Challenges to Accelerating the Site's Closure Page 42 GAO/RCED-99-100 Accelerated Closure of Rocky Flats times that number to meet its schedule for shipping transuranic wastes, at the same time that other DOE sites will also need to ship transuranic waste to WIPP. For example, under a court- approved consent order, the Idaho National Engineering and Environmental Laboratory must begin shipping transuranic waste off- site by April 30, 1999, ship 3,100 cubic meters of this waste off- site by December 30, 2002, and remove all transuranic waste from the site by 2018. As these dates approach, the laboratory's needs will grow more critical and could take priority over Rocky Flats'. The priority given to Rocky Flats for limited transportation and other resources will have an important impact on DOE's ability to close the site by the end of 2006. However, the Carlsbad Area Office has assured Rocky Flats that sufficient numbers of TRUPACTs will be available to support the shipping schedule for the site's accelerated closure. The question of how much priority will be given to Rocky Flats' needs is not limited to transportation resources. Rocky Flats is located organizationally under the Office of Environmental Management and often depends on receiving cooperation, priority for its needs, and budgetary support from other DOE organizations to move forward with activities required to close the site. In some instances, other DOE organizations have not given priority to such activities. For example, Rocky Flats depends on the Pantex Plant, which is managed by DOE's Office of Defense Programs, to receive and store the majority of its plutonium pits. In fiscal year 1998, Defense Programs' funding for the Pantex Plant to receive Rocky Flats' plutonium pits was not sufficient, and this, in part, caused some shipments to be delayed. This issue was resolved in June 1998 when Defense Programs and Environmental Management agreed that Defense Programs would provide the resources needed to support the transportation, receipt, and storage of the pits at the Pantex Plant. DOE Has Taken Steps to Promote Coordination DOE has made efforts to coordinate activities across the Department to support Rocky Flats' accelerated closure. These efforts include establishing a headquarters office, a senior management team, and a management plan. Under the Office of Environmental Management, the Rocky Flats Program Office at headquarters works to coordinate Rocky Flats' closure activities, primarily by working with the program people within various DOE organizations and sites. According to DOE officials, the staff in the Rocky Flats Program Office have worked to establish sites to receive Rocky Flats' materials and wastes, resolve issues raised under the National *** End of document. ***