Yardlines, June 2014

IN THIS ISSUE NNS ModSim on Full Display CVN 72 Team Working Smarter

Yardlines

Photo by Chris Oxley

Shipbuilders Enjoy a Healthy Fun Run

A Publication of Newport News Shipbuilding

June 2014

“It’s exciting to see just how different things are going to look once the new structure gets up there,” said Shipfitter Keith Rogers about the new top for the carrier’s island.

Rogers and his team helped the USS Abraham Lincoln (CVN 72) reach a milestone April 18 when the island’s new O10 and O11 levels were lifted into place in Dry Dock 11.

The 68-ton structure will contain Lincoln’s Primary Flight Control, or Pri-Fly, and function like a conventional airport control tower.

The structure is 88 feet long and 32 feet wide and was lifted by the 310ton gantry crane that straddles Dry Docks 10 and 11.

know when they are moving below or “topside.”

During a Nimitz-class carrier’s refueling and complex overhaul (RCOH), the new top level and mast (which will be installed later this summer) will give the island a new look. The change also differentiates the appearance of a post-RCOH ship from one yet to undergo a mid-life refueling and overhaul.

“We’re working to get the ship back into service,” said Shipfitter Foreman Silvester Browning. “Take a look at it now. It’s taking its personality back, the personality of a warship.”

Abraham Lincoln is on track to return to the fleet in 2016. I By Mike Dillard

So why is the new structure called a level and not a deck?

Aboard a carrier, all the floors below the hangar or “main deck” are referred to as decks. Above the hangar, everything becomes an “O level.” On a carrier, this system helps shipbuilders and ship’s force to

The 68-ton structure that will contain the ship’s Primary Flight Control is lifted atop USS Abraham Lincoln (CVN 72) April 18, 2014. Photo by John Whalen

When the whistle blew May 17 for the start of the shipyard’s seventh annual 5K, more than 1,100 people took off running and walking, and some were pushed in strollers.

“The 5K is always a fun event, and that’s important because we want to promote exercise as a fun and healthy way to spend time with family members, friends and co-workers,” said Brady Goggin, HealthWaves’ senior program coordinator.

The 5K started and ended at Victory Landing Park, where there was music, refreshments and balloons for the children. Participants also donated 244 lbs. of nonperishable canned items and $100 to the Virginia Peninsula Food Bank.

While every participant was a winner for exercising and

having fun, there were prizes. The Challenge Cup was presented to the shipyard’s Legal team for attracting the highest percentage of family and friend participation.

The Challenge Plaque was awarded to the Navy Programs team for gaining the highest percentage of craftsman participation. Awards were also presented to the top runners.

Top 3 Males: Chuck Love (17:41), James Brittain (18:35) and Colin Meigs (18:37). Top 3 Females: Ann-Germaine Danz (18:44), Kelsey Osborne (19:38) and Shameia Rogers (20:27). Top 3 Boys 12 and Under: Cameron Hagen (24:28), Makoa Teixeira (26:33) and Brett Hagen (26:48).

Top 3 Girls 12 and Under: Kaitlynne Costain (25:58), Claire Bauer (26:47) and Jessica Costain (28:42).

To see a highlights video of the event, visit www.huntingtoningalls.com/5K.

Benefits & Wellness Do your summer memories include days spent tanning with mayonnaise, baby oil mixed with iodine, or even solid shortening rubbed on your skin? If so, you’re not alone. A few decades ago, people didn’t know that just one serious sunburn increases the risk of developing skin cancer.

Today, there are more new cases of skin cancer than cases of breast, prostate, lung and colon cancers combined. It is so common that one in five Americans will develop skin cancer over the course of their life, according to the Skin Cancer Foundation. This fact is not a surprise to Electrical Engineer Charles Gorski. Gorski’s father and father-in-law have both had skin cancer. That’s one reason Gorski is vigilant about checking his skin.

“I had a DermaScan a year ago and got another one this year. The technology is pretty neat,” said Gorski. A DermaScan is used to identify possible sun damage by viewing the skin with ultraviolet light.

The scan doesn’t identify skin cancer, but can be used to highlight areas of concern and does lead some people to visit the dermatologist or their primary care physician for follow-up.

Any spots on your skin that aren’t symmetrical, have blurry or jagged edges, are more than one color, are larger than a pencil eraser or are raised above the surface or uneven should be shown to your doctor.

These characteristics are used to identify possible skin cancer.

Gorski wasn’t always aware of the importance of sun protection. “I didn’t do much with sunscreen when I was younger. I used Hawaiian Tropic’s suntan oil. But I’ve become a lot more aware about sun protection since my children were born.”

Current guidelines suggest at least one ounce of sunscreen be applied 20-30 minutes before sun exposure.

Employees who work outside should be sure to protect their skin with a combination of sunscreen and protective clothing. Skin cancer affects everyone, regardless of their skin tone or ability to tan, so everyone should take protective measures.

The American Cancer Society recommends people “Slip! Slop!

Slap! and Wrap” to ensure maximum sun protection.

• Slip on a shirt you can’t see through when held up to a light.

• Slop on broad spectrum sunscreen SPF 30 or higher.

• Slap on a wide-brimmed hat.

If you wear a baseball cap, protect your ears and neck with sunscreen.

• Wrap on sunglasses with 100 percent UVA and UVB absorption.

toward her degree at the University of Virginia, she spent one summer interning as an audiology tech in the shipyard’s clinic. “My job was to conduct hearing screenings for potential and current employees,” said Dennie. “It was during that summer that my passion for industrial audiology began.”

Before being hired by the shipyard, potential employees must undergo a hearing test at Newport News Shipbuilding’s on-site clinic. These tests are overseen by the shipyard’s audiologist.

For the first time in 40 years, a new doctor is leading the audiology team at the clinic. Her name is Dr. Helen Dennie and she took over after Dr. Chris Zambas retired in April.

Dennie is no stranger to NNS. While she was working

Since then, Dennie has received her doctorate from Central Michigan University and has worked in private practice and hospitals and has played an integral role in founding and managing hearing conservation programs for employers throughout Hampton Roads.

“I was thrilled when I found out I would be coming back to the shipyard,” said the Hampton native.

As the shipyard’s audiologist, Dennie leads NNS’ hearing conservation program, answers questions, refers employees to specialists as needed, meets with retirees and spends one-on-one time with shipbuilders who have shown a major shift in their hearing patterns over time.

Dennie is also responsible for researching and comparing

new hearing protection equipment for the shipyard.

“However, the absolute best part of my job is interacting with employees,” she said.

Dennie is a strong advocate for education. “I want shipbuilders to understand that hearing protection doesn’t stop when they walk out of the shipyard gates,” she said.

“We live in a very noisy world and, fortunately, hearing protection is something that can be controlled – which is why it’s so imperative that shipbuilders understand why they are wearing the safety equipment required for each work area.”

Dennie goes to the waterfront often to visit shops and tour ships. “The best way for me to understand the different noise environments at NNS is to experience them for myself,” she said. “By physically being in the environments and speaking with shipbuilders, I’m more knowledgeable about their work areas and better prepared to help protect them.”

She added, “It’s obvious to me that employees here take pride in what they do. That pride extends to me when I know I’m protecting those shipbuilders who are ultimately responsible for building the world’s greatest submarines and aircraft carriers for our Navy.” I By Lauren Ward

Dr. Helen Dennie is responsible for overseeing all audiology operations at the shipyard’s clinic. As part of those operations, Dennie examines shipbuilder Robert Hendrix’s ear to ensure his hearing is superb. Photo by John Whalen

Dr. Dennie’s

HEARING PROTECTION TIP Make sure to keep your ear muffs in good condition to ensure a proper seal. If the pads become flat or out of shape, replace them. AND remember, hearing protection doesn’t stop when you walk out of the gate.

For Facilities Maintenance Manager Rhonda King, moving to the Philippines during the last two years of high school would prove to be a life-changing experience.

“I didn’t really want to move because I wanted to finish out my most important years with my school friends,” she said. “But I’m glad I went; it was a great experience – it’s a beautiful country.”

The experience also changed her perception.

with every trade and nearly every profession across the shipyard.

“The Philippines and the changes I was forced to make made me more flexible to change and open to more challenging work conditions.”

Her teams have also been instrumental in the execution of every special event – such as christening and keel-laying ceremonies – at the shipyard since 2006, when General Foreman Jerry Owenby inherited the duty and asked her for support. This partnership has evolved and the two have become great friends, and now King has taken the reins from her mentor.

When she returned to the United States, King balanced school with a few part-time jobs before being accepted into The Apprentice School. The daughter of a rigger, she initially thought she would follow in her father’s footsteps, but with a nudge from a school administrator, she selected the electrician’s path instead. King said that her 25-year career has carried with it incredible opportunities and has forged lifelong friendships.

“We really are one big family at NNS,” she said. “We often spend more time with our co-workers than we do with our families.”

King’s teams provide and install critical support equipment and power services that make production possible. From shipboard repair and maintenance to temporary lighting and field machining service support, her team of more than 70 touches every ship and every shop and works

“We make a good tag team,” said Owenby. “I often know what Rhonda is thinking without either of us saying a single word.” Owenby believes that it’s also this type of collaboration that makes King’s teams so effective.

“No matter what the project is or what our day-to-day job is, our teams pull together to make sure we satisfy our customers and give our guests a great experience,” said Dennis Holmes, an industrial heat specialist.

Once a ship is painted and ready, they work hard to juggle the many demands of the event site. Everything from barges, staging, seating and lighting, to bunting, bow flags and bow medallions has been coordinated and installed by her teams.

Though King never saw herself as a shipbuilder growing up, she couldn’t imagine a different journey.

“It’s not anything I had ever imagined myself doing, but it has been such a rewarding and fulfilling experience being here.” | By Jeremy Bustin Facilities Maintenance Manager Rhonda King discusses an upcoming project with Industrial Heat Specialist Dennis Holmes. Photo by Ricky Thompson

As USS Abraham Lincoln (CVN 72) begins the second year of her refueling and complex overhaul (RCOH), thousands of shipbuilders are working hardafter to get the ship Several months leaving Dry back to the fleet on budget and on Dock 12, thousands of shipbuilders schedule.

Staying on schedule is no are continuing to get the nexteasy task because every ship arrives generation aircraft carrier Gerald R. with challenges.

Forto Ford unexpected (CVN 78) ready for delivery Lincoln, 25 years at sea had left the Navy. To date, the ship’s mainall four of her catapults badly corroded. engines have not been turned on – but that’s about to change.

“We needed to replace the bottom 22 inches on both wallssteaming down thethe “We’re working toward full length of the catapult,” said main engines, which is like turning Shipfitter Kenneth Freeman.

“After the engine on for the first time,” said cutting the old steel out, we needed Kyle Cox, foreman of the outside to bring in 52 new steel plates, each machinists who have lead on one weighing 320 pounds.” of the propulsion plants. “We are certifying that each system is ready Moving heavy steel is a routine for steam, which involves a lot of fluid task for shipbuilders, but this task flushes – kind of liking flushing the oil was unique. The catapult shed, a in a car, but on a much larger scale.” temporary structure that protects the catapults from uses weather While a car engine fourduring quarts of RCOH, posed a serious obstacle engine oil, Gerald R. Ford needs about to getting a crane in to that could get 25,000 gallons of oil flush its main the new plates into the catapult. engines.

“The flush ensures that each Every solution proposed system is clean – no dust affected or particles both cost and schedule for thesaid team that would harm the engines,” of 14 shipbuilders overhauling the Pompeyo Go, a mechanic on the team catapults.

They needed to find a who also served in the Navy. simpler solution.

Although turning an aircraft That simpler solution came in the carrier’s engine on is not as simple form of a skateboard, a long plank as turning a key, Cox’s mechanics on skateboard wheels that could are well-versed in how the system carry new steel plates down works.the Zach Higgins, a young, eager the length of the catapult.

Using mechanic who started at NNS less materials available, than a yearalready ago, can already the mapteam it all even added roller conveyors on top, out.

so the steel plates could be easily transferred without heavy lifting to avoid an obstacle in one of the catapults.

It took only two hours to assemble, and the idea worked beautifully.

“I moved here from California “The whole concept is to move the 320-pound plate because I heard the shipyard was a without hurting your back,” said Luis Bonilla, a shipfitter good place to work,” said 21-year-old who has worked every overhaul since USS Enterprise.

Higgins. “Now I work with people He had the initial idea of adding the roller conveyors, who really care about each other. I having worked with them on other projects. “We would love what I’m doing.” have had five people lifting these plates. This is not only simpler – it’s a lot safer.”

The whole team shares that attitude.

Despite working 7-day weeks for Freeman agreed. “My biggest thing is to work smarter, several months, Cox’s team is about not harder. Before, we would have had to schedule a to celebrate two years accident-free. crane, remove the shed and hope the weather would be The team stretches every morning in our favor. Now, two guys can do the work on a rainy and pins photos of their loved ones day. This is definitely something we can use on future on their community board to remind overhauls.” | By Peter Stern them of why safety is so important.

Shipfitters Kenneth Freeman (left) and Luis Bonilla move steel plates on a James Collins is the fourth generation simple, innovative system of conveyors on “skateboarders” in a catapult on USS of his family to work “My Abraham Lincoln (CVN 72), the at ideaNNS. that saved money, reduced risk of injury and kept grandfather was anbyapprentice the team on schedule.

Photo Chris Oxley who

started as a pipefitter and ended up doing pipe design. He always talked about working on Enterprise while she was being built. Now, I come to work and there she is – the old ship beside the new ship that will replace her.” | By Peter Stern

James Collins (left) and Pompeyo Go are part of the team flushing Gerald R. Ford’s (CVN 78) main engines in preparation for steam this summer. The steaming milestone is the equivalent of turning the ship’s engines on for the first time. Photo by John Whalen

The USS Abraham Lincoln (CVN 72) may be the fifth Nimitz-class aircraft carrier to undergo a refueling and complex overhaul (RCOH), but it is the first ship to receive an overhaul of some of its tanks using modeling and simulation ModSim as a measuring stick toward efficiency.

The tanks in question involve 138 processes during the overhaul, and getting them done on time has a direct correlation to when the dry dock is flooded to complete additional work. According to Apprentice Jeremy Hancock and Engineer Nick Drucker, simulation and visualization applications are being used to help identify cost- and schedule-saving measures. Hancock and Drucker presented the applications April 16 at the MODSIM World Conference in Hampton. Newport News Shipbuilding was among more than 25 organizations that shared ModSim best practices during the three-day conference.

The shipyard’s ModSim team gathered data during the RCOH of USS Theodore Roosevelt (CVN 71) and input it into a computer model, allowing shipbuilders to see the impact of decisions made then – and potential impacts during the RCOH process on Lincoln. A ModSim representative is assigned on the carrier to have daily interaction with shipbuilders to help identify ways to improve cost and schedule issues, and to provide the information during daily meetings with production management.

“It’s scheduling, manning and equipment,” Drucker said. “Maybe you don’t need to order those extra 600 parts. Maybe you only need 30 of them. It’s any of those areas that we can touch on and keep costs down.”

ModSim Technical Product Manager Irin Hall served as this year’s MODSIM conference chairwoman. She said the conference provided opportunities to highlight simulation-based solutions and share lessons learned along with new technologies across a variety of industries. “Modeling and simulation is widely recognized as a discipline that allows designing, testing, improving and training in a virtual environment, realizing savings in both cost and time to implementation, as well as providing risk reduction.”

Its success in refueling has enabled shipbuilders to implement modeling and simulation’s benefits elsewhere in the yard, said Bruce Easterson, CVN 72 RCOH program director. “In every case, we have improved our overall performance, including impact assessment, schedule forecasting and schedule predictability. We’re in the early stages of implementation, but we’re very excited about what ModSim has already done and the potential improvement we will see from our ModSim projects in the future.” | By Christie Miller Modeling and Simulation Apprentice Brad Joslin (seated) reviews work plans based on computer model data with Nick Drucker (left) and Jeremy Hancock (right), while construction supervisors Jim Wightman (left rear) and Erick Bowden have a similar conversation. Joslin is assigned on USS Abraham Lincoln (CVN 72) to work with shipbuilders to help identify ways that M&S can improve cost and schedule issues. Photo by John Whalen

Making a Difference

Sailing for a Cure

Calling Superintendent Alan Bomar “active” is an understatement. “When I’m not sailing, I’m on the water doing other things,” said Bomar. And that’s where he and his son were the day after Thanksgiving in 2008 when Bomar broke his leg surf kayaking at Virginia Beach.

Bomar recalled a doctor coming to his aid. “He took a look at my broken femur and said, ‘You don’t need me, I’m an oncologist.’” The following week, the irony of this comment was revealed when Bomar was diagnosed with multiple myeloma, a form of blood cancer that had weakened his body’s strongest bone to the breaking point.

After two stem cell transplants and medical isolation, Bomar was forced to slow down – but not for long. He spent time studying the disease he vowed to conquer, and got back on the water as quickly as he could. In 2009, Bomar and his crew competed in their first annual

Leukemia Cup Regatta to support the Leukemia and Lymphoma Society (LLS).

Since winning their first race, Bomar’s team has won three Leukemia Cup Regattas and placed third in 2013.

The team’s fundraising has helped to increase donations to LLS annually, and the event has become a popular Chesapeake Bay competition. With Bomar’s cancer in remission, next month his team will enter two race boats into the competition, drawing from a deep bench of shipyard employees for crew and support.

To learn more about the LLS regatta race, visit www. leukemiacup.org/pages/va/dvl14/ABomar. | By Dave Hamm Superintendent Alan Bomar (right) and Construction Supervisor Dave Hamm prepare for the 16th Annual Southern Chesapeake Leukemia Cup Regatta Race, which takes place July 11-13 in Deltaville, Va. Photo by John Whalen

Yardlines is published 10 times a year for the employees of Newport News Shipbuilding.

This issue of Yardlines was produced by: Jeremy Bustin, Gina Chew-Holman, Troy Cooper, Mike Dillard, Christie Miller, Eugene Phillips, LaMar Smith, Peter Stern, Susan Sumner, Lauren Ward and Kimberly Zayakosky. Photographs by: Chris Oxley, Ricky Thompson and John Whalen. Editor: Gina Chew-Holman Send comments, questions and story ideas to gina.chewholman@hii-nns.com or call 757-380-2627.

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Long Service MASTER SHIPBUILDERS

MAY

Gerry Bartos 40 years

Randy E. Burns 40 years

Mike Congleton 40 years

Carl Crowder 40 years

Kert Evans 40 years

Duwane Everett 50 years

Arthur D. Keyes 40 years

Henry Novell Jr. 40 years

Herbert L. Scott 50 years

Tom Sweeney 40 years

Jerry R. Taylor 40 years

Joseph White 40 years

Melvin “Moon” Williams 40 years

Buster Yarborough 40 years

50 YEARS Langston D. Everett X31 Herbert L. Scott X31

Arthur D. Keyes X31 Henry Novell Jr. X36 Thompson A. Sweeney X88 Jerry R. Taylor M53 Lorreen H. Thon O04 Sylvester Vines X36 Joseph L. White X42 Melvin L. Williams X32 William Yarborough X43

William H. Hamilton E30 Daniel E. Harrington O27 James A. Libertini E83 Jodie E. McGowan O48 Ronnie L. Moore E42 Richard A. Muhich O45 George S. Riefler X88 Boris A. Ruizgoubert E25 William E. Spruill Jr. E81 James G. Stevens II E18

George D. Currin Jr. X69 Dennis K. Dawkins E84 Andrew C. Ficklen E09 Michael W. Gravitt X70 Nelson L. Hale E45 Roger L. Lowman E88 Brian E. Miller X32 Murray O. Miller X42 Donald Mitchell X33 Gregory M. Nichols X33 Nancy E. Parker O14 James F. Petersen E56 Stephen J. Reilly E56 John M. Rice O19

James A. Salavejus E45 Neil B. Small X70 Cleveland R. Swain X11 Dewey L. Stinson III AMSEC Nam D. Vu E82 Stuart A. Watson O39 Robert E. Williamson Jr. E25

20 YEARS John R. Armstrong E79 Vance G. Carter X43 Gary K. Crockett O87 Steven S. Foretich E82 Paul A. Hamor E63 Kelly R. Kubisiak E34 Riley M. Little III E56 Roger R. McSwain X42 Jason W. Roach M40 William E. Smith E72 Larry S. Sweet E26 Glenn W. Wiggs E63 Stewart Yuen E82

45 YEARS Brenda R. Roth O18 40 YEARS Gerald A. Bartos E86 Randy E. Burns E86 Michael R. Congleton O27 Stanley L. Coppedge X36 Carl N. Crowder O51 Kerry C. Evans X33

35 YEARS Russell L. Brooks E89 Michael A. Bryant O38 Mike G. Christensen E42

30 YEARS Marvin A. Blizzard X67 Billy D. Byrd E18

25 YEARS William A. Elliott X10 Bernard R. Johnson Jr. O51 Elaine P. McGowan E25 Steven E. Moore O51 Thomasina R. Wright K71

Retirements APRIL James D. Adams X89 Gary E. Antonucci E83 Paul A. Bonser X43 George H. Bowers III X32 Carl W. Bradshaw N960 Robert C. Burch X89

James L. Christian X42 Mark A. Costa O22 John Curry Jr. O46 William G. Eaton Jr. E13 Jackie W. Fields M20 Randolph Freeman X36

Toney A. Garrett X42 Thomas Gatling X33 Bruce C. Howell X59 Asa K. Kilmon O57 Dennis G. Lefante O51 Rosemary Lovering O46

Quinton Rainey M53 Edward L. Ricks X32 Michael P. Roberts O46 Arthur L. Rogers X11 Vickie J. Rose E44 Fenton D. Royle X42

Henry W. Simpson E65 Anna M. Smith O43 Billy T. Sullivan Jr. N930 John N. Teague Jr. X59 Donald E. Watkins Jr. X31 Doris R. Wells X33

Garry L. White X31 Ronald L. Williams E86 Lamar E. Williams Jr. E44 Tony E. Wilson O43 Chris S. Zambas O28

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EAU CLAIRE WI PERMIT NO. 366

June 2014

NNS Safety Report *Compared to figures from April 2013

Year-to-Date Injuries 372

-21%

+2% Year-to-Date Injuries with Lost Time 133

Year-to-Date Lost Work Days 3,518

-1% Shipfitters Clifton Moore (left) and Robert Brown use a large drill supported by a jig to safely drill through a section of the John F. Kennedy (CVN 79) aircraft carrier’s deck plate. In March, Newport News Shipbuilding received a $1.295 billion extension to a previously awarded CVN 79 construction preparation contract. The contract extension enables NNS to complete an additional 343 structural units and purchase the majority of the remaining material for the ship, including items such as valves, controllers, pumps and raw materials.

Photo by John Whalen