Yardlines, Sept. 2014

IN THIS ISSUE 2014 Model of Excellence Award Winners Powerhouse Replaces 67-Year-Old Boilers

Yardlines

Photo by John Whalen

NNS Invests in New Welding Equipment

A Publication of Newport News Shipbuilding

September 2014

EQUIPPING WELDERS WITH THE BEST

Since last September, more than 1,000 new structural welding machines have been purchased and installed for welders across Newport News Shipbuilding.

“NNS welders are the most skilled craftsmen in the business, and they work in some of the most challenging environments in the world,” said Welding Trades Director Eddie Morris. “It’s only right that our welders have the most innovative, top-of-the-line equipment to work with that will make them the absolute best welders they can be.”

A team of shipbuilders from Welding Engineering, Facilities, Welding Services, Process Excellence, Technology Development and Welding Trades assessed the current state of NNS’ welding equipment and researched machines available in the industry.

“Structural welding machines are the most common welding machine used in the shipyard, so we decided to upgrade those first,” said Daniel Moniak, Continuous Improvement and Quality manager.

“Feedback from the welders was important to us, so we selected a diverse group of 50 waterfront welders to evaluate the machines in production and they made the choice.”

Master Shipbuilder Tony Davis was one of the welders who participated in testing. “This was the first time NNS gave me the opportunity to participate in the decision-making process before purchasing new equipment,” he said. “It was an honor to give my opinion and I appreciate the fact that NNS cared enough about me to ask for it.”

After testing three different machines on-site, NNS purchased the equipment preferred by the majority of the welders.

Structural Welders Brian Hudspath and Nastarsha Williams have been using the new welding machines for eight months.

“Welders and foremen are required to take an eight-hour training course before using the new machines,” said Williams.

Hudspath added, “The new welding machines provide improved arc control on welds requiring ultrasonic inspection testing, improved first-time visual quality, a consistent wire feed, and memory capabilities to save settings. And all the controls are located at the wire feeder. Before we had to get up and walk 150 feet to change the machine settings.”

Over the next four years, NNS plans to continue updating its welding equipment. Other types of structural and pipe welding equipment are currently being evaluated by Welding Engineering, and production welders and will be rolled out in the near future.

I By Lauren Ward

Foreman Terrance Roscoe (right) and Welder Pinky Jones discuss using one of the newlypurchased structural welding machines to complete a project. Photo by John Whalen

Three faithful giants are being laid to rest at the shipyard. Each weighs 145 tons and stands five stories tall. Together, they have created up to 330,000 lbs. of steam every hour since 1947. They are the Powerhouse’s massive steam boilers.

“I’ve had guys working here 30 years who thought they’d never see these boilers replaced,” said Wally Wallbillich, Powerhouse general foreman.

It all started with reducing air emissions. In the winter, the three old boilers could burn up to 300,000 gallons of thick black oil a week. Upgrading to natural gas boilers would reduce air emissions by over 80 percent. In 2011, the Environmental Engineering, Plant Operations and Plant Engineering departments began planning the complex project. While one boiler was removed, the other two had to keep churning out steam. The project also includes bringing the new natural gas line into the shipyard – a complex project in its own right.

The first boiler was removed earlier this year. The cavernous hole left behind is now being remodeled for the new boiler, scheduled to arrive in September. Though a third the size of its predecessor, the new boiler will produce the same amount of steam with less fuel. The new boilers will save the shipyard approximately $8 million a year in fuel alone.

“It’s a great project,” said Environmental Engineer Bill Cash-Robertson. “It’s a win on cost, a win for the environment, and a great team effort.”

Plant Operations maintains and operates the shipyard’s utilities, including boilers, river water pumps and centralized air compressors. From inside the Powerhouse, they watch over the shipyard’s utility systems in real time on large computer screens. Even with the computers, operators still check the boilers and pumps in person every hour to ensure system reliability. They do all this 24 hours a day, 365 days a year.

“It takes a special breed to be an operator,” said Kenneth Wilburn, a supervisor in the Powerhouse. “We have to be on watch all the time, because these services can’t go off.”

The first new boiler will begin delivering steam in December, when winter weather demands all three boilers work together. The two old boilers will keep humming away until their scheduled removal next year.

“The old giants are a testament to the operators who kept them running smoothly for almost 70 years. The next 70 years will be the same – only cleaner,” said Wallbillich. | By Peter Stern The Powerhouse has served the shipyard since 1891. The old massive boilers it has housed since 1947 are now being replaced with smaller, more efficient boilers that run on natural gas. Photo by Ricky Thompson

BIG

BLUE In 2005, Ricardo Palacios sold everything he owned and moved to the United States with his wife, an American citizen he met on a bus in Honduras. He moved in with his wife’s family in Virginia with only two suitcases, $100 in his pocket and very little English. Fishing on a boat in the James River, he would soon discover just how close he was to his dream of working at the shipyard.

As a teenager in Honduras, Palacios watched a lot of documentaries like “How It’s Made” on The Discovery Channel. He remembered seeing aircraft carriers, the shipyard, and “Big Blue” during one of the programs.

“I only worked in smaller scale most of my life, like on bicycles, so when I saw the size of the ships built at NNS, it fascinated me.”

When he saw the shipyard from his wife’s stepfather’s boat, its size was even more impressive than he remembered.

“My eyes lit up because I recognized ‘Big Blue’ from the TV program, and I asked, ‘What do I have to do to work there?’”

Determined to get a job at NNS, Palacios would spend the next four years becoming a U.S. citizen, while working, first as a salad bar assistant and then as a produce manager at Farm Fresh. He studied English to

improve his communication skills.

Palacios was thrilled in 2009 when The Apprentice School accepted him into the outside machinist program. During one of his rotations, he worked for Trades Director Stewart Brenegar, who saw something special in Palacios.

“He’s a natural leader and motivator and an inspiration for those he works with and those he works for,” said Brenegar.

As Brenegar learned about Palacios’ connection with “Big

Blue,” he asked if Palacios had ever been up in the crane.

When Palacios told him it was on his bucket list, Brenegar made it happen.

“Being on top of ‘Big Blue’ brings me full circle and tells me things are going to be OK,” said Palacios, an outside machinist in the CVN 72 program. “It was very challenging for me. I spoke no English when I came to the States. Now, I can say I have fulfilled the American Dream.”

But for Palacios, “Big Blue” is more than just a crane. It’s

NNS’ strongest team member.

“It’s because of ‘Big Blue’ that we’re capable of building the carriers we do,” he said. “That’s its power, its capability. It’s a strong arm and that’s what I see in myself. I know I’m capable of doing a lot, and I know as a company we’re just as strong as ‘Big Blue.’” I By Jeremy Bustin

Machinist Ricardo Palacios realized his dream of visiting the top of the “Big Blue” gantry crane. The iconic crane inspired the Honduras native to become a shipbuilder and work at Newport News Shipbuilding. Photo by Chris Oxley

THIS I S EX C EL L ENCE

Building aircraft carriers and submarines is one of the most complex and challenging jobs in the world. But more than 23,500 extraordinary shipbuilders at Newport News Shipbuilding come together every day to build and maintain these great ships for the United States Navy.

From design to construction to delivery, we are always committed to excellence.

CONGRATULATIONS TO THE 2014 MODEL OF EXCELLENCE AWARD WINNERS These shipbuilders have improved processes, increased efficiency and developed new and innovative ways to build the greatest ships in the world.

CUSTOMER SATISFACTION Business System Management Team Sandra Armstrong Marcia Capelli Kristina Lowry Zoltan Molnar Mary Ellen Nealy Kendra Queeney Gerald R. Ford (CVN 78) Power Unit Assembly and Installation Team Fred Darden Keith Davidson USS Montpelier (SSN 765) Complex Structural Pressure Hull Repair Team Tony Adams Jr. Andrew Alfred III Aaron Bonine Mark Brown Joshua Cantrell Jeffery Gravely Chazston Graziano Ronnie Hall Keith Hamlin Julie Hancock Bob Heard Benjamin Hellier Titus Key Joshua Phelps C. Pete Sargent Robert Skeps Kenneth Williams II

New Apprentice School Project Lead Daniel Brookman Earned Value Management System (EVMS) Compliance Team Lead Jim Myers

INNOVATION AND TECHNOLOGY Design, Qualification, and Implementation of the Gerald R. Ford (CVN 78) Electric Distribution System Team Andrew Bessen Anthony Buccellato Jason Johnson Douglas Mintz Eric Owen Paul Reitz James Wells Brian Zechmeister Rudder Gudgeon Repair and Alterations Team Michael Bousquet Michael Bridges Stephen Brown Greg Charron Charlie Jack Lee Jordan Michael Rhodes Darron Skinner Jr. Allen Smith Jack Wright Jr.

LEADERSHIP Gerald R. Ford (CVN 78) Construction Outstanding Leader Clyde Barden IV Lifting and Handling Safety Record Team Lead Robert Chappell

Ventilation for Preservation Team James Hadinger Robert Hannold Micah McCluer Kevin Phillips Ryan Somero

OPERATIONAL EXCELLENCE Process for Shooting Electrical Equipment Studs in Steel Fabrication Team Robert Drury Jason House Kendall Morgan Terry Riley James Skinner Duane Walker Chuck Wright USS Abraham Lincoln (CVN 72) Reserve Feed Inner Bottom Blast and Coat Process Team Willie Aursby Timothy Banks Tiffany Bottoms Charles Carden III Edward Carter Jeffrey Cooley Steven Dent Jr. Gregory Davis Cassandra Frisby Patrice Hargraves Wayne Hedgepeth Ronald Jones Micah McCluer Frederick Moody Kenneth Moore Drew Smith Damian Turner II Dameon Walker Continuous Improvement Grinding Project Team Amanda Brant Andrew Kramer Nathan McInnis Ralph Motley Jr. Joseph Powell Robert Powell Jr. Daina Reid Haley Stubblefield Patrick Woodington

Direct Attack Fire Suppression System (DAFSS) Team Ronnie Castillo Robert Cooley George Eastman Steve Hasselbar Lee Hill Trevor Jones Sammy King Ken Pearcy Welfredo Reyes Pete Siwek Fit to Fit Program Team Jeffery Gravely Jeffrey Hite Larry Jameson Jr. Rusty Johnson Jr. Scott MacFarlane Jr. Richard Machen Charles Massie Jr. Ryan Sparks John Thompson Neal Woodard John F. Kennedy (CVN 79) Double Bottom Flow Lane Team Houston Bailey Jr. Edward Belvin Stephen Bonneau Brandon Cook Johnny Duke Ronald Hall Nathan Hassell Leonard Jackson Jr. Joey Jones Joe Justice Kyle Lafountain Greg Neidlinger Dave Philpott Jr. Randall Pridgen Shelton Rankins Calvin Rock Ron Whiteman Matthew Wicke

Tougher

Than Steel Vontrease Williams says people are often surprised to learn she’s an electrician helping to build the aircraft carrier Gerald R. Ford (CVN 78). “They feel like it’s a woman doing a man’s job,” the third-shift worker explained.

The truth is, lugging heavy equipment, working in cramped spaces and adverse weather conditions, and solving problems as they arise — these on-the-job challenges aren’t unique to the men or the women at Newport News Shipbuilding. They’re just part of what makes being a shipbuilder tough.

“This is challenging work,” Williams said. “The electrical work we do is the lifeblood of the ship.”

In fact, there are more than 1,500 electricians in the shipyard. About 10 percent of them are women.

Williams is the latest Huntington Ingalls Industries employee — and the first from the night shift — to be featured in “Tougher Than Steel,” a branding campaign that celebrates shipbuilders as being as tough as the products they build. The campaign kicked off in 2013 and features full-page print ads in local newspapers and defense publications. A “Tougher Than Steel” page on HII’s website also includes a short video of Williams and other shipbuilders, including ones from HII’s Ingalls Shipbuilding division.

Williams comes from a family of shipbuilders. Her grandfather worked as a painter at Newport News for 30 years. “Watching them over the years build carriers and submarines for the Navy inspired me to want to do the same,” she said.

Her father wasn’t a shipbuilder, but he is an electrician, and that made an impression on her. “I felt like what he did was interesting,” she said.

He’d surely be impressed with the electrical distribution system on the first-of-class Ford, which will increase electrical capacity over the Nimitz-class carriers by 250 percent. Ford will also be the first ship to use the Electromagnetic Aircraft Launch System (EMALS) instead of steam catapults.

To say it’s a big job is an understatement. When finished, Ford will have 10 million feet of electrical cable — enough to span the distance from Washington, D.C., to Albuquerque, New Mexico — and 4 million feet of fiber optic cable — the length of more than 7,200 Washington Monuments stacked on top of each other. “It’s neverending,” Williams said.

In her seven years in the yard, Williams has worked on first, second and third shifts. She’s been on third shift — working from 11 p.m. to 7 a.m. — for the last three years.

“I love it,” she said. “With me, it’s a big help with my day-to-day schedule.”

The job comes with a tremendous sense of pride. “I feel like I’m making a difference by building something that is helping the government protect us,” Williams said.

“When I hook up something … to see it lit up or see it operating the way it’s supposed to operate just makes my day.”

For more “Tougher Than Steel” profiles, visit: www.huntingtoningalls.com/tougherthansteel.

Making a Difference

Teaching Children How to Fish

For years, Hampton Roads children ages 8 to 12 have cast their lines into Peninsula waters, and Newport News Shipbuilding employees have been there to help reel in their catch.

Different community organizations sponsored the 19th Annual Children’s Fishing Clinic held July 26 at Buckroe Beach Fishing Pier. The free event provided kids with lunch, snacks, T-shirts, bait, and fishing poles they got to take home.

Dozens of Newport News Shipbuilding employees volunteered to help organize the event, participate and chaperon the children. Shipbuilders Femi Audifferen and Cametrice Butcher shared duties of publicizing the fishing clinic at the shipyard and recruiting volunteers. “We had an overwhelming response this year for volunteers, the most I’ve ever seen,” said Butcher. “Events like this are needed and it feels great to be a part of it.”

This was the first year Audifferen led volunteer efforts, and the second year her 8-year-old daughter enjoyed fishing. “It shows the kids something different from the everyday; to be out in the sun, touching slimy fish, not sitting inside. It’s all about the kids,” said Audifferen.

Tommy Richardson, the chairman for The Apprentice School Alumni Association for this event, helped organize the fishing clinic and alumni volunteers. “It goes back to the old adage, ‘Give a man a fish, he eats for a night. Teach a man how to fish, he eats for a lifetime,’” said Richardson. “It’s a great way to see the community come together, so kids can learn something valuable.”

I By Ashley Key

General Foreman Bill Bassett spends an afternoon with his grandchildren Deserray and Mayson Moffitt at the 19th Annual Children’s Fishing Clinic at Buckroe Beach Fishing Pier July 26. Photo by Dar Deerfield Mook.

Benefits & Wellness

Felicia Holland in Newport News Shipbuilding Security Department used to be a ”candyholic,” spending $20 a week on chocolates. And then there were the cakes, pies and honeybuns she couldn’t turn down. Sugary treats and a lessthan-active lifestyle caught up with Holland in 2007. After participating in a voluntary health screening provided by HealthWaves, NNS’ wellness provider, she learned that she suffered from hypertension, also known as high blood pressure.

Holland, 47, returned for screening three times, but her readings didn’t change. On the third visit, a HealthWaves employee urged her to get serious about reducing her blood pressure, and Holland signed up for a company-sponsored weight loss program that day.

According to the American Heart Association, lack of physical activity and being overweight are common causes of hypertension. Normal blood pressure is anything below 120/80. The higher the pressure, the harder the heart has to pump, increasing the chance of heart failure, stroke or heart attack.

To kick-start her weight loss,

HealthWaves Coordinator Terry Holbert had Holland look at what she consumed. She swore off sweets, sodas and salt and began eating more fruits and vegetables. She began walking and started an at-home workout program using DVDs. Holland’s commitment to losing weight, along with Holbert’s support, paid off. Within a month, her blood pressure was back to normal, and within six months she lost 25 pounds, which she has kept off. An added bonus she said is, “I can get into smaller clothes! I also feel better when I exercise, and I can tell the difference when I don’t.”

To monitor your blood pressure, cholesterol, blood sugar and body composition, participate in the HealthWaves Take an Hour for Wellness program beginning late September or schedule a checkup with your physician.

Long Service MASTER SHIPBUILDERS

AUGUST

Curtis Artis 40 years

Ernest Blunt 40 years

Thomas “Cut” Callicutt III 40 years

Shirley H. Campbell 40 years

Tom Engelberger 40 years

Tyrone Epps 45 years

Ralph B. Gilley 50 years

Bob Hafer 40 years

Mitch Hilbourn 40 years

Mike Irving 40 years

Alvin A. Jenkins 40 years

Donnie Jones 40 years

Colin Kelly 55 years

Dennis Morris 45 years

Timothy Peterson 40 years

Terry Sowder 40 years

James Spratley 45 years

Nathan E. Tynes 40 years

55 YEARS Colin R. Kelly O39

Shirley H. Campbell K93 Thomas F. Engelberger Jr. E18 Georgia M. Guild X88 Robert R. Hafer X70 James M. Hilbourn N950 Michael L. Irving E88 Alvin A. Jenkins X33 Paul D. Jones X88 Timothy B. Peterson X36 Terry W. Sowder O15 Nathan E. Tynes X74 Ronald S. Waynick X91 Gregory L. Whitaker X36

Vernon E. Baskerville E82 Charles B. Bingman X42 Ernest C. Britt X32 Charles E. Bryant M53 Beverly T. Cottrell O53 Glenn A. Dorsey O84 Julian M. Dunning Jr. X36 Mark A. Echols X36 Larry D. Evans X31 Samuel F. Green X33 Scott J. Hallinger X18 Bernard C. Hatfield X31 Mark D. Horrell X59 Ricky L. Johnson O43 James L. Jones X88 William C. Jones X31 Gregory A. Kline O45 Harold J. Lee Jr. X33

Joseph T. McClarin X36 Mary F. McClees Baker X36 Randall R. McCrary X42 James M. Neel III O64 Kenneth A. Payne X32 Marvin J. Peterson X32 Bobby L. Phelps Jr. X70 Randy R. Pierce X70 David L. Saunders O19 Richard W. Scott X32 Donald A. Slack O84 Roger L. Smith X36 Thad D. Smith Jr. X42 Anthony L. Sparacia X32 Joseph E. Sych X70 Terry L. Taylor X31 Gerry E. Tillett X33 Julius R. Walker X33

Vanessa F. Walker X36 Thomas V. Waltrip O39 Virginia M. Warren X36 Shirley T. Watkins O46 Chauncey W. Whitby O43 Ronnie L. Whitfield X11 James O. Windham M53 Pattie W. Young E89

Tammy D. Cato O39 Rodney Champion O54 Kenneth P. Chaney II O64 Charles N. Claiborne II E81 Ruben T. Cook Jr. E25 Michael J. Cosky X43 Wade L. Cress Jr. X42 Walter J. Darby X42 Jeffrey L. Davis E17 William T. Dickinson X87 Danny J. Fields X10 Anthony T. Fisher X18 Lynn J. Fisher E25 Kurt E. Fortner X18 John S. Fuller X18 Michael J. Gadaleta E84 Dara A. Hare O26 Jerome B. Harriell O46

50 YEARS Ralph B. Gilley O46 45 YEARS Tyrone Epps E89 Randolph Favors E85 Dennis L. Morris X43 James M. Spratley X57 Theodore L. Stewart O61 40 YEARS Curtis L. Artis X88 Ernest L. Blunt X36 James E. Brothers X36 Thomas H. Callicutt III X36

35 YEARS Vincent B. Allmond X32 James R. Bailey Jr. M53 Leon R. Barbrey Jr. X70

30 YEARS Jeffrey S. Appleby AMSEC Clifton E. Barfield X11 Mark B. Bombelles K05 Frankie R. Boothe X32 Marion Bradley III X15 Michael T. Brown E88 Robert A. Bucklew Jr. O39 Jarrod A. Burke O22

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. Contributing writer: Ashley Key. 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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Look for more news at nns.huntingtoningalls.com.

Stephen W. Johnson O54 Leland K. Judkins X70 Mark S. Kasper E83 Dale R. Lamaine X87 Venetta R. Lamb O68 Eli L. Loiselle X18 Cynthia M. Mann O61 Richard L. Martin Jr. O67 William H. McGlothlin T53

Kent R. McPoland E86 Kim D. Melvin O55 Kenneth R. Midgett X36 Kevin W. Phillips AMSEC Peter P. Prokup O04 Albert L. Ronan E63 David L. Rowley E83 David W. Sauer X75 Gregory G. Scott E17

Timothy E. Slade X88 Robert G. Stuart X42 Robert F. Szymkowski X42 James K. Temple O48 Kevin J. Tooke E46 Donna M. Turley X31 Linwood D. Walker X88 David E. Wilmouth E85 Bennie Woodard III E79

Craig M. Wooden E86 25 YEARS Peggie F. Brooks O26 Melody R. Byrd E25 Michael L. Dillard O29 Robert G. Garrison E73 Alphonzo Hawkins X43 Rodney L. Hill K05

Park T. Jenkins Jr. O35 Jimmie V. King E83 Robert L. Myers E45 David M. Peck E83 Rodney T. Riddle E82 Deborah A. Riss E17 William J. Rumschlag AMSEC Shirley J. Smith-King O22 Raymond B. Spiggle II E15

Joe L. Wiggins A572 Donna M. Wrenn O11 20 YEARS Hugh Scott Bailey AMSEC Hona L. Jennings X59 Primitivo E. Manuel AMSEC Michelle L. Williams E62

Retirements JULY Frank W. Albertson X11 Terry J. Anderson X36 Russell A. Black O19 Raymond Boone X18 Willie M. Bracy X82 James S. Bristol E79

James M. Bush X36 Richard Caporale X42 Andres P. Celi E56 George A. Copeland X31 Edwin Feliciano O55 Alton H. Glass O43

John M. Green X67 Clyde J. Ihrig K01 Howard T. Jefferson T54 Regina C. Jenkins O19 Richard D. Jessie X42 Vitor G. Marques E45

Alonzo E. Marshall X43 Ray B. Massengill X42 Wallace E. McCafferty Jr. X11 James J. Moody X11 Kevin L. Morris E62 George P. Nichols X75

Robert G. Nielsen O39 Henry Novell Jr. X36 Lester E. Parker X33 John L. Parks X18 Welton D. Paxton X33 Douglas L. Perry X82

Melvin W. Poyner Jr. X42 Rodney L. Richardson X33 Ronnie L. Smith O53 William C. Smith Jr. O58 Willie E. Spencer X42 Tom G. Waters Jr. O15

EH&S to Host Household Hazardous Waste Day and Shredding Event Environmental, Health and Safety (EH&S) is sponsoring a Household Hazardous Waste Day (HHWD) and Shredding Event.

The HHWD and Shredding Event will be held SEPTEMBER 20, 2014 FROM 9 A.M. TO 1 P.M. in the North Yard Parking Area.

The event is only for Newport News Shipbuilding employees.

Shipbuilders will be asked to show their NNS badge to verify employment.

The GreeNN Team is at it again!

NNS Safety Report *Compared to figures from July 2013

Year-to-Date Injuries 756

-16

%

+9%

+4%

Year-to-Date Injuries with Lost Time 289

Year-to-Date Lost Work Days 10,710

PRST STD U.S. POSTAGE

PAID

4101 Washington Ave. Newport News, VA 23607

Yardlines is printed on recycled paper with vegetable-based inks.

EAU CLAIRE WI PERMIT NO. 366

September 2014

NNS Overseeing Maintenance on

USS Ronald Reagan

Newport News Shipbuilding was awarded a $13.7 million modification to a previously awarded maintenance contract for the aircraft carrier USS Ronald Reagan (CVN 76). NNS is responsible for program management and integration of all topside work performed at the ship’s home port in San Diego. The work, performed by NNS shipbuilders, Continental Maritime San Diego and other workers from the area, is scheduled to be completed in April 2015.

Prior to returning to its home port in August, CVN 76 participated in Rim of the Pacific (RIMPAC) 2014, the world’s largest international maritime exercise with ships from the navies of many nations along the rim of the Pacific Ocean. Photo by U.S. Navy