Audit Report: IG-0740

The Department cf Energy's Sandia National Laboratories are refurbishing the Spin
Rocket Motor, a 1:rime component of the B61 nuclear weapon system. Both the originai
motor produced i2 i906 and the version last produced in 1991 are the subjects of the
refurbishment. Rvth motors, which are essentially identical, produce thrust to arm thz
weapon. In Deceinber 2001, the National Nuclear Security Administration (NNSA)
received Nuclear Weapons Council Standing and Safety Committee (NWCSSC) approval
to study the feasibility and cost of replacement options. In April 2003, ihe MWCSSC
approved the development of a new Spin ~ o c k e t h ~ o tboarse d on Sandia's assei-tiolls that
test data collected between 1997 and 2002 showed the motors. due in largc: part to
"detrimental aging," were not performing according to specifications. Detrimental aging
occurs when a component's age prevents it from perfo~mingto meet military
requirements. The first production unit for this refurbishment effort 1s scheduled to be
completed in December 2006, at an estimated overall project cost of about $60 rnilllcn.
NNSA's 6.X process for managing refurbishrne~itsr equires the examination of various
design options and their cost impacts before proceeding to the development-engineering
phase. Pursuant to the 6.X process, a rationale for replacing components is to be
supported by test evidence indicating weapon defects and aging trends. In ~ r d etro be
used as part of a justification, test results must be obtained under "War Reserve"
conditions, that is, conditions similar to those experienced in wartime (e.g., climate
factors such as temperature). Furthermore, refurbishments are to be supported by
evidence indicating the cause and impact of any reported anomalies.
The Office of Inspector General received allegations raising serious questions concerning
the Department of Energy's decision to proceed with the B6 1 Spin Rocket Motor project.
As a consequence, we initiated this audit to evaluate the Department conclusion about the
performance of the motor.