PAR Systems Supports Safer Nuclear Cleanup at Savannah River Site
How PAR Systems Supports SRMC Through Advanced Simulation and Control
At the Savannah River Site (SRS) in South Carolina, one of the nation’s most important environmental cleanup efforts is underway. Savannah River Mission Completion (SRMC), operating on behalf of the Department of Energy’s Office of Environmental Management, is tasked with treating and eliminating millions of gallons of legacy radioactive liquid waste—some of it dating back to the 1950s.
This mission is as complex as it is critical. It spans five major facilities, decades of evolving infrastructure, and some of the most demanding safety requirements in the world. And increasingly, it depends on a combination of modern controls, simulation technology, and strategic partnerships—where companies like PAR Systems play a key role.
Photo Credit: Savannah River Mission Completion
A High-Stakes Mission, Decades in the Making
Since 1954, nuclear materials processing at SRS has generated over 83 million gallons of radioactive liquid waste. Today, that waste is safely stored in 51 underground tanks across the F-Area and H-Area Tank Farms.
SRMC’s job is to process this waste through a coordinated system of facilities:
Photo Credit: Savannah River Mission Completion
- Salt Waste Processing Facility (SWPF): Removes highly radioactive elements
- Defense Waste Processing Facility (DWPF): Vitrifies waste into stable glass
- Saltstone Production Facility (SPF): Immobilizes low-level waste in grout
- Effluent Treatment Facility (ETF): Treats and processes liquid effluents
Each step reduces risk and moves the site closer to long-term environmental stability.
But none of it works without highly trained operators.
The Growing Importance of Simulation
Operating nuclear waste facilities requires more than technical knowledge—it demands precision, situational awareness, and the ability to respond instantly to abnormal conditions.
With the help of operator training simulation, SRMC is able to replicate control rooms and plant behavior, allowing operators to train in a safe, controlled environment.
However, a shift in workforce demographics has made simulators more important than ever.
As experienced operators retire, institutional knowledge is harder to maintain. New hires must be trained faster—and to higher levels of proficiency. As a result, simulators are no longer just training tools, they are critical infrastructure.
From Training to Operational Excellence
Photo Credit: Savannah River Mission Completion
Today’s simulators at SRS go far beyond basic training. They are used to:
- Validate control system updates before deployment
- Test new operating procedures
- Explore “what-if” scenarios not yet encountered in the field
This shift reflects a broader trend: simulation is becoming central to both workforce development and operational reliability.
PAR Systems: Modernizing Critical Infrastructure
One of the most impactful examples of this transformation can be found at the Defense Waste Processing Facility (DWPF), where PAR Systems has played a pivotal role.
DWPF relies heavily on the Main Process Cell Crane (MPC Crane), a remotely operated system used for maintenance and material handling in highly radioactive environments where human access is impossible.
After more than 30 years of continuous operation, the crane’s aging control systems were becoming a risk to mission continuity.
Photo Credit: Savannah River Mission Completion
In 2021, SRMC partnered with PAR Systems—building on a legacy that dates back to the original crane’s design by Ederer Cranes (a PAR brand)—to deliver a comprehensive modernization.
PAR Systems designed and implemented a full upgrade of the MPC Crane’s:
- Operator control consoles
- Camera and visualization systems
- Supporting hardware and control architecture
Critically, the new system incorporates redundancy, ensuring the crane can continue operating—or safely recover to a maintenance position—even in the event of component failure.
This upgrade enhances both reliability and safety, while minimizing downtime in an environment where maintenance is difficult and costly.
Bridging the Skills Gap with Simulation
Photo Credit: Savannah River Mission Completion
Upgrading hardware was only part of the solution.
Operating the MPC Crane is exceptionally challenging. Operators rely entirely on camera feeds to maneuver heavy loads through tight, high-value spaces—often with multiple hoists and complex rigging.
Adding advanced automation features like collision avoidance or anti-sway control would require significant physical modifications inside a hazardous, contaminated environment—introducing additional risk.
Instead, SRMC and its partners took a smarter approach: simulate the experience.
Working alongside GlobalSim, PAR Systems helped deliver a high-fidelity MPC Crane simulator that combines:
- A physically accurate 3D model of the DWPF canyon
- Real-world crane behavior, including load sway and mechanical interactions
- An exact replica of the crane operator console, built by PAR Systems, including PLC-based controls
- Instructor tools for monitoring, guiding, and customizing training scenarios
Operators can now practice complex tasks—like lifting cell covers, moving equipment, and performing maintenance operations—without any risk to the facility.
This dramatically improves skill development while protecting critical infrastructure.
A Model for High-Risk Industries
The collaboration between SRMC and PAR Systems highlights a powerful model for modern industrial operations:
- Upgrade critical infrastructure with reliable, modern controls
- Pair those upgrades with realistic simulation environments
- Use simulation not just for training—but for validation, testing, and continuous improvement
In high-risk environments like nuclear cleanup, this approach delivers a clear advantage: better-prepared operators, safer operations, and more resilient systems.
At the Savannah River Site, the mission is clear—reduce risk, protect the environment, and safely eliminate decades of nuclear waste.
Achieving that mission requires more than technology alone. It requires skilled operators, reliable systems, and the ability to adapt to change.
Through advanced control systems and immersive simulation, PAR Systems is helping SRMC meet that challenge—ensuring that both people and technology are ready for what comes next.
