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Appendix C
Analysis of the Pine Bluff Non-Stockpile Facility Schedule
ANALYSIS OF SCHEDULE LEADING TO START-UP
AND FOR PROCESSING MUNITIONS
Table C-1 shows the major milestones for the design, con-
struction, and operation of the Pine Bluff Non-Stockpile Fa-
cility (PBNSF); Figure C-1 illustrates the schedule for their
completion.
The processing schedule is based on the following inven-
tory. As information from inspections and other records is
reexamined, the numbers may change slightly but not sig-
nificantly. The inventory consists of the following:
730 4.2-in. mortar rounds
32 (other) mortar rounds
470 German Traktor rockets (GTR), 38 with warhead
only, 31 that are full assemblies that is, they include
the rocket motor and propellant
· 9 bombs
· 17 projectiles
The operating plan for PBNSF is based on the following:
.
All chemical weapon items are to be processed in the
explosive containment chamber (ECC)- 1 or ECC-2; all
GTRs would be processed in the ECC-2 (U.S. Army,
2003a). However:
Mortars, bombs, and projectiles that are too sensi-
tive for further standard handling will be processed
through the EDS- 1 or EDS-2 (U.S. Army, 2003b).
The plan is still evolving for processing GTRs con-
taining both a motor and a burster classed as sensi-
tive. GTRs with motors contain too large a load of
energetics to process even in the EDS-2.
Joseph Cardito, Program Manager, Shaw, Stone & Webster, Inc., "Pro-
cess Design and Equipment Fabrication for PBNSF Overview and Status,"
briefing to the committee on March 19, 2003.
75
TABLE C-1 Major Milestones in the Overall PBNSF
Schedule
Milestone
Date
Resource Conservation and Recovery Act (RCRA)
permit application submitted to the Arkansas
Department of Environmental Quality (ADEQ)
Facility 65 percent design completion
Facility 95 percent design completion
Complete facility design package
Start-up of Pine Bluff munitions assessment system
(PBMAS)
Award facility construction contract
Receive RCRA permit from the ADEQ
Facility construction Notice to Proceed
Complete facility construction
Complete equipment systemization
Start PBNSF processing operations
PBNSF processing operations finisha
March 2003
April 2003
July 2003
October 2003
December 2003
February 2004
April 2004
May 2004
August 2005
May 2006
June 2006
March 2007
aProcessing operations finish date of March 2007 selected by Army as
one month in advance of April 29, 2007, CWC deadline.
SOURCE: J. Hawks, NSCMP, "Pine Bluff Non-Stockpile Chemical
Materiel Product," briefing to the committee on March 19, 2003.
Items with energetics but no agent fill will instead
be processed through the detonation chamber (U.S.
Army, 2003a).
Items with no energetics but with agent fill (and those
with no energetics and no fill) will instead be pro-
cessed through the projectile washout system (U.S.
Army, 2003a).
The design basis capacity is 10 rounds per shift (5
rounds per shift per ECC) (U.S. Army, 2003a).
The operations plan is for one 10-hour shift per day, 5
days per week. Operation at 6 days per week would be
a particularly expensive and cumbersome option. The
wide range of staff support functions provided through
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Representative terms from entire chapter:
total days
76
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APPENDIX C
TABLE C-2 PBNSF Base Case Processing Schedule Parameters
Start of operations
End of operations
Total days
Days of operation per week
Percent availability
Mortars, bombs, and projectiles to ECC-1 as a percent of the total
to ECC-1 and ECC-2
GTR warheads in ECC-1?
Percent GTRs for the EDS
Percent GTR warheads for the EDS
Percent of mortars, bombs, and projectiles that go to the EDS
Capacity (items per day per ECC)
Capacity (items per day per EDS)
6/1/06
3/31/07
303
80
81
No
o
o
o
Not applicable
TABLE C-3 PBNSF Base Case with GTR Campaign at Least Partially in Parallel with Campaigns for Mortars, Bombs,
and Projectiles
77
ECC-1
ECC-2
Munition TotalNumber Feed Number Total Days Feed Number Total Days
4.2-in. mortar rounds
Bombs
Projectiles
GTRs w/o propellant
GTRs "/propellant
Total days
Scheduled completion: days prior to March 31, 2007
732
9
17
439
31
593 208
7 3
5
14
NA
NA
NA
NA
215
88
139 49
2
439
31
154
11
215
88
concurrent stockpile disposal operations will not be
routinely available on the sixth day.
· After every 10 days, 1 day of maintenance is required.
This also fits well with the EDS operation of two days
per shot, two shots per week and 80 percent availabil-
ity expected for the equipment.
Two of seven GTRs that were examined contained ma-
terial not covered under the Chemical Weapons Conven-
tion. However, extrapolating this observation to project
that a significant number of GTRs can be processed after
the treaty deadline would be presumptuous.
.
THE BASE CASE: USE OF THE PINE BLUFF NON-
STOCKPILE FACILITY FOR ALL ITEMS
The processing schedule based on the above information
calls for completion 88 days ahead of the scheduled comple-
tion date of March 31, 2007, as shown in Tables C-2 and C-3
and Figure C-2. However, if only the ECC-2 can be used to
process GTRs and if mortars, bombs, and projectiles con-
taining a different agent cannot be simultaneously processed
in the ECC-1 because of limitations such as the single-agent
detection capabilities of the air monitoring analyzers, the
overall design capacity of PBNSF drops to five GTRs per
shift during the processing of GTRs. This may cause serious
capacity problems and reduce to only 6 days the flexibility
built into the schedule to meet an on-time completion of
PBNSF operations (see Table C-4 and Figure Cub.
OPTION 1: USE OF THE EDS-2 AT HIGH CAPACITY
BUT WITHOUT APPROVAL FOR THREE ROUNDS PER
SHOT IN THE EDS-1
Option 1 uses two EDS-12 units and one EDS-2 unit to
process mortars, bombs, and projectiles, and the EDS-2 unit
also is used for the GTRs (see Tables C-5 and C-6 and Fig-
ure C-4). The Army is confident that high-capacity opera-
tion of the EDS-2 processing six mortars, bombs, or projec-
2One of the 2 EDS-1 units is that which is associated with the PBMAS
operations and would be used to process both stable and sensitive rounds.
78
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APPENDIX C
79
TABLE C-4 PBNSF Base Case with GTR Campaign Necessarily Following Campaigns for
Mortars, Bombs, and Projectiles
ECC-1
Munition
Total Number Feed Number
ECC-2
Total Days Feed Number Total Days
4.2-in. mortar rounds 732 366 128 366 128
Bombs 9 5 2 5 2
Projectiles 17 9 3 9 3
GTRs w/o propellant 439 NA NA 439 154
GTRs "/propellant 31 NA NA 31 11
Total days 133 297
Scheduled completion: days prior to 170 6
March 31, 2007
TABLE C-5 Option 1 Processing Schedule Parameters
Start of EDS- 1 and EDS-2 operations
End of operations
Total days ECC-2 operations
Total days EDS-1 and EDS-2 operations
Days of operation per week
Percent availability
Mortars to EDS- 1 as a percentage of mortars to
EDS-1 and EDS-2
Capacity (items per day per ECC-2)
Shots per day per EDS- 1 or EDS-2
Number of mortars per shot in an EDS-1
Number of mortars, bombs, or projectiles per shot
in an EDS-2
Number of GTR warheads per shot in an EDS-2
1/1/05
3/31/07
Not applicable
819
Boa
58
Not applicable
0.5
1
6
3
a80 percent availability is based on availability 4 days in a 5-day work
week.
TABLE C-6 Option 1: Use of Only One EDS-2 Unit at High Capacity and Two EDS-1 Units
at Low Capacity
EDS-2
Munition
Total Number Feed Number
EDS-2a
Total Days Feed Number Total Days
4.2-in. mortar rounds 732 307 179 425 743
Bombs 9 9 5
Projectiles 17 17 10
GTRs w/o propellant 439 439 512
GTRs "/propellant 31 31 36
Total days 743 743
Scheduled completion: days prior to 76 76
March 31, 2007
Last day to start 3/18/05 3/18/05
Requires EDS capability to break
GTR agent cavity and neutralization
technology for GTRs to be
demonstrated and approved by 9/28/05
aTwo EDS-1 units, including that associated with PBMAS.
80
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APPENDIX C
tiles per shot in the EDS-2 or three or more GTRs per shot is
feasible, but this is still to be demonstrated and approved by
regulatory authorities. Likewise, EDS ability to break the
GTR agent cavity and the neutralization chemistry to be used
for processing the GTR agent fills must be demonstrated and
approved by regulatory authorities. A capacity greater than
one item per shot ("low capacity" in Table C-6) for the EDS-
1 is not needed. In addition to the processing benefits cov-
ered in Chapter 6 of this report, this approach avoids entirely
the need for the currently designed PBNSF while providing
for completion of non-stockpile disposal operations 76 days
prior to the scheduled completion date of March 31, 2007.
In summary, an all-EDS approach requires the following:
· Demonstration and permitting of decoupling of GTR
motors from warheads.
Demonstration and permitting of EDS-2 capability to
break GTR agent cavity and of neutralization chemistry
technology for GTRs by the date shown in Table C-6.
Demonstration and permitting of six rounds per shot in
the EDS-2 for mortars, bombs, and projectiles and dem-
onstration and permitting of at least three rounds per
shot in the EDS-2 for GTRs.
81
· Demonstration and permitting of multiple-round shots
in the EDS- 1 (not required, but helpful).
· Purchase and start-up of a second EDS-2 (not required,
and probably too expensive).
OPTION 2: USE OF MULTIPLE EDS UNITS ALONG
WITH USE OF THE PINE BLUFF NON-STOCKPILE
FACILITY ECC-2 TO PROCESS GERMAN TRAKTOR
ROCKETS
Option 2 uses two EDS-1 units and one EDS-2 unit to
process mortars, bombs, and projectiles along with the ECC-
2 for processing all of the GTRs. Although the Army is con-
fident that more than three mortars will fit into the EDS-2 for
each shot, such extra capacity is not essential that is, low-
capacity, single-shot operation was anticipated in develop-
ing Tables C-7 and C-8 and Figure C-5. The limiting opera-
tion is the processing of GTRs in the ECC-2. In addition to
the processing benefits covered in Chapter 6 this report, this
mixed approach for PBNSF using an ECC-2 and multiple
EDS units increases schedule flexibility by allowing for
completion 139 days prior to the scheduled completion date
of March 31, 2007.
TABLE C-7 Option 2 Processing Schedule Parameters
Planned start of PBMAS
Start of ECC-2 operations
Start of EDS- 1 and EDS-2 operations
End of operations
Total days ECC-2 operations
Total days EDS-1 and EDS-2 operations
Days of operation per week
Percent availability
Percent full-assembly GTRs to EDS-2
Percent GTRs to EDS-2
Mortars to EDS-1 as a percent of mortars to EDS-1 and EDS-2
Capacity (items per day per ECC-2)
Shots per day per EDS- 1 or EDS-2
Number of rounds per shot in an EDS-1
Number of mortars, bombs, and projectiles per shot in an EDS-2 ~
Number of GTR warheads per shot in an EDS-2 Not applicable
12/31/03
6/1/06
1/1/05
3/3 1/07
303
819
5
Boa
o
o
42
5
0.5
a80 percent availability is based on availability 4 days in a 5-day work week.
82
TABLE C-8 Option 2: Use of Multiple EDS Units at Low EDS-2 Capacity with All GTRs Processed in the ECC-2
APPENDIX C
EDS- 1 ECC-2 EDS- 1 sa
Munition
Total Number Feed Number
Total Days Feed Number Total Days
Feed Number Total Days
4.2-in. mortar rounds 732 425 495 307 538
Bombs 9 9 11
Projectiles 17 17 20
GTRs w/o propellant 439 0 0 439 154
GTRs "/propellant 31 0 0 31 11
Total days 526 165 538
Scheduled completion: days prior to 293 139 281
March 31, 2007
Last day to start 10/21/05 10/17/06 10/8/05
aTwo EDS-1 units, including that associated with PBMAS.
REFERENCES
U.S. Army. 2003a. Resource Conservation and Recovery Act Hazardous
Waste Permit Application for the Department for the Army Pine Bluff
Non-Stockpile Facility, February. Pine Bluff, Ark.: Pine Bluff Arsenal
Public Affairs Officer.
U.S. Army. 2003b. Proposed Deployment and Operation of an Explosive
Destruction System at Pine Bluff Arsenal, Arkansas, Environmental
Assessment, February. Prepared by Program Manager for Chemical De-
militarization, Product Manager for Non-Stockpile Chemical Materiel.
Aberdeen Proving Ground, Md.: Product Manager Non-Stockpile
Chemical Materiel.
