Assessment of the Army Plan for the Pine Bluff Non-Stockpile Facility (2004)

Below is the uncorrected machine-read text of this chapter, intended to provide our own search engines and external engines with highly rich, chapter-representative searchable text of each book. Because it is UNCORRECTED material, please consider the following text as a useful but insufficient proxy for the authoritative book pages.

Appendix C Analysis of the Pine Bluff Non-Stockpile Facility Schedule 75 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:1 • 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. — 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 TABLE C-1 Major Milestones in the Overall PBNSF Schedule Milestone Date Resource Conservation and Recovery Act (RCRA) March 2003 permit application submitted to the Arkansas Department of Environmental Quality (ADEQ) Facility 65 percent design completion April 2003 Facility 95 percent design completion July 2003 Complete facility design package October 2003 Start-up of Pine Bluff munitions assessment system December 2003 (PBMAS) Award facility construction contract February 2004 Receive RCRA permit from the ADEQ April 2004 Facility construction Notice to Proceed May 2004 Complete facility construction August 2005 Complete equipment systemization May 2006 Start PBNSF processing operations June 2006 PBNSF processing operations finisha 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. 1Joseph 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.

76 ID Ta sk N am e 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 Q tr 4 Q tr 1 Q tr 2 Q tr 3 Q tr 4 Q tr 1 Q tr 2 Q tr 3 Q tr 4 Q tr 1 Q tr 2 Q tr 3 Q tr 4 Q tr 1 Q tr 2 Q tr 3 Q tr 4 Q tr 1 Q tr 2 Q tr 3 Q tr 4 Q tr 1 Q tr 2 Q tr 3 20 02 20 03 20 04 20 05 20 06 20 07 65 % d es ig n pa ck ag e co m pl et e 95 % d es ig n pa ck ag e co m pl et e F ac ili ty d es ig n co m pl et e O bt ai n R C R A p er m it fr om A D E Q P B M A S o pe ra tio ns C on st ru ct P B N S F fa ci lit ie s A w ar d co ns tr uc tio n co nt ra ct O bt ai n no tic e to p ro ce ed fo r fa ci lit y co ns tr uc tio n C om pl et e fa ci lit y co ns tr uc tio n P B N S F e qu ip m en t s ys te m iz at io n P B N S F O pe ra tio ns E C C -1 , d es tr oy 4 .2 -in . m or ta r ro un ds E C C -2 , d es tr oy 4 .2 -in . m or ta r ro un ds E C C -2 , d es tr oy b om bs E C C -2 , d es tr oy p ro je ct ile s E C C -2 , d es tr oy G T R s w /o p ro pe lla nt E C C -2 , d es tr oy G T R s w / p ro pe lla nt F re eb oa rd ti m e F IG U R E C -1 G an tt c ha rt f or th e en ti re P B N S F p ro je ct . B as ed o n us in g on ly th e E C C s an d pr oc es si ng tw o ag en ts w he n ne ce ss ar y. T he th re e de si gn ta sk s (I D 3 1- 3) w er e as su m ed to s ta rt in e ar ly 2 00 2 fo r si m pl ic it y. A ct ua l s ta rt in g da te s do n ot a ff ec t t he c ha rt .

APPENDIX C 77 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 C-3). 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- TABLE C-2 PBNSF Base Case Processing Schedule Parameters Start of operations 6/1/06 End of operations 3/31/07 Total days 303 Days of operation per week 5 Percent availability 80 Mortars, bombs, and projectiles to ECC-1 as a percent of the total 81 to ECC-1 and ECC-2 GTR warheads in ECC-1? No Percent GTRs for the EDS 0 Percent GTR warheads for the EDS 0 Percent of mortars, bombs, and projectiles that go to the EDS 0 Capacity (items per day per ECC) 5 Capacity (items per day per EDS) Not applicable xxx 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. TABLE C-3 PBNSF Base Case with GTR Campaign at Least Partially in Parallel with Campaigns for Mortars, Bombs, and Projectiles ECC-1 ECC-2 Munition Total Number Feed Number Total Days Feed Number Total Days 4.2-in. mortar rounds 732 593 208 139 049 Bombs 009 007 003 002 001 Projectiles 017 014 005 003 001 GTRs w/o propellant 439 NA NA 439 154 GTRs w/propellant 031 NA NA 031 011 Total days 215 215 Scheduled completion: days prior to March 31, 2007 088 088 xxx

78 ID Ta sk N am e 1 2 3 4 5 6 7 8 9 M ay Ju n Ju l A ug S ep O ct N ov D ec Ja n Fe b M ar A pr Q tr 3, 2 00 6 Q tr 4, 2 00 6 Q tr 1, 2 00 7 Q tr 2, 2 00 7 S ta rt P B N S F o pe ra tio ns P B N S F o pe ra tio ns E C C -1 , d es tr oy 4 .2 -in . m or ta r ro un ds E C C -2 , d es tr oy 4 .2 -in . m or ta r ro un ds E C C -2 , d es tr oy b om bs E C C -2 , d es tr oy p ro je ct ile s E C C -2 , d es tr oy G T R s w /o p ro pe lla nt E C C -2 , d es tr oy G T R s w / p ro pe lla nt F re eb oa rd ti m e ID T as k N am e 1 2 3 4 5 6 7 8 9 10 11 M ay Ju n Ju l A ug S ep O ct N ov D ec Ja n F eb M ar A pr Q tr 3 , 2 00 6 Q tr 4 , 2 00 6 Q tr 1 , 2 00 7 Q tr 2 , 2 00 7 P B N S F s ta rt up P B N S F o pe ra tio ns E C C -1 , d es tr oy 4 .2 -in . m or ta r ro un ds E C C -1 , d es tr oy b om bs E C C -1 , d es tr oy p ro je ct ile s E C C -2 , d es tr oy 4 .2 -in . m or ta r ro un ds E C C -2 , d es tr oy b om bs E C C -2 , d es tr oy p ro je ct ile s E C C -2 , d es tr oy G T R s w /o p ro pe lla nt E C C - 2 , d es tr oy G T R s w / p ro pe lla nt F re eb oa rd ti m e F IG U R E C -2 G an tt c ha rt f or th e P B N S F o pe ra ti on s on ly . B as ed o n us in g on ly th e E C C s an d pr oc es si ng tw o ag en ts w he n ne ce ss ar y. F IG U R E C -3 G an tt c ha rt f or th e P B N S F o pe ra ti on s on ly . B as ed o n us in g on ly th e E C C s an d be in g ab le to p ro ce ss o nl y on e ag en t a t a ti m e.

APPENDIX C 79 TABLE C-5 Option 1 Processing Schedule Parameters Start of EDS-1 and EDS-2 operations 1/1/05 End of operations 3/31/07 Total days ECC-2 operations Not applicable Total days EDS-1 and EDS-2 operations 819 Days of operation per week 5 Percent availability 80a Mortars to EDS-1 as a percentage of mortars to 58 EDS-1 and EDS-2 Capacity (items per day per ECC-2) Not applicable Shots per day per EDS-1 or EDS-2 0.5 Number of mortars per shot in an EDS-1 1 Number of mortars, bombs, or projectiles per shot 6 in an EDS-2 Number of GTR warheads per shot in an EDS-2 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 EDS-2a Munition Total Number Feed Number 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 w/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.xx TABLE C-4 PBNSF Base Case with GTR Campaign Necessarily Following Campaigns for Mortars, Bombs, and Projectiles ECC-1 ECC-2 Munition Total Number Feed Number Total Days Feed Number Total Days 4.2-in. mortar rounds 732 366 128 366 128 Bombs 009 005 002 005 002 Projectiles 017 009 003 009 003 GTRs w/o propellant 439 NA NA 439 154 GTRs w/propellant 031 NA NA 031 011 Total days 133 297 Scheduled completion: days prior to 170 006 March 31, 2007 xxx

80 ID T as k N am e 1 2 3 4 5 6 7 8 9 Q tr 4 Q tr 1 Q tr 2 Q tr 3 Q tr 4 Q tr 1 Q tr 2 Q tr 3 Q tr 4 Q tr 1 20 05 20 06 20 07 S ta rt P B N S F o pe ra tio ns P B N S F op er at io ns E D S -1 , d es tr oy 4 .2 -in . m or ta r ro un ds E D S -2 , d es tr oy 4 .2 -in . m or ta r ro un ds E D S -2 , d es tr oy b om bs E D S -2 , d es tr oy p ro je ct ile s E D S -2 , d es tr oy G T R s w /o p ro pe lla nt E D S -2 , d es tr oy G T R s w / p ro pe lla nt F re eb oa rd ti m e ID Ta sk N am e 1 2 3 4 5 6 7 8 9 Q tr 4 Q tr 1 Q tr 2 Q tr 3 Q tr 4 Q tr 1 Q tr 2 Q tr 3 Q tr 4 Q tr 1 20 05 20 06 20 07 S ta rt P B N S F o pe ra tio ns P B N S F o pe ra tio ns E D S -1 , d es tr oy 4 .2 -in . m or ta r ro un ds E D S -2 , d es tr oy 4 .2 -in . m or ta r ro un ds E D S -2 , d es tr oy b om bs E D S -2 , d es tr oy p ro je ct ile s E C C -2 , d es tr oy G T R s w /o p ro pe lla nt E C C -2 , d es tr oy G T R s w / p ro pe lla nt F re eb oa rd ti m e F IG U R E C -5 G an tt c ha rt f or th e P B N S F o pe ra ti on s on ly . B as ed o n us in g th e E D S s fo r al l b ut th e G T R s an d pr oc es si ng tw o ag en ts w he n ne ce ss ar y. F IG U R E C -4 G an tt c ha rt f or t he P B N S F o pe ra ti on s on ly . B as ed o n us in g on ly t he E D S s, h av in g de m on st ra te d an a lt er na ti ve m et ho d to s ep ar at e G T R s fr om t he ir m ot or s an d pr oc es si ng tw o ag en ts w he n ne ce ss ar y.

APPENDIX C 81 TABLE C-7 Option 2 Processing Schedule Parameters Planned start of PBMAS 12/31/03 Start of ECC-2 operations 6/1/06 Start of EDS-1 and EDS-2 operations 1/1/05 End of operations 3/31/07 Total days ECC-2 operations 303 Total days EDS-1 and EDS-2 operations 819 Days of operation per week 5 Percent availability 80a Percent full-assembly GTRs to EDS-2 0 Percent GTRs to EDS-2 0 Mortars to EDS-1 as a percent of mortars to EDS-1 and EDS-2 42 Capacity (items per day per ECC-2) 5 Shots per day per EDS-1 or EDS-2 0.5 Number of rounds per shot in an EDS-1 1 Number of mortars, bombs, and projectiles per shot in an EDS-2 3 Number of GTR warheads per shot in an EDS-2 Not applicable a80 percent availability is based on availability 4 days in a 5-day work week. 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. • 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.

82 APPENDIX C 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. TABLE C-8 Option 2: Use of Multiple EDS Units at Low EDS-2 Capacity with All GTRs Processed in the ECC-2 EDS-1 ECC-2 EDS-1sa 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 w/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.xx 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.