NOTICE: The project that is the subject of this report was approved by the Governing Board of the National Research Council, whose members are drawn from the councils of the National Academy of Sciences, the National Academy of Engineering, and the Institute of Medicine. The members of the committee responsible for the report were chosen for their special competencies and with regard for appropriate balance.
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This is a report of work supported by Contract DAAH04-96-C-0016 between the U.S. Department of the Army and the National Academy of Sciences.
Library of Congress Catalog Card Number 96-67977
International Standard Book Number 0-309-05486-9
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COMMITTEE ON REVIEW AND EVALUATION OF THE ARMY CHEMICAL STOCKPILE DISPOSAL PROGRAM
RICHARD S. MAGEE, Chair,
New Jersey Institute of Technology, Newark
ELISABETH M. DRAKE, Vice Chair,
Massachusetts Institute of Technology, Cambridge
DENNIS C. BLEY,
Buttonwood Consulting, Inc., Oakton, Virgin
COLIN G. DRURY,
University at Buffalo, State University of New York
GENE H. DYER, Consultant
San Rafael, California
MG VINCENT E. FALTER,
U.S. Army (Retired), Springfield, Virginia
ANN FISHER,
The Pennsylvania State University, University Park
J. ROBERT GIBSON,
DuPont Agricultural Products, Wilmington, Delaware
CHARLES E. KOLB,
Aerodyne Research, Inc., Billerica, Massachusetts
DAVID S. KOSSON,
Rutgers—The State University, Piscataway, New Jersey
WALTER G. MAY,
University of Illinois at Urbana-Champaign
ALVIN H. MUSHKATEL,
Arizona State University, Tempe
PETER J. NIEMIEC,
Greenberg, Glusker, Fields, Claman & Machtinger, Los Angeles, California
GEORGE W. PARSHALL,
E.I. du Pont de Nemours & Company, Wilmington, Delaware
JAMES R. WILD,
Texas A&M University, College Station
JYA-SYIN WU,
Advanced System Concepts Associates, Inc., El Segundo, California (August 1995)
Staff
DONALD L. SIEBENALER, Study Director
MARGO L. FRANCESCO, Administrative Supervisor
SHIREL R. SMITH, Senior Project Assistant
DEBORAH B. RANDALL, Senior Secretary/Project Assistant
BOARD ON ARMY SCIENCE AND TECHNOLOGY
GENERAL GLENN K. OTIS, Chair,
U.S. Army (Retired), Newport News, Virginia
CHRISTOPHER C. GREEN, Vice Chair,
General Motors Corporation, Warren, Michigan
ROBERT A. BEAUDET,
University of Southern California, Los Angeles
GARY L. BORMAN,
University of Wisconsin, Madison
ALBERTO COLL,
U.S. Naval War College, Newport, Rhode Island
LAWRENCE J. DELANEY,
BDM Europe, Berlin, Germany
JAMES L. FLANAGAN,
Center for Computer Aids in Industrial Productivity, Rutgers University, Piscataway, New Jersey
GENERAL WILLIAM H. FORSTER,
U.S. Army (Retired), Westinghouse Electronics Systems, Baltimore, Maryland
ROBERT J. HEASTON,
Guidance and Control Information Analysis Center, Chicago
THOMAS MCNAUGHER,
RAND, Washington, D.C.
NORMAN F. PARKER,
Varian Associates (Retired), Cardiff by the Sea, California
STEWART D. PERSONICK,
Bell Communications Research, Inc., Morristown, New Jersey
KATHLEEN J. ROBERTSON,
Booz, Allen and Hamilton, McLean, Virginia
JAY P. SANFORD,
University of Southwestern Health Sciences Center, Dallas, Texas
HARVEY W. SCHADLER,
General Electric, Schenectady, New York
JOYCE L. SHIELDS,
Hay Management Consultants, Washington, D.C.
CLARENCE G. THORNTON,
Army Research Laboratories (Retired), Colts Neck, New Jersey
JOHN D. VENABLES,
Martin Marietta Laboratories (Retired), Towson, Maryland
ALLEN C. WARD,
University of Michigan, Ann Arbor
Staff
BRUCE A. BRAUN, Director
E. VINCENT HOLAHAN, Senior Program Officer
ROBERT J. LOVE, Senior Program Officer
DONALD L. SIEBENALER, Senior Program Officer
PATRICIA A. KIRCHNER, Administrative Associate
MARGO L. FRANCESCO, Administrative Supervisor
JACQUELINE CAMPBELL-JOHNSON, Senior Project Assistant
ALVERA GIRCYS, Senior Project Assistant
SHIREL R. SMITH, Senior Project Assistant
DEBORAH B. RANDALL, Senior Secretary/Project Assistant
Preface
The United States has maintained a stockpile of highly toxic chemical agents and munitions for more than half a century. In 1985, Congress, in Public Law 99-145, directed the Department of Defense to destroy at least 90 percent of the unitary chemical agent and munitions stockpile, with particular attention to M55 rockets, which were deteriorating and becoming increasingly hazardous. After setting several intermediate goals and dates, Congress, in the National Defense Authorization Act for fiscal year 1993 (P.L. 102-484), dated October 23, 1992, directed the Army to dispose of the entire unitary chemical warfare agent and munitions stockpile by December 31, 2004.
In the 1970s, the Army had commissioned studies of different disposal technologies and tested several of them. In 1982, incineration was selected as the method of disposing of agents and associated propellants and explosives and of thermally decontaminating metal parts. In 1984, the National Research Council (NRC) Committee on Demilitarizing Chemical Munitions and Agents reviewed a range of disposal technologies and endorsed the Army's selection of incineration.
Incineration technology is embodied in today's base-line incineration system, which was developed largely at the Chemical Agent Munitions Disposal System (CAMDS) experimental facility at Tooele Army Depot, Utah. The first full-scale operational plant, the Johnston Atoll Chemical Agent Disposal System (JACADS), is now in service on Johnston Island in the Pacific Ocean southwest of Hawaii. Also, a second plant, the Tooele Chemical Agent Disposal Facility (TOCDF), has been constructed at Tooele Army Depot and has recently undergone systemization (operational testing prior to the start of agent operations), using surrogates for agent to verify that the system and all components will work as designed.
The Committee on Review and Evaluation of the Army Chemical Stockpile Disposal Program (Stockpile Committee) was formed in 1987 at the request of the Undersecretary of the Army to monitor the Army's Chemical Stockpile Disposal Program (CSDP) and to review and comment on relevant technical issues. The Stockpile Committee is a standing committee, which will remain in service with rotating personnel until completion of the disposal program. The committee has monitored the development and implementation of the baseline system and has visited CAMDS numerous times, JACADS three times, and the TOCDF four times. The committee has also reviewed many reports and considerable technical information pre-pared by the government, government contractors, other agencies, interested civilian groups, and concerned individuals.
In 1993, the Stockpile Committee issued a letter report to the Assistant Secretary of the Army for Installations, Logistics and Environment recommending specific actions to further enhance the Chemical Stockpile Disposal Program risk management process. In early 1994, the Stockpile Committee issued three major reports that included recommendations to the Army concerning changes or improvements to be made to the TOCDF prior to the start of agent operations. These reports are:
- Evaluation of the Johnston Atoll Chemical Agent Disposal System Operational Verification Testing: Part II. (Part I was a short summary report issued in July 1993.)
- Review of Monitoring Activities Within the Army Chemical Stockpile Disposal Program.
- Recommendations for the Disposal of Chemical Agents and Munitions.
The present report continues the work of the four earlier reports by (1) addressing the completion of testing of certain secondary systems that had not been completely tested at JACADS, (2) reviewing the changes implemented by the Army in response to the Stockpile Committee's earlier recommendations pertaining to the Tooele Chemical Agent Disposal Facility, and (3) providing an overview of the status of the facility at the end of the
systemization period. This overview is based on the Stockpile Committee's prior knowledge about the base-line system, on information provided by the Army and others, and on site visits to the TOCDF, beginning in October 1991 (midway through the construction phase) through June 1995 (in the late stages of systemization).
The committee greatly appreciates the assistance in support of committee activities and in the production of this report provided by NRC staff members Donald Siebenaler, Margo Francesco, and Deborah Randall; consultants Harrison Pannella and William Spindell; and temporary assistant Julie Harlan.
RICHARD S. MAGEE, CHAIR
ELISABETH M. DRAKE, VICE CHAIR
COMMITTEE ON REVIEW AND EVALUATION OF THE
ARMY CHEMICAL STOCKPILE DISPOSAL PROGRAM
Contents
Tables and Figures
Tables
3-1 | Seventy Ranking Criteria | |||
3-2 | Criteria Used to Establish Qualitative Frequency Categories | |||
3-3 | Risk Assessment Code (RAC) | |||
3-4 | TODCF Pre-Operational Survey Team Members | |||
4-1 | Summary of Results from the TOCDF Liquid Incinerator #1 Surrogate Trial Burn | |||
6-1 | Reports Associated with the Expert Panel Review of the Tooele Chemical Agent Disposal Facility Quantitative Risk Assessment | |||
6-2 | Presentations to the Expert Panel Review of the Tooele Chemical Agent Disposal Facility Quantitative Risk Assessment | |||
B-1 | Composition of Munitions in the U.S. Chemical Stockpile | |||
B-2 | Chemical Munitions Stored in the Continental United States | |||
B-3 | Approximate Amounts of Metals, Energetics, and Agent Contained in the Unitary Chemical Stockpile (tons), by Site | |||
B-4 | Air and Exposure Standards | |||
C-1 | Recommendations from Evaluation of the Johnston Atoll Chemical Agent Disposal System Operational Verification Testing: Part I (OVT 1) and Part II (OVT 2) | |||
C-2 | Recommendations from Review of Monitoring Activities Within the Army Chemical Stockpile Disposal Program (MON) | |||
C-3 | Recommendations from the Letter Report to the Assistant Secretary of the Army to Recommend Specific Actions to Further Enhance the CSDP Risk Management Process (RISK), | |||
C-4 | Recommendations (REC) and Findings (FIND) from Recommendations for the Disposal of Chemical Agents and Munitions |
Figures
1-1 | Schematic drawing of the baseline incineration system | |||
3-1 | Outline of the Facility Construction Certification Process | |||
6-1 | Overview of the Risk Management Plan | |||
6-2 | Hierarchy of regulations that define safety at the TOCDF | |||
6-3 | Identifying upsets | |||
6-4 | Sample portion of a rocket handling process operational diagram | |||
6-5 | Schematic drawing of process operational diagram development | |||
B-1 | M55 rocket and M23 land mine | |||
B-2 | 105-mm, 155-mm, 8-inch, and 4.2-inch projectiles | |||
B-3 | Bomb, spray tank, and ton container | |||
B-4 | Types of agent and munitions and percentage of total agent stockpile (by weight of agent) at each storage site | |||
B-5 | Schematic drawing of the baseline system | |||
B-6 | Schematic drawing of a pollution abatement system |
Abbreviations and Acronyms
ACAMS
Automatic Continuous Air Monitoring System
ACS
Agent Collection System
AED
Atomic Emission Detector
AQS
Agent Quantification System
BDS
Bulk Drain Station
BRA
Brine Reduction Area
CAC
Citizens Advisory Commission
CAMDS
Chemical Agent Munitions Disposal System, Tooele, Utah
CDTF
Chemical Demilitarization Training Facility, Aberdeen, Maryland
CEM
Comprehensive Emergency Management (Utah Division of)
CEMS
Continuous Emission Monitoring System
CFR
Code of Federal Regulations
CHB
Container Handling Building
CPRP
Chemical Personnel Reliability Program
CSDP
Chemical Stockpile Disposal Program
CSEPP
Chemical Stockpile Emergency Preparedness Program
DAAMS
Depot Area Air Monitoring System
DEQ
Department of Environmental Quality
DFS
Deactivation Furnace System
DoD
Department of Defense
DPE
Demilitarization Protective Ensemble
DRE
Destruction Removal Efficiency
dscm
Dry standard cubic meter
DSHW
Division of Solid and Hazardous Waste (Utah)
DUN
Dunnage Furnace
EG&G
Edgerton, Germerhausen and Grier, Inc.
ENVCP
Environmental Compliance Plan
EOC
Emergency Operations Center
EPA
Environmental Protection Agency
EPZ
Emergency Planning Zone
ETA
Event Tree Analysis
FEMA
Federal Emergency Management Agency
FLLRT
Field Lessons Learned Review Team
FMEA
Failure Modes and Effects Analysis
FPEIS
Final Programmatic Environmental Impact Study
FTA
Fault Tree Analysis
FTIR
Fourier Transform Infrared
GA
Tabun
GB
Sarin
GC/FPD
Gas Chromatograph with Flame Photometric Detector
GC/MSD
Gas Chromatograph with Mass Spectrometric Detector
H, HD, HT
Blister or Mustard Agents
HEPA
High-Efficiency Particulate Air
HVAC
Heating, Ventilating, and Air Conditioning
HWMU
Hazardous Waste Management Unit
ID
Induced Draft
IDLH
Immediately Dangerous to Life and Health
in.
inch
IRZ
Immediate Response Zone
JACADS
Johnston Atoll Chemical Agent Disposal System
lb
pound
LIC
Liquid Incinerator
m3
cubic meter
mg
milligram
µg
microgram
MHz
Megahertz
min
minute
mm
millimeter
mM
millimolar
MPF
Metal Parts Furnace
ng/kg
nanogram per kilogram
NOx
Nitrogen Oxides
NRC
National Research Council
OSHA
Occupational Safety and Health Administration
OTA
Office of Technology Assessment
OVT
Operational Verification Testing
PAS
Pollution Abatement System
PCB
Polychlorinated Biphenyl
PCDD/F
Polychlorinated Dibenzo-p-dioxins and Dibenzofurans
PIC
Product of Incomplete Combustion
PLL
Programmatic Lessons Learned
PMCD
Program Manager for Chemical Demilitarization
PM-CSD
Project Manager for Chemical Stockpile Disposal
PMD
Projectile/Mortar Disassembly Machine
POD
Process Operational Diagram
POHC
Principal Organic Hazardous Constituent
PPE
Personal Protective Equipment
ppm
parts per million
QRA
Quantitative Risk Assessment
RAC
Risk Assessment Code
RCRA
Resource Conservation and Recovery Act
RSM
Rocket Shear Machine
RMP
Risk Management Plan
s
second
SAIC
Science Applications International Corporation
SAR
Subject Area Review
SDS
Spent Decontamination System
SHA
Systems Hazard Analysis
SOx
Sulfur Oxides
TOCDF
Tooele Chemical Agent Disposal Facility
TSCA
Toxic Substances Control Act
TWA
Time-Weighted Average
USACDRA
U.S. Army Chemical Demilitarization and Remediation Activity
USACMDA
U.S. Army Chemical Material Destruction Agency
USATHAMA
U.S. Army Toxic and Hazardous Materials Agency
VX
Organophosphate Nerve Agent
3X
Three-X Level of Decontamination
5X
Five-X Level of Decontamination