explosive destruction technology30 percent design update may 6, 2014

Explosive Destruction Technology30 Percent Design Update

May 6, 2014

Presented to:

Chemical Destruction Community Advisory Board’s Explosive Destruction Technology Working Group

Presented by:

Jeff Brubaker, ACWA Site Manager

John McArthur, Systems Contractor Environmental Manager

A Partnership for Safe Chemical Weapons Destruction

Bechtel Parsons Joint Venture team


3

Agenda

EDT Facility Layout Munitions Processing Steps Equipment Layout Other Materials Questions/Discussion


EDT Facility Layout

4


O2SF Outside Operations Support FacilityESB EDT Support BuildingMH Monitoring HouseESM EDT Service MagazineEEB EDT Enclosure BuildingCON Control RoomTOF Treaty Office Facility

5

EDT and OPS Facilities


6

ESM

ESB

EEB

MH

O2SF

O2SF

BGCAPP Site Plan / EDT Site Location


7

O2SF

EEB

ES

B

TOF

BGCAPP Site Plan / EDT Site Facility

ESMESBEEB

MH


Function: The purpose of the O2SF will be a primary location for support functions related to the start and end of daily and shift activities and routine facility support

O2SF will consist of the following areas to support the Project: 7 offices and 12 cubicles A Mask Issue, fit and test area First Aid Area (with a blood draw area and a small Laboratory for Medical personnel) Hazmat/decon Storage Area Toxicological Area Protective (TAP) gear storage Lunch Room Restrooms and Showers Locker Areas (with approximately 150 lockers) A Cotton Goods Issue Room An IT Help Desk and a small Communication Equipment Room

8

O2SF – Facility Design Description


Function: The purpose of the ESB is the primary support functions directly related to the operation of the EDT to support the disposal of the Mustard agent inventory at Blue Grass Army Depot (BGAD)

The ESB houses and supports the EDT operational crews and the direct support crew functions

ESB will have 6 offices, 10 cubicles, a Conference Room, a TAP Gear / Tool / Parts Storage Area, a Lunch Room / Crew briefing/training area, Restrooms, an Electrical Room, a Communications Room, and a small Custodial Utility Room

The offices are for general purpose and direct support services use, and planned to accommodate Plant Management, Engineering, Automation and personnel that directly support the EDT operations

It will support approximately 20 people on Day Shift and approximately 90 people on rotating shift that are part of the operational crews that work within the EDT Complex

ESB – Facility Design Description


A Conference Room will provide space for crew training, turn-overs, and meetings

The Lunch Room/Crew Room contains approximately 40 lockers. This area will have a seating area for approximately 27 personnel. This area also serves as a meeting area to be used for shift turn-over, crew training, meetings and presentations. It will also contain several computer workstations for general crew use (e.g. timekeeping, complete computer based training, complete Read and Sign requirement, etc.)

The building’s HVAC system can be shut down to utilize the ESB as a shelter-in-place facility

The ESB will not house any Chemical Weapons Convention (CWC) Treaty personnel

Adjacent to the ESB is the EDT Control Room (CON)

ESB – Facility Design Description


Function: The purpose of the EDT Process Monitoring House (MH) is a centralized area which contains the air monitoring equipment and some process monitoring equipment to support operator safety and verify environmental compliance during 24/7 processing operations of the EDT Facility.

The MH consist of a 16 by 36 foot raised structure, MiniCAMS, DAAMS, CEMS, and other air monitoring equipment.

11

MH – Facility Design Description


Function: The purpose of the ESM will be to hold a reserve of Mustard munitions to support 24/7 processing operations of the EDT Facility

The ESB consist of a 30 by 30 foot Non-Standard Storage Structure (NSS) with an HVAC unit, a Monitoring Shack, a Bottle Storage Area with overhead cover, and a 1,000 CFM Filter Unit mounted on a trailer.

ESM Capability:– Maximum explosive capability = 500 pound Net Explosive Weight (NEW) (1,206

projectiles)– Site Plan Safety Submittal (SPSS) Limit = 1,128 projectiles

Pallet stacking within the ESM is limited to two high

The floor is designed with secondary containment and water stops

The Monitoring Shack contains MiniCAMS and DAAMS to support air monitoring of the ESM, EONCs, and the 1,000 CFM Filter Unit 12

ESM – Facility Design Description


13

EONC Transport of Chemical Weapons


Function: The purpose of the EEB is to house the SDC and OTS process equipment

The EEB consist of a 77 by 120 foot building (approx.)

The building has an A, B, C, D Agent Areas with a Cascading Ventilation System and a Munitions Delivery Airlock

The SDC consist of a:– Loading Conveyor and Elevator Lift– Loading Chamber #1 and #2– The Detonation Chamber (DC)– A Buffer Tank– A Scrap Chute, Scrap Cooling Conveyor, Belt Conveyor, and a Scrap

Bin

14

EEB – Facility Design Description


The Off-Gas Treatment System (OTS) consist of a:– Thermal Oxidizer– Spray Dryer– Bag House Filter– Quench– Acid & Neutral Scrubber– ID Fans– Heat Exchanger and Cooler– A Re-Heater

The building has a 16,000 CFM IONEX Carbon Filter Unit

And the OTS has a 4,000 CFM IONEX Carbon Filter Unit

15

EEB – Facility Design Description


16

EDT Enclosure Building (EEB)

Layout is based on the Vendor’s Preliminary Design and EquipmentLayout Drawings


17

Airlock

OTS

Gears

Switch

MonitoringHouse

4000

IONEX16000

DC

ChillerScrapConveyor

Lift

FeedConveyor

THO

Air Tank

AirCompressors


BT

EDT Enclosure Building (EEB) Layout


18

EDT Enclosure Building (EEB)

SDC

OTS

MonitoringHouse

Airlock

IONEX4000



Agent Area Category

Color Code

Purpose Areas Included Remarks

A Red Primary Containment of liquid and vapor agent

Detonation Chamber (DC) and off-gas piping to the Thermal Oxidizer (THO)

Most negative pressure

B Orange Secondary Containment of vapor agent

Around the DC, off-gas piping to the THO, and the THO itself

More negative pressure

C Yellow Tertiary Containment providing an area under ventilated engineering controls

Munition Handling and loading areas within the building and around the Secondary Containment areas

Slight negative pressure. Will require both MHE and personnel air lock(s) from the D area

D Green No containment. Provides weather protection to EDT equipment and crew

The outer building No negative pressure on this structure

THO OTSDCLoading Area

Category D area

Category C area

Filter / Stack4,000

Vestibule

No Scale is given to any component of this concept drawing

19

Category B area

EEB – Agent Containment Areas

Carbon Filter16,000

Air is pulled from atmosphere pressure through process areas with progressing decreasing (negative) pressure as an engineering control measure


Function: The purpose of the CON is to serve as the Commend and Control (C2), and the operational center for EDT Facility.

The CON consist of a 16 by 20 foot structure.

Process Equipment include:– DC HMI stations 1 and 2– OTS MHI stations 1 and 2– Dynamic Pressure Sensing Station– CCTV HMI station with multiple monitors

The CON will be staffed by:– Shift Plant Manager (SPM)– Control Room Operators (CRO) (2 each)– Operations Support Tech– Automation Specialist (Day Shift only) 20

EDT CON – Facility Design Description


EDT Enclosure Building (EEB)– On a concrete pad– Personnel Entry/Exit– Emergency Exits– Munition Delivery Airlock– Scrap Handling Area

SDC System– Feed Conveyor– Lift– Loading Chamber 1– Loading Chamber 2– Detonation Chamber (DC)– Scrap Conveyor– Inspection Conveyor– Belt Conveyor– Scrap Bin– Buffer Tank– Dust Handling System

• Off-Gas Treatment System (OTS)– Thermal Oxidizer– Spray Dryer– Bag House Filter– Quench– Acid & Neutral Scrubber– ID Fans

• IONEX Carbon Filter Units (two)– OTS Filter Unit– Building Filter Unit

• Utilities– Natural Gas– Electrical– Water– Emergency Generator– Air Compressor– Hydraulics 21

EDT Equipment Components


Munitions Processing Steps

22


23

EDT Munitions Processing Steps(Based on the Preliminary 30% Design)

BGCA CW Storage Igloo

Wooden PalletsSteel Banding

CW Munitions are un-banded

CW placed in Staging Area

EDT CWService

Magazine

CW placed in Feed Tray

SDC

CW enters the Detonation Chamber

CW moved via Conveyor /

Elevator

CW moved through

Air-Locks

SDC

LC1 - 112LC2 - 114

LFT104

COV101

Information Sources: Updated Vendor PFD and P&ID drawings received 18 February 2014. Disclaimer: The above illustrated Process Steps are based on the general preliminary design information provided.

Equipment abbreviation code and ID number thatrelates to those on the PFDs and Mass Balance


24


Page 2 of 4

DustMetal - OxideVolatile / Semi-Volatile Heavy Metals (Pb, Be, Cr)

Dosing Station

Dry Salts &Particulates

AshLarge Particulates

Spray Dryer

Bag House Filter

Sodium Bicarbonate

DetonationChamber

BufferTank /

Cyclone Separator

Scrap Metal Recycled to DC(for 5X treatment)

THO310

BHF330

SPD320

BT160

ProcessWater Tank

Air

Nature Gas

Air

Water

IBC

Air

DC120

PWT424

ADS470 (NaOH)

NAS480

Bleed Water

Information Sources: Updated Vendor PFD and P&ID drawings received 18 February 2014. Disclaimer: The above illustrated Process Steps are based on the general information provided.

Scrap Conveyor 1Scrap Conveyor 2

Belt Conveyor

5X Scrap Metalfor Recycle

AirHeater

Emergency Water

Water

Process Vent Filter

Dust

Thermal Oxidizer

Air

PVF171

PVC170

Cyclone


25



QuenchTower

AcidScrubber

NeutralScrubber

Water

Feed/Recycle loops

Heat Exchanger

NaOH

AC366

SEP367

QUE340

HX362

NSC360

ASC350

Emergency Water Tank

Separator

AirCooler

EWT322

BWT430

BleedWater Tank

CondensateTank

COT363

NaO

H

Bleed Water

Emergency Water

DustChlorine, Hydrogen chloride

SOx

SOxChlorine Heavy Metals

Heater

AH370

Air


26



ID Fan 1

ID Fan2

PreFilter

HEPAFilter

HEPAFilter

CarbonFilter

SICCarbonFilter

Filter Bank(five filter element)

Carbon Filter Elements

STACKMonitoring

HouseION400

IDF1370IDF2371

Exhaust Stack

LaboratoryMonitoring

House

Water Vapor

MiniCAMSDAAMSCEMS

COO2

ID FanSamplePorts


Equipment Layout

27


28

Note: Our Scrap Conveyoris turned 90 degrees fromthe Cool Down Conveyor

Feed Conveyor

MunitionsLift

DustCollection

ScrapBin

BeltConveyor

Secondary Containment

Buffer Tank

EDT Process Equipment Layout


29

Tilting Cradle

Fragment Shield

Loading Chamber 1

Gate 2

Secondary Containment

Loading Chamber 2

Gate 1

EDT Process Equipment


30

FragmentLiner

DestructionChamber

Heating Elements

DC EmptingArrangement

Locking RingInsulation

EDT Process Equipment


31

1

4

3

2

EDT Feeding Cycle


Air Heater

32

DC Empting Cycle / Scrap Removal & Cooling


33 THO QUE ASCNSC

BHFSPD HXIDF1IDF2

Upgraded / Larger THO & OTS– Limiting Throughput (Pacing Station) for the Anniston unit

The THO is 98% larger: – Anniston unit is: 162 ft3

– BGCAPP unit will be: 321 ft3

The OTS is 75% larger

Closed Loop Process Water System

OTS - Key Design Elements


Reverse angle

Spray Dryer Dosing Station

Spray Dryer Waste Drum

Quench Venturi

Bag House Waste Drum

Emergency Water Tank

Bag House Filter

Spray Dryer

ThermalOxidizer

Scrubbers

34

OTS Process Equipment Layout


35 15B

1S3 42

5 6

15A

98

7 12 13

10

14

11

C/N Host

SP

SP

P1

P2

1 EONC Unload2 Service Magazine3 Carbon Midbed4 Fixed Perimeter5 Perimeter Trailer6 Perimeter Trailer7 Air Lock8 Loading Area

9 Buffer Tank Enclosure

10 D/C Enclosure11 Scrap Exit Area12 HVAC Midbed13 HVAC Stack14 OGT Carbon

Midbed15 OGT Stack A/B

EDT Personnel Safety Monitoring Locations


Other Materials

36


37

• Processing Rates - without Overpack– M110 155mm H Projectiles– At Peak and Normal Processing Rates:

• Peak Rate estimated: 6.1 projectiles per hour

• Peak Rate actual: To be determined during the Factory Acceptance

Test (FAT)

• Normal Rate estimated: 4.8 projectiles per hour (81% availability)

Processing Rates


Activity Date

EDT CW Operations Jan – Oct 2017Ramp-Up PeriodFull Rate PeriodRegulatory TestingOver-Pack Processing

EDT Closure and Turn-Over Nov 2017 – May 2018

DecontaminationRestorationDe-staffingSystem / Facility Turn Over

Main Plant CW Operations (forecasted Start date) Jan 2018

38

EDT Schedule and Key Milestones


39

• Day Crew arrive at O2SF – Change Out / Draw Mask / Transport to the EDT Complex• Crew Turn-Over / POD Briefing • Daily RCRA inspections (AM)• Verify FPIs and LCOs are completion and approval• Routine Activities:

Open, complete, and print Feed SheetsEstablish TCEAs – as required (EONC delivery / Munition transfer / EEB processing)Conduct munitions transfer from the ESM to the EEB Loading Area (twice per shift) Load Munitions in Feed Trays (twice per shift)Begin CW Processing - Feed Trays to the SDCScrap inspection and removal – as requiredDump Scrap Bin – as requiredDaily Operational Report

• Night Crew arrive at O2SF / – Change Out / Draw Mask / Transport to the EDT Complex• Crew Turn-Over • Repeat the above Routine Activities• Munitions Accountability paperwork• Midnight – Perform a Daily Munition Inventory – develop the COD packet for the prior 24 hrs• Equipment PM Checks are performed • Lab Perform equipment challenges (AM)• Resume CW Processing

Typical EDT Operational Day


Location: Anniston BGCAPPDescription SDC 1200 CM (Chemical Mobile) SDC 1200 C (Chemical)

Transportable unit Fix Facility unitCW Net Explosive Wt. (NEW) 2.2 lb HE / 6.61 Propellant TBD (min, 2.2 lb HE / 6.61 Propellant)Fragment Shield: Tube Shaped (sides only) Bowl Shaped (sides with a bottom)DC Heater: 3 on the bottom of the DC 3 on the bottom plus additional on sidesCooling Fan for Locking Ring: None Yes (added to minimize binding at high temps.)LC1 and LC2 Vents to THO: No Yes (to minimize/prevent agent migration to the Process Ventilation)Bypass valve around off-gas No Yes orifice: (to minimize press in the chamber to minimize agent migration to LC2)

Off-Gas Treatment System (OTS): Has a SDC 1200 sized OTS Has a larger SDC 2000 OTS (75% larger)Thermal Oxidizer (THO): 162 ft3 321 ft3 (98% larger)Bleed Water Tank: No Yes (added to support 24/7 operations)

Chiller to remove Condensate: No (collection pump to recycle H2O) Yes (added after the Neutral Scrubber)Re-Heater after Chiller: None initially – installed later IncludedCarbon Filter System: IONEX CD2000 IONEX CD4000

Building Type: Sprung Structure Steel BuildingBuilding HVAC: No - Portable AC unit added Yes Cascading Ventilation System: Vapor containment only Yes (with Category A, B, C, and D areas)

Number of Mustard Projectiles: 2,737 CW munitions processed Approx. 16,000 munitions to be processedAgent Types: HD and HT Mustard H Mustard (with solids and heels)DOT Bottles: None processed Two (2) are planned

40

EDT Unit Differences (Anniston vs. BGCAPP)


Questions/Discussion

41

explosive destruction technology30 percent design update may 6, 2014

Government & Nonprofit