A.3.5 High Explosives Fabrication

The HE fabrication mission requires explosives synthesis, formulation, pressing, machining, testing, evaluation, and component manufacturing. In addition to these fundamental capabilities, a variety of support activities is required. 

The explosives fabrication activity is important to the overall mission of the future DOE Complex. Over the past several years, economic trends have dictated a significant reduction in the domestic commercial support for this technology. In today's marketplace it is difficult to secure the small quantities of products necessary to sustain the reduced workload from commercial sources. The meticulous quality required of the explosives and components placed in nuclear weapons also disqualifies most commercial vendors. 

Assumptions. In addition to the general assumptions used in preparing this PEIS, the following assumptions apply specifically to the HE fabrication mission: 

General Functions and Layout. The general functions of HE fabrication are HE main charge manufacturing, small HE component manufacturing, HE formulation and synthesis, and HE testing and characterization. Production support functions include storage of raw materials and staging, packaging, and shipping of the intermediate and final product. These functions convert commercially available raw materials into HE and related components for weapons. These general functions also provide for testing and safe handling and storage of both raw materials and in-process and finished products. 

The facilities required to perform HE fabrication functions can be arranged in a variety of layouts to accommodate existing structures. Structures containing explosives operations are generally constructed with steel-reinforced concrete and are designed to mitigate the effects of an accidental explosion. Although insensitive HE materials can generally be processed in conventional steel structures, concrete construction is typically used to maintain the flexibility to process conventional explosives. The resulting facility design typically consists of a number of separate operating bays that could vent to an unoccupied area should a detonation occur. Structures that do not require concrete construction due to a lack of HE presence are generally constructed of steel, although portions of these buildings may be concrete. Most facilities include support areas for offices, break rooms, rest rooms, electrical equipment, heating, ventilation, and air conditioning equipment, maintenance, and in-process staging of materials, components, tooling, and supplies. Many production and laboratory facilities also include vacuum systems. Utilities required include water, steam, compressed air, and electricity. 

High Explosives Main Charge Manufacturing. This function manufactures main charge explosive subassemblies, main charge mock explosive assemblies, and explosive test specimens. An area must also be provided for conducting physical property testing on explosive components and materials. Each subfunction is described below. 

High Explosives Pressings . Rough shapes for HE main charge subassemblies and material test billets are manufactured by pressing. These presses also produce rough shapes for mock components from nonexplosive materials. Sufficient area is needed to include presses, ovens, powder inspection tables, loading tables, and shadowgraph equipment. 

Explosives Machining. The rough pressings are machined into hemispherical shapes or test elements using a combination of mills and lathes. HE machining is conducted wet, and a recirculating water treatment system is provided. Mock components may be machined in the same area or in the machine shop. Sufficient area is needed to include equipment for conducting density measurements, dye penetrant testing, and dimensional inspection. 

Main Charge Subassembly. The explosive hemispheres are assembled with electrical parts and hardware to produce main charge subassemblies. This is a manual operation that generally involves potting and bonding. 

Mechanical Properties Testing. The physical properties of explosive components and materials are tested to support War Reserve lot certification for materials and components and to support production development. The test configurations are assembled and tensile, torsion, and compression tests are conducted. 

Small High Explosives Component Fabrication. This process fabricates small HE weapon components and test assemblies. Various small components are fabricated from HE powders and binders, metal or plastic components, electrical components, hardware, and assembly materials. The fabrication process requires equipment for explosive powder heating, pellet pressing, laser welding, ultrasonic cleaning, extrusion loading, density testing, and mechanical assembly. Functions are described below. 

Pellet Pressing. Small pellets are pressed to density specifications from small energetic components assemblies. 

Extrusion Loading. Extrudable (paste) explosive is loaded onto small fixtures for small component assemblies. 

Small Component Assembly. Small HE pellets and/or fixtures containing extrudable paste explosives are assembled with inert parts to make small components. 

High Explosives Formulation and Synthesis. This process produces a variety of explosive materials from chemical reactants and commercially produced explosives. 

High Explosives Formulation. This function produces a variety of explosive materials from chemical reactants and commercially produced explosives. Material lots up to about 91 kg (200 lb) are produced through a series of batch operations. Some products are used to make small HE weapon components, while other products support the development of new explosives or explosives manufacturing processes. 

High Explosives Synthesis. The synthesis process integrates a variety of vessels, filters, and transfer pumps which are used to synthesize, recrystallize, blend, and wash explosive powders. The facility includes bays for mixing/milling, particle-size reduction, drying/weighing/packaging, solvent storage, and refrigerated storage for explosives and chemicals. 

High Explosives Testing and Characterization. Explosives test configurations are assembled and then detonated. The test data characterize the explosives performance and are required for the qualification of raw materials and production lots. Testing requires explosives containment chambers and an array of special instrumentation including streak cameras, rotating mirror framing cameras, an air image converter system, oscilloscopes and digitizers, flash x-ray systems, and velocity interferometers. 

High Explosives Test Firing. Energetic materials components are test fired at a remote firing facility which includes an outdoor firing capability to conduct large-scale explosives tests that cannot be performed in a test chamber, such as main charges for explosives lot certification. 

Nondestructive Evaluation. Explosive components are inspected using neutron radiography, x-ray, magnetic particle, and eddy current equipment to detect flaws, cracks, and voids in explosive and inert components. 

Mechanical Properties Testing. The mechanical properties of explosive components and materials are tested to support lot certification for materials and components and to support fabrication development. The test configurations are assembled and tensile and comprehensive tests are conducted. 

Analytical Laboratory. Chemical analyses are performed on explosive and nonexplosive materials to determine or verify their characteristics. The data obtained yield valuable information about the condition and composition of the material. This information is used to assure reliability of components and to statistically evaluate performance with material characteristics. The methods used include gas chromatography, liquid chromatography, size exclusion chromatography, infrared spectroscopy, thermal analysis, particle characterization, atomic spectroscopy, and emission spectroscopy. Surface chemistry, metallography, optical and scanning electron microscopy, and wet chemistry are also performed. 

Material Compatibility Testing. Test coupons are assembled such that the subject materials are in direct contact with each other. These coupons are then placed in environmental ovens to accelerate the aging process. Gas samples are periodically taken from the coupon containers and analyzed by the gas laboratory. Compatibility testing is required to certify new materials for weapon use. 

Production Support. The following functions and facilities are needed to support the HE fabrication missions. 

Bulk Explosives Storage. This function requires facilities to store collectively 31,800 kg (70,000 lb) of conventional HE powders awaiting transfer to/from the HE staging facility and offsite explosives vendors. These materials are typically received in 4,500 to 9,000 kg (10,000 to 20,000 lb) lots. Storage facilities also are needed for storing 182,000 kg (400,000 lb) of insensitive HE that is awaiting transfer to and from the explosive staging facilities. The bulk explosives facilities would be designed to provide separation between incompatible explosives types and would be remotely located from the production operations. 

Explosives Staging/Packaging/Shipping. This function would require staging a variety of explosive powders, components, and assemblies for supporting HE operations. These explosive materials include plastic bonded explosives for main charge manufacturing, completed main charges, small HE components, energetic feeds and products for HE formulation and synthesis, and explosive residues for disposal or recycling. The staging facilities would be designed to provide separation between incompatible explosives types. 

Process Support Systems. Process support for the HE manufacturing operation would include a machine shop and ES&H laboratory as well as other plant general services facilities. These facilities would directly support the HE fabrication mission as well as RD&T and other activities. 

Facility Utilities . HE fabrication utility requirements are a function of the size, condition, and location of the facilities as well as the production requirements. Therefore, the utility requirements vary at each of the three candidate sites. Utilities are described in subsequent sections for each candidate site. A typical water balance for HE fabrication is shown in figure A.3.5-1. 

Chemicals Required. The chemicals and materials consumed during operation primarily include water treating chemicals, reactants and solvents for explosives formulation and synthesis, explosives powders, materials for facility equipment and vehicle maintenance, and bottled gases. Specific lists of chemicals used by each site are provided under the site alternative description. 

The HE fabrication process also requires the following chemical support materials:  Transportation 

Intersite Transportation. The HE shipping/receiving facility would be designed to ship and receive bulk HE materials to and from the HE plant. These materials typically would be received in 4,500 to 9,000 kg (10,000 to 20,000 lb) lots. 

Shipping of completed charges would follow appropriate HE shipping regulations. All hazardous chemicals would be shipped using appropriate DOT requirements. The major type of hazardous material that would be transported to the plant would be HE materials. Bulk explosives powders would be delivered to the site by DOT-approved bulk commercial carriers. The powder would be unloaded at the bulk explosives storage facilities, which would isolate it from other facilities on the site. 

Intrasite Transportation. All intrasite transportation required for manufacture would occur within existing site boundaries and would not require use of public roads. Appropriate HE shipping regulations as defined by DOE and DOT would be followed. Shipment of HE components for testing may require the use of public roads. After testing and manufacturing, subsequent movements of HE and explosive components would be performed by trucks and battery-powered vehicles specifically designed for this purpose. The quantity of HE (conventional and insensitive) transported onsite by these trucks would be strictly limited. 

Explosives main charges and components would be transferred to staging areas while awaiting transfer to the A/D plant. In a similar manner, explosive components from the A/D plant would be transferred to the explosives production plant for demilitarization, sanitization, and disposition. Small quantities of hazardous wastes generated during operations would be collected, packaged, and transported by electric car to local accumulation sites and then by truck to a staging area. The waste would be transferred by truck for offsite disposal. 

Waste Management. The HE fabrication process generates the following waste and residual materials:  The waste management process for HE fabrication at the alternative sites follows in sections A.3.5.1 through A.3.5.3. 

A.3.5.1 Downsize at Pantex Plant

Pantex is the current DOE site for HE main charge manufacturing, small HE component manufacturing, HE formulation and synthesis, and HE testing and characterization. To efficiently meet the expected Complex workload, Pantex can downsize current HE fabrication operations. The following description assumes a downsized HE production mission at Pantex along with the A/D functions. 

Significant downsizing actions at Pantex focus on functional consolidation. This can be achieved by reducing the number of facilities operating in the explosives area to 11 or 12 and decreasing the direct, direct support, and direct operations support personnel to about 50. There are no processes to be transferred from offsite. All facilities identified under this plan meet Federal regulations and DOE orders as they pertain to explosives manufacturing. Table A.3.5.1-1 indicates specific products and capabilities that comprise the HE fabrication mission at Pantex. 

Table A.3.5.1-1.-- Pantex Plant High Explosives Fabrication Products 
and Capabilities

Products

Capabilities
High Explosives  Manufacturing Process Development 
  Stockpile stewardship support 
  Formulation 
  Synthesis 
  Surveillance 
Binders  Main Charge Manufacturing 
  Pressing 
  Machining 
  Subassembly 
  Receiving/storage 
  QA-mechanical/chemical/test fire 
  Disposition 
Main Charge Formulations  Energetic Component Manufacturing 
  Pressing 
  Machining 
  Subassembly 
  Receiving/storage 
  QA-mechanical/chemical/test fire 
Initiation High Explosives  Detonators 
Mock High Explosives Formulations Testing 
Note: QA - quality assurance.
Source: PX DOE 1995e.

Assumptions. Requirements are based on an annual production rate of 150 replacements or retrofits. The 150 replacements or retrofits consist of 100 warheads and 50 bombs. The capability of providing explosives for two weapons systems in any given year is maintained. The Stockpile Evaluation Program consists of 120 disassemblies and inspections, 110 rebuilds, and additional joint test assemblies, joint test assembly post mortems, and test beds consistent with current guidance and stockpile levels. Some existing programs in the enduring stockpile use main charges made from conventional HE. Insensitive HE machining and storage continue to be explosive hazard Class IV operations. All hexanitrostilbene-based explosives and micronized-triaminotrinitrobenzene materials required would be produced at the HE production plant. Spare equipment and facilities are not included in the minimum facility requirements. 

Facility and equipment maintenance would occur on the off-shift and the nonwork days when feasible. The Complex would be capable of producing materials and assembling replacement components and units for two weapon systems in any given year. This capability would be achieved by either simultaneous or sequential campaigns, as long as the sum of the product shipments for the year meets the annual production goals. The stockpile stewardship and management alternatives would not impact the ongoing plant missions, either during construction or during the life of the upgraded plant. Ongoing plant missions are defined as those functions performed today. 

Strategic reserve requirements for explosives would be stored at the HE production site. The selected site for the HE production mission would be operational within 2 years after the ROD for this PEIS. The baseline technology for HE production comprises the present techniques utilized at Pantex. If transferred, prebuilds at the donor site would fill any production capability gap between the donor and receiver site for the HE operations. If HE production missions are transferred, a 5-year period is required to accomplish the D&D activities at Pantex. 

Facility Description. As stated previously, there would be no product or process transfers; however, there would be substantial functional consolidation. For example, Pantex currently has seven functional test fire sites. All test activities identified as required to support the enduring stockpile can be consolidated into two sites: a fully contained indoor test chamber and an outdoor site to accommodate large charges. Explosives components fabrication would be reduced from four buildings to two. Chemical characterization, nondestructive evaluation, and mechanical testing would be consolidated from the current five facilities to two, as well. A comprehensive listing of the planned consolidations can be found in table A.3.5.1-2. Figures A.3.5.1-1, A.3.5.1-2, and A.3.5.1-3 show the locations of the zones and the facilities within these zones. 

Table A.3.5.1-2.-- Pantex Plant Functional Consolidation of Explosives Operations

Capabilities

Current Facilities

Consolidated Facilities (Projected)
Synthesis  11-36  11-55 
Formulation  12-19E, 12-62  11-50, 12-62 
Isostatic pressing  12-63  12-63 
Explosives machining  11-50, 12-121  12-121 
Explosives subassembly  12-31  12-121 
Explosives components  11-20, 12-17, 12-62, 12-63  12-62, 12-63 
Evaluation/characterization  11-5, 11-17, 11-51, 12-21, 12-59  11-51, 12-104A 
Test fire  11-18, 11-38, FS-10, FS-11, FS-21, FS-22, FS-24  FS-11, FS-22, FS-24 
Explosives storage  11-42, 12-65, 12-83, Zone 4 
(8 magazines)  		12-65, Zone 4 
(4 magazines) 
Explosives disposal Burning Ground  Burning Ground 
Source: PX DOE 1995e.

Pantex consists of 425 buildings containing approximately 232,300 m 2 (2.5 million ft 2 ) of floor space of which explosives operations occupy 37,200 m 2 (400,000 ft 2 ). Within 4,119 ha (10,177 acres), approximately 809 ha (2,000 acres) are dedicated to active facility operations. Approximately 3,270 ha (8,080 acres) are devoted to storage, disposal, and miscellaneous activities in support of plant operations. 

Pantex structures containing explosives operations comply with the DOE Explosives Safety Manual, DOE/EV/06194 and are generally constructed with steel-reinforced concrete and designed to mitigate the effects of an accidental explosion. Although insensitive HE materials can generally be processed in conventional steel structures, concrete construction is typically used to maintain the flexibility to process conventional explosives. The resulting facility design typically consists of a number of separate operating bays with remote and/or contact operating capability that are fully contained or could vent to an unoccupied area should a detonation occur. Most facilities include support areas for offices, break rooms, rest rooms, electrical equipment, heating, ventilation, and air conditioning equipment, maintenance, and in-process staging of materials, components, tooling, and supplies. Many production and laboratory facilities also include vacuum systems. Utilities required include steam, compressed air, and electricity. 

The HE facilities are primarily within the Applied Technology Division. These facilities would support main charge manufacturing, small component manufacturing, formulation and synthesis, and explosives testing and characterization, as well as HE storage and disposition. 

Design Safety. The following sections identify important safety considerations incorporated in the design of explosives facilities. Performance goals commensurate with the associated hazard are selected for all structures, systems, and components. The term "hazard" is defined as a source of danger, whether external or internal. Natural phenomena such as earthquakes, extreme winds, tornadoes, and floods are external hazards to structures, systems, and components; whereas toxic, reactive, explosive, or radioactive materials contained within the facilities are internal hazards. Usage category is established by DOE management. Guidelines for usage category (performance category) and the corresponding performance goals are given in Design and Evaluation Guidelines for DOE Facilities Subjected to Natural Phenomena Hazards (UCRL-15910). 

Earthquakes. All existing facilities meet the standards as cited below. Structures, systems, and components are designed for earthquake-generated ground accelerations in accordance with University of California Research Laboratory (UCRL)-15910. The applicable seismic hazard exceedance probability is 2x10 -3 for general use (performance category 1), 1x10 -3 for low and moderate hazard (performance categories 2 and 3), and 2x10 -4 for high hazard (performance category 4) for structures, systems, and components. 

Seismic design considerations for performance category 3 and 4 structures, systems, and components include provisions for such structures, systems, and components to function as hazardous materials confinement barriers and for adequate anchorage of building contents to prevent loss of critical function during an earthquake. In essence, design considerations are to avoid premature, unexpected loss of function, and to maintain ductile behavior during earthquakes. 

The fire protection system, emergency power, water supplies, and controls for the safety class equipment are some of the necessary emergency items that must be available following an earthquake. As stated in UCRL-15910, earthquake-resistant design considerations extend beyond the dynamic response of structures and equipment to include survival of systems that prevent facility damage or destruction due to fires or explosions. 

Wind . All existing plant structures, systems, and components at Pantex meet the wind or tornado load criteria and the corresponding facility usage and performance goals. Wind design criteria are based on annual probability of exceedance, importance factor, missile criteria, and atmospheric pressure changes as applicable to each performance (usage) category as specified in UCRL-15910. Wind loads are based on the annual probability of exceedance of 2x10 -2 for the general and low hazard (performance categories 1 and 2), 1x10 -3 for the moderate hazard (performance category 3), and 1x10 -4 for the high hazard (performance category 4) structures, systems, and components. Since tornadoes are the viable wind hazards, structures are designed for the annual probability of exceedance of 2x10 -5 as defined in UCRL-15910. 

Floods . All facilities required for the HE operations at Pantex are located above the critical flood evaluation. The extent of the flood hazard is determined using the appropriate usage (performance) category for determining the "Annual Hazard Probability of Exceedance": 2x10 -3 for the general use (performance category 1), 5x10 -4 for the important or low hazard (performance category 2), 1x10 -4 for the moderate hazard (performance category 3), and 1x10 -5 for the high hazard (performance category 4) facility as defined in UCRL-15910. 

Whenever possible, all facilities in performance categories above the general use category (performance category 1) are constructed with the lowest floor of the structure, including subsurface floors, above the level of the 500-year flood. This requirement can be met by siting and/or flood protection. Whenever possible, all facilities, including their basements, in all performance categories are sited above the 100-year floodplain. 

Fire Protection . The fire protection features for the plant and its associated support buildings are in accordance with DOE orders and the National Fire Prevention Association Fire Codes and Standards. Redundant firewater supplies and pumping capabilities are installed to supply the automatic and manual fire protection systems located throughout the site. Appropriate types of fire protection systems are installed to provide life safety, prevent large-loss fires, prevent production delay, ensure that fire does not cause an unacceptable onsite or offsite release of hazardous material that will threaten the public health and safety of the environment, and minimize the potential for the occurrence of a fire and related perils. Specific production areas and/or equipment are provided with the appropriate fire detection and suppression features, as required, with respect to the unique hazard characteristics of the product process. 

Safety Class Instrumentation and Contro l. The safety classification of instrumentation and controls are derived from the safety functions which they perform. The safety classification is based on appropriate DOE orders. Existing facilities at Pantex meet all safety class requirements. Safety instrumentation is designed to monitor identified safety-related variables in safety class systems and equipment over expected ranges for normal operation, accident conditions, and safe shutdown. Safety class controls are provided when required to control these variables. Safety class instrumentation is designed to fail in a safe mode following a component or channel failure. Safety class Uninterruptable Power Supply power is provided when appropriate. 

Ventilation . The heating, ventilation, and air conditioning system design of existing facilities meets all general design requirements in accordance with DOE orders, and American Society of Heating, Refrigerating, and Air Conditioning Engineers guides. The design includes engineered safety features to prevent or mitigate the potential consequences of postulated design basis accident events. 

Internal Explosion . Buildings containing HE are designed to mitigate the effects of accidental explosion within a bay or cell. The design is in accordance with the DOE Explosive Safety Manual , DOE/EV/06194, including the quantity-distance and the level-of-protection criteria for each class of explosives activities. 

Overall Facility Layouts and Design Description. Pantex facilities proposed for the HE fabrication mission are listed in table A.3.5.1-3 and described in this section. The table summarizes key facility data for existing buildings and support areas. Data for the facilities include building number, description, construction type (concrete or steel), gross square meters, number of levels in the structure, and explosives present. 

Structures containing explosives operations are generally constructed with steel-reinforced concrete and are designed to mitigate the effects of an accidental explosion. Although insensitive HE materials can generally be processed in conventional steel structures, concrete construction is typically used to maintain the flexibility to process conventional explosives. 

Table A.3.5.1-3.-- Pantex Plant High Explosives Fabrication Facility Data

 

Facility Function

Building 
Number

 

 

Construction Type

 

Gross 

Area

(m 2 )

 

Number of Levels

 
 
Special Materials
 
Bulk explosives storage  04-101 - 04-104  Concrete 

441

 1  HE 
Synthesis  11-55  Concrete 

279

 1  HE 
HE formulation  11-50  Concrete 

2,062

 2  HE 
Chemical testing/evaluation  11-51  Concrete 

1,078

 1  None 
HE main charge pressing  12-63  Concrete 

223

 1  HE 
Explosives staging/packaging/shipping  12-65  Concrete 

753

 1  HE 
Fabrication/assembly  12-62, 12-63  Concrete 

548

 1  HE 
Explosives machining/gaging/subassembly/ safety testing/physical testing/ nondestructive evaluation  12-121  Concrete 

4,562

 1  HE 
Test fire assembly  FS-11  Steel 

190

 1  HE 
Outdoor firing site  FS-22  Concrete 

167

 1  HE 
Contained firing site  FS-24  Concrete 

701

 1  HE 
HE disposal Burning Ground  Concrete 

56

 1  HE 
Source: PX DOE 1995e.

The resulting facility design typically consists of a number of separate operating bays that could vent to an unoccupied area should a detonation occur. Structures that do not require concrete construction due to the presence of HE are generally constructed of steel, although portions of these buildings may be concrete. Most facilities include support areas for offices, break rooms, rest rooms, electrical equipment, heating, ventilation, and air conditioning equipment, maintenance, and in-process staging of materials, components, tooling, and supplies. Many production and laboratory facilities also include vacuum systems. Utilities required include water, steam, compressed air, and electricity. 

High Explosives Main-Charge Manufacturing. These facilities manufacture explosive subassemblies, main charge mock explosive hemispheres, and explosive test specimens. An area is also provided for conducting physical property testing on explosive components and materials. Each functional area is described below. 

Isostatic Pressing (Building 12-63). Rough pressings for HE main charge subassemblies and material test billets are manufactured in Building 12-63. 

Explosives Machining (Building 12-121). The rough pressings are machined in Building 12-121. 

Main Charge Subassembly (Building 12-121). The explosives hemispheres are assembled in Building 12-121. 

Mechanical Properties Testing (Building 12-121). The physical properties of explosive components and materials are tested in a portion of Building 12-121. 

Small High Explosives Component Manufacturing (Buildings 12-63, 12-121) . Various small components are manufactured from HE powders and binders, metal or plastic components, electrical components, hardware, and assembly materials. The manufacturing process requires equipment for explosive powder heating, pellet processing, laser welding, ultrasonic cleaning, extrusion loading, density testing, inspection, and mechanical and electrical assembly. 

Test Firing (Buildings FS-11, FS-22, FS-24). Explosives test configurations are assembled and tested at Buildings FS-11, FS-22, and FS-24. The test data characterize the explosives performance and are required for the qualification of raw materials and production lots. Testing requires explosives containment chambers and an array of special instrumentation including streak cameras, rotating mirror framing cameras, digitizers, flash x-ray systems, and velocity interferometers. Outdoor firing sites are used to conduct explosives tests (e.g., skid and hydrodynamic tests greater than 1 kg [2.2 lb]) that cannot be performed in a test chamber. These facilities are remotely located from production operations. 

Nondestructive Evaluation (Building 12-121). Explosive components are inspected using neutron radiography, x-ray, magnetic particle, and eddy current equipment to detect flaws, cracks, and voids in explosives and inert components. Nondestructive evaluation also supports the A/D mission. 

High Explosives Formulation (Buildings 11-50 and 12-62) and Synthesis (Building 11-55). These facilities have the capability to produce a variety of explosives materials from chemical reactants and commercially produced explosives. Material lots up to about 91 kg (200 lbs) are produced through a series of batch operations. Some products are used to make small HE weapon components, while other products support the development of new explosives or explosives manufacturing processes. 

The HE formulation and synthesis facilities include several flexible processing bays that contain a variety of vessels, filters, and transfer pumps used to synthesize, recrystallize, blend, and wash explosive powders. The facilities also include bays for mixing/milling, reducing particle size, drying/weighing/packaging, storing solvent, and refrigerated storing of explosives and chemicals. Building 11-55 replaces the existing synthesis facility (Building 11-36), which is in deteriorating condition. Building 11-50 replaces an existing formulation capability in Building 12-19E. 

Production Support. The production support facilities house an analytical laboratory and material compatibility testing. 

Analytical Laboratory (Building 11-51). Chemical analyses are performed on explosive and nonexplosive materials in Building 11-51 to determine or verify their characteristics. The data obtained yield valuable information about the condition and composition of the material. This information is used to ensure components' reliability and to statistically evaluate performance with material characteristics. The methods used include gas chromatography, liquid chromatography, size exclusion chromatography, infrared spectroscopy, thermal analysis, particle characterization, atomic spectroscopy, and emission spectroscopy. Surface chemistry, metallography, optical and scanning electron microscopy, and wet chemistry are also performed. 

Material Compatibility Testing (Building 11-51). Test coupons are assembled such that the subject materials are in direct contact with each other. These coupons are then placed in environmental ovens to accelerate the aging process. Gas samples are periodically taken from the coupon containers and analyzed by the gas laboratory. Compatibility testing is accomplished in Building 11-51 and is required to certify new materials for weapon use. 

Bulk Explosives Storage (Buildings 4-101 through 4-104). These facilities are designed to store collectively 31,800 kg (70,000 lb) of conventional HE powders while awaiting transfer to or from the HE staging facility and offsite explosives vendors. These materials are typically received in 4,500 to 9,000 kg (10,000 to 20,000 lb) lots. These facilities also are used for storing 182,000 kg (400,000 lb) of HE awaiting transfer to or from the explosives staging facilities. The bulk explosives facilities would be designed to provide separation between incompatible explosives types and would be located remotely from the production operations. 

Explosive Staging/Packaging/Shipping (Building 12-65). These facilities are designed to stage a variety of explosives powders, components, and assemblies for supporting HE operations. These explosives materials include plastic bonded explosives for main charge manufacturing, completed main charges, small HE components, energetic feeds and products for HE formulation and synthesis, and explosives residues for disposal or recycling. These facilities are designed to provide separation between incompatible explosives types. 

Resource Requirements During Construction/Modification. Requirements during construction and modification to implement the downsized configuration for HE fabrication at Pantex are described below. 

Land Area Requirements During Modification. Downsizing in place of the explosives production operations at Pantex requires approximately 0.12 ha (0.3 acres) of land for construction laydown and warehousing and an additional 0.04 ha (0.1 acres) to accommodate construction parking. These activities would occur in previously developed land areas. 

Materials and Resources Consumed During Modification. The materials and resources consumed during downsizing of the explosives production operation at Pantex are shown in table A.3.5.1-4. These resources include utilities, construction materials, liquid fuels, and industrial gases. 

Table A.3.5.1-4.-- Pantex Plant High Explosives Downsizing Materials/Resources
Requirements

Material/Resource

Total Consumption

Peak Demand 1
Electricity 

257 MWh

2 MWe
Water (L) 

644,000

 
Concrete (m3) 

356

  
Steel (t) 

6

  
Liquid fuel (L) 

12,200

  
Industrial gases 2 (m3 ) 

258

  
Emissions During Modification. Air pollutants are emitted during modification activities required for the downsizing of the explosives production operations. The principal sources of such emissions are fugitive dust from site preparation for material laydown areas, other construction activities, and exhaust from construction equipment and vehicles. The estimated annual emissions generated during a 1-year period with peak construction activity are shown in table A.3.5.1-5. 

Employment During Modification. The number of workers required during each year of construction at Pantex for the HE downsizing alternative is presented in table A.3.5.1-6. 

Table A.3.5.1-5.-- Pantex Plant High Explosives Downsizing Construction Emissions

Pollutant

Quantity

(t)
Carbon monoxide  0.54 
Nitrogen oxides  0.19 
Particulate matter  0.08 
Sulfur dioxide  0.02 
Total suspended particles  0.19 
Volatile organic oxides  0.09 
PX DOE 1995e.

Table A.3.5.1-6.-- Pantex Plant High Explosives Downsizing Construction Workers

Employees

Year 1

Year 2

Year 3

Total
Craftworkers         
Carpenter  1  3  1  5 
Construction management and support staff  0  3  1  4 
Concrete mason  1  2  1  4 
Electrician  0  3  2  5 
Iron worker  1  3  1  5 
Laborer  1  3  1  5 
Millwright  0  1  1  2 
Operator  0  1  0  1 
Other craftworkers  0  2  1  3 
Pipe fitter  0  2  1  3 
Sheet metal worker  0  3  1  4 
Sprinkler fitter  0  2  1  3 
Teamsters  0  1  1  2 
Total Employment 4  29  13  46 
Source: PX DOE 1995e.

Resource Requirements During Operations--High Explosives Fabrication Mission. No additional land is required to operate the HE downsizing alternative at Pantex. 

The utilities consumed during operation include electric power, liquid fuels, natural gas, and water. Annual utility consumption rates and peak electric power rates for surge operation are shown in table A.3.5.1-7 and are incremental to the A/D mission at Pantex. 

All activities would be accomplished on a single, 40 hours-a-week shift. Any surge production would be achieved by increasing personnel and adding shifts (1-year lead time). The facilities would be operated under existing site labor agreements. Surge operation of the HE Fabrication Facility would require 37 direct workers (PX 1996e:1). Support workers for the A/D mission would provide sufficient support for the HE fabrication mission. 

Table A.3.5.1-7.-- Pantex Plant High Explosives Downsizing Surge Operation Annual Utility Requirements

Utility

Consumption

Peak Demand 3
Electricity  3,250 MWh  1 MWe 
Liquid fuel (L)  55,600   
Natural gas 4 (m3 )  500,000   
Water (L)  12,500,000   
Chemicals Consumed During Operation. The chemicals and materials consumed during operations primarily include water treating chemicals, reactants and solvents for explosives formulation and synthesis, explosive powders, materials for facility equipment and vehicle maintenance, and bottled gases. No radioactive materials are required for explosives production. Materials with annual consumption in excess of 227 kg (500 lb) during surge operations are listed in table A.3.5.1-8. 

Table A.3.5.1-8.-- Pantex Plant High Explosives Downsizing Surge Operation Annual Chemical Requirements

Chemical

Quantity

(kg)
Calcium chloride 

4,080
Ethyl acetate 

1,360
HE powders, insensitive 

31,600
HE powders, conventional 

15,800
Hydraulic/lubricating oil 

4,310
Nitrogen 

1,810
Paint 

2,380
Source: PX 1995a:6; PX DOE 1995e.  
Emissions During Operation. Gaseous environmental releases would result from operation of the thermal treatment units for bulk HE waste and nonradioactive HE-contaminated waste generated by Pantex for the explosives production operations. Emissions would also result from plant boiler operation, cleaning operations using solvents, and formulation and synthesis operations. The thermal treatment units would be designed and operated to attain and maintain temperatures which result in the destruction of hazardous constituents. Hazardous particulates would be trapped in filters. The releases would be limited to what is possible, using the best available control technology. The annual chemical emissions for the explosives production surge operations are shown in table A.3.5.1-9. 

Table A.3.5.1-9.-- Pantex Plant High Explosives Downsizing Surge Operation Annual Emissions

 

Quantity

(kg)

Pollutant

Incremental with Assembly/ Disassembly
Criteria Pollutant 

 
Carbon monoxide 

413
Nitrogen oxides 

1,560
Particulate matter 

68
Sulfur dioxide 

0.01
Volatile organic compounds 

122
Hazardous and Other Toxic Compounds 

 
Acetonitrile 

0.45
Aldehydes 

2.04
Ammonia 

0.02
Benzene 

3.00
Cresylic acid 

0.0014
Cyclohexane 

1.70
1,2-Dichloroethane 

0.03
Dimethyl formamide 

0.01
Dioxane 

0.04
Hexane 

0.09
Hydrogen chloride 

3.20
Hydrogen fluoride 

4.50
Mercury 

2x10 -8
Methanol 

2.7
Methyl ethyl ketone 

349
Toluene 

9.5
1,1,1-Trichloroethane 

0.54
Trichloroethylene 

0.45
Xylene 

8

PX DOE 1995e.
Waste Management 

Wastes Generated During Construction. The liquid and solid wastes generated during construction would include concrete and steel waste construction materials, hazardous wastes, and sanitary wastewater. The steel construction waste material would be recycled as scrap metal. No radioactive or mixed wastes would be generated during construction. 

The liquid and solid wastes generated during HE downsized fabrication functions are discussed in the subsections below. The annual quantity of solid and liquid waste generated by the explosives production operations at Pantex during surge operation is shown in table A.3.5.1-10. 

Hazardous toxic wastes would consist of solid residue (ash) from thermal treatment units, solvents from operations, wash water and residual reactants from explosives formulation and synthesis, and residue from painting and bonding operations. This waste would be stabilized and sent to an approved permitted RCRA disposal site. 

Solid nonhazardous, nonradioactive wastes generated by the explosives production operations would consist primarily of solid sanitary waste, residue from facility and vehicle maintenance, spent desiccants, and sanitized and demilitarized paper and parts. Nonrecyclable portions of this waste would be sent to an offsite landfill. Liquid sanitary wastewater and process wastewater would be treated and discharged to a permitted drainage channel. 

Transportation. The major type of hazardous material that would be transported to Pantex would be HE materials. Bulk explosives powders would be delivered to the site by DOT-approved bulk commercial carriers. The powder would be unloaded at the bulk explosives storage facilities, isolated from other facilities on the site. Subsequent movements of HE and explosives components would be performed by trucks and battery powered vehicles specifically designed for this purpose. The quantity of HE (conventional and insensitive) transported onsite by these trucks would be strictly limited. 

Explosives main charges and components would be transferred to staging areas for transfer to the A/D plant. In a similar manner, explosives components from the A/D plant would be transferred to the explosives production plant for demilitarization, sanitization, and disposition. Small quantities of hazardous waste generated during operations would be collected, packaged, and transported by electric car to local accumulation sites and then by truck to a staging area. The waste would be transferred by truck for offsite disposal. 

Table A.3.5.1-10.-- Pantex Plant High Explosives Fabrication Facility Waste Volumes

Category

Annual Average 
Volume Generated 
from Construction
(m3)

Annual Volume Generated from 
Surge Operations
(m3)

Annual Volume 
Effluent from 
Surge Operations
(m3)
Low-Level        
Liquid  None  None  None 
Solid  None  Minimal  Minimal 
Mixed Low-Level       
Liquid  None  None  None 
Solid  None  None  None 
Hazardous       
Liquid  None  0.23  0.23 
Solid  0.06  30  30 
Nonhazardous  
(Sanitary)  		     
Liquid  146  7,120  7,120 
Solid  None  17  8 5 
Nonhazardous  
(Other)  		     
Liquid  Included in sanitary  None  None 
Solid  2 6  Included in sanitary  Included in sanitary 

A.3.5.2 Relocate to Los Alamos National Laboratory

The HE processing facilities at LANL (figures A.3.5.2-1 and A.3.5.2-2) were designed and built for production scale operations and were operated as production facilities supplying nuclear weapons HE components for many years. LANL has continued to upgrade and modernize processing equipment in these existing facilities to provide prototype HE components to meet hydrodynamic and NTS program requirements. Using the existing HE manufacturing infrastructure along with state-of-the-art processing equipment, LANL produces high-quality complex HE components to meet one-of-a-kind prototype requirements or limited production runs of HE components used in test programs. Typically, LANL fabricates an average of 1,200 to 1,500 HE parts per year. Surveillance (returned stockpile) HE components are also processed for weapon aging studies. 

LANL's full range of HE-processing capabilities includes HE storage magazines, HE synthesis, HE formulation, pressing, machining, assembly, and subassembly of HE devices, proven quality assurance processes, and stringent disposal requirements. In addition, LANL has facilities for environmental, safety, and performance testing of HE and HE assemblies. In all, the inherent capacity of the LANL HE plant exceeds weapons R&D testing program requirements. Furthermore, expanding workloads at LANL to support the projected production would not tax or require full capacity of LANL's existing infrastructure. 

LANL would assume the responsibility for providing all HE feedstock, main charge, and component procurement, and fabrication as required by the HE fabrication mission. The products and capabilities for which LANL would be responsible are shown in table A.3.5.2-1. 

Table A.3.5.2-1.-- Los Alamos National Laboratory High Explosives Fabrication Products
and Capabilities

Products

Capabilities

High Explosives

 Manufacturing Process Development 
  Stockpile stewardship support 
  Formulation 
  Surveillance 
  Synthesis 
Binders  Main Charge Manufacturing 
  Pressing 
  Machining 
  Subassembly 
  Receiving/storage 
  Quality assurance-mechanical/chemical/test fire 
  Disposition 
Main Charge Formulations  Energetic Component Manufacturing 
  Pressing 
  Machining 
  Subassembly 
  Receiving/storage 
  Quality assurance-mechanical/chemical/test fire 
  Disposition 
Initiation High Explosives  Detonators 

Mock High Explosives Formulations

 Testing 

LANL 1995d.
Assumptions. The general and facility assumptions on which the data in this section are based follow. 

General Assumptions 

Facility Capacity/Capabilities Assumptions  Facility Description. LANL has all the facilities and equipment needed to carry out the HE fabrication mission. These HE processing facilities are located primarily in TAs -9 and -16. The synthesis, analytical laboratory, and pilot scale formulation activities are located at TA-9. These facilities, including administrative support and HE storage, comprise 39 buildings with over 3,700 m 2 (40,000 ft 2 ) of floor space. Formulation, pressing, machining, receiving, storage, subassembly, radiography, and disposal processes are carried out at TA-16, which houses 65 buildings covering over 8,900 m 2 (96,000 ft 2 ). Testing and nondestructive evaluation would be carried out in a variety of other TAs. TA-37 would provide storage of HE parts and components. All LANL facilities are designed to meet the requirements of the DOD Ammunition and Explosive Safety Standards (DOD 6055.9) and the DOE Explosives Safety Manual (DOE/EV/06194) for quantity-distance and operational criteria. The HE safety requirements applicable to operations involving the development, testing, handling, and processing of explosives or assemblies containing explosives are identified in DOE/EV/06194. This manual reflects the state of the art in HE safety. Again, no new construction or major equipment transfers from Pantex are required to support the HE fabrication mission at LANL. 

State- and Federal-permitted waste disposal facilities are located at TA-54 for hazardous materials (non-HE contaminated) and at TA-16 for HE and HE-contaminated waste. LANL operates in compliance with all state and Federal requirements and regulations, applying a process of continuous process improvements to drive an effective "best practices" program in waste minimization. 

Currently, processing routing flow sheets accompany HE components as they are moved through each processing step. Operators sign off as each process is completed. When the processing is completed, the flow sheets are sent to production control where the processing and inspection data are entered into databases and then filed in production control files. Database inventories and task order files are kept on all components, assemblies, and raw materials used in the HE Fabrication Facility. 

Although the facilities are in remote locations, they are well integrated into the infrastructure of LANL. They all have intrasite transportation connections so that transportation of explosives and components on public roads is not of concern for operations. Because of their location, HE facilities are well buffered and are not subject to population pressures. 

The HE facilities are primarily centralized in the Dynamic Experimentation and Engineering Sciences and Application Divisions and are used in support of DOE and DOD programs. These facilities will be used for the HE fabrication processes including synthesis and formulation, main-charge manufacturing, testing and characterization, small component manufacturing, HE storage, and disposition. The TAs used to support the production include TAs -8, -9, -11, -14, -15, -16, -21, -22, -28, -36, -37, -39, and -40. The majority of the HE processing operations are located at TAs -9, -16, -28, and -37. 

HE performance testing and characterization can be conducted at any of several firing sites operated by DX Division. TAs include TAs -14, -15, -16, -21, -22, -36, -39, and -40. Hazardous waste treatment and disposal facilities are located at TA-54, while HE disposal facilities are located at TA-16. 

Design Safety. Important safety considerations are incorporated into the design of DOE facilities. Performance goals commensurate with the associated hazard are selected for all structures, systems, and components. The term "hazard" is defined as a source of danger, whether external or internal. Natural phenomena such as earthquakes, extreme winds, tornadoes, and floods are external hazards to structures, systems, and components; whereas, toxic, reactive, explosive, or radioactive materials contained within the facilities are internal hazards. Usage category is as established by DOE management. Guidelines for usage category (performance category) and the corresponding performance goals are given in UCRL-15910. 

Earthquake. All existing HE fabrication structures located in Dynamic Experimentation and Engineering Sciences and Application Divisions meet all current applicable standards. An engineering study showed that the reinforced concrete structures used for HE processing buildings used for blast loading requirements exceed the seismic loading for structural capacity. New structures, systems, and components, when required, shall be designed for earthquake-generated ground accelerations in accordance with UCRL-15910, with applicable seismic hazard exceedance probability of 2x10 -3 for general use (performance category 1), 1x10 -3 for low and moderate hazard (performance category 2 and 3), and 2x10 -4 for high hazard (performance category 4) structures, systems, and components. 

Wind. All existing HE fabrication structures at TA-9 and TA-16 meet the wind criteria as discussed below. All new structures, systems, and components would be designed for wind or tornado load criteria when required in accordance with UCRL-15910 and the corresponding facility usage and performance goals. Wind loads shall be based on the annual probability of exceedance of 2x10 -2 for the general and low hazard (performance categories 1 and 2), 1x10 -3 for the moderate hazard (performance category 3), and 1x10 -4 for the high hazard (performance category 4) structures, systems, and components. Wind design criteria is based on annual probability of exceedance, importance factor, missile criteria, and atmospheric pressure change, as applicable, to each performance (usage) category as specified in UCRL-15910. 

Floods. All HE facilities and buildings at the LANL HE Fabrication Facility are located above the critical flood elevation from the potential flood source (river, dam, levee, precipitation, etc.). The extent of the flood hazard is determined using the appropriate usage (performance) category for determining the annual hazard probability of exceedance: 2x10 -3 for general use (performance category 1), 5x10 -4 for important or low hazard (performance category 2), 1x10 -4 for moderate hazard (performance category 3), and 1x10 -5 for high hazard (performance category 4) facilities as defined in UCRL-15910. 

The critical flood elevation is determined by obtaining the design basis flood level. The design basis flood level is the peak hazard level (flow rate, depth of water, etc.) corresponding to the mean annual hazard probability of exceedance or combinations of flood hazards (river flooding, wind-wave action, etc.) and corresponding loads associated with the peak hazard level and applicable load combination (hydrostatic and/or hydrodynamic forces, debris loads, etc.). LANL run-off site drainage conforms to the State of New Mexico and NPDES requirements. The minimum design level for the stormwater management system is the 25-year, 6-hour storm, but potential effects of larger storms up to the 100-year 6 hour storm are also considered. 

Fire Protection. The fire protection features for the existing HE Fabrication Facility and its associated support buildings are in accordance with DOE orders and the National Fire Prevention Association Fire Codes and Standards. 

Redundant firewater supplies and pumping capabilities (electric motor drivers with diesel generator backup) would be installed to supply the automatic and manual fire protections systems located throughout the site. One tank and one set of pumps would be designed to meet design basis event requirements. Appropriate types of fire protections systems would be installed to provide life safety, to prevent large-loss fires, to prevent production delay, to ensure that fire does not cause an unacceptable onsite or offsite release of hazardous material that would threaten the public health and safety or the environment, and minimize the potential for the occurrence of a fire and related perils. Specific production areas and/or equipment would be provided with the appropriate fire detection and suppression features, as required, with respect to the unique hazard characteristics of the product or process. 

A fire hazards analysis would be performed to assess the risk from fire within the individual fire areas of the facility. All fire sprinkler water that has been discharged during and after a fire would be collected in building sump systems, monitored, sampled, and, if required, retained until it could be disposed of. 

Safeguards and Security Systems Description. The HE fabrication facilities located at TA-9 and TA-16 are located within a security parameter with multiple fences surrounding the areas. The main large scale HE processing buildings, assembly area, and magazine storage areas at TA-16 and TA-37 are located within a separate fenced HE exclusion area. 

Safety Class Instrumentation and Control. The safety classification of instrumentation and controls is derived from the safety function each performs. This safety classification is based on appropriate DOE orders. HE facilities at LANL that utilize instrumentation for explosives operations currently meet all the safety class requirements. 

Ventilation. The heating, ventilation, and air conditioning system provides environmental conditions for the health and comfort of personnel and for equipment protection. 

Internal Explosion. New and existing buildings are designed for the effects of accidental explosion within a bay or cell. The design is in accordance with the DOE Explosives Safety Manual (DOE/EV/06194), including the quantity-distance and the level of protection criteria for each class of explosives activities. 

Overall Facility Layouts and Design Descriptions. The existing HE fabrication facilities at LANL would be used to support the production mission for HE fabrication. These facilities were designed to meet the DOD Ammunition and Explosives Safety Standards (DOD 6055.9) and DOE/EV/06194. Operations are segregated by hazard class: Class I processes, the most hazardous processes, were designed for remote operations with an accidental detonation venting the process bay via a frangible (blow-out) wall away from inhabited areas. Fragment distances and blast overpressure (interline distance) set the criteria for locating operating buildings. 

All LANL HE processing facilities are designed for Class I (remote) and Class II (operated attended) operations as defined by DOD 6055.9. While some processing operations require some minimal changes for processing conventional HE, there are no major differences in equipment or facilities. The just-in-time flexible manufacturing approach allows the facilities to alternately process both insensitive HE and conventional HE in the same equipment and facilities. This operational philosophy allows optimized fabrication of all HE and gives the flexibility to make production lots of materials, as required (i.e., plane wave lenses), as well as to manufacture a single quantity of weapon HE components for local hydrodynamic tests and custom HE part requirements. 

Structures containing HE and those in which HE operations are conducted are constructed with thick (0.6-m [2-ft]) thick, steel-reinforced, concrete walls designed to mitigate the effects of an accidental explosion. These facilities contain protective berms and are located to meet quantity-distance criteria. Most facilities include support areas for offices; break rooms; restrooms; electrical equipment; heating, ventilation, and air conditioning equipment; maintenance; and in-process staging of materials, components, tooling, and supplies. Table A.3.5.2-2 lists functional HE processing technology, building numbers, and working floor space. No new facilities or structures are required to support the HE manufacturing production mission. 

High Explosive Main-Charge Manufacturing. The HE processing facility is used to manufacture main charge subassemblies, mock main charge hemispheres, and explosive test specimens. An area is also provided for conducting physical property testing on explosives components and materials. Each functional area is described below: 

Isostatic Pressing. Rough pressings for HE main charge subassemblies, material test billets, and pellets for small components and boosters are fabricated in TA-16-430. 

Explosives Machining. Rough pressings are radiographed, inspected, and machined into hemispherical shapes or test charges in TA-16-260. 

Inspection. HE components are inspected in TA-16-260. 

Main Charge Subassembly. The explosives hemispheres are assembled in TA-16-410. 

Table A.3.5.2-2.-- Los Alamos National Laboratory High Explosives Fabrication Facility Data

Functional Area

Existing Facilities

High Explosives Technology

Gross Area 
(m 2 )

Building Number

 
Main Charge Fabrication     
HE pressing 

740

 TA-16-430 
HE machining, inspection 

930

 TA-16-260 
HE subassembly 

370

 TA-16-410 
Physical property testing 

185

 TA-11, All 
High Explosives Staging, Insensitive High Explosives, and Conventional High Explosives 

280

 TA-16-261 TYPICAL 
Main Charge Test Fire 

93

 TA-15, TA-40 
Energetic Components 

 

  
Small component fabrication 

700

 TA-16-340 
Test fire 

93

 TA-15, TA-40 
Component nondestructive evaluation 

560

 TA-8-22, -23 
Formulation and Synthesis 

 

  
HE synthesis 

460

 TA-9-45, -46 
HE formulation 

700

 TA-16-340 
Chemical storage 

47

 TA-16-344 
HE staging 

47

 TA-16-341, -343, -345 
Production Support 

 

  
Analytic/environmental lab 

460

 TA-9-21 and -32 
Metrology 

185

 TA-16-260, -410 
Materials compatibility testing 

280

 TA-9-21, -40, -42 
Machine shop 

185

 TA-16-370 
High Explosives Shipping/Receiving 

230

 TA-16-280 
Outdoor Test Fire 

93

 TA-15, TA-11 
High Speed Test Machining 

18

 TA-16-340, -476 
High Explosives Storage, Insensitive High Explosives, and Conventional High Explosives 

930

 TA-37-1 through -37 
High Explosives Tech Ramps 

2,790

 TA-16-413, -332 
Component Warehouse 

280

  

Total

10,655

  

LANL 1995d.

 

  
Small High Explosives Component Manufacturing. This facility manufactures small HE weapon components and test assemblies and conducts qualification and development testing for explosives components and materials. Various small components are manufactured in TAs-16-340, -430, -260, and -410 from HE powders and binders, metal or plastic components, electrical components, hardware, and assembly materials. The manufacturing process requires equipment for explosives powder heating, pellet pressing, laser welding, ultrasonic cleaning, extrusion loading, density testing, and mechanical assembly. 

Inert Machining. Small components are manufactured in TA-16-370 and TA-3-39. Additional facilities at the central shop (TA-13-39) include full service, high precision metal manufacturing capability. 

Synthesis (Technical Areas 9-45, -46) and Formulation (Technical Area 16-340). These facilities have the capability to produce a variety of explosives materials from chemical reactants or to formulate HE composites from commercially produced explosives. Material lots up to about 91 kg (200 lb) are produced through a series of batch operations. Some products are used to make small HE weapons components, while other products support the development of new explosives or explosives manufacturing processes. Blending capabilities for producing uniform blends up to 454 kg (1,000 lb) to minimize batch-to-batch variations are available at the TA-16-340 complex. The HE formulation and synthesis facility includes several flexible processing bays that contain a variety of vessels, filters, and transfer pumps which are used to synthesize, recrystallize, blend, and wash explosive powders. The facility also includes six bays for mixing/milling, particle size reduction (micronization), drying/weighing/packaging, solvent storage, and refrigerated storage for explosives and chemicals. 

High Explosives Shipping and Storage. The HE shipping/receiving facility in TA-16-280 and TA-37-1 through TA-37-26 is designed to ship and receive bulk HE materials to and from the HE Fabrication Facility. These materials are typically received in 4,500 to 9,000 kg (10,000 to 20,000 lb) lots. Parts would be shipped out as needed in small lots to the A/D Facility. 

High Explosives Disposal (Technical Area 16-389). LANL disposal facilities is in place and permitted by the State of New Mexico for disposal of HE waste and HE-contaminated materials. There is a large flash pad that thermally decontaminates items subject to trace HE contamination prior to burial. Two aboveground burning trays are used to destroy HE scrap and residue, and two sand filters are used to remove HE-contaminated water from sump sludge for drying and burning. One aboveground tray burns contaminated oil. An incinerator burns room trash from the HE area (potential contamination due to association only). All water is filtered to remove HE; treated with activated carbon for solvent removal; and measured for chemical oxygen demand, suspended solids, and acidity prior to release to the environment. 

Explosives Testing and Characterization. HE testing and characterization cover a wide range of activities and processes and provide quality assurance data that can be used to certify a HE lot for production use or to provide test firing information to qualify small HE component lots for use in production assemblies. LANL has facilities, instrumentation, and test equipment to support the certification of HEs and HE components that would be used for production. These facilities can be used for analytical chemistry evaluation, physical testing, nondestructive evaluation, materials compatibility testing, and firing sites for performance and safety evaluations of HEs and HE assemblies. The full complement of testing and characterization activities is used for surveillance evaluation of returned stockpile HEs. 

Analytical Laboratory. Chemical analyses are performed in TA-9-21 on explosives and on explosives materials to determine or verify their characteristics. Analysis methods include gas chromatography, liquid chromatography, ion chromatography, size exclusion chromatography, infrared spectroscopy, thermal analysis, particle characterization, mass spectroscopy, atomic spectroscopy, and emission spectroscopy. Small-scale safety tests required for evaluation of HEs are conducted in this facility. Tests include drop weight impact, friction, electrostatic discharge, and thermal tests. 

Material Compatibility Testing. Test coupons are assembled in TA-9-40, TA-9-21, and TA-9-42 so that the subject materials are in direct contact with each other. These coupons are then placed in environmental chambers to accelerate the aging process. Temperatures can be cycled between -55 °C (-67 °F) and +75 °C (+167 °F) in the chambers. Gas samples are periodically taken from the coupon containers and analyzed. Compatibility testing is required to certify new materials for weapon use and HE compatibility. Two large environmental chambers that can be used for cycling full scale weapons systems are located in TA-9-42. 

Physical Properties Testing. The physical properties of explosives components and materials are tested in TA-16-340 and TA-9-37 to support lot certification for materials and components and to support production development. The test configurations are assembled, and tensile, torsion, and compression tests are conducted. 

Nondestructive Evaluation. Explosives and nonexplosives components are inspected in TAs-8-22, -23, -70 and TA-16-260 with neutron, x-ray, magnetic particle, and eddy current equipment to detect flaws, cracks, voids, and foreign materials. 

Test Firing. LANL assembles and detonates explosive test configurations in TA-15, TA-40, and TA-11-25. Tests require explosive containment chambers and an array of special instrumentation including streak cameras, rotating mirror framing cameras, an air image converter system, digital oscilloscopes, flash x-ray systems, and velocity interferometers. LANL conducts large-scale safety tests such as skid tests and spigots at the TA-11 drop tower facility. Vibration test capabilities are also located in this area and can be used for full scale weapons tests as well as components tests. 

High Explosives Staging Areas and Corridors. In-process storage in TA-16 is required for a variety of HE powders, components, and assemblies for supporting the HE fabrication operations. These explosives materials include PBXs for main charge manufacturing, completed main charges, small HE components, energetic feed materials and products for HE formulation and synthesis, and explosives residues for disposal or recycle. Staging magazines exist in conjunction with each operational building. The staging magazines are connected with the operational buildings with enclosed corridors. These corridors are used for equipment and material transfers only. Major process buildings are not interconnected. 

Resource Requirements During Construction/Modification/Transition. Since only minimal new equipment is needed at LANL, there are no facility construction or modification requirements to conduct the HE fabrication mission at LANL. LANL already has all the technologies needed to provide HE materials, component fabrication, characterization, surveillance, and quality assurance for the future nuclear weapons requirement. The capacity of LANL HE fabrication facilities exceeds R&D mission requirements and can easily accommodate the required production load. 

LANL has a full spectrum of HE research, development, fabrication, and test capabilities managed by the Dynamic Experimentation and Engineering Sciences and Applications Divisions. The existing facilities, equipment, and infrastructure would be used to satisfy future production requirements for the HE fabrication mission. The existing capabilities are used to manufacture prototype weapon components for full scale testing that provide the basis for production specifications. Additionally, LANL has demonstrated the capability to manufacture limited production quantities of HE components. Typically, LANL produces 1,200 to 1,500 HE parts per year for use in the weapons research development and testing programs, which include requirements for small production lots (~500) of HE components. These components are manufactured to strict quality assurance requirements and are used in complex hydrodynamic and NTS program requirements. 

The equipment and processes used in the HE fabrication processes are very similar and in some cases identical to those used at Pantex for production. By using the same equipment and processing technologies, both LANL and Pantex manufacture parts by the same methods. The processes used by Pantex for HE component production would be used by LANL, except in rare cases where process and/or product improvements can be demonstrated to be cost effective and still meet production requirements. Transition of the HE fabrication processes from Pantex to LANL would require very little press development since equipment and processes are almost identical. 

The transition period for transferring the HE fabrication mission to LANL is estimated to take 2 years after the ROD of this PEIS. HE main-charge components may exhibit dimensional instabilities (material creep) when stored for periods of time in excess of 6 to 8 months. Production scheduling plans for "just-in-time" manufacturing of HE components to be used in weapon assemblies. Additionally, extrudable HE used in weapons application, must be stored at -30 °C (-22 °F), and have a 24-hour room temperature working life before the materials cure and setup. The shelf life of the extrudables, when stored at -30 °C (-22 °F), is typically on the order of 6 to 8 months. Because of these concerns, it is not feasible to prebuild HE components during the transition period. It will be necessary for Pantex to remain operational for producing HE components until the receiver site becomes operational. For LANL, this transition period would require 2 years, with steady state operations beginning in fiscal year 1999. 

Resource Requirements During Operations-High Explosives Fabrication Mission. HE operations are conducted within the existing LANL boundaries and occupy approximately 5,180 ha (12,800 acres). Table A.3.5.2-2 lists all the required facilities for HE fabrication operations at LANL and the footprint or area on the ground required for each facility. 

General utilities and resource requirements including electric power, steam, natural gas, liquid fuels, and water would be supplied by existing LANL infrastructure. Capacity of the general utilities support is sufficient to meet the current requirements of the HE Fabrication Facility for R&D operations and an increase in capacity to meet production requirements is not needed. The utilities and resources consumed during operations include electric power, liquid fuels, natural gas, and water. Annual utility resource consumption rates and peak electric power rates for surge operation are estimated in table A.3.5.2-3. 

Table A.3.5.2-3.-- Los Alamos National Laboratory High Explosives Fabrication Surge Operation Annual Utility Requirements

Utility

Consumption

Peak
Demand 7
Electricity  5,600 MWh  1.0 MWe 
Liquid fuel (L) 

94,600 

  
Natural gas 8 (m3 ) 

3,650,000 

  
Coal (t) 

0 

  

Water (L)

13,000,000 

  
LANL's HE fabrication processing facilities currently operate on a 4-day week, 10 hours per day, for 50 weeks per year. Maintenance personnel that support the HE processing equipment work a 5-day week, 8 hours per day. Routine and preventive maintenance is conducted on Fridays, as scheduling permits. Actual operational schedules will be dependent on workload and scheduling requirements. 

Table A.3.5.2-4 provides the estimated number of additional direct operating and direct support personnel required at LANL to meet the HE fabrication requirements under base case surge (three shifts per day) operation. The DOE production control documents for the enduring stockpile systems would be used for planning and scheduling of the HE components needed to meet the production requirements. In addition, manpower estimates for manufacturing quality assurance parts and preparing surveillance samples for testing and evaluation have been included. 

Table A.3.5.2-4.-- Los Alamos National Laboratory High Explosives Fabrication 
Surge Operation Workers

Labor Category

Number of Workers
Direct workers 

35
Direct support workers 

30
Operations support workers 

40
Indirect support workers 

95

Total

200 9
Chemicals Consumed During Operation. The chemicals consumed during all HE fabrication operations are shown in table A.3.5.2-5. 

Emissions During Operations. The HE fabrication operations at LANL do not require radiological materials. Under normal operations, no workers could be exposed to radiation. Emissions during operation are listed in table A.3.5.2-6. Gaseous environmental releases would result from operation of the thermal treatment units (incinerator baseline) for bulk HE waste and nonradioactive HE-contaminated waste. Emissions would also result from plant boiler operation, cleaning operations using solvents, and small scale synthesis operations, although the incremental amount of emissions over current operations would be very small. The thermal treatment units would be designed and operated to attain and maintain temperatures which would result in the destruction of hazardous constituents. Hazardous particulates would be trapped in filters. The releases would be limited to as low as achievable using the best available control technology. 

Waste Management. Liquid and solid waste streams generated by the HE fabrication operations are processed to meet state, Federal, and DOE requirements for the various types of nonhazardous, hazardous, radioactive, and mixed wastes. LANL waste management facilities would be used to receive, track, characterize, treat, package, store, and ship wastes generated by HE plant operations. These facilities include a waste management operation, waste storage facility, sanitary wastewater treatment unit, and a sanitary and industrial landfill. 

Table A.3.5.2-5.-- Los Alamos National Laboratory High Explosives Fabrication
Surge Operation Annual Chemical Requirements

Chemical

Quantity

(kg)

Chemical

Quantity

(kg)
Acetone 

2,722

 Ethylene glycol 

227
Acetonitrile 

1,814

 X-Ray film developer, fixer, and toners 

227
Acid neutralizers/spill kits 

272

 HE powders 

45,360
Adiprene polyurethane composition 

45

 Hydrochloric acid 

45
Activated carbon 

454

 Hydraulic lube oils 

2,268
Aluminum metal 

454

 Mild steel 

454
Argon 

907

 Nitrogen 

227
Carbon dioxide 

227

 Silicone elastomer 

91
Cyanuric acid 

454

 Sodium hydroxide 

227
Degreaser 

45

 Stainless steel 

454
Desiccants/molecular sieves 

136

 Talc 

454
Elastomer binders 

227

 Tetrahydrofuran 

113
Ethanol 

272

 Toluene 

680

Ethyl acetate

454

Water chemicals

91

LANL 1995b:4; LANL 1995d.

Table A.3.5.2-6.-- Los Alamos National Laboratory High Explosives Fabrication Surge Operation Annual Emissions

Pollutant

Quantity
(kg)
Criteria Pollutants 

 
Carbon monoxide 

4,540
Nitrogen oxides 

22,700
Particulate matter 

227
Volatile organics 

4,540
Hazardous and Other Toxic Compounds 

 
Ammonia 

454
Acetonitrile 

4.5
Cyclohexane 

2.3
Dioxane 

2.3
Hydrogen chloride 

113
Hydrogen fluoride 

45.4
Methyl ethyl ketone 

22.7
Toluene 

22.7

LANL 1995d.

 
Nonhazardous wastes generated at the HE Fabrication Facility would primarily consist of solid sanitary waste, sludge from sanitary wastewater treatment, maintenance residues, and scrap parts. Materials unsuitable for recycle would be appropriately disposed of in an approved landfill. Liquid sanitary wastewater will be discharged to the environment after treatment, subject to the NPDES requirements. 

Hazardous wastes generated by the HE Fabrication Facility would consist of solid residue from thermal treatment of scrap explosives and explosive-contaminated combustible materials, spent carbon from HE- and solvent-contaminated water treatment, and waste oils and paint residues from routine maintenance operations. LANL would stabilize all hazardous materials for disposal/treatment at an approved RCRA disposal site. 

Low-level radioactive waste would only be generated from A/D operations involving depleted uranium parts, or from processing of surveillance materials or other HE charges returned from stockpile with slight contamination. There would be no radioactive wastes associated with HE fabrication. In all cases, compliance with all appropriate regulations and standards concerning all wastes, including mixed waste, would be met. 

HE residual materials, such as bulk HE machining scrap, off-specification HE components, HE-contaminated materials (including gloves, wipes, and rags) and process water generated during HE fabrication operations are the source of most of the waste material that must be processed. LANL uses waste minimization and recycle processes to reduce the amounts of material that ultimately must be subjected to waste treatment processes. Recycled scrap HE and HE-contaminated process water are not considered waste and are handled as in-plant operations. 

Currently, thermal treatment of HE and HE-contaminated materials (open air burning and incinerators) are the preferred permitted techniques used to dispose of and decontaminate solid materials. LANL is looking at several alternative processes in the event state and Federal agencies do not approve permit applications. Some of these processes include base-hydrolysis decomposition of HE, followed by supercritical water oxidation, molten salt destruction, and bioremediation techniques. The open burning and incineration techniques at LANL are subject to environmental monitoring, and emissions must meet permit requirements. 

HE-contaminated process water generated by synthesis and formulation processes, vacuum pump seal water, and HE machining processes, would be collected in tanks and then treated with activated carbon filters to remove residual HEs and solvents. The water would then be recycled or discharged to the environment subject to NPDES permit requirements. LANL collects sanitary wastewater in a separate system and routes it to septic tanks or sanitary waste water treatment facilities. Stormwater is collected separately, and a stormwater pollution prevention plan is in place. 

The thermal treatment of HE scrap and HE-contaminated materials would result in emission of decomposition gases. Typical decomposition gases include carbon monoxide, oxide of nitrogen, volatile organics, hydrogen chloride, hydrogen fluoride, and ammonia. Small amounts of organic solvent vapors from materials such as toluene, acetone, methyl ethyl ketone, and ethyl acetate can also be generated during treatment processes as well as normal plant operations. 

All LANL operations involving HE, including waste disposal, must comply with DOE/EV/106194 and meet explosives safety requirements. Buildings meet blast-resistant building construction standards and quantity distance criteria. Remote operations capabilities exist for disposal processes. 

The HE fabrication process would generate the following waste and residual materials: 

Several facilities exist within LANL's waste management infrastructure that process the plant non-HE wastes. These facilities are used to receive, track, characterize, treat, package, store, and ship wastes generated by HE fabrication operations. Included are a waste storage facility, a sanitary wastewater treatment unit, a sanitary and industrial landfill, and stormwater ponds. Hazardous waste that has been HE decontaminated would be handled through the LANL waste management operations at TA-54. The increased loading on the LANL infrastructure which handles these types of wastes would be minimal, requiring no additional capacity or facilities. The radioactive wastes, mixed wastes, hazardous wastes, and nonhazardous wastes generated during the surge operations are quantified in table A.3.5.2-7. 

Transportation. All intrasite transportation required for manufacturing is done within existing site boundaries and does not require use of public roads. Appropriate HE shipping regulations as defined by DOE and DOT are followed. 

The HE shipping and receiving facility is designed to ship and receive bulk HE materials to and from the HE Fabrication Facility. These materials are typically received in 4,500 to 9,000 kg (10,000 to 20,000 lb) lots. All completed charges are shipped following appropriate HE shipping regulations. All hazardous chemicals are shipped using appropriate DOT requirements. 

Table A.3.5.2-7.-- Los Alamos National Laboratory High Explosives Fabrication 
Waste Volumes

Category

Annual Average
Volume Generated
from Construction

(m3)

Annual Volume Generated from
Surge Operations

(m3)

Annual Volume

Effluent from
Surge Operations

(m3)
Low-Level        
Liquid  None 

None

None
Solid  None 

Minimal

Minimal
Mixed Low-Level    

 

 
Liquid  None 

None

None
Solid  None 

None

None
Hazardous    

 

 
Liquid  None 

4 10

4
Solid  None 

13

13
Nonhazardous (Sanitary)   

 

 
Liquid  None 

5,900

5,880 11
Solid  None 

Included in liquid

17
Nonhazardous (Other)   

 

 
Liquid  None 

6,930 12

6,930
Solid  None 

28
  • 28

    		•

    A.3.5.3 Relocate to Lawrence Livermore National Laboratory

    LLNL maintains self-contained HE RD&T, and fabrication capabilities at the remote explosives testing area, Site 300, and at the HE Applications Facility at the Livermore Site. LLNL has the facilities, equipment, and infrastructure to satisfy the current production requirements for the HE fabrication mission for all weapon systems in the enduring stockpile. The health and safety, materials management, and materials characterization (nondestructive examination, test fire, and chemical analysis) infrastructures are already in place and available to support the production function as well as the R&D function. No significant HE Applications Facility or Site 300 upgrades are anticipated to receive the mission for HE fabrication in the Complex. No deviations from the current baseline technologies at Pantex are anticipated. 

    Site 300 is dedicated to all aspects of HE RD&T and is remotely situated on 2,800 ha (7,000 acres) in California's Central Valley, 24 km (15 mi) east of the Livermore Site (figure A.3.5.3-1). Large-scale synthesis, formulation, and test firing is done at Site 300. The HE Applications Facility staff administers the technical work from the Livermore Site. Small-scale process development/prove-in would be done in the HE Applications Facility. The HE Applications Facility meets or exceeds all the applicable ES&H requirements for explosives R&D and production support. Synthesis and formulation would be performed in this building and would be locally supported by the theory and modeling efforts in the HE Applications Facility. A full spectrum of other HE activities take place at this facility, ranging from detonator development to experiments involving 10-kg (22-lb) detonations. 

    Table A.3.5.3-1.-- Lawrence Livermore National Laboratory High Explosives Fabrication 
    Products and Capabilities

    Products

    Capabilities
    High Explosives  Manufacturing Process Development 
      Support stockpile stewardship 
      Formulation 
      Synthesis 
      Surveillance 
      Main charge manufacturing 
    Binders  Pressing 
      Machining 
      Subassembly 
      Receiving/storage 
      Quality assurance-mechanical/chemical/test fire 
      Disposition 
    Main Charge Formulations  Energetic Component Manufacturing 
      Pressing 
      Machining 
      Subassembly 
      Quality assurance-mechanical/chemical/test fire 
    Initiation High Explosives  Detonators 

    Mock High Explosives Formulations

    		 Testing 

    LLNL 1995j.

    		  
    No significant upgrades to the HE Applications Facility would be required. Larger-scale work at Site 300 is done in parallel with the HE Applications Facility's small-scale process development. Both sites are fully self-contained installations. Site 300's synthesis and formulation complex provides the capability to conduct both remote and contact HE operations in facilities that meet current DOE des