Weapons A/D is a key element of the DOE stockpile management responsibility. This function provides the capability to: dismantle retired weapons; assemble HE, nuclear components, and nonnuclear components into nuclear weapons; repair and modify weapons; perform weapons surveillance; and store strategic reserves of nuclear components (pits and secondaries).
Weapons A/D consists of five main functions:
The functions, as described in the following subsections, would vary between weapon programs. The plant must have the capability to vary production operations and quality assurance tests to meet the special needs of each program.
Weapons contain special nuclear material. Operations involving special nuclear material must be conducted within a critical assembly area. Weapons, joint test assemblies, and test beds contain HE and explosive detonators; therefore, operations involving these must be conducted in facilities designed for explosives operations.
Weapon Assembly. Weapon assembly is performed to produce a new weapon, to rebuild a weapon that has been disassembled for surveillance, or for modification or replacement of components. The assembly steps for a rebuild are the same as for a new build, except that the starting point varies, depending on the extent of disassembly.
Weapon assembly requires approximately 2,000 steps to combine hundreds of parts and subassemblies to form a weapon. The process is labor-intensive and includes many verification and quality control steps. Prior to the start of the assembly process, several bays would be configured with special tooling required for the specific weapons operations. As the assembly progresses, partially assembled weapons may be moved in series from bay to bay. At several points during assembly, the weapon would be moved from assembly bays to special purpose bays. These special purpose bays would be permanently configured with nonprogram specific equipment for performing verification or inspection operations, such as radiography inspection, leak testing, and mass properties determination.
Complete weapon assembly would be accomplished in three stages: physics package (also known as nuclear explosive package) assembly, mechanical weapon assembly, and ultimate user package assembly. The weapon assembly function is shown in figure A.3.1-1, and each stage is described below. Weapon parts would be unpackaged, cleaned, verified and, in some cases, tested prior to assembly.
Physics package assembly entails bonding or mating the main charge subassemblies to a nuclear pit and then enclosing this subassembly in a case along with other components. Prior to assembly, gamma spectrometry would be used to verify the authenticity of the nuclear components. The pit would also be leak-tested and weighed. After the physics package is cased, tests would be performed to ensure electrical continuity, and a radiographic inspection would be conducted to ensure that the internal subassemblies are correctly aligned.
When the main charge is made from conventional HE, the physics package assembly must be conducted in a specialized structure called an assembly cell. An assembly cell is designed to minimize the release of radioactive material in the event that the conventional HE detonates. After the physics package is cased, the potential for detonation is greatly reduced, and the physics package may be moved to an assembly bay. The physics package for a weapon using an insensitive HE main charge can be assembled in a bay. The completed physics package then continues to mechanical weapon assembly.
Mechanical weapon assembly entails placing the physics package in a warhead case and installing components for the arming, fuzing, and firing systems; the neutron generator; and the gas transfer system. At prescribed points during the assembly process, electrical testing and gas transfer system pressure testing would be conducted to verify proper installation. The completed mechanical package would be leak-tested, backfilled with a specified gas atmosphere, inspected with radiography, and subjected to mass properties testing. Leak-testing would ensure that the weapon case is properly sealed. Radiographic inspection would be used for verification of the weapon system. Mass properties testing measures the center of gravity and moments and products of inertia to ensure proper flying characteristics. The final stage of the mechanical weapon assembly is the user package assembly.
Ultimate user package assembly involves installing some additional components and packaging the weapon for shipment. This operation varies, depending on whether the mechanical assembly is used in a bomb or a warhead. For bombs, components such as the tail, nose, and/or preflight sections would be added. Tail and preflight sections would be preassembled prior to installation. The completed bomb would be loaded onto a trailer (roadable) for shipment. Warheads may have a separation subassembly installed and the completed warheads would be loaded into containers for shipment. The ultimate user assembly would be moved to the weapon staging area for shipment to DOD via safe secure trailer.
Weapon Disassembly. Weapon disassembly is performed to dismantle, modify, or evaluate a weapon. The operations conducted for each type of disassembly are similar, but the extent of the disassembly and procedures vary.
Dismantlement Disassembly . The weapon would be disassembled down to subassemblies and components that are suitable to be shipped to the originators, that facilitate recertification of usable parts, or that facilitate sanitization and demilitarization of unusable parts.
Modification (Retrofit) Disassembly. A weapon requiring modification would be disassembled to the extent necessary to gain access to the components requiring replacement. The disassembly procedures are intended to maximize reuse of parts.
Stockpile Evaluation Disassembly . The evaluations and tests required would be defined by the design laboratories. The extent of disassembly depends on which components require testing. Procedures include additional testing, and typically call for removing components in connected groups to facilitate further testing in test beds or joint test assemblies.
The weapon disassembly process is similar to the reverse of the assembly process and would be accomplished in three stages: ultimate user package disassembly, mechanical weapon disassembly, and physics package disassembly. Many of the facilities used for various disassembly and testing operations are the same facilities used for weapon assembly. The weapon disassembly function is shown in figure A.3.1-2, and each stage is described below.
Ultimate user package disassembly begins by performing a series of verification steps to ensure that the weapon is in a safe condition and that internal components are intact. The steps include tritium monitoring, electrical safing system test, gamma spectrometry safeguards verification, and a radiographic safing system verification. Bombs would be removed from trailers, and mechanical assemblies would be separated from the tail and nose sections. Warheads would be removed from ultimate user containers and then mechanical assemblies would be separated, as required, from separation subassemblies.
Mechanical weapon disassembly also begins with a series of tests. These tests include an internal atmosphere test check, a radiographic inspection, and a tritium pressure leak test. Evaluation of disassemblies may also require vacuum chamber leak test and mass property testing. The mechanical weapon disassembly entails removing the components for arming, fuzing, and firing systems; neutron generators; the gas transfer system; and the outer weapon case. The remaining physics package is further disassembled. The physics package may require a radiographic inspection for an evaluation disassembly.
Physics package disassembly would be accomplished by opening the case, removing the HE/pit subassembly and other components, and then separating the HE main charge from the nuclear pit. As described for weapon assembly, the physics package disassembly must be performed in a cell if the main charge is conventional HE.
The balance of the weapon disassembly function involves processing various weapons parts. These parts may be disassembled further on site or left intact. Parts may be recertified and staged for reassembly, shipped to the originating site for evaluation or disposition, or processed as residual material in the waste management process. Selected components may be assembled in a test bed or the bulk of the components may be used in a joint test assembly.
Joint Test Assembly and Post Mortem. As part of the ongoing stockpile evaluation program, weapons are randomly selected from the stockpile or new production inventory for conversion to joint test assemblies. A joint test assembly is a nuclear explosive-like assembly (mock weapon) that will be test flown by DOD. A joint test assembly generally contains most of the original weapon parts, except for the nuclear components and main charge subassemblies. A joint test assembly also contains telemetry components to monitor joint test assembly performance during flight, mock materials to simulate the size and weight of missing components, and witness plates to verify that energetic actuators performed as expected.
A process flow diagram of the joint test assembly support function is shown in figure A.3.1-3. Assembly of a joint test assembly is similar to weapon assembly, but some components are different. The physics package equivalent for a joint test assembly is called joint test subassembly. A high degree of quality control is required due to the high cost of the complex test.
After the flight test, joint test assemblies for bomb programs are generally recovered and returned for post-mortem disassembly and evaluation. Joint test assemblies for warhead programs are recovered if possible and returned for evaluation. The parts obtained from disassembly are processed for disposal. The procedures for joint test assembly are similar to those for a weapon disassembly, except that additional measures are taken to contain residues produced by the energetic actuators. The parts obtained from disassembly may be recertified and staged for reassembly, shipped to the originating site for evaluation or disposition, or processed in the waste management facility.
Joint test A/D operations, as well as the special evaluations such as radiography gamma spectrometry and leak-testing required for joint test assemblies, are performed in the same bays and special purpose bays used to conduct weapon assembly and disassembly operations.
Test Bed for Assembly and Disassembly. A test bed is an apparatus used for bench testing weapon systems, subsystems, and components. It is composed of parts removed from a weapon in evaluation disassembly and an explosive box. The explosive box contains the blast and fragments from the small explosive charges which detonate as the weapons systems are tested. The weapon parts are generally from the arming, fuzing, and firing systems and include antennas, radio frequency lines, radar, programmers, fire sets, detonator cables, and permissive action links. Prior to testing, some test beds are exposed to temperature extremes in environmental conditioning ovens. The testing is conducted at fully instrumentated test stations that can simulate deployment temperatures.
The test bed support function is shown in figure A.3.1-4 and is described below. Test bed assembly entails constructing the explosive box and parent part assembly and mounting these items on the test fixture. The explosive box is manufactured by enclosing explosive or electro-explosive components in an explosive barricade containing a fill material to damp the detonations. The explosive box may also contain a fiber optic sensing system to monitor the actuation timing. The parent parts assembly is composed of the removed weapon parts. The explosive box may also contain parent parts.
Optional Storage of Plutonium and Highly Enriched Uranium Strategic Reserves. Storage of the plutonium strategic reserve could occur at the weapons A/D Facility (as shown in figure A.3.1-5). If Y-12 is selected as the site for the secondary fabrication mission, HEU strategic reserve storage would remain at ORR. If Y-12 is not selected, then the HEU strategic reserve could also be stored at the weapons A/D Facility. The strategic storage of plutonium and HEU provides cased pits and canned subassemblies for replacement in the enduring stockpile and for use as feedstock for nuclear fabrication. The quantities associated with the storage are identified in classified documents. If the responsibility for strategic storage is transferred to the Office of Materials Disposition, then consolidated storage could be at one of five sites being considered in the Storage and Disposition PEIS.
The weapons A/D process constructs a weapon from approximately 200 parts and subassemblies. Assembly feeds include main charge subassemblies from the HE fabrication plant, special nuclear material components, weapon parts and subassemblies, electrical components, and hardware. A joint test assembly has approximately the same number of parts as a weapon. Feeds include most of the weapon parts removed from an evaluation weapon disassembly, telemetry components, mock HE and special nuclear material components, and witness plates. Test bed feeds include selected weapon parts removed from an evaluation disassembly, small explosive parts, the explosive box, the test fixture, electrical components, and hardware. The feeds for disassembly operations include nuclear weapons, joint test assemblies, and test beds.
Pantex is the existing A/D site for the U.S. nuclear weapons stockpile. To efficiently meet the workload established by DOE for fiscal year 2004 and beyond, operations would be consolidated into the facilities that exist at Pantex. No new facility construction is required to accomplish the consolidation of the A/D mission. Changes would only be required to allow the relocation and modification of some functions into the newer facilities and the upgrade of some infrastructure systems.
The five main functions for A/D operations discussed in section A.3.1 would be downsized and consolidated at Pantex. The site plans for the consolidated A/D operations at Pantex are shown in figures A.3.1.1-1 and A.3.1.1-2. The drawings depict the arrangement of plant buildings and site support areas for Pantex. Four types of security access areas exist at Pantex: material access area, protected area, limited area, and property protection area. Operations involving special nuclear material must be performed within a material access area. The material access area and some facilities supporting material access area operations are located in the protected area. The protected area is secured with a double fence and intruder detection systems. The protected area and operations involving classified materials and information are contained within a limited area. The property protection area surrounds the limited area and includes a buffer zone. Weapons A/D operations are performed within the material access area within Zone 12.
The downsizing and consolidation of A/D operations would enable Pantex to utilize existing structures. Consideration has been given to optimizing operations, as well as maximizing the use of facilities, in the downsizing analysis. No new construction would be required at Pantex to accomplish the reduced weapons A/D mission. Pantex has 59 A/D bays, of which only 31 bays are required to meet the A/D workload. Therefore, functions that reside in older facilities (not economically or technically feasible to upgrade) would be relocated to modern, heavy-type construction facilities.
All facilities at Pantex were built in compliance with design codes and standards in effect at the time of design and construction. At the time of any major modification, facilities were upgraded commensurate with codes and standards at the time of the modification. Where applicable, facilities were built to specific regional design criteria.
Structures containing explosives are generally constructed with steel-reinforced concrete and are designed to mitigate the effects of an accidental explosion. 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 special nuclear materials or 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 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.
Key facilities required to meet the mission of the A/D downsized and consolidated operations are listed in table A.3.1.1-1. A brief description of key facilities follows.
Assembly Bays. Assembly bays are used to manually assemble or disassemble nuclear weapons. Weapon assembly requires approximately 2,000 steps to combine hundreds of parts and subassemblies to form a weapon. The process is labor-intensive and includes many verification and quality control steps. Prior to assembly, several bays are configured with special tooling required for assembly of a specific weapon. As assembly progresses, partially assembled weapons move in series from bay to bay. The physics package for a weapons program using a conventional HE main charge must be assembled in an assembly cell. The weapon disassembly process is conceptually the reverse of the assembly process, although tooling used and testing required will vary. High fidelity joint test assemblies (those containing explosives and/or special nuclear material) are also assembled and disassembled in bays.
Pantex has several A/D bay facilities; however, only 31 bays in Buildings 12-084, 12-099, and 12-104 are required. Each bay includes an area to perform assembly operations, staging areas for tooling and weapon parts, and a mechanical room for heating, ventilation, and air conditioning equipment and controls.
Assembly Cells. Assembly cells are designed to support the manual assembly or disassembly of a physics package for weapon programs using a conventional HE main charge. Physics package assembly involves mating explosive and nuclear components and sealing these components in a metal case. Assembly cells are designed to mitigate the release of radioactive material in the event that conventional HE detonates. After the physics package is cased, the potential for a detonation is greatly reduced and the physics package may be moved to an assembly bay. Assembly in a cell is not required for a physics package using an insensitive HE main charge.
Each cell includes an area to perform assembly operations; staging areas for special nuclear material, tooling, and weapon parts; and a mechanical room for heating, ventilation, and air conditioning equipment and controls. Prior to the start of the assembly process, an assembly cell is configured with special tooling to facilitate the assembly or disassembly of a specific weapon program. Pantex has 13 assembly cells; however, only 4 of the assembly cells (three in Building 12-098 and the 12-96 cell) are required.
Special Purpose Bays. Special purpose bays are similar to assembly bays, but special purpose bays are permanently configured with special equipment to perform general testing or assembly operations. As with assembly bays, special purpose bays are grouped and share some common support areas. The functions performed in these bays are described in the following sections.
Test Bed Assembly/Disassembly. Test beds and training units are assembled and disassembled in part of Building 12-086. Training units are nuclear-explosive-like assemblies that are used for training Pantex and DOE personnel to build, repair, maintain, and handle nuclear weapons. The facility contains a number of universal assembly bays which are configured with program-specific tooling. No modifications are required in this facility to support test bed functions.
Nondestructive Evaluation. Linear accelerator, computed tomography, and x-ray radiography are performed in part of Building 12-104A. These functions are used to inspect components, assemblies, and complete weapons to confirm proper configuration. Ultrasonic testing detects voids in the material used to bond close fitting parts. Acoustic emissions testing detects flaws in material. Radiometric inspection identifies the types of encased radioactive materials. No modifications are required in this facility to support the downsizing of Pantex.
|
|
|
Area (m 2 ) |
Area (m 2 ) |
|
|
|
|---|---|---|---|---|---|---|---|
12-008 | Commercially procured weapon material | Steel |
56 | 56 | Limited area | 1 | None |
12-042 | Tester and tooling storage | Steel |
4,404 | 4,404 | Material access area | 1 | None |
12-042
| Weapons evaluation testing | Steel/concrete |
2,044 | 2,044 | Material access area | 1 | HE |
12-053/E | Metrology lab | Concrete |
474 | 474 | Material access area | 1 | None |
12-058 | HE component staging | Concrete |
242 | 242 | Material access area | 1 | HE |
12-059/E | Commercially procured weapon material/chemical lab | Steel |
771 | 771 | Limited area | 1 | None |
12-061 | Component warehouse | Steel |
2,230 | 2,230 | Material access area | 1 | None |
12-079 | Component warehouse | Steel |
2,666 | 2,666 | Material access area | None | |
12-082 | Special nuclear material container refurbishment/component tech acceptance | Concrete |
632 | 632 | Material access area | 1 | None |
12-084 | 17 assembly/disassembly bays, 1 pit laser bay, 1 nondestructive evaluation environmental bay, metallurgical evaluation | Concrete |
10,675 | 10,675 | Material access area | 1 | HE/special nuclear material |
12-086 | Test bed assembly, electronic testing, gas lab, metrology lab | Concrete |
4,479 | 3,627 | Material access area | 2 | HE |
12-092 | Component packaging | Steel |
88 | 88 | Material access area | 1 | HE |
12-095 | Explosives Class C staging | Concrete |
244 | 244 | Material access area | 1 | HE |
12-096 | 1 assembly/disassembly cell | Concrete |
731 | 731 | Material access area | 1 | HE/special nuclear material |
12-098/E | 3 assembly/disassembly bays, passive action link code activated process | Concrete |
3,192 | 3,192 | Material access area | 1 | HE/special nuclear material |
12-099 | 3 assembly/disassembly bays, weapon staging | Concrete |
5,639 | 5,639 | Material access area | 1 | HE/special nuclear material |
12-104 | 11 assembly/disassembly bays | Concrete |
7,917 | 7,917 | Material access area | 1 | HE/special nuclear material |
12-104A | Paint, mass properties, separations testing, accelerated aging, 2 staging bays, 1 vacuum chamber and purge backfill bay, 1 x-ray bay, 1 computed tomography, 1 linear accelerator bay | Concrete |
6,503 | 6,503 | Material access area | 1 | HE/special nuclear material |
12-104P | Generator buildings | Steel |
NA | NA | Material access area | 1 | None |
12-116 | Special nuclear material component staging, AT-400A processing | Concrete |
4,274 | 4,274 | Material access area | 1 | Special nuclear material |
12-117 | Special nuclear material loading dock | Steel |
576 | 576 | Material access area | 1 | None |
Total |
|
|
63,233 |
|
|
| |
|
Note: NA - not applicable. Source: PX MH 1995a. | |||||||
Environmental/Physical Properties Testing. A portion of Building 12-084 is used to perform nondestructive testing of weapon components. Weapon components are subjected to mechanical and thermal shock to simulate deployment conditions. Mechanical conditioning tests include vibration, hostile shock, mini-air gun shock, and steady-state acceleration shock. Environmental chambers are used to simulate temperature extremes and thermal shock conditions. Equipment would be relocated from other areas of the plant into Building 12-084 to support this function.
Leak Detection and Backfill.
Leak rate tests are performed in one bay of Building 12-104A with vacuum chambers (or fixtures) on all outgoing nuclear weapons and on units returned from the field to ensure that the weapon case is properly sealed and correct internal atmosphere is maintained. Backfill involves filling the inside of the weapon case with a specific gas. This operation is performed following completion of a leak rate test and an evacuation step. No modifications are required in this facility to support the downsizing of Pantex.
Mass Properties Determination. Mass properties are critical for ensuring proper flight characteristics of a weapon. Products of inertia and lateral center of gravity are determined with remotely operated dynamic balancing machines. Center of gravity and moments of inertia are determined with a special machine. Modifications are required in one bay of Building 12-104A to allow existing equipment to be relocated to support this function.
Accelerated Aging. Accelerated environmental aging is conducted to simulate the aging process on newly produced weapons and weapon components in a portion of Building 12-104A. For these tests, weapons or materials are placed in an environmental chamber and subjected to thermal cycling above and below ambient temperatures for an extended period, typically from 1 to 2 years. Gas samples are taken from the weapon and analyzed in the gas laboratory. The accelerated aging chamber consumes a significant amount of electrical power. After aging, weapons are disassembled and evaluated. No facility modifications are required to support this function.
Separations Systems Testing. Selected reentry body separation subassemblies are tested in a portion of Building 12-104A to provide data for evaluating release assembly hardware and associated installation procedures and for measuring service-related deterioration of the release assembly system. Facility modifications are required to allow the existing equipment to be relocated and operate in this area.
Special Nuclear Material Container Refurbishment. Containers used to ship radioactive components are reverified annually in a portion of Building 12-082. The structural integrity of containers is verified through leak tests, visual inspection, and maintenance. No modifications are required in Building 12-082 to support this function.
Pit Laser Sampling . A gas sample is taken for selected weapon system pits to determine the internal atmosphere type, percentage, and pressure. Pit laser sampling occurs in a bay in Building 12-084. No modifications are required in this facility.
AT-400A Processing. Pits are robotically packaged into the AT-400A, a hermetically sealed container. The AT-400A container meets requirements for long-term storage and shipping of pit items. This activity would occur in a portion of Building 12-116. The AT-400A robotics processing equipment and required modifications to Building 12-116 to accept this activity are included in the Pantex No Action alternative.
Component Packaging . Packaging of selected reaccepted weapon components occurs in Building 12-092, a special access area. No modifications are required in this facility.
Component Technical Acceptance . Components are reaccepted for assembly using a variety of inspection/verification techniques. This activity will occur in Building 12-082. No modifications are required to support this function.
Weapons Evaluation Testing Laboratory. Weapon system, subsystem, and component tests are conducted in Building 12-042 A/B/C/D/F by SNL personnel. Numerous fully instrumentated test stations are provided for heating, cooling, and test firing the tests beds. A cryogenic carbon dioxide system is used for cooling these units during testing. Environmental conditioning ovens and centrifuges are also provided for testing components under deployment conditions. No modifications are required in this facility.
Metrology Laboratory. Buildings 12-086 and 12-053 are used for metrology functions within the material access area. Instruments and testers for weapon assembly operations are calibrated here. Some areas within these facilities require tight heating, ventilation, and air conditioning temperature control to + 0.3 o C ( + 0.5 o F). Modifications are required in Building 12-086 to allow existing equipment to be relocated.
Gas Laboratory. Gas analyses are performed in Building 12-086 and are used to evaluate samples from accelerated aging tests and production operations. Information from these analyses provides data related to the internal atmosphere of weapons and effects of weapon material aging by measuring outgassing products. The three basic techniques used are gas fractionation, gas chromatography, and mass spectrometry. Facility modifications are required for this function which would relocate existing equipment into Building 12-086.
Weapon Material Testing Laboratory. A laboratory for testing and accepting commercially procured weapon material is located in Buildings 12-008 and 12-059. No modifications are required for these facilities.
Tooling/Tester Storage. Precision tools, instruments, testers, and special equipment for A/D operations are stored in Building 12-042. Generic assembly bays and cells are configured with program-specific tooling at the beginning of a production run. Tooling storage would contain tools for assembly, disassembly, and evaluation operations for all the weapon programs in the enduring stockpile. This function would be relocated from another facility into Building 12-042.
Weapon Staging. A portion of Building 12-099 is used for staging nuclear weapons awaiting transportation to and from DOD facilities. No facility modifications are required to accommodate weapons staging.
Special Nuclear Material Component Staging. The special nuclear material staging facilities, Buildings 12-116 and a loading area 12-117, are designed to ship, receive, and stage special nuclear material. The facilities include segregated staging bays and inspection equipment.
Inert Component/Container Warehouses . Buildings 12-058, 12-061, 12-079, and 12-095 are used for storing, repackaging, and distributing inert weapon components, materials, and containers for Pantex. HE components to support A/D are staged in Building 12-058. Weapons and special nuclear material are staged in other buildings. These facilities include storage racks, a loading dock, and areas designed for packaging and unpackaging and shipping and receiving. No modifications are required in these facilities.
Strategic Reserves Storage . The plutonium and HEU strategic reserves would be stored in Area 12.
Requirements for Construction and Operation. Downsizing and consolidating A/D operations at Pantex would require approximately 0.2 ha (0.4 acres) of land for construction material laydown. There would be no associated disturbed land area involved with downsizing of operations at Pantex. Materials and resources consumed during the 3-year construction period are listed in table A.3.1.1-2. The principal source of air emissions during construction would be fugitive dust from site preparation and construction activities and exhaust from construction equipment and vehicles. Annual emissions during a peak construction year are presented in table A.3.1.1-3.
The number of workers required during each construction year is presented in table A.3.1.1-4.
The weapon A/D process requires the following utilities: electricity, plant air for operating pneumatic tools and hoists, instrument air for radiation monitors, steam for heating test beds in environmental conditioning ovens, cryogenic carbon dioxide for cooling test bed test stations, and water for operating vacuum pumps. Utilities consumed during surge operation can be found in table A.3.1.1-5.
|
|
|
|---|---|---|
Electricity | 609 MWh | 4 MWe |
Water (L) |
1,400,000 |
|
Concrete (m 3 ) |
840 |
|
Steel (t) |
15 |
|
Liquid fuel and lube
| 28,800 |
|
Industrial gases (m 3 ) 2 |
600 |
|
|
|
|---|---|
Sulfur dioxide | 0.04 |
Nitrogen oxides | 0.46 |
Volatile organic compounds | 0.23 |
Carbon monoxide | 1.26 |
Particulate matter | 0.19 |
Total suspended particulates | 0.46 |
|
|
Chemicals consumed during operation primarily include water treatment chemicals, materials for facility equipment and vehicle maintenance, and bottled gases. Annual estimated chemical use during surge operations is listed in table A.3.1.1-6.
Emissions. Emissions result from plant boiler operation and cleaning operations that use solvents. Releases would be limited to what is possible, using best available control technology. Emissions for the downsizing and consolidating alternative A/D surge operations are shown in table A.3.1.1-7.
Radiological release for A/D operations are limited to uranium isotopes and tritium. These releases are the result of assembly and disassembly operations, as well as waste operations. Extremely small releases of plutonium (near background) are possible.
|
|
|
|
|
|---|---|---|---|---|
Craftworkers |
| |||
Carpenter |
1 | 7 | 2 | 10 |
Concrete mason |
1 | 5 | 1 | 7 |
Electrician |
0 | 6 | 5 | 11 |
Iron worker |
1 | 8 | 1 | 10 |
Laborer |
2 | 6 | 2 | 10 |
Millwright |
0 | 2 | 1 | 3 |
Operator |
0 | 3 | 1 | 4 |
Sheet metal worker |
0 | 7 | 2 | 9 |
Pipe fitter |
0 | 5 | 3 | 8 |
Sprinkler fitter |
0 | 5 | 1 | 6 |
Teamster |
1 | 3 | 1 | 5 |
Other craftworkers |
0 | 4 | 3 | 7 |
Total Craftworkers | 6 | 61 | 23 | 90 |
Construction management and support staff | 1 | 6 | 2 | 9 |
Total Employment |
7 | 67 | 25 | 99 |
| ||||
|
|
|
|---|---|---|
Electricity | 43,000 MWh | 10 MWe |
Liquid fuel (L) |
740,000 |
|
Natural gas (m 3 ) |
7,150,000 |
|
Water (L) |
196,000,000 |
|
|
| |
|
|
|---|---|
Acetone | 227 |
Argon | 8,165 |
Carbon dioxide | 49,896 |
Circlene FG 20 | 635 |
Clepox 143 | 635 |
Degreaser | 680 |
Desiccants | 454 |
Dispersant | 290 |
Dry air | 771 |
Eco-Star | 2,858 |
Ethyl acetate | 544 |
Ethyl alcohol | 227 |
Fixer and replenisher | 1,497 |
Glass beads | 408 |
Glass cleaner | 1,452 |
Helium | 1,769 |
Heptane | 318 |
Hydraulic/lubricating oil | 29,030 |
Inorganic proprietary | 2,722 |
Joint compound | 1,179 |
Micro liquid lab cleaner | 363 |
Mild steel metal | 5,897 |
Molecular sieve | 1,043 |
Neutrasorb acid neutralizer | 272 |
Nitrogen | 3,629 |
Paint | 16,330 |
Planisol-M concentrate | 363 |
Polyalkylene and ethylene glycol | 240 |
Potassium hydroxide | 408 |
Siliconized ammonium phosphate base | 590 |
Sodium chloride | 34,020 |
Solksorb solvent absorbent | 1,769 |
Specialty gas mixtures | 1,542 |
Stainless steel metal | 2,268 |
Sulfuric acid | 363 |
TISAB with CDTA | 862 |
Water treatment chemicals 3 |
11,340 |
|
|
|---|---|
Ammonia | <0.001 |
Carbon monoxide | 5.4 |
1,2-Dichloroethane | <0.001 |
Nitrogen oxides | 21.3 |
Particulate matter | 0.8 |
Sulfur dioxide | <0.001 |
1,1,1-Trichloroethane | 0.44 |
2,2,4-Trimethyl-1,3-Pentane diolbutyrate | <0.001 |
Volatile organic compounds | 11.3 |
|
|
Weapons Assembly Transportation. As illustrated in figure A.3.1.1-3, the two major types of radiological hazardous materials that would be transported to Pantex include special nuclear material components and HE components. Special nuclear material would be shipped in safe secure trailers. Upon arrival at the site, a safe secure trailer would proceed directly to the weapon staging facility. Movement of 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.
All major weapon assembly work would be performed in assembly bays and cells. Special nuclear material would be transferred from staging areas by battery-powered vehicles travelling on ramps. After final assembly and inspection, weapons would be transferred to the weapon staging facility on ramps. Weapons would then be shipped offsite by safe secure trailer.
Small quantities of low-level, mixed, and hazardous wastes generated during assembly of nuclear weapons would be collected, packaged, and transported by electric car to local accumulation sites and then by truck to a low-level staging area near the waste management facility. The wastes would be transferred by truck for offsite disposal.
Weapons Disassembly Transportation. As illustrated in figure A.3.1.1-4, returning weapons would be delivered in safe secure trailers. After a security inspection, weapons would be unloaded and temporarily stored in the same weapons staging area used for outgoing assembled weapons. Individual weapons would be transported to an assembly bay or cell by a battery-powered vehicle travelling on a ramp. After disassembly, the various special nuclear material components would be transported by battery-powered vehicles to staging areas for subsequent shipment offsite. HE components would be transported by electric vehicle to the HE staging area for subsequent transportation to the HE fabrication plant. Waste would be collected, transported, and disposed of in a manner similar to that described for weapons assembly.
Waste Management. Pantex waste management is described in detail in appendix section H.2.4. The liquid and solid nonhazardous wastes generated over a 3-year period would include concrete and steel construction waste materials and sanitary wastewater. The steel construction waste would be recycled as scrap material before completing construction. The remaining nonhazardous wastes generated during construction would be disposed of as part of the construction project by the contractor. Wastewater would be used for soil compaction and dust control or processed through the Pantex sanitary wastewater system. Wood, paper, and metal wastes would be shipped offsite to a commercial contractor for recycling. Hazardous wastes generated during construction would consist of such materials as waste adhesives, oils, cleaning fluids, solvents, and coatings. Hazardous waste would be packaged in Department of Transportation (DOT)-approved containers and shipped offsite to commercial RCRA-permitted treatment, storage, and disposal facilities. No radioactive waste would be generated during construction.
|
Volume Generated from Construction (m 3 ) |
Generated from Surge Operations (m 3 ) |
Effluent from Surge Operations (m 3 ) |
|---|---|---|---|
Low-Level |
| ||
Liquid | None |
0.06 | None |
Solid | None |
21 4 | 10 5 |
Mixed Low-Level |
|
| |
Liquid | None |
0.06 | 0.06 |
Solid | None | Minimal | Minimal |
Hazardous |
|
|
|
Liquid | None |
2 | 2 |
Solid |
0.25 | 0.05 | 0.05 |
Nonhazardous (Sanitary) |
| ||
Liquid |
315 | 141,000 | 141,000 |
Solid |
5 6 | 340 | 170 7 |
Nonhazardous (Other) |
|
|
|
Liquid | Included in sanitary | Included in sanitary | Included in sanitary |
Solid | Included in sanitary | Included in sanitary | Included in sanitary |
The project design incorporates waste minimization and pollution prevention. Segregation of activities that generate radioactive and hazardous wastes would be employed, where possible, to avoid the generation of mixed wastes. Where applicable, treatment to separate radioactive and nonradioactive components would be performed to reduce the volume of mixed wastes and provide for cost-effective disposal or recycle. To facilitate waste minimization, where possible, nonhazardous materials would be substituted for those materials that contribute to the generation of hazardous or mixed waste. Production processes would be configured, with minimization of waste production given high priority. Material from the waste streams would be treated to facilitate disposal as nonhazardous wastes, where possible. Future D&D considerations have also been incorporated into the design.
Table A.3.1.1-8 presents the estimated annual waste volumes from the A/D and pit recertification, requalification, and reuse facility during construction and surge operations. Solid and liquid waste streams are routed to the waste management system. Figure A.3.1.1-5 depicts the waste management system. Solid wastes would be characterized and segregated into LLW, hazardous, and mixed wastes, then treated to a form suitable for disposal or storage within the facility. Liquid wastes would be treated onsite to reduce hazardous and toxic elements before discharge or transport. All fire-sprinkler water discharged in process areas is contained and treated as process wastewater, when required.
Low-Level Waste. LLW generated from the recertification, requalification, and reuse operations would consist of tubes removed from the pits, personnel protective equipment, glove box gloves, filters, cleaning materials, and disposal supplies. Small amounts of LLW would be generated by A/D operations and would consist primarily of sanitized and demilitarized weapon parts, test residue, compacted wipes, rubber gloves, and vacuum filters. Compactible LLW would be processed at the solid waste compaction facility. Compactible and noncompactible waste would then be shipped to NTS or a commercial vendor for disposal. Liquid LLW, consisting of solvents used in cleaning operations, would be solidified prior to packaging.
Mixed Low-Level Waste. Pit recertification, requalification, and reuse operations would not generate any mixed LLW. Small amounts of mixed LLW would be generated from operation of the A/D facility and would consist primarily of sanitized and demilitarized weapons parts, test residue, compacted wipes, rubber gloves, and vacuum filters. Mixed waste would be stored onsite in RCRA-permitted facilities and shipped to an offsite commercial facility for processing. Liquid mixed waste would be managed in accordance with the Pantex Site Treatment Plan.
Hazardous Waste. Liquid hazardous wastes would be generated from solvents from cleaning operations and residue from painting and bonding operations, as well as sanitized and demilitarized parts. The cleaning solvents selected would be from a list of nonhalogenated solvents. Hazardous liquids would be sent to one of three onsite wastewater treatment facilities. The treated nonhazardous effluent would be discharged in accordance with NPDES permits. Hazardous effluents would be packaged and shipped offsite to a RCRA-permitted treatment, storage, and disposal facility.
Solid hazardous wastes would be generated from nonradioactive materials such as wipes contaminated with oils, lubricants, and cleaning solvents that are used for equipment outside the main processing units. All HE and HE-contaminated substances would be returned to the HE fabrication site. All hazardous solid waste would be shipped to a RCRA-permitted facility for disposal.
Nonhazardous (Sanitary) Waste. Sewage wastewater and process wastewater would be treated in the sanitary wastewater treatment facility. Most of the treated effluent would be recycled for use in the cooling tower and other processes. Excess effluent would flow into a lagoon which then either evaporates or leaches into the ground. The sludge and other nonrecyclable, nonhazardous solid sanitary and industrial wastes would be compacted and shipped to the city of Amarillo landfill for disposal.
Nonhazardous (Other) Waste. Small amounts of classified nonhazardous waste would be generated from operation of the A/D facility. This waste would be demilitarized and sanitized before disposal in a permitted landfill.
All functions described in section A.3.1 would be relocated to NTS in this alternative. Figure A.3.1.2-1 shows the location of NTS facilities. The proposed A/D plant site plan is shown in figures A.3.1.2-2 and A.3.1.2-3. The size, number, and arrangement of the plant building and support areas are conceptual and may change significantly as design progresses. The site plans are included to convey general layout information only.
The existing Device Assembly Facility would form the cornerstone of the A/D plant. All plant facilities located within the material access area either occupy existing buildings inside the Device Assembly Facility or are located in hardened new construction connected to the Device Assembly Facility. All plant facilities located within the limited area at the plant site (adjacent to the Device Assembly Facility) would be new construction.
Key facilities required to meet the mission of the A/D operations at NTS are listed in table A.3.1.2-1. The following sections describe the key facilities in more detail.
|
|
or Existing |
|
|
Type |
of Floors |
|---|---|---|---|---|---|---|
Assembly/Disassembly |
|
|
|
|
|
|
DAF 301-304 | Physics package cells | Existing | Material access area |
1,732 | Hardened concrete | 1 |
DAF 341, 343, 345 | Mechanical bays | Existing | Material access area |
624 | Hardened concrete | 2 |
M01-M24 | Mechanical bays | New | Material access area |
6,044 | Hardened concrete | 2 |
L01 | Test bed | New | Limited area |
186 | Steel | 1 |
Laboratories |
|
|
|
|
|
|
23-700 | Gas analysis lab | Existing | Area 23 |
828 | Steel | 1 |
L02 | Weapons evaluation testing lab | New | Limited area |
2,415 | Steel | 1 |
23-725 | Metrology lab | Existing | Area 23 |
1,353 | Steel | 1 |
M51 | Metrology lab | New | Material access area |
557 | Hardened concrete | 1 |
23-190 | Commercially procured material
| Existing | Area 23 |
701 | Concrete | 1 |
Warehousing/Staging |
|
|
|
|
|
|
L03 | HE components | New | Limited area |
279 | Hardened concrete | 1 |
23-160 | Inert components/containers | New | Area 23 |
4,682 | Steel | 1 |
L04 | Tooling/testers | New | Limited area |
2,323 | Steel | 1 |
M26-M31 | Weapons staging | New | Material access area |
836 | Hardened concrete | 1 |
Special Purpose |
|
|
|
|
|
|
M32 | Pit laser sampling | New | Material access area |
46 | Hardened concrete | 1 |
M33 | Accelerated aging | New | Material access area |
372 | Hardened concrete | 1 |
L05 | Special nuclear material container refurbishment/verification | New | Limited area |
139 | Steel | 1 |
DAF 351, 353 | AT-400 processing | Existing | Material access area |
426 | Hardened concrete | 1 |
DAF 494 | Mass properties | Existing | Material access area |
118 | Hardened concrete | 1 |
DAF 492 | Separations testing | Existing | Material access area |
118 | Hardened concrete | 1 |
DAF 310 | Vacuum chambers | Existing | Material access area |
215 | Hardened concrete | 1 |
L06 | Paint | New | Limited area |
111 | Steel | 1 |
DAF 491 | Permissive action link capability | Existing | Material access area |
213 | Hardened concrete | 1 |
M34 | Purge/backfill | New | Material access area |
46 | Hardened concrete | 1 |
DAF 493 | Component packaging | Existing | Material access area |
118 | Hardened concrete | 1 |
Special Purpose (Continued) |
|
|
|
|
|
|
DAF 495 | Component technical acceptance | Existing | Material access area |
118 | Hardened concrete | 1 |
DAF 331, 332 | Nondestructive evaluation | Existing | Material access area |
744 | Hardened concrete | 1 |
M35 | Nondestructive evaluation | New | Material access area |
325 | Hardened concrete | 1 |
M52 | Electronic testing | New | Material access area |
325 | Hardened concrete | 1 |
NT DOE 1995b. |
|
|
|
|
|
|
Assembly Cells. Four existing assembly cells in the Device Assembly Facility would support the manual A/D of a physics package. A fifth available cell would be held in reserve for test devices or expanded use if necessary. Each cell (standard Pantex design) includes an area to perform assembly operations, staging areas for special nuclear materials and weapon parts, and a mechanical room for heating, ventilation, and air conditioning equipment controls.
Assembly Bays. A new assembly bay facility would be constructed adjacent and connected to the Device Assembly Facility. This facility would contain 24 assembly bays; 20 of standard Pantex design and four with extended operational areas. Three additional bays of standard Pantex design are provided in the existing Device Assembly Facility. All assembly bays would be separated by a minimum of 4.1 m (13.6 ft) of earth fill for explosive blast shock mitigation. Each bay would include an area or areas to perform assembly operations, staging areas for tooling and weapon parts, and a second floor mechanical room for heating, ventilation, and air conditioning equipment and controls. Two additional assembly bays are held in reserve within the existing Device Assembly Facility for device assembly operations or expanded use, if required.
Test Bed . A new nonhardened facility would be constructed within the limited area, adjacent to the Device Assembly Facility for test bed fabrication. This facility would contain universal assembly bays configured with program-specific tooling.
Laboratories
Gas Analysis . Gas analysis would be performed in an existing nonhardened building in Area 23. This building would be configured with laboratory facilities equipped to provide analysis by gas fractionation, gas chromatography, and mass spectrometry.
Weapons Evaluation Testing. A new nonhardened facility would be constructed within the limited area, adjacent to the Device Assembly Facility for weapons evaluation testing. This facility would contain a number of fully instrumented test stations to provide for heating, cooling, and test firing the test beds. A cryogenic system would be used for the cooling of these units during testing. Environmental conditioning ovens and centrifuges would be provided for the testing of components under deployment conditions.
Metrology. Metrology laboratory facilities would be located in an existing nonhardened building in Area 23 and in a new hardened building within the material access area, connected to the existing Device Assembly Facility. These facilities would be equipped to calibrate instruments and testers used in weapon assembly operations. A class 1000 clean room with heating, ventilation, and air conditioning temperature control to + 2.8 o C ( + 5 o F) would be added to these buildings.
Commercially Procured Material Testing/Staging . An existing building located in Area 23 would be used to test and stage commercially procured materials used in the assembly process. This building would have both receiving and staging areas and a room equipped for performing standard material tests.
Special Purpose Bays
Pit Laser Sampling . A new hardened building would be constructed within the material access area, connected to the Device Assembly Facility, to perform laser sampling of pits.
Accelerated Aging. A new hardened building would be constructed within the material access area, connected to the Device Assembly Facility, to simulate accelerated environmental aging of newly produced weapons and weapon components. This building would contain five environmental chambers to provide thermal cycling above and below ambient temperatures for an extended period of time.
Special Nuclear Materials Container Refurbishment/Verification . A new building would be constructed within the limited area, adjacent to the Device Assembly Facility, to refurbish and verify processing of special nuclear material containers.
AT-400A Processing. Two existing hardened bays within the Device Assembly Facility would be used for AT-400A processing.
Mass Properties . Mass properties determination would be performed in an existing hardened bay within the Device Assembly Facility. This building would be equipped with remotely operated dynamic balancing machines to determine products of inertia and lateral center of gravity and a center of gravity and moments of inertia machine.
Separations Testing. An existing hardened bay in the Device Assembly Facility would be used for separations testing. This bay would be equipped to test selected reentry body subassemblies, measurements of service-related deterioration of the release assembly system, and for acquisition of data associated with the evaluation of release assembly hardware.
Vacuum Chambers. Two vacuum chambers would be installed in an existing hardened building in the Device Assembly Facility to perform leak rates on all outgoing weapons or on weapons returned from the field.
Paint . A new nonhardened building would be constructed within the limited area, adjacent to the Device Assembly Facility, to paint, repaint, or touch-up weapons, weapon components, and containers.
Purge/Backfill. A new hardened building would be constructed within the material access area, connected to the Device Assembly Facility, to conduct purge and backfill operations. This building would be equipped to either purge or fill the inside of the weapon case with a specific gas.
Component Packaging/Technical Acceptance. Component packaging and technical acceptance operations would be conducted in two existing hardened Device Assembly Facilities.
Nondestructive Evaluation. Explosive components would be inspected by linear accelerator, medium x ray, and computed tomography within the existing two radiography buildings in the Device Assembly Facility. Other weapon and component testing would be conducted in a new hardened building located within the material access area, connected to the Device Assembly Facility. This building would contain equipment to support mechanical conditioning tests including vibration, hostile shock, mini air-gun shock, and steady-state acceleration shock.
Electronic Testing. Electronic testing of weapon components would be conducted in a new hardened building located within the material access area, connected to the Device Assembly Facility.
Warehousing/Staging
High Explosives Components. Three new hardened bunkers would be constructed within the limited area, adjacent to the Device Assembly Facility, for the storage of HE components. These bunkers would be bermed and would provide a safe separation distance to all other occupied facilities at the plant site.
Special Nuclear Materials Components. A new hardened building would be constructed within the material access area, connected to the Device Assembly Facility, to stage and store special nuclear material components. This building would contain segregated staging bays and inspection equipment and would utilize the existing safe secure trailer loading dock within the Device Assembly Facility for secure receiving of special nuclear material components.
Inert Components/Containers Shipping and Receiving. An existing building located in Area 23 would be used to ship, receive, and store inert weapon components. This facility would include storage racks, a loading dock, and areas designed for packaging and unpackaging.
Tooling/Testers . A new nonhardened building would be constructed within the limited area, adjacent to the existing Device Assembly Facility, to control the storage of precision tools, instruments, testers, and special equipment used in A/D operations. Segregated storage areas would be provided for all specific tooling requirements supporting weapons programs in the enduring stockpile.
Weapons. Six new hardened bays would be constructed within the material access area, connected to the Device Assembly Facility, for the interim staging of a maximum of 100 weapon units. This facility would have a dedicated safe secure trailer dock for shipping and receiving weapons.
Strategic Plutonium/Canned Subassembly Storage . The strategic Plutonium/Canned Subassembly Storage Facility would consist of new hardened construction within the material access area connected to the existing Device Assembly Facility.
Weapons A/D facilities construction would take 6 years to complete. Materials and resources consumed during the entire construction period are listed in table A.3.1.2-2.
The principal sources of air emissions during A/D facility construction would be fugitive dust from land clearing, site preparation, excavation, and other construction activities, and exhaust from construction equipment and vehicles. The annual emissions generated during a 1-year period with peak construction activity are shown in table A.3.1.2-3.
|
|
|
|---|---|---|
Electricity | 38,000 MWh | 5 MWe |
Water |
98,400,000 L | 94,600 L/day |
Concrete (m 3 ) |
75,000 |
|
Steel (t) |
16,300 |
|
Liquid fuel and
| 3,030,000 |
|
Industrial gases (m 3 ) 9 |
65,100 |
|
|
|
|---|---|
Sulfur dioxide | 1.8 |
Nitrogen dioxide | 24 |
Volatile organic compounds | 7.3 |
Carbon monoxide | 36 |
Particulate matter | 13.6 |
Total suspended particulates | 31 |
|
|
The number of craftworkers, as well as construction management and support staff, required during each year of construction, are presented in table A.3.1.2-4.
The utilities consumed during operation include electric power, liquid fuels, and water. Annual utility consumption rates and peak electric power rates for surge operation are shown in table A.3.1.2-5.
The chemicals and materials consumed during operation primarily include water treating chemicals, reactants and solvents for explosives formulation and synthesis, explosive powders, materials for facility equipment and vehicle maintenance, metals for manufacturing tooling, and bottled gases. Annual surge operation material consumption is listed in table A.3.1.2-6.
Emissions. Gaseous environmental releases result from operation of the thermal treatment unit for nonradioactive HE contaminated waste and mixed HE contaminated waste. Emissions will also result from plant boiler operation, cleaning operations using solvents, and small scale synthesis operations. The thermal treatment units would be designed and operated to attain and maintain temperatures that result in the destruction of hazardous constituents and hazardous particulates that will be trapped in filters. The releases will be limited to what is possible using the best available control technology. The annual emissions for the A/D facility surge operations are shown in table A.3.1.2-7.
Waste Management. NTS waste management is described in detail in appendix section H.2.8. The liquid and solid nonhazardous wastes generated during the 6-year construction period would include concrete and steel construction waste materials and sanitary wastewater. The steel construction waste would be recycled as scrap material before completing construction. The remaining nonhazardous wastes generated during construction would be disposed of as part of the construction project by the contractor. Uncontaminated wastewater would be used for soil compaction and dust control, and excavated soil would be used for grading and site preparation. Wood, paper, and metal wastes would be shipped offsite to a commercial contractor for recycling. Hazardous wastes generated during construction would consist of such materials as waste adhesives, oils, cleaning fluids, solvents, and coatings. Hazardous waste would be packaged in DOT-approved containers and shipped offsite to commercial RCRA-permitted treatment, storage, and disposal facilities. No radioactive waste would be generated during construction.
|
|
|
|
|
|
|
|
|---|---|---|---|---|---|---|---|
Craftworkers |
|
|
|
|
|
|
|
Carpenter |
61 | 117 | 115 | 63 | 41 | 36 | 433 |
Concrete mason |
8 | 15 | 10 | 2 | 2 | 4 | 41 |
Electrician |
24 | 27 | 53 | 90 | 96 | 55 | 345 |
Iron worker |
30 | 75 | 67 | 23 | 16 | 16 | 227 |
Laborer |
38 | 62 | 52 | 20 | 17 | 20 | 209 |
Millwright |
3 | 7 | 10 | 20 | 19 | 7 | 66 |
Operator |
10 | 23 | 29 | 22 | 18 | 9 | 111 |
Sheet metal worker |
5 | 14 | 29 | 29 | 14 | 5 | 96 |
Pipe fitter |
15 | 32 | 75 | 82 | 78 | 32 | 314 |
Sprinkler fitter |
3 | 8 | 16 | 16 | 7 | 3 | 53 |
Teamster |
3 | 6 | 7 | 7 | 6 | 3 | 32 |
Other craftworkers |
4 | 8 | 15 | 24 | 20 | 6 | 77 |
Total Craftworkers | 204 | 394 | 478 | 398 | 334 | 196 | 2,004 |
Construction staff 10 |
29 | 59 | 73 | 61 | 51 | 30 | 302 |
Management and support staff 11 |
44 | 91 | 111 | 92 | 78 | 46 | 462 |
Total Employment |
277 | 544 | 662 | 550 | 463 | 272 | 2,768 |
|
|
|
|---|---|---|
Electricity | 45,000 MWh | 7 MWe |
Liquid fuel (L) |
432,000 |
|
Natural gas (m 3 ) |
3,680,000 |
|
Water (L) |
98,400,000 |
|
|
|
|---|---|
Acetone | 64 |
Acetonitrile | 64 |
Aluminum metal | 499 |
Argon | 8,165 |
Brass metal | 50 |
Carbon dioxide | 49,896 |
Circlene FG 20 | 227 |
Clepox 143 | 227 |
Copper/copper oxide wire | 295 |
Copper metal | 136 |
Degreaser | 227 |
Dispersant | 68 |
Dry air | 771 |
Eco-Star | 726 |
Electrode/probe solutions | 59 |
Ethyl alcohol | 59 |
Fixer/replenisher | 454 |
Glass cleaner | 454 |
Glass beads | 136 |
Helium | 1,769 |
Heptane | 113 |
Hydraulic/lubricating oil | 8,165 |
Hydrochloric acid | 68 |
Joint compound | 363 |
Kimwipes | 1,134 |
Lead metal | 136 |
Micro liquid lab cleaner | 113 |
Mild steel metal | 1,814 |
Molecular sieve | 295 |
Neutrasorb acid neutralizer | 68 |
Nitrogen | 3,629 |
Paint | 4,536 |
Planisol-M concentrate | 113 |
Polyalkylene and ethylene glycol | 68 |
Potassium hydroxide | 113 |
Siliconized ammonium phosphate base | 181 |
Sodium hydroxide | 113 |
Solksorb solvent absorbent | 499 |
Specialty gas mixtures | 1,542 |
Stainless steel metal | 612 |
Sulfuric acid | 113 |
Tetrahydrofuran | 4,990 |
TISAB and CDTA | 250 |
Toluene | 68 |
Water treating chemicals | 2,268 |
NT DOE 1995b; NTS 1995a:3. |
|
|
|---|---|
Carbon monoxide | 0.007 |
Nitrogen dioxide | 0.907 |
Particulate matter | 0.00227 |
Sulfur dioxide | 0.907 |
|
|
The project design incorporates waste minimization and pollution prevention. Segregation of activities that generate radioactive and hazardous wastes would be employed, where possible, to avoid the generation of mixed wastes. Where applicable, treatment to separate radioactive and nonradioactive components would be performed to reduce the volume of mixed wastes and provide for cost effective disposal or recycle. To facilitate waste minimization, where possible, nonhazardous materials would be substituted for those materials which contribute to the generation of hazardous or mixed waste. Production processes would be configured with minimization of waste production given high priority. Material from the waste streams would be treated to facilitate disposal as nonhazardous wastes, where possible. Future D&D considerations have also been incorporated into the design.
Table A.3.1.2-8 presents the estimated annual waste volumes from the A/D and pit reuse facility during construction and surge operations. Liquid and solid waste streams are routed to the waste management system. Solid wastes would be characterized and segregated into LLW, hazardous and mixed wastes, then treated to a form suitable for disposal or storage within the facility. Liquid wastes would be treated onsite to reduce hazardous and toxic and radioactive elements before discharge or transport. All fire-sprinkler water discharged in process areas is contained and treated as process wastewater, when required.
Low-Level Waste. LLW generated from reuse operations would consist of tubes removed from the pits, personnel protective equipment, glove boxes, filters, cleaning materials, and disposal supplies. Small amounts of LLW would be generated by A/D operations and would consist primarily of sanitized and demilitarized weapon parts, test residue, compacted wipes, rubber gloves, and vacuum filters. Bulk waste would be disposed of in Area 3, and packaged waste would be disposed of in Area 5, employing standard shallow land burial techniques.
Mixed Low-Level Waste. Pit reuse operations would not generate any mixed LLW. Small amounts of mixed LLW would be generated from operation of the A/D facility and would consist primarily of sanitized and demilitarized weapon parts, test residue, compacted wipes, rubber gloves, and vacuum filters. Mixed LLW would be stored in an onsite RCRA-permitted storage facility until treatment in accordance with the site treatment plan that was developed to comply with the Federal Facility Compliance Act of 1992.
|
Volume Generated from Construction (m 3 ) |
Generated from |
Effluent from Surge Operations (m 3 ) |
|---|---|---|---|
Low-Level | |||
Liquid |
None | 0.06 | None |
Solid |
None | 30 13 | 15 14 |
Mixed Low-Level |
|||
Liquid |
None | None | None |
Solid |
None | 2 | 2 |
Hazardous | |||
Liquid |
None | 6 | 6 |
Solid |
5 | 0.05 | 0.05 |
Nonhazardous (Sanitary) | |||
Liquid |
6,670 | 53,000 | 53,000 |
Solid |
260 15 | 100 | 50 16 |
Nonhazardous (Other) | |||
Liquid | Included in sanitary | Included in sanitary | Included in sanitary |
Solid | Included in sanitary | Included in sanitary | Included in sanitary |
Hazardous Waste. Liquid hazardous wastes would be generated from solvents from cleaning operations and residue from painting and bonding operations. The cleaning solvents selected would be from a list of nonhalogenated solvents. Solid hazardous wastes would be generated from nonradioactive materials, such as wipes contaminated with oils, lubricants, and cleaning solvents that are used for equipment outside the main processing units. Hazardous wastes would be collected in DOT-approved containers and sent to an onsite hazardous waste storage area. The hazardous waste storage area would provide a 90-day staging capacity prior to shipment to an offsite commercial RCRA-permitted treatment, storage, and disposal facility, using DOT-certified transporters.
Nonhazardous (Sanitary) Waste. Sewage wastewater and process wastewater would be treated using a series of facultative lagoons and evaporation ponds and disposed of in septic tanks, sumps, or ponds. Solid wastes are disposed of in landfills at various locations on the site.
Nonhazardous (Other) Waste. Small amounts of classified nonhazardous waste would be generated from operation of the A/D facility. These wastes would be sanitized and disposed of per site practice.
Cubic meters measured at standard temperature and pressure.
Chlorine, sodium sulfite, sodium sulfate, sulfuric acid, poly electroly, and phosphoric acid.
Includes 9.2 m 3 generated from A/D operations and 11.3 m 3 generated from pit reuse operations.
5 6 7Assumes 2/3 of solid is compactible by a factor of 4:1.
Cubic meters measured at standard temperature and pressure.
Peak demand is the maximum rate expected during any time.
Includes 18.3 m 3 generated from A/D operations and 11.3 m 3 generated from pit reuse operations.
14 15Includes 255 m 3 of concrete and 39 t (43 tons) of steel. Volume estimate made by using 0.127 m 3 /t for density of steel.
16Assumes 2/3 of solid is compactible by a factor of 4:1.
