A.3.6 Nonnuclear Fabrication

The nonnuclear fabrication function provides the capability to fabricate nonnuclear components and perform nonnuclear component surveillance. Nonnuclear component products and/or processes fall within the groupings of those manufactured onsite and those procured. Several common subgroups have been identified:

• System Level: e.g., firesets and radars
• Electrical Components: e.g., integrated circuits and semiconductors, interconnect cables, and passive components
• Mechanical Components: e.g., radio frequency and multipin connectors, Rolamites, actuator assemblies, and reservoirs and valves
• Materials and Explosives: e.g., nuclear grade steel and molded plastic parts

The following discussion briefly describes the site alternatives for the nonnuclear fabrication mission:

Kansas City Plant . This alternative consists of three major factories involved in electronics and mechanical and engineered materials product lines, as well as outsourcing some components. KCP would downsize but maintain all of its current missions, reducing the KCP footprint to 167,000 m 2 (1.8 million ft 2 ) for DP activities from the current 297,000 m 2 (3.2 million ft 2 ). Estimated start would be in April 1998 with steady-state operation proposed in October 2003.

Los Alamos National Laboratory . This alternative is based on the use of existing facilities which are organized into a plastics facility, a pilot plant, a detonator facility, and a reservoir/valve/steel facility. The mission would be to provide high energy detonator inert components and fabrication of reservoirs, valves, and nuclear grade steel. Construction could begin in fiscal year 2000 with steady-state operation starting in fiscal year 2003.

Lawrence Livermore National Laboratory. This alternative has LLNL fabricating nuclear system plastic components, instead of LANL. The LLNL nonnuclear manufacturing facility would provide the plastic components and polymers currently produced at KCP, including filled and unfilled molded parts; syntactic, rigid, and flexible foam parts; composite structures; and specialty polymers currently produced at the KCP pilot plant. The 7,200-m 2 (77,840-ft 2 ) facility would be housed in five existing buildings in a limited access area at LLNL. Construction would begin in fiscal year 1998 with steady-state operation starting in fiscal year 2003.

Sandia National Laboratories. This alternative would transfer the majority of current KCP missions to SNL, except for nuclear system plastic components and high energy detonator inert components. SNL could also fabricate reservoirs, valves, and nuclear grade steel instead of LANL. This alternative requires both modification of existing facilities and construction of new facilities. Depending on the specific approach, total area affected would range from 56,100 to 63,200 m 2 (605,000 to 680,000 ft 2 ), new construction would range from 33,900 to 58,100 m 2 (365,000 to 625,000 ft 2 ), and modifications would range from 5,000 to 22,000 m 2 (55,000 to 240,000 ft 2 ). Construction would begin in the first quarter of fiscal year 1998 with steady-state operation starting in the first quarter of fiscal year 2004.

A generic set of products and services required to produce a typical bomb or re-entry warhead was defined to provide a common basis for estimating. Current program look-alikes were established to determine the standard hour content of manufactured product, productive material costs, and the cost of procured components and services. Minimum quantities per year were developed to maintain a production capability for "in-house" manufactured product.

A make-buy determination was made for each product or service (see table A.3.6-1). KCP, SNL, LANL, and LLNL used the make-buy analysis to define the manufacturing area requirements, the direct and indirect support staff, the infrastructure support staff, and productive material cost required to support anticipated production requirements. The capacity of this basic capability supports all current schedules and anticipated retrofit needs.

Table A.3.6-1.-- Nonnuclear Fabrication Production Products Make/Buy Matrix

Product	KCP Fabricate	KCP Procure	SNL Fabricate	SNL Procure	LANL Fabricate	LANL Procure
WES/AF&F	X		X
Firesets	X		X
Printed wiring boards		X		X
Printed wiring assemblies	X		X
Multichip modules	X			X
Hybrid microcircuits	X		X
Housings (buy casting, forging, or bulk)	X	X	X	X
Electronic components		X		X
Radars (like firesets)	X		X
Antennas		X		X
Nose assemblies	X		X
Electrical component assemblies	X		X
Lasers and electro optics		X		X
Programmers	X		X	X
Filter packs		X		X
Voltage regulators		X		X
Accelerometers/ Environmental Sensing Devices	X		X
Interconnect/junction boxes		X		X
Preflight controllers	X		X
Ready-safe switches		X		X
Option select switches		X		X
Coded switches	X		X
Trajectory Sensing Signal Generators	X		X
Piezoelectric motors		X		X
Relays		X		X
Output switches	X		X
Category F - cases and electronics assemblies	X		X
Timers	X	X	X	X
Connectors		X
Lightning arrester connectors	X		X	X
Strong links	X	X	X	X
Actuator assemblies		X		X
Detonator cables	X				X	X
Interconnect cables		X		X
Flat flex		X		X
Fiber optic		X		X
RF and coaxial		X		X
High voltage		X		X
CF round wire		X		X
Valves	X		X		X
Reservoirs	X		X		X
Major mechanical parts	X	X	X	X
Molded plastic parts		X		X
Transfer molded		X		X	X 1	X 1
Compression molded		X		X	X 1	X 1
Injection molded		X		X	X 1	X 1
Machined		X		X	X 1	X 1
Cushions					X 1
RTV	X				X 1
Cellular silicone	X				X 1
Foam supports	X		X		X 1
Syntactic supports	X		X		X 1
Filled polymers	X				X 1
Desiccants	X		X
Getters	X		X
Parachute assemblies		X		X
Hand T gear		X		X
Trainer hardware and kits		X		X
Retrofit kits		X		X
D/855	X		X
Joint test assemblies	X	X	X	X
Transducers/detectors	X	X	X	X
Data and flight recorders	X	X	X	X
Special design hardware	X	X	X	X
Commercial hardware		X		X
Transportation Safeguards Division-Safe Secure Trailers	X	X	X	X
Trailers	X	X	X	X
Escort vehicles	X	X	X	X
TC firing systems		X		X
D/50 reprocessing	X		X
Services-DOE and/or product required
Test equipment field support	X		X
Storage	X		X
Testers	X		X
Tools	X		X
Gauges	X		X
Data/records	X		X
Material	X		X
Boron reclamation/certifi-cation/storage	X				X
Polymer pilot facility	X				X 1
Cellular silicone compounding	X				X 1
Classified automated data processing	X		X
Logistics and manufacturing center	X		X
Test equipment maintenance	X		X	X
Transportation containers	X	X	X	X
Tool and gauge fabrication	X	X	X	X
Tool and gauge design	X	X	X	X
Test equipment design and fabrication	X	X	X	X
SECOM	X		X
Nuclear grade steel acceptance/storage	X		X		X
Kirtland operations	X		X

A.3.6.1 Downsize at Kansas City Plant

KCP provides most of the nonnuclear components for the current nuclear weapons stockpile. KCP can effectively support the future stockpile management missions of the nuclear weapons program through a major downsizing of the physical plant and the functions required to support the production mission. The plant was designed, sized, and organized around the mission and workload of the Cold War era, and thus is not appropriately structured to efficiently accomplish the reduced workload of the future. The consolidation of the physical plant would allow a much more efficient organizational approach to be implemented to provide required direct and indirect support functions. The downsized plant would be referred to as KCP II.

The proposed KCP II consists of changing the existing plant and operational approach in four major aspects: (1) physically reducing the size of the facility, (2) changing the approach to manufacturing from product-based to process-based, (3) reducing the support infrastructure appropriate for the right-sized operation, and (4) changing the basic organizational structure to focus directly on the core manufacturing mission.

The proposed KCP II concept was developed to accommodate current and future active stockpile needs. The KCP II facility is to provide, with a 3-year notice, any conceivable combination of components for 150 factory retrofits as well as 150 field retrofits per year on a single-shift basis. These requirements are in addition to limited-life component exchanges, the stockpile evaluation program, and the stockpile surveillance program (joint test assemblies and warhead rebuild) currently scheduled.

Currently KCP consists of approximately 297,000 m 2 (3.2 million ft 2 ) of space contained in three connected buildings: the Main Building, the Manufacturing Support Building, and the Technology Transfer Center (figure A.3.6.1-1). Much of this floor space is underutilized and very costly to maintain. Many of the production departments are staffed with only a few people because of the low workload in some production technologies. The KCP II proposal and earlier independent space consolidation initiatives would reduce the size of the plant to approximately 167,000 m 2 (1.8 million ft 2 ) for DP activities. The Technology Transfer Center and Manufacturing Support Building facilities would be vacated of DP activities. All operations and support functions required for stockpile management would be accomplished within reduced floor space of the main buildings.

The KCP II proposal is based on the consolidation of similar processes in three separate production areas (the electronic, mechanical, and engineered materials factories) and several product-based departments.

Electronics Factory. The products described in this section consist of electronic systems and electrical subsystems that function within weapon systems. There are three process modules: microelectronics, interconnects, and final assembly. Table A.3.6.1-1 shows the major processes within each of the electronics modules and the product types produced by these procedures. Total production floor space requirement would be approximately 12,454 m 2 (134,000 ft 2 ).

Microelectronics . A significant portion of the microelectronics fabrication would be performed in an existing hybrid microcircuit production facility. This 2,970-m 2 (32,000-ft 2 ) facility is divided into a number of sub-areas. Some of these areas have unique cleanliness capabilities from Class 100 to Class 10,000. The facility is also designed to provide differing temperature and humidity controls, as required, for the various areas. The balance of the microelectronics fabrication would be performed 1,282 m 2 (13,800 ft 2 ) of the Electronics Factory Mezzanine.

Interconnects. The area for this work would occupy 2,304 m 2 (24,800 ft 2 ) of the Electronics Factory Mezzanine. It would include an environmentally controlled photo-imaging area and an etching area to support flat flex cables for detonator assemblies. The remaining areas would be temperature and humidity-controlled, consistent with traditional electronics manufacturing requirements.

Table A.3.6.1-1.-- Kansas City Plant II Electronics Factory Processes and Products

Process Module	Major Processes	Product Types
Microelectronics	Vacuum deposition	Leadless chip carriers
	Plating	Thick film networks
	Screen printing	Thin film networks
	Photo lithography	Multichip modules
	Beam lead bonding	Hybrid microcircuits
	Fine wire bonding
	Soldering
	Component placement
	Hermetic sealing
	Cleaning
Interconnects	Manual soldering	Printed wiring assemblies
	Wave and drag soldering
	Auto component placement
	Component insertion
	Robotic tinning and preforming
	Cleaning
	Electrical testing
	Photo imaging	Flat flex cables
	Etching	Detonator cables and assemblies
	Laminating
	Lead titanate processing	Lightning arrestor connectors
	Manual assembly
Final assembly	Manual assembly	Nose assemblies
	Hand soldering	Radars
	Welding	Firesets
	Encapsulation	Arming, fusing, and firing assemblies
	Bonding	ECA's
	Cleaning	Programmers
	Electrical testing	Timers
		Controllers
		Trajectory sensing signal generators
		Code activated processes
KC ASI 1995a.

Joint Test Assembly/Special Electronic Assembly Factory. Security, production, and quality requirements of the joint test assembly and special electronic assembly product lines are not conducive to integration with other factory areas. Products built within the joint test assembly and special electronic assembly are primarily electronics operations and use similar or identical processes. These are bonding, cleaning, coating, encapsulation, mechanical assembly, soldering, swaging, and electrical verification.

Since the joint test assembly mission supports weapons throughout their life in the stockpile, the product lines within the joint test assembly area are somewhat insensitive to changes in weapon production requirements. As a result, reductions in the joint test assembly area would not be as dramatic as in other factory estimates. For future capacity requirements, the joint test assembly operation would be sized to produce assemblies at a rate that would support stockpile evaluation schedules currently in planning for the enduring stockpile.

The current joint test assembly production area would shrink by 33 percent to 1,644 m 2 (17,699 ft 2 ) (excluding stores and storage). The special electronics assembly manufacturing area would be reduced by 55 percent to 1,352 m 2 (14,550 ft 2 ). The joint test assembly area would be relocated to the Electronics Factory Mezzanine, while the special electronics assembly operation would be downsized in place. The estimated reduction in floorspace would primarily result from the elimination of capital equipment, testers, and tooling that are unnecessary to support the baseline workload. No special environments or highly hazardous operations would be required as a part of the production processes.

The joint test assembly operation is a job shop environment which makes use of a very limited amount of highly automated assembly, cleaning, and soldering processes. Prior to the relocation of the area, the newer products requiring automated processes would be built. At the end of that period, related test equipment and capital equipment would be moved and requalified over an 8-month period. In the interim, the labor force would be directed to build those assemblies requiring only manual soldering and cleaning techniques. Phasing production by program and process would result in a negligible increase in cost. Based on past precedent, a requalification of each product would be unnecessary since most production processes are manual and the quality of joint test assembly products is controlled primarily by the operator.

The planned special electronic assembly operation rearrangement would keep critical manufacturing equipment in place. Process requalifications would be unnecessary.

Mechanical Factory. The proposed Mechanical Factory would maintain most of the capabilities presently available with significantly reduced capacity. The factory is based on projected production rates for reservoirs, transportation safeguards division products, and a small quantity of other unscheduled production requirements. This workload exercises key factory capabilities and maintains the ability to support currently unscheduled stockpile replacement product. Total productive floor space requirement would be 20,900 m 2 (225,000 ft 2 ).

Table A.3.6.1-2.-- Kansas City Plant II Alternative Mechanical Factory Products

Area	Products
Transportation safeguards products	Safe secure trailer/safeguards transport roadworthy refurbishment
	Safe secure trailer/safeguards transport retrofit/upgrades
	Safe secure trailer decommissioning
	Escort vehicle production
	Miscellaneous trailer production/repair
Metal machining	Metal parts to support:
	Mechanical assembly
	Electrical assembly
	Joint test assembly
	Cases and structural parts (limited)
Sheet metal and support processes	Sheet metal parts to support:
	Mechanical assembly
	Electrical assembly
	Liners and housings
	Support processes:
	Plating
	Painting
	Heat treatment
Mechanical welding	Support of mechanical assembly and sheet metal
Model shop/tool support	Tool repair and emergency fabrication
	Capability for prototype and evaluation hardware
KC ASI 1995a.

Engineered Materials Factory. The Engineered Materials Factory is designed to accommodate the minimum manufacturing capabilities required to support current and anticipated weapon program needs for all nonmetallic products. Basic processing capabilities have been retained to produce the following product families: polyurethane foam supports, syntactic foams, cushions, filled polymers, secure container assemblies, desiccants and getters, nonmetallic machining, and the polymer pilot plant. The minimum complement of manufacturing equipment to produce these products was determined and each production area sized appropriately.

Current manufacturing floor space of 11,241 m 2 (121,000 ft 2 ) within the main building would be reduced by more than 34 percent to 7,350 m 2 (79,150 ft 2 ). The polymer plant, a stand-alone facility used to produce unique materials not available from commercial suppliers, would not be reduced. Individual modules are described below:

• Compounding-164 m 2 (1,767 ft 2 ): This area supports the compounding of polymeric materials for urea-filled cellular silicone cushion material and metal-filled polymers for fabrication.
• Foam molding-492 m 2 (5,300 ft 2 ): Specially formulated polyurethane materials are mixed, poured, and cured to form structural parts for component packaging.
• Pressing--2,075 m 2 (22,335 ft 2 ): This facility molds-to-size all cushion and filled polymer products. Press capacity ranges from 9 to 1,814 t (10 to 2,000 tons).
• Machining--823 m 2 (8,864 ft 2 ): This environmentally controlled temperature and humidity area provides the capability to machine all nonmetallic products to their final configuration. Fabrication of syntactic foam products is also accomplished in this area.
• Assembly--2,404 m 2 (25,881 ft 2 ): This area supports lay-up, wrapping, and impregnating capabilities to manufacture secure container assemblies. Desiccant and hydrogen getter materials are blended, formed, and assembled in this facility.
• Polymer production--1,394 m 2 (15,000 ft 2 ): This external facility provides the polymer reactor capability to blend polyurethane materials that are unavailable from commercial suppliers. This facility has the capability to repackage bulk material into smaller unit quantities for production use.

Special environmental requirements were defined for machining, foam molding, and secure container assemblies, and appropriate areas were sized within the capability footprint of each module. Special security classification needs of secure container assemblies, cushion, and filled polymers have been considered and sufficient isolation provisions have been incorporated into the new factory concept.

Outsourcing Kansas City Plant-Made Products. A key tactic of the KCP II alternative is to aggressively pursue the outsourcing of products currently manufactured within KCP. KCP currently maintains most of the manufacturing technologies required to support weapons production. Anticipated reductions in production schedules and funding will no longer support maintaining all of these technologies in-house. Outsourcing is the preferred alternative as product designs become more compatible with commercial industry capabilities. Products to be outsourced are antennas, interconnect cables, retrofit kits, filter packs, molded plastic parts, trainer hardware, voltage regulators, parachute assemblies, piezoelectric motors, junction boxes, handling equipment, TC firing sets, ready-safe switches, test gear, printed wiring boards, option select switches, trainer kits, lasers/electro-optics, and actuator assemblies.

Facilities modification to establish the KCP II configuration would take approximately 4 years. The following list describes the facility modification required to accomplish the proposed plant consolidation:

• Design and construction of standard manufacturing facilities
• Installation of modular clean rooms
• Design and construction of a fire-rated wall separating DOE from other site occupants
• Installation of heating, ventilation, and air conditioning systems and controls
• Extension of existing utility systems for chilled water, steam, sanitary, and industrial drains, and other mechanical and electrical services
• Site preparation, modification, and installation of walls and partitions, floor and ceiling finishes, security and fire protection features, and material handling equipment
• Rearrangement of existing operations and relocation of production equipment

Materials/resources consumed during KCP II construction are listed in table A.3.6.1-3. Emissions during construction/plant reduction would be negligible. The numbers of KCP II alternative construction workers required for construction/plant reduction can be found in table A.3.6.1-4.

Table A.3.6.1-3.-- Kansas City Plant II Construction/Plant Reduction Materials/Resources Requirements

Material/Resource	Total Consumption	Peak Demand
Electricity	Negligible	Negligible
Concrete (m 3 )	286
Structural steel (t)	220
Water	Negligible
KC ASI 1995a; KCP 1995a:2.

Table A.3.6.1-4.-- Kansas City Plant II Construction/Plant Reduction Construction Workers

Employees	1998 Year 1	1999 Year 2	2000 Year 3	2001 Year 4	Total
Total craftworkers	87	162	104	40	393
Construction management and support staff	15	25	18	8	46
Total Employment	102	187	122	48	459
KC ASI 1995a.

Taking the renovation and upgrade activities into account, downsizing and reconfiguring the plant for KCP II would have no impact on the utility system capacities. KCP II alternative surge operation utility requirements are shown in table A.3.6.1-5.

Table A.3.6.1-5.-- Kansas City Plant II Nonnuclear Fabrication Surge Operation Annual Utility Requirements

Utility	Consumption	Peak Demand 2
Electricity	225,000 MWh	30 MWe
Liquid fuel (L)	0
Natural gas 3 (m 3 )	18,900,000
Raw water (dry site) (L)	1,340,000,000

Table A.3.6.1-6.-- Kansas City Plant II Nonnuclear Fabrication Surge Operation Annual Chemical Requirements

Chemical	Quantity
Nitrogen
Gas (m 3)	3,270
Liquid (L)	14,900,000
Argon
Gas (m 3 )	4,830
Liquid (L)	236,000
Carbon Dioxide
Gas (m 3)	322
Liquid (L)	122,000
Hydrogen
Gas (m 3)	0.1
Helium
Gas (m 3)	883
Liquid (L)	1,650
KC ASI 1995a.

Table A.3.6.1-7.-- Kansas City Plant II Nonnuclear Fabrication Surge Operation Annual Emissions

Pollutant	Quantity (t)
Acetone	0.32
Carbon monoxide	13.17
Chromium	<0.01
Cyanide	<0.01
Ethyl benzene	0.054
Formaldehyde	<0.01
Hydrochloric acid	0.018
Isopropyl alcohol	4.44
Methanol	0.009
Methyl ethyl ketone	0.14
Methyl isobutyl ketone	0.027
Particulate matter	1.03
Perc	0.29
Sulfur dioxide	0.35
Toluene	0.59
Toluene diisocyanate	<0.01
1,1,1-Trichloroethane	0.036
Trichloroethylene	3.82
Volatile organic compounds	13.05
Xylene	0.25
KC ASI 1995a; KCP 1995a:3.

Table A.3.6.1-8.-- Kansas City Plant II Nonnuclear Fabrication Facility Waste Volumes

Category	Annual Average Volume Generated from Construction (m 3 )	Annual Volume Generated from Surge Operations (m 3 )	Annual Volume Effluent from Surge Operations (m 3 )
Low-Level 4
Liquid	None	None	None
Solid	None	None	None
Mixed Low-Level4
Liquid	None	None	None
Solid	None	None	None
Hazardous
Liquid	None	60	60
Solid	786	61	61
Nonhazardous (Sanitary)
Liquid	None	570,000	570,000
Solid	745	310	310
Nonhazardous (Other)
Liquid	None	223,900	223,900
Solid	None	11,500	11,500

Table A.3.6.1-8 presents the estimated annual waste volumes from the nonnuclear fabrication plant at Kansas City during construction and surge operations. Solid and liquid wastestreams are routed to the waste management system. Solid wastes would be characterized and segregated into hazardous or nonhazardous wastes, then treated to a form suitable for offsite disposal. Liquid wastes would be treated onsite to reduce hazardous/toxic elements before discharge or transport. All fire sprinkler water discharged in process areas is contained and treated as process wastewater, when required.

Transuranic Waste. The Nonnuclear Fabrication Facility at KCP would not generate any TRU waste.

Low-Level Waste. The Nonnuclear Fabrication Facility at KCP would not routinely generate any LLW.

Mixed Low-Level Waste. The Nonnuclear Fabrication Facility at KCP would not routinely generate any mixed LLW.

Hazardous Waste. Hazardous wastes generated by the Nonnuclear Fabrication Facility at KCP would consist of acidic and alkaline liquids, solvents, and oils and coolants. Processes such as plating, etching, electronic assembly, metals and plastics machining and forming, and wastewater treatment are the principal generators. Liquid hazardous wastes would be collected in DOT-approved containers and sent to an onsite hazardous waste accumulation area. The hazardous waste accumulation 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. After compaction, if appropriate, the solid hazardous wastes would be packaged in DOT-approved containers and sent to a hazardous waste accumulation area for staging, characterization, and packaging prior to shipment to an offsite commercial RCRA-permitted treatment, storage, and disposal facility using DOT-certified transporters.

Nonhazardous (Sanitary) Waste. Nonhazardous waste generated at the Nonnuclear Fabrication Facility at KCP primarily consists of liquid sanitary, nonrecyclable, nonhazardous solid sanitary, and industrial wastes. Liquid sanitary wastes would be collected by sewer pipe systems from most of the support buildings and discharged directly to the Kansas City municipal sanitary sewer system. Process wastewater is sent to holding tanks for treatment and recycled, where appropriate. Process rinsewater waste streams are routed to the industrial wastewater pretreatment facility for treatment and then discharged to the Kansas City municipal sanitary sewer system.

Nonhazardous (Other) Waste. One-pass cooling water, fire sprinkler water, water from air dryers and vacuum pumps, as well as stormwater from areas of KCP would be discharged through the Blue River and Indian Creek NPDES outfalls.

A.3.6.2 Relocate to Los Alamos National Laboratory

Historically, LANL has designed nuclear weapons and has fabricated the development hardware to support the nuclear weapon design process. LANL has made a clear distinction between fabrication for production and fabrication for design agency requirements. At LANL production agency responsibilities would be separately managed. The LANL alternative would rely primarily on in-house production of nonnuclear components and services. Table A.3.6-1 shows the list of nonnuclear products and make-buy decisions. The following sections describe the nonnuclear fabrication products and processes that would be carried out at LANL.

Plastics, Detonators, and Pilot Plant Operations. Technologies currently in place at LANL, with the exception of parylene coating, large scale polymer pilot operations, cellular silicone compounding, and certain filled polymer molding, can support production of all components under consideration.

Generic descriptions of the products or processes to be transferred include inert components for high energy main charge detonators, inert components for high energy neutron generator detonators, blown and cellular silicone foams, polyurethane foams, silicone elastomer molding, composite molding, commodity material molding, filled silicone molding, and pilot scale synthesis of polymeric materials.

Due to the small scale and specialty nature of weapons components, most would be made internally. Materials that would most likely be procured include commodity molded materials. Polyurethane resin currently fabricated at the polymer pilot plant is made in relatively large lots, and, as such, may be procurable from outside vendors. In all cases, internal capability would be maintained to fabricate all materials and components. If internal capability to fabricate specialty items were lost, the technical risk of meeting scheduled or unscheduled production deadlines would be significantly increased. Additional processing capability would be required in the areas of polyurethane foam dispensing, intensive mixing, extruding and leaching of cellular silicone, flame spraying, and parylene coating. For pilot plant operations, additional processing capability would be required for large scale processing of up to 380 L (100 gal). All detonator flat cable processing capability is currently available; however, upgraded equipment would be required to better meet production requirements. High energy detonator fabrication capabilities would need to be installed.

Reservoirs and Valves. LANL has the capability for small scale fabrication for valves and reservoirs in support of R&D of new boost systems, NTS operations, and local hydrodynamic or other experimental testing. Generic descriptions of the products or processes to be transferred include the procurement, certification, and storage of all nuclear-grade materials needed by production. These materials include different alloys of stainless steel, beryllium, copper, aluminum, weld filler materials, and other specialty materials unique to boost system applications. These materials may take the form of raw billets, forging, partially machined parts, finished machine parts, subassemblies, and finished assemblies. Also included in this parts list are vendor purchased parts such as elastomer seals, metal seals, screws, and filters. Fabrication of boost systems includes the procurement of material stock, machining operations, mechanical and radiographic inspection, cleaning, welding, assembly, proof pressure testing, leak testing, volume measurement, packaging, storage, and shipment. As part of the product certification, shelf life storage units would be manufactured to represent the product and monitored throughout the stockpile life.

Facility Description. LANL occupies an area of 111,000 ha (274,000 acres) with 30 active TAs (figure A.3.6.2-1). Figures A.3.6.2-2 through A.3.6.2-5 show the detailed facility layout for project TAs. [figure A.3.6.2-3] [figure A.3.6.2-4]

The following facilities, with the specified installations/upgrades, would be used for nonnuclear production activities at LANL:

• Plastics production. TAs-16-302, -303, -304, -305, -306, and -307: New or transferred equipment would be installed in these facilities. Electrical system upgrades would be required in some of these facilities.
• Reservoir and valve production. TA-3-SM-39: Removal of existing machine tools and replacement with new or transferred machine tools would be required. No other upgrades would be necessary.
• Detonator component manufacture. TA-22-91: New or transferred equipment would be installed at this facility. Electrical systems upgrades would be required.
• Large scale pilot plant polymer synthesis. TA-16-340: New or transferred equipment would be installed at this facility. Electrical systems upgrades would be required.
• Small scale pilot plant polymer synthesis operations. TA-35-213; no additional installations or upgrades required.
• Mold storage. TA-16-332: no installations or upgrades required.

Table A.3.6.2-1 presents facility data for the nonnuclear fabrication missions at LANL.

Technical Areas-16-302, -303, -304, -305, -306, and -307. These buildings would contain the plastics production activities associated with the proposed production activities. Buildings 302, 304, and 306 are single story with equipment room basements. Buildings 303, 305, and 307 are single story. The buildings are each concrete-walled, roofed structures that currently house plastics-related production, fabrication, and storage functions. Each of the buildings is served by 480-volt power and each has existing process steam, vacuum, air, and ventilation systems required for plastics fabrication and manufacture. The proposed production activities would require that several types of new or transferred equipment (mixers, extruders, roll mills, presses, coaters, screeners, testing equipment, and quality assurance equipment) be installed in Buildings 303 through 307. Building 302 would be used for raw material storage and bonded material/product storage. Although the existing electrical power would accommodate the added equipment, power distribution panels and associated wiring would have to be upgraded in some facilities. The steam, ventilation, air, and vacuum systems would not require upgrades.

Technical Area-3-SM-39. This facility would contain the metal machining, inspection, packaging, and storage functions required for reservoir and valve production. The facility is a two-story (second floor is mezzanine), concrete-walled, roofed structure with steel beam construction. The facility was originally designed as and is currently used as a machine shop, with air ventilation systems required for metal machining. The proposed production activities would require that several types of new or transferred machine tools (lathes, mills, drills, grinders, welders, inspection/testing equipment) be installed. Although the existing electrical power would accommodate the added equipment, power distribution panels and associated wiring would have to be installed for the specific machines. Besides rearranging equipment and storage locations, no other upgrades would be required.

Technical Area-22-91. This facility would contain the inert detonator manufacture and assembly operations. The facility is a single-story, block and concrete structure with joist/concrete roof that was originally designed for detonator fabrication and assembly. The proposed production activities would require that several types of new or transferred equipment be installed. Although the existing electrical power would accommodate the added equipment, power distribution panels and associated wiring would have to be installed for the specific equipment. No other upgrades would be required.

Table A.3.6.2-1.-- Los Alamos National Laboratory Nonnuclear Facilities

Facility	Number of Stories	Total Space (m 2 )	Utilized Space 5 (m 2 )	Construction Type
TA-3-SM-39	2	10,405 6	2,323	Concrete with steel beam
TA-16-302	1	566	566	Concrete walls/roof
TA-16-304	1	566	566	Concrete walls/roof
TA-16-306	1	566	566	Concrete walls/roof
TA-16-303	1	273	273	Concrete walls/roof
TA-16-305	1	273	273	Concrete walls/roof
TA-16-307	1	273	273	Concrete walls/roof
TA-16-332	1	929	929	Steel joist/metal sheet
TA-16-340	2	2,111 6	149	Concrete walls/roof
TA-22-91	1	2,002	2,002	Concrete walls/roof
TA-35-213	3	7,880	1,125	Concrete walls/roof

Technical Area-35-213. This facility would contain the small scale plant polymer synthesis. The building is a three-story formed concrete structure with a joist/concrete roof. The proposed production activities would not require any modification or installations as all of the required equipment currently exists.

Technical Area-16-332. This facility would be used as a storage area for raw materials and/or components associated with the proposed production activities. The building is a single-story, steel-framed metal building. No upgrades or installations would be required.

Table A.3.6.2-2 presents a schedule for implementation of nonnuclear fabrication activities at LANL. Construction would consist of new or transferred equipment in existing facilities and upgrades to electrical systems within the proposed facilities. The proposed installations and modifications would occur over a 2-year period. The resources and raw materials would consist of only what would be required to install 50 pieces of equipment and to upgrade electrical systems. Materials/resources consumed during the entire construction phase are presented in table A.3.6.2-3.

Table A.3.6.2-2.-- Los Alamos National Laboratory Schedule of Activities for Nonnuclear Fabrication

Activity	Start	End
Research and development duration	1/96	1/97
Hazard/risk assessment, NEPA determination	1/96	1/98
Engineering design (conceptual, final)	1/97	1/00
Modifications/equipment installations	1/00	1/01
Mission transfer/qualification/ proof of operation	1/99	12/02
Steady-state operations	12/02
Decontamination/decom-missioning or conversion	1/30
LANL 1995c.

Table A.3.6.2-3.-- Los Alamos National Laboratory Nonnuclear Fabrication Construction/Upgrade Materials/Resources Requirements

Material/Resource	Total Consumption	Peak Demand
Electricity	105 kWh	3.8kWe
Electrical wiring (m)	762
Conduit (m)	3,050
Water (L)	9,500
LANL 1995c.

Only small quantities of nonhazardous solid and liquid wastes would be generated as a result of the equipment installation and electrical upgrade work required for the proposed activities. Table A.3.6.2-4 lists the total number of personnel that would be required to perform the installation/modification work. This includes only those actually involved with the work and does not include process development or design work. The number of employees listed are spread out over a 1-year period, and more than the listed quantity could be present at any time during the year (1.5 workers per year may consist of 3 workers for a 6-month period).

Table A.3.6.2-4.-- Los Alamos National Laboratory Nonnuclear Fabrication Construction Workers

Employees	2000	2001	Total
Total craftworkers	3.0	3.0	6
Construction (installation) management/support staff	0.25	0.25	0.5
Technical support personnel	2.0	2.0	4
Project support personnel	1.0	1.0	2
Total Employment	6.25	6.25	12.5
LANL 1995c.

It is noted that all of the facilities associated with the proposed activities are heated either by steam or by central gas heating systems. At the TA-16 facilities, steam is also used as a process heating method and for process washdown/cleaning activities.

Table A.3.6.2-5.-- Los Alamos National Laboratory Nonnuclear Fabrication Surge Operation Annual Utility Requirements

Utility	Consumption	Peak Demand 7
Electricity	525 MWh	0.23 MWe
Liquid fuel	None
Natural gas	340
Steam (m 3)	95
Raw water (L)	48,300,000

Table A.3.6.2-6.-- Los Alamos National Laboratory Nonnuclear Fabrication Surge Operation Annual Chemical Requirements

Chemical	Quantity
Raw materials/chemicals used for plastics formulation	38,600
Metals for valve/reservoir/detonator production (kg)	3,020
Machine tool cutting fluids/lube oils (kg)	511
Cleaning/developing fluids for detonator assembly (kg)	2,270
LANL 1995c.

Table A.3.6.2-7.-- Los Alamos National Laboratory Nonnuclear Fabrication Surge Operation Annual Emissions

Pollutant	Quantity (t)
Carbon monoxide	0.0002
Nitrogen oxides	0.0002
Particulate matter	0.00007
Sulfur oxides	0.000003
Volatile organic compounds	0.282
LANL 1995c.

The project design considers and incorporates waste minimization and pollution prevention. 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.3.6.2-8 presents the estimated annual waste volumes from the Nonnuclear Fabrication Facility at LANL during modification activities and surge operations. Solid and liquid waste streams are routed to the waste management system. Solid wastes would be characterized and segregated into hazardous and nonhazardous wastes, then treated to a form suitable for offsite disposal or storage within the facility. Liquid wastes would be treated onsite to reduce hazardous/toxic characteristics before discharge or transport.

Transuranic Waste. The Nonnuclear Fabrication Facility at LANL would not generate any TRU waste.

Low-Level Waste. The Nonnuclear Fabrication Facility at LANL would not generate any LLW.

Table A.3.6.2-8.-- Los Alamos National Laboratory Nonnuclear Fabrication Waste Volumes

Category	Annual Average Volume Generated from Construction (m 3 )	Annual Volume Generated from Surge Operations 8 (m 3 )	Annual Volume Effluent from Surge Operations (m 3 )
Hazardous
Liquid	None	11	11
Solid	None	0.11	0.11
Nonhazardous (Sanitary)
Liquid	None	568	566 9
Solid	None	10	6 10
Nonhazardous (Other)
Liquid	5 11	25 12	None
Solid	0.04	3 13	None

Hazardous Waste. Some hazardous wastes would be generated as a result of the Nonnuclear Fabrication Facility at LANL; however, no new hazardous waste streams would be generated. These wastes consist of liquid solvent wastes and solid beryllium wastes from machining operations. Liquid hazardous wastes would be collected in DOT-approved containers and sent to an onsite hazardous waste accumulation area. The hazardous waste accumulation 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. The solid hazardous wastes would be packaged in DOT-approved containers and sent to a hazardous waste accumulation area for staging, characterization, and packaging prior to shipment to an offsite commercial RCRA-permitted treatment, storage, and disposal facility using DOT-certified transporters.

Nonhazardous (Sanitary) Waste. Nonhazardous process wastes generated at the Nonnuclear Fabrication Facility at LANL consist of washdown and cleaning water containing soaps and other cleaning agents. These wastes would be discharged to the sanitary waste systems. Solid nonhazardous plastics waste and wastewater sewage sludge is disposed of in offsite industrial and sanitary landfills.

Nonhazardous (Other) Waste. Liquid nonhazardous wastes such as spent machine tool cutting fluids and spent lubricating oils will either be recycled or disposed of onsite or offsite by the LANL Waste Management Group. Solid nonhazardous wastes such as excess electrical wire, resins, and molds would also be generated. This waste would be salvaged, recycled, or disposed of offsite.

A.3.6.3 Relocate to Lawrence Livermore National Laboratory

Nonnuclear fabrication at LLNL would include production or procurement of all plastic components, polymers, and composite parts. Nearly all processes are currently, or have been, in operation at LLNL on the same scale as needed for the nonnuclear fabrication mission. The nonnuclear fabrication mission would be accomplished within 15 departments listed in table A.3.6.3-1.

Table A.3.6.3-1.-- Lawrence Livermore National Laboratory Existing Nonnuclear Fabrication Departments

Department Number	Function
1	Compression molding
2	Transfer molding
3A	Cellular silicone foam
3B	Brown silicone foam
4	Injection molding
5	Polyurethane foam molding
6	Casting and encapsulation
7	Machining
8	Composite fabrication
9	Repackaging
10	Polymer synthesis
11	Receiving
12	Packaging/shipping
13	Document control
14	Quality control
15	In-process material handling
LLNL 1995f.

Departments 1, 2, 3B, 4, 6, 7, 8, and 9 currently exist in dedicated facilities within the B231 complex at LLNL. Equipment for Department 5 is available but would be relocated to B131 in an existing low-relative-humidity operations area. Relative-humidity-sensitive and precision machining operations would also be located in this area. Department 3A would most likely be a scaled down version of the existing process and would be located in area B231. Department 10 would be an entirely new process which would be located in B232. Large scale storage of incoming and finished product would be accomplished in B131 adjacent to the Department 5 facility. Receiving inspections would be accomplished in B223. Finished product packaging and short-term storage would be in B227. In-process storage would be in the high bay area on B231. Support offices and in-process quality control would also be located in B231.

The process/products included in the LLNL nonnuclear fabrication alternative are transfer molded parts, compression molded parts, injection molded parts, machined plastic parts, silicone cushion (all types), syntactic components, filled polymers, and polymer synthesis.

This alternative covers processes for fabrication of nearly all plastic nonnuclear components needed to meet nonnuclear fabrication requirements. There are a few components that can be obtained more cost effectively through procurement. Some very specialized plastic film and tubing parts for certain assemblies may more effectively be produced or procured by the agency producing the assembly. Synthesis of basic polymers is included to provide raw materials that are not commercially available.

Compression Molding. The compression molding process would be used to produce filled and unfilled, elastomeric or rigid, thermosetting components.

Existing roll mill capacity would be sufficient for all products except cellular silicone. Currently ceramic rolls are used for high purity instead of beryllium oxide rolls utilized at KCP. The beryllium oxide rolls would have to be transferred or a modification made to the process specifications to allow for other materials. An intermediate size roll mill and Banbury mixer for use with cellular silicone are included in capital equipment. Scales, preform cutting, and in-process storage are available.

The facility is capable of utilizing integrally heated or platen heated tools. Thus, existing tooling should be sufficient in all cases. Tooling would be stored in the B231 complex in the 1300 Wing.

There is very little transfer molding involved in this alternative. Diallyl phthalate electronic components would be procured by the agency needing the components. However, the capability would exist within the production facility.

Preforming would be done on existing compression or transfer presses located in Department 2. The dielectric heater would be transferred from the production agency or purchased new. Post cure can be accomplished in the current oven capacity at the facility. In-process trim and inspection would be accomplished in the same area used for compression molded parts. Overflow inspection capability would exist in room 1240.

Cellular Silicone Compounding. The current production process for cellular silicone compounding could either be scaled down to a more appropriate size or the equipment could be transferred from the current production agency. The most economical approach would be to scale this process down to a much smaller batch size. Similar parts were made 10 years ago in the existing equipment at LLNL. This equipment includes the Banbury mixer, compounding roll mills, and sheeting roll mills. Production levels dictate an equipment size in-between those at LLNL and KCP. The current proposal allows for scaling down the process; however, there is an area set aside in the B231 high bay for installation of KCP equipment. Another option would be to transfer the production agency equipment to LLNL. In that case, the compounding operations would be installed in the high bay of B231 in place of existing temporary structures.

The urea screening operation either would be transferred from the production agency or a new system of smaller capacity would be installed at LLNL. This equipment would be scheduled for B231, in a dedicated area in either case. Washing and drying operations would be located in B231 in a newly enclosed area in Wing 1200. Two washers would be transferred from KCP. A reverse osmosis water system would be installed in B232 and piped to the 1200 Wing of B231. A new drying oven would be purchased. Molding operations would be conducted in the compression molding department.

Blown Silicone Foam Molding. The current operation for blown silicone foam molding in department 3B utilizes equipment in the compression molding department. There is some ancillary equipment in place that is functionally identical to that used at KCP.

Injection Molding. The installed injection molding (Department 4) capacity at LLNL includes machines of up to 260-g (9-ounce) and 100-t (110-ton) capacity. The capability at KCP includes machines of this size and also 400, 740, 790, and 2,270 g (14, 26, 28, and 80 ounces). The need for this larger equipment would be evaluated as the requirement warranted. The machines at LLNL are in excellent condition. The 100-t (110-ton) machine at LLNL utilizes dedicated computer control. This feature is very useful in a production environment when a variety of products are involved because of the rapid, error free setting of machine variables from stored programs. Large polymethylpentene blanks are currently made at KCP using the 2,270-g (80-ounce) injection molding machine in a specialized process that is somewhat similar to compression injection but on a very large scale. This process could be sent to an outside vendor if a change in grade of material could be approved. This would be the option of choice. However, there are two other options: install the 2,270-g (80-ounce) machine in the B231 high bay adjacent to existing injection molding facilities or qualify the process currently in use at LLNL for the production of large polymethylpentene castings.

Polyurethane Foam Molding. LLNL currently operates three machines in Department 5 that can be utilized for the polyurethane foam molding process. One is a resin transfer molding unit that can be modified for foam. This machine is extremely versatile and would be the machine of choice for most production.

This process would be located in Wings 1300 and 1400 of B131, less than 100 m ( 328 ft) from the Central Process Area in B231. This is the location of preference since 10 percent relative humidity control is installed and operational. Foam and other relative humidity sensitive and precision machining operations would be collocated in the same wing. Much of that machining capacity is already installed. Existing tooling could be used in all cases. Tooling storage would be in an adjacent storage area.

Casting and encapsulation. Casting and encapsulation is a routine operation in the current Department 6 facility, and no significant changes are anticipated. Vacuum/pressure encapsulators are available. Existing tooling should be adequate in all cases. Tooling storage would be similar to that for compression molding.

Machining. Machining operations would be conducted in Department 7 in the B231 Machine Facility in Wing 1500. Composite machining would occur in Room 1019, B231. This room is currently dedicated to this type of machining and has the proper tooling, including diamond tools, and the proper high speed machining heads. HEPA filtration and high velocity dust extraction is built into this facility.

Low relative humidity and precision machining would occur in B131.