18 September 2013Boone, CO

FINAL – OPSEC/ITAR REVIEW - 12 SEP 2013

Citizens’ Advisory Commission Meeting

Operational Readiness Review (ORR) The Road to Initial Agent Operations

Presented by: Paul Dent, PCAPP ORR Manager

Timeline - ORR

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Briefing Objective

Provide an overview of the PCAPP Operational Readiness Review (ORR) process and the incremental approach to be used to assess readiness for Initial Agent Operations (IAO)

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Operational Readiness Review Overview

The ORR process is used to validate that PCAPP “plant, paper, and people” collectively meet the required criteria to allow a new operation to begin.

PCAPP ORR process is led by the system-contractor (SC) to support a declaration of readiness.

ACWA provides ORR oversight; independent validation is used to support the SC’s declaration of readiness.

Stakeholders may observe the ORR process.

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People

PlantPaper

Achieve Readiness – by Responsible Managers

Validate Readiness – by ORR Board

Declare Readiness – by Project Manager

Accept Readiness – by ACWA

ORR Overview

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People Readiness

Paper Readiness

Plant Readiness

Ready for Agent Operations

Government Review and Concurrence

SPM ACWA concurrencewith BNI ORR

BPT declares readinessfor agent operations

The ORR process validates that PCAPP plant, paper, and people collectively meet the required

criteria to allow agent-operations to begin.

System Start-up, Testing, and Turnover to Operations

DevelopSystem Start-up, Testing, and Turnover to Operations

Approve Permits, Plans, Procedures,

Classes

Certify, Drill, Optimize

IOD

Crite

ria, A

ffida

vits

, CRA

Ds, F

indi

ngs,

Clos

eout

s

Train HireDevelop

Integrated OperationsDemonstration (IOD)

Readiness

The goal of Systemization is to achieve readiness for Initial Agent Operations.

Stages of an ORR

Planning: Define Scope of ORR in an Implementing Procedure using Performance

Objectives and Criteria (PO&Cs) Identify Responsible Managers and pool of Independent Reviewers Charter the ORR Board

Execution: Responsible Managers define how readiness is achieved using affidavits Independent reviewers conduct interviews, review documents, and observe

field work to assess the degree of compliance with readiness requirements ORR Board reviews documentation to assess readiness “Punchlist items” are defined as findings and tracked to closure Usually ends after an Integrated Operations Demonstration (IOD) to

exercise and assess plant, paper, and people functioning together

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ORR Planning

PO&Cs are requirements for readiness, defined in cascading levels of detail

Derived from contract defined requirements, such as:• Safety/environmental regulations (e.g., OSHA, RCRA, CAA)

• Army regulations and guidance (e.g., AR 50-6, DA PAM 385-61)

• Industry standards (e.g., ANSI, NFPA)

Developed by responsible managers and the ORR Team

Reviewed by ACWA and stakeholders

Approved by issuance of an ORR implementing procedure

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Criterion 1.1

Criterion 1.2

Criterion 1.3

Criterion 1.4

Criterion 1.5

Criterion 1.6

Criterion 2.1

Criterion 2.2

Criterion 2.3

Criterion 2.4

Functional Area (by Responsible Manager)

Performance Objective 1.0

Performance Objective 2.0

Develop Performance Objectives and Criteria (PO&Cs)

Level 3 CriterionA specific statement describing an element of readiness within a performance objective (e.g., “A process is in place to notify key treaty personnel when applying or removing treaty seals, to track treaty sealing information, and protocols are established for treaty seal application and removal. Treaty seals have been applied to the agreed upon doors/areas/equipment.“)

Level 2 Performance Objectives (POs)A statement describing an aspect or area of readinesswithin a functional area (e.g., “Treaty requirements are in place for initial agent operations.“)

Level 1 Functional AreasTypically follow organizational lines (e.g., Safety, Lab)

ORR Overview – Process

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Board accepts affidavit?

NO

Responsible manager completes affidavit

Board reviews CRAD

Finding Categories Assigned by Board

Responsible manager completes actions required to correct

deficiency

Finding closed?NO

YES

IR evaluates criteriaand affidavit

Board chartered

Functional areas defined

Board reviewsaffidavit

Requirements defined

Independent reviewers (IRs) selected

IR completes CRADAffidavit and CRAD packages finalized, archived for report

Board accepts CRAD?

YES

NO

YES

Criterion met?

Finding(s) generated or approved to address

identified deficiencies

NO

Readiness Planning Stage

Board reviews corrective actions and

finding closure document

All criteria met, all CAT1 findings closed, final report completed

Dec

lara

tion

of R

eadi

ness

Finding closure approved by the Board, archived

for report

YES

LORR Execution Stage (Single Criterion)

Finding categories assigned by ORR Board

Performance objectives & criteria developed

Key Readiness Milestones

COMPLETE

IN PROGRESS

NOT STARTED

2. Lab Stock A Dilute Agent Operations

1. Boiler Ignition Readiness

13. Readiness Declared for Initial Agent Operations

Major M

ilestones fo

r Incre

mental RAs L

eading to In

itial Agent O

perations

14. ACWA Readiness Endorsement

6. ERB Provisional Operations

5. Yard Provisional Operations

7. BTA Provisional Operations

8. APB Provisional Operations

10. Soft Plant Lockdown

12. Integrated Operations Demonstrations

11. Environmental Readiness

9. Crew Certifications

4. Agent Controls Readiness

1

8

9

6

5

4

2

7

11

12

13

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33. Training Facility Integrated Assessment

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ACRONYMS:

APB – Agent Processing Building

BTA – Biotreatment Area

ERB – Enhanced Reconfiguration Bldg.

IAO – Initial Agent Operations

ORR – Operational Readiness Review

RA – Readiness Assessment

Major Milestones for Initial Agent Operations (IAO) Readiness

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Initial Agent Operations (IAO) Criteria

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by Functional Area

Number of criteria subject to change through implementing procedure review process

Integrated Operations Demonstrations (IOD)

Near the end of ORR, integrated operations demonstrations (IODs) are performed to validate that people, plant, and paper are ready for initial agent operations.

IODs include exercises such as: Receive, transfer, and process munitions

Handle, transfer, and process simulated agent-contaminated waste

Perform toxic area entries; perform maintenance for critical equipment

Sample tanks/perform laboratory analysis

Perform treaty sampling

Respond to contingencies or equipment upset conditions

Upon successful completion of IODs and closeout of required Findings, SC will declare readiness.

Upon receipt of an endorsement of readiness by ACWA, PCAPP will be poised to begin Pilot Testing.

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QUESTIONS

An Overview of PCAPP’s Pilot Demonstration Testing

Presented by: Kim Jackson, PCAPP Operations Manager & George Lecakes, PCAPP Chief Scientist

Timeline – Pilot Test Demonstration

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PCAPP Pilot Test DemonstrationObjectives1

1. Demonstrate agent removal, agent neutralization, and related agent neutralization sampling and analysis.

2. Demonstrate munition body treatment (washout, thermal treatment).

3. Establish bounding operating ranges and set points for operating parameters critical to agent removal, munition body treatment, and agent neutralization operations.

4. Demonstrate energetics removal and establish bounding operating ranges and set points for operating parameters critical to ensuring energetics removal operations.

5. Validate monitoring protocols for all equipment and work areas in the ERB and APB.

6. Validate treatment and monitoring protocols for disposition of dunnage, energetics, and miscellaneous waste (e.g., OPP, PME, SDU, Autoclave as designated for each waste material)

7. Demonstrate removal of TDG and document removal of other organic compounds from hydrolysate waste stream (e.g., ICB, BRS)

8. Demonstrate processing systems can operate at a ramp rate that safely supports the operating schedule.

1DERIVED FROM THE TEST CONCEPT PLAN, APPENDIX D; 3/21/2011

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PCAPP Pilot Test DemonstrationObjectives (CONT.)

9. Demonstrate integrated facility operations with agent and energetics to verify the following:

a) Compliance with safety requirementsb) Compliance with surety and security requirements c) Integrated system operabilityd) Plant-wide operations while remaining within emissions requirements (as stated in the Multiple

Pathway Health Risk Assessment Report for PCAPP Project [MPHRA], 24852-RD-3RC-000-V0004)e) Handling and movement of munitions for current munitions campaignf) Sampling and analysis protocols (e.g., agent, hydrolysate, brine, emissions)g) Decontamination operationsh) Ability to perform routine and selected off-normal maintenance activitiesi) Waste handling and disposition, including dust and odor control

10.Validate agent monitoring protocols for detecting agent (e.g., MINICAMS, Depot Area Air Monitoring System [DAAMS]).

11.Demonstrate off-gas treatment performance. This will include demonstration of agent destruction and removal at the OTS and AFA, odor control at the BTA.

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Finally, the collection of site-wide emissions data for finalization of the RCRA Part B Permit

Block 1 – Systems, Fit, and Function

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Systems: Block 1 – Baseline and Enhanced Reconfiguration includes OPP Monitoring, Munitions Monitoring Table (Baseline Reconfiguration), PMD Operations and MME/PME Operations

Fit: After transport and receipt of munitions at PCAPP and prior to agent removal activities

Function: Prepares munitions for access and removal of agent by separating packing material (e.g., wooden pallets, strapping, boxes) and energetics/miscellaneous parts from the munitions bodies

Explosion ContainmentRoom

MWS

MTU

Block 2 – Systems, Fit, and Function

Systems: Block 2 – Munitions Body Treatment includes Munitions Washout System (MWS) and Munitions Treatment Unit (MTU)

Fit: After Baseline and Enhanced Reconfiguration and prior to Agent Collection and Neutralization

Function: Drains and washes agent from energetics-free munitions bodies and thermally treats munitions bodies to Clean Unrestricted, Releasable to the General Population (Clean Unrestricted)

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Block 3 – Systems, Fit, and Function

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Systems: Block 3 – Agent Collection and Neutralization includes the Agent Water Separators, Wash Water Holding Tanks, Agent Hydrolyzers, Hydrolysate Hold Tanks and 30-Day Storage Tanks

Fit: After Agent Collection and prior to Bio-Treatment of the cleared hydrolysate

Function: Separates the MWS agent drained and rinse water, hydrolyzes the mustard agent, and verifies destruction prior to treatment in the Immobilized Cell Bio Reactors

Block 4 – Systems, Fit, and Function

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Systems: Block 4 – Hydrolysate Treatment and Water Recovery includes the Bio-Treatment System, Water Recovery System (Brine Concentrate Feed Tanks), and the Brine Reduction System plus associated off-gas treatment units

Fit: After agent neutralization and clearing in Block 3 and prior to process water recycle or to off-site shipment of secondary wastes (salt cake / bio sludge)

Function: Removes thiodiglycol (TDG) and other organics through biodegradation, recovers process water, de-waters sludge for disposal and treats off-gasses for discharge.

Block 5 – Systems, Fit, and Function

Systems: Block 5 – Supplemental Decon Units and Autoclave

Fit: Receives materials, equipment, components, and waste materials from other process areas including ERB, APB, ESM, MSM.

Function: Reduces agent contamination levels to acceptable levels for either reuse and/or off-site disposal

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Block 6 – Systems, Fit, and Function

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Systems: Block 6 – Off-gas treatment system including thermal oxidizer and scrubbers, the agent filtration area (including particulate & HEPA filtration, granulated activated carbon and sulfur impregnated carbon) and the AFA stack

Fit: Receives process off-gas from the OTS and HVAC exhaust from ERB and APB ventilation systems

Function: Treat process off-gasses and HVAC exhaust from engineering controlled spaces to remove agent and other COC’s to prescribed levels before releasing to the atmosphere.

Process Layout by Blocks

PCAPP PROCESS DIAGRAM

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EDT REMOVED FROM PCAPP SCOPECONTAMINATED ENERGETICS AND IN-PROCESS

LEAKERS & REJECTS SENT TO G-BLOCK FOR SUBSEQUENT PROCESSING IN A GOVERNMENT

SYSTEM

Test Sequence

Pilot Testing (155mm) Block 1 Block 2 Block 3 Block 4 Block 5 Block 6

Changeover Testing 105mm Campaign 4.2in Campaign

• Testing ≡ to define optimized operating parameters

• Ramp-up ≡ capability of personnel and equipment to sustain operations

• Demonstration ≡ capability of each process system within the facility to process munitions for 4-hour periods per shift

Block 1 – Munitions Receipt and Enhanced Reconfiguration is to support the testing, ramp-up and demonstration of the other systems within Blocks 2, 3, 4 and 6.Block 5 – Secondary Waste Treatment

OperatingPermit

INTEGRATED FACILITY DEMONSTRATION TEST

• Emissions Sampling

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QUESTIONS