Concept Design Criteria for Standard Chemical Maintenance Facility

17 Concept Design Criteria for Standard Chemical Maintenance Facility

Downloaded by UNIV OF MASSACHUSETTS AMHERST on May 29, 2018 | https://pubs.acs.org Publication Date: April 6, 1979 | doi: 10.1021/bk-1979-0096.ch017

JAMES P. HENDRICKSON DARCOM Ammunition Center, SARAC-DEV, Savanna, IL 61074

Toxic chemical munitions, as well as other munitions within the stockpile, require periodic surveillance together with care and preservation, to be maintained i n a serviceable and issuable condition. TASKING: With limited facilities currently available f o r chemical maintenance, the DARCOM Ammunition Center, Savanna, I L , at the direction of the US Army Materiel Development and Readiness Command, was tasked to develop a concept design f o r a Standard Maintenance Facility f o r Toxic Chemical Munitions. The transportation r e s t r i c t i o n s prohibiting the movement o f toxic chemical munitions together with establishing that most maintenance and surveillance requirements are typically the same at storage i n s t a l l a t i o n s , resulted i n developing a standard modular facility design which could be sited at more than one installation. FACILITY OBJECTIVES: The primary objective and approach i n developing a total functional facility was (Figure 1) to provide a safe and secure environment i n which maintenance, preservation, and packaging, together with surveillance and assembly of chemical munitions, could be performed i n an e f f i c i e n t and productive manner. Facility design criteria was developed based on a variety of considerations, that would both satisfy operational and processing requirements, and comply with safety, security, and surety regulatory guidance. It i s important to note that demilitarization of chemical munitions was not considered as a requirement f o r this facility.

This chapter not subject to U.S. copyright. Published 1979 American Chemical Society

Scott; Toxic Chemical and Explosives Facilities ACS Symposium Series; American Chemical Society: Washington, DC, 1979.


Figure 1.

Standard chemical maintenance facility. Artist's concept,

DARCOM A m m u n i t i o n Center


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FACTORS INFLUENCING DESIGN: M a j o r f a c t o r s i n f l u e n c i n g d e s i g n ( F i g u r e 2) were i d e n t i f i e d as: regulatory c r i t e r i a , operational c a p a b i l i t i e s , current state of the a r t , and agent c r i t e r i a .


REGULATORY CRITERIA: R e g u l a t o r y c r i t e r i a a s p r o v i d e d i n t h e DARCOM S a f e t y M a n u a l , DARCOM S a f e t y R e g u l a t i o n s f o r C h e m i c a l A g e n t s , DOD Ammunition a n d S a f e t y S t a n d a r d s a n d t h e Army C h e m i c a l S u r e t y P r o g r a m were f o u n d to have a s i g n i f i c a n t i m p a c t on f a c i l i t y d e s i g n . I t s h o u l d be n o t e d t h a t r e g u l a t o r y a n d e n v i r o n m e n t a l g u i d a n c e was f o u n d p r i m a r i l y p e r t i n e n t t o s t o r a g e a c t i v i t i e s o r d e m i l i t a r i z a t i o n o p e r a t i o n s with l i m i t e d guidance r e l e v a n t t o maintenance operations. The S a f e t y Manual AMCR 385-100 p r e s c r i b e s g e n e r a l s a f e t y r u l e s f o r t h e US Army M a t e r i e l Command i n c l u d i n g t h o s e r e l e v a n t t o f a c i l i t y c o n s t r u c t i o n f o r e x p l o s i v e m a t e r i e l o p e r a t i o n s and storage requirements, personal p r o t e c t i v e c l o t h i n g and equipment t o g e t h e r with quantity distance standards o f e x p l o s i v e s . S a f e t y R e g u l a t i o n s f o r C h e m i c a l A g e n t s a s c o v e r e d i n DARCOM-R 385-102 a n d AMCR 385-31 e s t a b l i s h e s minimum s a f e t y c r i t e r i a f o r use i n p r o c e s s i n g , h a n d l i n g , s t o r a g e , t r a n s p o r t a t i o n , d i s p o s a l and d e c o n t a m i n a t i o n o f a g e n t s GB, VX, H, HD, a n d HT. T h e s e r e g u l a t i o n s a l s o p r o v i d e more s p e c i f i c g u i d a n c e r e l e v a n t to d i s a s s e m b l y a n d remote o p e r a t i o n s , t o g e t h e r w i t h many s p e c i f i c s for personnel p r o t e c t i o n as a i r monitoring, p r o t e c t i v e c l o t h i n g , showers, and communications. The requirements are a l s o i d e n t i f i e d f o r v e n t i l a t i o n a n d f i l t e r i n g o f e x h a u s t a i r t o i n s u r e no d i s charge o r escape o f agent t o the atmosphere. The DOD Ammunition a n d E x p l o s i v e s S a f e t y S t a n d a r d s DOD 5154.4S d e s c r i b e s s t a n d a r d s a p p l y i n g t o combined t o x i c c h e m i c a l a n d e x p l o s i v e h a z a r d s t o a maximum c r e d i b l e e v e n t a n d i t s e f f e c t on h a z a r d zone d i s t a n c e c a l c u l a t i o n s . A l s o w i t h i n t h e s t a n d a r d s a r e f o u n d safety c r i t e r i a r e l a t i n g t o s e l e c t i o n o f the type o f o p e r a t i o n a l containment r e q u i r e d , t o t a l versus vapor containment. The C h e m i c a l S u r e t y P r o g r a m R e g u l a t i o n AR 50-6 p r e s c r i b e s p r o c e d u r e s f o r t h e s a f e , s e c u r e a n d r e l i a b l e l i f e c y c l e management o f chemical agents and m u n i t i o n s . The chemical s u r e t y program i n c l u d e s both p h y s i c a l and s e c u r i t y d e s i g n requirements f o r chemical security structures. OPERATIONAL C A P A B I L I T I E S : F a c i l i t y o p e r a t i o n a l c a p a b i l i t i e s a n d r e q u i r e m e n t s were e s t a b l i s h e d with review o f the chemical munitions i n v e n t o r y i d e n t i f y i n g both c u r r e n t and f u t u r e maintenance r e q u i r e m e n t s . In i d e n t i f y i n g o p e r a t i o n a l c r i t e r i a , p r o c e s s f l o w s were d e v e l oped f o r e a c h i t e m t o be p r o c e s s e d . T y p i c a l l y , p r o c e s s f l o w s f o l -



D A R C O M A m m u n i t i o n Center

Figure 2.

Standard chemical maintenance facility. Factors affecting design.



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lowed much t h e same p a t t e r n f o r t h e m a j o r i t y o f t h e i t e m s . P r o c e s s f l o w c h a r t s f u r t h e r i d e n t i f i e d both s p e c i f i c a n d u nique o p e r a t i o n a l and equipment requirements o f each item f o r r e c e i v i n g , u n p a c k i n g , removal o f e x p l o s i v e c o m p o n e n t s , c l e a n i n g , and r e c o a t i n g o f i n t e r i o r s u r f a c e s , a b r a s i v e c l e a n i n g , a n d r e p a i n t i n g o f e x t e r i o r s u r f a c e s . T h i s was f o l l o w e d b y t h e r e a s s e m bly o f e x p l o s i v e components, r e p a c k i n g , and s h i p p i n g . O p e r a t i o n a l l a y o u t s were d e v e l o p e d p r o v i d i n g p h y s i c a l c a p a b i l i t i e s t o accommodate t h o s e r e q u i r e m e n t s a s d e f i n e d by t h e process f l o w c h a r t s . O p e r a t i o n a l l a y o u t s i d e n t i f i e d both space r e q u i r e m e n t s a n d r e q u i r e m e n t s f o r Ammunition P e c u l i a r E q u i p m e n t ( A P E ) , t o meet i n d i v i d u a l i t e m c o n f i g u r a t i o n s . In d e v e l o p i n g c o n c e p t u a l d e s i g n s f o r p r o c e s s e q u i p m e n t , i t s h o u l d be n o t e d e v e r y e f f o r t was t a k e n t o p r o t e c t w o r k e r s f r o m agent exposure. Operational philosophy d i c t a t e d that a l l operations i n v o l v i n g t h e o p e n i n g o r d i s a s s e m b l i n g o f m u n i t i o n s , which c o u l d r e l e a s e o r e x p o s e a g e n t v a p o r , would be p e r f o r m e d r e m o t e l y w i t h i n a v a p o r c o n t a i n m e n t chamber. P r i o r t o removal o f i t e m s f r o m v a p o r c o n t a i n m e n t c h a m b e r s , t h e y w o u l d be m o n i t o r e d a n d v e r i f i e d f r e e o f agent. F o l l o w i n g t h e o p e r a t i o n a l p h i l o s o p h y a s d e s c r i b e d , would p r o vide a safe working environment r e q u i r i n g only Level D o r E prot e c t i v e c l o t h i n g ( e x p l o s i v e h a n d l e r s c o v e r a l l s w i t h a s l u n g mask) (Figure 3). The f a c i l i t y r e q u i r e m e n t s f o r b o t h s e r v i c e a n d s u p p o r t e l e m e n t s , a s u t i l i t y a n d e n v i r o n m e n t a l systems t o g e t h e r w i t h t h e p e r s o n n e l s u p p o r t a r e a (change h o u s e ) , c h e m i c a l l a b o r a t o r y and s u r v e i l l a n c e a r e a were i d e n t i f i e d a n d i n c l u d e d w i t h i n t h e f r a m e work o f t h e d e s i g n . CURRENT STATE OF THE ART: The c u r r e n t s t a t e o f t h e a r t i n terms o f e q u i p m e n t and s u p p o r t m e a s u r e s h a d a s i g n i f i c a n t e f f e c t on f a c i l i t y d e s i g n . O f m a j o r i m p o r t a n c e was t h e a v a i l a b i l i t y o f a g e n t m o n i t o r i n g a n d d e t e c t i o n d e v i c e s , p r o t e c t i v e uniforms f o r personnel, and acceptable exhaust a i r f i l t e r s , together with the c a p a b i l i t y t o handle d i f f e r e n t t y p e s o f decon s o l u t i o n s . A g e n t e x p o s u r e l i m i t s a s e s t a b l i s h e d b y t h e Army Surgeon General ( F i g u r e 4) f o r unprotected p e r s o n n e l , d i c t a t e d the r e q u i r e ment f o r m o n i t o r i n g a n d d e t e c t i o n systems w i t h a f a s t r e s p o n s e time. The use o f t h e r e a l t i m e m o n i t o r (RTM) w i t h l o w l e v e l s e n s i t i v i t y c a p a b i l i t y (0.0001 mg/m f o r GB) a n d r e s p o n s e t i m e o f t e n m i n u t e s t o g e t h e r w i t h t h e M-8 A l a r m w i t h a h i g h e r l e v e l s e n s i t i v i t y (0.2 mg/m f o r GB) a n d r e s p o n s e t i m e o f o n e m i n u t e a r e p l a n n e d f o r use w i t h i n t h e f a c i l i t y . The r e q u i r e m e n t f o r use o f L e v e l A c l o t h i n g i s a n t i c i p a t e d t o be a t v e r y i n f r e q u e n t i n t e r v a l s , p r i m a r i l y , f o r h a n d l i n g o f l e a k 3

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Figure 3.

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Unprotected personnel exposure limits. Production worker exposure levels.



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e r s d i s c o v e r e d on t h e l i n e a n d f o r a r e a d e c o n t a m i n a t i o n . To p r o v i d e personnel with both i n c r e a s e d agent p r o t e c t i o n , m o b i l i t y , and c o m f o r t , t h e u s e o f t h e new d i s p o s a b l e p r o t e c t i v e ensemble (DPE S u i t ) ( F i g u r e s 5, 6, 7, 8, a n d 9) d e v e l o p e d f o r c h e m i c a l d e m i l i s planned f o r use. At present, a i r f i l t e r s capable o f meeting c u r r e n t p o l l u t i o n a b a t e m e n t r e q u i r e m e n t s a r e l i m i t e d t o c h a r c o a l o r p a c k e d column s c r u b b e r s . These f i l t e r s are bulky and expensive, and r e q u i r e c o n t i n u a l m a i n t e n a n c e t o meet o p e r a t i o n a l r e q u i r e m e n t s . I n a d d i t i o n , problems e x i s t w i t h the d i s p o s a l o f spent c h a r c o a l and b y p r o d u c t s f r o m t h e packed column s c r u b b e r s . AGENT CRITERIA: M a i n t e n a n c e o p e r a t i o n s i n v o l v e d w i t h i t e m s c o n t a i n i n g an a gent, present the p o t e n t i a l use o f decontamination s o l u t i o n s . These s o l u t i o n s are h i g h l y c o r r o s i v e and present h a n d l i n g , mixing, and s t o r a g e p r o b l e m s . T h e r e i s no one s o l u t i o n t h a t can be u t i l i z e d f o r t h e d e c o n t a m i n a t i o n o f a l l a g e n t s . T h e decon s o l u t i o n s a r e n o t c o m p a t i b l e w i t h e a c h o t h e r a n d r e q u i r e methods o f a s s u r i n g t h e p r o p e r decon s o l u t i o n i s a v a i l a b l e f o r t h e commodity b e i n g worked. The c h e m i c a l a g e n t s a l s o d i c t a t e t h e r e q u i r e m e n t f o r t h e u s e o f n o n - p o r o u s c o n s t r u c t i o n m a t e r i a l s , t o g e t h e r w i t h epoxy c o a t i n g s f o r the f l o o r and w a l l s o f o p e r a t i o n a l bays. O p e r a t i o n a l equipment with a p o t e n t i a l f o r agent exposure, r e q u i r e s a design capable o f decontamination and r e p a i r . FACILITY DESIGN: The f a c i l i t y d e s i g n c o n c e p t a s d e v e l o p e d , p r o v i d e s an o p e r a t i o n a l c a p a b i l i t y which s a t i s f i e s both p r o c e s s i n g and r e g u l a t o r y requirements as i d e n t i f i e d . An a r t i s t ' s c o n c e p t o f t h e c o m p l e t e d f a c i l i t y a s shown ( F i g u r e 10) c o n t a i n s f o u r m a j o r a r e a s . The p e r s o n n e l s u p p o r t a r e a , p r i m a r i l y a change house a n d t h e p e r s o n n e l c o n t r o l c e n t e r , i s c o n n e c t e d t o t h e main b u i l d i n g by a c o v e r e d walkway. The s e r v i c e a n d s u p p o r t a r e a , c e n t r a l l y l o c a t e d i n t h e main b u i l d i n g , p r o v i d e s f o r o p e r a t i o n a l c o n t r o l and support f u n c t i o n s such a s : s u r v e i l l a n c e , d e c o n t a m i n a t i o n f a c i l i t i e s , u t i l i t y a n d e n v i r o n m e n t a l systems a n d c h e m i c a l l a b o r a t o r i e s . The e x p l o s i v e w i n g c o n s i s t s o f i n d i v i d u a l o p e r a t i o n a l bays providing separation o f d i s s i m i l a r operations with explosive d i v i d i n g w a l l s , f o r the r e n o v a t i o n and maintenance o p e r a t i o n s r e q u i r i n g disassembly o r assembly o f e x p l o s i v e components. The n o n - e x p l o s i v e w i n g s u p p o r t s t h e m a i n t e n a n c e a n d r e n o v a t i o n of items not having e x p l o s i v e components. The f a c i l i t y ' s g e n e r a l a r r a n g e m e n t i s a s shown ( F i g u r e 1 1 ) . The l a y o u t shows t h e g e n e r a l c o n f i g u r a t i o n o f t h e main b u i l d i n g


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Figure 5.

Disposable protective ensemble (DPE suit)


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Figure 6.

Disposable protective ensemble (DTE suit)


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w i t h t h e e x p l o s i v e w i n g on t h e r i g h t , t h e n o n - e x p l o s i v e w i n g on the l e f t , and the support area i n the c e n t e r .


PERSONNEL SUPPORT AREA: The p e r s o n n e l s u p p o r t a r e a l a y o u t i s a s shown ( F i g u r e 1 2 ) . The l a y o u t o f t h e change house p r o v i d e s f o r an o r d e r l y f l o w a n d c o n t r o l o f p e r s o n n e l h a v i n g a s e c u r i t y c o n t r o l p o i n t , l o c k e r room w i t h shower f a c i l i t i e s , l u n c h room, c l o t h i n g / e q u i p m e n t i s s u e , a n d storage a r e a . In a d d i t i o n , medical f a c i l i t i e s r e q u i r e d t o support a chemical o p e r a t i o n i n c l u d e an ambulance. SERVICE & SUPPORT AREA: The s e r v i c e a n d s u p p o r t a r e a a s shown ( F i g u r e 13) i s l o c a t e d i n t h e c e n t e r o f t h e main f a c i l i t y p r o v i d i n g s e r v i c e t o b o t h o p e r a t i o n a l wings. Within the s e r v i c e and support area are found a personnel s e r v i c e area which i n c l u d e s : f a c i l i t i e s f o r donning and d o f f i n g o f DPE s u i t s , o f f i c e a n d o p e r a t i o n a l c o n t r o l c e n t e r , a i r c o n d i t i o n i n g system, emergency g e n e r a t o r and a i r compressors f o r p l a n t and l i f e s u p p o r t a i r s y s t e m s . The p a i n t a r e a p r o v i d e s n e c e s s a r y e q u i p m e n t f o r r e n o v a t i o n , p a i n t i n g , a n d r e s t e n c i l l i n g o f dunnage a n d p a c k a g i n g m a t e r i a l s , s e p a r a t i n g t h i s work a r e a f r o m p o t e n t i a l l y more h a z a r d o u s a r e a s . The f a c i l i t y e q u i p m e n t s u p p o r t a n d s t o r a g e a r e a s a r e p r o v i d e d for s e r v i c e and r e p a i r o f o p e r a t i o n a l and m a t e r i a l handling equipment. The c h e m i c a l l a b o r a t o r y , d e c o n t a m i n a t i o n a n d s u r v e i l l a n c e a r e a s a s shown have a p o t e n t i a l f o r a g e n t e x p o s u r e a n d t h e r e f o r e are provided with a i r lock s e p a r a t i o n . The d r y e r room, i n c i n e r a t o r a n d d e c o n t a m i n a t i o n f a c i l i t i e s provide the c a p a b i l i t y f o r d e t o x i f i c a t i o n and d i s p o s a l o f spent decon. The p o l l u t i o n a b a t e m e n t s y s t e m s , i n c l u d i n g s c r u b b e r s a n d e l e c t r o - s t a t i c p e r c i p i t a t o r s , e t c . , a s s u r e t h a t no a g e n t o r h a z a r d o u s m a t e r i a l s are r e l e a s e d t o the atmosphere. EXPLOSIVE WING: The e x p l o s i v e w i n g i s a s shown on t h e r i g h t s i d e o f t h e g e n e r a l arrangement ( F i g u r e 11). The e x p l o s i v e w i n g u t i l i z e s i n d i v i d u a l bays f o r m a i n t e n a n c e o p e r a t i o n s t h a t can i s o l a t e an a r e a c o n t a m i n a t e d by a l e a k e r o r a g e n t s p i l l . A l t h o u g h no e x p l o s i o n s a r e e x p e c t e d t o o c c u r i n t h i s f a c i l i t y , explosive b l a s t walls are incorporated t o permit f a c i l i t y u t i l i z a t i o n d u r i n g i t s 25 y e a r l i f e e x p e c t a n c y . T h e design o f the e x p l o s i v e b l a s t w a l l s i s i n accordance with TM 5-1300 f o r 1,000 pounds o f n e t e x p l o s i v e w e i g h t (NEW) p e r b a y r e q u i r i n g a w a l l t h i c k n e s s o f 30 i n c h e s .



Figure 12.

Standard chemical maintenance facility. Change house.



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n n

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HENDRICKSON

Standard

Chemical

Maintenance

Facility


17.

SCRUBBER SYSTEMS

ELECTROSTATIC PRECIPITATORS


Figure 13.

Standard chemical maintenance facility.

Service and support area.


289



290

FACILITIES

An e x p l o s i v e c o n t a i n m e n t chamber ( E C C ) , i s a s shown a t t a c h e d to the e x p l o s i v e wing t h a t w i l l permit c o n t i n u i t y t e s t i n g o f r o c k e t s , a s w e l l a s t h e d i s a s s e m b l y o f e x p l o s i v e components f r o m a g e n t f i l l e d m u n i t i o n s r e q u i r i n g undue f o r c e . The o p e r a t i o n a l sequence c y c l e o f t h e ECC p r o v i d e s f o r t o t a l i n t e r l o c k c o n t r o l a s s u r i n g c o m p l e t e v a p o r and e x p l o s i v e c o n t a i n m e n t d u r i n g p e r f o r m a n c e o f r e m o t e o p e r a t i o n s . P r i o r t o t h e s t a r t o f any o p e r a t i o n o r t e s t t h e i n t e r l o c k c o n t r o l r e q u i r e s c l o s i n g , s e a l i n g and l o c k i n g o f t h e d o o r i n c l u d i n g c l o s i n g and s e a l i n g o f f o f t h e v e n t i l a t i o n system. F o l l o w i n g completion o f an o p e r a t i o n c y c l e i n t e r l o c k c o n t r o l r e q u i r e s opening o f the v e n t i l a t i o n system, purging and m o n i t i r i n g t h e a t m o s p h e r e p r i o r t o o p e n i n g o f t h e d o o r and removal o f m a t e r i a l s . Vapor containment o n l y i s p r o v i d e d f o r a l l o p e r a t i o n s performed w i t h i n t h e e x p l o s i v e w i n g a s s u r i n g no e s c a p e o f a g e n t vapor to the o u t s i d e atmosphere. The g e n e r a l l a y o u t o f t h e e x p l o s i v e w i n g i s a s shown ( F i g u r e 1 4 ) . The l a r g e bays o n t h e l e f t a r e f o r unpack and r e p a c k o p e r a t i o n s with i n d i v i d u a l maintenance o p e r a t i o n s being performed i n the s m a l l e r bays. A t y p i c a l l a y o u t o f t h e unpack bay i s a s shown ( F i g u r e 1 5 ) . The a r e a t o t h e l e f t p r o v i d e s f o r t h e c o n t r o l and c o n t a i n m e n t o f a g e n t t h r o u g h t h e use o f a i r l o c k s , w h i l e t h e r e m a i n i n g a r e a o f t h e bay i s d e v o t e d t o u n p a c k i n g e q u i p m e n t . P e r s o n n e l w o r k i n g i n t h i s a r e a may work i n L e v e l D o r E p r o tective clothing. T y p i c a l m a i n t e n a n c e o p e r a t i o n s p e r f o r m e d under c o n t r o l l e d e n v i r o n m e n t s a r e a s shown ( F i g u r e s 16, 17, 18, 19, and 2 0 ) . NON-EXPLOSIVE WING: The n o n - e x p l o s i v e w i n g i s a s shown o n t h e l e f t s i d e o f t h e g e n e r a l a r r a n g e m e n t ( F i g u r e 1 1 ) . T h i s wing i s d e s i g n e d p r i m a r i l y to h a n d l e l a r g e b u l k y i t e m s h a v i n g no e x p l o s i v e s a s s e m b l e d . The l a y o u t o f t h e n o n - e x p l o s i v e wing i s a s shown ( F i g u r e 2 1 ) . The power and f r e e c o n v e y o r s y s t e m p r o v i d e s p r o c e s s o p e r a t i o n a l f l e x i b i l i t y f o r maintenance o p e r a t i o n s a s s o c i a t e d with a b r a s i v e c l e a n i n g , i n s p e c t i o n , p a i n t i n g and s h i p p i n g o f l a r g e i t e m s . The d e s i g n and l a y o u t o f t h e c h e m i c a l m a i n t e n a n c e f a c i l i t y p r o v i d e s f o r b o t h o p e r a t i o n a l f l e x i b i l i t y and a c a p a b i l i t y t o support process requirements as i d e n t i f i e d together with a safe working environment. The p r o t e c t i o n o f w o r k e r s f r o m a g e n t e x p o s u r e i s p r o v i d e d w i t h a n a i r l o c k s e p a r a t i o n between o p e r a t i o n a l areas, preventing spread o f agent vapor together with agent detect i o n equipment p o s i t i o n e d throughout the f a c i l i t y to monitor the environment. FACILITY COST ESTIMATE: The f a c i l i t y ( F i g u r e 1) was s i t e d a d j a c e n t t o t h e c h e m i c a l



Figure 14.

Standard chemical maintenance facility. Explosive wing.




TOXIC C H E M I C A L A N D EXPLOSIVES FACILITIES



HENDRICKSON

Standard

Chemical

Maintenance

Facility

293


Figure

16.

Standard chemical maintenance facility. concept.

Fiber

container unpack


Figure 17.

Standard chemical maintenance facility. Lid removed in vapor containment chamber.



294


FACILITIES


Figure 18.

Standard chemical maintenance facility. M-23 mine unpack station.


HENDRICKSON

Standard

Chemical

Maintenance

Facility


17.


295



296


FACILITIES


B.

A.

906.7 40.00 228.17 5,172.2 16.90 383.1 285.07 6,462.0

SF SF SF SF

8,393.8

1,887.6 5,529.7 976.5

TOTALS ($000) C.

GRAND TOTAL

TOTAL

CHANGE HOUSE MAGAZINES (40 X 25) MAGAZINE (2240 SF) ECC STRUCTURE

SF EA EA EA

SF

86.00 152,000 286,720 L. S.

44.65 45.60 32.80

UNIT PRICE


14,971 4 1 1

102,178

SF

56,650

SUBTOTAL TOTAL MAIN. BLDG.

SF SF SF

UNIT

56,650 56,650 56,650

QUANTITY

SERVICE & SUPPORT AREA GENERAL CONST. MECHANICAL ELECTRICAL

DESCRIPTION

Standard facility for maintenance, preservation and packaging, surveillance and assembly of chemical munitions. Cost estimate.

22,668

SUBTOTAL

Figure 22.

22,668 22,668 22,668

346.83

SF

24,200

SUBTOTAL

NON-EXP AREA GENERAL CONST. MECHANICAL ELECTRICAL

78.00 228.48 40.35

UNIT PRICE

SF SF SF

UNIT

24,200 24,200 24,200

BUILDING

QUANTITY

EXPLOSIVE AREA GENERAL CONST. MECHANICAL ELECTRICAL

l.MAIN.

DESCRIPTION


$24,258.7

2,432.2

1,287.5 608.0 286.7 250.0

21,826.5

6,970.7

2,529.4 2,583.0 1,858.1

TOTALS ($000)

TOXIC C H E M I C A L

298

A N D EXPLOSIVES FACILITIES


TOTALS

TOTALS

DESCRIPTION

($000)

DESCRIPTION

1.

STRUCTURES

24,258.7

d.

DRAINAGE PIPE (48" )

24.0

2.

CLEARING & GRUBBING

84.0

e.

H E A D W A L L S OR

76.8

3.

EARTHWORK

398.4

7.

GRASSING

57.6

4.

FLEXIBLE

8.

WATERLINE

349.4

a.

SURFACE COURSE

134.4

9.

SEPTIC

b.

BASE COURSE ( 6 " )

94.5

10.

RAILROAD

c.

SUBBASE

100.8

11.

150,000 G A L WATER

5.

RIGID

12.

FENCING

a.

P.

193.2

13.

M E C H A N I C A L EXT

257.1

b.

SUBBASE (6" )

35.9

14.

E L E C T R I C A L EXT

876.1

6.

STORM

15.

HELI P A D

a.

D R A I N A G E P I P E ( 18" )

9.4

TOTAL S I T I N G

b.

DRAINAGE PIPE ( 3 0 ' )

2.9

TOTAL F A C I L I T Y

c.

DRAINAGE PIPE (42" )

PAVEMENT

(6

M

( 2" )

)

PAVEMENT

C. CONCRETE

( 7" )

DRAINAGE

($000)

INLETS

TANK

16.0 224.0 TANK

348.0 99.0

28.8 COST

3,441.1

COST

$27,697.8

28.8


Figure 23. Standard facility for maintenance, preservation and packaging, surveillance and assembly of chemical munitions. Site preparation cost estimate.

$ FACILITY A N N I S T O N A R M Y DEPOT

EQUIPMENT

THOUSAND TOTAL

21235.8

7996.6

29232.4

29629.6

10508.8

40138.4

LEX-BLUE G R A S S

22638.6

4868.1

27506.7

P I N E BLUFF A R S E N A L

26743.8

5971.1

32714.9

P U E B L O DEPOT A C T IVITY

25989.8

4778.1

30767.9

TOOELE A R M Y D E P O T

29322.0

7292.3

36614.3

UMATILLA

30692.1

6243.1

36935.2

156622.1

37149.3

1 93771.4

165015.9

3 9661.5

204677.4

TOTAL

D E P O T A C T IV ITY

Figure 24. Standard facility for maintenance, preservation and packaging, surveillance and assembly of chemical munitions including support and process equipment. Total cost estimate.



17.

HENDRICKSON

Standard

Chemical

Maintenance

Facility

299

storage area a t i n s t a l l a t i o n s involved. S p e c i f i c s i t i n g r e q u i r e ments were i d e n t i f i e d w h i c h c o n s i d e r e d : t h e a v a i l a b i l i t y a n d e x tension o f u t i l i t y s e r v i c e s , roads and r a i l r o a d s i t i n g s . Siting i n f o r m a t i o n was p r o v i d e d t o t h e H u n t s v i l l e D i s t r i c t C o r p s o f E n g i neers which served as a b a s i s f o r d e v e l o p i n g s i t e p r e p a r a t i o n costs. Based on t h e d a t a p r o v i d e d by t h e i n s t a l l a t i o n s i n v o l v e d a n d the design data developed f o r the f a c i l i t y , the H u n t s v i l l e D i s t r i c t Corps o f E n g i n e e r s a s s e m b l e d a team o f e s t i m a t o r s a t t h e DARCOM Ammunition C e n t e r a n d p r e p a r e d f a c i l i t y c o s t e s t i m a t e s . The b a s i s f o r c o n s t r u c t i o n c o s t e s t i m a t e s were f o r t h e f a c i l i t y t o be i n t h e FY80 MCA p r o g r a m , w i t h c o n s t r u c t i o n c o s t s e s c a l a t e d t o r e f l e c t J a n u a r y 1971 t i m e f r a m e , a s t h e m i d p o i n t o f c o n struction. A l l e s t i m a t e s f o r t h e f a c i l i t y were b a s e d on u n i t p r i c i n g a t Anniston and f a c t o r e d f o r other s i t e s . The c o s t e s t i m a t e s were d e v e l o p e d a s shown ( F i g u r e 2 2 ) : t h e e x p l o s i v e w i n g $8,400,000; a n o n - e x p l o s i v e w i n g $6,500,000; a n d t h e s e r v i c e a n d s u p p o r t a r e a a p p r o x i m a t e l y $7,000,000 f o r a t o t a l o f $21,900,000 f o r t h e main b u i l d i n g . T h e change h o u s e , f o u r s e r v i c e magazines and a l a r g e c o n d i t i o n i n g b u i l d i n g add another $2,400,000 f o r a t o t a l o f $24,300,000. The s i t e p r e p a r a t i o n c o s t , a s d e v e l o p e d f o r d a t a p r o v i d e d , f o r A n n i s t o n i s $3,400,000 ( F i g u r e 2 3 ) . The t o t a l e s t i m a t e d c o s t f o r t h e p r o p o s e d f a c i l i t y s i t e d a t A n n i s t o n Army Depot i n c l u d i n g e q u i p m e n t i s $27,700,000. W i t h t h e d e v e l o p m e n t o f a m o d u l a r d e s i g n e d f a c i l i t y , i t was p o s s i b l e t o t a i l o r t h e f a c i l i t y t o meet t h e i n d i v i d u a l r e q u i r e ments o f e a c h i n s t a l l a t i o n . T h i s c h a r t ( F i g u r e 24) r e f l e c t s the combination o f the f a c i l i t y c o s t estimate together with the equipment c o s t estimate t a i l o r e d t o stocks c u r r e n t l y l o c a t e d a t the i n s t a l l a t i o n s . The del e t i o n o f the non-explosive wings from the A n n i s t o n , L e x i n g t o n Blue Grass and Pueblo f a c i l i t i e s i s r e f l e c t e d i n the f a c i l i t y and e q u i p m e n t c o s t s . The t o t a l e s t i m a t e d c o s t f o r t a i l o r e d s t a n d a r d c h e m i c a l m a i n tenance f a c i l i t i e s c o n s t r u c t e d a t each i n s t a l l a t i o n i s $193,700,000 w i t h o n e e x p l o s i v e wing a t A n n i s t o n o r $204,700,000 f o r two e x p l o s i v e w i n g s a t A n n i s t o n . CONCLUSIONS: The d e v e l o p m e n t o f t h e s t a n d a r d m a i n t e n a n c e f a c i l i t y d e s i g n as p r e s e n t e d ( F i g u r e 1) c o n c l u d e s t h a t b o t h o p e r a t i o n a l a n d e n v i r o n m e n t a l r e q u i r e m e n t s c a n be accommodated. I t s a t i s f i e s a r e a l need f o r a f a c i l i t y t h a t w i l l p r o v i d e a s a f e a n d p r o d u c t i v e e n v i ronment f o r t h e m a i n t e n a n c e o f t o x i c c h e m i c a l m u n i t i o n s . A l s o that s a f e t y , s e c u r i t y , and environmental c r i t e r i a are s t r i n g e n t b u t t h e f a c i l i t y d e s i g n a s p r e s e n t e d w i l l comply w i t h t h o s e known requirements.


TOXIC CHEMICAL AND EXPLOSIVES FACILITIES

300

Literature Cited: 1. S a f e t y Manual, AMCR 385-100, HQ US Army M a t e r i e l Command, Alexandria, VA, DARCOM Change 3 , 11 January 1977.


2. Safety Regulations f o r Chemical Agents GB and VX, DARCOM-R 385-102, HQ US Army M a t e r i e l Development and Readiness Command, Alexandria, VA, 28 February 1977. 3. Safety Regulations f o r Chemical Agents H , HD, and HT, AMCR 385-31, HQ US Army M a t e r i e l Command, A l e x a n d r i a , VA, 26 September 1975. 4. DOD Ammunition and Explosives Safety Standards, 5154.4S, Interim Change 2 - 1 , 15 July 1976. 5. Chemical Surety Program, AR 5 0 - 6 , HQ Department o f the Army, Washington, DC, 5 November 1976. 6. S t r u c t u r e s to R e s i s t the E f f e c t s o f A c c i d e n t a l E x p l o s i o n s , TM 5-1300, Department o f the Army, Washington, DC, 15 June 1969. RECEIVED

November 22, 1978.


Concept Design Criteria for Standard Chemical Maintenance Facility

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