4.3 PLANT FACILITIES AND INFRASTRUCTURE
4.3.1 Affected Environment
This section addresses the current status of Pantex Plant facilities and supporting infrastructure. Included are discussions of the plants buildings, operations, services, roads, railroads, and utilities. These discussions help the reader understand the current status of operations at the plant to allow for better comparison of the effects of implementing the Proposed Action or the Alternatives.
4.3.1.1 Facilities
Pantex Plant Facilities/BuildingsMajor operations performed at Pantex Plant include: assembly and disassembly of nuclear weapons, repair and modification of weapons, production of high explosive(s) (HE)high explosive(s) (HE) components, evaluation and testing of weapon components, research and development, staging (temporary storage) of nuclear weapons, packaging and shipping of weapons and components, and interim storage of pits. These operations are housed in 476 buildings, containing 230,674 square meters (2,483,020 square feet) of work space. The principal building classifications are administrative, storage, production, service, and research and development. An additional 144 structures, containing 39,928 square meters (429,780 square feet), support the principal operations (DOE 1994j:3-3). These structures include temporary buildings, leased trailers and buildings used for additional office space, and temporary storage containers. Zone 4 magazines (95 buildings) are used for staging of nuclear weapons, storage of explosives, and interim storage of pits (Pantex 1991:3).
Table 4.3.1.11 provides a summary of the buildings and their gross areas, by selected construction periods. Approximately 48 percent of the buildings at Pantex Plant were constructed prior to 1966. These buildings are being considered for shutdown after consolidation of functions into newer buildings (DOE 1995j:3, 7). Table 4.3.1.12 provides the number of buildings occupied by principal missions at the plant.
Table 4.3.1.1-1.--Buildings at Pantex Plant, by Construction Period (.pdf)
Pantex Plant Operations/ServicesThe operating contractor for Pantex Plant is Mason & Hanger Corporation. Under the office of the General Manager, the plant is organized into 13 divisions including: Capital Projects; Information Management; Quality; Safeguards, Security, and Fire Protection; Human Resources; Administrative Services; Operations Support; Applied Technology; Facility Operations; Manufacturing; Engineering and Design; Environment Safety and Health; and Waste Management and Environmental Restoration (Pantex 1996:2.1). Extensive descriptions of key operations and services are provided in the Pantex Plant Safety Information Document. Additionally, appendix D of the Pantex Plant Safety Information Document provides brief descriptions of each current and planned facility and its operations and services (Pantex 1996a:App D; Pantex 1996b:App C).
Table 4.3.1.1-2.--Mission Facilities Assembly (.pdf)
Pantex Plant has a mature maintenance upgrade program supported with appropriate NEPA related documentation. Since 1990, Pantex Plant has initiated 354 environmental checklists and other NEPA related documents; 206 of the 354 were identified as facility upgrades, repairs, improvements, and maintenance related activities (Pantex 1996b:App D).
4.3.1.2 Infrastructure
Two categories of infrastructure, transportation access and utilities, are described below for Pantex Plant Site. Transportation access includes roads, railroad, and airport operations. Utilities include steam, electricity, natural gas, water, and wastewater treatment.
RoadsAccess to the site is provided by the Texas Farm to Market roads bounding the site on the north, east, and west and by U.S. Highway 60, 1.6 kilometers (1 mile) to the south. Interstate Highways 40 and 27 provide access to the interstate highway system. Additionally, 76 kilometers (47 miles) of roads exist within the plant boundaries (Figure 4.3.1.21) (Pantex 1996:2.2).
Onsite transportation involves movement of nuclear explosives, nuclear components, HE components and materials, tritium, chemicals, and other hazardous materials, including waste. Nuclear explosives and components are transported to and from Pantex Plant in Safe Secure Tractor Trailer (SST)Safe Secure Tractor Trailers by the Transportation Safeguards Division. Onsite transportation is accomplished with hardened trailers and Safe Secure Tractor Trailers as well as other conventional vehicles, which include flatbeds, trailers, vans, trucks, pallet jacks, forklifts, and tow motors. Onsite transport of materials is on paved roadways or enclosed ramps between buildings (Pantex 1996b:3.9). Additional discussion on transportation is provided in section 4.12, Intrasite Transportation, and section 4.16, Intersite Transportation of Nuclear and Hazardous Materials. The Traffic Section of the Packaging and Shipping Department is responsible for the receipt of commercial materials from offsite and for handling materials to be transported out of the plant. Building 1619, Central Shipping and Receiving, handles commercial materials moving into and out of the plant (Pantex 1996a:5.5).
Figure 4.3.1.2-1.--Pantex Plant Site in Carson County, Texas.
RailroadsA major rail center for the Burlington Northern Santa Fe Railroad, formerly known as the Atchison, Topeka, and Santa Fe Railroad, is located in Amarillo, Texas. The railroad passes along the southernmost portion of the Texas Tech University (TTU) property at Pantex Plant Site (Pantex 1996:9.5). An operational spur of the railroad extends through the Texas Tech University (TTU)TTU property into Pantex Plant from the southwest (Figure 4.3.1.21). Except for occasional bulk concrete shipments, the site railroad track is currently unused (Pantex 1996:9.5).
AirportThe Amarillo International Airport is located approximately 12 kilometers (7.5 miles) southwest of Pantex Plant (Pantex 1996:9.5). The airport is primarily used for commercial aviation and is equipped for international commerce. Pantex Plant leases a small facility at the airport for its own transportation use (Pantex 1996b:2.2). Mason and Hanger Corp. Transportation Department provides the necessary ground transportation.
UtilitiesUtilities include steam, electricity, natural gas for fuel, water, and wastewater treatment. Table 4.3.1.21 provides current utility usage rates, Pantex Plant system capacity, and offsite utility net capacity for fiscal year (FY) 1994.
Table 4.3.1.2-1.--Utility Usage and Capacities at Pantex Plant (.pdf)
Steam. Pantex Plant provides steam for operations and facility heating. Building 1613, the plants boilerhouse, contains four boilers and operates on natural gas (Pantex 1996a:App D; DOE 1994f:7). Two of the boilers each have the capacity to produce 22,680 kilograms (50,000 pounds) of steam per hour and the other two have the capacity to produce 11,340 kilograms (25,000 pounds) of steam per hour each (DOE 1995j:9). Steam heat is used where open flames, flammable liquids, and flammable gases pose a potential safety risk.
Electricity. Pantex Plant receives electrical energy from Southwestern Public Service Company. In 1994, the company had a peak of 3,370 megawatts, a system net capability of 4,061 megawatts, and an excess capacity of 691 megawatts or approximately 6 million megawatthours. In 1994, Pantex Plant consumed approximately 84,420 megawatthours of electricity. In 1995, consumption decreased to 80,500 megawatt hours (Pantex 1996:9.1). Two 115-kilovoltampere electrical substations are located onsite with a capacity of 23 megawatts (DOE 1995j:9). There are several generators, both fixed and portable, that provide standby power in the event of an interruption of normal service to critical systems.
Natural Gas. The Texas Panhandle is one of the major oil and gas producing regions in the country with considerable reserves. Natural gas is supplied to Pantex Plant by Anthem Energy (Pantex 1996:9.1). The natural gas is delivered through a 25-centimeter (10-inch) main supply line, which is capable of supplying 289 million cubic meters (10,220 million cubic feet), sufficient capacity for all future plant requirements (DOE 1995j:10). Tank 12076 holds a reserve of 2,384,550 liters (630,000 gallons) of fuel oil for use, should interruption of the natural gas supply occur (DOE 1994j:121). In 1995, consumption decreased by 1.3 million cubic meters (46 million cubic feet) (Pantex 1996:9.1).
Water. Water for Pantex Plant is pumped from the Ogallala aquifer by five production wells located in the northeast portion of the site. A well and two reservoirs were completed in 1994. The plant pumped 836 million liters (221 million gallons) in 1994. Approximately 25 percent of the water pumped at Pantex Plant was used by Texas Tech University (TTU)TTU for irrigation (DOE 1995j:9). Net plant use was 617 million liters (163 million gallons) in 1995 (Pantex 1996:9.3). Water storage reservoirs are integrated into the water distribution system. Total storage capacity exceeds 20 million liters (5.2 million gallons) (DOE 1994f:6). The City of Amarillo has pledged 5,526 million liters per year (1,460 million gallons per year) of treated wastewater as part of potential plant expansion (DOE 1991b).
The Ogallala formation is capable of yielding adequate water for all current and foreseeable uses by Pantex Plant (PC 1994a:1). Additional discussion on the adequacy of groundwater resources is provided in section 4.6.1.2, Groundwater.
Wastewater Treatment. Pantex Plant has two types of wastewater treatment. The primary wastewater treatment operation is located just south of Playa 1. This system consists of a lagoon that is divided into an aerated section and a facultative (settlement and biotreatment) section. The water is disinfected with chlorine and discharged to Playa 1. Other wastewater treatments are operation specific. Examples are presented in Table 4.3.1.22. The wastewater treatment system is permitted to allow a daily average discharge of up to 2.5 million liters (0.65 million gallons). In 1995, wastewater volume decreased to 421 million liters (111 million gallons) (Pantex 1996:9.2). The FY 1996 Sewage Treatment Quality Upgrade will improve the plants sanitary sewage system to assure wastewater standards are maintained (DOE 1995j:8). The upgrade was covered as a categorical exclusion (NEPA LIN96003C) (Pantex 1996b:App D).
Table 4.3.1.2-2.--Examples of Facility Specific Wastewater Treatment Operations (.pdf)
Rights of Way and Easements. In addition to property owned by TTU, Burlington Northern Santa Fe Railroad owns parcels located between Highway 60 and TTU property along the Pantex Plant Site boundary. Anthem Energy and Southwestern Public Service Company have utility easements associated with utility operations. Carson County Farm to Market roads exist along the east, west, and north site boundaries (Pantex 1996:2.2; TNRCC 1995a).
4.3.2 Impacts of Proposed Action
4.3.2.1 Impacts of Continued Operations
Weapons-Related ActivitiesThis section discusses the impacts on plant facilities and infrastructure from continued operations at Pantex Plant. With regular maintenance and upgrades, all plant facilities and infrastructure would support the continuing activities and missions without any foreseeable capacity difficulties (DOE 1995j:1, 8, 10). A comparison of estimated utility resource needs for continued operations at three weapons levels is provided in Table 4.3.2.11 (see section 2.2). Projections indicate that sufficient capacities exist should demand exceed current expectations (DOE 1995j:1, 8, 10).
In 1994, Pantex Plant experienced a workload slowdown due to facility maintenance. Therefore, 1993 usage rates were chosen as the most recent representative year for the 2,000 weapons per year operational level. In addition, the 1993 consumption rates were higher for all utilities with the exception of electricity (DOE 1994f:7; DOE1995j:10). The 1,000 weapons level utility consumption rate is based on currently planned needs for FY 2005 (plus 10 percent) (DOE 1995j:10; Pantex 1996b:App A). The 500 weapons level consumption rates were prorated using straight-line reductions based on 2,000 weapons and 1,000 weapons level scenarios.
Data in Table 4.3.2.11 show a proportional straight-line decrease in utility consumption rates as the level of activities decreases from the 2,000 weapons level to the 500 weapons level. For example, electricity consumption ranges from 90,400 to 57,200 megawatthours per year; inversely, the system capacity remaining would increase from 111,280 to 144,480 megawatthours per year.
Two exceptions to proportional decrease in utility consumption exist for the 500 weapons level. Steam and natural gas consumption during the 500 weapons level scenario are reduced by 50 percent instead of a 26 percent straight-line reduction in steam and 15 percent straight-line reduction in natural gas. This is because an existing smaller natural gas boiler would be utilized in the 500 weapons level scenario.
Table 4.3.2.1-1.--Projected Utility Consumption Rates and Capacities (.pdf)
Pit Storage ActivitiesCurrently, all existing Modified Richmond and SAC magazinemagazines have the necessary utility support and material access control, and are supported by existing plant facilities and infrastructure. SAC magazines are used to stage nuclear assemblies and nuclear components, and require similar levels of infrastructure support as the Modified Richmond magazines (Pantex 1996a:3.2). No new construction of plutonium storage magazines is required as a result of increasing interim storage to 20,000 pits. Therefore, current levels of infrastructure and utility support are expected to continue (DOE 1994w:6-1).
Pit Repackaging OperationsThe repackaging of pits from AL-R8 containers into AT-400A containers is expected to begin in late 1996 or early 1997. This operation would be performed in existing bays within Zone 12 and as such will not require new construction nor extensive facility modifications. Utility usage for this operation would be minimal and well within the total usage described for the Proposed Action. The pit repackaging operations would not result in any impacts to land use, geology and soils, water resources, air resources, acoustics, biotics, cultural resources, socioeconomics, or environmental justice and, therefore, are not discussed in those sections. The intrasite transportation impacts have already taken the impacts for pit repackaging into account. The pit repackaging would involve waste management and would result in additional worker radiological exposures. These impacts are discussed in sections 4.13 and 4.14.
Environmental Restoration ActivitiesEnvironmental restoration activities are designed to maintain or improve the environment. Since 1989, environmental restorationenvironmental restoration (ER) activities have been assessing inactive sites through temporary field operations that, for the most part, require minimal usage of plant utilities and plant facilities (Pantex 1996:15.0). Heavy equipment such as drill rigs operate with self-sufficient power supplies while field sampling typically uses manual labor or portable power supplies. Portable toilets, fire protection, potable and nonpotable water, and temporary power and lighting are typically required and provided by the contractor (Pantex 1992:4-1, 9-1, Appendix B). By the year 2000, activities are expected to be reduced to monitoring and groundwater and soils management, such as bioremediation of soils and perched zone groundwater remediation. No new facilities would be needed for the environmental restoration activities.
Recycling restoration wastewater is currently under study. After 1999, 65,942 liters (17,420 gallons) could be reclaimed annually (Pantex 1996:14.5).
Waste Management ActivitiesWaste management activities utility consumption has been accounted for in the facility-wide totals presented in Table 4.3.2.11. Impacts of infrastructure support (closures, treatment, storage, and disposal) are discussed in section 4.13, Waste Management.
4.3.2.2 Impacts of New Facility Construction and Upgrades
A comparison of site infrastructure and facility resource needs for the proposed facility construction and upgrades is provided in Table 4.3.2.21. As noted in this table, sufficient utility capacity exists to handle the demand from these facilities. Gas Analysis Laboratory (GAL)The Gas Analysis Laboratory, the Materials Compatibility Assurance Facility (MCAF)Materials Compatibility Assurance Facility, the Nondestructive Evaluation FacilityNondestructive Evaluation Facility, and the Metrology and Health Physics Calibration and Acceptance FacilityMetrology and Health Physics Calibration and Acceptance Facility represent an operational consolidation effort that would not increase utility usage.
The Pit Reuse FacilityPit Reuse Facility represents a potential 0.18 percent increase in annual site utility consumption based on the addition of 7 new employees to a 3,800-employee baseline for all utilities except industrial water and steam. No industrial water or steam heat is needed to support the Pit Reuse Facility. The utility consumption increases would be minimal since the Pit Reuse Facility operations would occupy an existing facility (DOE 1995j:4, 5).
The Hazardous Waste Treatment and Processing Facility (HWTPF)Hazardous Waste Treatment and Processing Facility (HWTPF) project would modernize, consolidate, and expand existing waste operations capabilities (Battelle 1995:1). This project is expected to increase infrastructure requirements by 0.13 percent based on the addition of five new employees. Industrial water usage is estimated to increase by 3.4 million liters (0.9 million gallons) a year or 0.3 percent of 920 million liters (243 million gallons) used in 1993. Discharges of industrial water are expected to increase by 2.9 million liters (0.77 million gallons) per year.
Table 4.3.2.2-1.--Estimated Annual Utility Consumption by New Facilities (.pdf)
4.3.2.3 Summary of Impacts
Pantex Plant facilities and infrastructure have adequate capacities for all scenarios covered in the Proposed Action (DOE 1995j:1, 8, 10). As shown in Table 4.3.2.11, the largest demand is expected from the 2,000 weapons level. Expected electricity demand, 90,400 megawatthours, represents only 45 percent of the plants capacity, with an additional 111,080- megawatthour capability. Future water consumption is expected to utilize only 53 percent of capacity with 882 million liters (233 million gallons) per year net reserve. The wastewater treatment facility is predicted to operate at 78 percent capacity or 647 million liters (171 million gallons). The Boilerhouse (Building 1613) steam supply system is anticipated to function at only 30 percent capacity or 181 million kilograms (398 million pounds) per year. The natural gas needs of the plant utilize only 6 percent of the natural gas main supply line design capacity.
4.3.3 Impacts of No Action Alternative
Weapons-Related ActivitiesThe demands on infrastructure and utilities would remain the same under the No Action Alternative, until the interim storage of pits reached 12,000. At that point weapons disassembly operations would cease. Even after the disassembly operations cease, it is assumed for purposes of analysis that the weapons levels would remain at 2,000, 1,000, or 500, as described for the Proposed Action, because other weapons operations would continue. The infrastructure impacts due to the No Action Alternative would therefore be expected to remain similar to those described for the Proposed Action except that none of the proposed new projects would be built under the No Action Alternative.
Pit Storage ActivitiesNo impacts on plant facilities or infrastructure directly supporting pit storage would occur. Pit storage support operations (e.g., security) are currently in place (DOE 1994w:6-1).
Environmental Restoration ActivitiesEnvironmental restoration activities are independent of the No Action Alternative since these activities would continue even if the plant activities are reduced. Therefore, the impacts would be the same as discussed for the Proposed Action.
Waste Management ActivitiesWith the weapons levels remaining at the levels described for the Proposed Action, the waste management activities would not change substantially from those described for the Proposed Action. Further discussion of treatment, storage, and disposal impacts is provided in section 4.13, Waste Management.
4.3.4 Impacts of Pit Storage Relocation Alternative
4.3.4.1 Impacts of Relocating 20,000 Pits
Under the scenario of relocating 20,000 pits to other site(s), overall plant impacts would be similar to those identified for the Proposed Action. Only 18 magazinemagazines are currently used for pit storage. If all the pits are transferred elsewhere, these 18 magazines would become available for other uses. The 18 Modified Richmond magazines total less than 1,800 square meters (19,000 square feet) of nearly 0.23 million square meters (2.5 million square feet) or 0.8 percent of the total floor space at Pantex Plant. Zone 4 Zone 4 operations include weapon staging and special nuclear material staging. These storage operations, like pit storage, require access control, security, and electricity. Therefore, no reduction in infrastructure support or utility usage is anticipated as a result of relocating 20,000 pits.
4.3.4.2 Impacts of Relocating 8,000 Pits
Under the scenario of relocating 8,000 pits, overall infrastructure impacts would remain similar to those described for the Proposed Action. The storage of 12,000 pits would be satisfied from existing magazines at the plant site; no new building construction would be required, other than what is currently required. Increases in infrastructure requirements would not occur.
4.3.5 Cumulative Impacts
The cumulative impacts presented here include impacts of the continued operations at Pantex Plant combined with impacts associated with activities described in the WM PEIS, SSM PEIS, and S&D PEIS. Since the Pantex Plant EIS Proposed Action and the SSM PEIS No Action Alternative represent a continuum of operations, the impacts associated with any new mission or facility that could be implemented at Pantex Plant are discussed in the context of that continuum. The impacts from the WM PEIS program are combined with those of the Pantex Plant EIS Proposed Action. The impacts from the S&D PEIS are combined with those of the SSM PEIS No Action Alternative. A detailed discussion of this methodology is presented in section 4.2.
4.3.5.1 Impacts of Alternatives in the Waste Management Draft Programmatic Environmental Impact Statement
The WM PEIS Decentralized Alternative, which would generate the greatest impacts, would increase the electrical consumption by 3.33 megawatts. The existing total capacities of Pantex Plant and the local area utility system are adequate to handle this increase. Wastewater generation would increase by 43,660 liters (11,535 gallons) per day, The existing total capacity of Pantex Plant is adequate to handle this increase. Water usage would increase by 96,200 liters (25,416 gallons) per day. The existing capacity is adequate for this increase.
4.3.5.2 Impacts of Alternatives in the Stockpile Stewardship and Management Programmatic Environmental Impact Statement
The SSM PEIS includes three alternatives that apply to Pantex Plant: No Action, Downsize Existing Capability, and Relocate Capability. Under the No Action Alternative, no downsizing or modification of facilities would occur, and there would be no construction impacts. Due to the reduced workload expected, future infrastructure impacts are expected to be less than current impacts. Under the downsizing alternative, all construction activities would be modifications to existing facilities. Facilities would be consolidated and impacts would be expected to be less than current impacts. Under the relocation alternative, the facilities would undergo decontamination and decommissioning (DOE 1996b).
4.3.5.3 Impacts of Alternatives in the Storage and Disposition of Weapons-Usable Fissile Materials Programmatic Environmental Impact Statement
The S&D PEIS is considering Pantex Plant for long-term storage of inventories of nonsurplus weapons-usable plutonium and highly enriched uranium (HEU), storage of inventories of surplus weapons-usable plutonium and HEU pending disposition, and disposition of surplus weapons-usable plutonium. For storage, the strategy for long-term storage of weapons-usable plutonium and HEU, as well as the storage site(s), would be decided. The storage alternatives include upgrading existing plutonium storage facilities in Zone 12, consolidation of plutonium from other sites, and collocation of plutonium and HEU storage. The collocation alternative is used for analysis purposes in this EIS as the bounding storage alternative since it would have the greatest impacts.
Under the S&D PEIS Collocation Alternative, construction of new storage facilities would be required in order to store plutonium and HEU at Pantex Plant.
For site infrastructure, small increases in available oil resources would be required. During operations, all site infrastructure resource requirements would be less than those already available at the site.
For the disposition alternatives in the S&D PEIS, the emphasis at this stage in the NEPA decision process is on the strategy and technology mix rather than the actual site. The evolutionary Light Water Reactor is used for analysis purposes in this EIS as the bounding disposition alternative. Implementation of this disposition alternative would require the construction and operation of a pit disassembly and conversion facility, plutonium conversion facility, mixed oxide (MOX) fuel fabrication facility, and one or more light water reactors. The bounding alternative also assumes that all of the facilities previously mentioned would be collocated at the same site (potentially Pantex Plant).
For disposition only, construction and operation would require 24,333 and 1,154,000 megawatthours per year of electricity, respectively. Also, construction and operation would require 1,356,200 liters (354,100 gallons) per year and 844,750 liters (218,473 gallons) per year of oil, respectively. Operations would require 8,976,000 cubic meters (237 million cubic feet) per year of natural gas. Transmission lines would be constructed and upgraded for the increased and redistributed electrical load. Additional primary and secondary access roads as well as railroad right-of-way would be needed and are available. Fuel requirements would exceed current site availability, but can be accommodated through normal contractual means (DOE 1996a:chapter 4).
4.3.6 Potential Mitigation Measures
Since adequate capacities exist for infrastructure as described above at any level of the three weapons activity levels analyzed, no mitigations are currently required or justified under the Proposed Action, No Action, and Pit Storage Relocation Alternatives.
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