H.4 PIT REUSE FACILITY
H.4.1 Purpose and Need for Action
The Department needs to develop and demonstrate the capability to modify and upgrade pits generated from certain nuclear weapons dismantlement processes into a viable configuration for enhanced safety and reuse (Pantex 1996:App C). Existing weapons have a finite stockpile life, and at the conclusion of this life, these weapons must be disassembled. DOE has not produced new pits since the closure of the Rocky Flats Plant. As a result, the method for maintaining a minimum stockpile weapon count is to reuse these pits obtained from disassembled weapons (DOE 1995b:I.B 2; Pantex 1996:App C).
H.4.2 Proposed Action
The Proposed Action is to modify an existing facility to provide a state-of-the-art facility to modify and upgrade pits to meet future weapon stockpile requirements. The proposed Pit Reuse Facility would provide the necessary capabilities.
This project would consist of the design and construction of the additions and modifications necessary to convert a portion of Building 12-104, Zone 12, into the Pit Reuse Facility (DOE 1995b:I.A 1). A total area of 494 square meters (5,314 square feet) would be affected by the facility upgrades. This area would be modified to meet the requirements of a "moderate hazard, non-reactor nuclear facility," as specified in DOE Order 6430.1A, General Design Criteria.
The conceptual design calls for pit modifications to be conducted in a specially designed workstation with a glovebox-type enclosure in the Glovebox Bays. Two additional bays, a Pit Qualification Bay and a Purge and Backfill Bay would also be provided to clean, weigh, radiograph, leak check, inspect and backfill the pits. A fourth bay, known as the Auxillary Bay, would be provided to support training and production as needed (DOE 1995b:I.A 1).
New structures are proposed as a component of this project to provide support to the operations in this facility. A proposed new support area would include two changerooms, a decontamination area, a mechanical room, storage rooms, a janitor's closet, and an office area. Existing support areas include combustible storage rooms, electrical and uninterruptible power supply rooms, fan rooms, and a mechanical room. A new security area would be established to control access into this facility. The existing ramp and connecting road would be relocated to allow direct access from the Pit Reuse Facility to the new support area. The minimum space requirements are 122.1 square meters (1,314 square feet) for the new support building and 370 square meters (4,000 square feet) for the new relocated ramp, for a total space requirement of 494 square meters (5,314 square feet) (DOE 1995b:I.A 1-2).
The Pit Reuse Facility's ventilation system would be modified to allow the facility to be operated at a negative pressure. The workstations and welding areas would have HEPA-filtered exhausts. An argon supply system would be installed to facilitate an argon atmosphere in the workstations (DOE 1995b:I.A 1-2).
Physical modification of the bays would include flooring modification and repair, upgrading the existing exits to comply with Life Safety Code 101, restructuring to withstand a Design Basis Event, and improving stormwater drainage capacity around Building 12-104 to ensure adequate drainage relative to the Pit Reuse Facility upgrades (DOE 1995b:I.A 2).
This project would also upgrade equipment for health and safety; all fire protection, electrical, and mechanical systems would be seismically qualified. Radiation alarm monitors and Continuous Air Monitoring Systems would be installed in workstations, exhaust systems, and the rest of the facility to detect alpha, beta, gamma and neutron emitting radionuclides (DOE 1995b:I.A 2).
H.4.2.1 Environmental Considerations
This facility would meet all present environmental codes and regulations, and its normal operation would not have cumulative or long-term adverse effects on the environment. Operation of this facility would be in compliance with Federal and State pollution control standards. The proposed facility upgrades would provide an increased level of protection for the environment in the event of an accident because the new pit reuse operation would meet the requirements of a category 2, nonreactor nuclear facility. Additionally, a dual redundant HEPA filtration system would be utilized to protect the environment from a release of particles. No permits for air, water, or waste are expected.
For a discussion on water and energy conservation at Pantex Plant see appendix G, Pollution Prevention and Waste Minimization.
H.4.2.2 Health and Safety
This facility would operate under an approved Final Safety Analysis Report. The building would be protected by an automatic fire suppression system, alarms, emergency lighting, and fire extinguishers. The process areas would be kept under negative pressure with inert gas atmospheres and a glove box enclosure to minimize releases. HEPA filters, emergency showers and eyewash stations, and requirements for personnel protective equipment would be utilized. Approximately 60 percent of the tasks would be conducted in the workstations by remote handling to limit worker exposure (DOE 1995b:I.A 2, I.B 1).
H.4.2.3 Safeguards and Security
A new security area would be established through the use of barricades to detect and control unauthorized access into the pit reuse area. The four existing bays after modification would collectively be considered one vault area. As a result, when a pit is moved from one bay to another it would never leave the vault area. These barricades would limit access to qualified plant personnel (DOE 1995b:I.B 2).
H.4.3 Relationship to Other Projects
The proposed project has no direct relationship with other planned or current construction projects at Pantex Plant. The vacuum system technology utilized in the Pit Reuse Facility is similar to that of another project, Building 12-116. Other examples of similar operations and technologies include automated pit handling (robotics), automation and shielding (reducing operator exposure time and levels), and gas mixing. These technologies would be incorporated into the Pit Reuse Facility design where possible (DOE 1995b:I.C.1). The SSM EIS (DOE 1996) considers pit reuse capabilities at Savannah River Site (SRS) and Los Alamos National Laboratory (LANL).
H.4.4 Environmental Impacts
H.4.4.1 Infrastructure
Electrical usage would increase from 0 to 192 megawatthours per year. No natural gas or steam would be used at the facility (PC 1995:Table 3). The Pit Reuse operations would occupy an existing facility.
H.4.4.2 Land Resources
The Pit Reuse operations would occupy an existing facility.
H.4.4.3 Geology and Soils
Since this project involves interior modification of an existing building, no impacts to geology and soils are anticipated.
H.4.4.4 Water Resources
Water use is expected to increase from 0 liters per year (0 gallons per year) to 320,000 liters per year (84,000 gallons per year). The generation of wastewater is also expected to increase from 0 liters per year (0 gallons per year) to 320,000 liters per year (84,000 gallons per year) (PC 1995:Table 3).
H.4.4.5 Air Quality
Airborne particulate matter (i.e., dirt and equipment emissions) levels would be elevated during the construction period. However the majority of the construction work would be completed inside an existing building. Only very small amounts of chemicals (e.g. isopropyl alcohol) would be used during operations. Inert gases (i.e. helium, argon and nitrogen) would be used during routine glovebox operations. Two HEPA filters used in series would remove particulates prior to exhausting through the stack. The total effective dose equivalent to a maximally exposed offsite individual would be less than 0.1 millirem per year. The effective dose equivalent permissible limit is 10 millirem per year (DOE 1994c:31-32, 34-36).
H.4.4.6 Acoustics
Noise levels would temporarily increase during construction from operation of heavy construction equipment such as air compressors, cement mixers, and construction vehicle traffic. During pit reuse operations, noise would be emanating from air handling equipment and welding equipment. Local worker and transportation traffic would contribution to the ambient noise in the area. The operational areas design would include noise controls pursuant to OSHA standards (29 CFR 1910.95) (DOE 1994c:30, 32).
H.4.4.7 Biotic Resources
Flora and fauna that currently use the facility construction equipment laydown area would be temporarily removed or displaced by construction. No net loss of biotic resources are expected since the project will occupy an existing facility.
H.4.4.8 Cultural Resources
No archaeological sites or historical resources have been identified in or near the proposed construction site.
H.4.4.9 Socioeconomic Resources
The construction cost of this facility would be approximately $8.6 million. Construction of the facility is expected to employ 15 to 50 short-term employees and would probably result in a small temporary increase in local employment (PC 1995:Table 1). A substantial portion of the material costs would enter the wholesale and retail trade sector of the regional economy. This facility is designed for seven new employees who would represent 0.18 percent of 3,800 employees currently working at the Pantex Plant (PC 1995:Table 3).
H.4.4.10 Transportation
The construction of this facility would result in a temporary increase in onsite and area traffic during a 18-month construction period. Since construction is in the high security Material Access Area, normal day shift work hours, Monday through Friday, may not be possible. Also Pantex Plant personnel may report during a modified day shift or second shift depending on workloads, safety, and security issues. Based on previous construction activities in the Material Access Area, no major impacts would be expected. Regardless, plant security personnel would accompany construction workers to and from the construction site. Material supplies would be transported through Building 16-15 Central Shipping and Receiving. During operation, seven new employees would travel to the plant from the local area.
H.4.4.11 Waste Management
The construction debris and trash generated by the construction/modification activities would be disposed of at the onsite landfill and the Amarillo landfill, respectively. Generation of these wastes would not impact Pantex Plant or Amarillo waste management. The annual operation of this facility is expected to generate 0.5 cubic meters (0.6 cubic yards) of LLMW, 1.5 cubic meters (1.9 cubic yards) of LLMW, 0.6 cubic meters (0.8 yards) of HW, and 6.0 cubic meters (7.8 cubic yards) of NHW (PC 1995:Table 3).
H.4.4.12 Human Health Risks
There are no radiation risks during construction, since construction activities would not involve the use of any radioactive materials or waste. Chemical human health risks during construction are mitigated through compliance with OSHA Chapter 1926 regulations and an approved project-specific health and safety plan. The Contractor Safety and Health program requires a written plan for approval by the Fire, Waste Management, Industrial Hygiene, and Safety Departments. The plan establishes permits for safety, excavation, fire department, radiation work, and hot work as necessary (Pantex 1992).
The facility's contribution to risk is expected to be small. Potential sources of radiological exposures during operation would be alpha-, gamma-, and neutron-emitting materials. External and internal occupational exposure to radiation would be limited to the standards promulgated in DOE Order 5480.11. Through the use of engineering controls and administrative controls, personnel exposure would be ALARA. Potential sources of chemical exposures during operations would be from chemicals and materials used in managing special nuclear material. Personal protective clothing and equipment would be used to mitigate the potential health risks (DOE 1995b:I.A.2, I.B.1). Section 4.14 presents Human Health risks associated with all plant activities.
H.4.5 No Action Alternative
One of the alternatives to the construction of the Pit Reuse Facility is to take no action, i.e., not build any facility and allow the limited component life of pits to expire. No source of replacement pits would exist because the production of new pits has been discontinued.
H.4.6 Alternatives Eliminated from Detailed Study
Two alternatives were eliminated from detailed study. The use of temporary facilities to conduct pit reuse operations was not considered practical since DOE requires extensive design features for radiation control, emission controls, safety requirements, security, and fire protection. The second alternative requires offsite facilities located at LANL, or other DOE sites. However, the option was eliminated because of the need to provide close support for assembly and disassembly operations, location near storage facilities, and concern with safety and security associated with the potential for moving pits on National highways (DOE 1995b:I.D 1).
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