H.7 NONDESTRUCTIVE EVALUATION FACILITY
H.7.1 Purpose and Need for Action
The Department needs a facility in which to conduct nondestructive evaluation activities. The existing facility where these activities are currently conducted does not meet the design criteria for Class 2 operations, as required in the DOE Explosive Safety Manual (DOE 1991).
H.7.2 Proposed Action
This project would provide a new Nondestructive Evaluation Facility (NDEF) that would be located in Zone 12, north of Building 12-121 and west of Building 12-108. The purpose of the proposed facility is to provide replacement capabilities for radiography and other nondestructive evaluation activities on weapons, components, and other objects. Specific operations would include: radiography, ultrasonic, digital imaging penetrant testing, laser sampling radiometry, and computer tomography of non-nuclear weapon materials. The existing nondestructive evaluation activities housed in Building 12-21 are inadequate for operations by current criteria because the existing structure is not designed to meet the DOE Explosives Safety Manual for Class 2 Operations. Other facilities at the plant were not viable due to the cost of compliance with the DOE Explosive Safety Manual (DOE 1994:I.A.1; Pantex 1996:App C).
This facility would consist of two, single-story structures joined by a ramp with a gross area of 3,734 square meters (40,196 square feet) and a net usable area of 3,009 square meters (32,386 square feet). The NDEF would have five explosive bays for nondestructive evaluation activities and areas for a vault, electronic repair and spare parts staging area, office area, film reading room, dark room, conference room, offices, computer area and waste accumulation. The five proposed bays are: the 420 kV X-ray Bay, Miscellaneous Test Bay, High/Medium Energy Radiography Bay, High/Medium Energy Computer Tomography Bay, and Explosives Component Staging Bay. X-ray functions would be housed in three of the five explosives bays. Each of these bays are described below (DOE 1994:I.A 1-2).
The 420 kV X-Ray Bay would be used for radiography of medium size components, such as fire sets, and would have a net usable area of 107 square meters (1,151 square feet) with 6-meter (20-foot) ceilings. Operations in this bay would include radiography and packing and unpacking components. The explosives limits in this bay would not exceed 45 kilograms (100 pounds). There would be no chemicals, gases, or fume or vent hoods required in this bay; however, plant air and vacuum would be required. A 47-square meter (508-square foot) control room would be required primarily to house computer equipment.
The Miscellaneous Test Bay would be used to support the following types of tests: portable penetrant testing, portable ultrasonic testing, eddy current, acoustic emission, magnetic particle, radar testing, 150 kV x-ray, 320 kV Microfocus, temperature chambers, and cabinet x-rays. Operations would include packing and unpacking components as well as testing, radiography, and controlled temperature transfer to components. Room dimensions for this bay are 219 square meters (2,362 square feet) in area and 6 meters (20 feet) in height. The explosives limit in this bay would not exceed 45 kilograms (100 pounds). Chemicals, such as penetrant testing cleaner, developer, and fixer would be required. No gases would be required; however, plant air and vacuum are necessary. A control room would also be required in this bay to house computer equipment (DOE 1994:I.E 7-9).
A High/Medium Energy Radiography Bay would be used to perform radiography on large parts, and to pack/unpack components. Size requirements for this bay include an area of 361 square meters (3,887 square feet) and 7.6 meters (25 feet) in height. Explosives limits in this bay would not exceed 45 kilograms (100 pounds). There would be no chemicals or gases required in this bay; however, plant air and vacuum would be required in this area. Plant air should be the same as in Building 12-84, and Building 12-104A. A separate HE vacuum system or fume or vent hoods would not be required. The control room for this bay would be 71.2 square meters (767 square feet).
A High and Medium Energy Computer Tomography Bay would be used to analyze, determine the contents, and pack/unpack small to large parts. The conceptual design for this bay calls for an area of 364 square meters (3,290 square feet), a height of 7.6 meters (25 feet), and an explosive limit of 45 kilograms (100 pounds). In addition, the bay would be required to provide access to vehicles up to 11 meters (36 feet) long, 4.3 meters (14 feet) high, and have an entrance width of at least 3.6 meters (12 feet); the weight limit would satisfy the State of Texas maximum allowed over-the-road requirements. Gas and chemical requirements for this bay are similar to those described for the High/Medium Energy Radiography Bay. A 55.5-square meter (597-square foot) control room has been proposed in the conceptual design to primarily house computer equipment (DOE 1994:I.E 13-14).
An Explosives Component Staging Bay in the NDEF would occupy a 53-square meter (570-square foot) area, 6.1 meters (20 feet) high, with an explosive limit of 45 kilograms (100 pounds). Since no chemicals or gases would be required in this bay, there would be no fume or vent hood requirements.
The proposed NDEF would also contain a 37-square meter (400-square foot) vault area for film staging and retrieval. No explosives, chemicals, or gases would be stored in this area. Less than 10-percent humidity would be required.
In addition, usable space in the NDEF would also be occupied by administrative, support, and analysis areas. The buildings would be temperature- and humidity-controlled. The facility would be secure to conduct classified activities, and would be designed in accordance with all applicable environmental, safety, and health requirements. The NDEF would be built in an area with no known soil contamination, located in accordance with the Pantex Plant Site Development Plan (DOE 1994:I.A 1-2; DOE 1995c).
Current plans are to include technology transfer activities inside the proposed NDEF. Approximately 30 percent of the workload for this facility would result from technology transfer operations. The Stevenson-Wydler Technology Innovation Act of 1980, as amended, establishes technology transfer as a mission of the Federal government to enhance the industrial competitiveness of U.S. industries in a global economy by utilizing resources at Federal facilities. One strategy to accomplish the goal is to make news from DOE laboratories and facilities available as an integrated technical resource for existing manufacturing extension and technology outreach systems. To meet this goal, planning for the NDEF has included technology transfer activities in an upgraded facility (DOE 1994:I.B 4-5).
No decisions have been made regarding future use of existing facilities. The decision to reuse, modify, or demolish will be addressed in future NEPA documentation.
H.7.2.1 Environmental Considerations
Waste management issues for continued operations in Building 12-21 are of environmental concern. Film processing, performed in this existing facility for many years, has generated waste (e.g., silver, fixer, and developer) that was previously released to a nearby drainage ditch. The release site is one of 144 sites currently under investigation. The waste handling system for Building 12-21 was later redesigned to meet current discharge effluent requirements. However, since the waste accumulation site was not an integral part of the facility design, the piping for waste collection was retrofit. Building 11-29 collects facility-wide film processing wastes for silver recovery. Furthermore, Building 12-21 was not designed for chemical use or accumulation sites.
The current accumulation site, a hallway, is open to all general area traffic. The new NDEF would be a stand-alone facility that would be designed specifically to meet all present environmental codes and regulations. The current waste handling requirements are incorporated into the initial conceptual design criteria. Normal operation of this facility would be in compliance with Federal, State, and local air and water pollution control standards and would not have cumulative or long-term adverse effects on the environment (DOE 1994:I.B 2-3).
The site would be graded to drain surface water into the existing plant stormwater drainage system. Sanitary wastewater would be directed and processed through the plant sanitary sewage system. Solid domestic-type waste would be taken to a municipal sanitary landfill for offsite disposal (DOE 1994:I.E 36).
During construction of the proposed facility, environmental considerations would include pollution and soil erosion controls to mitigate impacts on air, water, and other environmental resources and to ensure compliance with Federal, State, and local laws and regulations. Construction debris would be collected and hauled to the Pantex Plant landfill on a regular basis. No open burning of construction refuse or other Class 2 and Class 3 would be allowed (DOE 1994:I.E 36-37).
The design of this facility includes an energy conservation analysis. Appendix G, Pollution Prevention and Waste Minimization, presents an additional discussion of water and energy conservation (DOE 1994:I.E 36).
No permits are currently required for existing facilities and would not be required for the replacement facility.
H.7.2.2 Health and Safety
Most of the safety concerns deal with inadequacies in construction of the existing facility, Building 12-21. This facility is inadequate for operations by current criteria and was not designed to meet the current safety design criteria for explosive operations (DOE Explosive Safety Manual [DOE 1991] for Class 2 level of protection) or radiation protection. Because of the age of the facility, the ability to deal with these design problems in the existing structure is limited. In addition, the current ventilation and fire protection systems are inadequate. There is also contamination in this facility. Lead contamination has resulted from the paint, lead bricks, and screens used in radiography. Explosives contamination has resulted from past HE processing activities, and asbestos is present in the ceiling. The conceptual design for the new NDEF call for Safety Analysis Reports for the NDEF project to be developed and implemented prior to the start of facility operation (DOE 1994:I.B 1-2, I.E 39).
H.7.2.3 Safeguards and Security
The NDEF would also provide upgrades to security; it would be located within the Protected Area. Classified material would be stored in the facility within the bays and in the vault. Special nuclear material would not be stored in this facility. In addition, the facility would be connected to the plant's existing security alarm network (DOE 1994:I.E 40).
H.7.3 Relationship to Other Projects
The NDEF would be related to the Gas Analysis Laboratory, which is also located in Building 12-21. Additionally, this project would relocate the Vibration Testing, Hostile Shock Test, Mini-Air Gun Shock Test, and the Centrifuge Test to Building 12-78 as part of an interim plan.
H.7.4 Environmental Impacts
H.7.4.1 Infrastructure
Electrical usage would remain the same at 1,150 megawatthours per year as for the existing facility. No natural gas would be used at the facility. Steam usage would remain the same at 2.9 million kilograms per year (6.5 million pounds per year) involving the use of 451,000 liters per year (119,000 gallons per year) of water and 0.2 million cubic meters per year (6.2 million cubic feet per year) of natural gas (PC 1995:Table 3).
H.7.4.2 Land Resources
The building site is located in the north end of Zone 12 South, nearly equidistant to the east and west perimeters of Zone 12 South. The facility is north of Building 12-121 and west of Building 12-108. The facility is designed with 3,734 square meters (40,196 square feet). The facility would consolidate and improve operations and increase the safety to the worker, the public, and the environment. There are no expected environmental impacts of the Proposed Action on the surrounding land resources.
H.7.4.3 Geology And Soils
There could be very minor impacts to the soils due to erosion during construction. The area of temporarily disturbed soil would be 7,468 square meters (80,392 square feet) (PC 1995:Table 1). Mitigation measures such as sediment traps, diversion of surface water runoff from the construction area, dikes, silt fences, and covering the disturbed area with rip rap would be used to minimize soil erosion.
H.7.4.4 Water Resources
Water use is expected to remain at its current level of 9,120,000 liters per year (2,407,000 gallons per year). The generation of wastewater is also expected to remain at its current level of 8,020,000 liters per year (2,107,000 gallons per year) (PC 1995:Table 3). The facility construction site is not located within a known, playa-associated 100-year floodplain (DOE 1994:I.E 36).
H.7.4.5 Air Quality
Airborne particulate matter (i.e., dirt and equipment emissions) levels would be elevated during the construction period. This facility is expected to generate the same types and quantities of air emissions as the existing facility it would replace. Therefore, there would be no changes in the impacts from current levels (DOE 1994:I.B 2-3; PC 1995:Table 3).
H.7.4.6 Acoustics
Noise levels would temporarily increase during construction from operation of heavy construction equipment such as graders, cement mixers, and construction vehicle traffic. During nondestructive evaluation operations, noise would be emanating from a Real Time Radiography system, x-ray machine, a Microfocus machine, a high/medium energy radiography system, a high/medium energy computer tomography system, and a computer network system (DOE 1994:I.E 92, 94). Local worker and transportation traffic would contribute to the ambient noise in the area. The majority of the ambient noise in the area would be expected during the operation of the heating, ventilation, and air conditioning system (DOE 1994:I.E 70-74, 83). The operational areas design will include noise controls pursuant to OSHA standards (29 CFR 1910.95).
H.7.4.7 Biotic Resources
Flora and fauna that currently use the facility construction site would be permanently removed or displaced by construction. Pollution and soil erosion controls will be implemented during construction activities to mitigate impacts on biotic resources (DOE 1994:I.E 36-37, 49-50).
H.7.4.8 Cultural Resources
No archaeological sites or historical resources have been identified in or near the proposed construction site and no impacts to cultural resources are anticipated (DOE 1994:I.E 41).
No decisions have been made regarding use of existing facilities which may qualify as historic resources. The decision to reuse, modify, or demolish will be addressed in future NEPA documentation.
H.7.4.9 Socioeconomic Resources
The construction cost of this facility would be approximately $51.5 million. Construction of the facility is expected to employ 130 to 224 short-term employees (PC 1995:Table 1). Construction of the facility would probably result in a small temporary increase in local employment. A substantial portion of the material costs would enter the wholesale and retail trade sector of the regional economy. This facility is designed for an estimated 42 employees; no new employees are expected. Employees working in the existing facilities would be relocated to new facilities (PC 1995:Table 3).
H.7.4.10 Transportation
The construction of this facility would result in a temporary increase in onsite and area traffic during a 42-month period. Normal day shift work hours, Monday through Friday, are expected. However, since Zone 12 includes the Material Access Area and conducts weapon operations and HE operations, some schedule changes can be expected due to workloads and HE safety issues. Since construction of the facility is in a Material Access Area, 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 Facility. Intrasite transportation impacts are presented in section 4.12.
H.7.4.11 Waste Management
This facility is expected to generate the same types and quantities of wastes as the existing facility it would replace. Therefore, there would be no changes in the impacts from current levels (PC 1995:Table 3).
H.7.4.12 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).
Potential sources of radiological exposures during operation are expected. Potential sources of chemical exposures during operations would be from chemicals and materials used in analysis of materials. Personal protective clothing, shielding, and equipment (e.g. ventilation hoods) would be used to mitigate the potential health risks. Plant-wide human health impacts are presented in section 4.14.
H.7.5 No Action Alternative
One of the alternatives to the construction of the Nondestructive Evaluation Facility is to continue operations in a deteriorating building. X-ray operations would continue in the existing facility through establishment of administrative exclusion areas for the protection of employees. The existing building lacks adequate engineering controls. Administrative controls will continue during explosive evaluation operations due to inadequate building design features. Workload scheduling conflicts with the Gas Analysis Laboratory are expected due to overcrowding.
H.7.6 Move to an Existing Facility Alternative
An alternative to the Proposed Action is the modification of an existing facility for evaluation operations. If a suitable facility is identified, it would be required to meet all present environmental codes and regulations and pollution control standards. The facility would be required to utilize design features and administrative controls to protect employees and the environment. No suitable facility so far has been identified for this purpose. If nondestructive evaluation operations were spread through multiple areas of the plant, it would create logistical problems with building management. The facility manager has direct line responsibility for the operation of a facility, including the authority to direct physical changes to that facility, operation reporting requirements, and providing corrective actions (DOE 1994:I.C 2).
H.7.7 Alternatives Eliminated from Detailed Study
Two alternatives were eliminated from detailed study during the preliminary evaluation of the Nondestructive Evaluation Facility project. The first alternative was to send Nondestructive Evaluation operations offsite. However, this option was deemed unacceptable because many of the parts tested are classified. The second alternative was to cease all nondestructive evaluation operations. However, these operations are required to support dismantlement, evaluation, retrofit, repair, modification, and new build activities (DOE 1994:I.C 2, I.D 3).
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