Evaluation Of Chemical Events At Army Chemical Agent Disposal Facilities

For over a decade the Army has been carrying out a program aimed at the destruction of accumulated chemical weapons stored at several sites. While destruction by incineration has been successful, several incidentsâ€"called chemical eventsâ€"occurred during the disposal process or decontamination activities that raised some public concerns about the safety of operations of three third generation incineration facilities. As a result, the Congress asked the NRC to investigate whether the incidents provide information useful to help ensure safe operation of the future sites. This book presents an analysis of causes of and responses to past chemical events, implications of such events for ongoing and future demilitarization activities, and recommendations for preparing for future events.

The U.S. Army's Chemical Materials Agency (CMA) currently oversees contracts for the operation of chemical agent stockpile incineration facilities at four disposal sites. Because the period of time required to dispose of these chemical agents has grown beyond that originally planned, the Army is becoming concerned about the possibility of growing operational problems as the processing equipment ages. To help address these concerns, the CMA requested the NRC to assess whether current policies and practices will be able to adequately anticipate and address facility obsolescence issues. This report presents a review of potential infrastructure and equipment weaknesses given that the facilities are being operated well beyond their original design lifetime; an assessment of the Army's current and evolving obsolescence management programs; and offers recommendations about how the programs may be improved and strengthened to permit safe and expeditious completion of agent stockpile destruction and facility closure.

In keeping with a congressional mandate (Public Law 104-484) and the Chemical Weapons Convention, the United States is currently destroying its chemical weapons stockpile. The Army must ensure that the chemical demilitarization workforce is protected from the risks of exposure to hazardous chemicals during disposal operations and during and after facility closure. Good industrial practices developed in the chemical and nuclear energy industries and other operations that involve the processing of hazardous materials include workplace monitoring of hazardous species and a systematic occupational health program for monitoring workers' activities and health. In this report, the National Research Council Committee on Review and Evaluation of the Army Chemical Stockpile Disposal Program examines the methods and systems used at JACADS and TOCDF, the two operational facilities, to monitor the concentrations of airborne and condensed-phase chemical agents, agent breakdown products, and other substances of concern. The committee also reviews the occupational health programs at these sites, including their industrial hygiene and occupational medicine components. Finally, it evaluates the nature, quality, and utility of records of workplace chemical monitoring and occupational health programs.

By the end of 2009, more than 60 percent of the global chemical weapons stockpile declared by signatories to the Chemical Weapons Convention will have been destroyed, and of the 184 signatories, only three countries will possess chemical weapons-the United States, Russia, and Libya. In the United States, destruction of the chemical weapons stockpile began in 1990, when Congress mandated that the Army and its contractors destroy the stockpile while ensuring maximum safety for workers, the public, and the environment. The destruction program has proceeded without serious exposure of any worker or member of the public to chemical agents, and risk to the public from a storage incident involving the aging stockpile has been reduced by more than 90 percent from what it was at the time destruction began on Johnston Island and in the continental United States. At this time, safety at chemical agent disposal facilities is far better than the national average for all industries. Even so, the Army and its contractors are desirous of further improvement. To this end, the Chemical Materials Agency (CMA) asked the NRC to assist by reviewing CMA's existing safety and environmental metrics and making recommendations on which additional metrics might be developed to further improve its safety and environmental programs.

This book responds to a request by the director of the U.S. Army Chemical Materials Agency (CMA) for the National Research Council to examine and evaluate the ongoing planning for closure of the four currently operational baseline incineration chemical agent disposal facilities and the closure of a related testing facility. The book evaluates the closure planning process as well as some aspects of closure operations that are taking place while the facilities are still disposing of agent. These facilities are located in Anniston, Alabama; Pine Bluff, Arkansas; Tooele, Utah; and Umatilla, Oregon. They are designated by the acronyms ANCDF, PBCDF, TOCDF, and UMCDF, respectively. Although the facilities all use the same technology and are in many ways identical, each has a particular set of challenges.

Under the direction of the U.S. Army's Chemical Materials Agency (CMA) and mandated by Congress, the nation is destroying its chemical weapons stockpile. Over the past several years, the Army has requested several studies from the NRC to assist with the stockpile destruction. This study was requested to advise the CMA about the status of analytical instrumentation technology and systems suitable for monitoring airborne chemical warfare agents at chemical weapons disposal and storage facilities. The report presents an assessment of current monitoring systems used for airborne agent detection at CMA facilities and of the applicability and availability of innovative new technologies. It also provides a review of how new regulatory requirements would affect the CMA's current agent monitoring procedures, and whether new measurement technologies are available and could be effectively incorporated into the CMA's overall chemical agent monitoring strategies.

The Department of Defense, through the Assembled Chemical Weapons Alternatives program, is currently in the process of constructing two full-scale pilot plants at the Pueblo Chemical Depot in Colorado and the Blue Grass Army Depot in Kentucky to destroy the last two remaining inventories of chemical weapons in the U.S. stockpile. These two storage sites together account for about 10 percent of the original U.S. chemical agent stockpile that is in the process of being destroyed in accordance with the international Chemical Weapons Convention treaty. Unlike their predecessors, these facilities will use neutralization technologies to destroy agents contained within rockets, projectiles, and mortar rounds, requiring the use of specially designed equipment. As part of its focus on safe operation of the planned facilities, the Program Manager for Assembled Chemical Weapons Alternatives asked the National Research Council (NRC) to conduct a study to offer guidance on the application of process safety metrics at the Pueblo Chemical Depot and Blue Grass Army Depot. Process safety is a disciplined framework for managing the integrity of operating systems, processes and personnel handling hazardous substances, and operations by applying good design principles, engineering, and operating practices. Process Safety Metrics at the Blue Grass and Pueblo Chemical Agent Destruction Pilot Plants discusses the use of leading and lagging process safety metrics that could provide feedback on the effectiveness of controls to mitigate risks and minimize consequences of potential incidents. The book makes several recommendations that will facilitate the development and application of process safety metrics at both sites.

Chemical warfare materiel (CWM) is a collection of diverse items that were used during 60 years of efforts by the United States to develop a capability for conducting chemical warfare. Nonstockpile CWM, which is not included in the current U.S. inventory of chemical munitions, includes buried materiel, recovered materiel, binary chemical weapons, former production facilities, and miscellaneous materiel. CWM that was buried in pits on former military sites is now being dug up as the land is being developed for other purposes. Other CWM is on or near the surface at former test and firing ranges. According to the Chemical Weapons Convention (CWC), which was ratified by the United States in April 1997, nonstockpile CWM items in storage at the time of ratification must be destroyed by 2007. The U.S. Army is the designated executive agent for destroying CWM. Nonstockpile CWM is being handled by the Non-Stockpile Chemical Materiel Program (NSCMP); stockpile CWM is the responsibility of the Chemical Stockpile Disposal Program. Because nonstockpile CWM is stored or buried in many locations, the Army is developing transportable disposal systems that can be moved from site to site as needed. The Army has plans to test prototypes of three transportable systems-the rapid response system (RRS), the munitions management device (MMD), and the explosive destruction system (EDS)-for accessing and destroying a range of nonstockpile chemical agents and militarized industrial chemicals. The RRS is designed to treat recovered chemical agent identification sets (CAIS), which contain small amounts of chemical agents and a variety of highly toxic industrial chemicals. The MMD is designed to treat nonexplosively configured chemical munitions. The EDS is designed to treat munitions containing chemical agents with energetics equivalent to three pounds of TNT or less. These munitions are considered too unstable to be transported or stored. A prototype EDS system has recently been tested in England by non-stockpile program personnel. Although originally proposed for evaluation in this report, no test data were available to the committee on the composition of wastes from the EDS. Therefore, alternative technologies for the destruction of EDS wastes will be discussed in a supplemental report in fall 2001. Treatment of solid wastes, such as metal munition bodies, packing materials, and carbon air filters, were excluded from this report. Review and Evaluation of the Army Non-Stockpile Chemical Materiel Disposal Program: Disposal of Neutralent Wastes evaluates the near-term (1999-2005) application of advanced (nonincineration) technologies, such as from the Army's Assembled Chemical Weapons Assessment Program and the Alternative Technologies and Approaches Project, in a semi-fixed, skid-mounted mode to process Rapid Response System, Munitions Management Device, and Explosive Destruction System liquid neutralization wastes.