t h e United 0. Nelson, LANL (NMT-6) C. Bronson, LLNL (ISAM) K. Dennison, LLNL (NMT-6) L. Cremers, LANL (NMT-4)

Transcription

1 (Rev.1).. h c Los Alamos Natonal Laboratory s operated TITLE AUTHOR(S): SUBMITTED TO: by t h e Unversty of Calforna for t h e Unted States Department of Energy under contract W-745-ENG-36 REc F v EB Advanced Recovery and Integrated Extracton System (ARIES) Program Plan [Rev. 13 T. M. D. P. T. L.. Nelson, LANL (NMT-6) C. Bronson, LLNL (ISAM) K. Dennson, LLNL (NMT-6) W. Massey, LAM, (EES-14) L. Cremers, LANL (NMT-4) S. Kreyer (ESH-14) DOE/Offce of Fssle Materals Dspostton (OFMD) ~- Ths report was prepared as an account of work sponsored by an agency of the Unted States Government. Nether the Unted States Government nor any agency thdreof, nor any of ther employees. makes any warranty, express or mpled, or assumes any legal lablty or responsblty for the accuracy, completeness, or usefulness of any nformaton, apparatus, product, or process dsclosed, or represents that ts use would not nfrnge prvately owned rghts. Reference heren to any specfc commercal product, process. or servce by trade name, trademark, manufacturer, or otherwse does not necessarly consttute or mply ts endorsement, recommendaton, or favorng by the Unted States Government or any agency thereof. The vews and opnons of authors expressed heren do not necessarly state or reflect those of the Unted States Government or any agency thereof. ~--- - ~- ~._ ~- By acceptance of ths arlcle. the publsher recognzes that t h e U.S. Government retans a nonexclusve. royalty-free lcense to publsh or reproduce Ihepublshed form of ths contrbuton. or to allow others lo do so. for U.S. Government purposes. The Los Alamos Natonal Laboratory requests that FOAM NO. 836 A4 ST. N /81 the publsher dentfy ths artcle a s work performed under the auspces of t h e U.S. Department of Energy. amm LosAlambs Natonal Laboratory LosAlamos,New Mexco 87545

2 DISCLAIMER Portons of ths document may be llegble n electronc mage products. Images are produced from the best avalable orgnal document.

3 Advanced Recovery and Integrated Extracton System (ARIES) Program Plan [Rev. I] by T.. Nelson, LANL (NMT-6) M. C. Bronson, LLNL (ISAM) D. K. Dennson, LLNL (NMT-6) P. W. Massey, LANL (EES-14) T. L. Cremers, LANL (NMT-4) L. S. Kreyer (ESH-14) February 2,

4 *I 1. INTRODUCTION The Advanced Recovery and Integrated Extracton System (ARIES) demonstraton combnes varous technologes, some of whch werdare beng developed under prevoudother Department of Energy (DOE)hnded programs. A R E S s an overall processng system for the dsmantlement of nuclear weapon prmares. The program wll demonstrate dsmantlement of nuclear weapons and retreval of the plutonum nto a form that s compatble wth long term storage and that s nspectable n an unclassfed form approprate for the applcaton of tradtonal nternatonal safeguards. The success of the ARIES demonstraton would lead to the development of a transportable modular or other faclty type systems for weapons dsmantlement to be used at other DOE stes as well as n other countres. The purpose of the ARIES process s to receve weapon pts, dsassemble them, and provde a product of ether a plutonum metal button or plutonum oxde powder approprately canned to meet all requrements for long term storage. Ths demonstraton s a 24-month program wth fll operaton planned durng the last three to sx months. The ARIES system s modular n desgn to offer credble scalng, ncorporaton of modfcatons or new concepts, and fture transportablty and exportablty capabltes. For the 24-month program, only pts wth a straghtforward desgn confguraton wll be processed. A R E S wll develop and demonstrate the followng modular elements: A pt bsecton module used to cut open and physcally separate the varous components of the weapon pts, A hydrde-dehydrde recycle module to remove the plutonum fom the weapon component substrate surfaces and cast t as a metal ngot, A parallel hydrde-oxde W O X ) module to remove plutonum fom the weapon component substrate surfaces and produce plutonum oxde, A module that results n a double contanment nspectable, long term storage package of ether the plutonum metal or oxde. The cannng task packages the materal n artght cans compatble wth materals dsposton long term storage requrements n conjuncton wth an electrolytc decontamnaton task to decontamnate the outsde surfaces of the materal cans for removal fomthe glovebox envronment, and A nondestructve assay (NDA)/nstrument support module for analyzng the sealed storage cans to provde acgountab1ty and process control of all the specal nuclear materal and waste tems produced by ARIES. Each module task ncludes the desgn, fabrcaton, and testng of the equpment, and nstallaton of the unt and assocated equpment nto a glovebox. Other equpment 2

5 nstallaton,such as part declassfcaton or a meltnglcastng furnace, may be ncluded for ths demonstraton, but have not yet been defned as module tasks. A fnal task conssts of all the actvtes necessary to ntegrate the ndvdual modules nto an operatonal system wthn the plutonum hclty (TA-55) at Los Alamos Natonal Laboratory (LANLJ. Ths task ncludes faclty preparaton actvtes, desgn and assembly of a conveyer system compatble wth all the modules, acquston of the gloveboxes, desgn and assembly of a control system to operate the ntegrated assembly, and preparaton of all system documentaton requrements. Addtonally, ths task represents the ntegrated demonstraton of the dsmantlement of the nuclear weapon prmares for the last three to sx months. 2. BACKGROUND In October 1994, the Secretary of Energy and the Congress created the Offce of Fssle Materal Dsposton (MD) wthn the DOE. The MD program s responsble for the DOE'S techncal and management actvtes n two major areas. Frst,DOE actvtes need to provde a safe, secure, envronmentally sound, and nspectable future storage opton for all weapons-usable fssle materals. Second, they must provde dsposton optons for those fssle materals declared surplus to natonal defense needs. The objectve of A R E S s to demonstrate feasblty of a process for dsassembly, extracton, and converson of plutonum fom weapons components nto forms sutable for dsposton and /or storage whle emphaszng polluton preventon. Currently, no ntegrated system exsts for the complete dsmantlement and recovery of nuclear materal fom dfferent weapons' desgns. A second objectve s to develop and demonstrate feasblty of a modular ARIES processng system that could be used by both the US and Russa. 3. SCOPE The ARIES program encompasses all admnstratve, techncal, engneerng, procurement, and nstallaton tasks necessary for desgn, procurement, fabrcaton, nstallaton, hot startup, and operaton of the complete system. The program ncludes the followng features: Admnstratve Scope: The key admnstratve tasks are organzaton of resources, defnton of requrements, development and mantenance of schedules, cost control, and progress trackng. Work packages wll be a prmary tool for achevng admnstratve success. Addtonal elements of admnstratve scope nclude the followng: resoluton of ES&H and TA-55 facty requrements, start-up actvtes, confguraton management, operatonal tasks, and formal mplementaton of close-out actvtes upon program completon. Techncal Scope: ARIES focuses on assmlatng all the ndvdual modules nto an ntegrated system wthn a TA-55laboratory. The completed system wll be szed, assembled, and operated to confrm the feasblty of the pt dsassembly and converson process. ARIES wll prove the functonalty of the processes and assess ther 3

6 transportablty. The system wll demonstrate straghtforward mantenance and flexblty to accommodate fture mprovements. The techncal scope requres that ARIES be desgned by experts n each fnctonal area: pt dsassembly, hydrdddehydrde plutonum removal and consoldaton, hydrddoxdaton plutonum removal and consoldaton, product cannng, electrolytc decontamnaton, NDA, control and nstrumentaton, and contanment desgn. The fnalaries confguraton wll combne the desgns of these techncal experts nto a practcal operatng system. Boundares: The ARIES program s bounded by the followng LANL factors: The program s ntated through formal acton by the FMDP to allocate fnds and by each Laboratory's ablty to obtan resources. The program s termnated at completon of assgned mplementaton tasks by ssuance of a program close-out package. The program s constraned by mpacts to other ongong work at the Laboratores. The constrants wll not mpact techncal scope, although schedule and extent of selfsuffcency of ARIES subsystems could be affected. Relatve prortes of ARES versus other work at each Laboratory s the key to the extent of constrants. ARIES s desgned and constructed wthn the safety envelope and avalable space at TA-55. ARIES s desgned for successful hot start-up by utlzng a set of processes that have already been demonstrated n plutonum operatons. The ARIES program wll be conducted wth a hgh degree of control over development, desgn, constructon, and start-up to ensure forward progress and testng of the ntegrated system begnnng 1 Aprl ORGANIZATION ARIES s unque because the project uses a matrx management approach wth dedcated M f o m two natonal laboratores responsble for the success of the project. Ths arrangement s descrbed below. 4.1 Confguraton A R E S s sponsored by the DOE'S Materal Dsposton program. It s conducted as a cooperatve program between LANL and Lawrence Lvermore Natonal Laboratory (LLNL) wth LANL as the lead laboratory. L W s Nuclear Materals & Stockple Management (NMSM) program offce s responsble for overall admnstraton of the ARIES program. The LLNL Nonprolferatodhs ControVInternatonal Securty Drectorate ( I S A M ) s responsble for admnstraton of the Lvermore portons of the ARIES program. The Nuclear Materals Technology (NMT) Dvson at LANL s responsble for overall project management and system mplementaton of ARIES as well as the operaton of 4

7 TA-55. The ARIES demonstraton project leader s an NMT staff member and he s supported by the LLNL A R E S project leader. Ths organzaton s structured to meet the dversty of technologes and staff needed for successful program mplementaton. The staff requred represents an ntegraton of several dscplnes fom both laboratores. Consequently, the team s matrxed, for the purpose of techncal work, to the LANL ARIES demonstraton project leader. Varous organzatons fom both labs provde supportng work for development, desgn, procurement, fbrcaton, nstallaton, and operaton. Requests for such servces wll be ntated ether by the organzatonswhose staffare matrxed to ARIES, or by the ARIES Physcal Integraton Team (PIT). In both cases, each laboratory project leader wll approve the work requests fom hs organzaton and track costs and schedule. 4.2 Program Organzaton Both organzatons wll develop selected modules at ther respectve laboratores. System ntegraton and operaton wll be performed by the team at TA-55. A LLNL team member has been assgned to LANL to serve as the LLNL ntegraton lead and on-ste representatve. An organzatonal chart of the ARIES project s shown n Fgure 1. The ARIES program requres desgn, procurement, fabrcaton, assembly and nstallaton, safety and envronmental revews, start-up procedures and readness revews, as well as, program admnstraton and resource allocaton. These requrements are met by establshng several module teams wth specfc responsbltes, as shown n Table 1. Each of the modules wll nvolve the desgn of the equpment, ts glovebox, and ts support equpment. Ths effort also ncludes fabrcaton and testng of the equpment, nstallaton of the equpment n the gloveboxes, and hot testng. In addton to the responsbltes lsted above and n Table 1, all Module Teams (MTs) wll support start-up revews, prepare requred documentaton, and nterface wth one another as needed through the PIT, and through drect contact wth other team members. Integraton of all modules nto an operatonal system ythn TA-55 conssts of several actvtes ncludng the followng: faclty preparaton, desgn and assembly of a conveyor system compatble wth all the modules, acquston of gloveboxes, desgn and assembly of a control system to operate the ntegrated assembly, and preparaton of all system documentaton requrements. Gloveboxes wll be procured fom a commercal suppler, or to expedte nstallaton, by adaptaton and relocaton of exstng gloveboxes. Commercal servces may also be used to decontamnate the demonstraton faclty room n preparaton for nstallng the ARIES gloveboxes ,

8 . Fgure 1: AWES Demonstraton Organzaton LLNL Program Lead LLNL ARlEs - Project Leader I I Bronson LANLprogramLead ARES Demonstraton Project Leader I Nelson PROGRAMMATICINTEGRATION TEAM Modular Desgn Team Systems Analyss Safeguards & Securty Operatons & ES&H Requrements PHYSICAL INTEGRATION TEAM LLNL Integraton Lead Module Team Leaders Systems Engneerng. I I I Pt Bsecton Ravenscrofl ly H;IrrlFurnace Colmenares HydrdeDehydrde Furnace Flamm ' Canout & Electrolytc Decontamnaton Non-Destructve (AutomatodRobotcs) I Huang Lawrence Lvermore Natonal Labomtory 6,. Sampson

9 Table I:ARIES Project Module Teams T&Utl Partcpaton Project Executve Team LANL/NMSM Dsposton Program Manager, UNUFssle Materals Program Manager, FW LANL ARIES Demo Project Leader, LLNL ARIES Project Leader Physcal Integraton kam PK)?rogrammatc ntegraton Team dodule Teams (MTs) Pt Dsassembly Module LANL ARIES Demo Project Leader, LLNL ARIES Project Leader, LLNL Integraton Lead Module Team Leaders, Other NMT Faclty group members, LANL/ESA-EPE, LLNLEE, others QualtyAssurance LANUNMSM Dsposton Program Manager, LLNUFssle Materals Program Manager, LANL ARIES Demo Project Leader, LLNL ARIES Project Leader, TSA, ESA,M y NlS, others Responsbltes Top level decsons Prortzaton of LANL TA-55and LLNL-332 ARIES actvtes Hgh-mpactchange control Techncal baselne approval TA-55faclty preparaton Module process ntegraton Glovebox desgn & procurement ARIES confguratoncontrol Law-mpactchange control Supervsory/dstrbutedsystem controller desgn, fabrcaton, and nstallaton ModularDesgnTeam Systems Analyss Safeguards&Securty operatons ES&H Requrements Lead: L L W ' I E D Smple pt bsector desgn, fabrcaton, assembly, cold-test, system ntegraton, test & operaton. Hydrdmehydrde Module Lead: LANLJNMT-5 support: LLNLASAh4 Hydrde dehydrde module desgn, Mrcaton, assembly, system ntegraton, test & operaton. HYDOXModule Lead: LLNWISAM support: LANLNMT-5 KYDOX module development, hot test, ARIES desgn, fabrcaton, cold test, system ntegraton, test & operaton. Electrolytc Decontamnaton & Canout Module Lead: LANLJNMT-6, ESA-EPE Nondestructve Assay/Instrumentaton Support Module Lead: LANuNIS-5 Nh4T-4, ESA-I" Support: LANLKSA-7 Electrolytc decontamnatonand canout task desgns, f-brcaton, assembly, system ntegraton, test & operaton. NDAllnstnunent Support module desgn, fabrcaton, assembly, system ntegraton, test & operaton. Includes fxed and robotc automaton desgn for NDA module. 7

10 5. REQUIREMENTS Development and placement,ofaries n TA-55 must conform to a comprehensve set of requrements and gudance governed by LANL and NMT Facltes and Safety Operatons groups. All phases of the mplementaton program, fom ncepton through desgn, constructon, and start-up, are revewed by these groups. The program must ensure that all requrements are met to mantanthe TA-55 safety envelope and to avod unnecessary delays durng pre-start-up revew. 5.1 Envronment, Safety, and Health (ES&H) Revews Safety of the envronment, the off-ste populaton, and the workers, s assured by performance of safety revews of the proposed ARIES desgn. The mechansm for ensurng that approprate revews are performed nvolves completon of a LANL ES&H Questonnare, followed by a large number of desgn and operatng envelope evaluatons performed by ndependent laboratory organzatons. These revews are governed by varous DOE Orders, Federal Regulatons and Rules, and State of New Mexco Regulatons. Natonal Envronmental Polcy Act INEPA) Evaluatons: The project management team (wth assstance fom LANL's ES&H organzaton) w ll assure complance wth all exstng laboratory NEPA requrements related to the nstallaton and operaton of ARIES n TA-55. A NEPA Categorcal Excluson was granted for ARIES by DOE on May 3 1, [See Appendx A] Worker and Faclty Safety: The ARIES project w l l follow all safety and health requrements as outlned n the TA-55 Safety Manual (LA , Rev. 1, Plutonum Faclty, October 1992). All applcable Occupatonal Safety and Health Act (OSHA) requrements and DOE Orders related to worker health and safety are addressed n the manual. Oversght of conformance to these documents s provded by the NMT Dvson Offce, NMT Facltes group, and the Envronmental Safety & Health Dvson (ESH). 5.2 Desgn and Installaton Work Desgn and nstallaton of ARIES must conform to varous standards and requrements to ensure equpment performance, securty, and safety of the plant workers and the publc. Current LANL TA-55 procedures have been wrtten and approved to assure complance wth all applcable DOE orders and ASWANSUASHE codes. Sgnfcant procedures and requrements are dentfed below. ARIES Project Qualty Assurance Plan (QAD-11-ROO, January 1996) LANL Readness Assessment Program (538-GEN-RO1, November 1995) LANL Confguraton Management Procedures Controllng Process Changes n PF-4 at TA-55 (564-GEN-ROO, May 1995) - 8

11 - Intatng Faclty and Process Changes at TA-55 (565-GEN-ROO.4, November 1995) Procurement Specfcaton for Process Enclosure (NMT-B-PS-1161-ROO) 5.3 Program Admnstraton The program to mplement ARIES s governed by varous gudance documents and polces. Whle these requrements prncpally deal wth large projects andor constructon, adherence to ther ntent wll expedte progress and allow conformance wth evolvng management practces at Los Alamos. The most sgnfcant requrements derve fom the control documents lsted below. NMT (Gen Seres 4 & 5) Safe OperatngProcedures TA-55 Work Order Control System Users Gude Polcy Book for NMT Dvson Los Alamos Natonal Laboratory Fnancal Management Handbook Los Alamos Natonal Laboratory AdmnstratvePolces and Procedures Manual Lawrence Lvermore Natonal Laboratory Admnstratve Polces and Procedures Manual 6. PROGRAM CONTROL The ARIES program reles on exstng capabltes at LANL and LLNL for control of costs, schedulng, preparaton and control of documents, and overall admnstraton of the program. Sgnfcant program control features, ncludng a descrpton of major documentaton, are dscussed below. 6.1 Documentaton Programmatc Documentaton Techncal Task Plans (TTPs): These plans defne the ARIES objectve, scopes of work, project responsbltes, current fscal year fndng levels, benefts, major mlestones, counterpart support, and assumptons necessary to meet task mlestones for each of the fve major modules and the ntegraton task. ARIES Promam Plan: The ARIES Program Plan s the chef document governng ntaton and admnstraton of the ARIES mplementaton program. It descrbes the msson and goals of ARIES, the confguraton of the mplementaton program, detaled mplementaton plans, requrements and regulatons that must be addressed, and resource needs for meetng program goals. Together wth other program documents descrbng desgns, resoluton of requrements and regulatons, procurement, nstallaton, and start-up, the Program Plan forms the foundaton of a comprehensve and retrevable database for revews, audts, evaluatons, and modfcatons. 9

12 ' ARIES Proect Oualty Assurance Pan KbW): The ARIES QAP descrbes the ARIES project organzatonal structure, hnctonal responsbltes, levels of authorty, and nterfhces. Functonal responsbltes nclude work such as requrements for program organzaton and project control, personnel tranng and qualfcaton, qualty mprovement, documentaton control, work processes, desgn processes, procurement processes, nspecton and acceptance testng, and management and ndependent revew assessment Desgn Documentaton Preconceptual Desm Report: Ths report descrbes the prelmnary nvestgaton that forms the bass for equpment selecton, system layout, TA-55 space selecton, and frther refnement n the conceptual desgn that follows. The process baselne dentfed n the Preconceptual Desgn Report s not expected to radcally change durng conceptual desgn; however, mechancal desgn of process equpment wll evolve as engneerng and supportng development studes progress. Conceutual Desm Report (CDR): Typcally, the CDR descrbes the prelmnary desgn for a lne tem project. Though ARIES s not a lne tem project, ths report s part of the ARIES desgn documentaton. CDRs contan constructon and cost estmate detal, narratves and drawngs, justfcatons relatng to msson and program requrements, szng, key feature requrements, and what drves them, relatonshps wth other projects and the ARIES objectve and msson. Sgnfcant alternatves addressed durng all phases of conceptual development are ncluded n the CDR along wth ratonale for choosng the approach beng proposed. Defntve Desm Packages: The defntve desgn completes the desgn as requred of the modules and provdes the documents necessary to prepare a bd package for equpment or glovebox constructon. The defntve desgn provdes: fnal specfcatons for constructon and equpment procurement, detaled drawngs as requred for equpment or glovebox constructon, desgn calculatons, constructon schedule, and dentfcaton of requred permts Procurement Packages: Procurement Packages nclude documents consstng of the Defntve Desgn Package, purchase request, specfcaton, sole source justfcaton, qualty assurance revew, purchase order, and ncomng nspecton report Start-up and Safety Revew Documentaton Safe Oueratnn Procedures (SOPS): Procedures used for long term operatons that may nvolve sgnfcant hazards such as those specfed n the Laboratory Envronment, Safety and Health Manual, AR 1-3 or other supportng AR sectons. 1

13 Crtcalty Safetv Revews: Revews performed by the group Crtcalty Safety Offcer (CSO) of crtcalty safety lmt postngs, operator complance wth crtcalty safety lmts, and new operatons and operatonal changes (n conjuncton wth HS-6). Acceptance Test Plan (each Module): A document that descrbes component testng necessary to ensure adequate performance of the ARIES process equpment. gperaton Test Plan: A document that descrbes testng necessary to ensure fnctonalty of the ARIES equpment. Calbraton Plan: A document that dentfes the ARIES measurng and test equpment (M&TE) and the requrements for calbratng and certflng those M&TE that requre perodc calbraton. Preventve Mantenance Plan: A document that dentfes A R I E S process equpment requrng preventve mantenance, mantenance actons to be performed, and the recommended mantenance ntervals. Confauraton Management Documentaton: ARIES nstallaton and room preparaton wll affect the PF-4, TA-55 Faclty. Confguraton Management revews the work package, requres numerous documents that depct alteratons and demonstrate faclty standards, provdes for approved as-bults as well as process and nstrumentaton drawngs (P&IDs), etc Operatng Procedures Overall system operaton: A document descrbng overall operaton of the ARIES system. Ths document collects ndvdual module procedures to gve an understandng of system performance. Indvdual module procedures: These are operatng procedures for each module of the ARIES system, ncludng operaton pror to system ntegraton. Indvdual module procedures nclude step-by-step nstructons for operaton of the module, as well as, warnngs and hazard notces As-Bult Desgn Packages (At completon of project): These packages contan documented data descrbng the condton actually acheved n the A R E S project, ncludng record drawngs, and specfcatons showng constructon as actually accomplshed Fnal Project Report: Ths report conssts of structured, wrtten analyses of the ARIES project, prepared to surfce aspects that should ether be perpetuated or mproved upon n future projects. 11

14 The report serves as a method for the module teams to mprove servces by evaluatng the lessons learned. 6.2 Document Control An mportant feature of ARIES s the creaton of a retrevable database for confguraton control, safety assessment, and hstorcal reference purposes. The database wll contan all major documentaton related to ARIES, such as the followng: fnal drawngs, calculatons, safety revew data, start-up nformaton and the major documents shown n Secton 6.1. The database wll consst of both electroncally stored nformaton and a hard copy lbrary. The hard copy lbrary wll be mantaned by the ARIES Physcal Integraton Team at TA-55. Both sets of records wll be sem-permanent fles remanng n exstence for fve years beyond dsassembly and decommssonng of the ARIES equpment. 6.3 CostISchedule Trackng The costs for the ARIES mplementaton program wll be tracked monthly by creaton of separate ARIES cost codes and work packages for both LANL and LLNL. Charges for contracts, nterdvsonal charges, procurement charges, and other expenses amenable to ll be tracked and montorng through exstng LANL and LLNL accountng procedures w reported n ARIES program status updates. An ntermedate schedule wll be created early n the program. More detaled schedules wll be developed as part of the TTPs and as nformaton s receved, such as craft schedulng through the Facltes and Safety Operatons group. In ether case, the schedule wll be updated monthly and crtcal path analyss used to hghlght areas of concern. Schedule data and cost data wll be ntegrated, as needed, to ndcate performance acheved by partcpatng organzatons and subcontractors. Schedulng s tracked to assess faclty resource needs. 7. IMPLEMENTATION PLAN Implementaton of ARIES nvolves many dscrete, but related, major actvtes. Falure n any one of these could jeopardze the antcpated hot start-up date. It s essental, therefore, that these actvtes be clearly defned, together wth key organzatons responsble for ther executon, to allow precse trackng of scheduled progress by the ARIES demonstraton project leader. Progress trackng wll enable early detecton of problems and potental delays, allowng the ARIES demonstraton project leader to focus resources on approprate resolutons and recovery plans. The major actvtes are brefly descrbed below together wth the prncpal organzatons nvolved. Organzaton Development: The ARIES techncal staff s assembled &om both laboratores usng a matrx management approach wth the ARIES demonstraton project leader provdng project drecton for ARIES-related work, and both 12

15 laboratory project leaders provdng techncal drecton, as descrbed n Secton 4. of ths report. Promam Plan: Development of the ARIES Program Plan s essental to meetng mlestones and accomplshnggoals. Completon of the Program Plan s the responsblty of the ARIES Physcal Integraton Team. Preconceptual Desdunctonal Desgn Crtera (FDC): A desgn concept wll be developed early n the mplementaton phase. Ths concept, together wth functonal crtera for process operatons, wll establsh a footprnt to be used for ARIES space selecton n PF-4 and for development of a techncal baselne. A preconceptual report wll be ssued at the concluson of ths actvty. Each module's DesgdDevelopment Team (DDT) s responsble for establshng a process system concept desgn that satsfes functonal requrements. Integraton of the concepts nto a feasble desgn s the responsblty of the Physcal Integraton Team. The process system DDTs wll develop layouts and requrements that correspond to TA-55 and LANL crtera. Conceptual Desgn: The conceptual desgn of ARIES follows fom the preconceptual desgn. It ncludes selecton of the most approprate locaton for the system, refhement of the process system desgn, establshment of a rudmentary materal balance for eventual test operatons, and descrpton of needed auxlary equpment and nterfaces. The DDTs are responsble for development of the conceptual desgn of each of the module components and for nput to a conceptual desgn report, to be assembled by the Physcal Integraton Team. Defntve Desgns: The conceptual desgn and results from development studes form the bass for the ARTES defntve, or Ttle II, desgns. The desgn packages, produced prmarly by the DDTs, nclude process and nstrumentaton dagrams, mechancal drawngs, equpment specfcatons, nstallaton drawngs, faclty layouts, and utlty te-n requrements. Each laboratory s nstrumental n desgn revew and approval durng ths phase. Procurement: After completon of each of the defntve desgn packages, the module teams, wth the approval of ther respectve laboratory project leader, wll ntate purchase requests for procured components. All purchase requests must follow approprate procurement procedures for each laboratory. M e r bd revews and awardng of contracts, purchased equpment s manufactured, nspected by the approprate desgn team, qualty assurance team, and delvered. Decontamnaton and DecommssonngD&D) of space: The room dentfed for ARIES contans exstng equpment and gloveboxes that must be removed. Ths nvolves preparaton of a D&D Plan, establshment of a work package that contans numerous work requests for LANL's support contractor, and cleanout of the desred 13

16 space. ARIES team members wll be responsble for much of the glovebox cleanng and waste removal, wth assstance from other LANL groups and support contractors. Installaton: Once decontamnated space for ARIES s avalable, gloveboxes and process equpment wll be nstalled. Development of an nstallaton plan by the Physcal Integraton Team, establshment of servce requests for contractor support, and actual nstallaton work by LANL's support contractor and ARIES staff are essental to nstallaton. Ths work wll proceed n two phases. The frst phase wll typcally consst of recept of gloveboxes and cold setup at both LANL and LLNL. The second phase nvolves transportng the gloveboxes to the selected space n PF-4 and fnal nstallaton. SdetyINEPA Revews: A seres of revews and assessments, performed prmarly by LANL's ES&H organzaton and NMT Dvson staff, are requred to ensure personnel and envronmental safety. Start-up Actvtes: Intaton of plutonum (hot) operaton actvtes for ARIES nvolves several related subtasks. Installed equpment must be tested, labeled, and posted wth pertnent safety lmts. Test data and as-bult desgn nformaton must be compled for the system confguraton database. Operatng procedures and accountablty parameters must be establshed. An ndependent system revew and an NMT Safety Commttee Revew must be performed, followed by cold operablty testng and operator tranng. These subtasks are governed by the TA-55START procedure and wll be performed prmarly by the ARIES staff and other approprate LANL and LLNL organzatons. The actvtes dentfed on Table 2 represent a much larger set of subtasks needed to mplement ARIES. Numerous dscrete steps are nvolved n ths program. Falure to acheve any one of the major mlestones shown n Table 2 could result n slppng the projected hot start-up date. Close program trackng and early detecton and resoluton of problems wll avod jeopardzng ths date.

17 Table 2: ARIES Demonstraton Intermedate Implementaton Schedule TASK NAME Project Plannng Documentaton TA-55 Faclty Plannng and Preparaton Faclty Layout and Glovebox Desgn Complete Indvdual Module ComponentsDesgned Gloveboxes Acqured, Purchased, and Receved Indvdual Module ComponentsPurchased and Bult Assembly and Cold Testng of Modules Integraton and Assembly nto TA-55, PF-4 Shpment of Cold-Tested U N L Modules Safety Revew, Hot Testng, and Operatonal System 8. PLAN ACTUAL START START 1/2/95 1/2/95 1/2/95 1/2/95 1/2/95 1/2/95 PLAN FINISH 2/2/96 9/3/96 3/29/96 % COMPLETE 1% 25% 5% 1/2/95 2/1/96 1/2/95 1/2/95 3/29/96 9/3/96 5% 5% 4/1/96 NA 9/3/96 % 1/1/96 1/1/96 1/16/97 4/1/97 NA NA NA NA 1/31/97 3/31/97 1/31/97 9/3/97 % % % % RESOURCES Executon of the ARIES demonstraton requres a varety of resources, ncludng both manpower and support servces. The matrx approach to staffng of ARIES reles on staff from several LANL and LLNL organzatons. Personnel wll report to ther lne management for admnstratve drecton and to ther respectve project leader for techncal drecton. Estmates for total manpower from partcpatng organzatons through FY96 are n each Techncal Task Plan. In addton to the manpower assgned to drectly work on ARIES, addtonal personnel and resources from other organzatons n both laboratores and some outsde vendors and contractors may be used for specal desgn or supportng equpment fabrcaton. Examples of these other resources are procurement servces, ES&H support, documentaton servces, craft support, etc. 15

18 a = - 9. BUDGET The fmdng needed to support the LANL and LLNL staff assgned to ARIES, acquston of materal and supples (M&S), acquston of captal equpment, and antcpated servces contracts are estmated n Table 3 for FY96 and Table 4 for FY97. Based on the estmates descrbed n both tables, the combned cost of the ARIES demonstraton LANL staffand LLNL staff for both fscal years s $26 mllon. Table 3: Budget (n $1) and Matrxed Manpower (n FTEs) Estmates for ARIES Demonstraton for FY96 f LANL f LLNL f Engneerng.,; SHORT TITLE ALLOC ALLOC Pu S t a f f Pu Techs f S U D D O ~r' ~ NDA Other :... L...L...L... L... :....,... L... Pt Bsecton : : 7: OSOf 3-15;.8: "... " :...:... :... : ; 1,OOO.25; 2.15:: ;.3 HYDOX... L L :... : Hydnde/Dehydnde f 57:... 15:.75:.75; 2.:: I...! : z... Cannng/Decon f... 8f <... < 1.: *...2.3:. : I A... : NDNlnst Support f 1,15.5;.4 1.; 2.:... L j... :... ;... I... 2,83: 95; 4.2: 1.25: , Integraton... -f t & Operatng Funds f $5,6 :$2,8f 6-7;...8-9: * *. : : : *... Captal Equpment ;... $4.!... 3 ;... $1.!OOO *r <... " ; TOTAL; $9,9 t $3,8j j 16 +

19 Table 4: Budget (n $1) and Matrxed Manpower (n FTEs) Estmates for ARIES Demonstraton for FY97 Ifthe ARIES Demonstraton s dsassembled after FY97, the estmated cost for decommssonng and decontamnaton for FY98 s $1.5 mllon. 1. OPERATIONAL PLANS The current ARIES program wll conclude wth the system test. A follow-on program may be nsttuted to nstall frther mprovements and addtons to the system. 17

20 Los Alamos APPENDIX A Los Alamos Natonal Laboratory Los Alamos. New Mexco TO memorandum Wolfgang Dworzak, NMT-DO,E5 MTE WL SYMBOL SUBJECT STOP~~ELEPHONE May 3 I, 1995 M ESH-2EARE NEPA Categorcal Excluson for ARIES ESH-2 ACCESSION NO.: 5465 ES&H ID NO.: DOE IDENTIFICATION NO.: LAN The Department of Energy has revewed the DOE Envronmental Checklst (DEC)for ths actvty and has categorcally excluded your project from the requrement to prepare h h e r Natonal Envronmental Polcy Act (NEPA) documentaton. Yoa can carry out the actvtes as descrbed n the DEC as soon as all other regulatory requrements have been met. If you have a queston about your project's complance wth envronmental, safety, or health requrements, consult wth the specalsts dentfed durng the ESH-IDprocess or wth me. If you make changes to your project so that the DEC s no longer accurate, please call me so we can reevaluate the NEPA documentaton. AP:jm/do Enclosure: DOE Letter Cy: T. Cremers, NMT-DO, MS E5 13 G. Barnes, ESH-3, MS K479

21 Dstrbuton: R Matthews, NMT-DO Chrstensen, NMT-DO D. Wallace, NMT-DO P. Cunnngham, NMSM-NM P. Arthur, NMSM-NM E. Toevs, NMSM-NM J. Trapp, NMSM-NM T. Avens, NMT-6 L. Cremers, NMT-4 T. Dworzak, NMT-6 W. FIa~nm., NMT-5 B. Huang, NMT-6 J. Jarvnen, NMT-6 G. Martnez, NMT-6 C. Mar@ NMT-5 J. Meehan, NMT-2 R T. Nelson, NMT-6 Trujllo, NMT-6 E. wllams, NMT-3 J. M a ~ ~ eees-i4lnmt-6 y, P. Dennson, LLNLAMT-6 D. Bronson, LLNL M. Jardne, LLNL L. Brough, LLNL W. Colmenares, LLNL C. Hnde, ESA-EPE R. Martnez, ESA-EPE E. Sayka, ESA-EPE P. Bronsz, ESA-MT L. Beugelsdjk, ESA-MT T. Kreyer, ESH-14 L. Gavron, NIS-5 A. Hansen, NIS-5 W. sampson, NIS-5 T. Brown, TSA-7 W. NMT-6 Fle 19