Operational Readiness Review (ORR) The Road to Initial Agent Operations Presented by: Paul Dent, PCAPP ORR Manager

1. 18 September 2013
Boone, CO
FINAL – OPSEC/ITAR REVIEW - 12 SEP 2013
Citizens’ Advisory
Commission Meeting

2. Operational Readiness
Review (ORR)
The Road to Initial Agent Operations
Presented by:
Paul Dent, PCAPP ORR Manager

3. Timeline - ORR
3

4. Briefing Objective
Provide an overview of the PCAPP Operational
Readiness Review (ORR) process and the
incremental approach to be used to assess
readiness for Initial Agent Operations (IAO)
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5. Operational Readiness Review Overview
 The ORR process is used to
validate that PCAPP “plant, paper,
and people” collectively meet the
required criteria to allow a new
operation to begin.
 PCAPP ORR process is led by the
system-contractor (SC) to
support a declaration of
readiness.
 ACWA provides ORR oversight;
independent validation is used to
support the SC’s declaration of
readiness.
 Stakeholders may observe the
ORR process.
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People
PlantPaper
Achieve Readiness – by Responsible Managers
Validate Readiness – by ORR Board
Declare Readiness – by Project Manager
Accept Readiness – by ACWA

6. ORR Overview
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People Readiness
Paper Readiness
Plant Readiness
Ready for Agent Operations
Government Review and Concurrence
SPM ACWA concurrence
with BNI ORR
BPT declares readiness
for agent operations
The ORR process validates that
PCAPP plant, paper, and people
collectively meet the required
criteria to allow agent-
operations to begin.
System Start-up, Testing, and
Turnover to Operations
System Start-up, Testing, and
Turnover to Operations
Approve Permits,
Plans, Procedures,
Classes
Certify, Drill,
Optimize
IOD
Integrated Operations
Demonstration (IOD)
Readiness
The goal of Systemization is to achieve readiness for
Initial Agent Operations.

7. Stages of an ORR
Planning:
 Define Scope of ORR in an Implementing Procedure using Performance
Objectives and Criteria (PO&Cs)
 Identify Responsible Managers and pool of Independent Reviewers
 Charter the ORR Board
Execution:
 Responsible Managers define how readiness is achieved using affidavits
 Independent reviewers conduct interviews, review documents, and
observe field work to assess the degree of compliance with readiness
requirements
 ORR Board reviews documentation to assess readiness
 “Punchlist items” are defined as findings and tracked to closure
 Usually ends after an Integrated Operations Demonstration (IOD) to
exercise and assess plant, paper, and people functioning together
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8. ORR Planning
PO&Cs are requirements for readiness, defined in cascading levels of detail
 Derived from contract defined requirements, such as:
• Safety/environmental regulations (e.g., OSHA, RCRA, CAA)
• Army regulations and guidance (e.g., AR 50-6, DA PAM 385-61)
• Industry standards (e.g., ANSI, NFPA)
 Developed by responsible managers and the ORR Team
 Reviewed by ACWA and stakeholders
 Approved by issuance of an ORR implementing procedure
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Criterion 1.1
Criterion 1.2
Criterion 1.3
Criterion 1.4
Criterion 1.5
Criterion 1.6
Criterion 2.1
Criterion 2.2
Criterion 2.3
Criterion 2.4
Functional Area (by Responsible Manager)
Performance
Objective 1.0
Performance
Objective 2.0
Develop Performance Objectives and Criteria (PO&Cs)
Level 3 Criterion
A specific statement describing an element of readiness
within a performance objective (e.g., “A process is in
place to notify key treaty personnel when applying or
removing treaty seals, to track treaty sealing information,
and protocols are established for treaty seal application
and removal. Treaty seals have been applied to the
agreed upon doors/areas/equipment.“)
Level 2 Performance Objectives (POs)
A statement describing an aspect or area of readiness
within a functional area (e.g., “Treaty requirements are in
place for initial agent operations.“)
Level 1 Functional Areas
Typically follow organizational lines (e.g., Safety, Lab)

9. ORR Overview – Process
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Board accepts
affidavit?
NO
Responsible manager
completes affidavit
Board reviews CRAD
Finding Categories
Assigned by Board
Responsible manager
completes actions
required to correct
deficiency
Finding closed?
NO
YES
IR evaluates criteria
and affidavit
Board chartered
Functional areas defined
Board reviews
affidavit
Requirements defined
Independent reviewers
(IRs) selected
IR completes CRAD
Affidavit and CRAD
packages finalized,
archived for report
Board accepts
CRAD?
YES
NO
YES
Criterion met?
Finding(s) generated or
approved to address
identified deficiencies
NO
Readiness Planning Stage
Board reviews
corrective actions and
finding closure
document
All criteria
met, all
CAT1
findings
closed, final
report
completed
DeclarationofReadiness
Finding closure approved
by the Board, archived
for report
YES
LORR Execution Stage (Single Criterion)
Finding categories
assigned by ORR Board
Performance objectives &
criteria developed

10. Key Readiness
Milestones
COMPLETE
IN PROGRESS
NOT STARTED
2. Lab Stock A Dilute Agent Operations
1. Boiler Ignition Readiness
13. Readiness Declared for
Initial Agent Operations
14. ACWA Readiness
Endorsement
6. ERB Provisional Operations
5. Yard Provisional Operations
7. BTA Provisional Operations
8. APB Provisional Operations
10. Soft Plant Lockdown
12. Integrated Operations
Demonstrations
11. Environmental Readiness
9. Crew Certifications
4. Agent Controls Readiness
1
8
9
6
5
4
2
7
11
12
13
14
3
3. Training Facility Integrated Assessment
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ACRONYMS:
APB – Agent Processing Building
BTA – Biotreatment Area
ERB – Enhanced Reconfiguration Bldg.
IAO – Initial Agent Operations
ORR – Operational Readiness Review
RA – Readiness Assessment
Major Milestones for Initial Agent
Operations (IAO) Readiness
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11. Initial Agent Operations
(IAO) Criteria
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by Functional Area
Number of criteria subject to change through
implementing procedure review process

12. Integrated Operations
Demonstrations (IOD)
Near the end of ORR, integrated operations demonstrations (IODs)
are performed to validate that people, plant, and paper are ready for
initial agent operations.
IODs include exercises such as:
 Receive, transfer, and process munitions
 Handle, transfer, and process simulated agent-contaminated waste
 Perform toxic area entries; perform maintenance for critical equipment
 Sample tanks/perform laboratory analysis
 Perform treaty sampling
 Respond to contingencies or equipment upset conditions
Upon successful completion of IODs and closeout of
required Findings, SC will declare readiness.
Upon receipt of an endorsement of readiness
by ACWA, PCAPP will be poised to begin Pilot Testing.
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13. 13
QUESTIONS

14. An Overview of PCAPP’s
Pilot Demonstration Testing
Presented by:
Kim Jackson, PCAPP Operations Manager &
George Lecakes, PCAPP Chief Scientist

15. Timeline –
Pilot Test Demonstration
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16. PCAPP Pilot Test Demonstration
Objectives1
1. Demonstrate agent removal, agent neutralization, and related agent
neutralization sampling and analysis.
2. Demonstrate munition body treatment (washout, thermal treatment).
3. Establish bounding operating ranges and set points for operating
parameters critical to agent removal, munition body treatment, and agent
neutralization operations.
4. Demonstrate energetics removal and establish bounding operating ranges
and set points for operating parameters critical to ensuring energetics
removal operations.
5. Validate monitoring protocols for all equipment and work areas in the ERB
and APB.
6. Validate treatment and monitoring protocols for disposition of dunnage,
energetics, and miscellaneous waste (e.g., OPP, PME, SDU, Autoclave as
designated for each waste material)
7. Demonstrate removal of TDG and document removal of other organic
compounds from hydrolysate waste stream (e.g., ICB, BRS)
8. Demonstrate processing systems can operate at a ramp rate that safely
supports the operating schedule.
1DERIVED FROM THE TEST CONCEPT PLAN, APPENDIX D; 3/21/2011
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17. PCAPP Pilot Test Demonstration
Objectives (CONT.)
9. Demonstrate integrated facility operations with agent and energetics to verify
the following:
a) Compliance with safety requirements
b) Compliance with surety and security requirements
c) Integrated system operability
d) Plant-wide operations while remaining within emissions requirements (as stated in the Multiple
Pathway Health Risk Assessment Report for PCAPP Project [MPHRA], 24852-RD-3RC-000-V0004)
e) Handling and movement of munitions for current munitions campaign
f) Sampling and analysis protocols (e.g., agent, hydrolysate, brine, emissions)
g) Decontamination operations
h) Ability to perform routine and selected off-normal maintenance activities
i) Waste handling and disposition, including dust and odor control
10.Validate agent monitoring protocols for detecting agent (e.g., MINICAMS, Depot
Area Air Monitoring System [DAAMS]).
11.Demonstrate off-gas treatment performance. This will include demonstration of
agent destruction and removal at the OTS and AFA, odor control at the BTA.
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Finally, the collection of site-wide emissions data for
finalization of the RCRA Part B Permit

18. Block 1 –
Systems, Fit, and Function
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Systems: Block 1 – Baseline and Enhanced Reconfiguration includes OPP Monitoring, Munitions Monitoring
Table (Baseline Reconfiguration), PMD Operations and MME/PME Operations
Fit: After transport and receipt of munitions at PCAPP and prior to agent removal activities
Function: Prepares munitions for access and removal of agent by separating packing material (e.g., wooden
pallets, strapping, boxes) and energetics/miscellaneous parts from the munitions bodies
Explosion Containment
Room

19. MWS
MTU
Block 2 –
Systems, Fit, and Function
Systems: Block 2 – Munitions Body Treatment includes Munitions Washout System (MWS) and Munitions
Treatment Unit (MTU)
Fit: After Baseline and Enhanced Reconfiguration and prior to Agent Collection and Neutralization
Function: Drains and washes agent from energetics-free munitions bodies and thermally treats munitions
bodies to Clean Unrestricted, Releasable to the General Population (Clean Unrestricted)
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20. Block 3 –
Systems, Fit, and Function
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Systems: Block 3 – Agent Collection and Neutralization includes the Agent Water Separators, Wash Water Holding
Tanks, Agent Hydrolyzers, Hydrolysate Hold Tanks and 30-Day Storage Tanks
Fit: After Agent Collection and prior to Bio-Treatment of the cleared hydrolysate
Function: Separates the MWS agent drained and rinse water, hydrolyzes the mustard agent, and verifies destruction
prior to treatment in the Immobilized Cell Bio Reactors

21. Block 4 –
Systems, Fit, and Function
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Systems: Block 4 – Hydrolysate Treatment and Water Recovery includes the Bio-Treatment System, Water Recovery
System (Brine Concentrate Feed Tanks), and the Brine Reduction System plus associated off-gas treatment units
Fit: After agent neutralization and clearing in Block 3 and prior to process water recycle or to off-site shipment of
secondary wastes (salt cake / bio sludge)
Function: Removes thiodiglycol (TDG) and other organics through biodegradation, recovers process water, de-
waters sludge for disposal and treats off-gasses for discharge.

22. Block 5 –
Systems, Fit, and Function
Systems: Block 5 – Supplemental Decon Units and Autoclave
Fit: Receives materials, equipment, components, and waste materials from other process areas including ERB, APB,
ESM, MSM.
Function: Reduces agent contamination levels to acceptable levels for either reuse and/or off-site disposal
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23. Block 6 –
Systems, Fit, and Function
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Systems: Block 6 – Off-gas treatment system including thermal oxidizer and scrubbers, the agent filtration area
(including particulate & HEPA filtration, granulated activated carbon and sulfur impregnated carbon) and the AFA stack
Fit: Receives process off-gas from the OTS and HVAC exhaust from ERB and APB ventilation systems
Function: Treat process off-gasses and HVAC exhaust from engineering controlled spaces to remove agent and other
COC’s to prescribed levels before releasing to the atmosphere.

24. Process Layout by Blocks
PCAPP PROCESS DIAGRAM
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EDT REMOVED FROM PCAPP SCOPE
CONTAMINATED ENERGETICS AND IN-PROCESS LEAKERS &
REJECTS SENT TO G-BLOCK FOR SUBSEQUENT PROCESSING
IN A GOVERNMENT SYSTEM

25. Test Sequence
Pilot Testing (155mm)
 Block 1
 Block 2
 Block 3
 Block 4
 Block 5
 Block 6
Changeover Testing
 105mm Campaign
 4.2in Campaign
• Testing ≡ to define optimized
operating parameters
• Ramp-up ≡ capability of
personnel and equipment to
sustain operations
• Demonstration ≡ capability
of each process system
within the facility to process
munitions for 4-hour periods
per shift
Block 1 – Munitions Receipt and Enhanced Reconfiguration is to
support the testing, ramp-up and demonstration of the other
systems within Blocks 2, 3, 4 and 6.
Block 5 – Secondary Waste Treatment
Operating
Permit
INTEGRATED FACILITY DEMONSTRATION TEST
• Emissions Sampling
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26. 26
QUESTIONS