Pantex Plant

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Pantex Plant is located in the Texas Panhandle, approximately 27 kilometers (17 miles) northeast of downtown Amarillo. The site consists of approximately 6,500 hectares (16,000 acres).

FACILITY MISSION

Pantex Plant was built by the United States Army in 1942 as a conventional bomb plant. It was decommissioned after World War II and sold to Texas Tech University as excess government property. In the 1950s, the Atomic Energy Commission recovered 4,000 hectares (10,000 acres) of the site, renovated portions of the plant, and constructed new facilities for the manufacture of high explosives used both in nuclear weapons and for the final assembly of nuclear weapons. During the mid-1960s, the plant was expanded to assume weapons maintenance and modification tasks from plants closed in San Antonio, Texas and Clarksville, Tennessee. The last expansion occurred when a sister plant in Burlington, Iowa closed in 1975. Pantex Plant has been the only plant of its type since that time.

The mission of Pantex Plant involves fabricating high explosives for nuclear weapons, assembling nuclear weapons, maintaining and evaluating nuclear weapons in the stockpile, and dismantling nuclear weapons as they are retired from the stockpile. At present, the principal operation is disassembly of nuclear weapons.

Most of the waste generated at Pantex Plant is generated from the assembly and disassembly operations. The primary objective of the Waste Management program at Pantex Plant is to manage all waste generated at the plant in an environmentally sound manner and in compliance with all applicable federal, state, and local laws and regulations. The program*s primary responsibility is the proper management of all plant waste generated, treated, stored, and packaged for disposal.

Under the current Environmental Restoration scope of work, Pantex Plant is to assess the contaminants present, remediate the problem through treatment, and remove waste to an approved facility (or store it within capped facilities). In some cases, the contaminant concentrations are low enough that No Further Action is required to meet Texas Natural Resources Conservation Commission requirements or Environmental Protection Agency regulations. In the case of the ground water, the treatment facilities will render the water below drinking water standards, but the water will likely be used for industrial purposes. Some sites will require further monitoring after a treatment plan has been initiated. The contaminants are not addressed individually in this summary; they are, however, addressed at some length within associated portions of this document.

The Waste Management and Environmental Restoration programs are managed within the same division at Pantex Plant. The organizational structure allows both programs to draw on the resources available to obtain the specific expertise required. Funding for environmental management activities began in 1987. The Waste Management program is involved in the characterization and certification of waste generated by environmental restoration. The principal regulatory drivers at the Pantex Plant include: the Resource Conservation and Recovery Act, the Comprehensive Environmental Response Compensation and Liability Act, the Toxic Substances Control Act, and Department of Energy Order 5400.1 (General Environmental Protection Program).

FUTURE USE

The plant's basic mission is not expected to change in the foreseeable future. Pantex Plant will continue to be the only facility used for the dismantlement and maintenance of the nation's nuclear weapons stockpile. It will also provide interim storage for plutonium until the Department of Energy reaches a final decision on its disposition. If the government suspends all further operations, the Industrial site might be leased to industry for operations that can use the plant's specialized security functions and facilities. The surrounding area may continue to be used for Agricultural operations. This report assumes that the future use of the industrial area will be Industrial/Commercial, while the future use of the rest of the site will be Agricultural.

NUCLEAR MATERIAL AND FACILITY STABILIZATION

Facility stabilization and maintenance began at Pantex Plant in 1995. The Office of Defense Programs currently provides funding for stabilization and maintenance. Transfer of facilities to the Environmental Management program is anticipated to occur in FY 2002. Eight facilities have already begun stabilization, including a chlorinating building, a digester, explosives machining, a synthesis building, and an electrical substation. This report assumes that the remaining facility (a sewage tank) will begin stabilization and maintenance activities in FY 1996. The resulting waste types are expected to include: radioactive process water, liquid and solid low-level waste, sanitary waste, heavy metals, and solvents. This report assumes the stabilization and maintenance process at Pantex Plant will be completed by FY 2010. Funding profiles and facility activities were generated through parametric modeling, using data from other Department of Energy facilities.

ENVIRONMENTAL RESTORATION

The production of explosives components for nuclear weapons has resulted in the contamination of soils primarily by organic solvents and explosives. In addition, tests of weapons components have contaminated some areas with explosives and heavy metals. The contaminants have gradually migrated to subsurface soils and the perched ground water. Ground-water contamination has been detected in the perched aquifer, which is located a few hundred feet above the Ogallala Aquifer, the primary water source for the region. Because of this contamination, the Environmental Protection Agency placed Pantex Plant on its National Priorities List in May 1994. The Department of Energy/Amarillo Area Office is currently negotiating a Tri-Party Federal Facilities Agreement with the Environmental Protection Agency and the Texas Natural Resources Conservation Commission. See the Site Map for the location of environmental restoration related activities.

Environmental restoration activities at Pantex are conducted in compliance with a Resource Conservation and Recovery Act permit that the Texas Water Commission (which has since become part of the Texas Natural Resources Conservation Commission) issued in April 1991. Activities began in 1992 and are expected to be completed during FY 2000.

Surveillance and monitoring will be performed to comply with regulatory drivers (as discussed in the AFacility Mission@ section above) once the site is remediated or decommissioned. A number of ground-water wells will be monitored for constituents of concern. Air monitoring will consist of radiological and nonradiological constituents analysis. Ecological/biota monitoring and surveillance will continue for those constituents that potentially pose a risk. This report assumes that these activities will continue for 30 years after remediation is complete.

The assessment activities at 12 of the 15 operable units have shown that most of the waste material generated is nonhazardous. In situ remediation will be the primary technology used for remediation of the hazardous portion of the waste. As a result, hazardous waste sent to the Waste Management program for disposal will be minimal.

Pantex Plant has implemented strategies to reduce the amount of waste generated during investigations, as well as the amount of waste handled, treated, or disposed of during site cleanups. A key point of this strategy is minimizing the amount of waste generated during remedial feasibility investigations by sonic drilling, geophysical and soil gas survey techniques, and other survey methods that generate minimal volumes of waste.

Waste investigated is sampled, and the samples are sent to a laboratory for analysis. Upon receipt of the validated analytical data, the investigative materials are classified appropriately. Solid waste (for example, construction debris) classified as Class III is disposed onsite in a permitted landfill. Class II solid waste is disposed of offsite in a permitted landfill in Amarillo. Class II liquids, personal protective materials, and Class I or hazardous waste is disposed of offsite at a permitted treatment disposal facility. If any interim waste storage handling is required, secondary containment of liquids is ensured.

The plant's 144 solid waste management units are grouped into 15 operable units for investigation and cleanup activities associated with them. The operable units included 114 potential release sites. Resource Conservation and Recovery Act Facility Investigations have been initiated for all operable units. For Operable Units PX-3 (Former Cooling Tower) and PX-4 (Old Sewage Treatment Plant Sludge Beds), work is being performed for chromium contamination. Unit PX-15, the Hypalon Pond, was closed in 1995. Currently, voluntary corrective actions are being taken at several sites, and No Further Action is planned at several other sites. Brief descriptions of the active operable units follow.

Waste Management and Environmental Restoration are cooperating to ensure coordination of work and personnel to accomplish the necessary tasks. A staff of Environmental Restoration program, planning, analysis and control personnel provides program management/support for all the operable units discussed below. The Environmental Restoration program estimate includes management of waste including characterization, packaging, treatment, storage and disposal of waste generated by Environmental Restoration program activities. Waste Management will assume the responsibility for waste generated from environmental restoration activities beginning in FY 1997, and the estimate includes characterization, packaging, treatment, storage, and disposal costs for Environmental Restoration program waste.

Operable Unit PX-1: Burning Ground Sites

The Burning Grounds in the north-central portion of Pantex Plant comprises approximately 140 hectares (58 acres). Operation at the Burning Grounds began as early as 1952. The site is used for the demilitarization of high explosive components and treatment of high explosive-contaminated material. Disposal of solvents is ongoing. Active units in the Burning Grounds include burn trays, racks, and demonstration-detonation sites. Closure plans for burn cages and flashing pits have been submitted to the Texas Natural Resources Conservation Commission. Inactive units yet to be investigated include the solvent evaporation pit and pans, the former chemical burn pit, burn pads, and the Burning Grounds landfills. The potential contaminants of concern are high explosives, solvents, volatile organic compounds, asbestos, polychlorinated biphenyls and small amounts of radionuclides. The Phase 1 fieldwork consisted of a geophysical survey, soil samples, and a ground-water investigation. This investigation was conducted from March through May 1994. Final data packages detailing the Resource Conservation and Recovery Act Facility Investigation have been submitted to the Texas Natural Resources Conservation Commission for review. Response from the Texas Natural Resources Conservation Commission initiated a Phase 2 investigation to determine the lateral extent of high explosures. In addition, a Risk Assessment of the Burning Grounds was also conducted. The results of this Phase 2 investigation will be incorporated into the Resource Conservation and Recovery Act Facility Investigation as an Addendum, and results of the risk assessment will be used to determine the possibility of No Further Action or additional remediation actions to be conducted at the Burning Grounds for closure.

ASSESSMENT

No Further Action is assumed for all closed sites associated with the Burning Grounds, except for the flashing pits and selected landfills. A Phase 2 assessment will be completed in FY 1996 to characterize waste in several inactive landfills not investigated during Phase 1. Additional Phase 2 work, a Resource Conservation and Recovery Act Facility Investigation, and a risk assessment will be conducted during FY 1996. Completion of work at PX-1 is scheduled for the fall of 1997. Cleanup of the site may be deferred until the Burning Grounds becomes inactive.

To prevent migration of contaminants beyond the landfill boundaries, limited landfill capping is assumed. These proposed basic caps will prevent runon and runoff of surface drainage.

Decommissioning of the two burning cages and the burn pit pans will occur in FY 1996. This report assumes that all waste generated during final cleanup will be treated and disposed of at a permitted facility.

Ongoing activities at the Burning Grounds will preclude closure activities of the Burning Grounds Solid Waste Management Units until these activities cease. Monitor wells have been installed in both the Perched and Ogallala aquifers at the Burning Grounds. Currently anticipated activities for Interim Corrective Measures or voluntary corrective action will include modification of the landfill surface for runoff control and removal and control of burrowing animals. Upon closure of the Burning Grounds, closure activities of existing solid waste management units will begin. This estimate includes no cost for remediation.

Operable Unit PX-2: High Priority Potential Release Sites

Various industrial operations supporting the Pantex Plant mission had the potential for release of hazardous constituents to the environment. These releases are associated with nine sites, collectively referred to the High Priority Potential Release sites Solid Waste Management Unit grouping. The Phase 1 fieldwork consisted of soil gas sampling and soil boring samples. The fieldwork was completed in February 1994. Three interim corrective measures were performed in the summer of 1995. Closure plans for all three of the interim corrective measures have been submitted to Texas Natural Resources Conservation Commission.

ASSESSMENT

The principal contaminants of concern for the High Priority Potential Release sites are high explosives, volatile organic compounds, and metals. These contaminants are present at levels both above and below Risk Reduction Standard 2 as defined under Texas Administrative Code Title 30, Section 335, Subparts A and S. No further assessment activities are required at this time. No Further Action is recommended for the nine High Priority Potential Release sites. Accordingly, a recommendation of No Further Action has been submitted to the Texas Natural Resources Conservation Commission. The Texas Natural Resources Conservation Commission is currently reviewing the request for No Further Action. This estimate also assumes assessment activities will generate 250 cubic meters (325 cubic yeards) of hazardous waste.

REMEDIAL ACTION

Three interim corrective measures were implemented during the summer of 1995. These consisted of: 1) removal of the sump and pond liner, including underlying sediment, at the evaporation pond adjacent to Firing Site 16; 2) removal of the concrete sump and adjacent soil at Building 12-68; and 3) removal of the container [the breach section of a 40-centimeter (16-inch naval gun)] from Firing Site 22. Requests for closure have been submitted to the Texas Natural Resources Conservation Commission. This report assumes no further action will be needed.

Operable Unit PX-3: Former Cooling Tower

The site includes Area of Concern Number 13 and is located in the east-central portion of the Pantex Plant, in a high-security area in Zone 12. The tower was used for water cooling from 1950 to 1964 for high explosives machining operations in nearby buildings. A large adjacent concrete basin was used as a water reservoir system. Contamination could have potentially resulted from the overflow of the water reservoir, leakage through or adjacent to the foundation, continuous dripping/leaking, and blow-down water.

ASSESSMENT

No Further Action was recommended to the Texas Natural Resources Conservation Commission in October 1993 based on low levels of contamination found in the soil. The Texas Natural Resources Conservation Commission Risk Reduction Standards state that contamination at these levels does not pose a threat to human health or the environment. Regulatory approval of the recommendation for No Further Action is pending. However, in March 1995, an investigation of ancillary piping that supplied water to the former cooling tower revealed the presence of chromium-contaminated soil under the piping. The extent of contamination has not been defined. In FY 1996, additional investigation of this site will define the vertical and lateral extent of this contamination.

REMEDIAL ACTION

This report assumes that an interim corrective measure will be performed in FY 1997 to remove immediate contamination of the chromate plume. In FY 1996, remediation activities will be performed under PX-6, Ground Water, to remediate the chromium ground-water contamination.

Operable Unit PX-4: Old Sewage Treatment Plant Sludge Beds

The Old Sewage Treatment Plant sludge beds are located in Zone 13 in the extreme northeast corner of Pantex Plant. The Old Sewage Treatment Plant was in operation from 1942 until 1987 and is now out of service. The facility treated wastewater from the Pantex Ordnance Plant, Amarillo Air Force Base, and Pantex Plant. The Old Sewage Treatment Plant consists of six rectangular, sloped, concrete-lined units filled with pea-sized gravel. Each bed is approximately 12 meters by 30 meters (40 feet by 100 feet). Sludge from the anaerobic sludge digester was discharged to the individual beds. Sludge residue was retained on top of the gravel, while excess liquid trickled through the gravel. The liquid then flowed along the sloped concrete liner surface and was collected in sumps at the edge of each bed before returning to the plant for processing.

ASSESSMENT

Regulatory approval is pending because of the levels of contamination in the soil that were very low. No Further Action for the Old Sewage Treatment Plant Sludge Beds was recommended to the Texas Natural Resources Conservation Commission in September 1993. This report assumes No Further Action is required.

Operable Unit PX-5: Fire Training Area Burn Pits

The Fire Training Area Burn Pits site is located northwest of Zone 12, adjacent to south 13th Street and the Pantex Plant Fire Training Center. The Resource Conservation and Recovery Act Facility Investigation area occupies approximately 1.7 hectares (4.25 acres). The main features of interest at the site are two underlined burn pits, (Pit 1 and Pit 2), which were used to contain training fires staged at the site, a crawl tube formerly used in fire/smoke training exercises, a former tank and storage area for drums of waste solvents and fuels used to set training fires, and a shallow unlined drainage ditch that periodically received runoff from the pits and surrounding areas.

The nature and volume of materials used in the past fire training exercises are only partially documented. Waste solvents, as well as fuels and oils (some possibly containing polychlorinated biphenyls), were reportedly burned in Pit 1. Before 1985, approximately 208 liters (55 gallons) of toluene, and 380 liters (100 gallons) of dimethylefromanide were reportedly burned in Pit 2. The extinguishing agents used included protein foam, ABC-type dry chemical mixtures, 1211 Halon, Aqueous Film-Forming Foam, and water. The Fire Training Area Burn Pits site was used from 1973 until 1990 for Pantex Plant Fire Department personnel training exercises. The site was used approximately twice a year.

An interim corrective measure was initiated to remove the upper 0.6 meters (two feet) of contamination (primarily pesticides and metals) during the summer of 1995. Hot spots (isolated areas that exceed acceptable levels of contamination) were removed to meet Risk Reduction Standards. After excavation, appropriate offsite disposal of contaminated soil was followed by confirmation sampling to document compliance with the Risk Reduction Standards cleanup levels. Approximately 1,041.2 cubic meters (1,370 cubic yards) of soil were removed. Additional Resource Conservation and Recovery Act Facility Investigation Phase 2 sampling was performed to complete characterization of the nature and extent of contamination at the Fire Training Area Burn Pits. The remediated area was backfilled with material obtained from the Pantex Plant Borrow Area. Reseeding of the area was done using native grasses. The Draft Final Interim Corrective Measures Closure report was submitted to regulators in November 1995. This estimate assumes No Further Action will be required.

Operable Unit PX-6: Ground Water in Zone 12

The Ground Water Operable Unit manages all perched aquifer contamination at the Pantex Plant which originated from various widespread sources within the plant. This report assumes that the major portion of the contamination in the perched aquifer originated in the industrial portion of the plant, which includes Zones 11 and 12. These zones include, or have included administrative and support facilities, vehicle and high explosives, operations, chemical and photographic laboratories, cooling towers, and other industrial operations.

ASSESSMENT

Argonne National Laboratory conducted an expedited site characterization. Three additional wells for monitoring perched aquifers and one well for monitoring the Ogallala aquifer were proposed as part of Phase 2 fieldwork. These Phase 2 wells were completed in 1995. An Accelerated Site Assessment Project was conducted in 1995. This project included both onsite and offsite exploratory drilling to determine the extent of the perched aquifer contamination. High explosives contamination was found offsite to the east of the plant.

REMEDIAL ACTION

Phase 2 fieldwork is complete. The Resource Conservation and Recovery Act Facility Investigations report has been prepared and submitted to regulators. The expedited site characterization was completed and a report of the findings was submitted in August 1995. The Accelerated Site Assessment Project was completed in November 1995. This project included the drilling of up to ten additional test holes to determine the extent of contamination within the perched aquifer, both onsite and offsite.

A treatability study for the perched aquifer on Pantex Plant was conducted in FY 1995. This study included the extraction and treatment of the contaminated perched ground water. The treatability system will be located east of Zone 12 and will include three ground-water extraction wells and a treatment unit.

Several alternatives are being studied to determine a beneficial reuse of the treated wastewater from the treatability system. These alternatives include: 1) reuse of water for steam generation, 2) sale of treated water to Texas Tech for irrigation purposes, and 3) discharge of treated water to Playa 4 for wetlands enhancement. Ground water will also be reinjected to enhance remediation.

All of the alternatives referenced above will reduce the Pantex Plant dependency on the Ogallala Aquifer for operations. This report assumes that remediation will be complete in FY 2000. It also assumes that activities will generate 3.4 million cubic meters (4.4 million cubic yards) of hazardous waste.

Operable Unit PX-7: Landfills

Since Pantex Plant was established in 1942, virtually all sanitary and industrial solid waste generated at Pantex Plant has been disposed of in landfills located throughout the facility. Twenty-three landfills exist at Pantex Plant, 16 of which are included in this group. The major types of waste that have been buried in the landfills are sanitary waste (waste from cafeteria and other general trash, such as paper, plastic, empty containers and food), construction debris (materials such as metal scrap, lumber, roofing materials, concrete, railroad ties/rails, drums, insulation, plastic, and wire), high explosive-contaminated waste, chemical waste, used batteries, residual ash, pesticides, and other miscellaneous trash and debris. These practices have been discontinued. Phase 1 fieldwork was completed in 1994 with the submittal of preliminary data packages in 1994 as well. Phase 2 fieldwork was completed in 1995 with the Draft Final Resource Conservation and Recovery Act Facility Investigation reports to be completed in 1996 (January and June, respectively).

The contaminants detected in the Phase 1 landfill investigation were: volatile organic compounds, semi-volatile organic compounds, metals, pesticides, polychlorinated biphenyls, and asbestos.

ASSESSMENT

The principal contaminants of concern for the landfills are high explosives, semi-volatile organic compounds, metals, pesticides, and asbestos. These contaminants are present at levels both above and below Risk Reduction Standard 2 as defined under Texas Administrative Code Title 30, Section 335, Subparts A and S. No further assessment activities are required at this time. Currently, the Resource Conservation and Recovery Act Facility Investigation reports are being prepared for submission to the Texas Natural Resource Conservation Commission.

REMEDIAL ACTION

Analysis of the data from the assessment phases is being reviewed to ascertain the applicability of interim corrective measures. Landfill 3, and possibly other landfills, will require a corrective measures study. Any remediation activities for Landfill 3 will be incorporated into the ground-water remediation activities currently under way (see Operable Unit 6). Closure strategies for the landfills are currently being reviewed, with emphasis placed on Risk Reduction Standard 2 and Risk Reduction Standard 3 closures. This report assumes that remediation will be complete in FY 1999.

Operable Unit PX-8: Ditches and Playas

This Solid Waste Management Unit grouping consists of the manmade ditches and natural flow system that drains the plant area. Pantex Plant rainfall and runoff enters the ditches and natural drainage system and ultimately flows to four onsite playas. Historically, drainage was also diverted offsite to Pantex Lake, located northeast of the Pantex Plant. In the past, the industrial operations in Zones 11 and 12 caused chemical releases that potentially entered the drainage ditches and playas located at the plant. Surface runoff from the Burning Grounds flowed into Playa 3, and effluent treated at the Old Sewage Treatment Plant (inactive since 1987) was pumped to Pantex Lake. The specific contamination at each site depends on the history of the site. However, some of the compounds being evaluated are volatile organic compounds, semi-volatile organic compounds, metals, high explosives, pesticides, polychlorinated biphenyls, and nitrites-nitrates. Interim corrective measures for the ditches are planned for the spring of 1996.

ASSESSMENT

Phase 1 Resource Conservation and Recovery Act Facility Investigation activities included surface and subsurface soil sampling for five of the six flow systems within this operable unit. The sixth flow system, ground water, had monitoring wells installed in a perched aquifer.

Based on the Phase 1 results, three of the six water flow systems in this operable unit required surface and subsurface sampling. Two of the others required sampling of surface areas only. The required samples were obtained on Phase 2 fieldwork during the spring of 1995. The sixth flow system requires the drilling of additional monitoring wells. This drilling was added to the Zone 12 ground-water (Operable Unit 6) assessment conducted during the summer of 1995. As part of the Phase 2 fieldwork, a number of samples were collected and analyzed in undisturbed areas offsite to determine background concentrations of naturally occurring constituents. The main contaminants of concern include metals, semi-volatile organic compounds, high explosives, and pesticides/herbicides. Site characterization is complete. The Resource Conservation and Recovery Act Facility Investigation report was submitted to the regulators in September 1995.

REMEDIAL ACTION

The Environmental Restoration staff is currently correlating flow system processes, including low flow conditions and pooling areas, with contaminant concentrations to delineate interim corrective measure candidate sites. Once identified, remedial actions to be employed include excavation and disposal, or in situ remediation, which will be conducted concurrently with additional site characterization. It is anticipated that all remedial activity will be completed in FY 1996.

Operable Unit PX-9: Firing Sites

The Firing Sites are located in the north-central portion of the Pantex Plant and were operational as early as 1952. The sites historically were used for the testing of high explosives in connection with quality control and research and development activities. Some radioactive materials, primarily depleted uranium, were involved in the testing program. The potential contaminants of concern include high explosives, metals and small amounts of radionuclides. Phase 1 fieldwork was completed in August 1995. This investigation included a radiological survey, and a surface and subsurface soil investigation. Since some of the sites are still active, only the inactive Firing Sites 5, 6 and 15 were included in this investigation. The remaining sites will be closed and investigated once the operational life is completed. Costs for these sites were not included in this estimate.

ASSESSMENT

Soil investigations for Firing Sites 5, 6, and 15 were completed in the summer of 1995. Firing Sites 6 and 15 will be closed, using the Risk Reduction guidelines promulgated by the Texas Natural Resources Conservation Commission. This estimate assume there are some assessment activities in FY 1996 and FY 1997 at Site 5.

REMEDIAL ACTION

At Firing Site 5 a pilot study is surveying and recovering visible depleted uranium from surface and near-surface soils. This interim corrective measure will also include surveying and removing visible depleted uranium within the berm area. The type of waste generated from decommissioning of the Firing Sites is low-level mixed. This estimate assumes that remediation will be completed FY 1997 and will generate 53 cubic meters (69 cubic yards) of low-level waste.

Operable Unit PX-10: Leaking Underground Storage Tanks

The site includes Area of Concern 6, which comprises two gasoline release sites, and Buildings 12-35 and 16-1. Underground storage tanks have been removed from both of these locations, and leaks are known to have occurred. From 1951 to 1976, five underground steel tanks were installed for storing gasoline, diesel, and motor oil southeast of Building 12-35. Two gasoline leaks occurred in 1974 or 1975 and 1985. As a result, all tanks were removed by 1988. In 1980, two fiberglass tanks were installed south of Building 16-1 to store diesel fuel and unleaded gasoline. One diesel fuel leak occurred in 1985. As a result, both tanks were removed in 1989.

ASSESSMENT

Phase 1 and 2 fieldwork has been completed. No significant soil contamination from underground storage tanks leaks was detected at Building 16-1.

REMEDIAL ACTION

On the basis of the Resource Conservation and Recovery Act Facility Investigation, no corrective actions have been recommended for the site of the underground storage tanks at Building 16-1 and the estimate includes no cost for remediation

Operable Unit PX-11: Miscellaneous High Explosives/Radiation Sites

This operable unit comprises several solid waste management units at 13 different sites. Each of the site's operations at one time generated waste from high explosives processing, high explosives treatment, stored radioactive/high explosives material or treated high explosives wastewater. Most of the sites contain high explosives, metals, semi-volatile organic compounds, volatile organic compounds, and soil contamination caused mainly by the discharge of wastewater activities.

ASSESSMENT

This operable unit comprises 13 sites. A number of surface and subsurface soil samples were collected during the Resource Conservation and Recovery Act Facility Investigation report. Contaminants of concern include high explosives, metals, and limited semi-volatile organic compounds/volatile organic compounds. A Resource Conservation and Recovery Act Facility Investigation report was submitted to the regulators in January 1996.

REMEDIAL ACTION

Data documents are complete, and an interim corrective measure is planned. It will combine in situ bioremediation, soil removal, and offsite disposal. Additional soil sampling was completed to delineate interim corrective measure candidate sites; the data is pending analysis. No Further Action will be recommended for other sites. However, based on the investigation material, some of the soil contamination involves hazardous waste. This estimate assumes a volume of 10,000 cubic meters (13,100 cubic yards) from the interim corrective measures remediation activities.

In situ remediation is planned for many of the sites. Those areas requiring excavation will be either Class I nonhazardous waste, which will be shipped offsite to an approved Department of Energy disposal facility; or Class II nonhazardous, which will be placed at the permitted environmental landfill cell at Pantex. This estimate assumes that remediation of this operable unit will be complete in FY 1997.

Operable Unit PX-12: Miscellaneous Chemical Spills and Release Sites

The miscellaneous Chemical Spills/Release sites consist of several locations at Pantex Plant where spills or releases occurred or may have occurred during routine plant operations. These sites are located in Zones 4, 10, 11, and 12, and in the central and southern portions of Pantex Plant. The Chemical Spills site has been or is currently being used for a variety of purposes, including: storage of scrap and salvageable materials; storage and recharging of batteries; collection and disposal of process waste; storage of transformers and other electrical equipment containing polychlorinated biphenyls; boiler house operations; storage and disposal of sulfuric acid; storage of solvents; mixing of pesticides/herbicides and rinsing of pesticide application equipment; and collection of wastewater, sludge, and solvents from degreasing and machine shop operations. Most of the spills/releases occurred between 1950 and 1980.

ASSESSMENT

Phase 1 soil investigations are complete. The results indicated Phase 2 soil sampling was necessary, and it was conducted during the summer of 1995. The Draft Final Resource Conservation and Recovery Act Facility Investigation was submitted to the regulators in August 1995. In November 1995, additional sampling was performed at nine sites to characterize risk drivers to background and to obtain data to facilitate closure. Chemical sample analyses included pesticides, polychlorinated biphenyls, lead, explosives, mercury, semi-volatiles, and synthetic precipitate leaching procedure for pesticides and lead.

REMEDIAL ACTION

No Further Action is recommended for six sites, one of which remains active. Closure will be deferred until the building is decontaminated and decommissioned. Another site was closed subsequent to a records search and a visual inspection which indicated no contamination. The results of synthetic precipitate leaching procedures support a recommendation of No Further Action; therefore, the estimate includes no remediation costs.

Operable Unit PX-13: Supplemental Verification Sites

The Supplemental Verification sites Solid Waste Management Unit grouping is made up of eight landfills and other miscellaneous surface sites throughout the facility that are known or suspected of receiving hazardous constituents or present unknown potential for contaminant risk, requiring verification. Various operations and maintenance activities at the Pantex Plant have resulted in onsite chemical usage, incidental disposal of spent material, and demolition of structures with disposal in onsite rubble landfills.

ASSESSMENT

The principal contaminants of concern for the supplemental verification sites are polynuclear aromatic hydrocarbons, semi-volatile organic compounds, metals, and pesticides. No further assessment activities are required at this time. Currently, the Resource Conservation and Recovery Act Facility Investigation reports are being prepared for submission to the Texas Natural Resource Conservation Commission.

REMEDIAL ACTION

No Further Action has been recommended; therefore, no remediation costs were included in this estimate. Further consideration of any potential remedial action will proceed upon receipt of the Draft Resource Conservation and Recovery Act Facility Investigation report. All waste generated during site investigation and has been shipped offsite for disposal.

Operable Unit PX-14: Underground Storage Tanks at Other Locations

Four underground storage tanks (7, 9, 38, 39) were located in Zone 12 and one at the existing Vehicle Maintenance Facility. One of the five underground storage tanks (Number 30) is identified as Solid Waste Management unit 133. All of the underground storage tanks except Number 30 contained diesel fuel for emergency power generators. Underground storage tank Number 30 contained waste oils generated from vehicle maintenance activities. The remaining four are included because their investigation is warranted due to the potential release of hydrocarbons. All five tanks have been removed.

ASSESSMENT

Phase 1 and 2 fieldwork has been completed. Potential constituents of concern included benzene, toluene, ethylbenzene, and xylene, and total petroleum hydrocarbons. Two corrective action reports were submitted to the regulators. The Draft Final Corrective Action report for underground storage tanks 7, 30, 38, and 39 was submitted on October 14, 1994, while the report for underground storage tank 9 was submitted on April 24, 1995. This report assumes no corrective action nor further investigation is warranted for all sites in this operable unit.

Operable Unit PX-15: 11-14 Hypalon Pond

This site consists of a former surface impoundment (11-14 Pond) located at Building 11-14. Constructed in 1975, the pond treated acidic wastewaters from high explosives operations in Building 11-36. Pond operations were discontinued as a hazardous waste treatment unit in March 1989. The existing wastewater sludge residues were removed and disposed of at an offsite hazardous waste disposal facility. The pond was backfilled and graded in May 1990. The former pond was approximately 9.2-meters (30-feet) wide, 30.5-meters (100-feet) long, and 2.3- meters (7.5-feet) deep from the top of the surrounding berm. At times, wastewater containing residual concentrations of solvents was discharged into the pond.

Resource Conservation and Recovery Act Closure activities began in 1992 and consisted of soil sampling along the pipe trench, borings drilled in the center of the former pond, and the installation of four perched zone monitoring wells. Wastewater, sludge residues, and the hypalon liner were removed from the pond and disposed of at a permitted facility. The pond was backfilled and graded in March 1990. Regulatory approval was granted for the pond closure on May 19, 1995, with the completion of deed certification in the Carson County Registry of Deeds.

WASTE MANAGEMENT

Pantex Plant operations generate various types of waste. The waste produced by the assembly and disassembly of weapons includes high explosives and solvents. These operations also produce radioactive process water, debris contaminated with radioactive materials, low-level waste, low-level mixed waste, hazardous waste, sanitary waste, heavy metals, and solvents. Waste is also produced by various support operations such as the chemistry laboratories, maintenance, and the vehicle fleet.

Pantex Plant does not generate high-level waste or transuranic waste during routine operations. Three drums of transuranic waste generated from an isolated event are being stored at the plant on an interim basis until they can be shipped to the Waste Isolation Pilot Plant for disposal or to another Department of Energy site for interim storage. Storage and inspection costs are extremely small and not included in the estimate. Transportation costs to the Waste Isolation Pilot Plant are in the Waste Isolation Pilot Plan estimate.

In the future, the volume of operations-generated waste is expected to decrease as a result of waste minimization efforts and reduced dismantlement levels. As operations-generated waste decreases, the backlog of stored waste will be disposed.

Although the overall totals for the waste generation forecast are expected to have a fairly high confidence factor, several factors cause the level of confidence in the forecast figures for individual waste streams to be low. Pantex Plant uses waste stream descriptions to match waste types defined by the State of Texas. Because of changes made by the State of Texas, effective January 1994, the historical reference period of waste generation is relatively short for the current descriptions. Additionally, the waste minimization effort continues to provide benefits that reduce the amount of hazardous or mixed waste generated, but thereby often increase the amount of nonhazardous or low-level waste. Because the waste minimization effort continues at a good pace, the benefits can be expected to accumulate, but the effect will be to change the categories where waste generation is reported, and consequently the figures for individual waste streams are less accurate than the overall totals. Improvements are expected in the confidence factor for individual waste streams as additional background information is collected.

Low-Level Mixed Waste

GENERATION AND HANDLING

Pantex Plant produced a Site Treatment Plan, as required by the Federal Facility Compliance Act, resulting in a Consent Order with the State of Texas. The Consent Order governs schedules and milestones for low-level mixed waste treatment. Waste Management is involved in developing waste management plans for the disassembly of weapons to minimize the amount of waste generated.

The Office of Defense Programs (assembly and disassembly of weapons) and environmental restoration activities generate low-level mixed radioactive waste at Pantex Plant. After the generator initially characterizes and packages the waste, it will be transferred to the Waste Management program. Waste Management will not assume responsibility for environmental restoration-generated waste until FY 1997. Prior to FY 1997, treatment, storage, and disposal costs related to waste generated by environmental restoration activities are included in the remedial action costs of the Environmental Restoration program.

Onsite generation of low-level mixed radioactive waste was 9,429 kilograms (20,954 pounds) in FY 1995. This estimate assumes that 4,649 cubic meters (6,080 cubic yards) of waste will be generated in the life cycle.

TREATMENT

Pantex Plant developed a Site Treatment Plan for low-level mixed radioactive waste as required by the Federal Facility Compliance Act. The plan calls for the development and use of (1) existing onsite facilities, (2) commercial treatment, and (3) onsite treatment using mobile treatment units. The engineering and design of the mobile treatment units will start in FY 1996. Validation and startup will occur in FY 1999, with regular treatment operations beginning in FY 2001. Mobile treatment units are expected to require upgrading every 12 years (FY 2010 and FY 2022). Not all waste streams are ready for treatment, and disposal facilities will not be available in FY 1996.

The proposed Hazardous Waste Treatment and Processing Facility is designed for low-level waste, low-level mixed waste, and hazardous waste. It will also accommodate the mobile treatment units. Construction is expected to be completed in FY 1998, with processing beginning in FY 2000. See the Site Map for the location of Waste Management program activities.

STORAGE

Low-level mixed waste is currently being stored onsite in compliance with the Federal Facility Compliance Act Order and Compliance Plan, which the Department of Energy and the Texas Natural Resources Conservation Commission negotiated. The waste will be stored pending development of approved treatment technologies.

A Resource Conservation and Recovery Act hazardous waste staging facility has been designed, and completion in FY 1996 is planned. This facility will provide storage for 1,600 drums of hazardous, mixed, and low-level radioactive waste. The estimate assumes that the staging facility will require upgrading in FY 2026. At the end of FY 1995, Pantex Plant had approximately 67,000 kilograms (147,800 pounds) of low-level mixed waste in storage.

DISPOSAL

Low-level mixed waste is disposed at offsite commercial disposal facilities. Waste Management program costs for disposal, offsite transportation, and onsite support including review of the waste against the Waste Acceptance Criteria of the receiving facility. The estimate assumes 4,702 cubic meters (6,150 cubic yards) of waste will be disposed.

Low-Level Waste

GENERATION AND HANDLING

The Waste Management program is involved in developing waste management plans for the disassembly of weapons to minimize waste generated.

Low-level radioactive waste at Pantex Plant is generated by the Office of Defense Programs (assembly and disassembly of weapons) and environmental restoration activities. Waste Management will assume the responsibility for Environmental Restoration-generated waste beginning in FY 1997. After initial characterization and packaging are performed by the generator, waste is transferred to the Waste Management program. Prior to FY 1997, the estimate includes characterization and packaging costs in the generator's estimate. After FY 1997, the waste management estimate includes characterization and packaging, as well as treatment, storage, and disposal.

Low-level radioactive waste is divided into two categories: 1) waste approved for shipment to Nevada Test Site for disposal, which is routinely shipped when appropriate shipping increment quantities are accumulated; and 2) waste not yet approved for shipment to the Nevada Test Site, which is stored onsite pending approval for shipmentto the Nevada Test Site or other offsite disposal facility.

Onsite generation of low-level waste was approximately 53,000 kilograms (116,900 pounds) in FY 1995. This estimate assumed that 8,544 cubic meters (11,175 cubic yards) will be disposed.

TREATMENT

Treatment for low-level waste consists of stabilization and solidification to meet the acceptance criteria for the Nevada Test Site. Also included is the separation of liquid waste from solid waste.

STORAGE

Pantex Plant provides for onsite storage of low-level radioactive waste generated at Pantex Plant that is not approved for disposal at the Nevada Test Site. This includes operation of the waste tracking system data base; issuance of waste containers, labels and markings; maintenance of waste disposition forms; generation of inventory reports; monthly, quarterly, and annual waste summary reports for submittal to the Texas Natural Resource Conservation Commission; monthly inspections of low-level radioactive storage areas; loading and off-loading of waste at the storage facilities; and documentation of cradle-to-grave tracking of low-level radioactive waste.

A Resource Conservation and Recovery Act hazardous waste staging facility has been designed with completion expected in FY 1996. This facility will provide storage for 1,600 drums of hazardous, mixed, and low-level waste. The estimate assumes that the staging facility will require upgrading in FY 2026.

At the end of FY 1995, Pantex Plant had 190,600 kilograms (420,000 pounds) of low-level waste in storage.

DISPOSAL

In the near future, two shipments of low-level waste will be made to the Nevada Test Site quarterly.

Pantex Plant shipped approximately 24,300 kilograms (53,700 pounds) of low-level waste to offsite commercial disposal facilities in FY 1995. The Department will continue to evaluate commercial facilities for cost-effective disposal.

Hazardous Waste

GENERATION AND HANDLING

The Department of Energy's Office of Defense Programs (assembly and disassembly of weapons) and environmental restoration activities generate hazardous waste at Pantex Plant. Various support operations such as chemistry laboratories, maintenance, and the vehicle fleet also produce hazardous waste. After initial characterization and packaging are performed by the generator, waste will be transferred to the Waste Management program. Waste Management will not assume responsibility for environmental restoration-generated waste until FY 1997. Beryllium waste will be disposed in FY 1996, and no further generation of beryllium waste is anticipated.

Approximately 81,700 kilograms (190,100 pounds) of hazardous waste was generated onsite in FY 1995.

TREATMENT

The proposed Hazardous Waste Treatment and Processing Facility is designed for low-level waste, mixed waste, and hazardous waste. It will also accommodate the mobile treatment units. Construction is expected to be completed in FY 2000, with processing beginning in FY 2001.

Waste contaminated with high explosives is treated at the Pantex Plant Burning Grounds. Residual ash from the Burning Grounds is packaged and disposed of offsite. In FY 1995, approximately 25,400 kilograms (56,000 pounds) of waste contaminated with high explosives was treated at the Burning Grounds.

The Burning Grounds are scheduled to be upgraded pending approval of Resource Conservation and Recovery Act permit application. The upgrade is expected to be complete in FY 1997. Alternatives to burning, such as base hydrolysis and molten salt extraction, are being explored. However, this estimate assumes the burning grounds will continue to be used.

STORAGE

Pantex Plant provides for the compliant onsite storage of hazardous and non-Resource Conservation and Recovery Act regulated waste generated at Pantex. A Resource Conservation and Recovery Act hazardous waste staging facility has been designed, and completion is planned for FY 1996. This facility will provide storage for 1,600 drums of hazardous, mixed, and low-level radioactive waste. The staging facility will require upgrading in FY 2026.

At the end of FY 1995, Pantex Plant had approximately 15,100 kilograms (33,300 pounds) of hazardous waste in storage.

DISPOSAL

Hazardous waste is shipped monthly to offsite commercial disposal facilities. Costs associated with disposal, offsite transportation, and onsite support by waste operations personnel are included in the Waste Management program estimate.

Pantex Plant shipped approximately 91,000 kilograms (200,600 pounds) of hazardous waste to offsite commercial disposal facilities in FY 1995. The estimates assume 15,647 cubic meters (20,500 cubic yards) will be disposed within the life cycle.

Sanitary Waste

GENERATION AND HANDLING

Sanitary waste at Pantex Plant is generated by Office of Defense Programs (assembly and disassembly of weapons), environmental restoration activities, and various support operations, such as the cafeteria, the chemistry laboratories, maintenance, and the vehicle fleet. In FY 1995 there was 2.5 million kilograms (5.5 million pounds) of nonhazardous/sanitary waste generated. Environmental restoration-generated sanitary waste is not the responsibility of the Waste Management program in FY 1996, and in FY 1997 it will become the responsibility of Defense Programs. Thus, no costs for sanitary waste disposal have been included after FY 1996.

DISPOSAL

Nonhazardous/sanitary waste is either disposed of offsite at commercial facilities (Texas Class II waste to Amarillo Landfill) or onsite (wastewaters discharged to playa, and construction debris waste to the onsite Class III landfill). In FY 1995 there was 2.7 million kilograms (6 million pounds) of nonhazardous/sanitary waste disposed of at onsite and offsite landfills. This figure does not include wastewater discharged to the playa. The costs include the operation of heavy equipment to move and cover waste, as necessary; receiving and weighing incoming waste loads; validating that incoming waste meets the landfill's waste acceptance criteria; developing and maintaining operating logs and disposal records; and ensuring compliance with Texas Natural Resource Conservation Commission regulations concerning landfill operations.

Direct Program Management/Support

All program management activities are performed within the budgets for waste management and environmental restoration activities. For FY 1996 through FY 2001, program management activities at the site account for approximately 20 percent of the total budget.

Under an Agreement-in-Principle between the Department of Energy and the State of Texas, payments to local communities and state and federal agencies are made by the Department of Energy Amarillo Area Office.

Waste Management Activities Cost Estimate

(Five-Year Averages, Thousands of Constant 1996 Dollars)
	FY 1996-2000	2005	2010	2015	2020	2025	2030
Low-Level Mixed Waste
Treatment	329	278	278	278	278	278	278
Storage and Handling	357	328	328	328	328	328	328
Disposal	152	59	59	59	59	59	59
Low-Level Waste
Treatment	222	216	216	216	216	216	216
Storage and Handling	383	358	358	358	358	358	358
Disposal	504	402	402	402	402	402	402
Hazardous Waste
Treatment	53	53	53	53	53	53	53
Storage and Handling	590	547	547	547	547	547	547
Disposal	1,712	1,471	1,471	1,471	1,471	1,471	1,471
Sanitary Waste
Disposal	22
Direct Program Management/Support	5,449	3,746	3,603	3,603	3,603	3,603	3,603
Total	9,774	7,458	7,315	7,315	7,315	7,315	7,315
	FY 2035	2040	2045	2050	2055	2060	2065
Low-Level Mixed Waste
Treatment	278	278	278	278	278	278	278
Storage and Handling	328	328	328	328	328	328	328
Disposal	59	59	59	59	59	59	59
Low-Level Waste
Treatment	216	216	216	216	216	216	216
Storage and Handling	358	358	358	358	358	358	358
Disposal	402	402	402	402	402	402	402
Hazardous Waste
Treatment	53	53	53	53	53	53	53
Storage and Handling	547	547	547	547	547	547	547
Disposal	1,471	1,471	1,471	1,471	1,471	1,471	1,471
Sanitary Waste
Disposal
Direct Program Management/Support	3,603	3,603	3,603	3,603	3,603	3,603	3,603
Total	7,315	7,315	7,315	7,315	7,315	7,315	7,315
	FY 2070	2075	2080	2085	2090	2095	2100	Life Cycle*
Low-Level Mixed Waste
Treatment	278							21,106
Storage and Handling	328							24,743
Disposal	59							4,892
Low-Level Waste
Treatment	216							16,229
Storage and Handling	358							26,977
Disposal	402							30,659
Hazardous Waste
Treatment	53							3,975
Storage and Handling	547							41,240
Disposal	1,471							111,532
Sanitary Waste
Disposal								112
Direct Program Management/Support	3,603							280,173
Total	7,315							561,638
* Total Life Cycle is the sum of the annual costs in constant FY 1996 dollars.

DESCRIPTION OF PERSONNEL

Current Composition

Pantex Plant Environmental Management staff consists of individuals who represent a number of professions, disciplines, and specialties. These include: biology, chemistry, general science, health physics, geology, engineering, technical project management, Geographical Information System operation, hydrology/ground-water modeling, contaminant fate and transportation modeling, environmental protection, and waste management integration. Current staffing requirements are presented in the table below.

* The Projections for Full-Time Equivalent employees are based on FY 1996 planning baselines (see Reader's Guide).

Site Management Structure

Federal procurement reform legislation has mandated changes in the contracting process to increase use of competitive awards, enhance socioeconomic diversity and increase the use of fixed price contracts. The Federal Acquisition Streamlining Act, which revised the Federal Acquisition Regulation, has been implemented at Pantex Plant to increase procurement of commercial items, implement electronic procurement through the use of a credit card system, implement changes in the guiding principles for certification of cost and price data to $500,000 purchases, and raise the small business set aside threshold to $100,000. Other contract reform changes include development of effective performance criteria measures tied to the procurement evaluation plans in source selection. Pantex Plant has also implemented a cost incentive and cost avoidance (cost savings) program. Currently, Pantex Plant procurement personnel are investigating mechanisms to manage effectively uncosted balances of Fiscal Year-end funds.

The Management and Operations contractor is Mason and Hanger, Inc., who holds a cost plus award fee contract. The contract expires at the end of FY 1996 and negotiations are currently under way to extend the contract beyond FY 1996.

Future Full-Time Equivalent Needs

In the future, it is anticipated that the number of laborers and technicians will decrease slightly in Environmental Restoration as more sites reach the point of closure. The numbers of management and administrative Full-Time Equivalents will also decrease slightly as the management duties decrease because of the closures. There will be changes in the mix of scientists and engineers as the nature of the work changes. The staffing mix in waste management is anticipated to remain level.

FUNDING ESTIMATE

The following tables present estimated funding information for the Pantex Plant.

COMPARISON WITH PREVIOUS ESTIMATE

There are no major changes in the FY 1996 estimated total from the FY 1995 Report. However, the individual programs have changed significantly.

The Environmental Restoration program estimate is 57 percent lower because technical assumptions regarding remediation life-cycle costs have changed based on data from the assessment program. In addition, the site will apply a regulatorily required risk-based approach to remediation that will result in lower life-cycle costs.

The most notable Waste Management program change is that the duration of support to the Office of Defense Programs has increased from 40 years to almost 75 years. This increase in costs has been somewhat offset by cost reductions associated with low-level mixed waste treatment. Schedules for developing mobile treatment units have also been enhanced, thereby increasing confidence in the cost estimates.