The Pueblo Plant: A Year in Review 2013

1. The Pueblo Plant:
A Year In Review
2013
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2. Staffing
2
 Rick Holmes
became the
Bechtel Pueblo
Team project
manager on
May 13.
 Steve Warren
was named
deputy project
manager on the
same day.
Rick Holmes Steve Warren
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3. Staffing
3
 Frank Fredrickson began work as the plant’s systemization manager in January.
 Dr. Donna Tillotson was named medical director on Feb. 7.
 Danny Cuillier became the project controls manager in February.
 Bill McCune, surety manager, joined the PCAPP team on June 3.
 Bill Fischlein, security manager, arrived Aug. 12.
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4. Plant Highlights - Winter
4
 In January, the PCAPP workforce achieved a milestone when the
English Boiler was the first of 17 major systems to become
operational.
 In February, workers installed monitors in the Control Room, a
necessary step in bringing communication on line.
 The February, the Citizens’ Advisory Commission held their meeting
in the newly completed Training Facility.
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5. Plant Highlights - Spring
5
 On April 18, Program Executive Officer, Assembled Chemical
Weapons Alternatives Conrad Whyne, announced selection of an
Explosive Destruction System (EDS) to augment PCAPP. The
EDS will be used to destroy a number of problematic chemical
munitions, including overpacked munitions and rejects, that
cannot be easily processed through the plant.
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6. Plant Highlights - Spring
6
 ATE (Assembled Chemical Weapons Alternatives Test Equipment) arrived at
PCAPP on April 3. Their arrival was significant as it allowed for
commissioning of first-of-a-kind equipment.
 PCAPP held its first Job Symposium in Pueblo on April 29, attracting more
than 400 local job seekers. A second symposium was held Nov. 13.
 Initial testing of a Projectile/Mortar Disassembly system took place on
May 9 in an Explosion Containment Room inside the Enhanced
Reconfiguration Building.
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7. Plant Highlights - Summer
7
 Three Automated Guided Vehicles (AGV) arrived at the plant on June 26. The
AGVs will safely transport munition bodies between processing buildings.
 This summer, workers applied protective coatings to a variety of surfaces
throughout the site. These special coatings provide an extra layer of protection
and create an environment for easier clean-up during munitions processing.
 Hon. Katherine Hammack, Assistant Secretary of the Army for Installations,
Energy and Environment, toured the PCAPP site on Aug. 14.
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8. 8
Plant Highlights – Fall/Winter
 In September, installation of the Munitions Washout System, and other
equipment, was completed at the PCAPP Training Facility.
 In October, the laboratory received a Declaration of Readiness from the
Laboratory Operational Readiness Review Board recommending receipt and
storage of chemical agent standards.
 On Dec. 10, startup and operations workers assist Ionex personnel, a
subcontractor, with unpacking carbon filters and loading them into one of 10
Exhaust Air Filter Units at the Agent Filtration Area.
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9. 9
Key Results
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10. Mission Readiness
10
APB 49%
ERB 34%
BTA 33%
System Complete
UTILITIES 55%
HVAC 51%
FACILITIES 73%
October 2013
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11. Mission Readiness—The Road to Initial
Agent Operations
11
*Major Milestones per the
PCAPP Integrated Master
Schedule (IMS)
1
7
9
8
5
4
3
6
14
15
Lab Dilute Agent Operations Mini-Operational Readiness Review (ORR)
Boiler Ignition Readiness Assessment
Start Operational Readiness Demo (IOD) – JUN 2015
Agent Entry Readiness and Agent Containment and Confinement Controls – JUL
2014
Start ERB Provisional Operations/Operations Certifications – SEP 2014
Start APB Provisional Operations/Operations Certifications – NOV 2014
Contingency Training Readiness/Crew Certification – JAN 2015
Begin Plant “Soft” Lockdown (Familiarization) – FEB 2015
Start BTA Provisional Operations/Operations Certifications – NOV 2014
(Optional – Not required per ACWA Policy #26)
Yard Provisional Operations – JUL 2014
Systemization Complete/Declare
Readiness – JUL 2015
Complete PCAPP
Systemization (for Pilot
Testing) – SEP 2015
Training Facility Available for Practical Factors – Readiness Check
Pre-Systemization Complete
Training Facility Available for Toxic Area Training – Readiness Check
10
11
12
13
Environmental Readiness – MAR 2015
16
Key Readiness
Milestones
COMPLETE
IN PROGRESS
NOT STARTED
* Incremental Readiness
Assessments will overlap –
they are not strictly sequential
2
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12. One Team One Mission—Pueblo Applicants
increased from 12.5 to 38%
12

13. One Team One Mission
13
 PCAPP
Communicator—Daily
communication with
employees
 Monthly Meetings
with Project Manager
(PM)
 Quarterly All Hands
Meetings
 Leadership Training
for PCAPP staff
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14. World Class Safety Program
14
2.38
0.93
1.32
0.95
0.80 0.91
0.00
1.00
2.00
3.00
4.00
5.00
2008 2009 2010 2011 2012 2013
Recordable Injury Rate
1.30
0.53
0.00 0.00
0.17
0.09
0.00
0
0.25
0.5
0.75
1
1.25
1.5
2008 2009 2010 2011 2012 2013
Lost Time Rate
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 Lost workday case rate  Total recordable injury rate

15. World Class Safety Program
15
 Hazard School Board
 Safety awareness and education through accident
simulations
 Incorporate “See, Hear, Do”
 QUEST Team
 Improving Quality, Safety Environmental
and Toxic Area Entrance Excellence
 FOCUS Team
 Friendly Observers Coaching Us on Safety
 Mission is to encourage safe behavior
 Voluntary Protection Program (VPP)
Steering Committee
 Subcommittee of QUEST
 Ensures VPP criteria is met
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16. Professional, Dedicated
Workforce
 Leadership Training
• 50 hour course
• More than 150 leaders planning to take
course
• 17 modules
 Human Performance
Improvement/Accountability
Training
• 10 hour course (single day)
• Everyone attends (including government
team)
• Seven Modules
 Training Items
• Completed 22,334 training items as of Nov.
30 2013
• This includes all PCAPP employees, vendors,
visitors and subcontractors who received
training during 2013
• PCAPP employees completed 17,876
training items
16
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17. Compliance Excellence
Risk Reduction
 Storm Water: 297 deficiencies identified; 152 resolved through
Environmental on-the-spot correction and 142 Service Requisitions
tracked to completion through work control
 Hazardous Materials: 30 deficiencies identified; resolved on the spot
and corrected through Operations Support focus on weekly Preventive
Maintenance inspections
 Coatings: All issues were resolved through operations support
management; conducted open and constant communication with
Colorado Department of Public Health and Environment (CDPHE)
 Waste Water: Use of Pueblo Chemical Depot East lagoons to avoid
off-site disposal costs
 Hazardous Waste: No findings (CDPHE)
17
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18. Community Involvement
18
 ACE Mentor Program
 PAWS for Life
 Habitat for Humanity
 Operation Paintbrush
 Rake Up Pueblo
 Posada Picnic and Health Fair
 Take a Turkey to Work Day
 Bonfils Blood donations
 Salvation Army’s Angel Tree
 United Way of Pueblo County
PCAPP Employees volunteered more than 1,440 hours to assist
the Pueblo community in 2013.
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19. Project Vision
In 2014, the PCAPP project personnel will:
• Through the consolidated efforts of PCAPP,
U.S. Army Pueblo Chemical Depot (PCD) and
the Bechtel Pueblo Team, provisional
operations will begin in conjunction with
achieving certifications throughout the plant
site (Enhanced Reconfiguration Building,
Agent Processing Building, Biotreatment
Area and yard)
• Continue to ramp up hiring and training
• Bring PCAPP Explosive Destruction System
online and operational
• Remain committed to safety while attaining
Voluntary Protection Program Certification
19
PCAPP
VISION
STATEMENT
Continuous
movement toward
our ultimate
goal—the safe
and
environmentally
protective
destruction of the
chemical
munitions
stockpiled at
PCD.
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20. Questions?
20
PCAPP staff pledged 350 Angels for the Salvation
Army’s Angel Tree Program. Each Angel represents
the wish list of 2-3 toys per child in need.
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