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Program Executive Office, Assembled Chemical Weapons Alternatives (PEO ACWA)Program Executive Office, Assembled Chemical Weapons Alternatives (PEO ACWA)Program Executive Office, Assembled Chemical Weapons Alternatives (PEO ACWA)Program Executive Office, Assembled Chemical Weapons Alternatives (PEO ACWA)
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      Program Executive Office, Assembled Chemical Weapons Alternatives (PEO ACWA)


      Mission: The safe elimination of chemical weapons at Pueblo and Blue Grass by Sept. 30, 2023

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      BGCAPP is safely destroying the chemical weapons stockpile currently in storage at the Blue Grass Army Depot near Richmond, Kentucky.

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Blue Grass Team Develops Simulator, Saves Project Funds

Published: December 7, 2016 | Category: BGCAPP News, Technology
A multi-departmental team of Blue Grass Chemical Agent-Destruction Pilot Plant technicians discusses programming the simulator that will be used to train Control Room operators.

A multi-departmental team of Blue Grass Chemical Agent-Destruction Pilot Plant technicians discusses programming the simulator that will be used to train Control Room operators.

The Blue Grass Chemical Agent-Destruction Pilot Plant (BGCAPP) Automation Department saved the project more than $300,000 by using an existing computer system to train Control Room, or CON, operators.

“With the Facility Control System software developed and installed, we could utilize parts of the system for other purposes,” said Dave Richards, automation control staff lead, Bechtel Parsons Blue Grass (BPBG). “It is in excellent condition and provides the functionality and operability needed to give CON operators realistic, hands-on training with the control system without interrupting the ongoing plant systemization.”

The Automation Engineering Team used a development system to create and test the plant’s control system software before installation in the field. The team then developed an option so the equipment can function as a Control and Automation Training Simulator System to train operators.

“We ask our people to focus on cost management and reduce waste project-wide,” said Ron Hink, project manager, BPBG. “This is an excellent example of a team stepping up where they saw a need and providing a way to fill it, which saved procurement time and effort as well as money.”

Team members were enhancing software and planned to purchase training simulator hardware through a vendor, said Richards, when they realized their existing equipment could fit the need. They did research and collaborated with related departments and stakeholders to ensure the system would meet their requirements then presented their alternative to project leadership.

Existing support and spare parts are also on site to maintain the equipment, said Richards. This results in additional cost savings.

 

“Our light-off process is akin to someone trying to start their barbecue grill or gas fireplace for the first time in a season,” said Lee. “It might take several tries to get the gas to the burner and get everything properly set before it lights. And we run a 15-minute purge cycle after each attempt, so it’s not a very fast process.”

The workers are testing the repeatability of the light-off process with this activity, said Lee. Each TOX will need to demonstrate it can reliably start and stop its light-off before the next activity, the curing of the liner brick within each unit, can begin. Once the cure is complete, the TOX units can be tested at their full operating temperatures to get them ready to perform their essential jobs.

More BGCAPP Technology Articles

  • Vicky J., Container Handling Building/Unpack Area lead operator, reviews a munition image in the Rocket Non-Destructive Evaluation equipment at the Blue Grass Chemical Agent-Destruction Pilot Plant.

    Common Technology Making a Difference at Blue Grass

    Published: March 8, 2023
  • The first boxes of containerized, drained GB nerve-agent rocket warheads sit on a conveyor to be processed in the Blue Grass Chemical Agent-Destruction Pilot Plant Static Detonation Chamber (SDC) 2000 Jan. 27. The SDC 2000 is being used to destroy secondary waste, overpacked M55 rockets, M55 rockets deemed unsuitable for processing in the main plant and undrained rocket warheads.

    Static Detonation Chamber 2000 Begins Operations at Blue Grass Plant

    Published: January 27, 2023
  • Munitions handlers crimp a seal onto the end of a container holding a simulated rocket warhead in the Static Detonation Chamber (SDC) 1200 storage magazine at the Blue Grass Chemical Agent-Destruction Pilot Plant in September. The simulated containerized warheads were developed to test the Blue Grass SDC units prior to their operations.

    Simulated Warheads Prepared for Systems Testing

    Published: October 27, 2022
  • A munitions handler at the Anniston Field Office binds the fins of a Blue Grass rocket motor partially removed from its shipping and firing tube prior to its placement into the Anniston Static Detonation Chamber unit for destruction.

    Former Destruction Site Aiding Blue Grass Mission

    Published: September 14, 2022
  • Workers in protective suits make updates to the Punch and Drain Station in the Munitions Demilitarization Building at the Blue Grass Chemical Agent-Destruction Pilot Plant in preparation for upcoming GB nerve agent M55 rocket destruction. This automated system will punch holes in the rocket warheads and drain them of their chemical agent. (Portions of this photograph have been blurred in accordance with Department of Defense guidelines.)

    Rocket Destruction Efficiencies Applied for Final Destruction Campaign

    Published: June 30, 2022
  • Entrants in Demilitarization Protective Ensembles work to decontaminate a portion of the Munitions Washout System room at the Blue Grass Chemical Agent-Destruction Pilot Plant where VX nerve agent projectiles were destroyed in early 2021. This work is being done in the changeover period between the destruction of the VX M55 rockets and the start of the GB nerve agent M55 rockets. (Portions of this photograph have been blurred in accordance with Department of Defense guidelines.)

    Changeover Period Begins at Blue Grass Plant

    Published: May 31, 2022
  • Workers lower a 30,000-pound buffer tank into the Blue Grass Static Detonation Chamber 1200 building through an opening in the roof. This tank will buffer exhaust gases from the destruction process of the drained nerve-agent rocket warheads before the gases are processed in the off-gas treatment system.

    New Tank Safely Lowered Through Roof

    Published: March 30, 2022
  • Workers pass a piece of plywood up the Static Detonation Chamber 1200 stairs in preparation for opening the roof to allow a new piece of equipment to be lowered into the building. The building passed decontamination verification testing in January, which means workers do not have to wear chemical protective gear as they prepare for the system’s next activity.

    Former Mustard Destruction Facility Passes Crucial Test

    Published: March 1, 2022
  • Demilitarization Protective Ensemble entrants decontaminate equipment in the Munitions Washout System room at the Blue Grass Chemical Agent-Destruction Pilot Plant. Since all projectiles have been destroyed, much of this equipment is no longer needed for chemical weapons destruction.

    Decontamination Efforts Begin on Projectile Equipment

    Published: February 8, 2022
  • An operator cuts up the buffer tank from the mustard-processing off-gas treatment system at the Blue Grass Static Detonation Chamber 1200 site Jan. 11. The tank pieces are being disposed of as scrap and a new buffer tank will be installed for the upcoming drained VX rocket warhead destruction campaign.

    Equipment Removed for Site Upgrade

    Published: February 1, 2022
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Program Executive Office, Assembled Chemical Weapons Alternatives (PEO ACWA)