LCAAP_Industry_Day_2_-_MOD_Brief.PDF

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Final As of 26 MAR 18

Dennis Durkin Lake City Army Ammunition Plant (LCAAP) Modernization Projects Overview 11 April 2018

Industry Day #2

26MAR18 FINAL

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• LCAAP Modernization has provided significant investment to upgrade production equipment and processes

• Objective has been to continue modernization activities

• Focus on obsolete equipment and processes

LCAAP Modernization Effort (2013-2018)

FY13 FY14 FY15 FY16 FY17 FY18 Total

$17.5M $23.6M $25.0M $9.1M $9.1M $49.6M $133.9M

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LCAAP Modernization Effort (2013-2018)

Project Number Project Title FY Awarded

SC-41 Single Point of Fire 13 $7,508,053

SC-42 Covered Accuracy Range - Design 13 $997,367

SC-43 SCAMP Case Simulators 13 $2,176,172

SC-44 Chemical/Metal Lab Upgrade 13 $4,628,440

SC-45 Cal .50 Bullet Front End - Design 13 $1,933,096

SC-52 Explosive Neutralization - Develop/Bench Scale 13 $275,704

SC-45 Cal .50 Bullet Front End - Execution 14 $8,171,483

SC-62 5.56 BAM Refurbishment Phase I 14 $1,661,924

SC-64 Link Heat Treat Furnace 14 $4,777,771

SC-65 Range Safety Automation - Design 14 $495,090

SC-66 Manurhin Loader Refurbishment 14 $2,577,482

SC-67 TNR Distributive Control System 14 $1,308,617

SC-81 5.56mm Case Cup Anneal 14 $4,580,538

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Project Number Project Title FY Awarded

SC-65 Range Safety Automation - Execution 15 $3,693,372

SC-84 5.56mm Tracer Charging Modernization - Ph 1 15 $383,457

SC-86 5.56mm Safe Pack Unloader - Line 1 15 $3,228,131

SC-87 Link Press Modernization 15 $6,801,192

SC-88 Explosive Lab Equipment Upgrade 15 $191,328

SC-89 5.56 Manurhin Tip ID Upgrade 15 $1,393,156

SC-80 SCAMP Propellant Delivery Upgrade - Design 16 $1,299,439

SC-62 5.56 BAM Refurbishment Phase II 16 $2,122,693

SC-94 5.56mm Isotopic Gage Upgrade 16 $1,940,445

SC-103 SCAMP Material Handling - Concept Design 16 $804,266

SC-104 5.56mm Crate Closure System (5) 16 $2,290,843

LCAAP Modernization Effort (2013-2018)

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LCAAP Modernization Effort (2013-2018)

Project Number Project Title FY Awarded

SC-125 Cal .50 Ammunition Can Leak Test System 17 $599,850

SC-126 Primer Component Wash System Upgrade 17 $2,804,195

SC-127 7.62mm Crate & Cal .50 Can Printing Upgrades 17 $2,766,322

SC-128 7.62mm & Cal 0.50 Crate Assembly Equipment 17 $2,960,756

SC-129 M249 Magazine Marker Upgrade 18 $1,136,653

SC-134 Cal .50 Link Press Replacement 18

SC-139 5.56mm Clip Pack Line Upgrades 18

SC-140 West Charging Wing Facilitization for 7.62 18

SC-141 7.62mm Long Lead Equipment 18

SC-142 Pyrotechnic Drying Ovens 18

SC-143 Primer Mix House Upgrades 18

SC-144 Energetic Neutralization Upgrades 18

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LCAAP Modernization Efforts – Ballistic Range

Project Description Status

Single Point of Fire • Relocate all down range production gun houses to main building

• Establish new trace performance observation houses based on firing from main building

• Establish new bunkers at 1300 & 1625 yards to support trace performance testing

• Install new Trace Observation Evaluation System (TOES) hardware in new observation houses

Complete

• Waiting on AAIE for TOES

Range Safety Automation

• Replace manual Command and Control of range operation with automated system using existing Lenel badging system

• Replace manual tracking of down range personnel via log book

• Upgrade gate access points to operate from Lenel system

In Process

• All hardware installed

• Debugging interface to plant wide Lenel system

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LCAAP Modernization Efforts – Ballistic Range

Single Point of Fire

Down range 7.62 Trace Performance Gun House

New Trace Performance Firing Positions in Main Building

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LCAAP Modernization Efforts – Ballistic Range

Single Point of Fire

Old 7.62 Trace Performance Observation House

New Trace Performance Observation House with TOES Camera

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LCAAP Modernization Efforts – Ballistic Range

Single Point of Fire

Bunker view from Main Building

New Bunkers

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LCAAP Modernization Efforts – Ballistic Range

Single Point of Fire

Screen shot of TOES Engineering Test

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LCAAP Modernization Efforts – Ballistic Range

Range Safety Automation

Current Range Controls with Logbook and Lock-Outs

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LCAAP Modernization Efforts – Ballistic Range

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LCAAP Modernization Efforts – Ballistic Range

Motorized Vehicle Gate with Badge Reader

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LCAAP Modernization Efforts – Ballistic Range

Range Safety Automation

Tracer Observer Station with Badge-In Sensor

Tracer Observer House Door with Door Position Sensors

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LCAAP Modernization Efforts – Link Manufacturing

Project Description Status

Link Press Modernization

• Refurbish seven 30 ton link presses used for 5.56 and

7.62 links

• Replace two Danly 100 ton link presses with a single press used for cal .50 links

• Upgrade ancillary equipment for link manufacture

In Process

• Four presses refurbished

• New 100 ton Minster

• New die-set for 7.62

• New strip de-coiler, straighten and feed systems Link Heat Treat Furnace

• Replace four obsolete heat treat furnaces with a single austempering heat treat system

• Replace furnace atmosphere generator

• Replace molten salt holding tank

Complete

• All equipment in production

Cal .50 Link Press Replacement

• Replace two 100 ton link presses used for cal .50

• Upgrade ancillary equipment for link manufacture

In Process

• Funded but not yet awarded

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LCAAP Modernization Efforts – Link Manufacturing

Existing 30 ton press and ancillary feed equipment

Link Press Modernization

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LCAAP Modernization Efforts – Link Manufacturing

Refurbished 30 ton press

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LCAAP Modernization Efforts – Link Manufacturing

New ancillary feed equipment

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LCAAP Modernization Efforts – Link Manufacturing

Existing 100 ton Minster and Danly presses

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LCAAP Modernization Efforts – Link Manufacturing

New 100 ton press

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LCAAP Modernization Efforts – Link Manufacturing

Link Heat Treat Furnace

1960 vintage Heat Treat Furnace

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LCAAP Modernization Efforts – Link Manufacturing

New Heat Treat Furnace with Salt Quench and Rinse

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LCAAP Modernization Efforts – Link Manufacturing

New Endothermic Gas Generator

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LCAAP Modernization Efforts – Energetics

Project Description Status TNR Distributive Control System

• Replace controller used for synthesis of TNR, Lead Styphnate and Tetracene

• Replace controller without impacting production

Complete

• Replaced obsolete ABB System Six with

DeltaV DCS

Energetics Neutralization Upgrades

• Replace ten flat bottom rectangular tanks uses to neutralize explosive waste from energetic manufacturing operation

• Upgrade process to remotely monitor/control neutralization operations

In Process

• Funded but not yet awarded

Pyrotechnic Drying Ovens

• Replace 1940 vintage pyrotechnic constituent drying ovens

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LCAAP Modernization Efforts – Energetics

TNR Distributive Control Upgrade

Original TNR Control Room and Controller

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LCAAP Modernization Efforts – Energetics

TNR Distributive Control Upgrade

TNR Controller Graphical Screen – New Controller

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LCAAP Modernization Efforts – Energetics

• Rectangular, flat bottom tanks

• Steam sparging used to heat and mix waste water

• Neutralized “sludge”

Neutralization Upgrades

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LCAAP Modernization Efforts – Energetics

Neutralization Upgrades

Manual feed of neutralization agents from behind Lexan shielding

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LCAAP Modernization Efforts – Energetics

Pyrotechnic Drying Ovens

Steam Heated Drying Ovens for Pyrotechnic Constituents

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LCAAP Modernization Efforts – Packaging

Project Description Status

5.56 Crate

Closure System

• Replace manual crate assembly stations on five packaging lines with semi-automated systems

In Process

• Three systems installed and operating

• Two systems competing acceptance testing

7.62 & Cal .50 Crate Closure System

• Replace manual crate assembly stations on two cal .50 packaging lines and three 7.62 packing lines with semi-automated systems

In Process

• CDR complete, fabricating equipment

7.62 Crate & Cal

.50 Ammo Can Printing Upgrades

• Replace existing contact pad printing equipment for 7.62mm ammunition crates

• Replace existing contact pad printing equipment for Cal .50 ammunition cans

In Process

• PDR complete, CDR in May

5.56 Clip Pack

Line Upgrades

• Replace existing clipping machine, point protector carton assembly and ancillary feeders on three packing lines

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LCAAP Modernization Efforts – Packaging

5.56 Crate Closure System

Manual Crate Assembly Operation

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LCAAP Modernization Efforts – Packaging

5.56 Crate Closure System

Semi-automated Carte Assembly Machine Similar systems will be installed for 7.62 and Cal .50

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LCAAP Modernization Efforts – Packaging

7.62 Crate & Cal .50 Ammo Can Printing

System

Contact Print Roller for Existing Crate Printing Equipment

Lot Number

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LCAAP Modernization Efforts – Packaging

7.62 Crate & Cal .50 Ammo

Can Printing System

ATK Developed Cal .50 Crate Printing and Palletizing System

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LCAAP Modernization Efforts – Packaging

7.62 Crate & Cal .50 Ammo Can Printing

System

ATK Developed Ammo Can Printing System

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LCAAP Modernization Efforts – Packaging

5.56 Clip Carton Packing System

Existing Cartridge Clipping Operation

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LCAAP Modernization Efforts – Packaging

5.56 Clip Carton Packing System

Existing Point Protector Carton Insert Operation

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LCAAP Modernization Efforts – 5.56mm

Project Description Status

SCAMP

Propellant Delivery System - Design

• Design a replacement propellant handling system for SCAMP Loading Lines

• Conduct destructive testing of system components to validate design safety

In Process

• Vacuum propellant delivery design developed.

• Initial test of propellant receiver failed.

SCAMP Case Simulators

• Replace/upgrade 1970 hydraulic case simulators used for the off-line adjustment of case tool modules

Complete

• Simulators installed for initial and final draw, heading, head-turn, 1st and 2nd taper, final trim and pierce operations

5.56 Primer Safe

Pack Unloader

• Develop a primer delivery system for 5.56 that will handle Safe Pack Carriers (Hazard Classification 1.4)

• Replace 1970 vintage bulk primer delivery system on SCAMP Priming Line 1 (Hazard Classification 1.1)

In Process

• Equipment is installed, acceptance test complete and equipment turned over to production.

• Follow-on effort for lines 2-5 is funded but not yet awarded

5.56 Isotopic

Gauge Upgrades

• Develop a replacement for existing obsolete isotopic detectors, no longer available from vendor

• Replace isotopic detectors on Loading lines 1-5

In Process

• Prototype detector is complete and being tested

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LCAAP Modernization Efforts – 5.56mm

Existing Propellant Delivery System Layout

Cart track system (1970s)

Vacuum system (1980s)

Propellant Delivery System - Design

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LCAAP Modernization Efforts – 5.56mm

Propellant Delivery System - Design

Existing Drum CarrierExisting Drum Dumping Station

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LCAAP Modernization Efforts – 5.56mm

Case Simulators

Tool Module

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LCAAP Modernization Efforts – 5.56mm

Case Simulators

Hydraulic Simulator Upgraded, Servo Driven, HMI Controlled Case Simulator

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LCAAP Modernization Efforts – 5.56mm

Primer Safe Pack Unloader

Current primer storage at priming line

Primers delivered in bulk cardboard boxes, 1.1 Hazard

Classification

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LCAAP Modernization Efforts – 5.56mm

Primer Safe Pack Unloader

Primer delivery to feeder bowl Primers being loaded into current delivery system

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LCAAP Modernization Efforts – 5.56mm

Primer Safe Pack Unloader

Primer Safe Pack Carrier

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LCAAP Modernization Efforts – 5.56mm

Primer Safe Pack Unloader

Safe Pack Elevator Safe Pack Unloader inside

Barricade

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LCAAP Modernization Efforts – 5.56mm

Isotopic Gauge Upgrade

Isotopic Gauges (3)

• Propellant Height

• Bullet Core

Presence

• Redundant

Propellant Height

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LCAAP Modernization Efforts – 5.56mm

Isotopic Gauge Upgrade

Radioactive “Device” approved by NRC and licensed NRC Region 3

Source upgraded to Americim-241 in 2010 when Cesium-137 source reached its half-life.

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LCAAP Modernization Efforts – Other

Project Description Status Cal .50 Bullet Front End

• Replace bullet jacket 1st Draw Presses

• Replace Inter-draw Anneal

• Replace bullet jacket final Draw Presses

• Eliminate jacket Trim operation

Complete

• Equipment operating in production

West Charging Wing Facilitization for 7.62

• Refurbish a charging wing to be used for Load Assemble and Pack of developmental ammunition

• Upgrade infrastructure to support loading operations of developmental cartridges

In Process

• Funded but not yet awarded

7.62 Long Lead

Equipment

• Procure and install 7.62 loader

• Install vacuum propellant delivery system

• Install high speed deluge

• Procure and install die-set bullet assembly machine

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LCAAP Modernization Efforts – Other

Cal .50 Bullet Front End

Cal .50 Bullet Jacket 1st Draw Press

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LCAAP Modernization Efforts – Other

Jacket Trim Machines

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LCAAP Modernization Efforts – Other

Cal .50 Bullet Front End

Cal .50 Bullet Jacket Draw Presses Pinch Trim eliminates Final Trim

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LCAAP Modernization Efforts – Other

Cal .50 Bullet Jacket Anneal, Pickle, Wash

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LCAAP Modernization Efforts – Other

West Charging Wing Facilitization for 7.62

Exterior view of west wing

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LCAAP Modernization Efforts – Other

Interior view of west wing

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LCAAP Modernization Efforts – Other

Pyrotechnic Pass Through

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LCAAP Modernization Efforts – Other

Long Lead Equipment

Cartridge Loading Machine

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LCAAP Modernization Efforts – Other

Long Lead Equipment

Bullet Assembly Machine

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Production Base Support (2013-2018)

• Production Base Support has provided significant investment to LCAAP Infrastructure since 2013.

• Objectives are safety, environmental, process improvements, energy, and employee quality work environment (QWE) enhancements.

• Focus area is “mainly outside the production buildings”.

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Production Base Support (2013-2018)

PBS Infrastructure and LIF Project Title Plant Impact

New Emergency Services Center - Complete Safety

Interior Buss Replacement 7.62/Cal .50 - Complete Continuity of Production and Safety

5.56 Electrical Switchgear Upgrade - Complete Continuity of Production

HVAC for 5.56/7.62/Cal .50 Production Buildings - Construction Complete, Commissioning Summer 2018

Quality Work Environment

5.56 Exterior Switchgear Replacement - Complete Continuity of Production and Safety

Conductive Floor Replacement - Complete Continuity of Production and Safety

Hard Road Surface Recapitalization - Complete Continuity of Production and Safety

Fire Station & Waste Water Treatment Plant Partial Roof Replacement - Complete

Continuity of Production

Structural Upgrades Ballistic Testing, Lead Shop and Water Treatment Plant

Continuity of Production and Safety

OSHA Guarding Phase 4 Safety

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Production Base Support (2013-2018)

PBS Infrastructure and LIF Project Title Plant Impact

Steam Plant PLC and Economizer Controls Upgrade Safety and Environmental

Exterior Steam Main Supports Phase 1 - Complete Continuity of Production

5.56 Compressed Air System - Complete Continuity of Production

Structural Upgrades for 5.56/7.62/Cal .50 and Primer Production Buildings (Design) - Complete

Continuity of Production and Safety

Water Wells Continuity of Production

Switchgears Upgrades for 5.56/7.62/Cal .50 and Primer Production Buildings

Continuity of Production

HVAC for Explosive Wings of 5.56/7.62/Cal .50 Production Buildings (Design)

Continuity of Production and Safety

Water Treatment Plant (Design) Continuity of Production and Safety Propellant Storage Buildings Temperature Control and Monitor Upgrades

Continuity of Production and Safety

Water Supply and Tower Upgrades Continuity of Production and Safety Bldg. 3 Roof Replacement for 7.62 and Cal .50 Production Building

Continuity of Production

Warehouse Replacement Study Continuity of Production

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LCAAP Modernization Efforts – Summary

• Significant investments have been made at LCAAP from a production, infrastructure, and QWE perspective.

• Modernized LCAAP is cornerstone to follow on production/facilities contract.

• Army supports continuous improvement at LCAAP notwithstanding budget environment.

• Modernization of LCAAP will continue through the next contract, pending availability of funding.