Eng edge sept newsletter 2014

THE ENGINEERING EDGE

EDGEWOOD CHEMICAL BIOLOGICAL CENTER

Volume 6, Issue 9

September 2014

New Engineering Facilities Support Unique Customer Needs Employee Spotlight: Dr. Christopher Karwacki pg. 3 Engineering Test Facilities Offer Unique Options for Surety and Non-Surety Testing pg.4-5 New Laboratory and Expertise Expands Operations for Packaging Branch pg. 6-7

To access the electronic version of this newsletter, visit: http://www.ecbc.army.mil/news/ENG/ APPROVED FOR PUBLIC RELEASE

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2 | EDGEWOOD CHEMICAL BIOLOGICAL CENTER

INSIDE THIS MONTH’S ISSUE: pg.2|Business Management Tool Upgrade Streamlines Engineering Directorate’s Business Development Efforts pg.2|SharePoint Tip: Sending a Link to a File through Email pg.3|Employee Spotlight: Dr. Christopher Karwacki pg.3|Ask a Tech Tip: Emergency Uses for Common Household Chemicals and Ingredients pg.4-5|Engineering Test Facilities Offer Unique Options for Surety and Non-Surety Testing pg.6-7|New Laboratory and Expertise Expands Operations for Packaging Branch pg.8|ADM Summer Picnic and Technology Challenge: Food, Fun and Friendly Competition

Business Management Tool Upgrade Streamlines Engineering Directorate’s Business Development Efforts

T

he Engineering Directorate Business Development (BD) Core Team is launching an upgraded version of the online tool that facilitates and streamlines the strategic business and resource planning for the Directorate’s future.

The Business Management Tool (BMT) 2.0 features a direct link to the Engineering Pipeline Tool 2.0, creating an integrated BD process.

The Engineering Pipeline Tool 2.0 is used to manage potential business opportunities. When new business is indicated as “Won” in the Engineering Pipeline Tool 2.0, it is automatically transferred to the BMT 2.0, where it will need to be assigned as core business, adjacent work or white space.

The upgrades are a direct result of feedback received from the workforce since the tool was first launched in April 2014. The new features streamline the process, reducing the burden for those with responsibility of entering information into the tool, while identifying opportunities to collaborate across Divisions and pool resources to best serve customer needs.

The new tool was demonstrated for the BD Core Team on July 29 and the Engineering Front Office leadership on Aug. 12. “The strength of the BMT 2.0, and its newly created link to the Engineering Pipeline Tool 2.0, is the integrated process that it now creates,” said Engineering Acting Director Bill Klein.

The official launch of both the BMT 2.0 and Engineering Pipeline Tool 2.0 is set for Sept. 15.

Instructions for using the tools will be provided at that time, along with feedback from the BD Semi-Annual Review held on May 15 and a list of significant changes that have been incorporated into the tool since it was first introduced.

Training on the tools will be conducted on Sept. 16, 17 and 24 in small groups for those with primary responsibility for updating the information for their Branch or Division. Sessions will be hands-on and will simulate actual project updates using the tools. The next BD data call is planned for Oct. 6–24, and the next BD Semi-Annual Review is scheduled for Nov. 5.

This newsletter was published through the Balanced Scorecard.

For article suggestions, questions or comments please contact Ed Bowen at edward.c.bowen8.civ@mail.mil.

“The BMT 2.0 is not a budgeting tool ― it’s a planning tool that will help to ensure that the labor and non-labor costs associated with our work are funded and that we have the resources needed to pursue business moving forward,” said Humberto Galarraga, Chief of the Detection and Decontamination Engineering Division and leader of the Directorate’s BD initiative. “The BD Core Team is looking forward to building fidelity in the tool as the workforce becomes more acclimated to its usage and capabilities.”

SharePoint Tip: Sending a Link to a File through Email When communicating through email, sending a link directly to the SharePoint file is more efficient than adding an email attachment. Not only does it ensure that the latest copy of your file is being accessed, but it also reduces network traffic and email storage.

To email a link, navigate to the file that you want to reference and right-click on it; then select “Copy Shortcut.” Then paste the link into a new email.

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THE ENGINEERING EDGE |September 2014| 3

Employee Spotlight:

Dr. Christopher Karwacki This month the spotlight is on Dr. Christopher Karwacki, who serves as Chief Scientist for the Physical and Chemical Sciences for the ECBC Engineering and Research and Technology (R&T) Directorates.

The Chief Scientist role is dual-hatted to serve both the Engineering and R&T Directorates. How are you approaching this new role?

This role is about bridging two critical areas for the Center ― the foundational science and research, and the engineering applications and capabilities that will help field technologies and equipment to our Warfighters. I will work to bring subject matter experts (SMEs) together from across the Center, and from our government, industry and academic partners to create a multidisciplinary approach to solving complex science and engineering problems. This means involving SMEs early and in all stages of a project, and listening to our customers every step of the way. My experience in materials science and surface science will be used to explore new opportunities for engineering functional materials, and to grow customer programs that involve the design, manufacture and testing of advanced functional materials and devices.

What do you hope to accomplish in this role?

My goals are to strengthen collaboration across the Center and with our partners, while focusing on proper and accurate characterization of important materials and devices; to develop a system of referee standards for materials and instrumentation, as well as to improve the methodologies and quality of our testing capabilities; and to grow our technology innovation by helping to identify novel materials that can rapidly transition into functional, engineered products. I am a strong advocate for all ECBC employees having the opportunity for handson experience in a laboratory environment ― to foster teamwork, creativity and innovation so all of us gain a deeper understanding of the work we do for the Army and our customers. I am also a proponent of ECBC’s participation in technical seminars, publications and other valuable exchanges with the CBRNE community.

How is having a Chief Scientist beneficial to the Engineering Directorate?

The problems we are challenged with are becoming more complex scientifically by the very nature of new and emerging materials and devices. Virtually all new science and technology innovation will emerge from the nanosciences; that is, complex materials will originate from a bottom-up approach on an atomic and molecular scale. This new class of materials requires non-traditional tools, techniques and skill sets for interrogating, and understanding properties and their interaction with chemical-biological hazards. In order to do this, the methodologies and instrumentation we are used to with traditional military standards will need to be augmented with advanced instrumentation. We can do this successfully by adopting a multidisciplinary approach to problem-solving; bringing together SMEs with diverse expertise; and fully utilizing the sophisticated instrumentation and computational tools we have here at ECBC. As Chief Scientist, I look forward to being an advisor, catalyst and facilitator of this process on behalf of both the R&T and Engineering Directorates.

Tell us more about yourself. What are your hobbies outside of work?

All of us at ECBC support education in science, engineering, technology and mathematics (STEM), and I take great interest in mentoring and tutoring students in these disciplines. Many of my colleagues may not know that I am a cabinetmaker and have a fully equipped cabinet shop on my property in Churchville, Md. I am also a salt and freshwater angler ― this is my favorite escape.

Ask a Tech Tip: Emergency Uses for Common Household Chemicals and Ingredients Mike Kauzlarich, of the Pyrotechnics and Explosives Branch, reveals how the techniques and lessons learned in labs can help you solve your household problems. Submit a question to him at usarmy.APG.ecbc.mbx.engineering-directorate@mail.mil.

September is the American Red Cross National Preparedness Month, and there’s no time like the present to prepare your home in case of emergency or natural disaster. Here is a list of some common household chemicals and pantry ingredients that are multipurpose and could prove useful to you and your family in an emergency.

Plain Household Bleach (Without Additives): Very useful for a disinfectant, and even better to purify water. Buy a gallon and write the amount needed to purify water on the container with a permanent marker: 1 teaspoon per 5 gallons of water, or ¼ teaspoon per gallon of water, or 5 drops per quart. Pay close attention to the amounts. And since bleach will not remove chemical pollutants and may not kill all disease-causing organisms, a mechanical purifier will be needed for any water sources that may be contaminated in a disaster.

Sodium Bicarbonate (Baking Soda): This has a variety of medicinal uses, such as for heartburn, indigestion, high potassium levels in the blood and high acid levels in the blood or urine. Also use it to

fight small fires on the stove; as a cleaner; or to “sweeten” the taste of chemically purified water.

Isopropyl Alcohol (Rubbing Alcohol): Use as an antiseptic to clean minor cuts and abrasions; as an astringent to stop bleeding in minor cuts and scrapes; and as a surface disinfectant.

Salt: Can be used to treat burns or injuries, as well as bee stings, mosquito bites and poison ivy. It can also be used to preserve meats.

Apple Cider Vinegar: Use as an anti-inflammatory when diluted with water. It’s also a household-stain remover.

Honey: Antibacterial and anti-inflammatory properties and can be used as a cough-suppressant. Honey also contains hydrogen peroxide; when applied on an open wound, the glucose is diluted and gradually releases the chemical. It also prevents wounds from sticking to the bandage and reduces the appearance of scars.

For more information on how to prepare your family and home for an emergency, visit www.redcross.org.

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4 | EDGEWOOD CHEMICAL BIOLOGICAL CENTER

Engineering Test Facilities Offer Unique Options for

Surety and Non-Surety Testing

R

ecent upgrades to two ECBC Engineering Directorate test facilities have added tremendous capability to its roster of state-of-the-art facilities located on the Edgewood area of Aberdeen Proving Ground (APG). Now the Directorate is even more equipped to handle the chemical, biological, radiological, nuclear and explosive (CBRNE) defense testing requirements of the U.S. military and other customers.

Protection Factor/Toxic Chamber A multi-million-dollar renovation to one of ECBC’s explosive hazardous material test chambers has enhanced the Center’s unique surety capabilities for customers that need a test facility large enough to handle complex, large-scale operations involving the most dangerous CBRNE agents.

Protection Factor/Toxic Chamber Capabilities • Chemical agent liquid, aerosol, particulate and vapor testing

The Protection Factor/Toxic Chamber is cylindrical, with a volume of 16,000 cubic feet, and specifically designed for total-containment testing of equipment and materials using chemical agent liquids, aerosols, particulates or vapors. It can also be used for testing with explosives and energetic materials, as well as radiological agents.

The chamber is currently approved to handle up to 170 gallons of chemical agent and up to 10 pounds of explosives ― and can even support the use of chemical agent and explosives at the same time, allowing for customizable test scenarios under extreme conditions.

• Simultaneous tests of chemical agent and explosives

“The ability to test both chemical agent and explosives fully contained in the same chamber allows for the unique and specialized testing that the U.S. military and our customers require,” said Alex Pappas, facility manager and chief of the Protection Factors Chamber Branch in the Engineering Test Division. “This capability makes the chamber the only one of its kind in the continental U.S.”

• Two cylindrical (32’ diameter x 20’ height) chambers with 16,000-cubic-foot volume

The chamber is currently undergoing a $3 million renovation to add to its laboratory space, and enhance its equipment and safety conditions. The renovation includes an upgraded control room and mini-cam room for sophisticated test operation and observation; brand-new ingress and egress rooms for the safety of test personnel; an onsite surety laboratory (including storage vault) to handle sample collection and analysis; and improved environmental controls for various climatic conditions.

• Vehicle access door and 19 access ports

• Biosafety Level 2 laboratory conditions • Personnel Reliability Program (PRP) Category I trained in chemical agent and explosives handling and hazardous operations Features/Equipment

• 5,000-cubic-feet-per-minute filtration systems for chemical, biological and radiological agents • 10,000-gallon hazardous waste storage • 1,000-gallon decontamination solution storage • Upgraded control room and mini-cam room • New ingress and egress rooms • New surety laboratory and storage vault POC: Alex Pappas, 410-436-3338

The chamber will be operated by ECBC scientists and engineers with deep levels of experience in handling military-unique chemicals, military munitions, hazardous industrial chemicals and hazardous waste. ECBC also operates a second toxic chamber with similar features and capabilities, but at a lower explosive rating.

The chamber renovation will be completed and operational in early 2015. “We are excited to bring the new capabilities of this chamber online to support the testing needs of our Department of Defense and government agency customers,” said Pappas. “The chamber will also be ideal for universities and private industry who want to conduct complicated tests with the support of ECBC’s vast knowledge and resources in CBRNE defense.”

Credit: ECBC PAO. The facility includes 18,000-cubic-foot chamber, new ingress and egress rooms, and new surety laboratory.

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THE ENGINEERING EDGE |September 2014| 5

M Field The nation’s oldest military proving ground, APG was designed for ordnance testing of all kinds ― weapons, artillery, vehicles, aircraft and other equipment. ECBC is its resident leader in test and evaluation using chemical and biological agents, toxic industrial materials and explosives. In addition to several one-of-a-kind laboratories and test chambers, ECBC’s Engineering Directorate offers another unique option for testing ― a secured, open-air area called M Field.

M Field is ideal for testing using high explosives (up to 10 pounds) and smoke/obscuration material, and can handle IED detonation at a 75-meter distance. In addition, it has several new laser-testing capabilities, including a high-velocity vortex chamber for particulate testing; Class 4 laser capabilities; and infrared laser testing for grenades.

“While our customers appreciate the utility of the unique features of M Field, what’s most remarkable is its adaptability,” said Mark Hull, an electronics technician with the Environmental Field Testing Branch in the Engineering Test Division. “The facility can be customized for a variety of customer needs and test scenarios ― everything from small arms and munitions testing, to tests using unmanned aerial vehicles.”

The branch operates and maintains M Field, in cooperation with a cadre of trained experts and range technicians from across the Engineering Directorate, with years of experience on a variety of tests, equipment, materiel and customer requirements.

In addition to testing, the facility has been used for military, FBI, and Special Operations demonstration and training purposes. “We also invite industry to explore options for using our facilities for research and development and prototype testing,” said Hull.

Other benefits for customers include security and other controls, convenient location between major cities (Washington/Baltimore/ Philadelphia), and access to Phillips Army Airfield and helicopter pads on APG if needed.

M Field Capabilities • Open-air, non-surety testing • Secure, controlled-access facility • Combine environment and rough handling conditioning with operation and durability trials • Determine exposure to battlefield contaminants, and effects of interferents and simulants • Evaluate munitions, smoke and countermeasures, including hazardous classification assessments and developmental grenade tests • Provide demonstration support for military, FBI and Special Operations forces • Helicopter smoke and drop tests • Up to Class 4 laser testing, laser technology and radar targets Features/Equipment • 400-acre downrange test field with 1,000-meter line of sight • 300-square-foot test pad with observation bunker • Grenade grid for measuring smoke cloud dispersion • High-velocity vortex chamber for measuring the laser effects from particle dust clouds • Trailers for environmental control conditions and observation POC: Stephen Harper, 410-436-3765

“The greatest benefit to our customers is the expertise across our organization and with our APG partners; not only our testing capabilities, but also what we offer in design, manufacturing and logistics support,” said Hull. “All can be leveraged to meet the customer’s goal and the mission of protecting the Warfighter.”

Grenade grid used for interferent grenade test

Smoke test conducted on M Field APPROVED FOR PUBLIC RELEASE

6 | EDGEWOOD CHEMICAL BIOLOGICAL CENTER

New Laboratory and Expertise Expands Operations for

Packaging Branch

B

y capitalizing on the utility of its new packaging laboratory, the ECBC Engineering Directorate’s Packaging Branch is fulfilling its role as the go-to experts in customized packaging and handling support for both internal and external customers.

The 1,200-square-foot packaging laboratory opened in December 2013, allowing the Branch to combine their capabilities in one location, streamline their prototyping and packaging operations and expand their expertise in HAZMAT and other specialized capabilities.

“The convenience of the packaging lab being located here on Aberdeen Proving Ground ― so close to many of our customers ― has been a catalyst for the growth of our business and the kind of support that we are able to provide,” said Dexter Jennings, a packaging specialist and HAZMAT certifier. “We have received many more calls this year for our HAZMAT expertise, as well as for advice on proposals and regulation requirements.”

This type of expertise was evident by the Branch’s support to the Joint United States Forces Korea Portal and Integrated Threat Recognition (JUPITR), which included packaging and shipping of HAZMAT compressors, lithium batteries, generators, fire extinguishers, carbon dioxide fire extinguishers and other materials needed for the program. There were two stages of packaging support: one for the biosensor and another for inactive bio agents and simulants, which had to be packaged in special cooler-like containers using dry ice. The Branch has also been involved in developing the response kit for HAZMAT materials collected through the JUPITR program, including proper containment and instructions for handling by certified personnel.

Jennings served as a packaging subjectmatter expert on the program. “I was contacted to support this program based on my HAZMAT certification and long-time experience in military packaging,” said the Army veteran. He also advised on proper shipping and handling of the materials, which had to follow numerous regulations based on shipping items by air, land or sea, and by commercial or military means.

“The regulations are complex and understanding them can be tricky,” said Jennings. “We encourage our customers to reach to us to advise not only the best packaging method, but also the safest and most efficient transportation option for their materials across all of the regulations.”

The in-house capabilities of the packaging laboratory also support small-scale prototyping and specialized packaging designs. For example, the Branch recently created a new design for a container for the CS capsules used for gas mask training for Soldiers and Marines.

The same packaging method has been used since the 1960s.

“ECBC is the original author for the technical data for this packaging,” explained Mary K. Peck, packaging specialist.

“While updating the specifications, we thought the packaging could use an upgrade as well, and suggested this to our customers, the U.S. Army and U.S. Marine Corps.”

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THE ENGINEERING EDGE |September 2014| 7

The team evaluated different packaging materials on the market (both military and commercial options) that would meet the requirements storage of the capsules based on their expected lifecycle. “Our analysis determined that commercial packaging could be used for the capsules,” said Peck. “We recommended a pre-tested, pre-certified commercial container that met the military’s requirements for the safe storage of the material and also provided a cost-savings for the customer.”

Peck also noted how the team’s packaging experts stay on top of packaging trends, including new materials and designs, as well as environmental standards and policies. “This knowledge is especially helpful for our customers when they identify their packaging needs early in a project’s lifecycle. The combination of our expertise with the capabilities of the packaging laboratory will translate into efficiencies ― both time-savings and costsavings ― that ensure the worldwide transportation of necessary materials to our Warfighters.”

Dexter Jennings certified the packaging of HAZMAT material for the JUPITR program. Materials included compressors, lithium batteries, generators, fire extinguishers, and carbon dioxide fire extinguishers.

The Packaging Branch team suggested a commercial packaging method for the CS capsules, which provided convenience and cost-savings for the customer.

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8 | EDGEWOOD CHEMICAL BIOLOGICAL CENTER

ADM Summer Picnic and Technology Challenge: Food, Fun and Friendly Competition

W

hen the ECBC Engineering Directorate’s Advanced Design and Manufacturing (ADM) Division gathered at Flying Point Park on Aug. 7 for their annual summer picnic, it was not just to enjoy steamed crabs, pit beef, and conversation with colleagues and their families ― it was also to partake in a friendly competition called the Technology Challenge.

The Technology Challenge is a popular event that gives the workforce a chance to exercise its rapid-prototyping, creativity, and problem-solving skills in a relaxed and fun atmosphere. “I started this competition about 12 years ago at a time when we were focused on building our team,” explained ADM Division Chief, Mark Schlein. “It recognizes our natural competitive spirit and fosters teamwork, innovation, communication and networking in a way that complements how we approach our day-to-day work for our customers.”

This year’s challenge was to build a cardboard bridge that was long enough to cross a water obstacle and strong enough to support team members carrying canned goods across, where the cans were collected and weighed. Teams were given cardboard, duct tape and supplies, a set of rules, and one hour to design and construct their bridges. Teams are always encouraged to exploit loopholes in the rules and think outside of the box in order to give their design an

advantage. Safety is also a consideration, and competition plans and rules are reviewed by the ECBC Safety and Risk Management Office.

The team that carried the heaviest load of canned goods across their bridge was declared the first-place winner. Trophies (with custom toppers designed by ADM model-makers) were also awarded for second place, third place and best design. A special “Galloping Gertie” trophy was awarded for most spectacular design failure.

Previous competitions have included a cardboard canoe race, catapulted egg catch, rubber band aircraft and water bottle rockets. “The same skills that apply to our work ― rapid-response, prototyping, design, engineering, fabrication ― can all be applied to the Technology Challenge,” said Lester Strauch, chief of ADM’s Engineering Design and Integration Branch. “The competition is meant to be fun, and non-technical folks and families are also encouraged to participate.”

The ADM picnic and Technology Challenge are open to the entire APG community. For the first time this year, a charitable donation was integrated into the event and this is something Schlein plans to continue. All of the canned goods donated by the workforce benefited a local food bank.

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