Appendix B
SCWO Reliability and Maintenance (RAM) Log for 500-Hour HD Hydrolysate Run

The data in Table B-1 were collected during the General Atomics engineering design study testing on the use of supercritical water oxidation (SCWO) technology as a secondary treatment step in the General Atomics Total Solution (GATS) for disposal of the mustard-agent-containing munitions stored at the Pueblo Chemical Depot.

REFERENCE

General Atomics. 2001. Assembled Chemical Weapons Assessment (ACWA), Engineering Design Studies, Draft Test Report, February 10. San Diego, Calif: General Atomics, Inc.



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OCR for page 83
Analysis of Engineering Design Studies for Demilitarization of Assembled Chemical Weapons at Pueblo Chemical Depot Appendix B SCWO Reliability and Maintenance (RAM) Log for 500-Hour HD Hydrolysate Run The data in Table B-1 were collected during the General Atomics engineering design study testing on the use of supercritical water oxidation (SCWO) technology as a secondary treatment step in the General Atomics Total Solution (GATS) for disposal of the mustard-agent-containing munitions stored at the Pueblo Chemical Depot. REFERENCE General Atomics. 2001. Assembled Chemical Weapons Assessment (ACWA), Engineering Design Studies, Draft Test Report, February 10. San Diego, Calif: General Atomics, Inc.

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Analysis of Engineering Design Studies for Demilitarization of Assembled Chemical Weapons at Pueblo Chemical Depot TABLE B-1 SCWO Reliability and Maintenance (RAM) Log for 500-Hour HD Hydrolysate Run ID Date Time Description of Item GA Log Book No. Page No. Shutdown Caused? Fix Time (hr) Problem Type System/ Component Involved 1 1/4/01 0:56 Nozzle plug 11574 56 Y <1 Operational Feed nozzle 2 1/5/01 12:07 Liquid letdown valve (Badger) repair 11574 58 N 2 Mechanical Liquid letdown 3 1/5/01 12:07 Liquid letdown valve cannot hold level 11574 58 N 2 Mechanical Liquid letdown 4 1/5/01 14:30 Gas/liquid separator gasket fails 11574 58 N 4 Mechanical Gas/liquid separator 5 1/5/01 17:00 Low-pressure feed pump housing cracked NA NA N 2 Error Feed recirculation pump 6 1/5/01 17:40 Feed pump erratic 11574 59 N <1 Operational Feed pump 7 1/6/01 4:00 Gas analyzers erratic 11574 62 N <1 Operational Gas analysis train 8 1/6/01 8:10 TE-600 faulty reading 11574 62 N <1 Operational Reactor 9 1/6/01 8:20 Heat tracing on hot line 11574 62 N <1 Error Reactor 10 1/6/01 8:20 PT-463 faulty reading 11574 62 N <1 Electrical Air line 11 1/6/01 9:15 Letdown system solids accumulation 11574 63 N 1 Operational GLS, hydroclone 12 1/6/01 9:18 Fuel pump packing repair 11574 63 N 2 Mechanical Fuel pump 13 1/6/01 10:18 Gas analyzers not consistent with computer 11574 64 N <1 Electrical Gas analysis train 14 1/6/01 10:55 Feed pump erratic 11574 64 N <1 Operational Feed pump 15 1/6/01 16:38 Liquid letdown valve (Badger) repair 11574 66 N 2 Mechanical Liquid letdown 16 1/6/01 18:45 Fuel line plug 11574 66 Y 2 Operational Fuel tank 17 1/6/01 22:00 Fuel pump packing repair NA NA N 2 Mechanical Fuel pump 18 1/6/01 23:30 Gas sample line plug 11575 2 N <1 Operational Gas analysis train 19 1/7/01 14:20 Reactor plug 11574 71 Y 3 Operational Reactor 20 1/7/01 19:23 Air flow control poor 11574 71 N <1 Operational Air line 21 1/8/01 12:49 Reactor bypassing 11574 75 Y 4 Operational Reactor 22 1/8/01 15:33 Thermowell replacement 11574 76 N <1 Corrosion Reactor 23 1/8/01 18:00 Letdown system solids accumulation NA NA N 1 Operational GLS, hydroclone 24 1/8/01 20:33 Feed cross leak 11574 76 N 2 Error Reactor 25 1/8/01 21:57 Reactor dump valve leak 11574 76 N <1 Mechanical Reactor 26 1/8/01 22:49 Nozzle plug 11574 76 N 4 Operational Feed nozzle 27 1/8/01 22:57 Water pump ruptured diaphragm 11574 76 N 2 Mechanical Water pump 28 1/9/01 2:32 Reactor surface TEs (thermocouples) faulty readings 11574 77 N 1 Electrical Reactor 29 1/9/01 3:27 Badgers not working in auto mode 11574 77 N <1 Computer Computer 30 1/9/01 4:45 Computer type mismatch 11574 77 N <1 Computer Computer 31 1/9/01 6:47 Feed pump erratic 11574 77 N 1 Operational Feed pump 32 1/9/01 6:50 Computer type mismatch 11574 77 Y <1 Computer Computer 33 1/9/01 9:50 Low-pressure feed pump seized 11574 78 N 1 Operational Feed recirculation pump 34 1/10/01 10:00 Gas sample line plug 11574 85 N <1 Operational Gas analysis train 35 1/11/01 0:00 pH electrode fouled NA NA N <1 Operational Liquid analysis train 36 1/11/01 16:36 Gas sample line plug 11574 94 N <1 Operational Gas analysis train 37 1/11/01 5:30 Clean P-350B check valves 11574 98 N 1 Operational Feed pump 38 1/12/01 7:00 Badgers not working in auto mode 11574 99 N <1 Computer Computer 39 1/12/01 7:00 Bypassing behind Ti liner 11574 99 N <1 Mechanical Reactor 40 1/12/01 7:00 Potential computer problems 11574 99 N <1 Computer Computer 41 1/12/01 7:00 Thermowell replacement 11574 99 N <1 Corrosion Reactor 42 1/12/01 10:32 Liner thermocouple malfunction 11574 99 N 1 Mechanical Reactor 43 1/12/01 15:07 pH meter apparently broken 11574 100 N 2 Mechanical pH meter 44 1/12/01 15:35 Fuel tank runs dry 11574 100 Y 3 Error Fuel system 45 1/12/01 19:00 PCV-437A not holding pressure NA NA N <1 Operational Fuel system 46 1/12/01 19:39 Ruptured cooling water hose 11574 101 Y <1 Operational Cooldown HX 47 1/12/01 22:00 Added scaling chemicals to cooling water NA NA N <1 Operational Cooling water system 48 1/13/01 14:14 Gas sample line plug 11575 2 N <1 Operational Gas analysis train 49 1/13/01 14:49 Compressor filters need replacing NA 2 N 1 Operational HP air compressors 50 1/13/01 21:58 PCV-357B not holding pressure 11575 4 N <1 Operational Feed system 51 1/13/01 21:58 Clean P-350B check valves 11575 4 N 1 Operational Feed pump 52 1/13/01 21:58 P-420B B head leaking 11575 4 N <1 Operational Fuel pump 53 1/14/01 18:30 Air flow fluctuations 11575 10 N <1 Operational HP air compressors 54 1/14/01 23:50 Discharge and suction check valves cleaned NA NA N <1 Operational Feed system 55 1/15/01 4:00 Added scaling chemicals to cooling water NA NA N <1 Operational Cooling water system

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Analysis of Engineering Design Studies for Demilitarization of Assembled Chemical Weapons at Pueblo Chemical Depot Component ID Maintenance/ Fix Type Root Cause of Problem Resolution to Problem NA Operational modification Feed precipitation Leave preheaters on at low setting FCV-654A Change-out Faulty installation, stem bent Change-out valve, rebuild correctly FCV-654B Change-out trim Solids in valve Better solids separation prior to valve GLS-630 Replace gasket Temporary gasket in use Procure proper gasket P-300B Replace Pump overpressured during cleanout Replace pump, exercise care when blowing out lines P-350B Clean (flush) Solids in pump Periodic cleaning/flushing, including inlet strainer GS-680 Drain Water carryover Modify post-V-680 trap TE-600 Reposition Thermocouple out of position Replace and secure thermocouple NA Reposition Incorrect installation Reposition heat tracing PT-463 Replace TBD TBD GLS-630, SS-640 Clean (flush) Titanium corrosion Periodic flushing P-420B Repair Normal wear Normal maintenance GS-680 Check connections Connections incorrect Correct connections P-350B Clean (flush) Solids in pump Periodic cleaning/flushing, including inlet strainer FCV-654A Adjustment Improper adjustment Adjust TK-400B Clean Dirty fuel Screen fuel when adding P-420A Repair Normal wear Normal maintenance V-680 System modification Mist carryover with salt deposition Modify post-V-680 trap R-550 Clean (flush) Failure to rinse after prior run Rinse reactor before restarting if feed processed for >0.5 hr FCV-461 Adjustment Improper adjustment of control pressure Reset control pressure R-550 Clean (flush) Nonoptimal top insert and gasket Install new top insert and gasket R-550 Replace Corrosion Replace GLS-630, SS-640 Clean (flush) Titanium corrosion Periodic flushing R-550 Replace Improper installation Review assembly procedures with pipe fitters FV-550 Replace Normal wear Rebuild NA Clean (flush) Metal burr from feed cross (see no. 15) Assemble fittings without galling P-120B Repair Nozzle plug Assemble fittings without galling TE-554 Replace Wet leads Waterproof thermocouple connections NA Programming Software problem Edit program NA Programming Software problem Switch computers P-350B Clean (flush) Solids in pump Periodic cleaning/flushing, including inlet strainer NA Programming Software problem Edit program P-300B Clean (flush) Solids precipitation in pump and lines Clean V-680 System modification Mist carryover with salt deposition Modify post-V-680 trap AE-670 Clean (flush) Solids buildup in probe housing Periodic cleaning/flushing V-680 System modification Mist carryover with salt deposition Modify post-V-680 trap P-350B Clean Preventative maintenance Clean NA Programming Software problem Edit program R-550 Redesign Mismatched components New top insert and gasket NA Reboot Power fluctuations Reboot R-550 Replace Corrosion Replace TE-572x, 574x Replace Normal wear Replace AT-670 Replace Unknown Not resolved at this time TK-400B Refill Hourly rounds neglected Carry out hourly rounds PCV-437A Repair Stem and seat worn Rebuild HX-610 Repair Hose overheats, presumably blockage Rework hoses Cooling water Added Nalco chemicals Potential scaling in cooling water Treat cooling water V-680 System modification Mist carryover with salt deposition Modify post-V-680 trap C-450 Change filter Preventative maintenance Changed desiccant air dryer filters on all compressors PCV-357 Rebuild Stem and seat worn Rebuild P-350B Clean Preventative maintenance Clean P-420B Replace packing B head leaking (packing) Changed packing on B head C-450 Adjustment Insufficient compressor pressure Set start pressure lower P-350B Clean Preventative maintenance Disassemble and clean Cooling water Added Nalco chemicals Potential scaling in cooling water Treat cooling water

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Analysis of Engineering Design Studies for Demilitarization of Assembled Chemical Weapons at Pueblo Chemical Depot ID Date Time Description of Item GA Log Book No. Page No. Shutdown Caused? Fix Time (hr) Problem Type System/ Component Involved 56 1/15/01 16:24 Gas sample line plug 11575 17 N <1 Operational Gas analysis train 57 1/16/01 0:35 Scaling in the DPT lines 11575 20 N <1 Operational Reactor DPT 58 1/16/01 0:35 Hose replacement for cooling water to CDHX 11575 20 N 1 Operational Cooling water system 59 1/16/01 0:35 Bad trim for FCV-654B 11575 20 N <1 Operational Liquid letdown 60 1/16/01 0:35 PCV-357B not holding pressure 11575 20 N <1 Operational Feed system 61 1/16/01 0:35 Discharge and suction check valves cleaned 11575 20 N <1 Operational Feed system 62 1/16/01 0:35 Thermowell replacement 11575 20 N <1 Corrosion Reactor 63 1/16/01 0:35 TE-571 broken on disassembly 11575 20 N <1 Mechanical Reactor 64 1/16/01 11:00 PCV-357A not holding pressure NA NA N <1 Operational Feed system 65 1/16/01 17:27 Gas sample line plug 11575 26 N <1 Operational Gas analysis train 66 1/16/01 3:00 Discharge and suction check valves cleaned 11575 28 N <1 Operational Feed system 67 1/17/01 3:00 Added scaling chemicals to cooling water 11575 28 N <1 Operational Cooling water system 68 1/17/01 12:17 Gas sample line plug 11575 31 N <1 Operational Gas analysis train 69 1/17/01 17:00 HP air compressor C malfunction 11575 32 N 2 Mechanical HP air compressors 70 1/18/01 2:45 PCV-460 not controlling properly 11575 35 N <1 Operational HP air line to reactor 71 1/18/01 9:35 Gas sample line plug 11575 37 N <1 Operational Gas analysis train 72 1/19/01 5:00 TE-571 broken on disassembly 11575 42 N <1 Mechanical Reactor 73 1/19/01 5:00 Thermowell replacement 11575 42 N <1 Corrosion Reactor 74 1/20/01 12:15 pH meter apparently broken 11575 48 N 2 Mechanical pH meter 75 1/20/01 14:00 TE-641 malfunction 11575 48 N <1 Mechanical Letdown system 76 1/20/01 19:27 Gas sample line plug 11575 49 N <1 Operational Gas analysis train 77 1/20/01 20:10 Line from PT-551 to reactor head leaking 11575 50 Y 2 Mechanical Reactor plumbing 78 1/20/01 22:12 Shutoff valve on gas letdown leaking 11575 50 N 2 Mechanical Gas letdown 79 1/20/01 22:12 Reactor dump valve leaking 11575 50 N 2 Mechanical Reactor 80 1/20/01 22:12 BPR on gas letdown not holding pressure 11575 50 N 2 Mechanical Gas letdown   Source: General Atomics, 2001.

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Analysis of Engineering Design Studies for Demilitarization of Assembled Chemical Weapons at Pueblo Chemical Depot Component ID Maintenance/ Fix Type Root Cause of Problem Resolution to Problem V-680 System modification Mist carryover with salt deposition Modify post-V-680 trap DPT-550 Clean (flush) Salts build up in DPT lines Flush lines HX-610 Replace Possible coolant overheating Replace with high-temperature hose FCV-654B Replace Scored trim, trim too large Replace with M trim PCV-357B Clean Dirty stem and seat Disassemble and clean P-350B Clean Preventative maintenance Disassemble and clean R-550 Replace Corrosion Replace TE-571 Replace Thermowell corrosion Replace PCV-357A Clean Dirty stem and seat Disassemble and clean V-680 System modification Mist carryover with salt deposition Modify post-V-680 trap P-350B Clean Preventative maintenance Disassemble and clean Cooling water Added Nalco chemicals Potential scaling in cooling water Treat cooling water V-680 System modification Mist carryover with salt deposition Modify post-V-680 trap C-450C Repair Check valve broken Repair PCV-460 Replace Oil contamination/clogging frit Disassemble and rebuild V-680 System modification Mist carryover with salt deposition Modify post-V-680 trap TE-571 Replace Thermowell corrosion Replace R-550 Replace Corrosion Replace AT-670 Replace Interference from power wiring Rearrange wiring TE-641 Replace Unknown Replace with surface thermocouple V-680 System modification Mist carryover with salt deposition Modify post-V-680 trap NA Replace Fatigue/wear/corrosion Weld new fitting to modified AE drilled through plug FV-640B Replace Contamination in gas letdown Replace FV-550 Replace body Overheating soft goods Replace PCV-646 Replace Corrosion/erosion internals Replace