BOX 3-1

The Technical Risk Reduction Program (TRRP) 05c Heat Transfer Test

The TRRP #05c Heat Transfer test will be performed in accordance with Appendix R of the BGCAPP Design-Build Plan, using the minimum equipment arrangement and testing material (at the Parsons Technology Development and Fabrication Complex) necessary to accomplish the objectives outlined within this Test Protocol and the corresponding Test Plan (to be developed as a follow-on to this protocol). As currently recognized, the overall test program objectives for resolution of the issues identified are described below.

  1. Demonstrate design fixes to the PCAPP MPT Test Unit such as: seals, doors, bearings, projectile jamming, etc. as identified in the overall study protocol and the various reports and recommendations emanating from that effort.

  2. Demonstrate BGCAPP-specific design improvements such as: effect of projectile orientation, steam injection orientation, gas take-off orientation, tray design to improve heatup. Calibrate the CFD Model of the test Unit on VX 155 mm projectiles to serve as a basis for FOAK full scale unit modeling.

  3. Demonstrate treatment of simulated EBH rocket warhead debris.

  4. Demonstrate limited Secondary Waste treatment options to gather data for further effort with the CFD Model.

  5. Perform test runs and cycles of components to make observations of critical design parameters that apply to the FOAK unit under design—particularly those that affect the risk of scale-up to the full scale unit. These include, but are not limited to: projectile paint debris generation and accumulation, thermal expansion stresses and deformation points, interferences, Gaussian field measurements and localized heating effects, wall temperature distribution, etc.

  6. Major Test Acceptance Criteria

The following test results are considered acceptable (Note: see test matrix acceptance criteria for specific values):

  1. Objective 1:

  1. Heat rate testing will be acceptable if 5X treatment is achieved as measured by temperature indicating for devices or paints (dosimeters, thermal indicating paints, thermocouples, optical pyrometer, etc.) values of at least 1000 degrees F for 15 minutes; with “coldest spot” thermal treatment duration times under 90 minutes this yields an overall tray duration of 105 minutes. This timing may be adjusted based on further CFD modeling underway for the new tray design and under-tray steam distribution header.

  2. New door structure travels without binding, operates smoothly with cycle times of no more than 60 seconds to open and 60 seconds to close. Actuating mechanism is not unacceptably heated or mechanically stressed. Two-axis door operating motion remains trouble free and the door seats to the main chamber with no fit issues.

The shadowing is being addressed by redesign of the projectile trays, the superheated steam inlet header, and the off-gas outlet header. The choice of mounting projectiles nose up or nose down in the trays is still a concern for full-scale MPT projectile trays. The BPBGT intends to resolve this issue by further analysis using the full-scale CFD model results (see Chapter 4).


Finding. The proposed redesigns for the projectile trays and headers to reduce “shadowing” of parts of the projectiles are appropriate. (See Chapter 4 for further information and support.)


Recommendation 3-4. The proposed header and tray redesigns to reduce “shadowing” of parts of the projectiles should be tested at the full-scale MPT operating conditions at the fabrication facility.

SECONDARY AND CLOSURE WASTE TREATMENT

Pyrolysis testing of secondary waste simulants was carried out at Hazen Research Inc. (HRI, 2005). This was followed by MPT TRRP testing of secondary waste treatment at the Parsons facility in Kennewick, Washington, in 2007.

Waste to Be Treated in the MPT

A flow diagram of the BGCAPP waste treatment system is provided in Figure 1-1 in Chapter 1. Waste to be treated in the MPT includes the washed munitions bodies from the munitions washout system (MWS), solid residues from the EBH, and secondary and closure waste. Estimated secondary waste generation and MPT processing rates for BGCAPP are given in Table 3-1.

Table 3-1 shows the waste streams in generic form: metal waste, butyls, PVCs, sludge, wood, and so on. Specific



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