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Appendix B: SCWO Reliability and Maintenance (RAM) Log for 500-Hour HD
Pages 83-87

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From page 83... ... technology as a secondary treatment step in the General Atomics Total Solution (OATS) for disposal of the mustard-agent-containing munitions stored at the Pueblo Chemical Depot. Read the entire page →
From page 84... ... 11574 77 N 1 Electrical Reactor faulty readings 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 Read the entire page →
From page 85... ... Insufficient compressor pressure Preventative maintenance Potential scaling in cooling water Resolution to Problem Leave preheaters on at low setting Change-out valve, rebuild correctly Better solids separation prior to valve Procure proper gasket Replace pump, exercise care when blowing out lines Periodic cleaning/flushing, including inlet strainer Modify post-V-680 trap Replace and secure thermocouple Reposition heat tracing TBD Periodic flushing Normal maintenance Correct connections Periodic cleaning/flushing, including inlet strainer Adjust Screen fuel when adding Normal maintenance Modify post-V-680 trap Rinse reactor before restarting if feed processed for >0.5 hr Reset control pressure Install new top insert and gasket Replace Periodic flushing Review assembly procedures with pipe fitters Rebuild Assemble fittings without galling Assemble fittings without galling Waterproof thermocouple connections Edit program Switch computers Periodic cleaning/flushing, including inlet strainer Edit program Clean Modify post-V-680 trap Periodic cleaning/flushing Modify post-V-680 trap Clean Edit program New top insert and gasket Reboot Replace Replace Not resolved at this time Carry out hourly rounds Rebuild Rework hoses Treat cooling water Modify post-V-680 trap Changed desiccant air dryer filters on all compressors Rebuild Clean Changed packing on B head Set start pressure lower Disassemble and clean Treat cooling water continued Read the entire page →
From page 86... ... (fur) Type 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. Read the entire page →
From page 87... ... APPENDIX B 87 Component Maintenance/ Root Cause ID Fix Type 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 end seat Disassemble end clean P-350B Clean Preventative maintenance Disassemble end clean R-550 Replace Corrosion Replace TE-571 Replace Thermowell corrosion Replace PCV-357A Clean Dirty stem end seat Disassemble end clean V-680 System modification Mist carryover with salt deposition Modify post-V-680 trap P-350B Clean Preventative maintenance Disassemble end 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 Oilcontamination/cloggingfrit Disassemble end 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 Contaminationin gas letdown Replace FV-550 Replace body Overheating soft goods Replace PCV-646 Replace Corrosion/erosion internals Replace Read the entire page →

From page 83...

... technology as a secondary treatment step in the General Atomics Total Solution (OATS) for disposal of the mustard-agent-containing munitions stored at the Pueblo Chemical Depot.

Read the entire page →

From page 84...

... 11574 77 N 1 Electrical Reactor faulty readings 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

Read the entire page →

From page 85...

... Insufficient compressor pressure Preventative maintenance Potential scaling in cooling water Resolution to Problem Leave preheaters on at low setting Change-out valve, rebuild correctly Better solids separation prior to valve Procure proper gasket Replace pump, exercise care when blowing out lines Periodic cleaning/flushing, including inlet strainer Modify post-V-680 trap Replace and secure thermocouple Reposition heat tracing TBD Periodic flushing Normal maintenance Correct connections Periodic cleaning/flushing, including inlet strainer Adjust Screen fuel when adding Normal maintenance Modify post-V-680 trap Rinse reactor before restarting if feed processed for >0.5 hr Reset control pressure Install new top insert and gasket Replace Periodic flushing Review assembly procedures with pipe fitters Rebuild Assemble fittings without galling Assemble fittings without galling Waterproof thermocouple connections Edit program Switch computers Periodic cleaning/flushing, including inlet strainer Edit program Clean Modify post-V-680 trap Periodic cleaning/flushing Modify post-V-680 trap Clean Edit program New top insert and gasket Reboot Replace Replace Not resolved at this time Carry out hourly rounds Rebuild Rework hoses Treat cooling water Modify post-V-680 trap Changed desiccant air dryer filters on all compressors Rebuild Clean Changed packing on B head Set start pressure lower Disassemble and clean Treat cooling water continued

Read the entire page →

From page 86...

... (fur) Type 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.

Read the entire page →

From page 87...

... APPENDIX B 87 Component Maintenance/ Root Cause ID Fix Type 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 end seat Disassemble end clean P-350B Clean Preventative maintenance Disassemble end clean R-550 Replace Corrosion Replace TE-571 Replace Thermowell corrosion Replace PCV-357A Clean Dirty stem end seat Disassemble end clean V-680 System modification Mist carryover with salt deposition Modify post-V-680 trap P-350B Clean Preventative maintenance Disassemble end 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 Oilcontamination/cloggingfrit Disassemble end 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 Contaminationin gas letdown Replace FV-550 Replace body Overheating soft goods Replace PCV-646 Replace Corrosion/erosion internals Replace

Read the entire page →

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Appendix B: SCWO Reliability and Maintenance (RAM) Log for 500-Hour HD Pages 83-87

Appendix B: SCWO Reliability and Maintenance (RAM) Log for 500-Hour HD
Pages 83-87