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Analysis of Engineering Design Studies for Demilitarization of Assembled Chemical Weapons at Pueblo Chemical Depot (2001)

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

« Previous: Appendix A: Description of Munitions in the Pueblo Chemical Depot Stockpile
Suggested Citation:"Appendix B: SCWO Reliability and Maintenance (RAM) Log for 500-Hour HD." National Research Council. 2001. Analysis of Engineering Design Studies for Demilitarization of Assembled Chemical Weapons at Pueblo Chemical Depot. Washington, DC: The National Academies Press. doi: 10.17226/10182.
×

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.

Suggested Citation:"Appendix B: SCWO Reliability and Maintenance (RAM) Log for 500-Hour HD." National Research Council. 2001. Analysis of Engineering Design Studies for Demilitarization of Assembled Chemical Weapons at Pueblo Chemical Depot. Washington, DC: The National Academies Press. doi: 10.17226/10182.
×

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

Suggested Citation:"Appendix B: SCWO Reliability and Maintenance (RAM) Log for 500-Hour HD." National Research Council. 2001. Analysis of Engineering Design Studies for Demilitarization of Assembled Chemical Weapons at Pueblo Chemical Depot. Washington, DC: The National Academies Press. doi: 10.17226/10182.
×

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

Suggested Citation:"Appendix B: SCWO Reliability and Maintenance (RAM) Log for 500-Hour HD." National Research Council. 2001. Analysis of Engineering Design Studies for Demilitarization of Assembled Chemical Weapons at Pueblo Chemical Depot. Washington, DC: The National Academies Press. doi: 10.17226/10182.
×

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.

Suggested Citation:"Appendix B: SCWO Reliability and Maintenance (RAM) Log for 500-Hour HD." National Research Council. 2001. Analysis of Engineering Design Studies for Demilitarization of Assembled Chemical Weapons at Pueblo Chemical Depot. Washington, DC: The National Academies Press. doi: 10.17226/10182.
×

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

Suggested Citation:"Appendix B: SCWO Reliability and Maintenance (RAM) Log for 500-Hour HD." National Research Council. 2001. Analysis of Engineering Design Studies for Demilitarization of Assembled Chemical Weapons at Pueblo Chemical Depot. Washington, DC: The National Academies Press. doi: 10.17226/10182.
×
Page 83
Suggested Citation:"Appendix B: SCWO Reliability and Maintenance (RAM) Log for 500-Hour HD." National Research Council. 2001. Analysis of Engineering Design Studies for Demilitarization of Assembled Chemical Weapons at Pueblo Chemical Depot. Washington, DC: The National Academies Press. doi: 10.17226/10182.
×
Page 84
Suggested Citation:"Appendix B: SCWO Reliability and Maintenance (RAM) Log for 500-Hour HD." National Research Council. 2001. Analysis of Engineering Design Studies for Demilitarization of Assembled Chemical Weapons at Pueblo Chemical Depot. Washington, DC: The National Academies Press. doi: 10.17226/10182.
×
Page 85
Suggested Citation:"Appendix B: SCWO Reliability and Maintenance (RAM) Log for 500-Hour HD." National Research Council. 2001. Analysis of Engineering Design Studies for Demilitarization of Assembled Chemical Weapons at Pueblo Chemical Depot. Washington, DC: The National Academies Press. doi: 10.17226/10182.
×
Page 86
Suggested Citation:"Appendix B: SCWO Reliability and Maintenance (RAM) Log for 500-Hour HD." National Research Council. 2001. Analysis of Engineering Design Studies for Demilitarization of Assembled Chemical Weapons at Pueblo Chemical Depot. Washington, DC: The National Academies Press. doi: 10.17226/10182.
×
Page 87
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The Program Manager for Assembled Chemical Weapons Assessment (PMACWA) of the Department of Defense (DOD) requested the National Research Council (NRC) to assess the engineering design studies (EDSs) developed by Parsons/Honeywell and General Atomics for a chemical demilitarization facility to completely dispose of the assembled chemical weapons at the Pueblo Chemical Depot in Pueblo, Colorado. To accomplish the task, the NRC formed the Committee on Review and Evaluation of Alternative Technologies for Demilitarization of Assembled Chemical Weapons: Phase II (ACW II Committee). This report presents the results of the committee's scientific and technical assessment, which will assist the Office of the Secretary of Defense in selecting the technology package for destroying the chemical munitions at Pueblo.

The committee evaluated the engineering design packages proposed by the technology providers and the associated experimental studies that were performed to validate unproven unit operations. A significant part of the testing program involved expanding the technology base for the hydrolysis of energetic materials associated with assembled weapons. This process was a concern expressed by the Committee on Review and Evaluation of Alternative Technologies for Demilitarization of Assembled Chemical Weapons (ACW I Committee) in its original report in 1999 (NRC, 1999). The present study took place as the experimental studies were in progress. In some cases, tests for some of the supporting unit operations were not completed in time for the committee to incorporate results into its evaluation. In those cases, the committee identified and discussed potential problem areas in these operations. Based on its expertise and its aggressive data-gathering activities, the committee was able to conduct a comprehensive review of the test data that had been completed for the overall system design. This report summarizes the study.

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