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
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.
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 |
|
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 |
|
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. |
|||||||||
|
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 |
