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 |
