heated sample transfer lines lesson learned

Heated Sample Transfer Lines Lesson Learned

25-27 May 2016

Presented to:

The 19th Annual International Chemical Weapons Demilitarisation Conference

Presented by:

Jeffrey M. Kiley

PEO ACWA Risk Management Directorate

APPROVED FOR PUBLIC RELEASE – DISTRIBUTION UNLIMITED

A Partnership for Safe Chemical Weapons Destruction

Greetings from ACWA

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Today’s Agenda:

Heated Transfer Sample Lines Initial Efforts

Flow Rate Investigation

Recommendations

Test Approach

Path Forward and Results


Heated Transfer Sample Lines

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Due to size of the Pueblo Chemical Agent-Destruction Pilot Plant, Heated Transfer Sample Lines are necessary to transport air sampled from the point of collection to an instrument for analysis


Sample Line Quality Assurance

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Methods/stations with sampling lines for agent transport

– All sample lines must pass performance criteria before start of agent operations

– All sample line distal end challenges must be within ± 25 % of the challenge during the initial plant baseline


Sample Line Quality Assurance (Continued)

Operations sample line quality control challenges

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– Sample line challenges most accurate measures of the “whole” monitoring system’s ability to detect agent at the alarm level

– Pueblo Chemical Agent-Destruction Pilot Plant initial baseline testing determined majority of sample lines could not meet performance criteria


Pueblo Chemical Agent-DestructionPilot Plant Initial Efforts

Routine test approach

– Pressure test

– Air wash

– Solvent flush

– Distal end agent challenge

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Flow Rate Investigation

Flow rate test

– Air wash at temperature for 24 hours

– Record daily line temps

– Perform daily challenges for 3 weeks

– Perform second set of challenges for 3 weeks

– Tests performed with distal end 5 µL injection and MINICAMS® for detection

– Tests conducted 25 Jul 14 through 12 Aug 14

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Varied Flow Rate

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0.0%

20.0%

40.0%

60.0%

80.0%

100.0%

120.0%Red Lines

Red 450 Red 800

0.0%

20.0%

40.0%

60.0%

80.0%

100.0%

120.0%Green Lines

Green 450 Green 800

0.0%

20.0%

40.0%

60.0%

80.0%

100.0%

120.0%

Clear Lines

Clear 450 Clear 800

0.0%

20.0%

40.0%

60.0%

80.0%

100.0%

120.0%Black Lines

Black 450 Black 800


Material of Construction

Pueblo Chemical Agent-Destruction Pilot Plant sample line specifics

Sample tubes constructed from virgin perfluoroalkoxy polymer

Red sample lines

Line recoveries

Recoveries confirmed

Single tube bundle

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Recommendations

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Follow on test recommendations

– Determine if polytetrafluoroethylene tubing pulled into existing perfluoroalkoxy lines can form a liner

– Perform second set of aggressive tests

– Create a new sample line bundle

– Test

– Continue to challenge remaining sample lines


Follow on Test Approach

Second round of testing initiated

– Test A – Hexane Rinse

– Test B – Nitric Acid

– Test C – Agent Passivation

– Test D – Hydrolysis

– Fabricated gray conduit polytetrafluoroethylene (PTFE) bundle

– Blue Grass Chemical Agent-Destruction Pilot Plant PTFE bundle

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Test A Hexane Rinse

Test A

– Hexane rinse to remove surface contamination by non-polar chemicals/impurities

12

0

0.2

0.4

0.6

0.8

1

19-Aug 20-Aug 20-Aug 21-Aug 21-Aug 22-Aug 22-Aug

As found - Black

As Found - White

Hex Sr 1 - Black

Hex Sr 1 - White

Hex Sr 2 - Black

Hex Sr 2 - White

Hex Sk 1 - Black

Hex Sk - White

Hex Sk2 - Black

Hex Sk2 - White

Results

– Significant initial improvement

• HD recoveries for the black line improved

• Recoveries for the white line improved


Test B Nitric Acid

Test B

– Nitric acid treatment to remove surface metal contamination

Results

– No significant change in HD recoveries

13

0

0.2

0.4

0.6

0.8

1

18-Aug 19-Aug 19-Aug 20-Aug 20-Aug 21-Aug 21-Aug 22-Aug 22-Aug

As found Red

As found Green

Acid Soak - Red

Acid Soak - Green

DI Soak - Red

DI Soak - Green

Hexane Soak - Red

Hexane Soak - Green


0

0.2

0.4

0.6

0.8

1


As found - Red

As found - Green

Passivate - Red

Passivate - Green

Test C Agent Passivation

Test C

– Passivation using a large mass of HD (in solution)

Results

– No significant improvement

1414


0

0.2

0.4

0.6

0.8

1


As found - Black

As found - White

Dry Purge - Black

Dry Purge - White

Test D Hydrolysis

Test D

– Dry Air (Hydrolysis effects)

Results

– No improvement

15


0.0%

20.0%

40.0%

60.0%

80.0%

100.0%

120.0%

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21

Red Line Green Line Black Line Clear Line

Sample Line Results – Gray Bundle (Polytetrafluoroethylene)

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8/21 8/258/23 9/89/38/28


0.0%

20.0%

40.0%

60.0%

80.0%

100.0%

120.0%

1 4 7 10 13 16 19 22 25

Line 1 Line 2 Line 3 Line 4

Sample Line Results – Blue Grass Chemical Agent-Destruction Pilot Plant Bundle (Polytetrafluoroethylene)

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8/22 8/23 8/24 8/26 9/89/3


Path Forward and Results

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Path Forward

– Insertion of 1/8” polytetrafluoroethylene (PTFE) liner was not an option

– Replace installed sample bundles

– Procure polytetrafluoroethylene (PTFE) Teflon

– Test PTFE tubing prior to installation

Results

– Replaced 15,000 feet of perfluoroalkoxy polymer heated sample transfer lines (HSTLs)

– Completed work May 15 (approximately 7 months)

– Completed testing of new PTFE tubing

• Recovery for 133 new PTFE polymer HSTLs tested is 84 ± 9 %

– Prevented delay in plant startup


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19

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