Past Accomplishments
MCAAP MCDF Startup/Checkout Effort by Week
|
Week |
Task |
Complete |
|
|
|
|
|
CY 2003 |
|
|
|
Aug 25 |
Completed Installation/Startup Preparation |
Yes |
|
Sept 1 |
Completed Installation/Startup Preparation |
Yes |
|
Sept 8 |
RKS Feed System Tested : Debris Separation, Debris Transport System, SEAS, and PFS |
Yes |
|
Sept 15 |
Debris Processing System Tested : Debris Separation System, In-Process Deactivation System, and Drum and Packaging System |
Yes |
|
Sept 22 |
Cryofracture System Tested : Fixture Heating System, Munition Transport Conveyor, Cryobath, Press Munition Loader robot, Cryofracture Press System, and Debris Discharge System |
Yes |
|
Sept 29 |
Ran integrated operations in air. Began processing previously functioned ADAM mines (inert) referred to as Yuma Mines. LN2 delivered on-site. |
Yes |
|
Oct 6 |
Ran integrated operations in air and also processed |
Yes |
|
Oct 13 |
MCAAP performed grounding testing no operations. Continued with detailed operator training. Ran in air no LN2. |
Yes |
|
Oct 20 |
Ran integrated operations in air and also process |
Yes |
|
Oct 27 |
Plant outage (maintenance and minor repairs) |
Yes |
|
Nov 3 |
Ran integrated operations in air (no LN2 on-site) and continued with operator training |
Yes |
|
Nov 12 |
Ran ADAM QA mines to test and tune the induction heater system and the conveyor speed (System 19 : In-Process Deactivation System [IPDS]) |
Yes |
|
Nov 17 |
Continued to test and tune the IPDS. Established Feed rate, residence time, and required power levels. |
Yes |
|
Nov 24 |
Plant Outage (Thanksgiving |
Yes |
|
Dec 1 |
Continued to test and tune the IPDS. Established coil geometry, GN2 purge levels, and Dust and emission Collection System air flow rates. |
Yes |
|
Dec 8 |
Installed new control room furniture and performed plant shutdown for Christmas Holiday |
Yes |
MCAAP MCDF Startup/Checkout Effort by Week
|
Week |
Task |
Complete |
|
|
|
|
|
CY 2004 |
|
|
|
|
|
|
|
Jan Mar |
Procuring IPDS component upgrades |
Yes |
|
March 1 - 18 |
Site Preparation and upgrades |
Yes |
|
March 3 9 |
APE-1236 RKS/APCS Mini-burn |
Yes |
|
March 22 |
Install IPDS upgrades |
Yes |
|
March 29 |
Complete IPDS upgrades. Perform low and high power tests. Run small batches of ADAM QA mines to test IPDS. Test results are excellent. |
Yes |
|
April 5 |
Ran ADAM QA mines. Two day grounding test to verify equipment, building, and outside grounding continuity. |
Yes |
|
April 12 |
Ran ADAM QA mines to make up previous week Test results are excellent. Prepared to run APs but APE-1236 RKS repairs are required. |
Yes |
|
April 19 |
APE-1236 RKS repairs complete. Ran AP mines (slow rampup from 1 mine per minute to 6 mines per minute with large fixture spacing). Test results are excellent. |
Yes |
|
April 26 |
Plant shutdown perform equipment maintenance |
Yes |
|
May 3 |
Plant shutdown site unattended |
Yes |
|
May 10 |
Plant shutdown site unattended |
Yes |
|
May 17 |
Preparation for Global Demil tour at MCAAP on May 21 using stimulant mines (no energetics/no LN2) |
Yes |
|
May 24 |
Plant shutdown prepare for Dem/Val tests |
Yes |
|
May 31 |
Plant shutdown prepare for Dem/Val tests |
Yes |
|
June 7 11 |
APE-1236 RKS/APCS Mini burn #2 |
Yes |
|
June 14 |
Run ADAM AP mines for final checkout. Prepare system for Dem/Val Test. |
Yes |
|
June 21 |
Complete system preparation for Dem/Val Test. Start Dem/Val Test. |
Yes |
|
June 28 |
Continue Dem/Val Test with ADAM AP mines. Perform DU stack test |
Yes |
|
July 5 |
Plant shutdown Prepare for PDWC GA Equipment installation |
Yes |
|
July 12 |
Begin installation of PDWC HPU Hydraulic lines |
Yes |
|
July 19 |
Continue installation of PDWC HPU Hydraulic lines |
Yes |
|
July 26 |
Continue installation of PDWC HPU Hydraulic lines Meet to discuss Cryofracture system upgrades |
Yes |
|
Aug 2 |
Plant shutdown site unattended |
Yes |
|
Aug 9 |
Install stabilizer and Fixture Transfer System robot Continue installation of PDWC HPU Hydraulic lines |
Yes |
MCAAP MCDF Startup/Checkout Effort by Week
|
Week |
Task |
Complete |
|
|
|
|
|
CY 2004 |
|
|
|
Aug 16 |
Continue stabilizer and Fixture Transfer System robot installation Continue installation of PDWC HPU Hydraulic lines Perform MCAAP APE-1236 RKS Mini-burn III |
Yes |
|
Aug 23 |
Begin Munition Queuing System conveyor installation Complete installation of stabilizer and Fixture Transfer System robot Complete installation of PDWC HPU Hydraulic lines |
Yes |
|
Aug 30 |
Begin PDWC conduit installation Continue Munition Queuing System conveyor installation |
Yes |
|
Sept 6 |
Continue Munition Queuing System conveyor installation Continue PDWC conduit installation Meet to discuss
cryofracture technology selection process |
Yes |
|
Sept 13 |
Continue PDWC conduit installation Continue Munition Queuing System conveyor installation Begin to install PDWC Process Air Install PDWC Cryobath supply lines GA receives final PDWC 90% document package |
Yes |
|
Sept 20 |
Continue PDWC conduit and wire installation Complete Munition Queuing System conveyor installation Continue installation of process air Run integrated test of conveyor, robot, & stabilizer with cryofracture system |
Yes |
|
Sept 27 |
Complete PDWC conduit and wire installation Continue installation of process air Software and sensor integrated check (loop checks) PDWC 90% document package issued |
Yes |
|
Oct 4 |
Complete installation of process air Integrated equipment checkout and test |
Yes |
|
Oct 11 |
Run integrated test of conveyor, robot, & stabilizer with cryofracture system |
Yes |
|
Oct 18 |
90% PDWC design review/HAZOP at MCAAP |
Yes |
|
Oct 25 |
No site work planned Demil Users Group meeting |
Yes |
|
Nov 1 |
No site work planned |
Yes |
|
Nov 8 |
No site work planned |
Yes |
|
Nov 15 |
No site work planned GA receives final 100% PDWC design package |
Yes |
MCAAP MCDF Startup/Checkout Effort by Week
|
Week |
Task |
Complete |
|
|
|
|
|
CY 2004 |
|
|
|
Nov 22 |
Thanksgiving |
Yes |
|
Nov 29 |
No site work planned |
Yes |
|
Dec 13 |
Acceptance test of PDWC robot download equipment at SNL |
Yes |
|
Dec 20 |
|
Yes |
|
Dec 27 |
|
Yes |
|
|
|
|
|
CY 2005 |
|
|
|
Jan 3 |
Retest of PDWC Staubli robot controller problem |
Yes |
|
Jan 10 |
Retest of PDWC Staubli robot controller problem |
Yes |
|
Jan 17 |
Retest of PDWC Staubli robot controller problem |
Yes |
|
Jan 24 |
Retest of PDWC Staubli robot controller problem |
Yes |
|
Jan 31 |
Retest of PDWC Staubli robot controller problem |
Yes |
|
Feb 7 |
Retest of PDWC Staubli robot controller problem |
Yes |
|
Feb 14 |
Retest of PDWC Staubli robot controller problem |
Yes |
|
Feb 21 |
Retest of PDWC Staubli complete problem solved |
Yes |
|
Feb 28 |
Pack and ship Truck #1 to MCAAP Unload Truck #1 at MCAAP |
Yes |
|
Mar 7 |
Pack and ship Truck #2 to MCAAP Unload Truck #2 at MCAAP |
Yes |
|
Mar 14 |
Continue to prepare for next round of shipments |
Yes |
|
Mar 21 |
Pack and ship Truck #3 to MCAAP Unload Truck #3 at MCAAP |
Yes |
|
Mar 28 |
Sort and Segregate site shipment Begin installation of MPS 1 and MPS 2 equipment |
Yes |
|
Apr 4 |
Continue MPS 1 and MPS 2 installation Begin electrical MPS 1 and MPS 2 installation |
Yes |
|
Apr 11 |
Continue MPS 1 and MPS 2 installation Continue electrical MPS 1 and MPS 2 installation |
Yes |
|
Apr 18 |
Pack and ship Truck #4 to MCAAP Unload Truck #4 at MCAAP |
Yes |
|
Apr 25 |
Project Hold |
Yes |
|
May 2 |
Project Hold |
Yes |
MCAAP MCDF Startup/Checkout Effort by Week
|
Week |
Task |
Complete |
|
|
|
|
|
CY 2005 |
|
|
|
May 9 |
Begin TVT punch and die tooling design |
Yes |
|
May 16 |
Continue TVT punch and die tooling design |
Yes |
|
May 23 |
Continue installation of MPS 1 and MPS 2 Begin installation of the PHS Begin electrical installation of the PHS Begin control room installation of the PDWC equipment Continue TVT punch and die tooling design |
Yes |
|
May 30 |
Continue installation of MPS 1 and MPS 2 Continue installation of the PHS Continue electrical installation of the PHS Continue control room installation of the PDWC equipment Finalize TVT punch and die tooling design Connect up SEAS press hydraulics and test Begin fabrication of SEAS tooling, support, and shields |
Yes |
|
June 6 |
Complete installation of MPS 1 and MPS 2 Continue installation of the PHS Continue electrical installation of the PHS Continue control room installation of the PDWC equipment TVT Planning and safety meeting at MCAAP Connect up SEAS press hydraulics and test Continue fabrication of SEAS tooling, support, and shields Begin PDWC SOP integration into MCDF SOP |
Yes |
|
June 13 |
Complete installation of the PHS Continue electrical installation of the PHS Continue control room installation of the PDWC equipment Continue fabrication of SEAS tooling, support, and shields Continue PDWC SOP integration into MCDF SOP MCAAP Operator selection and evaluation |
Yes |
|
June 20 |
Complete electrical installation of the PHS Complete control room installation of the PDWC equipment Continue fabrication of SEAS tooling, support, and shields Continue PDWC SOP integration into MCDF SOP MCAAP Operator selection and evaluation |
Yes |
MCAAP MCDF Startup/Checkout Effort by Week
|
Week |
Task |
Complete |
|
|
|
|
|
CY 2005 |
|
|
|
June 27 |
Continue fabrication of SEAS tooling, support, and shields Grounding check of PDWC (PHS & MPS) Complete PDWC SOP integration into MCDF SOP MCAAP Operator selection and evaluation |
Yes |
|
July 4 |
Complete fabrication of SEAS tooling, support, and shields Checkout MPS 1 and MPS 2 with inerts Begin assembling MCDF SOPs for release to MCAAP MCAAP Operator selection and evaluation |
Yes |
|
July 11 |
Assemble SEAS press with new tooling, support, and shields Reposition and install new cameras Operate DTS and PFS for incineration support Checkout MPS 1 and MPS 2 with inerts Complete Assembling MCDF SOPs for release to MCAAP Begin Operator training for PDWC operations |
Yes |
|
July 18 |
Continue installation of the PHS & MPS Install LN2 and Process air piping |
Yes |
|
July 25 |
Continue installation of the PHS & MPS Continue to Install LN2 and Process air piping |
Yes |
|
Aug 1 |
Continue installation of the PHS & MPS Complete Installation LN2 and Process air piping Install TVT Equipment |
Yes |
|
Aug 8 |
Continue installation of the PHS & MPS Install PHS & MPS Platforms Install TVT Equipment |
Yes |
|
Aug 15 |
Continue installation of the PHS & MPS Continue to install PHS & MPS Platforms Install TVT Equipment |
Yes |
|
Aug 22 |
Continue installation of the PHS & MPS Install LN2 and Process air piping Complete TVT Equipment installation TVT Status review meeting at MCAAP |
Yes |
|
Aug 29 |
Continue installation of the PHS & MPS Continue to install PHS & MPS support systems |
Yes |
|
Sept 5 |
Labor Day Break |
Yes |
|
Sept 12 |
Complete installation of the PHS & MPS Install personnel protection barriers around PDWC equipment |
Yes |
MCAAP MCDF Startup/Checkout Effort by Week
|
Week |
Task |
Complete |
|
|
|
|
|
CY 2005 |
|
|
|
Sept 19 |
Begin PHS & MPS startup operations Perform TVT SOP review and TVT equipment startup tests |
Yes |
|
Sept 26 |
PDWC effort on hold until TVT complete Perform TVT Readiness review |
Yes |
|
Oct 3 |
Execute TVT |
Yes |
|
Oct 10 |
Execute TVT |
Yes |
|
Oct 17 |
Execute TVT |
Yes |
|
Oct 24 |
Complete TVT Execution |
Yes |
|
Oct 31 |
Perform RAT-A Calibration for the APE-1236 RKS (MCAAP Staff) |
Yes |