ODS_Support_Leak_Monitoring_and_Detecting_Procedures-May_2010.doc

Updated 12/18/2013

DEPARTMENT OF DEFENSE

OZONE DEPLETING SUBSTANCES RESERVE

LEAK MONITORING AND DETECTION PROCEDURES

May 2010

TABLE OF CONTENTS

21.0 Introduction:

22.0 Purpose:

23.0 Scope:

24.0 Objective:

25.0 Responsibilities:

26.0 Authorities and References:

37.0 Procedures:

47.1 Leak Detection:

57.2 Operation of the Model XP-1A Detector:

57.3 Determining Leak Rates:

67.4 Defense Depot Richmond (DDRV) Storage Facility:

87.5 Naval Weapons Station, Yorktown, VA Storage Facility:

87.6 DDJC Sharpe Storage Facility, San Joaquin, CA:

97.7 DDGM Guam/Marianas Storage Facility, Western Pacific Theater of Operations:

97.8 DDRV ISO Tanks, Refrigerated Container and 1,1,1 Storage Tote Nitrogen Pressure Verification:

107.9 Recording/Reporting:

10FIGURE 1: SAMPLE FORM

ODS RESERVE

LEAK MONITORING, DETECTION AND REPORTING PROCEDURES

1.0 Introduction:

All ODS Reserve cylinders containing product must be periodically inspected for leakages. Class I ODS are not replaceable, as manufacture has ceased. The Military Services depend on DLA to maintain the ODS Reserve quantities in their inventories. Periodic leak monitoring is necessary to prevent loss of product and release of ODS into the stratosphere. The planned leak detection program includes checking all cylinders at time of receipt, regularly scheduled surveys of material in storage, and installed fixed environmental monitoring systems at two satellite storage sites.

2.0 Purpose:

To ensure accurate and timely leak monitoring of CFCs, Refrigerants and Halons, and ensure necessary reports are completed in a timely manner. This will help to ensure the quantities maintained by the ODS Reserve Program Office for the Department of Defense and other Agencies are protected from product loss through leaking cylinders.

3.0 Scope:

This procedure governs Leak Monitoring for all ODS products, including those stored at DDRV, Yorktown, VA and San Joaquin CA.

4.0 Objective:

To leak monitor all cylinders as frequently as possible, with a target interval of twice per month but a minimum interval of once per month.

5.0 Responsibilities:

Leak monitoring is the responsibility of the DoD ODS Reserve Program Office. Contractor support personnel under the supervision of the ODS Program Manager will be used at the Richmond and Yorktown facilities to accomplish the leak monitoring task. Correction of reported leaks at the DDRV ODS storage facility is the responsibility of the Defense Depot Richmond, VA (DDRV) Cylinder Operations Division; at the DDJC, Sharpe site storage facility by DDJC-E; and at Yorktown by ODS Reserve Program contractor support personnel.

6.0 Authorities and References:

US Code of Federal Regulations, 40 CFR Part 82, Subpart H, Protection of Stratospheric Ozone.

7.0 Procedures:

7.0.1 Leak Monitoring and Safety Inspection During Initial Receipt:

ODS cylinders are routinely delivered by truck. When opening the truck's trailer doors, use a XP-1A hand-held leak detector to determine if there has been an accidental discharge while in transit. If there is a reading, stand back for a few minutes to let any heavy concentrations of product dissipate. Visually inspect the cylinders on each pallet to identify the types of cylinders and the types of valves. Conventional storage or recovery cylinders should be unloaded, leak checked, sorted and stored in accordance with the ODS Reserve Customer Return Material Check-In and Tagging Procedure. Fire suppression system cylinders, commonly referred to as “System Cylinders”, are handled differently, depending upon the type of valve they are equipped with:

a. Burst Disk/Initiator Valves: Check for initiators and safety caps and proceed as follows:

(1) With no initiator but safety cap in place, proceed with unloading and storage.

(2) With initiator and a safety cap in place, proceed to unload, but place in temporary restricted storage and call ODS Reserve Program Office for initiator removal. Take care not to release any static electricity to initiator or initiator wiring.

(3) With initiator and no safety cap in place, proceed to unload, but place in temporary restricted storage then call DDRV Cylinder Operations to install a safety cap, plug or plate over the outlet, taking care not to release any static electricity to initiator or initiator wiring. After safety measures are done call ODS Reserve Program Office for initiator removal.

(4) With no initiator and no safety cap, call DDRV Cylinder Operations to install cap.

b. Mechanical/Cutter Valves: Check for safety caps and proceed as follows:

(1) With cutter mechanism removed and safety cap in place, or with cutter mechanism in place with a safety cap in it, proceed with unloading and storage.

(2) With cutter mechanism in place but no safety plug, DO NOT INSTALL A SAFETY PLUG. Assure that cylinder is secured to pallet, proceed to unload, but place in temporary restricted storage and alert Supervisor to have cylinder reclaimed. Take care that base of cylinder and cutter mechanisms are not hit hard against anything.

c. Schrader Valve/Core-Type Valves: Check for safety caps and proceed as follows:

(1) With safety caps on outlet port and release valve/mechanism or release mechanism secured, proceed with unloading and storage.

(2) With no safety cap on outlet port and/or release mechanism or release mechanism unsecured, proceed to unload but place in temporary restricted storage, call DDRV Cylinder Operations to install appropriate safety caps and/or secure release mechanism.

7.0.2 Leak Monitoring in Storage:

To be environmentally prudent and to insure integrity of inventory, the most important aspect of the storage plan is leak monitoring and the ability to properly react to leaks as they occur. The ODS Reserve Leak Monitoring Program includes systematic checks with hand-held detectors and a fixed installed system in enclosed buildings at satellite storage sites. Stored cylinders should be arranged to provide access to individual pallets to facilitate the leak monitoring and detection process. Transfer/pumping equipment and empty cylinders must be available to transfer the product from any leaking cylinders.

The monitoring and leak detection of ODS cylinders at any site must be done in a logical, methodical pattern to facilitate accounting for completed tasks, as well as accounting for those cylinders yet to be done. Most any monitoring pattern is acceptable, but the monitoring scheme must be contiguous, i.e. there should be no physical gaps in the locations/cylinders visited. Example: Complete storage bay 1 before proceeding to storage bay 2, aisle 1 before aisle 2, location 1 before location 2, etc. The pattern in this example could be reversed as long as locations are not skipped. However, to ensure the most efficient monitoring path, the travel pattern should be optimized to reduce travel distance between cylinders. Monitoring path optimization can be achieved by a number of different methods, depending on the layout of the warehouse.

7.1 Leak Detection:

7.1.1 Finding Leak Sources:

CFCs and Halons generally fall to the lowest elevation upon escape, but rise up into the atmosphere as they warm to ambient temperature. Consequently, when performing leak checks on larger quantities of containers, the first checks should be performed by searching/detecting in the low elevation accumulation areas at the base of the pallets. The second accumulation area is the carton or crate that cylinders may be stored in. The detector probe should be inserted into the top of the carton/crate to detect the presence of CFCs or Halons.

The 1,000-pound water capacity cylinders have numerous threaded connections within the protected collar area on the top of the cylinder that are potential leak sources. Additionally, some 1,000-pound cylinders have a threaded plug on the bottom of the cylinder that is also a potential leak source. Specially sized rubber bands have been purchased to cover the vent holes in the protective collar and contain product leaks so initial detection can be made with a single insertion of the probe into the containment area. Cylinders with a bottom plug will be checked at the plug for possible leaks.

During routine monitoring, personnel shall fold aside the rubber bands to insert the leak detector probe. No change in the audible tone or in the indicator lights of the monitor would indicate no leakage, so the rubber bands would be folded back into place to retain the containment area for subsequent monitoring. When the detector indicates there is a leak, the concentration will not be indicative of the leak rate because the cavity has an accumulation of contained product. To determine the rate of leakage, the containment area must be opened and aired out so the detector probe can be utilized to detect the actual source of the leak. For those cylinders that do not have the rubber bands installed, follow instructions in section 7.2 below.

In some cases an entire pallet of cylinders may be wrapped with plastic or encased in a bag to serve as a device for containment of any gas from leaking cylinders. If a cylinder should leak when stored on an encapsulated pallet, the gas will be uniformly distributed throughout the space, thereby facilitating a much faster leak detection operation. A portal type access will be provided for the entry of the leak detection probe into the encapsulated space. Again, the detector should be operated in accordance with the operation manual and the instructions outlined in section 7.2 below.

One ton (2,000-pound) water capacity tanks are used for storage of Halon 1301 at the DDRV and Yorktown sites. Properly sized plastic bags and rubber bands are utilized to encapsulate each end of the tank in order to contain any leakage, thereby facilitating more efficient and accurate leak detection. A portal that is cut into the bag, and identified for easy access, is used for insertion of the leak detector probe. As above, if there is no change in the audible tone or indicator lights, there is no leak and the operator shall remove the probe and move to the next tank. When there is a rise in the tone and number of indicator lights, a leak is present, but the concentration can not be determined because of the accumulated product. The operator shall remove the plastic bag and allow the area to air out. Subsequent monitoring shall follow the procedures in paragraph 7.2 below.

7.2 Operation of the Model XP-1A Detector:

Operation of the TIF Model XP-1A Leak Detector shall be in accordance with the procedures in the Owners Manual supplied with the detector. Before using the detector, operators shall become familiar with the features, parts and controls, operating instructions, tips and maintenance instructions.

Emphasis is placed on the fact that slower and closer movement of the probe by the source of the leak improves the accuracy of the leak detection. The probe must move at no greater than 1 inch per second and be within ¼ inch of leak sources. Any indication of a leak must be verified by moving the probe at approximately 2 to 5 millimeters (mm) per second and within 2 mm of the leak source. Further, movement of the ambient air around the leak source will dilute the concentration and distort the detection by the probe. Measures must be taken to restrict air movement around the containers while leak monitoring is being performed.

Initial operation of the detector shall be at the default level, which is Sensitivity Level 5. The presence of a constant audible tone and one green light on the indicator panel indicates there is no leak. In the presence of a leak, the tone will change distinctly to a more siren type sound, and the visual indicator lights progressively change.

7.3 Determining Leak Rates:

Upon detection of a leak, the action required depends on the severity of the leak. Leak rates are determined by the number and color of alarm indicator lights displayed by the XP-1A Leak Detector. There are six alarm indicator lights (discounting the first LED light to the left, which is a level 1 sensor light and an on/off indicator light). The alarm lights may be on or off, and if on they can be one of 3 colors, starting with green and progressing from orange to red from left to right. The colors indicate sensitivity level read by the XP-1A sensing tip, i.e. Green being the weakest detection and red being the strongest detection. Based on lab research findings, the quantification of the leak rate based on the number of alarm lights turned on and the color of the lights is shown below:

At XP-1A Default Sensitivity Level 5:

- If the XP-1A Leak detector has up to 6 Green or Orange alarm lights, this indicates an unstable detection, or the leak is 1 oz or less per year

- If the XP-1A Leak detector has any red alarm lights – this indicates a leak rate greater than 1 oz per year. Reset the sensitivity to Level 3 to determine the actual leak rate.

At XP-1A Sensitivity Level 3:

The table below shows the number of alarm lights and colors that correspond to a particular leak rate.

All ODS Products Level 3 Sensitivity Reading

Each cylinder that has been leak checked will be recorded on a worksheet. The NSN, product name, warehouse location, quantity, and date checked shall be entered on the worksheet (see attachment 1 for format).

7.4 Defense Depot Richmond (DDRV) Storage Facility:

7.4.1 Cylinder Leak Detection:

Upon detection of a leak, the action required depends on the severity of the leak. The table below describes actions to be taken for selected leak rates.

Actions Required for Specific Leak Rates

Flag location as a leaker and Monitor.

Flag location as a leaker and Monitor

Flag location as a leaker and Monitor

Flag location as a leaker and Monitor

Flag location as a leaker and Monitor

Leaks reported at DDRV that warrant transfer to a new cylinder will require appropriate notification to the DDRV Cylinder Operations Division.

a. All cylinders requiring transfer will be weighed by Support Contractor Personnel prior to being moved to Warehouse 3 for pumping. The weight will be marked on the shoulder of the cylinder using a black ink marker.

b. A telephone Product Transfer Request will be made from the ODS Reserve Program Office to the POC in the DDRV Cylinder Operations Division, followed by an e-mail confirmation, and will cite the urgency of the product transfer as per the above table.

c. DDRV Cylinder Operations will respond to the time frame specified in the Product Transfer Request for transfer of product from the leaking cylinder to a new cylinder.

d. DDRV will provide a weekly report of all product transfers to the ODS Reserve Program Office. The report will contain the NSN, Product Name, cylinder serial number, date of product transfer, and name of the person who performed the transfer.

7.5 Naval Weapons Station, Yorktown, VA Storage Facility:

7.5.1 Cylinder Leak Detection:

Upon detection of a leak, the action required depends on the severity of the leak. The table above in Section 7.4 describes actions to be taken for selected leak rates.

ODS Reserve Program Office Support Contractor personnel will perform the leak monitor functions and product transfers as required.

Leaks reported at Yorktown that warrant transfer to a new cylinder will require appropriate notification to the ODS Reserve Program Office.

All cylinders requiring transfer will be weighed by ODS Reserve Support Contractor Personnel prior to pumping. The weight will be marked on the shoulder of the cylinder using a black ink marker.

ODS Reserve Support Contractor will provide a weekly report of all product transfers to the ODS Reserve Program Office. The report will contain the NSN, Product Name, cylinder serial number, date of product transfer, and name of the person who performed the transfer.

7.6 DDJC Tracy Storage Facility, San Joaquin, CA:

7.6.1 Cylinder Leak Detection:

The DDJC-E, Tracy storage facility is operated entirely by government personnel. Both leak detection and transfer of product from leaking cylinders is accomplished by DDJC employees. The table above in Section 7.4 describes actions to be taken for selected leak rates.

Leaks reported at DDJC that warrant transfer to a new cylinder will require appropriate notification to the DDJC-E and ODS Reserve Program Office. The timing of the product transfer is based on the severity of the leak. The table in Section 7.4 above identifies the action required for different leak rates.

All cylinders requiring transfer will be weighed by DDJC-E personnel prior to being moved for pumping. The weight will be marked on the shoulder of the cylinder using a black ink marker.

DDJC-E will provide a weekly report of all product transfers to the ODS Reserve Program Office. The report will contain the NSN, Product Name, cylinder serial number, date of product transfer, and name of the person who performed the transfer.

7.7 DDGM Guam/Marianas Storage Facility, Western Pacific Theater of Operations:

7.7.1 Cylinder Leak Detection:

The DDGM Guam, Marianas storage facility is operated entirely by government personnel. Both leak detection and transfer of product from leaking cylinders is accomplished by DDGM employees. The table above in Section 7.4 describes actions to be taken for selected leak rates.

Leaks reported at DDGM that warrant transfer to a new cylinder will require appropriate notification to the DDGM and ODS Reserve Program Office. The timing of the product transfer is based on the severity of the leak. The table in Section 7.4 above identifies the action required for different leak rates.

All cylinders requiring transfer will be weighed by DDGM personnel prior to being moved for pumping. The weight will be marked on the shoulder of the cylinder using a black ink marker.

DDGM will provide a weekly report of all product transfers to the ODS Reserve Program Office. The report will contain the NSN, Product Name, cylinder serial number, date of product transfer, and name of the person who performed the transfer.

7.8 DDRV ISO Tanks, Refrigerated Container and 1,1,1 Storage Tote Nitrogen Pressure Verification:

7.8.1 There are nine (9) ISO tanks containing R-113 stored in the DDRV open shed. Positive pressure of a minimum of 2 PSI of nitrogen must be maintained on each tank. The pressure gauge is located on the top of each tank. Currently one nitrogen bottle is used to fill ISO tanks using a long hose. When the pressure drops below 2 PSI, attach the hose to the refill fitting on the top of the tank, then open the valve to allow nitrogen to flow. Fill to 10 PSI and Shut of valve.

7.8.2 A single refrigerated ISO container (reefer) contains Solvent 1,1,1 stored in eight (8) totes that should be checked for positive nitrogen pressure and temperature daily.

(a) Open the container and check the temperature gauge inside the container. It should read 58o F, plus or minus 3 degrees, however opening the doors could cause inside temperature to rise or fall, depending on the outside temperature. If the temperature difference is significant, the gauge may be faulty and should be reported to the ODS Reserve Program Office.

(b) A nitrogen bottle in the container is connected to a distribution system that feeds nitrogen pressure to each tote through a regulator. The regulator mounted on the nitrogen bottle should show a pressure of 1 to 1.5 PSI. If the pressure is below 1 PSI on the gauge, open the valve on the nitrogen bottle and slowly increase the flow of nitrogen until the regulator gauge reads 1.5 PSI. Each tote also has a pressure gauge located on top, but accuracy of the gauges has not proven reliable. It is better to rely on the regulator gauge to determine the amount of nitrogen pressure.

(c) If the nitrogen bottle is below 100 PSI, it must be replaced with a full one. There are spare full nitrogen cylinders located inside OS-6. If not, a new one should be ordered from DDRV. They will purchase it from a local supplier.

7.8.3 In addition to the eight (8) totes inside the refrigerated ISO container, there are 58 Solvent 1,1,1 totes stored in OS-6 (adjacent to the ISO container) that should be checked for positive nitrogen pressure daily. Each row of totes has a dedicated nitrogen bottle secured to the first tote in the row which is connected to a distribution system that feeds nitrogen pressure to each tote through a regulator. The regulator mounted on the nitrogen bottle should show a pressure of 1 to 1.5 PSI. If the pressure is below 1 PSI on the gauge, open the valve on the nitrogen bottle and slowly to increase the flow of nitrogen until the regulator gauge reads 1.5 PSI. Each tote also has a pressure gauge located on top, but accuracy of the gauges has not proven reliable. It is better to rely on the regulator gauge to determine the amount of nitrogen pressure. If the nitrogen bottle is below 100 PSI, it must be replaced with a full one. There are spare full nitrogen cylinders located inside OS-6. If not, a new one should be ordered from DDRV. They will purchase it from a local supplier.

7.9 Recording/Reporting:

Personnel executing the ODS Reserve Program Office Leak Monitoring Program shall record (log) the results of the leak monitoring process daily, and maintain all records, including hard copy, for 5 years. Each cylinder that has been leak checked shall be recorded on a worksheet. The NSN, product name, warehouse location, quantity, and date checked shall be entered on the worksheet (see Figure 1 below).

FIGURE 1: SAMPLE FORM

Cylinder Size� Leak Rate� Site� Product� Warehouse Loc� 45 Lb� 150 Lb�

Enc� 1000 Lb� 2000 Lb� Zero leaks� < 1 Oz/Yr� 1-7 Oz/Yr� > 8 Oz/Yr� Date

MM/DD/YY�

Action Taken/ Comments� R� R� R� R� R� R� R� R� R� R� R� R� R� R�

Cylinder Size� Leak Rate� Site� Product� Warehouse Loc�

Dr� 45 Lb� 150 Lb�

Enc� 1000 Lb� 2000 Lb� Zero leaks� < 1 Oz/Yr� 1-7 Oz/Yr� > 8 Oz/Yr� Date

MM/DD/YY�

Action Taken/ Comments� R� R� R� R� R� R� R� R� R� R� R� R� R� R�

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