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HomeMy WebLinkAboutNCD980602163_20011005_Warren County PCB Landfill_SERB C_Detoxification NCSO ID# 01044010A Appendix J - Plant Operations Report-OCRCopy l Warren County Landfill PCB Detoxification NCSCO ID #010440101A AppendixJ Plant Operations Report Prepared by Earth Tech 710 Corporate Center Dr. Suite 475 Raleigh, NC 27607 (1 of 1) Plant Operations Report Thursday January 9, 2002 The plant went down about 1500 at the end of the stack test The recirculation pump on the scrubber in the air control system failed A new motor was obtained in Henderson and installed The plant restarted about 2240. Scheduled shutdowns There are no scheduled shutdowns at this time. There are two cyclones mounted above the kiln discharge to remove fines from the off-gas. One cyclone is a spare. During the shutdown that occurred the first weekend of January the gas flow was shifted to the spare cyclone. At some point, probably next month, the used cyclone will be removed and rebuilt A crane will be required to remove the cyclone. Total down time for the day was 7.6 hours. Friday January 10, 2002 The plant sent off spec material to bin five from 0020 till O 118. The shutdown was caused by a failure of the flame purge safety system that shut down the burners. Monday, January 13, 2003 · Plant went down at O 130 because of problems with the kiln diesel burners. The burners were carboning up and had to be removed and cleaned The automatic feed shut off was activated because of a high temperature signal from the off.gas after the chiller. These problems were solved and the system went back on line at 0930. The plant ran smoothly the rest of the day. Total down time for the day: 8 hours. Percent on line since 1/9/03: 83% Tuesday January 14, 2003 The plant ran all day. Total down time for the day: 0 hours. Percent on line since 1/9/03: 86% Wednesday January 15, 2003 The plant ran all day. Total down time for the day: 0 hours. Percent on line since 1/9/03: 88% Wednesday January 16, 2003 As of 0730 today the plant is running smoothly. Friday January 17, 2003 The plant ran all clay. Total down time for the clay: 0 hours. Percent on line since 1/9/03: 92% Saturday January 18, 2003 The plant ran all clay. Total down time for the day: 0 hours. Percent on line since 1/9/03: 93% Plant Operations Report Sunday January 19, 2003 The plant shut down at 0316 because a lifter in the drum broke loose and fell into the discharge chute. This also damaged the discharge chute. MSR expects the repair to be completed Monday afternoon at which time operations will resume. Total down time for the day: 21 hours. Percent on line since 1/9/03: 86% Monday January 20, 2003 Repairs were completed and the plant started up at 17:30. Total down time for the day: 17.5 hours. Percent on line since 1/9/03: 81% Tuesday January 21, 2003 The plant ran all day. Total down time for the day: 0 hours. Percent on line since 1/9/03: 82% Wednesday January 22, 2003 The plant ran all day. Total down time for the day: 0 hours. Percent on line since 1/9/03: 84% Thursday January 23, 2003 As of 0645 the plant is operating smoothly. Total down time for the day: 1 hour Percent on line since 1/9/03: 84% Friday, January 24, 2003 The plant was down until 17:00 hours with burner problems. The igniters were failing. Very cold temps have caused some other operational problems as well. Total down time for the day: 17 hours Percent on line since 1/9/03: 81 % Saturday, January 25, 2003 The plant came down at 08:00 because the main condensate recirculation pump failed. This is the same pump that failed after the stack test. The first failure was due to the motor fai ling. This time the bearing on the pump failed. The plant was down for the rest of the day while a replacement bearing was procured. Total down time for the day: 16 hours Percent on line since 1/9/03: 78% Sunday, January 26, 2003 The main condensate recirculation pump bearing was replaced and the plant was back on line at 2300 hours. Total down time for the day: 23 hours Percent on line since 1/9/03: 74% Monday, January 27, 2003 The plant ran all day. Total down time for the day: 0 hours. Percent on line since 1/9/03: 75% Tuesday, January 28, 2003 The plant went down at midnight. The shutdown was caused by a crack in the drum that was noticed when dirt (seen through the fire eye) started accumulating on a burner. The crack was repaired and the plant started back up at 7:00 PM and ran the rest of the day. Drums cracks have occurred before and are probably caused by the expansion and contraction that occurs when the unit starts up and cools down. Other than to minimize these startup/shutdown cycles, which we always try to do, there is no known way to reduce this problem. Total down time for the day: 19 hours. Percent on line since 1/9/03: 73% Wednesday, January 29, 2003 The plant ran all day. MSR announced that they will take Saturday off to give the crew a break. The plant will be shut down by 0630 Saturday and will begin startup at 0630 Sunday. Total down time for the day: 0 hours. Percent on line since 1/9/03: 74% Thursday, January 30, 2003 The plant ran all day. Total down time for the day: 0 hours. Percent on line since 1/9/03: 75% Friday, January 31, 2003 The plant ran all day. Total down time for the day: 0 hours. Percent on line since 1/9/03: 76% Saturday, February 1, 2003 The plant was down all day for a scheduled shutdown. Total down time for the day: 24 hours. Percent on line since 1/9/03: 73% Sunday, February 2, 2003 Maintenance was done Sunday morning and the plant started up at 1800 hours. Total down time for the day: 18 hours. Percent on line since 1/9/03: 71% Monday February 3, 2003 The plant was down from 0615 to 0715. A relay failed in the burner control system that caused a brief burner failure. A spare relay was obtained and is on hand in case the relay fails again, however it has worked properly since the failure. Total down time for the day: 1 hour. Percent on line since 1/9/03: 72% Tuesday February 4, 2003 The plant went down at 0715 because dust started coming out of the cyclone heater vent. The plant came back on line at 2300 hours. The problem was a gasket failure in the cyclone soil discharge duct. This allowed some of the treated soil to escape through the gasket instead of going to the soil cooler. The gasket was replaced. Total down time for the day: 15.75 hours Percent on line since 1/9/03: 71% Wednesday February 5, 2003 The plant ran all day. Total down time for the day: 0 hours. Percent on line since 1/9/03: 72% Thursday February 6, 2003 The plant went down from 0130 to 0215 because all the burners shut down. This was apparently caused by a blink in the 120 volt power supply. MSR is planning to get a UPS system to back up this power supply. At 1630 hours CP&L dropped off one leg of the 480 volt power and shut down the plant. At 1930 hours all power at the site was lost. MSR personnel left the site. The power came back on at 2030 hours. Total down time for the day: 8.25 hours. Percent on line since 1/9/03: 72% Friday February 7, 2003 The 0630 MSR shift arrived to start the plant back up. The plant went back on line at 1345 hours and operated the rest of the day. Total down time for the day: 13.75 hours. Percent on line since 1/9/03: 71% Saturday February 8, 2003 The plant was down from 2330 till 2400 because a momentary power outage caused the burners to drop off line. Total down time for the day: 0.5 hours. Percent on line since 1/9/03: 71 % Sunday February 8, 2003 The plant was down from 2400 till 2402 on the power outage that occurred the previous day. Another brief power outage took the plant off line from 0145 to 0320. Total down time for the day: 1.62 hours. Percent on line since 1/9/03: 72% Monday February 10, 2003 The plant operated smoothly all day. Total down time for the day: 0 hours. Percent on line since 1/9/03: 73% Tuesday February 11, 2003 The plant operated smoothly all day. MSR is planning for a maintenance shutdown early next week. Total down time for the day: 0 hours. Percent on line since 1/9/03: 74% Wednesday February 12, 2003 The plant went down at 1715 hours because the scrubber vent fan failed. This is the fan on the discharge end of the kiln that blows the steam out of the treated soil cooler. Another motor will arrive Thursday morning and the unit will be repaired. MSR is taking the opportunity to do many of the items that were scheduled for the maintenance shutdown next week. They will probably not have to do this planned shutdown. Total down time for the day: 6.75 hours. Percent on line since 1/9/03: 74% Thursday February 13, 2003 Repairs were completed and the plant started up at 2225 hours. Total down time for the day: 6.75 hours. Percent on line since 1/9/03: 72% Friday February 14, 2003 The plant operated smoothly all day. Total down time for the day: 0 hours. Percent on line since 1/9/03: 73% Saturday February 15, 2003 The plant operated smoothly all day. Total down time for the day: 0 hours. Percent on line since 1/9/03: 73% Sunday February 16, 2003 The plant operated smoothly all day. Total down time for the day: 0 hours. Percent on line since 1/9/03: 74% Monday February 17, 2003 The plant operated smoothly all day. Total down time for the day: 0 hours. Percent on line since 1/9/03: 75% Tuesday February 18, 2003 The plant went down at 0200 hours because they ran out of diesel fuel. The fuel supplier would not make a delivery because of the icy road conditions. Total down time for the day: 22 hours. Percent on line since 1/9/03: 73% Wednesday February 19, 2003 Fuel was delivered and the plant started up at 0640. The plant moved to the off spec bin at 0745 because of burner problems. These problems were solved and the plant started back up at 0900. The plant ran the rest of the day. Total down time for the day: 7.92 hours. Percent on line since 1/9/03: 73% Thursday February 20, 2003 The plant operated smoothly all day. Total down time for the day: 0 hours. Percent on line since 1/9/03: 74% Friday February 21, 2003 The plant operated smoothly all day. Total down time for the day: 0 hours. Percent on line since 1/9/03: 74% Saturday February 22, 2003 The plant operated smoothly all day. Total down time for the day: 0 hours. Percent on line since 1/9/03: 75% Sunday February 23, 2003 The front seal on the kiln started leaking and the unit went down at 0930. The seal was repaired and the unit came back on line at 2030. Total down time for the day: 11 hours. Percent on line since 1/9/03: 74% Monday February 24, 2003 The unit moved to the off spec bin at 0340. The burners failed because of a bad relay. The problem was repaired and the unit went back on line at 0535 and operated smoothly the rest of the day. Total down time for the day: 1.92 hours. Percent on line since 1/9/03: 75% Tuesday February 25, 2003 The plant operated smoothly all day. Total down time for the day: 0 hours. Percent on line since 1/9/03: 75% Wednesday February 26, 2003 The plant operated smoothly all day. Total down time for the day: 0 hours. Percent on line since 1/9/03: 76% Thursday February 27,2003 The plant operated smoothly until 0715 when a brief power outage shut the plant down. While they were working to go back on line the power dropped off again at 0845 and was out for about an hour. The outages were due to the ice storm. MSR decided to not to · start the plant up until the weather improved because other outages were likely (and in fact occurred). Total down time for the day: 16.75 hours. Percent on line since 1/9/03: 75% Friday February 28, 2003 MSR arrived at 0630 to start the plant back up. The burners fired in late afternoon but other problems prevented MSR from starting feed to the unit. The plant was down all day. Total down time for the day: 24 hours. Percent on line since 1/9/03: 73% Saturday March 1, 2003 The plant started producing product at 0200 and went down at 1345 because of a scrubber plug. MSR is taking the opportunity to do some major manantiance items. They are replacing roolers on the conveyors and have replaced the feed auger bearings. The cyclone will be opened and inspected today. If no additional problems are encountered the plant should start up this evening. Total down time for the day: 10.25 hours. Percent on line since 1/9/03: 73.0% Sunday March 2, 2003 The plant was down all day doing maintanince. Total down time for the day: 24 hours. Percent on line since 1/9/03: 71.6% Monday March 3, 2003 The plant was down all day doing maintenance. Structural problems were found in the kiln that will require additional work. Material has also baked onto the inside surface of the kiln shell. That material is being removed. The plant will probably start up Wednesday. Total down time for the day: 24 hours. Percent on line since 1/9/03: 70.3% Tuesday March 4, 2003 The plant was down all day for repairs and maintenance work. Total down time for the day: 24 hours. Percent on line since 1/9/03: 69.0% Wednesday March 5, 2003 The plant started up at 0700 and ran smoothly for the rest of the day. Total down time for the day: 7 hours. Percent on line since 1/9/03: 69.1% Thursday March 6, 2003 The plant ran smoothly all day. Total down time for the day: 0 hours Percent on line since 1/9/03: 69.6% Friday March 7, 2003 The plant ran smoothly all day. Total down time for the day: 0 hours Percent on line since 1/9/03: 70.1 % Saturday March 8, 2003 The plant went down at approx. 0815 this morning. A fire eye failed and caused burner problems. The plant was back on line at 12:21 and ran the rest of the day. Total down time for the day: 4.1 hours Percent on line since 1/9/03: 70.3% Sunday March 9, 2003 The plant ran smoothly all day. Total down time for the day: 0 hours Percent on line since 1/9/03: 70.8% Monday March 10, 2003 The plant ran smoothly all day. Total down time for the day: 0 hours Percent on line since 1/9/03: 71.3% Tuesday March 11, 2003 The plant went down at 0300. Some paddles on the soil cooling pug mill broke off and jammed in the unit. They had to be cut out. The plant was down the rest of the day. Total down time for the day: 21 hours Percent on line since 1/9/03: 70.4% Wednesday March 12, 2003 The plant started up at 1250 and ran smoothly the rest of the day. Total down time for the day: 12.8 hours Percent on line since 1/9/03: 70.0% Thursday March 13, 2003 The plant operated smoothly all day. Total down time for the day: 0 hours Percent on line since 1/9/03: 70.5% Friday March 14, 2003 The plant operated smoothly all day. Total down time for the day: 0 hours Percent on line since 1/9/03: 70.9% Saturday March 15, 2003 The plant operated smoothly all day. Total down time for the day: 0 hours Percent on line since 1/9/03: 71.3% Sunday March 16, 2003 The plant went off line at 0900 because the bearing in the fan that recirculates the gas in the kiln was failing. We will not be able to get new parts until Monday. MSR personnel left the site at noon and will return at 0630 Monday. We anticipate that the plant will be back on line Monday evening. Total down time for the day: 15 hours Percent on line since 1/9/03: 70.8% Monday March 17 2003 The bearing was replaced, the fan rebalanced, and the unit started up at 1930 hours and ran smoothly the rest of the day. Total down time for the day: 19.5 hours Percent on line since 1/9/03: 70.1% Tuesday March 18, 2003 The plant ran smoothly all day. Total down time for the day: 0 hours Percent on line since 1/9/03: 70.5% Wednesday March 19, 2003 The plant ran smoothly all day. Total down time for the day: 0 hours Percent on line since 1/9/03: 70.9% Thursday March 20, 2003 The plant ran smoothly all day. Total down time for the day: 0 hours Percent on line since 1/9/03: 70.9% Friday March 21, 2003 The plant went down at 0_200 because a structural part came loose in the drum. The loose part did structural damage to other parts in the drum until the drum rotation could be stopped. Repairs will take at least a week. The unit will be down until repairs are completed. These reports will be resumed when an actual start up time is determined. Total down time for the day: 22 hours Percent on line since 1/9/03: 70.5% Sunday March 30, 2003 As of 2400 the plant is still down. The plant will probably start up Tuesday April 1. Total down time to date since Friday March 21: 216 hours Percent on line since 1/9/03: 62.6% Tuesday April 1, 2003 The plant started up at 1730 and ran smoothly the rest of the day. Total down time to date since Sunday March 30: 41.5 hours Percent on line since 1/9/03: 61.5% Wednesday April 2, 2003 The plant ran smoothly all day. Total down time for the day: 0 hours Percent on line since 1/9/03: 61.9% Thursday April 3, 2003 The plant went off line at 1400 hours. The cyclone stack was starting to emit dust and the plant was having problems with the chiller. Total down time for the day: 10 hours Percent on line since 1/9/03: 61.9% Friday April 4, 2003 The plant was down all day for maintenance. Total down time for the day: 24 hours Percent on line since 1/9/03: 61.2% Saturday April 5, 2003 The plant was down all day for maintenance. Total down time for the day: 24 hours Percent on line since 1/9/03: 60.4% Sunday April 6, 2003 The plant started up at 0650 and ran smoothly the rest of the day. Total down time for the day: 6.83 hours Percent on line since 1/9/03: 60.6% Monday April 7, 2003 The plant ran smoothly all day. Total down time for the day: 0 hours Percent on line since 1/9/03: 61.0% Tuesday April 8, 2003 The plant ran smoothly all day. Total down time for the day: 0 hours Percent on line since 1/9/03: 61.5% Wednesday April 9, 2003 The plant ran smoothly all day. Total down time for the day: 0 hours Percent on line since 1/9/03: 61.9% Thursday April 10, 2003 The plant went down at 0300 because of a seal leak on the feed end of the kiln. The seal was repaired and the plant went back on line at 15:00. The plant ran smoothly the rest of the day. Total down time for the day: 12 hours Percent on line since 1/9/03: 61.7% Friday April 11, 2003 The plant ran smoothly all day. Total down time for the day: 0 hours Percent on line since 1/9/03: 62.2% Saturday April 12, 2003 The plant ran smoothly all day. Total down time for the day: 0 hours Percent on line since 1/9/03: 62.6% Sunday April 13, 2003 The plant ran smoothly all day. Total down time for the day: 0 hours Percent on line since 1/9/03: 63.0% Monday April 14, 2003 The plant went down at 0130. A flight came loose in the kiln and damaged the pug mill. The kiln was repaired and came back on line at 11 :00. The plant ran smoothly the rest of the daY: Total down time for the day: 9.5 hours Percent on line since 1/9/03: 62.9% Tuesday April 15, 2003 The plant ran smoothly all day. Total down time for the day: 0 hours Percent on line since 1/9/03: 63.3% Wednesday April 16, 2003 The plant ran smoothly all day. Total down time for the day: 0 hours Percent on line since 1/9/03: 63.7% Thursday April 17, 2003 The plant ran smoothly all day. Total down time for the day: 0 hours Percent on line since 1/9/03: 64.0% Friday April 18, 2003 The plant ran smoothly all day. Total down time for the day: 0 hours Percent on line since 1/9/03: 64.4% Saturday April 19, 2003 The plant ran smoothly all day. Total down time for the day: 0 hours Percent on line since 1/9/03: 64.8% Sunday April 20, 2003 The plant ran smoothly all day. Total down time for the day: 0 hours Percent on line since 1/9/03: 65.1% Monday April 21, 2003 The plant went down at 1445 because the steam scrubber vent fan failed. The pug mill also needs rework and that will be done during this shutdown. Total down time for the day: 9.25 hours Percent on line since 1/9/03: 65.1% Tuesday April 22, 2003 The plant was down all day for maintenance. Total down time for the day: 24 hours Percent on line since 1/9/03: 64.4% Wednesday April 23, 2003 The plant started up at 1300 hours and ran smoothly the rest of the day. Total down time for the day: 13 hours Percent on line since 1/9/03: 64.3% Thursday April 24, 2003 The plant sent product to the reject bin from 2045 to 2200. Otherwise the plant operated smoothly all day. Total down time for the day: 1.25 hours Percent on line since 1/9/03: 64.6% Friday April 25, 2003 The plant ran smoothly all day. Total down time for the day: 0 hours Percent on line since 1/9/03: 64.9 % Saturday April 26, 2003 The plant ran smoothly all day. Total down time for the day: 0 hours Percent on line since 1/9/03: 65.2 % Sunday April 27, 2003 The plant went down from 2015 until 2130 because of a brief power outage. Total down time for the day: 1.25 hours Percent on line since 1/9/03: 65.5% Monday April 28, 2003 The plant was off line from 1145 to 1300 to allow a vendor to balance the fan on the soil cooler. Total down time for the day: 1.25 hours Percent on line since 1/9/03: 65 .8% Tuesday April 29, 2003 The plant ran smoothly all day. Total down time for the day: 0 hours Percent on line since 1/9/03: 66.1 % Wednesday April 30, 2003 The plant ran smoothly all day. Total down time for the day: 0 hours Percent on line since 1/9/03: 66.4 % Thursday May 1, 2003 The plant ran smoothly all day. Total down time for the day: 0 hours Percent on line since 1/9/03: 66.7 % Friday May 2, 2003 The plant ran smoothly all day. Total down time for the day: 0 hours Percent on line since 1/9/03: 67.0 % Saturday May 3, 2003 The plant went down at 1100 to replace the feed end kiln seal, clean the mist eliminator in the off gas recirculation line, and rebuild some pumps. The plant was down the rest of the day. Total down time for the day: 13 hours Percent on line since 1/9/03: 66.8 % Sunday May 4, 2003 The plant was down all day to complete the work started Saturday. Total down time for the day: 24 hours Percent on line since 1/9/03: 66.2 % Monday May 5, 2003 The repairs were completed and the plant started up at 0 130. Then plant ran smoothly the rest of the day. Total down time for the day: 1.5 hours Percent on line since 1/9/03: 66.4 % Tuesday May 6, 2003 The plant ran smoothly all day. Total down time for the day: 0 hours Percent on line since 1/9/03: 66. 7 % Wednesday May 7, 2003 The plant went down at 2100. The reason for the outage and the planned startup time has not yet been communicated to Shaw. This information will be provided later. Total down time for the day: 3 hours Percent on line since 1/9/03: 66.9 % Thursday May 8, 2003 The plant was down all day. A broken flyte in the kiln caused the initial shutdown. An inspection of the water treatment system during the cool down period revealed the oil/water separator packing to be past its effective service life. New packing was ordered and shipped via a dedicated courier. Total down time for the day: 24 hours Percent on line since 1/9/03: 66.3% Friday May 9, 2003 The plant was down all day. Total down time for the day: 24 hours . Percent on line since 1/9/03: 65.8% Saturday May 10, 2003 Repairs were completed and the plant started back up at 1800 hours. Total down time for the day: 18 hours Percent on line since 1/9/03: 65.4% Sunday May 11, 2003 The plant was down from 1830 to 2230 to repair a broken hose. Total down time for the day: 4 hours Percent on line since 1/9/03: 65.6% Monday May 12, 2003 The plant ran smoothly all day. Total down time for the day: 0 hours Percent on line since 1/9/03: 65.9% Tuesday May 13, 2003 The plant ran smoothly all day. Total down time for the day: 0 hours Percent on line since 1/9/03: 66.1 % Wednesday May 14, 2003 The plant ran smoothly all day. Total down time for the day: 0 hours Percent on line since 1/9/03: 66.4% Thursday May 15, 2003 The plant shifted into bin 5 from 1600 to 1615 to recover from a power blip that shut down motors and burners. Total down time for the day: 0.25 hours Percent on line since 1/9/03: 66. 7% Friday May 16, 2003 At 0945 dust was seen coming out of the cyclone and the plant stopped the feed. The plant was shut down at 1030. MSR decided to perform other maintenance in addition to fixing the dust leak while the plant was down. Total down time for the day: 14 hours Percent on line since 1/9/03: 66.5% Saturday May 17, 2003 The plant was down all day performing maintenance. Total down time for the day: 24 hours Percent on line since 1/9/03: 66.0% Sunday May 18, 2003 MSR took a day off and there was no activity on the site. Total down time for the day: 24 hours Percent on line since 1/9/03: 65.5% Monday May 19, 2003 A Trunion bearing is bad and must be replaced. The plant was down all day performing maintenance and repairs. Total down time for the day: 24 hours Percent on line since 1/9/03: 65.0% Tuesday May 20, 2003 Repairs were completed and the plant started up at 1930 hours. Total down time for the day: 19.5 hours Percent on line since 1/9/03: 64.6% Wednesday May 21, 2003 The plant ran smoothly all day. Total down time for the day: 0 hours Percent on line since 1/9/03: 64.9% Thursday May 22, 2003 The plant was down from 0215 till 0245 because of a burner problem. Total down time for the day: 0.5 hours Percent on line since 1/9/03: 65.1 % Friday May 23, 2003 A power outage shut the plant down at 0230. The plant started back up at 1000, then went down again from 1035 till 1125. The plant ran the rest of the day. Total down time for the day: 8.3 hours Percent on line since 1/9/03: 65.1 % Saturday May 24, 2003 The plant went down at 0740 because the cyclone stack was emitting dust. The problem was a leak from the breech of the kiln into the hot gas stream that heats the cyclone. We decided to perform other maintance during the outage, in particular rebuilding the pug mill. Total down time for the day: 16.3 hours Percent on line since 1/9/03: 64.9% Sunday May 25, 2003 The plant was down all day performing maintinance and repairs. Total down time for the day: 24 hours Percent on line since 1/9/03: 64.4% Monday May 26, 2003 The plant started up at 1120 and ran smoothly the rest of the day. Total down time for the day: 11.3 hours Percent on line since 1/9/03: 64.3% Tuesday May 27, 2003 The plant went down at 0610 because of excessive pressure drop in the kiln gas recirculation system. The blockage was cleared and the plant started back up at 1950. Total down time for the day: 13.7 hours Percent on line since 1/9/03: 64.2% Wednesday May 28, 2003 The plant went down at 0730 to repair a leaking seal between the drum and discharge breech. A leak in the cyclone was also repaired. The plant came back on line at 2220. Total down time for the day: 14.8 hours Percent on line since 1/9/03: 64.0% Thursday May 29, 2003 The plant ran smoothly all day. Total down time for the day: 0 hours Percent on line since 1/9/03: 64.2% Friday May 30, 2003 The plant was down from 1004 until 1015 because of a brief power outage. Total down time for the day: 0.2 hours Percent on line since 1/9/03: 64.5% Saturday May 31, 2003 The plant was down from 0800 until 1100 because of a brief power outage. Total down time for the day: 3 hours Percent on line since 1/9/03: 64.6% Sunday June 1, 2003 The plant was down from 1000 till 1245 because of an electrical problem in the auger. Total down time for the day: 2.75 hours Percent on line since 1/9/03: 64.8% Monday June 2, 2003 The plant operated smoothly all day. Total down time for the day: 0 hours Percent on line since 1/9/03: 65.0% ✓ Tuesday June 3, 2003 The plant operated smoothly all day. Total down time for the day: 0 hours Percent on line since 1/9/03: 65.3% Wednesday June 4, 2003 The plant ran smoothly all day. Total down time for the day: 0 hours Percent on line since 1/9/03: 65.5% Thursday June 5, 2003 The plant ran smoothly all day. Total down time for the day: 0 hours Percent on line since 1/9/03: 65.8% Friday June 6, 2003 The plant ran smoothly all day. Total down time for the day: 0 hours Percent on line since 1/9/03: 66.0% Saturday June 7, 2003 The plant ran smoothly all day. Total down time for the day: 0 hours Percent on line since 1/9/03: 66.2% . Sunday June 8, 2003 The plant ran smoothly all day. Total down time for the day: 0 hours Percent on line since 1/9/03: 66.4% Monday June 9, 2003 The plant went down at 1730 because analytical results came back that showed the previous two batches had failed. The reason for the failures will be detennined and fixed before the unit starts back up. Total down time for the day: 6.5 hours Percent on line since 1/9/03: 66.5% Tuesday June 10, 2003 The plant was down all day perfonning maintinance and repairs. We anticipate starting back up Thursday. Total down time for the day: 24 hours Percent on line since 1/9/03: 66.0% Wednesday June 10, 2003 The plant was down all day perfonning maintinance and repairs. Total down time for the day: 24 hours Percent on line since 1/9/03: 65.6% Thursday June 11, 2003 The plant started up at 2130 and ran smoothly the rest of the day. Total down time for the day: 21.5 hours Percent on line since 1/9/03: 65.3% Friday June 13, 2003 The plant ran smoothly all day. Total down time for the day: 0 hours Percent on line since 1/9/03: 65.5% Saturday June 14, 2003 The plant ran smoothly all day. Total down time for the day: 0 hours Percent on line since 1/9/03: 65.7% Sunday June 15, 2003 The plant ran smoothly all day. Total down time for the day: 0 hours Percent on line since 1/9/03: 65.9% Monday June 16, 2003 The plant ran smoothly all day. Total down time for the day: 0 hours Percent on line since 1/9/03: 66.1 % Tuesday June 17, 2003 The plant was down from 1945 till 2115 to repair a bearing failure. Total down time for the day: 1.5 hours Percent on line since 1/9/03: 66.3% Wednesday June 18, 2003 The plant ran smoothly all day. Total down time for the day: 0 hours Percent on line since 1/9/03: 66.5% Thursday June 19, 2003 The plant ran smoothly all day. Total down time for the day: 0 hours Percent on line since 1/9/03: 66.7% Friday June 20, 2003 The plant ran smoothly all day. Total down time for the day: 0 hours Percent on line since 1/9/03: 66.9% Saturday June 21, 2003 The plant ran smoothly all day. Total down time for the day: 0 hours Percent on line since 1/9/03: 67.1% Sunday June 22, 2003 The plant was down from 1200 till 1300 to repair a bearing. Otherwise the plant operated continuously. Total down time for the day: 1 hour Percent on line since 1/9/03: 67.3% Monday June 23, 2003 The plant ran smoothly all day. Total down time for the day: 0 hours Percent on line since 1/9/03: 67.5% Tuesday June 24, 2003 The plant went down at 1930 for repairs and was down the rest of the day. Details on the required repairs will be described tomorrow. Total down time for the day: 4.5 hours Percent on line since 1/9/03: 67.6% Wednesday June 25, 2003 The plant was down all day for repairs and maintenance. The bearings in two trunions were replaced. The plant should start up during the day shift. Total down time for the day: 24 hours Percent on line since 1/9/03: 67.2% Thursday June 26, 2003 The plant restarted at 17:00 hours. Startup was delayed about 5 hours when a piece of metal broke loose in the pug mill and stopped it cold. Total down time for the day: 17 hours Percent on line since 1/9/03 : 67.0% Friday June 27, 2003 The plant ran smoothly all day. Total down time for the day: 0 hours Percent on line since 1/9/03: 67.2% Saturday June 28, 2003 The plant ran smoothly all day. · Total down time for the day: 0 hours Percent on line since 1/9/03: 67.3% Sunday June 29, 2003 The plant ran smoothly all day. Total down time for the day: 0 hours Percent on line since 1/9/03: 67.5% Monday June 30, 2003 The plant ran smoothly all day. Total down time for the day: 0 hours Percent on line since 1/9/03: 67.7% Tuesday July 1, 2003 The plant ran smoothly all day. Total down time for the day: 0 hours Percent on line since 1/9/03: 67.9% Wednesday July 2, 2003 The plant went down at 1800 because a bearing in the desludging centrifuge was failing. The new bearing should come in today and MSR will install it. While they are down they are also doing work on the pug mill. The new stainless steel separator plates for the oil water separator came in and they will be installed. Assuming that the bearing is the only thing wrong with the centrifuge the plant may start up Thursday evening but it will probably be Friday. Total down time for the day: 6 hours Percent on line since 1/9/03: 67.9% Thursday July 3, 2003 The plant was down all day for repairs and maintenance. Total down time for the day: 24 hours Percent on line since 1/9/03: 67.6% Friday the 4th of July, 2003 When MSR opened the centrifuge to replace the pillow block bearing they found that they needed some additional parts. Because of the holiday the parts will not be in until Saturday morning. They will repair the centrifuge Saturday and test it. If it works they will probably be able to start up Saturday evening. There is a good chance that the centrifuge will require balancing. If this be the case it will have to be sent off site. There is a facility in Washington, NC that can do this work. MSR has not spoken to the person who does the balancing because he was out this week and will not be back until Monday. If balancing is required we should be able to provide a schedule for that sometimes Monday. Total down time for the day: 24 hours Percent on line since 1/9/03: 67.2% Saturday July 5, 2003 The plant was down all day for repairs and maintenance. The bearings arrived Saturday afternoon and were installed. Total down time for the day: 24 hours Percent on line since 1/9/03: 66.8% Sunday July 6, 2003 The plant was down all day. The new bearings were installed. Total down time for the day: 24 hours Percent on line since 1/9/03: 66.4% Monday July 7, 2003 The plant started up at O 115 and operated smoothly the rest of the day. Total down time for the day: 1.25 hours Percent on line since 1/9/03: 66.6% Tuesday July 8, 2003 The plant operated smoothly all day. Total down time for the day: 0 hours Percent on line since 1/9/03: 66.8% Wednesday July 9, 2003 The plant operated smoothly all day. Total down time for the day: 0 hours Percent on line since 1/9/03: 67% Thursday July 10, 2003 The plant operated smoothly all day. Total downtime for the day: 0 hours Percent on line since 1/9/03: 67.1% Friday, July 11, 2003 The plant was down from 1800 to 1900 because of a CP&L power outage. Total downtime for the day: 1 hour Percent on line since 1/9/03: 67.3% Saturday July 12, 2003 The plant operated smoothly all day. Total downtime for the day: 0 hours Percent on line since 1/9/03: 67.5% Sunday July 13, 2003 The plant operated smoothly all day. Total downtime for the day: 0 hours Percent on line since 1/9/03: 67.6% Monday July 14, 2003 The unit went down at 0 l 00 because the trunions were out of alignment and the kiln shell was shifting out of position. The trunions were realigned and the unit started back up at 1400. Total downtime for the day: 13 hours Percent on line since 1/9/03: 67.5% Tuesday July 15, 2003 The plant operated smoothly all day. Total downtime for the day: 0 hours Percent on line since 1/9/03: 67.7% Wednesday July 16, 2003 Thunderstorms caused power outages that caused the plant to be down from 1915 to 2200. Total downtime for the day: 2.75 hours Percent on line since 1/9/03: 67.8% Thursday July 17, 2003 The plant operated smoothly all day. Total downtime for the day: 0 hours Percent on line since 1/9/03: 68.0% Friday July 18, 2003 The plant went down at 1745 to change out the vapor phase carbon and patch a hole in the cyclone. The plant came back on line at 2400. Total downtime for the day: 6.15 hours Percent on line since 1/9/03: 68.0% Saturday July 18, 2003 The plant operated smoothly all day. Total downtime for the day: 0 hours Percent on line since 1/9/03: 68.2% Sunday July 20, 2003 The plant operated smoothly all day. Total downtime for the day: 0 hours Percent on line since 1/9/03: 68.3% Monday July 21, 2003 A bearing in the centrifuge failed and the centrifuge was taken to a machine shop in Raleigh for repair. The new bearing is in. There is also damage to the shaft due to the bearing failure that is being repaired. Total downtime for the day: 24 hours Percent on line since 1/9/03: 68.0% Tuesday July 22, 2003 The repaired centrifuge was reinstalled and the plant started back up at 2300. Total downtime for the day: 23 hours Percent on line since 1/9/03: 67. 7% Wednesday July 23, 2003 The plant was down from 1800 to 1900 because of an electrical problem in the feed auger system. Total downtime for the day: 1 hour Percent on line since 1/9/03: 67.8% Thursday July 24, 2003 The plant operated smoothly all day. Total downtime for the day: 0 hours Percent on line since 1/9/03: 68.0% Friday July 25, 2003 The plant operated smoothly all day. Total downtime for the day: 0 hours Percent on line since 1/9/03: 68.1% Saturday July 26, 2003 The plant operated smoothly all day. Total downtime for the day: 0 hours Percent on line since 1/9/03: 68.3% Sunday July 27, 2003 The plant went down at 1900 because bolts holding the feed screw augers failed. Total downtime for the day: 5 hours Percent on line since 1/9/03: 68.3% Monday July 28, 2003 As of0750 the augers were repaired. We did some more mantinance and inspected the inside of the kiln drum. The plant started up at 1700 and ran smoothly the rest of the day. Total downtime for the day: 17 hours Percent on line since 1/9/03: 68.2% Tuesday July 29, 2003 The plant ran smoothly all day. The clay run started at 1010. Total downtime for the day: 0 hours Percent on line since 1/9/03: 68.3% Wednesday July 30, 2003 The plant ran smoothly all day. The clay run ended at 2110. Total downtime for the day: 0 hours Percent on line since 1/9/03: 68.5% Thursday July 31, 2003 The plant was down from 0200 till 0600 to repair the conveyor belt between the pug mill and the radial stacker. Total downtime for the day: 4 hours Percent on line since 1/9/03: 68.5% Friday August 1, 2003 The plant was down from 0915 till 0415 to repair the feed augers. Total downtime for the day: 7 hours Percent on line since 1/9/03: 68.5% Saturday August 2, 2003 The plant operated smoothly all day. Total downtime for the day: 0 hours Percent on line since 1/9/03: 68. 7% Sunday August 3, 2003 The plant was down from 1300 to 1700 to rapair a bearing that failed in the kiln off gas recirculation fan. Total downtime for the day: 4 hours Percent on line since 1/9/03: 68.8% Monday August 4, 2003 The plant went down at 1200 because the twin soil feed augers were getting out of alignment. The plant was down the rest of the day repairing the augers. Total downtime for the day: 12 hours Percent on line since 1/9/03: 68.7% Tuesday August 5, 2003 The auger repairs were completed and the plant started back up at 0230. They went down again at 0315 to make repairs and came back up at 0515. As of0700 the plant is operating smoothly. Total downtime for the day: 4 hours Percent on line since 1/9/03 : 68.8% Wednesday August 6, 2003 The plant was down from 1100 to 1700 to replace a bearing in the off-gas recirculation fan. Total downtime for the day: 6 hours Percent on line since 1/9/03: 68.8% Thursday August 7, 2003 The plant was on line all day. Total downtime for the day: 0 hours Percent on line since 1/9/03: 68.9% Friday August 8, 2003 The plant was down from 1620 to 1920 because of a bearing problem. Total downtime for the day: 3 hours Percent on line since 1/9/03: 69.0% Saturday August 9, 2003 The plant was on line all day. Total downtime for the day: 0 hours Percent on line since 1/9/03: 69.2% Sunday August 10, 2003 The plant was on line all day. Total downtime for the day: 0 hours Percent on line since 1/9/03: 69.3% Monday August 11, 2003 The radial stacker belt failed causing the plant to be down from 2030 through the rest of the day. Total downtime for the day: 3.5 hours Percent on line since 1/9/03: 69.4% Tuesday August 12, 2003 The radial stacker belt was repaired and the plant went back on line at 0600. Total downtime for the day: 6 hours Percent on line since 1/9/03: 69.4% Wednesday August 13, 2003 The plant ran smoothly all day Total downtime for the day: 0 hours Percent on line since 1/9/03: 69.5% Thursday August 14, 2003 The plant was shut down at 0830 to repair the pug mill bearings. We have decided to perform some major maintenance work and anticipate restarting Sunday. Total downtime for the day: 15.5 hours Percent on line since 1/9/03: 69.4% Friday August 15, 2003 The plant was down all day for maintenance. Total downtime for the day: 24 hours Percent on line since 1/9/03: 69.1% Saturday August 16, 2003 The plant was down all day for maintenance. Total downtime for the day: 24 hours Percent on line since 1/9/03: 68.8% Sunday August 17, 2003 The plant started up at 0800 Total downtime for the day: 8 hours Percent on line since 1/9/03: 68.8% Monday August 18, 2003 The plant went down at 2340 because the augers failed. Total downtime for the day: 0.33 hours Percent on line since 1/9/03: 68.9% Tuesday August 19, 2003 Repairs were completed and the plant started up at 2130. Total downtime for the day: 21.5 hours Percent on line since 1/9/03: 68.6% Wednesday August 20, 2003 The plant ran smoothly all day Total downtime for the day: 0 hours Percent on line since 1/9/03: 68.8% Thursday August 21, 2003 The plant ran smoothly all day Total downtime for the day: 0 hours Percent on line since 1/9/03: 68.9% Friday August 22, 2003 The plant ran smoothly all day Total downtime for the day: 0 hours Percent on line since 1/9/03: 69.0% Saturday August 23, 2003 The plant ran smoothly all day Total downtime for the day: 0 hours Percent on line since 1/9/03: 69.2% Sunday August 24, 2003 The plant was down from 1300 to 1800 to repair the kiln rear seal. Total downtime for the day: 5 hours Percent on line since 1/9/03: 69.2% Monday August 25, 2003 The plant ran smoothly all day Total downtime for the day: 0 hours Percent on line since 1/9/03: 69.4% Tuesday August 26, 2003 The plant ran smoothly all day Total downtime for the day: 0 hours Percent on line since 1/9/03: 69.5% Wednesday August 27, 2003 The plant was down from 1530 till 1900 to replace the feed end kiln seal. Total downtime for the day: 3.5 hours Percent on line since 1/9/03: 69.6% Thursday August 28, 2003 The plant was down from 16:30 to 19:00 to repair recirc fan bearing. Total down time for the day: 2.5 hours Percent on line since 1/9/03: 69.6% Friday August 29, 2003 The plant was down from 2100 to 2400 hours bcause of an electrical problem in the stacker motor. Total down time for the day: 3 hours Percent on line since 1/9/03: 69.7% Saturday August 30, 2003 The plant was down from 0000 to 1300 hours because of an electrical problem in the stacker motor. The plant was down from 1800 to 2100 because of a problem in the soil cooler blower motor. The plant was down from 2300 to 2400 because of a power outage. Total down time for the day: 17 hours Percent on line since 1/9/03: 69.5% Sunday August 31, 2003 The plant was down from 0000 to 0200 because of a power outage. Total down time for the day: 2 hours Percent on line since 1/9/03: 69.6% Monday September 1, 2003 The plant ran smoothly all day. Total down time for the day: 0 hours Percent on line since 1/9/03: 69.8% Tuesday September 2, 2003 The plant ran smoothly all day. Total down time for the day: 0 hours Percent on line since 1/9/03: 69.9% Wednesday September 3, 2003 The plant ran smoothly all day. Total down time for the day: 0 hours Percent on line since 1/9/03: 70.0% Thursday September 4, 2003 The plant was down from 1800 to 2300 because the conveyor between the soil cooler and the radial stacker broke. Total down time for the day: 5 hours Percent on line since 1/9/03: 70.1 % Friday September 5, 2003 The plant was down from 1600 to 2200 to work on the soil cooler scrubber and replace two belts on the soil cooler pug mill. Total down time for the day: 6 hours Percent on line since 1/9/03: 70.1 % Saturday September 6, 2003 The plant ran smoothly all day. Total down time for the day: 0 hours Percent on line since 1/9/03: 70.2% Sunday September 7, 2003 The plant ran smoothly all day. Total down time for the day: 0 hours Percent on line since 1/9/03: 70.3% Monday September 8, 2003 The plant was down from 1600 to 2300 to work on the pug mill. Total down time for the day: 7 hours Percent on line since 1/9/03: 70.3% Tuesday September 9, 2003 The plant ran smoothly all day. Total down time for the day: 0 hours Percent on line since 1/9/03: 70.5% Wednesday September 10, 2003 The plant ran smoothly all day. Total down time for the day: 0 hours Percent on line since 1/9/03: 70.6% Thursday September 11, 2003 The plant ran smoothly all day. Total down time for the day: 0 hours Percent on line since 1/9/03: 70.7% Friday September 12, 2003 The plant ran smoothly all day. Total down time for the day: 0 hours Percent on line since 1/9/03: 70.8% Saturday September 13, 2003 The plant ran smoothly all day. Total down time for the day: 0 hours Percent on line since 1/9/03: 70. 9% Sunday September 14, 2003 The plant was down from 1530 to 2200 because the recirculation pump on the soil cooler scrubber failed. Total down time for the day: 6.5 hours Percent on line since 1/9/03: 70.9% Monday September 15, 2003 The plant ran smoothly all day. Total down time for the day: 0 hours Percent on line since 1/9/03: 71.1 % Tuesday September 16, 2003 The plant ran smoothly all day. Total down time for the day: 0 hours Percent on line since 1/9/03: 71.2% Wednesday September 17, 2003 The plant ran smoothly all day. Total down time for the day: 0 hours Percent on line since 1/9/03: 71.3% Thursday September 18, 2003 The plant went down with a power failure caused by Isabel at noon and stayed down the rest of the day. Total down time for the day: 12 hours Percent on line since 1/9/03: 71.2% Friday September 19, 2003 The plant was down all day as a result of no power from Isabel. Total down time for the day: 24 hours Percent on line since 1/9/03: 70.9% Saturday September 20, 2003 As of 0900, the site has power to the support area, but only partial 3-phase power. A service call has been placed with Progress Energy (CP&L). The problem was repaired and the plant started up at 1800. Total down time for the day: 18 hours Percent on line since 1/9/03: 70.7% Sunday September 21, 2003 The plant ran smoothly all day. Total down time for the day: 0 hours Percent on line since 1/9/03: 70.9% Monday September 22, 2003 (Note correction on report for 9/20, the plant started up at 1800 hours, not at 1000 hours as previously reported.) The plant ran smoothly all day. Total down time for the day: 0 hours Percent on line since 1/9/03: 71.0% Tuesday September 23, 2003 The plant ran smoothly all day. Total down time for the day: 0 hours Percent on line since 1/9/03: 71.1 % Wednesday September 24, 2003 The plant ran smoothly all day. Total down time for the day: 0 hours Percent on line since 1/9/03: 71.2% Thursday September 25, 2003 The plant was down from 1400 to 1900 hours to work on the soil cooler scrubber and repair a hole in the product conveyor belt. Total down time for the day: 5 hours Percent on line since 1/9/03: 71.2% Friday September 26, 2003 The plant ran smoothly all day. Total down time for the day: 0 hours Percent on line since 1/9/03: 71.3% Saturday September 27, 2003 The plant ran smoothly all day. Total down time for the day: 0 hours Percent on line since 1/9/03: 71.4% Sunday September 28, 2003 The plant ran smoothly all day. Total down time for the day: 0 hours Percent on line since 1/9/03: 71.6% Monday September 29, 2003 The plant ran smoothly all day. Total down time for the day: 0 hours Percent on line since 1/9/03: 71.7% Tuesday September 30, 2003 The plant ran smoothly all day. Total down time for the day: 0 hours Percent on line since 1/9/03: 71.8% Wednesday October 1, 2003 The plant was down all day with pugmill maintenance. Total down time for the day: 20 hours Percent on line since 1/9/03: 71.6% Thursday October 2, 2003 The plant ran smoothly all day. Total down time for the day: 0 hours Percent on line since 1/9/03: 71.7% Friday October 3, 2003 The plant ran smoothly all day. Total down time for the day: 0 hours Percent on line since 1/9/03: 71.8% Saturday October 4, 2003 The plant ran smoothly all day. Total down time for the day: 0 hours Percent on line since 1/9/03: 71.9% Sunday October 5, 2003 The plant was down from 0815 to 1515 to repair the feed augers and work on the feed end seal. Total down time for the day: 7 hours Percent on line since 1/9/03: 71.9% Monday October 6, 2003 The plant ran smoothly all day. Total down time for the day: 0 hours Percent on line since 1/9/03: 72.0% Tuesday October 7, 2003 The plant was down from 16:00 to 23:45 to replace the conveyor belt between the kiln and the radial stacker. Total down time for the day: 7.75 hours Percent on line since 1/9/03: 72.0% Wednesday October 8, 2003 The plant ran smoothly all day. Total down time for the day: 0 hours Percent on line since 1/9/03: 72.1% Thursday October 9, 2003 The plant ran smoothly all day. Total down time for the day: 0 hours Percent on line since 1/9/03: 72.2% Friday October 10, 2003 The plant went down at 1400 because of a broken feed auger. The auger was repaired and the plant started back up at 2100. Total down time for the day: 7 hours Percent on line since 1/9/03: 72.2% Saturday October 11, 2003 The plant ran smoothly all day. Total down time for the day: 0 hours Percent on line since 1/9/03: 72.3% Sunday October 12, 2003 The plant ran smoothly all day. Total down time for the day: 0 hours Percent on line since 1/9/03: 72.4% Monday October 13, 2003 The plant ran smoothly all day. Total down time for the day: 0 hours Percent on line since 1/9/03: 72.5% Tuesday October 14, 2003 A power failure brought the plant down at 2300. Total down time for the day: 1 hours Percent on line since 1/9/03: 72.5% Wednesday October 15, 2003 The plant was taken down at 0840 because of a brief power failure. The plant was back on line at 0940. Total down time for the day: 1 hours Percent on line since 1/9/03: 72.6 Thursday October 16, 2003 The plant went down at 0415 because of burner problems. As of 0647 the plant started back up and ran smoothly the rest of the day. Total down time for the day: 2.5 hours Percent on line since 1/9/03: 72.7 Friday October 17, 2003 The feed was cut off briefly about 4 times during the day because the kiln soil discharge chute plugged. Total down time for the day: 1 hour Percent on line since 1/9/03: 72.8 Saturday October 18, 2003 Processing of contaminated soil was completed at 1900 today.