Table 3 Summary of STREAM component errors, causes, and mitigation approaches

Manufacturing and contextual:

Leaking reaction chamber

Scaling in the reaction chamber or outlet port due to calcium in the water clogging and building up pressure inside the cell, which led to leaking.

• An emergency pressure-relief rupture disk was added to the brine inlet port of the cell. The rupture disk provides a point of pressure relief for the cell when the cell needs to be cleaned.

• An outer titanium plate was added to the cathode housing to prevent the cathode housing from warping (where the oxidant was leaking).

• Cleaning protocols were updated.

Manufacturing:

Poorly soldered circuit board connections

Energy demands require more robust, higher-amp socket connectors.

• All socket connectors were replaced with stronger, more robust, click-to-connect connectors that prevent accidental shorts and keep wires from becoming dislodged.

• The connector between the power supply and control box was upgraded to a 42A connector to prevent overheating.

Contextual:

Power supply vulnerability to voltage spikes

Severe power surges led to tripped thermal switches and damaged power componentry.

• Aqua Research redesigned the power supply to include a 120-277 V surge protector and added a 42A connector from the power supply to the control box.