Gentlemen,
My experience in ordnance did not include use of powders such as 4895 or any such slow burning powders. The devices I worked on usually required production of a lot of gas at relatively low pressures (.38 SPL +/- pressures but in a large volume) in a very short time.
In my experience, old propellant does not present a hazard to the hobbyist. On the other hand, it may well affect your internal ballistics.
Deflagration retardants are not part of my vocabulary outside my hobby of reloading, so there is much I do not know of this art.
At the end of my career I did work with gas generators/propellants for automotive air bags but there is little to compare between the two (some of the gas generator grains were as big as your thumb or more). I do not pose as an artillery propellant expert in any way, so if the US Army resolves to destroy all propellant at 20-40 yrs, that's OK by me. Your car airbag inflators are designed for a 10 year life.
Well I was interested in your posts. I don't know what design lifetime powder manufacturers use, but assuming that 20 years is a good number, your tests with 24 year old powder, plus or minus a standard deviation or two, it would not be unreasonable to expect that your DB lot was not degraded sufficiently to show up on your instrumentation. You needed to wait a couple more decades, and see what might happen.
If you could get Nasa to fund this, you could have a job for life. Sit in an easy chair for the next thirty years and watch that can of Bullseye get old.
The Navy does things a little differently. They put samples in a test tube, with methyl violet paper. Nitric acid gas will turn the paper red. If the Methyl violet paper turns red in weeks, the Navy then tests a powder sample for the percent of stabilizers in the powder.
The Navy keeps original powder lot information, and knows how much stabilizer was in the new powder. My recollection is that if the amount of stabilizer is less than 12%, 15%?, the powder lot is scrapped.
Clock time is an easy way to determine stockpile condition. I am certain the numbers are a bit conservative, the Army neglected ammunition insensitivity issues for years, (just get waivers!) and then they started having accidents.
http://www.eaglehorse.org/3_home_station/doha/doha.htm
http://www.ordnance.org/mishaps.htm
As I stated earlier, DB powders degrade sooner than SB. The rate of deterioration is directly related to temperature, as the reduction reaction follows the Arrhenius equation. The higher the temp, the faster powder deteriorates.