| Your air pollution control system represents a | | | | installed. |
| significant investment in not only initial capital but also | | | | 5. Remove the UV scanner and clean the view lens |
| ongoing maintenance and operation. Routine | | | | with a lint free cloth. |
| inspections performed by your staff combined with | | | | 6. Replace the spark ignitor. |
| thorough maintenance plans provided by qualified | | | | 7. Verify burner flame visually at burner or system |
| Service Technicians will ensure you get the most from | | | | Peep-Site for: |
| your investment over the entire life of the system. | | | | · Color - Color should typically be "Blue" with |
| Following the recommendations made below will help | | | | "Orange/Yellow" tips. |
| keep your system operating both efficiently and | | | | · Intensity - Verify flame strength, flame should |
| effectively, reducing costly repairs and avoiding | | | | not be "Lazy", verify at several different firing rates. |
| downtime. | | | | 8. Inspect the exterior of the burner for damage or |
| Routine Inspections: The checklist below is meant to | | | | areas showing excessive heat. |
| be a general guide for servicing your oxidizer, however | | | | 9. Inspect all fan flex joints and replace as necessary |
| equipment varies and you will need to refer to the | | | | 10. The T-dampers and linkage (if applicable) should be |
| original maintence documents for exact procedures | | | | inspected for proper operation and the linkage |
| and safety notifications. | | | | checked for tightness. |
| Inspections include a combination of equipment checks | | | | Yearly Inspection |
| on the "high use" items and data recording to build a | | | | Preventive Maintenance Evaluations (PMEs): Generally, |
| history of unit performance. When performing | | | | Preventive Maintenance Evaluation (PME) are a |
| equipment checks refer to manufacturer's O&M | | | | two-day thorough evaluation of your system |
| Manuals for detailed procedures. For the | | | | performed by a qualified Service Technician. Typically, |
| data-gathering items, refer to historical data and note | | | | PMEs are scheduled on an annual or semi-annual |
| any significant changes from typical values. | | | | basis. It does require the system be cooled down and |
| Weekly Maintenance Checks - To be performed by | | | | not running for one day to complete the internal |
| the local maintenance staff of the equipment owner | | | | inspection. On the second day of a PME the availability |
| user. | | | | of process airflow is recommended in order for the |
| 1. Check air inlet filters for dirt and obstruction, clean or | | | | system to be inspected under normal operating |
| replace as necessary. | | | | conditions. |
| 2. During the oxidizer's normal operation, check for fan | | | | The inspection is based upon a comprehensive |
| vibration, abnormal sounds or increased noise levels. | | | | checklist and should be followed up with a written |
| 3. Check the fan mounting bolts to ensure they have | | | | formal report for your records. The formal reports are |
| remained tight. | | | | an important component of a proper maintenance / |
| 4. Visually inspect and listen for unusual sounds during | | | | record-keeping program and are often very helpful |
| poppet valve operation. Valves should shift smooth | | | | when working with local regulatory agencies. In some |
| and evenly in both directions. | | | | cases, record keeping and regular maintenance are |
| 5. Check to ensure all fan/motor guards are in place | | | | required as a component of an air permit. The |
| and properly secured. | | | | checklist is broken down into the following four areas |
| 6. Prior to operating the system, ensure that all oxidizer | | | | of your system: |
| doors and access panels are closed and latched. | | | | 1. Mechanical |
| 7. View the oxidizer and fuel train for leaks or loose | | | | An external and internal inspection of the oxidizers |
| hardware. | | | | mechanical components will be performed. This |
| 8. View all temperature device read-outs to confirm | | | | includes items such as: ductwork, valves, linkage, heat |
| temperature operation is within normal ranges. | | | | exchanger, reactor, fan, motor assembly, burners, |
| 9. View pressure device read-outs for to confirm | | | | catalyst, stack & observation ports. |
| operation is within normal range. | | | | 2. Electrical |
| 10. Verify temperature chart recording device is "On" | | | | The electrical components will be inspected and |
| and recording data. | | | | electrically tested to insure that they are functioning |
| Monthly Maintenance Checks - To be performed by | | | | properly. This includes: switches, lights, relays, timers, |
| the local maintenance staff of the equipment owner | | | | controllers, recorders, motors, starters, actuators, |
| user. | | | | disconnects, and wiring. Additionally, the system's |
| 1. Check the burner linkage and external burner | | | | "Safety Circuit" will be tested for proper operation and |
| components for wear or signs of loosening that could | | | | a new spark ignitor (s) installed. |
| cause gradual slipping out of adjustment. | | | | 3. Process Control Loops |
| 2. Check fan drive belts for correct alignment, | | | | The temperature and pressure control loops should be |
| alignment and wear. The belts should have enough | | | | inspected and tested to verify correct operation and |
| tension to allow only ½" movement when | | | | sequence. This entails a visual inspection and |
| pushed or pulled, up or down by hand. A quick check | | | | adjustment of the air/fuel mixture ratio of the burner, if |
| for alignment can be done by checking the tension on | | | | necessary. Also, an operational review of various |
| the inner and outer belts. The tension should be equal. | | | | controllers, actuators, thermocouples, pressure |
| 3. Remove all pressure switch sensing lines and ensure | | | | switches and variable speed drives will be performed. |
| they are clear and dry. | | | | Technicians should also evaluate the system (or |
| 4. The supply fan/motor bearings should be greased. | | | | catalyst) ready circuit, the inlet and atmospheric |
| Rotate the shaft slowly by hand while applying the | | | | bypass damper circuits, the warning alarm circuits, and |
| grease. Avoid over-greasing. | | | | the shutdown alarm circuits. |
| 5. Drains or weep holes on all fan motors should be | | | | 4. Oxidation Efficiency Test |
| checked for debris and cleaned as necessary. | | | | An optional oxidation efficiency test can be performed |
| 6. Verify Oil level of compressed air Lubricator, add as | | | | by using portable detector units or collecting 1-Hour |
| necessary | | | | process inlet / outlet samples for laboratory analysis. |
| Semi-Annual Maintenance Checks - Can be | | | | This service keeps you alert of any potential problems |
| performed by maintenance staff of the equipment | | | | related to your system's Destruction Rate Efficiency |
| owner/user or an Experienced Service Technician. | | | | (DRE). and is ideal as a pre-test to help eliminate |
| 1. The interior of the oxidizer should be inspected. While | | | | "surprises" during expensive formal compliance testing. |
| inside, inspect the insulation for signs of deterioration, | | | | Upon completion of a PME you will receive a formal |
| damage or gaps. Use extreme caution when entering | | | | evaluation report detailing the current condition of your |
| or exiting the oxidizer to avoid damaging the door or | | | | oxidizer as well as our recommendations for improving |
| the door threshold insulation (if applicable). Clean the | | | | performance, efficiency, reliability and safety. |
| inner lens of the burner view port with a soft, dry cloth. | | | | Additional testing and maintenance ideas to consider |
| 2. Check the ceramic media for buildup of particulate | | | | Repeat Training Sessions: Your maintenance team |
| or residue and visible damage. | | | | may require additional training sessions as a refresher |
| 3. Before closing access doors, inspect the gasketing | | | | or due to employee turnover. |
| replace or repair as necessary to maintain a leak free | | | | Catalyst Maintenance |
| seal. | | | | If your system includes catalyst, regular evaluation is |
| 4. Visually inspection (only) of poppet (flow control) | | | | key to maintaining catalyst performance. A standard |
| valve shafts, seats, and disks. | | | | laboratory activity test should be performed yearly, |
| · Access by removing access doors. | | | | with additional follow-up testing as necessary. A formal |
| · CAUTION: To be performed by trained | | | | evaluation report will be provided. Catalyst services |
| authorized personnel only, after adhering to all | | | | such as catalyst rejuvenation or catalyst replacement |
| Lock-Out/Tag-Out safety precautions. | | | | may be necessary. Make sure to inquire about a |
| · Note: The poppet (flow control) valves may | | | | "catalyst buy-back" program for spent catalyst. |
| shift without warning if the mechanical pins are not | | | | |