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How To Properly Maintain And Service Your Oxidizer
Your air pollution control system represents a significant investment in
not only initial capital but also ongoing maintenance and operation.
Routine inspections performed by your staff combined with thorough maintenance
plans provided by Anguil Environmental Service Technicians will ensure
you get the most from your investment over the entire life of the system.
Anguil has almost three decades of experience servicing a full range
of oxidizer technologies, regardless of manufacturer, make or model.
Following the recommendations made below will help keep your system operating
both efficiently and effectively, reducing costly repairs and avoiding
downtime.
Routine Inspections: It is our goal here at Anguil to provide owners
of our equipment the necessary checklists and training to comfortably
perform the routine inspections with their own personnel. In the event
you own another manufacturer’s equipment the checklist below may vary slightly.
Inspections include a combination of equipment checks on the "high use" items
and data recording to build a history of unit performance. When performing equipment
checks refer to manufacturer's O&M Manuals for detailed procedures. For the
data-gathering items, refer to historical data and note any significant changes
from typical values.
- Check air inlet filters for dirt and obstruction, clean or replace as necessary.
- During the oxidizer’s normal operation, check for fan vibration,
abnormal sounds or increased noise levels.
- Check the fan mounting bolts to ensure they have remained tight.
- Visually inspect and listen for unusual sounds during poppet valve
operation. Valves should shift smooth and evenly in both directions.
- Check to ensure all fan/motor guards are in place and properly secured.
- Prior to operating the system, ensure that all oxidizer doors and access
panels are closed and latched.
- View the oxidizer and fuel train for leaks or loose hardware.
- View all temperature device read-outs to confirm temperature operation is
within normal ranges.
- View pressure device read-outs for to confirm operation is within normal
range.
- Verify temperature chart recording device is “On” and
recording data.
- Check the burner linkage and external burner components for wear or signs of
loosening that could cause gradual slipping out of adjustment.
- Check fan drive belts for correct alignment, alignment and wear. The belts
should have enough tension to allow only one-half-inch movement when pushed
or pulled, up or down by hand. A quick check for alignment can be done by checking
the tension on the inner and outer belts. The tension should be equal
- Remove all pressure switch sensing lines and ensure they are clear and dry.
- The supply fan/motor bearings should be greased. Rotate the shaft slowly by
hand while applying the grease. Avoid over-greasing.
- Drains or weep holes on all fan motors should be checked for debris and cleaned
as necessary.
- Verify Oil level of compressed air Lubricator, add as necessary.
- The interior of the oxidizer should be inspected. While inside, inspect the
insulation for signs of deterioration, damage or gaps. Use extreme caution
when entering or exiting the oxidizer to avoid damaging the door or the door
threshold insulation (if applicable). Clean the inner lens of the burner view
port with a soft, dry cloth.
- Check the ceramic media for buildup of particulate or residue and visible damage.
Before closing access doors, inspect the gasketing replace or repair as necessary
to maintain a leak free seal.
- Visually inspection (only) of poppet (flow control) valve shafts, seats, and
disks. Access by removing access doors.
- Remove the UV scanner and clean the view lens with a lint free cloth.
- Replace the spark ignitor.
- Verify burner flame visually at burner or system Peep-Site for:
- Color - Color should typically be “Blue” with “Orange/Yellow” tips.
- Intensity – Verify flame strength, flame should not be “Lazy”,
verify at several different firing rates.
- Inspect the exterior of the burner for damage or areas showing excessive heat.
- Inspect all fan flex joints and replace as necessary
- The T-dampers and linkage (if applicable) should be inspected for proper operation
and the linkage checked for tightness.
The Anguil Preventive Maintenance Evaluation (PME) is a two-day thorough evaluation
of your system performed by a qualified Anguil Service Technician. Typically,
PMEs are scheduled on an annual or semi-annual basis. It does require the system
be cooled down and not running for one day to complete the internal inspection.
On the second day of a PME the availability of process airflow is recommended
in order for the system to be inspected under normal operating conditions.
The inspection is based upon a comprehensive checklist followed up with a written
formal report for your records. The formal reports are an important component
of a proper maintenance / record-keeping program and are often very helpful
when working with local regulatory agencies. In some cases, record keeping
and regular maintenance are required as a component of an air permit. The checklist
is broken down into the following four areas of your system:
- : An external and internal inspection of the oxidizers mechanical
components will be performed. This includes items such as: ductwork, valves,
linkage, heat exchanger, reactor, fan, motor assembly, burners, catalyst, stack & observation
ports.
- : The electrical components will be inspected and electrically tested
to insure that they are functioning properly. This includes: switches, lights,
relays, timers, controllers, recorders, motors, starters, actuators, disconnects,
and wiring. Additionally, the system’s "Safety Circuit” will
be tested for proper operation and a new spark ignitor(s) installed.
- : The temperature and pressure control loops will be inspected
and tested to verify correct operation and sequence. This entails a visual
inspection and adjustment of the air/fuel mixture ratio of the burner, if necessary.
Also, an operational review of various controllers, actuators, thermocouples,
pressure switches and variable speed drives will be performed. We will also
evaluate the system (or catalyst) ready circuit, the inlet and atmospheric
bypass damper circuits, the warning alarm circuits, and the shutdown alarm
circuits.
- : If requested - an optional oxidation efficiency
test can be performed by using portable detector units or collecting 1-Hour
process inlet / outlet samples for laboratory analysis. This service keeps
you alert of any potential problems related to your system’s Destruction Rate Efficiency
(DRE) and is ideal as a pre-test to help eliminate “surprises” during
expensive formal compliance testing.
Upon completion of a PME you will receive a formal evaluation report detailing
the current condition of your oxidizer as well as our recommendations for improving
performance, efficiency, reliability and safety.
: Your maintenance team may require additional training
sessions as a refresher or due to employee turnover. Anguil will travel to
your site and perform follow-up training sessions, often coupled with any of
the inspection visits listed above.
: If your system includes catalyst - Anguil can help you
remain in compliance and build a catalyst performance history with regular
testing of your catalyst. Regular evaluation is key to maintaining catalyst
performance. A standard laboratory activity test should be performed yearly,
with additional follow-up testing as necessary. A formal evaluation report
will be provided. Additionally, Anguil can provide other catalyst services
such as catalyst rejuvenation, catalyst replacement, and also a “catalyst buy-back” program for
spent catalyst.
About the Author: Jerry Sikora is the Parts & Service Sales Manager for Anguil
Environmental Systems. He is responsible for aftermarket program activities such
as equipment Spare Parts Packages, Preventive Maintenance Evaluations (PMEs),
Maintenance Contracts, and General Services. Jerry has over thirteen years of
experience commissioning ovens and air pollution control equipment. He can be
reached at: (414) 365-6400.
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