RTO_Operating_Manual

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					21 Unionville Road,PO Box 568   Douglassville, PA 19518   (610) 323-7670




          12,000 SCFM REGENERATIVE THERMAL OXIDIZER

                OPERATION AND MAINTENANCE MANUAL
                              TABLE OF CONTENTS

Chapter 1 – Operation and Maintenance Manual
       Section 1 – Scope of Manual
       Section 2 – General Description of System
       Section 3 – Description and Function of Components
       Section 4 – Sequence of Operations
       Section 5 – Maintenance (with Spare Parts List)

Chapter 2 – Bill of Materials
       Section 1 – RTO Component List
       Section 2 – RTO Electrical List

Chapter 3 – Drawings
       Section 1 – Mechanical Drawings
       Section 2 – Process & Instrumentation Drawings
       Section 3 – Electrical Schematics

Chapter 4 – PLC Program
       Section 1 – Mechanical Drawings
       Section 2 – Process & Instrumentation Drawings

Chapter 5 – Vendor Literature
       Section 1 – Panel Instrumentation
               Purge Timer Relay
               General Purpose Time Delay Relays
               Power Transformer
               Fireye Amplifier Module
               Fireye Modular Flame Supervisor
               Fireye Programmer Module
               Honeywell Chart Recorder
               Honeywell Digital Controller
               Ethernet Switch
               Grace Port Ethernet Port/Receptacle
               Circuit Breakers / Contactors
               Push/Pull Operator pushbutton
               General Purpose 2 Pole Relays
               3 KVA Control Transformer
               IEC Contactor 10HP
               Main Circuit Breakers 3 Pole
               24 Volt DC Power Supply
       Section 2 – PLC & HMI
               Allen-Bradley SLC-5/05
               Panelview Plus 1000 Touch Screen
       Section 3 – RTO Field Instrumentation
                      TABLE OF CONTENTS

        NESTEC Inc. Temperature Control Thermocouples
        Pressure Switches
        Pressure Transmitter
Section 4 – RTO Fan & Motor
        Chicago Blower RTO Fan
        RTO Fan Motor
Section 5 – Variable Frequency Drive
        Allen Bradley Power Flex 700 Vector VFD
        Allen Bradley Input Line Reactors
Section 6 – Combustion System
        American Fan Combustion Air Blower
        Combustion Air Pressure Switch
        Low Gas Pressure Switch
        Pilot Solenoid Valves
        High Gas Pressure Switch
        Ignition Transformer
        Fireye UV Flame Scanner
        Pilot Gas Regulator
        Fuel Control Valve Motor(s)
        Ball Valves
        Maxon Kinemax Burner / Spark Ignitor
        Maxon Safety Shut-off Valves
        Maxon MicroRatio Fuel Control Valve
        Pressure Gages
        Rubber Boot Coupling
        Y-Strainer
        Main Gas Regulator
        WEG Combustion Air Fan Motor
Section 7 – Poppet Valves and Pneumatic Air System
        Allen-Bradley Proximity Switches
        Ball Valves
        Pressure Relief Valve
        Pressure Gages
        NESTEC Poppet Drawings
        Poppet Valve Air Cylinders
        Solenoid Valves
        Filter / Regulator
        Pressure Switch



Section 8 – Dampers / Actuators
        Solenoid Valve
                     TABLE OF CONTENTS

       Fresh Air Actuator
       Isolation Damper Actuator
       Position Indicator

Section 9 – Miscellaneous RTO Items
        NESTEC Inc Heat Exchange Media
        Ceramics Fiber
    CHAPTER 1  OPERATIONAL INSTRUCTIONS


                          Section 1 – Scope of Manual
This manual covers the NESTEC, Inc. Regenerative Thermal Oxidizer (RTO) Installation.
The manual is intended for use by plant operations and maintenance personnel. The
manual covers emergency shutdown procedure, overall description of the equipment,
process, operation, and maintenance of the NESTEC RTO system. The description of the
operation includes system start-up, shutdown, and safety procedures. The maintenance
section describes recommended maintenance, record keeping, and lists required to
properly maintain the system. It also provides a list of recommended spare parts with any
special tool requirements. For any questions not addressed in the manual, please contact
NESTEC, Inc at either of the following numbers:

      Rick Reimlinger            (908) 233-3709 – Office
                                 (215) 692-4607 – Mobile
      Frank DeSantis             (201) 437-9001 – Office
                                 (215) 692-4608 – Mobile
      Jim Nester                 (610) 323-7670 – Office
                                 (215) 565-6189 - Mobile
      Lewis Hastings             (843) 294-2625 – Office
                                 (908) 247-3117 – Mobile

1.2 Emergency Procedure

NOTE: Operation of the RTO system is simple and emergency shutdown straightforward.
The system is controlled by a PLC (Programmable Logic Controller), so the operator can
initiate the Emergency Stop with one button. Upon depressing the E-Stop button the PLC
will lose all control power, instantaneously stopping all motors and other control devices.
The E-Stop feature should be used in an EMERGENCY SITUATION ONLY. It is not
intended to replace the normal shutdown procedure controlled by the PLC. Repeated use
of the emergency shutdown could result in equipment damage. For a description of the
normal shutdown procedure please see Section 4 – Sequence of Operations, page 4-1, in
this manual.
                         TABLE OF CONTENTS

Emergency Shutdown

  1. Press the RTO E-Stop Button. This button is located on the main control panel.
  2. Notify Operations Supervisor Immediately.
    CHAPTER 1  OPERATIONAL INSTRUCTIONS


              Section 2 – General Description of the System
The NESTEC Regenerative Thermal Oxidizer (RTO) is designed to operate at a production
facility. The RTO is designed to remove volatile organic compounds (VOCs) from the
exhausted gas stream from the plant process. The purpose for this equipment is to control
odor/opacity, VOC emissions or, in general comply with regulatory emission standards for
the production facility. As such, operation of the plant process without operation of this
unit could be in violation of State and Federal Laws. Please consult the Air Permit and / or
your facilities environmental manager before operating or maintaining this equipment.

Removal of VOCs is accomplished by increasing the temperature of the effluent stream to
approximately 1,500°F. At this temperature most VOCs will oxidize. The resulting
products are carbon dioxide and water vapor.

At the inlet of the RTO is a centrifugal fan, which is designed to pull the gas stream from
the process and push it through the equipment. This is termed a “forced draft” system.
The internal pressure in the RTO is therefore always positive and will range from a
maximum of approximately +16 inches of water column at the fan discharge to +0 inches of
water at the stack. Downstream of the fan, the RTO ducting leads to either of two diverter
valves that control the process gas flow direction through the RTO. These diverter valves
are pneumatically controlled “poppet” type valves and operate very quickly in tandem.
The valves will shift approximately every three minutes. Above each of the two dampers
is a heat recovery chamber, normally identified as either chamber “A” or chamber “B”;
referenced from the burner side of the RTO system. In each chamber is ceramic heat
transfer media that acts as a heat sink.

The two heat recovery chambers are connected by a common combustion chamber. The
combustion chamber contains the burner. The burner is fueled by natural gas (and/or
diluted LP) and is used to initially heat up the system to oxidation temperature and
control the oxidation temperature during operation.

During normal operation, the diverter valves direct the flow of the gas stream into the
media bed of one of the chambers (for discussion purposes called chamber “A”) where the
stored heat in the media increases the temperature of the gas stream. The gas stream then
enters the combustion chamber where the temperature is maintained at approximately
     CHAPTER 1  OPERATIONAL INSTRUCTIONS

1,500°F. The process gas then passes down through heat recovery chamber “B” where heat
is collected in the ceramic media. The gas stream is then is pushed through second diverter
valve, the exhaust stack, and out to atmosphere.

After a predetermined time (approximately 3 minutes), the diverter valves will shift and
change the flow direction so that the process gas enters chamber “B” and exits from
chamber “A”. This type of heat recovery is termed “Regenerative”. Based on normal
operating conditions, a typical temperature rise or increase from the inlet to the outlet of
the RTO system is 80 - 125°F (operating above 93% Thermal Efficiency).
    CHAPTER 1  OPERATIONAL INSTRUCTIONS

         Section 3 – Description and Function of Components

This section will identify the major and ancillary components of the NESTEC, Inc RTO and
describe the design specifications and the basic function of each. The P&ID reference
number for each component will be noted, when applicable. A Bill of Materials is also
included that will identify the specific model or part number of each item, an instrument
number to correlate the item to the P&ID drawing, and the tab section reference that
contains the specific catalogue cut.

3.1 Fresh Air / Isolation Dampers

The process air enters the NESTEC, Inc RTO system through a single inlet duct pulling
VOC laden air from the process exhaust points or production source. This single inlet duct
supplies process air to this new NESTEC Inc RTO and the existing RTO-1. Should the
RTO system loose the “RTO Ready” signal, the RTOs fresh air inlet damper FV-101 will
fully open. The isolation damper FV-100 will close at the same time the fresh air damper
opens. At this point, the process air stream will continue to enter RTO-1 if operational, or
spill to atmosphere if the process is equipped with vent to atmosphere dampers (by
others). This action will also cause the variable frequency drive (VFD) to reduce to
minimum speed (typically set at approximately 20 Hz). Limit switches located within each
actuator will verify the full open and closed position of each damper listed above.
Proximity switches (ZSO-101, ZSC-101) verify the full open and closed position of the
fresh air damper. All damper actuators as provided by NESTEC are detailed in the Bill of
Materials (BOM). Fresh air enters the RTO system through the fresh air inlet damper FV-
101. The fresh air / isolation / abort dampers all work together to allow clean air to enter
the RTO during the purge, start up, warm up or emergency sequences while blocking the
flow of process air. The abort damper (by others) allows process effluent to be diverted to
the atmosphere during process emergencies or down periods of the RTO.
    CHAPTER 1  OPERATIONAL INSTRUCTIONS

3.2 Main System Fan and VFD

The main system fan FN-100 is a forced draft (ID) centrifugal fan that pushes process gas
through the heat recovery beds, the burner chamber, and out through the exhaust stack.
The fan is manufactured by Chicago Blower and has the following design specifications:




            14,654 ACFM at 0.073 pounds per cubic foot density
            3500 RPM (nominal)
            31.6” wc static pressure
            Arrangement 4, SWSI, CW rotation, bottom horizontal discharge

The fan is driven by a direct-coupled motor M 100. The motor is a premium efficiency motor
rated for inverter duty and with the following design specifications:
              460 Volts / 60Hz / 3phase
              3600 RPM, TEFC
              405TS Frame
              100HP
The flow of process gas delivered by the system fan is automatically controlled by an Allen
Bradley Power Flex 700 vector series variable frequency drive, VFD-100. A pressure
transmitter (PDT-100) which is located in the inlet duct and upstream of the isolation
damper (FV-100) continuously measures static pressure. The PLC makes speed
adjustments to the VFD via a PID loop (within the PLC) with static pressure being the
control variable. This pressure transmitter will work in tandem with the pressure
transmitter located on the existing RTO-1. The VFD has the following design
specifications:

           100 HP variable torque
           4-20mA control signal
           120V digital I/O remote start/stop, drive fault and drive running signals.
           HMI for monitoring located on main panel exterior.
The differential pressure across the RTO unit is measured by a pressure switch (PDSL-
100). The direction of gas flow through the RTO is proved by two pressure switches
(PDSL-104 and PDSL-105).
    CHAPTER 1  OPERATIONAL INSTRUCTIONS

During periods of low process exhaust volume (approximately 25% of rated capacity or
below), the fresh air damper will modulate open, bleeding in sufficient fresh air to make
up the difference between the actual process volume and that needed to operate the RTO.
This system will split range the signal from the pressure transmitter feeding the lower
range to the RTO VFD and the upper range to the modulating fresh air damper. As the
process volume drops below minimum flow for the RTO, the VFD will automatically slow
to minimum speed, after which, the fresh air damper will modulate to maintain proper
suction pressure in the duct system. The RTO will only operate in this mode when the
RTO is Ready, the process isolation damper is open (On-Line), and the VFD has reached its
minimum speed.

3.3 Poppet (Diverter) Valves

The RTO has two main diverter valves (FV-104, left and FV-105, right) that direct the
process gas flow into and out of the heat recovery chambers. They are a “poppet” style
flow control valve designed and custom fabricated for each project. The body, seats and
disks are constructed of mild steel and the shaft is constructed from 304L stainless steel.
The seats have a machined metal surface that gives an airtight metal to metal contact
between the disc and the seat. The valves are pneumatically actuated and are very fast
acting to minimize the loss of un-destructed VOCs when the valves switch. The valves are
designed to operate up to 750 degrees F. The pneumatic actuators (P-104 and P-105) are 6”
diameter bore with a 12.75” stroke length. They are manufactured by Numatics, Inc., and
have a nominal static thrust of 1,960 pounds at 70 psi air pressure. A four way, two port,
two position (spring return) solenoid valve (SV-104, left and SV-105, right) controlled by
the PLC operates each pneumatic actuator. The position of the actuator is verified by
proximity switches (ZSO-104 / ZSC-104, left and ZSO-105 / ZSC-105, right). The RTO is
equipped with an air accumulator manifold that will provide a minimum of three
actuations in the event of a loss of compressed air pressure. These tanks are equipped
with a pressure relief valve (PSV-101), condensate drain valve (HVD-101), low pressures
switch (PSL-101), and pressure indicator (PI-101).

3.4 Heat Recovery Chambers

The RTO has two heat recovery chambers. These vessels are lined with 10# density
ceramic fiber modules. The coldface support grid is filled with 1” ceramic saddles for air
distribution and the regenerative chambers are each filled with NESTEC Inc 40-Cell
structured media. The temperature at the middle of the heat recovery chambers is
    CHAPTER 1  OPERATIONAL INSTRUCTIONS

monitored by thermocouples embedded in the ceramic media (TE-103, chamber “A” and
TE-106, chamber “B”) which is transmitted back to the PLC control system for display on
the PanelView screen. The function of the heat recovery chamber is to act as a heat sink.
As the hot process air leaves the combustion chamber the heat is transferred to the ceramic
media and this media hold this heat until flow is reversed. When the flow is reversed the
process air entering the RTO will pass through the ceramic media and the heat energy
absorbed from the last cycle is transferred to the incoming flow thus preheating it. Since
the thermal recovery of the RTO system is above 93%, the unit is able to operate with a
much smaller burner.
    CHAPTER 1  OPERATIONAL INSTRUCTIONS


3.5 Burner / Combustion Chamber

The RTO is equipped with one burner located on the side of the combustion chamber. The
function of the burner is to pre-heat the combustion chamber to oxidation temperature at
start up, and to maintain oxidation temperature during operation. The burner system
includes a combustion air system and gas train. It is a pre-piped system designed for
approval by Factory Mutual (FM). All gas train components are UL listed and designed for
normal operating environment so that the system is in compliance with NFPA
requirements. The burner has a maximum output of 2,400,000 BTU/hr. and a turndown
ratio of approximately 10:1. The burner is equipped with a high temperature hard
refractory discharge sleeve to protect the soft refractory lining in the vessel and allow for
long life times. The combustion air system is composed of a blower (FN-140) to supply the
combustion air and a flow control valve (FFC-133, micro-ratio valve) that regulates the
amount of combustion air to the burner. The flow control valve is linked to a modulating
valve (M-133) on the gas train. Therefore, the desired air to fuel mixture is always
maintained. The combustion blower is manufactured by American Fan Company and is
all steel construction with a direct drive design with a 10 HP, 3600 RPM motor. The rated
delivery of the fan is 434 ACFM at 48.6” static pressure. The gas train consists of an
assembly to supply natural gas to the burner, the fuel enhancement valve (optional), and
the burner pilot flame. The main components of the burner feed assembly are a main
pressure control regulator (PCV-131), a block arrangement with two automatic blocking
valves (FSCV-131, FSCV-132), and a micro-ratio valve (FFC-133) that modulates the flow
of fuel to the burner. The micro ratio valve is linked to the combustion air valve as
discussed above and has an electric actuator that is modulated by an analog signal from
the PLC. A pressure control valve (PCV-133) and two solenoid valves (FSCV-134, FSCV-
135) control the fuel to the pilot flame.
    CHAPTER 1  OPERATIONAL INSTRUCTIONS

3.6 Control Panel and PLC components

The operation of the RTO unit is controlled from a custom-built control panel that houses
an Allen Bradley SLC series PLC 5/05 processor system. There is one PLC system for the
RTO unit. All reference material for the PLC system can be found in CHAPTER 5 –
VENDOR LITERATURE section of this manual. The PLC system is supplied with
additional I/O points for use by the client that will permit a “process ready” signal to be
sent to the oxidizer PLC and will also send an “oxidizer ready” signal that can be used by
the client’s process equipment to facilitate process tie-in. Each system is equipped with the
following major components and features:
     Allen Bradley processor, power supplies, thermocouple input cards, analog input
        cards, analog output cards and discrete digital I/O cards.
     The main operator interface terminal will be an Allen Bradley PanelView 1000, plus.
        This terminal will allow an operator to monitor the operation of the system, change
        set points, and start/stop the system.
     A Tru-Line circular chart recorder.
     A flame supervision system that provides safeguards for the burner operation.
     A high combustion chamber temperature-limiting device that protects the vessel
        from damage due to extreme heat.
     An external mounted VFD HMI operator keypad.
     A duplex GFI utility receptacle with ethernet port.
     Panel alarm sounder.
     Emergency stop pushbutton.
    CHAPTER 1  OPERATIONAL INSTRUCTIONS

                        Section 4 – Sequence of Operations

This section will describe the operation of the NESTEC RTO system. The sequencing of
the RTO is controlled by the Allen Bradley SLC 5/05 Series PLC that makes the operation
fully automatic and straightforward.
4.0 Startup Checklist
The following checklist should be followed prior to startup:
   1. Ensure that NO ONE is inside the RTO unit and that all access doors are bolted
       tightly in place.
   2. Ensure that all hand valves on the gas train and on the piping leading to the burner
       and fuel injection are open.
   3. Ensure that all hand valves on the pneumatic lines are open.
   4. Ensure that all hand valves on the pneumatic control lines are open.
   5. Ensure that all lock out devices have been removed and that all breakers are in the
       closed position.

4.1 Startup

Start up of the RTO unit can be initiated by utilizing the function keys at the bottom of the
Allen Bradley PanelView 1000 Plus human to machine Interface (HMI) module located on
the front of the main control panel. All usable function keys/buttons are labeled as
described throughout this section. In addition, the upper center portion of the HMI will
identify the current mode/status of the system and the upper left-hand corner will identify
the current screen name.
4.1.1 System Start
Energize the main panel power supply 480VAC disconnect switch. The following steps
must be followed to initiate a start when all the power circuits are on:
   1. Access the startup screen on the HMI. This is accomplished by pressing the startup
      screen navigation button located at the lower portion of each screens display area.
   2. From the startup screen press the system stop operator function button. This action
      will reset the system to pre-start ready state.
   3. Press the system start operator function button. This action will now start the
      system fan and the combustion blower.
    CHAPTER 1  OPERATIONAL INSTRUCTIONS

   4. Should any failure occur during this start up sequence the failed status component
      indicator (located in the screen center) will illuminate red or remain red, indicating
      the point of sequence failure.
   5. When the compressed air, system fan and combustion blower indicators are
      established and the Limits Complete indicator is green, then a burner start
      command is now required to complete the startup process. At this time, press the
      start burners operator function button.

This action begins a burner pre-purge sequence that typically will last 3–4 minutes and is
required to purge the unit by exchanging the air in the unit four times. The purge state
indicator will change to “purging” and be illuminated in yellow.

Following a successful unit purge, the “purge complete” indicator will be green. An
automatic (10 second) trial for ignition sequence of the burner will then begin. During this
burner ignition sequence side bar indicators will show status of ignition transformer and
pilot gas solenoid operation. When a suitable Flame signal value is detected then the main
fuel valve will indicate open green and pilot and ignition sidebars will extinguish to red.
The burner indicator will be “burner on”, green.

Once burner main flame operation is established, the PLC will start modulating fuel flow
to the main burner and the unit will begin/continue to warm up. Warm up can take up to
three hours depending on the temperature inside the unit prior to startup. Once the unit
has reached operational temperature (approximately 1,650° F) the unit will “soak” at this
temperature for a period of time (30 - 60 minutes). Once the soak cycle time has completed
the unit is now ready to accept process air. Process air may be diverted into the RTO once
the RTO isolation damper (FV-100) is open and the RTO fresh air damper (FV-101) has
been commanded to it’s normal “process online” operational position.

4.2 Shutdown

There are two different shutdown modes depending on the purpose for the shutdown.
The first shutdown mode is called a retained heat shutdown. This mode is used when it is
desirable to keep as much heat in the recovery chambers as possible. The second mode is
called the maintenance shutdown. This shutdown is used when it is desirable to cool the
unit down to ambient outside conditions.
    CHAPTER 1  OPERATIONAL INSTRUCTIONS


4.2.1 Retained Heat Shutdown
A retained heat shutdown can be initiated using the operator function button located on
the HMI startup screen. The following steps must be followed to initiate a retained heat
shutdown:
   1. Access the startup screen in the HMI as previously described in section 4.1.1.
   2. Once in the startup screen press the r-h shutdown operator function button. This
       will immediately take the unit offline and after sixty seconds the burner system and
       the draft fan will shut down. When the fan has reached zero RPM the diverter
       valves will then go to their retracted position holding the heat within the recovery
       chambers.


4.2.2 Maintenance Shutdown
A maintenance shutdown can be initiated using the function keys on the HMI. The
following steps must be followed to initiate a maintenance shutdown.
    1. Access the startup screen in the HMI as previously described in section 4.1.1.
    2. Once in the startup screen press the maint shutdown operator function button. This
       will immediately take the unit offline and shutdown the burner system. The draft
       fan will remain in operation and the diverter valves will cycle until the unit has
       cooled to 200° F. At this time the fan will stop and when it has reached zero RPM
       the diverter valves will go to their retracted position.

4.3 HMI Interface: (PanelView Plus Touch Screen Terminals)

4.3.1 Screen Conventions and Operator Interactions
As an aid to operator navigation and familiarization all screens will conform to the
following standard color and icon style formats as described below:
         Dark Blue (Raised) – Screen navigation push buttons.
         Yellow (Raised) – Operator function pushbuttons momentary contact state.
         Green (Raised) – Operator function pushbuttons maintained contact state.
          Green/Red alternates to indicate contact state.
         Red/Green/Yellow (Indent) - Multifunction indicators for system status. Green
          normal, red abnormal, yellow or other intermediate state.
         Cyan screen header banners – Indicates screen name, system operating mode and
          current time. No operator function.
    CHAPTER 1  OPERATIONAL INSTRUCTIONS

         Red Terminal (Raised) – Special operator function pushbutton returns terminal to
          it’s configuration mode menu.
         Alarms Red/Green (Indent) – Indicator box red indicates an Alarm State.
         Light Blue – Numeric indicator box typically on PID loop screens. Allows operator
          input of numeric data.
         White Text Black Background – Status or numeric syatem information only.



4.3.2 Welcome Screen
Upon initial system power up the welcome screen is displayed. The welcome screen
displays information pertaining to contacts at NESTEC as well as the screen navigation
buttons that allow an operator to select other screens within the system.
4.3.3 System Status Screen

From any screen pressing the system status screen navigation button will access this
screen. The screen provides a convenient quick overview of general system status and
equipment conditions.

4.3.4 Overview Screen
From any screen pressing the overview screen navigation button displays the overview
screen. The top of the overview screen displays the screen title, the system status bar and
the current time of day. This screen displays the states of primary components such as the
system fans, the fresh air and isolation dampers, burner, diverter valves and time
remaining until the next diverter shift. This screen also displays instrument readings such
as inlet, outlet, and combustion chamber thermocouple readings, as well system inlet
pressure transducer readings. The alm silence operator function button allows the
operator to silence the alarm horn. The step bakeout operator function button allows an
operator to manually step through all five phases of a normal bakeout operation if it is
desired to bypass any of the normal automatic bakeout stages. See section 4.4.3.
4.3.5 Chamber Temps Screen
From any screen pressing the chamber temps screen navigation button displays the
chamber temps screen. The top of the chamber temps screen displays the screen title, the
system status bar and the current time of day.
 This screen displays the states of primary components such as the burner, diverter valve
position, bakeout mode diverter valve configuration, thermal auto correction mode
feature, bakeout step position, bakeout stage temperature setpoint entry operator function
     CHAPTER 1  OPERATIONAL INSTRUCTIONS

buttons and the time remaining until the next diverter shift. This screen also displays the
combustion chamber temperature, heat recovery mid-bed temperature and hopper exit
temperature. In addition to the step bakeout operator function button previously
described, a thermal balance auto mode operator function button and a bakeout sw off
operator function button is available from this screen. Related numeric operator input
function buttons are also provided. These operator functions are listed below:

   Thermal balance auto mode, see section 4.4.7.
   Thermal balance manual mode, see section 4.4.8.
   Bakeout switch, see section 4.4.3.
   Stage SP numeric inputs, see section 4.4.3.
   A + B Outlet time numeric inputs, see section 4.4.8.
4.3.6 Startup Screen
From any screen pressing the startup screen navigation button displays the startup screen.
The top of the startup screen displays the screen title, the system status bar and the current
time of day. The startup screen contains the system start and systems stop function
buttons, the stop burners and start burners function buttons, the r-h shutdown and maint
shutdown function buttons and burner reset operator function button. In addition, this
screen also contains other operator function buttons if available, such as soak bypass, idle
sw off, bakeout sw off described elsewhere in this manual. The primary purpose of this
screen is to display the expected normal start up sequence for the major components such
as system fan, the combustion fan, purge interlocks and burner, fuel enhancement valve
(optional). The alm silence function button allows the operator to silence the alarm horn,
while other screen navigation buttons allow the operator to select other screens within the
system.
4.3.7 PID Control Screen
From any screen pressing the pid control screen navigation button displays the pid control
screen. The top of the control screen displays the screen title, the system status bar and the
current time of day. The control screen displays the status of the system control loops.
Selection of auto/manual output mode control for any loop is available depending on the
current operating status of the system. Generally speaking auto manual mode selections
are only available when the equipment is in a normal state and is oxidizer ready. Manual
mode will allow an operator to input a % output value via the numeric entry input
function key for manual control of the 4-20 ma control loops. Setpoint entry function keys
      CHAPTER 1  OPERATIONAL INSTRUCTIONS

are provided that allows the operator to set specific operating parameters for their process
requirements.
4.3.8 Alarms Screen
From any screen pressing the alarms screen navigation button displays the alarms screen.
The top of the firstout screen displays the screen title, the system status bar and the current
time of day. This screen displays normal / failure status of the fans, burner, system, and
thermocouples. The alm silence operator function button allows the operator to silence
the alarm horn, while the alarm reset operator function button allows the operator to clear
and reset an alarm that is no longer valid. A description of each alarm tag is as follows:

I.      Burner Shutdown Types:

    Compressed air pressure switch tag transitions from green to red indicating loss of
     system air pressure.
    High combustion chamber temp limit tag transitions from green to red indicating the
     temperature in the combustion chamber is above the high limit setpoint. Manual reset
     is required at the device.
    Low gas pressure tag transitions from green to red indicating loss of gas pressure to
     the main burner (manual reset required).
    High gas pressure tag transitions from green to red indicating high gas pressure to the
     main burner (manual reset required).
    Delta pressure switch inlet to chamber tag transitions from green to red indicating the
     differential pressure across the RTO inlet and burner chamber is above the alarm limit.
    Delta pressure switch chamber to outlet tag transitions from green to red indicating
     the differential pressure across the burner chamber and RTO outlet is above the alarm
     limit.
    System draft air pressure switch tag transitions from green to red indicating that the
     system airflow switch contact is not closed.
    Combustion air/flow switch tag transitions from green to red indicating that the
     combustion airflow switch or blower starter auxiliary contact is not closed.
    High exhaust temperature limit (Option) tag transitions from green to red indicating
     the temperature of the RTO exhaust is above the high limit setpoint (this is a manual
     reset push button).
       CHAPTER 1  OPERATIONAL INSTRUCTIONS

II.      Burner Will Not Light Status:

     Burner on/off tag transitions from green to red indicating that the main burner has
      failed. (Operator burner reset required from start up screen and alarm reset from the
      alarms screen).
     Purge time has been altered tag normally only visible if true indicating that the hard
      wired purge timer relay has been set to a value of less than 3 minutes.
     Low fire position interlock tag normally only visible if the burner gas/air valve
      damper is not at low fire position prior to a burner ignition attempt.
        CHAPTER 1  OPERATIONAL INSTRUCTIONS


III.      Loss Of Oxidizer Ready Types:

      E-Stop engaged tag transitions from green to red indicating that an Emergency Stop
       button has been pressed on either the main or remote control panels.
      Low process static pressure (positive value above 0) tag transitions from green to red
       indicating the inlet static pressure is below the alarm limit.
      High process static pressure (negative value below 0) tag transitions from green to red
       indicating the inlet static pressure is below the alarm limit.
      High system differential pressure tag transitions from green to red indicating the
       differential pressure across the RTO is above the alarm limit.
      Poppet status normal / oxidizer airflow failure multifunction tag transitions from
       green to red indicating a failure in the diverter poppet valves A or B.
      Chbmr temp too low for oxidizer ready tag normally only visible if oxidizer ready
       state has been lost due to a fall in burner chamber temperature. Transitions to red
       indicating the temperature in the combustion chamber is below the alarm value.
      Chbmr temp too hot for oxidizer ready tag normally only visible if oxidizer ready
       state has been lost due to an increase in burner chamber temperature. Transitions to
       red indicating the temperature in the combustion chamber is below the alarm value.
      High chamber temp (warning only) tag transitions from green to red indicating the
       temperature in the combustion chamber is approaching the alarm limit.
      Low chamber temp (warning only) tag transitions from green to red indicating the
       temperature in the combustion chamber is below the alarm limit.
      High outlet temperature multifunction tag transitions from green to red indicating the
       various high outlet temperature conditions and consequences.
      All thermocouples valid tag transitions from green to red indicating that one or more
       thermocouples are above alarm limits. See T/C alarms screen for individual values.
      Fresh air inlet damper ok tag transitions from green to red indicating that the fresh air
       damper (optional) is not properly positioned for system startup and purging.
      Process inlet damper ok tag transitions from green to red indicating that the process
       isolation damper (optional) is not properly positioned for system startup and purging.
      Main fan VFD fault tag transitions from green to red indicating that the main process
       fan VFD is in a fault condition.
      Purge min temp bypassed tag normally only visible if the heat soak function has been
       selected with a chamber temperature that is too low.
       CHAPTER 1  OPERATIONAL INSTRUCTIONS

IV.      T/C Alarms:

     Any of the thermocouple status tags transitioning from green to red indicates that that
      particular thermocouple has failed.

V.       Alarm History:

     The alarm history status screen will hold and record individual alarm occurrences with
      a time/date stamp until such time as the alarm clear history operator function button is
      pressed.

4.4 Operating Modes

4.4.1 Normal Operation
The Regenerative Thermal Oxidizer Systems operation is initiated from the startup screen.
Pressing the system start operator function button starts the system fan and the
combustion blower providing the compressed air pressure switch is made. The diverter
valves begin cycling on a time only basis and the system fan runs at a fixed minimum
speed (approximately 20 Hz). The system fan and combustion blower status indicators
transition from red to green indicating normal operation. The limits complete indicator
transitions from red to green indicating that the burner is ready to be started and the start
burner indicator will blink. Burner operation is started by pressing the start burners
operator function button, the remaining status indicators will transition from red to green
in the following sequence:

         The purge indicator transitions from red (purge required) to yellow (purging) to
         green (purge complete).

         The ignition indicator transitions from red to green indicating that ignition trial has
         begun.

         With successful burner ignition the burner status indicator transitions from red to
         green indicating that the burner is in operation. The flame signal indicator displays
         the strength of flame signal (0 - 10 volts).
    CHAPTER 1  OPERATIONAL INSTRUCTIONS

Pressing the pid control screen navigation button from any screen displays the pid control
screen. The system status bar (located at the top of the control screen) displays the warm-
up set point, while the burner controller status indicator transitions from red to green
indicating that the burner loop is active. The warm-up set point finishes ramping when it
equals the target set point displayed in the burner loop display. The first soak time period
begins when the temperature at the top of the media beds is equal to the target set point.
With the completion of the first soak time period, the oxidizer ready condition will be
indicated. Once the process is online and the fresh air and isolation dampers are in
position, the pid control loop is activated placing the system fan under modulating control
(changing its status indicator from red to green to confirm the mode of operation).
4.4.2 Low Temperature Idle Mode (Optional)
The system is placed into the low temp idle mode by pressing the idle sw off operator
function button from startup screen.

With the system in low temp idle the system returns to a pre-oxidizer ready condition.
The isolation & fresh air dampers close any abort damper or valve (not provided by
NESTEC) should now open and the system fan returns to minimum speed. The low temp
idle setpoint is displayed in the status bar at the top of the screen.

Pressing the idle sw off operator function button again will terminate the low temp idle
mode operation and this starts the system ramping back to the target setpoint, the
sequence continues as described above until with the warm-up setpoint equals the target
setpoint.
    CHAPTER 1  OPERATIONAL INSTRUCTIONS


4.4.3 Equipment Bakeout Mode (Optional)
The system is placed into bake out mode by pressing the bakeout sw off operator function
button located on either the startup or chamber temps screens. Note: Selecting Bake out
mode will cause a loss of oxidizer ready and process online condition will terminate or
remain unavailable for the duration of the Bake out.

With the system placed in the bake out mode the system status indicator banner on any
operator HMI screen will indicate Oxidizer Bakeout. The isolation damper will be closed
to process, the fresh air damper will be open to atmosphere and the system fan will be
running at a fixed minimum speed.

The diverter poppet valves now cycle based on lower bed (outlet) temperatures such that
when one beds lower region reaches its bake out set point, the diverter valves shift to bake
out the other bed. The Bake out procedure is a five step process that alternately heats can
A and then can B to a lower temperature setpoint pre-heat bake out stage (stage 1) and
then repeats the sequence to a higher actual bake out temperature setpoint stage (stage 2).
The final stage setpoint (final sp) step re-heats can A to allow for temperature stabilization
to occur at both the A and B mid bed thermocouple locations prior to terminating bake out
and restoring oxidizer ready state.

The bake out control stage SP temperature settings are available only from the chamber
temps screen. The stage 1 SP numeric entry button sets the lower temperature value (350 F
Typ) and the stage 2 SP numeric entry button sets the upper temperature value (700 F
Typ). The final step bed stabilization SP numeric entry button sets the re-heat value for can
A (150-200 F Typ).

A step bakeout operator function button is also available from this screen that permits an
operator to sequentially step through any or all of the (5) bake out steps. Bake out may also
be terminated at any time by turning bake out off.

Once both beds are baked out the diverter valves return to a normal sequence and the
Oxidizer Bakeout Complete message will be displayed. An operator must now turn bake
out off at the HMI screen before another bakeout can be initiated.
    CHAPTER 1  OPERATIONAL INSTRUCTIONS


4.4.4 Bakeout Damper Operating Mode (option)

4.4.5 (Optional 4.4.4 Retained Heat Shutdown Mode (Optional)
Pressing the rh-shutdown operator function button on the startup screen places the system
in the retained heat shutdown mode.

When the system is placed in the retained heat shutdown mode the burner is stopped, the
isolation damper is closed, the fresh air damper is opened, and the system returns to a pre-
oxidizer ready condition and the status bar at the top of the screen indicates that the
system is in retained heat shutdown mode. The system fan is allowed to operate at
minimum speed with the diverter valves cycling on a time only basis for a short duration
of time.
At the end of the time duration the fan is stopped and the diverter valves go to their
resting position.


4.4.6 Maintenance Shutdown Mode
Pressing the maint shutdown operator function button on the startup screen places the
system in the maintenance shutdown mode. When the system is placed in the
maintenance shutdown mode the burner is stopped, the isolation damper is closed, the
fresh air damper is opened and the system returns to a pre-oxidizer ready condition and
the status bar at the top of the screen indicates that the system is in maintenance shutdown
mode. The system fan is allowed to operate at minimum speed with the diverter valves
cycling on a time only bases until the combustion chamber temperature falls to a preset
value. When the preset combustion chamber temperature is achieved the fan is stopped
and the diverter valves are extended isolating the process inlet from the heat recovery
beds. Pressing the system stop operator function button on the startup screen takes the
system out of the maintenance shutdown mode.


4.4.7 Thermal Balance Auto Mode
A mid bed thermal auto temperature balancing feature is provided and is set to auto mode
by default. The thermal balance auto mode operator function button is only available at
the chamber temps screen. In normal auto mode operation it compares and calculates
differences between the peak mid bed thermocouple temperature values of chambers A
and B at the time of their transitions between inlet and outlet states.
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If a peak temperature difference of 200 Degrees F or greater exists then a correction timing
value change is made to the poppet valve cycle timers to introduce an offset or bias with
respect to either chamber A or chamber B inlet or outlet duration times. This correction
value will remain active until such time as the peak mid bed temperature differences
become less than 50 Degrees F. At that time normal symmetrical (equal) timing values will
be restored to the poppet valve cycle timers.
4.4.8 Thermal Balance Manual Mode

The thermal balancing feature may also be placed into a manual correction-timing mode
by pressing the thermal balance auto mode function operator function button. In this
mode, the operator numeric entry function buttons ch A outlet time and ch B outlet time
at the chamber temps screen become enabled. These numeric input function buttons
permit a value of + or – (0-30) seconds to be added or subtracted to either the chamber A or
chamber B cycle timers. The base timing value is 150 seconds for each cycle; therefore a
minimum value of 120 or maximum value of 180 is possible.

Caution: It is highly recommended that auto correction mode is used exclusively to correct
any thermal imbalance conditions that may arise. Manual correction mode should only be
engaged by properly trained and qualified maintenance personnel who understand and can
observe the effects of any timing value changes made. Leaving an RTO unattended in
manual correction mode will result in one chamber or the other reaching its high outlet
temperature shutdown limit, potentially causing catastrophic damage to other equipment
or components.


4.4.9 Integration with RTO-1 and Process Tie-in

This section to be completed following equipment commissioning and field testing of
existing RTO integration with the NESTEC, Inc RTO equipment.
    CHAPTER 1  OPERATIONAL INSTRUCTIONS


4.5 Safeties and Interlocks

4.5.1 Emergency Stop
Pressing the Emergency Stop button located on the main control panel immediately stops
all oxidizer operation. With the emergency stop engaged the system fan is stopped, the
diverter valves retract, the burner is stopped, the isolation damper is closed, the fresh air
damper is opened and the system returns to pre-oxidizer ready condition. The E-stop
engaged alarm status indicator transitions from green to red on the firstout screen
indicating that the emergency stop must be reset before the system can be restarted. The
emergency stop is reset by pulling out the Emergency Stop button located on the main
control panel. The system must then be restarted as described under the normal operation
section.
4.5.2 Combustion Chamber High Temp Limit
The combustion chamber high temp limit device (located on the front of the control panel)
monitors the chamber for a high temperature condition. If the temperature in the
combustion chamber increases above the high limit setpoint the controller latches in the
limit condition (as indicated by the word LIMIT flashing in the display), the temperature
in the combustion chamber must now fall below the limit setpoint and the controller must
then be reset by pressing the combustion chamber high limit reset button on the controller
keypad before normal operation can continue. When the high limit condition occurs, the
burner is stopped, the isolation damper is closed, the fresh air damper is opened, and the
system returns to a pre-oxidizer ready condition. The high combustion chamber
temperature limit status indicator transitions from green to red on the firstout screen
indicating that the high temp limit must be reset before the burner can be restarted. The
system fan is allowed to operate at minimum speed with the diverter valves cycling on a
time only bases. Once the limit condition is cleared the burner must then be restarted as
described under the normal operation section.
4.5.3 Oxidizer Exhaust High Temp Limit (Optional)
The oxidizer exhaust high temp limit device if supplied, (located on the front of the control
Panel) monitors the air stream for a high temperature condition. If the temperature of the
exhaust air increases above the high limit setpoint the controller latches in the limit
condition, the temperature of the exhaust air must now fall below the limit setpoint and
the controller must then be reset by pressing the exhaust temperature high limit reset
button on the front of the main panel before normal operation can continue.
    CHAPTER 1  OPERATIONAL INSTRUCTIONS


When the high limit condition occurs, the burner is stopped, the isolation damper is
closed, the fresh air damper is opened and the system returns to a pre-oxidizer ready
condition. The high exhaust temperature limit status indicator transitions from green to
red on the firstout screen indicating that the high temp limit must be reset before the
burner can be restarted. The system fan is allowed to operate at minimum speed with the
diverter valves cycling on a time only bases. Once the limit condition is cleared the burner
must then be restarted as described under the normal operation section.
4.5.4 Compressed Air Pressure Switch
The compressed air pressure switch (located on the compressed air manifold) monitors the
air supply to the entire system. If the air pressure falls below the minimum air pressure
setpoint the pressure switch contacts close. Air pressure must then be restored before
operation can continue.

When the low-pressure condition occurs, the burner is stopped, the isolation damper is
closed, the fresh air damper is opened and the system returns to a pre-oxidizer ready
condition. The compressed air pressure switch status indicator transitions from green to
red on the firstout screen indicating that the air pressure must be restored before the
system can be restarted. The system fan is stopped and the diverter valves are extended
isolating the process inlet from the heat recovery beds. Once the low-pressure condition is
cleared the system must then be restarted as described under the normal operation section.


4.5.5 Main Burner Low Gas Pressure Switch
The main burner low gas pressure switch monitors the gas supply pressure to the burner.
If the gas pressure falls below the minimum gas pressure setpoint the pressure switch
contacts close. Gas pressure must then be restored and the switch reset by pressing the
burner low gas pressure reset switch located at the switch before burner operation can
continue.
When a low-pressure condition occurs, the burner is stopped, the isolation damper is
closed, the fresh air damper is opened and the system returns to a pre-oxidizer ready
condition. The main burner low gas pressure switch status indicator transitions from
green to red on the firstout screen indicating the low gas pressure alarm. The system fan is
allowed to operate at minimum speed with the diverter valves cycling on a time only
bases. Once the low-pressure condition is cleared the burner must then be restarted as
    CHAPTER 1  OPERATIONAL INSTRUCTIONS

described under the normal operation section. Note: It may be necessary to perform a
burner reset operator function from the startup screen before the burner can re-light.
4.5.6 Main Burner High Gas Pressure Switch
The main burner high gas pressure switch monitors the gas supply pressure to the burner.
If the gas pressure rises above the maximum gas pressure setpoint the pressure switch
contacts close. Gas pressure must then be reduced and the switch reset before burner
operation can continue.

When a high-pressure condition occurs, the burner is stopped, the isolation damper is
closed, the fresh air damper is opened and the system returns to a pre-oxidizer ready
condition. The main burner high gas pressure switch status indicator transitions from
green to red on the firstout screen indicating that the gas pressure must be reduced and
the switch reset before the burner can be restarted. The system fan is allowed to operate at
minimum speed with the diverter valves cycling on a time only bases. Once the high-
pressure condition is cleared the burner must then be restarted as described under the
normal operation section.
4.5.7 System Fan Air Flow Switch
The system fan airflow switch (located on the inside of the pneumatic panel) monitors the
differential pressure related to the flow of air through the system fan. If the differential
pressure falls below the minimum differential pressure setpoint the pressure switch
contacts close.

When the low differential pressure condition occurs, the burner is stopped, the isolation
damper is closed, the fresh air damper is opened and the system returns to a pre-oxidizer
ready condition. The system fan is allowed to operate at minimum speed with the diverter
valves cycling on a time only bases. The system airflow switch status indicator transitions
from green to red on the firstout screen indicating that the system fan has failed.
    CHAPTER 1  OPERATIONAL INSTRUCTIONS


4.5.8 Combustion Air Flow Switch
The combustion airflow switch monitors the differential pressure related to the flow of air
through the combustion fan. If the differential pressure falls below the minimum
differential pressure setpoint the pressure switch contacts close.

When the low differential pressure condition occurs, the burner is stopped, the isolation
damper is closed, the fresh air damper is opened and the system returns to a pre-oxidizer
ready condition. The combustion airflow switch status indicator transitions from green to
red on the firstout screen indicating that the combustion fan has failed. The system fan is
allowed to operate at minimum speed with the diverter valves cycling on a time only
bases. Once the combustion fan failure condition is cleared the burner must then be
restarted as described under the normal operation section.

4.5.9 Fresh Air / Isolation Damper Position Switches
The fresh air / isolation damper position switches (field located or internal) monitor the
actual damper position relative to the commanded position upon system startup. If the
operator attempts to start the system with the isolation damper not closed and the fresh air
damper not open, the system will not be allowed to start. The fresh air inlet / isolation
damper not in position status indicator transitions from green to red on the firstout screen
indicating that the system cannot be started.
4.5.10 Diverter Valve Proximity Switches
The diverter valves extended / retracted proximity switches (field located) monitor the
actual diverter position relative to the commanded diverter position. When a diverter is
commanded to extend and the diverter extended proximity switch is not made (after a
short time period of approximately 6 seconds, 3 seconds with fuel enhancement to allow
for travel) the diverter has failed.

When a diverter failure occurs, the burner is stopped, the isolation damper is closed, the
fresh air damper is opened and the system returns to a pre-oxidizer ready condition. The
diverter status indicator transitions from green to red on the firstout screen indicating that
a diverter failure has occurred. The system fan is stopped and the diverter valves are
retracted. Once the diverter failure is cleared the system must then be restarted as
described under the normal operation section. The system is also not allowed to start if
    CHAPTER 1  OPERATIONAL INSTRUCTIONS

both diverter valves are not in the full-retracted position when the system start function
key is pressed.
4.5.11 Diverter Valve Maintenance Mode Switches (option)
At each diverter poppet valve assembly location if supplied is a local 3-position keyswitch
enclosure that is provided to facilitate both maintenance safety and troubleshooting
activities. The normal locked on keyswitch removed position is AUTO.

If it is necessary to perform local maintenance manipulations of the poppet valve assembly
or to place the valve in a fixed extended or retracted position, then the switch may be
selected to either the OFF or EXTEND position. OFF means that the valve will be retracted
and EXTEND means the valve will be extended. Any position other than AUTO will cause
the RTO burners to shutdown and the RTO will not be available or ready for online VOC
processing operations.

Caution: It is highly recommended that the station switch keys be removed at all times
during normal operation and be made available only to properly trained and qualified
maintenance personnel as required by plant operating procedures. For any internal or
external inspections of the unit poppet valves or any other equipment, all electrical and
hydraulic or pneumatic energy sources must be locked out and off.


4.5.12 Chambers Air Pressure Switch
Each media bed chamber is monitored for differential pressure to that of the opposite
media bed chamber to assure airflow into and out of each. Static pressure impulse lines are
connected above the respective chambers diverter valves and below the media beds and
set-up in such a way as to allow positive displacement to the pressure switch indicating
flow through its respective chamber. When flow direction reverses then the opposite air
pressure switch will have positive displacement proving airflow through its respective
chamber. These particular pressure switches are set-up and adjusted to prove airflow
during the lowest airflow condition.

When the chamber’s air pressure switch “not-made” condition occurs, the burner is
stopped, the isolation damper is closed, the fresh air damper is opened and the system
returns to a pre-oxidizer ready condition. The chambers air pressure switch indicator
transitions from green to red on the firstout screen indicating that either switch has failed.
The system fan is allowed to operate at minimum speed with the diverter valves cycling
    CHAPTER 1  OPERATIONAL INSTRUCTIONS

on a time only bases. Once the chambers air pressure switch failure condition is cleared
the burner must then be restarted as described under the normal operation section.
4.5.13 Flame Supervision
The Fireye flame supervision control is composed of the following components:
MEC120D, MEP560, MEUVS4, 61-3060. Functions provided by the Fireye flame
supervision include automatic burner sequencing, flame supervision, system status
indication, system or self-diagnostics and troubleshooting. Additional safety features
include:

   1.   Self check ultra-violet scanner - 45UV5-1009
   2.   Closed loop logic test
   3.   Dynamic ampli-check
   4.   Dynamic input check
   5.   Dynamic safety relay test
   6.   Dynamic self check logic
   7.   Internal hardware status monitoring
   8.   Tamper resistant timing and logic
    CHAPTER 1  OPERATIONAL INSTRUCTIONS


                            Section 5 – Maintenance

5.1 General

NOTICE: The NESTEC RTO system will consist of a number of spaces with limited
access. In addition, the atmosphere can consist of a hazardous atmosphere. As such, the
RTO is considered a “Permit Required Confined Space” as defined by OSHA 29 CFR
1910.146, and entry into these spaces must follow these guidelines.

The NESTEC Regenerative Thermal Oxidizer (RTO) installation requires regular
maintenance in order to operate successfully. The following is a summarization of the
actions needed as well as the time intervals involved.

5.1.1 Daily

It is recommended that an operator “walk around” the RTO at least once a day, preferably
once a shift. This is to observe the normal operation of the system and attempt to spot any
potential problems before they become serious and cause the unit to be taken off line for
emergency repairs. By listening to the unit’s operation, especially at the diverter valves
and the main fan, problems involving lubrication or alignment can be identified and
corrected before damaging the equipment.

5.1.2 Weekly

All lubrication points should be checked.

5.1.3 Monthly

All safety related controls should be verified on a regular basis in order to comply with
NFPA guidelines. All pipelines should be inspected to insure there are no leaks. Check the
combustion blower inlet filter to insure it is not becoming clogged. Check all air lines to
insure there is no moisture or dirt present which could disrupt proper operation.

5.1.4 Quarterly
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The hatches at the diverter valves should be removed while the unit is off-line (confined
space entry procedure, along with all other plant requirements, must be followed). Valve
seating areas should be inspected for any wear or buildup from process stream
contaminants. Each poppet valve should be cycled manually and observed from a safe
distance outside the poppet housing to insure total closure is occurring when the valves
are in the extended and retracted positions. The main fan bearings should be observed
while the unit is on line to insure there is no excessive heat or vibration. Records should be
kept of all observations.

5.1.5 Annually

The RTO should be taken off line and allowed to cool down sufficiently to allow vessel
entry to occur. All standard plant safety procedures for vessel entry are to be fully
complied with. Appropriate respiratory protection for personnel performing vessel entry
shall be mandatory. The burner/combustion chamber should be inspected internally to
insure that all refractory modules are in good shape and that the ceramic media shows no
signs of degradation. The main fan access hatch shall be removed and the wheel examined
for signs of particulate deposition or corrosion. The main fan coupling should be examined
to insure proper alignment is being maintained. The combustion blower internals should
be examined as well. All instrumentation calibration should be verified.

Note: To insure reliable operation of this RTO, it is recommended that a NESTEC service
engineer/technician perform an internal and external inspection annually.
    CHAPTER 1  OPERATIONAL INSTRUCTIONS

5.2 Recommended Spare Parts List
NESTEC recommends that the following parts be kept at the site in order to minimize
downtime when a component requires replacement. Many of these items are common
with similar systems, such as boilers, so this list should first be checked with existing
inventory.



   Component             PID                             Description
    Number             Drawing
      FN-100         717-PID-02     RTO Fan, Forced Draft, A36 Carbon Steel. 14,654
                                      ACFM, 31.6"wc pressure @ 85F & 94.6 BHP
     FTR-101         717-PID-02                 Filter, Compressed Air

   FV-104 / 105      717-PID-02        Poppet Valve Guide Roller (4 recommended)

   FV-104 / 105      717-PID-02      Poppet Valve seating Surface (2 recommended)

   FV-104 / 105      717-PID-02            Poppet Valve disc (2 recommended)

   FV-104 / 105      717-PID-02      Poppet Valve backing disc (2 sets recommended)

   FV-104 / 105      717-PID-02       Poppet Valve Packing Gland (2 recommended)

   FV-104 / 105      717-PID-02      Poppet Valve Shaft (1 assembly recommended)

      M-100          717-PID-02       Motor, 100HP, 3600 RPM Inverter Duty, 460/3/60,
                                                      405TS Frame
      P-100          717-PID-02        Double Acting Pneumatic Actuator, 614 in-lbs
                                                    torque @ 60 psig
      E-101          717-PID-02      Quarter turn electric actuator for modulating seervice
                                        with 2 SPDT Aux switches, 4-20 mA control
    P-104 / 105      717-PID-02       6" Bore x 12 3/4" Stroke Pneumatic Actuator for
                                                    operation @ 60 psig
    P-104 / 105      717-PID-02                          Rebuild Kit

    PDSL-100         717-PID-02       Switch, Pressure .2-1"wc, located in NEMA 4
                                                        enclosure
  PDSL-104 / 105     717-PID-02      Switch, Pressure .05-.25"wc, located in NEMA 4
                                                        enclosure
     PDT-100         717-PID-02     Transmitter, Pressure. 0 - 25"wc range, 4 - 20 mA
                                      output, 24 VDC, located in NEMA 4 enclosure
  CHAPTER 1  OPERATIONAL INSTRUCTIONS

 Component           PID                           Description
  Number           Drawing
   PSL-101        717-PID-02       Pneumatic air pressure switch 10-250 PSI

    RG-101        717-PID-02   Coalescing Regulator, Compressed Air, with gage

    SV-100        717-PID-02      Valve, Direct Mount Solenoid, Pneumatic Air.
                                                      120/1/60
 SV-104 / 105     717-PID-02    3/4" port, 2-position, 4-way spring return solenoid
                                              valve. 120/1/60, 0.37A
 SV-104 / 105     717-PID-02                         Rebuild Kit

      TE-         717-PID-02   Thermocouple, KK, 3/8" dia. x 12" active length with
101/103/106/110                      screw cover head and inconel sheath
      TE-         717-PID-02   Thermocouple, KK, 3/8" dia. x 36" active length with
102/105/108/109                      screw cover head and inconel sheath
   TSH-109        717-PID-02       Combustion Chamber High Temp Switch

   VFD-100        717-PID-02        100 HP (110KW) Variable Torque Drive
                                 3PH/480V/60Hz with line reactor on power feed
                                                     side
 ZSC/ZSO-100      717-PID-02               Box, Switch 2 Switches

ZSC/ZSO-104 /     717-PID-02         PV Proximity Switch (2 recommended)
     105
   B-131          717-PID-03             2.4 MM BTUH Kinemax Burner

    BE-131        717-PID-03                      Spark Igniter

   BW-131         717-PID-03       Ignition Transformer. Primary Volts - 120;
                                             Secondary Volts - 6,000
 EXP-140 / 141    717-PID-03          4" Type I Mission Standard Coupling

   FFC-133        717-PID-03         Microratio Valve (Gas / Combustion Air)

    FN-140        717-PID-03     Combustion Air Blower. 510 ACFM @ 49.8"wc
                                        pressure, 8.1 BHP & 3,550 RPM
FSCV-131 / 132    717-PID-03   1 1/4"" Safety Shut Off Valve. 115V60, 1.7a, w 1-1
                                                       trim
FSCV-134 / 135    717-PID-03        1/2" Pilot Gas solenoid valve, 17.1 watts

    M-133         717-PID-03   Modulating Motor - Natural Gas. 120V/1/60 electrics
CHAPTER 1  OPERATIONAL INSTRUCTIONS

Component      PID                         Description
 Number      Drawing
  M-140     717-PID-03   Motor, 10 HP, 3600 RPM. 460/3/60. TEFC / IP55
                                            enclosure
 PCV-131    717-PID-03    Regulator, Main Gas, 1 1/4", 10 PSI IN - 6"-12"
                                              OUT
 PCV-133    717-PID-03                 Regulator, Pilot, 3/8"

 PSH-133    717-PID-03    High Gas Pressure Switch. 15psi range, 10psi
                                 factory set, 0.5-1.5 deadband
 PSL-131    717-PID-03     Low Gas Pressure Switch. 1-20" operating
                                    pressure. 125/250 VAC
 PSL-140    717-PID-03             Comb. Air Pressure Switch

 RIT-131    717-PID-03                     UV Scanner

 STR-131    717-PID-03                Strainer, Y type, 1 1/4"