Restoring RTO Performance Through Advanced Troubleshooting & Field Service
CleanCap restored critical RTO functionality through comprehensive field repairs involving advanced burner troubleshooting, plugged heat recovery media, fan vibration, and pressure-control system restoration, addressing multiple reliability concerns for an industrial processing facility.
Successful Ceramic Media Cleaning
Full bakeout programming installed and tested
High Performance Damper Operation Restored
Supply of new dampers and actuation
Pressure Instruments Replaced and Calibrated
More Efficient Control Implemented
Project At A Glance
Challenge
Process Buildup, Fan Repairs, & Pressure-Control Issues
Methodology
Comprehensive mechanical and electrical repairs, systematic fault isolation, component replacement, controls verification, and calibration to restore critical RTO functionality.
Outcome
- Full bakeout programming installed and tested: Successful Ceramic Media Cleaning
- Supply of new dampers and actuation: High Performance Damper Operation Restored
- More Efficient Control Implemented: Pressure Instruments Replaced and Calibrated
Executive Summary
CleanCap Technologies & Services provided comprehensive field service to address multiple reliability and operational concerns affecting a three-can Regenerative Thermal Oxidizer (RTO). Through mechanical and structural repairs, advanced combustion troubleshooting, electrical diagnostics, and controls verification, the team identified and resolved recurring burner ignition failures and restored automatic inlet pressure control. The final transmitter replacement was completed without requiring a full RTO shutdown, and a dedicated calibration port was installed to simplify future maintenance.
Customer Background
A leading rendering company relies on a Regenerative Thermal Oxidizer (RTO) as part of its industrial emissions and odor control system. Maintaining dependable equipment operation and effective process controls is important to supporting facility operations and ongoing environmental compliance requirements.
Project Background
The RTO required a series of service visits to address mechanical, structural, electrical, and control-related concerns. Initial work focused on equipment supports, damper systems, actuator components, and insulation. Subsequent service visits addressed recurring burner ignition failures and identified deficiencies affecting automatic inlet pressure control. The main process fan required new bearings, an alignment, and professional balance to increase reliability. CleanCap was engaged to troubleshoot the interconnected systems, perform corrective repairs, and verify equipment functionality.
The CLEAN Approach
Consultation and Initial Assessment
- Reviewed RTO operational concerns and previous equipment findings.
- Evaluated less than ideal odor control performance and control-related issues to guide troubleshooting.
Planning and Preparation
- Reviewed equipment conditions and identified corrective repair requirements.
- Coordinated staged service activities and obtained components needed for troubleshooting and repairs.
Execution of Repairs and Troubleshooting
- Completed structural, mechanical, electrical, insulation, and damper repairs.
- Replaced and calibrated process control dampers, a failed inlet pressure transmitter and corrected underperforming heat recovery media and the main processing fan.
Assessment and Verification
- Verified successful burner ignition and stable operation.
- Tested PLC logic, combustion controls, fan sequences, and damper responses.
- Confirmed proper automatic inlet pressure control following transmitter replacement.
Nurturing Ongoing Support
- Installed a dedicated calibration port to simplify future testing and maintenance.
- Recommended periodic pressure-sensing inspections and calibration checks.
- Identified deteriorating conduit for consideration during future scheduled maintenance.
Results & Impact
Operational Improvements
- Verified automatic inlet pressure control and proper fresh-air damper response.
- Completed final transmitter replacement without a full RTO shutdown.
Maintenance Enhancements
- Installed a dedicated calibration port for future pressure measurements and testing.
- Improved access for transmitter calibration and troubleshooting.
- Provided preventive maintenance recommendations for pressure-sensing components and deteriorating electrical conduit.
"Through comprehensive field repairs, systematic troubleshooting, and targeted component replacement, CleanCap resolved critical RTO operational issues and restored essential burner and pressure-control functionality. The project demonstrates CleanCap's ability to combine mechanical, electrical, and controls expertise to address complex industrial equipment challenges while supporting operational continuity and future maintenance needs."