US Furnaces Max 4000 Operation, Maintenance and Monitoring Plan

Complete Operating Instructions (SOP)

–Turn power and main gas valves on and record the gas meter reading.
–Raise all doors and inspect all chambers.  

1. Start combustion blowers. Start “Primary 1”, “Primary 2” “Holding chamber” and “Afterburner burners” by turning the selector switches to the on position. There is a 2 minute built in purge prior to ignition. Observe that each burner did in fact ignite by observing burner on lights and physically observing the flame by sight.
2. Close all doors.
3. Prepare work area for production day.
4. Install the afterburner data logger.
5. Select material to be charged and load on the table. Note: Refer to “Items not to be charged into the chamber” as described by the permit, i.e. magnesium, cadmium, radioactive, PCB’s, PVC’s, etc. materials.
6. When the afterburner temperature has reached at least 1600 deg. F and the primary and holding chamber have reached the desired set point the furnace may be charged.
7. The afterburner temperature is recorded as 15-minute block averages and also 3-hour block averages by a data logger.
8.  Turn the “Hi – Low Fire” switch to low. Raise the primary charge door and push material into the chamber.
9. Close the door and observe the temperature controls. Note: Specifically observe that the afterburner chamber did not drop below 1600 deg. F. If said chamber does drop below the required temperature, the set point will need to be raised to prevent a violation during the time the door is open. The standard set point is 1650 deg. F to prevent a violation.
10. Record the charge time, material type, afterburner temperature and the size of the load in the “Daily Operators Log”.

This unit is equipped with an interlock system that prevents the primary charge door from being opened should the afterburner temperature drop below 1600 degrees. There is however, a manual override keyed switch which will allow the door to operate under any temperature condition. This mode is primarily used for maintenance only.  A red light on the control panel indicates that the interlock is in the manual mode. Do not charge material into the chamber if the red interlock light is illuminated. This unit also has a visual/audible alarm that indicates the afterburner has dropped below 1600 deg. F.

Turn the “Hi-Low Fire” switch to high after most of the combustible material has burned off (if automatic high fire delay, turn to high as soon as door is closed). Stir and rake the material as required by the material being processed. Average stir time is 10 to 15 minutes after charging the load. An additional stir and preliminary rake is usually required within 5 to 10 minutes. Average final rake out time is 25 to 40 minutes after charging. Record all stir and rake times on the “Daily Operators Log”.

11. Observe temperature controls throughout the operating day to assure proper operation of all chambers.
12. Observe the exit of the stack for emissions after each charge and make the proper adjustments to the draft controls if necessary.
13. Drain the holding chamber as necessary. Note: Follow all required safety procedures during the draining of the holding chamber.
14. When process day is complete, turn off all burners and leave the combustion fans on until the temperature has dropped below 500 deg. F.
15. Turn off the main gas valve.
16. Clean all chambers thoroughly.
17. Record the weight of material processed on the daily log sheet.

Spare Parts On Hand

Refer to the recommended spare parts list for items that need to be in your inventory. Add a spare Tc-hr data logger to that list. Keep an inventory list of parts on hand.

Maintenance Schedule

Furnace is to be maintained and records kept of the following:

1. Weekly Inspection and Maintenance
a) Inspect all chambers for refractory damage and repair as needed.
b) Inspect door raise cables for wear and replace if needed.
c) Inspect burner tube areas for blockage.
d) Clean blower fans.
e) Inspect, adjust, or replace door seal material.
f) Inspect data logger connections by using a laptop and real time test function.
g) Inspect all temperature probes.

2. Bi-weekly Inspection and Maintenance
a) Remove and clean igniters.
b) Inspect ignition cable and replace when necessary.
c) Clean UV Scanners.
d) Grease door raise bearings.
e) Oil any unsealed type motor bearings.
f) Drain all gas line drip legs at the main and each burner.
g) Clean vaporizer as described in vaporizer manufacture’s instruction.

3. Monthly Inspection and Maintenance
a) Inspect and repair any structural area of the furnace.
b) Inspect and/or repair tap-out hole and spout.
c) Inspect and repair afterburner and stack refractory.
d) Perform leak test on all gas lines.

4. Semi-Annual Inspection and Maintenance if required (to be performed by RSI)
a) Calibrate all controls and data logger.
b) Inspect afterburner structural refractory areas.  
c) Inspect structural areas.
d) Inspect, clean and service all burners.
e) Adjust all burner settings.
f) Observe overall furnace operation.
g) Check data logger records.
h) Operators training refresher course is performed and training certificates are issued where appropriate.

5.  Annual Inspection and Maintenance (to be performed by RSI)
a) Inspect all burners, pilot light assemblies, and pilot light sensing devices for proper operation.
b) Clean the pilot light sensors.
c) Inspect the combustion air for proper adjustment.
d) Inspect baffles and other internal structures to ensure their structural integrity.
e) Inspect dampers, fans, and blowers for proper operation.
f) Inspect for proper sealing.
g) Inspect motors for proper operation.
h) Inspect the refractory lining of the combustion chamber.  Clean and replace the refractory lining as necessary.
i) Inspect the shell of the afterburner for corrosion and hot spots.
j) For the burn cycle that follows the inspection, document the proper operation of the afterburner.  Document adjustments to the afterburner.
k) Verify that the afterburner is in good operating condition.
l) Follow the operation, maintenance and monitoring plan when making repairs.

1.  Afterburner temperature is recorded as 15-minute block averages and also3-hour block averages by a data logger.
2.  Retain data logger back up discs for five (5) years.
3.  Manually record the temperature on the Daily Operators Log when recording the charge time and material.
4.  Maintain a log of repairs performed and any periods of visible emissions.
5.  If the temperature goes below 1600°F in the afterburner, follow the procedures in the Startup, Shutdown and Malfunction Plan, including completing the Malfunction Report with specifics on the date and time of emissions exceedance and corrective action taken.