Catalytic Products International (CPI)

Maintenance solutions for air pollution control equipment


Manufacturing facilities are constantly under pressure to meet production forecasts at the lowest possible cost. These two goals; production output and cost control, can be difficult to obtain consistently in any manufacturing operation. Additional frustration to meet these goals can be exaggerated in today’s lean manufacturing climates that have trimmed budgets and reduced workforce. Further complicating any Plant Manager’s responsibilities are EPA compliance requirements and working within the demands of EPA operating permits.

To make life even more difficult, many plant operators have human and material limitations. Human errors include unintended adjustment or plain old lack of understanding that end up shutting down a production operation. Equipment fatigue and failure can leave a device shut-down or operating in unsafe conditions. Timely resolution to any of these problems is very difficult without the proper planning procedures in place.

Avoiding equipment shut-down is the primary responsibility for any maintenance department. Once production machinery or the associated control device unexpectedly shuts down, the whole maintenance department moves into scramble mode.

In this white paper, we describe one facility’s experience with installing and maintaining a Volatile Organic Compound (VOC) control system. This is a typical example of how a preventive maintenance plan can ensure the control system operates with 100% reliability, how such a plan can be designed so implementation does not interfere with production, and how the low cost of a preventive maintenance plan makes sense for every plant’s bottom line.

This paper also examines the challenges and benefits of establishing an appropriately designed preventive maintenance program for the operator’s of a VOC abatement device. These systems can include: catalytic, thermal, regenerative oxidizers or concentration devices designed to destroy VOC/HAP emissions and satisfy state or federal clean air act permit requirements. It’s the kind of challenge that thousands of Plant Manager’s face every day and meeting it means lowest operating costs with highest uptime reliability and assured EPA permit compliance, thus meeting the primary goal of production output at the lowest cost!

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