SAMPLE 1 Plant Operation Consulting Reports

Dust Filter

The exhaust air turns brown when the bags are pulsed. The entire plenum is dust laden. Most all bags have dust in them. The bag insides are coated with dust. The outside of some show carbon deposits. Some bags have patches. The bags have been washed once. Bags have 750,000 tons of drum mix exhaust with 10-20% recycle and #5 fuel oil at lower fuel temperatures. The baghouse is due for a near immediate stack test. The plant has to produce much mix in a short period of time.  If bags needed patches a year ago, they probably need more patches now. Patching meets with limited success. If patching is necessary, it’s hard to believe that all holes can be found. Each washing of bags weakens the material. After one washing, the return on another washing investment is little if any. I recommend the old bags be replaced with new bags. The stack test set to take place after 30, 000 ton of mix has been run. About $21000
The fuel preheater to be operating at start up. $
A combustion analysis be taken and the burner be tuned accordingly. About $1000
Neutralite to be added to the bags $
The bags to be pulsed to keep baghouse pressure drop to no more and no less than 5" w.c..
A UL, FM Approved High temp limit installed to protect the bag house $400
Pressure drop indicator, pressure gauge and pulse cycle adjustment to be placed inside $200
The fire door be hooked up and made operable. $50

Dust Evacuation

Install Baghouse dust level alarm. About $700
Replace and/or rebuild vane feeder. About $4000
Interlock blower to vane feeder to augers to pulsers About $40

Burner control recommendations

Burner is not running safe. This was demonstrated by operator. This was confirmed by myself to be very hazardous. The burner control subject was to be an issue addressed at another time. I feel it my duty to let you know that the operator’s concerns are not frivolous and affects personnel safety, equipment and production costs if a catastrophe were to happen. I recommend that decision makers investigate this further. About $6500

Miscellaneous

Install a current transformer for Drag slat About $100