KonoCARE Oxidizer Preventive Maintenance Service
Regenerative thermal oxidizers (RTO) are one of the most common and cost-effective means of industrial emissions control. Because RTOs operate at high temperatures and are often exposed to risk from particulate plugging or organic build-up, small issues can quickly become big problems unless they’re identified and corrected promptly.
Kono Kogs, Inc (KKI) will create a custom KonoCARE preventive maintenance program for your plant and equipment, regardless of oxidizer OEM. Over our 25+ year history we’ve worked with virtually all makes and models, and our core team has 150+ years of combined application and technical experience.
Maintenance Programs Optimized for YOUR Specific Needs
KonoCARE preventive maintenance (PM) plans have been developed with the help of our Fortune 500 customers. The goal: maximum oxidizer uptime. Starting with a goal of zero non-scheduled downtime, we set out to define the most practical path to that goal. Our KonoCARE program is new in 2022, but our service rates are unchanged since 2020.
The number one cause of oxidizer lost time is part failure. Identifying at-risk parts or deteriorating oxidizer health well before they impact performance or up-time is what drives our KonoCARE PM plans. These plans also point to the importance of collaboration between Kono Kogs and our customers in this effort. Equipping, training and communicating with your in-house maintenance team will lead to the success we each desire.
KonoCARE Plan Options
Silver is the most popular plan among our clients. However, it’s not the answer for every facility, or every emission airstream. Difficult applications or stringent emission regulations will require more diligent and frequent PM to keep your oxidizer running efficiently and your facility in compliance.
We offer 4 plan levels to meet your uptime goals:
- Diamond: Our most comprehensive plan
- Platinum: Gold level plus very high-end support, oversight and reporting
- Gold: Silver level plus minimum remote support and reporting
- Silver: Minimum recommended preventive maintenance as described below
KonoCARE Diamond Level
The Diamond level PM plan is our top-of-the-line offering and has been well received by our largest customers and plants with no ability to produce goods without a functioning oxidizer.
KonoCARE Diamond includes:
Extensive spare parts package covering:
- Critical level
- Secondary level
- “What if” level
Remote monitoring hardware/setup (if not already installed)
Extensive onsite training for plant leadership & maintenance personnel
- In-class training
- Principles of oxidizer operation
- Control loop review
- Importance of recordkeeping
- On-machine training
- Component identification
- Identify data point locations for recordkeeping
Highest level of on-demand 24/7 remote monitoring of oxidizer; with option for additional billed support
Weekly and monthly maintenance reminders: e-mails or text
Extensive plant & maintenance personnel training during initial PM visit
- Review operation & maintenance requirements with plant personnel
- Review recordkeeping requirements: visual, pressures, temperatures, amperages
- Discuss KonoCARE maintenance reports and what to expect in the reports
Quarterly onsite PM inspections
- Review the following with plant personnel:
- Past KonoCARE maintenance reports and any open items
- Service calls since previous PM visit
- Alarms since previous PM visit
- Parameter sheets (stressing the importance of recordkeeping)
- Trends seen in parameter records and their meaning
Monthly remote monitoring of oxidizer operation
- Record parameters: pressure, temperature, amperage
- Report on observable trends in parameters
- Identify at-risk parts and oxidizer health risks
Why our largest clients love KonoCARE Diamond: The combination of trained eyes on the equipment both quarterly and remotely, plus engaged and trained onsite maintenance personnel, will ensure the oxidizer system can be relied on in both the short and long term.
KonoCARE Gold and KonoCARE Platinum include services that fall between Diamond (above) and Silver (below). Each KonoCARE plan is optimized to suit your needs. Share your application with us for a custom recommendation and quote.
KonoCARE Silver Level
What to Expect in a Preventive Maintenance Visit
All KonoCARE plans include at least one annual onsite preventive maintenance visit.
Typically, preventive maintenance service takes place over two days. The air pollution control system will need to be shut down (and cooled) before our technician begins, and remain shut down for the first day of preventive maintenance. This involves a complete internal and external mechanical inspection, including consumable component replacement. On subsequent days the system will be on and off as we perform operational testing.
Day one includes mechanical inspection of:
- Combustion chamber
- Compressed air piping
- Gas train
- Poppet/Rotary valves
- Ceramic media
- Exhaust stack
- Expansion joint(s)
- Control panels
- Flame safeguard unit
- Cold face
- External hot spots
Kono Kogs maintains a large inventory of replacement oxidizer parts. We also have our own fab shop and can produce custom components if necessary. Even more importantly, our team has the skills and knowledge to keep your process running reliably at peak efficiency.
The second day involves performance evaluation, including a complete review of system operation in on-line and off-line modes, electrical inspection and component testing. On day two the system will be started up and shut down to conduct process control and operational analysis.
Day two evaluation and testing includes but isn’t limited to:
- System startup cycle
- Online conditions
- Safety shutdown
- Valve cycling
- Pressure control loops
- Temperature profile
- Pressure/temperature controls
- Test all safety switches/logic
- Burner tuning
- Burner controls
- Airflow switches
- Internal hot spot inspection/repair
- Thermocouples (replace TCs in combustion chamber)
- Variable frequency drive (VFD)
- HMI & communication devices
- Data recorder
After each preventive maintenance visit you’ll get a detailed report including:
- Full checklist of system components & operations reviewed on site
- Work completed by technician
- Results of testing
- Critical findings requiring action
- Photo record of all areas, especially critical areas
- Recommended monthly maintenance plan
To better understand the level of inspection and detail covered during a preventive maintenance visit by Kono Kogs, view or download our RTO inspection sample report PDF:
Customizing Your KonoCARE Plan
In most cases we recommend an annual evaluation of all air pollution control equipment, though semi-annual or quarterly evaluations may be necessary depending on system complexity and the service requirements in your environmental operating permit.
Preventive maintenance visits can be flexible to accommodate your schedule. For example, a one-day preventive maintenance visit every six months instead of two consecutive days each year. Together we’ll design a program that meets your needs with minimal disruption to operations.
We can also bundle other oxidizer services with your preventive maintenance visit, including:
- New operator training (or refresher)
- Operating cost review
- Any pending aftermarket services
Remote Access & Troubleshooting
KKI also offers remote monitoring and troubleshooting services. These can be included as part of your customized KonoCARE plan, or billed hourly outside of our KonoCARE program.
Benefits of Oxidizer Preventive Maintenance
Preventive maintenance offers several benefits directly affecting your bottom line:
- Minimize unplanned downtime & lost production
- Minimize oxidizer repair costs
- Extend the practical service life of your RTO
- Optimize equipment performance for energy efficiency
- Improve safety
- Establish a record of DRE compliance
Many states require facilities with thermal oxidizers to keep records of their equipment maintenance program. Fines can be issued for noncompliance in recordkeeping, even if the system is operating properly. If a device fails to meet the control requirements defined in the permit, the monetary penalty can be significant, and also gets you “noticed” in a way that you don’t want – another good reason to create and maintain a regular DRE compliance record.
The experts at Kono Kogs give you peace of mind, keeping your oxidizer operating and compliant, energy costs in check, and interactions with the EPA to a minimum.
Maximize Oxidizer Uptime with the KonoCARE Program
No matter how challenging your airstream or how long it’s been since your last oxidizer inspection, Kono Kogs is up to the task. We can provide you with a cost/benefit analysis clearly showing the advantages of preventive maintenance services. You have nothing to lose but unnecessary risk and expenses!