Importance of Regular Maintenance
A valve safety train controls the flow of fuel into thermal processing equipment. By controlling the desired ratio of fuel and air, the connected burner then properly oxidizes the mixture, safely releasing the energy needed to heat your furnaces, boilers, HVAC heaters, thermal oxidizers and other equipment. In turn, the thermal process equipment performs critical production tasks such as drying gypsum boards, roasting and baking foods, heat-treating metals, fluid heating, and pollution control.
Owing to the presence of hazardous vapors and gases, poorly designed or inadequately maintained trains have led to catastrophic explosions, fires, asphyxia and burns, multi-million dollar loses, injuries and fatalities. A recent study of equipment explosions over the last decade discovered more than 20 incidents that resulted in nearly 50 injuries and fatalities. Thankfully, you can significantly reduce the potential for accidents by getting regular safety inspections.
Rockford Combustion Solutions provides field services including combustion and oxy-fuel system tuning to maximize efficiency and decrease combustion safety risks, preventative maintenance to keep systems running smoothly and identify opportunities for improvement, and start-up and commissioning to ensure new equipment is properly and quickly installed to manufacturer and code requirements. Other field service offerings include equipment upgrades and repairs, electrical reviews and debug, gas booster maintenance, furnace optimization, testing for NOx and other flue-gas emissions, and more.
The field service team utilizes numerous checklists to screen fuel-delivery systems and equipment for NFPA/ANSI/ASME/NEC/EPA code compliance, identify installation-operational-maintenance issues, provide information on technological advances and best practices, and uncover training deficiencies. Inspections utilize proprietary software and include formal reporting, including a detailed list of all findings including critical issues that may impact life safety. A cloud-based customer portal helps managers track issues from identification to resolution. Technicians and engineers can troubleshoot burner management systems, diagnose operational issues, analyze test emissions, perform calibrations, review wiring schematics, and more.
The last time your equipment went down maintenance quickly returned it to service. Great. Now the equipment is running. But were the correct repairs done? Were components correctly installed and function tested to ensure they are fail safe? Was the underlying root cause ever found and truly fixed? What if the building gas regulator failed, would the incoming pressure surge overwhelm your equipment? Is your outdoor equipment properly rated for the electrical environmental hazards? Is the furnace you want to repurpose suitable for the new operating conditions? Really, just how safe are you? These are all difficult questions, and we can help with all of them.
Whether it be an existing system, a repair, a refurbishment, or a new equipment being brought to your site, our Compliance Audits assess these details and provide guidance. A Compliance Audit can usually be conducted while the appliance is operating. Often no scheduled down time is necessary. We review what you have, and what you need to comply with current code and safety guidelines, whether it be an NFPA rated appliance or a boiler. Let us help.
Annual Safety Inspections
Many owners and users of combustion equipment are unaware that NFPA encumbers the responsibility of annual inspection and testing of their appliances upon them. Few municipalities have annual inspectors assigned or qualified to assess equipment health, and some require independent inspections. For these reasons, Rockford Combustion Solutions provides code mandated inspection services. Our independent annual inspections help keep equipment running safely and operating at peak performance.
Our expert inspectors provide peace of mind by testing and verifying the individual safety interlocks and components of your system. We go in-depth by cycling the power and status of each component to ensure all properly function and are properly wired. Safety valves are tested for tightness and integrity. Components are checked for recall notices along with verifying appropriate setup and ranges. All safety devices and components are verified against customer specifications, current codes and standards requirements.
Plant accidents are a reality for manufacturers across all industries, one that results in the loss of lives, numerous injuries, and millions of dollars in fines.
To help organizations needing emergency support, Rockford Combustion Solutions offers 24X7 technical support. Simply call when encountering an unplanned downtime incident or employee accident.
In manufacturing, the financial cost of downtime can be significant. Enterprise Strategy Group (ESG) estimates the average downtime lasts approximately 1.5 hours, while other studies suggest a higher average of three to four hours. Factoring in idle employees, lost production, equipment repairs, catch-up overtime, and potential fines and lawsuits, and other variables, calculations put the typical downtime costs to industrial manufacturers between $30,000 and $50,000+ per hour.
Rockford Combustion Solutions will be there to support your needs following a serious incident involving an entire plant, loss of human life, or when a critical production process has been shut down.
5795 Logistics Parkway Rockford, Illinois, USA 61109