When you’ve worked long enough at heavy industrial plants, the equipment starts to feel so familiar that you think you have it all figured out. You might even think you know them well enough that you can start skipping a step or use your own process of shortcuts to get things started. 

An ACI System isn’t like the old truck your uncle left you in his will – there’s not a “little trick” to get things started. A proper startup process is essential for not only safe operation but to keep your system from needing major repairs all too soon.

Whether you are starting a newly installed system for the first time or restarting from an outage, we carefully instruct our clients on proper startup protocols for everything we install (of course, we also show you how to properly take ACI systems offline) 

It might even be worthwhile for you to bookmark this page. 

Safe Startup Procedures for ADA-ES or Motus Group ACI Systems

1 – Check manifold and lances for plugs

If your system was recently in a lay-up, you should have checked for plugs. Before startup, check each of the lances for plugs by doing the following:

Take an initial reading of the eductor vacuum with the blowers shut off and all lances open

Isolate all lances (close valves, remove piping, etc.) except the first and take a vacuum reading for that lance

Repeat this process for each lance on the system

If the eductor reading reads zero or close to zero, blow or rod out the lance that is being tested

2 – Start Equipment In Maintenance Mode

After placing the system in maintenance mode, align diverter valves to the trains you will run in auto-mode. 

If the blowers are not already running, put the system in maintenance mode and turn on blowers. Verify that blower pressure and eductor vacuum readings are within acceptable ranges (compared to alarm logic)

Verify scales are reading at Zero lbs. 

Validate scale calibration by adding known weight values.

If needed, recalibrate the scales (C2 calibration button)

Once scales are verified, open knife gate valves

Turn on rotary feeders in maintenance mode and fill the hoppers for the trains you will be running in auto mode. Do not fill trains if they are not going to be used right away.

3 -Starting ACI Systems In Auto-Mode

Switch system operation from maintenance mode to auto mode

Press the auto-start button on the HMI or at the DCS

Ensure that the equipment starts in the following order:

Blowers

Feeders

Rotary Feeder

Aeration

Take notice of any alarms that may go off. 

4 Switching Between Trains

The hopper for the train you’re switching from should be emptied before switching to the new train. 

Swap diverter valve position to auto mode

Fill hopper of the newly selected train

Run the system in auto-mode by following the instructions in step 3