What We Suggest For Preventative ACI System Maintenance

As the saying goes, “a stitch in time saves nine.” And while there aren’t a lot of textiles on the job site, taking care of the heavy industrial equipment on site is a crucial part of the job. Machines move, and things that move eventually wear down, tune out, and could start to run inefficiently – or even dangerously. 

In our experience, we notice that plants that skip regular preventative maintenance frequently see equipment failure sooner and more often than those that don’t.

Regarding the bottom line, preventative maintenance is always more cost-effective than the alternatives. For every system we install and service, we have regular maintenance recommendations that ensure your plant stays running longer and at top capacity.

While we can only recommend certain preventative maintenance, it is always a good idea to follow manufacturer and OEM recommendations if they are more rigorous – especially when it comes to routine equipment lubrication.

Overall, you should be swapping between your “trains” (paired feeding and conveying equipment) every 2-4 weeks. If you cannot do this, whatever equipment isn’t locked out and still functioning should be cycled out every 2-4 weeks. 

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Need additional guidance? Have questions about your system? Give us a call; we’re more than happy to answer your questions, schedule an inspection, or tell you a friendly joke. 

Weekly Preventative Maintenance

Blower Inlet Filters

Physically inspect the filters monthly, but check the differential pressure indicators weekly. 

o Filters should be replaced when DP reaches 12 IWC 

o If indicators read above 9 IWC during the inspection, it is possible they will need replacing before the next inspection. Replace immediately or check daily until the DP reaches 12 IWC

Eductor Pressure Transmitters

o Verify pressures are within acceptable ranges and adjust if necessary 

▪ If eductor pressure is high (heading away from 0) open hand valve 

▪ If eductor pressure is low (headed towards 0) close hand valve 

o Verify that transmitters are functioning correctly 

Monthly Preventative Maintenance

Knife Gate Valves

o Cycle valves monthly 

o Inspect for PAC leaks when valves open and close 

Rotary Feeder

o Bump rotary feeder motors monthly 

o Inspect for PAC leaks 

o Inspect for oil/lubricant leaks 

o Replace oil/lubricant per the OEM’s O&M manual recommendations

Screw Feeders

o Bump screw feeder motors monthly 

o Inspect for PAC and oil/lubrication leaks 

o Inspect gearbox belts and gears for wear and proper tension 

Feeder Hoppers/ Scales (Monthly, when swapping trains).

o Empty hoppers before swapping feed trains 

o Verify that the scales read 0 lbs. after hoppers are emptied 

▪ Keep in mind that it is possible that the scales will not zero out. In this case, continue feeding until the weight reading stops changing. Then add known weights to the scales to validate a correct calibration. If the weight reading doesn’t match up, your scale will need calibration.

Diverter Valves

o Diverter valve positions should be swapped every 2-4 weeks 

o When diverter positions are swapped, check for seal leaks 

▪ If leaks are observed, the inspection hatches need to be removed and checked for PAC buildup. There is an inspection hatch on the piston side and at the end plate to allow access to each side of the valve. PAC buildup on either side of the valve should be removed and seal plates should be tightened as much as possible to prevent further leaks. 

If leaks continue, the valve seals may need to be replaced. 

Injection Manifold

o Inspect for leaks 

o Inspect for damaged or collapsing hoses 

o Actuate isolation valves 

Heaters & Fans

o Verify the heaters, fans, and thermostats in the silo are operating correctly. 

o Thermostats should be wired correctly for the equipment they are controlling

 ▪ For heating applications (heaters), the thermostat should activate equipment when the temperature setting is raised above ambient conditions 

▪ For cooling applications (fans), the thermostat should turn on as the temperature setting is lowered below ambient conditions

Quarterly Preventative Maintenance (Every three months)

Bin Vent Filter Cartridges

o Bin vent filter cartridges should be inspected for damage and cleanliness quarterly 

o Differential pressure should be monitored during silo filling. A high DP during filling is a good indication that cartridges are plugged and will need to be replaced. 

o DP readings consistently above 5 IWC indicate that filters should be replaced 

Silo Pressure Relief Valves

o Check that valve spring cycles (compresses and releases) 

o Open valve hatch and inspect internal components and gasket for damage 

Screw Feeder Outlet/ Drop Tube Expansion Joint

o Inspect drop tube expansion joints for wear (cracking, tears, etc.)