RTO
Executive summary
Significant particulate buildup is present throughout the lower inlet manifold of Coater 2 RTO, including heavy ash piles on the manifold floor, coating on divider walls, and fouling at the inspection hatch face. Media support baffles and main valve sealing surfaces were inspected post-cleaning and are in serviceable condition with no warping, scoring, or seal ring degradation observed. Primary next step is to remove the accumulated material from the inlet manifold and confirm root cause before flow distribution to the media beds is compromised.
Prioritized actions
- 1 WARNINGVacuum and remove ash accumulation from inlet manifold floor, divider walls, and inlet duct.
- 2 WARNINGClean inspection hatch interior face and verify gasket condition after deposit removal.
- 3 WARNINGInvestigate upstream source of particulate loading driving manifold fouling rate.
- 4 INFOWipe residual yellow and pink process residue from baffle plate surfaces during next entry.
- 5 INFORe-inspect main valve seal ring and valve face seating at next scheduled internal inspection.
- 6 INFODocument manifold deposit depth at fixed reference points to trend accumulation rate.
Findings
Findings
123Perforated support screen under the baffle plate is clear and unobstructed following cleaning, and the plate-to-housing seat is intact. A yellow process residue remains on the baffle plate surface but does not affect flow area.
Wipe down residual process deposit from the baffle plate surface at next entry. No structural action required.
123Perforated screen face is fully open post-cleaning with fastener seated correctly at the perimeter. Light residual buildup remains along the frame edge but does not obstruct perforations.
Brush the frame edge during the next cleaning cycle to prevent edge buildup from migrating across the screen.
123Diagonal seam between baffle plates is sound and the perforated support plate is clear after screen cleaning. Light pink residue on the baffle surface is cosmetic and consistent with process carryover.
No action required beyond routine cleaning at the next planned outage.
1234Main valve seal ring is seated uniformly against the valve face, with no scoring of the sealing surface and no warping of the inlet baffle. Minor debris at the inlet floor is housekeeping-level only.
Clear debris from the inlet floor during next entry and continue periodic seal ring inspection.
123Conical inlet baffle surface is clean and undistorted, and the seal ring interface against the valve face appears continuous. Valve face edge shows no warping at the visible sector.
No action required. Reconfirm seal ring continuity at next scheduled valve service.
123Seal ring tracks intact along the full visible perimeter of the valve face and the valve face sector itself shows no warping. Light particulate accumulation is present on the inlet baffle edge.
Remove particulate from the baffle edge during routine cleaning; no repair needed.
123Particulate accumulation is building along the perforated distributor plate edge inside the manifold. Distributor holes remain open at this time, but the deposit layer on the manifold wall indicates active fouling.
Vacuum the manifold and clear the perforated distributor edge before holes begin to blind off and distort flow distribution.
123Interior manifold surfaces are coated with particulate, and the inside face of the inspection hatch carries a heavy deposit layer. Hatch fasteners and flange seal are intact with no evidence of external leakage.
Clean the hatch face and manifold walls; inspect the hatch gasket during reassembly and replace if deposits have impressed into the sealing surface.
123Significant ash pile has accumulated on the manifold floor, with coating on the divider walls and buildup encroaching on the inlet duct flow path. This level of accumulation will begin to restrict cross-section and skew distribution to the media beds if left.
Remove accumulated ash from the manifold floor and inlet duct immediately, and identify the upstream source driving the loading rate.
123Overall exterior of the RTO main vessel and auxiliary enclosure is sound with no external defects observed. Findings of concern are concentrated in the lower base piping manifold area as documented in the preceding photos.
Address lower manifold buildup as the priority work scope; no external vessel action required.