CleanSwitch
Executive summary
Lift cylinder pneumatic fittings on the main control panel circuit failed to hold high lift pressure after retape and retighten; fittings were replaced during this visit. A loose screwdriver was also found inside the live internal PLC panel — an immediate FOD and arc-flash hazard. Remainder of the CleanSwitch RTO (vessel, stack, ductwork, gas train, platforms, electrical cabinet wiring) is in serviceable condition. Verify the lift cylinder repair holds pressure under a full switch cycle before returning the unit to unattended operation.
Prioritized actions
- 1 CRITICALRemove screwdriver from internal PLC panel and audit enclosure for any other FOD
- 2 WARNINGVerify replaced lift cylinder fittings hold high lift pressure through full switching cycles
- 3 WARNINGLeak-check remaining pneumatic fittings on switching valve actuator circuit
- 4 INFOInvestigate staining at exhaust stack base flange and confirm joint integrity
- 5 INFOSpot-treat surface oxidation on insulated process ductwork to arrest corrosion
- 6 INFOTorque-check terminal blocks and inspect overhead harness for chafing in main control panel
Findings
Findings
1234A screwdriver is resting on the internal panel chassis between the PLC module and the breaker bank. Breakers, terminal rows, and controller indicators are otherwise in good order, but a loose ferrous tool inside an energized enclosure is an immediate FOD and short-circuit hazard.
Remove the tool now and perform a tool/FOD sweep of the enclosure before closing. Reinforce tool-control discipline with site technicians.
1234Overall view of the CleanSwitch RTO shows intact exhaust stack, sound external ductwork and process piping, and a sealed control cabinet. Gas train is accessible with no leaks observed on visual inspection.
No action. Maintain current PM cadence.
1234Second elevation view confirms the RTO exhaust stack, blue VOC inlet duct coatings, and yellow gas supply piping are intact. Caged access ladder and maintenance platform remain serviceable.
No action required.
1234Electrical cabinet interior shows neatly ferruled terminal blocks, organized vertical wireways, and a fieldbus gateway mounted on DIN rail. PLC I/O indicators are visible and wiring service loops at the cable entry are properly dressed.
No action. Include in next scheduled torque-check and thermographic survey.
1234Main control panel houses the pneumatic fittings feeding the valve lift cylinder; those fittings leaked and would not hold high lift pressure after retape and retighten, so they were replaced during this visit. Surrounding terminal blocks, overhead harness, and cabinet door seal are intact.
Cycle the switching valve under full load and confirm lift pressure is stable. Leak-check the remainder of the cylinder pneumatic circuit and torque-check adjacent terminal blocks.
1234Side elevation shows insulated inlet ductwork, coated RTO vessel housing, and accessible skid piping with no deformation. CleanSwitch nameplate is legible.
No action required.
1234Unit is shown with caged access ladder secured and platform guardrail intact. A portable fiberglass step ladder is staged for service access; housing exterior is undamaged.
Stow the portable ladder when not in use to keep the platform area clear.
1234CS-350 main chamber cladding and yellow natural gas supply line are intact. Surface oxidation is visible on the insulated process ductwork and staining is present at the discharge stack base flange — neither is currently a structural concern but both warrant tracking.
Spot-treat ductwork oxidation and inspect the stack base flange joint for weep or gasket distress at the next outage.