APOLLO AUTOMATIONJAMES WARREN · ENGINEERING & PROJECT LEADERSHIP

CASE-011 · Engineering case

A6 Acetator Low Grain Conversion and Airflow Investigation

Converted a low grain-conversion event into a structured acetator troubleshooting, controls-update, and mechanical-inspection protocol.

Conceptual engineering visualization: A6 Acetator Low Grain Conversion and Airflow Investigation
Conceptual engineering visualization · AI generated

Why the Work Mattered

Purpose and Operating Need

A6 performance dropped after reseeding from A5 following a cooling-pump VFD fault, foaming, and loss of several thousand gallons, so the response had to separate biological/process effects from mechanical aeration problems.

Engineering Approach

Engineering Approach

Compared HMI airflow against manual meter readings, converted CFM to m3/hr, compared expected versus measured airflow, checked bearing temperatures with thermal imaging, inspected noise and shaft wobble, ruled out visibly open inlet air valves and apparent RPM differences, and recommended tank drainage, ventilation, internal aerator inspection, seal/coupling checks, motor-bearing PM review, alarm/trend updates, and operator monitoring.

Outcome & Engineering Context

Outcome and Context

Improved acetator troubleshooting, controls monitoring, and recommissioning readiness.

Workstream Results & Impact

Workstream Portfolio Rollup

66,885,000 USD

Vinegar Acetation and Fermentation-Support Modernization

Recorded workstream portfolio reference. This is the workstream-level value and is not a project expenditure or a new total of reassigned projects.

Measures & Operating Detail

MeasureValueType & meaningAttribution & operating context
Grain Conversion2.8 grainTarget
Expected

Applies to: Investigate declining grain conversion

Grain Conversion1.7 to 1.8 grainObservation
Observed range

Applies to: Investigate declining grain conversion

Airflow198 CFMObservation
Manual measured

Applies to: Compare HMI airflow with manual meter readings

A6 airflow and bearing-temperature investigation

Airflowapproximately 335 m3/hObservation
Manual equivalent

Applies to: Compare HMI airflow with manual meter readings

A6 airflow and bearing-temperature investigation — Recorded approximate metric-unit equivalent of the 198 CFM manual airflow reading; retain the recorded 335 m3/h value.

Airflow320 m3/hObservation
HMI displayed

Applies to: Compare HMI airflow with manual meter readings

A6 airflow and bearing-temperature investigation

HMI/Manual Deviation-4 to 4 %Observation
Reported band

Applies to: Compare HMI airflow with manual meter readings

A6 airflow and bearing-temperature investigation — Reported HMI-to-manual comparison band; retained as the source-reported band rather than a newly calculated percentage.

Airflow280 CFMTarget
Expected

Applies to: Compare expected and measured airflow

A6 airflow and bearing-temperature investigation

Airflowapproximately 475 m3/hTarget
Expected equivalent

Applies to: Compare expected and measured airflow

A6 airflow and bearing-temperature investigation — Recorded approximate metric-unit equivalent of the 280 CFM expected airflow reference; retain the recorded 475 m3/h value.

Airflow Deficitapproximately 30 %Observation
Observed airflow deficit

Applies to: Compare expected and measured airflow

A6 airflow and bearing-temperature investigation — Approximately 30% below expected airflow during the A6 investigation; this is a diagnosed shortfall, not an achieved improvement.

Bearing Temperature150 degFObservation
thermal imaging verified

Applies to: Check bearing temperature with thermal imaging

A6 airflow and bearing-temperature investigation

Bearing Temperature130 degFBaseline
Comparison asset

Applies to: Check bearing temperature with thermal imaging

A6 airflow and bearing-temperature investigation — A5 bearing temperature used as the comparison equipment reading; separate from the A6 150 degF reading.

Engineering scope and design basis

Improved root-cause clarity, operator monitoring, alarm coverage, maintenance PM discipline, and readiness for internal inspection before returning A6 to service.

Improved A6 troubleshooting accuracy, measured by 198 CFM / 335 m3/hr measured airflow versus 280 CFM / 475 m3/hr expected airflow, grain conversion decline from 2.8+ to 1.7-1.8, and bearing-temperature validation at 150 F on A6 versus 130 F on A5, by linking airflow analysis, thermal imaging checks, operator trends, PM review, and planned internal aerator inspection.

198 CFM / 335 m3/hr measured airflow; 320 m3/hr HMI airflow; +/-4 percent HMI-to-manual deviation; 30 percent airflow deficit; expected 2.8 grain conversion; actual 1.7-1.8; A6 bearing 150 F; A5 bearing 130 F; alarm recommendation at 230 F.

Used airflow verification and thermal imaging checks to define trend corrections, amp-load monitoring, bearing-alarm settings, operator checklists, PM review and the planned tank-entry, fiber-seal and acetator-coupling inspection protocol.

Actions, Methods & Controls

ACTIVITIES IN CONTEXT

Additional Technical Detail

Roles & contributions

  • Project Ownership

    Full lifecycle project ownership

    Direct Work

    Compared airflow readings and unit conversions, checked bearing temperatures with thermal imaging and inspected external mechanical symptoms; developed the follow-up monitoring, PM and internal-inspection protocol.

    Owned the full project lifecycle: capital planning and prioritization, need definition, feasibility and scope development, engineering and AFE justification, procurement and vendor coordination, construction sequencing and field oversight, commissioning, turnover, and post-startup support. Connected operating requirements with technical scope, funding decisions, execution readiness, and the needs of operations and maintenance.

Workstream context
Vinegar Acetation and Fermentation-Support Modernization ↗
A6 equipment context

The temperature comparison relates an invalid 617°F display to a 150°F thermal-imaging reference. The 4,000-gallon startup loading question remains unresolved.

Additional technical detail
Explore 1 detail record
  • Inspection preparation

    Defined the A6 tank-preparation and internal-inspection protocol, including drainage, rinsing, ventilation, and component-inspection actions.

All portfolio connections
All portfolio connections (22)
Related analysis and application artifacts

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