CASE-036 · Engineering case

A6 Acetator Workstream Updates and Inspection Protocol

Defined controls, operator, maintenance, and vendor actions to improve A6 monitoring and inspection readiness.

Why the Work Mattered

Purpose and Operating Need

The A6 issue exposed a monitoring gap: bearing temperatures and motor amps existed but were not configured correctly or captured for historical trending.

Engineering Approach

Coordinated the A6 monitoring updates: motor-amp alignment with panel readings, amps-versus-percent-FLA trending, correction of the erroneous 617 F display using the 150 F thermal imaging reference, the 230 F bearing alarm and airflow-trend repair. Defined the full-load airflow reference, +/-5 percent operator checks, bearing-grease PM review, and the drainage, rinsing, 24-hour ventilation and internal fiber-seal/air-piping inspection protocol.

Outcome & Engineering Context

Outcome and Context

Improved A6 monitoring, alarm response, PM quality, and inspection 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

Measure	Value	Type & meaning	Attribution & operating context
Erroneous Bearing Display	617 degF	Observation Invalid displayed value	Applies to: Specify correction of the erroneous bearing display using the thermal imaging reference A6 airflow and bearing-temperature investigation — Erroneous displayed value observed on the HMI; the independent thermal imaging bearing-temperature reference was 150 degF.
Bearing Temperature	150 degF	Observation Validated reference	Applies to: Specify correction of the erroneous bearing display using the thermal imaging reference A6 airflow and bearing-temperature investigation
Bearing Alarm	230 degF	Operating Control Recommended setting	Applies to: Specify the 230 F bearing-temperature alarm A6 recommended bearing alarm
Bearing Alarm	230 degF	Operating Control Configured setting	Applies to: Specify the 230 F bearing-temperature alarm A6 recorded alarm configuration
Airflow Tolerance	-5 to 5 %	Operating Control Operating Control	Applies to: Specify operator airflow checks during charge and discharge Charge/discharge
Motor Loading	<= 80 % FLA	Operating Control Operator upper limit	Applies to: Define the steady-state motor-loading threshold for operator checks Steady state
Ventilation Duration	24 h	Operating Control Inspection preparation condition	Applies to: Specify the 24-hour ventilation preparation period before internal inspection Before internal inspection — Recorded 24-hour ventilation preparation before internal inspection; retained as protocol/readiness rather than completed tank-entry evidence.
Startup Volume Context	4,000 gal	Unresolved Value Open-question context	Applies to: Retain startup FLA question at 4000 gallons Startup — Unresolved question concerning startup motor loading at 4,000 gallons.

Engineering scope and design basis

Improved monitoring and trend visibility through coordinated controls updates; defined operator checks, PM review and internal-inspection preparation.

Defined the A6 monitoring and inspection protocol using a 230 F bearing alarm, <=80 percent FLA steady-state operator threshold, +/-5 percent airflow check and 24-hour tank-ventilation preparation, with separate controls, operator, maintenance and vendor actions.

230 F bearing alarm; <=80 percent FLA steady-state threshold; +/-5 percent airflow tolerance; 24-hour ventilation before entry; 4000-gallon startup FLA question to resolve.

Coordinated PLC/HMI monitoring updates and developed the operator checklist and PM review; specified tank-entry preparation, pre-kitted parts, fiber-seal inspection and acetator-coupling verification.

Actions, Methods & Controls

ACTIVITIES IN CONTEXT