EMTOS Annual Preventative Maintenance Report
This Annual procedure outlines the steps for conducting Annual preventative maintenance on the EMTOS asset, including inspection, cleaning, and finalization actions. This provides enhanced safety, operational reliability, and regulatory compliance by proactively identifying and addressing equipment issues before they cause failures. This reduces downtime, extends asset lifespan, and lowers long-term repair costs.
Envent Corporation
10/22/2025
EMTOS Annual Preventative Maintenance Report
This Annual procedure outlines the steps for conducting Annual preventative maintenance on the EMTOS asset, including inspection, cleaning, and finalization actions. This provides enhanced safety, operational reliability, and regulatory compliance by proactively identifying and addressing equipment issues before they cause failures. This reduces downtime, extends asset lifespan, and lowers long-term repair costs.
EMTOS Annual PM
Date
Inspectors
Unit #
License Plate #
Unit Hours Start
Air Compressor Hours Start
Gas Meter Start
No Power on Unit
1. Trailer
Inspect leg stands and grease all Zerk fittings. Check firebox to trailer bolts and holes for integrity. Ensure BIT inspection (California only), Annual inspection and Registration ate up to date, communicate to the mechanic and shop supervisor if due.
2. Bonding and Grounding
Check all bonding and grounding cables for good wire, proper clamps, and connections. Each unit should have at least one ground and two bonding spools. With an Ohms meter, check continuity; the reading should be less than 5
3. Fire Extinguishers
Verify that the two fire extinguishers on the unit are ready to use, not damaged, the seal is intact, the UL tag is in place, and they are up to date on their annual inspection. Replace if needed.
4. Air Compressor
If equipped, check air compressor oil, change if necessary, drain tank of any condensation, check belt integrity and replace if needed. AT WHAT HOUR INTERVALS
5. Process Blower
Open belt cover and shaft cover, check fan bushings or bearings, fan sheave, motor sheave, and belts for proper integrity and alignment - replace or tighten if needed. Grease process blower motor through zerk fittings. (Only use polyrex Em grease)
6. Process Blower/ Combustion Blower/ Air Compressor
Remove electrical motor cover, inspect wire terminations. Repair or replace connectors if needed.
7. Capsuhelics & Magnehelics
Ensure all Caps & Mags are reading 0. Adjust or replace if needed.
8. Flow Tubes (DS-300, DS-400)
Remove all DS-300/400 and blow out with shop air, inspect and reinsert or replace if needed..
9. KO Pot
Ensure sight glass valves are open. Drain KO Pot if necessary. Visually inspect gasket and PI, replace if needed.
10. Ignitor/Ignition Transformer
Clean igniter, verify no corrosion on the connection point to transformers or to the igniter. Mark igniter position before removing. Replace if necessary.
11. UV Scanner
12. Rotary Gas Meter (Totalizer)
Ensure the numbers on the pressure indicators and gas totalizer are readable.
13. Burner
Verify Burner gaskets are intact (Visual).
Verify that the modulating actuator moves to high during the 90 second high fire purge and moves to low when the BMS says to start. Ensure no rust/corrosion along linkage arm.
14. Propane Fuel Train Pressure Gauges
Check 0-30 PSIG Gauge on Main Fuel Line Upstream of Pancake Regulator. Verify When Valve is Closed and Gauges Removed that Pressure Goes to 0. Replace if Bad.
Check 0-30" WC Guage on Main Fuel Line Downstream of Pancake Regulator. Verify When Valve is Closed and Gauges Removed that Pressure Goes to 0. Replace if Bad.
Check 0-30" WC Gauge on Pilot Fuel Line. Verify When Valve is closed and Gauge Removed that Pressure Goes to 0. Replace if Bad.
Check 0-15" WC Gauge on Pilot Fuel Line. Verify When Valve is closed and Gauge removed that Pressure Goes to 0. Replace if Bad.
15. Firebox
Verify that the stack and firebox inlet sample ports are functional.
16. Maxon or Eclipse Valves (SSOV 1&2)
Open Side Panels, Inspect Gasket, check for water intrusion. Check Wire Terminations. Add Oil if Applicable.
17. Vaporizer
Check all wiring in vaporizer and make sure connections are secure (recrimp connections if necessary). Check Controller and ensure in good operating condition. Check silicone integrity around pilot ignitor transformer.
Ensure inlet valve installed properly in TOP position (Look for Tack Weld- Should be on Top).
Inspect and clean fire ring.
Pressure Relief Valve, Inspect it and Replace if it is damaged or has not been changed out in 5 years or more. (By Manufacturer)
Remove top cover held by 6 screws to inspect refractory and doughnut gasket. Ensure doughnut gasket is still in its place and not obstructing the space around tank.
18. Panels
Open each panel and tighten every wire termination. Remember, there are multiple panels: Main Control Panel, Ignitor Transformer panel, and LEL readout Auxiliary Panel on some units.
Check for open holes in each panel and plug them. Address any sign of rust or water intrusion. Ensure each panel is dry and water-tight. At the main control panel verify that LEL sensor wires are not jumpered (Bypassed) and there is a dessicant pack, add if missing or replace if saturated.
Inspect the condition of every wire, ensure no wire is rubbing against sharp edges, if so, ask an engineer for help.
Ensure Spiral wrap is placed correctly to protect wires. Ensure the wire tie downs are operational, replace if necessary.
No Power On Unit
Annual Checks
Dilution Filter
If applicable. Remove dilution filter cover, inspect and clean or replace filter.
Rotary Gas Meter
Drain oil in all three chambers and refill (left, right, and center). Inspect and replace screen gasket on inlet side and outlet side.
Remove the gas meter and send it to be calibrated and certified
KO Pot
Remove and clean demister pad. Let it dry and re-insert.
Chart Recorder
Replace the (2450) battery located behind the chart paper holder and pen.
Vaporizer
Remove burner ring from vaporizer, take off burner ring tips, clean using shop air, replace or re-use burner ring tips.
Replace Pilot Orifice if necessary.
High Temperature Limit Thermocouple
Replace the internal elements of the combustion chamber thermocouple, check continuity and verify operation during subsequent test fire
Combustion Chamber Thermocouple
Replace the internal elements of the combustion chamber thermocouple, check continuity and verify operation during subsequent test fire
Fire Box
Pull man way door and inspect the refractory on the floor roof, walls process inlet and burner
Burner
Verify burner cone integrity. Observe air gap on burner either by removing burner or going inside of combustion chamber. There should be at least ~1cm air gap around the burner housing and cone.
Inspect burner damper and linkage assembly
Inspect burner refractory discharge sleeve, check for cracks or broken studs.
Clean burner site glasses
4" Process Trim Valves
Open gear assembly and grease gears (If applicable)
MAIN Process Trim Valves
Open gear assembly and grease gears
Dilution Valve
Open gear assembly and grease gears
Power on Unit and Connected to Propane
Process Blower
Check motor rotation and observe/ listen for abnormal sounds or vibrations.
Combustion Blower
Check motor rotation and observe/ listen for abnormal sounds or vibrations.
Air Compressor
If equipped, turn on compressor, check rotation and observe/listen for abnormal sounds or vibration, check for leaks, and verify units stops at ~135psi (main tank)
Chart Recorder
Verify proper time and date stamp, and legible temperature recordings. Report if abnormal recordings found.
Panel Light Check
Check all buttons and switches as they are turned on to insure that the switch or button is lit when turned on.
Area Lights
Ensure all area light work, replace lightbulb if needed, look for and address signs of rust or water.
Vaporizer
Check burner ring to ensure all burner parts lit
Ensure burner ring turns off when vaporizer gets to 120 F of temperature.
Maxon or Eclipse Valves
Cycle solenoid valve prior to starting burner and verify that they do not open. Verify that the valves open after starting burner
Flame Arrestor
While the blower is on, check differential pressure across FA to ensure it is clean (should not be greater than 5" wc). If differential pressure is greater than 5" WC, remove and clean.
Rotary Gas Meter
Check Pressure gauges on rotary meter and read out gauges. Check differential pressure between gauge (In./H20) behind of main gas (pancake) regulator and first gauge on gas meter is less than 10" wc. If greater, change gasket screen on Totalizer.
Detonation Arrestor
While the unit is at temperature (both manual and actuated valves are open) check the differential pressure across the DA (should not be greater than 15" wc) and test drain for plugging (open valve and verify suction while the blower is on)
KO Pot
Check KO Pot demister pad for plugging - Open bottom drain and verify suction to ensure bottom drain is not plugged and KO Pot is empty.
Flow Gauges
Test all flow sensors and verify proper readings based on increasing and decreasing process and total flows
Process Isolation Valve
Check integrity of automatic process isolation valve by opening the process manual valve and verify no suction while unit is below 1400F
Drain moisture in airline to actuator and verify actuator opens valve once temperature is above 1400F
Process Manual Trim Valves
Check integrity of 4" process bypass valve and 10" process valve by bringing unit above 1400F with both valves closed and verify no suction at inlet
Propane Fuel Train
With unit running and at temperature, soap test all vaporizer connections and entire fuel train
With unit running and at temperature, trip the unit and ensure the SSOVs close and stop the flow of propane
Verify that the high and low pressure switches are intact and that the wires are not jumped together
High PS. If equipped, with hand pump testing port, isolate the switch from the fuel train and use the hand pump port to test the switch to ensure it shuts the unit down
Low PS, Close the main valve to the vaporizer and burn out line. If equipped with hand pump testing port, isolate the switch from the fuel train and release pressure from line or use a hand vacuum pump to ensure switch turn the unit down.
Interlock Testing
Check all Interlocks on unit
High Limit Temperature
While BMS is going into purge, change the set point below the chart recorder temperature and verify a "stoppage" in BMS activity
While unit is running, lower high temperature set point below chart recorder temperature and verify burner shut down.
UV Scanner
Remove UV Scanner from unit. Do not expose to direct sunlight. Cover optical lens and ensure that the unit shuts down.
LEL Analyzer
Calibrate LEL in accordance with the procedures, verify analyzer is not bypassed by valves or by jumped wires behind LEL controller.
Test high LEL shutdown by lowering the setpoint to 10%, then apply the span gas to the LEL analyzer and verify unit shuts down
Process Blower Pressure Switch
Open cover of pressure switch and verify that sensor is not jumped. Remove tubing from sensor and verify that interlock is tripped on BMS. Verify that one wire is on common and one wire is on NO (normally open).
Combustion Blower Pressure Switch
Open cover of pressure switch and verify that sensor is not jumped. Remove tubing from sensor and verify that interlock is tripped on BMS. Verify that one wire is on common and one wire is on NO (normally open).
FA Temperature Switch
Remove Temperature switch. Wrap heating element around probe, set temp to 410 degree F. Verify contacts open w/ohms meter at 400 degree F (for test fires check by disconnecting the common wire)
Firebox
Analyze entire exterior firebox wall with temperature gun and notate any part of the wall that exceeds 200°F
Burner
Verify that the modulating actuator moves to high during the 90 second high fire purge and moves to low when the BMS says to start
Trailer Deck
Perfomr a 360 walk around the unit and ensure no tools or fittings were left anywhere on the deck. Ensure it is fit for traveling.
Spare Parts
Verify Spare Parts are in Job Box
if the answer is "empty "
If spare is not stocked due to inventory, let a Maintenance Tech at the Yard know what needs to be ordered and then list below what this unit does not have.
End Hours
Unit End Hours
Meter name
Unit
Air Compressor End hours
Generator Meter End
Technician Closure Signature
Technician Sign Off
Supervisor Closure Approval Signature
Supervisor Sign Off
Click here to sign
Source: Envent Corporation (Community Member)