Total Issues
39
Critical
3
Total Downtime
122.0h
Avg Downtime
6.1h
MTBF
30.8h
Uptime
89.8%
Showing 39 of 39 issues
ISS-2025-001CRITICALmechanical
2025-01-08 14:23 | Gasifier Grate Motor
7.0h downtime
M. Dubois
Description: Grate motor seized during operation, causing feedstock accumulation
Root Cause: Bearing failure due to high temperature exposure (>180°C)
Resolution: Replaced motor bearings, installed heat shield, upgraded to high-temp bearings
Resolved: 2025-01-09 21:23Duration: 7.0 hours
ISS-2025-002MEDIUMsensor
2025-01-15 09:45 | TI-103 (Gas Temperature)
0.0h downtime
L. Martin
Description: Temperature sensor reading 40°C lower than actual
Root Cause: Sensor drift due to tar coating on thermocouple
Resolution: Cleaned sensor, recalibrated, implemented weekly cleaning schedule
Resolved: 2025-01-15 12:30Duration: 0.0 hours
ISS-2025-003HIGHfeedstock
2025-01-22 16:12 | Pelletizer
3.0h downtime
P. Laurent
Description: Pelletizer jamming repeatedly with sewage sludge feed
Root Cause: Moisture content exceeded 25% (spec: <20%), foreign objects in feedstock
Resolution: Enhanced pre-screening, adjusted dryer parameters, moisture monitoring
Resolved: 2025-01-23 01:12Duration: 3.0 hours
ISS-2025-004HIGHprocess
2025-02-03 11:30 | Gasifier Bed
6.0h downtime
M. Dubois
Description: Clinker formation in gasifier bed, restricting gas flow
Root Cause: High ash content in horse manure batch (18% vs typical 12%)
Resolution: Manual clinker removal, adjusted ER ratio, feedstock blending optimization
Resolved: 2025-02-04 05:30Duration: 6.0 hours
ISS-2025-005CRITICALsafety
2025-02-11 08:15 | H2S Detection System
12.0h downtime
Safety Team
Description: H2S sensor alarm triggered at 850 ppm (threshold: 500 ppm)
Root Cause: Biological methanation reactor pH drop to 5.2, sulfur-reducing bacteria activity
Resolution: Emergency shutdown, pH adjustment to 7.0, reactor restart with monitoring
Resolved: 2025-02-13 08:15Duration: 12.0 hours
ISS-2025-006LOWsensor
2025-02-18 14:50 | PI-205 (Steam Pressure)
0.0h downtime
L. Martin
Description: Pressure transmitter showing intermittent signal loss
Root Cause: Loose electrical connection in junction box
Resolution: Tightened connections, applied dielectric grease, tested signal integrity
Resolved: 2025-02-18 15:45Duration: 0.0 hours
ISS-2025-007HIGHmechanical
2025-03-05 19:30 | Particle Filter
4.0h downtime
P. Laurent
Description: Excessive pressure drop across particle filter (>200 mbar)
Root Cause: Filter cake buildup, inadequate pulse cleaning frequency
Resolution: Filter element replacement, increased pulse frequency to 90s intervals
Resolved: 2025-03-06 07:30Duration: 4.0 hours
ISS-2025-008MEDIUMprocess
2025-03-12 10:20 | Water Gas Shift Reactor
8.0h downtime
M. Dubois
Description: CO conversion efficiency dropped to 68% (target: >85%)
Root Cause: Catalyst deactivation, sulfur poisoning from upstream H2S breakthrough
Resolution: Catalyst regeneration procedure, improved H2S removal upstream
Resolved: 2025-03-14 10:20Duration: 8.0 hours
ISS-2025-009MEDIUMfeedstock
2025-03-20 13:45 | Dryer
2.0h downtime
L. Martin
Description: Dryer unable to reduce moisture below 22% for MSW feedstock
Root Cause: Rainy season MSW with 45% initial moisture, insufficient dryer capacity
Resolution: Extended drying time, reduced throughput by 15%, pre-drying protocol
Resolved: 2025-03-21 01:45Duration: 2.0 hours
ISS-2025-010LOWmaintenance
2025-03-28 07:15 | Flare System
3.0h downtime
P. Laurent
Description: Scheduled maintenance: flare tip inspection and cleaning
Root Cause: Preventive maintenance per 500-hour schedule
Resolution: Cleaned flare tip, inspected ignition system, tested flame stability
Resolved: 2025-03-28 13:15Duration: 3.0 hours
ISS-2025-011CRITICALmechanical
2025-04-04 16:40 | Screw Conveyor
9.0h downtime
M. Dubois
Description: Screw conveyor drive chain failure, feedstock delivery stopped
Root Cause: Chain fatigue failure after 800 operational hours, inadequate lubrication
Resolution: Replaced drive chain, installed automatic lubrication system, alignment check
Resolved: 2025-04-06 08:40Duration: 9.0 hours
ISS-2025-012HIGHsensor
2025-04-11 11:25 | O2 Analyzer
0.0h downtime
L. Martin
Description: O2 sensor reading stuck at 4.2%, not responding to process changes
Root Cause: Sensor membrane failure, exposure to condensate water
Resolution: Replaced O2 sensor, installed condensate trap, calibrated new sensor
Resolved: 2025-04-11 14:50Duration: 0.0 hours
ISS-2025-013MEDIUMprocess
2025-04-19 09:00 | Biological Methanation
0.0h downtime
Bio Team
Description: CH4 yield dropped to 62% (target: >75%)
Root Cause: Nutrient depletion in bioreactor, trace element deficiency
Resolution: Added nutrient solution (N, P, K + trace elements), adjusted retention time
Resolved: 2025-04-21 09:00Duration: 0.0 hours
ISS-2025-014MEDIUMsafety
2025-04-26 15:30 | Emergency Shutdown System
0.0h downtime
Safety Team
Description: ESD valve test failed, valve did not close within 3 seconds
Root Cause: Actuator air supply pressure low (4.2 bar vs required 6 bar)
Resolution: Repaired air compressor, replaced pressure regulator, tested all ESD valves
Resolved: 2025-04-26 18:45Duration: 0.0 hours
ISS-2025-015HIGHmechanical
2025-05-07 12:15 | Ash Removal System
5.0h downtime
P. Laurent
Description: Ash discharge valve stuck closed, ash accumulation in gasifier
Root Cause: Valve seat erosion and ash bridging
Resolution: Replaced valve internals, installed vibrator to prevent bridging
Resolved: 2025-05-08 05:15Duration: 5.0 hours
ISS-2025-016LOWfeedstock
2025-05-14 08:45 | Feedstock Storage
0.0h downtime
QC Team
Description: Horse manure batch contaminated with plastic waste (>5% by weight)
Root Cause: Inadequate source separation at supplier facility
Resolution: Rejected batch, implemented supplier quality audit, enhanced inspection
Resolved: 2025-05-14 10:30Duration: 0.0 hours
ISS-2025-017MEDIUMprocess
2025-05-22 17:20 | Tar Removal System
4.0h downtime
M. Dubois
Description: Tar accumulation in gas cooling section, increased pressure drop
Root Cause: Gasifier temperature fluctuation (750-850°C), incomplete tar cracking
Resolution: Stabilized gasifier temp at 820°C, installed tar collection system
Resolved: 2025-05-23 13:20Duration: 4.0 hours
ISS-2025-018LOWmaintenance
2025-05-29 10:00 | Full System
16.0h downtime
Full Team
Description: Scheduled 1000-hour major maintenance inspection
Root Cause: Preventive maintenance per manufacturer schedule
Resolution: Complete system inspection, replaced wear parts, recalibrated all sensors
Resolved: 2025-06-01 10:00Duration: 16.0 hours
ISS-2025-019MEDIUMsensor
2025-06-08 14:30 | Flow Meter FI-301
0.0h downtime
L. Martin
Description: Syngas flow meter reading erratic, ±15% variation
Root Cause: Particulate buildup on sensor element, inadequate filtration
Resolution: Cleaned flow sensor, upgraded upstream filtration to 5 micron
Resolved: 2025-06-08 17:15Duration: 0.0 hours
ISS-2025-020MEDIUMmechanical
2025-06-15 11:50 | Steam Generator
6.0h downtime
P. Laurent
Description: Steam generator efficiency dropped, increased fuel consumption
Root Cause: Scale buildup on heat exchanger tubes, poor water quality
Resolution: Descaling procedure, installed water softener, water quality monitoring
Resolved: 2025-06-17 11:50Duration: 6.0 hours
ISS-2025-021LOWprocess
2025-06-23 09:30 | Gas Cooling
0.0h downtime
Operations
Description: Gas outlet temperature 5°C above setpoint (45°C vs 40°C)
Root Cause: Cooling water temperature increase due to summer ambient conditions
Resolution: Adjusted cooling water flow rate, acceptable deviation documented
Resolved: 2025-06-23 11:00Duration: 0.0 hours
ISS-2025-022HIGHsafety
2025-07-05 16:45 | Pressure Relief Valve
7.0h downtime
Safety Team
Description: PRV-101 failed to reseat after test, continuous venting
Root Cause: Foreign material on valve seat, corrosion on sealing surface
Resolution: Replaced PRV, implemented quarterly testing schedule, material upgrade
Resolved: 2025-07-07 04:45Duration: 7.0 hours
ISS-2025-023HIGHfeedstock
2025-07-12 13:20 | Pelletizer Die
8.0h downtime
M. Dubois
Description: Pelletizer die cracked, producing irregular pellets
Root Cause: Metal fatigue from cyclic loading, 900 hours operation
Resolution: Replaced pelletizer die, reduced throughput by 10%, scheduled replacement at 800h
Resolved: 2025-07-14 13:20Duration: 8.0 hours
ISS-2025-024LOWsensor
2025-07-20 10:15 | Level Sensor LI-402
0.0h downtime
L. Martin
Description: Ash hopper level sensor showing intermittent readings
Root Cause: Dust accumulation on ultrasonic sensor face
Resolution: Cleaned sensor, installed air purge system for continuous cleaning
Resolved: 2025-07-20 11:30Duration: 0.0 hours
ISS-2025-025MEDIUMmechanical
2025-07-28 15:00 | Air Blower
4.0h downtime
P. Laurent
Description: Air blower vibration increased to 8.5 mm/s (limit: 7.0 mm/s)
Root Cause: Impeller imbalance due to erosion from particulate entrainment
Resolution: Balanced impeller, installed inlet filter, vibration monitoring enabled
Resolved: 2025-07-29 07:00Duration: 4.0 hours
ISS-2025-026MEDIUMprocess
2025-08-06 09:45 | Syngas Composition
0.0h downtime
Operations
Description: H2 content dropped to 18% (typical: 22-25%)
Root Cause: Steam-to-biomass ratio too low (0.4 vs optimal 0.6)
Resolution: Increased steam injection rate, adjusted SBR control algorithm
Resolved: 2025-08-06 14:30Duration: 0.0 hours
ISS-2025-027LOWmechanical
2025-08-14 12:30 | Rotary Valve
3.0h downtime
M. Dubois
Description: Feedstock rotary valve leaking air, reducing system efficiency
Root Cause: Worn rotor seals after 1100 hours operation
Resolution: Replaced rotor seals, adjusted clearances, leak test passed
Resolved: 2025-08-14 21:30Duration: 3.0 hours
ISS-2025-028MEDIUMsafety
2025-08-22 16:00 | Gas Detection System
0.0h downtime
Safety Team
Description: CO detector in control room failed self-test
Root Cause: Sensor end-of-life (24 months), electrochemical cell exhausted
Resolution: Replaced CO detector, tested all gas detectors, updated replacement schedule
Resolved: 2025-08-22 17:45Duration: 0.0 hours
ISS-2025-029HIGHsensor
2025-09-03 11:15 | PLC Communication
0.0h downtime
Controls Team
Description: Lost communication with gasifier temperature sensors (TI-101 to TI-105)
Root Cause: Network switch failure, power supply fault
Resolution: Replaced network switch, installed redundant power supply, restored comms
Resolved: 2025-09-03 14:45Duration: 0.0 hours
ISS-2025-030MEDIUMfeedstock
2025-09-11 08:30 | Sewage Sludge Feed
0.0h downtime
QC Team
Description: Sewage sludge batch with high chlorine content (0.8% vs spec <0.3%)
Root Cause: Industrial discharge into municipal wastewater system
Resolution: Rejected batch, coordinated with wastewater treatment plant, enhanced testing
Resolved: 2025-09-11 10:00Duration: 0.0 hours
ISS-2025-031LOWprocessmonitoring
2025-09-18 14:20 | Biomethane Quality
0.0h downtime
Operations
Description: CH4 purity at 94.2% (target: >95% for grid injection)
Root Cause: CO2 removal efficiency slightly reduced, membrane aging
Resolution: Adjusted membrane pressure, acceptable for current use, replacement scheduled
Resolved: 2025-09-18 16:00Duration: 0.0 hours
ISS-2025-032LOWmaintenance
2025-09-25 10:45 | Lubrication System
2.0h downtime
P. Laurent
Description: Scheduled lubrication service for all rotating equipment
Root Cause: Preventive maintenance per 300-hour schedule
Resolution: Lubricated all bearings, checked oil levels, replaced filters
Resolved: 2025-09-25 16:45Duration: 2.0 hours
ISS-2025-033HIGHmechanicalmonitoring
2025-10-07 15:30 | Gasifier Refractory
10.0h downtime
M. Dubois
Description: Refractory lining crack detected during inspection, heat loss observed
Root Cause: Thermal cycling stress, 1150 hours at 800-900°C
Resolution: Patched refractory, scheduled full relining at 1500 hours
Resolved: 2025-10-09 15:30Duration: 10.0 hours
ISS-2025-034MEDIUMsensor
2025-10-15 09:00 | Gas Chromatograph
0.0h downtime
L. Martin
Description: GC analysis showing baseline drift, inaccurate H2 readings
Root Cause: Column contamination, carrier gas impurity
Resolution: Replaced GC column, installed carrier gas purifier, recalibrated
Resolved: 2025-10-15 16:30Duration: 0.0 hours
ISS-2025-035MEDIUMprocess
2025-10-23 13:45 | Ash Quality
0.0h downtime
Operations
Description: Ash carbon content at 12% (target: <8%), incomplete combustion
Root Cause: Air distribution uneven in gasifier, low ER in bottom zone
Resolution: Adjusted air injection ports, optimized ER profile, improved mixing
Resolved: 2025-10-24 09:45Duration: 0.0 hours
ISS-2025-036LOWsafety
2025-10-30 11:20 | Fire Suppression
0.0h downtime
Safety Team
Description: Annual fire suppression system test and inspection
Root Cause: Regulatory compliance requirement
Resolution: Tested all fire detectors, suppression nozzles, updated certification
Resolved: 2025-10-30 14:00Duration: 0.0 hours
ISS-2025-037MEDIUMmechanical
2025-11-05 16:15 | Condensate Drain
3.0h downtime
P. Laurent
Description: Condensate drain line frozen, water backup in gas cooling section
Root Cause: Ambient temperature dropped to -2°C, inadequate insulation
Resolution: Thawed drain line, installed heat tracing, added insulation
Resolved: 2025-11-06 01:15Duration: 3.0 hours
ISS-2025-038LOWfeedstock
2025-11-12 10:30 | MSW Quality
0.0h downtime
Operations
Description: MSW batch with high moisture (38%) and low calorific value
Root Cause: Rainy weather, outdoor storage without cover
Resolution: Extended drying time, implemented covered storage requirement
Resolved: 2025-11-12 14:00Duration: 0.0 hours
ISS-2025-039LOWprocessmonitoring
2025-11-18 14:00 | System Efficiency
0.0h downtime
Engineering
Description: Overall system efficiency at 68% (target: >70%)
Root Cause: Cumulative minor inefficiencies, aging components at 1200 hours
Resolution: Scheduled comprehensive optimization and component refresh
Resolved: 2025-11-19 10:00Duration: 0.0 hours