How to Effectively Maintain Industrial Stacks

Industrial stacks undergo a lot of activity and stress. They constantly pump out exhaust and steam, which exposes the interior of the stack to an immense amount of heat, moisture, gas, and debris similar to sawdust. When you consider the effects of all those factors over time, you can see how the wear and tear of regular use can add up quickly.

Stacks confronted with such elements may become vulnerable to corrosion, which can lead to structural damage when left unmaintained. Serious hazards, like partial or complete collapse, can occur when repairs are not performed in a timely manner. Not only is that a dangerous situation for workers and surrounding structures, but it will be very costly to the industrial plant. The cost to replace a stack and to repair all the damage caused could result in a complete loss.

That is why it is important that stacks at industrial plants are properly maintained. The best way to ensure that is done is with regular inspections by an experienced industrial turnkey provider for plant maintenance and repair service

Why Ongoing Maintenance and Inspections Are Important

Regular industrial stack inspections are important for worker safety and plant production, but they are also important to help keep your plant compliant with regulations and laws. The American Society of Civil Engineers (ASCE), there are two classes, or types, of inspections that must be conducted. Industrial stacks must be inspected as follows:

Class 1: Inspections using binoculars should be performed several times throughout the year, especially when stacks are wet due to freezing weather conditions. These checks should look for cracks, spalling brick faces, broken lightning rods, broken lightning rod cables, bellowing courses, damaged bands, and accumulation of water in brick courses.

Class 2: Inspections using rope access should be performed every five years. A drone may be used to help assess how much deterioration is present but can’t qualify the type of deterioration or the extent of repairs. Class 2 inspections cannot be conducted completely by drones. An inspector must get up on the stack to do a visual, up-close inspection of the interior and exterior of the stack.

What Are the Risks of Foregoing Regular Stack Maintenance and Inspection?

Industrial stack maintenance sometimes has different concerns and maintenance requirements. The type of plant and production and environmental concerns impact maintenance needs and frequency requirements. The location of the plant may also play a part in how stacks can be restored to optimal working conditions. Some maintenance and repairs may require a custom engineered solution to mitigate damages.

Here are just a few of the most common risks you may face if you forego regular industrial stack maintenance and inspections:

Stack Leaks

One of the primary purposes of an industrial stack is to make sure there is clean, regulated airflow throughout the environment where power production takes place. If a stack isn’t functioning properly, it poses a risk to you workers with a lack of safe air to breathe while working. Stacks that are not maintained sufficiently can develop gas leaks outside of the liner of the stack or into the building. Another issue that can arise from foregoing regular maintenance is a build-up of fly-ash or liner collapse that causes back pressure in the system. These situations can be hazardous to employees, creating health issues that you cannot afford to take on.  

Structural Damage

Foregoing regular, scheduled maintenance plans can result in dangerous situations. Without comprehensive inspections as part of your maintenance program, you may be overlooking or neglecting significant structural problems that worsen over time. What starts as normal wear and tear can ultimately lead to having to demolish and replace industrial stacks when it’s left unaddressed.

Emergency or Unplanned Shutdowns

Stacks that go without maintenance don’t always suffer from dangerous leaks, loose material being ejected, or structural damage. However, there is still the risk of causing the plant to have to shutdown for other, even less serious problems. While scheduling planned outages and appointments for inspections and maintenance may seem like an expense that you could avoid when things are going well, it could ultimately be the very thing that saves you money in the long run.

Final Thoughts

Stack inspections are the most important part of an effective maintenance plan. Visual inspections should be performed on a regular basis – a few times during the year. Full inspections, including interior and exterior examinations, should be conducted every three to five years, depending on the specifics of the plant. Having a proper maintenance plan is essential to avoid deterioration, which can quickly lead to potential injuries, as well as emergency shutdowns. Maintaining the stacks at your industrial plant will help keep your workers safe and ensure that production is trouble-free.