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Service/Maintenance Programs
Summary
KVB manufactures custom and standard CEMS, developing the sample interface system, sample conditioning system, probes, gas analyzer system, and data acquisition and handling system in-house. Factory acceptance tests and trained quality-control experts ensure high-reliability components that reduce start-up delays. In the field, KVB installation experts' knowledge of port and probe placement and stack modifications allows for safe and timely installations - whether for a single CEMS or for a multi-unit, multi-site project.
KVB's start-up/certification procedures and training programs are administered by experienced CEMS personnel. Certification teams provide the necessary performance audits and system testing. On-site, factory or regional training sessions offer site-specific information for operators, technicians and managers.
KVB's service and maintenance organization provides programs to maintain data availability at the required 95% level or higher. Programs range from individual maintenance and repair services to complete packages, in which KVB personnel take full responsibility for CEMS operation and maintenance. Regional service crews and parts distribution warehouses keep response time and maintenance costs to an absolute minimum.
KVB Capabilities
- Project Managers with experience in both system instrumentation and regulatory environments have the authority to commit company resources to meet contractual agreements.
- Comprehensive experience in both the custom and standard design of source-level extractive and dilution systems.
- KVB ECOTRAXTM software packages have been developed by in-house software engineers to deliver full functionality to KVB systems, transforming CEMS data into an emissions and operations Information Management System based on our networking, operating system, and database flexibility.
- KVB has the largest CEMS fabrication plant in the industry, with state-of-the-art manufacturing facilities and the necessary capacity to meet customer schedule requirements.
- Trained Project Teams are assigned to a project from start to finish, ensuring a smooth transition from design and fabrication to start-up and certification.
- Our site-specific training programs are based on either actual field exercises, when appropriate, or interactive case studies.
- KVB offers assistance in preparing local, state, and federal regulatory plans, and can provide experienced systems and regulatory consultants to manage permit changes caused by operating or environmental modifications.
- A network of 25 regional service technicians, regional warehouses and service vehicles ensure cost-efficient maintenance and immediate emergency response.
- KVB offers comprehensive post-installation services, including a selection of maintenance contracts, regulatory consulting to meet changing environmental requirements, and retrofit or software upgrades.
- KVB can provide complete turnkey systems, contract operations, or professionally expedite any segment of the CEM System life-cycle.
KVB CEM Systems Experience
- Largest installed CEMS base in the industry.
- Since the inception of continuous gas monitoring two decades ago, KVB has designed and built over 500 Acid Rain and 700 Pre-Acid Rain CEM Systems.
- Comprehensive experience in developing CEM systems for electric utility and independent power plants, waste incinerators, cogeneration facilities, pulp and paper mills, petroleum refineries, chemical plants, steel mills, glass plants, cement plants, automotive facilities, food processing plants and many other industrial facilities.
- In 20 years of operation, KVB has never failed to certify a KVB system.
- Successfully managed complicated jobs with systems at multiple sites, such as a utility project with 46 systems installed at four sites, and single system projects.
- Simultaneously executed the two largest CEMS projects ever attempted in the United States. Both projects were completed on time and to the clients' specifications:
At Southern California Edison, 29 systems were installed at seven sites, certified under tough California regulations, and are operating at 99% availability without redundancy.
At Westinghouse, six CEM Systems were installed with over 140 ports.
As illustrated by the information briefly outlined above, KVB brings a depth and breadth of services to Continuous Emissions Monitoring Systems that is unmatched in the industry. We have been generating highly reliable, conservative designs for over 20 years, and have the necessary experience, life-cycle services, proven designs, total capacity, guaranteed certification, and proven performance to confidently assure your deadlines will be met.
No other supplier can offer the experience, talent, organization or knowledge consolidated in KVB. We are committed to managing your CEM Systems project with the quality service expected from a partner in your emissions monitoring program.
Customer Service
KVB provides a wide range of comprehensive services to support your Continuous Emissions Monitoring Systems (CEMS) anywhere in the United States. With over two decades of experience, and in strategic locations across the country, our service technicians are trained in every aspect of maintenance and troubleshooting for each principal component used in all CEM systems. Our professional technicians are experts in maintaining not only KVB CEMS, but all other major manufacturers systems as well.
We have provided operations and maintenance services for hundreds of CEMS under a broad range of operating conditions and monitoring applications while ensuring system availability, reliability and accuracy. Our specialized CEMS service expertise is rooted in experience, not only in CEM operations and maintenance, but also in system design, engineering, installation and certification. We can provide 95% guaranteed on-line availability, 24-hour response for most parts and service, and a complete parts and maintenance plan with a guaranteed total maintenance cost. Programs range from individual maintenance and repair services to complete packages, in which KVB personnel take full responsibility for CEMS operation and maintenance. Regional service crews and parts distribution warehouses keep response time and maintenance costs to an absolute minimum. A network of multiple regional service technicians, regional warehouses and service vehicles ensures cost-efficient maintenance and immediate emergency response.
No other service provider can offer the experience, talent, organization or knowledge consolidated in KVB. We are committed to maintaining your CEM systems with the quality service expected from a partner in your emissions monitoring program, and we back up this commitment with the most comprehensive customer service program in the industry, including:
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Customers have access to trained service personnel 24 hours-per-day. One toll-free telephone call handles everything: (800) 722-3047. Each service representative arrives at the job site equipped to handle a wide range of potential situations. Each Rep carries a full tool box, a selection of spare parts and, when necessary, a portable computer. By utilizing a professional service staff with broad-based experience in all phases of emissions monitoring and systems analysis, KVB provides you with the support and dedication you need to keep your emissions monitoring systems operating properly.
Contract Maintenance
KVBs contract maintenance is designed to provide you with experienced technicians who are thoroughly familiar with your system. KVB is the only major CEM manufacturer who guarantees 95% on-line systems availability and backs it up with 24-hour spare parts and service response. And should regulations change, KVB can upgrade your system to meet the new requirements.
Using service experts from the industrys premier system designer and builder means you can always be assured of maintenance by people who really know your system, people who insist upon using the right parts, people who will ensure that your systems operate efficiently and remain in compliance with all regulatory requirements.
Benefits derived from a KVB Contract Maintenance Program include:
- Reduced annual operations and maintenance costs
- Easy budgeting of your system costs with our fixed price annual service charge
- Avoidance of possible downtime, fines or plant closure
- Meeting deadlines for submission of monitoring reports
- Receive guaranteed re-certification, if required, and assistance with preparing and filing regulatory agency reports
KVBs annual contract maintenance services include:
- Regularly scheduled maintenance visits to the CEM site at an agreed-upon time interval. These visits are designed to identify potential system problems before they arise, minimizing the need to shut down the system for major repairs.
- An appropriate number of emergency service visits during the contract maintenance period.
- Each visit includes routine system inspections, preventative maintenance adjustments and checks, corrective actions, and full system checkout. A KVB Service Report will be completed for each visit and will be co-signed by the appropriate operating plant individual.
- All service labor, travel and living expenses for the above scheduled and unscheduled service visits.
- Guaranteed supply of appropriate consumable and spare parts for your CEM system.
- Discount on all parts purchased.
- Guaranteed emergency response for service and parts.
KVB also operates a complete in-house repair service. At their discretion, customers can replace a component and send the inoperative unit to KVB for expedited overhaul/repair.
System Upgrades
KVB can update your CEM system hardware and/or software to meet new process and/or regulatory requirements. All upgrading recommendations will be accompanied by a complete cost breakdown and installation schedule.
- Meet new regulatory or process requirements
- Make new or revised emission measurements by modifying hardware and/or software
- Modify analyzers, sampling equipment or DAS
- Upgrade, modify or customize software
- Rebuild or convert parts of your system in order to incorporate state-of-the-art improvements
- Make older systems as "good as new" and often better
Start-up Services
KVBs service technicians will start up your CEM system upon completion of installation. Start-up procedures include operational tests of all systems to ensure their proper performance. During start-up, KVB representatives are available to informally train plant personnel. As they work, KVB representatives share their knowledge about the operation and maintenance of CEM systems with site personnel. They dispense valuable service tips and offer site employees the benefit of years of experience with specialized, state-of-the-art monitoring systems. Assuming proper plant operating conditions, your CEM system will be ready to begin certification test procedures at the conclusion of start-up activities.
- Avoid costly start-up problems
- Get powered up and on line as quickly as possible
- Make sure no damage has occurred during system shipment or installation
- Make sure installation of equipment was performed properly -- check out enclosure location, probe location and mounting, sample lines, heat tracing (if required), interconnect wiring and terminations
- Ensure hardware systems perform properly -- check out sample extraction and conditioning systems, analytical instruments, and control and data acquisition/reporting systems
- Ensure proper data reduction with DAS software -- check out calculations, display and reporting functions
Installation Supervision
KVBs installation supervision services will ensure the correct installation, setup and interconnecting wiring for your CEM system. Using KVB professionals for installation supervision is your best assurance that the job will be done right -- the first time. All important areas will be addressed. Experience has taught our representatives to be on the lookout for signs of potential problems and the best possible alternatives for proper installation. Knowledgeable supervision of all aspects of installation can increase overall system life, improve performance, and reduce on-going maintenance costs.
- Provide direction and guidance to appropriate plant installation personnel and/or subcontractors who will perform the actual installation
- Make sure that designated installation personnel are qualified and aware of all system requirements
- Return to plant site at the end of the installation schedule to review the work and ensure proper system installation
- Conduct system orientation class for plant staff
Quality Assurance/Quality Control Plans
In order to comply with environmental regulations, KVB can prepare a comprehensive Quality Assurance/Quality Control (QA/QC) plan for submittal to the appropriate regulatory agencies which will satisfy all applicable regulatory requirements for your CEM systems. KVB, in conjunction with its staff and affiliates, prepares a document which serves as the QA/QC "cookbook" to meet or exceed USEPA 40CFR60, Appendix F guidelines. It is written for plant staff to interpret the regulations and to translate them into step-by-step procedures with straightforward corresponding reports to expedite all reporting submittals to the regulatory agencies. Accurate formulas are completely defined and appropriate data sheets are clearly explained.
- Calibration drift testing
- Data reporting and out-of-control procedures
- Preventative maintenance
- Quarterly relative accuracy (RA) and calibration gas audits
- Pre-formatted report forms for submittals
Training
KVB can provide in-depth training to plant management, supervisory personnel and instrumentation/control technicians to help ensure your CEM systems are properly understood and operated. Proper training of your staff in CEM systems and their operation provides several benefits:
- Avoids costly plant shutdowns
- Reduces operation and maintenance costs
- Prevents expensive mistakes with delicate analytical instruments
- Keeps your system in top operating condition
- Develops your own internal system experts
A typical two-day training session would include:
- Introduction/Overview
- System Operation
- Functional Component Descriptions
- Hardware Demonstrations
- Computer Description/Operation
- Analyzer Description/Operation
- Software Description/Operation
- Warnings and Alarms
- Generating Reports
- Question & Answer Session
- Continued Hands-On Hardware Operation
- Continued Hands-On Software Operation
- Troubleshooting
- Maintenance
- Spare Parts
- Question & Answer Session
If desired, KVB can also arrange special factory training sessions for your personnel.
Certification Services
KVB can perform required CEM certification, including test plan, drift and relative accuracy tests, and report preparation.
- Have your test plan prepared and submitted correctly.
- Get relative accuracy (RA) tests performed by an independent contractor
- Have your test reports prepared properly and submitted on time to the regulatory agency.
- Get your equipment certified as quickly as possible.
KVBs USEPA certification services include a complete review of the permit conditions, the specific federal, state or local test requirements and the report submittal process. A test plan will be prepared by KVB, submitted for client review then to the appropriate regulatory agency. This test plan will fully describe the CEM equipment being tested, the testing procedures to be used, and the data collection, reduction and reporting procedures.
Upon plan approval, KVB will schedule the required certification tests, including CEM drift tests and relative accuracy (RA) tests for each emission parameter. To ensure complete impartiality, all RA tests will be performed by an independent testing contractor who is experienced in source testing and analysis.
The certification tests will meet all USEPA 40CFR60, Appendix B, PS 1-4 requirements and/or other specific criteria as dictated by the regulatory agency. Relative accuracy testing may be by instrumental methods or, if necessary, will utilize designated source test methods and laboratory analysis techniques. Upon completion of the testing, KVB will perform the data reduction and report preparation. The test report, including all required data, will be submitted to the client for review, approval and transmittal to the regulatory agency. KVBs professional certification services, performed by our experienced engineering personnel, provide the greatest assurance that the certification will be successfully performed, on schedule and with a minimum of client involvement. In fact, KVB guarantees that all KVB compliance CEMS will successfully pass the initial regulatory certification tests when a contract is awarded to KVB to perform the certification. This guarantee means that if the KVB CEM fails to certify (for any reason related to either the CEM performance or the certification tests), KVB will correct the problem and/or re-run the necessary tests at no additional charge, until the certification is successful. KVB has never failed to successfully certify a KVB CEM system to the USEPA certification requirement.
KVB carries more than $1 million in spare parts inventory. Spare parts warehousing is maintained by both the East and West coasts. This inventory is managed by a dedicated MIS computer using a "min-max" approach to tracking inventory levels.
- Eliminate system downtime and expense.
- Get the right part the first time.
- Buy only what you need.
- Get your parts from a source uniquely qualified to support your system.
- Buy from people who know your system, who know how to keep your system cost-effective.
- Dont be satisfied with quick-fix, temporary "bandages". Use only parts that are supported by manufacturers data, specifications and certifications.
Replacement parts are a vital element of KVBs over-all service, and our spare parts listings are provided to assure you of the highest level of system availability and performance. Having spare parts on-site can often eliminate downtime and expense. Only those parts that meet KVBs highest quality standards are included.
The following spare parts listings are tailored to your individual system:
- Level A -- Consumable Items. These parts are expended during normal system operation.
- Level B -- Basic Spare Parts. All parts/components that have a life expectancy of less than two years.
- Level C -- Critical Repair Items. All parts/components that are absolutely essential for system availability.
- Level D -- In-Depth Repair Items. Parts/components that are important for optimum system performance.
The above-listed spare parts are ready for shipment to your plant.
In order to assure our customers of the best possible response, we maintain a complete history of every KVB system on file. This is your assurance of receiving the correct part with every order. Our database library for each system includes:
When a customer calls KVB for a parts order, the person receiving the call will use a computer terminal to immediately access information involving availability and price. He will also receive information regarding possible part(s) obsolescence and superseding part number(s).
After the parts order is taken, another person with field service experience will compare what has been ordered with the type of equipment the customer has. This is the "extra dimension" you get from KVB. Because KVB has hundreds of custom systems in the field, "taking a second look" helps ensure that our customers get the correct part.
Because virtually all the parts required to build or maintain a KVB system are stocked, parts orders will normally ship within one business day.
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Revised: July 23, 1997.