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IX
System Maintenance

English/Metric Conversions English 1 inch 1 foot 0.3937 inches 3.281 feet 1 ounce 1 pound 0.205 pounds 1 U.S. gallon 0.2642 U.S. gallons 1 sq. foot 1 cubic foot 35.31 cubic foot 1 Btu 1 Btu 1 sq. inch Metric 2.54 centimeters 0.3048 meters 1 centimeter 1 meter 28.35 grams 0.4536 kilograms 1 kilogram 3.785 liters 1 liter 0.0929 sq. meters 0.0283 cubic meters 1 cubic meter 1,054.8 joules 0.2520 kg.-calories 6.452 sq. cm. F 10 0 10 20 30 40 50 60 70 80 90 100 110 120 130 150 200 300 400 500

Temperature Equivalents C 23.0 17.8 12.2 6.7 1.1 4.4 10.0 15.6 21.1 26.7 32.2 37.8 43.0 49.0 54.0 66.0 93.0 149.0 204.0 260.0 C 20 10 0 5 10 15 20 25 30 35 40 50 60 80 100 120 150 180 200 250 F 4 14 32 41 50 59 68 77 86 95 104 122 140 176 212 248 302 356 392 482

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System Maintenance

Overall system maintenance affects worker comfort, productivity, product quality, and operating cost. The least expensive and most effective maintenance of a coating system is a formalized planned maintenance program. Planning what will be done, who will do it, what resources they need to do it with and committing the time and resources to the task is the correct way to keep the system running well. Fixing things when they break is the most expensive and least effective way to operate a system. Throughout this manual there are references to specific maintenance practices and the importance of keeping the system in good working condition. There are often situations where systems are not properly maintained and excuses are offered; we are too busy to take time out for maintenance, management does not supply us with parts or time for maintenance. In reality, there is no good reason for not maintaining the system. When it is new it runs correctly. When it is used it will gradually deteriorate. To keep production at the best possible level and meet quality goals requires a well designed planned maintenance program that is performed on a regular basis. Planned maintenance starts with the development of a Standard Operating Procedure (SOP). Development of a planned maintenance SOP involves certain steps. Step 1: What needs to be done? Study the process with these questions in mind; what components of the system need periodic cleaning? what components of the system need to be replaced periodically? what needs to be lubricated? what items need to be inspected? what items need to be tested?

Step 2: How often? Determine how often these tasks need to be performed in order for the system to run at peak efficiency. Step 3: How long will it take? Determine how many man-hours are required for each task.

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Step 4: Who will do it? Select the employee(s) who is/are best suited for each task. Step 5: What materials are needed? List the materials that will be required for each task. Step 6: When will it be done? Determine when each task will be performed. Step 7: What tools will be required to do the work? List all of the equipment that will be necessary to conduct the maintenance plan. With the list of what, who, when, where and how the job will be done it is possible to design a plan, schedule the activities, maintain a supply of the materials needed and keep the system operating properly. A Standard Operating Procedure is a document that clearly defines all aspects of a specific maintenance requirement. Task Frequency Supplies
Figure 9-1 Requirements for Planned Maintenance

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System Maintenance

Tools Objectives Safety precautions Steps of the process Like any plan, the maintenance SOP must be monitored for effectiveness and adjusted if necessary. The following list is the recommended tasks that are typically required for a powder system and the frequency that they should be performed. Other items may be needed in a particular system. It is important to identify the maintenance items that affect system performance and schedule the activities for servicing them. In addition to the maintenance performed by company personnel, it is advisable to have an outside contractor come in bi-annually to inspect, clean, calibrate and adjust the mechanical components of the system. A qualified contractor can check all belts for wear, inspect and clean fan blades, dismantle, clean, inspect and adjust all burners, inspect the pumps and motors for wear, and test all of the vital safety and operating controls. This provides an additional layer of protection from emergency break-down and keeps the system operating at peak efficiency Summary Do not underestimate the value of good maintenance. Proper attention to the systems working components can be the difference between failure and success of a powder coating system. Once a plan is in place and the work is performed regularly, it takes very little time away from production and makes production time more profitable.

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Frequency Weekly Weekly Monthly Monthly Monthly Monthly Monthly Monthly Bi-annually Quarterly Quarterly Daily

Equipment Conveyor

Maintenance Task Inspect drive chain (even if you have automatic lubrication) and manually lubricate Provide automatic lubrication of wheels, trolleys, and chain; inspect the lubricator and fill reservoir Inspect and lubricate the drive unit frame Lubricate back-up rollers on the drive unit Lubricate take-up components Inspect belts and pulleys on drive unit for wear Lubricate roller and wheel turns Inspect and lubricate all switches on power & free Empty and refill lubricant reservoir Lubricate drive unit bearings Lubricate chain drive sprocket

Washer

Inspect and clean tank screens

Inspect, clean, adjust and change nozzles as needed to Weekly avoid plugging Lubricate bearings and lip seals on solution pumps Lubricate fan shaft pillow blocks Lubricate fan motor bearings Inspect and clean tank floors when sludge excess 2 Flush out external heat exchangers Inspect internal burner tubes Ovens Remove fallen parts from oven Clean oven interior Inspect all burner flame failure system and ignition system Inspect and clean or replace burner combustion filter Inspect the interior of the burner box for carbon build-up Lubricate fan bearings Test safety shut-off valves Open fuel line drip leg and empty sediment Powder Application Equipment Thoroughly clean all items in the powder path (guns, hoses, pumps, attachments, inserts, pumps & pick-up tube) Inspect all wear parts Inspect feed hoses for wear or plugging Inspect the charging electrode Check gun output current readings Check and clean all gun cables and connections Clean and inspect feed hopper level probes Clean and inspect fluidized bed membrane Monthly Bi-annually Annually As required As required Whenever the tank is empty Daily Weekly Weekly Weekly Weekly Monthly Monthly Monthly Every shift, minimum Every shift, minimum Every shift Daily Daily Weekly Weekly Weekly, minimum

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Equipment Powder Recovery Equipment

System Maintenance

Maintenance Task Empty sieve waste container

Frequency Every shift

Clean interior of booth Check powder transfer pump pressure Check fluidization in collector module Check filter monitor gauges Check rotary sieve bearing air seals Clean exterior of booth and recovery system Inspect blower gaskets and collector module seals Clean and inspect transfer pumps and hoses Clean and inspect rotary sieve housing Clean and adjust cartridge back-pulse Clean feed hopper vent hose Inspect cyclone for impact fusion or leaks Clean and inspect collector fluidized bed membrane Test fire detection system Lubricate fan bearings Inspect fan belts and pulleys for wear Change cartridge filters (as needed) Air Compressor Change oil & Air Piping Drain moisture from air receiver Check filters and drain as necessary Blow out drain legs Check air dryer for proper operation Check air piping for leaks Check control devices Inspect inlet filters Inspect belts and pulleys Inspect and test air receiver and surge tanks for proper operation Gun Movers Lubricate moving parts Lubricate bearings and drive chains Check gear reducer lubricating oil and replace if necessary

Daily, minimum Daily Daily Daily Daily Weekly, minimum Weekly Weekly, minimum Weekly Weekly Weekly Weekly Monthly Monthly Monthly Quarterly Annually is typical 500 hours Daily Daily Daily Daily Weekly Weekly Weekly Monthly Bi-annually Monthly Quarterly Bi-annually

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