1、Manufacturing Standards Ford Motor Company ANGDICELECTBOCOATINGSYSTEM CLEANING AND MBI-CE TABLE OFCONTENTS 21: Introduction . Mp endReservoir Tanks 2-y ;: Electrical System Inspections 7-9 Paint Feed System 9 . 5. Paint Filtration System 9 ;: paint Recirculation Agitation System . 10 Paint Heat Exch
2、angers 10 i* Chilled and Condenser Water System . U 16. ultrafilter Deionized Water system . . gr- gi;g K-1 Spray Rinse Equipment 15-16 U-3 Recirculating Ultrafilter Permeate Rinse Tenk 13.3 Exit Tunnel 2 K-4 Permeate Tank 16 13. Miscellaneous 13.1 Overhead Paint Ccmve 16-17 13.2 COO 13.4 Level Cont
3、rols . 13.5 Lubrication i; 13.6 Motors . 17-18 13.7 pipe Line Identification . 13.8 Pressure Gauges z 13.9 Annps I.8 13.10 Gate Valves end Valve Stems 18 13.U Compressed Air Lines . 13.12 Rping Identification i; 13.13 Safety Recmtions . 13.14 Equipment Housing and Tanks :; 13.15 Waste Dispcsel . 20
4、21 22 Manufacturing Staff February, 1978 ?wlIw 10 U.S.A. MAINTENANCE PAINT COATING Spsppis B2Fl Pagelof 22 B2 GEiD Manufacturing Standards Ford Motor Company ANODIC EiLEC!l!ROCOA SYSTEM 1. Ir4TRoDlJcTIoN Ihe pexformance of the electrocoat process depends pFimarilsonapaint maintainedfnaBpeciiiedtempe
5、arrRtrerangewithamiiormendaBpeciiic bath composition. Ihepaintchemistryis controlledonanon-golngbasis throqhmaterialmuter8toe instructione should be on file in (2) it cleans the sides of the,tank WEUS; and (3) it allows visual observation of the effectivenss and directiona oftheeductor agitation. Af
6、ter the teds18 fffledwithdll and/or city water and prior to activating the recirculation e4ndfiltrationpmxpf3, clesningmaterisl shouldbepumpeddirectlyto theresermiFpsrtof the tank. B2Fl Page 4 of 22 MHU.U MimmNANcE PAmT COATING SYSTEMS Manufacturing Staff February, 78 Manufacturing Standards Ford Mo
7、tor Company CO Cawtic scda liquid mercury cell grade 50% (31B) is acceptable. The liquid is suggestedpe adjusted correctly prior to charging tank. Hisers and eductors shouldbe securedtightlypreventleaks andadjusted to the design direction. ESrterior of pumping equipnent should be checked and cleaned
8、. hsulated guide rails should be repositioned weir shouldberepaired so thatitiseasily duringnomal production activity. end secured if required. Adjustable adjustable to different elevations Interior of electrocoatenclosure including windows and drip enclosure should be cleaned. B2Pl Page 6 of22 m- w
9、l U.S. insulators must have damage-free surfaces end no cable insulation cracks or splits should be evident. . Check electrode clamping “dogs“ for build-up, excessive roughness and wear. Replace, rep and at permeate connections for ruptured membrsnes permeate leaks. Check andrecordpaintinletpressure
10、 to, andpaintoutletpressure from ultrafilter( Check and record paint temperature to ultrafilter if thermometer(s) proddedin system. Check and record permeate flow rate and clarity (from each ultrafilter). Check and note level of permeate in tank. Check and note permeate pump flow rate. Check functio
11、n of permeate tank solenoid valves including high level pump down. Check and record permeate rinse pump operation including discharge pressure and operating problems, i.e., bearing noise, seal leak, loose coupling, etc. Check condition of filtrate through sight glass. 10. DEIONIZED WATERCONDITIONING
12、 SYSIEM 10.1 Cation and Anion Exchangers 10.1.1 General Information and Precautions When equipnentshutdownisrequired a followshutdownprocedure reconmtended by equipDent supplier. Kske sure enough acid and caustic is always available. Always regenerate damineralizer . per supplier*s instructions. Any
13、 changes in flow rates must be . done with prior concurrence of Plant Engineering and equipment suppUer. 10.1.2 Daily Procedure . Check and record deionized water pressure. . Check flow meter to insure water is flowing. Check conductivity instrument for proper alarm setting. : Check conductance of t
14、he deionized water and maintain equipment to produce as low a condnctivity as possible. . Record readings in micromhos. B2P1 * Page 12 of 22 h.M n U.S.A. MAmmANcE PAINT C(3RTING SXSTR4S Manufacturing Staff Fe-, 1978 Manufacturing Standards Ford Motor Company .B2 10.1.3 102.4 10.1.5 Week4 Procedure .
15、 Impect the deminerslizer equlpmnt and facilities for leakage frompumps, piping, valves, and tanks. Remove any debris accumulation from drain deck. Spilled chemlcds shouldberemvedimmediatelybyflushlng withlargemountsofvatar. Check sll painted equipment for chipped paint or rust spots. Spots should b
16、e sanded down, then apply tw coats of primer paint aud a ffnish coating of paint. All equipment such as UQIS, valves, etc. requiring lubrication should be lubricated according to demimrslizer manufactmers tiecommendation. Check control panel to be sure all electrical and pneumatic (or hydraulic) con
17、trols are operational. Check drains for signs of resin washout. Opemwntvalve at eachdemimraliaer tazkendvent accllmulated dir. Afterallsirhasbeen expelled from each tank, close vent valve. Duxdngregemeration checkuorldngpreasure. Note any significantdr*viations. During this time check regenersnt pum
18、p adjustments to supplier recommndations. Keep any chemical solution tanks cleau and free of sludge acctmlations, which could Interfere uith proper operation of pumps. Check solenoid Tmpve action. Any deviation from normB1, such as sticHug or noisy solenoids, shouldbe fixed. Montbb Procedure Verify
19、that the various operational controls.dealing uith service flowrate; backwash flowrate and water temperature; regenerant concentration, dosage and flowrate; slow-rinse flowrate and volume; fast rinse flourate and w3lume; and total hardness lewls in the softened water and fast-rinse effluent ere bein
20、g optimally met. Remove boanets from diaphragmvalves and inspectdiaphrems, valve seats, and gaskets. Scored valve seats or defective valve diaphragms shouldbe replaced. Manufacturing Staff Febnrary, 78 ?nlum H U.S.A. MARrrEMNcE PAINT COATING SYSTEMS B2Pl Page 13 of 22 B2 Manufacturing Standards Ford
21、 Motor Company 10.1.5 Annual Procedure . . . . . . Zhspect other types of valves for wesr; replace -. if necessey. Check gauge glasses and rate of flow controller glass, clesn if necessary. Check concrete floor, piping and equipment for deterioration. Apply chemical resistant finish to deteriorated
22、concrete floors. Clean, prime andrepaintcorroded equipment surfaoes. If facilitized to transfer anion and cation resin perform the following: . Inspect CF demineralizer tank interiors and repalrsnybreaksintanklining. Inspect internal lateral screens for wear or damage. . . Meanaure Treeboardw (dista
23、nce from tip of resin bed and some fixedpointattop of maintenance hopper), record and compare this measurement to compare distance during eachyearlycheckout procedure. Replace any lost resin. . 4 . Closely inspect all mechanical equipment and replace any wrn or damaged parts. . Follow manufacturers
24、ra2ommendations for resin transfer equipment flushing, equipment shutdown and startdlp. 3uchfou&ntsaslron,copper,sluminum, calciml carbonate, magnesium hydroxide, organic matter and calcium surfate can contribute to resin degradation. Periodic checks of water distribution andregenerantchemical distr
25、ibution systems is desirable in determining if adverse conditions exist. Also, core resin samples oan be obtained and checked for the presence of chemical degradation foulants. Chemical cleaning can be used to remove these foulants. Because inlet water chsracteristics can change, anewwater anslysis
26、should be performed to compare this new water analysis with the original. If water characteristics change, operational adjustments to your equipent may be required to maintain efficient operation. 11. VENTILATION SYSTEM 11.1 General Information Building air make-up units are provided to supply filte
27、red fresh air, heated or unheated to the enclosure around the dip tank. B2Fl Page 14 of 22 hmw en U.S.A. MAINmANcB PAINT COATING SpslpIs E =l!JLl=lLbll 0053276 943 D Manufacturing Staff - February, 1978 Manufacturing Standards Ford Motor Company B2 11.2 Weekly Procedure Check for accumulation of sed
28、iment and algae Fn air washer water reservoir. Drain and clean as required to control odor. Il. 3 Semi-Monthly Procedure Check and, if required, change disposable air filter elements. Make sure that filter elements are flnnly positioned and frames are not being by-passed. Il.4 Quarterly Procedure .
29、Check blower wheels for accumulation of dirt and clean if necessary. . Check gas pm-mixers and burner nozzles and clean if necessary. Also, during this time, check action of ratio valves, gas shut-off and regulator valves, motorized operators and Ii&ages. Clean, lubricate, and adjust as required. .
30、Check dampers for proper adjustment, linkage operation, and condition of vanes. Clean, adjust, and straighten as required. Il. 5 Semi-Annual Procedure . Check exhaust fans for deposits on blade and housing interior, and clean if needed. . Clean ducts by vacuuming or wiping. Also, check condition of
31、ducts and repair or paint as needed. . Inspect roof opening for condition and leaks, and repair as needed. 11.6 Annual Procedure . Drain and clean the units including the strainer to the pump suction and drain connections. Also, check and clean reservoir walls and ceilings. De-scale if necessary and
32、 paint. Use zinc-chrcmete primer, M-jJ75A or M-6J92 red lead primer if surface is black iron and M-&Y29 primer if galvanized metal. Use M5J33 chlorinated rubber base paint for a finish coat. (Severely deteriorated systems are generally repaired by using reinforced resin coatings.) . Check operation
33、of float valves after filling tank, and set rate of overflow. . Flush out pumps, clean and/or replace spray nozzles and strainers as required. 12. POST-DIP OPERATIONS 12.1 Spray Rinse Equipment X2.1.1 Deily Procedure . Inspect and clean all plugged nozzles in deionized and ultra- filter rinse statio
34、ns. Manufacturing Staff Fe-, 1978 hryU.U MAINTEz?ANcE PAINT CQATINTI.Smrms B2Fl Page 15 of 22 m =iClCl=iLbO 005l,277 BEiT m Manufacturing Standard8 Automotive Assembly Division 12.1.2 Weekly Recedure With pumps off, wslk through rinse section and inspect nozzles l with fbsblight. . Check nozzle tips
35、 for obstmctions and indications of foulded orifices. Replace any plugged nozzles with clean ones. . Check ell nozzle angles to determine if they have been knocked out of position. Realignaa required to insure effective rinsing. . Tum pumps on and check system pressures. 12.1.3 Quarterti Procedure .
36、 Check headers for solids build-up. 12.2 Recirculatfnn Ultrafilter Permeate Rinse sank 12.2.1 Daily Procedure Level should not exceed the tip of screen strainers. Screen handles shouldbeshowing. Level should not be lower than 8 inches below top of screen. 12.2.2 Semi-Amual Procedure 1 Draintsnk. Fte
37、mvesnyaccumilatedaludge. Inspect pump inlet and pump after tank has been cleaned. . Flush and remove water. . Finsl flush with deionized water and remove water from tank. 12.3 Exit %nnel 12.3.1 &mthl Procedure . Clean drain troughs of paint build-up and residue with scrapers. . Remove grates in tunn
38、el, clean floor and grates and then replace. Remove andreplacepaperused to catch paint drippings. : Remove old filters and install new filters on blow-off. 12.4 Permeate Tank 12.4.1 Dails Procedure Level should be aroximately l-4+ 2 inches below %a& top. 13. MISCELLANEOUS 13.1 Overhead Paint Convevo
39、r 13.Ll Mmthlv Procedure Check hanger hooks for being vent or distorted. Repair as required. B2Fl Page 16 of 22 MAINTENANCE PAINT COATING S-S hryhU& February, 178 Manufacturing Stan& Ford Motor ComparVf B2 13.1.2 AIWI Procem . Clean conveyor chain and trolleys by wire brushing, scrapirg and vam.umin
40、g. (C onveyor chain can also be cleaned with a high pressure liquid cleaning unit.) * Inspect rail and supports for excess veal, misslieut loosened connections. . Remove any accumulated lubricant. 13.2 c001ln Tower Water Test and treat the water with chemicals as required. (See Maintenance Bulletin
41、No. 59 for additional details.) 13.3 DrFlins 13.3.1 CJuarterly Procedure Floor drains should be open. If plugged, open with mechanical sewer cutters. 13.4 Level Controls 13.4.1 Geheral Information Whenever a particular tank is emptied, the level control devices, indicator warning lights, meters, etc
42、., should be checked, cleaned and recalibrated as necessary. 13.4.2 Semi-Annual Procedure AU elements of the control system should be checked, cleaned, and ajusted. This Includes si&t glasses, float operated valves, level alams, flow meters, etc. 13.5 Lubrication See Manufacturing Standard LZX-2, “S
43、uggested Lubrication Guide“ for additional lubrication data. 13.6 Motors 13.6.1 General Information Lubricate motor bearings per inanufacturers reccmnendation. February, 1978 Cnr*lHU.S.A MAINTRUCE PAINT COATING SpsppIs B2Fl Page 17 of 22 Manufacturing Standards Ford Motor Company 13.6.2 arterl Roced
44、urq l Check motor munting bolta for tightness. . Check alignment and condition of coupling. Note any excessipe running temperature or tibration. . Wipe rotor clean. 13.7 Piuimq 13.7.1 MonthLs Rocedure Check for leaks. Repair as required. 13.8 Pressure Gawes 13.8.1 13.9 Puma 13.9.1 13.9.2 DaiLs Proce
45、dure 13.9.3 lkmthb Procedure All system pressure gauges should be checked and repaired or replaced as necessary. General Recautiong Fllowpumpmanufacturers rommendationa for pump packing replacement and othern3aintenance instmctions. Check and record aJl pump pressures. This includes pmqs servicing t
46、he heat exchanger, filter $ransfer, ultrafilter, mix and feed, recirmJating r-Be, permeate, fine filter supply. MmthlvRocedure Check pump packing and pipe connections for leakage, and bearings for heating and/or vibration. 13.10 Gate Valves and ValwStems 13.10.1 General Recmitions Follow mamfactaare
47、rs recommendation for lubrication and other nmintenance. Also, periodically operate all system valves nom&.ly closed to prevent themfrombecomingpluggedup and inoperable. 13.10.2 Months Procedure Check for leaks. Keep valve stem packing nuts tight. Replace packing as needed. B2FI Page 18 of 22 hlnwo
48、n U.S.A. MAINTEZIANCE PADIT COATING SYSTEMS Manufacturing Staff Febntary, 1978 Manufacturing Standards Ford Motor Company B2 13.11 Comvressed Mr Unep Compressed air line drip legs and filters should be cheoked on a monthly basis and blown doun to preclude the introduction of suoh con- taminants as o
49、il into the phosphating system. 13.X2 PiLine IdentjJicatQ& - 13.13 Safety Precautions Such chemicals as SOlUbiliZerS, neutralizers and various cleaning agents, etc., used in paints are either acid or alkaline. Their improper handling can represent a serious hazard. moyes handling paint residues containing these ingredients shall wear impexvious gloves and chemical goggles as minImum protective equipment. If splashing or spilling of these materials is anticipated, full face shields, chemical aprons and impervious footwear shaU. also be worn. Erect co
