1、Manufacturing Standards Ford Motor Company B 1 .o Scope 2.0 Tank Construct ion 3.0 Exterior Tank Access 6.0 Phosphate Tank Air Agitation 5.0 Tank Filters and Auxiliary Sludge Settling Tank 6.0 Tank Auxiliary Equipment 7.0 Tank Water Fill and Make Up 8.0 Interior Part Silhouettes, Walkway and Tank Co
2、vers 9.0 Enclosure and Drain Sheets 10.0 Skid and Part Guides/Guards 11 .o Vestibule Air Seals 12.0 Tank Heating 13.0 Spray System 11.0 Dip Clean and Rinse Alternate 15.0 Downtime Misting System 16.0 Conveyor Rail and Guard 17.0 !laintenance Facilities 18.0 Deionized Water Rinse 19.0 Automatic Chemi
3、cal Control System 20.0 General 21.0 Electrical Standard 22.0 Piping Standard 23.0 Approvals 2G.O Acceptance Test 25 .o Highlights of Operational Sequence 26.0 Reference Sketches BJX ZINC PHOSPHATE EQUIPMENT - Manufacturmg Staff June 1.981 c. .,#a *” US. ZINC PHOSPHATE EQllI!XENT m 7007Lbcl 005L3bL
4、3-l-3 m BJX. Page 1 Manufacturing Standards Ford Motor Company ZINC PHOSPHATE EQUXPMENT 1.0 SCOPE 1.1 The intent of this standard is to describe process equipment to be utilized in applying Zinc Spray Phosphate coating. Performance requirements are outlined in Engi- neering Specification ESB-H3Pl-A
5、for Zinc Phosphate. Process Standards PL-53-33(F) (1 minute process 1, PL-53-36(F) (2 minute process). The issuing Division shall determine and specify the applicable Process Standards. Division Plant Engineering Department shall specify requirements regarding concrete drain decks. 1.2 The issuing D
6、ivision shall specify the following particulars and requirements of the equipment being considered. Number of Stages in Zinc Phosphate Equipment Type of Cleaning Method Stage 1 or Rinsing State 2, i.e., Dip or Spray Applicable Materials and Process Standard Temperature of Solutions Use of an auxilia
7、ry sludge settling tank or filtering equipment for the cleaner and phosphate stages Heating medium to be used, i.e., steam, gas, etc. Auxiliary equipment such as Deionized Rinses and Blow Offs. Part or parts to be processed, part weight, and pieces per hour. Method of conveying, and conveyor seal an
8、d insulation requirements. 1.3 Construction materials, ards: referred to herein, shall confons to the following stand- Structural, mild sheet, plate ASTM A?-58T Mild steel pipe ASTM A53-59T Stainless sheet and plate ASTM A240-58T Stainless steel pipe ASTM A-312-59T 2.0 TANK CONSTRUCTION 2.1 All tank
9、s except the phosphate, the recirculating D.I. rinse and the fresh D.I. rinse tanks shall be constructed of reinforced l/4” (6.35 mm) mild steel plates. The phosphate tank, the recirculating D.I. rinse and the fresh D.I. rinse tanks shall be constructed of l/4” (6.35 mm) (minimum) reinforced stainle
10、ss steel plates. All seams shall be welded continuous inside and outside of tank and conform to standards of American Welding Society. After being set at the job site, tanks shall be tested for leaks. All leaks shall be repaired and tank retested prior to the installation of drain sheets, filter uni
11、ts or any encumbrance that would block accessibility for welding. BJX Page 2 P. .,., en lJ.5 l . ZINC PHOSPHATE EQUIPXENT Manufanturlna Staff June 1981 Manufacturing Standards Ford Motor Company B ZINC PHOSPHATE EQUIPMENT BJX 2.2 All tanks shall have access for cleaning and extend beyond housing on
12、pump side to xow for easy access to screens, chambers, pumps, filters and cleanout doors. Tanks shall be sized for double the total stage pump GPM (LPM) for a calculated pump through of all solution each two minutes. Tanks will be sized larger as necessary to provide capacity required for specified
13、screen sizes or phosphate tank transfer (See Section 3.21. See screen size definition under Section 6.0 “Tank Auxiliary Equipment.” All tank attachments in contact with phosphate solution and recirculating or fresh D. I. water shall be stainless steel. 3.0 EXTERIOR TANK ACCESS 3.1 Tank covers shall
14、be hinged complete with handles, cover support arm and counter weighted if weight exceeds 15 pounds (6.8 Kg). A side access clean-out door shall be provided on the pre-clean stage sized 18” x 36” (457.2 esn x 414.4 sun). watertight doors with four dogs and square corners. All doors must stay open un
15、til operator closes doors. Bottom of clean out door frame shall be flush with tank bottom. 3 3 The volume of the cleaner stage tank shall be used to accept the full phosphate .- tank capacity when cleaning the phosphate tank. (Before transferrine the ohosphate contents into the cleaner stage tank, i
16、t must be cleaned.) A pump capable of pumping phosphate solution to and from the above tank at a minimum of 300 GPM ( 1135.6 LPM) shall be provided. The rinse stages prior to and after the phosphate stage tank will be operated in a spraying mode to act as seals during the acid cleaning of the phosph
17、ate stage. The spray seals will act to protect the chemical properties of phosphate solution safely stored in the cleaner stage. Valves, fittings, piping and pump for the trcnslcr of phosphate solution shall be stainless steel. i.0 PHOSPHATE TANK AIR AGITATION I, . 1 The phosphate tank shall have a
18、compressed air agitation system designed to xminace sludge packing on the tank bottom. The system shall consist of l-1/7-” (38 mm) diameter stainless steel pipe manifolds arranged as follows: . 3” (76.2 nun) Stand-off from tank bottom . 16” ta 20” (406.4 to 508 mm) center/center spacing . 3/32” (2.4
19、 mm) diameter air holes located on 12” (304.8 IIZII) staggered centers - S5 0 each side of the pipes vertical centerline. To complete the system, a five-minute repeat cycle timer, solenoid and necessary controls which can be set to provide an ON/OFF compressed air cycle shall be included. The air-on
20、 cycle shall be set for 20 seconds each 5 minutes at 60 psi for non-production p,lriods and should be set i,r 8-10 PSL of continuous air agitation during production periods. 4.2 Suitable grillage shall be provided under all tanks made of structural steel shapes ( I-beams or Channels 1 and properly s
21、paced to support load and conform to slope al tank bottom. Tack weld grillaee to all tanks at time of fabrication or installa- tion. Gr i 1 lage to be shimmed and zrouted to level tanks and pump supports. Shims under tanks shall be sized large enough to prevent crushing or cracking of concrete deck.
22、 Shim stacks shall bc welded together and welded to tank bottom. Manufacturing Staff * -1w .” * r . . June 1981 Z I NC PHOSPHATE EQUIPMENT BJX Page 3 Manufacturing Standards Ford Motor Company BJX ZINC PHOSPHATE EQUIPMENT 5.0 TANK FILTERS AND AUXILIARY SLUDGE SETTLING TANK 5.1 The type and capacity
23、of filtration and/or sludge settling towers required for the cleaner and phosphating stages will be determined by the issuing Division. The follow- ing items should be defined: - Best control equipment to use (e.g., timers, level controls, etc.) - Design considerations important to insure movement o
24、f sludge to filter (e.g., solu- tion level, filter location, etc.) - Bath turnover volume through filter per hour to insure adequate filtration. - Best design to preclude sludge pick up by circulating pump. - Filtration equipment interlocking requirements (e.g., should filter operate when the convey
25、or stops). - Degree of filtration required. - Maintenance accessibility. - Compressed air agitation requirements. - Sludge settling tower characteristics should be specificed (e.g., solution transfer requirements, compressed air agitation requirements, etc.). 5.2 Each (bed type or moving screen type
26、) filter shall be complete with removable sludge-wagon (with one (1) additional wagon of each size for each machine) sized to suit area and aisles including maintenance conditions. All filters shall be installed with a bolt/punch out trap to prevent filter screens from being torn. All filters shall
27、be sized for maximum pump discharge volume. Bolt/punch out traps shall be equipped with an easily removable wire mesh basket to facilitate daily or as required dumping. 5.3 Plant experience indicates bag type filters 25 GPM/ft.2 (61 m3/hr./m2) (F.S.I. or Equal) may also be used to filter cleaning ,
28、rinsing and D.I. rinsing stages. 6.0 TANK AUXILIARY EQUIP?IENT 6.1 Each tank including phosphate tank shall include a 4” (101.6 nun) drain with plug zve and constant level water make-up unless specified by Division. 6.2 Minimum pump pressure shall be calculated for normal piping and valve losses, he
29、at exchanger pressure losses, and for a minimum pressure drop as indicated by the nozzle schedule. Pumps used on the phosphate stage and recirculating D.I. rinse shall be stainless steel. Pumps shall be top pull out type for ease of maintenance, Kerry- Deming , Series 5600 or approved equivalent. Al
30、l pumps shall be vertical chair mount having all bearings above the coverplate with absolutely no bearings below the solution level. All pumps are driven by standard, U-frame horizontal motors mounted in a vertical position on a chair bracket. Chair brackets are to be provided with adjusting BJX Pag
31、e I, 6 .,I, ,I ., , . . Manufacturing Start Z INC PHOSPHATE EQU ZP3lENT June 1981 Manufacturing Standards Ford Motor Company ZINC PHOSPHATE EQUIPYENT BJX screws to facilitate motor alignment in the event that the motor is replaced. The chair bracket and motor are to be removable from the assembly wi
32、thout disturbing the coverplate or the piping. The chair bracket to rotating element fit is maintained on the pump assembly by registered fit at the coverplate. Pump shaft, bearings and impeller are to be removable from the assembly without dis- turbing the coverplate or the piping. Pump to have sha
33、ft extension as required below the coverplate with provisions for pump-down service. Pumps to have extended tail pipe at least one size larger than pump inlet, terminating a minimum of one pipe diameter from the tank bottom or as specified by pump manufacturer. Individual pump capacity shall be dete
34、rmined by the issuing division. Maximum pump motor horsepower shall be 75. 6.3 All overflows shall be piped directly to one of the concrete drain sumps to keep drain decks dry. 6.4 All pump inlets (unless noted) shall be protected by double screens. Two screens, one behind the other, shall be provid
35、ed in a ratio of one sq. ft. of screen area for each 100 gallons -(378.5L) of solution pumped per minute. The two screens vi11 slide into place each vithin a slot to permit cleaning the screen nearest the solution tank, while a back-up screen remains in place. 6.5 Screens shall extend above normal s
36、olution level, be removable, sized so that one man can easily handle removal and replacement, and shall be provided with suitable f ramrs and hand le s . Screen material shall be type 304 stainless steel No. 18 (0.047 mm) gauge #4 mesh vire. Hairpin construction shall be used to frame the vire mesh.
37、 Ten percent additional screens or no less than four extra per stage shall be provided to the Plant Maintenance Department. All screens for all stages and all extra screens shall be alike. Removable baffle plates shall be provided at the base of the inlet screens to form a sludge dam. 7.0 TANK WATER
38、 FILL AND ME-UP 7.1 All tank vater make-up supply lines shall be piped to provide a air gap above the tank top. Fresh vater make-up “shall enter the tank side opposite the overElou to induce solution turnover. Supply lines shall be sized to fill tanks within 2 hours and maintain stage processing req
39、uirements such as pH, conductivity, etc. 8 .O INTERIOR PART SILHOUETTES, WALKWAY AND TANK COVERS 8.1 A silhouette shall be provided at each of the following locations. Entrance to the machine, the beginning and end of each stage and at the exit of the machine. The silhouette shall be sized for a min
40、imum part clearance of 6 inches (152.4 mm) inches. ( NOTE : The 6 inch (152.4 mm) door open requirement in the process specification for a Body System. 1 8.2 An interior walkvay shall be provided for the entire length of the machine and xl1 be located on the pump side. Walkway shall be at least 18”
41、(508 mm) in width and sh3:l consist of removable steel bar grating. A valkway similar in design shall be provided on the opposite side, but extending only the length of each spray section. Manufacturing Staff June 19 the heat exchanging apparatus shall be external. 12.3 For gas operation, a gas fire
42、d indirect exchanger “Thermal Kombustioner” or Ford approved equal is acceptable. 12.4 On steam heated system, only “shell and tube” heat exchangers are acceptable. Grn heating must be used for the phosphate stage and can be used for all other stages. 12.5 Shell and tube exchangers, product flov thr
43、ough tubes, shall be Sims, American Standard or Ford approved equal. Tubes and caps in all stages shall be type 316 stain- less Steel. Tube diameter shall be a minimum of 1” (25.4 as111 Allowable pressure drop, product side, shall be in the 3-7 PSIG (20.7 to 48.2 kPa) range, the lower level of 3 PSI
44、C (20.7 kPa) preferred. 12.6 Steam supply shall be 55 PSIC (378.9 kPa) unless noted. Control valves will be sized to provide 30 PSIG (206.7 kPa) steam to pre-clean, cleaner and rinse stages; and reducing station with control valve will provide 10 PSIC (68.9 kPa) steam to phosphate stage. All equipme
45、nt shall be designed to withstand main line steam pressure. No heat shall be provided to rinse stages 4 and 5. 12.7 Incorporated in the product side piping of the exchangers shall be fittings and valves, which will permit the chemical cleaning of the exchanger making use of an external portable clea
46、ning system as specified by Division. Valves used to isolate pumps, heat exchangers, etc., shall be equipped with stainless steel discs and shafts and teflon seats and seals. Valves shall be Wtco, Dezerek or Ford approved equal. Temperature of the heated stages shall be controlled by air operated, m
47、odulating controls. The alkali and phosphate stages shall be equipped with recording control- lers. The first rinse stage shall be equipped with indicating non-recording control- ler . Controls shall be selected to match those predominating in the plant or to meet the preference of the local plant e
48、ngineering manager in case two or more makes are in use. Reference Supplemental Division Drawings for typical piping schematic. Solution piping shall be arranged to permit stage bring-up without the solution. being passed through the flow and spray nozzles. 12.8 For gas fired equipment , manufacturi
49、ng standard BHSX-2 shall be applicable except forthose sect ions which relate only to oven operations. 12.9 The use of lead-bearing compounds on piping joints shall not be permitted for steam heated equipment. 12.10 Steam traps shall conform to the following specifications: 12.10.1 Traps shall consist of cast iron or semi-steel body, inverted bucket with thermostatic vent; stainless steel or approved equal hardened alloy valve and seat, and stainless steel working parts. BJX F. “me .” u 2 Manufacturing Staff ZINC PHOSPHATE EQUIPHENT June 1981 Page 8 a Manufacturing Standards Ford Motor Co
