2-8 j. kelley - preventive maintenance
TRANSCRIPT
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Preventive Maintenance
John L. Kelley
JLK Consulting, LLC
New Castle, Delaware
www.jlkconsulting.net
What is it?
Preventive Maintenance
•Something you do once a year?
•Something that gets done the next time you shut down?
•Has a written procedure?
•Or
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What happens when you don’t
•Hysterical Maintenance
Who is responsible?
Operators?Helpers?Maintenance?Management?All of the Above
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Treating Stations
CoronaFlame
Corona Carbon
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Corona Oxidation on Roll
Dirty treater bar and roll
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Are the ports clean
Uneven Flame
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Dies
DecklesKeep them clean
Dirty Deckles
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Leaks
Barrel AdapterFlangesHoods
Leaking Flange
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Erosion From Leak
Chip on Barrel and Erosion
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Leaking Adapter
Condensed Smoke on Hood
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Rolls
Glazed, Chipped, Not Turning
Glazed Roll
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Chipped Roll
Glazed Roll
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What is wrong with this picture?
Lubrication
Right Grease or OilDon’t over lubricate
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Oil Bearings
To Much Grease
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To Much Grease
Filters
Computer Control CabinetWaterExtruder DriveHopper Loaders/Silos
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Control Cabinet
Control Cabinet
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Drive Filter
Water Filter
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Water Flow
Hopper Filters
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Hopper Filters
SILO
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Electrical
Wiring in cabinets and heater bands
Wiring Cabinet
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Heater Bands
Are they shifting
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Have a planFlame Treater Example
Date Initials Procedure
__/__/__ _____ Check all gas lines and control valves for natural gas leaks
__/__/__ _____ Check air lines for signs of heat damage - replace as needed
__/__/__ _____ Check pneumatic lines, fittings and solenoids for leaks
__/__/__ _____ Check rotary unions for freedom of movement or leaks
__/__/__ _____ Lubricate rotary unions
__/__/__ _____ Check igniters at gas burners for signs of wear
__/__/__ _____ Remove end caps and clean gas burners
__/__/__ _____ Check exhaust ducts for blockage
__/__/__ _____ Check and Lubricate exhaust fan located on roof.
__/__/__ _____ Check operation of safety interlocks
Extruder Carriage ExampleDate Initials Procedure
__/__/__ _____ Check transfer case on all three extruders (use synthetic oil only)
__/__/__ _____ Check water solenoids on carriage and extruder barrels
__/__/__ _____ Change or clean air filters
__/__/__ _____ Lubricate all grease points
__/__/__ _____ Clean carriage tracks
__/__/__ _____ Lubricate gear drives under carriage
__/__/__ _____ Check water separators and drain as needed
__/__/__ _____Check exhaust duct for restrictions or corrosion and replace flex hoses
__/__/__ _____ Check all water lines and solenoids (flush if necessary)
__/__/__ _____ Check oil level in gear reducers (use synthetic oil only)
__/__/__ _____ Change water filter and clean sump
__/__/__ _____ Change oil filters
__/__/__ _____ Lubricate carriage wheels and jack points
__/__/__ _____ Check operation of blast gate on exhaust and lubricate
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Preventive Maintenance
Do it and do it oftenDon’t waitIt’s everyone’s responsibility– Management– Operator’s– Maintenance
Thank You
Contact John L. Kelley at [email protected]