2-8 j. kelley - preventive maintenance

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1 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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1

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]