Operations & Maintenance Manual

For

Gimsa Monclova SA de CV
SERIAL No. 0841

ABRASIVE BLAST SYSTEMS, LLC

250 S. Shiloh Rd Garland, Tx 75042 (972) 205-9309

INDEX
WARNINGS SECTION I. SECTION II. SECTION III. SECTION IV. HOUSEKEEPING PROCEDURES OPERATING PROCEDURES GENERAL MAINTENANCE PROCEDURES MAINTENANCE ADJUSTMENTS AND PARTS REPLACEMENT PROCEDURES A. B. C. D. E. SECTION V. SECTION VI. SECTION VII. SECTION VIII. Elevator Module Operation, Maintenance and Adjustments Elevator Head Section Elevator Belt Installation / Repair Drive Units - Operation, Maintenance and Adjustments Rotary Screen Abrasive Separator

BLAST POT AIRLINE FILTER & CO-MONITOR DUST COLLECTOR OPERATION AND INSTALLATION DRAWINGS A. General Arrangement Drawing, Sub assembly details Electrical Schematic Drawing

B.

ABRASIVE BLAST SYSTEMS, LLC 1

THIS MANUAL CONTAINS SPECIFIC PRECAUTIONARY STATEMENTS RELATIVE TO WORKER SAFETY IN APPROPRIATE SECTIONS. READ THIS MANUAL THOROUGHLY AND COMPLY AS DIRECTED. IT IS IMPOSSIBLE TO LIST ALL OF THE POTENTIAL HAZARDS OF DUST CONTROL EQUIPMENT OR BLAST & RECLAIM SYSTEMS. IT IS IMPERATIVE THAT USE OF THE EQUIPMENT BE DISCUSSED WITH AN ABRASIVE BLAST SYSTEMS REPRESENTATIVE. PERSONNEL INVOLVED WITH THE EQUIPMENT OR SYSTEMS SHOULD BE INSTRUCTED TO CONDUCT THEMSELVES IN A SAFE MANNER.

WARNING

These products & equipment are not, under any circumstances, to be used with sand or silica products of any type, and use of such materials will void warranty. Also, as with the use of any product or equipment, you must be sure to use the proper safety equipment, and to properly train your employees in the use of any equipment or products. The manufacturer, wholesaler and distributor assume no responsibility arising from the failure to use proper safety equipment or the failure to properly train employees in the use of the products and equipment.

WARNING

1. Operating blasting equipment without following written instructions and recommended safety procedures could result in serious injury or death. Before using the equipment, read all instructions, literature, owners manuals, labels, specifications and warnings sent with and affixed to the unit. If operation of the unit is unclear after reading the instruction manual, contact your supervisor for instructions. 2. It is the responsibility of the employer to read all labels, warnings and instructions to users of the equipment who are unable to read. Periodic inspections and instructions in the use of this equipment should be made by supervisory personnel to assure the equipment is being properly used and maintained. 3. To prevent delayed lung injury, do not use abrasives containing free silica. Personal protective equipment is required for all abrasive blasting operations. Observe all applicable local, state and federal safety regulations in conjunction with air line filters and respiratory protection (Reference OSHA 29CFR1910.134.1910.1000 and all subsequent additions or modifications). 4. OSHA regulations require the use of an approved breathing air compressor when using NIOSH approved respirators. Before attaching breathing air lines to the compressor and air filter, determine that the compressor is rated suitable as a supply or breathing air entering the respirator(s). If an oil lubricated compressor is used, it shall have a high temperature or carbon monoxide monitor alarm (or both). Gross contamination of the inlet air to the air compressor or serious compressor malfunction will adversely affect the quality of the breathing air entering the respirator(s). 5. All personnel in the vicinity of abrasive blasting operations should wear NIOSH approved air fed respirators, hoods or helmets. 6. All ways depressurize any vessel before loading media or any maintenance is performed. 7. Never operate blasters without remote controls. OSHA regulations require remote controls on all blast machines. Failure to use remote controls can cause serious injury or death to the operator(s) or other personnel in the blasting area. (Reference OSHA Specifications 29CFR1910.244(b) and all subsequent additions or modifications). 8. Do not modify or alter any equipment or controls without written consent from Abrasive Blast Systems, LLC. 9. The use of modified remote controls or door limit switches can cause unintentional start-up without warning which can result in serious personal injury. 10. Periodically check all hoses and dead-man controls to see that they are in good condition. Repair or replace any valves, hoses or controls 1 that show any sign of wear or leakage.

WARNING

WARNING-CONVEYOR SCREWS

WARNING OPERATOR PROTECTIVE EQUIPMENT

WARNING

WARNING

WARNING

WARNING

AIRBLAST RECLAMATION SYSTEM

SECTION I. HOUSEKEEPING PROCEDURES
1) 2) 3) 4) 5) 6) 7) Do all housekeeping following each shift. Always run system during housekeeping cleanup procedures. Allow to run after cleanup to empty all screws and elevator. Clear away discharge from hoses and pipes each shift. Make sure discharge pipes and hoses are clean and not clogged. Make sure dust collector hopper is empty each shift. Watch for good abrasive in dust collector discharge hopper. If excessive, a line trap might be required. Keep covers on all trash receptacles. Do not let trash receptacles overfill. 9) Keep pieces of wire, steel, wood, paper and other large trash picked up and kept out of system. Do not depend upon reclaim system to dispose of any and all trash. Keep all pit areas clean and dry. Moisture is hazardous to this system. Keep all materials and objects away from inlet plenums. Check and clean debris from rotary screen at end of each shift. Check dust collector pressure gauge reading during cleanup. DO NOT let reading exceed "6". (See SECTION VII - Dust Collector)

(972) 205-9309

10) 11) 12) 13)

NOTE: The Pressure gauge should operate between 2 & 4 of static pressure For most of the operating life of the filter elements

All motors should be locked-out at the disconnect during all maintenance procedures.

WARNING

SECTION II. OPERATING PROCEDURES

1. 2. 3. 4. 5. 6. 7. 8. Make sure pressure tank and abrasive storage hopper is full at the beginning of each shift. Always have system running during abrasive additions and clean-up. Always run entire system during blasting and cleanup operations. Make abrasive additions slowly as to not to overload the reclaim system. Make sure the system does not overload during abrasive additions or by dumping cleaned parts with voids which hold additional abrasive. Keep abrasive 12" below separator lip after additions and cleanup have been made and elevated into hopper. Check for full abrasive curtain in separator daily. Elevator must be running full load for this to occur, usually at cleanup or abrasive additions. Check to see if good abrasive is coming out of trash pipe weekly after set properly. Adjust slide gate on the back of the air wash separator accordingly. 1/4" is a large adjustment and it will take time for the results to surface. (See SECTION IV. C-8 in Parts Book)

These products & equipment are not, under any circumstances, to be used with sand or silica products of any type, and use of such materials will void warranty. Also, as with the use of any product or equipment, you must be sure to use the proper safety equipment, and to properly train your employees in the use of any equipment or products. The manufacturer, wholesaler and distributor assume no responsibility arising from the failure to use proper safety equipment or the failure to properly train employees in the use of the products and equipment.

WARNING

SECTION II. OPERATING PROCEDURES Continued

9. 10. Be certain rotary screen is clear of debris before startup of each shift. Always listen for squeaks, banging, etc. This could be a sign that a problem is occurring with the mechanical system. Shut the equipment down and identify the problem. Keep all floor grate in proper position during operation. Visually check for screw rotation. If they are not turning, find out why. Do not allow screws to get bent out of round with debris. Check for air leaks in system weekly. Keep all covers on during operation. Listen for elevator belt making excessive clanging. The belt needs to be tightened or tracked properly if this occurs. (See SECTION IV. B - Elevator Head Section # 1 in Parts Book) Check elevator belt tracking weekly. The belt should remain on the center of the head pulley while in operation. The take up adjustments on either side of the head pulley will adjust up/down to obtain proper tracking and belt tension. Make sure all dust collector slide gates are open at all times, except when emptying 55 gallon dust drums. START system with Green Button at each station. STOP system with each Red Pushbutton OFF station. When any portion of this system fails, NEVER push electrical overload reset buttons and continue blasting without contacting foreman and maintenance to determine initial problem. Only use RED mushroom emergency shut-off for emergencies. Keep all interlocks and buttons clean and in working order. Watch for excessive wear in all areas and provide added lining as necessary.

11. 12. 13. 14. 15. 16.

17.

18. 19. 20. 21.

22. 23. 24.

All guards and cover plates need to be on the equipment prior to starting the equipment.

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WARNING

SECTION III. GENERAL MAINTENANCE PROCEDURES

1) belt tracking once per week after it stabilizes. Check it daily for two (2) weeks after changing or adjusting. Center the belt in the housing by tightening or loosing the take-up bolts

Belt Tracking-Check elevator

Take-up Bolts

2)

Guards- Keep

guards on chains and cover plates on at all times during the operation of the equipment. CHAIN GUARD

ELEVATOR TOP VIEW

3)

Changing Lubricant (Do NOT change oil in sealed for life reducers)
After the first 100 hours of operation, drain out initial oil, flush out the worm gear case with an approved nonflammable, non-toxic solvent, such as Lubriplate Syn Flush, Lubriplate Pure Flush, Whitmores Flushing Oil (#06802030) or Medallion Flushing Oil Kosher (#06812010), and refill. Thereafter, oil should be changed at least every 2,500 operating hours (5,000 for synthetic oil lubricant) or every 6 months (12 months for synthetic oil lubricant), which ever occurs first. Make sure reducer is lubed prior to startup.

4)

Adjustments- Only allow one individual to adjust the Air-wash separator and slide gate adjustments. It takes time for results to surface. The separator abrasive curtain should be no thicker than 1/8 thick.

Rotary Screen

4)

Adjustments- Continue

Note the "Full width" Curtain Keep full abrasive curtain. Set according to dimensions shown on the following page RotaryScreenAbrasiveSeparator)

Note 1/8" Curtain shown in red

5)

Wear- Watch for wear areas.

Add lining to prevent excessive maintenance and wear.

7)

Auger damage- Watch for bent

screws. Debris that falls into the screw hoppers (ie. Large bolts, steel angle etc. can cause screw to bend. problem. Remove debris.

This can be prevented easily!

8) 9)

Noise- Listen for squeaks and excessive scraping, and isolate the Walking screws- Watch screw positioning and make sure they do

not shift in positioning. They will always shift in the opposite direction of the abrasive flow. This is due to loose-set screws in bearings extreme overloading, or loose locking collar on the shafts positioned on the ends of the screw. The screw should be repositioned. Loosen all connections and walk the screw back to its original position. Once in position, tighten all connections and locking collars.

Set screws Locking collar

10) 11) 12)

Rotary screen Clogging- Check rotary

screen for clogging and loose debris.

Chains- Check all chain tightness

monthly.

Reclaim Bearings-

Do not grease bearings. They are all slow in revolution and they are pre-lubricated and sealed for life.

13)

Fan Bearings- Dust collector fan

bearings require lubrication once every four months due to high RPM. (1750)

Chain

SECTION IV. MAINTENANCE ADJUSTMENTS AND REPLACEMENTS

A ELEVATOR MODULE BOOT SECTION: OPERATION, MAINTENANCE AND ADJUSTMENTS A. ELEVATOR MODULE OPERATION, 1)

Boot pulley- is rubber lagged and should be in good

condition.

Rubber lagged Boot Pulley Use shims between mounting angle and pillow block bearing

2)

Adjustments- Adjust boot pulley belt tracking by using shims

between mounting angle bracket and pillow block bearing. Make sure you use shim plates. Do not use washers. This is necessary only when alignment problems exist that cant be resolved by adjusting the take up bolts on the head section.

3)

Bearings- Bearings are pre-lubricated and sealed for life. Do

not grease.

4)

Dust Leakage- Seal removable doors to minimize

abrasive leakage.

5)

Rubbing- Make sure elevator belt does not rub side walls of housing. It will usually favor one side. Adjust from head section (Top Portion Take-Up bolts)
NOTE: damage caused by rubbing An example of rubbing

ELEVATOR MODULE HEAD SECTION

1)

Take-Up adjustment- Head pulley take-up

controls both the belt tension and belt center in housing. This take-up is controlled by loosening or tightening the take-up bolts on each side of the head section from the top of the elevator. Take-up Bolts

2)

Pulley- The head pulley must be rubber

lagged and crowned for proper operation. This pulley is a one piece solid cast assembly. Rubber lagged Head Pulley

3)

Oil- (Do NOT change oil in sealed

sealed for life reducers) Make sure that Mobil 600W Cylinder (460 wt.) oil is used. Mobil SHC 634 (460 wt.) is a synthetic oil that can be used for high temperature applications. The reducers box lubricant is used. New units usually require lubricant.

4) 5) 6) 7) 8)

Belt center- Make sure the elevator belt is centered in both the head
and boot section of the elevator.

Noisy elevator- If buckets constantly hit the elevator housing, the

belt requires tightening and/or tracking.

Belt tension- Proper tension is the elimination of bucket housing

clanging. Do not over tighten

start-up

Elevator alignment- Make sure elevator is in perfect plumb prior to Loose buckets- Do not allow buckets to fall off elevator belts.

ELEVATOR MODULE BELT INSTALLATION, MAINTENANCE AND ADJUSTMENTS a) Hang belt (buckets facing proper direction). Buckets will feed into the separator screw. Attach stretching brackets to buckets each side of pulley. Stretch with "come along" until quite tight. Locate clamps square to belt and tighten to top of head pulley. Clamp with vice grips, etc. Drill and tighten two (2) or more bolts. Remove vise grips and finish drilling and bolting process. Trim off excess belt smooth with belt clamp belt face. Add buckets at regular intervals to fill in void if splicing existing belt. Make sure belt tension and tracking is set EXAMPLE: Installed Belt splice properly prior to operation. Make sure the elevator belt is centered in both the head and boot section of the elevator.
EXAMPLE: Installed Belt splice Note Bucket rotation direction

b)

c)

d)

e) f) g)

h)

i)

j)

k)

EXAMPLE of centered belt

DRIVE UNITS (ALL) - OPERATION, MAINTENANCE AND ADJUSTMENTS 1) 2)

Chain tightness- Keep chains tight with adjustable device supplied

with units or use half (1/2) links whenever feasible.

After the first 100 hours of operation, drain out initial oil, flush out the worm gear case with an approved nonflammable, non-toxic solvent, such as Lubriplate Syn Flush, Lubriplate Pure Flush, Whitmores Flushing Oil (#06802030) or MedallionFlushing Oil Kosher (#06812010), and refill. Thereafter, oil should be changed at least every 2,500 operating hours (5,000 for synthetic oil lubricant) or every 6 months (12 months for synthetic oil lubricant), which ever occurs first.

Changing Lubricant (Do NOT change oil in sealed for life reducers)

3)

Oil- (Do NOT change oil in sealed for life reducers) Make sure that Mobil 600W Cylinder(460 wt.) oil is used. Mobil SHC 634 (460 wt.) is a synthetic oil that can be used for high temperature applications. The reducers box lubricant is used. New units usually require lubricant. Sprocket alignment- Make sure that drive sprockets are
in-line with driven sprockets.

4)

All motors should be locked-out at the disconnect during all maintenance procedures.
5)

WARNING

Reducer base- Make sure

that the reducer mounting bracket is secure to the base.

6) 7)

Housekeeping- Clean abrasive

and debris out of drive pits.

Water damage- Make sure that

no water is entering into the pits that will damage the equipment. If water is present a sump pump should be positioned in the elevator pit recess area to pump the reclaim pits dry.

Water will damage reclaim components. Keep all areas dry and free of debris.

WARNING

EXAMPLE: Water can damage your equipment

AIR WASH SEPARATOR WITH ROTARY SCALPING DRUM: OPERATION, MAINTENANCE AND ADJUSTMENTS 1) operation.

Rubbing- Make sure no rubbing occurs with housing during

Slide gate Rotary Screen

6 Flex hose from Dust collector

2) 3)

Clogging- Make sure it does not clog. Clean debris from drum if such
occurs.

2/3rd Baffle location- Make sure 2/3rd baffle is located toward

elevator side of separator.

Elevator is to the right

4)

2/3rd Baffle adjustment- Set 2/3 baffle 3/8" above angle of repose of abrasive. Make sure it is parallel.

5)

Swing Baffle adjustment- Set swing baffle so 1/8" clearance exists below bottom of baffle and separator lip. This distance is set according to abrasive size. Do not allow jams. The Baffle must swing easily and clear any obstructions. Swing Baffle- Make sure Swing baffle hangs in a vertical position. Counter weights- Adjust
counterweight on the swing baffle (See green arrow) so that it holds back abrasive flow until a full width curtain of abrasive is obtained. Remove some weights if required, especially with lighter abrasives.

6) 7)

Note the "Full width" Curtain

8)

Slide gate adjustment-

Adjust slide gate behind separator to remove desired contamination and spent abrasive. Do not pull out excessive good abrasive. If too much good abrasive is being removed, slightly close the slide gate. Note: Small increments (i.e. 14) are large adjustments.

9)

between edge of abrasive curtain and face of lip. This adjustment is very important and changes drastically with steel grit, Garnet, Coal slag, etc. `

Adjustable baffle- Set bottom adjustable baffle lip so that 1/2" exists

10)

Abrasive level- Check abrasive level each shift. By adding new abrasive into the system on a regular basis, you will have a more consistent blasting profile.
in air to clean the abrasive.

12)

Airflow- Do not cover opening in front of separator. The unit is pulling