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Aqueous Parts Washers

Field Demonstration of New and Improved Parts Cleaning Systems. Productivity, Reliability, Availability, and Maintainability (PRAM) Program. Objective. Identify and evaluate recent APW technology advancements to improve the overall USAF parts cleaning capability and reduce manpower requirements for cleaning while continuing to meet environmental metrics..

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Aqueous Parts Washers

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    1. Aqueous Parts Washers Rick Miles, Ph.D. NCI Information Systems, Inc. 811 Park Drive Warner Robins, GA 31088 rmiles@nciinc.com Phone: (478) 975-0744 Fax: (478) 975-0756

    3. Objective Identify and evaluate recent APW technology advancements to improve the overall USAF parts cleaning capability and reduce manpower requirements for cleaning while continuing to meet environmental metrics.

    4. Project Goals Demonstrate that with the proper engineering analysis being performed upfront, the automatic aqueous cleaning process is a viable replacement for most solvent cleaning systems. Eliminate the need for supplemental cleaning operations and all corrosion problems associated with the aqueous cleaning process. Address the problem of hazardous waste generation from aqueous cleaning processes.

    5. Deliverables APW Selection Guideline Provides guidance to maintenance personnel for selection of new APW equipment for maximum leverage of the technology in the specific cleaning applications Operational Guidelines Developed for field tested equipment Final Technical Report Summarizes field trial results

    6. Baseline Comparison Equipment Manufacturers Better Engineering 25 Models 80% MART 2 Models Wheel & Tire Shop Others Classes of Equipment Small Intermediate Large

    7. Small Class Tabletop Usually costs under $5K Can clean multiple small parts at one time Most widely used: Impulse model by Better Engineering

    8. Intermediate Class 2’ X 3’ Parts $3K-15K Most widely used in Air Force maintenance shops

    9. Large Class Top loaders used when space is premium Can cost over $60K Mainly used in Wheel & Tire Shops

    10. Screening Criteria Stainless Steel Unique qualities (Not a clone) Meets shop specific requirements User friendly Easy clean out Less maintenance

    11. Field Test Locations APWs Small Intermediate Large Bath Treatment Systems Filtration Evaporation Eglin 33rd FW Propulsion Shop Armament Shop Wheel & Tire Shop Barksdale AFB 2nd Wheel & Tire Shop 917th Jet Engine Shop

    12. 33rd FW Propulsion Shop Small augmentor parts (F100 engine) T.O.s 2-1-111 2J-F-100-36-10 3 authorized cleaning processes Aqueous cleaning (substitute for solvent) Daraclean 235XL Large BE Top Loader 180 F water Damaged small parts Bucket of room temperature water Whole afternoon

    13. 33rd FW Armament Shop 2 different sized BE front loaders Difficult to clean out (1 person, 2-3 hrs) Large amounts of maintenance downtime No fresh water rinse (T.O. 11W1-7-14-2) Soap Natural Orange w/o d-limonene (MIL-C-29602 Type II [Powder]) Multiple wash cycles Replacement of sock filter every 2 weeks

    14. 33rd FW Wheel & Tire Shop Large BE Top Loader (No longer operational) All new shop personnel Hand cleaning w/ general aircraft cleaning soap Most difficult cleaning task Baseline: Seymour Johnson AFB, NC

    15. 2nd Wheel & Tire Shop B-52 Wheel rims Bath hazardous w/ significant amount of cadmium 1732 pounds annually MART Tornado 40 w/ Daraclean 235

    16. 917th Jet Engine Shop Engine depot for A-10 engines 2412 pounds annually (6 55-gallon drums) 3 different APWs w/ different cleaning solutions

    17. Field Test Results

    18. 33rd FW Propulsion Shop JR-1 APW Compact size (Small footprint) Nozzles close to parts Can be moved about shop Blue Gold Spray Wash identified as authorized cleaner No way to tell when machine reaches desired temperature

    19. 33rd FW Propulsion Shop

    20. 33rd FW Armament Shop EMC 100E-SS APW KISS Principle Perforated filter screens Hollow rectangular bars w/ drilled out holes Basket rotated from top Slanted tank bottom Internal weir oil skimmer Insulated Switch to MIL-C-29602 Type I (Liquid) Soap

    21. 33rd FW Armament Shop Cleaning

    22. 33rd FW Armament Shop Maintenance

    23. 33rd FW Armament Shop CLEANING EFFICIENCY: 57.2% IMPROVEMENT 357 WASH CYCLES MANHOUR SAVINGS: 143 HOURS PROCESS TIME SAVINGS: 428 TO 101 HOURS MAINTENANCE SAVINGS: 340 TO 4 HOURS

    24. 33rd FW Wheel & Tire Shop Harry Major Machine Swash 500 Limited Floor Space Guillotine Door Hinged access doors No hard plumbing Touch screen control panel Water level controls Viewing window Axial drying fan Insulation Easy access bath cleanout door Belt skimmer Pull out parts tray Flow through brush Racks and fixturing

    25. 33rd FW Wheel & Tire Shop

    26. 33rd FW Wheel & Tire Shop

    27. 33rd FW Wheel & Tire Shop

    28. 33rd FW Wheel & Tire Shop

    29. Seymour Johnson AFB, NC Wheel & Tire Shop

    30. 33rd Wheel & Tire Shop (Main Wheels)

    31. 33rd Wheel and Tire Shop (Nose Wheels)

    32. 33rd FW Wheel & Tire Shop CLEANING EFFICIENCY: 46.2% IMPROVEMENT 895 MAINS MANHOURS: 127 TO 45 HOURS 312 MAINS MANHOURS: 21 TO 10 HOURS

    33. 2nd Wheel & Tire Shop

    34. 2nd Wheel & Tire Shop

    35. 2nd Wheel & Tire Shop

    36. 917th Jet Engine Shop

    37. Summary 400% increase in life cycle 50% reduction in life cycle costs Maintenance reduced 60% Cleaning efficiency improved 57% Manhours reduced 66% Process time reduced 36% Water Eater reduced waste by 90% EQ-1 allowed recycling of cleaning materials

    38. Aqueous Parts Washer Performance Improvement-Phase II Pollution Prevention (P2) Program

    39. Better Engineering APWs • Vast majority currently fielded by the Air Force • 25 different models • Made from mild carbon steel • Makes up approximately 80% of fielded systems

    40. APW Baseline Requirements Deteriorated APW used in Air Force maintenance shop To assess requirements in rehabilitating a rundown washer Better Engineering Models Some of the most widely used in the Air Force Serious disrepair – extensive rusting and missing parts

    41. Initial Problems with APW Test Bed Reservoir drained of liquid but not cleaned of solid waste Sludge and other material blocked nozzles Significant buildup of sludge – oil, grease, rust and other unidentified residue Seriously damaged piping to filter housing Non-reusable metal particulate filter

    42. Pre-Modification

    43. Pre-Modification

    44. Post-Modification

    45. Post-Modification

    46. Rust Removers and Inhibitors Problem Aerated cleaning solution + elevated temperatures = rapid corrosion of mild carbon steel High pH(13 –14) minimized corrosion High pH not compatible with other materials Solution Rust inhibitors from APW manufacturers / other sources Added to rinse water – prevent flash rusting Can be added to cleaning solution Effective in reducing rusting of parts May be effective in reducing rust on interior surfaces of APWs

    48. Rust Removal Evapo-Rust cabinet cleaner

    49. Rust Removal Evaluation

    50. Modification Alternatives APW Possesses Several Subsystems 1. The Machine’s Ability to Clean Pump Assembly Spray Nozzles Heaters Cleaning Solution 2. Maintaining Bath Quality Particulate Filtration Oil Removal System Rust Inhibitors 3. Meeting Shop Specific Technical Requirements Fresh Water Rinse Drying System 4. Addressing Phase I Concerns Secondary Cleaning Bath Cleanout Insulation

    51. Cleaning Options Fresh Water Rinse Technical orders requiring fresh water rinse Use to remove any remaining soap from parts May also remove any rust inhibitors from parts Can be added to current systems

    52. Nozzle Optimization Nozzle calculations to determine proper nozzle angles Cleaning efficiency determined on a weight difference method

    53. Nozzle Optimization

    54. Nozzle Optimization Results (Painted Panels)

    55. Nozzle Optimization Results (Bare Panels)

    56. Nozzle Optimization Results

    57. Cleaner Evaluation Results (60 psi Cone)

    58. Cleaner Evaluation Results (60 psi Cone)

    59. Cleaner Evaluation Results (100 psi)

    60. Cleaner Evaluation Results (100 psi)

    61. Secondary Cleaning Results Minor quantity of soil removed, but significant improvements achievable in appearance

    62. Oil Removal System Majority of APWs possess an oil skimmer Majority of currently approved cleaners are emulsifying type - soils are mixed into solution Non-emulsifying types – soils are forced to the top Oil skimmer used effectively when bath cools Belt oil skimmer may provide better cleaning efficiency In line absorbent filters another option

    63. Particulate Filtration Use to remove particulate and help purify the solution Keeps the jet nozzles from clogging Stops sediment build up Enables bath waste to be classified non-hazardous in some cases Porosity of filter bag key factor

    64. Particulate and Oil Removal Oil absorption filter Failed fairly quickly Did great job of removing oil from bath Particulate filter 10 micron Oil Skimmer Did an excellent job of removing soils from bath Even when cooled more soil could be removed from non-emulsifying compared to emulsifying cleaners Little to no soils were removed from emulsifying cleaners at elevated temperature

    65. Tank Cleanout Modifications

    66. Recommended Changes to T.O. 1-1-691 Insert sections on Fixturing Supplemental Cleaning Drying/Dewatering Bath Life Maintenance Daily, Weekly, & Monthly Maintenance Schedules Tank Cleanout/Sludge Removal Remove all references to MIL-C-29602 in reference to AF Drawing 9825019 Insert caution to not use sacrificially coated parts Fluid entrapment should be addressed in terms of cleaning efficiency not corrosion Oil skimmer use Excessive temperature use Powdered soap Low water level concerns

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