Aqueous Parts Washers

1
Aqueous Parts Washers
David Ellicks Air Force Corrosion Prevention
Control Office 325 Richard Ray Blvd., Bldg.
165 Robins AFB, GA 31098

• Rick Miles, Ph.D.
• NCI Information Systems, Inc.
• 811 Park Drive
• Warner Robins, GA 31088
• rmiles_at_nciinc.com
• Phone [phone]
• Fax [phone]

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Field Demonstration of New and Improved Parts
Cleaning Systems

• Productivity, Reliability, Availability, and
  Maintainability (PRAM) Program

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.

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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

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Baseline Comparison

• Equipment Manufacturers
• Better Engineering
• 25 Models
• 80
• MART
• 2 Models
• Wheel Tire Shop
• Others

• Classes of Equipment
• Small
• Intermediate
• Large

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Small Class

• Tabletop
• Usually costs under 5K
• Can clean multiple small parts at one time
• Most widely used Impulse model by Better
  Engineering

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Intermediate Class

• 2 X 3 Parts
• 3K-15K
• Most widely used in Air Force maintenance shops

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Large Class

• Top loaders used when space is premium
• Can cost over 60K
• Mainly used in Wheel Tire Shops

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Screening Criteria

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

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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

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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

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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

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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

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2nd Wheel Tire Shop

• B-52 Wheel rims
• Bath hazardous w/ significant amount of cadmium
• 1732 pounds annually
• MART Tornado 40 w/ Daraclean 235

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917th Jet Engine Shop

• Engine depot for A-10 engines
• 2412 pounds annually (6 55-gallon drums)
• 3 different APWs w/ different cleaning solutions

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Field Test Results
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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

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33rd FW Propulsion Shop
Cleaning efficiency 66.7 improvement Manhours
Reduced from 85 to 7annually
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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

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33rd FW Armament Shop Cleaning
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33rd FW Armament Shop Maintenance
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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

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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

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33rd FW Wheel Tire Shop
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33rd FW Wheel Tire Shop
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33rd FW Wheel Tire Shop
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33rd FW Wheel Tire Shop
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Seymour Johnson AFB, NC Wheel Tire Shop
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33rd Wheel Tire Shop (Main Wheels)
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33rd Wheel and Tire Shop (Nose Wheels)
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33rd FW Wheel Tire Shop

• CLEANING EFFICIENCY 46.2 IMPROVEMENT
• 895 MAINS
• MANHOURS 127 TO 45 HOURS
• 312 MAINS
• MANHOURS 21 TO 10 HOURS

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2nd Wheel Tire Shop
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2nd Wheel Tire Shop
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2nd Wheel Tire Shop
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917th Jet Engine Shop
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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

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Aqueous Parts Washer Performance
Improvement-Phase II

• Pollution Prevention (P2) Program

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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

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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

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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

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Pre-Modification
B.E. washer Rusted and Missing parts
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Pre-Modification
Sludge
Clogged Pipes
Corrosion / Rust
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Post-Modification
Particulate Filtration
Fresh Water Rinse
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Post-Modification
Brush Pump
Belt Skimmer
New Heater Elements
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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

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Rust Removal
Before Evapo-Rust
After Evapo-Rust
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Rust Removal

• Evapo-Rust cabinet cleaner

Inner Cabinet
Inner Door
Tank Area
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Rust Removal Evaluation
72 hrs after evaporust
2 hrs after evaporust
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Modification Alternatives

• APW Possesses Several Subsystems
• 1. The Machines 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

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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

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Nozzle Optimization

• Nozzle calculations to determine proper nozzle
  angles
• Cleaning efficiency determined on a weight
  difference method

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Nozzle Optimization
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Nozzle Optimization Results (Painted Panels)
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Nozzle Optimization Results (Bare Panels)
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Nozzle Optimization Results
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Cleaner Evaluation Results (60 psi Cone)
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Cleaner Evaluation Results (60 psi Cone)
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Cleaner Evaluation Results (100 psi)
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Cleaner Evaluation Results (100 psi)
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Secondary Cleaning Results

• Minor quantity of soil removed, but significant
  improvements achievable in appearance

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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

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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

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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

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Tank Cleanout Modifications
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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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QUESTIONS?