Iti Services Introduction

Integrated Technologies, Inc.Integrated Technologies, Inc. Services for Surface FinishingServices for Surface Finishing

April 2008April 2008

2007 2007 ©©COPYRIGHT Integrated Technologies, Inc.COPYRIGHT Integrated Technologies, Inc.

Integrated Technologies, Inc.Integrated Technologies, Inc. Range of ServicesRange of Services

Master Planning Master Planning Process Mapping and ModelingProcess Mapping and ModelingProcess Improvement & ControlProcess Improvement & ControlSurface Finishing Facility and Systems Design Surface Finishing Facility and Systems Design

Process (Wet & Dry)Process (Wet & Dry)Water & WastewaterWater & WastewaterVentilation & Air Emission ControlsVentilation & Air Emission ControlsInstrumentation & Control SystemsInstrumentation & Control Systems

Information SolutionsInformation Solutions


Integrated Technologies, Inc.Integrated Technologies, Inc. Range of ServicesRange of Services

Project Planning & Implementation Support Project Planning & Implementation Support Project ManagementProject ManagementConstruction ManagementConstruction ManagementTrainingTrainingStartup and CommissioningStartup and Commissioning

Operations and Maintenance SupportOperations and Maintenance SupportAuditsAuditsTroubleshootingTroubleshootingTrainingTrainingBest Management PracticesBest Management PracticesContinuous Process ImprovementContinuous Process ImprovementPreventative Maintenance and Asset Management PlanningPreventative Maintenance and Asset Management Planning

Opportunity AssessmentOpportunity Assessment


Opportunity Assessment MethodologyOpportunity Assessment Methodology

Process Equipment Process Equipment and Systems and Systems ManagementManagement

Asset ManagementAsset Management


Asset EvaluationAsset Evaluation Equipment Condition and Risk RatingEquipment Condition and Risk Rating


PESMP Report ExcerptPESMP Report ExcerptProblem:Problem:Tank TTank T--400 Deoxidizer liner is constructed of 316L stainless steel mate400 Deoxidizer liner is constructed of 316L stainless steel material and is not compatible with the mixed acid bath chemistry whrial and is not compatible with the mixed acid bath chemistry which includes HF. ich includes HF. The liner (which replaced an earlier FRP liner) is expected to fThe liner (which replaced an earlier FRP liner) is expected to fail prematurely.ail prematurely.

Level of Risk Level of Risk ImportanceImportance

Condition Condition RatingRating

Application Application RatingRating

Impact RatingImpact Rating Areas of ImpactAreas of Impact

Extremely High Extremely High 33 00 II P, S, M, H P, S, M, H

Recommendation:Recommendation:

A flexible PVC dropA flexible PVC drop--in liner (1/8in liner (1/8”” thick) liner should be installed over the existing stainless stthick) liner should be installed over the existing stainless steel liner. The saddle clips to hold the flight bar will eel liner. The saddle clips to hold the flight bar will require redesign. The drip shields and channel moats will requirequire redesign. The drip shields and channel moats will require redesign and are covered as a separate problem. A leak detecre redesign and are covered as a separate problem. A leak detector should be tor should be installed between the PVC and stainless steel liners. A spare linstalled between the PVC and stainless steel liners. A spare liner can be purchased for use in this tank or others for emergeniner can be purchased for use in this tank or others for emergency for cost of cy for cost of approximately $13,000. Note: A more robust solution would be to approximately $13,000. Note: A more robust solution would be to install a Koroseal liner but this would increase cost.install a Koroseal liner but this would increase cost.

Estimated Cost (ROM):Estimated Cost (ROM): $35,000$35,000Includes installationIncludes installation of dropof drop--in liner, shipping and leak detection plus rental of in liner, shipping and leak detection plus rental of temporary storage for five days. temporary storage for five days.

Design ServicesDesign ServicesOverviewOverview


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20%

40%

60%

80%

100%

0% 10% 20% 30% 40% 50% 60% 70% 80% 90% 100%

Abi

lity

to In

fluen

ce T

otal

Cap

ital C

ost Advanced

Planning

ManufacturingOptimization

PreliminaryDesign

DetailedDesign

Construction and EquipmentInstallation

ProjectDefinition

Maximum Maximum Project Cost Project Cost ControlControl is is Gained Gained through through EffectiveEffective and and EarlyEarly Planning Planning and and EngineeringEngineering

Advanced Planning and Effective Concept Advanced Planning and Effective Concept Development and Visualization Development and Visualization

Facilitate Project Cost EffectivenessFacilitate Project Cost Effectiveness

Total Project Cost

Project Time Line

Commissioning

ConceptualDesign

ContractorSelection


Production Basis ExampleProduction Basis Example


Production PlanningProduction Planning Tank Sizing & QtyTank Sizing & Qty


Phased Renovation Plan for Surface Phased Renovation Plan for Surface Finishing Lines and Associated ProcessesFinishing Lines and Associated Processes

HNO3 HoldTank

Current Nickel/EN

HF/H2SO4 Etch

ChromeEtch/Plate

w/ Fog Rinse2

Load/Unload

ChromeEtch/Plate

w/ Fog Rinse1

Maintenance Aisle (pit level)

CadmiumTitanium

Plate

Atmospheric Evaporator


Rinse 1Rinse 2Chromic

Rinse

NitricAcid(Cd)

Hot Rinse

CadmiumChromate

HNO3 Etch(Temper

Etch)

HCl Desmut(Temper

Etch)

Alkaline Neutralize(Temper

Etch)

CadmiumPlate

Hot Rinse

Load/Unload

Cadmium Strip

HCl Pickle

PHASE I AREA A

Operator Aisle (floor level)

Operator Aisle

Maintenance Aisle and Rectifier Mezzanine

Hot Rinse

AlkalineChrome Strip

w/Fog

Load/Unload

12' Deep Tanks

8' DeepTanks

4' DeepTanks

Note 1: Fixture storage will be overhead using a power & free conveyorNote 2: Scrubbers will be on roofNote 3: Layout does not show hazard material/waste storage or mechanical utilities (heating, cooling, compressed air, etc.)Note 4: Phase 1 requires relocation of existing grit blast unitNote 5: Existing Cd/TiCd will not be decommissioned until all workload is transitioned to new small manual line or large automated line.

Secondary Containment

PHASE 1 CHROME/NICKEL/CADMIUM STRIP

PHASE 1C CADMIUM, TiCD, CHROMATE & TEMPER ETCH

CHROME PLATE PHASE 1C XL CHROME PLATE Part 1

AlkalineChrome Strip

w/FogRinse

AlkalineNickel/EN

Strip

Load/Unload

ChromePlate

w/ Fog Rinse7

ChromePlate

w/ Fog Rinse4

ChromePlate

w/ Fog Rinse5

ChromePlate

w/ Fog Rinse6

TITLE

SCALE

1: 48

FILENAME

VISIODOCUMENT

DRAWN BY

PETER A. GALLERANI

DATE

1/25/2007

REVISED

1/25/2007

2025

AnodeCleaner

4275 4275

22504275 4275

Load/Unload

Load/Unload

Slurry

Person 2

Person 2

Rectifier Rectifier

Load/Unload

Person 2

Person 2

Person 2

Person 2

Person 2Person 2


Maintenance Aisle (pit level) Operator Aisle (floor level)

Rinse 1 Rinse 2

2025

Rinse 1 Rinse 2Rinse 1 Rinse

18001800

1800 180018002025

Rinse 2 Rinse 1Aqueous Clean Rinse 1 Rinse 2

Aqueous Clean Rinse 2

Rinse 2 Rinse 1

RectifierSlurry

Rectifier

Rinse

Inspection

Rinse 1Rinse 2

ChromeEtch/Plate

w/ Fog Rinse3

Rinse 1Rinse 2

2250

HF/H2SO4 Etch

Aqueous CleanRinse 1Rinse 2

1800

2025

Wax CrDewax Wax

NiWaxCure

Load/UnloadHot Rinse

Person 2 Person 2 Person 2 Person 2

Temporary Oven Area (Phase 3); Future HVOF, IVD Al, Shot Peen, etc.Current Wax/Dewax/Vapor Degrease

Note: Current Vapor Degreaser may be required with reduced usage and improved management beyond Phase III

Load/Unload

Load/Unload

Out of TankNickelPlate

Station

ENPlate

w/ Fog RinseRinse

1800

2250 4275 4275 4275 4275 4275 4275 4275 2250

2025

2025

2025

PHASE 3 XL CHROME PLATE Part 2

Rinse 1 Rinse 2

Alkaline Zinc/NickelPlate

w/ Fog Rinse

2250

NickelPlate

w/ Fog Rinse

4275

2025

HCl

1800

NickelPlate

w/ Fog Rinse

4275

NickelStrike

(Sulfamate)Rinse 1Rinse 2

NickelStrike

(Woods)

Fixture Storage (Pit Level)

Part Setup – Fixturing, Mask/Unmask (Floor Level)

Note: Alternate use of pit level is future water/wastewater treatment

HVOFStrip Rinse RinseUltrasonic

CleanUltrasonic

Clean

1800

2250

2250 2250 2250

Tape Removal Hand WipeArea

Membrane Electrolysis

RecirculationTank Holding Tank Holding Tank

Out-of-TankEN

Plate


Paint Cure

UnLoad

Load

UnLoadAqueous

Clean1-01

R11-03

R21-04

Etch1-02

FutureExpansion

Type IC and/or Type IIAnodizing

Prime Side 1

Prime Side 2

Paint (Prime) Cure Chromate Cure3' x 10'3' x 10'

132'-4 7/8"

68'-0

"

132'-6"

12'-0

"

Filter

Filter

Deox1-05

R11-06

R21-07

AnodizeTIw/

Spray Rinse1-08

Chem Film1-09

R11-10

R21-11

Seal1-12

R11-13

R21-14

HWR1-15

Dryer1-16 UnLoadLoadLoad

Setup Area Rack/Unrack15'-0

"

Operator Aisle

Maintenance Aisle

Operator Aisle

Operator Aisle

6'-6

"8'

-0"

Paint B

ooth(future)

Paint B

ooth(future)

Paint B

ooth

Paint B

ooth

Paint Cure

UnLoad

Paint Kitchen

Water & Wastewater Treatment

Setup Area Rack/Unrack, Mask/UnMask

Fans

Fans & Scrubbers

Mechanical

Chiller, Blowers, Compressors

Laboratory

Chemical, Fixture and Spare Parts Storage

FPI

Operator Aisle

12'-0

"6'

-6"

Paint (Prime) Cure

UnLoad

Conceptual Design for IntegratedConceptual Design for IntegratedAluminum Anodizing and Paint ProcessesAluminum Anodizing and Paint Processes


RAFB AMFF RAFB AMFF Designing for LEEDDesigning for LEED

Leadership in Energy and Environmental DesignLeadership in Energy and Environmental Design


Robins AFB Process AutomationRobins AFB Process Automation

Fully Automated Wet Process Lines Provide

Better Quality, Productivity and Safety


Integrated Hazard and Energy ManagementIntegrated Hazard and Energy Management

Bulkhead with Automated Doors

Separates Operator Setup Area from Wet

Process Area

Air in Operator Setup Area is Positive Relative to Wet and Dry Process

Areas



Air in Operator Setup Area can be Cost

Effectively Comfort Cooled due to Reduced

Ventilation Rate



Push/Pull Ventilation is Very Efficient with

Improved Capture due to Front and Back Shields



Obstructions of Push/Pull Ventilation System are

Minimized



Sliding Isolation Shields Protect Operator from Splashes and Fumes and Improve Capture

Efficiency

Interior Washdown of panels and hoods is

Integrated in Design with Spray Manifolds and Collection Troughs


Integrated Hazard and Energy ManagementIntegrated Hazard and Energy ManagementVentilation Design Segregates each Process Line and Provides Energy

Efficient Duct Design


Preventative Maintenance and Asset Preventative Maintenance and Asset ManagementManagement

Facility Design facilitates Frequent Washdown of Process Equipment to

Control Corrosion

Robust Corrosion Resistant Materials and

Coatings are Required to Minimize PM Costs and

Protect Assets


Lean MaintenanceLean Maintenance

Efficient Mechanical Design and Layout

Reduces Maintenance Time and Cost


Main Level Maintenance AislesMain Level Maintenance Aisles

Alternating Operator and Maintenance Aisles Facilitate Efficient

Equipment Maintenance

Instrument Sensors are Located for Easy Access


Integrated Spill Prevention/Control and Integrated Spill Prevention/Control and Corrosion ManagementCorrosion Management

Floor Coating Penetrations are Above Spill Zone.

All Equipment Sits on Pads

Above Spill Zone.



The Basement Level Floor Slopes to

Collections System of Trenches



Trenches Slopes to Collections Sumps



Collections Sump


Water & WastewaterWater & WastewaterNet Water Usage can be Reduced Through

Conservation and Recycling

Well Designed Storage Tanks Provide Holding Capacity for Process

Solutions During Tank Maintenance/Inspection or Bleed to Treatment

Treated Wastewater is Recycled as Scrubber

Makeup


Energy EfficiencyEnergy Efficiency Automatic CoversAutomatic Covers


FiniteFinite--Element Analysis Modeling Helps Element Analysis Modeling Helps Quantify Tank Structural RequirementsQuantify Tank Structural Requirements


Process CommissioningProcess Commissioning


Fixture DesignFixture Design

Stud clamp

Left Side Clamp Support

Right Side Clamp Support

Journal Clamps

Internal Anode Support

Internal Anode Support

10 in Hook

Internal Anode

Plating Instructions:1. Cover chrome areas with copper tape.2. Assemble the left and right side clamp supports with a 10 inch hook and hang from a work bar.3. Locate and tighten the journal clamps in place on the tension strut.4. Attach the journal clamps to the left and right side supports as shown.5. Assemble the stud clamp and attach to the stud and the left side clamp support.6. Assemble the internal anode supports lossely and attach to the clamp supports.7. Insert the internal anode through the internal anode support clamps and hand tighten the internal anode cap onto the internal anode. Make sure the internal anode saw cuts point toward the cap.8. Tighten the internal anode support clamps and adjust the position of the internal anode so that it is centered in the tension strut bore. Tighten the support bolts to the lock the internal anode in position.9. Cover all rack surfaces below the top internal anode support with plater’s tape. Mask the inside area of each bushings location with plater’s tape10. Place a circulation pump near the plating tank.11. Attach a 10 foot piece of ½” ID PVC tubing to the bottom of the internal anode and wire to the rack assembly.12. Pre-process and plate at 55 ASF (part area 860 in2) 330 amps.13. After plating has started attach anode clamp to the internal anode.14. Attach the internal anode tubing to the circulation pump and turn on.15. Half through the plating raise the part and remove the plater’s tape from the bushing areas. Complete the plating cycle.

Bushing area

Bushing area

1.00

0.38

14" Hook

Center Internal Anode

Internal Anode Power Crossbar

Center Anode Alignment bar

Internal Anode Vertical Bar

Base Journal Clamp Bracket

Upper Journal Clamp Bracket

Plating Instructions1. Cover the chrome plated areas. Also cover the edge and top of the bottom flange with metal tape.2. Attach the Base Journal and Upper Journal Clamp Brackets and tighten them over the metal taped areas.3. Attach The Clamp Brackets to the 14" Hooks.4. Attach the Center Anode Alignment Bar5. Attach the Internal anode Power Crossbar.6. Thread a ¼-20 nut onto each of the internal anodes approximately 2".7. Position the Internal Anode Vertical Bars over each internal anode as shown. Thread a second nut onto the Anode.8. Attach the Internal anode vertical bars to the Internal Anode Power Crossbar with a 10-32 screw. Adjust the position of the Vertical bars on the internal anodes by adjusting the nuts. When vertical bars are properly aligned, tighten the nuts to lock the bars in place.9. Thread the Center Anode into the Internal Anode Power Crossbar and through the Center Anode Alignment Bar. Be sure the gap between the Center Anode and the part is at least 3.5".

10. Attach the tubing to a Y and attach 6 feet of tubing to the Y.11. Place a small circulation pump at he plating tank.12. Pre-process and begin plating at 55 ASF (area 75.0 in2) 28.6 Amps fro 5 min.13. after plating has started connect to the tubing to the circulation pump and turn the pump on.14. After cycle rinse.15. Remove the Center Plug and remove all 5 Stud Plugs.16. Unscrew the Base Plug and the Cap Plug completely and slide out on the anode as far as they will go. Then adjust the nut inside the part on each anode to hold the plugs in place outside the part.17. Thread the Center Anode into position so that it extends slightly through the bottom of the center hole.18. Re-activate the part for 30 seconds in HCl and plate at 55 ASF (area 89.in2) 34 amps for 4 min.19. After cycle rinse and remove racking. Inspect the inside surfaces for signs of trapped gas bubbles and brush plate any that are evident.

3.01 3.75

Cost EstimatingCost Estimating


Cost EstimatingCost Estimating Excerpted (comments excluded)Excerpted (comments excluded)

Process Process Improvement and ControlImprovement and Control


Benefits of Process Benefits of Process Mapping & ModelingMapping & Modeling

VisualizationVisualization……process cost, process flow, process cost, process flow, information flow, inputs/outputs, waste (lean), information flow, inputs/outputs, waste (lean), PrioritizationPrioritization……improvementsimprovementsCommunicationCommunication……process managementprocess managementIntegrationIntegration……leverage process knowledge and leverage process knowledge and resourcesresourcesKnowledge Based Process ImprovementKnowledge Based Process Improvement


Process MappingProcess Mapping

Mask Chrome Plated Areas w/ Plater’s Tape

Strip topcoat, primer and cadmium plate by blasting with plastic media at < 60

PSI

Chemical Paint Strip

Remove Bushings

MPI

Aqueous Clean Vapor Degrease

Mask for Cadmium Stripping as Required

Blast Clean with 100 Grit Garnet at 40-60 PSI

Mask for Abrasive Blasting

Strip Cadmium

Inspect:Remove Minor Scratches,

Nicks, Burrs and Sharp Edges

Strip Chromium as Required:

Temper Etch

Polish Collar Set Flange Area to 63 RMS Finish

Mask Chrome Plated Areas w/ Plater’s Tape

Fixture for Vertical Chromium Plating per WDC

PDS

Inspect Chrome Plated Areas

Demask as Required

FPI

Fixture for Cadmium Plating per WCD PDS:

Mask per WCD PDS for Cadmium Plating

Cadmium Plate (0.0002 to 0.0003 thick Cadmium)

Inspect Axle Lower Attach Lug dimensions

Inspect Bushing Areas (4) dimensions

Chromate

Insert Bushings

Strip Paint

Clean

Vapor Degrease

OptionalPreferred

Strip Cadmium?

Yes

No

Bearing Journal Collar Attach Area (2)

Collar Set Flange Area (2)

Actuator Attach Lug

Grind as Required:



Actuator Attach Lug

Inspect

Shot Peen to intensity of 0.008 to 0.012 A using 230 shot as

Required:



Actuator Attach Lug

Blow part clean w/ 15 psi max. compressed air

Remove Tape

Chrome Plate as Required per Work Control

Document: Bearing Journal Collar Attach Area (2 places)

Mask for Plating as Required and per WCD

PDS:Bearing Journal Collar Attach Area (2 places)

Mask for Plating as Required and per WCD PDS:


Actuator Attach Lug

Hand Wipe Clean Area to be Plated

Pumice Scrub Clean Area to be Plated and Rinse

Chrome Plate as Required and per WCD PDS:


Actuator Attach Lug

Pumice Scrub Clean Area to be Plated and Rinse

Fixture for Horizontal Chromium Plating per WCD

PDS

Vapor Degrease

Inspect Chrome Plated Areas

Demask as Required

Vapor Degrease

Grind Chromium as Required:

Bearing Journal Collar Attach Area (2 places) to 63 RMS finish

Collar Set Flange Area (2 places) to 75 RMS finish

Actuator Attach Lug to 75 RMS finish

Vapor Degrease

Blow part clean w/ 15 psi max. compressed air

Inspect

Inspect

Inspect

Inspect

F16 MLG Tension Strut PFDPart No. 2006004-105

T.O. 4S1-109-312/15/2003 PAG

Hand Wipe Clean Area to be Plated

Vapor Degrease

HER Bake 4 hrs within 8 hrs @ 375 ± 25 F




Paint as Required



Mask Chrome Plated Areas w/ Platers Tape

and Laquer

Remove Tape

Mask as Required for Shot Peen

Set Up Chrome Tank per WCD PDS

Set Up Chrome Tank per WCD PDS


Process PlanningProcess Planning Sequence/General ArrangementSequence/General Arrangement


Process MappingProcess Mapping Wet Process ControlWet Process Control


Material PrepShearRouter

NC Turret

Aluminum Substrates2024, 7075, 6061

Magnesium SubstratesAZ31

Stainless Steel Substrates304,316, 321, 347

Steel Substrates

Chem Film

DeburrTimesaver

FormHydro

HammerBrake

Aqueous Clean

Solution TreatSalt Bath

(900F)

Freezer

Aqueous Clean

AgeBake 375F

Aqueous Clean Deox Anodize

TI, TICAnodize

TII Seal PaintPrime

PaintPaint

Material PrepLaser

NC Turret

Aqueous Clean PassDeburr

FormHydro

HammerBrake

Aqueous Clean Pickle

Material PrepLaser

NC Turret

Aqueous Clean

Cd.Plate

DeburrFormHydro

HammerBrake

Aqueous Clean Pickle Chromate

PaintPrime

PaintPaint

MgTreat

Aqueous Clean

MgPickle

PaintPrime

PaintPaint

Dichromate

PaintPrime

PaintPaint

Note 1: No cyanide

Note 2: Pickle/Treat = CrO3/HNO3/HF

Note 3: part size med to large, low workload, may drive size of second line

Note 1: Optimize in-process cleaning

Note 2: Could Primer be applied E-Coat rather than Electrostatic Spray?

Note 1: No cyanide or chromate

Note 2: Pickle = HNO3/HF

Note 3: Small -medium sized parts, low workload

Note 1: Cyanide Process impacts wastewater treatment design

Note 2: Small –medium sized parts, low workload

Note: Rinse Tanks are not Shown




Process MappingProcess MappingWork Flow by Substrate (Al, Mg, SS, Fe)Work Flow by Substrate (Al, Mg, SS, Fe)

Process ModelingProcess Modeling

BenefitsBenefits

• Reduce energy usage/cost • Reduce water usage/cost

• Reduce material usage/cost • Reduce hazardous waste generation

• Reduce total process cost

• Evaluate process/facility change• Evaluate production change

• Evaluate process chemistry change• Evaluate wastestream recycling

• Evaluate water quality cost impact • Evaluate agitation type cost impact

• Model/visualize facility water balance• Model/visualize/improve wastestream

characteristics & wastewater treatment

• Model/visualize air emissions• Model/visualize/improve material

utilization• Model/visualize/improve process

rinsing• Model/visualize process recovery

• Determine activity based cost by process, process sequence, line,

facility

TM

Visualize Cost Visualize Cost & Prioritize & Prioritize ImprovementsImprovements


Case HistoriesCase Histories

BoeingBoeingBurns & McDonnellBurns & McDonnellCH2M HillCH2M HillColtColt’’s Manufacturings ManufacturingCorneliusCorneliusCP TechCP TechGeneral DynamicsGeneral DynamicsGeneral ElectricGeneral ElectricGoodrich AerospaceGoodrich AerospaceHarHar--Conn ChromeConn ChromeHeroux Heroux DevtekDevtekHill AFBHill AFB

Lockheed MartinLockheed MartinNADEP Cherry PointNADEP Cherry PointPlainville ElectroplatingPlainville ElectroplatingPratt & WhitneyPratt & WhitneyPrice IndustriesPrice IndustriesQuality Rolling & DeburringQuality Rolling & DeburringRobins AFBRobins AFBSikorskySikorskySouthwest UnitedSouthwest UnitedTinker AFBTinker AFBTobyhanna Army DepotTobyhanna Army DepotTreffers PrecisionTreffers PrecisionUS FilterUS Filter

PLATO has been used at dozens of plants for design planning and PLATO has been used at dozens of plants for design planning and process optimization.process optimization.Major users and applications include:Major users and applications include:


Process ModelingProcess Modeling Document, Analyze, Prioritize, ImproveDocument, Analyze, Prioritize, Improve


Activity Based CostActivity Based Cost

Iti Services Introduction

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