TIPS: OPERATION AND

MAINTENANCE OF AIRLESS
BLAST CLEANING MACHINES
blank inside front cover
 TABLE OF CONTENTS

INTRODUCTION ..................................................................................................................................................................... 1

FIVE BASIC ELEMENTS OF THE AIRLESS BLAST CLEANING SYSTEM ........................................................................................ 1

AIRLESS WHEELS ................................................................................................................................................................... 2

THE BLAST WHEEL .......................................................................................................................................................... 2

CONTROL CAGE ............................................................................................................................................................. 2

BLAST PATTERNS ............................................................................................................................................................. 3

IMPELLER ........................................................................................................................................................................ 3

PATTERN CHANGES CAUSED BY WEAR ........................................................................................................................... 4

THE AMMETER ...................................................................................................................................................................... 4

LOW AMPERAGE ............................................................................................................................................................ 4

FLOODED WHEEL ............................................................................................................................................................ 5

STARVED WHEEL ............................................................................................................................................................. 5

WHEEL HOUSING .................................................................................................................................................................. 6

ABRASIVE FLOW .................................................................................................................................................................... 6

WHEEL TUNE UPS .................................................................................................................................................................. 6

MEDIA HANDLING SYSTEM ................................................................................................................................................... 7

ELEVATORS ..................................................................................................................................................................... 7

SEPARATORS ................................................................................................................................................................... 8

TUMBLAST MILL .................................................................................................................................................................... 9

VENTILATION AND DUST COLLECTION .................................................................................................................................. 9

CARTRIDGE STYLE DUST COLLECTOR ........................................................................................................................... 10

PULSE BAG STYLE DUST COLLECTOR ............................................................................................................................ 10

SHAKER STYLE DUST COLLECTOR ................................................................................................................................. 10

ABRASIVE OPERATING MIX .................................................................................................................................................. 11

ABRASIVE CONTROL DATA .................................................................................................................................................. 11

CONTROLLING COSTS OF BLAST CLEANING ........................................................................................................................ 11

WHEEL HOUR SYSTEM .................................................................................................................................................. 12

EFFECTIVE OPERATION KEYS ......................................................................................................................................... 12

GENERAL GUIDELINES ................................................................................................................................................... 12

PEAK PERFORMANCE CHECK LIST ................................................................................................................................. 13

MAINTENANCE ............................................................................................................................................................. 13

TRAINING SEMINARS .............................................................................................................................................. 14

SPARE PARTS .......................................................................................................................................................... 14

INTRODUCTION

PRODUCTIVITY AND PROFITABILITY—YOU ARE THE KEY

You cannot make money on “downtime!” Airless surface preparation equipment, by its very nature, is self-destructive
and wears from the inside to the outside. Skilled operators must use the equipment cost effectively, and skilled
maintenance personnel must follow preventive and predictive maintenance programs to assure maximum cost effective
productivity.

Your Wheelabrator® equipment designs and the materials used for their construction are products of years of operating
and engineering experience. Cost effective and trouble-free performance in the long run depends upon the care and
attention given the equipment by both operating and maintenance personnel. Since you will be using the finest airless
surface preparation equipment available, we hope these TIPS will assist you in keeping your equipment in top operating
condition at all times.

FIVE BASIC ELEMENTS: YOUR AIRLESS BLAST CLEANING SYSTEM

Your airless blast cleaning system contains five basic elements:

1. AIRLESS BLAST WHEEL

One or more airless blast wheels propel the abrasive by centrifugal force in a
controlled pattern and direction
2. CABINET
A cabinet contains the abrasive material as the wheel performs its cleaning function
3. WORK HANDLING SYSTEM
1. Wheel unit A work handling system presents the work to be cleaned to the abrasive action of the
wheel
4. ABRASIVE CLEANING AND RECYCLING SYSTEM
An abrasive cleaning and recycling system transports, conditions and cleans the
abrasive, removing contaminants and fines from the abrasive going back to the wheel
5. DUST COLLECTOR
A dust collector removes all dust contaminants and abrasive fines from the blast
machine environment for a clean and safe operating atmosphere
2. Cabinet

3. Work handling system 4. Abrasive cleaning and recycling 5. Dust collector

1
THE AIRLESS BLAST WHEEL

THE HEART OF THE MACHINE

A major revolution in blast cleaning occurred in 1932 with the introduction of the airless
abrasive blast wheel. Instead of using compressed air to propel abrasive, controlled centrifugal
force was used with abrasive being thrown from a rapidly rotating wheel onto the work to be
cleaned.

Each machine is fitted with the right size, type and quantity of wheels powered by motors
with the horsepower required to achieve the desired abrasive velocity and flow rate.
The blast
A number of wheel designs have been developed over the years with current models wheel uses
centrifugal force
providing the best combination of features for smooth abrasive flow, focused blast patterns, to propel abrasive
impact energy, longer life and ease of adjustment and maintenance.

HOW IT WORKS
Abrasive from an overhead storage hopper is metered to the center of the wheel unit, which is rotating at high speed. A
feed spout provides a smooth transition from the feed line into the cast alloy impeller rotating with the wheel. The
impeller moves the abrasive through its multiple tapered openings and out through the single stationary opening in the
cast alloy control cage. Controlled quantities of abrasive
are then distributed onto the rotating cast alloy blade
surface at precisely the right time. The abrasive par-
ticles picked up on the inner ends of the blade throw-
ing face are rapidly accelerated as they move to the
end of the blades at the outer edge of the wheel.
Abrasive then leaves the wheel in the form of a pattern
with a narrow width and variable length that must be
properly focused on the work surface for the desired
results.

CONTROL CAGE
One of the most critical components in the wheel is the Control Cage. This part governs the direction of the blast out of the wheel and
onto the work to be cleaned. As little as a 10% error in the location of the "hot spot" can reduce the cleaning efficiency and increase
blast time cycles by 25% or more. At the same
time, the wear rate on certain parts can increase up Control cage set at
to 100%. 11:00 o’clock

The pattern sketch shown here indicates a

Leading edge
clockwise downblast wheel. The center of the
"hotspot" is located 8-3/4" to the right of the
vertical centerline of the wheel. This particular
location is directly controlled by the setting of
the leading edge of the control cage opening
at 11:00 o'clock. Test sheet

Wheel centerline 8 3/4” Hot spot centerline

Individual control cage settings are affected by
cage opening size and shape, wheel rpm and Blast pattern test sheet: elevation view

diameter, and abrasive media size and density. 2

BLAST PATTERNS

FALSE INDICATORS AND WEAR HINTS

The blast pattern needs to be focused directly on the work for maximum efficiency. All wheel parts need to be properly
positioned, adjusted and in acceptable condition.

Two of the more common causes and cures of pattern related malfunctions are as follows:

A. Control cage turned too far in direction of rotation causing excess wear on wheel housing end liner at trailing end
of housing. False blast pattern will reduce cleaning efficiency. Turn cage CCW as needed to correct error.

B. Control cage turned too far in opposite direction of rotation causing excess wear on end liner at leading end of
housing. False blast pattern will reduce cleaning efficiency. Turn cage CW as needed to correct error.

IMPELLER

Control cage at Control cage at

1:00 o’clock 10:00 o’clock

A B

Equally important in maintaining the desired blast pattern is the effect of abrasive wear on the impeller. To properly
distribute the abrasive onto the blade throwing surface, there must always be a "lead" between each impeller segment
and its corresponding blade.

If the leading edge of any segment of the impeller becomes worn so that it becomes parallel with the blade, the
abrasive will hit and split on the bottom edge of the blade. Abrasive hitting this edge will bounce rather than slide on
the primary and trailing blade surfaces. This slows down the flow of abrasive. Bouncing abrasive also accelerates wear
on the blade surfaces and blade retention components. Abrasive staying on the blades too long will increase wear on
housing liners and on outer surfaces of wheels and hubs.

Impeller Impeller worn—

lead blades no lead can cause
unbalanced wheel

Why worn parts change the blast pattern

3
PATTERN CHANGES CAUSED BY WEAR

Wear affects wheel blast efficiency. Complaints of longer than normal cleaning cycles, inadequate cleaning and higher
than normal maintenance costs can usually be traced directly to loss of control over the blast pattern. The blast pattern
must be set properly in the first place, but it can change for a variety of reasons.

Wear on the primary wheel parts that control the "hot spot"—blades, cage, impeller—is the chief cause for changes in
the blast pattern. This wear slows down the flow of abrasive and creates erratic patterns with increased wear and less
effective surface preparation results. The key to optimal efficiency is to inspect these parts on a regular basis and to
replace parts before excessive wear is detected.

Worn blade Worn control cage Worn impeller

Blast pattern changes as wheel parts wear

THE AMMETER

The ammeter for each wheel motor is an important tool to help control cleaning
efficiency. It is the easiest way of determining, at a glance, how much abrasive is being
thrown by the wheel. Full load = 100% efficiency = maximum abrasive flow for the
particular wheel.

Efficiency is the percentage of "work amps" being used. Work Amps are the difference
between full load (nameplate) amps and no-load amps (motor running without abrasive
flow).

For example, a 50 HP, 3600 rpm motor at 460V, with a full load rating of 63 amps and a
no-load reading of 20 amps would equal 43 work amps. Mounted to a Direct Drive
wheel with a maximum flow rate of 960 lbs./min. equals approximately 22 lbs. per amp. When full load is 63 amps, operating at
Operating at 57 amps (6-amp drop) = 14% loss = 86% efficiency (132 lb. minute loss). 57 amps equals a 14% loss in efficiency.

LOW AMPERAGE: ISOLATION TEST

Wheels operating at less than full amperage (nameplate rating) usually means a problem with abrasive flow to or
through the wheel. The problem may be traced to incorrect abrasive supply, part wear or improper adjustment. In any of
these cases, a simple method is available to help identify the more common causes of the flooded or starved condition.
Understanding the instructions shown here and using them to determine the most likely cause of a low amperage
problem will save you time and money.

Knowing the cause of the problem will permit prompt and effective action. Returning to a full amperage operating
condition as soon as possible will produce the desired surface preparation results.

1. With wheel running, turn on abrasive. Turn off abrasive flow and observe ammeter reading.

2. If amperage increases slightly before falling to ""NO LOAD," the problem is a "FLOODED WHEEL."

3. If amperage falls immediately to "NO LOAD," the problem is a "STARVED WHEEL." 4

FLOODED WHEEL: TOO MUCH FLOW FOR CONDITIONS

A flooded wheel indicates more abrasive is reaching

the wheel than it can take away. This actually results
in a reduced feed of abrasive onto the blades and a
Low amperage reading may
corresponding low amperage reading on the ammeter. be due to a flooded wheel

The abrasive valve may be open too far or be too large.

Never try to fill the feed spout to capacity with abrasive
as this will "choke" the wheel. Make sure the abrasive
control valve opening is adjusted for an air gap and free
flow of abrasive into the throat of the feed spout. Dipper valve may be
Worn impeller
opened too far
The feed spout should fit as close to the impeller as
possible and should be centered and parallel with the
rotating opening into the impeller. Confirm that the Misaligned feed spout
Power loss due to loose
impeller vanes are not worn too far and that any motor drive belts
drive belts are tensioned properly.
Flooded wheel: too much flow for conditions

STARVED WHEEL: ABRASIVE SHORTAGE

The machine must be charged with a sufficient quantity

of abrasive to protect the storage hopper and feed the
proper amount of abrasive to the wheel(s). Abrasive
must be added at frequent and regular intervals to
maintain the required level in the storage hopper. No Under-supplied
abrasive hopper
more than 10% – 15% of the hopper capacity should be
added at one time in order to ensure a well-conditioned Low amperage reading may
be due to a starved wheel
operating mix.
Feed-line obstruction
Inspect the machine for any tramp material that could be
lodged in the impeller, caught in the feed pipe or valving,
or blocking flow of abrasive from the hopper into the
feed piping. Check for any interference with abrasive
flow to the lower screw or shaker system, through the
rotary or tray screens and inside the feed spout.
Starved wheel: abrasive shortage

5
WHEEL HOUSING

LINER PROTECTION
The blast wheel is usually enclosed within a housing serving as a safety guard and abrasive
seal around the rapidly rotating wheel. To minimize wear on the housing, a series of
special alloy fabricated or cast liners are installed inside the housing. A set of liners
should consist of a minimum number of pieces with labyrinth type joints, providing
an abrasive tight seal between the liners.

ABRASIVE FLOW: CONTROL VALVES

The abrasive flow to each surface preparation system wheel must
be regulated to match the mechanical capacity of the abrasive
reclaim system components and must stay within the amperage
capacity of the electric drive wheel motor.

Manual slide plates, enclosed air operated (Soundabator™) cup

valve, butterfly valves and magnetic valve systems are all part of
the family of devices currently in use.

Noise control is an additional key factor for selecting enclosed

valves. They were originally developed to reduce noise levels and
protect the open feed area to the wheel. Tests have shown a
Control valves reduction of 25 decibels (A scale) when measured three feet from
the feed inlet.

WHEEL TUNE UPS: COMPONENT KITS

The wheel parts are the highest wear components of any surface
preparation system. Keeping the wheel parts in good condition
permits peak operating efficiency.

When the key parts need to be replaced, they can often be part of a
Tune-Up Kit. This is a handy, single package, usually containing a set
of blades, control cage, impeller, impeller bolt, washer and appli-
cable feed spout seal.

Experience has shown that these key parts can often be replaced at
the same time. Leaving worn parts in the wheel too long will cut
machine efficiency drastically. As blast patterns begin missing the
work target, wear accelerates on parts in line with the abrasive flow,
maintenance labor requirements increase and production capacity is
reduced at the same time that costs are increasing. Keep your wheel fit! Use the tune-up kit.

6
MEDIA HANDLING SYSTEM

The media handling system, or the abrasive cleaning and recycling system, is one of the five basic elements of the airless
blast cleaning system. Every Wheelabrator® blast cleaning system contains the following elements to recirculate, clean
and control the abrasive material used for the surface preparation process. Certain elements are discussed in greater
detail.

1. Lower Reclaim 3

Gravity hopper • Screw conveyer • Shaker conveyer

2. Elevator
4
3. Upper Reclaim
5
Gravity chute • Screw conveyer • Shaker conveyer

4. Separator
6
5. Storage Hopper

Upper or Lower 2

6. Abrasive Feed Control

Manual slide • Air operated • Magna valve

1

ELEVATOR
Belt and bucket elevators handle all the abrasive and contaminants passing through the recycling system. This constant
wear must be monitored to maintain a cost effective operation. The main concerns are elevator belt speed, wear,
tracking and pickup and discharge point efficiency. Belt assemblies must always be capable of moving a minimum
volume of material. The correct lineal feet per minute travel speed moves a fixed volume at an effective material discharge
speed to the upper distribution point.

Front edges of the buckets will wear and cause a significant reduction in carrying capacity from the boot section load
point. Belts must be centered on the pulleys and in the center of the elevator casing. This prevents belt edge wear and
casing wall wear while centering the discharge in the head section of the elevator. Upper elevator discharge points have
expendable wear devices to prevent excess abrasive falling back into the elevator casing. These metal or rubber compo-
nents require frequent inspection and periodic adjustment or replacement. Failure to maintain these components will
increase wear on the elevator system components and reduce the volume of abrasive and contaminants entering the
recycling system.

Elevator components: check and maintain for optimum performance

7
SEPARATORS– AIRWASH OR MAGNETIC

Airwash Style

The media separator must be able to remove sand, scale, media fines and
other contaminants from the abrasive operating mix. This allows only
clean, properly sized media to return to the blast wheel for reuse. Success-
ful operation of the separator has a major impact on (1) parts life, (2)
abrasive consumption, (3) type of finish and (4) speed of surface prepara-
tion. Proper mechanical settings, routine inspections and adjustments,
along with consistent airflow, are all part of the requirements for an
effective separator operation.

Single lip airwash

Compensating Flow

The highest efficiency airwash type separators are designed to utilize the
angle of repose for the particular media as a functional component. Each
type and size of media will provide its own slope for abrasive flow while
protecting metal surfaces from wear. Multiple baffles are used to spread out
and control the media flow. A full width curtain of material must flow through
the air stream to effectively wash the contaminants from the mixture. A uni-
formly thick, low velocity curtain permits a more thorough washing of the
media. Provisions must also be made for removal of any tramp metal or over-
size material from the blasting media. Rotary screens, screened shaker decks
and tray or pan screens are all methods that can be used.
Single drum magnetic

Slide gate (in main line)

Sliding
Dust outlet baffle 3/8"

Swing baffle
1/8"

1/2" SHOT SAND

Sand, scale
and fines

Operating mix

Dribble valve

Compensating
flow type
separator

Secondary drum magnetic

8
TUMBLAST MILL

Tumblast™ work conveyors are exposed to wear and tear from the work product, the
abrasive media and the contaminants being removed from the product. Compo-
nents will gradually deteriorate with use and reduce the reliability of your blast
cleaning equipment. Reliability problems are reduced by maintaining proper
conveyor tension and alignment to prevent jams and subsequent component
damage or breakage.

Steel flighted conveyors will develop increased gaps between flights due to link
and pin wear. Conveyor pitch dimensions change causing articulation
misalignment, overstressed drive points and frequent cracking or breakage of Steel mill
links and pins. Wear on drive sprockets is accelerated by these same stresses. The
chain pitch dimensions should be monitored as an indicator of link pin wear for
scheduling pin replacement or rotation. New drive sprockets and traction wheels
should always be installed with new sets of links and pins.

Rubber belt conveyors will develop enlarged drain holes, torn or missing tumbling
cleats, gouges in the top layer of rubber and tears through the fabric plies. These
problems can be caused by processing unsuitable parts, improper loading, incorrect
blast patterns, badly worn or mis-aligned barrel head and corner shield lining and
inoperative or incorrectly adjusted mill overloads. Localized erosion wear patterns
may indicate drive roll slippage and lack of belt movement during the blast cycle.
Maintain correct belt tension and roll alignment to track straight without slipping and
Rubber mill ensure proper operating practices are followed to prevent serious or catastrophic
wear patterns.

VENTILATION AND DUST COLLECTION

A properly sized and efficiently operating dust collector system is required for effective control and disposal of broken
down abrasive media and dust contaminants removed by the blasting action. Each ventilation point requires a specific
volume and velocity of air to avoid dusting at the machine, a reduction in surface preparation effectiveness, or other
gradual process degradation. After effective operation of the ventilation system has been confirmed, air volume and
velocity readings should be taken at each vent point and recorded as the standard. Periodic checks should be made to
watch for changes in these readings that would indicate potential ventilation problems.

Clean air side

4" Ø; 300 CFM Duct usually same
size as fan inlet

8 1/2" Ø;
1,300 CFM Dust collectors sized for
8" Ø; 1,000 CFM total air volume from
14 1/2" Ø; blast machine
Air inlet Dusty air outlet
4,050 CFM

12" Ø; 2,750 CFM

Baffles

Blast gates for

balancing system
Empty hoppers often
(should slide
horizontally)
Velocity in dusty air
lines should be at
least 3,500 FPM
9 Machine
DUST COLLECTOR MAINTENANCE TIPS
1. Empty hopper and waste containers regularly

2. Inspect shaker mechanism or pulse system

3. Check fan drive for loose belts and correct impeller rotation

4. Dust on exhaust side of cell plate floor or cartridge seal plate indicates leakage
between clean and dirty side of collector

5. Inspect for worn vent piping and worn blast gate slides

6. Check manometer, magnehelic or photohelic gauge reading

DUST COLLECTOR TYPES

Cartridge Style Cartridge style dust collector

A cartridge style dust collector is a continuous, automatic, pulse-type unit. Its

construction offers a compact design with ease of servicing. Dust particles are effectively captured on the outer surfaces
of cartridge filter elements made of various materials appropriate to the individual applications. Cleaning is performed
by various venturi systems using periodic metered pulses of high pressure air into the center of the cartridges. This
reverse air pulse halts the inflow of air and releases the collected dust from the outer surface of the cartridge. Each
pulse sequence causes the dust particles to work their way down the side of the cartridge into the waste hopper and
container.

Pulse Bag Style

The pulse bag dust collector is a continuous, automatic, pulse-type unit. Its construction incorporates multiple tubular
bags supported by tubular steel wire cages. Access may be from outside or from an integral enclosure on the roof. Dust
particles are effectively captured on the outer surface of the tubular bags as the air flows through the material into the
center of the cage frames. The bags may be made of various fabrics with the most
common being cotton sateen or polyester for blast equipment applications. Cleaning is
performed by various venturi systems using periodic metered pulses of high pressure air
down the center of the wire cages. This reverse air pulse halts the inflow of air and
releases the collected dust from the outer surface of the bags. Each pulse sequence frees
the dust particles to work their way down the bags and into the hopper.

Shaker Style

The shaker style dust collector is an intermittent duty, automatic

or manual shaker type unit. Its construction incorporates multiple
tubular bags with internal access required for maintenance and
Jet pulse style collector inspections. Dust particles are captured on the inner surfaces of
the inflated bags when the fan is operating. Bags may be made of
various fabrics with the most common being cotton sateen or polyester for blast equipment
applications. Incoming air is diverted by a baffle and slowed via expansion into the hopper. Large
contaminants drop into the hopper, and finer material is collected on the inside of the bags.
Cleaning is performed by stopping the fan to allow the bags to go slack before shaking them for
a specific interval, usually about three minutes. This action removes most of the dust from the
Shaker style
inner surface of the bags so the dust can then fall into the hopper.

10
ABRASIVE OPERATING MIX

Three (3) important factors to be considered in evaluating the performance of abrasive used for general cleaning are:

1. How fast cleaning can be

completed S-460 OPERATING MIXES THE ABRASIVE OPERATING MIX DOES THE WORK

2. Uniformity of appearance
Operating mix
3. Cost of achieving desired finish Sand/scale
BAD - 82,000 pellets/pound Base metal
These factors are determined by the
abrasive particle size and shape, the Operating mix
abrasive breakdown characteristics
GOOD - 330,000
(metallurgy and hardness) and the pellets/pound
abrasive-size distribution in the
Balanced
machine. Maintaining an operating
Number of pellets per pound = the number
mix of the optimal sizes will permit a of CLEANING IMPACTS per pound
consistent and cost effective A balanced abrasive operating mix is the key to efficient cleaning action.
operation. Choose the smallest size
shot or grit that will do the job. Choose shot over grit whenever possible to minimize wear. Balance the use of faster-
cleaning hard steel abrasives against their higher wear and breakdown rates.

ABRASIVE CONTROL DATA

Consumption of abrasive is determined by the size of the particle removed ABRASIVE CONSUMPTION
from the system at the separator. Separator adjustments should be made to depends on the size of the pellets at removal
ensure that the smallest useful-size particles are left in the operating mix.
Additions of abrasive should be made in small amounts and at frequent
intervals. The added quantity should never exceed 10 to 15% of the storage
hopper capacity. Ventilation air to the machine, elevator and separator must
meet proper volume and velocity requirements. Carryout losses of abrasive
with the work or from leaks should be returned to the machine system.
Attempt to reduce or eliminate these losses wherever possible.
The larger the pellets removed, the greater the
CONSUMPTION RATE and ABRASIVE COST.

CONTROLLING THE ABRASIVE COST OF BLAST CLEANING

Wheel blast cleaning operations involve the flow of billions of abrasive pellets per hour. Any loss of this abrasive out of
the machine means increased operating costs due to the extra abrasive cost and maintenance on other equipment near
the blast machine. Control the abrasive operating mix with proper

1. Abrasive additions (steel shot or steel grit)

Additions = consumption rate

2. Removal size setting

3. Ventilation control: separator and dust collector

4. Control of carryout losses: with work, machine leaks

11
Cost Control – Wheel-Hour System
The most effective measure of an airless blast cleaning system’s efficiency is the blast cost per wheel hour. These costs
are a combination of the required utilities, abrasive, parts, tools, materials, maintenance labor, and operator labor. Each
machine should have an accurate, functioning “wheel” hour meter recording the number of actual blasting hours. It must
be linked to the abrasive flow control device for the wheels. It is the operator’s responsibility to use the individual ma-
chine capabilities as effectively as possible for each hour of blasting.

OPERATING COSTS
+
MAINTENANCE COSTS
÷
ACTUAL WHEEL HOURS OF BLASTING TIME
=
BLAST COSTS PER WHEEL HOUR
The wheel-hour system of cost control

Effective Operation Keys

Prompt attention to wear signs and use of a PPM (Preventive/ Predictive Maintenance) program will allow the highest
operating efficiencies along with the lowest operating costs.

Three key items must be remembered:

1. Observation of existing conditions and understanding the cause and effect relationships of the various self-destructive
components is critical. Knowing what is really wrong before taking any action puts first things first. Be sure that you
are dealing with the true cause of a problem instead of treating a symptom.

2. Adjustments, replacements and repair work must be performed quickly and correctly. Know what to do and when to
do it.

3. Control of the operation will depend on your ability to LOOK - THINK - ACT!

OBSERVATION ADJUSTMENT CONTROL

General Guidelines
A. Understand the self-destructive nature of a blast system and the “inside wears first” characteristics
B. Utilize predictive and preventive maintenance practices as part of the overall operational requirements
C. Provide periodic introductory and refresher training covering fundamentals of operation and maintenance
D. Establish and maintain usage cost records by machine for parts, abrasive and labor expense in terms of wheel blast hours
E. Identify and group problem issues by system component and focus efforts on highest cost reduction potential
F. Evaluate component performance and set minimum standards for wear and replacement

G. Support in-house efforts with OEM expert technical assistance at scheduled intervals

12
Peak Performance Check List

Operating costs can vary drastically and rise rapidly if the blast cleaning system is not kept in optimal condition. Poor
maintenance or operating practices are the most frequent causes of serious problems. Routine inspections, evaluations,
and record keeping are required to prevent unnecessary and unexpected breakdowns. Costly repairs can often be avoided
or postponed by conscientious operation and maintenance of the surface preparation equipment.

Focus on the items in this list as the basis for your expanded predictive maintenance and operating practice instructions.

1. Check abrasive in hopper daily

2. Check pre-blast part condition daily

PREDICTIVE
3. Check ammeter reading for each blast cycle MAINTENANCE

4. Check hot spot cleaning weekly

5. Check analysis of operating mix weekly

CONTROLLED
TRAINING COSTS SUPERVISION
6. Check analysis of separator discharge weekly

7. Check analysis of dust collector discharge weekly

OPERATING
8. Check surface finish uniformity daily COST RECORDS

9. Check internal machine wear condition weekly

10. Record hour meter reading daily

MAINTENANCE

PREVENT OR PREDICT
It is rarely possible to prevent the need for maintenance on an airless surface preparation machine. It is always possible to
predict most maintenance requirements and schedule most major repairs or replacements with an effective
Predictive/Preventive Maintenance Program (PPM). Maintenance costs will be lower and productivity will be higher with a
focus on quickly taking care of small wear problems before they become major problems. The management team for
each operation must commit to a balanced sharing of time for maintenance and production needs. A thorough plan must
be developed and specific responsibilities assigned for a clear understanding of the schedule requirements. Your local
Wheelabrator® product representative will be glad to assist you in developing a comprehensive plan.

Operators will need to play an integral part in any PPM program. They should be individuals who take pride in their
work, are capable of handling responsibility and are thoroughly trained in the basic operating requirements of the blast
equipment. The operator is the first person who should see, hear or feel the external symptoms of problems.

A check sheet for the operator should be developed covering the key daily items to be
observed and recorded. Accurate information is needed to determine abnormal perfor-
mance. The comprehensive elements for this list can be identified with the help of your 1. Check tune-up kit
local Wheelabrator product representative. parts

Maintain an adequate stock of regular spare parts to support routine maintenance work. 2. Check separator
curtain operation
Review what should be stocked with your local Wheelabrator representative.
3. Check collector
pulse cycle and
differential pressure

13
PAID SERVICE PROGRAM
PPM Preventive/Predictive

PPM services can be the decisive link in your overall effort to safely obtain faster, better cleaning, less downtime and
lower operating costs in your blast cleaning or peening operation. The self-destructive nature of the blasting operation
actually causes more cost and performance variables than do most other types of plant equipment. It is also not unusual
for companies to postpone or overlook necessary maintenance and training when peak business periods cause high
production demands with tight schedules. Control of this operating environment will depend on implementing the
necessary PPM programs and operating and maintaining blast equipment with fully trained personnel.

Custom designed PPM services are available from Wheelabrator® technical service representatives. The special require-
ments for each plant's equipment will be analyzed based on the application criteria, and a recommended program of
scheduled visits will be presented. Training needs, Blast Cleaning Reports (BCR's), parts inventory control, general
maintenance suggestions, major repair/ rebuild potential and cost control record management are all part of the scope of
the PPM service program.

Typical quarterly inspections will cover the blast machine and directly related equipment such as vent piping, dust
collectors, loaders, and external work conveyors. A detailed written report is provided, listing the observed operating
conditions along with recommended replacement parts and/or adjustments. These visits can include instruction of
selected operating and maintenance personnel in the actual repairs and adjustments noted on the inspection report.
Applicable suggestions for machine system upgrades will be included when a potential exists for greater productivity,
improved cleaning or significant cost reduction.

Major repairs or rebuilds can be handled by the Wheelabrator technical service PPM representatives on a contract basis.
Advance scheduling and clearly defined work responsibilities can be arranged to take advantage of shutdown, vacation
and reduced production schedules. Choose the level of service that meets your needs from a parts list to a turnkey
system.

TRAINING SEMINARS
Effective operation and maintenance depends on well trained personnel using their knowledge and capability to do the
right thing at the right time in the right way. Training classes are offered periodically in specific geographic areas as
Operation & Maintenance Seminars and at various plant sites as In-Plant Training Seminars. Agendas cover the
general requirements for all blast systems, along with specialized topics appropriate for the attendees. Specialized
programs can also be developed for In-Plant Programs focusing on specific machines. Contact your Distribution Center
representative for further details on cost, scope and seminar schedule.

SPARE PARTS
Successful PPM (Predictive/Preventive Maintenance) programs require an adequate stock of critical service parts for
routine replacement needs and a parts control system to order, receive and stage long lead items for planned repairs
during scheduled shutdown periods. The system should provide reliable inventory control and cost summary information
by machine. Wheel hour operating data should be integrated with the part usage record system.

Ordering Requirement:

• Machine Serial Number

• Part Number

• Description of Part

• Drawing Reference

• Quantity Required 14
NOTES

15
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 SERVICES
Call your Wheelabrator® OEM or Distribution Center for any of these services:
• Analyzing your cleaning needs • Complete installation, start up, repair and rebuild
• Proposing solutions for your cleaning services
problems • PPM maintenance and inspection services
• Designing standard and custom blast • Operator and maintenance training
cleaning systems
• Building and testing equipment, including
custom designs

EQUIPMENT
Wheelabrator equipment includes the following:
• Tumblasts • Roll conveyor • Drum cleaning • Dust collectors
Batch Horizontal
Continuous Vertical • Pipe cleaning • Blast and paint lines
Rocker barrel
• Skew roll • Billet cleaning • Repair parts
• Wire mesh belt Single roll • Rocker barrel
In-line Dual roll • Equipment upgrades
Rotary table • Monorail
• Rod and bar Pass thru • Peening supplies
• Tables In-line Spinner hanger Almen strips
Swing table Coil Gauges
Multi-table • Rail car Mounting blocks
Rotary door • Vibra tunnel External
Car table Internal • Gripper

Canada United States

1219 Corporate Drive 1606 Executive Drive
Burlington, Ontario Canada L7L 5V5 LaGrange, GA 30240 USA
Tel: (905) 319-7930 Tel: (706) 884-6884
800-845-8508 800-544-4144
fax: 905-319-7561 fax: 706-884-0710 www.wheelabratorgroup.com

email: info@wheelabratorgroup.com
Products manufactured and marketed by Wheelabrator Group, Inc. and its affiliates are protected by patents issued or pending in the ©2005 Wheelabrator
United States and other countries. Wheelabrator Group, Inc. reserves the right to change the specifications referred to in this literature
at any time, without prior notice. Tumblast is a registered trademark owned by Wheelabrator Group, Inc.. Wheelabrator is a registered
trademark of Wheelabrator Technologies, Inc..

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