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Troubleshooting Guide for Cleaners
- By Mike Pelham
- May 15, 2006
- Article
- Tube and Pipe Production
This guide is part of an article series "Flushing out four-letter words-rust, dirt, and wear; Part II: Removing soils effectively," by Mike Pelham, International Chemical Co., Philadelphia, reprinted from the June 2006 issue of The Tube & Pipe Journal®. The article addresses how to eliminate tube producing and fabricating problems related to dirt, rust, and wear. To read the article series online, enter "Pelham" in thefabricator.com search field.
Problem | Cause | Corrective Action |
Poor Cleaning | Mechanical | |
Plugged spray nozzles resulting in poor coverage. Insufficient coverage and inadequate direction of cleaner solution. | Inspect and clean nozzles; clean and descale washer if necessary. | |
Low pump pressure or damaged pump impeller. | Check, repair or replace impeller; adjust pump pressure. | |
Excessive foam. | See Foam section. | Chemical |
Incorrect cleaner solution. | Adjust concentration to manufacturer's recommendation. | |
Cleaning temperature too low. | Increase temperature. | |
Change in soils being cleaned; a new lubricant or coolant may not be effectively removed with the existing cleaner or at the current temperature. | Evaluate cleaner and adjust temperature to manufacturer's recommendation; monitor cycle times. | |
Foam | Mechanical | |
Air leaks in the piping to the pump inlet or in the pump itself, causing aeration and/or cavitation of the cleaner solution resulting in excessive foaming. | Find the leak and seal it; check all hose clamps for tightness. | |
Sump level is below pump intake level which causes aeration and subsequent foaming. | Raise solution to correct level. | Chemical |
Incorrect cleaner concentration. | Adjust concentration to manufacturer's recommendation. | |
Incorrect cleaner temperature. | Adjust temperature accordingly. | |
Cleaner solution contaminated with a foreign material. | Use a defoamer as a short-term solution, then identify the source of contamination. For a one-time occurrence, dump and recharge washer; if foam changes continually, change cleaning product. | |
Streaking or Spotting | Mechanical | |
Part configuration causes uneven coating, resulting in uneven washing. | Insert or adjust air blowoff. Tilt parts to facilitate runoff of excess solution. | |
Rinse nozzles misaligned. | Adjust nozzles. | |
Rinse temperature and/or cleaner temperature too high, causing flash drying or cleaner breakdown. | Adjust temperature to manufacturer's recommendation. | Chemical |
Cleaner concentration elevated in the rinse because of excess carryover (flowover) of cleaner on the parts or overspray running into rinse tank.g |
Tilt parts to facilitate runoff of excess solution. Adjust nozzle direction to eliminate overspray. | |
Cleaner cannot be removed effectively. | Change to a nonsilicated cleaner. Check for soils in bath. Consult with cleaner manufacturer. | |
Temperature too high, causing detergent to dry on parts. | Adjust temperature to manufacturer's recommendation. | |
Parts don't dry. | See Wet Parts section of this guide. | |
Rust on Cleaned Parts | Mechanical | |
Rust-protective film rinsed from the workpieces by fresh water. | Adjust concentration to manufacturer's recommendation. | |
Parts rusted before entering the washer. | Inspect parts before washing. If rust is present, determine its origin. | |
Parts not clean. | See Poor Cleaning section of this guide. | |
Work left in the washer over a shutdown period | Verify wash cycle is finished and washer is empty before shutdown. Keep washer doors open to reduce humidity. | |
Contact between parts. | Separate parts. Use a water-displacing rust prevention agent. | |
Wet parts. | See Wet Parts section of this guide. | Chemical |
Incorrect cleaner concentration | Adjust concentration to manufacturer's recommendation. | |
Cleaner not appropriate for the application. | Consult the manufacturer to select a cleaner that matches the soils. | |
Wet Parts | Mechanical | |
Air blowoff nozzles out of alignment. | Adjust direction and temperature of air blowoff nozzles. | |
Rinse temperature too low. | Adjust temperature to manufacturer's recommendation. | |
Conveyor speed too fast. | Adjust conveyor speed. Increase air blowoff temperature. Increase air blowoff volume. | |
Hard Water | Cleaner not compatible with water's mineral concentration. | Change to a cleaner compatible with hard water. Use softened or deionized water in the rinse stage. Use a rinse aid. |
About the Author
Mike Pelham
2628-48 N. Mascher St.
Philadelphia, PA 19133
215-739-2313
About the Publication
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