Iti Services Introduction

Integrated Technologies, Inc.
Services for Surface Finishing
April 2008

Range of Services
Master Planning
Process Mapping and Modeling
Process Improvement & Control
Surface Finishing Facility and Systems Design
Process (Wet & Dry)
Water & Wastewater
Ventilation & Air Emission Controls
Instrumentation & Control Systems
Information Solutions

2007 ©COPYRIGHT Integrated Technologies, Inc.

Range of Services
Project Planning & Implementation Support
Project Management
Construction Management
Training
Startup and Commissioning
Operations and Maintenance Support
Audits
Troubleshooting
Training
Best Management Practices
Continuous Process Improvement
Preventative Maintenance and Asset Management Planning


Opportunity Assessment Methodology

Asset Management
Process Equipment
and Systems
Management

Asset Evaluation
Equipment Condition and Risk Rating


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

Level of Risk Condition Application Impact Rating Areas of Impact
Importance Rating Rating
Extremely High 3 0 I P, S, M, H

Recommendation:

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

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


Advanced Planning and Effective Concept
Development and Visualization
Facilitate Project Cost Effectiveness
100%
Ability to Influence Total Capital Cost

Advanced
Planning

Manufacturing
80% Optimization

Project Maximum
Definition
Project Cost
Conceptual

60%
Design Total Project Cost Control is
Preliminary Gained
Design
through
40%
Detailed
Design
Effective
Contractor
and Early
Selection
Planning
20%
Construction and Equipment
Installation
and
Engineering
Commissioning
0%
0% 10% 20% 30% 40% 50% 60% 70% 80% 90% 100%

Project Time Line


Production Basis Example


Production Planning
Tank Sizing & Qty


Phased Renovation Plan for Surface
Finishing Lines and Associated Processes

Person 2 Person 2 Person 2 Person 2

Current Wax/Dewax/Vapor Degrease
Temporary Oven Area (Phase 3); Future HVOF, IVD Al, Shot Peen, etc. Current Nickel/EN
Note: Current Vapor Degreaser may be required with reduced usage and improved management beyond Phase III

2025 2250 1800 1800 2025
2025 1800 4275 4275
Out of Tank
Nickel Nickel
Nickel HF/H2SO4 Aqueous Cadmium
Strike Strike Rinse 2 Rinse 1 HCl Rinse 2 Rinse 1 Load/Unload Chromic Cadmium
Plate Etch Clean Titanium
(Woods) (Sulfamate) Load/Unload Load/Unload Hot Rinse Rinse 2 Rinse 1 Rinse Rinse 2 Rinse 1 Plate
Station Plate

Person 2

Rectifier Rectifier Rectifier Rectifier
Slurry Slurry

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

Person 2
Out-of- Alkaline Zinc/ Fixture Storage (Pit Level)
EN Nickel Nickel
Tank Nickel
Plate Rinse Plate Plate Rinse 1 Rinse 2 Hot Rinse Load/Unload
EN Plate Part Setup – Fixturing, Mask/Unmask (Floor Level)
w/ Fog Rinse w/ Fog Rinse w/ Fog Rinse
Plate w/ Fog Rinse
Nitric
Note: Alternate use of pit level is future water/wastewater treatment Aqueous Cadmium
Load/Unload Load/Unload Rinse 1 Rinse 2 Hot Rinse Rinse 2 Rinse 1 Acid HCl Pickle Rinse 1 Rinse 2
Clean Chromate
1800 4275 4275 2250 2025 (Cd)
Person 2

2025 2025 1800 1800 1800
Hold
HNO3
Tank Operator Aisle (floor level) Maintenance Aisle (pit level) PHASE I AREA A
Membrane Recirculation
Holding Tank Holding Tank
Electrolysis Tank

2250 2250 2250 2025 1800 1800 2025

Alkaline
HNO3 Etch HCl Desmut
Wax Wax Wax HVOF Ultrasonic Ultrasonic Tape Removal Hand Wipe Aqueous Neutralize
Dewax Rinse Rinse Load/Unload Load/Unload Rinse 1 Rinse 2 (Temper (Temper Rinse 1 Rinse 2 Rinse Hot Rinse Inspection
Cure Cr Ni Strip Clean Clean Area Clean (Temper
Etch) Etch)
Etch)
Person 2

PHASE 1C CADMIUM, TiCD, CHROMATE & TEMPER ETCH

Person 2

Person 2

PHASE 1 CHROME/NICKEL/CADMIUM STRIP CHROME PLATE Operator Aisle
PHASE 3 XL CHROME PLATE Part 2 PHASE 1C XL CHROME PLATE Part 1
Person 2 Person 2

Chrome Chrome Chrome Chrome Chrome Chrome Chrome
Alkaline Alkaline Alkaline
Anode Plate Plate Plate Plate Etch/Plate Etch/Plate Etch/Plate HF/H2SO4
Chrome Strip Chrome Strip Rinse Cadmium Strip Nickel/EN Rinse Load/Unload Load/Unload Rinse 2 Rinse 1 Rinse 2 Rinse 1
Cleaner w/ Fog Rinse w/ Fog Rinse w/ Fog Rinse w/ Fog Rinse w/ Fog Rinse w/ Fog Rinse w/ Fog Rinse Etch
w/Fog w/Fog Strip
7 6 5 4 3 2 1

4275 4275 2250 2250 2250 4275 4275 4275 4275 4275 4275 4275 2250

Atmospheric Atmospheric Atmospheric
Evaporator Evaporator Evaporator
Maintenance Aisle and Rectifier Mezzanine

Note 1: Fixture storage will be overhead using a power & free conveyor 4' Deep
Note 2: Scrubbers will be on roof Tanks
Note 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 unit 8' Deep
Note 5: Existing Cd/TiCd will not be decommissioned until all workload is Tanks
transitioned to new small manual line or large automated line.
12' Deep
TITLE DATE REVISED
Tanks
1/25/2007 1/25/2007

Secondary FILENAME DRAWN BY SCALE
Containment VISIODOCUMENT PETER A. GALLERANI 1: 48


Conceptual Design for Integrated
Aluminum Anodizing and Paint Processes

Paint Kitchen

Mechanical

Paint Booth

Paint Booth

Paint Booth

Paint Booth

Paint Cure

Paint Cure

UnLoad
(future)

(future)
Setup Area Rack/Unrack,
Chiller, Blowers, Compressors
Mask/UnMask

Filter Operator Aisle
Prime Side 1

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

Prime Side 2
Load
Filter
Operator Aisle

UnLoad

Paint (Prime) Cure

UnLoad
15'-0quot;

Setup Area Rack/Unrack
68'-0quot;

Water & Wastewater Treatment

Operator Aisle
6'-6quot;

132'-6quot;

Anodize
TI Future
Aqueous Chem
12'-0quot;

Etch R1 R2 Deox R1 R2 w/ R1 R2 Expansion Seal R1 R2 HWR Dryer
Load Load Clean Film UnLoad UnLoad
1-02 1-03 1-04 1-05 1-06 1-07 Spray 1-10 1-11 Type IC and/or Type II 1-12 1-13 1-14 1-15 1-16
1-01 1-09
Fans & Rinse Anodizing
Scrubbers 1-08
8'-0quot;

Maintenance Aisle
12'-0quot;

FPI

Laboratory

Operator Aisle
6'-6quot;

Chemical, Fixture and Spare Parts Storage

132'-4 7/8quot;


RAFB AMFF
Designing for LEED
Leadership in Energy and Environmental Design


Robins AFB Process Automation

Fully Automated Wet
Process Lines Provide
Better Quality,
Productivity and Safety


Integrated Hazard and Energy Management

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

Bulkhead with
Automated Doors
Separates Operator
Setup Area from Wet
Process Area

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


Interior Washdown of
panels and hoods is
Integrated in Design with
Spray Manifolds and
Collection Troughs

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


Ventilation Design
Segregates each
Process Line and
Provides Energy
Efficient Duct Design


Preventative Maintenance and Asset
Management

Robust Corrosion
Resistant Materials and
Facility Design facilitates Coatings are Required to
Frequent Washdown of Minimize PM Costs and
Process Equipment to Protect Assets
Control Corrosion


Lean Maintenance

Efficient Mechanical
Design and Layout
Reduces Maintenance
Time and Cost


Main Level Maintenance Aisles

Instrument Sensors are
Located for Easy Access

Alternating Operator and
Maintenance Aisles
Facilitate Efficient
Equipment Maintenance


Integrated Spill Prevention/Control and
Corrosion 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 & Wastewater
Well Designed Storage
Net Water Usage can
Tanks Provide Holding
be Reduced Through
Capacity for Process
Conservation and
Solutions During Tank
Recycling
Maintenance/Inspection
or Bleed to Treatment

Treated Wastewater is
Recycled as Scrubber
Makeup


Energy Efficiency
Automatic Covers


Finite-Element Analysis Modeling Helps
Quantify Tank Structural Requirements


Process Commissioning


Fixture Design
10 in Hook
Plating Instructions:
1. Cover chrome areas with copper tape.
2. Assemble the left and right side clamp supports with a 10 14quot; Hook
inch hook and hang from a work bar. Internal Anode
3. Locate and tighten the journal clamps in place on the Support
Center
tension strut. Internal
4. Attach the journal clamps to the left and right side supports Anode
as shown.
5. Assemble the stud clamp and attach to the stud and the left
side clamp support. Internal Anode
6. Assemble the internal anode supports lossely and attach to Internal Anode
the clamp supports. Power Crossbar
7. Insert the internal anode through the internal anode
Journal Clamps
support clamps and hand tighten the internal anode cap onto
the internal anode. Make sure the internal anode saw cuts
point toward the cap. 0.38

8. Tighten the internal anode support clamps and adjust the Bushing area 1.00
position of the internal anode so that it is centered in the
tension strut bore. Tighten the support bolts to the lock the Center Anode
internal anode in position. Alignment bar
9. Cover all rack surfaces below the top internal anode Left Side Clamp
support with plater’s tape. Mask the inside area of each Support
bushings location with plater’s tape
10. Place a circulation pump near the plating tank. Internal Anode
Vertical Bar 3.01 3.75
11. Attach a 10 foot piece of ½” ID PVC tubing to the bottom
Right Side
of the internal anode and wire to the rack assembly.
Clamp Support
12. Pre-process and plate at 55 ASF (part area 860 in2) 330
amps. Base Journal
13. After plating has started attach anode clamp to the Clamp Bracket
internal anode. Upper Journal
14. Attach the internal anode tubing to the circulation pump Clamp Bracket
and turn on.
15. Half through the plating raise the part and remove the Plating Instructions
1. Cover the chrome plated areas. Also cover the edge and 10. Attach the tubing to a Y and attach 6 feet of tubing to the Y.
plater’s tape from the bushing areas. Complete the plating 11. Place a small circulation pump at he plating tank.
top of the bottom flange with metal tape.
cycle. Stud clamp 2. Attach the Base Journal and Upper Journal Clamp 12. Pre-process and begin plating at 55 ASF (area 75.0 in2) 28.6
Brackets and tighten them over the metal taped areas. Amps fro 5 min.
3. Attach The Clamp Brackets to the 14quot; Hooks. 13. after plating has started connect to the tubing to the circulation
4. Attach the Center Anode Alignment Bar pump and turn the pump on.
5. Attach the Internal anode Power Crossbar. 14. After cycle rinse.
6. Thread a ¼-20 nut onto each of the internal anodes 15. Remove the Center Plug and remove all 5 Stud Plugs.
Bushing area approximately 2quot;. 16. Unscrew the Base Plug and the Cap Plug completely and slide
7. Position the Internal Anode Vertical Bars over each out on the anode as far as they will go. Then adjust the nut inside
internal anode as shown. Thread a second nut onto the the part on each anode to hold the plugs in place outside the part.
Anode. 17. Thread the Center Anode into position so that it extends
8. Attach the Internal anode vertical bars to the Internal slightly through the bottom of the center hole.
Internal Anode Anode Power Crossbar with a 10-32 screw. Adjust the 18. Re-activate the part for 30 seconds in HCl and plate at 55 ASF
Support position of the Vertical bars on the internal anodes by (area 89.in2) 34 amps for 4 min.
adjusting the nuts. When vertical bars are properly aligned, 19. After cycle rinse and remove racking. Inspect the inside
tighten the nuts to lock the bars in place. surfaces for signs of trapped gas bubbles and brush plate any that
9. Thread the Center Anode into the Internal Anode Power are evident.
Crossbar and through the Center Anode Alignment Bar. Be
sure the gap between the Center Anode and the part is at
least 3.5quot;.


Cost Estimating
Excerpted (comments excluded)


Process
Improvement and Control

Benefits of Process
Mapping & Modeling
Visualization…process cost, process flow,
information flow, inputs/outputs, waste (lean),
Prioritization…improvements
Communication…process management
Integration…leverage process knowledge and
resources
Knowledge Based Process Improvement


Process Mapping
Strip Paint
Temper Etch Mask for Plating as Pumice Scrub Clean Area FPI
Inspect: Required and per WCD to be Plated and Rinse
Remove Minor Scratches,
Nicks, Burrs and Sharp PDS:
Preferred Optional Bearing Journal Collar
Edges Attach Area (2 places)
Inspect Vapor Degrease
Chrome Plate as Required and
per WCD PDS:
Mask Chrome Plated Areas Mask Chrome Plated
w/ Plater’s Tape Areas w/ Platers Tape Strip Chromium as Required: HER Bake 4 hrs within 8 Hand Wipe Clean Area to Collar Set Flange Area (2) Fixture for Cadmium Plating
and Laquer hrs @ 375 ± 25 F be Plated per WCD PDS:
Bearing Journal Collar
Attach Area (2) Actuator Attach Lug
Strip topcoat, primer and
cadmium plate by blasting Chemical Paint Strip Mask as Required for Pumice Scrub Clean Area Mask per WCD PDS for
with plastic media at < 60 Collar Set Flange Area (2) Shot Peen to be Plated and Rinse Cadmium Plating
PSI
Inspect Chrome Plated
Remove Tape Actuator Attach Lug Areas
Shot Peen to intensity of 0.008 to Chrome Plate as Required Blast Clean with 100 Grit
Blow part clean w/ 15 psi 0.012 A using 230 shot as per Work Control Garnet at 40-60 PSI
max. compressed air Required: Document:
Vapor Degrease Bearing Journal Collar Bearing Journal Collar Demask as Required
Inspect Attach Area (2) Attach Area (2 places)
Blow part clean w/ 15 psi
Remove Tape max. compressed air
Collar Set Flange Area (2) Vapor Degrease
Grind as Required: Inspect Chrome Plated
Areas
Bearing Journal Collar Actuator Attach Lug Cadmium Plate (0.0002 to
Remove Bushings Attach Area (2) HER Bake 23 hrs within 4 0.0003 thick Cadmium)
hrs @ 375 ± 25 F
Demask as Required
Collar Set Flange Area (2)
MPI Polish Collar Set Flange Inspect Axle Lower Attach
Area to 63 RMS Finish Grind Chromium as Required: Lug dimensions
Actuator Attach Lug Vapor Degrease
Bearing Journal Collar
Attach Area (2 places) to 63
Clean RMS finish
Inspect Inspect Bushing Areas (4)
HER Bake 23 hrs within 4 dimensions
Inspect hrs @ 375 ± 25 F
Collar Set Flange Area (2
Mask Chrome Plated Areas places) to 75 RMS finish
w/ Plater’s Tape HER Bake 23 hrs within 4
Aqueous Clean Vapor Degrease Set Up Chrome Tank per hrs @ 375 ± 25 F
WCD PDS Actuator Attach Lug to 75
RMS finish
Blast Clean with 100 Grit
Garnet at 40-60 PSI Chromate
Fixture for Horizontal
Mask for Abrasive Blasting Chromium Plating per WCD
PDS Inspect
Set Up Chrome Tank per Insert Bushings
WCD PDS
Blast Clean with 100 Grit
Garnet at 40-60 PSI Mask for Plating as Required Vapor Degrease
and per WCD PDS: Paint as Required
Fixture for Vertical
Chromium Plating per WDC Collar Set Flange Area (2)
PDS
Strip Cadmium?
Actuator Attach Lug
Yes

Mask for Cadmium
Stripping as Required Hand Wipe Clean Area to
be Plated

Strip Cadmium No

F16 MLG Tension Strut PFD
Part No. 2006004-105
T.O. 4S1-109-3
12/15/2003 PAG


Process Planning
Sequence/General Arrangement


Process Mapping
Wet Process Control


Process Mapping
Work Flow by Substrate (Al, Mg, SS, Fe)
Solution Treat
Material Prep Salt Bath Form
Aluminum Substrates Shear Deburr Aqueous (900F) Hydro Aqueous Age Aqueous Chem Anodize Anodize Paint Paint
Deox Seal
2024, 7075, 6061 Router Timesaver Clean Hammer Clean Bake 375F Clean Film TI, TIC TII Prime Paint
NC Turret Freezer Brake

Note 1: Optimize Note 2: Could Primer be
in-process applied E-Coat rather than Note: Rinse Tanks are not Shown
cleaning Electrostatic Spray?

Magnesium Substrates Aqueous Mg Mg Paint Paint
Dichromate
AZ31 Clean Pickle Treat Prime Paint

Note 1: No Note 2: Pickle/ Note 3: part size med to
cyanide Treat = CrO3/ large, low workload, may
HNO3/HF drive size of second line
Note: Rinse Tanks are not Shown

Form
Stainless Steel Substrates Material Prep
Deburr Aqueous Hydro Aqueous Paint Paint
304,316, 321, 347 Laser Pickle Pass
Clean Hammer Clean Prime Paint
NC Turret
Brake

Note 1: No Note 2: Pickle = Note 3: Small -
cyanide or HNO3/HF medium sized parts,
chromate low workload Note: Rinse Tanks are not Shown

Form
Material Prep
Steel Substrates Deburr Aqueous Hydro Aqueous Cd. Paint Paint
Laser Pickle Chromate
Clean Hammer Clean Plate Prime Paint
NC Turret
Brake

Note 1: Cyanide Note 2: Small –
Process impacts medium sized Note: Rinse Tanks are not Shown
wastewater treatment parts, low
design workload


• Reduce energy usage/cost
• Reduce water usage/cost
• Reduce material usage/cost
• Reduce hazardous waste generation
• Reduce total process cost TM

• Evaluate process/facility change
• Evaluate production change
• Evaluate process chemistry change
Process Modeling
• Evaluate wastestream recycling
• Evaluate water quality cost impact
• Evaluate agitation type cost impact

• Model/visualize facility water balance
• Model/visualize/improve wastestream
Benefits
characteristics & wastewater
treatment
• Model/visualize air emissions
Visualize Cost
• Model/visualize/improve material
utilization
• Model/visualize/improve process
rinsing
& Prioritize
• Model/visualize process recovery

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

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

Boeing Lockheed Martin
Burns & McDonnell NADEP Cherry Point
CH2M Hill Plainville Electroplating
Colt’s Manufacturing Pratt & Whitney
Price Industries
Cornelius
Quality Rolling & Deburring
CP Tech Robins AFB
General Dynamics Sikorsky
General Electric Southwest United
Goodrich Aerospace Tinker AFB
Har-Conn Chrome Tobyhanna Army Depot
Heroux Devtek Treffers Precision
Hill AFB US Filter


Process Modeling
Document, Analyze, Prioritize, Improve


Activity Based Cost


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