SKILL BUILDER EXTENDED-SHUT DOWN PLAN
QUAKER HOUGHTON METALWORKING FLUIDS AND CLEANERS The following actions are recommended to help maintain system integrity during extended shutdown periods. This shutdown plan is not intended to offer any guarantee to the condition of the fluid upon returning from shutdown but will optimize the performance of the metalworking fluids and cleaners upon plant start-up.
Metalworking Fluids and Washers Prior to shutdown it is recommended for washers to go to the “summer rust protection” concentrations and rust protection protocols should be followed.
Poor control during shut down periods can result in:
• Worker complaints, illness, headaches, eye irritation, etc • Community complaints, notices of violation and safety issues, dermatitis, hypersensitivity • Health pneumonitis • Filtration problems • Equipment damage (rusting and seizing) • Poor quality, tooling issues
is typically running the concentration at the upper • This control limit or at the higher spec target for summer
To prevent and minimize issues the following measures are strongly recommended.
MUST be circulated at least 4 hours every • A48ll washers hours
should be tested a minimum of twice per week • Systems (Monday & Thursday) to ensure health coming out of
operation. At the minimum increase concentrations to upper limit
f this is something that cannot be done then any • Iwasher less than 1,000 gallons should be dumped until the plant is ready to start back up
washers > 1,000 gallons find a way to circulate them • Fatorthe above frequency
On-Site Testing (if possible) and going into a weekend
testing should include pH, alkalinity twice per • Minimum week and biologicals once. This applies to metalworking and washer systems
ecommended to cycle all parts out of washers and • Rkeep washer doors open to reduce corrosion potential
On-Site Personnel
During extended shut down periods washer and water based coolant systems can become stagnant and grow bacteria and fungus. Bacteria and fungus can greatly impact the work environment and communities where we operate. These are the typical recommendations and precautions we take during our regular maintenance shutdown periods.
site teams should also be trained/have knowledge • Our on how to turn systems on/off to assist with circulation
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Onsite personnel will be needed to start and stop systems and provide support as needed.
during the shutdown
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EXTENDED-SHUT DOWN PLAN
QUAKER HOUGHTON METALWORKING FLUIDS AND CLEANERS Large, Centralized, Water-Based Coolant Systems and Washer Systems
Small Single Sump Systems and Smaller Washers
At Minimum: Should be circulated for several hours to allow mixing and aeration at least every 48 hours. This reduces the growth of anaerobic bacteria which creates acids that break down fluids. Many central systems have a weekend mode where circulation pumps are continuously running. Weekend mode would be the preferred mode of operation for extended shutdowns.
These systems can be drained and if possible cleaned. These systems have been the source of odor problems when not maintained. Doing this will minimize the number of personnel needed in the facility. If they cannot be drained and cleaned they should be circulated and maintained.
Systems should be monitored for critical quality parameters such as pH, concentration and biological growth.
of coolant systems should target 9.0. If pH is below • pH 9.0 consult your Quaker Houghton representative for the proper pH additive
system concentration recommended at upper • Coolant control level specification
Any system showing signs of biological acitivey prior to the shutdown should be treated with appropriate biocide to minimmize the potential for bacterial blooms during system stagnation. For those plants with biocide restrictions, systems concentrations should be increased 2-3% above normal operating parameters. (Please consult Quaker Houghton technical resource for appropriate recommendations)
production has stopped, manually index the filter • Once beds to introduce fresh media throughout the system and to remove all metallic debris from inside the dirty tank to minimize oxidation
all chip/filter media hoppers to eliminate the risk • Empty of fire. Stagnant hoppers may start to oxidize and create fires under certain conditions
the systems are indexing at least once per week • Ensure during the down time – this will ensure some turnover of the clean tanks
any visible tramp oil via rope skimmer, • Remove centrifuge or by any other available methods to minimize stagnation
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