Layup of Manufacturing Facility

April 30, 2020

When evaluating the layup of a manufacturing facility, the task can be broken down by classification of equipment and systems into categories as follows:

• Structures
• Equipment
• Work in progress
• Finished goods
• Air systems
• Water systems

Each category will be broken into subsets with specific recommendations for products and applications.

Structures:

• Concrete foundations, walls, ceilings, etc.
  • Wash all surfaces to remove all contaminants (10% solution of VpCI^®-414)
  • Visually inspect for damage
  • Repair damaged areas using MCI^® repair mortar (https://www.cortecmci.com/)
  • Coat all concrete surfaces with MCI^®-2020 or MCI^®-2022
• Structural steel
  • Inspect for areas of rust and/or peeling paint
  • Power wash or use high pressure air to remove all loose rust and contaminants
  • Determine if cross-section in rusted areas meets acceptable design parameters
  • Options to address rust
    • Option 1: Convert hematite to magnetite using CorrVerter^® Rust Converter Primer; then topcoat with EcoShield^® 386 clear or color match
    • Option 2: Remove rust with VpCI^®-423; remove VpCI^®-423 with 10% solution of VpCI^®-414; and topcoat with EcoShield^® 386 clear or color match
  • Loading bay doors
    • Clean with 10% solution of VpCI^®-414
    • Spray all hinges, rollers, and roller trac/guides with CorShield^® 369 Wet Film Corrosion Inhibitor and Lubricant
  • Fasteners, locks, hinges, etc.
    • Spray with CorShield^® VpCI^®-369 Wet Film Corrosion Inhibitor and Lubricant

Fire Protection Systems:

• Wet systems
  • Drain the system
  • Recharge the system adding VpCI^®-649 at 1% by weight to the water
• Dry systems
  • Set up system to force air being fed into system through a bed of VpCI^®-308 Powder

Electricals:

• Control panels, power panels, and MCC
  • Deenergize the system
  • Spray all contacts and exposed metal with ElectriCorr^® VpCI^®-239
  • Insert appropriately sized emitter
    • VpCI^®-105 – 5 ft³ (0.14 m³)
    • VpCI^®-111 – 11 ft³ (0.31 m³)
    • VpCI^®-308 Pouch – 35 ft³ (1 m³)
  • If vented, shrink wrap with either MilCorr^® VpCI^® Shrink Film or VpCI^®-126 HPUV
• Motors
  • Deenergize system
  • Closed frame motor
    • Remove any rust with VpCI^®-423
    • Remove VpCI^®-423 residual with 10% solution of VpCI^®-414
    • Coat exposed machined surfaces with VpCI^®-391
    • Insert VpCI^®-101 Device into junction box
  • Open frame motor
    • Remove any rust with VpCI^®-423
    • Remove VpCI^®-423 residual with 10% solution of VpCI^®-414
    • Coat exposed machined surfaces with VpCI^®-391
    • Insert VpCI^®-101 Device into junction box
    • Fog ElectriCorr^® VpCI^®-239 into motor core
    • As a minimum, shrink wrap fan end with either MilCorr^® VpCI^® Shrink Film or VpCI^®-126 HPUV
  • Air systems
    • Piping
      • Purge and fill air lines, gauges, reservoirs with air pumped through VpCI^®-308 Powder
    • Compressors
      • Air side – Fog with VpCI^®-337 at 0.5 oz./ft³ (0.5 mL/L)
      • Lubrication side – depending on type of lubricant, apply one of the below products by fogging at 0.5 oz./ft³ (0.5 mL/L), or add to oil at 5% by volume
        • M-528 – PAG
        • M-529 – PAO
        • M-530 – Mineral
        • M-531 – PAO

• Manufacturing equipment – lathes, drills, grinders, etc.
  • Deenergize equipment
  • Remove any rust with VpCI^®-423
  • Remove VpCI^®-423 residual with 10% solution of VpCI^®-414
  • Lubrication side – depending on type of lubricant apply one of the below products by fogging at 0.5 oz./ft³ (0.5 mL/L) or add to oil at 5% by volume
    • M-528 – PAG
    • M-529 – PAO
    • M-530 – Mineral
    • M-531 – PAO
    • Coolants - https://www.cortecvci.com/Publications/Brochures/Metalworking%20Broch.pdf
    • Lathes, drills, grinders, tumblers, etc. – Add VpCI^®-345 to coolant at 10% by volume; circulate and drain
  • Guides, screws, etc. (surfaces subjected to relative motion) – Coat with VpCI^®-369D
  • Cross slides, headstock assembly, tailstock (components with lubrication oil)
    • Depending on type of lubricant, apply one of the below products by fogging at 0.5 oz./ft³ (0.5 mL/L) or add to oil at 5% by volume
      • M-528 – PAG
      • M-529 – PAO
      • M-530 – Mineral
      • M-531 – PAO
    • Work in process and finished goods
      • Clean with a 10% solution of VpCI^®-414
      • Spray with either ElectriCorr^® VpCI^®-239 or CorShield^® VpCI^®-369 Wet Film Corrosion Inhibitor and Lubricant
      • Wrap with appropriate VpCI^® film or VpCI^® paper: https://www.cortecpackaging.com/wp-content/uploads/2018/09/Packaging_Brochure_09-18.pdf
    • Boilers
      • Drain
      • Add Boiler Lizard^® pouches (one per 1000 gallons [3.8 m³]) to water side or fog with Boiler Dragon^™ at 1 oz./ft³ (1 L/m³)
      • Fog fire side with Boiler Dragon^™ at 1 oz./ft³ (1 L/m³)
      • Fog all piping with Boiler Dragon^™ at 1 oz./ft³ (1 L/m³)
      • Spray all valve stems, bushings, packing body, and bonnet nuts with CorShield^® VpCI^®-369 Wet Film Corrosion Inhibitor and Lubricant
    • HVAC systems
      • Spray evaporator and condenser coils with 10% solution of VpCI^®-414 to clean
      • Spray evaporator and condenser coils with VpCI^®-337
      • Place VpCI^®-308 Pouch (35 ft³ [1 m³]/pouch) inside HVAC enclosure
      • Shrink wrap with either MilCorr^® VpCI^® Shrink Film or VpCI^®-126 HPUV
      • HVAC ducting
        • Close air register
        • Fog with VpCI^®-337 at 1 oz./ft³ (1 L/m³)
      • Toilets
        • Secure water, flush, and add either of the below products to the tank and bowl
          • ECO-SEPT^™
          • PORTA-TREAT^™

Case Histories:

Copper Mine Layup
https://www.corteccasehistories.com/?s2member_file_download=access-s2member-level1/ch124.pdf

Boiler Lizard^® Protecting College Boiler https://www.corteccasehistories.com/?s2member_file_download=access-s2member-level1/ch146.pdf

Layup of Offshore Rig
https://www.corteccasehistories.com/?s2member_file_download=access-s2member-level1/ch662.pdf

For a PDF version please click here.