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Maintenance for shot blasting machine

    Pre-Shift Verification: Before each shift, check the work diary and verify the operational status of the shot blasting machine. Ensure work assignments are orderly, responsibilities are clearly defined and assigned to specific individuals, and all records are accurate and traceable.

    Post-Shift Cleanup & Securing: Upon completing daily work, immediately clean up any steel abrasive spillage on the floor. Securely shut down the equipment by disconnecting all power sources and isolating the air supply.

    Pre-Maintenance Safety Lockout:

  • Before any maintenance begins, ensure the machine is completely isolated from all power sources (Lockout/Tagout).
  • Clearly display “UNDER MAINTENANCE” signage at all relevant access points.
  • For Internal Maintenance: If personnel must enter the machine, place additional conspicuous warning notices. The equipment must be in a zero-energy state (fully locked out), under continuous supervision, and controlled to prevent unauthorized operation.

Daily maintenance of shot blasting machine:

  1. Fastener Integrity:Inspect all fixing bolts on shot blasters and motors for looseness. Tighten immediately if found loose.
  2. Wear Component Inspection:
    • Check wear condition of turbine wearing parts and chamber protective liners. Replace worn components promptly.
    • Inspect turbine blades. Replace all blades as a complete set (1 group/8 pieces)when any blade reaches 50% wear. Never replace single blades.
  3. Deflector Calibration:Verify the deflector pointer is in the correct position.
  4. Chamber Integrity:Ensure all shot blasting room inspection doors are securely closed and sealed.
  5. Dust Collector System:
    • Inspect dust collection pipes for air leaks.
    • Check inside the dust collector for dust residue, damage to filter bags, or clogging. Clean or replace as needed.
  6. Separator System:
    • Inspect the separator screw shell and filter screen for sediment or debris. Clean promptly.
    • Verify the flow curtain is even and forms a complete, unbroken curtain.
  7. Abrasive Supply:Confirm the magnetic/electronically controlled abrasive supply valve is fully closed.
  8. Electrical & Controls:
    • Test the status of all limit switches and proximity switches for proper function.
    • Verify the operational status of all signal indicators on the control console.
    • Check that the shot blasting motor current draw is within its rated range.
    • Clean accumulated dust from the exterior and ventilation areas of the electric control box.
  9. Seal & Containment:
    • Inspect wear on the chute tube gasket, working door rubber guard plate, and top seal. Replace worn seals promptly to prevent steel shot loss.
  10. Shot Recovery & Management:
    • Remove debris from the bottom plate grid to ensure unobstructed steel shot recovery.
    • Check the total steel shot level in the abrasive silo. Replenish shot regularly to maintain sufficient operating levels.

Weekly maintenance of shot blasting machine:

  1. Turbine & Drive Components:
    • Impeller Wear: Inspect the impeller. Replace immediately if wear exceeds 3mm.
    • Deflector Wear: Inspect the deflector. Replace if the wear opening exceeds 6mm.
    • Shot Wheel Liners: Inspect protective liners on the shot wheel for severe wear or misalignment/misplacement.
    • V-Belt Tension: Check V-belt tension on the shot blaster motor. Adjust if deflection exceeds 10mm when pressed inward at the midpoint.
    • Partitions & Slide Rails: Inspect wear on partitions and slide rails. Replace if worn beyond acceptable limits.
  2. Shot Recovery & Conveyance Systems:
    • Recyclable Shot: Check the fine powder tube and bulk tube. Assess if sufficient qualified steel shot is present for recovery/recycling.
    • Elevator: Inspect elevator belt tension, bolts, and joints. Check for misalignment (off-track) and excessive wear. Adjust or replace as necessary.
    • Screw Conveyor: Inspect the screw conveyor for signs of abnormal material buildup, wear, or damage.
    • Bottom Plate Grid: Inspect the bottom plate grid. Repair any holes or damage promptly.
  3. Dust Collection & Containment:
    • Casing Seals: Inspect all casing joints for integrity. Seal immediately to prevent air and dust leakage.
    • Filter Cartridge Cleaning: Check dust accumulation on the dust collector filter cartridges. Trigger the pulse blowback cleaning cycle as needed to maintain efficiency.
  4. Lubrication & Fluid Management:
    • Blower Lubrication: Lubricate the blower bearing housing with the specified grease (once per specified interval).
    • Compressed Air System Drainage: Drain condensate from the air compressor receiver tank, gas storage tank, and oil-water separator (once per shift/day as required).

Monthly maintenance of shot blasting machine:

  1. Shot Blast Motor Calibration:
    • Set Gate Valve Position: Adjust the abrasive gate valve position to achieve a shot blasting motor operating current between 25A and 30A during standard operation. Verify setting while monitoring ammeter.
  2. Drive System Maintenance:
    • Chain Drive: Inspect transmission chain tension. Adjust to specified slack and lubricate with recommended chain oil/grease.
    • Bucket Elevator:
      • Inspect and adjust belt tension to manufacturer’s specification.
      • Inspect and tighten all hopper mounting bolts.
  3. Lubrication & Fluid Management:
    • Reducer Oil Level: Check reducer lubricant oil level. Replenish with the specified grade oil if below the minimum mark on the sight glass/dipstick. Do not overfill.
    • Monthly Greasing: Lubricate bearing housings at both ends of the elevator, separator, and screw conveyor with ISO VG 2 Calcium Sulfonate Complex Grease (or equivalent as specified). Quantity/Frequency: As per OEM manual or plant lubrication schedule.
    • Air Compressor Oil: Change air compressor crankcase oil monthly (or per OEM hour-based schedule). Use specified compressor oil grade.
  4. Electrical System Integrity:
    • Contactors & Switches: Inspect contact points of AC contactors and switches for pitting, wear, or contamination.   Perform compressed air dust blow-out and cleaning. Replace damaged components.
    • Terminal Security: Inspect wire and cable terminations in power supply and control panels for looseness. Tighten securely to specified torque.
  5. Motor Performance Testing:
    • Run & Monitor: Perform a no-load test on each motor individually (conveyor, elevator, fan, etc.). Listen for abnormal noises (bearing rumble, scraping, imbalance) and measure no-load current. Run each motor for ≥ 5 minutes during test. Investigate any anomalies immediately.
  6. Air System Inspection:
    • Fan & Ducting: Inspect fan blades/impeller for wear, imbalance, or damage. Inspect air ducting for wear, leaks, and secure mounting. Repair or replace as needed.

Quarterly maintenance of shot blasting machine:

  1. Bearing & Control Box Inspection:
    • Inspect bearings (condition, noise, temperature) and the electric control box (cleanliness, connections).
    • Lubricate bearings with the specified high-temperature grease (e.g., ISO VG 2 Lithium Complex or as per OEM). Do not overgrease.
  2. Wear Liner Assessment:
    • Inspect the wear condition of all protective liners within the shot blasting chamber and turbines. Document wear levels and schedule replacements as needed.
  3. Critical Bearing Relubrication:
    • Repack the blower main shaft bearing and shot blasting motor bearing with new, specified high-speed, high-temperature grease (e.g., NLGI 2 Grade). Perform under Lockout/Tagout (LOTO).
  4. Fastener Integrity Check:
    • Inspect and torque all fixing bolts and flange connections on motors, reducers, fans, and screw conveyors to the manufacturer’s specifications.

Yearly maintenance of shot blasting machine:

  1. Bearing Lubrication:
    • Inspect lubrication status of all bearings (including motor bearings).
    • Repack with new, specified high-temperature grease (e.g., NLGI 2 Lithium Complex). Perform under Lockout/Tagout (LOTO).
  2. Chamber Liner Maintenance:
    • Inspect main chamber protective liners for wear or damage.
    • Repair significant damage via qualified welding or Replace liners if beyond repairable limits.
  3. Control System Integrity:
    • Verify functional reliability of communication between PLC and inverter. Monitor for signal dropouts or errors during operation.
  4. Instrumentation Calibration:
    • Verify calibration of the ammeter. Compare readings against a known reference meter if accuracy is suspect.
  5. Dust Collector Maintenance:
    • Inspect filter elements for damage or excessive dust loading.
    • Replace damaged filters immediately.
    • Clean heavily loaded intact filters using low-pressure compressed air (< 30 PSI). Never clean damaged filters.
  6. Air Duct System Service:
    • Inspect air ducts for blockages, leaks, and structural damage.
    • Clear obstructions and Repair leaks/damage promptly.

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