Preventative Maintenance
As part of your process validation requirements you may need to document that your cleaning equipment is regularly serviced either by your own maintenance staff or external staff.
It may well be that, although your staff can undertake the daily maintenance, that you require external assistance periodically.
This service maintenance schedule is designed to support existing users of the component cleaning systems to reduce costs, ensure the continued efficient safe operation of the system and maintain the integrity of the system.
With a comprehensive maintenance schedule we have reduced downtime for some companies by up to 60-70%. As a result there is typically a reduction in overall operational costs in the region of 4-5%.
Layton personnel have over 20 years’ field experience with this equipment and they also have access to a full range of spare parts to keep your equipment functioning correctly. Approximately 30% of Layton’s customers are long term users having purchased equipment and received ongoing support over the last 20 years.
Clients are provided with a signed service agreement which demonstrates cover for the required period.
Preventative Maintenance Service - Schedule 1
- Carry out full system check as detailed below to ensure all ultrasonic units are working as optimised. Scope of work to include the following:-
- Fully check electrical systems, mechanically and functionally including earth bonding points, over current devices, input/output voltages, power supplies and drive motors.
- Replace any faulty or suspect parts.
- Check functionality of PLC logic and functionality of all safety and alarm devices.
- Check for fail safe operation.
- Check functionality of all PLC operator accessible functions.
- Replace any suspect or faulty components as necessary.
- Discuss with customer any modifications required to the program. In stall software updates as applicable to the system and verify.
- Reprint ladder program.
- Check operation of heaters, pumps, motors, speed control drives, check for leaks and smooth operation.
- Calibrate and repair as necessary. Report suspect major component failures to customer.
- Check and calibrate functionality and accuracy of thermostats and thermocouples adjustment or replace as necessary.
- Replace all disposable filter elements with a type and micron size as specified by the customer.
- Check and clean out strainers fitted prior to the pumps. Customer to drain fluids if required.
- Check all seals, pipework, compression fittings, welded unions, manifold, joints, valves etc, for signs of leakage, check with halogen leak detector for signs of excessive fluid losses (where applicable).
- Replace all faulty or suspect components. In the event of a suspected leak from welded union or joint report fault to customer.
- Check all other sensors i.e. level sensors, leak detectors (if fitted). Replace suspect or faulty components.
- Check all ultrasonic generators and transducers as follows.
- Resistance test to 2500 volts to each individual transducer from co-axial connection at the generator.
- Resistance test to 5000 volts to each individual transducer from co-axial connection at the generator.
- Capacitance test to ensure total capacitance of each individual transducer is within tolerance range up to co-axial connection at the generator.
- Operate each individual transducer with a standard generator and test with scope.
- Ensure frequency and peak to peak volts are within tolerance range.
- Operate each individual generator with a standard dummy load and test with scope.
- Ensure frequency and peak to peak volts are within tolerance range. Produce a test report for each individual transducer and generator.
- Check functionality of Handling System.
- Check for correct operation.
- Check functionality and wear of all motors, drives, gearboxes and brakes.
- Replace any suspect or faulty components as necessary.
- Discuss with customer any modifications or adjustments which may be required.
- Test run machine and ensure satisfactory operation.
- Complete maintenance log, list all PMS work undertaken on service sheet.
- Discuss PMS findings with customer.
- Advise on any further work required. Update manual and document any changes.
- Do an Ultrasonic Foil Test.
Preventative Maintenance Service – Schedule 2
- Fully check electrical and pneumatic systems, mechanically and functionally including earth bonding points, over current devices, input/output voltages, power supplies and pressure switches.
- Replace any faulty or suspect parts.
- Check functionality and reliability of ultrasonic generators and transducers (where fitted), inspect for signs of any component breakdown, verify that volts, frequency and watts output are within tolerance, replace any faulty or suspect components as necessary.
- Check functionality of PLC logic and functionality of all safety and alarm devices.
- Check for fail safe operation.
- Check functionality of all PLC operator accessible functions.
- Replace any suspect or faulty components as necessary.
- nstall software updates applicable to the system and verify.
- Reprint ladder program.
- Check functionality of fill and drain connections, ensure integrity of seals.
- Check operation of heaters, pumps, diaphragm pumps, rodless cylinders, door short stroke cylinders, check for leaks and smooth operation.
- Check lift lower cables.
- Calibrate repair as necessary.
- Report suspect major component failures to customer.
- Check and calibrate functionality and accuracy of thermostats and thermocouples only, no adjustments or replacements.
- Check pressure switches, sight glasses and functionality of cooling systems.
- Log readings and advise customer of any faults or suspected gas losses or associated reliability issues with refrigeration circuit.
- Replace all disposable filter elements with a type and micron size as specified by the customer. Check and clean out strainers fitted prior to the pumps.
- Check all seals, pipework, compression fittings, welded unions, manifold, joints, valves etc, for signs of leakage, check with halogen leak detector for signs of excessive fluid losses (where applicable).
- Replace all faulty or suspect components. In the event of a suspected leak from welded union or joint report fault to customer.
- Check all other sensors i.e. level sensors, alcohol leak detectors (if fitted). Replace suspect or faulty components.
- Check operation and verify leak free operation of vapour bag where fitted.
- Test run machine and ensure satisfactory operation.
- Complete maintenance log, list all PMS work undertaken on service sheet.
- Discuss PMS findings with customer.
- Advise any further work required. Update manual and document any changes.