DAQ-2024-007998

Operation and Maintenance Plan
Rocky Mountain Machine Shop
Part 1
(A) Operation and maintenance criteria cover the affected source, add-on control equipment,
if used. And process and control system monitoring equipment. Rocky Mountain
Machine Shop is a hydraulic equipment repair shop. Part of the process I shard chrome
plating shop, which consists of (6) hard chrome plating tanks. Three (3) 5,000 (2) 8,000
amp rectifiers, (1) 10,000 amp rectifier. Also, (1) KCH manufactured composite mesh
pad chrome scrubber system, which is duct from each tank to the scrubber system. Rocky
Mountain also has an electrical read out control devise for monitoring the airflow from
the plating tanks through the air scrubber, Manometer.
(B) Operation and maintenance check list for documentation of routine activities. Rocky
Mountain has in place a daily sheet monitoring daily activity, which consists of
equipment plating in each tank, amps for each specific part, list of daily manometer
reading for each monitored station of (a) shtions including the total air flow across
scrubber,
(C) Preventative operation and maintenance procedures. Rocky Mountain Machine Shop has
in place a check list for procedures used for daily sue of preventative measures. Such as
making sure that there are no air leaks in the manometer system, and KCH scrubber
system. No cracks or leaks in all hoods and duct systems. Checking motor and fan belts
on scrubber motor.
(D) A planned response list for malfunction of emission and control equipment. Rocky
Mountain Machine Shop has in place a no activity tolerance on our chrome emission
control equipment. When emission control fails for whatever reason the chrome shop is
shut down immediately, which includes all plating tanks, and all rectifiers. After this has
been complete, the plating supervisor and maintenance supervisor will assess the problem
and repair completely before re-startup of plating shop shut down at Rocky Mountain
Machine Shop.
(E) If Rocky Mountain Machine Shop has an ongoing problem and emission control
equipment, we will address it with complete attention from all parties involved at our
facility. If necessary, shut down plating shop until we completely repair malfunction of
equipment failure. Also, will document all equipment malfunction and repairs.
REVIEWED
lnitials: ('G ou,"
Compliance Statusl
UTAH DEPABTMENT OF
ENVIBON^'IENTAL OUAUTY
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Operation and Maintenance Plan
Rocky Mountain Machine Shop
z./ r'n e
PART 2:
(A)To maintain the air scrubber, KCH, and all ducting from the six (6) chrome plating
tanks, and the stack outside the chrome shop. We have a monthly check list of work
practice standards which physically walked through and checked off and inspected. A
copy of this form is attached to this plan.
(B) Procedures for inspecting the control equipment or the manometer. Check all plastic
air lines from control box to scrubber. Making sure there are no leaks in any of the
lines or connections from scrubber to control box. Check the (a) meters on control
making sure all are functioning properly. If there is a leak, it will show on the meter.
Usually reading zero means there is a leak. Take apart and repair line that is leaking.
(C) Procedures for repairing equipment such as KCH scrubber, ducting, fan and fan
motor. If there is a crack in the ducting, the procedure is as such: shut down scrubber
and all rectifiers connected to plating tanks. Specify area in need of repair and re-
fiberglass ducted damaged area. If there are cracks in the ducting on the plating tanks,
follow the same procedure as with fiberglass. If fan motor malfunctions, repair or
replace. If fan belts break, replace while system is down. Check and grease bearing
f,rttings where necessary.
(D)The process for malfunctions of the control equipment. A monthly check list is
attached to this plan for inspecting equipment such as inlet and outlet zones, spray
nozzles, fiber beds, drain lines, fan motor, and fan fibration. Dated and initialed.
(E) Depending on the seriousness of the problem, the plating manager and maintenance
manager will evaluate and ask accordingly such as: fan or motor of scrubber goes out,
this would be a complete shutdown, If there is a leak in an airline to manometer, then
repairs can be made without a shutdown. If ducting is cracked or leaking (depending
on how bad) could be repaired while operating. In a serious situation, a shut down
may occur to repair fiberglass, etc.
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OP&N,UON AND IT{AINTENANCE CEECKLIST
.j (for fiber-bed mist elimtnators)
Applicable Rule: 4O CFR-Part 63, ,-9;trpart N-National Emission Sundards for Grromium
Emissions from [Ia.d and Decorative Chronium Electroplating and Chromiu.n
Anodizing Tanls
Control Device ID #:
Installation Datc: I I
Date of Last Performance Test: I I
Tanla Ducted to Control Svstem:
Inspection/Maintenance checklist (insert inspector's initiars in boxes):
Control Device
Inspection
inlet aad outlet
tr'ansiligs zones
spray nozzles ok q6
fiber beds
P f er d ir.r-La g tiev i,;.ok to6
drain lines
, hard cluome, decorative
chrome anodizing)
fan motor
I orL
i)age I of 2
Eb 3Z0l
OPMATION AND II4AINTENANCE CUECKIJST
.. (for fiber-bed mist eliminators)
Applicable Rule: 4O CFR Part 63, .-9;bpart N-National Emissiou Strndards for Ctrromium
Emissions from Ha.d and Decorative Chromium Elecuoplating and Chromiu.n
Anodizing Tanls
Plant Name/I-ocation:
Control Device ID #:
InstallationDate: / I,
Date of Last Perfonnance Test: I I
Tanla Ducted to Control System:
Inspection/Maintenance checklist (insert inspector's initials in boxes) :
Control Device
Inspection
Dare: "tJ601 Daa: / I Date: / /
inlet and outlet
traruition zones
o.Y
146
spray nozzles ok
^.6
(leo'-N o Lc^L-s
fiber beds xN4 n^ 6
Prerurs.,li:s tievic" i or ili6
drain lines oK ,^6 (/ un^"- "P l€a,K r
an motor x "#::l
fan vibration I al( uB
!
Page I of 2
1:::-
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OPERATION AITD IT{AINTB{ANCE CEECKLIST
.. (for fiberied mist ehminators)
Applicable Rule: 4O CFR-Part 63, .l;tlpart N-National Emission Standards for Chromium
Emissions from Ha.d and Decorative Chromium Electroplating and Chromiu"n
Anodizing Tanls
Plant Nane/I-ocation:
Contol Device ID #:
InstallationDate: I I,
Date of Last Performance Test: I I
Tanlcs Ducted to Control System:
Inspection/Maintenance checklist (insert inspector's initiars in boxes):
Control Device
Inspection
inlet and outlet
6enciliqa zones
spray nozzles
prerdG.i::S tievi.*,.ok fo6
draiu lines
fan motor
Tlpe of tank (i.
Clc*n
l.*l.u
fan vibration | ,',e
n0
t)age I of 2
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OPMATION AI{D IT{AINTENAT.TCE CEECKLIST
.: (forfibYned mtst ehmnutors)
Applicable Rule: 4O CFR.Part 63, .9;bpart N-NationaI Emission Standards for Ctrromium
Emissions from Ha.d and Decorative Chromium Electroplating and Ctrromiu.o
Anodizing Tanls
Plant Name/I-ocation:
C.ontrol Device [D #:
Installation Date:
Date of Last Performance Test: I I
Tank Ducted to Control System:
inspection/Maintenance Checklist (insert inspector's initials in boxes):
Confrol Device
Inspection
inlet and outlet
transition mues
spray nozzles
Pferri is.^-L-S der. ic.ok l^6
drain lines
Tlpe of tqnk (i.e
fal motor
Page I of 2
Rocky Mountain Machine - Hard Chrome Plating Process
Heavy Machinery Hydraulic Process Repair for Hard Chrome plating
Step 1- Clean and Evaluate
1. Part steam cleaned in Steam Bay
2. Disassembly area to inspect condition and identifiT specifications
Step 2 - Prep
1. Grinding Department to grind part to clean up to .010 to .015 undersize.
2. Polish to a 100 grit finish
Step3-ChromePlate
1. Move part to Chrome Shop for Plating; verify specs for sizing and condition
2. Clean part thoroughly with MEK (Methyl Ethyl Ketone)to remove any oils or contaminants
3. Mask area of part not to be plated with stop-offtape
4. Place part in Chrome Plating Solution and make electrical connections to part
5. Reverse current. Plate part for 13 minutes to remove any possible contaminants
6. After 13 minutes, reverse current. Manually scrub part with Scotch-Brite to remove reverse
etch scale
7. Place part back into plating solution. Reverse etch for 1 minute, then forward current for the
amount of time needed.
a. Time is set for.010 chrome over the finish size of the rod specs. Approximately.002
chrome plated per hour.
b. Current set at proper controls compared to size of part.
8. After proper time of plating, take part out of plating solution. Remove tape, wash to prepare
for G rinding Department.
Chemicols used: Chromic Acid Flakes; 32 oz. /gollon, Sulfuric Acid used for Cotolyst; L-700 parts
Step4-FinishGrind
1. Grinding Department to Finish grind to part specifications
\
Revision January 2015
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Table 2-Summary ol Wor[ PraEtice Standards
Contrd msttod Wort pnctice ctrndrrds Frcqutne,y
Gornposltc mcsFprd
(CfvfP) Eyttcur
A-JJ iig,
l. Viually inspeet dcricc !o co$Ee tbcrc k propcr
dniurgc, no chrooic acid buildup on rhc peds.
rnd no gvldencc of cicmical uacls ou,the ctruc-
nud inariry of 6c dcvie.
2, Visually inspcct back portion of thc ncsh pd
cloacgto tbc frrt !o custrc ther€ is no brerk-
through of clusmic seid mis:.
=3. lIrsully iuspect ductwork fum tartk or trnki to
tDo conrml deivioe ro sirsure 0rc$ att uo lcek;
4. Perform wuhdown of thq porpoeite oeeh paqs
in accordurce wi0r uunuficnrrsr's rocornmdodr-
" tions.
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Table 2-Summary ol Wor[ Pnaice Srandards
C+mpositc mcsFpad
(CfvrP) Eysto
l. Vinrally hspect deyicc to eosurc therE is proper
draiurgc, no chrouric acid buildup on rhc pads,
rnd no erridence of cbcrnical anack ol,the etuc-
nmt inariry of 6c devicc.
2, ftsually inspecr ba* ponion of thc nesh pad
clocceito rbc fari !o rnsurc ther€ is m brcrk-
thmlghof ctuomic eeid misr. i3. Vist ally iuspect ducwork frotn tank or tanE to
the co.aml dorrioe ro cluure tbcru arc uo tslc.
4. Perform washdown of rbq ponpoeire mesh pa{s
in Eccordurce wi0ruuiufacturir,s rgcomm6nd&
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2. l/Euger. ,eh<<L-a,( Oluts
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Table 2-Summary of Vlfor[ Praaice Smndarde
Control motfiod Wort practice ctrndrrds Frequrney
Gornpositc mcshprd
(CIvfP) EystGD
a--lJ i,rg,
1. Visrlly inspect dcvicc ro eosrre therc is proper
drahege, no chromic acid buildup on rhc prds.
rnd uo widcnce of chcmlcal rrrrl on,the etruc-
trrrl iilryiry of drc dcvicc.
2. Visually inspect ba* porthn of thc ncsh pad
closccrm rbc fall to Ecnrrs therc is no brcrk-
through of clrmcric ecid misr. r3. Visualty hspect ductrvork fron tank or unli to
the cootrol dwie ro crlxue drelg rr! no lca;Xc.
4. Perform washdown of he ponrpoeite oesh pr{p
in accorduce wittr manufdcnuir's recorundndr-
2. l/qurter .
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3. l/ouarterN;r,-T::ff
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Table 2-Summary of Wor[ Pnaice Standards
Control mathod Wolt pmctice standards Frcguoncy
Cqmpositc mathprd
(ClvfP) EystErtr
4--lJ i,rg,
l. Viually inspcet devicc to eosurc tbelu h prsper
drainegc, no cluomic rcid buildup on thc peds.
rnd uo widence of ctrcmical anack on,the *ruc-
nrat iilqdry of 0rc dcvicc.
2, Visually inspect back ponion of thc mesh pad
cluen n thc fan !o mure there is oo brerk-
through of cluomic rcid EiBt. r
3. Visrully iuspecr ducrwork frour tank or 3116 to
the co.atml dwioe to ensure 0rero are no le,h.
4. Perform vashdown of r.[e forpoeire nesh pa{s
in accordance wi0r rnsiufacnrir's recomm6odr-
tions.
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Chrome $hmp f,);a[l'y - UXontlrly [-og , r' '
? *"t- - l/on o n Yn clob Acnd ; ai s
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1
2
3
4
5
6
7
B
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
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#1
#2
#3
#4
5
Total(
llo urs
\-r',
Chrome $hoP ffiallY
folo^-o ^)on
- Monthly Log
Yl.^J ; ng s
(t
Day
1
2
3
A.+
5
6
7
8
I
10
11
12
13
14
15
16
17
.18
19
20
21
22
23
24
.EZJ
26
27
28
29
30
31
Tarrk
#1
#2
#3
#4
4rsrs5
(3.0060 6zg
porrds Pcn' o tnO't(h
O,O@rlB'0-B
6or[ i "3hte
Hourr;
l.-t_
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Chronre Shop D;rilv - [VXontlr\ l"oU,,
- afi '{ear 3oz</ - -- /i/lono r7.to n L4e*digt
Month ll4 ft,t I lf
Day :. .. ;;
1
-;.a
J
4
5
6
7
D
o
10
11
12
1aiJ
14
16
17
1Q
igl
111
21
,:
24
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_) i,
tl
&.;:
U
1E
Total
Chrome ShoP DeltY - NlonthlY LoE
NnnsYng'lor f\eadtYtf\, Yert
\ a Month
Day
(r
1
2
3
4
5
6
7
8
I
10
11
12
13
14
15
16
17
1B
19
20
21
22
23
24
25
26
27
28
29
30
31
Tank
#1
#2
#3
#4
415ts5
Time
aO?
Hourr;
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Hard Chrome Plating Procedures for RMMS
Chemicals used-
Chrome Acid Flakes32 oz. per gallon
Sulfuric Acid used for catalyst I to 100 parts.
Product Plated heavy machinery hydraulics repair
Step I
(1) Product steam cleaned in steam bay
(2) Taken to disassemble dept. check hydraulic Rod specs and rod condition.
(3) Rod then goes to the grinding dept. to grind rod to clean up size to .010 to 015 undersize.
Then polish rod to a 100 grit finish.
(a) Rod then goes to chrome shop for prep and plating.
Step 2
(A)Check rod specs for sizing and condition
(B) Clean rod thoroughly with MEK methyl ethyl ketone, to remove any oils or
contaminants.
(C) Mask areas of rod not to be plated with stop off tapes.
(D)Place rod in chrome plating solution and make electrical connections to part.
(E) Reverse current plate rod for l3 min to remove any possible contaminant.
(F) After 13 min reverse current. Manually scrub rod with scotch brite pads to remove
reverse etch scale.
(G) Place rod back into plating solutions reverse etch for I minute, then forward current for
the amount of time needed times set for .010 chrome over the finish size to rod specs.
Approx. .002 chrome plated per hour current set at proper controls compared to size of
part.
(H)After proper time of plating take part out of plating solution. Remove tape wash and
move part to grinding dept. to finish grind rod to specs.
Chrome plating solutions samples are taken weekly and analyzed, additions made as needed.
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