Embed Size (px)
Citation preview
Revision G 1 27/10/2015
BIG BLASTER AIR CANNON WITH XHV VALVE
Installation Operations Manual
Revision Description of Change Changed By Date
A First Issue TT 1/5/13
B Suffix added to P/N 51042000 (page 14) SD 4/2/14
C Inserted updated drawing F0253 KO 10/2/14
D Updated office details KO 10/3/14
E Updated ESS Logo & Karratha contact details KO 4/6/14
F Updated office details KO 7/7/15
G Updated F0253 KO 27/10/15
Revision G 2 27/10/2015
ENGINEERING SERVICES and SUPPLIES
OFFICE DETAILS
Location Address Phone & Fax
CURRUMBIN 11 – 13 Traders Way PO Box 121 Currumbin QLD 4223 [email protected]
Phone: (07) 5589 2000 Fax: (07) 5521 0347
EMERALD 8 Coaker Dr PO Box 1861 Emerald QLD 4720 [email protected]
Phone: (07) 4982 4855 Fax: (07) 4987 5118
GLADSTONE Unit 2/34 Chapple Street PO Box 1475 Gladstone QLD 4680 [email protected]
Phone: (07) 4972 3759 Fax: (07) 4972 2866
KALGOORLIE Unit A 255 Dugan St Kalgoorlie WA 6430 PO Box 10471 Kalgoorlie WA 6433 [email protected]
Phone: (08) 9021 7991 Fax: (08) 9021 7291
KARRATHA 26 Midas Road Malaga WA 6090 [email protected]
Phone: (08) 9248 4111 Fax: (08) 9272 5130
MACKAY 1 Progress Street Paget, QLD 4740 PO Box 5755 Mackay Mail Centre QLD 4741 [email protected]
Phone: (07) 4952 4600 Fax: (07) 4952 4717
MAITLAND Unit 2 Barton Court 6 Johnson Street Maitland NSW 2320 [email protected]
Phone: (02) 4932 3544 Fax: (02) 4932 3611
PERTH 26 Midas Road Malaga WA 6090 [email protected]
Phone: (08) 9248 4111 Fax: (08) 9272 5130
TOWNSVILLE 5/42 Carmel St Townsville QLD 4814 [email protected]
Phone: (07) 4755 2776 Fax: (07) 4779 6236
SOUTH AUSTRALIA 5 Cormorant Court. Middleton. SA . 5213 [email protected]
Mobile: 0408 948 175
VICTORIA Unit 4 / 314 Governor Road Braeside VIC 3195 [email protected]
Phone: (03) 9580 0388 Fax: (03) 9587 5199
WOLLONGONG Unit 1 / 20 Doyle Avenue PO Box 343 Unanderra NSW 2526 [email protected]
Phone: (02) 4272 4422 Fax: (02) 4272 4434
TOLL FREE 1800 074 446 FROM ANYWHERE IN AUSTRALIA VSS TOLL FREE 1800 300 877
Revision G 3 27/10/2015
WARRANTY NOTE ESS guarantees the Big Blaster Air Cannon with XHV Valve to be free of defects both in materials and workmanship for a period of 12 months from the date of despatch of the product from the ESS factory. The warranty given by ESS in this regard will extend only to replacing or repairing product shown to be defective. The warranty also is subject to the following restrictions: (a) Installation of the product contrary to the instructions contained in the supplied manual will void
such warranty absolutely; (b) The warranty will not extend to any liability for injuries incurred and which result from the use of
the product contrary to the instructions in the manual; (c) Save as prescribed by law, ESS will not be liable for any damage sustained by a purchaser or a
third party by way of consequential loss arising out of defects in the product. You are asked to note that ESS offers purchasers a service whereby either: (a) It will install the product and certify the correctness of such installation, or (b) Certify the correctness or otherwise of the installation of the product by third parties. This certification service is designed to ensure that you obtain the full benefit of the ESS warranty hereby provided. If you would like to take advantage of the installation certification service provided, please contact ESS regarding the service. Visit the ESS website www.esseng.com.au to register your product warranty.
THE CONTENTS OF THIS MANUAL ARE COPYRIGHT TO: ESS ENGINEERING SERVICES AND SUPPLIES PTY LTD ALL RIGHTS RESERVED Information contained herein is for use in the operation of the Big Blaster Air Cannon with XHV Valve, purchased from ESS and cannot be passed on to any other party without express permission, in writing, from ESS.
Revision G 4 27/10/2015
INDEX
SECTION 1 INTRODUCTION
SECTION 2 SAFETY
SECTION 3 INSTALLATION
SECTION 4
OPERATION
SECTION 5
COMMISSIONING
SECTION 6 PREVENTATIVE MAINTENANCE
SECTION 7
TROUBLE SHOOTING
SECTION 8 DIMENSIONS
SECTION 9 PARTS LIST
Revision G 5 27/10/2015
SECTION 1 - INTRODUCTION 1.1 GENERAL INFORMATION
The Big Blaster® Air Cannon is a pressure vessel with an attached valve mechanism that is designed to discharge the stored air in the vessel at very high velocity. The resultant air blast is used to dislodge adhering, bridging or built-up bulk materials in bins, silos and stockpiles. The air blast is directed to the required location via fully welded and secured blast pipework. On most applications, a number of Big Blasters will be utilised as a system approach to solving a material flow problem. ESS provides recommendations for the location of the blast points as a free service to purchasers of the Big Blasters. Correct positioning of the Big Blasters and the blast points is critical to the successful operation of the Big Blaster system. ESS Engineering Services and Supplies Pty Ltd is the sole Licensed Manufacturer of Martin Big Blaster® Air Cannons in Australia. The Big Blaster range of tanks was redesigned and converted to metric sizing in 2008. At the start of 2012, ESS established the XHV Valve as the standard discharge valve for the entire Big Blaster range in Australia. All Big Blaster® tanks are pressure vessels designed and manufactured to AS1210-1997, Class 3. The appropriate vessel manufacturing and test documentation will be forwarded to the customer shortly after despatch of the Blaster(s). Big Blasters® are designed to operate on plant compressed air (or nitrogen) in the range of 280 - 820 kPa (40 -120 psi). The safety valve is set to operate at 970 kPa (140 psi). The available models are as follows:
Model Number
Part Number
Tank Capacity Litres
Shipping Weight KG
Discharge Pipe Size
BB2-15
50220816
15
41
DN50 (2”)
BB2-15 Double Ended
50230816
15
54
DN50 (2”)
BB4-50
50221230
50
100
DN100 (4”)
BB4-50 Double Ended
50231230
50
120
DN100 (4”)
BB4-150
50222030
150
116
DN100 (4”)
BB4-150 Double Ended
50232030
150
136
DN100 (4”)
BB4-250
50222048
250
149
DN100 (4”)
BB4-250 Double Ended
50232048
250
169
DN100 (4”)
BB4-375
50222548
375
175
DN100 (4”)
BB4-375 Double Ended
50232548
375
195
DN100 (4”)
BB6-600
50223060
600
300
DN150 (6”)
BB6-600 Double Ended
50233060
600
350
DN150 (6”)
Revision G 6 27/10/2015
1.2 XHV VALVE The XHV discharge valve is now the standard valve offered by ESS with the Big Blaster range. The XHV is a robust and reliable discharge valve which, when correctly installed and applied, will provide many years and many thousands of trouble free operations. It is capable of operating in a range of harsh conditions, including elevated temperatures. Consult ESS for more specific advice in relation to special or unusual applications. The XHV Valve is easily identified by its cast aluminium surface finish, and the large XHV letters in the side of the outer housing casting. 1.3 PACKAGING The Big Blasters are despatched individually mounted on a timber or steel pallet to facilitate fork handling, and are orientated with the vessel lifting lug at the top to allow crane handling if required. The blasters are also plastic wrapped to ensure good weather resistance during handling and pre-installation storage. Connection accessories are shipped separately packaged. 1.4 HOW THEY WORK The Big Blaster® Air Cannon bulk material activating systems utilise the instantaneous release of a volume of compressed air from a storage tank. This sudden release of energy is directed through a transition pipe into compacted, adhering or bridging material in a bin, silo or stockpile to dislodge that material and restore flow. Compressed air stored in the Big Blaster® Air Cannon’s reservoir is released via the XHV valve. The high speed of discharge of the XHV valve allows the released energy to be delivered as an “explosive charge”. This initial shock dislodges the material whilst the expanding air then aerates the material, encouraging it to flow freely through the bin outlet. Big Blaster® Air Cannons are safe to operate, being remote from personnel, and causing no sparks or flame. For sensitive materials, the Big Blaster may be used with nitrogen in place of compressed air.
Revision G 7 27/10/2015
Figure 1 - Sequence of Operation: A) The operation of the Big Blaster is controlled by a Solenoid Operated Valve installed in the
incoming air line. There are two options for this and they are detailed in Section 4. B) Compressed air is directed into the top of the XHV via Solenoid Operated Valve and the incoming
air line. Small holes in the XHV Piston allow air to pass through the piston and enter the tank. The piston is seated against the upper edge of the outlet tube, preventing any air from escaping.
C) Once the tank and XHV valve are pressurised to line pressure, the airflow ceases. The piston is held in the seated position by the air pressure. The Blaster will remain in this state until firing is initiated.
D) To fire the Blaster the Solenoid Operated Valve is energised, closing off the incoming air supply and opening the line to exhaust. The compressed air above the piston is dumped and the air in the tank pushes the piston open. The tank air is then discharged at very high velocity through the XHV and via the blast pipework to the blast point.
A BA
CA
DA
Incoming Air Line
XHV Piston
Solenoid Operated Valve
Revision G 8 27/10/2015
SECTION 2 - SAFETY
Caution: Danger: DO NOT under any circumstances attempt to operate, pressurise or fire an unsecured blaster. The blaster must be permanently mounted to a structure, and all of the appropriate blast directing pipework connected to ensure that the blast effect is contained within the area where it is intended. Before attempting any work or maintenance on a blaster, ensure that all air pressure is drained from the blaster. This is done by closing the isolating valve on the air supply to the blaster, and opening the drain valve on the bottom of the blaster tank. Allow all pressure to drain before attempting any disassembly. Take appropriate means to ensure that the blaster cannot be repressurised whilst the maintenance work is in progress. Disconnection of the air supply line or hose is recommended. Before attempting ANY work which requires personnel to be in the area of the blast discharge nozzles (i.e. inside the bin, hopper or duct) ensure that blasters are isolated and drained as described above. Accidental firing of a blaster could result in serious injury or death to any personnel in close proximity to the discharge nozzle. A Blaster with XHV Valve is often used on applications involving high temperature ductwork, cyclones and the like. Ensure that all safety precautions are followed to prevent the installer / maintainer being exposed to high temperature gasses. Severe burn hazards may exist. Ensure that only suitably qualified and trained personnel install and service this product. Ensure that all site and statutory safety procedures are followed. Some hazards that may be present when installing this equipment include:
Hazard Hazard
Hot Work Other:
Stored Energy – Compressed Air Other:
Stored Energy – Hot Gasses Other:
Working at Heights Other:
Heavy Lift Other:
Persons Working Overhead Other:
Persons Working Below Other:
Electrical & Cabling Other:
Pinch Points
Trip Hazards
Once all hazards have been identified, the installer should undertake and document a comprehensive Job Hazard Analysis according to site requirements and good safe-working practice. The installer must identify all hazards and apply appropriate controls to manage the hazards before proceeding with the installation of this equipment.
Revision G 9 27/10/2015
SECTION 3 - INSTALLATION IMPORTANT NOTE Sketches are provided within this manual that show typical Big Blaster® installations. Most applications, however, will be different in some way to this. Unless you have already done so, or you are duplicating an existing installation, we strongly advise that you contact ESS for assistance. ESS can provide you with a supplementary drawing that will show suggested Blaster positions, mounting details and transition pipe details for your application.
ESS also has a range of special nozzles suitable for many applications, including high temperature applications. This equipment can enhance the effectiveness of the Big Blaster system. ESS cannot guarantee the effectiveness of Blasters placed contrary to, or without our recommendation.
3.1 BLAST PIPE INSTALLATION FOR STEEL BINS
Locate and mark points for installation of blaster pipes as per installation drawing or ESS instructions.
The transition pipe must exit the bin horizontally or inclined upwards. Pipes below horizontal will suffer material build-ups and subsequent loss of blaster power.
A minimum of 300mm vertical run is required to prevent material dust entering the piston assembly.
Cut a hole in the hopper large enough to allow insertion of the transition pipe at the desired angle. This hole will probably be an ellipse, the shape of which depends on the hopper angle and the transition pipe angle. If a compensating plate is to be used, cut the hole in the bin slightly larger than that in the compensating plate.Tack weld the compensating plate in position (if used).
NOTE: the installation procedure of the transition pipe is the same with or without the compensating plate. Insert the transition pipe through the compensating plate to the distance indicated by the drawing or ESS instructions (usually level with inside of bin wall). Check that the other end (i.e. Blaster end) of the pipe is vertical, then tack weld the pipe to the compensating plate.
NOTE: Ensure that there is enough clearance from the hopper to install the blaster onto the pipe. Fully weld compensating plate to hopper and pipe to compensating plate.
If not already done, fit a flange to the top end of the pipe where the Blaster will be attached. Ensure that the flange orientation is correct to align the Blaster as required and is offset far enough from the bin that the tank does not interfere. See figure 2 following.
An anchor or suspension bracket is welded to the bin above the Blaster to allow attachment of the suspension assembly. This is a supplementary Blaster support that eliminates bounce of the Blaster tank during firing, and also provides tank support during maintenance.
Figure 2 – Blast Pipe and Flange Arrangement
Square bin, perpendicular entry
Round bin, tangential entry
Flange holes off centre to line parallel to bin wall
Revision G 10 27/10/2015
Big Blaster Model Dim A (min)
BB2-15 170
BB4-50 250
BB4-150 340
BB4-250 340
BB4-375 410
BB6-600 480
Table 1 – Blaster Clearance Dimensions from Figure 2
Figure 3 – Typical Big Blaster Pipe Arrangement on a Steel Bin
Suspension Assembly
Blaster discharge vertically downwards – If not achievable contact ESS
Big Blaster Air Cannon
Site weld Blast transition pipe with long radius bends
Compensating Plate where required
Site weld
Revision G 11 27/10/2015
3.2 BLAST PIPE INSTALLATION FOR CONCRETE BINS Installation of Big Blasters® on concrete hoppers is exactly the same as for steel hoppers except a hole will need to be drilled through the concrete hopper wall. Diameters required are:
BB2 - 70mm
BB4 - 125mm
BB6 - 175mm A mounting plate is welded to the transition pipe and then bolted to the outside of the hopper wall, after insertion of the pipe through the drilled hole. Typical mount plates are:
BB2 - 225 x 225 x 6mm plate 4 only 16mm bolts
BB4 - 400 x 400 x 10mm plate 8 only 16mm bolts
BB6 - 500 x 500 x 12mm plate 8 only 20mm bolts The anchor bracket for the suspension kit will need to be bolted to the wall above the Blaster.
Figure 4 – Typical Big Blaster Pipe Arrangement on a Concrete Bin
Big Blaster Air Cannon
Blast transition pipe with long radius bends
Bolts through wall
Bolts through wall
Mounting plate welded to pipe
Suspension Assembly
Revision G 12 27/10/2015
3.3 BLASTER INSTALLATION
Select a blaster and remove the plastic wrapping and straps. The blaster will now be free to lift from its shipping pallet.
Using appropriate lifting gear (see shipping weights), hoist the blaster to the mounting position.
Fit the supplied gasket to the flange of the transition pipe, align the discharge flange of the Blaster with the flange of the transition pipe, and then secure the Blaster in place with the bolts supplied.
Fit the suspension (Blaster support) assembly to the pre-installed bracket and the lifting lug of the Blaster. Adjust the suspension assembly to just take the weight of the Blaster tank.
Remove the lifting gear.
If attachment as above is not achievable, the Blaster tank may be supported on a purpose built cradle, support bracket or similar. Ensure that the tank is secured to the cradle, and the cradle is secured to structure, but also ensure that there is room for pipe movement or expansion, especially in high temperature applications. Suitable flexible pipe sections, or rubber mounting pads may be used to achieve this.
The Blaster is now installed and ready to be connected up. 3.4 INSTALLATION OF DOUBLE ENDED BLASTERS ESS offers all current Big Blaster XHV models in a double ended configuration. This involves fitting of an XHV discharge valve to each end of one tank. The double ended configuration effectively creates two Blasters from a single tank, saving both initial cost and space. The installation of a double ended Blaster is the same as a single ender, but a few points should be considered:
The Double Ended Blaster is suitable where blast points are close together, allowing sharing of the vessel without long blast pipe runs. Where blast points are more than 3 metres apart, or are at substantially different heights, single ended Blasters are generally used.
The Double Ended Blaster should be installed as per the previously described criteria. The minimum 300 mm vertical pipe run must be maintained from the highest blast point (where blast points are not at the same level), meaning that the pipe run to the lower blast point will be longer.
Drawings in this manual will give the centre distances between the discharge flanges of the double ended units. The installer may choose to pre-fabricate the two pipes before installing the Blaster, but will need to very accurately align the flanges in terms of hole alignment, centres and level.
Alternatively the installer may install one pipe and the Blaster as described for a single ender, then fabricate the second pipe in-situ to suit.
Care must be taken to avoid inducing stresses into the Blaster XHV discharge valve when making the second pipe closure.
Revision G 13 27/10/2015
SECTION 4 – CONNECTING UP THE BIG BLASTER
Fit the safety valve (mandatory) to the top socket and drain valve (recommended) to the bottom socket of the blaster – see figure 5. The Blaster is fired by energising a Solenoid Operated Valve. There are two valve systems offered, each with advantages for different applications. 4.1 ESS ACCESSORY KIT (only available for 2” and 4” XHV models) This system has been used by ESS for many years and has proven to be extremely reliable. It consists of a solenoid operated diaphragm valve, a non-return valve and fittings. The Accessory Kit is simply screwed into the threaded opening (1” BSP) in the top of the XHV. The compressed air supply is connected to the ½” BSP inlet side of the non-return valve. The electrical cabling is connected to the DIN plug on the solenoid operated diaphragm valve. A range of voltages is available.
Figure 5 Big Blaster Accessory Kit Set-up
Advantages Disadvantages
Very simple Incoming air not shut off – some air loss
Very reliable Noisier
Low cost The electrical components are installed direct to the Blaster which may not be suitable for high temperature or hazardous zone applications
NOTE : In cases where noise output needs to be minimised, a silencer may be fitted to the pilot air discharge point of the diaphragm valve of the Accessory Kit. This must be a free flow silencer, and it must be inspected and cleaned regularly to ensure correct operation of the Big Blaster. ESS part number 51092105 is available for BB2 and BB4 model Big Blasters.
Safety Valve
Air Connection ½” BSP
Electrical Connection DIN plug
Pilot Air Discharge
Drain Valve
Accessory Kit P/N 51041105
Enlarged View
1” BSP
Revision G 14 27/10/2015
4.2 3-WAY VALVE with QUICK EXHAUST VALVE
A DN25 Quick Exhaust Valve is attached directly to the XHV inlet with a 1” BSP nipple. A ½” hose is connected from the inlet side of the QEV to a 3 way normally open Solenoid Operated Valve. Hose length can be up to 5 metres.
Figure 6 – Arrangement for BB2 and BB4 XHV Blasters
Advantages Disadvantages
Incoming air supply shut off at firing– no air loss Slightly higher cost
Lower Noise levels
The electrical components are remote from the Blaster. Better for high temperature or hazardous zone applications
DN25 Quick Exhaust Valve, ESS P/N 51092104, with 1” BSP nipple to XHV and ¾” - ½” nipple to air supply hose.
½” Hose, maximum length 5 metres (ESS Standard 1.5m)
Pilot air exhaust 1” BSP
½”, 3 way, normally open solenoid operated valve.
Solenoid Valve and 1.5m Hose Assembly ESS P/N 51042000_xxx Substitute xxx for voltage _24A = 24 VAC _24D = 24 VDC _110 = 110 VAC _240 = 240 VAC
Electrical Connection DIN plug
Air in ½” BSP
Valve Exhaust ¾” BSP
Revision G 15 27/10/2015
Figure 7 – Arrangement for BB6 XHV Blasters
On the BB6 XHV Blaster, the QEV is replaced by dual QEV’s connected by tube and fittings. This allows faster evacuation of the larger volume of air above the BB6 piston. The Solenoid Operated Valve and hose are the same as used for the BB2 and BB4 models.
4.3 PRESSURISING the BLASTER
Recheck the following:
The Blaster is installed and secured
The control valves are installed and air lines connected
The safety valve and drain valve are installed
The Blaster can now be pressurised and tested. With either valve system described previously, connecting an air hose to the designated inlet and turning on the supply will initiate pressurising of the tank. Air will travel through the fittings or Solenoid Operated Valve and QEV into the top of the XHV, and will pressurise the tank as described in section 1.4.
The Blasters are pre-tested for leaks before leaving the factory, but once the blaster is connected and pressurised, it should be visually inspected for leaks at any of the site connection points or site installed fittings.
BB6 Fill Kit – P/N 51041110 with dual QEV’s, connecting tube and fittings. Elbows are fitted to the QEV exhaust to direct exhaust air as desired.
ESS P/N 51042000_xxx (refer to previous page) Solenoid Valve and 1.5m Hose Assembly
Revision G 16 27/10/2015
The blast transition pipes (discharge pipes) are not normally pressurised and therefore will not show any leaks except during firing, the duration of which is less than one second. Therefore, only a very major leak in the transition pipework will be detectable or have any effect on the blast force.
4.4 LUBRICATION NOTE
The XHV valve will operate under very extreme conditions without lubrication, but ESS recommends that whenever possible a filter/lubricator unit should be installed in the air supply line to each Blaster. Like most compressed air operated equipment, entry of water and contaminants will cause deterioration of the XHV over time and lubrication will help protect against this.
Ensure that the filter / lubricator unit is regularly serviced.
4.5 DOUBLE ENDED BLASTERS
As previously noted ESS can supply the Big Blaster Air Cannon with XHV valve in optional Double Ended configuration.
To connect up the double ended Blaster, simply duplicate the control arrangement at both ends. This means that there will be two electrical connection points for each double ended Blaster. It will also result in quicker fill of the Blaster tank because the air will be entering through both ends.
As mentioned previously, the double ended Blaster is effectively two Blasters sharing one tank, and should be treated as such in any firing sequence used.
Revision G 17 27/10/2015
SECTION 5 - OPERATION Big Blasters® are designed to operate on plant compressed air in the range of 80 – 120 psi (550 – 820 kPa). For pressures outside of this rage, contact ESS. To fire a pressurised Big Blaster® Air Cannon is simply a matter of energising the solenoid operated valve in either of the configurations detailed is section 4. This allows the air on the top of the piston to evacuate. The pressure in the vessel immediately pushes the piston open, allowing all of the compressed air in the vessel to escape through the discharge orifice. Refer to operating sketch in section 1.4. The solenoid can be supplied in a number of voltages to suit clients’ requirements, with 240V AC being standard supply. The solenoid only needs to be energised for about 0.5 – 1.0 seconds. 5.1 MANUAL OPERATION For manual operation a simple non-retaining push button is normally used. This applies to single units, or for the manual mode of a multiple Blaster system. Pressing of the button will close a circuit and energise the solenoid. As soon as the blaster fires, the button is released.
Where multiple blasters are installed, the lowest blaster should be fired first. After a short period of time to allow the dislodged material to clear, the next lowest blaster is fired, and so on. Always ensure that dislodged material has somewhere to go, i.e. bin gates are open, feeder belt is running, etc. Firing blasters into a closed bin may result in further material compaction in some materials, or excessive material aeration in other materials. Always allow at least 30 seconds between consecutive firings of the same blaster to allow vessel refill – longer for larger models.
5.2 AUTOMATIC OPERATION Automatic operation may be controlled using a number of switching devices including sequence timers and PLC’s. The same criteria are required to fire the blaster – i.e. a signal of the appropriate voltage, and duration of 0.5-1.0 seconds.
Frequency of operation of Blasters depends entirely on plant requirements – i.e. how soon the flow problem re-emerges after having been cleared by the previous blaster operation. Therefore, cycle times will need to be adjustable.
ESS can advise and assist with your particular plant requirements, including supply of an automatic system to suit. All other operational constraints are as for the manual system.
5.3 OPERATION of DOUBLE ENDED BLASTERS As previously noted, Double Ended Blasters should be treated as two separate Blasters. This means that the two solenoid operated valves are energised separately, and are never operated simultaneously. It is essential that only one end of the Double Ended Blaster is fired at a time, and the Blaster must be given time to re-fill before either the same end or the opposite end is fired.
Revision G 18 27/10/2015
SECTION 6 - HIGH TEMPERATURE APPLICATIONS
Big Blaster Air Cannons are commonly used in high temperature applications such as Cement Plant preheater ducts to prevent material build-up, and the XHV valve was specifically developed for use in these applications. The design of the XHV has eliminated potential seal failures when exposed to elevated temperatures. ESS offers both application advice and specialised equipment when using Big Blasters on elevated temperature applications. ESS has a range of high temperature cast nozzles available for the 4” XHV versions (the majority of these applications will use a 4” (DN100) outlet Blaster). The function of the Blaster in many of these applications is to sweep an area of wall inside a square, rectangular or round duct or feed tube. For this reason, the high temperature nozzles are of a fan design to maximise the swept area. As an alternative for small diameter feed tubes, high temperature rated pipe entries may be used. Some typical high temperature nozzle and Blaster arrangements are shown below.
Figure 8 – Typical High Temperature Blaster and Nozzle Arrangements
Nozzle positioned to direct air blast across face of refractory
Nozzle welded to outer casing and flanged for ease of replacement
Inner face of nozzle coated with refractory to protect against heat
High temperature pipe nozzle used in small diameter cyclone
Revision G 19 27/10/2015
Figure 9 – ESS High Temperature Nozzle Straight – P/N 51240410
Figure 10 – ESS High Temperature Nozzle 90° – P/N 51240415
Revision G 20 27/10/2015
SECTION 7 – COMMISSIONING
When commissioning Big Blasters, the following steps are recommended:
Safety Warning: Ensure that no personnel are inside the chute, bin or silo where the Blaster(s) are installed.
Safety Warning: Ensure that all access doors are closed and locked.
Safety Warning: Ensure that No Entry - Air Blast Hazard warning signs are placed at any point where personnel can access the Blaster operating area. (ESS can provide adhesive signs).
Safety Warning: Even though personnel will be remote from the air blast, other hazards may be present, such as noise, dust and debris disturbed by the pilot air discharge etc. Ensure that appropriate protective equipment is worn by all personnel.
Open the valve to supply compressed air to the Blaster(s).
Listen for the sound of the Blasters filling – this should cease within about 1 minute as the Blaster fills, depending on the air supply flow rate and the Blaster size and number.
If the air running sound continues, look for air leaks.
If air continues to run and no leaks can be found, a piston may not have seated – isolate and drain Blaster, and follow maintenance procedure to dismantle valve assembly and remedy.
Once Blaster(s) have filled, place controller in Manual mode, and test fire first Blaster. Listen for a crisp discharge, and for subsequent re-filling of Blaster.
Repeat for all Blasters.
Place controller in Auto mode. Observe operation of sequence during plant operation. Ensure sequence initiates as required, and that Blasters fire in correct sequence.
Inform production operators of Blaster operations, and ensure they know to contact a trained service person if the Blasters cease to operate. Untrained personnel should not attempt to modify or repair a non-operational Blaster.
Follow all safety precautions outlined in the manual, plus normal safe working procedures for compressed air devices for any future maintenance work.
If Blaster sequence operates correctly and Blasters fire as required, but blockages or hang-ups are not removed, contact ESS for advice and assistance.
An in line lubricator unit should be placed in the air supply line to the Blaster(s). Adjust for very light lubrication. If excess oil is discharged from the solenoid operated valve pilot port, reduce the oil feed rate. Standard light compressed air tool oil is suitable for the Blasters.
Revision G 21 27/10/2015
SECTION 8 – PREVENTATIVE MAINTENANCE The Big Blaster® Air Cannon requires little maintenance, however, the following schedule of preventative maintenance is recommended to eliminate the possibility of system shutdown due to failure.
IMPORTANT DO NOT discharge blaster while any person is inspecting device. Eye protection should be worn by persons in the area of blaster in the event that air from the Solenoid or Quick Exhaust valves should create flying debris.
8.1 ROUTINE EXTERNAL INSPECTION (MONTHLY)
Inspect all air lines and air line connections for leaks.
Air hoses should be checked for deterioration.
Ensure hoses are secured.Inspect accessory kits, filter and regulators for correct operation.
Check operation of the Safety Valve by lifting the tab on the valve.
Drain accumulated moisture in the Blaster tank by cracking the drain valve.
If fitted, inspect the silencer on the Accessory Kit.
If silencer is dirty, isolate and drain the Blaster, then remove and clean or replace the silencer.
8.2 SHUTDOWN SERVICE (SIX MONTHLY)
Visually inspect each of the Big Blaster® Air Cannons.
Isolate the air supply and drain blasters as described in the safety notes.
Allow any water to drain from blaster tanks and lines.
Check mounting at hopper to be sure there is no damage to mount plate, welds or fixing screws.
Check suspension turnbuckle to ensure that it is taut, and relieving the bulk of the blaster assembly weight.
Check QE valves for loose screws and clean out any dirt accumulation.
If leaks are detected from blaster during normal operation, disassemble as described in section 8.3 and inspect internal surfaces.Alternatively, an exchange XHV Valve may be installed. The XHV can be returned to ESS for overhaul and then placed back in stock as a spare.
Also at this time inspect the interior of the pressure vessel and remove any scale build-up etc.
Check all electrical connections to be sure there are no loose, broken or damaged wires.
Having completed above, reconnect all the air lines and power source and cycle each blaster individually to be sure of proper operation while checking that they charge fully to line pressure.
8.3 DISASSEMBLY PROCEDURE
If a fault is detected in the operation of the Blaster that requires the disassembly or replacement of the XHV discharge valve, the following procedures should be followed. Before commencing any work on the Blaster, ensure that the incoming air supply has been isolated, and that all air in the Blaster tank has been drained. Disconnect the air supply lines to prevent accidental re-pressurising. 8.3.1 XHV DISCHARGE VALVE REPLACEMENT
A complete change-out of the XHV Valve is the quickest and easiest way to overcome a fault
in the operation of the valve. ESS can supply an exchange unit, and then repair or re-furbish the old unit at ESS factory.
Revision G 22 27/10/2015
The following procedure should be followed:
Isolate and drain the Blaster as previously described.
Disconnect the air supply line from the accessory kit.
Loosen and disconnect the Accessory Kit, QEV or Fill Kit – refer to section 4 to determine which system has been used.
Ensure that the Blaster tank is supported by a supplementary support at the lifting lug (ESS Suspension Kit or similar) or in a cradle. Support the XHV Valve with approved lifting gear (a BB6 XHV weighs 60 kg) and remove the nuts securing the XHV to the Blaster tank. Take extreme care as the XHV and tank may separate suddenly. Do not lose the tank flange gasket.
The Blaster tank will now be loose and suspended by the lifting lug or cradle only, but the XHV will still be supported by the transition pipe. Remove the bolts that attach the XHV to the transition pipe. Lift the XHV clear and lower it to the required maintenance position.
Installation is a reversal of the previous steps. Ensure that new gaskets are installed and that the bolts / nuts are secured to “snug tight”.
8.3.2 XHV DISCHARGE VALVE DISASSEMBLY
At times it may be necessary to inspect and / or replace some of the internal components of the XHV in-situ. This is easily done as follows:
Isolate and drain the Blaster as previously described.
Disconnect the air line at the Accessory Kit, QEV or Fill Kit. The Accessory Kit, QEV or Fill Kit may be left in place, but care should be taken to avoid damage on removal of the XHV Cap.
Remove the bolts that attach the XHV Cap to the XHV valve body. The Cap will be lightly spring loaded and should begin to lift as the bolts are removed. If not, be careful in case the Cap suddenly releases. Carefully remove the Cap with the Accessory Kit, QEV or Fill Kit attached and place in a safe position, taking care not to lose the O-ring in the Cap.
The exposed piston will be visible in the bore of the XHV. The piston sleeve can be inspected and the piston holes checked for blockages.
If the piston is loose it may be gripped and withdrawn. Otherwise, if piston removal is required, it will be necessary to remove the XHV from the Blaster as described previously. Once clear, the piston can be lightly driven out from below using a timber or soft metal drift.
If the Piston Seat needs to be removed or replaced, again with the XHV removed, remove the securing the Discharge Flange Weldment to the lower portion of the XHV body. The Piston Seat will release from the XHV body on removal of the Discharge Flange Weldment. Take care not to lose the O-ring seal on the Piston Seat.
Check all parts for damage or wear. Replace parts as required.
Re-assembly is the reverse of the above. Lightly oil the bore of the XHV before inserting the piston.
Ensure that all parts are carefully assembled and that all bolted connections are tightened securely. Use new gaskets between the Discharge Flange Weldment and the Transition pipe and between the XHV and Blaster tank.
On completion, re-pressurise the Blaster and check for leaks.
Test fire the Blaster. If the Blaster operates correctly, return the unit to service.
Revision G 23 27/10/2015
SECTION 9 – TROUBLE SHOOTING 7.1 BIG BLASTER® AIR CANNON DOES NOT CHARGE (fill with compressed air)
POSSIBLE CAUSE REMEDY
a) Accessory Kit, QEV or Fill Kit installed incorrectly
a) Re-install following diagram
b) QEV not sealing b) Remove and replace rubber piston
c) Piston not seating c) Check piston and seat for damage
d) Piston fill-holes blocked (holes through piston)
d) Clean piston holes and check air filtration
e) Safety Valve faulty e) Replace Safety Valve
f) Tank drain valve open f) Close drain valve
7.2 BIG BLASTER® AIR CANNON DOES NOT DISCHARGE
POSSIBLE CAUSE REMEDY
a) Solenoid valve air lines not connected properly
a) Check to be sure air line connections are to correct port, check electrical connections
b) Solenoid valve dirty or damaged b) Clean or replace solenoid valve
c) Solenoid valve exhaust port blocked c) Open port to atmosphere, clean or replace silencer if fitted
d) Piston lodged in sleeve d) Remove and replace Piston. Check for sleeve damage.
e) Solenoid valve not operating e) Check electrical connections and coil condition
Revision G 24 27/10/2015
7.3 BIG BLASTER® AIR CANNON DISCHARGE FORCE LOW
POSSIBLE CAUSE REMEDY
a) Low air pressure a) Check and increase pressure
b) Big Blaster® Air Cannon not completely filled before it discharges
b) Allow longer period between Big Blaster® operations
c) Material in tank c) Remove and clean. Check installation set-up to prevent material entry
d) Water accumulated in tank d) Drain tank and take measures to prevent moisture accumulation
e) Optional Accessory Kit silencers partially blocked
e) Clean or replace silencers
7.4 BIG BLASTER® AIR CANNON DOES NOT FILL FAST ENOUGH
POSSIBLE CAUSE REMEDY
a) Restriction in airline a) Trace airline to restriction and remove. Check filtration
b) QEV obstructed b) Clean QEV
c) Piston fill holes blocked c) Remove and clear, check air line filtration
d) Air compressor too small d) Go to larger air compressor
IF YOU REQUIRE ANY ASSISTANCE IN REGARD TO THE OPERATION AND/OR MAINTENANCE OF THE BIG
BLASTER® AIR CANNON PLEASE CONTACT ESS FOR IMMEDIATE ATTENTION
Revision G 25 27/10/2015
SECTION 10 – PARTS LISTS
Revision G 26 27/10/2015
Revision G 27 27/10/2015
Revision G 28 27/10/2015
SECTION 11 – DRAWINGS
Revision G 29 27/10/2015
Revision G 30 27/10/2015
Revision G 31 27/10/2015
Revision G 32 27/10/2015
Revision G 33 27/10/2015
FINAL CHECKLIST Site: ____________________________ Number: _____________________ Date: ___________________ Site Equipment No./Location: _________________________ Site Contact: _________________________ Completed By: _____________________________________ ((CCiirrccllee YYeess oorr NNoo BBeellooww))
1. Was equipment to ESS Specification? _______________________________ Yes/No
Drawing No. Ref: _________________________________________Attached? Yes/No If No, WHY _______________________________________________________________________________ ________________________________________________________________________________________ Will this affect performance? Yes/No If Yes, WHY ______________________________________________________________________________ ________________________________________________________________________________________
2. Was this a standard service inspection installation? Yes/No If No, WHY _______________________________________________________________________________ ________________________________________________________________________________________ ________________________________________________________________________________________
3. Was work carried out as per procedure and JSA? Yes/No If No, WHY _______________________________________________________________________________ ________________________________________________________________________________________
4. Is equipment fit for commissioning? Yes/No If No, WHY _______________________________________________________________________________ ________________________________________________________________________________________
5. Was a final inspection carried out while plant was running? Yes/No If No, WHY _______________________________________________________________________________ ________________________________________________________________________________________
6. Has anything changed from previous service / inspection / installation? Yes/No If Yes, WHAT _____________________________________________________________________________ ________________________________________________________________________________________
7. Is equipment performance to Client expectations? Yes/No If No, WHY _______________________________________________________________________________ ________________________________________________________________________________________ ESS Signature: ______________________________ Client Signature: ____________________________
