INSTALLATION, OPERATION & MAINTENANCE MANUAL · 33 Abrasive Vibrator 33 Water System 33 Blast Hose 33 Blast Nozzle 34 Hose Connection PRE-OPERATION PROCEDURES 35 Abrasive Blaster

M-Series Abrasive Blaster

www.BlastOne.com

INSTALLATION, OPERATION & MAINTENANCE MANUAL

2

MANUAL CONTENTS

INTRODUCTION

4 Warning

6 Using This Manual

7 WarningDecalIdentificationandLocations

RULESFORSAFEROPERATION

9 GeneralRuleForSaferOperation

9 KnowYourEquipment

9 ReceiveProperTraining

9 ProtectYourFeet

10 ProtectYourEyes

10 ProtectYourLungs

10 BreathingAirQuality

11 ProtectYourHearing

11 ProtectYourPerson

11 AdhereToAllRegulations

11 StayAlert

11 DoNotUseDrugs,AlcoholOrMedication

12 ProtectBystanders

12 KeepChildrenAndVisitorsAway

12 AvoidDangerousEnvironments

12 ElectricallyGroundEquipment

12 MaintainVesselIntegrity

13 NeverOperateOverMaximumWorkingPressure

13 InstallPressureReliefDevice

13 NeverOperateBeyondAllowableTemperatureRange

13 As1210-2010Class3NameplateRequired

13 DoNotModifyVessel

14 DoNotHammerOnVessel

14 FireDamageNotice

14 InspectVesselRegularly

14 CheckForLeaksInVessel

14 NeverModifyBlowDown

14 DepressuriseVesselBeforePerformingMaintenance

15 AlwaysUseRemoteControls

15 NeverUseBleederTypeDeadmanVales

15 CheckForDamagedParts

15 AlwaysUseSafetyPinsOnHoseCouplingConnections

15 AlwaysUseCorrectReplacementPartsandAccessories

16 AlwaysUseCorrectPressureRatedAccessories

16 NeverAimBlastNozzleTowardsAnyPerson

16 NeverUseAbrasiveNotIntendedForBlastEquipment

16 CheckAbrasiveForDebris

16 StopOperationImmediatelyIfAnyAbnormalityIs Detected

16 Maintain Warning Decals

17 SaveThisOperationandMaintenanceManual

17 SafetyReferences

SPECIFICATIONS&GENERALINFORMATION

18 NotesToDistributorsandOwners

18 MiniAbrasiveBlastingSystemOperationalSpecifications

19 ImportantReferenceNumbers

19 VesselInformation

19 DimensionalSpecifications

20 LiftingDiagram

SYSTEMREQUIREMENTS&PPE

21 CompressedAirRequirements

21 AirCompressorSize

21 BlastSystemAirSupplyLine

21 BlastSystemAirPressure

21 BlastSystemAirQuality

21 ElectricalRequirements

22 AbrasiveSelection

22 BreathingAirQuality

23 PersonalProtectiveEquipment(Ppe)

GENERALOPERATION

24 GeneralOperation

27 AirSupplyConnection

27 AirInletBallValve(Pressurize)

27 BlowdownBallValve(Depressurize)

28 PopupWithEyebolt(AbrasiveInlet)

28 AirSupply

3

Fillinyourmodelandserialnumberintheblankspacesbelow.Thesecanbeusedforreferencewheneverservice ormaintenanceisrequired.

UnitSerialNumber

DateOfIssue

Donotattempttooperatethisequipmentwithoutfirstreadingandunderstandingthemanualenclosedwiththisdevice.Suitabilityforuseofthisdeviceliessolelywithuser.

WARNING

29 RegulatedTank/BlastPressureRegulator

29 FullPressureBypass

29 GateValve(DifferentialPressureControl)

29 AutomaticAirValve

30 ThompsonValve®Ii

30 AbrasiveShutoffValve

31 DeadmanValve/Switch

32 AbrasiveCut-Off

33 AbrasiveVibrator

33 WaterSystem

33 BlastHose

33 BlastNozzle

34 HoseConnection

PRE-OPERATIONPROCEDURES

35 AbrasiveBlasterSetupProcedure

36 AbrasiveBlasterDepressurizingProcedure(Blowdown)

38 HandwayCoverInstallationProcedure

OPERATIONINSTRUCTIONS

40 FillingTheBlasterWithAbrasive

41 BeginningTheBlastingOperation

42 EndingTheBlastOperation

MAINTENANCE&INSPECTIONINSTRUCTIONS

44 Maintenance&InspectionInstructions

48 MaintenanceSchedulesQuickReferenceChart

DRAWING&PARTSLISTS

49 Drawing&PartsLists

SPAREPARTSLISTS

65 SparePartsLists

TROUBLESHOOTING

67 MalfunctionWithDeadmanLeverInThe“Off”Position

68 MalfunctionWithDeadmanLeverInThe“On”Position

69 NotesOnAbrasiveFlowProblems

WARRANTY

71 Warranty

71 WarrantyPolicy

72 SafetyInformationSources

BLASTINGDATA

73 TableOfBlastAbrasiveCharacteristics

73 ApproximateAirConsumption(Cfm)PerBlastNozzle

74 AbrasiveConsumption(Lbs.PerHour)PerBlastNozzle

74 HoseSelectionGuide(Blasting@100Psi)

74 AdditionalInformationOnBlastingProductivity

4

INTRODUCTION

WARNING1. Anypersonintendingtooperatethisequipmentoranypersonintendingtobeinthevicinity

duringitsoperationmustreceivepropertrainingfromhis/hersupervisor,employerand/orsupplier.Ifthisequipmentistobeleasedorrented,thesuppliermustassurethatthelesseeorrenterhasreceivedpropertrainingbeforethelesseeorrentertakespossessionoftheequipment.ConsultBlastOne.

2. AnypersonauthorizedtooperatethisequipmentoranypersonintendingtobeinthevicinityduringitsoperationandwhoisnotcapableofreadingandunderstandingthismanualmustbefullytrainedregardingtheRulesforSaferOperationandalloperatingprocedures,andmustbemadeawareofalltheDangers,Warnings,andCautionsidentifiedherein.ConsultBlastOne.

3. DoNotoperateanyabrasiveblasterorblastequipmentbeforereadingandcompletelyunderstandingallthewarnings,operatingproceduresandinstructions,andtheRulesforSaferOperationcontainedinthismanual.

4. DoNotoperateanyabrasiveblasterorblastequipmentwithoutfollowingtheRulesforSaferOperationandalltheoperatingproceduresandinstructions.Failuretoproperlyuseblastequipmentcouldresultinseriousinjuryordeath.

5. DoNotperformanymaintenanceonanyabrasiveblasterorblastequipmentwhileitispressurized.Alwaysdepressurizetheabrasiveblastervesselbeforeloadingabrasiveorperforminganymaintenance.

6. DoNotuseabrasivescontainingfreesilica.Silicacancausesilicosisorotherrelatedrespiratorydamage.Youmustwearpersonalprotectiveequipmentforallabrasiveblastingoperations.Observeallapplicablelocal,stateandfederalsafetyregulationsinconjunctionwithairlinefiltersandrespiratoryprotection. ReferenceOSHA29CFR1910.134.

7. DoNotenterareasduringabrasiveblastingoperationswithoutbreathingprotection.AllpersonnelinthevicinityofabrasiveblastingoperationsshouldwearNIOSHapprovedairfedrespirators,hoodsorhelmets.

8. DoNotmodifyoralteranyabrasiveblaster,blastequipmentorcontrolsthereofwithoutwrittenconsentfromBlastOne.

9. DoNotusebleedertypedeadmanvalvesonanyBlastOneabrasiveblaster.TheuseofA-BEC,Clemcoorasimilarbleedertypedeadmanvalvecancauseunintentionalstart-upwithoutwarning,whichcanresultinseriouspersonalinjury.

10.DoNotsell,rent,oroperateabrasiveblasterswithoutremotecontrols.OSHAregulationsrequireremotecontrolsonallblastmachines.Failuretouseremotecontrolscancauseseriousinjuryordeathtotheoperator(s)orotherpersonnelintheblastingarea.ReferenceOSHA29CFR1910.244(b).

5

INTRODUCTION

11.DoNotrepairorreplaceanyportionofBlastOneequipmentusingcomponentsthatarenotBlastOneoriginalfactoryreplacementparts.UseofreplacementcomponentsthatarenotBlastOneoriginalfactoryreplacementpartsmayresultinequipmentfailurewhichcanresultinseriouspersonalinjuryandinadditionwillvoidallwarranties.

6

INTRODUCTION

USING THIS MANUALThismanualcontainsinformationneededtooperateandmaintainyourabrasiveblaster.Readthisentireoperationsandmaintenancemanualbeforeusingyourabrasiveblaster.PaycloseattentiontotheRulesforSaferOperation(page9),andtheDangers,Warnings,andCautionsidentified.

Thepurposeofsafetysymbolsandexplanationsaretoalertyouofthepossiblehazardsandexplainhowtoavoidthem.Thesafetysymbolsandexplanationsdonotbythemselveseliminateanydanger.However,followingtheinstructionsgivenandtakingproperaccidentpreventionmeasureswillgreatlylowertheriskofinjurytopersonnel.Belowarethehazardlevelsasusedinthismanual.

WHITE LETTERS with a RED BACKGROUND

Indicatesanimminentlyhazardoussituation,that,ifnotavoided,willresultindeathorseriousinjury.Thissignalwordislimitedtothemostextremesituations.

DANGER

WHITE LETTERS with an ORANGE BACKGROUND

Indicatesapotentiallyhazardoussituationthat,ifnotavoided,couldresultindeathorseriousinjury.Itmayalsobeusedtoalertagainstunsafepracticesthatmaycausepropertydamage.

WARNING

Thismanualcontainstermsthatmaybespecifictotheabrasiveblastindustry.Understandingthesetermswillhelpyouunderstandtheproceduresandinstructionsgiveninthismanual.Pleasefamiliarizeyourselfwiththefollowingtermsandrefertothemasneededwhilereadingthismanual.

TERM DEFINITION

PressureVessel Afabricatedtank(orreservoir)thatispartoftheabrasiveblasterwhichisfilledwithcompressedairandabrasive.(Alsoreferredtoas“blastvessel”or“vessel”.)Pressurize Tomanuallyorautomaticallyfilltheabrasiveblastvesselwithcompressedair.

Depressurize Tomanuallyorautomaticallyreleaseallthecompressedairfromtheinsidetheabrasiveblastvessel.(Alsoreferredtoas“blowdown”)

Blowdown Tomanuallyorautomaticallyreleaseallthecompressedairfrominsidetheabrasiveblastvessel.(Alsoreferredtoas“depressurize”.)

DeadmanAmanuallyoperatedvalveorswitchthatallowsremotestartingandstoppingoftheblastoperation.Alsoreferredtoas“deadmanvalve”(pneumaticblastcontrols)or“deadmanswitch”(electricblastcontrols.)

Popup Anairpressureoperatedvalvethatsealstheabrasiveinletatthetopoftheabrasiveblasterpressurevessel.Itsoperationmaybemanualorautomatic.

Abrasive Agranularsubstanceusedinanairblastoperationthatisthemeansforblastingthesurfaceofanobject.(Alsoreferredtoasabrasiveblastingmedia.)

SilicaThecrystallinechemicalcompoundsilicondioxide(SiO2)whichcanbefoundinmanynaturalabrasivesandothersubstances.Breathingsilicadustcancauserespiratorydiseasessuchassilicosis.(Alsoreferredtoascrystallinesilica)

7

INTRODUCTION

WARNING DECAL IDENTIFICATION AND LOCATIONSListedbelowarethewarningsdecalsandthecorrespondinghazardsrelatedtothisequipment.RefertoFigure3to5forimagesofthewarningdecals.RefertoFigure6forthelocationsofthesewarningdecalsontheMistBlaster.

NO. QTY. PART NO. DESCRIPTION HAZARD

1 1 “BlastOne” NotApplicable

2 1 7031-054“Warning”Airborneparticlesandloudnoisehazard

Airborneparticlesandloudnoisefromblastnozzleandblowdowncancauseinjuryandlossofhearing.Wearapprovedeyeandearprotection.SeeWarningonpage5andFigure9.

3 1 7031-007A

“Danger”Pressurizedvessel

Propelledobjectswillcauseseriousinjuryordeath.Depressurizevesselpriortoperforminganymaintenance.SeeAbrasiveBlasterDepressurizingProcedure(Blowdown)onpage36.

4 1 7031-057“Warning”Readmanualbeforeusingthismachine.

Readandunderstandoperator’smanualbeforeusingthismachine.Failuretofollowoperatinginstructionscouldresultininjuryordamagetoequipment.SeeWarningonpage5.

5 1 7034-001

Welded“Warning”plate.Generalhazardandadvisorynotes.

Steel“Warning”plateweldedtopressurevesselwhichisagenerallistofrequiredactionstotakebeforeandduringtheoperationofthisequipment.SeeWarningonpage5.

Figure1

Figure2

Figure5

8

INTRODUCTION

Figure3 Figure4

Figure6

9

RULES FOR SAFER OPERATION

GENERAL RULE FOR SAFER OPERATIONMistBlastershavebeendesignedtobesafewhenusedinthepropermanner.AllMistBlastersarepotentiallydangerousifallsafetyprecautionsarenotrigorouslyfollowed.Propertrainingisrequiredbeforeoperation.Properproceduresmustbefollowed.TheMistBlasterandallcomponentsmustbeproperlymaintained.Failuretooperate,serviceandmaintaintheMistBlasterassetforthinthismanualmaycauseinjuryorevendeathtoanypersonusing,servicingorinthevicinityoftheMistBlaster.

Thismanualidentifiespotentialhazardsbydanger,warningandcautionsymbols.However,alltherules,proceduresandrecommendationsmustbefollowed.Failuretooperateproperlyisverylikelytoplacepersonsandpropertyathighriskofdamage,injuryorevendeath.

MistBlastersandtheabrasiveblastoperationarepotentiallydangerousifallsafetyprecautionsarenotfollowed.Failuretooperatetheabrasiveblasterwithoutfollowingalltherulesforsaferoperationsmayresultinseriousinjuryordeathtooperatingpersonnelorpersonintheoperatingvicinity.

DANGER

KNOW YOUR EQUIPMENTDoNotoperatethisequipmentinamannerotherthanitsintendedapplication(seeSystemRequirements&PPEonpage21).

DoNotoperatethisequipmentoranyotherBlastOneequipmentwithoutfollowingtheRulesforSaferOperationandalltheoperatingproceduresandinstructions.Learntheapplicationsandlimitationsaswellasthespecificpotentialhazardsrelatedtothismachine.Failuretodosocouldresultinseriousinjuryordeath.

RECEIVE PROPER TRAININGDoNotoperatethisequipmentunlessyouhavereceivedyouroperationalandmaintenancetraining.Beginbythoroughlyreadingandunderstandingthisoperationandmaintenancemanualandallincludedinformation.ConsultanauthorizedBlastOneconsultantorattendaBlastOnetrainingsession.

PROTECT YOUR FEETDoNotoperatethisequipmentwithoutwearingOSHAapprovedfootprotection.Observeallapplicablelocal,stateandfederalregulations.SeeFigure9andOSHA29CFR1910.136.

Heavyobjectscanshiftwhilebeingblastedandmayfallonoperators.Wearfootprotectiontopreventinjury.SeeFigure9andOSHA29CFR1910.136.

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Abrasiveblastingproducesdustwhichmaycontainsilicaandothertoxicsubstancesthatcancausesevereandpermanentlungdamage,cancer,andotherseriousdiseasesifinhaled.WearOSHAapprovedrespiratoryprotection.SeeFigure9andOSHA29CFR1910.134.

DANGER

PROTECT YOUR EYESDoNotoperatethisequipmentwithoutwearingOSHAapprovedsafetyglasses.Observeallapplicablelocal,stateandfederalsafetyregulations.SeeFigure9andOSHA29CFR1910.133.

Whenfillingtheblastvesselandduringtheblastoperation,abrasivecanbeblowninthefaceandeyesofoperators.WearOSHAapprovedsafetyglasses.SeeFigure9andOSHA29CFR1910.133.

WARNING

PROTECT YOUR LUNGSDoNotoperatethisequipmentwithoutwearingOSHAapprovedrespiratoryprotection.Abrasiveblastingproducesdustcontaminatedwithtoxicsubstancesfromtheabrasiveused,thecoatingbeingremoved,andtheobjectbeingblasted.ThisdustmaycontainSilicawhichcancausesevereandpermanentlungdamage,cancer,andotherseriousdiseasesifinhaled.DoNotbreathethedust.DoNotrelyonyoursightorsmelltodetermineifdustisintheair.Silicaandothertoxicsubstancesmaybeintheairwithoutavisibledustcloud.Ifair-monitoringequipmentforSilicaisnotprovidedattheworksite,thenallpersonnelMUSTwearappropriaterespiratoryprotectionwhenusingorservicingthisequipment.Breathingairsuppliedtorespiratorsmustbeofacceptablequality.ConsultyouremployerandOSHAregardingtheappropriaterespiratoryprotectionandbreathingairquality.SeeFigure9,andOSHA29CFR1910.134.

BREATHING AIR QUALITYDoNotusebreathingairthatdoesnotmeetOSHAClassDstandards.Extremecautionmustbetakenwhenselectingasourceofbreathingair.Breathingairprovidedbyanoil-lubricatedaircompressorcancontaincarbonmonoxideandthereforeuseofacarbonmonoxidedetectorisrequired(SeeFigure9).Carbonmonoxidecanbeinthecompressedairproducedbyanoillubricatedaircompressorwhenitisoperatedatextremelyhightemperature;thereforeahightemperaturealarmisrequiredtoalerttheoperatorswhenthisconditionexists.ReferenceOSHA29CFR1910.134(i).

Extremecautionmustbetakenwhenconnectingtofactoryairsources.Factoriescanhavesourcesofcompressedgasessuchasnitrogenwhichisfatalifusedasabreathingairsource.Verifythattheairsourceisbreathableair.

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BreathingairmustmeetOSHAClassDstandards.UseofbreathingairsourcesthatdonotmeetClassDstandardscancauseasphyxiationandresultindeath.Verifythatallairsourcesarebreathablequalityanduseahigh-temperaturealarmandacarbonmonoxidemonitorwhenrequired.SeeFigure9andOSHA29CFR1910.134(i).

EnclosedblastareasmustbeventilatedtoreduceairbornedusttoanacceptablelevelasrequiredbyOSHA29CFR1910.1000

DANGER

PROTECT YOUR HEARINGDoNotoperatethisequipmentwithoutwearingOSHAapprovedhearingprotection.Observeallapplicablelocal,stateandfederalsafetyregulations.SeeFigure9andrefertoOSHA29CFR1910.95.

Loudnoiseisgeneratedbytheblastnozzleandtheblowdownoperationofthisequipment.WearOSHAapprovedhearingprotection.SeeFigure9andrefertoOSHA29CFR1910.95.

WARNING

PROTECT YOUR PERSONAbrasiveblastingproducesdustcontaminatedwithtoxicsubstancesfromtheabrasiveused,thecoatingbeingremoved,andtheobjectbeingblasted.Allblastoperatorsandotherpersonnelinvolvedintheblastoperationorinthevicinityoftheblastoperationshouldwearprotectiveclothing.Theprotectiveclothingshouldbedisposableorwashableworkclothesthatshouldberemovedattheworksitesothatcontaminateddustisnottransferredintoautomobilesorhomes.SeeFigure9andrefertoOSHA29CFR1910.94and1910.134.

ADHERE TO ALL REGULATIONSDoNotoperatethisequipmentwithoutobservingalllocal,state,andfederalsafetyregulationsincluding,butnotlimitedto,OSHA(OccupationalHealthandSafetyAdministration).

STAY ALERTDoNotoperatethisequipmentwhenyouaretiredorfatigued.Usecautionandcommonsensewhileoperatingand/orperformingmaintenanceonthisequipment.

DO NOT USE DRUGS, ALCOHOL OR MEDICATIONDoNotoperatethisequipmentwhileundertheinfluenceofdrugs,alcohol,oranymedication.

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PROTECT BYSTANDERSDoNotallowblastequipmentoperatorsandotherpersonneltoenterthevicinityoftheblastoperationwithoutprovidingrespiratoryprotectiveequipmentthatmeetsOSHAregulations.IfdustconcentrationlevelsexceedthelimitationssetinOSHA29CFR1910.1000thenrespiratorsarerequired.

KEEP CHILDREN AND VISITORS AWAYDoNotallowchildrenorothernon-operatingpersonneltocontactthisequipmentortheconnectinghosesandcords.Keepchildrenandnon-operatingpersonnelawayfromworkarea.

AVOID DANGEROUS ENVIRONMENTSDoNotoperatethisequipmentwithoutfamiliarizingyourselfwiththesurroundingenvironment.Theblastoperationcreateshighlevelofnoisewhichwillpreventtheoperatorfromhearingotherpossibledangers(i.e.Trafficormovingequipment).Insuchsituationsastand-bywatchpersonmaybenecessarytopreventinjurytopersonnel.

DoNotusethisequipmentinareasclutteredwithdebris.Debrisintheworkareacancreatetrippinghazardswhichcancausetheoperatortoloosecontroloftheblasthoseandresultininjurytooperatingpersonnel.Keepworkareacleanandwelllit.Whenworkingatanelevatedlocation,payattentiontoarticlesandpersonsbelow.

DoNotoperatethisequipmentinelevatedareaswithoutusingfallprotectionequipment.Certainapplicationsofthisequipmentmayrequiretheuseofscaffolding.Useofscaffoldingcreateshazardoussituationssuchastrippingandfallhazardswhichcanresultinseriousinjuryordeathtooperatingpersonnel.ConsultOSHA29CFR1910SubpartD.

DoNotblastobjectsthatarenotproperlysecured.Theblastoperationcancausetheblastedobjecttoshiftormove.Extremelylargeobjectstobeblastedcancreateacrushhazardtooperatingpersonnelwhichcanresultinseriousinjuryordeath.Properlysecuretheobjecttobeblasted.

DoNotblastobjectsusedtostoreflammablematerials.Theblastoperationcancausesparkswhichcanignitefumesorresidualflammablematerialsinsideenclosedcontainerswhichcanexploderesultinginseriousinjuryordeathtooperatingpersonnel.

ELECTRICALLY GROUND EQUIPMENTStaticelectricityisgeneratedbytheabrasiveflowthroughtheblasthose.Topreventstaticelectricalshocktooperatingpersonnelonlyusestaticdissipatingblasthoseandinstallagroundingstrapontheabrasiveblaster.SeeDeadmanValve/Switchonpage30andAbrasiveBlasterSetupProcedureonpage35.

MAINTAIN VESSEL INTEGRITYDoNotoperatethisequipmentwiththepressurevesseldamaged,orwithanypartofitwornordamaged.DoNotoperatethisequipmentinaconditionthatmaycausefailureofthepressurevessel.SeeDoNotModifyVesselandCheckforDamagedPartsonpages13-15.

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AnabrasiveblasterisaPressurizedVessel.Alterations,damage,ormisuseofthepressurevesselcanresultinrupturing.Damagedorincorrectcomponentsusedontheabrasiveblastercanresultinrupturing.Thecompressedairinsideapressurizedvesselcontainsadangerouslyhighlevelofenergywhichcanpropelobjectsandcauseseriousinjuryordeath.

DANGER

NEVER OPERATE OVER MAXIMUM WORKING PRESSUREDoNotoperatethisequipmentabovemaximumallowableworkingpressure(MAWP)atmaximumoperatingtemperature(°F)shownontheAS1210-2010Class3nameplateattachedtothevessel.SeeKnowyourEquipmentonpage8andMaintenance&InspectionInstructions(list#1)onpage44.

INSTALL PRESSURE RELIEF DEVICEDoNotoperatethisequipmentwithoutapressurereliefdeviceinplace.TheAS1210-2010Class3requiresthatallvesselsbeequippedwithpressurereliefdevicespriortoinstallation.Thepressurereliefdevicemustbesetatthemaximumallowableworkingpressureoftheabrasiveblaster.SeetheAS1210-2010Class3nameplateattachedtothevesseltypicallylocatedabovethehandyway.SeeAbrasiveBlasterSetupProcedure(list#2)onpage35forinformationregardingthepressurereliefvalve.

NEVER OPERATE BEYOND ALLOWABLE TEMPERATURE RANGEDoNotoperatethisequipmentabovethemaximumallowabletemperatureattheallowablepressureorbelowtheminimumdesignmetaltemperature(MDMT)shownonthepressurevesselnameplate.Thecharacteristicsofthepressurevesselmetalareweakenedwhenthetemperatureisoutsidetheoperatingrange.Operatingthepressurevesseloutsideofallowabletemperaturerangecanresultinrupturingandcauseseriousinjuryordeath.

AS1210-2010 CLASS 3 NAMEPLATE REQUIREDDoNotoperatethisequipmentiftheAS1210-2010Class3pressurevesselnameplateismissing.ContactBlastOnefortechnicalsupport.

DO NOT MODIFY VESSELDoNotmodifyoralteranyabrasiveblaster,blastequipment,orcontrolsthereofwithoutwrittenconsentfromBlastOne.DoNotweld,grind,orsandthepressurevessel.Itwillnotbesafetooperate.Non-authorizedmodificationscouldleadtoseriousinjuryordeath.Non-authorizedmodificationswillvoidthewarrantyandtheAS1210-2010Class3certification.

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AnabrasiveblasterisaPressurizedVessel.Thecompressedairinsideapressurizedvesselcontainsadangerouslyhighlevelofenergywhichcanpropelobjectsandcauseseriousinjuryordeath.Depressurizevesselbeforeperforminganymaintenance.SeeAbrasiveBlasterDepressurizingProcedure(Blowdown)onpage36.

DANGER

DO NOT HAMMER ON VESSELDoNothammeronorstrikeanypartofthepressurevessel.Hammeringonthepressurevesselcancreatecracksandcauserupturing.

FIRE DAMAGE NOTICEDoNotoperateifthepressurevesselhasbeendamagedbyfire.Ifdamaged,takeoutofserviceimmediatelyandhaveitinspectedand/orrepairedbyaqualifiedfacility.ContactBlastOnefortechnicalsupport.

INSPECT VESSEL REGULARLYDoNotoperatethisequipmentwithdamagetothepressurevessel.Itisnotsafe.Inspectoutsideandinsideofthepressurevesselregularlyforcorrosionordamage(i.e.dents,gougesorbulges).Ifdamaged,takeoutofserviceimmediatelyandhaveitinspectedand/orrepairedbyaqualifiedfacility.ContactBlastOnefortechnicalsupport.SeeMaintenance&InspectionInstructionsonpage44.

CHECK FOR LEAKS IN VESSELDoNotoperatethisequipmentifthereisaleakinthepressurevessel.Ifleaking,takeoutofserviceimmediatelyandhaveitinspectedand/orrepairedbyaqualifiedfacility.ContactBlastOnefortechnicalsupport.

NEVER MODIFY BLOW DOWNDoNotconnecttheblowdownonthisequipmentontoacommonheaderwithanyotherunitofanydescription,oranyothersourceofcompressedair,withoutfirstmakingsureacheckvalveisusedbetweentheheaderandthisunit.DoNotinstallthisequipmentsharingpipingwithanotherunitofhigherdischargepressureandcapacity.Asafetyhazardcouldoccurintheformofaback-flowcondition.

DEPRESSURISE VESSEL BEFORE PERFORMING MAINTENANCEDoNotremove,repair,orreplaceanyitemonthisequipmentwhileitispressurized.DoNotattempttoperformmaintenanceorloadabrasivewhilethisequipmentispressurizedorisevencapableofbeingpressurized.Thismeanstheinletballvalveshouldbeclosedandtheairsupplyshouldbeshutoffordisconnected.Anytimethemanualblowdownvalveiscloseditshouldbeassumedthattheabrasiveblastvesselispressurized.

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ALWAYS USE REMOTE CONTROLSDoNotsell,rent,oroperateabrasiveblasterswithoutremotecontrols.OSHAregulationsrequireremotecontrolsonallabrasiveblasters.Allabrasiveblastersmustbeequippedwithautomatic(deadman)typeremotecontrols(eitherpneumaticorelectric).Failuretouseremotecontrolscancauseseriousinjuryordeathtotheoperator(s)orotherpersonnelintheblastingarea.ReferenceOSHA29CFR1910.244(b).

NEVER USE BLEEDER TYPE DEADMAN VALESDoNotusebleedertypedeadmanvalvesonanyBlastOneabrasiveblaster.TheuseofA-BEC,Clemco,orasimilarbleedertypedeadmanvalvecan,withoutwarning,causeunintentionalstartupwhichcanresultinseriouspersonalinjury.Aparticleofdirtfromtheairhosecanplugthebleedholeinthedeadmanvalveandcausetheblastoutlettoturnon.

CHECK FOR DAMAGED PARTSDoNotusethisequipmentwithdamagedcomponents.Damagedcomponentscanfailduringoperationandresultinseriousinjuryordeathtooperatingpersonnel.Periodicallycheckallvalves,hoses,andfittingstoseethattheyareingoodcondition.Repairanycomponentthatshowsanysignofwearorleakage.SeeMaintenance&InspectionInstructionsonpage44.

ALWAYS USE SAFETY PINS ON HOSE COUPLING CONNECTIONSDoNotusethisequipmentwithouthosecouplingsafetypinsinplaceandhosewhipchecksinstalledonallairandblasthoses.Allblasthosecouplingsandairhosecouplingshavepinholesthatmustbesafetypinnedtopreventaccidentaldisconnections.Accidentalhosedisconnectioncancauseseriousinjuryordeath.SeeWaterSystemonpage32andMaintenance&InspectionInstructions(#6)onpage46.

ALWAYS USE CORRECT REPLACEMENT PARTS AND ACCESSORIESDoNotusereplacementpartsoraccessoriesthatarenotratedforpressuresequaltoorhigherthantheabrasiveblasteroperatingpressure.Improperhosesand/orfittingsusedon,orconnectedtoyourabrasiveblastercanruptureandcauseseriousinjuryordeath.

DoNotusereplacementpartsthatarenotBlastOneoriginalfactoryreplacementparts.Non-originalpartsmaynotfitproperlyandcancauseequipmentdamageand/orfailurewhichcanresultinseriousinjurytooperatingpersonnel.ConsultBlastOnefortechnicalsupport.

UseofreplacementcomponentsthatarenotBlastOneoriginalfactoryreplacementpartsmayresultinequipmentfailurewhichcanresultinseriousinjurytooperatingpersonnel.

WARNING

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ALWAYS USE CORRECT PRESSURE RATED ACCESSORIESDoNotuseairreservoirsormoistureseparatortanksthatarenotratedforuseincompressedairapplications.Airreservoirsandmoistureseparatortankslargerthan6inchesinsidediametermusthaveanAS1210-2010Class3codestamp.

AnairreservoirormoistureseparatortankisaPressurizedVessel.Thecompressedairinsideapressurizedvesselcontainsadangerouslyhighlevelofenergywhichcanexplodepropellingobjectsandresultinseriousinjuryordeathtooperatingpersonnel.AirreservoirandmoistureseparatortanksmustbeASMEcodedtanks.

DANGER

NEVER AIM BLAST NOZZLE TOWARDS ANY PERSONDoNotaimtheblastnozzletowardsyourselforanyperson.Systemmalfunctioncancauseaccidentalstartupandresultininjurytopersonnel.

NEVER USE ABRASIVE NOT INTENDED FOR BLAST EQUIPMENTDoNotuseabrasiveblastmediacontainingfreeSilica.Silicacancausesilicosisorotherrelatedrespiratorydamage.Verifythattheabrasiveisintendedforuseinblastingequipment.Personalprotectiveequipment,includingairlinefiltersandrespirators,mustbeusedforallabrasiveblastingoperations.Observeallapplicablelocal,stateandfederalsafetyregulations.SeeFigure9andreferenceOSHA29CFR1910.134.

CHECK ABRASIVE FOR DEBRISDoNotuseblastabrasivethatcontainstrashorotherdebris.Trashordebriscancreateablockageandcauseequipmentmalfunction.Screenrecycledabrasivetoremovetrash.

STOP OPERATION IMMEDIATELY IF ANY ABNORMALITY IS DETECTEDDoNotoperatethisequipmentifanythingabnormalisseenduringoperation.Stopoperationimmediatelyforinspection.

MAINTAIN WARNING DECALSDoNotremove,cover,obstruct,orpaintoveranywarnings,cautions,orinstructionalmaterialattached.Warningdecalsmustbeinstalled,maintained,andlocatedtobevisibleandwithenoughlightforlegibility.SeeWarningonpage4andMaintenance&InspectionInstructions(#11)onpage47.

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SAVE THIS OPERATION AND MAINTENANCE MANUALRefertothisoperationandmaintenancemanualasneededaswellasanyadditionalinformationincludedfromothermanufacturers.Neverpermitanyonetooperatethisequipmentwithouthavinghim/herfirstreadthismanualandreceivepropertraining.Makethismanualreadilyavailabletoalloperatingandmaintenancepersonnel.Ifthemanualbecomeslostorillegiblereplaceitimmediately.Thisoperationandmaintenancemanualshouldbereadperiodicallytomaintainthehighestskilllevel;itmaypreventaseriousaccident.

SAFETY REFERENCESSeeSafetyInformationSourcesonpage72forsafetyinformationsourcesandcontactinformation.Usethesesourcestoobtainadditionalinformationregardingallaspectsofblastoperationsafety.UseofreplacementcomponentsthatarenotBlastOneoriginalfactoryreplacementpartsmayresultinequipmentfailurewhichcanresultinseriousinjurytooperatingpersonnel.

18

SPECIFICATIONS & GENERAL INFORMATION

NOTES TO DISTRIBUTORS AND OWNERS1. Verifythatthedeadman,twinline(orcord),andtheoperationandmaintenancemanualare

withtheblastervesselwhenitisreceived.Verifythatthedeadman,twinline(orcord),andtheoperationandmaintenancemanualarewiththeblastervesselwhenitisdeliveredtothepurchaser.

2. Thisequipmentisintendedforknowledgeableandexperiencedusers.Nopersonorpersonsshouldbeallowedtooperatethisequipmentwithoutfirstreceivingpropertraininginabrasiveblastingoperationanduseofthisequipment.

3. ImmediatelynotifyBlastOneofanyinstancesofuseofthisequipmentinanymannerotherthantheintendedapplication.SeeSystemRequirements&PPEonpage21.

4. Onlyqualifiedpersonnelshouldloadandunloadthisequipmentforshipping.Slingsorotherliftingdevicesmustonlybeattachedtothedesignatedliftingpoints(SeeBreathingAirQualityonpage10).

5. Forfurtherinformationcontact:

BlastOneInternational 1-12BruceAvenue, Marleston,SouthAustralia5033

Phone:1800882229 Fax:(08)82922001 Website:www.BlastOne.com.au

MINI ABRASIVE BLASTING SYSTEM OPERATIONAL SPECIFICATIONSMaximumWorkingPressure 150psig@250°F(seeASMEnameplate)

MinimumMetalTemperature -20°F@150psig(seeASMEnameplate)

AirConsumption SeeBlastingDatatable1onpage73

AbrasiveConsumption SeeBlastingDatatable2onpage73

BlastHoseSize SeeBlastingDatatable3onpage74

Electricalrequirements SeeLiftingDiagramonpage20

Abrasivecapacity M11:1.8cuft M21:2.0cuft M31:3.0cuft

19


IMPORTANT REFERENCE NUMBERSFillintheMiniAbrasiveBlastermodelnumberandserialnumberintheblankspacesbelow.Thesewillbeusedforreferencewheneverserviceormaintenanceisrequired.

M11SlurryBlasterPartNumber________________________________________________

M11SlurryBlasterModelNumber______________________________________________

M11SlurryBlasterSerialNumber______________________________________________

VESSEL INFORMATION1. AllpressurevesselsusedinMiniAbrasiveBlastersaremanufacturedinstrictaccordancewith

theprovisionsoftheASMECodeSectionVIII,Div.1.ShouldManufacturer’sDataReportsberequired,theymaybeobtainedfromBlastOneforasmallfee.

2. Inordertomaintainthehighlevelofqualityandqualitycontrolusedinthemanufactureofthisvessel,itisrequiredthatanyandallweldedrepairstothisvesselbeperformedbyareputableshopholdingaNationalBoard“R”Stampand/oranASME“U”stamp,dependingonstateorcitylaw.WeldingonthevesselperformedbyweldersnotproperlyqualifiedpertheASMECodevoidstheASME/NBintegrityofthatparticularvessel.

DIMENSIONAL SPECIFICATIONS

MODEL NO. PART NO. HEIGHT INCHES (MM)WIDTH INCHES (MM)

LENGTH INCHES (MM)

WEIGHT LBS (KG)

M 11 8720-011 48(1219) 22(559) 33(838) 186(84)

M 21 8720-021 50(1270) 24(610) 33(838) 294(133)

M 31 8720-031 56(1422) 24(610) 33(838) 307(139)

20


LIFTING DIAGRAM

Figure7

Figure8

21

SYSTEM REQUIREMENTS & PPE

COMPRESSED AIR REQUIREMENTSTheprimaryairconsumptionisbytheblastnozzle(s).Thisusagecanvarygreatlydependinguponthenumberofblastoutlets,nozzlesizeofeachoutlet,andtheblastpressure.SeeTable1inBlastingDataonpage73forairconsumptionbynozzlesizeatvariouspressures.

AIR COMPRESSOR SIZETheaircompressormustbelargeenoughtosupply:

• Thesumofblastairrequirementsforeachnozzleatthehighestpressurethatwillbeused.(SeeBlastingData,Table1onpage73).

• The12CFMbreathingairsuppliedtotheblastoperatorrespirator.Note: Reference OSHA regulations regarding requirements for breathing air, especially when an oil lubricated air compressor is used.

BLAST SYSTEM AIR SUPPLY LINETheairsupplyhoseandfittingsmustberatedataminimumof150psioperatingpressure.Theairsupplyhosefromtheaircompressortotheblastunitshouldbeatleastthesamediameterastheairinletpiping(seeDrawing&PartsListsonpage49).Thissizehosewillbelargeenoughtosupplytherequiredairflowtooperatetheblastunitcontrolsandeachblastnozzle.Note: If other equipment will be using the same source of air as the abrasive blaster, install a check valve at the air inlet. This will prevent back flow, which would carry abrasive into the control system.

BLAST SYSTEM AIR PRESSUREThemaximumoperatingpressurefortheabrasiveblasterisstampedontheASMEnameplateattachedtothevessel.TheMiniabrasiveblasterisequippedwithasystemairpressureregulatortoadjustblastpressurehowever,itisimportantthattheairsupplytothecontrolsystembeaminimumof55psig.Forthatreasontheairsupplytotheblastcontrolsistakenupstreamoftheregulator.SeeFigure14and15.

BLAST SYSTEM AIR QUALITYMoisturecondensationinablastsystemcausesabrasiveflowproblems.Condensationoccurswhenthehotvapourfilledcompressedaircoolsasitreachestheabrasiveblaster.Therefore,amoistureremovaldeviceisrecommended(i.e.Coalescingmoistureseparator,air-cooledaftercoolerordeliquescentdryer).

ELECTRICAL REQUIREMENTSOnunitsequippedwithelectricblastcontrolsthesupplyvoltageis12Vdcor24Vac.Themaximumpowerrequiredis:

1-outletwithoutabrasivecut-off:7watts

1-outletwithabrasivecut-off:14watts

22


ABRASIVE SELECTIONAbrasiveselectionislikelythemostdifficultdecisionrelatedtotheblastoperation.Choiceofabrasiveisbasedonfactorssuchasblastapplicationtype,desiredfinish,coatingrequirements,characteristicsofobjecttobeblasted,cost,abilitytorecycle,availableequipment,safety,andenvironmentalconstraints.

Therearemanyabrasivesavailablethatareeithernatural,manufactured,orprocessingby-products.Abrasivesareavailableinvaryingsizes,shapes,andhardness.Thesecharacteristicsdeterminetheresultingeffectonthesurfacetobeblastedandlimitationsofitsuse.Theeffectsontheblastedsurfacearemeasuredbyitsdegreeofcleanlinessandthesurfaceprofile.StandardsandrequiredlevelsofthesemeasurementsareestablishedbyorganizationssuchasSteelStructuresPaintingCouncil(SSPC),NationalAssociationofCorrosionEngineers(NACE)andcoatingmanufacturers.SeeSafetyInformationSourcesonpage72forcontactinformationoftheseorganizations.Usethesesourcestoobtaininformationregardingallaspectsofsurfacepreparationandabrasiveselectionguidelines.

Theabrasiveblasterisdesignedforhighproductionopenabrasiveblastingandisbestforusewithmineralandslagabrasives.Itistheresponsibilityoftheemployerandoperatorstoselecttheproperabrasive.Itistheresponsibilityoftheemployertomakecertainthattheabrasiveselectedissafetouseforabrasiveblasting.

AlwaysobtaintheMaterialSafetyDataSheet(MSDS)fortheabrasivetobeused.TheMSDSprovidesthechemicalmakeupoftheabrasive.DoNotuseabrasivescontainingtoxicmaterials.RefertoOSHA29CFRforacceptablelimitsofvarioustoxicsubstancesandadditionalmeasurestobetakentoprotectoperatingpersonnel.Alwaysuseabrasivescontaininglessthan1%ofcrystallinesilica.AlwaysuseaNIOSHapprovedrespiratorwhenhandling,loadingandcleaningupabrasives.OrganicsubstanceswhicharecombustiblemayonlybeusedinautomatedblastsystemswithventilationthatmeetsOSHA29CFR1910.94

WARNING

BREATHING AIR QUALITYAllblastoperatorsmustbesuppliedwithandrequiredtouseNIOSHapprovedair-fedrespirators.BreathingairsuppliedtotheserespiratorsmustmeetGradeDairqualitystandardsasspecifiedbyOSHA29CFR1910.134(i)andtheCompressedGasAssociationSpecificationsANSI/CGAG-7.1.Consultthesespecificationswhenselectingasourceofbreathingair.

Breathingairmustbeclean,dry,contaminant-free,andprovidedatapressureandvolumespecifiedbyNIOSH.UseNIOSHapprovedairfiltersonallsourcesofbreathingair.SeeFigure9.

Breathingairfiltersdonotremovecarbonmonoxideoranyothertoxicgases.Useacarbonmonoxidemonitortodetectunacceptablelevels.ConsultOSHA29CFR1910.134(i).

DANGER

23


Manysourcesofbreathingairareavailablesuchasaircylinders,free-airpumps,oil-lessaircompressors,andoillubricatedaircompressors.Themostcommonlyusedisthesameaircompressorthatisusedfortheblastairwhichmostoftenisoillubricated.Breathingairprovidedbyanoil-lubricatedaircompressorcancontaincarbonmonoxideandthereforerequirestheuseofacarbonmonoxidedetector(SeeFigure9).Carbonmonoxidecanbeinthecompressedairproducedbyanoil-lubricatedaircompressorwhenitisoperatedatextremelyhightemperature;therefore,ahightemperaturealarmisrequiredtoalerttheoperatorswhenthisconditionexists.

Oillubricatedaircompressorscanproducecarbonmonoxide.Carbonmonoxidecancauseasphyxiationandresultindeath.Useahigh-temperaturealarmandacarbonmonoxidemonitorwhenanoillubricatedaircompressorisusedtosupplybreathingair.ConsultOSHA29CFR1910.134(i).

DANGER

PERSONAL PROTECTIVE EQUIPMENT (PPE)Abrasiveblastinghasmanyhazardsthatmaycauseinjuriestooperators.ToprotectoperatorsfrominjuryeachmustbesuppliedwithandrequiredtousePersonalProtectiveEquipment.TheOccupationalHealthandSafetyAdministration(OSHA)requirestheemployertoassesstheworkplacetodeterminewhatPPEisnecessaryandsuppliedtoeachoperator(Reference29CFR1910SubpartI).OSHArequiresthatthisequipmentmeetorbeequivalenttostandardsdevelopedbytheAmericanNationalStandardsInstitute(ANSI).Figure9belowidentifiestheminimumpersonalprotectiveequipmentrequiredforeachabrasiveblastoperator.AlsoidentifiedaretheOSHAreferencesforeachandtheANSIstandardeachPPEitemmustmeet.

AllPPEclothingandequipmentshouldbeselectedforsafedesignandqualityofconstruction.Selecteachforproperfitandforcomfortwhichwillencourageoperatoruse.

24


Figure9

25

GENERAL OPERATION

ThefunctionoftheBlastOneabrasiveblasteristoprovideamixtureofoperatorselectivewetordryabrasiveandcompressedairtoablastnozzle.Theabrasiveblaststreamthroughtheblastnozzleisusedforremovingrust,paint,orotherunwantedsurfacedefects.Afterabrasiveblasting,thesurfaceisreadyfornewpaintorcoating.

Theabrasiveblasterisoneofagroupofcomponentsusedinanabrasiveblastingjob.Thetypicalcomponentsareanaircompressor,moistureremovaldevice,anabrasiveblaster,blasthose,ablastnozzle,operatorpersonalprotectiveequipment,andblastabrasive.SeeFigure10.

Theblastabrasiveisloadedintotheabrasiveblasterthroughatopfillport.Allthecompressedairmustberemovedfrominsidetheabrasiveblasterbeforeitcanbefilledwithabrasive.Theabrasivecanbebagloaded,orloadedfromarecoverydevice.Tobeginblastingthefillportpopupvalveismanuallyclosedandtheabrasiveblasterisfilledwithcompressedairfromtheaircompressor.Sincemoisturecreatesproblemsintheblastoperation,itiscommonforthecompressedairtobefedthroughamoistureremovaldevice,suchasaBlastOneAirPrepSystem.TheairpressureintheabrasiveblastvesselisequaltotheairpressureintheblasthosewhereitconnectsattheThompsonValveII.Thisequalpressureisneededtoallowtheblastabrasivetoflowdownwardbygravity.TheabrasiveflowiscontrolledbytheabrasiveThompsonValveIIatthebottomoftheblaster.Atthispoint,theblastabrasiveflowsintotheblastairstreamandthroughtheblasthose.Thespeedofblastairandabrasivemixtureisgreatlyincreasedbytheblastnozzleontotheworksurface.Thehighspeedoftheairandabrasiveiswhatgivesittheenergytoblastrustandpaintoffofsurfaces.Theabrasiveblaststreamandthedustitcreatesisharmful,thereforeallblastoperatorsmustusepersonalprotectiveequipmentduringtheblastoperation.

AllthecomponentsrequiredfortheblastoperationareavailablefromBlastOne.

Figure10

26

GENERAL OPERATION

Figure11

SeeFigure11belowtohelpunderstandthegeneraloperation.Donotattempttooperatetheabrasiveblasterbeforereadingallsectionsofthismanualandfollowingallsetupprocedures.SeeAirSupplyConnectiononpage27throughHoseConnectiononpage34andPre-operationProceduresonpage35.

Theabrasiveblasterisdesignedtobeusedwithabroaderrangeofblastingabrasivesthanatypicalblaster.Theblasterhasfeaturesforblastingathighorlowpressureandhasfeaturesforimprovedabrasiveflowandflowcontrol.

Theblaster(#12)willpressurizewhentheblowdownballvalve(#1)isclosedandtheairinletballvalve(#5)isopened.Thecompressedairentersthemoistureseparator(#7)andthenisbranchedofftotheblastoutletandpressurizestheabrasiveblastvessel.Theairflowintotheblastvesselinternalpipingwillpushthepopup(#41)againstthegasket(#40).Thiswillsealtheabrasiveinletwhichallowstheairflowtofillandpressurizetheabrasiveblastvessel(#12).

Blastingbeginswhenthedeadmanlever(#26)ispresseddownwhichwillpneumaticallyorelectricallyopentheblastcontrolvalve(#13).Whenthecontrolvalveopensitsendsanairsignalthatopensboththeautomaticairvalve(#17)andtheThompsonValve®(#11).Compressedairwillpressurizetheblasthose(#25)whentheautomaticairvalve(#17)isopened.AtthesametimetheThompsonValve(#11)willopenandabrasivefallsthroughandintotheblastairstream.TheabrasiveflowcanbeincreasedordecreasedbyturningtheknobontopoftheThompsonValve.

Blastingstopswhenthedeadmanlever(#26)isreleased.Thiswillclosetheblastcontrolvalve(#13)andventtheairsignaltotheautomaticairvalve(#17)andtheThompsonValve(#11).Whenthesignalairvents,bothvalvesspringreturnintotheir“normallyclosed”position.Theabrasiveblaster(#12)remainspressurizedwhentheautomaticairvalveandThompsonValveareturnedoff.Theabrasiveblaster(#12)isdepressurizedbyclosingtheairinletballvalve(#5)andthenopeningtheblowdownballvalve(#1)tocompletelyventthecompressedair.

27

GENERAL OPERATION

AIR SUPPLY CONNECTIONAirissuppliedtotheabrasiveblasterthroughahoseconnectionattheairinletapprovedminsuporthreadedhoseconnection(#6).Theairsupplyhoseconnectedtotheabrasiveblastermustbethesamediameterastheairsupplypiping.SeethedrawingsandpartslistsinDrawing&PartsListsonpage49andrefertoImportantReferenceNumbersonpage18andWaterSystemonpage33.

AIR INLET BALL VALVE (PRESSURIZE)Theairinletballvalve(#5)isusedtoturnonandturnofftheairflowtotheabrasiveblaster.Whentheinletballvalveisopenedairflowwillautomaticallyclosethepopupvalveattheabrasiveinletandpressurizetheabrasiveblaster(seeFigure12).Theblowdownballvalve(#1)mustbeclosedbeforeopeningtheairinletballvalve.

Theabrasiveblasterisapressurizedvessel.Propelledobjectswillcauseseriousinjuryordeath.Readandfollowallpre-operationandoperatingprocedurespriortopressurizingtheabrasiveblaster.SeePre-operationProceduresonpage35andOperationInstructionsonpage40.

DANGER

BLOWDOWN BALL VALVE (DEPRESSURIZE)Theblowdownballvalve(#1)isusedtoreleaseallthecompressedair(depressurize)frominsidetheabrasiveblaster.Theabrasiveblastermustbedepressurizedtofillwithabrasiveorbeforeperforminganymaintenance.Theairinletballvalve(#5)mustbeclosedbeforedepressurizingtheabrasiveblaster.

Airborneparticlesandloudnoisehazardsfromblowdownexhaustaircancauseseriousinjuryandlossofhearing.Wearapprovedeyeandearprotection.Stayclearofblowdownairpath.DONOTplacehandsorotherbodypartsintheblowdownairpath.Makesurenopersonnelareintheblowdownairpath.

WARNING

28

GENERAL OPERATION

Pinchpointhazard.Vesselpressurizationwillclosethepopup.Keepfingersclearofthepopupopening.Disconnectairsupplypriortoperformingpopupmaintenance.

WARNING

POPUP WITH EYEBOLT (ABRASIVE INLET)Theblasterisfilledwithabrasivethroughtheopeningatthetopofthepressurevessel.Thisopeningissealedbythepopuphead(#36)whenitispulledupagainstthegasket(#35)andtheblasterispressurized.Whentheairinletballvalve(#5)isopened,airwillflowintotheblastvesselandtheairpressurewillcompressandholdthepopupagainstthegasket.SeeFigure12.

Figure12

AIR SUPPLYWhentheairinletballvalve(#5)isopenedtheairflowpassesthroughtheairfilter(#7)whichremovesmoisture,oilanddirtparticles.Thewaterthatisremovedbythefiltercanbedrainedbyopeningthepetcockvalve(#9)locatedatthebottomofthefilter.Thisvalveshouldbeleftslightlyopenedanytimetheblasterisinoperation.Thisallowswatertobedrainedasitisfilteredfromtheblastair.Afterpassingthefiltertheairflowbranchesofftosupplytheaccessorycontrols,theregulatedtank/blastairpressurepiping(#4)andthebypasspiping(#37).Theregulatedairpipingandthebypassairpipingarethetwowaystopressurizetheabrasiveblastvesselandsupplytheblastairline

29

GENERAL OPERATION

REGULATED TANK/BLAST PRESSURE REGULATORToblastobjectsthatarefragileitisnecessarytoreducetheblastairpressure.Thetankandblastairpressurecanbothbeadjustedbythepressureregulator(#4).Thepressureisadjustedbyturningtheknobontopoftheregulatorvalvebody(CW-increasespressure,CCW-decreasespressure).Thetank/blastpressureisshownbythepressuregauge(#8).Thebypassballvalve(#37)mustbeclosedtousetheregulatedairpressurepiping.Note: The air pressure regulator (#4) is non-relieving which means that when the pressure is decreased by turning the knob the tank air pressure will not reduce on the pressure gauge. The pressure will reduce only while blasting. The non-relieving feature prevents air from flowing backwards from the tank to the regulator which would carry abrasive.

FULL PRESSURE BYPASSThebypasspipingisadetouroftheregulatedairsupplytoprovidefulllinepressuretothetankandblastairline.Thisallowsblastingatfullpressurefortougherapplicationswithoutchangingthesettingoftheairpressureregulator(#4).Openballvalve(#37)tobypassthepressureregulatorandallowblastingatfullairpressure.Thenclosetheballvalve(#37)togobacktousingtheregulatedpressurecontrol.Note: Bypass piping is not available on model M11.

GATE VALVE (DIFFERENTIAL PRESSURE CONTROL)Whentheautomaticairvalveopensinletairsupplyflowsthroughthegatevalve(#18)totheThompsonValve(#11)whereitmixeswithabrasiveforblasting.Thepurposeofthegatevalveistoreducetheblastairpressureslightlybelowthetankpressure.Thisadjustmentiscalled“differentialpressure”(blastpressurelowerthantankpressure).DifferentialpressureisusedwhenblastingwithfinegrainabrasiveswhichdonotflowwelloutoftheblastvesselandthroughtheThompsonValve.Turnthegatevalvehandleclockwisetoclosethevalveanddecreaseblastpressure.Thiswillincreasethedifferentialpressurewhichwillincreaseabrasiveflow.Turnthehandlecounter-clockwisetodecreasedifferentialpressurewhichwilldecreaseabrasiveflow.Thisdifferentialpressureadjustmentmustbemadewhileblastingsothattheeffectsarevisible.Theblastpressureisindicatedbythepressuregauge(#38).Differentialpressurecanbeviewedonthedifferentialpressuregauge(#3).

AUTOMATIC AIR VALVETheautomaticairvalve(#17)isanormallyclosedvalvethatopenstosupplyblastairtotheblasthoseandblastnozzle(#25&#29).Theautomaticairvalveopenswhenitreceivesairtoitssignalport.Thishappenswhenthedeadmanlever(#26)ispresseddownwhichopenstheblastcontrolvalve(#13)sendinganairsignaltotheautomaticairvalve.Whenthedeadmanleverisreleasedtheairsignalfromtheblastcontrolvalveventsandautomaticairvalvespringclosestostopblastairtotheblasthoseandnozzle.

30

GENERAL OPERATION

THOMPSON VALVE® IITheThompsonValve(#11)isadual-purposevalve.First,itisanormallyclosedvalvethatopenstosupplyabrasiveintotheblastairstream.TheThompsonValveopenswhenitreceivesairtoitssignalport.Thishappenswhenthedeadmanlever(#26)ispresseddownwhichopenstheblastcontrolvalve(#13)sendinganairsignaltotheThompsonValve.WhenthedeadmanleverisreleasedtheairsignalfromtheblastcontrolvalveventsandThompsonValvespringclosestostopabrasiveflowtotheblasthoseandnozzle(#25&#29).

Secondly,theThompsonValve®(#11)isanabrasivemeteringvalve.WhentheThompsonValveisopentheabrasiveflowismetered(controlled)byanadjustableorifice.TheamountthisorificeopensiscontrolledbyturningtheknobatthetopoftheThompsonValve.Theknobsetsthestoppingpointoftheplunger.Turntheknobclockwisetoreducetheorificesizewhichdecreasesabrasiveflow.Turningtheknobcounter-clockwiseincreasestheorificesizewhichwillincreasetheabrasiveflowtotheblastnozzle(#29).TheThompsonValvespringretainerhaslinesonthesidetouseasreferencepointstotheamountthattheorificeisopen.Adjustmentstotheabrasiveflowshouldbemadebyturningtheknobalittleatatime.Testtheadjustmentbystartingtheblastforashortperiodtodetermineiffurtheradjustmentisneeded.

TheThompsonValveIIhasabuiltincleanoutportwhereaballvalvecanbeinstalled.Thisballvalvecanbeusedtopurge(blowout)trashthatblocksabrasiveflow.Thisisdonebyclosingtheabrasiveshutoffvalve(#10),openingthecleanoutvalve(#19),andthenpressingdownthedeadmanlever(#26).TheblastairflowsthroughtheThompsonValveandpurgesanytrashthroughthecleanoutvalve.Note:Iftheabrasiveblasterisequippedwiththeabrasivecut-offfeaturesetthecut-offvalve(orswitch)totheon-positionfortheThompsonValve®toopenforpurging.

Airborneparticlesandloudnoisehazardsfrompurgeaircancauseseriousinjuryandlossofhearing.Wearapprovedeyeandearprotection.Stayclearofpurgeairpath.DONOTplacehandsorotherbodypartsinthepurgeairpath.Makesurenopersonnelareinthepurgeairpath.

WARNING

ABRASIVE SHUTOFF VALVETheabrasiveshutoffvalve(#10)allowstheoperatortoremovetheThompsonValvefromtheblastvesselwithoutemptyingtheabrasive.Turntheabrasiveshutoffvalvehandletothehorizontalpositionwillblockabrasiveflowfromtheblastvessel(#12)intotheThompsonValve.Thenthespringclamp(#16)isremovedtoseparatetheThompsonValvefromblastvessel.

TheabrasiveblasterisaPressurizedVessel.Propelledobjectswillcauseseriousinjuryordeath.Depressurizevesselbeforeperforminganymaintenance.SeeAbrasiveBlasterDepressurizingProcedure(Blowdown)onpage36.

DANGER

31

GENERAL OPERATION

DEADMAN VALVE/SWITCHTheDeadmanvalve/switchispartofasystemthatcontrolstheblastoperation.Thedeadmanvalve/switch(#26)allowstheoperatortoremotelystartandstoptheblastoperation.TheDeadmanismountedattheendoftheblasthoseassembly(#25)closetotheblastnozzle(#29)togivetheoperatoreasycontroloftheblastoperation.

TheDeadmaniseitherapneumaticvalveoranelectricswitchdependingonthetypeofabrasiveblastercontrolsystem.Whenthedeadmanleverispresseddownitsendseitherapneumaticorelectricsignaltotheblastcontrolvalve(#13).Thecontrolvalveopensandsendsanairsignaltotheautomaticairvalve(#17)andtheThompsonValve(#11).

Pneumatic Deadman System

Whenthepneumaticdeadmanleverispresseddownairsupplyfromtheorangehoseofthetwinlinehose(#23)flowsintotheblackhose.Airflowsthroughtheblackhosetothesignalportofthecontrolvalve(#13)causingittoopenandsendairsignalstotheautoairvalve(#17)andtheThompsonValve®(#11).Whenthedeadmanleverisreleasedtheairsignaliscutoffandtheremainingairventsfromthebreather(#44).SeeFigure5.3andthedrawingsinDrawing&PartsListsonpage49.

Electric Deadman System

Whentheelectricdeadmanleverispresseddownitclosestheelectriccircuitandsupplieselectriccurrenttothecontrolvalve(#13).Thecontrolvalveopensandsendsairsignalstotheautoairvalve(#17)andtheThompsonValve®(#11).Whenthedeadmanleverisreleasedtheelectriccircuitiscutoffclosingthecontrolvalve.Thesignalairventsfromthebreather(#44).SeeFigure14.

Figure13

32

GENERAL OPERATION

Figure14

ABRASIVE CUT-OFFAnoptionalfeatureofablasterisanabrasivecut-off.Thepurposeoftheabrasivecut-offistoallowblastingairwithoutabrasive.Thisisusefulforblowingoffabrasivefromtheblasteditem.Toblastwithaironlysettheabrasivecut-offvalve(orswitch)totheoff-positionthenpressdownthedeadmanlever(#26).Thiswillsendacontrolsignaltotheautomaticairvalveonly,thereforeonlyblastairwillexittheblastnozzle(#29).Fortheabrasivecut-offtoworkasecondcontrolvalveisneededthatprovidesasignaltotheThompsonValve®separateoftheairsignaltotheautomaticairvalve.

Figure15

33

GENERAL OPERATION

ABRASIVE VIBRATORThepurposeoftheabrasivevibrator(#31)istovibratetheabrasiveinthepressurevessel(#12).SomeabrasivesdonotflowaswellasothersandthevibrationtothevesselimprovestheflowintotheThompsonValve®.Thelevelofvibrationiscontrolledbytheanglevalve(#15)whichcanalsoturnoffthevibration.

WATER SYSTEMThewatersystemoftheabrasiveblastergivestheoperatortheoptiontowetblast.Fineabrasivessuchassodiumbicarbonatecreatedustcloudsthatreducevisibility.Thewatermistcreatedbythewetblastattachment(#30)reducesthedustcloud.Astandardgardenwaterhoseisconnectedtothehoseconnection(#32).Thewaterthenflowsthroughandisfilteredbythey-strainer(#33).

They-strainerhasafinescreentoremovesmallparticlesofdebristhatmaycloguptheatomizingtipofthewetblastattachment(#30).Trashcollectedatthey-strainerelementisflushedoutbyopeningthedrainballvalve(#35).Thepetcockvalve(#27)allowstheoperatortocontrolhowmuchwaterisusedortoturnthewateroffcompletely.

BLAST HOSETheblastair/abrasivemixtureflowsfromtheThompsonValve®totheblastnozzle(#29)throughtheblasthoseassembly(#25).Thetypicallengthoftheblasthoseis50ft;howeverblasthoseextensionscanbeaddedforlongerlengths.Forhigherefficiencykeeptheblasthoseasshortaspossible.Increasedblasthoselengthcausespressuredropattheblastnozzlewhichreducestheblastefficiency.Forhigherefficiencyuseablasthosewithaninsidediameterthatisthreetimesthenozzlethroatdiameter.Keepblasthoseasstraightaspossible.Sharpbendscreatehighwearpoints.Staticelectricityisgeneratedbytheabrasiveflowthroughtheblasthose.Topreventstaticelectricalshocktooperatingpersonnelonlyusestaticdissipatingblasthoseandinstallagroundingstrapontheabrasiveblaster.

BLAST NOZZLETheblastnozzle(#29)isanimportantpartoftheblastoperationsincethesizeofitdeterminestheairflowandabrasiverequirement.Theamountofairflowandabrasivedeterminehowquickblastingcanbedone.Thelargerthenozzle,themoretheairandabrasivewillbeneeded.

Thelargerthenozzlesizethegreatertheblastproductivity.However,forafixedamountofairsupply,increasingthenozzlesizewillreducetheblastpressure.Forbestperformancetheblastpressuremustbemaintainedashighaspossible.Therefore,selectthenozzlesizebasedontheamountofairavailableandthenadjusttheabrasiveflowattheThompsonValve®accordingly.

Thenozzlesizecanbeidentifiedbyasmallnumbervisibleontheoutside.Thisnumberrepresentsthenozzlethroatdiameterinsixteenthsofaninch;forexample,a#5nozzlehasathroatdiameterof5/16”.SeethetablesinBlastingDataonpage73forapproximateairandabrasiveconsumptionforeachnozzle.Note:Forthebestpossiblemixtureofairtoabrasive,theblasthoseandpipingmustbeatleastthreetimesthesizeoftheblastnozzle.

34

GENERAL OPERATION

HOSE CONNECTIONAllairhose,blasthose,andthreadedcouplingshavepinholesthatalignwhenconnected.Topreventaccidentalhosedisconnectionssafetypinsmustbeinstalledthroughtheseholes.Asasecondarysafetymeasureeachhoseconnectionshouldalsoincludeahosewhipcheckthatwillholdthehoseifthereisanaccidentaldisconnection.ConnectonelooptoeachsideoftheconnectionandstretchoutasshowninFigure16below.Allairhose,blasthose,andthreadedcouplingshaveagasketthatsealstheconnectionandshouldbereplacedwhenairisleaking.

Figure16

35

PRE-OPERATION PROCEDURES

Failuretofollowtheproceduresbelowcouldresultinseriousinjuryordeath.Inadditiontotheseprocedures,completelyreadandunderstandallsectionsofthisabrasiveblasterOperationandMaintenanceManual.Theabrasiveblasterisapressurizedvessel.Propelledobjectswillcauseseriousinjuryordeath.Depressurizevesselbeforeperforminganymaintenance.SeeAbrasiveBlasterDepressurizingProcedure(Blowdown)onpage36.

DANGER

ABRASIVE BLASTER SETUP PROCEDURE (SEE FIGURE 18)1. Staticelectricityisgeneratedbytheabrasiveflowthroughtheblasthose.Topreventstatic

electricalshocktooperatingpersonnelonlyusestaticdissipatingblasthoseandinstallagroundingstrapontheabrasiveblaster.

2. DoNotoperatethisequipmentwithoutapressurereliefdeviceinplace.TheASMECoderequiresthatallvesselsbeprovidedwithpressurereliefdevices.Localregulationssetthespecificationsforpressurereliefvalves;thereforeitistheresponsibilityoftheowneroftheabrasiveblastertoinstallapressurereliefvalvethatmeetsallapplicableregulations.Thepressurereliefdevicemustbesetatthemaximumallowableworkingpressureoftheabrasiveblaster.SeetheASMEvesselnameplate(#39).

3. Makecertainthattheabrasiveblasterisnotpressurized.FollowthedepressurizingproceduregiveninAbrasiveBlasterDepressurizingProcedure(Blowdown)onpage36.


WARNING

Failuretousepersonalprotectiveequipmentcouldresultinseriousinjuryordeath.

WARNING

4. Properlyinstallthehandwaycover(#2)andgasket.SeeHandwayCoverInstallationProcedureonpage38.

5. Verifythatallrequiredpersonalprotectiveequipmentisavailableforeachoperatorandingoodoperatingcondition(safetyglasses,safetyshoes,earplugs,gloves,airlinefilter,respirator,&carbonmonoxidemonitor).Critical:Adheretoalllocal,state,andfederalregulationsincluding,butnotlimitedto,OSHA(OccupationalHealthandSafetyAdministration).Paycloseattentiontorequirementsregardingbreathingairquality.Whenanoil-lubricatedaircompressorisused,additionalrequirementsforahightemperaturealarmand/oracarbonmonoxidemonitorbecomenecessary.

36


Failuretoinstallsafetypinsonallblasthosecouplingscouldresultinseriousinjuryordeath.SeeHoseConnectiononpage34andMaintenance&InspectionInstructions(list#6)onpage46.

WARNING

Failuretoinstallsafetypinsonallairhosecouplingscouldresultinseriousinjuryordeath.SeeMaintenance&InspectionInstructions(list#6)onpage46.

WARNING

6. Screwnozzle(#29)intothenozzleholderatendoftheblasthoseassembly(#25).

7. Slidethewetblastattachment(#30)overtheendoftheblastnozzle(#29).

8. Hoseclampthedeadman(#26)totheblasthoseassemblyinacomfortablepositionbehindthenozzleholder.

9. Connectthemalefittingattheendofthewetblastwaterline(#24)totheswivelfittingonthewetblastattachment(#30).

10.Wiretiethewetblastwaterline(#24)andthetwinlinehose(#23)orelectricdeadmanextensioncordstotheblasthose(#25).

11.Connecttheblasthosecoupling(#22)tothehosecoupling(#36)ontheThompsonValve®(#11).Theninstallsafetypinsandahosewhipchecktopreventaccidentaldisconnectionsduringoperation.SeeHoseConnectiononpage34andMaintenance&InspectionInstructions(list#6)onpage46.

12.Connectthetwinlinehosequickdisconnects(20)ortheelectricdeadmanextensioncordtothematingdisconnectsontheabrasiveblasterpiping(#14).

13.Connectthewetblastwaterlinequickdisconnect(#21)tothequickdisconnect(#34)onthey-strainer.

14.Connectastandardgardenhosetothewaterinletconnection(#32)onthey-strainer.

15.Connecta150psirated(minimum)airsupplyhosetotheairinletcrowfoot(#6)andinstallsafetypinsandahosewhipchecktopreventaccidentaldisconnectionsduringoperation.SeeHoseConnectiononpage34andMaintenance&InspectionInstructions(list#6)onpage46.

ABRASIVE BLASTER DEPRESSURIZING PROCEDURE (BLOWDOWN)1. Closetheairinletballvalve(#5).Theballvalveisclosedwhenthehandleisfullyturnedtothe

positionshowninFigure18(handleperpendiculartobody).Thehandletabwillbottomagainsttheballvalvebodyintheclosedposition.

2. Slowlyopentheblowdownballvalve(#1).Astheblowdownballvalve(#1)isopenedairpressureinsidewillexhaustoutanddepressurizetheblastvessel(#12).

37



WARNING

Whenthepopupvalveopensafterdepressurizingabrasivecanbeblownoutoftheblastvesselandintothefaceandeyesoftheoperator.WearOSHAapprovedsafetyglasses.SeeFigure9.

WARNING

3. Theabrasiveblastvessel(#12)iscompletelydepressurizedwhentheairinletballvalve(#5)isclosedandtheblowdownballvalve(#1)isopenwithnoairflowfromit.Thepopuphead(#41)willfallopenwhentheblastvesseliscompletelydepressurized.

Figure17

38


HANDWAY COVER INSTALLATION PROCEDURE (SEE FIGURE 6.5(A))1. Checkthatthehandwaycover,crab,bolt,andgasketaredimensionallycorrectforthesize

handwayweldringofthepressurevessel.

a) Measureandwritedowntheinsidedimensions“A”and“B”ofthehandwayweldring.SeeFigure18(a).

b) Verifythesizeofthehandwayassemblybycomparingtheweldringmeasurementsfromstep“a”tothedimensionsshowninTable6.5(c).

c) Verifythatthedimensionsofthecover,crabs,bolts,andgasketmatchthecorrespondingdimensionsgiveninTable6.5(c).Note:Theactualdimensionsmayvarybyupto1/4”fromthosegivenin6”x8”HandywayDimensionstableonpage39.

d) Replaceanycomponentthatisnotdimensionalcorrect.Incorrectdimensionsindicatethatthecomponentispartofadifferentsizehandwayassembly.

ThehandwayassemblyispartofaPressurizedVessel.Useofincorrecthandwaycomponentswillresultinassemblyfailure.Assemblyfailurewillpropelobjectscausingseriousinjuryordeath.

DANGER

2. Inspectthehandwaygasketfortears,cracks,orotherwear.Replaceifnecessary.

3. Inspectthehandwayweldringsealingsurfaceinsidethevessel.Inspectthehandwaycoversealingsurface.Bothsurfacesmustbesmooth.

4. Placethegasketonthehandwaycoverthenfitboththroughtheopening.

5. Placethecoverandgasketinpositionagainsttheinsideedgeofthehandwayweldring.Applyapullingforcetoholdinpositionthenproceed.

6. Centrethegasketonthehandwayweldring.

7. Centrethehandwaycoveronthegasket.

8. Centrethehandwaycrabontheoutsideweldring.

9. Slidethehandwaycrabbolttotheinsideedgeoftheslotbeforetightening.SeeFigure18(a).

10.Whenallcomponentsarecentredandthecrabboltisbottomedintheslot,tightenthenutontotheboltwithawrenchuntilsnug.

11.Onlyaftercompletingallthepre-operationproceduresinPre-operationProceduresonpage35andtheabrasiveblastvesselisthenpressurized,re-tightenthenutwithawrenchuntilsnugagain.

12.Donotover-tightenthecrabnutandbolt.Over-tighteningcouldbendthecraboutofshaperesultinginmalfunctionoftheassembly.

13.Periodicallycheckforleaks.

39


Figure18

Figure19

COMPONENT A B

Weld Ring 6-5/8” 8-1/2”

HandywayCover 7-11/16” 9-7/8”

HandywayGasket 7-3/4” 9-3/4”

HandywayCrab 2-3/8” 8-3/4”

SquareHeadBolt 3/4”-10UNC 4-1/2”

6” x 8” Handyway Dimensions

40

OPERATION INSTRUCTIONS

FILLING THE BLASTER WITH ABRASIVE1. Theabrasiveblastermustbecompletelydepressurizedbeforefillingcanbegin.Depressurize

theabrasiveblasterperthedepressurizingprocedureinAbrasiveBlasterDepressurizingProcedure(Blowdown)onpage36.

Airborneparticlesandloudnoisehazardsfromblowdownexhaustaircancauseseriousinjuryandlossofhearing.Wearapprovedeyeandearprotection.Stayclearofblowdown7.0OperatingInstructionsairpath.DONOTplacehandsorotherbodypartsintheblowdownairpath.Makesurenopersonnelareintheblowdownairpath.

WARNING

Pinchpointhazard.Vesselpressurizationwillcompressthepopupagainstthepopupgasket.Keepfingersclearofthepopupopeningwhilepressurizingtheblastvessel.Disconnectairsupplypriortoperformingpopupmaintenance.

WARNING

2. Removethevessellid(#42)andscreen(#43)tocheckthatthepopup(#41)hasdroppedopen.Thisindicatesthattheblastvesselisdepressurized.SeeFigure20.

3. Filltheabrasiveblasterwithdryabrasivethoughthescreen(#43)toremoveunwantedtrash.Donotover-filltheblastvessel.Anexcessiveamountofabrasivepiledabovethepopup(#41)aftertheblastvesselisfullmaypreventthepopupfromclosingandsealingproperly.

4. Onlyaftercompletingallthepre-operationproceduresinPre-operationProceduresonpage35andFillingtheBlasterwithAbrasiveonpage40,andtheblastvesselisthenpressurizedperBeginningtheBlastingOperationonpage41,checkthepopupforleaks.Periodicallycheckthepopupforleaksthereafter.

Figure20

41


BEGINNING THE BLASTING OPERATION (SEE FIGURE 21)1. Theabrasiveblastermustbeproperlypreparedandalloperatingpersonnelmustbethoroughly

trainedbeforebeginningtheblastoperation.Completelyreadandunderstandallsectionsofthismanualbeforebeginningtheblastoperation.Seethepreoperationproceduresgivenin Pre-operationProceduresonpage35.

2. Performtherequiredinspectionsandmaintenancebeforebeginningtheblastoperation.SeetheinstructionsgiveninMaintenance&InspectionInstructionsonpage44.


DANGER

3. Fullyopenboththeabrasiveshutoffvalve(#10)andgatevalve(#18).

4. Ifwetblastingwillbeusedturnonthewatersupplytothey-strainer(#33).

5. Forinitialstartupbacktheknoboftheairpressureregulator(#4)allthewayoutbyturningtheknobcounterclockwiseuntilnoresistanceisfelt.Thenturntheknobclockwiseafewturnsforalowinitialpressuresetting.Furtheradjustmentcanbemadelaterasneeded.

6. Closetheblowdownballvalve(#1).Theballvalveisclosedwhenthehandleisperpendiculartothebody.

7. Thevesselmaynowbepressurizedbyslowlyopeningtheairinletballvalve(#5).

8. Checkthepopup,handway,hoses,andpipingforleaksafterpressurizing.Periodicallycheckforleaksthereafter.

9. Slightlyopenthepetcockvalve(#9)onbottomoftheairfiltertopermitmoisturetocontinuallydrainduringtheblastoperation.Onceeachdayopencompletelytoblowoutexcessaccumulation.

10.Thefollowingstepsareforblastpressureandabrasiveflowsettingwhichmayrequireseveraladjustmentsandtestingoftheblastflow.Itisrecommendedthattestingoftheblastbemadeonatestpiecesonottodamageanythingofvalue.

11.Settherequiredtankpressurebyturningtheknobonthetank/blastpressureregulator(#4).Turnclockwisetoincreasepressureorcounterclockwisetodecreasepressure.Theairregulatorisnon-relievingthereforeareductionoftankpressurechangewillnotbeevidentonthegaugeuntilblastingbegins.Forthemostaccuratesetting,thisadjustmentshouldbemadewhileblastingwiththegatevalve(#18)fullyopened.Thispressureisindicatedbythetankpressuregauge(#8)whileblasting.Bypassvalve(#37)mustbeclosed.Note:Furthertank/blastpressureadjustmentmayberequiredwhenactualblastingisbegun.

12.Tooperateatfullpressure(withouttherestrictionoftheregulator)openthebypassballvalve(#37).Thisallowsfullairpressureintothecontrolpipingregardlessoftheairregulatoradjustment.Note:BypasspipingisnotavailableontheM11.

42


13.SetpreliminaryabrasiveflowbyadjustingtheknobontheThompsonValve®(#11).Turnclockwiseforlessabrasiveflowandcounterclockwiseformoreabrasive.Duetothelengthoftheblasthosetherewillbeaslightdelayincontroloftheabrasiveflowatthenozzle,thereforeallowafewsecondsbeforeadjustingfurther.Note:Iftheblasterisequippedwiththeoptionalabrasivecut-offfeaturetheswitchmustbesettothe“on”positiontoblastwithabrasive.

14.Withonehandgriptheblasthoseassembly(#25)andwiththeotherhandpressinthedeadmansafetybutton.Tobeginblasting,aimtheblastnozzleattheobjecttobeblasted,thenfirmlypressdownthedeadmanlever(#26).Airandblastabrasivewillflowintotheblasthose(#25)andoutoftheblastnozzle(#29).Releasethedeadmanlevertostopblasting.

Donotaimblastnozzletowardsyourselforanyperson.Systemmalfunctioncancauseaccidentalstartupandresultininjurytopersonnel.

WARNING

15.Whenusingfineparticleabrasivesimprovedflowisachievedbyusingthedifferentialpressurefeature.Differentialpressureisaslighthigherpressureintheblastpotoverthatoftheblasthose.Thisdifferentialpressureallowstheoperatortopreciselycontroltheabrasiveflow.

Usethegatevalve(#18)tosetthedifferentialpressure.Adjustthedifferentialpressurebyturningthegatevalvehandleclockwise(todecreaseblastpressure)orcounterclockwise(toincreaseblastpressure).Decreasingtheblastpressureincreasesthedifferentialpressureandabrasiveflow.Conversely,increasingtheblastpressuredecreasesthedifferentialpressureandhencedecreasestheabrasiveflow.Theidealdifferentialpressureisabouta2psigreatertankpressurethanblastpressure.Theblastpressureisindicatedbypressuregauge(#38).Thedifferentialpressureisshownbythelargergauge(#3).

Optimumdifferentialpressureadjustmentisdonewhileblasting,thereforetheoperatorshouldgetassistancefromasecondperson.Itisimportanttorememberthatduetothelengthoftheblasthosetherewillbeaslightdelayincontroloftheabrasiveflowatthenozzle,thereforeallowafewsecondsbeforeadjustingfurther.

16.Withcertainabrasivesflowmaybeimprovedbyuseoftheabrasivevibrator.Opentheanglevalve(#15)slightlytostartthevibratorandturncounterclockwisetoincreasevibration.Turntheanglevalveknobclockwisecompletelydowntoturnoffthevibrator(#31).

17.Openthepetcockvalve(#27)ontheblasthosewaterlineifwetblastingisrequiredfordustprevention.

18.Re-testtheblastairandabrasivemixtureagainonatestpiecetodetermineisfurtheradjustmentisneeded.Releasethedeadmanlevertostopblasting.

ENDING THE BLAST OPERATION (SEE FIGURE 21)1. Closetheairinletballvalve(#5).Theballvalveisclosedwhenthehandleisfullyturnedtothe

positionshowninFigure7.3(handleperpendiculartobody).Thehandletabwillbottomagainsttheballvalvebodyintheclosedposition.

43


Donotturnofftheaircompressorandallowtheabrasiveblasterairpressuretobackflowthroughthesystem.Backflowwillcarryabrasiveintotheairfilter(#7)andcontaminatethecontrols.

WARNING


WARNING

2. Completelyopenpetcockvalve(#9)atthebottomoftheairfilter(#7)toallowalltheaccumulatedmoisturetobedrainedout.Closethepetcockafterdraining.

3. Completelydepressurizetheabrasiveblastvessel(#12)byslowlyopeningtheblowdownballvalve(#1).SeeAbrasiveBlasterDepressurizingProcedure(Blowdown)onpage35forblowdownprocedure.

4. Forlongperiodsofnon-usageremoveremainingblastabrasivefromblastvesseltopreventmoisturecontamination.

Figure21

44

MAINTENANCE & INSPECTION INSTRUCTIONS


DANGER

1. TheASMECodeisastandardcoveringmaterials,design,fabrication,andinstallation.Vesselintegritysubsequenttopurchaseistheresponsibilityoftheownerand/oruser.Atintervalsrequiredbystatelawand/orlocalauthorities,thevesselshouldbesubjectedtoahydrostatictestasdescribedintheASMECode,SectionVIII,Division1.DoNotsubjecttheabrasiveblasterpressurevesseltoapneumaticprooftestexceedingthemaximumallowableworkingpressure.

Innocaseshouldthehydrostatictestpressureexceed1.3timesthemaximumallowableworkingpressure(MAWP)shownonthepressurevesselnameplate(#39).Thoroughlycleananddrythevesselbeforere-assembly.Moistureordebrisleftinvesselcancauseequipmentmalfunction.

2. Anydamagetoanabrasiveblastercanmakeitunsafe.Inspecttheexterioroftheabrasiveblastvesseldailyforcorrosion,pitting,orotherdamage(i.e.dents,gougesorbulges).Ifdamaged,takeoutofserviceimmediatelyandhaveitinspectedand/orrepairedbyaqualifiedfacility.

3. Theinteriorconditionoftheabrasiveblastvessel(#12)shouldbeinspectedquarterly.Pittingcausedbycorrosionwillreducethewallthicknessofthevessel.Ifexcessivecorrosionisfound,havetheabrasiveblastvesselinspectedbyaqualifiedfacility.Checkthepressurevesselinternalpipingforcorrosion,cracks,andholes.SeeFigure22.

4. Thepopupalignmentandoperationistestedbythemanufacturer,howevervibrationandcreepingduringshipmentmaycausetheinternalpopupsupportpipingtoshiftresultinginmisalignment.Priortoinitialusageandperiodicallythereafter,thepopupgapandalignmentshouldbechecked.Inspectthepopupasfollows:

a. DepressurizetheabrasiveblasterperAbrasiveBlasterDepressurizingProcedure(Blowdown)onpage36.

b. Disconnectairsupplyhosefromthecrowfoot(#6).

c. Inspectthepopupgasket(#40)andpopuphead(#41)sealingsurfacesforwearordeformations.Replaceeitherifnecessary.

d. Checkthatthepopupiscenteredwithinthegasketopening.Ifnecessary,useaprybarasaleverbetweenthepopupandgaskettodeflecttheinternalsupportpipingandshiftthepopuptothecenterofthegasketopening.

e. Checkthepopupgap(distancebetweenthepopupsurfaceandthegasket).Itshouldbebetween0.625”and0.840”.SeeFigure22.Anexcessivegapiscreatedbyaverticalnipplethatistooshort.Anexcessivegapwillexposethetopoftheverticalnippletoabrasivewhenthepopupcloseswhichcouldresultinprematureweartothepopup.

f. Aftercheckingthealignmentandgap,theblastvesselcanbere-pressurizedandthepopupisthencheckedforleaks.Ifaleakispresent,repeattheabovestepstoisolatetheproblem.

45


Pinchpointhazard.Vesselpressurizationwillcompressthepopupagainstthepopupgasket.Keepfingersclearofthepopupopeningwhilepressurizingtheblastvessel.Disconnectairsupplypriortoperformingpopupmaintenance.

WARNING

Figure22

5. Allairhoses,blasthoses,controlhoses,andwiresshouldbeinspecteddailyforwear,dryrotting,crackingorleakage.Repairorreplaceanyhosesorwiresthatshowanysignsofwear,leakageorotherdamage.Damagedwiresand/orhosescancausesystemmalfunctionsandcanresultinseriousinjuryordeathtooperatingpersonnel.

Blasthosesareahighwearcomponentoftheabrasiveblastsystem.Sharpbendsintheblasthosecreatehighwearpointsresultinginsoftspotsthatcanrupturewhileblasting.Checkthefulllengthoftheblasthoseassemblyforsoftspotscausedbywear.Topreventseriousinjurytopersonnelreplaceblasthoseswithsoftspots.Note:Staticelectricityisgeneratedbytheabrasiveflowthroughtheblasthose.Topreventstaticelectricalshocktooperatingpersonnelonlyusestaticdissipatingblasthoseandinstallagroundingstrapontheabrasiveblaster.

Wornblasthoseassembliescanrupturewhileblastingandtheresultingabrasiveblaststreamcancauseseriouspersonalinjury.

WARNING

46


Figure23

6. Allairhose,blasthose,andthreadedcouplingshavepinholesthatalignwhenconnected.Topreventaccidentalhosedisconnectionssafetypinsmustbeinstalledthroughtheseholes.Eachhoseconnectionmustalsoincludeahosewhipcheckthatwillholdthehoseifthereisanaccidentaldisconnection.ConnectonelooptoeachsideoftheconnectionandstretchoutasshowninFigure23below.Checkhoseconnectionsdailyandreplacemissingordamagedpinsandwhipchecks.

7. Allairhose,blasthose,andthreadedcouplingshavegasketsthatsealtheconnection.Topreventlossofairpressureand/orprematureabrasivewearreplacethesegasketswhenleaksarefound.Inspectthecouplingsdailyforleaksandwear.Replacegasketswhenvisiblewearorleaksarefound.Wheninstallingorreplacinghosecouplingscutthehoseendsquareforsecurefit(seeFigure24).Toinsurepropercouplingconnectionalwaysusefittingsthatarethesamebrand.

Figure24

8. Removetheblastnozzledailyandcheckthejacketandthreadcondition.Checknozzlethroatdiameter.Anover-sizedthroatdiameterreducesblastefficiency.Replacetheblastnozzleifwornordamaged.

47


9. TheThompsonValveII,Automaticairvalve,anddeadmanvalveshouldbedisassembledandinspectedquarterly,ormorefrequentlyifheavilyused.TheThompsonValveIIcylindershouldbecleanedandlubricatedwithananti-seizecompound.ReplacepartsasneededwithBlastOneoriginalfactoryreplacementpartsfurnishedbyBlastOne.Periodicallycheckifairisleakingfromendofblastnozzlewhentheblastoperationisoff.AwornThompsonValveIIseatusuallycausesthis.Itisreplacedbyremovingthethreeboltsinthetopofthevalvetoallowdisassembly.RefertovalvedrawingsinDrawing&PartsListsonpage49.

Depressurizevesselbeforeperforminganymaintenance.SeeAbrasiveBlasterDepressurizingProcedure(Blowdown)onpage35.RemovingtheThompsonValveboltswiththeabrasiveblasterpressurizedwillresultinseriousinjuryordeath.UseofreplacementcomponentsthatarenotBlastOneoriginalreplacementpartsmayresultinequipmentfailurewhichcanresultinseriouspersonalinjury.

DANGER

Failuretousepersonalprotectiveequipmentcouldresultinseriousinjuryordeath.

DANGER

10.Checkdailytoverifythatallpersonalprotectiveequipmentisavailableforeachblastoperator.Checkdailytoverifythatallpersonalprotectiveequipmentisingoodoperatingcondition.ConsulttheoperatingandmaintenanceinstructionsprovidedbythemanufacturerofeachPPEitem.SeeFigure9andreferenceOSHA29CFR1910SubpartI.

11.Checkmonthlytoverifythatallthewarningdecalsareinpositionandlegible.

Failuretomaintainwarningdecalsrisksthepossibilityofnotalertingtheabrasiveblasteroperatortopotentialdangerswhichcanresultinseriousinjuryordeath.SeeIntroductiononpage5.

WARNING

48


MAINTENANCE SCHEDULES QUICK REFERENCE CHART

Maintenance Schedule

ITEM MAINTENANCE REQUIRED DAILY WEEKLY MONTHLY QUARTERLY

BlasterVesselHydrostaticTest

SeeMaintenance&InspectionInstructions(list#1)onpage44.

Asrequiredbystatelawand/orlocalauthorities.

BlasterVesselCheckforexteriordamage(corrosion,dents,bulges).


X

BlasterVesselCheckforinteriordamage(corrosion/pitting).


X

PopupChecksealingsurfacesandpopupalignment.


X

Blast&AirHoses

Checkhosesforsoftspots,wear,cracks,orairleaks


X

RemoteControlHoses

Checkhosesforsoftspots,wear,cracks,orairleaks


X

RemoteControlWires

Checkwiringforbarespots,fraying,orcracks


X

Blast&AirHoseCouplings

Checkforsafetypinsandwhipchecks


X

HoseCouplingGaskets

Checkforleakyairandblasthosecouplinggaskets


X

BlastNozzleCheckblastnozzlethreadsandjacketandforairleaks


X

ValvesDisassemble,inspect,andlubricate.


X

PersonalProtectiveEquipment

Checkconditionofallpersonalprotectiveequipment

SeeFigure9andMaintenance&InspectionInstructions(list#10)onpage47.

X

Warning Decals

Checktheconditionofwarningdecals.

SeeIntroductiononpage3andMaintenance&InspectionInstructions(list#11)onpage47.

X

49

DRAWING & PARTS LISTS

50

DRAWING & PARTS LISTSIT

EMPA

RTD

ESCR

IPTI

ON

124

01-504

Blowdo

wnba

llvalve1/2"

270

00-001

-11

Han

dway,crabassembly6"x8"

320

10-013

Differen

tialP

ressureGau

ge,0-5psi

*420

03-006

Airpressu

rereg

ulator

*524

01-506

Airinletb

allvalve

*642

08-106

Crowfoot

*723

02-206

-50

Airfilter,50

micron

887

10-400

07A

Tank

pressurega

uge,0-160

psi

9—

Drainvalvefo

rairfilter

1087

10-361

01Med

iaValveShu

t-off,1-1/4"

*11

2152

-216

Thom

pson

ValveII

®w/slotted

sleeve

1287

20-011

-01

Blastpot,M

SeriesMod

elM

11

1322

29-000

Con

trolvalve,p

neum

atic

1442

24-300

-02

4224

-301

-02

Quickcon

nectplug,1/4"

Quickcon

nectsocket,1/4"

1524

30-804

Vibratorcon

trolang

levalve,1/4"

1687

10-923

01S

Tri-Clamp,1-1/2"

1787

20-000

-02

2014

-300

Automaticairvalve1"

Breathe

rvent,1/8"

1824

23-906

Gatevalve,blastpressurecontrol

1924

01-506

Clean

outb

allvalve,1"(TVII)

2042

24-300

-02

4224

-301

-02

Quickcon

nectplug,1/4"

Quickcon

nectsocket,1/4"

2142

24-710

-02

Waterquickcon

nectplug,1/4"

2242

13-XXX

Blasthosecoup

ling

ITEM

PART

DES

CRIP

TIO

N

2341

00-501

Twinlin

eho

seassem

bly,3/16x55"

2441

01-002

Waterhose,1/4"pu

shon

2541

04-XXX

-XX

Blasthoseassembly

2622

63-002

G2Dea

dman

valve

2720

24-001

Petcockvalve,1/4"FX1/4"F

2842

15-XXX

XNozzleho

lder

2950

00-XXX

XBlastnozzle

3080

20-000-02

Wetblastattachm

enta

ssem

bly

3120

20-013

Vibrator

3242

27-304-05

4227

-305-99

Garde

nho

secou

pling

Garde

nho

segasket,3/4"

3323

00-305-02

Y-strainer,60mesh3/4"

3442

24-711-02

Waterquickcon

nectsocket,1/4"

3524

01-502

Drainballvalve,1/4"

3642

14-108-01

Thread

edcou

pling

37—

Fullpressu

rebypassba

llvalve

3887

10-40007A

Blastpressurega

uge,0-160psi

39—

Pressu

revesseln

amep

late

4021

00-011

Popu

pGasket

4121

00-010

Popu

pHea

d

4250

10-010

Lid,12"

4350

11-010

Screen

,12"(1

/4"mesh)

4420

13-402

Dus

telim

inator,1/4"mnp

t

4570

46-003

70

19-519

Whe

el&Tire

NylockNut3/4"

51


52


EMPA

RTD

ESCR

IPTI

ON

124

01-504

Blowdo

wnba

llvalve1/2"

270

00-001

-11

Han


320

10-013

Differen

tialP

ressureGau

ge,0-5psi

*420

03-007

Airpressu

rereg

ulator

*524

01-507

Airinletb

allvalve

*642

08-107

Crowfoot,4-lug

*723

02-207

-50

Airfilter,50

micron

887

10-400

07A

Tank

pressurega

uge,0-160

psi

9—

Drainvalvefo

rairfilter

1087

10-361

01Med

iaValveShu

t-off,1-1/4"

*11

2152

-217

Thom

pson

ValveII

®w/slotted

sleeve

1287

20-021

-01

8720

-031

-01

Blastpot,M

SeriesMod

elM

21

Blastpot,M

SeriesMod

elM

31

1322

29-000

Con

trolvalve,p

neum

atic

1442

24-300

-02

4224

-301

-02

Quickcon

nectplug,1/4"

Quickcon

nectsocket,1/4"

1524

30-804

Vibratorcon

trolang

levalve,1/4"

1687

10-923

01S

Tri-Clamp,1-1/2"

1721

23-107

20

14-300

Automaticairvalve

Breathe

rvent,1/8"

1824

23-907


1924

01-506

Clean

outb

allvalve,1"(TVII)

2042

24-300

-02

4224

-301

-02

Quickcon

nectplug,1/4"

Quickcon

nectsocket,1/4"

2142

24-710

-02

Waterquickcon

nectplug,1/4"

2242

13-XXX

Blasthosecoup

ling

ITEM

PART

DES

CRIP

TIO

N

2341

00-501

Twinlin

eho

seassem

bly,3/16x55"

2441

01-002

Waterhose,1/4"pu

shon

2541

04-XXX

-XX

Blasthoseassembly

2622

63-002

G2Dea

dman

valve

2720

24-001


2842

15-XXX

XNozzleho

lder

2950

00-XXX

XBlastnozzle

3080

20-000-02

Wetblastattachm

enta

ssem

bly

3120

20-025

Vibrator

3242

27-304-05

4227

-305-99

Garde

nho

secou

pling

Garde

nho

segasket,3/4"

3323

00-305-02


3442

24-711-02

Waterquickcon

nectsocket,1/4"

3524

01-502

Drainballvalve,1/4"

3642

14-107-01

Thread

edcou

pling

3724

01-507

Fullpressu

rebypassba

llvalve

3887

10-40007A

Blastpressurega

uge,0-160psi

39—

Pressu

revesseln

amep

late

4021

00-011

Popu

pGasket

4121

00-010

Popu

pHea

d

4250

10-060

Lid,12"

4350

11-060

Screen

,12"(1

/4"mesh)

4420

13-402

Dus

telim

inator,1/4"mnp

t

4570

46-003

70

19-519

Whe

el&Tire

NylockNut3/4"

53


54


EMPA

RTD

ESCR

IPTI

ON

124

01-504

Blowdo

wnba

llvalve1/2"

270

00-001

-11

Han


320

10-013

Differen

tialP

ressureGau

ge,0-5psi

*420

03-006

Airpressu

rereg

ulator

*524

01-506

Airinletb

allvalve

*642

08-106

Crowfoot,4-lug

*723

02-206

-50

Airfilter,50

micron

887

10-400

07A

Tank

pressurega

uge,0-160

psi

9—

Drainvalvefo

rairfilter

1087

10-361

01Med

iaValveShu

t-off,1-1/4"

*11

2152

-216

Thom

pson

ValveII

®w/slotted

sleeve

1287

20-011

-01

Blastpot,M

SeriesMod

elM

21

1322

29-000

Con

trolvalve,p

neum

atic

1471

09-301

71

09-300

Quickcon

nectplug,1/4"

Quickcon

nectsocket,1/4"

1524

30-804

Vibratorcon

trolang

levalve,1/4"

1687

10-923

01S

Tri-Clamp,1-1/2"

1787

20-000

-02

2014

-300

Automaticairvalve

Breathe

rvent,1/8"

1824

23-906


1924

01-506

Clean

outb

allvalve,1"(TVII)

2071

09-301

71

09-300

Quickcon

nectplug,1/4"

Quickcon

nectsocket,1/4"

2142

24-710

-02

Waterquickcon

nectplug,1/4"

2242

13-XXX

Blasthosecoup

ling

2370

74-055

70

72-012

Dea

dman

exten

sion

cord,55ft.

Powercord(12vdc)

ITEM

PART

DES

CRIP

TIO

N

2441

01-002

Waterhose,1/4"pu

shon

2541

04-XXX

-XX

Blasthoseassembly

2622

63-400-01

Dea

dman

switc

hw/plug

2720

24-001


2842

15-XXX

XNozzleho

lder

2950

00-XXX

XBlastnozzle

3080

20-000-02

Wetblastattachm

enta

ssem

bly

3120

20-013

Vibrator

3242

27-304-05

4227

-305-99

Garde

nho

secou

pling

Garde

nho

segasket,3/4"

3323

00-305-02


3442

24-711-02

Waterquickcon

nectsocket,1/4"

3524

01-502

Drainballvalve,1/4"

3642

14-108-01

Thread

edcou

pling

37—

Fullpressu

rebypassba

llvalve

3887

10-40007A

Blastpressurega

uge,0-160psi

39—

Pressu

revesseln

amep

late

4021

00-011

Popu

pGasket

4121

00-010

Popu

pHea

d

4250

10-010

Lid,12"

4350

11-010

Screen

,12"(1

/4"mesh)

4420

13-402

Dus

telim

inator,1/4"mnp

t

4570

46-003

70

19-519

Whe

el&Tire

NylockNut3/4"

55


56


EMPA

RTD

ESCR

IPTI

ON

124

01-504

Blowdo

wnba

llvalve1/2"

270

00-001

-11

Han

dway,crabassembly,6"x8"

320

10-013

Differen

tialP

ressureGau

ge,0-5psi

*420

03-007

Airpressu

rereg

ulator

*524

01-507

Airinletb

allvalve

*642

Documents

INSTALLATION, OPERATION & MAINTENANCE MANUAL · 33 Abrasive Vibrator 33 Water System 33 Blast Hose 33 Blast Nozzle 34 Hose Connection PRE-OPERATION PROCEDURES 35 Abrasive Blaster