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Clemco Industries Corp.
presents
Design Considerations for Abrasive Blast Rooms
&
Recovery Systemsby Bob Kerr
Business Development Manager
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p g
Report Documentation PageForm Approved
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1. REPORT DATE
FEB 2010 2. REPORT TYPE
3. DATES COVERED
00-00-2010 to 00-00-2010
4. TITLE AND SUBTITLE
Design Considerations for Abrasive Blast Rooms & Recovery Systems
5a. CONTRACT NUMBER
5b. GRANT NUMBER
5c. PROGRAM ELEMENT NUMBER
6. AUTHOR(S) 5d. PROJECT NUMBER
5e. TASK NUMBER
5f. WORK UNIT NUMBER
7. PERFORMING ORGANIZATION NAME(S) AND ADDRESS(ES)
Clemco Industries Corp,445 Bush Street,San Francisco,CA,94108-3730
8. PERFORMING ORGANIZATION
REPORT NUMBER
9. SPONSORING/MONITORING AGENCY NAME(S) AND ADDRESS(ES) 10. SPONSOR/MONITOR’S ACRONYM(S)
11. SPONSOR/MONITOR’S REPORT
NUMBER(S)
12. DISTRIBUTION/AVAILABILITY STATEMENT
Approved for public release; distribution unlimited
13. SUPPLEMENTARY NOTES
2010 U.S. Army Corrosion Summit, Huntsville, AL, 9-11 Feb. U.S. Government or Federal Rights License
14. ABSTRACT
15 SUBJECT TERMS
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PLANNING CONSIDERATIONS
• ENCLOSURE
• LOCATION OF ROOM
• COMPLETELY INSIDE
• ROOM INSIDE, COLLECTOR OUTSIDE
• COMPLETELY OUTSIDE
• PARTIALLY OUTSIDE• RECOVERY SYSTEM LOCATION
• ON TOP OF EXISTING FLOOR
• FLUSH-MOUNTED (RECOVERY SYSTEM IN PIT)
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Flange Bolt Room
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Column Bolt Room
• Structural steel
framework
• Galvanized steel
panels
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COMMON FEATURES
• GALVANIZED CONSTRUCTION
• FLOOR-TO-CEILING DOORS CAN BE
INSTALLED INTO ONE OR BOTH ENDS
• PERSONNEL DOORS CAN BE
INSTALLED IN ANY WALL PANEL
– REQUIRED EVERY 30 FEET PER O.S.H.A.
• OPTIONS
– EXTERIOR WORK STATIONS
– SPECIAL LIGHTING
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Inlet Door Installation
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AIR INLETS
• Baffled inside &
outside
• Filtered
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MANDOOR
• Panic Hardware
• Viewer with cover
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ILLUMINATION
• TYPICALLY, 50-80 FOOT CANDLES IS
SUFFICIENT
• FLUSH-MOUNTED TO CEILING – PROTECTED FROM INADVERTENT BLASTING
– SEALED TO AVOID DUST INGRESS
• ADDITIONAL WALL-MOUNTED LIGHTSPROVIDE SHADOW FREE ILLUMINATION
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Light Module
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EXTERIOR WORK STATION
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RECOVERY FLOOR TYPES
• SWEEP-IN
– 2x2 AND 3x3 HOPPERS
• MECHANICAL RECOVERY
• FOR DENSE MEDIA, SUCH AS STEEL GRIT AND SHOT
– M-SECTION STRIP• PNEUMATIC RECOVERY
• FOR LIGHTWEIGHT MEDIA, SUCH AS GLASS BEADS,
ALUMINUM OXIDE, AND PLASTIC
• PARTIAL FLOOR
– MULTIPLE M-SECTIONS
– SCREW
– -BELT
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RECOVERY FLOOR TYPES
continued
• FULL FLOOR
– MECHANICAL RECOVERY
• FLAT-TRAK
• SCREW CONVEYORS
• BELT CONVEYORS
– PNEUMATIC RECOVERY• M-SECTION
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FULL FLOOR RECOVERY
• COMPLETELY AUTOMATES THE
MEDIA RECOVERY PROCESS
• MECHANICAL RECOVERY
– SCREW CONVEYOR
– -BELT CONVEYOR
– FLAT-TRAK
• PNEUMATIC RECOVERY
– M-SECTION
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PARTIAL FLOOR RECOVERY
• REDUCES MANHOURS SPENT ON
RECOVERY, COMPARED TO SWEEP-IN
• SCREW OR BELT CONVEYOR(S) TO BEUSED WITH DENSE MEDIA SUCH AS
STEEL
• M-SECTION STRIPS TO BE USED WITHLIGHTWEIGHT MEDIA SUCH AS ALOX
AND GLASS BEADS
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HOPPER RECOVERY SYSTEMS
• SURFACE MOUNTED OR RECESSED
• LOW INITIAL COST
• REQUIRES MANUAL LABOR
– SWEEPING OR SHOVELING
• 120 MESH MEDIA OR COARSER
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3 x 3HOPPER
RECOVERY
SYSTEM
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3 x 3 HOPPER SWEEP-IN
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BELT RECOVERY
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SCREW RECOVERY
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FLAT-TRAK • LOW PROFILE
– 6-1/2” TALL
– MINIMAL EXCAVATION REQUIRED FOR PIT
– SHORT RAMPS ON SURFACE MOUNTS
• FAST INSTALLATION
– FAST DELIVERY - COMPONENTS SHIPPED
FROM STOCK
– MODULAR FLOOR
– TRACKS WELDED TO STEEL FLOOR
– FRAMES DROP IN PLACE BETWEEN TRACKS
• EASY MAINTENANCE
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Flat Trak Drive
• Booted for protection
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Flat Trak
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FLAT-TRAK
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FLAT-TRAK
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Bucket Elevator
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Underspeed
Monitor
• Used on all bucket
elevators
• Prevents belt breakage
MEDIA CLEANING
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MEDIA CLEANING
MECHANICAL SYSTEMS
• ABRASIVE CLEANER – BEST FOR HEAVIER MEDIA, I.E. STEEL GRIT
– ROTARY SCALPING DRUM
• REMOVES OVERSIZED PARTICLES / DEBRIS – HIGH VOLUME STREAM OF AIR
• REMOVES DUST --- TO DUST COLLECTOR
– INCLUDES 10 CUBIC FOOT STORAGE HOPPER
– CAN PROCESS UP TO 15 TONS PER HOUR
– CAN FEED 1, 2, 3, OR 4 BLAST MACHINES
• MULTIPLE POT STAND REQUIRED FOR MORE
THAN ONE BLAST MACHINE
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ABRASIVE
CLEANER
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M-Section
• Pneumatically operated channels
• No vibration or screw conveyors
• Handles all light-weight media
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SWEEP-IN M-SECTION
WITH DRY FILTER
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SWEEP-IN M-SECTION WITH
RP COLLECTOR
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M-SECTION
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M-section Floor
• Full recovery system
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Crossdraft Transition
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PNEUMATIC SYSTEMS• CYCLONE SEPARATOR FOR USE WITH
LIGHTWEIGHT MEDIA
• MEDIA, DUST, AND DEBRIS ENTER
RECLAIMER WHERE THEY SPIN
• DUST, FINES, AND BROKEN MEDIA AREDRAWN OUT WITH EXHAUST AIR TO DUST
COLLECTOR
• ONLY CLEAN, REUSABLE MEDIA ENTERSBLAST MACHINE
• RUBBER-LINED TOP SECTIONS ARE NEEDED
WITH AGGRESSIVE MEDIA
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Blast &
Reclaim System• Reclaim
• Storage Hopper
• Blast Machine
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M-SECTION
RECOVERY & TRANSITION
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M-SECTION FULL-FLOOR (note wall sheeting for improved illumination)
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PRE-ASSEMBLED
BLAST ROOMS• AVAILABLE FOR ALL TYPES OF
RECYCLABLE MEDIA
– FLAT-TRAK RECOVERY SYSTEM WITHABRASIVE CLEANER FOR USE WITH HEAVY
MEDIA, I.E. STEEL GRIT
– M-SECTION RECOVERY SYSTEM WITHRECLAIMER FOR USE WITH LIGHTWEIGHT
MEDIA, I.E. GLASS BEADS OR ALOX
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Preassembled Room
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Preassembled Room
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BLAST MACHINES
• AUTOMATICALLY REFILLED AFTER
MEDIA HAS BEEN CLEANED
• MEDIA VALVE(S) MUST BE SUITABLE
FOR THE ABRASIVE BEING USED
• BOTTOM CONE MUST ACCOMMODATE
ANGLE OF REPOSE OF MEDIA BEING
USED
• MUST BE EQUIPPED WITH REMOTE
CONTROLS
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VENTILATION
• PROVIDED BY DUST COLLECTOR FAN
• INLET VELOCITY: 500 FT/MIN MINIMUM
• CROSSDRAFT VENTILATION RATES – 50 FEET/MIN FOR STEEL OR GLASS BEADS
– 80 FEET/MIN FOR ALUMINUM OXIDE
– 100 FEET/MIN FOR SAND OR DUSTY MEDIA
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VENTILATION
• REVERSE-PULSE CARTRIDGE – FILTERS 99.85% – EXHAUSTED AIR IS 0.00218 GRAINS/CUBIC FT – AIR TO CLOTH RATIO OF 2:1 OR LESS – COMPACT, MODULAR UNITS
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Dust Collector
• 4000 - 300000 CFM
• Sloped roof
• Modular construction
D C ll
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Dust Collector
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DUST COLLECTION
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Dust Collector
• Magnehelic
Gauge
• Pressure Gauge
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DUST COLLECTION / DUCTING
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VENTILATION• TO DETERMINE THE SIZE OF THE DUST
COLLECTOR, USE THIS FORMULA:
CFM of collector = A
Room Width = WRoom Height = H
Ventilation Rate = V
A = W x H x V
For a room 10’ x 10’ x 20’
with steel grit, we use:
A = 10’ x 10’ x 50’/min
A = 5000 CFM
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WORK-PIECE HANDLING
• FORKLIFTS
• RAIL-MOUNTED WORK CARS
• OVERHEAD MONORAILS• EXTERIOR WORK STATIONS
• TURNTABLES
• HORIZONTAL ROTATION DEVICES
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OVERHEAD MONORAIL
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Workpiece Handling
• Powered
horizontal
rotation
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TURNTABLE/WORKCAR/TRACK
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DROP-DOWN
TURNTABLE
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ELECTRICAL CONTROL PANEL
• INCLUDES MOTOR STARTERS
• AUTOMATED START-UP PROGRAM
– AVOIDS MEDIA JAMMING AND EQUIPMENTDAMAGE
• HOUR METER MONITORS USAGE
– AIDS IN SCHEDULED MAINTENANCE TASKS
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COMPRESSED AIR SUPPLY
• POWER FOR MANY COMPONENTS
– AUTOMATED FLOORS
– REVERSE PULSE COLLECTORS
– BLASTING OPERATION
• NOZZLE ORIFICE
• NUMBER OF OPERATORS
– SUPPLIED AIR RESPIRATORS
• CONSIDER OTHER DEMANDS ON SHOP AIR
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OPERATOR SAFETY EQUIPMENT
• AIR-FED RESPIRATOR – APOLLO 60 OR APOLLO 20
• AIR FILTER
– CPF-20 OR CPF-80• CO MONITOR AND ALARM
– CMS-1
• PROTECTIVE CLOTHING – BLAST SUITS
• HELMET COMMUNICATION SYSTEMS
– HCS-1
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APOLLO 60 RESPIRATOR
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CPF-20
BREATHING
AIR FILTER
CARBON MONOXIDE
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CARBON MONOXIDE
MONITOR ALARM
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CLEMCO
BLASTSUIT
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HELMET COMMUNICATIONS
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BLAST & PAINT ROOM
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AIRCRAFT STRIP BOOTHS
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MEDIUM SIZED &
SMALL BOOTHS
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Thank you
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CLEMCO WORLDWIDE
The demand for abrasive blastingis extensive. Ship building and
maintenance in Singapore,
construction in Saudi Arabia,
refining in Houston… these are buta few of the major industries
where abrasive blasting has kept
pace with demand calling for
Clemco specialization and
innovation. Manufacturing and
distribution throughout 6
continents… wherever there is
i d Cl i h