KAVERI AIR BLASTER SYSTEM MANUAL

KAVERI ULTRA POLYMERS (P) LTD. BANGALORE

KOLKOTA

MUMBAI

'MultiTech Centre' (Opp. John Fowler)

Kaveri House,

115, Creative Estate,

13211, M.G. Road,

72, N.M. Joshi Marg,

Kolkota - 700 007 Tel. 32920103 122695791 Fax - 22690473 E-mail – [email protected]

Mumbai - 400 011 Tel. 32911397, 23054878 Fax - 23072861 E-mail [email protected]

Rommasandra Ind. Area Off Hosur Road Bangalore 560 099 Ph. +(91 80) 4166 3444 Fax +(91 80) 4166 3555 E-mail – [email protected]

Web: www.kaveri.in

CONTENTS

00.00

SPECIFICATIONS

01

0 1. 0 0

INTRODUCTION

02

0 2. 0 0

02

0 2. 0 1

FLOW PROBLEM IN BULK SOLIDS Storage Equipments

0 2. 0 2

Transfer Equipments

0 2. 0 3

Pre-heater and Riser Pipe/Ducts of Kilns

0 3. 0 0

CONSTRUCTION OF KAVERI AIR BLASTER

03

0 4. 0 0

KAVERI AIR BLASTER DESIGN ADVANTAGES

04

0 5. 0 0

WORKING PRINCIPLE OF KAVERI AIRBLASTER

06 06

0 6. 0 1

AIRBLASTER APPLICATIONS Thermal Power Station

0 6. 0 2

Cement Plants

0 6. 0 3

Steel Plants

0 6. 0 0

0 7. 0 0

SELECTION AND LOCATION

07

0 8. 0 0

CONTROL

07

0 9. 0 0

AIR VESSEL ASSEMBLY WITH RECOMMENDED SPARES DRAWINGS

09

1 0. 0 0

SCHEMATIC DIAGRAM

10

1 1. 0 0

KAVERI AIRBLASTER OPERATIONAL MANUAL

11

INTRODUCTION Serial Number Warnings Damages

12

INSTALLATION Inspections Nozzle Installation Mounting Air Blaster Air Supply Electrical Connection Blaster identification

13

1 2. 0 0 1 2. 0 1 1 2. 0 2 1 2. 0 3 1 3. 0 0 1 3. 0 1 1 3. 0 2 1 3. 0 3 1 3. 0 4 1 3. 0 5 1 3. 0 6

14.00

OPERATION CONTROL PHILOSOPHY OF AIR-BLASTER

16

14.01

TRIAL 1 OPERATION

18

15.00

TROUBLE * H O O U N G

19

15.01

Air Vessel Not Developing Pressure

15.02

Blast not taking place

15.03

Blast Force low

16.00

PREVENTIVE MAINTENANCE

* KAVERI ULTRA POLYMERS LTD. BANGALORE * M U M B A I * K O L K A T A

21

00.00 SPECIFICATIONS 1.

PRESSURE VESSEL DESIGN CODE MAX. WORKING PRESSURE DESIGN PRESSURE HYDROSTATIC PRESSURE

2

8Kgf/cm2 8.8Kgf/cm2 13.5 Kgf / cm2

AIR SEALING PISTONASSEMBLY PISTON HOUSING

PISTON INNER SEAL (SEATING MATERIAL) BUFFER SEAL `O' RING SPRING EXHAUST PIPE ASSEMBLY 3.

IS 2825 CLASS 3

VALVE ACCESSORIES

SEAMLESS CARBON STEEL WITH INTERNAL HARD CHROME PLATED. ALUMINIUM ALLOY SYNTHETIC RUBBER SYNTHETC RUBBER TEFLON SELF LUBRICATED SPRING STEEL IS 1239, ‘B’ CLASS ---------------- M S I S 2 0 6 2

SOLENOID BANK HEADER ISOLATING VALVE NON RETURN VALVE SOLINOID VALVE

MS IS 1239, `B' CLASS BALL I PLUG VALVE PLATE SPRING LOADED TYPE 312 WAY POPPET / PISTON NORMALLY OPEN TYPE. Contd..4..

.-lAMS 1S 1239 CLASS / SS TUBES FOR SPECIAL CASE 3/2 WAY DIAPHRAGM TYPE. 0-14 Kgf / cm2

PIPING QUICK EXHAUST VALVE PRESSURE GAUGE 2.

MOUNTING ACCESSORIES CONNECTING PIPE

MS IS 1239, 'B' CLASS MS IS 1239, `B' CLASS MS IS 2062

BEND

MOUNTING PLATE GASKET

CAF (COMPRESSED ASBESTOS FIBRE)

ING I RETAINING FRAME

----------------M S I S 2 0 6 2

NOZZLE

5.

A. NORMAL TEMP MS IS 2062 B. HIGH TEMP. HRCS GR. 4, 7, 9 AND STAINLESS STEEL.

C O M P R E S S E D __ A I R L I N E A C C E S S O R I E S MOISTURE SEPARATOR

AIR FILTER LUBRICATOR

MS IS 2062 BAFFLE PLATE TYPE. POLYCARBNATE BOWL TYPE. POLYCARBONATEB OWL TYPE

Contd..5..

00.01 INTRODUCTION KAVERI Air Blaster is equipment used as a flow promoting aid in Handling Bulk Solids. Basically, this has an air vessel in which compressed air at a certain pressure, in the range of 4-8 Kgf / sq.cm. is stored. The full quantity of air is discharged through the exhaust pipe of the air blaster within a fraction of a second. By this a blast is produced, which helps in dislodging of material build-up and thereby flow of bulk solid. ,

00.02 FLOW PROBLEMS IN BULK SOLIDS 2.01 Storage Equipments

The frequency of occurring flow problems in hoppers, bunkers and silos are arching, bridging. Funneling or rat holing (as shown in above Figures). These problems can be overcome by using Kaveri Air-Blaster and in certain particular situations by reducing the wall friction o f the material on the hopper wall by using the Polymer Liner and supplemented by Air-Blaster System. Contd..6..

2.02 Transfer Equipments The build-up of materials in transfer equipments like chutes may also be tackled by using Air-Blaster or Air-Blaster in combination with Polymer Liner.

2.03 Pre-heater & Riser pipe of Kilns The cases of build-up of material and chocking of riser duct and preheater cyclone of kilns in cement plants are common. Kaveri AirBlaster system can be the best solution for these situations_

00.03 CONSTRUCTION OF KAVERI AIR-BLASTER SYSTEM Kaveri Air-Blaster has design based on study of various types of situations and observing the performance of several Air-Blaster systems abroad_ Kaveri Air-Blaster is of Piston type construction i.e., the retaining and release of air pressure from the air vessel is achieved by actuating the piston by using 3/2 way normally open type SOLENOID VALVE through QUICK RELEASE VALVE. The piston is located in such a way that the piston assembly is inside the vessel but is approachable from outside and also any maintenance on the piston assembly is possible without dismantling the Air-Blaster. 1. AIR - VESSEL

2. PISTON HOUSING

4. MOUNTING FLANGE

5. SPRING

3. EXIIAUT PIPE

6 . PISTON 7.INNER SEAL

Contd..7..

5 :-8-:

00.04 KAVERI AIR-BLASTER DESIGN ADVANTAGES 1)

Piston Assembly is located inside the vessel thus sheltered from extreme environment heat, dust etc.

2)

Piston Assembly and discharge chute outlet are positioned at two ends opposite to each other leading to drop in temperature due to longer distance from the bulk material compared to that of external valve type Air-Blaster .

3)

Piston is positioned at the entrance of the air vessel and the entire piston assembly can be removed by unscrewing only 8nos bolts and nuts. Thus, maintenance work on the piston can be carried out without

4) 5)

dismantling the vessel. Internal piston assembly does not lead to damage due to mishandling Force of discharge is maximized by air being released in a linear direction in preference to 90-degree outlet.

6)

Spring loading of the piston seals perfectly with the exhaust pipe seating flange. a)

No air leakage hence saving compressed air and power.

b)

allows any conceivable variations of mounting.

c)

No likelihood of any dust or material penetrating the vessel as the spring

pushes/back

the

piston,

immediately

after

the

blast/

operation. d)

No likelihood of dust or material entering into the piston assembly when supply of compressed air is stopped.

It is evident from the above that KAVERI DESIGN developed years back with our own indigenous R&D and site experience is now being accepted by leading

manufacturers

of

the

world

such

as

MARTIN

ENGINEERING

COMPANY, U.S.A. who have also introduced Internal Piston discarding their design of External Piston. Contd.-S..

:-10-:

00.05 WORKING PRINCIPLE OF KAVERI AIR-BLASTER SYSTEM:The incoming supply of compressed air says pressure of 4 to 8 Kgf/sq.cm. es through a 3/2 or 5/2 way Normally open type solenoid valve, ed through 3/2 way Quick Exhaust valve and enters the piston cavity Trough an orifice of the piston, the compressed air gets filled up into the air vessel. (The compressed air should be purified fully before enterin g in solenoid valve by using Moisture separator & Air Filter. And the air should carry lubricating oil to solenoid valve & Air vessels for trouble free operation.) Now the system is ready for operation. When the blasting is required, the solenoid valve coil should get energized up to one second to actuate the solenoid valve for creating the minimum pressure differential through the control or push the manual override provided on the solenoid as a result the Quick exhaust valve gets actuated, and it releases air thereby created pressure differential between Air vessel piston housin g causing shifting of piston position by Air vessel air pressure. The capacity of air vessel compressed air releasing through the exhaust pipe fitted with specially designed nozzle under high pressure in a fraction of second, gives the blasting. The total operation is taking place within a fraction of second .

00.06 AIR-BLASTER APPLICATIONS 06.01 Thermal Power Stations a)

Coal hoppers

b)

Raw coal bunkers / Chutes

06.02 Cements Plants Normal temperature Applications at a) b)

Gypsum Hopper Limestone Hopper

c)

Clay Hopper

d)

Cement Silos

High temperature Applications at a) b)

Pre-heater Cyclones 3 rd , 4th , 5th Stages. Feed pipes

c)

Riser duct / Smoke chamber

d)

Kiln inlet chamber

e)

cooler

06.03 Steel Plants a)

Iron Ore hoppers

b)

Coal hoppers

c)

Lime Stone hoppers

00.07 S E L E C T I O N S AND L O C A T I O N OF A I R - B L A S T E R The selection and location of Air-Blaster is very important for Bulk solids storage Bunkers, Silos, Bins, Riser ducts, Preheaters and Grate coolers to make FREEFLOW the bulk materials. We at KAVERJ can suggest as per our design the proper capacity of Air-Blaster and location on these of the equipments considering the bulk solids characteristics & other parameters, equipments configuration, geometry and plant layout. For this, one must submit us the full details and accompanied by the detailed dimensional drawing of the equipment.

00.07 CONTROL For the purpose of blasting at convenient intervals, KAVERI control have to be used.

These are available in TWO versions. a)

Auto control .

i)

FCU (Tinier) Microprocessor based Sequential control

ii]

FCU (CCR) Relay based (PLC in Client's scope) control Cantd..8..

4

ffesfeet b) Manual Control . For logic and control philosophy of above control

refer

manual of control , which is applicable.

For any further details and specific enquiries, please KAVERI. ************************************************************************************************

This information given is for general guidance only. Owing to constant efforts of improvements and developments, specifications are subject to change_

4

KAVERI AIR BLASTER SYSTEM

Control (FCU-Timer) Manual

KAVERI ULTRA POLYMERS (P) LTD. BAN GALORE 'MultiTech Centre.' (Opp. John Fowler) Bommasandra Ind. Area Off. Hosur Road Bangalore 560 099 Ph. +(91 80) 4166 3444 Fax +(91 80) 4166 3555 E-mail - [email protected]

KOLKOTA Kaveri House, 13211, M.G. Road, Kolkota - 700 007 Tel. 3 2920103 122695 791 Fax - 22690473 E-mail – sales.cal@kaveri_in Web: www.kaveri.in

MUMBAI 115, Creative Estate, 72, N.M. Joshi Marg, Mumbai - 400 011 Tel. 32911397, 23054878 Fax - 23072861 E-mail - kaveri [email protected]

CONTENTS

PAGE NO.

00.01

Introduction

1.

00.02

Air Blaster And Its Working Principle

2.

00.03

Control Philosophy Of Air Blaster System

3.

00.04

Micro process Based Sequential Timer

3.

Technical Specification And Salient Features.

00.05

Principle Of Programming

5.

00.06

To Programme The Timer

5.

00.07

Wiring & Controlling Of Air Blaster System

8.

00.08

To Run The System

8.

00.09

To Stop The System

9.

00.10

Manual Operation

9.

00.11

To Operate The System

10.

00.12

Installation Procedure

10.

00.13

Wiring Diagram

11.

00.0 1 INTRODUCTION. Kaveri’s Air Blasters are being controlled through the micro process based sequential logic Flow Control unit with integrated timing of on time, off time, cycle time, by Arrangements etc..

The Flow Control Units are of two types. 1.

Flow control unit controlled by micro process based sequential timer (FCU TIMER).

2.

Flow control unit controlled by programmic logic controller from plant central control room (FCU CCR). Kaveri has designed Flow Control Unit (FCU) with potential free relay outputs consisting of 6 and 10 outputs to suit different application and its required group of air blasters. The basic design philosophy is to combine all the control and timing features into one unit.

unit.

.-17-.

00 02 AIRBLASTER AND ITS WORKING PRINCIPLE:It is an equipment used as a flow promoting aid in bulk solids handling.

Basically, the air blaster has an air vessel in which compressed air at a pressure 6 to 8 kg/sq.cm. Is stored and the full quantity of air is discharged through the exhaust pipe of air blaster within a fraction of a second. By this, a blast is produced through fan jet divergent nozzle on the inside hopper/bunker walls surface and raw material which helps dislodging of material build up, rat holding, arching, bridging etc. The incoming air supply of compressed air say 6 to 8 kg/sq.cm es through 3/2 way normally open type solenoid valve & es 3/2 way quick exhaust valve and enters the piston cavity. And through orifice of piston the compressed air gets filled up into the air vessel. Now the system is ready for operation. When the blasting is required the solenoid valve coil should get energized up to minimum one second to actuate the solenoid valve for creating the minimum pressure differential As a result, the quick exhaust valve gets actuated and releases air thereby creating pressure differential quickly between piston and air vessel. Due to that the pistol takes forward movement, which creates free to discharge the build up capacity compressed air through exhaust pipe and specially designed fanjet divergent room, under high pressure with high velocity. The total operation is taking place within fraction of second.

contd..:

.-18-.

00.03 CONTROL PHILOSOPHY OF AIR BLASTER SYSTEM. For making materials continues fluidization and flow promotion, the air blasters operation should

be always from bottom to top working sequentially and cyclically.

The above philosophy operation controlled through micro process based sequential timer flow control unit (FCU). And its programmned integrated times of on time, o$ time, cycle time and etc_ The FCU is consisting of controlling valves and sequential timer.

00.03 FLOW CONTROL UNIT FCU (TIMER) Technical specification and salient features. 01. No. Of output

- 6 output and 10 output. Changeover relays are used for each output

04.

Input power supply Output control supply

05.

Rated frequency

- 230/110 V. AC. -- 230/110 V AC or 24 V DC -. _ 50 Hz.

02. 03.

Range of time setting. Off or changeover time 06.

_

0.1 sec. To 99 hrs.- 59 min.

On or firing time Relay rating

0.1 sec. To 99 hrs.- 59 min.

-

N.O. relay s rated 10 a. @ - 230/110 V AC and 24 V DC

07 Relay's status and Air blaster operation

Led indication displays. -

eo*ntd..4.

08 9.

Program to process values retention in case of power failure. Option to restart or continue a cyclic operation in program through "restart/hold" mode in the event of power failure.

10.

Choice of single cycle or continuous cyclic operation.

11.

By arrangement of output to output.

12.

Mode of programming

by using 5 nos. push buttons.

13.

Mode off time counting -

ascending order

14.

Main on) off supply

switch provided on front to control

--

the in coming power supply to timer. Indication lamp provided for on/off supply. 15. Auto manual mode

--

Selector switch provided on the front for the auto manual selection. Indication lamp provided for auto manual mode.

16. By facility

_

provided to skip the particular output if the present time (on & off) for the output is 00.00 then the cannel is skipped. Also the output indication doesn't glow.

17. Enclosure

_

IP 55.

00.05 Principle of Programming The micro process based sequential controller has the following options for setting and controlling the air blaster system. a.

"RUN/PROGRAMME" selector switch_

b.

"RESTART/HOLD" selector switch_

c.

"CHANNEL BUTTON" to select the output_

d

"ON/OFF" buttons to select either "ON" mode/ "OFF " mode.

e.

"RANGE" button to select the range for the "ON" or "OFF" time setting.

f

For chosen channel of "SEC-SEC"/ "MIN-SEC''/ "HOUR- MIN".

g

"ADV. (LEFT)" to increment the left most digit value.

h.

"ADV. (RIGHT)" to increment the right most digit value.

00.06 To Programme The Timer.

1.

Slide the "run/prog" switch to "prog." Mode pervious set timing will get displayed.

2_

Press "sequence/channel" button to select to the channel no. O. Immediately previous set will get displayed.

3.

Press "on/off" button to select either "on" mode or "off" mode for seating "on" time and "off" time.

4

Press the "range" button to select the range for the on time or off time setting for chosen channel_ The range is independent and can be the same or different for on and off time. The sec-sec range denotes the leftmost 2 display digits for in seconds and the right most 2 digits for seconds. Similarly choosing 'Ears-min range denotes the leftmost 2 digits for hrs and right most 2 digits for minutes.

Cotat,&__20.

5.

Use adv (left) button to make increment in the lift most 2 digit value.

6.

Use adv (right) button to make increment in the right most 2 digit value. If the selected range mode

a)

SEC.-SEC. then left 2 digits values rolls between 00 to 99 and right 2 digits values rolls between 00 to 59

b)

MIN.-SEC. ------- then left 2 digits values rolls between 00 to 59 and right 2 digits values rolls between 00 to 99.

c)

HRS.-MIN.---- then left 2 digits value rolls between 00 to 99 and right 2digit value rolls between 00 to 59.

7.

Follow the above steps to program the other channels.

8.

When all the channels are programmed. Switch the “run / prog” mode to “run” position.

9. 10.

The timer is now ready for operation. Select the "restart hold" mode as considering the requirement of cyclic operation whether from the beginning or where the operation stopped. Advisable to keep always in restart mode.

Cuut .. i.

Recommended ON TIME

Minimum one second should be provided for each channel outputs / air blasters. OFF TIME

Minimum 60 seconds interval should be provided for channel output to channel output / air blaster to air blaster. CYCLE TIME

Between one cycles to next cycle i.e. last no. channel output to first channel output/ last No. air blaster to first no. Air blaster can be selected 5 minutes to 10 minutes. The cycle time should be selected considering the following parameters.. a) Material flow characteristics. b) Storage equipments geometry. c) Rate of feeding and discharging.

Example: - when cycle time is in 10 minutes then no. Of air blaster operation is 6 operation/hour. When cycle times are in 5 minutes then no. of air blasters operation is 12 operation/hour. During the setting of cycle time, one should ensure that the requirement of air qty. is available with 6 kg/cm2 pressure at main line considering no. of operation per hour.

00.07 Wiring And Controlling Of Air blaster Svstcnl 1)

The incoming power supply 240/110 V AC 50 Hz should be given to terminal block x 3. ------ & 2.

2)

For making materials continues fluidization and flow promotion, the air blasters Operation should be always from bottom to top working sequentially and cyclically. The output control supply from terminal block x2- (1, 2)(3,4)....(19.20) should be connected to air blaster no. 1, 2……..10 respectively.

00.08 To Run The System. I.

After doing all the settings press the "channel/sequence" button until channel no. 0 appear on the channel no. Display.

2.

Select the "programme/run" mode and put it run position. Now all the selling will be saved and the cyclic operation will be taking place immediately.

3.

The system start functioning from first channel output with "on" time displaying and the corresponding "led" & preset time "range" "led" glows up to counting preset time of "on" time completion.

4,

After that the "off" time will be displayed and with corresponding "led" & preset time"range" "led" glows up to counting preset time of "off' time completion

5.

Like that the next channel output relay action will be taking place up to the last output After completion of one cycle that next cycle will be continuing.

6.

The cycle repeat until put off the power supply or changing mode from auto to manual.

('i mtd..23.

Type of Operation In Auto Mode. If the "restart/hold" mode selector button selected to restart mode the operation of cycle will be continuing from beginning i.e. first output always when changing auto/manual mode (manual to auto or put off power supply and then power on).

If keeping the selector button is in "hold" mode the operation will be taking place where the system gets stopped. Generally the "hold" is not advisable for operating system. Always should be restart mode only for operation of air blaster system from bottom to top.

To Skip The Output By Arrangement From Output To Output. When the particular output or channel is to be skipped, set the p m t time of "on" Time and "off" time as oo oo oooo. Then that output or channel will be skipped with delay of 150 millisecond and the output or channel is switch over to the next output or channel and also the skipped output to channel led (relay) does not glow.

04.09 To Stop System Simply the changeover "auto" to "manual" mode or put off the main supply.

00.10 Manual Operation The flow control unit consists of no. Of solenoid valve which are provided for each air blaster to operate The system. Individual solenoid valve has manual override for operation manually.

11.00 To Operate The System. Select which particular air blaster to be operated and push the respective solenoid valve override for minimum I second. Always the system should be operated from the first to last. The system also can be used to check up the system testing. NOTE: l)

During running the system can be stopped using main on/off switch or auto manual selector switch.

2)

All the setting buttons are dead when the system is running.

3)

After programming press "sequence/channel" button to select to the channel no. O. before "run' the system.

4)

Run/ program should be kept at nm mode for system operation.

5)

In case, the system is not working after programming all the time in program mode and keeping in run mode then the sl & s2 terminal should be short minimum 150 milli seconds through reset push buttons.

00.12 Installation Procedure: 1)

Fix the instrument at appropriate place very near the air blaster.(FCU unit and air vessel distance should be within 8000 mrn.)

2)

The flow control unit has brackets for wall mounting to mount on the existing structure or fabricated structures.

3)

Connect the power supply to the respective terminal as mentioned in the drawing.

4)

Ensure that the system is properly terminated using glands, lugs & ferrule nos. Etc.

5)

Ensure that proper earthing for flow control unit is provided.

6)

Now the system is ready for operation.