KAVERI AIR BLASTER SYSTEM

MANUAL

KAVERI ULTRA POLYMERS (P) LTD.

BANGALORE KOLKOTA MUMBAI

'MultiTech Centre' Kaveri House, 115, Creative Estate,
(Opp. John Fowler) 13211, M.G. Road, 72, N.M. Joshi Marg,
Rommasandra Ind. Area Kolkota - 700 007 Mumbai - 400 011
Off Hosur Road Tel. 32920103 122695791 Tel. 32911397, 23054878
Bangalore 560 099 Fax - 22690473 Fax - 23072861
Ph. +(91 80) 4166 3444 E-mail – [email protected] E-mail [email protected]
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 FLOW PROBLEM IN BULK SOLIDS 02

0 2. 0 1 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

0 6. 0 0 AIRBLASTER APPLICATIONS 06
0 6. 0 1 Thermal Power Station
0 6. 0 2 Cement Plants
0 6. 0 3 Steel Plants

0 7. 0 0 SELECTION AND LOCATION 07

0 8. 0 0 CONTROL PANEL 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

1 2. 0 0 INTRODUCTION 12
1 2. 0 1 Serial Number
1 2. 0 2 Warnings
1 2. 0 3 Damages
1 3. 0 0 INSTALLATION 13
1 3. 0 1 Inspections
1 3. 0 2 Nozzle Installation
1 3. 0 3 Mounting Air Blaster
1 3. 0 4 Air Supply
1 3. 0 5 Electrical Connection
1 3. 0 6 Blaster identification
14.00 OPERATION CONTROL PHILOSOPHY 16
OF AIR-BLASTER

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 21

KAVERI ULTRA POLYMERS LTD.

BANGALORE * M U M B A I * K O L K A T A
00.00 SPECIFICATIONS
1. PRESSURE VESSEL
IS 2825 CLASS 3
DESIGN CODE
8Kgf/cm2
MAX. WORKING PRESSURE
8.8Kgf/cm2
DESIGN PRESSURE
13.5 Kgf / cm2
HYDROSTATIC PRESSURE

2 AIR SEALING
PISTONASSEMBLY

PISTON HOUSING SEAMLESS

CARBON STEEL
WITH
INTERNAL
HARD CHROME
PLATED.
PISTON ALUMINIUM
ALLOY
INNER SEAL SYNTHETIC
(SEATING MATERIAL) RUBBER
BUFFER SEAL SYNTHETC
RUBBER
`O' RING TEFLON SELF
LUBRICATED
SPRING SPRING
STEEL
EXHAUST PIPE ASSEMBLY IS 1239, ‘B’ CLASS

3. VALVE ACCESSORIES ---------------- M S I S 2 0 6 2

SOLENOID BANK

HEADER
MS IS 1239, `B'
CLASS
ISOLATING VALVE BALL I PLUG
VALVE
NON RETURN VALVE PLATE SPRING
LOADED TYPE
SOLINOID VALVE
312 WAY POPPET /
PISTON
NORMALLY
OPEN TYPE.
Contd..4..
 .-lA-

MS 1S 1239
CLASS / SS TUBES
PIPING
FOR SPECIAL CASE
3/2 WAY
QUICK EXHAUST VALVE DIAPHRAGM TYPE.
PRESSURE GAUGE 0-14 Kgf / cm2
2. MOUNTING ACCESSORIES

CONNECTING PIPE
MS IS 1239,
BEND 'B' CLASS
MS IS 1239,
`B' CLASS
MOUNTING PLATE MS IS 2062

GASKET CAF (COMPRESSED

ASBESTOS FIBRE)

SUPPORTING I RETAINING ----------------M S I S 2 0 6 2

FRAME

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

5. 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 MS IS 2062

BAFFLE PLATE
TYPE.
POLYCARBNATE
AIR FILTER BOWL TYPE.
POLYCARBONATEB
LUBRICATOR 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 pre-
heater cyclone of kilns in cement plants are common. Kaveri Air-
Blaster 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 3. EXIIAUT PIPE

4. MOUNTING FLANGE 5. SPRING 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
dismantling the vessel.
4) Internal piston assembly does not lead to damage due to mishandling
5) 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.

Passes through a 3/2 or 5/2 way Normally open type solenoid valve,
passed 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 panel 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) Gypsum Hopper
b) Limestone Hopper
c) Clay Hopper

d) Cement Silos
High temperature Applications at
a) Pre-heater Cyclones 3 rd , 4th , 5th Stages.
b) 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 4

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

These are available in TWO versions.

a) Auto control panel.

i) FCU (Tinier) Microprocessor based Sequential control

ii] Panel FCU (CCR) Relay based (PLC in Client's scope) control panel

Cantd..8..
 ffesfeet

b) Manual Control Panel.

For logic and control philosophy of above control panel refer
manual of control panel, which is applicable.

For any further details and specific enquiries, please contact

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 Panel
(FCU-Timer)
Manual

KAVERI ULTRA POLYMERS (P) LTD.

BAN GALORE KOLKOTA MUMBAI

'MultiTech Centre.' Kaveri House, 115, Creative Estate,
(Opp. John Fowler) 13211, M.G. Road, 72, N.M. Joshi Marg,
Bommasandra Ind. Area Kolkota - 700 007 Mumbai - 400 011
Off. Hosur Road Tel. 3 2920103 122695 791 Tel. 32911397, 23054878
Bangalore 560 099 Fax - 22690473 Fax - 23072861
Ph. +(91 80) 4166 3444 E-mail – sales.cal@kaveri_in E-mail - kaveri [email protected]
Fax +(91 80) 4166 3555
E-mail - [email protected] Web: www.kaveri.in
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 pass
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 contact 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 passes through 3/2 way
normally open type solenoid valve & passes 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
02. relays are used
for each output
03. Input power supply - 230/110 V. AC.
04. Output control supply -- 230/110 V AC or 24 V DC
-.
05. Rated frequency _ 50 Hz.

Range of time setting.

Off or changeover time _ 0.1 sec. To 99 hrs.- 59 min.

06. On or firing time 0.1 sec. To 99 hrs.- 59 min.

Relay rating - N.O. relay contacts rated 10 a. @

- 230/110 V AC and 24 V DC
07
Relay's status and Air blaster Led indication displays.
operation -

eo*ntd..4.
08 Program to process values retention in case of power failure.
9. 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 pass 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 panel 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
panel for the auto manual selection.
Indication lamp provided for auto
manual mode.
16. Bypass 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. The timer is now ready for operation.

10. 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 Bypass 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.