Operating Instructions: Air Slide, A1,30 NP LSP Complex Project - Ash Handling System

Operating instructions
Air slide, A1,30 NP

LSP Complex Project - Ash Handling System
Order No. Job No. Type KKS
1980079 4303-A1-A2 A1 60-FD-6177A
1980079 4303-A21-A22 A1 60-FD-6177B
1980079 4303-A13-A14 A1 /
1980079 4303-A33-A34 A1 /
© FLSmidth Hamburg GmbH
Haderslebener Strasse 7
DB_0720_Foerderrinne.fm Revision: 00
25421 Pinneberg
Germany
Tel.: +49 4101 788-0
Fax: +49 4101 788-140
E-mail: [email protected]
Internet: www.flsmidth.com
Translation of the original manual

15.01.2020
2 Air slide Size XY | 12345

Table of contents
1 General ............................................................................................................. 5
1.1 Information on the manual .............................................................................5
1.2 Limitation of liability .......................................................................................5
1.3 Copyright .........................................................................................................5
1.4 Explanation of symbols ..................................................................................6
1.5 Text attributes ..................................................................................................6
1.6 Disposal ...........................................................................................................7
2 Safety ................................................................................................................ 8
2.1 Intended use ....................................................................................................8
2.2 Basic safety instructions ................................................................................9
2.3 Safety information for normal operation .......................................................9
2.4 Information about particular types of danger .............................................10
2.5 Repair and maintenance instructions .........................................................10
2.6 Operator's obligations ..................................................................................10

2.6.1 Personnel qualification ....................................................................................10
2.6.2 Personal protective equipment (PPE) .............................................................11
2.7 Behaviour in the event of danger or accidents ..........................................11
3 Technical data ................................................................................................ 13

BA0720_Foerderrinne_Ausf1+2IVZ.fm Revision: 00
3.1 Structure and function ..................................................................................13
3.2 Dimensions, weight .......................................................................................15

3.2.1 Conveyor duct .................................................................................................15
3.2.2 Materials ..........................................................................................................16
3.2.3 Installation location and position .....................................................................16
3.2.4 Material ............................................................................................................16
3.2.5 Temperatures ..................................................................................................16
3.2.6 Pressures ........................................................................................................16
Air slide 3
4 Installation and commissioning .................................................................. 17
4.1 Safety instructions ........................................................................................ 17
4.2 Performing a transport inspection .............................................................. 17
4.3 Transport ....................................................................................................... 18

4.3.1 Delivery ........................................................................................................... 18
4.3.2 Transport on the installation site ..................................................................... 18
4.4 Installation ..................................................................................................... 18

4.4.1 Mechanical installation .................................................................................... 18
4.4.2 Pneumatic connections ................................................................................... 19
4.5 Commissioning ............................................................................................. 19

4.5.1 Installation testing ........................................................................................... 19
4.5.2 Settings ........................................................................................................... 19
5 Maintenance .................................................................................................. 20
5.1 Safety instructions ........................................................................................ 20
5.2 Fault rectification .......................................................................................... 21
5.3 Inspection and maintenance intervals ........................................................ 21
5.4 Maintenance work ......................................................................................... 21

5.4.1 Remove foreign bodies ................................................................................... 21
5.4.2 Replacement of fluidisation webbing ............................................................... 21
6 Equipment overview – spare parts and wear parts ................................... 24

6.1 Introduction ................................................................................................... 24
6.2 Airslide ........................................................................................................... 25

BA0720_Foerderrinne_Ausf1+2IVZ.fm Revision: 00
4 Air slide
General
1 General
1.1 Information on the manual

This manual describes the safe and efficient use of the component. Compliance
with all prescribed safety and handling instructions is a prerequisite for safe
working and correct use.
The manual is a component of the product. Before starting any work, trained
personnel must have carefully read and understood this manual.
Furthermore, the local applicable accident prevention regulations and general
safety provisions for the area of use of the component must be complied with.
In order to present the contents being explained, depictions in these instructions
are not necessarily true to scale, and may differ very slightly from the actual
layout.
1.2 Limitation of liability

All details and notes in this manual were compiled taking into account the
applicable standards and directives, the current state of technology, and our
many years of knowledge and experience.
The manufacturer accepts no liability for damages arising from:

– Non-compliance with this manual
– Unintended use
– Use of insufficiently trained personnel
– Unauthorised conversion and/or technical modifications
– Failure to use manufacturer's original parts
Translations of the manual into the official language(s) of the Community of

Member States were carried out by qualified specialist translators in good
conscience. The attached version of this manual, indicated as the original
manual, is authoritative.
For special models, for additional options which were ordered, or because of
technical developments, the actual scope of delivery may vary slightly from the
explanations and graphical presentations included in this document.
Kapitel_Allgemeines_001_5.0.fm Revision: 00
We reserve the right to technical modifications to the product in order to improve

its performance characteristics and for the purposes of further development.
1.3 Copyright
This manual is protected by copyright, and is intended exclusively for the
internal use of the operating organisation.
Air slide 5
General
Passing the manual on to third parties, reproduction in any manner or form

whatsoever - even partially - as well as exploitation and/or sharing of the
contents are forbidden without written agreement from the manufacturer, except
for internal purposes.
Contravention will result in compensation for damages. We reserve the right to
make further claims.
The contents, texts, drawings, illustrations, and other representations are
protected by copyright, and are subject to additional industrial property rights.
Any misuse is punishable.
1.4 Explanation of symbols

Safety instructions in this manual are indicated by symbols. Three signal words
indicate different degrees of hazard:
indicates that death or serious injury is certain to occur, unless

the stated measures for prevention of the danger are complied
with.
Danger!
indicates that death or serious injury will probably occur,

unless the stated measures for prevention of the danger are
complied with.
Warning!
indicates that moderate to slight injury or material damage will

occur, unless the stated measures for prevention of the danger
are complied with.
Caution!
In addition, the following symbol is also used:

NOTICE
This symbol emphasises tips and information which should be

complied with to ensure efficient and failure-free operation.
1.5 Text attributes

Operating instructions in which the sequence must be followed are numbered:
1. Operation 1
2. Operation 2
6 Air slide
General
3. Operation n
Handling instructions which may be executed in any sequence are indicated

with bullet points:
• Operation
• Operation
• Operation
Listings are indicated with hyphens:

– Part 1
– Part 2
– Part n
1.6 Disposal
If no agreement was reached on return or disposal, send components for
recycling after suitable disassembly:
• Send residual metal material for scrap
• Send plastic components for plastic recycling
• Sort other components according to their material properties, and dispose of
appropriately
Components and operating materials which are incorrectly disposed of can
create dangers for humans and for the environment.
• Electric scrap, electronic components, lubricants and other auxiliaries are
subject to handling as hazardous waste, and should be disposed of only via
authorised specialist operations.
• Remove operational materials such as greases, oils, and conservation and
cleaning materials from the component separately according to type, and in
an environmentally friendly way. For this, use suitable collection and storage
containers authorised for the relevant operational materials.
• Clearly mark containers with the content, volume, and date, and until final
disposal, store in such a way that misuse is not possible.
Air slide 7
Safety
2 Safety
This section gives you a general overview of all important safety aspects of this
component. In order to avoid health hazards and dangerous situations, comply
with the safety instructions included here, as well as with the handling-related
safety instructions in further sections of this manual.
2.1 Intended use

The component is designed and built exclusively for the intended use described
here. Compliance with all details in this manual is an intrinsic part of intended
use.
Intended use:
The air slide is used for transporting material along a conveyor line. The air slide
is part of a plant, and is intended for use exclusively in this plant. Use the
component exclusively in a closed system.
Danger from unintended use!

The operator alone is responsible for damages resulting from
unintended use. Any other use of the component is forbidden,
Danger! and is deemed not to be its intended use.
• The component may not be used to stop the flow of
environmentally hazardous, explosive, flammable, or toxic
materials, or of materials other than those named in the
specification.
• Additionally, the component may not be used to close off
zones from one another when they have different pressure
levels.
02_0720_001_Sicherheit_2.0.fm Revision: 00
8 Air slide
Safety
2.2 Basic safety instructions

The following section specifies basic residual risks which may result from the
component.
Life-threatening danger due to pneumatic energy!

Pneumatically powered components can cause severe injuries.
Danger!
• Perform tasks on pneumatic components only if you are
specially qualified in the area of pneumatics.
• Before starting work, depressurise the component.
• During operation, you must not reach into moving
components, or remove covers.
Danger of injury due to inadequate personal protective

equipment!
When working on the component, inadequate personal protective
Warning! equipment can result in injuries.
• Wear personal protective equipment.
Danger of burns from hot surfaces!

There is a risk of burns at high operating temperatures. Skin
contact with the component can result in burns.
Warning! • Wear personal protective equipment.
• Before working on the component, wait until its temperature
allows you to work safely.
Possible irreparable damage to the component

from water or high pressure cleaner!
Moisture in the housing has a negative effect on the
Warning! operation of the component (e.g. from rusting fast,
caking-on of conveyed material), and results in
damage to bearings, gaskets and other parts.

• Use mechanical cleaning devices.
2.3 Safety information for normal operation

Cease to practice any working method whose safety is questionable!
Before opening the blind flange on the handhole, ensure that the material supply
to the air slide is interrupted, and that the air slide has been completely emptied.
Air slide 9
Safety
2.4 Information about particular types of danger

Work on pneumatic devices may be carried out only by persons with special
knowledge and experience of pneumatics!
Regularly check all connections, hoses, and threaded connections for leaks and
damage which is externally recognisable. Correct damage immediately.
Before starting repair work, depressurise system sections and pressure
connections (compressed air) which are to be opened, in accordance with the
descriptions for the assemblies.
Lay and install compressed air connections correctly. Do not get connections
mixed up. Fittings, length, and quality of hose connections must comply with the
requirements.
Take care when handling hot operating materials and auxiliaries (danger of
burning or scalding).
2.5 Repair and maintenance instructions

Comply with the adjustment, maintenance, and inspection activities and
intervals prescribed in the operating instructions, including details on the
replacement of parts and equipment. These activities may be carried out only by
specialist personnel.
Inform the operating personnel before carrying out special and maintenance
work. Specifically name supervisory staff.
Always tighten loose threaded connections during repair and maintenance work.
2.6 Operator's obligations

The component is used in an industrial operation. The operator is therefore
subject to statutory industrial safety requirements.
At regular intervals, and taking into account local safety regulations, the operator
is obliged to carry out the following tasks and to demonstrably document their
completion:
• The operator must ensure sufficient local lighting for working on the
component.
• Testing of all safety devices for their technically perfect condition,
functioning, and effectiveness.

• The component cannot be controlled locally. It must be connected to the
control system of the plant.
2.6.1 Personnel qualification
The component must be operated and maintained only by authorised, trained,

and instructed expert personnel.
10 Air slide
Safety
A trained person is deemed to be someone who has been

instructed, and where necessary qualified, in the tasks assigned
to him and the possible dangers in the case of incorrect
behaviour, as well as in the protective devices and protective
measures.
An expert is deemed to be someone who, on the basis of his
specialist training, knowledge, and experience, as well as
knowledge of the applicable regulations, can assess the work
assigned to him and recognise possible dangers.
2.6.2 Personal protective equipment (PPE)
When working on and with the component, personal protective

equipment must be worn:
– Protective work clothing
Tight-fitting work clothing (low tear resistance, no wide sleeves,
no rings or other jewellery, etc.)
– Protective gloves
to protect the skin from friction, abrasion, cuts, deeper injuries to
the hands and from contact with harmful substances
– Safety shoes, category S3

to protect from heavy falling parts, electrostatic charges and from
slipping on slippery surfaces
– Safety helmet
to protect from heavy falling parts and flying objects and
materials
– Safety goggles
to protect the eyes from harmful influences, such as bright light,
chemicals, dust or splinters
2.7 Behaviour in the event of danger or accidents
Preventive measures
– Always be prepared for accidents or fire.
– Keep first-aid equipment (first-aid kit, blankets, etc.) and fire extinguishers at
hand.
Air slide 11
Safety
– Make personnel familiar with the location and use of the safety, accident-
warning, first-aid and emergency equipment and provide proof of this.
– Clear access routes for emergency vehicles.
If worse comes to worst: take appropriate action!

1. Immediately use the EMERGENCY STOP device to shut down the
component/equipment.
2. Inform those responsible at the operating site.
3. Call for a doctor and the fire brigade.
4. Evacuate persons from the danger zone, initiate first aid measures.
5. Keep access routes for emergency vehicles clear.
12 Air slide
Technical data
3 Technical data
3.1 Structure and function

The conveyor duct is used for the transport of fluidisable bulk materials. The
conveyor duct consists of an upper (1) and a lower (4) part. In between, a
webbing (2) is clamped; this is permeable to air. The webbing is stabilised by a
support (3).
The bulk material is located above the webbing. By supplying air underneath the
webbing, the bulk material is fluidised. The bulk material flows away in the
direction of conveyance.
4
03_0720_002_TechnDaten_1.0.fm Revision: 00
1 Upper part 3 Support

2 Webbing 4 Lower part
Air slide 13
Technical data
The conveyor duct can be fitted with the following additional components:
– Grating to support the webbing
– Handhole cover
– Sight glass
– Air connection nozzles
– Measurement pipe
– Inlet nozzle
– Venting pipe
– Cover flange
– Separating flange to separate the air channel
– Rain hood to cover the flange connection
– Seal or sealing string
The conveyor duct has normal profile (NP) height or increased profile (EP)
height.
An overview of the installed additional components is found in the section
"Equipment overview, replacement and wearing parts".
14 Air slide
Technical data
3.2 Dimensions, weight
3.2.1 Conveyor duct
L9
L3
L1
W3
W4
H1
H2
H3
L7
L4
L4
L2
L2
Weight
flange
flange
Model
Outlet
Basic
Inlet
size
Job item L* L1 L2 L3 L4 L7 L9
[kg] [mm] [°]

4303-A1-A2 - 1102 - - - 200 - - 30 1 0 0
4303-A21-A22 - 2500 - - - 200 - - 30 1 0 0
4303-A13-A14 - 177 - - - - - - 30 1 - -
4303-A33-A34 - 956 - - - - - - 30- 1 - -
* Refer to the installation drawing for the exact installation lengths of the
conveyor ducts.
Air slide 15
Technical data
3.2.2 Materials
See section "Equipment overview, wear and replacement parts"
3.2.3 Installation location and position
The installation location and position are shown in the installation drawing.
3.2.4 Material
It must be possible to fluidise the bulk material, i.e. it must be dry, pourable, and
non-sticking. It must comply with the material specification (component of the
higher-level equipment documentation).
3.2.5 Temperatures
The ambient temperature is 20 to 55°C.

The temperature of the bulk material may not exceed -20°C bis +160°C.
3.2.6 Pressures
The fluidisation air pressure must be at least 0.03 bar and must not be more
than 0.6 bar.
16 Air slide
Installation and commissioning
4 Installation and commissioning
4.1 Safety instructions


– Safety helmet
materials
– Safety goggles
Danger of injury!
Incorrect installation and commissioning can result in serious
04_0720_002_Montage_Inbetriebnahme_2.0.fm Revision: 00
personal and/or material injuries.

Warning!
• Installation and commissioning work may therefore be carried
out only by trained expert personnel who comply with the
safety regulations.
4.2 Performing a transport inspection

• Upon receipt, check the delivery without delay for correctness,
completeness, and transport damage.
• If any external transport damage is identified, do not accept the delivery, or
only accept the delivery conditionally.
Air slide 17
• Note the scope of the damage on the carrier's transport documents and/or
delivery note and register a complaint.
• Claims for damages can be made only within the applicable claim period.
Make a claim to the manufacturer for latent defects immediately after they
are detected.
4.3 Transport
4.3.1 Delivery
The components of a conveyor duct have been functionally tested and pre-
mounted before they leave the factory. They are delivered on a pallet to which
they are attached by strapping.
The customer is to carry out an inspection on receipt for correctness and
completeness of delivery, and for possible transport damage.
4.3.2 Transport on the installation site
Convey the components of the conveyor duct - resting on their pallet - by means
of lift trucks to the installation location, or as close to this as possible. Remove
the strapping bands only at the installation location.
Risk of injury due to the self-tightening strap springing

back suddenly!
Injuries to eyes or face due to a self-tightening strap springing
Caution! back suddenly may occur when the strap is cut.
• Wear personal protective equipment.
• Hold self-tightening straps firmly and cut them with care.
4.4 Installation
4.4.1 Mechanical installation
Danger of electric shock!

For the safe discharge of electrical currents, the
component must be included in the plant's
Warning! potential equalisation.
• To achieve electrical potential equalisation,
apply a toothed washer under the bolt head
and the nut on both sides of at least one
bolt on each of the flange connections.
• Re-establish potential equalisation when
reinstalling the component in the plant.
18 Air slide
The component must be installed free of stress.

First make the flange connection at one side of the component, and then at the
other side.
The following applies for all flange connections:
– insert the seals supplied,
– Use washers and toothed discs,
– connect the flanges so that they are centred,
– Tighten opposed bolts, avoid tensions.
4.4.2 Pneumatic connections
Connect pressure connections and socket ball valves to the air connection
nozzles.
4.5 Commissioning
4.5.1 Installation testing
Check the correct installation location and position against the installation
drawing.
Confirm that the compressed air connections are firmly seated and correctly
sealed.
4.5.2 Settings
Pre-set the fluidisation compressed air to 0.3 bar, and open the socket ball
valves completely.
Adjust the compressed air and the opening of the ball valves as part of the
optimisation of the conveyor transport.
Air slide 19
Maintenance
5 Maintenance
5.1 Safety instructions
Danger due to escaping bulk material!

Disassembly of a component loaded with bulk material will result
in uncontrolled expulsion of bulk material.
Warning!
• Before starting work, shut off the corresponding plant section.
• Empty the plant section.

When component parts are removed, deposited conveyed material
can fall out.
Warning!
• Especially for overhead work, protect the eyes, mouth and nose.


– Safety helmet
05_0720_002_Wartung_2.0.fm Revision: 00
materials
– Safety goggles
20 Air slide
Maintenance
5.2 Fault rectification
Fault Cause Correction

Dust leak Worn seal Replace seal
little or no transport Air supply interrupted Re-establish the air supply
Worn fluidisation webbing Replace fluidisation webbing
Foreign body in the conveyor Remove foreign body
duct
5.3 Inspection and maintenance intervals
at least every ...

operating hours
every 14 days
3-monthly
6-monthly
monthly
weekly
yearly
daily
Activity
Visual examination for escaping dust 500 X
Check the control air supply for leaks 4000 X
Check the mesh for wear 8000 X
5.4 Maintenance work
5.4.1 Remove foreign bodies
5.4.2 Replacement of fluidisation webbing

When component parts are removed, deposited conveyed material
can fall out.
Warning!
• Especially for overhead work, protect the eyes, mouth and nose.
Prerequisites:
– The equipment is not conveying, and has been emptied.

– The roll with webbing is available on a suitable unwinding stand.
Procedure:
Air slide 21
Maintenance
9
1
8
6
4
5
1. Remove the conveyor duct from the system.

2. Remove all threaded connections (6, 7, 8, 9) between the upper (1) and
lower (4) parts.
3. Remove the upper from the lower part.
4. Remove the threaded connections from the mid-piece (3, 5).
5. Remove the fluidisation webbing (2).
6. Tension the webbing from the roll over the lower part (4).
7. Visually examine the webbing for damage. Only undamaged webbing may
be used.
8. Fix the webbing, leaving an overhang of approx. 3 mm.

9. Make holes in the webbing for the threaded connections:
– use a glowing spike for polyester webbing.
– use a pointed auger for Nomex webbing.
10. Screw the webbing to the mid-pieces (3, 5).
11. Lay the upper part (1) flush onto the lower part (4), put the webbing (2) in
place, and bolt together (6, 7, 8, 9).
12. Cut off the webbing flush with the duct, at the side of the roll.
22 Air slide
Maintenance
13. Seal cut edges.

– For polyester webbing, melt the cut edges.
– For Nomex webbing, seal the cut edges with silicone.
14. Install the conveyor into the channel (See “Mechanical installation”
page 18.).
Air slide 23
Equipment overview – spare parts and wear parts
6 Equipment overview – spare parts and wear parts
6.1 Introduction
In the following equipment overviews, spare parts are marked with an E, and
wear parts are marked with a V. This designation is non-binding. The order-
based spare parts range is always binding. Parts marked in bold are further
subdivided into sub-part lists.
We generally recommend that parts marked with V (wear parts) in the lists are
kept in stock.
When ordering spare parts and wear parts, the following must be specified:
– the designation of the component
– the description of the spare part according to the spare parts list
– the item number according to the spare parts list.
Ordering address:
FLSmidth Hamburg GmbH
Customer service
Haderslebener Str. 7
25421 Pinneberg, Germany
Telephone: +49 4101 788-0 (Central office)

Fax: +49 4101 788-108 (Customer service)
+49 4101 788-140 (Central office)
E-mail: [email protected]
06_0720_001_AEV_1.0.fm Revision: 00
24 Air slide
6 Equipment overview – spare parts and wear parts
Equipment overview – spare parts and wear parts
6.2 Airslide
E - Replacement part
Part within a range

V - Wearing part
No. on diagram
Item number
Quantity
Weight
Description Material
[kg]
1 Airslide Size 30 NP model 1 815.645

1 1 Airslide Size 30 housing 639.169
4 10 Hexagon bolt M8×25 8.8 tZn 106.124 0.10
5 22 Hexagon nut M8 125.343 0.22
6 10 Washer B8,4 Steel hot galvanized 140.032
7 12 Pan head screw LK M8×25 4.6 gavanized 131.101 0.24
8 1 Mesh Polyester 273.205 V 0.49
15 10 Sealing Ring DIN 7603 A 8x11.5 218.372
Al
06_0720_001_AEV_815.645_1.0.fm Revision: 00
Air slide 25
U4_Letzte_Seite.fm Revision: 00
Edited by: FLSmidth Hamburg GmbH
Air slide 27

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Operating instructions

Air slide, A1,30 NP

Order No. Job No. Type KKS

1980079 4303-A1-A2 A1 60-FD-6177A

1980079 4303-A21-A22 A1 60-FD-6177B

Translation of the original manual

2 Air slide Size XY | 12345

1.2 Limitation of liability .......................................................................................5

1.3 Copyright .........................................................................................................5

1.4 Explanation of symbols ..................................................................................6

1.5 Text attributes ..................................................................................................6

1.6 Disposal ...........................................................................................................7

2.2 Basic safety instructions ................................................................................9

2.3 Safety information for normal operation .......................................................9

2.4 Information about particular types of danger .............................................10

2.5 Repair and maintenance instructions .........................................................10

2.6 Operator's obligations ..................................................................................10

2.7 Behaviour in the event of danger or accidents ..........................................11

3 Technical data ................................................................................................ 13

3.1 Structure and function ..................................................................................13

3.2 Dimensions, weight .......................................................................................15

4.2 Performing a transport inspection .............................................................. 17

4.3 Transport ....................................................................................................... 18

4.4 Installation ..................................................................................................... 18

4.5 Commissioning ............................................................................................. 19

5.2 Fault rectification .......................................................................................... 21

5.3 Inspection and maintenance intervals ........................................................ 21

5.4 Maintenance work ......................................................................................... 21

6 Equipment overview – spare parts and wear parts ................................... 24

6.2 Airslide ........................................................................................................... 25

1.1 Information on the manual

1.2 Limitation of liability

The manufacturer accepts no liability for damages arising from:

Translations of the manual into the official language(s) of the Community of

We reserve the right to technical modifications to the product in order to improve

Passing the manual on to third parties, reproduction in any manner or form

1.4 Explanation of symbols

indicates that death or serious injury is certain to occur, unless

indicates that death or serious injury will probably occur,

indicates that moderate to slight injury or material damage will

In addition, the following symbol is also used:

This symbol emphasises tips and information which should be

1.5 Text attributes

Handling instructions which may be executed in any sequence are indicated

Listings are indicated with hyphens:

2.1 Intended use

Danger from unintended use!

2.2 Basic safety instructions

Life-threatening danger due to pneumatic energy!

Danger of injury due to inadequate personal protective

Danger of burns from hot surfaces!

Possible irreparable damage to the component

damage to bearings, gaskets and other parts.

2.3 Safety information for normal operation

2.4 Information about particular types of danger

2.5 Repair and maintenance instructions

2.6 Operator's obligations

functioning, and effectiveness.

2.6.1 Personnel qualification