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M M OVERSEAS (INDIA)

Operation & Maintenance Manual for

M M AIR BLASTER

CLIENT : HOLCIM.
INDONESIA

MM Overseas (India) Your Trusted partner & Solution Provider

An ISO 9001:2000 certified company
64/2, Industrial Area, Faridabad – 121 001, INDIA
PH : + 91 129 4113225
Fax : + 91 129 4113224
E mail : mmo@airtelmail.in / mmfblr@dataone.in
Visit us @ www.airblastermanufacturer.com
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INDEX

S/NO. Description Page No.

1 Introduction 3
2 Advantages of Air blasters 3-4
3 Operating Principles. 4-6
4 Assembly/ Erection Instructions 6-10
5 Mounting Details of Air blaster 11
6 Installation details of Pneumatic Panel 12
7 Details of Main line accessories 13
8 Details of Pneumatic Control Panel 14
9 Details of SS pipe line 15
10 Air consumption and electrical requirements 16
11 Commissioning Procedure 17
12 Maintenance Schedule 18-19
13 Safety during manual inspection 20

14 Servicing procedure 21-22

15 Trouble shooting 23-24

16 Recommended Spares 25

17 Drawings 26-27
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M M AIR BLASTER

INTRODUCTION

Air Blaster system is very effective and economical method of removing

jamming in Bunkers, Smoke Chambers, Kiln Inlet, Coolers, Chutes and Silos
etc and it ensures smooth and continuous flow of materials. It can be
installed at any place and its operation is very simple. Even an unskilled
worker can operate it with full satisfaction.

It works on compressed air (6-7 Kgf/Cm2) which is delivered through

pipelines. Generally plant air is adequate. Incase when plant air is not
available at site, small compressor can be installed as the air requirement
for operation of Air Blaster is not much. It is operated whenever
jamming takes place.

By installing these equipments, hazardous manual pocking with rods can be

avoided. The costs of installing Air Blasters are quickly recovered
through the increased efficiency and reduce down time from the creation
of free material flow.

EVEN A SINGLE PREVENTED ACCIDENT CAN PAY

FOR A COMPLETE INSTALLATION.

Advantages of Air blaster system

In Pyro processing system

a. Reduction of manual cleaning for removal of coatings/build ups.

Reduction in worker’s exposure to hot zones.

b. Reduction of heat losses by avoiding frequent opening of poking

holes for manual cleaning and also avoids use of high pressure
water jets.
c. Average Kiln output is increased due to constant draft. (Kiln feed
reduces due to increased draft in gas ducts because of coatings.)
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d. Life of refractory increases. (Damage to the refractory by manual

cleaning and high pressure water guns.)

In storage Bunkers, Hoppers, Silos.

a. Capacity utilization of storage bins increases.

b. Avoids hazardous manual poking.

c. Optimum utilization of storage area ensures increase in life of

material handling system used to load the storage area.

d. Energy saving by minimum use of loading system.

OPERATING PRINCIPLE

A large quantity of air stored in an air receiver at pressure approx.

6-7 Kgf/Cm2. This air is discharged with explosive suddenness through a
100/150 mm opening by the action of Pneumatically Controlled Valve.

The Air Blaster introduces air under pressure into the material at a rate
faster than the material can absorb it. Thus causing the material to
move. The force is totally controlled so that it is only transmitted into
the material without having any effect on the structure and produces no
noise effect or vibration. CHARGING and DISCHARGING can be
characterized as follows.
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Compressed air is supplied to the air blaster through (3/8”) stainless

steel pipeline controlled by a Solenoid Valve to Quick Exhaust Valve. The
diaphragm of Quick Exhaust Valve closes the 1” outlet. The compressed
air flows past the diaphragm into the piston chamber. The spring-loaded
piston keeps the blast discharge pipe closed. The compressed air flows
through an opening in the Piston into the receiver and charge it with air
until the pressure in it become equal to that in the supply pipeline. The
pressure in the receiver is maintained and the unit is now ready for
FIRING.
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By actuating the Solenoid Valve both the control air in the pipeline and
the compressed air stored up behind the piston are released by
simultaneously actuation of Quick Exhaust Valve. The compressed air
stored inside the receiver make the piston to lift off its seat and after
moving equal to only one forth of the outlet pipe diameter release the
whole discharge cross section without restriction loss.

The air is blown very rapidly within milliseconds into the

Bunker/Hopper/Silos and Chutes etc. so that an almost explosive effect
is obtained. The piston spring now forces the piston back to its initial
position so that the outlet is closed again and no material can get into the
interior of vessel.
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ASSEMBLY / ERECTION INSTRUCTIONS

Marking at the site

In running plant, the troublesome areas are inspected and studied to

decide appropriate and effective locations, capacity wise quantities of
the Air Blaster units and types of Nozzle. For new plants, generally past
experience helps in deciding the locations, No. of Air Blasters,
direction/orientation, nozzle type, capacity of unit etc. These are the
vital factors for the effective and satisfactory Air Blaster installation.
MMO always prefer to help our valued customers in taking such decisions
to avert any future problems. After deciding the locations, the proper
markings are done at the site.

Preparation of holes and fixing of nozzles in hoppers, silos, bunkers

Accumulated material is removed from the inner surface of the

Hopper/Bunker.
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• M S BUNKER/HOPPER

1. Incase of M.S Bunker/Hopper, 118 mm diameter hole is gas cut at the

marked location.
2. Remove the threaded flange from the nozzle.
3. Nozzle is to be taken inside the Hopper/Bunker either through man
hole or from top.
4. Put back the threaded flange to the nozzle pipe.
5. Insert the nozzle thru the hole and position in correct
direction/orientation.
6. Tak weld the nozzle pipe with the hopper body.
7. 5mm thickness MS pad plate to be welded with the nozzle pipe as
shown.
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• Concrete / RCC bunker

1. In case of RCC Hopper/Bunker about 175 mm diameter hole is chipped

off preferably without cutting any re-enforcement bars.
2. Nozzle is taken inside the Hopper/Bunker from top of manhole and
matched with the hole in the correct direction/orientation.
3. The nozzle pipe is welded with the reinforcement rods. If required,
12 mm or 16 mm dia bars can be additionally welded to the pipe for
securing it firmly.
4. The open space all around the pipe is filled in with concrete. 5mm
thickness MS pad plate to be welded with the nozzle pipe as shown.
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• Pre heater kiln inlet

1. Incase of Pre-heater and Cooler walls, the shape and size of holes for
Nozzles would depend upon the respective Nozzles.
2. For e.g., For 90 deg. and 20 deg. Nozzles preparatory holes shall be
approx. Sq. 118 mm.
3. For other Nozzles, details can be obtained from our site Engineer /
Supervisor.
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Mounting of Bend and Air Blaster unit.

1. Tight the threaded flange of the nozzle with little clearance.

2. Fix the 90 deg. Flanged M S bend to the nozzle flange by bolt & nuts
3. To other end of this M.S. bend, the Air Blaster unit is bolted.
4. By rotating the whole vessel little proper orientation is achieved.
5. The best position for this is the drain plug of the blaster is in the
bottom most position.
6. After achieving desired orientation, tak weld the nozzle flange at
four points.
7. Air blaster should be supported with Hanger support at right place.

IMPORTANT

NOZZLE FLANGE TO BE TAK WELDED AFTER ACHIVING THE DESIRED

ORIENTATION OF AIR BLASTER.
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Installation of Pneumatic Control Panel & Timer Panel.

3 POINT 600 475 225 75 440 450 175 30 Kgs.

MODEL A B C D E F G U WT.

1. Pneumatic Control Panel is designed to operate for a set of 3 blasters.

2. Pneumatic panel is installed in close vicinity of a group of Air Blaster
units.
3. The distance between air blaster and pneumatic panel should not
exceed 6 to 7 meters.
4. It can be conveniently fixed close to the hand rails without disturbing
the walkway, with suitable M.S. angle frame and support. However the
panel should be protected from any falling material and dust etc.
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Details of Main air line and accessories

The compressed air is supplied to the Pneumatic control panel header

thru 3/4” M.S. pipe line. Oil lubricator, pressure gauge and isolation
valve should be provided as shown.

• Provision has been made at both ends of the header for air inlet.
Connections shall be made as per the site conditions.

IMPORTANT

Look at the arrow mark showing the flow direction on the oil
lubricator, Isolation valve, Non return Valve, etc to make sure the
flow is correct.
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Details of Pneumatic Control Panel

Wiring details inside the pneumatic panel

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SS pipeline details

Pneumatic Control Panel and Air Blasters are connected with S.S.
pipeline (3/8”) with almost 90 degree routings. Necessary SS unions
may be used to join the SS pipe wherever necessary. Proper
clamping to be made for SS Pipe line.

IMPORTANT

Look at the arrow mark on the quick exhaust valve showing IN, OUT
and EXHAUST connections to make sure the flow is correct.
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Air consumption per blast

For Air Blaster of 150 Ltrs. capacity at pressure : 7 Kgf/Cm2.

Considering 1 atmospheric pressure : 1 Kgf/Cm2.

Free Air required per blaster : 150 x 6 = 900 Ltrs.

Considering 10 minutes blast cycle i.e. 6 blasts per hour

= 900 x 6 = 5400 Ltr/Hr.

= 5.4 M3/Hour

For a set of 10 Nos. 150 Ltrs. Cap. Air Blaster = 5.4 x10 = 54 M3/Hour.

Electrical requirements

Power supply to AMS/SQT - 110 / 230 V AC

The Coil of Solenoid Valve (24 V DC).

Cable requirement
1 AMS/SQT to pneumatic panel 4/5 core armed 1.5 Sq.mm
2 Power supply to AMS/SQT 3 core armed 1.5 sq mm

Note : The length of the cable required shall be decided as per the
location of the pneumatic panels and AMS/SQT.
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SAFETY PRECAUTIONS (ERECTION)

⇒ Proper care must be taken before shifting of materials to the site. The
materials should be shifted carefully so that the equipments do not get
scratches on their painted surfaces.

⇒ While installing Nozzle/Mounting Package inside the Smoke chamber/Pre

heater walls, proper care should be taken for sturdiness of Scaffoldings.

COMMISSIONING PROCEDURE

1. Clean all the air lines connected to Pneumatic panel by flushing by

compressed air. Make sure that there should not be any dust particle or
sand inside the air line.

2. Remove the SS pipe line connection from Quick Exhaust Valve.

3. Open the Isolation valve of individual Air Blaster to flush out the dust in
the SS tube.

4. Check for leakages at all the joints. If any leakage found arrest the
same with proper sealing.

IMPORTANT

Air blaster will blast randomly if leaks are present.

5. Reconnect the SS pipe line to Quick Exhaust valve.

6. Blast the Air Blasters manually by pressing the manual override of

Solenoid Valve.
7. Test the air blaster thru SEQUENTIAL TIMER.

Note :All the air blasters should be test fired only after getting
Concurrence from the concerned authorities.
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MAINTENANCE SCHEDULE

DAILY MAINTENANCE SCHEDULE

1. Check the Air pressure in all the pressure gauges of pneumatic

panel.

2. Check the working of air blaster at least once in a shift by watching

the sequence thru Auto mode and also thru manual operation thru

AMS.

NOTE :Turn the Auto/Manual switch in the AMS to manual mode.

Operate the air blasters one by one by pressing the push button.

Put back the Auto/Manual switch to auto mode.

NOTE : NEVER FORGET TO PUT BACK THE SWITCH TO AUTO

MODE

Check the healthiness of the air blasters by hearing the sound and

also seeing the pressure drop in the pressure gauge mounted on the

air blaster. If any abnormality found first check the diaphragm of

the quick exhaust valve and then open the air blaster as described

in servicing part.

3. Check the leakages in line. If found arrest the same.

4. Check the oil level in the lubricator. If found empty fill the oil.

(Otherwise, once in a week is enough).

IMPORTANT
Before filling the oil, close the air inlet valve of the particular pneumatic

panel and then only open the lubricator bowl. Fill the oil and replace the

bowl. Then open the air inlet valve.

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⇒ EVERY MONTH

• Check all airlines and pipe connections for leaks.

• Check all mounting areas for loose screws, nuts and welds etc.
• Check all valves including Solenoid Valve, Quick Exhaust Valve
(Rubber Diaphragm) for its proper operation.
• Drain water from air blaster vessel

IMPORTANT

Before drain the moisture from the air blaster vessel

1. Close the isolation valve of the particular air blaster.

2. Discharge the air blaster by pressing manual override of the
solenoid valve. Ensure that no air in the vessel by seeing the
pressure gauge.
3. Open the drain valve and drain the water from the air blaster
vessel.
4. Close the drain valve.
5. Open the isolation valve of the air blaster.

⇒ EVERY SIX MONTH

• Check Hose whips, if damaged, change it.

• Check Nozzles and Mounting Accessories.
• Check wires and wires connections of Electrical Control.
• Service the air blaster completely as described in the servicing
part.
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SAFETY NEEDS
DURING INSPECTION / MANUAL CLEANING THROUGH POKING HOLES

1. CLOSE AIR INLET VALVES FEEDING TO PNEUMATIC

PANEL.

2. PURGE ALL THE AIR BLASTERS MANUALLY BY PRESSING

MANUAL OVERIDE ON THE SOLENOID VALVE.

3. CHECK THE PRESSURE GAUGES MOUNTED ON THE AIR

BLASTER TO ENSURE NO AIR IN THE AIR BLASTER.

4. OPEN THE DRAIN VALVE.

5. CARRY ON INSPECTION / MANUAL CLEANING/SAMPLE

COLLECTION, ETC.

6. AFTER INSPECTION / CLEANING, CLOSE THE DRAIN

VALVES OF THE AIR BLASTERS.

7. OPEN THE AIR INLET VALVES.

8. WAIT AND CONFIRM THE SEQUENCE OF BLASTERS

WORKING IN AUTO MODE.
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SERVICING OF M M AIR BLASTER

1. Close the ball valve of the particular air blaster in the

pneumatic panel.

2. Discharge the air in the air blaster by pressing the manual

override on the solenoid valve.

3. Open the drain valve and flush out the moisture in the vessel

4. Remove the SS tube connection from the Quick Exhaust

Valve (QEV).

5. Open the QEV nut and check the rubber diaphragm. If it

found hard/damaged replace the same.

6. Otherwise clean it and put it in position after applying oil.

7. Open the cover plate by removing the bolts.

8. Take out the compression spring and rubber pad.

9. Take out the piston carefully with the help of piston puller.

Check the piston rubber seat. Check the two rubber ‘O’

rings. (Top ‘O’ ring is split ‘O’ ring)

10. Clean the piston and piston cylinder with diesel.

11. Place the cylinder inside the vessel.

12. Apply paste of grease & oil mixture on the inner surface of

the cylinder. Replace the ‘O’ rings if found damaged.

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13. Apply oil & grease paste on the piston surface and put it

inside the cylinder.

14. Clean the compression spring & rubber pad and put it

position.

15. Bolt the cover plate.

16. Connect the SS tube to the QEV and open the ball valve.

(Approximate time required 30 min.)

SAFETY PRECAUTIONS

• Only trained and authorised persons should service the

equipment.

• Before servicing, make sure that the servicing platform should

be firm & sturdy.
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TROUBLESHOOTING
If the air blaster will not charge or discharge find the cause and solution from
the following chart.
If air blaster will not charge
Ball valve in the Pneumatic Turn on the Ball valve inside the Pneumatic
Panel not turned on. Panel
Main Ball valve not turned on Turn on the Main valve
Quick Exhaust valve installed Check the IN, OUT & EXE port connections
improperly
QEV diaphragm damaged Check the QEV diaphragm, if found damaged
/hardened replace the same
Hose whip blocked or damaged Check and clean the Hose whip. If found
damaged replace it
Drain plugs, Pressure gauge / Check for the same if found leaking arrest
safety valve socket leak the leak with proper sealing
SS tube blocked Check the SS tubes at every joints for flow.
Clean it and reconnect
PU tubes damaged or blocked Check for any leakages of PU tubes inside
the pneumatic panels
NRV properly installed Check for in and out connections
Solenoid valve blocked Check for 3 way valve normally open type.
If coil is continuously energized. It will
close the inlet port. Check for the same.
Restriction in Air filters, oil Check air filters, regulators and lubricator
lubricators
Piston seat /piston damage Open the air blaster and check the same. If
found damaged replace the piston
Air blaster will not blast
Quick exhaust valve blocked or Check the diaphragm
Diaphragm damaged
Solenoid valve manual override Check the manual override by pressing it
not properly seated
Solenoid valve not operating Check the electrical connections
Piston ‘O’ ring / seat damage Open the cover plate and check the same as
described in the servicing part.
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RECOMMENDED SPARES FOR AIR BLASTER

For a set of 10 Air Blasters for 2 years operation

Qty (No.)
SL Description Part No.

Spares for 100 mm discharge air blasters

1 Cylinder ‘O’ Ring (DN100) AB-10-120 20 Nos.
2 Piston (DN100) AB-100121 2 Nos.
3 Piston ‘O’ Ring (DN100) AB-100122 40 Nos.
4 Rubber Pad (DN100) AB-100123 5 Nos.
5 Piston Spring (DN100) AB-100124 5 Nos.
6 Gasket-Cover plate (DN100) AB-100125 10 Nos.
Spares for 150 mm discharge air blasters
7 Cylinder ‘O’ Ring (DN150) AB-10-120 NA
8 Piston (DN150) AB-150121 NA
9 Piston 'O' Ring (DN150) AB-150122 NA
10 Rubber Pad (DN150) AB-150123 NA
11 Piston Spring (DN100) AB-150124 NA
12 Gasket -Cover plate(DN150) AB-150125 NA
Spares common for 100 & 150 mm discharge air blasters
13 Hose whip 3/4" * 6" long AB-100126 10 Nos.
14 Safety Valve AB-100127 5 Nos.
15 Quick Exhaust Valve ¾” BSP QV-100130 5 Nos.
16 Rubber diaphragm –QEV QV-100131 50 Nos.
17 QEV 'O' Ring QV-100132 20 Nos.
18 Non return Valve NP-00143 2 Nos.
19 PU tube NP-00145 2 Mtrs.
20 Solenoid valve 24 V DC NP-00147 5 Nos.
21 Oil Lubricator 3/4" BSP ML-00158 2 Nos.
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