Rod/pipe/tube Cleaning Machine
`Surfex` Airless Shot Blasting Machine Conveyor type for cleaning of Metallic Pipes with Blast Cabinet, Bucket Elevator, Abrasive Cleaning System, Abrasive Separator, dust collector, Control Panel & electric Motors but without Blast Wheel Assembly Qty. 2 Nos. & Skew Roller Conveyor System.
STANDARD ACCESSORIES :
a) Blast Cabinet with Inspection Door, Bucket Elevator, Abrasive Cleaning System & Abrasive Storage Silo.
b) Automatic Abrasive Control Valve cum sound reducer.
c) Cabinet Liner –The entire cabinet is lined with long life Mn. Steel sheet having thickness 8mm are provided. The Door is also lined with 6mm Mn. steel plate.
d) Vibratory Shaking type Dust collector.
e) Independent Cubical Control Panel with ammeter and Voltmeter and timers, push button, contactor, thermal overload relays, overload protection, indicating lamps and main isolator, soft starters, sensors, transformer etc.
f) Electrical Motors Various motors as details in the technical specification sheet having TEFC Construction 3 phase, 415 volts, 50 cycles, ABB, CG make . Generally as per enclosed Technical Specification Sheet.
TECHNICAL SPECIFICATION SHEET
Note: Above specifications are subject to change due to continuous development of product.
|Size of Component (Maximum)||4″ to 56″ dia ( Pipes) Length – 4500mm- 12000mm max|
|Turbines (Blast Wheel)|
|No. of Blast Wheel||2|
|No. of Blades (each wheel)||8|
|Size of Blast Wheel||50R210|
|H.P. of Blast Wheel||100 HP x 2 Nos.|
|R.P.M. of Blast Wheel||1850|
|Approx. Shots flow rate||700 Kg /minute|
|Shot Velocity||70-80 Mtrs./Sec.|
|Shots Consumption rate||0.13 kg/hp/ hr|
|Initial Charge of Shots||4000 Kg.
(to be provided by purchaser)
|Drive For Bucket Elevator||15 HP|
|Drive For Screw Conveyor (total)||7.5 HP|
|Skew Roller Conveyor Systems||Upto 2mtr/min|
|Length of conveyor (inlet)||10000 mm|
|Length of conveyor (outlet)||13000 mm|
|Compressed Air requirement at 6 Kg/Cm² pressure||25 CFM AT 7 Kg./cm²|
|Dust collector System||Vibratory Shaking type|
|Capacity of dust collector||15000 cfm|
|Filter cloth area||316 sq mtr|
|No of bags||300 nos|
|Type of bags||Fabric Bag type|
|Geared Motor||4 Nos|
|HP of geared motor||1.0 HP each|
|Bag Cleaning||Vibratory Shaking type through sequential timer|
|Noise Level||80-85 dB (A) at 3 Mtr. From Machine.|
|Cleaning Standard||SA 2.5-3|
|Job Movement||Rotational with linear movement|
|Control Panel||Centralised Cubical type panel|
|Overall Dimension of Machine||Length 28000mm
|Floor Space required for Machine without Reverse Pulse Jet type Dust Collector||Length 28000mm
|Pit Requirement||Length 6000mm
|Total Power Required||268.5 HP(200 kw)|
|Blast Wheel 100 HP x 2||200.0|
|Bucket Elevator 15 HP x 1||15.0|
|Upper Screw Conveyor 7.5 HP x1||7.5|
|Inlet Conveyor 1 HP x 3||3.0|
|Outlet Conveyor 1 HP x 3||3.0|
|Dust Collector 40 HP||40|
GENERAL SPECIFICATION OF THE MACHINE
The pipe is kept on inward side of the Skew conveyor system. The pipes are transferred into work chamber. The work chamber houses 2 Nos. of bottom mounted blast wheel station which fire abrasive from bottom side of rotating pipe. The pipes duly shot blast cleaned while they are passing through blast stream zone. The pipes come out from the outlet portion of the machine and removed manually. The conveyor speed is variable. The machine is provided with inlet and outlet vestibules. Sufficient No. of rubber curtain are provided to trap escaping shots. The entire machine is ventilated by powerful Pulse Jet type continuously operated Dust Collector.
Operating Principle :
It consists of substantially built Blast cabinet. 2 Nos. of Blast Wheel of size 21″ x 100 HP are positioned at bottom side of cabinet. The entire cabinet is lined with Mn. Steel Tile. The inlet and outlet side cabinet is proivided through suction rubber curtain of different size matching different OD of pipe. Rubber curtain prevent escaping of shots. The entire machine is adequately ventilated by powerful Pulsejet type Dust Collector. The pipes are kept on inner side of screw conveyor system and are taken into blast chamber. In blast chamber, the outside of piping is thoroughly blast cleaned. The cleaned blasted pipe come out from outlet portion of conveyor from where they are taken out to suitable plates.
Blast Cabinet :
The Blast Cabinet is fabricated from 6-8-10mm thick heavy-duty prime quality steel plates, supported by strong rolled structure welded construction and engineered suitably for strength and rigidity to guarantee the optimum sturdiness. This robust rolled structure with thick plate foundation holds stand the machine and helps to reduce vibration keep within permissible limits. The Blast cabinet bottom is provided with 12mm Mn. perforated sheet.
Blast Cabinet Liners::
The entire cabinet is lined with 10mm Mn. Overlapping type tile.
Blast Wheel Assembly:
Two No. of blast wheel stations, Size 21 ½” x 4 ½’’are mounted on 20mm thick heavy duty prime quality steel plate & strategically around the cabinet and the pass-line of the work. All blast wheels are arranged to blast at an angle with the line of job movement. The unit consists of fabricated steel casing having installation of different alloy steel liners, rotor, blades, control cage, impeller and feed spout. The rotor is made out of EN grade material duly hardened. The drive system of blast wheel (rotor) entails a set of self-lubricated and self-aligning pedestal bearings. The rotor is dynamically balanced. The drive shaft of blast wheel is made out of EN grade material and duly precision grinded to the finest accuracy. The fabricated casing of blast wheel assembly can be easily opened up through bolts/levers for examination of various liners and parts of wheel assembly. Individual ammeter is provided on control panel to indicate abrasive flow rate / loading of turbine in terms of current loading on ammeter.
A vestibule extends beyond the work entrance slot of the blast cabinet. The entrance vestibule is fabricated from 6mm thick steel plates and combined with two set of hanging rubber seals. The spent abrasive trapped within the entrance vestibule is returned to the main abrasive system through hopper.
A Photo electric sensor is provided near inlet vestibule. The blast Wheel will start only when job move into the vestibule.
Abrasive Separator, Rotary Screen & Storage Hopper:
The rotor of blast wheel assembly unit fires down the abrasive on the component moving on conveyor. The spent abrasive falls into hopper of the cabinet. The abrasive from hopper slides down to the screw conveyors, which transfers them to the boot of the bucket elevator. These shots are elevated to the desired height with the help of buckets mounted on rubber belt. The separator is AIR WASH TYPE. Oversize contaminants and the media mixture are discharged from the head section of the bucket elevator into the trash by means of an upper screw conveyor. The trashes will be directed by the internal screw flight to a trash and air currents remove the contaminants. The dust and useless fines will be air borne to an expansion chamber from where coarse material will drop into a refuse hopper and thereafter to the floor level through drain tubing and dribble valve control. The fine dust particles will be conveyed through vent piping to the dust collector. The usable abrasive is transferred into the storage hopper for re-circulation purpose. The abrasive from the storage hopper are transferred into blast wheel unit through feed gates. These gates are enclosing to reduce noise within 80-85 dB. The rotational movement of impeller constantly accelerates the incoming abrasives and feed them to the blades of rotor. An electro-pneumatic valve operated by pneumatic cylinder and solenoid valve regulates the flow of abrasive to the blast wheel unit. The abrasive at high velocity are thrown by rotor on to the job. The flow of abrasive to the wheel is controlled by specially designed dribble valve, which is mounted before the storage hopper. The valve is opened and closed with an air cylinder, which is actuated electrically by a 4-way solenoid pneumatic valve, consuming a few Cfm of compressed air at 80 psi.
Abrasive Controls Mechanism :
The abrasive flow from storage hopper can be regulated by electro pneumatic 4 way type solenoid valve operated fully enclosed soundabrator valves by a screw regulator. This system consumes small amount of compressed air at 80 psi. The opening of valve can be done through a screw as per ampere meter setting of blast wheel motor. The totally enclosed design of this valve muffle the sound emanated from blast wheel. It is reported lowering of sound level by 5 to 10 dB.
Surfex Vibratory Shaking type Dust Collection System:
`Surfex` Vibratory Shaking type Dust Collector of capacity 15000 cfm / 25500M³ per hour with filter cloth area of 316 sq. meter with fabric bag type filter bags .A Superior quality of material is used for making bags with double machine stitches. The dust collector is based on vibratory shaking type mechanism for cleaning of bags. The dust-laden air enters the dust collector housing through side inlet and passes through dust collector bags. All fine particles are filtered and settled in hopper of dust collector. Only clean air will be exited through blower. The dust collector system is having two compartments to maintain continuity of operation. When one compartment is in filterering mode, the other compartment will be in shaking mode. Hence the continuity of operation is maintained. A sequential timer regulate the mode of operation of dust collector. The air inlet duct of both compartment is regulated by pneumatic cylinder operated valve for opening and closing of the same. This system does not require compressed air.
The dust is collected in the tray of dust collector. The trays are taken out periodically and emptied. The blower unit of dust collector is dynamically balanced. The dust collector is fabricated in modular design and all the joints are sealed with high quality sealing compound.
The exhaust fan is with backward curved blades and driven by 40 HP drives
Skew Conveyor: (JSL SCOPE)
Tyre type conveyor is provided at inlet and outlet side of machine, this system can handle pipe from 4 ‘’ -56’’ dia
- Control Panel: It is an independent dust proof IP-54 aesthetic look control panel manufactured according to TEC regulations and EC directives, having the latest control system with inter-locking.
- Instrumentation: The ammeter for each throwing wheel and voltmeter are fitted for instant and accurate reading. The various timers of reputed make are provided for blasting operation.
- Protection: It is entails by contactors, relays, push buttons, main isolation switch, safety limit switch, emergency switch, grounding system, HRC fuses, indicating lamps etc. The time control device is provided with visual lamp indicator depicting the passage of time. Various safety features are inbuilt in the system like blast wheel motor will not operate if door is opened.
- Electrical Power distribution: It is with transformer for low voltage internal consumption, complete wiring on the machine with cables, protection guides, cable with terminal connections and complete wiring inside the electric panel.
- All exposed power drives are equipped with totally enclosed Safety vibration free wire mesh guards. The safety guards may be easily and quickly removed and refitted for equipment maintenance.
- The blast cabinet doors are equipped with safety interlock switches to automatically shut off the blast wheel units, if by accident either door should be opened during the blasting operations. The switch also prevents starting the wheels unless the doors are completely closed.
- When blast wheel casing is opened, machine will not operate.
Inside and outside surface of equipments will be brush cleaned and given two coats of Epoxy Primer. Final coat on exterior of the system is Shaded: RAL:6017 shade and all the guards of motor are Yellow Enameled. .