Cardox CO2 Blaster Manual

Transcription

Blockage Elimination System
TECHNICAL MANUAL
110 Mohr Drive
Mankato, MN 56001
1-800-458-9446
www.pneumat.com
Cardox Technical Manual
Pneumat Systems would like to thank you for your purchase of a Cardox Blockage Elimination System. Employees’ safety will be enhanced and steady state
processes will improve due to a reduction in interruptions in material flow. We are
constantly striving to keep Cardox and our other products the best bulk storage
cleaning equipment available. One way we can continue to do so is to listen to
you. Many of the improvements we have incorporated over the years, have come
from customer input. So please give us a call with any suggestions or questions
you may have. Included in your purchase is the commitment from us to stand
behind our product and keep you up and running. If something is needed in a
timely fashion Pneumat Systems will make the extra effort to get it to you as quick
as possible.
1
INTRODUCTION
The purpose of this manual is to provide the user with useful information on the Cardox Blockage Elimination
System by covering the following:
What is Cardox?
Step by Step Instructions:
- Installation
- Rebuilding a Cardox Tube
- Filling a Cardox Tube
- Firing a Cardox Tube
Troubleshooting
Exploded Parts Drawings and Lists
THE TECHNOLOGY
Cardox is a high pressure CO2 Blockage Elimination System that is designed to safely and quickly break-up
material from a wide variety of areas. The system’s main component is a high strength reusable steel tube filled
with liquid CO2, a chemical energizer, a rupture disc and a gasket. When initiated with a small electrical charge,
the chemical energizer begins a reaction that develops within milliseconds enough heat and pressure rise to
shear the center out of the rupture disc. This releases a high pressure, non-explosive blast of CO2 through the
discharge ports at the end of the tube that breaks-up and dislodges the surrounding material. After each use
the Cardox tube can be rebuilt with a new energizer, rupture disc, gasket, and recharged with liquid CO2 for use
again.
Page Cardox Technical Manual
Cardox Use
3.00 The Cardox system is a good tool for dislodging build up material in a hot process vessel during operation.
3.01 The Cardox system can safely dislodge blockage that reduces material flow in cold applications. These being load
out silos, packing silos, etc.
Cardox System Components
consists of but is not limited to:
M.
A. Auto fill and activating head
B. 2 and 4 way discharge heads
C. Cardox tube
D. Pneumat Safety Heater
H.
E. Copper washer
O.
N.
I.
P. Q.
F. Shear disk
G. Tube vise
G.
H. Impact wrench
I.
R.
Filling station
J. Safety Heater storage magazine
K. Quik-Lok base socket
L. Quik-Lok tube clamp
L.
K.
M. MSHA approved blaster’s OHM
meter
N. MSHA approved blaster’s activator
D.
O. Firing cables
S.
P. 1/4” hex wrench for bleeder screw
Q. 3/16” hex wrench for check valve
R. Torque wrench with 7/16” deep
socket for tightening fill head electrode
E.
F.
T.
B.
S. Rock drill
T. Rock drill bit and drill shaft
A.
C.
CO2
5.00 Liquid CO2 is pumped into the properly prepared tube to make the activation work.
5.01 Only liquid can be used. This is accomplished by getting the CO2 from a cylinder that is equipped with a
siphon tube or dip tube.
5.02 CO2 gas is heavier that air so the tube packing and filling room should have a vent located near the floor.
5.03 When CO2 changes state from liquid to gas it passes through a solid ordry ice state. This chills any surface it
touches. When releasing CO2 from a tube the tube may get very cold. Gloves should be used.
2 INSTALLATION
360° PNEUMATIC VISE HOOK-UP
The Pneumat Vise and Toolholder Assembly makes
rebuilding Cardox tubes much easier and more convenient. The tool hanger bar/shelf assembly contains
a compressed air manifold that takes a single plant air
connection and distributes compressed air power to the
foot actuator and tools you will need to quickly teardown and rebuild Cardox Tubes. It also provides a port
for compressed air out to the Fill Stand Assembly.
IMPACT
WRENCH
SUPPLY
BLOW
GUN
SUPPLY
Connect
to Cardox
Fill Stand
FOOT
VALVE
SUPPLY
FILL
STAND
SUPPLY
Page Connect
Compressed
Air Supply IN
COMPRESSED
AIR SUPPLY IN
FILL STAND PUMP HOOK-UP AND OPERATION
Cardox tubes are “charged” by pumping liquid CO2 from a 50 lb. bottle
into the fill head of the tube until the desired amount of CO2 is contained in the tube. The Cardox Fill Station makes this a quick and
simple operation. Proper hook-up and operation of the fill station are
as follows:
Connect
CO2
Bottle
1. Connect the CO2 supply line from the inlet of the pump to the
supply bottle.
NOTE: A bottle with a siphon tube is preferred but if not
available, invert the bottle to supply liquid to the discharge
valve. Always use an approved bottle inverter.
2. Open the discharge valve on the CO2 bottle fully by turning it
counter-clockwise.
3. Purge the supply line from the pump to the fill head by opening the fill valve on the pump stand near the fill nipple.
4. Bleed the line until liquid CO2 exits the fill nipple. The liquid
will appear as white discharge from the nipple that quickly
turns to clear gas. Close the fill valve.
Connect
Compressed
Air
5. Connect the air supply line to the pump air inlet valve. Adjust
regulator 80-100 psi supply to pump.
6. Test the pump, with the fill valve closed, open the ball valve
supplying air to the pump. The pump should pump two or
three cycles, after which the pump “deadheads” against the
liquid between the pump discharge and the fill valve.
AIR SUPPLY IN
(FROM VISE MANIFOLD)
3 REBUILDING A CARDOX TUBE
1.
Center Tube in Vise
Rotate the jaws of the
Rotary Air Vise so that
the Cardox Tube may be
placed horizontally into
the jaws. Center the tube
with the Fill Head on the
right.
2. Open the Manual
Bleed- off Valve
Open the manual
bleed off valve on the
tube fill head with a
1/4" hex wrench.
3.
Rotate Tube so Fill
Head is Facing Up
Pull up on the vise rotation lock and rotate the
vise 90° counter-clockwise until it locks in a
vertical position so the fill
head is at the top.
Make sure the fill
head discharge hole
is pointed away from
you.
4.
5.
6.
Page Loosen and Remove
Fill Head
Remove the fill head with
1-1/2” socket and 3/4” air
impact wrench.
Inspect Fill Head
Inspect the fill head for
buildup around the electrode, and CO2 fill hole.
Clean with rag to ensure
proper filling if necessary.
Check Electrode
Torque
Check torque of electrode with torque
wrench set to 40 ft/lbs.
7.
Remove Heater
Remove the spent heater
remains.
8.
Blow Out Debris
Use the compressed air
nozzle to blow off the
threads and seat area.
Then wipe them down
with a clean rag.
9.
Inspect Tube End
Threads and Seat
Inspect the threads and
seat area for pitting and
wear. If acceptable,
proceed; otherwise send
tubes to Pneumat for
repair.
10. Rotate Tube 180º
Rotate the tube 180º so
the discharge head is
now on top.
11. Loosen and Remove
Discharge Head
Again, using the air
impact wrench remove
the discharge head from
the tube.
12. Remove Spent Shear
Disc & Copper Gasket
Remove the ruptured
shear disc and copper
washer.
13. Blow Out Debris
Again, use the compressed air nozzle to
blow off the threads and
seat area. Then wipe
them down with a clean
rag.
14. Inspect Tube End
Threads & Seat
Again, inspect the
threads and seat area
for pitting and wear. If
acceptable, proceed;
otherwise send tubes to
Pneumat for repair. 15. Install New Copper Gasket
Place a new copper gasket in the tube making
sure it is sitting flat down
against the seat.
16. Install New Shear Disc Place a new shear disc in
the tube, rounded edge
down, so it is resting
flat against the copper
washer.
17. Inspect Discharge
Head
Inspect the cutting edge
of the discharge head
looking for a clean sharp
corner. If the edge is not
sharp send to Pneumat
for repair.
18. Oil Discharge Head
Threads
Place a small amount
of oil along threads to
lubricate them.
19. Re-install and Tighten
Discharge Head
Start threading the
discharge head by
hand into the tube end.
Tighten securely with the
air impact wrench.
NOTE: Pneumat does not recommend the use of a pneumatic
rotary brush to clean the equipment. This will degrade the
threads and ultimately shorten tube and head life.
20. Rotate Tube 180º in
Vise
Again, rotate the tube
180º so the fill head end
is up.
21. Install New Cardox
Safety Heater in Tube
Place a new Cardox
Safety Heater into the
tube. Inspect the heater
to insure the center contact wire is in place and
will be contacted by the
electrode in the fill head.
22. Oil Fill Head Threads
Place a small amount
of oil along threads to
lubricate them.
23. Re-install & Tighten Fill
Head
Start threading the fill
head by hand into the
tube end. Tighten securely with the air impact
wrench.
24. Check Continuity
Check circuit continuity
with the Blasters Ohmmeter (1-3 ohms). If
not in range, remove
the fill head and check
electrode for cleanliness. Replace heater if
contacts were good and
re-tighten.
25. Rotate Tube & Remove
Rotate the tube 90º in
the vise. Release pressure on the vise with
the manual foot valve,
remove tube.The tube is
now ready for storage or
charging with CO2 in the
fill stand.
4
FILLING A CARDOX TUBE
1.
2.
6.
Check Safety Bleed-off
Valve
With a 1/4” hex wrench
check to make sure the
Safety Bleed Off Valve in
the fill head is closed.
Secure Tube in Fill
Stand
Turn the handle on the
tube clamp to securely
clamp the fill head to the
fill nozzle.
7.
Weigh Empty Tube
Place the EMPTY rebuilt
tube on the scale using
the supplied plactic tube
rest to keep the tube
from rolling off the scale.
Open CO2 Fill Valve
Make sure the discharge
valve is closed. Then
open the fill valve on the
fill station to begin the
flow of CO2 into the tube.
8.
Turn Air ON/OFF Valve
to ON
Open the Air Valve on the
pump to begin pumping.
9.
After Pump Stops
Close CO2 Fill Valve
Allow the pump to
run until there is about
5-10 seconds between
cycles of the pump, and
then close the fill valve.
Fill times are normally
around one minute.
3.
Set Tare Weight to Zero
Set the tare weight by
pressing the tare button
on the digital display.
The readout should display a zero weight.
4.
Place Tube into Fill
Stand
Put the tube assembly
into the fill manifold at
the top of the Cardox Fill
Station by entering from
the bottom.
5.
Page Make certain the Cardox firing tube has
been properly rebuilt
before charging the
tube.
Align Fill Port & Fill
Nozzle
Align the fill port in the
tube fill head with the fill
nozzle on the fill station
by rotating the tube assembly until the port can
be fitted over the plastic
nozzle.
10. Open CO2 Discharge
Valve
Open the Discharge Valve
to release the trapped
pressure from the fill
manifold.
11. Remove Tube from Fill
Stand
Loosen the clamp securing the tube to the fill
nozzle and remove tube.
Hold under water for a
few seconds and watch
for bubbles rising up
from the tube end.
12. Weigh Filled Tube
Place the filled tube back
on the scale to check the
weight of CO2 that was
pumped into the tube.
15. Put Back in Vise & Reseal (IF LEAKS)
If tube is leaking clamp it
into the vise and review
troubleshooting section
of this manual. Repeat fill
procedure.
13. Adjust Air Pressure &
Refill
If the tube does not have
a sufficient CO2 charge
(see chart below) put it
back into the fill station and repeat Steps 4
through 11. The air pressure to the pump may
need to be increased
to obtain a proper fill
weight.
16. Tape Over Contacts
If there are no leaks cover
the electrical contacts on
the Cardox fill head with
14. Check Each End of
Tube for Leaks
Dip both ends of tube in
a bucket of water at an
angle to check for leaks.
CO2 Charge Weights (min):
Series 3700 Tube Series 5700 Tube
1.3 lbs
1.8 lbs
0.60 kg
0.82 kg
5
FIRING A CARDOX TUBE - BASICS
Charged Cardox Tubes are safe to be transported and handled with reasonable care and safety.
Once a Cardox tube is filled with the proper amount of CO2 it is ready for activation. A filled Cardox tube should always be respected. Dropping a tube will not cause it to activate, but it could
break the copper washer seals on either end and cause the tube to leak
Tube Placement
Drill a 2-1/8” diameter hole into the effected material to a depth that will put the discharge
ports of the Cardox Tube in a position 12” – 18” from a free face. Try to take less material with
initial shots, until you learn more about the solidity and cohesiveness of the material.
Tube Securing
In securing a Cardox tube hold the tube into the material before initiation to prevent ejection of
the tube and to allow for retreival of the tube after initiation. There are three basic methods for
Cardox Tube retention:
1. Quik-Lok Socket and Clamp (available from Pneumat)
A Quik-Lok Socket is welded or bolted permantly to the tower, hopper or bin wall in the
effected area and is sealed with a removable plug when not in use. A Quik-Lok Clamp is
affixed to the Cardox Tube at point that will yield the desired tube insertion depth. The
tube/clamp assembly is now inserted into the hole through the socket on the vessel
and secured with a half turn of the bayonet-style coupling between the clamp and the
socket.
2. Quik-Clamp (available from Pneumat)
A Quik-Clamp is fastened to the outside of a Cardox tube to provide an anchor point
for attaching a chain, wire rope or come-along to act as a retaining line. Make sure the
retaining line is secured to something substantial that can withstand the power of a
Cardox tube.
3. Cardox Activating Head With Eyebolt
Cardox Activating Heads have a threaded hole that will accept an eyebolt that can be
used for tube retention and retrieval. Smaller heads have a 1/2” threaded hole and
larger heads have a 1” threaded hole. After securing an eyebolt into the head, attach a
chain, wire rope or come-along to the eyebolt to act as a retaining line. Make sure the
retaining line is secured to something substantial that can withstand the power of a
Cardox tube.
Wiring
All wiring should be done at the point of use for each tube. DO NOT pre-wire tubes and then
transport to the point of use. Wiring should be done with well-insulated 14–18 gauge wire. .
First short-circuit one end of the wires and then secure the other end of the wires to the activating head with a few wraps of black electrical tape. Complete wiring to the a High Energy
Activating Machine when EVERYONE is safely away from the area and behind substantial
protection from flying material.
Page 10
Activating
Proper activation of a Cardox Tube should be done with an activating machine. Disconnect the
short-circuit and insert and tighten the leads into the screw-down connectors on the activating
machine.
READ the instructions on the activating machine to become familiar with its operating procedures. Verify by sight and sound that everyone is clear. Then, hold down the charging button
until the red indicator light comes on to signal that the activating machine is now charged and
ready. Depress the firing button and the Cardox Tube will be initiated.
Misfires
CAUTION – Misfired tubes can be partially energized and may be very hot to the touch. Consider every misfire to be HOT until verification that it is not.
If a Cardox Tube does not fire when activated, first check for connection problems such as loose
wires and check the continuity (1-3 ohms). If a connection has been found as the source of the
misfire, clear the area again and try to reactivate.
If no connection problem exists, the very FIRST thing to be done is to release the pressure inside
the Cardox Tube. Locate the release valve on the activating head and open it with a 1/4” Hex
Wrench which will let the pressurized CO2 exit the tube to atmosphere. This must be done
before anything else, since once the pressure is relieved from inside the tube, that tube can
no longer discharge unexpectedly. If the continuity is out of range the heater will need to be
replaced (see page 6).
Removal
Disconnect wires from the activating machine and short-circuit them, remove wires and tape
from the activating head connections, whether a tube is charged or discharged, before removal
from the material. The tube can now be safely removed and rebuilt if neccesary.
6
STANDARD OPERATING PROCEDURES -SPECIFIC AREAS
Purpose and Scope
To provide the user with the proper and most current operating procedures for safe Cardox
tube preparation, tube filling, and tube activation. Also to highlight issues of safe operation of
the Cardox system. and to provide an understanding of the Cardox system and its usefulness as
an in operation tool for reducing process blockage.
Responsible Roles
2.00 Pneumat Systems, Inc. endeavors to provide the users of the Cardox system the proper
and safe operating procedures
2.01 The user of the Cardox system is to be aware of the safe procedures and follow them.
2.02 The user of the Cardox system is encouraged to respect the proper handling procedures
and to not take short cuts in the use of the Cardox system.
2.03 The user is encouraged to follow all the proper steps in preparation, filling and activating
the Cardox tube.
Page 11
WHERE TO USE CARDOX
Cooler
Cardox can be used throughout your material handling line anywhere build-ups, hang-ups and
blockages occur. It also can be used in storage silos that contain stone, gypsum, clay, coal and
finished cement to name a few. Throughout the preheater and precalciner tower is an area where
Cardox is used extensively and is extremely effective. Other areas include the feedshelf, kiln and
cooler areas.
One feature that makes Cardox easy and safe to use is the Quik-Lok Socket and Tube Clamp
System. By placing Quik-Lok Sockets on a vessel, access points through the wall are created that
provide precise and secure tube placement. These inexpensive sockets can be easily installed
anywhere a problem occurs, and the adjustable tube clamp allows consistent and controlled
discharge depth into the material which protects refractory and vessel walls.
Using Cardox in TOWER applications:
A) Get prepared completely,
B) Only put tube into the tower when prepared,
C) Only have the tube in the heat a minimum time, and
D) Keep the firing cable wires at the activator end shunted together when setting up and
dismantling the application.
8.02 In most applications the base port needs to be used for tower applications. The base port
is welded in place on the tower and sealed by the plug between tube insertions.
8.03 With the base port a Quik-Lok Tube Clamp should be used to secure the tube while making the blast. The Quik-Lok Tube Clamp secures to the tube and them locks the tube into
the base port.
8.04 A hole should be drilled into
the material build up for the
blast to be most effective.
After drilling through the material one should use a round
rod with a curve on its end
to measure the depth of the
build up.
8.05 One needs to know the thickness of the refractory at the
point of the planned blast.
The end of the male part of
the Quik-Lok Tube Clamp
should never be any closer
than 6” beyond the refractory.
This 6” is measured from the
end of the tube to the surface
of the male end of the clamp.
Page 12
D
A
B C
D = Total Depth (From Tube End to Clamp Face)
D=A+B+C
A = Depth into Material
B = Thickness of Refractory
C = Thickness of Wall & Quik-Lok Socket
EXAMPLE:
A = 10 Inches
B = 9 Inches
C = 3/4 inch + 2-3/4 inch = 3-1/2 ~ 4 inch
D = 23 inches (From end of tube to Clamp Face)
8.06 The clamp needs to be securely tightened in place on the tube. Hitting the clamp with
the wrench will verify that the clamp is in place securely.
8.07 When the base port is located close to a tower edge or corner wall only a 2-way discharge head should be used. Mark the direction of discharge by aligning the handle or
the bolt on the clamp with the 2-way discharge outlet opening. When the tube is locked
in the base port, observe the direction the blast will go. Adjust the positioning of the
clamp so that the discharge will be in the vertical direction.
8.08 Next the firing wires should be placed in the activation auto fill head. The electrical application is not polarity sensitive and as such no particular orientation of the firing cable
wires is needed. The opposite end of the firing cables should remain shunted (twisted)
together until the tube is placed in the base port, this prevents static electricity from the
tube prematurely.
8.09 Place the tube with clamp into the base port and twist it into a locked position. Move to
the opposite end of the firing cable, which should be around a corner or out of the line
of the tube direction by 25’ – 30’. Hook up the MHSA approved blaster.
8.10 Observe that the area around the blast is secured. Hold the left button down on the
blaster until the red light comes on. Continue to hold the left button with the light on
and depress the right button to activate the safety heater inside the tube.
8.11 The blast should occur immediately. NOTE: the goal is to have the tube inside of the
tower heat for less than 5 minutes. Once the blast has occurred remove the blaster and
re-shunt that end of the firing cables.
8.12 If a blast does not occur, immediately approach the tube. Observe the location of the
relief hole in the fill head. Make certain that the relieved gas will not strike you in the
face. Open the safety bleeder valve using a 1/4” hex wrench. Let the gas bleed off before
removing the tube. Relieving this pressure will cause the inside of the tube to go back
to equal pressure with the outside. The heater in the tube cannot function unless it has
a constant pressure around it that is greater than 275 PSI. After relieving the gas from
inside of the tube will be less than the 275 PSI.
8.13 Remove the tube. Remember that by now the discharge end of the tube is very hot; so
handle accordingly.
8.14 This failed to blast tube should be marked properly or take it to the filling room and carefully dismantle it according to section #6.03
Cardox Activation – KILN
8.15 To properly use Cardox to break up kiln build up rings – the base ports need to be
installed in the kiln wall while shut down in the locations that the ring is expected to be
based on past experiences.
8.16 The kiln can be drilled with it “hot” or “cold”. Proper precautions need to be taken to work
the kiln hot. The work can be done off a man lift machine or off a catwalk. The kiln can
be stopped for 15 – 30 minutes at a time and the hole drilled in the build up. The kiln
can then be rotated for the desired number of rotations.
Page 13
8.17 The kiln can then be stopped and the tube can be placed in the clamp and into the
base port.
8.18 One needs to know the thickness of the refractory at the point of the planned blast.
The end of the male part of the Quik-Lok Tube Clamp should never be any closer than 6”
beyond the refractory. This 6” is measured from the end of the tube to the surface of the
male end of the clamp.
8.19 The clamp needs to be securely tightened in place on the tube. Hitting the clamp with
the wrench will verify that the clamp is in place securely.
8.20 Move to the opposite end of the firing cable, which should be around a corner or out of
the line of the tube direction by 25’ – 30’. Hook up the MHSA approved blaster.
together until the tube is placed in the base port, this prevents static electricity from the
tube prematurely.
8.23 The blast should occur immediately. NOTE: the goal is to have the tube inside of the kiln
heat for less than 5 minutes. Once the blast has occurred remove the blaster and reshunt that end of the firing cables.
removing the tube. Relieving this pressure will cause the inside of the tube to go back
to equal pressure with the outside. The heater in the tube cannot function unless it has
a constant pressure around it that is greater than 275 PSI. After relieving the gas from
inside of the tube will be less than the 275 PSI.
handle accordingly.
8.26 This failed to blast tube should be marked properly or take it to the filling room and
carefully dismantle it according to section #6.03
8.27 Please note: multiple tubes can be shot at the same time to break the ring quicker.
Please contact a Pneumat Systems, Inc. Technician to discuss this possibility if desired.
Cooler
Page 14
Cardox Activation – COOLER
8.28 When blasting cooler buildups and “snowmen”; the material is usually not close to the
“wall”. This means that the set up must be made to reach out into the distant hot material. Proper Cardox attachments should be used for this application.
8.29 The firing head of the tube must remain outside of the heated container. To do this a prolongation attachment is used in place of the discharge head. The tube is prepared according to the normal procedures. When completed an attachment tube extension is added to
the prolongation attachment and the regular discharge head is added to the attachment.
8.30 Planning and care needs to be taken for this kind of set up. Have the tube completely
assembled, make certain that enough personnel is available to lift this assembly into the
opening. Also, prepare the assembly to be secured in place. A eye bolt attachment (available from Pneumat) should be threaded into the Pneumat filling head to use to attach
the hook of a cable wench. Properly plan where the cable wench will be attached to the
cooler.
together until the tube is placed in the cooler, this prevents static electricity from the tube
prematurely.
8.32 Place the assembly in the cooler and properly secure that assembly in place. Move to the
opposite end of the firing cable, which should be around a corner or out of the line of the
tube direction by 25’ – 30’. Hook up the MHSA approved blaster.
blaster until the red light comes on. Continue to hold the left button with the light on and
depress the right button to activate the safety heater inside the tube.
8.34 The blast should occur immediately. NOTE: the goal is to have the tube inside of the cooler
heat for less than 5 minutes. Once the blast has occurred remove the blaster and re-shunt
that end of the firing cables.
8.35 If a blast does not occur, immediately approach the tube. Observe the location of the relief
hole in the fill head. Make certain that the relieved gas will not strike you in the face. Open
the safety bleeder valve using a 1/4” hex wrench. Let the gas bleed off before removing the tube. Relieving this pressure will cause the inside of the tube to go back to equal
pressure with the outside. The heater in the tube cannot function unless it has a constant
pressure around it that is greater than 275 PSI. After relieving the gas from inside of the
tube will be less than the 275 PSI.
handle accordingly.
8.37 This failed to blast tube should be marked properly or take it to the filling room and carefully dismantle it according to section #6.03
Cardox Activation – RAW/FINISHED SILOS
8.38 Pneumat Systems, Inc. has designed and does provide excellent attachments for the Cardox tubes that make them very functional in all cold applications.
8.39 A hole needs to be drilled in the material chunk or the material build up. This can be done
with a Pneumat drill with extension shafts and drill bit. This hole should be deep enough
that about 1/2 of the tube can be placed into it.
Page 15
8.40 A regular filled tube needs to be placed firmly into that hole. This can be accomplished
by using a #5790-0031 Adapter CDX that is threaded into the Pneumat fill head and
connects extension drill shafts (#5300-0013) to the tube. An eyebolt #5731-0004 can be
used to connect the shafts to the cable wench for securing the assembly to the silo.
8.41 Place the tube tightly in the drilled hole and secure the assembly. Since this is a “cold”
application there is no concern with the time in the material and no concern about having the fill head into the vessel.
8.42 The firing cables should be taped with electrical tape to hold them in the fill head as the
assembly is extended deeper into the vessel.
8.43 Place the assembly in the silo and properly secure that assembly in place. Move to the
opposite end of the firing cable, which should be around a corner or out of the line of
the tube direction by 25’ – 30’. Hook up the MHSA approved blaster.
8.45 The blast should occur immediately. Once the blast has occurred remove the blaster
and re-shunt that end of the firing cables.
removing the tube completely. Relieving this pressure will cause the inside of the tube
to go back to equal pressure with the outside. The heater in the tube cannot function
unless it has a constant pressure around it that is greater than 275 PSI. After relieving the
gas from inside of the tube will be less than the 275 PSI.
8.47 Remove the tube.
8.48 This failed to blast tube should be marked properly or take it to the filling room and
carefully dismantle it according to section #6.03
Safety Recap
9.00 Remember to respect the Cardox tube. When properly filled it will have 4000-5000 PSI of
pressure inside the tube. When it is activated it will exhaust out of the discharge end at
27,000-30,000 PSI.
9.01 CO2 is heavier than normal air, therefore there should be a vent located near the floor or
in the floor of the filling room.
9.02 To have success with the Cardox system the tube must be filled with liquid CO2. CO2 is
always trying to get to its gas state. As it passes from liquid to gas, it goes through a solid
dry ice state and makes metal surfaces very cold. Gloves should be used when handling
tubes that have CO2 released from inside.
9.03 When there is a failed activation the safety bleeder screw should be opened before
removing the tube from the base port.
Page 16
9.04 If a tube has failed to activate special care should be taken when dismounting the heads.
Use the air impact wrench to start loosening the fill head. DO NOT SPIN THE HEAD LOOSE.
Remove the wrench and try to loosen the fill head. If it is hard to turn by hand note that
there is still pressure inside the tube. STOP removing the fill head. Turn the tube over and
use the air impact wrench to loosen the discharge head. Do not attempt to impact the
discharge head off the tube. Use a hand wrench or a screwdriver in the discharge openings and slowly unscrew the discharge head. While doing this use a metal object as a
hammer and tap on that end of the tube. Watch the position of your face and be aware
that you are going to eventually dislodge the copper washer and the gas inside the tube
will start escaping. When the gas starts escaping stop un- screwing the discharge head
and move from the tube until all the gas escapes. When the pressure is gone continue to
dismantle the tube. When this fill head is removed inspect the inside to try to see what
blocked the bleeder screw opening. Reassemble the tube leaving out the heater. Fill it
with CO2 and then open the bleeder screw to verify that it can be emptied. If all the gas is
properly relieved the fill head is safe to use. If not return it to Pneumat Systems, Inc. for the
proper repairs.
9.05 Make it a goal to place the tube for activation, activate it successfully, and remove the tube
in under 5 minutes in hot applications.
9.06 Be aware that the discharge head will be very hot when removed from the base port.
9.07 Never use electricians Ohmmeter or an unapproved multimeter for continuity checks.
Only use a blaster approved Ohmmeter.
9.08 Do not stand in line with the tube when rebuilding it.
9.09 Only hook the blaster to the firing cables at the time the tube is set and activation is ready
to be made.
9.10 Keep the blaster connection end of the firing cables shunted (shorted) together when not
in use.
9.11 Only use an approved blaster instrument for activation.
9.12 Never activate an unsecured tube. Secure in a base port or with a come-along.
9.13 Learn to follow all steps quickly and efficiently and misfires will be non-existent and the
system will function safely.
9.14 Every 2 years the Cardox tube, Activating Head and Discharge Head should be sent back
to Pneumat Systems, Inc. for a safety review. The exposure to heat stresses the tubes over
time. Pneumat Systems Inc. has an independent lab do all the metallurgical tests. Pneumat
Systems Inc. verifies that there is a proper fit of the components, and the approved tube is
returned for use.
Page 17
6 TROUBLESHOOTING
Problem
Pump cycles without "deadheading."
Cause
CO2 bottle may not be connected.
Bottle may not have siphon tube.
Bottle is empty.
Solution
Check CO2 supply to insure liquid is
supplied to the pump.
Invert bottle for gravity feed of liquid
or replace with siphon tube bottle.
Replace empty bottle.
Tubes do not reach minimum weight.
Low air pressure to pump.
Pump will not operate.
Pump not primed.
Pump not funcitioning.
Adjust air pressure to 80–100 PSI. The
higher the air pressure the greater
volume of CO2 will be conveyed to the
tube. Adjust air regulator at pump inlet to maximize application of available
plant air.
Follow procedure to prime pump.
Pump will need to be repaired. Call
Pneumat and a loner pump will be
sent overnight to your facility.
If Cardox is required while the pump is
out of service, bypass the pump with
the bottle discharge fill line. Connect
the fill line direct to the pump stand
assembly inlet nipple. Use the liquid
CO2 in the
bottle to chill the Cardox firing tube,
bleed CO2 into and out of the firing
tube until liquid CO2 is readily discharged from the tube (two to four
cycles). Then, weigh tube to insure
proper weight.
Page 18
Problem
Bubbles appear when the discharge
the discharge head is placed under
water.
Cause
Bad seal between discharge head and
tube.
Solution
The head is not tight to the body. Use
the impact wrench, rattle the discharge head for additional tightness
and retest.
Bubbles appear when the fill head is
placed under water originating from
the connection between the fill head
and tube.
Bad seal between fill head and tube.
When bubbles originate from the
threaded connection of the head to
the tube body the fill head may not
be tight to the body. Use the impact
wrench and rattle the fill head for additional tightness. If bubbles continue
the copper seat on the heater element
is not functioning properly. Bleed off
the tube, remove the fill head, remove
the heater element and inspect for
damage, clean the threads, seating
shoulder in the tube and seating surface on the head, replace the heater element, lubricate, assemble and tighten
with the impact wrench. Recharge the
tube and retest.
If bubbles continue following retightening, inspect the washer and shear
disk assembly to ensure it to be seated
properly. Bleed off the CO2, remove
the discharge head, remove the shear
disk and copper washer, inspect components for possible explanation, reclean the seat and threads, reassemble
with new washer and disk, re-torque
using the impact wrench. Recharge
the tube and retest.
Loose valve or bad seal in bleed valve.
placed under water, from the bleed-off
valve.
bleed off valve retighten with 1/4"hex
wrench. If leakage continues replace
the bleed valve assembly, recharge the
tube and retest.
Page 19
Problem
placed under water, originating from
the auto-fill check valve.
Cause
Bad seal in check valve assembly.
Soulution
check valve assembly, bleed off CO2
and remove assembly from head.
Replace parts as required. Often times
only the o-rings need replacement.
Inspect the seat and plunger and
replace as required. Recharge the tube
and retest.
placed under water originating from
the electrical contacts.
Loose electrical spindle assembly or
bad seal in electrical spindle assembly.
electrical contact bleed off CO2 and
remove fill head from tube. Torque
the electrical spindle nut to 30 ft/lbs.
Tighten fill head back onto tube,
recharge and re-inspect for leaks. If
leak continues bleed off CO2 and
remove fill head from tube. Replace
the electrical spindle assembly with a
new assembly. Be sure the insulating
and sealing washers are in the correct location. The insulating washer
must be placed between the electrical
spindle and the spindle nut. The sealing washer must be placed between
the electrical spindle and the seat in
the fill head. Recharge tube and retest.
Torquing the spindle nut above 30
ft/lbs. may result in the crushing of
the insulating washer and the loss of
torque or dielectric seal.
Continuity check indicates less than
1.00 ohm of resistance.
Short circiut between electrical spindle Replace electrical spindle as outlined
and fill head body.
in previous solution and recharge tube
and retest.
Continuity check indicatesan open
circuit (infinite resistance).
Bad contact between electrical spindle Bleed off CO2, remove fill head, and inand heater wire lead.
spect contacts between the electrical
spindle and heater wire lead. Rebuild,
refill tube and retest.
Tube Misfies.
Bad ground contact between copper
ferrule and fill head.
Page 20
Bleed off CO2, remove fill head, and inspect contact between copper ferrule,
ground wire and fill head. Rebuild,
Problem
Cause
Solution
Tube misfires, cont.
Defective Safety Heater.
Bleed off CO2, remove fill head, and remove bad heater and replace. Rebuild,
Loss of continuity in circuit.
Check connections at blaster and at
fill head. If connected properly check
continuity through firing wire. If continuity is correct see solution for open
circuit in previous section.
Low voltage from blasting unit.
Periodically test fire blaster prior to
use. If the "fire" light is dim replace the
9-volt battery and retest.
Low CO2 volume in charged tube.
Low CO2 volume will result in either
an unburned heater or a partially
burned heater and a unruptured shear
disc. Rebuild, recharge and reweigh
to insure correct volume of CO2. If still
low check the CO2 cylinder for a low
level. Replace cylinder if necessary. If
CO2 level in tank is fine clamp the tube
back into fill stand, increase the pump
input pressure and recycle pump.
Repeat this until CO2 volume is above
minimum amount.
The shear disc may be bulged but not
sheared through. The cutting shoulder
on the discharge head must be sharp
and unpitted. If edge is not sharp the
shear disc will bulge but not rupture. If
cutting shoulder is rounded send head
to Pneumat Systems for repair.
Page 21
12
4
10
14
15
7
13
11
3
8
8 A
5
4 A
OR
17
7 A
8
2
4
7
9
16
6
9
1
Cardox Fill Stand Assembly Parts List
Ref
Part No.
Description
Qty
Ref
Part No.
Description
Qty
1
5781-0055
Cardox Fill Stand
1
8A
2200-0087
Adaptor, 4MJ x 6MP
2
2
5781-0013
Cardox Pump Assy
1
9
2200-0082
Adaptor, 6MJ x 8MP
2
3
5781-0025
Tube Clamp Assy
1
10
2210-0004
Elbow, 6MJ x 4FP
1
4
2500-0009
Ball Valve - 3/8 NPT Ports
2
11
2200-0019
Nut, CO2 Bottle Adapter
1
4A
2500-0054
Ball Valve - 4 SAE Ports
2
12
2200-0018
Nipple, CO2 Bottle Adapter
1
5
2100-0070
Inlet Hose Assy
1
13
5781-0014
Plastic Gasket CO2 Bottle Adapter
1
6
2100-0070
Outlet Hose Assy
1
14
1245-0061
Fill Fitting
1
7
2210-0009
Elbow, 6MJ x 6MP
2
15
4500-0006
O-ring, Buna
1
7A
2210-0049
Elbow, 6MJ x 4MB
2
16
4210-0054
HHCS 1/2" x 7"
2
8
2200-0042
Adaptor, 6Mp x 6MP
2
17
5781-0081
Pump Muffler
1
Page 22
Cardox 360° Vise Diagram
47
28
29
46
12
11
7
16
22
17
5
32
20
26
3
2
10
31
18
19
1
41
21
45
27
38
24
23
4
14
44
15
8
8
13
21
25
34
6
40
39
30
43
33
36
42
35
Page 23
Cardox 360° Vise Parts List
Ref
Part No.
Description
Qty
Ref
Part No.
Description
Qty
1
5781-0040
Outer Ring Assy
1
24
4215-0008
SHCS 3/8" x 1"
1
2
5781-0041
Inner Ring Assy
1
25
4235-0010
Lock Washer, 3/8"
2
3
1215-0036
Back Plate
1
26
4235-0011
Lock Washer, 1/2"
8
4
5781-0048
Push Rod Assy
1
27
4260-0056
Dowel Pin, 5/16" x 1"
2
5
2500-0050
Air Cylinder
1
28
5790-0014
Air Impact Wrench Assy
1
6
1415-0010
Vise Bushing
1
29
5790-0015
Tool Balancer
1
7
1215-0038
Retainer Plate
4
30
5781-0054
Vise Stand
1
8
5781-0045
Clamping Jaw, 2-1/8"
1
31
5781-0056
Impact Wrench Hanger
1
9
5781-0044
Sationary Jaw, 2-1/8"
1
32
5781-0083
Air Line, Impact Wrench
1
10
5781-0043
Indexing Pin
1
33
5781-0085
Air Line, Quick Exhaust
1
11
5781-0042
Indexing Nut
1
34
5781-0084
Air Line, Foot-Manifold
1
12
4260-0057
T-Handle
1
35
1215-0051
Mount, Foot Valve
1
13
4260-0053
Rivet, C-Sunk Head
2
36
2500-0051
Air Foot Valve
1
14
1345-0003
Button
28
37
5790-0017
Air Blowgun
1
15
4260-0054
Return Spring
1
38
5781-0059
Air Manifold
1
16
4260-0055
Index Pin Spring
1
39
4210-0055
HHCS 3/8" x 1/2"
2
17
4110-0013
Bushing 1-1/2" x 1-3/4" x 3/4"
1
40
4210-0051
HHCS 5/8" x 2"
4
18
2200-0086
Adapter, Swivel 4MP x 4MP
1
41
4210-0056
HHCS 5/16" x 2-1/4"
2
19
2500-0052
Quick Exhaust Valve - 1/4"
1
42
4210-0002
HHCS 3/8" x 3/4"
2
20
4210-0005
HHCS 1/2" x 1-1/4"
8
43
4215-0023
SHCS 1/4" x 5/8"
2
21
4210-0026
HHCS 3/8" x 1"
4
44
4230-0002
Whiz Nut, 5/16"
2
22
4210-0022
HHCS 5/16" x 1"
12
45
4230-0009
Hex Nut, 5/8"
4
23
4215-0021
SHCS 5/16" x 1-1/2"
2
46
5790-0007
Drive Socket, 1-1/2" x 3/4"
1
47
1215-0057
Shelf, Vise Stand
1
Page 24
18
1
2
16
17
5
6
7
19
8
9
15
3
10
11
4
12
13
14
5730-0003 Auto Fill Activating Head w/ Eyebolt Parts List
Ref
Part No.
Description
Qty
Ref
Part No.
Description
Qty
1
5731-0002
Body, Auto Fill Head
1
10
5731-0013
Washer, Electrode Insulating
1
2
5731-0021
Bleed Screw Assy
1
11
1245-0123
Electrode Spindle
1
3
5731-0022
Check Valve Repair Kit
1
12
5731-0014
Washer, Electrode Sealing
1
4
5731-0010
Electrode Assy
1
13
1445-0026
Sleeve, Electrode Nut
1
5
4260-0052
Spring, Check Valve
1
14
5731-0011
Electrode Spindle Nut
1
6
1245-0129
Plunger
1
15
1345-0002
Ground Tube
1
7
4500-0008
O-ring, Teflon
1
16
1445-0027
Sleeve, Contact Tube
1
8
4500-0009
O-ring, Viton
1
17
1345-0001
Contact Tube
1
9
1245-0128
Seat, Check Valve
1
18
5731-0004
Eyebolt
1
19
5730-0003
Auto Fill Activating Head w/ Threaded Hole Assy
1
Page 25
Series 37
Consumables
1
Consumables
Part No : 1-00
Lot No :
5
8
8
Made In USA
4
Series 57
Part No : 1-00
Lot No :
12
Made In USA
3
2
7
6
Series 37 Cardox Consumable Sets
Parts List
Series 57 Cardox Consumable Sets
Parts List
Ref
Part No.
Description
Qty
Ref
Part No.
Description
Qty
1
5741-0023
Safety Heater (77.5g) Size 8
1
5
5741-0025
Safety Heater (115g) Size 12
1
2
5741-0001
Shear Disc, 27 Kpsi
1
6
5741-0004
Shear Disc, 27 Kpsi (Series 57 Tube)
1
2
5741-0002
Shear Disc, 34 Kpsi
1
6
5741-0005
1
2
5741-0003
Shear Disc, 19 Kpsi
1
6
5741-0006
1
3
5741-0031
Copper Gasket
1
7
5741-0033
Copper Gasket (Series 57 Tube)
1
4
5740-0003
Consumable Set, Size 8 - 27 Kpsi
1
8
5740-0006
1
4
5740-0004
1
8
5740-0007
1
4
5740-0013
1
8
5740-0005
1
Page 26
10
2
3
7
6
5
4
Series 3700 Firing Head, Tube Body & Discharge Head Parts List
Ref
Part No.
2
5730-0003
3
Description
Qty
Ref
Part No.
1
6
5720-0015
4-Port Discharge Head
1
5710-0002
Auto Fill Head w/ Threaded Hole
(All Series)
Cardox Tube Main Body
7
5720-0003
1
4
5720-0004
Hydrox Discharge Head
1
10
5731-0004
Eyebolt
1
5
5720-0014
2-Slot Discharge Head
1
1
Description
Qty
Page 27
Series 5700 Firing Head, Tube Body & Discharge Head Parts List
Ref
Part No.
Qty
Ref
Part No.
1
5730-0002
Auto Fill Head (All Series)
1
8
5721-0010
SR Discharge Head 4-Port
1
2
5730-0003
1
9
5720-0011
Self Restraint Assy
1
3
5710-0003
Auto Fill Head w/ Threaded Hole
(All Series)
Cardox Tube Main Body
10
5731-0004
Eyebolt
1
4
5720-0005
Hydrox Discharge Head
1
11
1445-0025
Self Restraint Buffer
1
5
5720-0018
2-Slot Discharge Head
1
12
5721-0012
Self Restraint Bolt
1
6
5720-0016
1
13
5721-0011
Self Restraint Bolt Housing
1
7
5720-0019
1
14
1445-0023
Self Restraint Collar
1
15
1445-0024
Self Restraint Bushing
1
16
1245-0119
Self Restraint Cone
1
Page 28
Description
1
Description
Qty
2
1
3
1
2
3
4
Quik-Lok Base Socket & Plug
Parts List
Quik-Lok Tube Clamp
Parts List
Ref
Part No.
Description
Qty
Ref
Part No.
Description
Qty
1
5750-0004
Base Socket and Plug Assy
1
1
5750-0001
Tube Clamp Assy (Series 5700)
1
2
5750-0002
Base Socket Assy
1
1
5750-0005
Tube Clamp Assy (Series 3700)
1
3
5750-0003
Plug Assy
1
2
5751-0002
Bolt, Tube Clamp
1
3
5751-0001
Body (Series 5700)
1
3
5751-0008
Body (Series 3700)
1
4
5751-0004
Handle
2
Page 29
110 Mohr Drive • Mankato, MN 56001
Toll Free:.................................................(800) 458-9446
Phone:.....................................................(507) 345-4553
Fax:............................................................(507) 345-3639
Website:...............www.pneumat.com
©2004 Pneumat Systems, Inc.
Revision D (12/08-2004)
Page 30

Cardox CO2 Blaster Manual

Transcription

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