Client : Chanderpur Works Pvt.

Ltd,
Yamuna Nagar, Haryana,
Proj: Dhofar Cement pvt. Ltd.

Ref. : P.O. No CPW/TRD/21220011370 dt. 09.06.2021

Plot No. 370, Sector-24, Faridabad-121 005, Haryana, India.

Æ : +91 129-4024185 & 4024186,
Email : mmairblasters@gmail.com
 Index

S.No DESCRIPTION PAGE No

1. Client List 01

2. Introduction 02

3. Operating Principles 03

4. Assembly / Erection Instructions 04-05

5. Commissioning Procedure 06

6. Safety Precautions 07

7. Maintenance Schedule 08 & 09

8. Servicing Procedure 10

9. Recommended Spares with drawings. 11 to 14

1. INTRODUCTION

Air Blaster is very effective and economical method of removing jamming in Bunkers,
Smoke Chambers, Kiln Inlet, Coolers, Chutes, Hoppers 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.

2
It works on compressed air (5-7 Kgf/Cm ) which is delivered through pipelines.
Generally plant air is adequate. Incase when plant air is not available at the site,
small compressor can be installed as the requirement for operation of Air Blaster is
not much. It is operated whenever jamming takes place. By installing this
equipment’s, hazardous manual pocking with rods can be avoided. The cost of
installing Air Blasters is quickly recovered through the increased efficiency and
reduces down time from the creation of free material flow.

EVEN A SINGLE PREVENTED ACCIDENT CAN PAY FOR A COMPLETE

INSTALLATION

Operating Sequence of Air Blasters should be maintained from TOP to BOTTOM in

case of Pre-heater Riser Duct.

Operating Sequence of Air Blasters should be maintained from BOTTOM to TOP

incase of Hopper, Bunker, Chute, Cyclone etc.

 Details of the Products, supplied

S/N Item Description Quantity

1. Air Blaster Model AB-10-160 of 160 litres capacity 29 Nos.
2. HRCS Nozzle Assy. (Gr.-9) suitable for application. 29 Nos.
3. Pneumatic Control Panel Assy. consisting of Ball Valve, Non-return Valve 10 Sets
(Kaybee), Solenoid Valve 220V AC (Rotex) with fittings.
4. Oil lubricator ¾” BSP. 10 Nos.
5. Ball Valve ¾” BSP for Air Blaster. 10 Nos.
6. Quick Exhaust Valve ¾” BSP 29 Nos.
7. Safety Valve ½” 29 Nos.
8. M.S. Bend 4” x 90o with both side welded flange 29 Nos.
9. Hose Whip ¾” x 6” long 29 Nos.
10. Pressure gauge (0-10kg) ¼” x 2.5” dia (Make : H – Guru) 10 Nos.
11 Sequential timer Model 4G-40 of 10 output with enclosure, Canopy & P.B.S. 01 No.
12. Sequential timer Model 4G-40 of 30 output with enclosure, Canopy & P.B.S. 01 No.

Page No. 2
2. OPERATING PRINCIPLES
2
A large quantity of air stored in an air receiver at pressure approx. 5-7 Kgf/Cm . This
air is discharged with explosive suddenness through a 100 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 produce no noise effect or vibration. CHARGING and
DISCHARGING can be characterized as follows.

2.01 Charging.

Compressed air is supplied through stainless steel tube (3/8”) controlled by a

Solenoid Valve to Quick Exhaust Valve. The diaphragm of Quick Exhaust Valve
close the 3/4” 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.

2.02 Discharging.

By actuating the Solenoid Valve both the controls airs 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 fourth 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.

Page No. 3
3. ASSEMBLY / ERECTION INSTRUCTIONS

3.01 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.
Therefore, we MMF, 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 of all installation with chalk or other available marker.

3.02 Preparation of holes.

Accumulated material is removed from the surface of the Hopper/Bunker. In case of

M.S Bunker/Hopper, 120 mm diameter hole is gas cut at the marked location. In
RCC Hopper/Bunker suitable hole is chipped off preferably without cutting any
reinforcement bars.

3.03 Fixing of Nozzle in the hole.

Nozzle is taken inside the application from top of manhole and matched with the
gascut hole in the correct direction/orientation. This nozzle is welded with the
surface inside the Bunker/Hopper.

In case of RCC hopper walls, the nozzle is welded with re-enforcement. If required,
12 mm or 16 mm dia bars can be additionally welded to the pipe for securing its
firmly. The open space all around the pipe is filled in with castable material or
concrete.

Kindly note that the Nozzle should be properly welded with Flange after
positioning / orientation of the Air Blaster.

Page No. 4
3.04 Mounting of Bend and Air Blaster unit.

To the outside projected portion of the nozzle pipe, a screwed flange is fitted
followed by bolting a 4” diameter, 90 degree flanged M.S.Bend. To other end of this
M.S. bend, the Air Blaster unit is bolted and proper orientation is achieved. The best
position for this is the drain plug of the blaster is in the bottom most position. After
achieving desired orientation, if it is not possible to further tighten the flanges, the
flanges should be tack welded at four points. Hanger bracket is welded at right place
ensuring the hole of the hanger support gets accommodated for proper bolting.

3.05 Installation of Pneumatic Control Panel & Timer Panel.

Pneumatic panel is installed in close vicinity of a group of Air Blaster units.

Preferably this distance should not exceed 4 to 5 meters. However the panel should
be protected from any falling material and dust etc. It can be conveniently fixed to
hand rails, walls through suitable M.S.angle frame and support. If space is available,
it is preferable to fabricate free standing type M.S. angle stand to which the panel
can be bolted. Approximate weight of pneumatic control panel is 20 Kgs. The timer
panel is preferably installed in air-conditioned room.

3.06 Laying of S.S. & M.S. Pipelines.

Pneumatic Control Panel and Air Blasters are connected with S.S. tube 3/8” making
routes of almost 90 degree. Adopters are properly welded at both ends of pipe with
S.S. electrodes.

The compressed air tapping and pneumatic control panels are connected by 1/2”
G.I. pipe. The compressed air supply is given to the control panel through Oil
lubricator, Isolating Valve and pipe fittings.

Page No. 5
4.0 COMMISSIONING PROCEDURE

4.01 The Quick Exhaust Valve are connected with the Air Blaster unit with
Hose whip.

4.02 Proper sealings are done with tefflon tapes.

4.03 Air Blaster units are connected with Pneumatic Control Panel by S.S.
Pipelines. It is recommended that in the pipelines, there should not have any
dust particle or sand inside.

2
4.04 Vessels are charged with compressed air at 5-7 Kgf/Cm and discharged by
pressing the manual override of Solenoid Valve. Afterwards, same tests can
be conducted with the help of SEQUENTIAL TIMER.

Page No. 6
5. SAFETY PRECAUTIONS

5.01 All the Flanges should be properly welded at the site after proper Nozzle
orientation.

5.02 The Safety Valve shall be checked for proper flow atleast once in every three
months.

5.03 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
scratched on their painted surfaces.

5.04 While installing Nozzle / Mounting package inside the Smoke chamber/pre-
heater walls, proper care should be taken for sturdiness of Scaffoldings.

5.05 After complete installation, the Air Blasters should be test fired only after
getting permission from concerned authorities.

Page No. 7
6. MAINTENANCE SCHEDULE

6.01 EVERY DAY

 Check the Air Pressure.

6.02 EVERY WEEK

 Check the oil level in oil Lubricator / FRL.

 Drain moisture / water from pipelines, header and Air Receiver.

6.03 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 it’s proper operation.

6.04 EVERY SIX MONTH

 Check Hose whips, plated pipe nipples. If damaged, change it.

 Drain water from vessel of Air Blaster. Use tefflon tape for proper sealings.

 Open cover plate, check rubber pad, Piston & Cylinder ‘0’-Rings. Clean and
re-assemble after proper oiling.

Page No. 8
 6.05 CAUTION

BEFORE DRAINING, AIR MUST BE REMOVED FROM THE TANK BY

FIRING THE AIR BLASTER.

 Check Nozzles and Mounting Accessories.

 Check wires and wires connections of Electrical Control.

6.06 Servicing Procedure.

 The equipments should be serviced only by trained and authorised persons.

 Before servicing, make sure that the servicing platform should be firm &
sturdy.

 Discharge Air Blaster before servicing and shut the air supply off and cut off
the power supply. For discharging Air Blaster, use manual override of the
Solenoid Valve.
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Page No. 9
7. SERVICING PROCEDURE

7.01 Remove the Quick Exhaust Valve from the Blaster.

7.02 Remove the Cover Plate by removing the bolts which fasten the cover plate
with Blaster.

7.03 Lift the Piston Assembly very carefully. Inspect all the parts and replace the
parts that have been worn out. It is recommended that the new `O’ rings and
Gaskets be used.

7.04 Inspect the Cylinder and clean it properly.

7.05 Inspect the air hole in the Piston and clean it.

7.06 Lubricate the Cylinder with clean oil before Piston and `O’ rings. Insert the
Piston back into the Cylinder bore without damaging the bore and ‘O’ ring.

7.07 Keep the Spring and Rubber Pad in position. Install the Cover Plate and
tighten the bolts. Connect the Quick Exhaust Valve to the Air Blaster.

Page No. 10
 RECOMMENDED SPARES FOR AIR BLASTER FOR 2 YEARS

S.NO. DESCRIPTION QUANTITY

01 Piston 05 Nos.
02 Piston ‘O’-Rings 10 Nos.
03 Cylinder ‘O’-Rings 05 Nos.
04 Solenoid Valve (3 port) ¼” 220V AC (Rotex) 04 Nos.
06 Diaphragm for Quick Exhaust Valve 10 Nos.
07 Non-Return valve 04 Nos.
08 Rubber Pad 05 Nos.
09 ‘O’-Ring for Quick Exhaust Valve 05 Nos.
10 Compression Spring 04 Nos.
11 Hose whip ¾” x 6” Long 02 Nos.
12 P.U.Tube (For Panel) 02 Mtrs.
13 Gasket 04 Sets
14 Safety Relief Valve ½” 05 Nos.
15 Quick Exhaust Valve ¾” BSP 05 Nos.
16 Pressure gauge ¼” x 2.5” dia, (Make : ‘H’- Guru) 05 Nos.

Page No. 11
 All dims are in MM,Unless specified otherwise.

1 11 2 3 4 5 6 7 8 9 10
Matching Flange.

4a
Drain Plug.

11 Safety valve.1/2"BSP. 1 AB10-1001.11

10 Hose whip.3/4"Male ends. 1 AB10-1001.10
9 Hex.bolt.5/8" with Spring washer's 8 set AB10-1001.09
8 Cover plate. 1 AB10-1001.08
7 Gasket for cover plate. 1 AB10-1001.07
6 Rubber pad. 1 AB10-1001.06 Client : Project :
5 Compression spring. 1 AB10-1001.05
4a Piston 'O'-Rings. 2 AB10-1001.04 Title : Scale : Dgn.
Spares For Air Blaster Drn. Rajat
4 Piston. 1 AB10-1001.03
( For DN-100) Chd.
3 Cylinder. 1 AB10-1001.02 Appd.
2 Cylinder 'O'-Ring. 1 AB10-1001.01 Drawing No. Rev.
1 Vessel. 1 AB10-1001.00
S.No. Description Qty. ID Number. 370, Sector-24, Faridabad. MMF/SPR/21-014007.00 A0
 All dims are in MM,Unless specified otherwise.

5 4 3 2 1 6

Quick Exhaust Valve Assembly

QE-1005.00

Client : Project :

6 Adopter 1/2" x 1/4" BSP. 1 QE-1005.05

Title : Scale : Dgn.
5 G.I.Bend.3/4"BSP. 1 QE-1005.04 Spares Of Quick Exhaust Valve. Drn. Rajat
4 Exhaust Valve. 1 QE-1005.03 Chd.
Appd.
3 'O'-Ring (40 ID x 3 Dia) 1 QE-1005.02
2 Rubber Diaphragm 1 QE-1005.01 Drawing No. Rev.
1 Quick Exhaust Valve Body 1 QE-1005.00A
370, Sector-24, Faridabad. MMF/SPR/21-014009.00 A0
S.No. Description Qty. ID Number
 All dims are in MM,Unless specified otherwise.

10 11 12 13

14

9
6
8

7
6
5
18 17 16 15
4 6

Air Inlet
Wiring Diagram of 2-Points Panel.

P C
Cable from Timer.
P

18 Ball Valve.3/4"BSP 1 No. PCP-1004 .18 Terminal Strip.

17 Pressure Gauge. 1 No. PCP-1004 .17A
16 Union.3/4"BSP 1 No. PCP-1004 .16

SV-1

SV-1
15 Oil Lubricator.3/4"BSP. 1 No. PCP-1004 .15A
14 Terminal Strip (15 Points) 1 No. PCP-1004 .14
Solenoid Valves(Rotex)
13 SS Tube.3/8" (SS-304) 8 Mtrs PCP-1004 .13
with 220 V.DC Coils.
12 Connecting Nipple with Bush 1 No. PCP-1004 .12
11 Bulkhead Adopter.1/4"BSP 1 No. PCP-1004 .11
10 Female Connector.1/4"BSP 1 No. PCP-1004 .10
9 P.U.Tube.(7x10) x 225mm Long. 1 No. PCP-1004 .09
8 Solenoid Valve.(3-port)1/4"BSP.(Rotex make) 1 No. PCP-1004 .08 Client : Project :
7 Manifold for Solenoid Valve. 1 No. PCP-1004 .07
6 Male Connector 1/4"BSP. 3 Nos. PCP-1004 .06 Dgn.
Title : Scale :
5 P.U.Tube.(7x10) x 175mm Long. 1 No. PCP-1004 .05 Drn. Rajat
Spares For Pneumatic Panel Chd.
4 Non Return Valve.1/4"BSP. 1 No. PCP-1004 .04
Appd.
3 Ball Valve.1/4"BSP. 1 No. PCP-1004 .03
2 Hex.Nipple 1/4"BSPMale. 1 No. PCP-1004 .02 Drawing No. Rev.
1 Aluminium Header / M.S. Header. 1 No. PCP-1004 .01
370, Sector-24, Faridabad. MMF/SPR/21-014010.02 A0
S.No. Description Qty. Remarks.
APPROVED
DATE: 06.08.2021
APPROVED
DATE: 06.08.2021
APPROVED
DATE: 06.08.2021
APPROVED
DATE: 06.08.2021