Industrial facility planning_guide


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Industrial facility planning_guide

  1. 1. 1 The major componentsof a properly planned blastfacility are sizedfor efficient operation and maximum return on investment. More and more companies chemicalsis reduced. Chemical Yet even for theselarge projects, are turning to indoor blasting as an disposalcosts are eliminated. In most statesrequire that temporary alternative to chemical stripping or many cases,processingtimes and structuresbe erectedto contain the outdoor blasting. Blast cleaning labor costsare reducedas well. dust and abrasive. with abrasivemedia removes old Switching to blasting can reduce Bringing blasting indoors coatings, rust, and other unwanted chemical stripping VOCs (Volatile results in substantialsavings, material from a surface,and creates Organic Compounds)by 100 particularly when you switch from an anchor pattern to allow new percent,becausethe processis dry. expendableabrasives,suchas silica coatings to adherebetter. Blasting Blasting technology has been sandor mineral slag, to recyclable with peening media increasesthe around sincethe late 1800s,though abrasives. fatigue life of many materials, the dust generated blasting, and by including steel and alloys. Indoor blasting allows you to the cleanuprequired afterward scheduleproduction independentof Manufacturerswho turn to relegatedit to use outdoors. weather,time of day, or other blast cleaning as an environmentally Today'sever-tightening nearby activities. responsiblealternativeto chemical environmentalregulationshave stripping processes, often realize An efficient, high-production restricted the useof outdoor substantialcost savingsas well. blast facility can pay for itself in as blasting to structuresand other Employeeexposureto toxic little as one year. items too large to bring indoors.
  2. 2. 2 m Becauseconditions and applications vary, every blast room is customized to some extent. Careful planning will maximize the benefits of a new blast facility or extend the useful life of an existing facility. The componentsyou selectdetermine the return you can expect from this investment. This guide has beenpreparedto presentyou with options and assistyou in making the best choices for your specific needs.The function of each major componentis explained and comparisonsare presentedfor the options available. Clemco and its worldwide network of distributors will assistwith every step in planning, installation and start-up. Clemco is the only manufacturerthat offers a complete line of pneumatic and mechanical conveyancesystemsfor abrasiverecovery. Clemco can even show you how to breathenew life into an aging, inefficient blast facility. Use the Request Quotation form in the center of this book to record the for information your Clemco, ZERO, or Aerolyte Distributor win need to help you get the best system at the best price. MAJOR COMPONENTS AND OPTIONS Enclosure 3-4 Column-bolt. Flange-bolt. Pre-assembled,Lighting, Doors Blast Equipment 5 Blast machines,Compressed air supply, Operator safety equipment Recovery System 6-8 Pneumatic,Mechanical, Manual, Flat- Trak, Flo-FlorTM, Screw Floor, M-Section Abrasive Cleaner 9 Air washcleaner, Cyclonereclaimer Dust Collector 10 Workpiece Handling 11 Forklift, Work car, Rails, Monorail, Hoist C/emcos txptritnctd staff of designtrs and tngint'ers and our worldwide nttwork of distributors and dealersht'tp you gt't tht' mostfrom your blastfacility.
  3. 3. 3 The enclosurekeepsin the If you plan to build your own enclosure,get your Clemco, ZERO, or 18 abrasiveand dust and keepsout the Aerolyte Distributor involved before the fIrst drawings are made. While Clemco elements. This allows the abrasiveto can adapt equipment to an existing enclosure,it is far more cost effective to plan be cleanedand reused,often hundreds for recovery, ventilation, lighting, controls, and blast machinesin the original of times. Efficiently recycling the drawings even if all of thesecomponentsare not budgeted. abrasivecan make your blast facility cost effective. The size of the part being pro- cessedand the production rate desired will dictate the size of the enclosure. Allow room for the part, plus four feet on all sides for the blast operator to work. To increaseproductivity, you can build a bigger enclosure,increasing the number of operatorsand/or the number of parts in the enclosure at one time. This also increasescapacity require- ments for other blast facility compo- nents -- such as the dust collector and blast machines. The enclosure'scubic capacity influences the size of the dust collector. In planning the facility, balancethe convenienceand productivity of the I I arger enc osure WI .th th tra e ex expense . . Column-boltenclosures for InclusIon an overhead a/Jow of . monoraIl. In of the larger dust collector. To begin planning your enclosure, Column- Bolt describe part or partsyou anticipate the .. blastcleaning.Includeasmuch Clemcooffersblastenclosures two construction m styles. In a column-bolt informationaspossible aboutthepart facility, prefabricatedsteelpanels bolt to a structural steelframe. This design andtheprocesses goesthrough. it allowsfor widerroomsandwill supportanoverhead monorailfor partshandling. Makesureyou indicatethe dimensions . . f th I t art I t bl t For most applIcations,the enclosurewalls are made of 10- to 14- gauge 0 e arges p you p an 0 as, I If th f .Ii ill d th I k ' f ' all . . includingproducts in planningthat s~e. still e aCI ty w o~erate faun e ~ oc . o~1.especi y aggre~s~ve media may be part of production. will be used, rubber curtains on the wall will minimiZe wear. The addItional investment for the curtains, and for their periodic replacement, will greatly extend thelife of theenclosure. (~
  4. 4. 4 In a flange-bolt facility, the wall panelsbolt directly to each other, without the support of a frame. Flange-bolt construction limits the room to 14 feet wide and 14 feet high, though the length is not restricted. If your facility can be 14 feet wide (or less) and does not need to support a monorail, the flange-bolt design could result in substantial savings when comparedto a column- bolt enclosureof the samesize. Flange-bolt room with reclaimer and reverse pulse dust collector: Doors Bright, well-positioned lights The parts handling doors must 11 Dry-strip boothidealfor automotive jobs, increaseproductivity in the blast open with sufficient clearancefor the room, The amount of light needed part and your work handling equipment. Dry-Strip Booth dependson the type of work being Additional doors at the rear of the The flange-bolt room is also done, Typica~lybetw~en 50 and 80 facility let you pa.~s parts through en- available for lighter applications in the foot candlesIS sufficIent. route to the paint booth or finishing area. form of the dry-strip booth which has Lights may be mounted in the walls of lighter gauge steel, and is ceiling or walls, Most blast rooms Personneldoors, required by suitable for use with lightweight blast have flush-mounted ceiling fixtures, OSHA every 30 feet in large facilities, media such as plastic and wheat starch. but a tall component may block allow easyentry and exit without havin~~ to open the main doors. Position the Pre- Assem hIed ceiling lights. Wall-mounted lights provideeven,shadow-free illumina- personneldoors for the best work flow, such as allowing quick access control to Flange-bolt enclosures be can tion on verticalsurfaces. ordered pre-assembled readyto set -- panels,media storage,and changing " For a smaII to medlum sIzed , . m place at your site. A pre-assembled rooms. . , bl as t room, rfull ' ht t d dim . f 7 ~ powe Ig s moun e room has mtenor enSlons 0 leet .d 14 teet 1 and 8 teet hIg h. . at an angle where the walls meet the WI e, ong, ~ ~ . li ' d II ill . . Work Stations sow... t e room to truc e . Thi all h be k d cel ng provl e exce ent Uffilnation , . ,, on the top and sIdesof the part, A work station, built into the wall, mtact, Once the room ISpoSItionedon ' . . M ounting the IIght modu1 hi gh ' es SIte, the dust collector, abrasIve . pro te c ts th em fr om ma d ve rt en t ' allows you to usethe blast room as a cleaner, and blast machine are con- bl ' blast cabinet. It consistsof a view th fl . asting. window, work rabIe,and rubber-lined nected, Because e recovery oor IS built in, no excavation is required for a To ensureadequatelight levels gloves. pre-assembled room, but it can be in a room fitted with wear curtains, placed in a pit to reduce entry height, If consider ordering optional light- necessary, room can easily be the colored curtains instead of the relocated. standardblack rubber.
  5. 5. 5 Blast Machines Compressedair supplies the Clemco offers single and power for the blast machine, pulses the multiple operator packages. Multiple dust collector cartridges, provides operator packagesinclude additional breathing air for operators,and in blast machinesand a storagehopper to somesystems,powers the recovery channel media from the reclaimer or abrasivecleaner into the blast ma- floor. chines. Using multiple blast machines The orifice size of the blast allows the blast operatorsto work nozzles, the type of recovery floor, and independently. Oversized blast the type of respirators worn by the machinescan be ordered.but they blast operatorswill greatly affect increasethe abrasive storagecapacity compressedair consumption. without increasing production rates. Most problems associatedwith If you plan to use plastic, wheat blasting can be traced to the air supply. starch or other lightweight media, you Blast cleaning requires an abundant must use a blast machine specifically supply of clean, dry air. Your Clemco, designedfor such material. ZERO, or Aerolyte Distributor can Blast machinescan be ordered determine whether your existing plant complete with remote controls, 50 ft. compressorcan power your new coupled blast hose, nozzle and mois- facility or if you need an additional ture separator.In addition, the system compressor. includes operator safety equipment; Apollo helmet with Climate Control Tube, breathing air filter, large blast suit and leather gloves. Aerolyte blast machinesat McCk/Jan AFB. According to OSHA and NIOSH regulations, operator safety equipment, including air-fed respirators, air filters, carbon monoxide monitors and alarms, and abrasiveresistant clothing is required for all blast operators. Plan to provide equipment storagelockers and a changing areanear your blast room. Improper use of abrasiveblast cleaning equipment can causesevere injury, terminal illness, or death. Read and follow the instructions in all owner's manuals and warning labels, and obtain proper training before using ~ Blast suit, glovesand respirator. this equipment. Clnnco's CPF-20 breathing air filter:
  6. 6. 6 With open air blasting, cleaning up the dust and abrasiveis usually the most labor-intensive, time-consuming part of any project. Picking up, packing, and disposing of spent abrasivecan easily account for 60 percent or more of a project's cost. Recovery systemsperform two functions: . Catch the media for delivery to a recovery point. . Transport the media to a cleaner. For a truly high-production blast facility, use as much of the floor for recovery as possible. This reducesthe labor costs associatedwith abrasive cleanup and makes for fewer interrup- tions to blasting. Clemco makesfour types of Some applications call for built- remove abrasivefrom crevices or recovery systemssuitable for full or in vacuum recovery systemsto remove containers,plan to include vacuum partial floor areainstallation. These abrasivefrom the inside of tank cars or recovery in addition to your floor four systemsare either pneumatically other containers. If you needto recovery system. or mechanically powered. Pneumatic M-Section Floor Pneumaticrecovery works best with lightweight media, such as agricultural, plastic, glass bead,or aluminum oxide. In Clemco's M- Section pneumatic recovery system, dust and media fall through funnel shapedholes into channelsbeneaththe floor. High-velocity air carries this media and dust to the reclaimer. Becausethere are no moving parts, pneumatic floors are simple to operateand maintain. Pneumatic recovery requires the use of a reclaimer --a type of cyclone separa- tor -- to separateblast media from the dust, debris, and rmes. The efficient and easily maintained M-section pneumatic float:
  7. 7. 7 Mechanical Flat-Trak Floor The Flat-Trak floor requiresless maintenance dian other mechanical Clemco's exclusive Flat-Trak floors which contributesto its greater system,the newesttype of recovery operationaleconomy. floor, usespneumatic power and a Additionally, the Flat-Trak takes ladder-like arrangementof steel vanes lesstime to install than other mechani- to move the blast media. The vanes cal systems. This featurehelpscut down push the media on the forward stroke. on lost productiontime when the Flat- then ride up and over the mounds on Trak is installedas a replacement the backstroke. systemin an existing enclosure. Developedinitially for steelgrit Because Flat-Trak is offered die and shot.the Flat-Trak works well with in standard-sizemodules,most compo- most blastmedia. Its key advantages nentsare readily availablefrom stock. includea low profile. requiring little or This recoverysystemis available no excavation. low purchase and exclusivelythroughClemco,ZERO, installationcosts,and readyavailability. Installing the F/at- yak air lint's andAerolyte Distributors. Control panel Air lines Pneumatic drive module Vanes ', Stationary I "'" ,!i!,i~ ,~ yanes frame /'" ~~ The innovative F/4t- Trak offin efficient, low-profile recowry. easeof installation, and low maintenance
  8. 8. 8 Screw Floor Screw floors move the heaviest abrasiveswith ease,and are often used for steel grit and shot. They operate quietly, even in high production applications. Due to their complexity, screw floors require a diligent mainte- nanceprogram. Depending on the number and size of the screws,thesefloors are generally more expensiveto purchase and require deeper,more expensive excavation. Screwfloors conveyheavy media at high production rates. Sweep- Systems In Manual recovery, via a sweep-in or wall-mounted hopper recovery system,requires periodic shutdown for media cleanup. If you plan to blast intermittently, the low initial cost may outweigh the increasedlabor costs for blowing or shoveling the media into the hopper. Pan floors moveangular abrasive easily. Sweep-in systemscan be mechanical (with a grate over the feed to a bucket elevator) or pneumatic Flo-Flor (with a grate over a single M-Section In pan floors, such as Clemco's at the rear of the blast room). If site Ao-AorTM, abrasivefalls into long conditions preclude excavation, a wall- pans that are continuously rocked by mounted systemmay be the only rotating cams at one end. This rocking option for manual recovery. motion moves the abrasiveand dust A sweep-in systemis inexpensiveto install. slowly toward a crossoverpan or a screw conveyer,which transportsit to a bucket elevator. Pan floors are durable and simple to operate.They work best with angular abrasive. ~
  9. 9. 9 AbrasiveCleaner ,~ The efficiency with which reusablemedia is separatedfrom dust and fines affects the cost per media cycle and the life expectancyof the dust collector's fIlter elements.Too much usableabrasivereaching the dust collector may wear out the filter cartridges prematurely. Clemco'sAbrasive Cleaner is a gravity-fed air wash cleaner designed to be used with mechanicalrecovery floors. A rotating scalping drum culls debris from the media stream. The spentmedia. dust, and fines cascade over a seriesof baffles. A high- volume streamof air is drawn through the falling media to remove dust and fines. Reusablemedia is carried either to a storagehopper or drops directly back into the blast machine. Designed into the product is its ability to spreadthe media into a uniform curtain as it cascades each off baffle and, control of the flow of air """ passingthrough that curtain of media. This design keepsthe media curtain from developing gaps.If the curtain is not uniform, the air will remove dust and fines unevenly. Reclaimer A reclaimer is a cyclone separatorthat spins the heavier media particles in the air streamto the outside of a cyJinder,while dust and broken media are drawn out with the exhaustair. RecJaimers work best with pneumatic recovery systemsusing Jightweight media. A reclaimer can be precisely tuned to mini- mize the amount of usable media carried over into the dust collector. If alumi- num oxide or other aggressiveabrasiveswill be used, order the reclaimer with optional rubber-lined wear-plates. ~ Reclaim"s are usedin pneumatic systems.
  10. 10. 10 Most blast facilities built or The requirementsfor blast room of filter element. This is commonly refurbished during the past 10 years ventilation vary from state-to-state. referred to as the air-to-cloth ratio, have included a reversepulse cartridge The size of the room, the condition of though modern filter cartridges use dust collector. The dust collector has a the part being blasted,the amount of pleated polyester/paperto trap the dust. powerful exhaustmotor to draw dust- dust from the blast media, the airflow Clemco dust collectors provide a 2-to-l laden air out of the enclosure and trap required for the media reclaimer or air-to-cloth ratio, though the filter area the dust in filter elements. abrasivecleaner -- all will affect the can be increasedfor especially dusty The cylindrical cartridges of the size of the dust collector needed. applications. reversepulse dust collector are open at At a minimum, the dust collector The dust collector is among the one end and have a reinforced pleated must generate50 feet per minute of air most expensivecomponentsof a blast paper filter element. The advent of flow through the enclosure.Dusty facility. Paying for more dust collection pleated,high-efficiency filter elements applications or those that generate than you needis wasteful; buying an greatly reducedthe size requirements hazardousmaterial, may require flow inadequatecollector can be disastrous. of blast facility dust collectors. rates of up to 100 fpm. Your Clemco, ZERO, or Aerolytf: To extend the life of the filter The dust collector's filtering Distributor can recommendthe appro- cartridge, the dust that collects on the capacity is measuredby amount of air priate size of dust collector for your filter element must be removed flow in relation to the total squarefeet application. periodically. Modem dust collectors clean their cartridges with a pulse of compressedair that momentarily reversesthe flow of air through the Pulse jet air Reverse pulse manifold - - jet valves filter element. This pulse knocks the caked-on dust into a hopper or dust drum below. Clean exhaust air If the pulse cleaning is auto- Dirty matic, the dust collector can operate incoming Dust filter for long periods without stopping. air --- cartridges Clemco provides only automatically pulsed dust collectors. The pulse can Dust laden be actuatedby a timer or by sensing air Debris -' devices that detect dust build up by deflector plate measuringthe difference in pressure Heavy debris betweenthe clean and dirty side of the particles filter. --- Position the dust collector as Magnahelic close to the blast enclosureas possible Controlpanel- gauge for maximum ventilation efficiency and reducedinstallation costs. Locat- ing the dust collector outside simpli- fies emptying dust hoppers and saves valuable plant floor space. Dust Collector Size The dust collector must be -- Debris barrel sufficiently powerful to ventilate the room and have filtering capacity to trap the dust generatedduring blasting. A cartridge dust collector cleansits filter elementswith periodic blastsof compressed ail:
  11. 11. 11 Forklifts, rail-mounted work cars, overheadmonorails, and other common systemsthat already exist or are planned for your plant can be integratedinto a Clemco blast facility. For parts weighing more than 5,<XX> pounds,modifications in the enclosure floor or roof beamsmay be required. If you plan to drive equipment into the blast room, tell your Clemco, ZERO, or Aerolyte Distributor so that special load-bearingfloors or heavy-duty floor gratescan be incorporated. A blastfacility can take advantage of any existing or newly installed work handling equipment -from forklifts to monorails to work cars with and without tracks. To co-ordinate the operation of the various components,most blast rooms include a central control panel. Controls range in complexity from simple on/off buttons to computer- controlled parts handling systems. The control panel enclosure servesas the interface betweenyour existing power supplies and the blast room. Standardblast room control panels meet NEMA-12 specifications. Explosion-proof panels or other special power requirementswill affect componentsbeyond the panel itself, and must be specified in the request for quotation. Control panels serve as the interface betweensources power and the blastfacility. of
  12. 12. 12 ta Clemco has establisheda profes- sional relationship with a group of experiencedblast facility installation contractors throughout the U.S. and Canada. These contractors can prepare: the site, install the blast room, and connect your existing work handling system to the blast room's. Complete or partial installation can be included ill the price of the blast facility. Some companieselect to use their own employeesor to hire local contrac- tors to perform all or part of the installation. Clemco provides complete drawings for site preparation, equip- ment arrangement,electrical and sheet metal connections,and finish work. Installation by our t'xpmenced contractorscan be included in the price of your facility; Training is frequently overlooked as an important component of a new or refitted blast faciljty. Even experi- encedoperatorsmust learn how the systemswork, how to troubleshoot, and how to work safely. Clemco recommendsstartup supervision for major new components and complete facilities, and training for employeesnew to abrasiveblast- ing. Clemco conductsmost new- facility training on-site, in conjunction with the startup of the facility. Also, Clemco has a fully equipped training center at its Washington,Missouri, headquarters. Ckmco can provide completetraining and start-up supervision. n
  13. 13. 13 Adjoining Modules These adjoining blast room modules combine to form a 72-foot enclosurefor blasting large parts on a regular, but not daily, basis. The modules are capableof operating independentlyfor smaller parts or linking to handle large parts. Work cars ride on rails set into a concrete slab flanked by Clemco's FIo-FiorTM recovery pans. The slab remains relatively clean during blasting. What little abrasivedoes land on the slab is blown into the pans before the doors are opened. Each module has its own blast systemand dust collector. The installation runs two shifts a day, with two bla...terseach shift. OverheadMonorail. Overhead Monorail In Clemco's own plant, partiany assembled product.~ move through finishing and final assemblysus- pendedfrom an overheadmonorail. This 120 square-footroom is manned by a single operator free to walk anywhereon the Flat-Trak's 250 lb./ft? man-load grating. Becauseproducts are suspended from the monorail, the fun floor catchesthe abrasivescattered throughout the room. Shedplates along either side direct media into the recovery floor. The modules are ~ ;? --~Y ~-o ~ ~
  14. 14. 14 Customer Built Enclosure A remanufacturerof "piggyback" railroad cars built its own lOO-foot ", enclosureusing Clemco's specifications and components. The cars move along a spur track into the blast room, then to a paint facility, and on to rejoin the main track. The cars are blasted thoroughly, including the undercarriages,which meansa substantialamount of abrasivefalls under the cars. The huge facility has a full floor recovery system,including the area under the tracks. Recovery is fully automated,so the two blasters spendtheir entire shift blasting, with no interruptions for abrasivecleanup. Customer-built t'nc/osurt'. , "'"-/"""'- L~ O~O~; (:c,.,~ ~, ~ ~ ',' . '0 .~ ~~y - ~b... ) ~o~ ~ ~ ~~ ~ /..,-~ ~~~ .o~~1 ) ~ ,~ , ~ ~ ~ ~ ~ ~ ~ ,., ~~:: "" ~ I &' ...0" Wall-mounted lighting. Wall-mounted light modules ... . - ; .' .. (")~ ~ C'.~~ n~v-n illuminate all areasof the railcars ' ~~ °--- ,. ~ ... ~ '>~~: during blasting. A centrally located panel controls all start/stop functions (except actual blasting). Two dust collectors, representingmore than ..- {"l~' ~,",6-6 ~p 10,000 squarefeet of filter cloth, maintain ventilation and visibility. ~.,~~ -- ~
  15. 15. We have manufacturedquality abrasiveblast cleaning equipment for more than 50 years. You will find our products available through more than 450 independentClemco, ZERO, and Aerolyte Distributors in the U.S. and Canada. Clemco International, Inc., operatesa worldwide network of subsidiaries,licensees,and distributors. In addition to blast facilities, we offer the most complete line of blast cleaning equipment. We are proud of our worldwide reputation, a reputation basedon the quality, innovation, and value engineeredinto all our products. Becausewe engineer and manufacture all of the componentsthat go into your blast facility, and becausethe parts are designedto work together, the result is a balancedsystem,free of the compatibility problems found in someblast rooms. We can even show you how to breathenew life into an aging, inefficient blast facility. A blast facility is a major investment. Our staff will work closely with you to plan and create a facility that provides lasting value and maximum return on investment. We keep you informed at each step and rely on your direction to make sure we are producing a systemcapableof doing the job. Our comprehensiveinstallation, operation, and maintenance manualshelp your employeeslearn how the systemworks and how to keep it operating at peak efficiency for years to come. CLEMCO () Stock No. 09292 Job No. 115-0877 . Date of Issue; August. 1977 . Rev. B; (X)/94