Operating Instructions
Contents
1. 1 5 PNEUTRANS GmbH GmbH Wage und Anlagentechnik Flugfeldstrasse 56 AT 2540 Bad V slau 43 0 2252 76015 0 6 43 0 2252 76015 20 Norwegen Norway La Norv ge Noruega Alfsen og Gunderson AS P O box 6052 Etterstad NO 0601 Oslo 2 447 22 70 77 00 91 47 122 70 77 81 T rkei Turkey La Turquie Turqu a YENI Farmakon Pharmaceutical Industry Cosmetic amp Food Co Ltd Kore Sehitleri Cad Renk Apt No 42 D 7 TR 34394 Zincirlikuyu Istanbul 2 47 67 121 020 47 67 591 618 Via Fabio Filzi 25 a 20124 Milano 39 02 669 867 77 1 39 02 669 00 35 Ingenj rsbyr Duvn sgatan 12 SE 11634 Stockholm 46 8 641 35 30 46 8 641 46 10 Kroatien Slowenien Croatia Slovenia La Croatie Slov nie Croacia Eslovenia Dipl Ing Branko Gabric Schikanedergasse 11 14 AT 1040 Wien 22 443 1 943 53 95 43 1 943 53 95 USA USA E U E E U U Powder Technologies Inc PTI P O Box 2277 US 08046 Wilingboro NJ T 1 2157 414 630 6 1 2157 415 101 Finnland Finland La Finlande Finlandia ORILING OY Yhteisty nkatu 13 SF 53300 Lappeenranta 35 85 6133 340 Ej 35 85 6133 350 Basilien Brazil Le Br sil Brasil MHS Industria e Comercio Ltda R Anisio da Mota 72 jd Mirante Sao Paulo Brasilien 05801 020 5511 585 121 84 El 5511 585 138 62 Mitropoleos str 43 GR 151 24 Maroussi Athen T 30 2102. 5 con AR OR s e Su GOOD RS B i 23 6 1 COMMISSIONING WITHOUT PRODUCT 4 4 11 0 24 6 2 CONTROL OF INDIVIDUAL 24 6 2 1 BLOW VESSEL CLOSING 24 6 2 2 CONTACT PRESSURE GAUGE 24 6 23 SIGNALLING PROBE LEVEL HIHG 24 6 24 SINGALLING PROBE LEVEL LOW LL 24 6 25 CONVEYING AIR isc nett iet eer is cette ads b Pee 24 6 2 6 OUTEET VAEVE irte teles m ets 24 6 27 EXHAUST VAEVE incen erre Ru de 24 6 3 OPERATIONAL CHECK IN MANUAL 25 6 4 TEST RUN IN MANUAL MODE WITH 25 6 5 TEST RUND IN AUTOMATIC MODE WITH PRODUCT eee 26 6 6 PURGING OPTION SEE 4 6 1 IN MANUAL MODE 26 6 7 DECLOGGING OPTION SEE 4 6 2 IN MANUAL 26 SERVICING AND MAINTENANCE INTERVALS 27 72 27 7 2 PARTS SUBJECT TO PARTIAL 27 7 3 MAINTENANCE WORKS BE PERFORMED EVERY TIME AFTER 100 SERVI
3. GERICKE AG Althardstrasse 120 Industrial CH 8105 Regensdorf 74 41 1871 36 36 Deutschland Germany L Allemagne Alemania GERICKE GmbH Max Eyth Strake 1 DE 78235 Rielasingen 49 7731 929 0 Frankreich France France Francia GERICKE SAS 7 rue Guy Moquet 2 1 du val d argent FR 95100 Argenteuil 33 139 98 29 29 za LT LPS Grossbritannien Irland Great Britain Ireland Grande Bretagne Irlande Gran Bretafia Irlanda GERICKE LTD Victoria House Cavendish Street GB Asthon under Lyne Lancs OL6 7DJ 22444 161 344 11 40 Niederlande Netherlands Les Pays Bas Pa ses Bajos GERICKE B V Postbus 46 Zuiderinslag 18 Industrieterrein Overhorst NL 3870 CA Hoevelaken 31 332 542 100 S dostasien Southeast Asia L Asie du Sud Est Asia Sudeste GERICKE PTE LTD 436 Tagore Avenue Singapore787813 65 6 452 81 33 91 41 1871 36 00 49 7731 929 310 33 1 39 82 29 74 44 1 161 308 34 03 31 332 542 600 65 6 452 03 92 Vertretungen Agencies Repr sentations Representaciones mum HNEN TEENS a E B mE ay Osterreich Italien Schweden Griechenland Danemark Ungarn Austria Italy Sweden Greece Denmark Hungary L Autriche L Italie La Su de La Gr ce Le Danemark La Hongrie Austria Italia Suecia Grecia Dinamarca Hungr a LENZ amp ATZL Systeme RAVIZZA amp CO SRL AB OSCAR LINDBERG TEXKOM Engineering Ltd
4. 0 1 to 0 2 bar so that with the blow vessel in off position the previously adjusted pressure level is only just underrun The cabling must be realised in a cable break proof manner break contact 4 43 SAFETY PRESSURE SWITCH P2 CONVEYING The pressure level to be adjusted at this switch must be by 0 3 to 0 5 bar below the actual conveying pressure level Actuated by this pressure the contact P2 serves to maintain the ongoing conveying procedure Once the previously defined pressure level is being underrun during the conveying procedure i e in the event the blow vessel is empty the pressure switch triggers the subsequent conveying cycle The duration of the subsequent conveying cycle is adjusted by means of a timer see separate operating instructions established for the control system STP 51 for ex Small blow vessels in particular can also be operated time controlled only This however also goes along with a loss of comfort As for level low probe equipped Systems please refer to sub section 4 3 4 herein 4 4 5 PRESSURE SWITCH EXCESS PRESSURE OPTION Once the pressure level adjusted at this switch is underrun the system is disconnected and made voltage free and a corresponding fault message on the display of the control system The cabling has be carried out in a wire break proof manner break contact Caution The system is still under pressure and contains product Prior to performing any activities the sys
5. Blow vessel outlet bend Non return valves and pressure regulators 7 3 MAINTENANCE WORKS TO BE PERFORMED EVERY TIME AFTER 100 SERVICE HOURS Check of all safety devices Check of all wear parts see sub section 7 1 Check of the blow vessel venting system must not be filled with product or be clogged Refilling of the oil mist devices in the control air system if existing Emptying of the water separators Control of the blow vessel safety valve for internal dirtying through product or dust Control of the system incl the conveying pipe for the escape of dust and eventually loose screwed or bolted connections or loose hose clips Check of the system settings and comparison with the values recorder during commissioning All changes attributable to operational reasons to be protocolled Control measurement of the conveying performance Control of the setting of the contact P1 safety at contact pressure gauge Control of the setting of the contact P2 conveying at the contact pressure gauge Control of the setting of the contact P3 excess pressure at the contact pressure gauge Check of all earthing connections With PulseLine activators option check of the pressure transmitter via status indication on the control display 7 4 MAINTENANCE WORKS TO BE PERFORMED EVERY TIME AFTER 650 SERVICE HOURS Check of all parts that are subject to partial wear see sub section 7 1 Check for tightness as describe in sub section 6 3 OPERATIONAL CHECK
6. IN MANUAL MODE New adjustment of the level probes in the event of scale formation on the probe stick Execution of a general operation check Operational check of the pipe diverters filters excess pressure flaps on both the silos and the receiver vessels Gericke ac 32080127 0 E doc April 2007 Page 27 of 33 Pneumatic Dense Phase Conveyor PTA Check of the conveying pipe with regard to scale formation In most cases scale will form up only in pipe bends Mount a bend at the end of the conveying pipe for control purposes A cleaning procedure is required if the conveyance is troubled through the scale formed up inside the tube frequent clogging of the line 7 5 INSPECTION OF THE BLOW VESSEL PRESSURE VESSEL Normally the construction and design of the pressure vessel used with the conveying system described herein complies with the regulations established by the T V Germany technical inspectorate officially authorized inspection agency or if so required also with the regulations established by the T V Austria or those established by the Swiss SVTI SVTI Swiss Association for Technical Inspections It is of great importance that the customer provides one copy of the two also provided acceptance attests design amp construction and pressure test to the competent recognized inspection agency It is beyond that also important to ensure that the second copy is available in the customer s facilities for use within th
7. Pneumatic Dense Phase Conveyor PTA When utilising an already existing conveying pipe however the pipe must be recalculated by GERICKE or be re dimensioned accordingly in order to obtain the best possible conveying performances To enable this the customer must provide GERICKE by all means with an allying ISOMETRY This isometry must contain the following additional information Desired or existing pipe dimensions outside diameter x wall thickness material Position of possibly existing pipe extensions Size of connecting pieces that possibly exist at the receiver vessels Position and inside diameter of already existing or desired sight or inspection glasses Position type make and inside diameter of already existing or desired pipe diverters In the event the new GERICKE system is intended for the replacement of an existing system all eventual difficulties or problems encountered with the old system must be communicated to GERICKE As of certain conveying pressures the conveying pipe needs in order to keep the air velocities within bounds to be extended periodically in backward direction In the event the customer places an order with regard thereto GERICKE will take charge of the calculation of these gradations In the event the customer himself undertakes to supply the conveying pipe the customer must wait with the ordering of further system parts and components until the definitive calculation with regard to the conveying pipe
8. The same also applies with regard to the expert and workmanlike connection of all electrical and pneumatic equipment to the related supply networks through the operator of the machine The operator must also take all precautions that are needed in order to ensure that no unauthorised persons can perform any works on the pneumatic conveyor put it into operation or perform any other works on it whatsoever SAFETY INFORMATION FOR THE OPERATOR All works performed on or with the device may only be carried out by duly trained or instructed personnel The operator must equip the machine with an appropriate emergency shutdown Each time after the completion of the electrical installation or after repair works all actually mounted protective devices and all precautions implemented need to be checked e g safety limit switches earthing etc addition to the present operating instructions generally applicable legal and other binding regulations for the prevention of accidents and regulations concerning the environmental protection too need to be followed and complied with and their observance be instructed Greatest attention must be paid to the control and maintenance of the safety valve fitted on the blow vessel NOISE EMISSIONS The A weighted equivalent continuous sound intensity level of this machine comes to a value below 70 dB A measured without product charge This limit applies with regard to a distance of one meter to the outside of
9. be observed with regard to the pressure and temperature levels admitted with the supplied system can be learned from an additional plate affixed on the blow vessel GERICKE guarantees a conveyance only with regard to the products based on the characteristics of which the dense phase conveyor described herein has been dimensioned and designed see system specifications Any modification or change of the product to be conveyed and also any change of the conveying path or distance to be covered requires that a new verification of the machine dimensioning be made Without special confirmation the following temperature levels are assumed to be correct Maximum product temperature 80 e Maximum ambient temperature 40 C 4 9 EXTERNAL FIRE Always make sure to avoid the existence of combustible materials in the vicinity of the system as these could lead to or cause an external fire Danger Gericke ac 32080127 0 E doc April 2007 Page 21 of 33 Pneumatic Dense Phase Conveyor PTA 5 ASSEMBLY AND INSTALLATION 5 1 TO BE PROVIDED BY THE OPERATOR OF THE SYSTEM 5 1 1 COMPRESSED AIR A specification of the required compressed air supply can be learned from the system data sheet The compressed air needs to be free from water and oil A specification of the pipe fitting dimensions too is indicated on the system data sheet 5 1 22 CONTROL AIR CONDITIONING The control air must only be supplied into the correspo
10. components including the control system for correctness and compliance with the specifications Danger Check of all safety devices emergency off facilities Programming of the control parameters see corresponding operating instructions Adjustment of the control air pressure by means of reducing valve customer supplied to the required control valve pressure level solenoid valves 5 to 6 bar pinch valves 2 to 4 bar 6 2 CONTROL OF INDIVIDUAL COMPONENTS 6 2 1 BLOW VESSEL CLOSING DEVICE e Blow vessel closing device butterfly valve Adjustment of the flap disc closing angle by means of the two adjusting screws that exist at the rotary cylinder see also separately furnished instructions The flap must open smoothly but still close in an absolutely tight manner see operating instructions established for the butterfly valve After that adjustment of the valve opening speed via the one way restrictor in such manner that the flap will open after 2 to 3 seconds Adjustment of the limit switches if included in the scope of the delivery Calotte type closing device KG specially suited for the conveyance of granules or Calotte type closing device K see also the related instructions Adjustment of the final position damping and of the control speed via the one way restrictor KG 1 to 2 seconds up to complete opening and 3 to 4 seconds for closing Adjustment of the limit switches if included in the scope of the delive
11. exhaust valve b and partially via the blow vessel closing device After completion of the filling procedure and the closure of the blow vessel closing device overpressurised conveying air is in order to start the transport of the bulk material to be conveyed admitted rhythmically at the top of the blow vessel in an alternating manner top air c and at the bottom into the pulsator bottom air d tha is installed downstream the blow vessel outlet pulse cycle operation The top air generates the required counter pressure and presses the solid material to be conveyed into the conveying pipe thereby forming a so called slug The bottom air pulsator causes the formation of an air cushion based on which the solid materials is being conveyed through the conveying pipe in the form of a slug The loading of these slugs i e the solid material volume per conveying air volume is determined through the different top and bottom air phase times These phase times can be adjusted at the control system STP 51 for ex which also controls all other operating sequences of the conveyor when using the control system STP 51 for example please refer to the corresponding operating instructions established for it As soon as the overall solids were conveyed out of the blow vessel the air in the blow vessel is exhausted and a new filling procedure starts running PulseLine activators option The PulseLine activators are added on or activated in dependence
12. g when changing the product to be conveyed in the case of longer stop times or in the event the blow vessel is weighed in order to check the actual material flow 4 6 2 ATTACHED DECLOGGING COMPONENTS OPTION These components if attached enable the declogging of the conveying pipe i e if the material in the pipe clogs up by reason of unoptimal settings or changed product characteristics The declogging is possible only with the conveying program in stopped condition 4 6 3 COMPONENTS FOR THE GENERATION FLUIDIZATION AIR OPTION These components enable to fluidize the product in the outlet area which in turn can influence the product charging operations 4 7 CONVEYING PIPE OPTION The conveying pipe serves for the transport of the bulk material from the blow vessel to one or several receivers The dimensioning and gradation of the conveying line can be learned from the GERICKE system data sheet Even if the conveying pipe does not form part of the scope of the delivery of the GERICKE dense phase conveyor described herein it is nevertheless an essential system constituent the correct dimensioning and assembly of which is decisive with regard to a troublefree operation of the overall system Concerning the provision of the conveying line 3 options are possible a Supply by the customer b Supply by GERICKE c Utilisation of an already existing conveying pipe Gericke ac 32080127 0 E doc April 2007 Page 17 of 33
13. is on hand PRESSURE STRENGTH The components actually applied must be able to withstand the maximum possible blow vessel pressure triggering pressure of the blow vessel safety valve Recommendation at least PN 6 The utilisation of pipe diverters at the end of the conveying pipe is admissible if the internal density of the diverters comes to 0 5 bar However the enclosure of the pipe diverter must in extreme cases be able to absorb the triggering pressure of the blow vessel safety valve INTERNAL PROTRUSIONS AT THE PIPE TRANSITIONS Negative protrusions i e protrusions seen in conveying direction must in relation to the corresponding pipe diameters not exceed the following sizes DN 50 0 5 mm DN 65 DN 80 1 0 mm DN 100 DN 150 1 5 mm DN 200 2 0 mm Unavoidable protrusions must in general be chamfered flush with the pipe Turbulences can thus be avoided The inside diameter of the conveying line must be adjusted to the actually applied system components pipe diverters sight or inspection glasses flexible hose connections etc STRAIGHT PIPE SECTIONS The following materials are suited for this purpose Normal steel pipes smoke pipes smooth at the inside precision steel tube Wall thicknesses in mm DN 50 65 80 DN 100 DN 125 DN 150 DN 200 Normal 2 3 2 5 3 5 3 4 3 4 3 5 5 4 6 Abrasive products 4 5 4 6 4 7 5 7 5 7 6 8 Page 18 of 33
14. on the pressure situation in the conveying line They serve to admit in a pulsating manner additional air wherever this is necessary inside the conveying line BLOW VESSEL The pressure vessel used as for blow vessel is a quality tested device It takes via the blow vessel closing device the bulk material in that needs to be conveyed After that the blow vessel is through the air admitted to it being put under pressure until to the moment the bulk material to be conveyed is pneumatically pressed into the conveying line infeed During this procedure the conveying air is admitted in an alternating manner i e in phases either as top or as pulsator or so called bottom air The pressure vessel must in as far as its quality is Page 10 of 33 32080127 0 E doc April 2007 Gericke ac Pneumatic Dense Phase Conveyor PTA concerned comply with the relevant local regulations and prescriptions enacted with regard thereto The gross volume as well as the maximum admissible operating excess pressure and operating temperature is indicated on the type plate affixed on the blow vessel The available volume depends on the bulk material actually to be conveyed dependent on the angle of repose For further details with regard thereto please refer to the additionally enclosed GERICKE system data sheet The prevailing operating pressure can be read off the contact pressure gauge installed in the top air supply line 431 BLOW VESSEL CLOSING
15. performing any such works these operating instructions must have been read completely When doing so all safety information contained therein should be made a matter of particular attention Caution 5 3 1 INSTALLATION MOUNTING AND ASSEMBLY Regarding the mounting and assembly of the machine the following order of steps needs to be followed corresponding assembly platforms to be provided by the customer if need be Deployment of the blow vessel both the hand hole and the level detectors need to be accessible The blow vessel must be fastened in a tilt proof manner Mounting of the outlet assembly of the blow vessel including outlet bend outlet valve if included in the scope of the delivery and of the pulsator Conveying pipe as for the pipe dimensions and line extensions please refer to the isometry and the system data sheet The conveying pipe must in order to be able to absorb the occurring pulse forces be fastened in a solid and stable manner All relevant parts need to be accessed easily in order to enable a perfect maintenance Installation of the exhaust line Installation of the conveying air fittings maximum length of the hose up to the blow vessel 5 m The fittings unit must not be changed when mounting it Installation of the control air supply line going from the locking organ up to the solenoid valve bank and from there to the consumers blow vessel closing device venting system exh
16. position number and size of the activators please refer to the related GERICKE system data sheet The activators can either be operated manually by means of manually operated valves or electro pneumatically via the superordinated control system STP 51 for ex 4 7 10 PULSLINE ACTIVATORS 4 7 11 The PulseLine activators are controlled based on measuring results and need to the attached to the conveying pipe as specified on the corresponding isometry sheet Regarding the construction and design of the PulseLine activators please refer to the enclosed drawing Prinzip PulseLine Gruppe PulseLine activator group operating principle INJECTION INTO THE RECEIVER VESSEL Tangential injection Causes the production of rather high volumes of dust and dust deposits on the walls inside the receiver vessel Injection in vertically downward direction Care must be taken with this injection method to ensure that the nominal diameter of the pipe bend that unites the horizontal and the vertical axes and the nominal diameter of the vertical pipe segment that leads to the receiver vessel is preferably by one size lager than the nominal diameter of the conveying pipe The inlet speed will thus be reduced Silo terminals flow diverter with strongly enlarged outlet Silo terminals are excellently suited in order to deaden the speed energy of the bulk material actually conveyed Radial injection Although this injection method is very product sparin
17. take care to ensure that all persons charged with the assembly disassembly commissioning operation maintenance servicing and repair of the device have read these operating instructions which particularly applies to the chapter on safety and all further safety information contained in these instructions The same applies also with regard to the control system used with the device control system STP 51 for ex and the operating instructions established by the manufacturers of other equipment that is delivered along with the pneumatic dense phase conveyor such as for example the inlet or outlet valve 2 1 SAFETY SYMBOLS This prohibition sign has been applied to all dangerous spots and places on the pneumatic conveying machine It indicates to the user that an increased level of attentiveness needs to be executed Always make sure to comply imperatively and without any fail with the corresponding safety information specified in these operating instructions This hazard warning sign has been used to mark all safety information of particular importance in these operating instructions Any such information must be complied with by all means The non compliance with any such information may result in injuries to the operator or user Danger This warning sign has been used to mark all safety information of particular importance in these operating instructions It has been applied to indicate that the related in
18. the blow vessel and a point in a height of 1 6 meters above the outlet of the machine WORKPLACES Owing to the fact that the machine is delivered in non employable condition no specific workplaces can be determined beforehand The determination of the individual workplaces depends on and is subject to the integration of the machine into the overall system Page 6 of 33 32080127 0 E doc April 2007 Gericke ac Pneumatic Dense Phase Conveyor PTA 3 SCOPE OF DELIVERY 3 1 3 2 3 3 3 4 3 5 3 6 In addition to the basic design of the dense phase conveyor different solution options can be realised with regard to the outlet or exhaust valves of the device e g installation of a diaphragm valve pinch valve ball valve butterfly valve or cut off slides slide valves The following table provides an overview of the extras and special components the delivered dense phase conveyor PTA has been equipped with An explanation of the role of the different solution options can also be learned from these operating instructions Regarding individual components such as the inlet flap the outlet valve the exhaust valve and the control system please refer to the also provided operating instructions established by the manufacturers of these devices SINGLE OR DOUBLE BLOW VESSEL Single blow vessel Double blow vessel BLOW VESSEL CLOSING DEVICE INLET SIDE Dbutterfly valve L KG1 OUTLET L Without out
19. the display of the control system STP 51 for ex Regarding thereto please refer to the separate operating instructions established for the control system STP 51 for ex section 10 4 Danger 9 1 MALFUNCTIONS REASONS AND REMEDIES Conveying pressure too high Formation of product bridges inside Clean and remove lumps or little or no product in the the blow vessel by reason of the conveying pipe formation of scales or lumps in the outlet cone pipe clogged conveying pipe Load to high Change the timer cycle times as explained in sub section 6 4 herein pressure network insufficient Locking organs or safety valves leaky Check by putting the blow vessel under pressure see sub section Formation of scales in the Check all bends in particular conveying pipe and clean doesn t close anymore Product rushes into the conveying No outlet valve installed or outlet pipe during the feeding of the blow valve defective to be repaired vessel Conveying pressure too low System settings changed Check using the setting protocol conveying performance too weak Locking organs or safety valves on the Check by putting the blow vessel blow vessel leaky under pressure Formation of ratholes or funnels in the Check and clean blow vessel cone due the formation of scales No conveyance No compressed air available Check the compressed air network and the related fittings Page 30 of 33 32080127 0 E doc April 2007 Gericke
20. 150 m 200 m distance 25m Timer 1 5s 1 2s 1 0 1 0 Blow vessel air ON Bottom air ON Once the conveying pressure is too low or the conveying performance too weak the timer blow vessel air ON needs to be set to a higher time value and the timer bottom air ON to a smaller one Once the conveying pressure is too high or the system clogged up the time value at the timer blow vessel air ON needs to be reduced and one at the timer bottom air ON be increased Regarding the air speed at the end of the conveying line the following standard values do apply Extremely slow conveyance 4 8 m s Slow conveyance 6 10 m s e Dense phase conveying without special requirements 7 20 m s These data apply to small and medium conveying pipe diameters and a conveying distance of 100 m length The bigger the nominal width of the pipe the stronger the air speed needed for proper conveying The product speed is equivalent to approx 50 of the air speed standard value Gericke ac 320801 27 0 E doc April 2007 Page 25 of 33 Pneumatic Dense Phase Conveyor PTA 6 5 6 6 6 7 TEST RUND IN AUTOMATIC MODE WITH PRODUCT The loading i e the air quantity per transported solid quantity can be changed through the corresponding adjustment of the blow vessel air and bottom air cycle times which in turn enables to adjust the desired product quantity to be conveyed Contingently the conveying air volume too needs t
21. 32080127 0 E doc April 2007 Gericke ac Pneumatic Dense Phase Conveyor PTA 4 7 5 4 7 6 Stainless steel pipes longitudinally welded or seamless smooth at the inside Wall thicknesses in mm ipm DN 80 DN 100 DN 125 DN 150 DN 200 Normal 1 3 2 3 2 3 2 4 3 4 3 5 215 29 32 34 3 4 4 5 4 6 4 6 Plastic pipes antistatic for the conveyance of aggressive or scale forming products Materials and wall thicknesses to be adapted to the individual case Hoses antistatic for adhesive or fat containing products Materials and wall thicknesses need to be adjusted to the individual case of application With hoses with an invulcanized steel wire spiral the self cleaning effect is usually more worse than with spiral free hoses DEFLECTION BENDS The following bends are suited for deflection Steel pipe bends materials and wall thicknesses as described in the section hereinbefore Plastic pipe bends hose bends any type of wear bends flow diverters With scale forming products a combination of straight steel pipe segments and hose diverters will often lead to success since the tendency to form scales is often to be observed in pipe bends only Mean radius Rm mm of pipe bends DN 50 65 600 800 DN 80 100 800 1000 DN 125 150 1000 1200 DN 200 1200 1500 PIPE CONNECTIONS Usually smooth flanges suit best for the realisation of pipe connections Wit
22. 61 47 900 30 210 61 47 902 Tschechische Republik Czech republic La r publique tch que Rep blica Checa GP POTRAVINOPROJEKTA s r o GPP Josefsk 15 CZ 663 02 Brno 1224420 5 422 18485 0 420 5 422 11670 Chile Chile Le Chili Chile Anherco LTDA Canada no 253 Depto D Providencia Santiago Chile RO 5600 Piatra Neamt 22 562 223 73 91 0 562 223 73 58 Skandrups alle 20 DK 3500 Vaerlgse 122445 44 44 12 55 345 44 44 80 06 Spanien Spain L Espagne c Roses 99 101 ES 08980 Sant Feliu de Llobregat Barcelona 22434 93 473 46 76 1 34 93 473 25 67 Rum nien Romania La Roumanie Rumania Mecanotech 2002 SRL Str Plevnei BI L3 Scara E AP 78 T 40 233 225 740 40 233 225 74 Beregsz sz t 141 HU 1112 Budapest 22436 1 246 23 62 0 36 1 246 23 62 Polen Poland La Pologne Polonia PROORGANIKA S A UI Krasinskiego 69 PL 01755 Warschau 48 22 3260 350 El 48 22 3260 351 Gericke ac 32080127 O E doc April 2007 Page 33 of 33
23. AND CONTAINERS MOUNTED ABOVE THE BLOW VESSEL In this event the utilisation of a cut off locking organ is of advantage In the event a hopper type discharge vibrator without cut off locking organ is used the sleeve used for the connection between the discharge vibrator and the blow vessel can burst on account of the leakage flow that can be called into being in the event of the blow vessel locking device is leaky The hopper content would be discharged down onto the floor This can be avoided when installing a small exhaust line equipped buffer Danger hopper above the blow vessel 5 2 CONTROL OF THE DELIVERY The machine is delivered pre assembled in different groups Prior to the installation of machine the delivery should be checked for the following Completeness including operating instructions see order confirmation and chapter 3 SCOPE OF DELIVERY Transport damages Correct type designation see order confirmation Supply voltage of the electrical equipment The pressure required for the connection of the control and conveying air supplies Page 22 of 33 32080127 0 E doc April 2007 Gericke ac Pneumatic Dense Phase Conveyor PTA 5 3 TRANSPORT AND INSTALLATION Always make sure to dispose of the appropriate ropes and ribbons when transporting the blow vessel by means of a lifting machine or device The installation mounting and assembly of the machine may be performed by trained personnel only Prior to
24. CE HOURYJS eines 27 7 4 MAINTENANCE WORKS TO BE PERFORMED EVERY TIME AFTER 650 SERVICE HOURS sissies ctccsscasaazcatsgaseaystaaazeasastcatadstasaceasasctacainctasasaaasaaadsoaiaacisaacieiuaacaabasdazaeainadiaahaddsaasaaaadiaaanad saan 27 7 5 INSPECTION OF THE BLOW VESSEL PRESSURE VESSEL 28 EcL cre 29 8 1 OUTSIDE CLEANING 44 2 47 2 0244 41 42 2 1 1 1 Sansoain seda sinas 29 82 INSIDE CLEANING 250 rias PL Dea ER RA RB CE EE XR AR EA 29 9 REPAIRING OF FAULTS 321i aisi ae dics ixsada 30 9 1 MALFUNCTIONS REASONS AND 1 30 92 FAULT INDICATION ON THE DISPLAY OF THE CONTROL SYSTEM STP 51 FOR EX 31 10 DISPOSAL jit pO GE ON IE TUA B ROS R PIN RE 32 TT LIST OF ADRESSES 33 Gericke ac 32080127 0 E doc April 2007 Page 3 of 33 Pneumatic Dense Phase Conveyor PTA 1 INTRODUCTION These operating instructions have been specially generated for the circle of persons charged with the assembly disassembly commissioning operation and repair of the pneumatic dense phase conveyor pulse cycle type A safe and troublefree operation of the machine can be obtained only when observing all information contained in these o
25. DEVICE ON THE INLET SIDE The blow vessel closing device closes the blow vessel in a pressure resistant manner and if in opened condition enables the filling of the vessel As for standard GERICKE offers the following closing device types Butterfly valve D universally applicable Calotte type closing device KG specially suited for the conveyance of granules Can close in a pressure tight manner while the granular material to be conveyed is flowing and can also close pressure tight in the event of a material pile up With this closing device the maximum admissible size of the particles conveyed depends on the construction size of the machinee For the blow vessel closing device used with your system please refer to the system data sheet and the sub chapter 3 SCOPE OF DELIVERY herein as well as to the separately established operating instructions To meet with the requirements in special cases cut off slides slide valves ball valves and mechanical pinch valves are available in addition The blow vessel closing device feed orifice must under no circumstances be opened as long as the blow vessel is still under pressure neither in manual nor in automatic mode The safety contact P1 on the contact pressure gauge must for this reason always be adjusted to a value close to zero i e 0 1 to 0 2 bar The software used by the electronic control system STP 51 for ex has been optimised for the control of this type of closing dev
26. Pneumatic Dense Phase Conveyor PTA pulse cycle type incl PulseLine activators option and control system e g STP 51 Operating Instructions To be kept for future use Manufacturer GERICKE AG Order No Althardstrasse 120 CH 8105 Regensdorf Zurich 41 0 1 871 36 36 Serial No E 41 0 1 871 36 00 Gericke ac 32080127 0 E doc April 2007 Page 1 of 33 Pneumatic Dense Phase Conveyor PTA T INTRODUC TION oie 25 ORE 4 2 SAFETY unione nte BM NEU E Db NE M CH SEP B Eu dS LTEEE 5 241 SAFETY SYMBOLS cci etresca ka eiui res seeds ka vu eR CR eR ERE A RN DEA PR ERO D 5 2 2 SPECIFIED 1 11 5 2 3 lt 2 5 cia P USE ERE DN RR Dod 6 2 4 ADVICE CONCERNING RESIDUAL RISKS 6 2 5 SAFETY INFORMATION FOR THE 6 2 6 NOISE 4 4 1 sa setas a assa 6 227 MORKPLAGCES icis niani Dad dc e ETUR RD 6 3 SCOPE OF DELIVERY nra EEES TRARNE ETRE E 7 3 1 SINGLE OR DOUBLE BLOW 44 4 11 7 32 BLOW VESSEL CLO
27. SING DEVICE INLET SIDE 0 7 3 9 OUT ETa e A E e e aaa a OaE AEEA 7 3 4 BLOW VESSEL PRESSURE 7 3 5 VENTING OF THE BLOW 11 7 3 6 ASSEMBLY CONVEYING AIR 8 4 44400 4 7 37 CONVEYING LINE 8 3 8 CONTROL 5 8 2 0011010 8 BD OTHER e E KA E Ped 8 3 10 INFORMATION CONCERNING THE ENCLOSED OPERATING INSTRUCTIONS 8 4 FUNCTIONING AND 9 41 CONSTRUCTIONAL DESIGN 2 104205 9 4 2 OPERATING PRINCIP E 10 4 3 BEOWVESSEL 5 2 tectis teta kann eaa Deer ne a EE 10 4 3 1 BLOW VESSEL CLOSING DEVICE ON THE INLET 506 11 4 32 EXHAUST VALVE AIR EXTRACTION 0002021 11 433 SIGNALLING PROBE LEVEL HIGH nenne 12 434 SIGNALLING PROBE LEVEL LOW LL 2 0 4042211 12 435 OUTLET ti tea rt tke ih bee redes 12 44 SAFETY DEVICES centeno Hace Da dd ie d
28. The pipe is under pressure if no blow noises are to be heard anymore in the conveying air fittings or if the inlet pressure regulator does no longer indicate a pressure loss manometer readout Deactivate the bottom air pulsator Open the outlet valve Bulk material flows back into the blow vessel Air escapes through the exhaust valve Repeat this procedure until the conveying pipe is completely declogged and again ready for normal operation Page 26 of 33 32080127 0 E doc April 2007 Gericke ac Pneumatic Dense Phase Conveyor PTA 7 SERVICING AND MAINTENANCE INTERVALS A GERICKE PTA dense phase conveyor pulse cycle type has only a few moved parts and is thus very easy to maintain 7 1 WEAR PARTS Sleeves of directly operated diaphragm pinch valves outlet valve exhaust valve 2 2 way diphragm valve installed in the blow vessel and pulsator air systems diaphragm in particular Activators and PulseLine activators Sealing diaphragm of the diaphragm valve used for venting Sleeves of mechanically operated pinch valves 7 2 PARTS SUBJECT TO PARTIAL WEAR Sealing collars of butterfly valves at the blow vessel closing device the outlet and the fittings Shafts and calottes as well as plain bearing bushes and V rings of the calotte type closing device K and the calotte type closing device KG special type for use with granules Ball seals of ball valves Pulsator during the conveyance of abrasive products
29. ac Pneumatic Dense Phase Conveyor PTA 9 2 FAULT INDICATION ON THE DISPLAY OF THE CONTROL SYSTEM STP 51 FOR EX See separately furnished operating instructions Gericke ac 320801 27 0 E doc April 2007 Page 31 of 33 Pneumatic Dense Phase Conveyor PTA 10 DISPOSAL The dense phase pulse cycle conveyor is a long lasting and solidly constructed machine Should it nevertheless be necessary to dispose it of this can be done in different ways The device can in clean condition be returned to its manufacturer GERICKE will then take charge of its competent disposal The costs incurred for the environment friendly and professional disposal will be billed to the customer The customer himself undertakes the disposal of the device The actual system consists of electronic components separate disposal required and of parts of synthetics plastic and metal For disposal the system must be disassembled completely and the different parts be assorted according to the different material groups The disposal of the different materials or material groups thus obtained must be effected via the local waste recycling and disposal companies or via the competent authorities Page 32 of 33 32080127 0 E doc April 2007 Gericke ac Pneumatic Dense Phase Conveyor PTA 11 LIST OF ADRESSES 7 lt Internet http www gericke net Gruppe Group Groupe Grupo Schweiz Switzerland Suisse Suiza
30. arking in consequence of the electrostatic charging Gericke ac 32080127 0 E doc April 2007 Page 19 of 33 Pneumatic Dense Phase Conveyor PTA 4 7 7 PIPE DIVERTERS Regarding pipe diverters the use of types is admitted only that according the following list do not if seen in conveying direction cause any excessive narrowing of the pipe cross section Regarding the pressure requirements to be met please refer to section 4 7 1 PRESSURE STRENGTH herein The following diverter construction types can be applied Drum diverters Tongue diverters Pinch valve diverters with abrasive products or product temperatures gt 50 C mechanically operated pinch valves to be used e Ball valve diverters e Hose diverters slide diverters Hose or rotary diverters EARTHING When conveying dust explosive or other potentially explosive products or when operating in an explosive environment all pipe connections need to be provided with stranded earthing wires The conveying pipe ends as well as the blow vessel need all be connected to earth potential ACTIVATORS OPTION With longer conveying lines of usually more than 80 m length activators are installed as additional conveying and or declogging components Conveying gas is injected all along the conveying line With products of more difficult conveying characteristics it is recommendable to install activators even with shorter lines Regarding the determination of the
31. aust valve cut off locking organ Installation of the electronic control system in compliance with the seperately furnished operating instructions The control system must to be installed in an easily accessible manner and need to be well visible depending on the case installation of an external emergency off facility required Electric cabling works to be performed by trained personnel only Earthing of the corresponding system parts Control of all actually installed mechanical and or electrical parts elements and components 6 COMMISSIONING Prior to the commissioning of the machine described herein these operating instructions have to be read thoroughly To ensure a smooth commissioning we recommend to ask for our experts who will take charge of the instruction of the operator s staff An instruction through our responsible experts ensures a far more efficient instruction of the operator s staff cuts down on the time otherwise spent for the commissioning of the machine and provides the safety of the correct recording of all settings and adjustments made on the machine Caution Gericke ac 32080127 0 E doc April 2007 Page 23 of 33 Pneumatic Dense Phase Conveyor PTA 6 1 COMMISSIONING WITHOUT PRODUCT Prior to the activation of the control system all electrical connections need to be checked for their professional realisation i e control of all voltages and current types of all elements and
32. e limits of recurring inspections This arrangement however does not apply with regard to pressure vessels with which the produce made up of the admissible maximum working pressure times the gross volume in litres p x Vol does not transcend a certain value that is officially acknowledged in the country within which the machine is operated Germany f ex p x Vol x 200 Regarding these cases the presentation of a corresponding manufacture confirmation concerning the execution of the necessary design amp construction and pressure test will suffice The putting into circulation of pressure equipment the characteristics of which do not comply with the requirements specified and laid down in the harmonised European Pressure Equipment Directive PED97 23 EC is as of 29 May 2002 is prohibited In order to meet with these requirements GERICKE designs the pressure equipment offered by it in conformance with the AD2000 regulations Note The pressure vessel needs to be checked and inspected in accordance with the applicable national regulations The recurring inspection times need to be fixed by the national supervisory body in cooperation with the operator of the machine Caution Page 28 of 33 32080127 0 E doc April 2007 Gericke ac Pneumatic Dense Phase Conveyor PTA 8 CLEANING With toxic or otherwise dangerous products the safety data sheet generated with regard to this particular product mu
33. f the safety valve the air supply is deactivated Once the safety valve closes again the blow vessel pressure must not drop any further Then exhaust the blow vessel cautiously in a pulse wise manner TEST RUN IN MANUAL MODE WITH PRODUCT Regarding the adjustment of the values specified herein below please refer to the operating instructions established for the control system STP 51 for ex section 6 3 Regarding the control of the blow vessel air and bottom air pulsator operation cycle only a first recommendation can be given here The ideal values strongly depend on the type of the bulk material actually to be conveyed and on the conveying distance to be covered The timer blow vessel air determines the duration of the top air supply and thus also the length of the product slug that gets into the conveying pipe Usually long product slugs produce higher pressures than short slugs With shorter slugs the conveyance procedure is actually more gentle The timer bottom air determines the duration of the bottom air flow and thus the length of the air cushion between the individual product slugs If using PulseLine activators option the configuration and parameterisation of the activators must be made in compliance with the specifications contained in the operating instructions established for the control system Regarding the commissioning the following standard values do apply Standard value Conveying 50
34. formation must be strictly complied with in order to prevent from damages to the system or to the machine Caution 2 2 SPECIFIED APPLICATION The pneumatic dense phase conveyor described herein may constitute hazards or risks if it is used in an improper or careless manner or if it is used for purposes not within the limits of the intended use the machine has been specified for The conveyor may only be used for the conveyance of dusty up to coarse grained types of bulk materials The construction and design of the conveying system corresponds to the material to be conveyed as sampled and described precisely upon order placing Any use beyond that will be considered as not intended Changes or mutations of the physical characteristics of the bulk material to be conveyed such as changes or mutations in regard to its granulation or moisture content can change the conveying characteristics vis vis the initially provided design purposes The manufacturer refuses to assume any liabilities for any damages consequent to any such mutations or changes Unauthorized modifications or alterations that result in the impairment or disturbance of the safety and or proper functioning of the pneumatic conveyor are prohibited Owing to its pressure vessel based design the pneumatic conveyor described herein is in many other countries subject to special pressure vessel regulations Modifications or alterations of the device may result in the extinguishme
35. g it can only be applied with very big silos If otherwise the product would be projected against the silo wall When using this method care must be taken to ensure that circa the last 3 0 m of the conveying pipe are widened by one nominal width size in order to reduce the product inlet speed When in doubt please do not hesitate to consult us for check back Page 20 of 33 32080127 0 E doc April 2007 Gericke ac Pneumatic Dense Phase Conveyor PTA 4 7 12 CONVEYING AIR DEDUSTING FACILITIES OPTION Both the conveying air and the product are separated at the end of the conveying distance Normally the conveying air needs still to be dedusted Usually automatic filters are used for this purpose If the filter is not included in the scope of the delivery the required filter can be dimensioned on the basis of the specifications on the system data sheet 4 7 13 PRESSURE RELIEF FLAP Pressure relief flaps are mechanically operated excess pressure protection devices burst protection that serve to prevent dedusting facilities and silos from bursting The provision of pressure relief flaps by the operator is compulsory When conveying dangerous products the operator must in the course of a safety analysis verify if or if not the product escaping from the system in the event of a reaction of these pressure relief flaps can be collected Danger 4 8 OPERATING CONDITIONS A specification of the operating conditions to
36. h pipes of large nominal widths or heavy thick walled pipes the use of centering shoulder equipped flanges is recommended in order to ensure an offset free installation Regarding gaskets or seals types made of Klingerit or similar material only should be used if ever possible to ensure that the gasket cannot get into the pipeline when tightening the connections With rubber gaskets the use of types the shore hardnesses if which is 60 is prohibited If using rubbers gaskets special qualities with a fabric insert need to be employed The inside diameter of the gasket must at least be 7 0 mm bigger than the nominal inside diameter of the related pipe Clamping joints or quick release couplings are provided however they are able to absorb the axial and pulse forces called into being through the existing internal pressure admissible SIGHT AND INSPECTION GLASSES Sight and inspection glasses may be used only if they dispose of an appropriate splinter protection Usually sight and inspection glasses of limited inside diameters are available on the market mostly 1 size per DN only In consequence of that the inside diameter of the related pipe must be adjusted to the glasses in such manner that no excessive narrowing of the cross section comes into being see section 4 7 2 INTERNAL PROTRUSIONS AT THE PIPE TRANSITIONS CAUTION There are no antistatic sight or inspection glasses available This is why it is always to be reckoned with sp
37. ial is not supplied to the blow vessel in a metered manner scilicet all cases where the blow vessel is mounted directly underneath of a silo that doesn t dispsoe of a product metering facility The use of outlet valves is likewise recommendable in all cases where big volumes need to be conveyed If need be the outlet valve enables the unclogging of the pipe With all PTA dense phase conveyors that dispose of a declogging installation the outlet valve is included in the scope of the delivery Page 12 of 33 32080127 0 E doc April 2007 Gericke ac Pneumatic Dense Phase Conveyor PTA 4 4 SAFETY DEVICES 441 SAFETY VALVE The safety valve is a mechanical spring loaded element that protects the blow vessel against too important pressure loads Once an excessive load is detected the valve opens and exhaust air along with perhaps some product escapes into the environment In the event this was inadmissible or even dangerous the exhaust air needs to be collected accordingly option The safety valve must be serviced and controlled regularly Danger 4 4 2 SAFETY PRESSURE SWITCH P1 SAFETY When operating in manual or in automatic mode the safety pressure switch prevents the opening of the blow vessel closing device intake as long as the pressure adjusted at the pressure switch contact is transcended i e as long as the blow vessel is under pressure This contact needs to be adjusted near to zero excess pressure of
38. ice However the control of the closing device is deactivated when Danger opening it by way of manual emergency actuation solenoid valve Y 1 2 4 3 2 gt EXHAUST VALVE AIR EXTRACTION CONDUIT Care must be taken to ensure that the air extraction conduit connection between exhaust valve and dedusting facility must in order to ensure that bulk material residues can flow back into the blow vessel not be laid horizontally risk of clogging The complete venting installation must periodically be checked for proper passage and correct functioning When operating in manual mode the exhaust valve may once the blow vessel is still under pressure only be opened cautiously scilicet by admitting short pulses risk of bursting of the dedusting facility Danger When filling feeding the blow vessel with well fluidizable or erratically flowing products the complete blow inlet assembly i e exhaust valve safety valve and contact pressure gauge must be displaced slightly by approx 80 cm in vertical or upward direction Gericke ac 32080127 0 E doc April 2007 Page 11 of 33 Pneumatic Dense Phase Conveyor PTA 4 3 2 1 DEDUSTING FACILITY REQUIRED FOR BLOW VESSEL VENTING OPTION When filling or feeding solids into the blow vessel air and whirled up solids are being displaced through the exhaust valve These solids need to be separated from the gas flow This may either happen in a central aspiration
39. l e Don DV EN E NERA HO DIEA 13 4 4 1 SAFETY VADVE iet i et wes ca ke i E ca ATEA A AUER 13 442 SAFETY PRESSURE SWITCH P1 13 4 4 8 SAFETY PRESSURE SWITCH P2 nnns 13 444 PRESSURE SWITCH EXCESS PRESSURE 13 4 5 CONTROL AIR UNIT ccc 111111 14 4 6 CONVEYING AIR FITTINGS UNIT 16 461 ATTACHED PURGING COMPONENTS 17 4 6 2 ATTACHED DECLOGGING COMPONENTS 17 463 COMPONENTS FOR THE GENERATION OF FLUIDIZATION AIR OPTION 17 47 CONVEYING PIPE 17 4 7 1 PRESSURE 5 ie tbe a edebat ede queer pe redu uae 18 4 7 2 INTERNAL PROTRUSIONS AT THE PIPE 18 473 STRAIGHT PIPE 18 4 4 DEFLECTION BEND iie eed eeu ea tci ete see rbd en dece ete te eee n eda 19 4 5 5 CONNECTIONS iiie en ete ette etr eise guerre cer ir en ee rte qe ru eee ed 19 4 7 6 SIGHT AND INSPECTION 19 BPIPEDBIVERTERS itinere ed pained ceu e tr aee aset and 20 CHE MEE
40. let valve L Pinch valve cite donee na tars Pulsator long L Pulsator short BLOW VESSEL PRESSURE VESSEL Excess pressure switch monitor option Signalling probe level high LH Signalling probe level low LL option Fluidization Option VENTING OF THE BLOW VESSEL Pinch valve Diaphragm valve ASSEMBLY OF CONVEYING AIR FITTINGS Pressure regulator Purge air L Air for fluidization see separate operating instructions calotte type closing device specially suited for the conveyance of granules see separate operating instructions see separate operating instructions see separate operating instructions see separate operating instructions see separate operating instructions See separate operating instructions See separate operating instructions See separate operating instructions see separate operating instructions see separate operating instructions Gericke ac 32080127 0 April 2007 Page 7 of 33 Pneumatic Dense Phase Conveyor PTA 3 7 3 8 3 9 3 10 CONVEYING LINE Conveying line Activators Available on option or to be provided by the customer Dedusting facility required for blow vessel venting See separate operating instructions Conveying air dedusting facility See separate operating instructions PulseLine activators OO O OO CONTROL SYSTEM Control system e g STP 51 see separate operati
41. n optional excess pressure flap inside the receiver silo S 3 to Y2 to Y4 Picture 1 1 Pressure vessel 2 Pneumatic control unit for the control of the in and outlet organs and the venting of the system Gericke ac 32080127 0 E doc April 2007 Page 9 of 33 Pneumatic Dense Phase Conveyor PTA 4 2 4 3 Exhaust valve Butterfly valve drive Bottom air connection no A Oo Fluidisation Type designation The type plate bears a type designation such as for instance PTA 300 D PTA 2300 KG1 or PTA80 K PTA DS D double blow vessel with butterfly valve PTA pneumatic dense phase conveyor pulse cycle type 300 gross volume of the pressure vessel blow vessel in litres D blow vessel closing device butterfly valve KG1 calotte type closing device specially suited for the conveyance of granules plus size indication K calotte type closing device DS double blow vessel see corresponding additional information in the separate operating instructions OPERATING PRINCIPLE The system picture 1 is operated intermittently The blow vessel is exhausted via the exhaust air valve and subsequently filled via the blow vessel closing device a standard equipment butterfly valve optional equipment calotte type closing device or calotte type closing device which is specially suited for use with granules The air in the blowing vessel is during this procedure primarily displaced via the
42. nding valves after its compression to an excess pressure level of 5 to 6 bar The conditioning unit needed for this customer supplied includes a water separator a pressure regulator and an oiler The control overpressure required for the actuation of the directly operated pinch valves that exist at the blow vessel needs to be adjusted by means of a separate pressure regulator that has to be provided by the customer Depending on the pressure level that prevails inside the pinch valve a pressure level of 2 to 4 bar will suffice In order to attain a best possible lifetime of the sleeve the adjustment of the minimum required pressure level should be aimed for The control air requires no oiling although oiling would contribute to increase the serviceable life of the solenoid valves and the mechanical actuators and control elements When using directly operated pinch valves no oil should be added risk of an ingress of oil into the product in the event of a breakage of the sleeve Size required for the connection of the control air 2 Inch at the minimum Control air stop cock The stop cock enables to stop the supply of control air in the event of maintenance works 5 1 3 PRESSURE RELIEF FLAP This flap serves for mechanical excess pressure protection burst protection purposes and is used to protect dedusting facilities and silos against bursting Pressure relief flaps need for security reasons to be provided by all means 5 1 4 SILOS
43. ng instructions INFORMATION CONCERNING THE ENCLOSED OPERATING INSTRUCTIONS The original operating instructions established by the manufacturers of the various parts elements and components installed in or attached to the machine such as the blow vessel closing devices the outlet valves the exhaust valves the contact pressure gauge the safety valves solenoid valves limit switches pressure switches and level probes are all delivered enclosed with the machine These operating instructions contain also a list of the related spare and wear parts Page 8 of 33 32080127 0 E doc April 2007 Gericke ac Pneumatic Dense Phase Conveyor PTA 4 FUNCTIONING AND DESIGN 4 1 CONSTRUCTIONAL DESIGN Picture 1 below represents a schematic drawing of the constructional design of the pneumatic dense phase conveyor PTA described herein The conveying system consists of a blow vessel pressure vessel a special assembly of conveying air fittings a special control air unit that serves for the control of the in and outlet organ and the venting of the system and consists further of an electronic control system STP 51 for ex that enables to control the conveying operations actually performed separate operating instructions included Additional elements and components are the conveying pipe and as an optional supplement activators and dedusting facilities for the venting of the blow vessel and for the dedusting of the conveying air including a
44. nt of the operating licence Gericke ac 32080127 0 E doc April 2007 Page 5 of 33 Pneumatic Dense Phase Conveyor PTA 2 3 2 4 2 5 2 6 2 7 SAFETY HAZARDS Prior to all works be performed on the pneumatic conveyor such as assembly maintenance cleaning etc care must be taken to ensure that the device is in absolutely idle condition and that the blow vessel pressure vessel is unpressurized With all works requiring to render the existing safety devices and appliances inoperative beforehand care must be taken to ensure that the blow vessel is not under pressure and that no material can get into or out of the blow vessel and the conveying pipes in an uncontrolled manner and that the compressed air supply is disconnected Prior to all assembly disassembly or servicing works the power supply too must be disconnected Beyond that the power supply needs to be protected against an unin tentional reclosure by means of a lockable switch for example not included in the scope of the delivery Never remove any safety devices and or appliances nor render them inoperative by making any unauthorised modifications or alterations to the machine ADVICE CONCERNING RESIDUAL RISKS The pneumatic dense phase conveyor PTA is delivered by its manufacturer in a non employable condition It may only be operated after its professional assembly and installation and only after the expert connection of the required mechanical connections
45. o be changed via the Laval nozzle inlet pressure to be adjusted while blowing Caution The difference between inlet and conveying pressure must come to approx 20 The calculated performance data are attained through the optimisation of the air quantity and of the relevant timers PURGING OPTION SEE 4 6 1 IN MANUAL MODE The conveying pipe can be purged only with the conveying program in stopped condition The purging operation can be activated via the control system see seperately furnished operating instructions generated for control system STP 51 for ex section 6 4 4 DECLOGGING OPTION SEE 4 6 2 IN MANUAL MODE Declogging is needed only in case the conveying line is clogged up by reason of nonoptimal settings or changed product characteristics Declogging is possible only in manual mode and only with the conveying program in stopped condition The declogging operation can be activated via the control system see seperately furnished operating instructions generated for control system STP 51 for ex section 6 4 3 Line of action to be taken after the occurrence of an obstruction Vent and exhaust the system cautiously pulse wise risk of bursting of the dedusting facility Once system is unpressurized open the exhaust valve Close the outlet valve Use the bottom air pulsator to the conveying pipe under pressure must not be any higher than the admissible operating pressure of the blow vessel
46. on of a level high signalling probe can be dispensed with as in these cases the product feed operation is controlled by a timer The timer controlled operation of the device however is less comfortable than the level high signalling probe supported one SIGNALLING PROBE LEVEL LOW LL OPTION The machine is also delivered accompanied by separate operating instructions concerning this probe The probe emits a signal to the superordinated control system STP 51 for ex once the blow vessel reaches the probe level while being discharged After that the pre adjustable subsequent conveying time starts running Once this time is over the system is relieved until to the point where upon the lower deviation of pressure switch level P2 the venting of the blow vessel is activated Normally the pressure switch P2 is adjusted to a value that is equivalent to 50 96 of the conveying pressure These setting options enable to operate in an operation mode where the conveying pipe depending on the actually adjusted subsequent conveying time is not discharged completely The material to be conveyed is thus treated more gently OUTLET VALVE OPTION The outlet valve is fitted shortly after the blow vessel and prevents the feeding of product into the conveying line while the blow vessel filling procedure is in progress Outlet valves need to be used with well fluidizable and erratically flowing products This applies to all cases where the bulk mater
47. perating instructions The non observance of any of this information and instructions and especially the chapter concerning safety and all further safety information contained therein can result in hazards and risks for the life and limbs of the operator s staff or of the servicing staff and all other persons that stay or work in the vicinity of the machine The non observance of these operating instructions can also result in damages to the machine or the surrounding equipment and facilities The pneumatic dense phase conveyor has been designed for the integration into a bigger system and is not an immediately employable product therefore These operating instructions must always be at hand near the place of operation of the machine The manufacturer of the machine refuses to assume any liabilities for damages operating troubles and or breakdowns resulting form the non observance of these operating instructions We reserve the right to make modifications to the machine for the purpose of its advancement and further perfectioning Regarding some parts of the equipment used and delivered with the machine these operating instructions may contain different information and instructions To learn the equipment variant s realised with the machine described herein please refer to the related equipment specification sheet Page 4 of 33 32080127 0 E doc April 2007 Gericke ac Pneumatic Dense Phase Conveyor PTA 2 SAFETY The operator must
48. ry K 1 to 2 seconds up to complete opening and 2 to 3 seconds for closing Adjustment of the limit switches if included in the scope of the delivery 6 2 2 CONTACT PRESSURE GAUGE Operational check of the contacts P1 P2 P3 6 2 3 SIGNALLING PROBE LEVEL HIHG LH Setting of the probe in compliance with the data specified in the separate operating instructions 6 2 4 SINGALLING PROBE LEVEL LOW LL Setting of the probe in compliance with the data specified in the separate operating instructions 6 2 5 CONVEYING AIR Adjustment of the required Laval nozzle inlet pressure Regarding the required air volume please refer to the GERICKE system data sheet Q mom 6 2 6 OUTLET VALVE Operational check opening closing 6 2 7 EXHAUST VALVE Operational check opening closing Page 24 of 33 32080127 0 E doc April 2007 Gericke ac Pneumatic Dense Phase Conveyor PTA 6 3 6 4 OPERATIONAL CHECK IN MANUAL MODE Actuation of individual elements The blow vessel needs to be checked for tightness To enable this the outlet valve if existing needs to be closed first or if otherwise a blind flange be installed between the conveying pipe and the pulsator e First admit blow vessel air until to a maximum pressure level of 1 bar The pressure must not fall after the deactivation of the blow vessel air supply e After that increase the blow vessel pressure until the safety valve reacts After the reaction o
49. st be consulted Danger 8 1 OUTSIDE CLEANING Prior to the execution of all works described hereafter the conveyor must have been discharged exhausted and disconnected from the power supply and be protected against an unintentional re start Danger Depending on the degree of the contamination or type of dirt Cleaning by way of vacuuming Wiping or sweeping off Wet cleaning with water 8 2 INSIDE CLEANING The cleaning of the machine inside depends exclusively on the individual situation and case and can therefore not be specified in more detail In many cases however the purging of the blow vessel and the conveying pipe will suffice see sub section 4 6 1 The blow vessel can for a more careful and thorough clean up also be filled with a cleaning fluid solution consisting of water and special solvent which after that is being conveyed through the conveying pipe Prior to that it must be ascertained whether or not the subsequent parts elements and components of the overall system receive vessel filter s etc are at all suited for the execution of any such wet cleaning procedure After wet cleaning air must be admitted for drying Gericke ac 32080127 0 E doc April 2007 Page 29 of 33 Pneumatic Dense Phase Conveyor PTA 9 REPAIRING OF FAULTS Trained personnel only may remove remedy and or fix faults and or malfunctions occurred with the conveying system Certain faults will be indicated on
50. stem The corresponding cycle time can be adjusted at the superordinated control system STP 51 for ex Modules for purging and or fluidization purposes can be attached to this fittings unit in addition This fittings unit is delivered as an assembly group including all connecting hoses to the blow vessel and must be mounted in unchanged condition The maximum admissible hose length is 5 meters As for standard the nominal operating voltage of the solenoid valves is 24 V DC Legend Top air Fluidization option U Bottom air L Purging or declogging in the event an outlet valve is mounted options Y4 2 2 way solenoid valve top air Y5 2 2 way solenoid valve additional air supply for fluidization 2 2 way solenoid valve additional bottom air 2 1 Inlet pressure regulator for Laval nozzle air volume metering 2 2 Laval nozzle Standard valves solenoid valve ISO indirectly actuated type Page 16 of 33 32080127 0 E doc April 2007 Gericke ac Pneumatic Dense Phase Conveyor PTA Power at24 V 2 5 Watt consumption at 110 V 3 7 Watt at220V 3 7 Watt Always make sure to equip all coils with special damping elements extinction of sparks Maximum length of the hose between the fittings unit and the blow vessel in each case 5 0 m Detail X Laval nozzle Laval nozzle 4 6 1 ATTACHED PURGING COMPONENTS OPTION These components if attached enable to purge the system e
51. tem needs to be exhausted manually in a circumspect manner see manual operating mode Danger Gericke ac 32080127 0 E doc April 2007 Page 13 of 33 Pneumatic Dense Phase Conveyor PTA 4 5 CONTROL AIR UNIT Arranged on a base plate mounted on the blow vessel there exist up to four solenoid valves that serve for the control of the blow vessel closing device of the exhaust valve the blow vessel outlet option and the cut off locking organ option see illustration 1 1 Druckluftaufbereitung Kundenseitig comressed air processing of customer side pr paration de air comprim c te li de client sh ort zz 1 35 34 33 Y1 15 2 way solenoid valve Y1 25 2 way solenoid valve Y2 5 2 way solenoid valve 5 2 way solenoid valve Vorabsperrorgan before block off object le organe de arr te ENA Senderverschluss colseing vesselvale serrure de sas on off Entl ftung aeration aeration JE Y2A on off 32 LUN Auslaufabsperrorgan outlet lock object organe sortie de arr te Ya HEH 3 1 of on on off on off off jon zh zz Y11 Y2 Y3 blow vessel closing device cut off locking organ option blow vessel venting blow vessel outlet option 3 1 One way restrictor for speed regulation 3 2 Hoses screwed connections and
52. threaded joints supplied loose 3 3 Servicing unit customer supplied 3 4 Stop cock customer supplied 3 5 Control air network customer supplied Standard valves Power consumption ISO 1 solenoid valve Y1 1 Y2 Y3 2 5 Watt at 24 V 3 7 Watt at 110 V 3 7 Watt at 230 V Page 14 of 33 32080127 0 E doc April 2007 Gericke ac Pneumatic Dense Phase Conveyor PTA Piloted by the electronic control system those solenoid valves are actuated which enable the pneumatic activation of the peripheral equipment The solenoid valve Y1 1 serves for the control of the blow vessel locking device The solenoid valve Y 1 2 serves for the control of an optionally existing cut off locking organ The solenoid valve Y2 serves for the control of the exhaust valve The solenoid valve Y3 serves for the control of an optionally existing outlet valve As for standard the coils of the 5 2 way solenoid valves have been dimensioned for 24 V DC operation With double blow vessels the valve groups can be integrated into one unit designated by the indexes A or B Gericke ac 32080127 0 E doc April 2007 Page 15 of 33 Pneumatic Dense Phase Conveyor PTA 4 6 CONVEYING AIR FITTINGS UNIT The conveying air fittings united in this unit serve to supply certain conveying air volume that is defined in compliance with the Laval nozzle inlet pressure and the nozzle actually installed to the top and to the bottom air supply sy
53. unit with separation facility or in a filter that is subject to mechanical or compressed air cleaning The exhaust conduit connection between the venting system and the dedusting facility must in order prevent from clogging up and in order to ensure that probably existing solid residues are able to flow back into the blow vessel not be laid horizontally The cross section of the exhaust conduit must in order to prevent from too high blow speeds be as big as possible analogous to the nominal width of the exhaust valve The complete venting system must periodically be checked for proper passage and functioning The exhaust valve must once the blow vessel is under pressure which may be the case in the event of a clogged up conveying line only be opened cautiously by admitting short pulses risk of bursting of the dedusting facility In the event the blow vessel is filled fed with well fluidizable or erratically flowing products the exhaust valve needs to be displaced by approx 80 cm in vertical Danger direction 4 3 3 SIGNALLING PROBE LEVEL HIGH LH The machine is delivered accompanied by separate operating instructions concerning this probe The probe emits a signal to the superordinated control system STP 51 for ex once the blow vessel is filled After that the filling feeding procedure is terminated and the blow vessel closing device intake closed With smaller blow vessels in particular the applicati
54. zMdsallcp EET 20 47 9 ACTIVATORS OPTION iii tert tette eei 20 4 7 10 POULSLINE ACTIVAT ORS incite ceci te er Le taba teneat x nue 20 4 7 11 INJECTION INTO THE RECEIVER VESSEL serene 20 4 7 12 CONVEYING AIR DEDUSTING FACILITIES 21 44 13 PRESSURE RELIEF FLAP tito tht beet bete stie hoe 21 4 8 OPERATING 8 2 4 21 4 9 EXTERNAL FIRE srcccisccccrsscicascassccntavacseasastacdacsvadsnsuasineiacadeasieaaassshacxadsactadadistaasehdaaienaseisaasaain tans 21 5 ASSEMBLY AND 22 5 1 TOBE PROVIDED BY THE OPERATOR OF THE SYSTEM 22 5 1 1 COMPRESSED AIR te teet e dae Letra rd ea ats 22 5 1 2 CONTROL AIR 22 5 1 3 PRESSURE RELIEF ELAP tr era tic e ee d deed 22 Page 2 of 33 32080127 0 E doc April 2007 Gericke ac Pneumatic Dense Phase Conveyor PTA 5 1 4 SILOS AND CONTAINERS MOUNTED ABOVE THE BLOW VESSEL 22 5 2 CONTROL OF THE 22 5 3 TRANSPORT AND INSTALLATION 44 8 23 5 3 1 INSTALLATION MOUNTING AND ASSEMBLY 23 6
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