Airlocks Ppt 2005-02-18 Dgl

8/13/2019 Airlocks Ppt 2005-02-18 Dgl

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Airlocks

Field Operator Certification

Airlocks

8/13/2019 Airlocks Ppt 2005-02-18 Dgl


Airlocks

13/02/2014Field Operator Certification 2

Lesson Objectives

1. State the purpose of Airlocks

2. State the different types of Airlocks used in cement

manufacturing

3. Explain the principle of operation for each type of Airlock4. State the applications for Airlocks in cement manufacturing

5. Describe the running & static inspections for each type of

Airlock

6. Describe the troubleshooting for common Airlock problems

7. Identify safety hazards associated with the operation of

Airlocks

8. Perform running & static inspections on Airlocks (OJT)

8/13/2019 Airlocks Ppt 2005-02-18 Dgl


Airlocks


Objective 1 - Purpose

To control the flow of

solids & fluids from one

process stream to

another.

8/13/2019 Airlocks Ppt 2005-02-18 Dgl


Airlocks


Objective 2 – Types of Airlocks

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Airlocks


Objective 2 – Types of Airlocks

Rotary Valves

Tipping / Gate

Obturator Valves

Pneumatic Pinch Valves

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Airlocks


Principle of Operation

Rotary Valve

Cast iron machined casing

within which multi vane

rotor revolves

Tight tolerances between

rotor & casing are critical in

maintaining proper seal

Material introduced into

Rotary Valve through an

inlet flange located on top

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Airlocks



Rotary Valve (cont’d)

Material evacuated from bottom of Rotary Valve once

pockets pass into open discharge point

Material falls by gravity through discharge flange intodownstream equipment

Rotary Valve can be driven at constant speed for

continuous evacuation of material at controlled rate

Can also be driven at variable speeds allowing RotaryValve to be used as material feeder

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Airlocks



Rotary Valve (cont’d)

Visualize the operation of revolving

doors commonly used in hotels &

other building entrances

Principle of operation is the same -

“controlled flow of solids & fluids

from one stream to another”

People enter or exit building while atthe same time reduce energy losses

associated with heating or air

conditioning

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Airlocks


Principle of Operation – Tipping

Valves

Fabricated or cast body

with an inlet & outlet

flange connected between

two process streams

Between the two flanges,

internal gate is used to

control flow of material

between two streams

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Airlocks



Tipping Valves (cont’d)

Material gate commonly fixed to pivoting shaft supported

by bearing assembly at each end

Material introduced into Tipping Valve through inlet flange Material accumulates above gate until either mechanical

drive forces gate open, or mass of material above gate

overcomes externally mounted counterweight which in

turn forces gate to open

In both cases material is released through Tipping Valves

discharge flange into downstream equipment

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Tipping Valves (cont’d) Those with mechanical

drives are commonly openfor predetermined period oftime or until ideal materiallevel is achieved

Those using external

counterweight open onlylong enough to releaseenough material to resetcounterweight

2 commonly used in seriesto ensure proper Airlock

One of 2 gates remainsclosed at all times ensuringpositive seal between 2streams

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Airlocks



Tipping Valves (cont’d)

Visualize the operation ofdouble doors commonlyused in shopping malls &other building entrances

Principle of operation is thesame - “controlled flow ofsolids & fluids from onestream to another”

People enter or exitbuilding with doors closingbehind them before doorsare opened ahead

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Obturator Valve

Consists of 2 molded & pre-

stressed elastomer diaphragms

connected together at sides &

inlet flange

Open area at bottom adjusted by

2 positioning rods that ensure

proper orientation of side

diaphragms

Absence of material, negative

static pressure of upstream

vessel forces 2 diaphragms

together creating tight seal,

isolating upper & lower streams

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Airlocks



Pneumatic Pinch Valves

2 piece cast iron body with

integrated flanges on both

ends

Contained within 2 piece

body is gum rubber tube

insert with integrated

flanges on both ends

Insert flanges match

casting flanges for aneffective air seal within

valve casing

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Airlocks



Pneumatic Pinch Valves (cont’d)

Commonly installed in round duct between 2 process

streams to provide isolation & or flow control similar to

installation of Tipping Valve or Rotary Valve

To provide isolation, compressed air is introduced into

void between 2 piece assembled casting & gum rubber

insert

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As pressure is increased from atmospheric to typically 50

psi, rubber tube insert is forced to collapse within casting

Collapsed insert creates a seal between upper & lower

process streams isolating the two from one another

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Typical configuration - operation controlled by level

detectors in process stream

When target level is reached, compressed air vented fromPinch Valve & rubber tube opens (material flows)

Once level detectors clear, Pinch Valve closes, isolating

system

Pinch Valve can be configured for flow control by applyingvariable pressure through controller to Pinch Valve

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Airlocks


Objective 5 - Applications

Pneumatic PinchValves

Dust Collectors

Cyclones

Feeders Pneumatic

Transport

RotaryValves

Tipping / GateValves

ObturatorValves

Dust Collectors

Cyclones

ClinkerCooler Under

Grate

Compartments

Gravel Bed

Filters Vertical Roller

Mill Feed &

Rejects Chute

HES Rejects

Chutes

Dust Collectors

Cyclones

Dust Collectors

Cyclones

Slurry FlowControl

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Airlocks


Objective 6 - Inspections

Running Inspection… Rotary Valves

Tipping Valves

Obturator Valves

Pinch Valves

Static Inspection … Rotary Valves

Tipping ValvesObturator Valves

Pinch Valves

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Airlocks


Objective 7 - Troubleshooting

Pneumatic PinchValves

Rotary Valve

will not start

Noisy drive

Valve noisy

Packing seals

leaking

Bearings noisy

Product will notdischarge

RotaryValves

Tipping / GateValves

ObturatorValves

Valve will not

operate

Valve not

sealing

properly

Noisy drive

Valve

operation isnoisy

Bearings noisy

Valve will not

discharge

product

Valve will not

seal

Valve will not

discharge

product

Pinch Valve

will not isolate

material flow

Material does

not evacuate

from Pinch

Valve

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Airlocks


Objective 8 - Safety

Mechanically driven Airlocks can start & stop

automatically

Casing & internal material temps can be extremelyhot

External Tipping Valve arms can be under extreme

pressure from material above valve

Creates pinch point in many applications

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Airlocks


Objective 8 – Safety (cont’d)

Inspect all guards for damage & support integrity

regularly

Never attempt to remove build-up off componentswhile in operation

Keep clothing, fingers, hair, & other parts of body

away from drive components

Report all unsafe conditions or practicesimmediately

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Airlocks


Lesson Review

What is the purpose of an Airlock?

To control the flow of solids & fluids from one process

stream to another

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Airlocks


Lesson Review

List 4 types of Airlocks commonly found in cement

manufacturing

1. Rotary Valves2. Tipping Valves – Gravity, Pneumatic, Hydraulic, Motor

Driven

3. Pinch Valves

4. Obturator Valves

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Lesson Review

Describe the unique limitation to the application of

an Obturator Valve

Can only be used in applications where the upperprocess stream is under negative pressure

Common applications are Dust Collectors & Cyclones

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Lesson Review

What real world application best illustrates the

operation of a Rotary Valve, and why?

Rotary Valve concept can be visualized in the real world

through the operation of revolving doors commonly usedin hotels & other building entrances

Principle of operation is the same - “the controlled flow

of solids & fluids from one stream to another”

In this case people entering or exiting the building whileat the same time reducing energy losses associated with

heating or air conditioning

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Airlocks


Lesson Review

What real world application best illustrates the

operation of a Tipping Valve, and why?

Tipping Valve concept can be visualized in the real world

through the operation of double doors commonly used inshopping malls & other building entrances

The principle of operation is the same - “the controlled

flow of solids & fluids from one stream to another”

In this case people entering or exiting the building withdoors closing behind them before the doors are opened

ahead

Ai l k

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Airlocks


Lesson Review

How does a pinch valve control the flow of solids

and fluids between two streams?

The pinch valve uses compressed air to collapse theinsert within the valve body isolating the two streams

from one another.

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Ai l k

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Airlocks


Lesson Review

Describe 5 inspection points for each of the 4 types

of Airlocks described in this module

As per Inspection information

Airlocks

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Lesson Review

Describe 3 conditions that could explain why

product would not discharge from a Rotary Valve

As per Troubleshooting information

Airlocks

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Airlocks


Lesson Review

Describe 3 conditions that could explain why a

Pinch Valve would not isolate a material flow

As per Troubleshooting information

Airlocks

8/13/2019 Airlocks Ppt 2005-02-18 Dgl


Airlocks

Lesson Review

Describe 3 safety hazards associated with any of

the Airlocks described in this module

As per Safety information

Documents

Airlocks Ppt 2005-02-18 Dgl