Part-1 for FF

8485 Parkhill DriveMilton,Ontario.Canada L9T 5E9(905) 693-9301

M-25 Slaker (Right hand)

OPERATION &MAINTENANCE

MANUAL

CERRO VANGUARDIA

M-25 Slaker (Right hand)WITH VIBRATORY SCREEN

J0# 1724

SANTA CRUZARGENTINA

Web Site: www.limeslakers.com E-Mail: [email protected]

PREPARED FOR:CERRO VANGUARDIA

VENDOR: ZMI PORTEC INC. 8485 Parkhill Drive, Milton, Ontario, CANADA L9T 5E9 Phone: (905) 693-9301 Fax: (905) 693-3432 Email: [email protected] CUSTOMER: STANCO PROJECTS CERRO VANGUARDIA, SANTA CRUZ, ARGENTINA M-25 Right Hand Slaker and Vibratory Screen SECTION 1…….……………………………………………..Safety & First Aid SECTION 2………………………….……………General Slaking Information SECTION 3……………………….…………Slaker Component Specification SECTION 4………………………….……..……Slaker General Maintenance SECTION 5………………………….…………….……Slaker Seal Assembly SECTION 6………………………….……….………Slaker Aspirator System SECTION 7………………………….……………………..Drive Components SECTION 8………………………….……………………….Inspection Doors SECTION 9……………………….………………..Temperature Transmitter SECTION 10………………………….………………………….…Flow Meter SECTION 11………………………….……….Seal Water Pressure Gauges SECTION 12………………………….…..…………Valves & Spray Nozzles SECTION 13………………….……………...Component & Spare Parts List SECTION 14………………………….…………….…Electrical Components SECTION 15……………..………Field Service Rates & Authorized Service SECTION 16…………………...……………GA, P&ID & Electrical Drawings

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Operation & Maintenance Manual JO# 1724 PO#P22782 0001

mailto:[email protected]

SAFETY & FIRST AID

Lime and dust from lime are strong caustic irritants, affecting the skin, eyes, mucous membranes, and upper respiratory tract. Operators exposed to lime should observe the necessary safety precautions as listed below:

1. Dust from lime is very irritating if inhaled. Where dust concentrations are prevalent, approved respirators should be worn.

2. Approved eye protection is required for lime operators. Workers should wear

either tight fitting safety glasses with side shields or a tight fitting monogoggle.

3. The problem of protection from lime burns is more serious. This becomes especially prevalent in hot weather when workers perspire freely, and in wet and damp weather when exposed skin is wet. Along with adequate eye protection and respirators, workers exposed to lime should be fully clothed. Denim-quality shirts and trousers are preferable. Workers should wear long sleeved shirts with both the collar and sleeves buttoned. Trousers should be cuffless and long enough to cover the tops of tall shoes or boots. Low shoes are not recommended. Clothing should not bind too tightly around the neck wrists or ankles. Approved protective gloves should also be worn.

4. The use of sweatbands is advisable to prevent perspiration from mixing with lime

dust and trickling into the eyes.

5. In heavy dust concentrations, it is advisable for workers to apply a protective cream to the exposed parts of the body, especially the neck, face, wrists, waist, and ankles. Petroleum jelly is an excellent protective cream, and prevents lime dust from running into the eyes.

6. Workers should shower after handling lime. If clothes are permeated with dust or

splattered with lime slurry they should be removed and laundered. It is highly recommended that clean clothes be worn for every shift.

Lime burns on skin should be treated similar to caustic burns. The affected area should be thoroughly washed with soap and warm water and then with vinegar to remove all residual traces of lime. A physician should be consulted as soon as possible. Lime burns to the eyes can be especially serious. If contact with the eyes has been made, large amounts of clean water should be available for flushing the eyes. The eyes should be flushed for at least 15 minutes. Consult physician immediately. NOTE: Loose clothing should not be worn around moving equipment. Guards must be on the equipment at all times. An approved lockout procedure must be followed during equipment maintenance.

IMPORTANT

1. NEVER OPERATE THE SLAKER WITH ANY OF THE SAFETY DEVICES (LIMIT SWITCHES ETC.) DISABLED.

2. FOLLOW ALL SAFETY INSTRUCTION IN THE MANUAL AND SAFETY SIGNS ON THE SLAKER.

3. Ensure that the gearbox is filled to the required level with manufacturer’s recommended lubricating oil. Please contact Stanco Projects at 905 693 9301 if you require information in this regard.

4. Please check for correct motor rotation. The arrow on the drive belt guard indicates the direction of agitator rotation.

LIME SLAKING

Lime slaking is an exothermic reaction. A considerable amount of heat is generated during this

reaction. A good quality lime (lime content>90% and highly reactive) could achieve a

temperature rise of as much as 104oF in 5 minutes or less during slaking process. If the feed

water is too cold, slaking reaction is impeded which could result in slower slaking and formation

of a lumpy slurry with low lime surface area. Thus the slaking water temperature plays an

important role in overall slaking process.

Water to lime ratio is another important parameter from a slaker operation and quality of the

slurry stand point. Too high a water to lime ratio will cool down the reaction too much and

could result in what is called ‘drowning of lime’. Too low a water to lime ratio could result in

slurry that is too thick to flow out of the slaker and in extreme situations temperature ‘run off’

can happen. For ZMI Portec detention type slakers, the ideal water to lime ratio is 4:1 (CaO

weight basis). Please refer to the feed chart in this section to determine amount of slaking

water required for a given lime feed rate.

Stanco Projects’ M-25 model slaker is rated for a maximum feed rate of up to 5,500 lbs/hr (CaO

basis). The slaker is designed with a water preheat jacket. This jacket allows preheating of the

incoming slaking water, thus increasing the rate of the slaking reaction. Internal baffles in the

jacket maximize the surface area available for heat transfer. Slaking water enters the pre-heat

jacket at the discharge end of the slaker and makes its way back to the front (feed) side passing

through the baffled jacket, where it enters the slaking chamber

Lime is added to the slaker by attaching lime feed system to a lime inlet transition mounted on

the slaker lid. This lime inlet transition is designed to allow air flow into the slaker as well as

lime feed. This flow of air through the slaker is required for efficient operation of the dust and

steam removal system. Unless its location is pre determined, the lime inlet transition is field

installed so it aligns correctly with the rest of the equipment. A target area is shown on the

General Arrangement drawing, supplied by Stanco Projects, for this purpose. It should be noted

that the lime inlet is always biased towards the downward stroke of the agitator.

Lime Slaker General Operation:

As mentioned above, lime slaking is an exothermic reaction between water and CaO (lime) to

produce Ca(OH)2 (Calcium Hydroxide) in the form of slurry. To produce lime slurry of good

quality (high Ca(OH)2 particle surface area) it is required that the reaction takes place at the

optimum temperature and between water and lime of good quality. Stanco Projects’ detention

slakers produce high quality lime slurry by operating at a temperature of 170oF – 180oF, thus

resulting in a higher surface area of the slurried lime.

When fitted with automatic control, the slaking reaction is controlled by continuously

monitoring the slaking temperature and maintaining water to lime ratio. Stanco Projects

detention slakers are supplied with a temperature transmitter which monitors slurry

temperature in the slaking zone. A combination of a magnetic flow meter and a pneumatically

actuated flow control valve control and adjust the water to lime ratio, while maintaining

required slaking temperature.

General Operation Philosophy

Stanco Projects slakers operate at optimum slaking temperature by controlling water to lime

ratio based on the lime feed rate. A Lime feed rate signal from the lime screw feeder VFD is

used to calculate the required slaking water flow rate in the PLC. The output of this calculation

is used to adjust the slaking water flow rate. A combination of a flow meter/transmitter and a

flow control valve adjust the water flow rate to achieve the required 4:1 water to lime ratio (by

weight). Once the target water flow rate is achieved, a delay timer allows for the process to

stabilize. After a predefined delay, temperature control takes over and the water flow is

trimmed based on the output of temperature transmitter which monitors the temperature in

the slaking zone. This allows for the slaker to operate at a pre set target slaking temperature

(170 – 180oF) in steady state.

A change in lime feed rate results in the flow meter taking over again for adjusting water flow

rate to the target value calculated by the PLC. As described above, slaking water temperature

signal takes over after the delay timer is expired.

Lime Slaker Interlocks:

There are certain components of the lime slaker that should be operated interlocked with each

other. If the programming was done by Stanco Projects, the interlocks will already be in place. If

the client will carry out their own programming, the following items should be kept in mind:

1. Slaker agitator and seal water solenoid should always be interlocked. Agitator should

never be operated without seal water.

2. If the slaker aspirator is connected to a vacuum system, the vacuum system must be on

at all times while the slaker is in operation. If the slaker needs to be taken out of service

for maintenance or should be put in standby etc. the vacuum system must be operated

long enough to remove all dust and steam.

3. Stanco Projects lime slaker is equipped with a dual setpoint temperature switch (or

temperatures transmitter). This temperature switch acts as a slaker temperature control

device. Under normal operating conditions, the slaker should operate at a temperature

of 170 – 180oF. If a dual setpoint temperature switch is supplied, the first setpoint is set

at 185oF. If this setpoint is reached, the cooling/emergency water solenoid is opened to

bring additional water into the slaker. This brings the slaker operating temperature

down. If for any reason, slaker temperature does not drop and continues to rise, the

second setpoint is reached. This is set at 190OF. This trigger will result in cutting off the

lime feed to the slaker. However, the agitator should continue to operate and hence,

the seal water should continue to flow as well.

4. The slaker is supplied with a proximity switch on the agitator shaft on the tail/discharge

end. This switch continuously monitors agitator rotation. No lime should be fed to the

slaker when the agitator is not turning.

Startup

1. Refer to the feed rate chart in this section to determine the water flow rate for the

required lime feed rate.

2. Set the feeder at desired feed rate. Do not start lime feed at this time.

3. Turn the slaker agitator to ON in manual mode.

4. Use the slaking water inlet globe valve and the water flow meter to set the water feed

rate to desired value.

5. When the water can be heard being thrown by the agitator bars start lime feed at the

preset rate (step-1).

6. When the level of slurry rises to about 6-inches below the discharge port (as seen

through the inspection door), turn the lime feed and slaking water selector switches to

OFF.

7. Let the slaker agitate until the temperature indicator control indicates a temperature of

100oF. Depending on the feed water temperature and lime quality, this could take up to

20 minutes.

8. After the above mentioned temperature is reached, turn the lime feed switch to auto.

At this time, lime feed may have to be adjusted so a slaking temperature of 170-180oF is

reached and maintained.

9. The slaker will now operate automatically until it is shut down or a fault condition is

reached.

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Chemical Feed RateQuick / Pebble Lime

Cerro Vanguardia M-25 SLAKER8.34 LB/GAL.5 - 45 GPM55 LB/CU FT.95% ESTIMATED5500 LB/HOUR5500 LB/HOUR

10.0% 12.5% 15.0% 17.5% 20.0% 22.5% 25.0% 26.4% 27.5% 30.0%Feed Rate

(VFD)%lb/hr lb/hr

5% 275Useable

CaO 6.4 5.0 4.1 3.4 2.9 2.5 2.2 2.1 2.0 1.8

10% 550 523 12.7 10.0 8.1 6.8 5.8 5.1 4.5 4.2 4.0 3.615% 825 784 19.1 15.0 12.2 10.2 8.8 7.6 6.7 6.3 6.0 5.320% 1100 1,045 25.5 20.0 16.3 13.7 11.7 10.2 8.9 8.4 7.9 7.125% 1375 1,306 31.8 25.0 20.4 17.1 14.6 12.7 11.2 10.4 9.9 8.930% 1650 1,568 38.2 29.9 24.4 20.5 17.5 15.2 13.4 12.5 11.9 10.735% 1925 1,829 44.6 34.9 28.5 23.9 20.5 17.8 15.6 14.6 13.9 12.440% 2200 2,090 51.0 39.9 32.6 27.3 23.4 20.3 17.9 16.7 15.9 14.245% 2475 2,351 57.3 44.9 36.7 30.7 26.3 22.9 20.1 18.8 17.9 16.050% 2750 2,613 63.7 49.9 40.7 34.2 29.2 25.4 22.3 20.9 19.8 17.855% 3025 2,874 70.1 54.9 44.8 37.6 32.2 27.9 24.6 23.0 21.8 19.560% 3300 3,135 76.4 59.9 48.9 41.0 35.1 30.5 26.8 25.1 23.8 21.365% 3575 3,396 82.8 64.9 52.9 44.4 38.0 33.0 29.0 27.1 25.8 23.170% 3850 3,658 89.2 69.9 57.0 47.8 40.9 35.6 31.3 29.2 27.8 24.975% 4125 3,919 95.5 74.9 61.1 51.2 43.9 38.1 33.5 31.3 29.8 26.680% 4400 4,180 101.9 79.9 65.2 54.7 46.8 40.7 35.8 33.4 31.7 28.485% 4675 4,441 108.3 84.8 69.2 58.1 49.7 43.2 38.0 35.5 33.7 30.290% 4950 4,703 114.6 89.8 73.3 61.5 52.6 45.7 40.2 37.6 35.7 32.095% 5225 4,964 121.0 94.8 77.4 64.9 55.5 48.3 42.5 39.7 37.7 33.7

100% 5500 5,225 127.4 99.8 81.4 68.3 58.5 50.8 44.7 41.8 39.7 35.5

SHADED AREA INDICATES WATER RATES ARE OUTSIDE FLOW METER RANGE.SLASHED AREA NOT RECOMMENDED FOR INITIAL SLAKING, SHOWN FOR REFERENCE

ASSUMPTIONS: Water =RECOMMENDED (TYPICAL) FLOW METER RANGE =

DENSITY QUICK LIME =QUICK LIME (CaO) AVAILABLE (PURITY)=

M-25 MAX (DESIGN) FEEDER RATE =TARGET (NOMINAL) FEEDER RATE =

Slurry concentration

Water Rate in GPM

Yellow area is target flow rate for total flow into slaker (including seal flush that does not drip out) to obtain nominal 4:1 WATER TO LIME (CaO) RATIO. 26.4% SOLIDS (without inert's)

GPM =(1.32*(LBS CaO USEABLE) - (LBS CaO USEABLE)*% SOLUTION)

(%SOLUTION*8.34*60)

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STANCO PROJECTS.

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STANCO PROJECTS.

SECTION 3: COMPONENT SPECIFICATION DESCRIPTION: Stanco Projects Lime Slaker Model M-25 Lime Slaker. The unit is provided with the following features and options:

A) Capacities (max.): 1) Lime: 2,500 Kg/hr.. # CaO/hr 2) Slaking Water: 170 LPM

B) Construction: Carbon Steel

1) Drum shell, liner, water jacket, end plates: Carbon Steel 2) Agitator breaker bars: Abrasion Resistant Steel 3) Agitator Scraper bars: Abrasion resistant with Hard Surface welded face 4) Agitator stub shafts:

a) One (1) drive end: standard 51mm dia. x 622 mm” long, 17-4 ph SS round.

b) One (1) discharge end: standard 51” dia. x 403 mm long, 17-4 ph SS round

5) Seal a) Packed seal, Teflon b) Double Face Mechanical Seal

C) Bearings: 1) One (1) drive end: pillow block, 2 bolt, non-expandable, 2” (Reliance PB

S2000) 2) One (1) discharge end: pillow block, 2 bolt, expandable, 2” (Reliance PB

S-2000) D) Drive:

1) One (1) motor (Baldor # M3615T-50) a) HP: 5 b) RPM: 1450 c) Electrical rating: 230/380 Volt, 3 Phase, 50 Hz d) Insulation: Class F e) Service Factor: 1.15 f) Enclosure: TEFC g) Application: Chem Duty h) Frame: #145T

2) One (1) reducer: double reduction, straight bore, torque arm speed reducer (Dodge Series 25, Size TXT425S)

3) One (1) motor mount for reducer (Dodge TA4M) 4) One (1) drive sheave: 3 groove-3/3V3.15 X SH 5) One (1) driven sheave: 3 groove-3/3V6.0 X SDS 6) One (1) drive bushing: QD SDS X 1 7/16” 7) One (1) driven bushing: SH X 1-1/8” 8) Two (2) V-belt: 3V x 630

SECTION 4: OPERATION AND MAINTENANCE (O &M) INSTRUCTION MANUAL

Stanco Projects Lime Slaker, Model M-25

GENERAL The ZMI Model M-25 Lime Slaker is a heavy duty construction and will provide manyyears of excellent slaking service, if properly maintained. Periodic equipment checks should be done, along with the following listed maintenance instructions: 1) On each end of the Slaker, where the drive shaft enters and exits the barrel, there is

a seal assembly. The assembly is provided with a continuous supply of flush water. A proper seal flush water supply should be maintained during slaking operation; ½ GPM at 10-15 PSI.

2) Inside each seal assembly there are three rings of Teflon packing. The purpose of the packing is to prevent the seal water from leaking out from around the drive shaft. During system operation, seating of the packing will occur and tightening of the packing gland will be necessary. Replacement of the packing will be required approximately every 1000 working hours. For both adjustment and replacement instruction, refer to Section on Seal Assembly in this manual.

3) Provided on the cover of the Slaker is a wet lime dust/steam removal system. The

system consists of a spray nozzle chamber, aspirator tube, baffle arrangement and canister. A spray nozzle mounted in the chamber sprays a cone of water down the aspirator tube. The discharge through the nozzle is manually adjusted. The cone of water spraying down the aspirator tube creates a negative pressure within the slaker mixing chambers and draws off any dust/steam. The scrubber system should be properly adjusted and periodically cleaned. For these instructions, refer to Section on aspirator assembly in this Manual.

4) On the drive end of the Slaker is 2” non-expandable, spherical pillow block (SPB)

bearing. And on the discharge end there is a 2” expandable, (SPB) bearing. These bearings should be greased approximately every 100 working hours. Each bearing is provided with a fitting for use with a standard grease gun. When lubricating the bearings, add the grease slowly while the shaft is rotating. When grease begins to come out of the seal, the bearing will contain the correct amount of grease. DO NOT OVER GREASE! Use one of the following recommended greases or equivalent:

For general duty: For heavy duty: Mobil Oil Co. Mobilux #2 Exxon Lidok #2EP Shell Oil Alvania #2 Shell Oil Co. Alvania #2EP Texaco, Inc. Multifak #2 Union Unoba HT #2EP

5) Lime slurry from the Slaker is carried to the grit separator via a 4” dia. pipe. Lime can cake on the inside of this pipe, so periodic checks and regular cleaning is required. To clean this line, stop the Slaker and prevent it from being started. Remove the clean out plug and flush with water. To remove extreme build-up, rodding may be necessary. When finished, reinstall the clean out plug and restore Slaker operation.

6) On the Slaker cover there is a feed inlet transition (normally provided and field installed by others). Through this inlet is where pebble lime is fed into the Slaker. It is important to keep lime build-up, in this chute, to a minimum. Check for build-up every 24 to 48 hours of operation, and clean as required. Be sure to stop the Slaker and prevent it from starting before cleaning the chute! Clean the chute with spray water, or by scrapping if required. NEVER ATTEMPT TO REACH INTO THE SLKAER WITH THE AGITAOR TURNING. ALWAYS LOCK OUT THE AGITATOR BEFORE PERFORMING ANY SERVICE ON THE SLAKER.

The lime inlet transition is designed to allow for air to enter the freely slaker. This is important for effective operation of the dust/steam removal system.

7) The slaker is provided with a temperature transmitter. This temperature transmitter not only monitors and maintains the slaking temperature; it also triggers alarms if an alarm condition is reached (high/low slaking water temperature etc.). Slaker controller program should be programmed to cut off lime feed if an excessively high slaking temperature is reached. It is very important that this control is properly adjusted and functions correctly.

8) Maintain the electric drive motor according to the operation and maintenance instructions provided in the Drive components Section of this Manual.

9) Maintain the reducer according to the operation and maintenance instructions

provided in the Drive Components Section of this Manual.

OPERATION AND MAINTENANCE (O & M) INSTRUCTION MANUAL

STANCO PROJECT’S DETENTION SLAKER SEALS

Stanco Project’s detention slaker comes fitted with a combination of a mechanical and a packed seal. This combination seal approach provides added protection against any potential seal leak issues. An exploded view of the packed seal is shown in figure-1 below.

Figure-1: Stanco Projects’ Combination Slaker Seal – Exploded View The seal flange is welded on the slaker end plate and provides for a means to hold the seal housing in place. The four threaded rods on the seal flange are used to bolt the seal housing in place with the seal flange. The two O-rings, one on either side of the seal spacer, prevent any seal leaks in radial direction. The mechanical seal is placed in the seal housing. This seal is mainly responsible for preventing the slurry from leaking out of the slaker along the agitator shaft. Three rings of Teflon based packing are placed in the seal housing behind the mechanical seal. This provides second level of protection against any potential leak issues. A packing retainer with hex bolts keeps the three rings of packing in place

Flush Port

Startup and Normal Operation: Stanco Projects’ slakers are shipped with seals preinstalled to factory standards. However, minor adjustment discussed below might be required at the time of startup.

1. Seal Water Flow: The slaker is supplied with a seal water pressure and seal water flow indicator. At the time of startup, ensure that the seal water is properly connected to the seal water flush port (figure-1). The seal water discharges from the discharge port on the opposite side of the seal housing. The seal water discharge should be run to drain. This water is responsible for cooling and lubrication of the seal. Prior to slaker startup, ensure that the seal water is flowing freely through the housing at approximately 0.5 gpm.

2. Seal Packing: The three rings of packing should be tightened in place with the

help of bolts on the seal retainer at the time of startup. Only tighten the bolts enough to prevent any visible leaks from the packing gland. Do not over tighten the bolts.

3. Once the slaker is started check for any leaks in the seal water. Please refer to

trouble-shooting steps discussed in the next section if a leak is found. Slaker Seal Trouble-shooting and Maintenance: Stanco Projects’ slaker seals require little attention while in operation. However, a regular maintenance schedule will prevent any unexpected emergency situation. Please follow the guideline given below for developing a seal maintenance schedule:

1. Seal Water Flow Rate: Check the seal water flow rate on the supplied flow indicator on a regular basis to ensure correct flow for seal cooling and flushing.

2. Seal Water Quality: On a regular basis, collect a sample of the water seal water

discharge port and look for any signs of lime particles or turbidity (not coming from the water supplied to the seal). This might be an indication of the mechanical seal starting to wear out and slurry leaking from the slaker. Schedule seal repair and maintenance. Contact Stanco Projects for guidance on seal repair.

3. Seal Water Quantity: On a regular basis, collect a sample of water from the seal water discharge port over a period of time and compare its flow rate with the flow rate indicated by the seal water flow indicator. If the volume of seal water collected is lower than indicated by seal water flow indicator, there might be issues with the mechanical seal and the seal water could be going into the slaker, diluting the produced lime slurry. Schedule seal repair and maintenance. Contact Stanco Projects’ for guidance on seal repair.

4. Packed Seal Maintenance: Look for any signs of leaks around the seal housing and the seal retainer. If any leaks are found, the seal retainer nuts should be tightened enough to stop the leak. If the leak cannot be stopped by tightening the retainer ring bolts, there might be a need to replace the packing material. For this purpose, remove the retainer to expose the packing. Remove the packing from the packing gland. Place new packing rings in the gland, making sure the cut in the three rings of packing is staggered. Replace and tighten the retainer.

OPERATION AND MAINTENANCE (O & M) INSTRUCTION MANUAL

STANCO PROJECT’S WET TYPE FORCED DRAFT SCRUBBER

Stanco Project’s ZMI slaker is supplied with a forced draft dust and steam removal system installed on the slaker lid. This system effectively captures the steam and the lime dust that enters the slaker with lime feed and returns it to the slaker to maintain the overall mass balance. In the absence of an effective dust/steam removal system, steam can back up into the lime feed chute and over time can cause lime build up which in turn results in inefficient slaker operation and an increase in maintenance workload. The design of the wet scrubber prevents the lime dust from coming in contact with any moving parts. Figure-1 shows a 12” diameter wet scrubber with 6” inch venturi eductor. The wet scrubber and venturi eductor diameter for a given Stanco Projects detention slaker depends on the size of the slaker. Theory of operation: Please refer to figure-1 below. A venturi eductor driven by a centrifugal blower and connected to the top of the wet scrubber creates a draft through the scrubbing column. A damper on the blower discharge allows control of airflow through the scrubber and thus the draft produced by the eductor. The wet scrubber, which is mounted directly on top of the slaker lid, pulls lime dust and steam into the wetting zone (figure-2), under negative pressure. In the wetting zone, a fine mist spray nozzle forces the rising stem to condense. The same spray of fine mist makes the dust particles wet and heavy and dislodges them from the air moving upwards. The second nozzle sprays a coarser spray of water removing any remaining dust particles and steam. In the next step, the upwards moving mass of air is passed through a set of baffles which force it to change direction quickly. The rapid change in direction causes any heavier particles (water droplets or lime dust etc.) to drop out of the stream of air. This ensures that both lime dust and water droplets are completely removed from the air before it is exhausted. The clean mass of air is vented to the outside. Wet Scrubber System Components and Functions: As shown in figure 2, the wet scrubber assembly consists of a wetting zone, a knock out zone, a diameter reduction connection, motor/blower driven venturi eductor and the connection between the eductor and the scrubber. Wetting Zone: Dual spray nozzles are mounted at the center of the wetting zone.

The first (bottom) nozzle sprays a fine mist of water. The fine mist covers the entire diameter of the wetting zone. All steam and dust pulled into the wet scrubber goes through the mist. This results in condensation of steam, which is returned to the slaker in the form, of water droplets. As the lime dust particles come in contact with the mist, they coalesce and become heavy. The heavier lime dust particles start to drop out of the rising mass of air.

Above the first nozzles is the second spray nozzle which sprays a coarser spray of water. This spray also covers the entire diameter of the wetting zone. Coalesced particles that were not separated from the rising mass of air before are now wetted further and made even heavier to facilitate removal. The wetting chamber and the spray nozzles are made from stainless steel to prevent corrosion and ensure long useful life.

Knock Out Zone: Immediately above the wetting zone is the knock out zone. This zone

has the same diameter and material of construction as the wetting zone. Three baffles made from stainless steel are installed in this zone. The baffles are staggered to force air to change direction. As the air passes through the baffled zone, water droplets and lime dust if any is separated from it. The water particles and lime dust particles are returned to the slaker by gravity.

Diameter Reduction: The diameter of the wet scrubber is reduced above the knock out

zone to match the diameter of the eductor/eductor connection hose. Venturi Eductor: The venturi eductor is responsible for creating vacuum to draw dust

and steam into the wet scrubber. The venturi eductor is of stainless steel construction. With the help of air from the blower, the eductor creates negative pressure on its suction side. The suction end of the eductor is connected with the wet scrubber. The vacuum produced by the eductor pulls the air from the slaker into the wetting zone and out through the eductor discharge.

A manual damper on the blower discharge facilitates control of

vacuum created by the eductor. The blower is driven by a direct drive motor. The size of the blower and motor depends on the application.

Water Control: Control of water flow is critical to the efficient operation of the dust

control system. Not enough flow will result in the lime dust particles not getting wet sufficiently and escaping the system. Too high a flow will result in addition of excessive water to the slurry or carryover of water droplets to the venturi eductor. Water to the scrubber is controlled with the help of supplied rotameter and a needle valve. Adjustment of correct flow is discussed in the subsequent sections.

Start-up and Normal Operation: For normal operation, the damper on the blower discharge is adjusted such that a negative pressure is created inside the slaker. Care should be taken while adjusting the blower discharge damper. Too low a vacuum will

not pull enough air through the slaker thus allowing the lime dust and steam to back up on the lime inlet side of the slaker. Conversely, too high a vacuum will result in lime dust getting pulled into the wetting zone before it gets a chance to fall into the slaker for reaction/slaking. Follow the following steps for wet scrubber startup.

1. Ensure that all water and electrical connections are made as per the supplied drawings.

2. Before the eductor blower is started, water flow to the nozzles must be adjusted to ensure full wetting of the rising dust and steam. To adjust water flow, open clamp A (figure-2) and remove the knockout section of the wet scrubber. Ensure the needle valve just before the rotameter is closed. Force open the solenoid valve on the scrubber water supply line (figure-1). Slowly open the needle valve and monitor the flow pattern of the two nozzles while adjusting the needle valve. Water flow through the nozzles should be adjusted such that the mist like water spray from the bottom nozzle and spiral water spray from the top nozzle is reaching the walls of the wetting zones. Note down the flow rate from the rotameter. This is the minimum water flow required by the wetting scrubber at all times while it is in operation.

3. Close the solenoid valve and reinstall the baffled zone of the wet scrubber. 4. Turn the eductor blower on with blower discharge damper fully closed. Slowly

open the damper and allow the airflow to the eductor to increase. 5. Check for air flow through the slaker by feeling the airflow at the lime inlet. There

should be a clear flow of air into the slaker if a hand is put above the lime inlet. Never attempt to put your hand inside the slaker while the slaker agitator is in operation. SERIOUS INJURY CAN OCCUR IF THIS SAFETY PRECAUTION IS NOT FOLLOWED.

6. Follow the slaker startup procedure to start the slaker. 7. Once the slaker is operating at required process conditions, re-adjust the blower

discharge damper such that no steam or lime dust is seen coming out of slaker lime feed chute end. Also check the eductor discharge for any water droplets or lime particles. This is an indication of excessive vacuum. Adjust blower discharge the damper to control water and lime particles from the eductor discharge.

Wet Scrubber Maintenance: The wet scrubber should be inspected regularly for the following items:

1. Correct air flow: Check the air flow at the lime inlet. Ensure there is no lime dust or steam coming out of the feed chute end. A clear flow of air should be felt by putting a hand above the lime inlet. If insufficient draft is noticed, adjust (increase damper opening) the blower damper until no steam or lime dust is seen coming out of the lime inlet end of the slaker. Check for water droplets and/or lime dust at the exhaust of the eductor. Blower discharge damper may have to be adjusted (decrease damper opening) if any particles are seen coming out on the eductor discharge end.

2. Lime Buildup: The wet scrubber has a modular design and it can be taken apart

easily (always follow all lock out/tag out procedures before performing any service on the wet scrubber). At regular intervals, check for any lime buildup in the wetting zone and knock out zone of the wet scrubber. This can be done by turning off the blower and water supply to the wet scrubber and removing clamp C (figure-2). Highest likelihood of lime buildup is in the baffled knock out zone. If lime buildup is noticed in the baffled zone, remove it to gain access to the wetting zone. Ensure there is no lime buildup in the wetting zone. Any lime buildup can be easily removed by a hand water wash and gentle scrubbing. If required, the baffled zone can be soaked in mild acetic acid to dissolve tougher lime buildup (never use HCl for cleaning the wet scrubber – always follow safety instructions for acid handling). The wetting zone can also be soaked in mild acid but the spray nozzles should be removed prior to any contact with acid.

3. Follow instructions provided in the manufacturer’s manual for maintenance of the

eductor blower and motor.

Figure-1: Stanco Project Wet Scrubber (12” design) with Blower and 6” Venturi Eductor Figure-2 below shows an exploded view of the wet scrubber.

Blower discharge damper

Figure-2: Exploded view of Stanco Project’s Wet Scrubber

Spray Nozzles

Clamp A

Clamp B

Clamp C

INSTALLATION REQUIRED:

PART NO.: 40352S

N/A

INSPECTION ACCESS DOOR

TAG NO.:

DESCRIPTION:

SPECIFICATION:

EQUIP LOCATION:

COMPONENT DATA SHEET

SLAKER LID NO

NEPONSET, IL 61345-9766

INSTALLATION REQUIRED:

ADDRESS: ONE MARTIN PLACE

9" X 12"

EQUIP. LOCATION:

MANUFACTURER:

SIZE

SLAKER LID

MODEL NO.: CYA-0912 - STAINLESS STEELMARTIN ENGINEERING

NO

COMPONENT SPECIFICATIONS AND FEATURES:

9" X 12"

350F

SIZE

TEMPERATURE

MATERIAL STAINLESS STEEL

D W M Q S A HOURS

X

MAINTENANCE REQUIREMENTS LUBE CODE

TIGHTEN FASTENER

X

X

CODE CODE

CLEAN WARNING LABEL

LUBRICANT TYPE

CHECK FOR PHYSICAL DAMAGE

MANUFACTURER LUBRICANT TYPE MANUFACTURERCODE

1 4

2 5

3 6

TAG#

PART# QTY: MFR.: MODEL:

LUBRICANT TYPE MANUFACTURER LUBRICANT TYPE MANUFACTURER

RECOMMENDED SPARE PARTS MOTOR DATA

PART NAME

HP.: VOLTS: PHASE: HZ.

RPM: ENCLOSURE: FRAME: S.F.

DESIGN: INSULATION: DUTY:

HI-ALT: TROPICAL M&CWASHDOWN:

@75% @50%

@75% @50%EFFICIENCY @100%:

POWERFACTOR @ 100%:

FULL LOAD AMPS:

LOCKED ROTOR AMPS:

One Martin PlaceNeponset, IL 61345-9766 USA

800-544-2947 or 309-594-2384FAX: 309-594-2432www.martin-eng.com

We Make Your Bulk Materials HandlingCleaner, Safer and More ProductiveThrough Personalized Performance.




Go to MARTIN® Inspection Door web page

Form No. M3127-09/09© 1984, 2009 MARTIN ENGINEERING COMPANY. All rights reserved.

Operator’s ManualM3127

MARTIN® Inspection Door

http://www.martin-eng.com/products/martin-inspection-doors

ImportantMARTIN ENGINEERING HEREBY DISCLAIMS ANY LIABILITY FOR: DAMAGE DUE TO CONTAMINATION OF THE MATERIAL; USER’S FAILURE TO INSPECT, MAINTAIN AND TAKE REASONABLE CARE OF THE EQUIPMENT; INJURIES OR DAMAGE RESULTING FROM USE OR APPLICATION OF THIS PRODUCT CONTRARY TO INSTRUCTIONS AND SPECIFICATIONS CONTAINED HEREIN. MARTIN ENGINEERING’S LIABILITY SHALL BE LIMITED TO REPAIR OR REPLACEMENT OF EQUIPMENT SHOWN TO BE DEFECTIVE.Observe all safety rules given herein along with owner and Government standards and regulations. Know and understand lockout/tagout procedures as defined by American National Standards Institute (ANSI) z244.1-1982, American National Standard for Personnel Protection - Lockout/Tagout of Energy Sources - Minimum Safety Requirements and Occupational Safety and Health Administration (OSHA) Federal Register, Part IV, 29 CFR Part 1910, Control of Hazardous Energy Source (Lockout/Tagout); Final Rule.

The following symbols may be used in this manual:

DANGER!

Danger: Immediate hazards that will result in severe personal injury or death.

WARNING!

Warning: Hazards or unsafe practices that could result in personal injury.

CAUTION!

Caution: Hazards or unsafe practices that could result in product or property damages.

IMPORTANTImportant: Instructions that must be followed to ensure proper installation/operation of equipment.

NOTENote: General statements to assist the reader.

Martin Engineering M3127-05/10 i MARTIN® Inspection Door

Table of Contents

Section PageList of Figures and Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ii

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

MARTIN® Inspection Door materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Materials required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Before Installing MARTIN® Inspection Door. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Installing MARTIN® Inspection Door. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3MARTIN® Rubber Inspection Door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

MARTIN® Steel Inspection Door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

MARTIN® Inspection Door with Screen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

After Installing MARTIN® Inspection Door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Weekly Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Part Numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Appendix A. MARTIN® Inspection Door Labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1

Appendix B. MARTIN® Inspection Door Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1

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Martin Engineering M3127-05/10 ii MARTIN® Inspection Door

List of Figures

Figure Title Page1 Installing MARTIN® Inspection Door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

2 Installing MARTIN® Steel Inspection Door . . . . . . . . . . . . . . . . . . . . . . . . . . 5

3 Installing MARTIN® Inspection Door With Screen. . . . . . . . . . . . . . . . . . . . . 6

4 Installing MARTIN® Inspection Door With Screen (Side Detail) . . . . . . . . . . 7

5 Cutting Screen for “L” Bracket Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

6 MARTIN® Rubber Inspection Door Assemblies, P/N CYAR-XXXXXXXX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

7 MARTIN® Steel Inspection Door, P/N CYA-XXXXXXXX . . . . . . . . . . . . . . 14

8 MARTIN® Steel Inspection Door, P/N CYA-XXXXXXXX . . . . . . . . . . . . . . 16

9 MARTIN® Extended-Height Steel Inspection Door, P/N CYAE-XXXX-XXXXXX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

10 MARTIN® Round Steel Inspection Door Assembly,P/N CYARD-XXXX. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

List of Tables

Table Title PageI MARTIN® Inspection Door Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . 1

II MARTIN® Rubber Inspection Door Part Numbers and Quantities . . . . . . . . 13

III MARTIN® Steel Inspection Door Part Numbers and Quantities . . . . . . . . . . 15

IV MARTIN® Steel Inspection Door Part Numbers and Quantities . . . . . . . . . . 18

V MARTIN® Extended-Height Steel Inspection Door Part Numbers and Quantities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

VI MARTIN® Round Steel Inspection Door AssemblyPart Numbers and Quantities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

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Martin Engineering M3127-05/10 1 MARTIN® Inspection Door

Introduction

General MARTIN® Inspection Doors are used to access mechanical equipment for service or to clean out material buildup. They can also be used as electrical switchboard covers, splash covers, and visual inspection doors. MARTIN® Inspection Doors were not designed to be mounted horizontally in areas where they may be stepped on.

Appendix A shows MARTIN® Inspection Door labels and Appendix B shows MARTIN® Inspection Door dimensions.

MARTIN® Inspection Door materials

MARTIN® Inspection Doors are made of a variety of materials to meet most needs. The nitrile and silicone doors are oil resistant and can be used in higher-temperature applications (see Table I). The silicone door is approved by the Food and Drug Administration (FDA) for use in the food industry (see Table I).

If you have questions about a particular MARTIN® Inspection Door’s compatibility with certain chemicals, consult the Elastomer Chemical Compatibility Chart for MARTIN® Conveyor Products, available from Martin Engineering or representative. Table I shows the specifications for MARTIN® Inspection Doors.

Table I. MARTIN® Inspection Door Specifications

References The following documents are referenced in this manual:

• American National Standards Institute (ANSI) z244.1-1982, American National Standard for Personnel Protection - Lockout/Tagout of Energy Sources - Minimum Safety Requirements, American National Standards Institute, Inc., 1430 Broadway, New York, NY 10018.

• Federal Register, Volume 54, Number 169, Part IV, 29 CFR Part 1910, Control of Hazardous Energy Source (Lockout/Tagout); Final Rule, Department of Labor, Occupational Safety and Health Administration (OSHA), 32nd Floor, Room 3244, 230 South Dearborn Street, Chicago, IL 60604.

• Elastomer Chemical Compatibility Chart for MARTIN® Conveyor Products, Martin Engineering.

Safety All safety rules defined in the above documents and all owner/employer safety rules must be strictly followed when installing and servicing this equipment.

Materials required Only standard hand tools are required to install and service this equipment.

Type of MARTIN® Inspection Door

Max. Operating Temperature

Max. Pressurepsi (bar)

Max. Vacuumpsi (bar)

Rubber 155°F (68°C) .29 (.020) .36 (.025)

Nitrile 250°F (121°C) .29 (.020) .36 (.025)

Silicone 400°F (204°C) .29 (.020) .36 (.025)

Screen 155°F (68°C) — —

Steel 350°F (177°C) — —

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Before Installing MARTIN® Inspection Door

IMPORTANTThe delivery service is responsible for damage occurring in transit. Martin Engineering CANNOT enter claims for damages. Contact your transportation agent for more information.

1. Inspect shipping container for damage. Report damage to delivery service immediately and fill out delivery service’s claim form. Keep any damaged goods subject to examination.

2. Remove MARTIN® Inspection Door from shipping container. Equipment in container should include the following:

• MARTIN® Inspection Door.

• MARTIN® Inspection Door Warning Label, P/N 30382.

3. If anything is missing, contact Martin Engineering or representative.

WARNING!

Before installing or servicing equipment, turn off and lock out/tag out energy source to conveyor and conveyor accessories.

4. Turn off and lock out/tag out energy source according to ANSI standards (see “References”).

WARNING!

If equipment will be installed in an enclosed area, test gas level or dust content before using a cutting torch or welding. Using a cutting torch or welding in an area with gas or dust may cause an explosion.

5. If using a cutting torch or welding, test atmosphere for gas level or dust content. Cover conveyor belt with fire retardant cover.

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Installing MARTIN® Inspection Door

IMPORTANTRead entire section before beginning work.

WARNING!

Do not mount MARTIN® Inspection Door as follows: facing downward, in direct path of material, where door can be used as a step, or where material can collect in cover.

1. Determine location of MARTIN® Inspection Door on wall.

2. Follow the procedure under “MARTIN® Rubber Inspection Door,” “MARTIN® Steel Inspection Door” or “MARTIN® Inspection Door With Screen.”

MARTIN® Rubber Inspection Door

IMPORTANTMARTIN® Rubber Inspection Doors should only be used

when belt cleaner mainframe is required to extend through the door.

1. Remove rubber door (A, Figure 1) from door frame (B).

2. Using door frame as template, mark location of mounting holes and inside dimension of door (access opening) on wall.

NOTEMartin Engineering recommends bolting rather than welding MARTIN® Inspection Door frame to wall.

3. Using saw or cutting torch, cut hole for access opening 1/8 in. (3 mm) larger than access opening marked on wall. If you are bolting door frame to wall, drill holes for mounting screws. Remove burrs and sharp edges.

Figure 1. Installing MARTIN® Inspection Door

A

B

C

D

A.B.C.D.

Rubber doorDoor frameCableHex head cap screw (8)Flat washer (8)

Hex nut (8)Compression washer (8)

E

E. Stud (4 or 8)

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4. Grind wall surface smooth where door frame will contact it.

5. Bolt or weld MARTIN® Inspection Door frame (B) and cable (C) to wall as follows.

a. If bolting, do the following:

(1) Place cable eyelet on one of eight hex head cap screws (D).

(2) Install eight hex head cap screws, flat washers, compression washers, and hex nuts in drilled mounting holes. Install screw holding cable in a corner hole.

(3) Caulk around door frame to seal it to wall.

b. If welding, do the following:

(1) Tack weld door frame to wall, then skip weld 1/2 in. (12.7 mm) every 2 in. (51 mm).

(2) Tack weld cable to wall or door frame.


6. Push holes in rubber door (A) over studs (E) on door frame (B) until door opening is sealed.

MARTIN® Steel Inspection Door

NOTEMartin Engineering recommends installing MARTIN® Steel Inspection Door with hinges to the side or bottom.

1. Remove two cotter pins (A, Figure 2) and two clevis pins (B) from door hinges. Remove steel door (C) from frame (D).

2. Using door frame as template, mark location of mounting holes and inside dimension of door (access opening) on wall.

NOTEMartin Engineering recommends bolting rather than welding MARTIN® Inspection Door frame to wall.

3. Using saw or cutting torch, cut hole for access opening 1/8 in. (3 mm) larger than access opening marked on wall. If you are bolting door frame to wall, drill holes for mounting screws. Remove burrs and sharp edges.

4. Grind wall surface smooth where door frame will contact it.

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Figure 2. Installing MARTIN® Steel Inspection Door

5. Bolt or weld MARTIN® Inspection Door frame to wall as follows.

a. If bolting, do the following:

(1) Install eight hex head cap screws, flat washers, compression washers, and hex nuts in mounting holes.


b. If welding, do the following:

(1) Tack weld door frame to wall, then skip weld 1/2 in. (12.7 mm) every 2 in. (51 mm).


IMPORTANTInsert clevis pins so that holes for cotter pins are on the bottom.

6. Line up holes in door with hinges on frame and replace clevis pins and cotter pins.

A.

B.

C.

D.

Cotter pin (2)

Clevis pin (2)

Steel door

Door frame

AC

D

B

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MARTIN® Inspection Door with Screen

WARNING!

Screen is designed to limit access where possible hazards exist. Do not use screen to absorb impact or retain material inside wall.

1. Remove rubber door (A, Figure 3) or open steel door, and remove four mounting screws (B), and screen (C) from door frame (D).

Figure 3. Installing MARTIN® Inspection Door With Screen

NOTEMartin Engineering recommends bolting rather than welding MARTIN® Inspection Door with screen to wall. Screen is secured to wall with tabs that are located on door frame mounting holes. Welding the door frame makes it difficult to properly locate tabs on wall.

2. Follow steps 2 through 4 under either “MARTIN® Rubber Inspection Door” or “MARTIN® Steel Inspection Door.”

3. Install four hex head cap screws with flat washers (A, Figure 4) through holes in door frame (B) and wall (C) that align with mounting screw (D) holes for screen (E).

4. Place inspection screen tab (F) over hex head cap screw inside wall.

5. Install four compression washers and hex nuts on four hex head cap screws and flat washers.

A

B

A.B.C.D.

Rubber doorMounting screw (4)ScreenDoor frame

C

D

CablesE.

E

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Figure 4. Installing MARTIN® Inspection Door With Screen (Side Detail)

6. If using “L” bracket or another assembly for mounting a belt cleaner, cut a 2-1/2-in. (63.5-mm) arch in screen as shown in Figure 5, and install mount assembly. (See applicable belt cleaner operator’s manual for mount installation instructions.)

Figure 5. Cutting Screen for “L” Bracket Installation

7. Install four mounting screws (D, Figure 4) through screen (E) and inspection screen tabs (F).

8. Place rubber door cable eyelet and screen cable eyelet (E, Figure 3) on one of four hex head cap screws not installed.

9. Install remaining four hex head cap screws, flat washers, compression washers, and hex nuts (A, Figure 4). Install screw holding cables in a corner hole.

10. Caulk around door frame to seal it to wall.

11. Push holes in rubber door (G) over studs (H) on door frame until door opening is sealed.

F

A

D

E

B

C

G

H

A.

B.C.D.E.F.G.H.

Hex head cap screw (8)Flat washer (8)Compression washer (8)Hex nut (8)Door frameWallMounting screw (4)ScreenInspection screen tabRubber doorStud

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Notes


After Installing MARTIN® Inspection Door

1. Thoroughly wipe wall clean above MARTIN® Inspection Door. Place MARTIN® Inspection Door Warning Label, P/N 30382 on wall visible to anyone using MARTIN® Inspection Door.

2. Observe MARTIN® Inspection Door during normal operations. If material is escaping through door, make sure rubber door is securely seated against door frame or steel door is firmly seated against rubber silicone seal. Check caulk around door frame for leaks.

Weekly Maintenance

1. Make sure all fasteners are tight. Tighten if necessary.

2. Wipe all warning labels clean. If labels are damaged or are not readable, contact Martin Engineering or representative for replacements.

3. Check rubber door for tears, holes, or cracks. Replace as necessary.

4. Check silicone sponge seal around steel door for tears or cracks. Replace as necessary.

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Part Numbers

This section provides product names and corresponding part numbers for MARTIN® Inspection Doors and related equipment. Please reference part numbers when ordering parts:

MARTIN® Inspection Door Assemblies

With rubber door: See Figure 6.

9 X 12 in. (229 X 305 mm): P/N CYAR-0912XXXX





With steel door: See Figures 7, 8 and 10.

4 in. (114 mm) Diameter: P/N CYARD-4XXX



9 X 12 in. (229 X 305 mm): P/N CYA-0912XXXX








With extended-height steel door: See Figure 9.

9 X 12 in. (229 X 305 mm): P/N CYAE-0912-XXXXXX





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MARTIN® Inspection Screen Kit

For use with MARTIN® Rubber Inspection Doors:

9 X 12 in. (229 X 305 mm): P/N 38414-0912

12 X 14 in. (305 X 356 mm): P/N 38414-1214

12 X 18 in. (305 X 457 mm): P/N 38414-1218

18 X 24 in. (457 X 610 mm): P/N 38414-1824

24 X 24 in. (610 X 610 mm): P/N 38414-2424

For use with MARTIN® Steel Inspection Doors:

9 X 12 in. (229 X 305 mm): P/N 38409-0912

12 X 12 in. (305 X 305 mm): P/N 38409-1212

12 X 14 in. (305 X 356 mm): P/N 38409-1214

12 X 18 in. (305 X 457 mm): P/N 38409-1218

18 X 18 in. (457 X 457 mm): P/N 38409-1818

18 X 24 in. (457 X 610 mm): P/N 38409-1824

20 X 20 in. (508 X 508 mm): P/N 38409-2020

24 X 24 in. (610 X 610 mm): P/N 38409-2424

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Figure 6. MARTIN® Rubber Inspection Door Assemblies, P/N CYAR-XXXXXXXX*

*The first four Xs indicate the approximate door size in inches: -0912, -1214, -1218, -1824, or - 2424. The next X indicates the door frame material: 304 stainless steel (C), painted mild steel (Blank); The next X indicates rubber door temperature range: with high-temperature door (H), with standard rubber door (Blank); The next X indicates if mounting hardware is included: with mounting hardware (M), without mounting hardware (Blank); The next X indicates if a safety screen is included: with safety screen (G), without safety screen (Blank).

2

1

5

6

™

™

3

4

Item Description Part No. Qty.

1 Door Frame Table II 1

2 Rubber Door Table II 1

3 Grommet Eyelet 32407-01 1

4 Grommet Washer 32407-02 1

5 Ø .0625 Galvanized Cable Table II 1.25 ft

6 Cable Clip Table II 2

7 (NS) MARTIN® Door Warning Label 30382 1

8 (NS) Operator’s Manual M3127 1

9 (NS) Kit Mounting Hardware Table II 1

10 (NS) Safety Screen Kit Table II 1

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Table II. MARTIN® Rubber Inspection Door Part Numbers and Quantities

Part No. P/NItem 2

CYAR-XXXX 28246-XXXX

CYAR-XXXXXH 28557-XXXX

Part No.P/N

Item 5P/N

Item 6 Part No.P/N

Item 9

CYAR-XXXX 102249 28112 CYAR-XXXXM 38228

CYAR-XXXXC 100598 33832 CYAR-XXXXCM 38228-SS

Part No. P/NItem 1

P/NItem 10

CYAR-0912XXXX 38412-0912 38414-0912

CYAR-1214XXXX 38412-1214 38414-1214

CYAR-1218XXXX 38412-1218 38414-1218

CYAR-1824XXXX 38412-1824 38414-1824

CYAR-2424XXXX 38412-2424 38414-2424

CYAR-0912CXXX 38412-0912WC 38414-0912C

CYAR-1214CXXX 38412-1214WC 38414-1214C

CYAR-1218CXXX 38412-1218WC 38414-1218C

CYAR-1824CXXX 38412-1824WC 38414-1824C

CYAR-2424CXXX 38412-2424WC 38414-2424C

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Figure 7. MARTIN® Steel Inspection Door, P/N CYA-XXXXXXXX**The first four Xs indicate the approximate door size in inches: -0912, -1212, -1214, -1218, or -1818. The next X indicates the door material: 304 stainless steel (C), painted mild steel (Blank); The next X indicates if mounting hardware is included: with mounting hardware (M), without mounting hardware (Blank); The next X indicates if the latch is lockable: with lockable latch (L), with standard nonlockable latch (Blank); The next X indicates if a safety screen is included: with safety screen (G), without safety screen (Blank).

1

3

5

4

2

6

7

8


1 Door Frame Weldment Table III 1

2 Steel Door Weldment Table III 1

3 Gasket Rubber Door Seal Table III 1

4 Pin, Clevis Stainless Steel 1/4 x 1-5/8 34952 2

5 Hairpin Cotter .06 DIA x 1.13 SS 34951 2

6 Over Center Lever Latch Table III 1

7 Screw PHPM #10-32NF x 1/2 with washer Table III 4

8 Label Martin Product 38048 1

9 (NS) Label Door Warning 30382 1


11 (NS) Kit Mounting Hardware Table III 1

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Table III. MARTIN® Steel Inspection Door Part Numbers and Quantities

Part No. P/NItem 3

CYA-0912XXXX 38400-0912

CYA-1212XXXX 38400-1212

CYA-1214XXXX 38400-1214

CYA-1218XXXX 38400-1218

CYA-1818XXXX 38400-1818

Part No.P/N

Item 6 Part No.P/N

Item 7 Part No.P/N

Item 11

CYA-XXXX 37051 CYA-XXXX 38182 CYA-XXXX 38228

CYA-XXXXL 37051-L CYA-XXXXC M453-SS CYA-XXXXCM 38228-SS

Part No. P/NItem 1

P/NItem 2

CYA-0912XXXX 38399-0912 38398-0912

CYA-1212XXXX 38399-1212 38398-1212

CYA-1214XXXX 38399-1214 38398-1214

CYA-1218XXXX 38399-1218 38398-1218

CYA-1818XXXX 38399-1818 38398-1818

CYA-0912CXXX 38399-0912WC 38398-0912WC

CYA-1212CXXX 38399-1212WC 38398-1212WC

CYA-1214CXXX 38399-1214WC 38398-1214WC

CYA-1218CXXX 38399-1218WC 38398-1218WC

CYA-1818CXXX 38399-1818WC 38398-1818WC

Par

t N

umbe

rs


Figure 8. MARTIN® Steel Inspection Door, P/N CYA-XXXXXXXX*

*The first four Xs indicate the approximate door size in inches:-1824, -2020, or -2424. The next X indicates the door material: 304 stainless steel (C), painted mild steel (Blank); The next X indicates if mounting hardware is included: with mounting hardware (M), without mounting hardware (Blank); The next X indicates if the latch is lockable: with lockable latch (L), with standard nonlockable latch (Blank); The next X indicates if a safety screen is included: with safety screen (G), without safety screen (Blank).

1

2

3

4

5

6

7

8

9

10

171314

11 12

15

16

18

1920

Par

t N

umbe

rs


Figure 8. MARTIN® Steel Inspection Door, P/N CYA-XXXXXXXX


1 Door Frame Weldment Table IV 1

2 Steel Door Weldment Table IV 1

3 Gasket Rubber Door Seal Table IV 1


5 Hairpin Cotter .06 DIA x 1.13 SS 34951 2

6 Handle Rod Table IV 1

7 Cam 38574-X 2

8 Bottom Latch 38571-X 1

9 Washer Nylon 3/8 24835 3

10 Handle 38573-X 1

11 Washer Flat 3/8 Wide ZP Table IV 3

12 Screw HHC 3/8-16NC x 1-1/4 ZP Table IV 2

13 Nut Hex Jam 3/8-16NC ZP Table IV 2

14 Cushion Spindle Bottom 3/8 38570 1

15 Bolt Carriage 3/8-16NC x 1 ZP Table IV 1

16 Pin Wire Lock 3/8 x 1-3/4 Table IV 1

17 Nut Hex Elastic Lock 3/8-16NC ZP Table IV 2

18 Pin Slotted Spring 1/4 x 1-1/8 ZP Table IV 4

19 Cable Aircraft 1/16 dia 102249 1.5

20 Cable Clip 1/16 28112 2

21 (NS) Label Martin Product 38048 1

22 (NS) Label Martin Engineering Logo 22193-02 1



25 (NS) Kit Mounting Hardware Table IV 1P

art

Num

bers


Table IV. MARTIN® Steel Inspection Door Part Numbers and Quantities

Part No. P/NItem 1

P/NItem 2

CYA-1824XXXX 38399-1824 38398-1824H

CYA-2020XXXX 38399-2020 38398-2020H

CYA-2424XXXX 38399-2424 38398-2424H

CYA-1824CXXX 38399-1824WC 38398-1824WCH

CYA-2020CXXX 38399-2020WC 38398-2020WCH

CYA-2424CXXX 38399-2424WC 38398-2424WCH

Part No.P/N

Item 3P/N

Item 6

CYA-1824XXXX 38400-1824 38577-24X

CYA-2020XXXX 38400-2020 38577-20X

CYA-2424XXXX 38400-2424 38577-24X

Part No. P/NItem 11

P/NItem 12

P/NItem 13

P/NItem 15

P/NItem 16

P/NItem 17

P/NItem 18

CYA-XXXX 18007 12215 38582 36628 37126 14201 38578

CYA-XXXXC 16055 32438 31366 36628-SS 37126-SS 16204 38578-SS

Part No. P/NItem 25

CYA-XXXX 38228

CYA-XXXXCM 38228-SS

Par

t N

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Figure 9. MARTIN® Extended-Height Steel Inspection Door, P/N CYAE-XXXX-XXXXXX**The first four Xs indicate the approximate door size in inches:-0912, -1214, -1218, -1824 or -2424. The next XX indicates the frame band height in inches: -03, -04, -05, -06, -07, -08, -09, -10, -11, or -12 (-08 is maximum height for -0912, -1214, and -1218 doors). The next X indicates the door material: 304 stainless steel (C), painted mild steel (Blank); The next X indicates if mounting hardware is included: with mounting hardware (M), without mounting hardware (Blank); The next X indicates if the latch is lockable: with lockable latch (L), with standard nonlockable latch (Blank); The next X indicates if a safety screen is included: with safety screen (G), without safety screen (Blank).

3

6

7

5

2

1

4

8


1 Door Frame Weldment 38499-XXXX-XXXX 1

2 Steel Door Weldment Table V 1

3 Rubber Door Gasket Table V 1


5 Hairpin Cotter 0.6 DIA x 1.13 SS 34951 2

6 Over Center Lever Latch Table V Table V

7 Screw PHPM #10-32NF x 1/2 w/washer Table V Table V


9 (NS) Label Martin Engineering Logo 22193-02 Table V



12 (NS) Kit Mounting Hardware Table V 1

13 (NS) Safety Screen Kit Table V 1

Par

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Table V. MARTIN® Extended-Height Steel Inspection Door Part Numbers and Quantities

Part No.Qty

Item 6Qty

Item 7Qty

Item 9P/N

Item 3

CYAE-0912-XXXXXX 1 4 0 38400-0912

CYAE-1214-XXXXXX 1 4 0 38400-1214

CYAE-1218-XXXXXX 1 4 0 38400-1218

CYAE-1824-XXXXXX 2 8 1 38400-1824

CYAE-2424-XXXXXX 3 12 1 38400-2424

Part No. P/NItem 6

Part No. P/NItem 7

Part No. P/NItem 12

CYAE-XXXX-XXXX

37051CYAE-

XXXX-XXXX38182

CYAE-XXXX-XXXX

38228

CYAE-XXXX-XXLX

37051-LCYAE-

XXXX-XXCXM453-SS

CYAE-XXXX-XXCMX

38228-SS

Part No. P/NItem 2

P/NItem 13

CYAE-0912-XXXXXX 38398-0912 38409-0912

CYAE-1214-XXXXXX 38398-1214 38409-1214

CYAE-1218-XXXXXX 38398-1218 38409-1218

CYAE-1824-XXXXXX 38398-1824 38409-1824

CYAE-2424-XXXXXX 38398-2424 38409-2424

CYAE-0912-XXCXXX 38398-0912WC 38409-0912C

CYAE-1214-XXCXXX 38398-1214WC 38409-1214C

CYAE-1218-XXCXXX 38398-1218WC 38409-1218C

CYAE-1824-XXCXXX 38398-1824WC 38409-1824C

CYAE-2424-XXCXXX 38398-2424WC 38409-2424C

Par

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Figure 10. MARTIN® Round Steel Inspection Door Assembly, P/N CYARD-XXXX**

**First X indicates door diameter in inches; The next X indicates door material: 304 stainless steel (C), 316 stainless steel (S), painted mild steel (Blank); The next X indicates if mounting hardware is included: with mounting hardware (M), without mounting hardware (Blank); The next X indicates if the latch is lockable: with lockable latch (L), with standard nonlockable latch (Blank).


1 Frame Weldment Table VI 1

2 Door Weldment Table VI 1

3 Gasket Rubber Door Seal Table VI 1

4 Pin Clevis 1/4 x 1-7/8 SS 38641 1

5 Hairpin Cotter .06 Dia. x 1.13 SS 34951 1

6 Over Center Lever Latch Table VI 1

7 (NS) Screw PHPM #10-32NF x 1/2 with Washer Table VI 4




11 (NS) Kit Mounting Hardware Table VI 1

8

4

5

32

1

6

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Table VI. MARTIN® Round Steel Inspection Door AssemblyPart Numbers and Quantities

Part Number Item 1P/N

Item 2P/N

CYARD-4XXX 38639-4 38638-4

CYARD-6XXX 38639-6 38638-6

CYARD-8XXX 38639-8 38638-8

CYARD-4CXX 38639-4WC 38638-4WC



CYARD-4SXX 38639-4WS 38638-4WS



Part NumberItem 3

P/N Part NumberItem 6

P/N

CYARD-4XXX 38400-4 CYARD-X 37051

CYARD-6XXX 38400-6 CYARD-XL 37051-L

CYARD-8XXX 38400-8



CYARD-X 38182 CYARD-XM 38228-04

CYARD-XC M453-SS CYARD-XCM 38228-04SS

CYARD-XS M453-SS CYARD-XSM 38228-04SS

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Martin Engineering M3127-05/10 A-1 MARTIN® Inspection Door

MARTIN® Inspection Door Warning Label, P/N 30382

Appendix AMARTIN® Inspection Door Label

App

endi

x A

Notes

Martin Engineering M3127-05/10 B-1 MARTIN® Inspection Door

Appendix BMARTIN® Inspection Door Dimensions

App

endi

x B


AB

C

D

EF

G

H

.75

(19.

05)

1.82

LJ

MK

Par

t N

um

ber

Ru

bb

er In

spec

tio

n D

oo

r D

imen

sio

ns—

in. (

mm

)

AB

CD

EF

GH

JK

LM

CYA

R-0

912

12.6

3 (3

21)

11.8

8 (3

02)

9.06

(2

30)

2.81

(7

1)2.

81

(71)

5.94

(1

51)

8.75

(2

22)

9.50

(2

41)

11.2

5 (2

86)

14.3

8 (3

65)

10.0

8 (2

56)

13.2

0 (3

35)

CYA

R-1

214

14.7

5 (3

75)

14.0

0 (3

56)

11.1

9 (2

84)

2.81

(7

1)2.

81

(71)

9.19

(2

33)

12.0

0 (3

05)

12.7

5 (3

24)

14.5

0 (3

68)

16.5

0 (4

19)

13.8

8 (3

53)

15.7

5 (4

00)

CYA

R-1

218

18.5

0 (4

70)

17.7

5 (4

51)

14.9

4 (3

79)

2.81

(7

1)2.

81

(71)

8.88

(2

26)

11.6

9 (2

97)

12.4

4 (3

16)

14.1

9 (3

60)

20.2

5 (5

14)

13.0

2 (3

31)

19.0

8 (4

85)

CYA

R-1

824

24.4

4 (6

21)

23.6

9 (6

02)

18.8

8 (4

80)

4.81

(1

22)

4.81

(1

22)

12.9

4 (3

29)

17.7

5 (4

51)

18.5

0 (4

70)

20.2

5 (5

14)

26.1

9 (6

65)

18.9

5 (4

81)

25.0

2 (6

36)

CYA

R-2

424

24.1

9 (6

14)

23.4

4 (5

95)

18.6

3 (4

73)

4.81

(1

22)

4.81

(1

22)

18.6

3 (4

73)

23.4

4 (5

95)

24.1

9 (6

14)

25.9

4 (6

59)

25.9

4 (6

59)

24.9

5 (6

34)

24.9

5 (6

34)

(46)

MA

RT

IN®

Ru

bb

er In

spec

tio

n D

oo

r D

imen

sio

ns

(see

ch

art

abo

ve)

App

endi

x B


Part Number

MARTIN® Steel Inspection Door Dimensionsin. (mm)

A B C D E

CYA-0912XXXX 11.25 (286) 14.38 (365) 8.25 (210) 11.38 (289) 2.56 (65)

CYA-1212XXXX 14.19 (360) 14.38 (365) 11.19 (284) 11.38 (289) 2.56 (65)

CYA-1214XXXX 14.19 (360) 16.25 (413) 11.19 (284) 13.25 (337) 2.56 (65)

CYA-1218XXXX 14.19 (360) 20.25 (514) 11.19 (284) 17.25 (438) 2.56 (65)

CYA-1818XXXX 20.25 (514) 20.25 (514) 17.25 (438) 17.25 (438) 2.56 (65)

EC

1.0(25)

D

E

B

A

1.79(45)

Chute Wall Cutout

App

endi

x B


Part Number

MARTIN® Steel Inspection Door Dimensionsin. (mm)

A B C D E

CYA-1824XXXX 20.25 (514) 26.19 (665) 17.25 (438) 23.19 (589) 4.56 (116)

CYA-2020XXXX 22.25 (565) 22.25 (565) 19.25 (489) 19.25 (489) 4.56 (116)

CYA-2424XXXX 25.94 (659) 25.94 (659) 22.94 (583) 22.94 (583) 4.56 (116)

EC

1.0(25)

D

E

B

A

Chute Wall Cutout

4.11(104)

App

endi

x B


*XX indicates the frame band height in inches: 03, 04, 05, 06, 07, 08, 09, 10, 11, or 12 (08 is maximum height for -0912, -1214, and -1218 doors).

Part Number

MARTIN® Extended-Height Steel Inspection Door Dimensionsin. (mm)

A B C D E

CYAE-0912-XXXXXX 11.23 (285) 14.36 (365) 8.75 (222) 11.88 (302) 2.81 (71)

CYAE-1214-XXXXXX 14.17 (360) 16.23 (412) 12.00 (305) 14.00 (356) 2.81 (71)

CYAE-1218-XXXXXX 14.17 (360) 20.23 (514) 11.69 (297) 17.75 (451) 2.81 (71)

CYAE-1824-XXXXXX 20.23 (514) 26.17 (665) 17.75 (451) 23.69 (602) 4.81 (122)

CYAE-2424-XXXXXX 25.92 (658) 25.92 (658) 23.44 (595) 23.44 (595) 4.81 (122)

EC

.75(19)

D

E

B

A

Chute Wall Cutout

1.79(45)

XX*

App

endi

x B


Part Number

MARTIN® Round Steel Inspection Door Dimensionsin. (mm)

A B C

CYARD-4XXX 7.75 (197) 5.25 (133) 4.50 (114)

CYARD-6XXX 9.25 (235) 6.25 (159) 6.00 (152)

CYARD-8XXX 11.25 (286) 7.75 (197) 8.00 (203)

1.79(45)

5.78(147)

A

A

C

C

B

B

App

endi

x B

Any product, process, or technology described here may be the subject of intellectual property rights reserved by Martin Engineering Company. Trademarks or service marks designated with the ® symbol are registered with the U.S. Patent and Trademark Office and may be proprietary in one or more countries or regions. Other trademarks and service marks belonging to Martin Engineering Company in the United States and/or other countries or regions may be designated with the “TM” and “SM” symbols. Brands, trademarks, and names of other parties, who may or may not be affiliated with, connected to, or endorsed by Martin Engineering Company, are identified wherever possible. Additional information regarding Martin Engineering Company’s intellectual property can be obtained at www.martin-eng.com/trademarks.

http://www.martin-eng.com/trademarks




Form No. M3127-05/10© 1984, 2010 MARTIN ENGINEERING COMPANY. All rights reserved.

Operator’s ManualM3127

MARTIN® Inspection Door

Documents

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