Cook Legacy College

Training Module P3021:

AirBurst Fundamentals

Goals of This 15-Minute Module

Know how an AirBurst works

including the basic physics

Understand major components and

features

Operate an AirBurst System

Troubleshoot AirBurst Problems (You’ll need your AirBurst Troubleshooting Guide)

3

AirBurst Fundamentals

AB 103:

Review and Quiz

AB 102: Fundamentals

AB 101: Overview and Background

4

Passive Screens Often Use Airburst

Cleaning

Passive screens often include an AirBurst diffuser within the internal of the screen. The diffuser size and perforation pattern vary based on the screen type and orientation. The goal is to ensure that all of the screen surface is struck by coarse bubbles with sufficient velocity and mass to carry away debris.

5

Physics of Compressed Air: Theory

Understanding an AirBurst™ System requires understanding of some basic physics of compressed air.

Two Implications:

1) The volume of air in the tank (at

150 PSI) is smaller than the volume at

the screen (at around 10 PSI)

2) Air bubbles injected at depth will

“grow” and split as they experience

lower pressure while rising through

the water.

6

Physics of Compressed Air: Practice

Hydrostatic Pressure is impacted by

depth

Burst Pressure is impacted by pipe size, length, friction factor, tank

size, and tank pressure

7

Physics of Compressed Air: Practice

When the burst valve opens, pressure in the system drops rapidly.The compressed air rapidly expands into the pipeline, overcomes friction loss, and comes out of the diffuser.

8

Typical AirBurst™ PID

9

AirBurst System Major

Components

An AirBurst™ System consists of the compressed air system, the control air system, valves, controls, and any necessary instrumentation.

10

AirBurst System Major Components

11

Compressed Air SystemThe compressed air system includes

the compressor, filters, and gauges to

provide air to the system.

12

Compressor Air System: Rotary or Recip

Reciprocating machines are low

cost, put out a lot of air, and are

very simple to run. Rotary machines

are more complicated but offer

better efficiency.

We generally use rotary on multiple

valve systems with more than 2

screens.

13

AirBurst Manifold

14

AirBurst Valves

Valve

Assembly

Butterfly Valve-Controls the flow of

air through the pipeline. Typical

features are the body, stem, seat,

connection, and disc. We typically

use painted carbon steel bodies,

brass or stainless discs, buna-n

seats, and lug style connections

(which bolt up to a flange, rather than

wafer style which pin between 2

flanges).

Limit Switch—

The combination

indicator beacon

and limit switch is

used to indicate

valve status. The

beacon provides

visual indication,

while the limit

switch provides

electric feedback.

Solenoid—The direct

mount solenoid bolts up to

the actuator itself. When

energized it opens up to

allow air flow. We typically

use premium direct mount

solenoids which include a

manual override screw, as

this is useful for field

troubleshooting.

Pneumatic Actuator—Uses compressed

air to exercise the valve. We typically use

an air-open; spring-close model, such that

when a system fails the valve will shut

off. These are more expensive than 2 way

air actuated valves. We offer a standard

ABZ Valve, we also use DeZurik valves,

and a premium option with Henry Pratt

Valves.

15

Major Components

Drain Valve: Drains

condensate from

system

Pressure Switch:

Opens or closes when

tank reaches a set

pressure

GP Filter:

Removes bulk

particulate

Ball Valve: Shut

Off

Components

HE Filter:

Removes fine

particulate

AC Filter:

Removes very fine

particulate

16

Major Components

Transmitter: Indicates

pressure

Regulator: Adjusts

pressure to a set

pointCheck Valve:

Maintain

Pressure

Safety Relief

Valve: Keep

Tank &

System at

Pressure

Pressure Gauges:

Indicates pressure

17

Skid

2

Major components:

1. Control box—This is

basically a switch-board.

2. Air compressor—This

provides air to the

system.

3. Control air receiver—this

provides pneumatic

supply to the valves

4. Compressor supply

line—This provides air to

the big tank.

Note that there is a bypass

around the filters for

maintenance. Set valve

position accordingly.

18

Control Panel

19

Control Panel

20

Inside of Compressor

21

System PowerThis is inside the

compressor

housing.

If the leads are

flipped (so the one

that’s supposed to

go to L1 goes to L3

or whatever) the

compressor will

spin backwards and

sound like cats

dying.

The location of this

tie-in varies by

model, but always

looks like this.

22

AirBurst™ System Testing Air Burst system Hydrostatic test per job completion form. The hydrostatic test

follows ASME Protocol to ensure that the welds are properly performed. We typically use

the safest procedure, “Air over water” where a suitable section of the work is filled with

water, capped with blind flanges, and then pressurized with a regulated amount of

compressed air. It is then tested over time to ensure that there are no leaks and the

pressure holds.

Control system inspection. The control system is visually inspected to ensure a clean,

orderly set up of all components, proper labels and stickers, compliance with raceway

and other physical layout requirements, and the accurate termination of wires.

Control system continuity test. The control system is tested to ensure continuity

between the PLC, instruments and terminals.

Control system HMI and PLC testing. Once the basic function of the system is

confirmed we test the control system using the real or simulated instruments to ensure

that all of the functions are present. For example a simple toggle switch might be used in

place of a limit switch.

Complete functional testing of the AirBurst system. When the system component

testing is complete we focus on testing the system against the O&M Manual to ensure

that all functions and alarms are available and functional.

23

Troubleshooting a Project

• A valve on the AirBurst System

does not operate. What do you

do to troubleshoot the problem?

• The system is not building

pressure. What do you need to

do?

24

Review Questions

• What are the components of P1 when

calculating burst pressure and volume?

• What is the purpose of the control tank within

an AirBurst™ System?