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Spray Bar

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									                                                                                                                                          Quality
                                                                                                                                        Endorsed
                                                                                                                                        Company




      Water Management Installation & Service Hand Book

      Spray Bar
      Issued: November 2008




                                                         Table of Contents
      Installation, Commissioning and Operating .................................................................... 2
      Overview ........................................................................................................................ 2
      Water Application Device Storage .................................................................................. 2
      Spray Bar Installation Procedure .................................................................................... 3
      Spray Bar Servicing ........................................................................................................ 5
      General Arrangement Drawing ....................................................................................... 6




Water Management Installation and Services Hand Book                                                                                        Page 1
                                                                                                        Quality
                                                                                                      Endorsed
                                                                                                      Company




      Installation, Commissioning and Operating

      Overview
      The application of water as an aid to belt cleaning is proven
      to enhance belt cleaner performance by up to 75% over
      corresponding dry belt cleaning systems.
      The additional advantages of using water as an aid to belt
      cleaning are: -
      > Extended belt cleaner component life.
      > Extended belt top cover life.
      > Dust suppression at transfer chutes.
      > Cleaner chutes through material saturation and product
        build up reduction.

      There are two (2) components to the CQMS Razer Water
      Management System .
      > The    Water Control Board which controls water
        quality, water pressure and the on/off condition of the
        provision of water.
      > The     Spray   Bar   which    takes     water     from    the
        Water Control Board and applies it to the belt in a mist spray
        that covers 100% of the belt width.

      Spray Bar Storage
      Provided goods remain stored within boxes or on pallets wrapped with plastic, CQMS Razer Spray Bars
      can be stored outside in all weather conditions. If packaging is damaged or removed, CQMS Razer
      recommends that Spray Bars be stored under cover and out of direct sunlight to minimise deterioration
      of components on Spray Bars.




Water Management Installation and Services Hand Book                                                     Page 2
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                                                                                                           Endorsed
                                                                                                           Company




      Spray Bar Installation Procedure
      It is imperative that personnel familiarise themselves with all site safety requirements
      prior to commencement of any work on site; and meet and adhere to all site safety
      requirements as a minimum standard while on site.
      The supply of suitable power, plant air and water must be available at the point of installation.
      1. Ensure all personnel have current site specific and generic inductions and confined space
          training if required.
      2. Ensure all personnel are qualified and competent.
      3. Ensure all appropriate OH&S requirements are met in accordance with company and site policies
          and procedures.
      4. Identify the conveyor and its associated equipment.
      5. Isolate conveyor in line with site isolation procedure.
      6. Conveyor belt cleaner installation must be fully completed before installing Spray Bar .
      7. Position the mounting brackets of the Spray Bar so that, when installed, the centre line of the
          Spray Bar is 165mm from the centre line of the pole of the secondary cleaner and
          165mm below the return surface of the belt. This will enable materials removed by the cleaner
          to fall freely between the two poles.
      8. Tack weld the mounting bracket to the conveyor structure and fit the Spray Bar Clamp Blocks
          loosely to the Spray Bar Pole .
      9. Ensuring that the Spray Bar Jets are directed toward the Head Pulley, pass the partially
          assembled Spray Bar under the return strand of the conveyor belt and fix one clamp block to
          the mounting bracket.
      10. Secure the second clamp block to the second mounting bracket and slide both clamp blocks
          in the mounting brackets until the pole of the Spray Bar is at the same height at the pole of the
          secondary belt cleaner.
      11. Rotate the Spray Bar in its clamp blocks until the spray jets point at the belt return strand such
          that the water spray will contact the belt at 45º.
      12. Lock the Spray Bar clamp blocks into position and tighten the clamping bolts to prevent further
          rotation of the Spray Bar .
      13. Fully weld the brackets to the chute.
      14. Locate the hose tail provided with the Spray Bar to the end of the Spray Bar that corresponds
          with the side where the Water Control Manifold is installed. Locate the Spray Bar Plug to the
          opposite end of the Spray Bar .
      15. Complete the welding of the mounting brackets to the conveyor structure.
      16. Connect the flexible hose from the Water Control Board to the hose tail of the Spray Bar .
      17. Remove all tools and equipment. Dispose of all scrap and rubbish accumulated.
      18. Remove conveyor isolation in line with site isolation procedure.
      19. Start belt on test or manual control. Check correct operation of Spray Bars.
      20. Return conveyor to service.




Water Management Installation and Services Hand Book                                                           Page 3
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Water Management Installation and Services Hand Book     Page 4
                                                                                                           Quality
                                                                                                         Endorsed
                                                                                                         Company




      Servicing of Spray Bar
      During routine conveyor inspections, check the Spray Bar to ensure that: -
      1. Clamp Blocks are secure and the Spray Bar has not rotated.
      2. Clamp Blocks have not come loose in their Mounting Brackets allowing the Spray Bar to slide
          out of position.
      3. All spray jets are functioning.
      Where any of the events above have occurred, they/it should be corrected as follows: -
      Under no circumstances should a physical inspection of any belt cleaner be undertaken with
      the conveyor in operation.
      4. Ensure all personnel have current site specific and generic inductions and confined space training
          if required.
      5. Ensure all personnel are qualified and competent.
      6. Ensure all appropriate OH&S requirements are met in accordance with company and site policies
          and procedures.
      7. Identify the conveyor and its associated equipment.
      8. Isolate conveyor in line with site isolation procedure.
      9. Remove cleaner from chute and assess for service work
          > Check all tips for damage such as wear or chipping
          > Check cushions for fatigue or splitting in rubber and/or bond failure and corrosion
               of metal plates
          > Ensure correct operation of end assemblies and refurbish as required
          > Inspect Pole for straightness, corrosion and erosion.
          > Inspect Spray Jets for blockages
      10. Isolate conveyor inline with site isolation procedure.
      Rotated Spray Bar
      11. Rotate the Spray Bar in its clamps until the spray jets point toward the return strand of the belt
          and so that the water from the Spray Jets will contact the belt approximately 45º.
      12. Tighten the clamp block bolts to prevent further rotation.
      Spray Bar Out Of Position
      13. Slide the Spray Bar and clamp bolts in the mounting bracket so that the Spray Bar is at the same
          height as the Secondary P Series belt cleaner pole.
      14. Secure the clamp block bolts to the mounting bracket.
      Blocked Spray Jet
      15. Activate the mains pressure bypass circuit of the Water Control Board . The high pressure will
          assist in dislodging any Spray Jet blockage.
      16. If this fails to free the blockage, cleaning can be achieved by using a wire brush fastened to the
          end of a pole. By brushing the blocked Spray Jet, the blockage should come free.
      17. In severe cases, the pole should be removed from service and a tip cleaner or fine wire used to
          clear the blocked jet. In this event, the Water Control Board Filter should be inspected as well.
      18. Remove conveyor isolation in line with site isolation procedure.
      19. Start belt on test or manual control. Check correct operation of Spray Bars .
      20. Remove all tools and equipment. Dispose of all scrap and rubbish accumulated.
      21. Return conveyor to service.




Water Management Installation and Services Hand Book                                                       Page 5

								
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