sponge-jet, inc basic equipment exposure course content

7/24/2019 Sponge-Jet, Inc Basic Equipment Exposure Course Content

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Sponge-Jet, Inc.Basic Equipment Exposure Course

Sponge-Jet Feed Units All Models


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For Safe Operation ofAll Sponge-Jet Manufactured Equipment:

Always review and understand all operational manuals and instructional videos, prior toany equipment operation.

Inspect all hoses and couplings for wear.

All hoses must be restrained with coupling pins and cables, (whip-checks).

All operators, tenders and laborers, as well as local trades must be equipped with allnecessary P.P.E. including but not limited to, eye ear and respiratory protection.

Never perform any maintenance to the unit while under pressure.

ALL UNITS ARE EQUIPPED WITH A SINGLE EMERGENCY STOP BUTTON WHICH WILLRENDER THE UNIT INOPERABLE WHEN DEPRESSED.

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Benefits of a Feed Unit over a common Pressure Vessel

Sponge-Jet Feed Units are specifically designed and engineered to flow Sponge-Jet

Media. Sponge-Jet utilizes components such as Augers, Actuators, Tree Assembliesand advanced pneumatic logic to facilitate the flow of media through the Feed Unit,allowing for consistent and reliable operation.

Unlike a conventional abrasive blasting machine, which uses gravity as its primaryfeeding mechanism, assisted by a compressed air flow through the pressure vessel.Sponge-Jet Feed Units rely on an automated mechanical device called the Actuator

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which assures that the media flows from the vessel, to the Auger and is then fedinto the blast hose rather than dropped into the air stream through a cone valve.

Sponge-Jet medias change in size and density as they progress through their lifecycle, the ability to adjust and compensate for those changes are critical. The

designed components engineered into Feed Units allow for this compensation insimple and mostly autonomous ways. We accomplish this through adjustment of theAuger Speed/Media Feed Rate. Recommended pressures are listed on each unit.


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Why Not A Standard Blast Pot?

Auger Actuator Air Motor

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Control Valve Timer


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Two component, open-cell, particle

-Pliant, polyurethane carrier

-Abrasive particle/cleaning agent

Wide range of abrasives

All these components are needed to reliably flow Sponge-Media

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Multitude of performance characteristics

Grit size can vary within the base color group


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Sponge Media Grades

Sponge-Media consists of the unification of a composite, dust and contaminantcontrolling agent, Sponge and an encapsulated cleaning or abrasive agent.

The composite structure of the medias provides the dust control benefit as well as thecontaminant control for all grades. While there are some minor differences in cell

structure as a result of the abrasive or cleaning agent embedded, the general compositeis the same throughout all of the grades.

Media choice is based on several conditions that must be evaluated prior to finalselection. Too frequently, the decision of what media has been based on how fast do you

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application, they can also be manipulated to a point where they contribute more to failure,than they contribute to success.

Good painting practices dictate that the profile should never exceed 50% of the primercoat thickness. It is certainly mechanically sound to expect that bigger abrasive particleswill cut through a coating faster than will smaller abrasive particles. However one of the

items to consider though is with any abrasive smaller, finer, abrasive particles produce adenser grouping and remove coatings or contamination more efficiently than do largerabrasive particles. This can easily result in a larger abrasive requiring more dwell time toproduce equal cleaning results.


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Sponge Media Grades

The most critical consideration when choosing the abrasive grade is the profilerequirement of the follow-on coating. Producing a profile, that exceeds the data sheetrequirements of the future coating system leads to pinpoint rusting, added paint and laborcosts and the greater potential for immediate or premature coatings failure.

Conventional abrasives are commonly sold in varying size ranges, Fine, Standard,Course and Extra Course for example. While these ranges do produce both ends of thespeed and efficiency spectrum previously noted, they do as well provide the opportunityto produce both inadequate and excessive profile results. Often times these blended sizecombination are based on the lower or ex endable abrasives overhead cost limitations.

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Utilizing a tight and consistent size of abrasive, results in a consistent and repeatableprofile generation. This condition is not only known to produce improved coatingperformance, but is often times a noted and documented testing procedure, required forthe acceptance of the coatings process by both the owner and the paint suppliers qualitycontrol standards.

Being able to achieve these consistent readings is why Sponge-Jet medias are classifiedand named utilizing specific numerical designations, S-120, S-30 S-16 or R-G40. Thistight sizing also helps limit the human error factors associated with media feed ratesettings or nozzle pressures.


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Sponge Media - Recyclability

Sponge Medias are intended to be recyclable. While there are other recyclable

medias on the current open market, these abrasives are all suspect to degradationin size after each collision with the substrate. This degradation in size can obviouslyproduce inconsistent profile depths, negative changes to the angular quality and

orientation of the profile and potentially leaving fragments of the abrasive particleembedded in the substrate. Depending on the type of abrasive used, theseremaining deposits could contribute to the corrosion condition or hinder the

successful mechanical bond of the coating to the substrate.

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s ponge- e on s mu p e p eces o qua y an g y s ze a ras ve or c ean ngagents into each granule of Sponge media, even as multiple recycles of the mediaare attained, the degraded material that separates from the granule is removed andsegregated by the Recycler unit, leaving only the appropriately sized abrasiveresident for the remaining blasting cycles. This helps assure that the profileconsistency remains at a high level from beginning to end of media lifecycle.


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Primary Requirements and Components

Air volume requirements are specific to the nozzle size utilized, balanced againstthe desired blast pressure. Larger nozzle diameters require increased volumes of

compressed air to sustain desired pressures.Current units utilize 2.0 inch piping components so as to have the lowest pressuredrop internally. Any reduction it the supply air fitting below this 2.0 inch diameter willdefeat this benefit and limit the system throughput to that size fittings capacity.

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The smallest fitting or coupling supplied to the unit will ultimately determine thesuccess or failure of the required production regardless of the pressure the supply

source can produce.


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Components

Standard supply connections areattached to a supplied Chicago 4 lugcoupling with a Primary Supply Air

Ball Valve behind it. This isolates themachine from the customer supplied airflow.

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This fitting is mounted to a 2.0 inch NationalPipe Thread Straight nipple. This fitting can

easily be removed or adapted to a fitting morebroadly accepted in your geographic region. ITIS CRITICAL HOWEVER THAT THEINTERIOR DIAMETER NOT DECREASE AS ARESULT OF THIS CHANGE.


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Components

Moisture is removed automatically from

compressed air source by a Secondary

Moisture Separator.

It utilizes a 40 micron element as its

standard.

It is equipped with an automatic dumpmechanism to expel accumulatedmoisture into an appropriate collection

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device. It is not intended to fully dry or clean thesupply of air, but to simply remove

moisture accumulated in the last lengthof supply line.

Most compressed air sources haveindependent moisture and temperaturecontrol devices, but this cannot beassumed as always existing.


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Components

After moisture is removed, the full volume

of supply air is held at the Main Air On Off

Valve until the operator depresses theDeadman trigger on the hose.

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The inbound pressure from the source is

measured and displayed on the Line

Pressure Gauge. This should be thehighest reading gauge on the unit.


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Components

Once the Main Air On/Off Valve isopened the air passes through theBlast Pressure Regulator, which will

determine how much of the pressureof the supply air is utilized.

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Components

The operator determined BlastPressure is displayed on the Blast

Pressure Gauge and adjusted by thePanel Mount T handle regulator below

it.



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Components

Media is prevented from passing back

into these valves and control items bya one way Check Valve. It has noadjustment or maintenance.



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Components

Media inside the vessel is fed out the

bottom of the vessel by a Media Actuator,which is controlled by various valves andtimers on the back of the Control Plate.

This Media Actuator moves in 45 degreeback and forth segments (Nor ContinuousRotation) and keeps the pressure in thevessel from compressing the media to the


po n o poor or no ow.

A welded cross or Tree Assembly

attached to the Media Actuator forcesmedia into the Auger Assembly in theLower End of the Feed Unit.


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Components

Augers are intended to feed media into

the blast hose.

They control the volume of media, which in

turn manages dust and media

consumption.

They are durable units, but are the pointwhere any foreign matter allowed into thereclaimed media is likely to lodge and

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inhibit flow.


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Components

The Auger is adjusted by the Media FeedRegulator, which is mounted on thecontrol plate.

The pressure provided to the Auger is

represented on the Media Feed Gauge.

The recommended pressures aresuggested in the chart below the regulatorand gauge.

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They are based on how many times themedia has been reused.

The activity of the Media Actuator insidethe vessel can be monitored externally bythe activity of the Media Actuation

Indicator Eye. It will alternate from NeonGreen to Black as the unit makes its 45degree rotations.


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Components

Exhaust of the unit occurs when theDeadman handle is released. Automaticallythe unit vents any pressure inside the vesselthrough the Exhaust System. This includes

the Exhaust Valve itself, the ExhaustMuffler, which diffuses the escaping air andcatches any media that is ejected with this air.

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The Exhaust System also houses an Over-Pressure Relief Valve, which will open

automatically if the inbound pressure in thepot exceeds approximately 150 psi.

This Valve is supplied to relieve the volume

and pressure of air supplied to support up to a#10 5/8 inch (16mm) standard abrasive blastnozzle. INCREASING THE COMPRESSEDAIR SUPPLY ABOVE THIS VOLUME MAY

REQUIRE A VALVE CHANGE.


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Operational Overview/Summary

1. Assure a complete understanding of all Safety and Operational procedures before

pressurization or utilization of this equipment. Read and understand all manualsthoroughly.

2. Attain and utilize per manufacturers instructions all PPE required based on the

specific activity, local and or other guidelines.

3. Confirm air supply valves are closed and Emergency Stop Systems are engaged.

4. Connect adequate sized supply (Bull) hoses and Blast hoses with safety pins and

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.

5. Charge the system with compressed air and assure it reaches and maintains thepressure requirements for this activity.

6. Pressurize the system and adjust the Blast Pressure and Media Feed Rate todesired settings, based on media type, lifecycle conditions and activity specificrequirements.

Prepare the surface to the desired condition.


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System Depressurization

1. Release the Deadman and allow the system to fully depressurize before

relinquishing control of the Deadman and Blast Hose.

2. Discontinue the supply of compressed air from its source.

3. With this supply confirmed as discontinued, with the Main Air Ball Valve of the

Feed Unit open and the Emergency Stop Button disengaged, activate the DeadmanHandle and expel any remaining pressure inside the Sponge-Jet Feed Unit.

4. Once all gauges read 0 psi, release the Deadman trigger, activate the

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,

the compressed air supply source.


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Course Complete

This Course qualifies for a completion certificate based on a passing result to anonline exam.

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