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IDEC Bulk Plant

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IDEC Bulk Plant

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  1. IDEC Barite Bulk Plant

  2. IDEC Bulk Storage and Transfer Equipment System • Custom Solutions for Barite, Bentonite, and Calcium CarbonateHandling • The bulk storage and transfer system is a complete solution for bulk barite, bentonite, and Calcium Carbonate handling. Each IDEC system is custom-engineered to meet the production requirements and offers efficiency-enhancing. Design considerations include tank and piping design and bulk transfer capacity. • IDEC Bulk plant designs include varying degrees of technology from big bag handlers to automatic sack cutters. Regardless, the IDEC has established requirements overseeing the design and construction of bulk handling systems that stipulate, among other considerations: • bulk silos must be approved vendors with a U stamp certification. This allows for the safe operation of bulk handling systems, material traceability, and vessel repair options. • Engineered piping layouts to maximize transport delivery efficiency while maintaining egress and access within the plant. • Air delivery systems that are designed to meet the particular facility’s material handling requirements, and service air and blow-down needs. • Emission control systems with dust collectors that meet or exceed local and national emissions requirements into the atmosphere as well as reclaim of materials.

  3. Bulk Plant Principles of Operation • There are several ways to move large quantities of powdered or granular solid materials like Barite, Bentonite, CaCO3, or cement. Augers, conveyor belts, and hand-carrying sacks are a few of the methods that have been used to move these types of materials. The method IDEC uses most often to transport that material is called pneumatic transport. Pneumatic transport is a system that uses compressed air to fluidize the dry material and carry it from one place to another within a bulk system. A bulk system is defined here as all the associated equipment used to store, blend, and move bulk material. • Pneumatic bulk systems are the most popular way to move powder material and other materials because of the following features • Purpose • – Bulk Storage • – Dry Blending (Pneumatically) • – Move Bulk Material • Advantages Over Sacks • – Higher Transfer Rates • – Low Manpower Requirements • – Less Material Lost or Damaged • – Environmentally Cleaner

  4. Principles of Pneumatic Conveying • Compressed air flows through bulk material and tends to "fluff" or suspend the particles. The particles of bulk material are carried by the air as it move to a lower-pressure area. • The amount of material carried by the compressed air depends on several factors: • Amount of air • Size and weight of material particles • Size of piping between Bulk Tanks • Length of piping or hose between Bulk Tanks • Pressure in the Holding Tank • Pressure in Receiving Tank

  5. Bulk System Components • Pressure Tanks (P-Tanks) • Piping • – Air Supply • – Bulk Loading • – Bulk Discharge • – Venting • Surge Tank • Cutting Bottle • Compressor • Air dryer • Filters

  6. Pressure Tank(P-Tank) & Associated Piping • Vent/Fill line usually 4” or 5”. • Discharge line usually 5” and always located at bottom of tank. Air line - 2” or 3” • Jet lines connected to main air line and direct air into tank or through a butterfly valve. • Pressure gauge and popoff valve on vent line. • Pads allow flow of air through bulk material

  7. Pressurized Silo (P-Tank) Operation • Fluff transfer tank prior to discharge by opening vent and air line to the pads. • Close vent to pressurize the transfer tank. • Open vent and fill on receiving tank. Pass air through this tank to check for plugging. • Open discharge valve on transfer tank. • Air pressure will drop when all Bulk transferred. • Close transfer discharge valve and bleed psi off. • Close vent and fill on receiving tank.

  8. Non-pressure tank Non-pressure bulk tanks used in pressure vacuum systems are constructed as shown here. Most components of the tank perform the same function as when used on a pressure tank. The components with different functions are described below. Pressure/ vacuum plants require zero pressure tanks for storage containers. They require a full open (preferred 5-in) vent on top of the tanks to a vent collection tank. This tank has a single line going to the dust collector, which sits on top of a dust collection tank. The vent tank is also the blow-down tank for products being returned to the plant at the completion of the job.

  9. Bulker Banana Bulker Banana is pressurized tank is designed and built to operate at pressures up to 30 PSI. Air Slides and Commercial Haulers have "non-code" tanks and these tanks are limited to pressures under 15 PSI. A pressure regulator set for 15 PSI and a safety relief valve set for 18 PSI are used on these units.

  10. Dust Collectors • Every Bulk System should have some sort of Dust Collection System • Control Device designed to meet local air quality regulations. • All Bulk Tanks are piped into Dust Collector • Clean filtered air exits collector, to the atmosphere. • Filtering System consists of either of two types: • Cloth Sock Filters • Pleated Paper Cartridges • Some contain a vibrator assembly. • Collection Tank provides void space for dust particles. • Filters and Socks should be routinely inspected. • Water bath on the outlet of the dust collector.

  11. Sampling • Bulk Samples should be collected during the third transfer: • – Collect sample during middle third of the blend. • – 25 lb minimum sample size. • – Each blend must be sampled. • – Store sample in sealed plastic bag. • – Properly label sample. • Date • Customer • Well name and number • Bulk truck unit number • Batch number • Customer number • Marked lead or tail cement • Samples retained 30 days.

  12. Operational Safety Guidelines • When any bulk tank is under pressure, no one is permitted to be on or under the tank for any reason whatsoever. • Under no circumstance may any piping, connections, unions or manways be connected or disconnected tightened or worked on while the vessel is under pressure. Even very low pressures can be dangerous. View the film "Don't Tease the Tiger" for a graphic example of the dangers of even very low (4 to 5 PSI) pressures. • Never hammer onpressure vessels for any reason. Hammering may weaken the bulk tank by introducing stress points in the steel. The metal may fail catastrophically at these stress points. • Always monitor each tank's pressure gauge. Don't depend on the air compressor's unloader system to maintain the correct pressure.

  13. Operational Safety Guidelines • Don't depend on the pressure gauge's accuracy. Ensure the vent is open before opening a manway or working on the valves and lines. Always assume that a tank has pressure on it. • The bulk operator must learn how to estimate the level in a tank. A weight indicator would be the preferred method of estimating the amount of material in a tank. A suggested method is to slap the side of the tank with an open hand. The vibration of the metal as well as the sound of the slap can be used to estimate the level of material in the tank. • Do not hit the tank with a hammer!

  14. Basic standard operating procedure • Check the following before starting the operation, Work Environment & Safety Equipment , BULK TANKS/SILOS, CUTTING PODS, AIR COMPRESSOR • Ensure personnel wear PPE appropriate for the area in which they are working. • Hook Up the rock catcher at the cutting pod. • Hook-up Bulk Hose from the rock catcher to Silo/Storage Tank. • prior to cutting the materials into the Cutting Pod, Check the following : filling lines and valves are open / cleared, Check the vent hose is in place, Pressure the Cutting Pod to safe working pressure after closing the discharge valve, hopper valve, and vent line valve, Open the Cutting Pod discharge valve when the pressure is 40 psi, Check for leaks at Cutting Pod, Check if there is any blockage, Check the valves, Check the vent line and make sure the vent line comes out bubbles/air, Once the Cutting Pod pressure is zero, close the air pressure valve, Close the Cutting Pod discharge valve, Open the cutting Pod vent line valve, Open the Cutting Pod hopper valve • Check the bulk bag loops prior to lifting. • Use the 4 Bulk Bag Loops to hoist up to the Cutting Pod. • When lifting the bulk bag to the cutting pod, check the forklift mask so it will not touch the roof • Put the bulk bag directly above the hopper, so that it can be cut easily • Once the bulk bag is empty, close the Cutting Pod valve • Open the Cutting Pod discharge valve when the pressure reaches 40 psi • Once the Cutting Pod operation is completed, check the following, Cutting Pod must be empty, Clear the discharge line, Clear the rock catcher

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