Air Blasting with Steel Abrasives A Practical Guide to Improving Productivity 11/26/2018 air blasting with steel abrasives www.satactics.com

If you can’t measure, you can’t manage To follow this program, you will need: some simple tools to measure key operational performance factors 11/26/2018 air blasting with steel abrasives www.satactics.com

air blasting with steel abrasives www.satactics.com ESSENTIAL MEASUREMENTS AND INFORMATION ABRASIVE COST PER TON LABOUR COST PER NOZZLE HOUR FLOW RATE OF ABRASIVE – KG per hour per nozzle – can be average or specific AIR COST PER NOZZLE HOUR CYCLES ABRASIVE RE-USED AIR PRESSURE AT BLAST NOZZLE – measured with hypodermic needle pressure gauge MAINTENANCE AND CONSUMABLE COST PER NOZZLE HOUR PRODUCTION RATE – Square meters per hour 11/26/2018 air blasting with steel abrasives www.satactics.com

Basic Rules and Principles Site Management Abrasive - use the smallest abrasive particle size that is capable of removing the contaminant Nozzles – Correct type (Venturi) at the correct air pressure AND monitor wear Designed air pressure for blasting steel is 7 bars or 100 psi 11/26/2018 air blasting with steel abrasives www.satactics.com

air blasting with steel abrasives www.satactics.com Site Management Equipment Audit and daily check list (e.g. nozzle wear, hose wear etc) Materials handling and logistics (Removing bottle necks and constraints) Personnel management and goal setting (Leadership and innovation at all levels) 11/26/2018 air blasting with steel abrasives www.satactics.com

Abrasive Particle Size, Nozzle Design and Air Pressure Use the smallest particle size capable of removing the contaminant – WHY? More impacts per second increases productivity Steel grit >< 150 and 400 microns (GH80) will remove any contaminant if blasted through a venturi nozzle at 7 Bars (100 psi) 11/26/2018 air blasting with steel abrasives www.satactics.com

air blasting with steel abrasives www.satactics.com Particle Velocity through a venturi nozzle Air 500 M/S 100µ S/S 400 250µ S/S 300 500µ S/S 120 0.1 0.2 0.3 0.4 0.5 Meters 11/26/2018 air blasting with steel abrasives www.satactics.com

Abrasive Particle Energy = mass (weight) X Velocity (speed) ² Energy at 7 bars = 250 X 300² = 225 energy units 250 micron Energy at 7 bars = 500 X 120² = 72 energy units 500 micron 11/26/2018 air blasting with steel abrasives www.satactics.com

air blasting with steel abrasives www.satactics.com Blasting Nozzles are designed to work at 7 bars (100 psi) Bore Diameter Exit Diameter 14 10.5 Bars 7.0 3.5 1 1.2 1.4 1.6 1.8 2.0 2.2 2.4 Area Ratio = exit diameter/bore diameter 11/26/2018 air blasting with steel abrasives www.satactics.com

air blasting with steel abrasives www.satactics.com Blasting Efficiency decreases with air pressure by 1.25% per 1 psi - 14psi = 1 bar 100% 66% 50% @ 7 Bar @5.6 Bar @4.2 Bar 11/26/2018 air blasting with steel abrasives www.satactics.com

Operating costs per nozzle hour Square meters cleaned per hour   Blasting Costs and Productivity - ALFACAMP analysis Variables Actual Change Abrasive cost per ton Change Labour cost per nozzle hour Change air cost per nozzle hour Change cycles of abrasive re-use Change air pressure (psi) New Combined Actual Abrasive cost per ton R5400 R 4,700 R 5,000 R 4,700 Labour cost per nozzle hour R 80 R 60 R 96 R 96 Flow rate of abrasive per nozzle hour (kg) 600 Air cost per nozzle hour R 55 R 55 R 60 Cycles of abrasive re-use 50 55 Air Pressure (psi at nozzle) 70 85 Maintenance and consumables % 12 Production Rate Sq Meters per nozzle hour 10.0 13 13.0 Cost per square meter R 22.38 R 19.20 R 23.63 R 20.16 R 18.99 R 15.08 R 17.86 Instructions 1) You will need to measure the variables of your existing operation and record them in the "Actual" Column 2) Enter a new cost for abrasive, labour and air cost and see what effect it will have on overall cost per square meter 3) Look at improving abrasive recovery systems to increase the number of cycles of abrasive use and enter this number 4) Investigate ways to improve nozzle operating air pressure and enter the new operating pressure 5) Refine the operating system targeting the largest savings first (usually air pressure) 6) Target new combined costs after adjusting variables through preformance management systems Cost calculations are derived by: Operating costs per nozzle hour Square meters cleaned per hour   11/26/2018 air blasting with steel abrasives www.satactics.com

air blasting with steel abrasives www.satactics.com A detailed implementation program to improve productivity is available at no cost – simply use abrasives from Simple Active Tactics Thank you for your time! 11/26/2018 air blasting with steel abrasives www.satactics.com