SMARTER DRIER NOZZLES
10 FACTSSPRAY DRIER NOZZLE DESIGN FOR
Pressure Code Compliance Spray Performance
Product QualityFire Risk Safety
WARNINGHIGH PRESSURE
LIQUID IN USE
WARNINGEXPLOSIVE
ENVIRONMENT
WARNINGHIGH
TEMPERATURE
WARNINGCOMBUSTIBLE
POWDERS
WARNINGHIGH PRESSURE
LIQUID IN USE
WARNINGEXPLOSIVE
ENVIRONMENT
WARNINGHIGH
TEMPERATURE
WARNINGCOMBUSTIBLE
POWDERS
•FIRE RISK!•ASSET RISK!•SAFETY RISK!
WORTH THE RISK?
NOZZLE FAILURE IS:•LOST PRODUCTION RISK! •CONTAMINATION RISK!•QUALITY RISK!
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10 FACTSSpray Drier Nozzle Design for
Pressure Code Compliance
Spray Performance
Product Quality
Fire Risk
Safety
“Our intention with this book is to illustrate the risks,
responsibilities & opportunities for improvements using nozzles
in the field of high pressure spray drying.
•risksthatpeoplemaynotbeawareofuntilitstoolate
•responsibilitiestowardsactingwithinformation&knowledge
•opportunitiesforqualityimprovementstohelpdelivermarket
leading product. ” SMARTER DRIER NOZZLES
•LOST PRODUCTION RISK! •CONTAMINATION RISK!•QUALITY RISK!
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WHY THE 10 FACTS?SPRAY DRY NOZZLE DESIGN FOR RISK PREVENTION IS NOT NEW TO STATUTORY SAFETY BODIES GLOBALLY . . . . . OS&H - DEPT. OF LABOUR - NEW ZEALAND
- Approved Code of Practice for The Prevention, Detection and Control of Fire & Explosion in New Zealand Dairy Industry Spray Drying Plant.
Since 1993 an approved code of practice provides clear guidelines for operators regarding spray dry nozzle use.
3.1.3 ATOMISATION3.1.3.2 Pressure nozzleAll components of a pressure nozzle atomisation system including the high pressure pump, feed line, flexible couplings, valves, nozzles & other fittings shall be constructed of appropriatematerialswithadequatestrengthtowithstandthepressures necessary for effective atomisation. . . .
3.2.2 ATOMISERS3.2.2.2 Pressure nozzleNozzles must be correctly assembled by trained & competent personnel. Correct tools & spare parts must be provided for thispurpose.Iffrequentchangesofproducttypeoccur,(withanassociated need to use a variety of nozzle sizes), it is important to ensure that the proper nozzle parts are installed. Damaged or worn nozzle parts should be removed from the area in which the maintenance is conducted.
KEY POINT 10 FROM 3.1 PROCESSING EQUIPMENT FIGURE 1bPressure nozzle atomiser - Correct assembly by competent personnel-Replaceworn/damagedcomponents(gaskets, orifices, internal parts) - Monitor leaks Concentrate pipe must be able to sustain the pressure!
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SOURCE: Occupational Safety & Health Service Department of Labour, Wellington, New ZealandOctober 1993ISBN 0-477-03470-5
SOURCE: Occupational Safety & Health ServiceDepartment of LabourWellington New ZealandJune 2001ISBN 0-477-03648-1OSH 4270
Spray Nozzle Engineering - a responsible supplier working with spray dry plant owners towards meeting well
established code compliance obligations.
- Approved Code of Practice for Pressure Equipment - PECPR
2001 introduced an approved statement of preferred work practices in New Zealand by the Minister of Labour in respect to PRESSURE EQUIPMENT. It is noted a court may have regard to this in relation to employer compliance. This means that if compliance to this code by an employer is shown a court will consider this compliance within the provisions of the Health, Safety & Employment Act - 1992. The PECPR is very clear in the following parts;
2.2 DUTIES OF CONTROLLERS (OWNERS) - Information held onpressureequipment- Design verification onpressureequipment - Catalogues manuals, drawings & other specification data held toestablishthatthepressureequipmenthasbeenfurnishedwith accordance the PECPR regulations.
The PECPR also outlines numerous other responsibilities within this code including other detailed general technical requirementsincludingthefollowingparts;3.1 - 3.9 covering materials, design verification, inspection & testing, operation & maintenance
CODE COMPLIANCE IS A RESPONSIBILITY
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Spray Nozzle Engineering actively working with customers &
making a difference!
“Customer feedback & recognition from leaders in the field is very special & carries great value to us.”
THE 10 FACTS is not just about risk it’s also about improved quality, productivity & bottom line.Spray Nozzle Engineering is a leader in recognising & implementing the code of practice in the field of nozzle design & nozzle handling systems with these codes in mind.
As a Fonterra Excellence Award finalist for new product development with the CLICK&DRY™ nozzle, Spray Nozzle Engineering have been recognised by its customers as leaders in the field of spray dry nozzle design.
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Spray Nozzle Engineering actively working with customers &
making a difference!
★ SER VICING THE ★
★ D
AIRY INDUSTRY ★
2 5 Y E A R S
SMARTER DRIER NOZZLES
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Nozzle stress compliance is critical - spray dry nozzles are requiredtocomplytopressurepipingcodesformaximumallowablepressurestress.Allplantsarerequiredtocomplytoapressurepipingcode. What is your site pressure piping code & do your nozzles comply?
High pressure sealing code compliance is essential - high pressure dictates consideration towards global sealing codes in the design of sealing systems for spray dry nozzles. These codes prescribe NO GAP seal arrangements to prevent seal extrusion & leakageatdrieroperatingpressures.Radialsealarrangementsrequirea very tight fit to comply, as a result, severe seal face damage is typical with daily use. Even worse, less visible damage could point to radial seal face gaps which are only remedied with the use of troublesome & expensive radial seal back-up rings, further complicating sealing. All these issues can be addressed using No Gap Axial seals. Are your seal faces “metal to metal” - No Gap & do they comply to pressure sealing codes? When was your last safety spray dry nozzle audit?
Wear part concentricity is critical for consistent performance - spray nozzle internal components must always be concentric to prevent inconsistent performance across lances that can impactproductquality.Wear part clasps(holders)canpreventthis.Are your nozzle wear parts concentric & your nozzle test pressures across lances consistent?
Are your wear parts concentric? Go to quick wear part concentricity test on page 15
10 FACTS START HERE.The importance of understanding spray dry nozzle performance, code compliance & safety.
Do you have seal face gaps? Go to quick seal gap compliance test on page 13
SMARTER DRIER NOZZLES
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Product build up (Bearding) can be greatly reduced - the continued pursuit of build up reduction on spray nozzle caps is criticaltoimproveproductquality&fireriskreduction.Do your older nozzles have excessive product build up?
Nozzle check valves reduce scorched particles - the ability to retrofit non drip valves in your existing nozzle systems will help control nozzle drips which can lead to increased scorched particles. Can you readily fit nozzle check valves if required?
Easy assembly & handling of nozzles reduces opportunity for leakage - older nozzle systems may allow assembly error which can lead to leakage & fire risk. Wear part clasps (holders)cansignificantlyassistoperatorsincorrectassembly. Custom tools&handlingequipmentcanincreasethelifeofyournozzle systems making handling safer & easier. Do you have the best nozzle tools for the job? Have your nozzles ever leaked?
Thread damage is not normal! - your nozzles should utilise anti-thread “binding” including larger thread type to eliminate cross threading & provide easier operator assembly. Have your nozzle ever suffered impact thread damage that can lead to expensive replacement?
Nozzle sealing face damage can be avoided - sealing gland faces should not be exposed to direct contact damage in normal handling. Damage will compromise seal integrity. Nozzle seal skirts protect sealing faces. Have you inspected your seal faces lately for damage & are they protected?
Wear part consumption can be significantly reduced - Press extraction of wear parts in older nozzle systems greatly increases the opportunity for wear part breakage. A clasp system easily extracts wear parts to greatly reduce breakage using current disassembly methods? Do you suffer costly wear part breakage using current disassembly methods?
Proper handling guides should be available for your nozzle system - Are durable user placards & operating data available from your nozzle supplier & do you make them readily visible in your control room?
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MAXIMUM ALLOWABLE NOZZLE STRESS & PIPING CODE COMPLIANCE IS CRITICALASME B31.3 - A global pressure code guiding compliance.
Nozzlesarerequiredtobedesignedtofunctionsafelyatmaximum operating pressures of the drier. Many spray dry nozzles found in use, operate in a highly stressed condition with reference to standards such as ASME B31.3 & others, with stresses exceeding that allowable within these standards, greatly increasing opportunity for failure.
PROBLEM In many driers today, much of the nozzle hardware in use is of an age that far exceeds its recommended fatigue cycles & exist in a worn condition, which heightens risk of failure.
Industries working with pressure systems & vessels, typically stipulate a safety factor based upon the yield stress of materials inuse.Operatingbelow‘twotimes’thesafetyfactorrequiresathorough understanding of your fatigue cycles; operating below a factor of ‘one’ ensures imminent failure based upon known engineering protocol & material properties. Such a condition must be addressed.
Q: What is your site pressure piping code & do your nozzles comply?
SOLUTIONStrict pressure code compliance may have already been adopted on your plant pipe work, but did this also extend to the nozzles welded to this very pipe work? The CLICK&DRY™ Nozzle system is shown to be a fully compliant design meeting ASME B31.3 pressurestressrequirements.
CLICK&DRY™ was developed to function within a range of operational safety factors, with reduced wear, which far exceed thatofothercompetitiveequipmentinthefield.
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Codes such as ASME B31.3 govern piping & nozzle use in your plant
Nozzlecarriersarerequiredtobedesignedtofunctionsafelyat the maximum operating pressure of the drier. These carriers (above)werenonASMEcompliantattherequiredoperatingpressure. As a result, they have suffered significant yield stress failure, the result of which could be catastrophic.
NOTE STRESS BULGE & CRACK
The image above left depict stress concentrations on a common generic type nozzle in use. Red shaded areas show around 8 times allowable stress. CLICK&DRY™ above right depicts stress concentrations well within the allowable stress of the material.
802.5MPa
-85.90.0
CLICK&DRY
WITHIN ALLOWABLE STRESS LIMITS
TM
228.3MPa
-48.9
0.0
COMMON NOZZLE TYPES
EXCEEDS ALLOWABLE STRESS x 8 WELL WITHIN STRESS LIMITS
CLICK&DRY™
ASME B31.3 350 BarG
220oc
CLICK&DRY™ nozzle hardware is designed with safety factors approaching 2 & above, in keeping with ASME B31.3.
Q: What is the condition of your hardware & does it have a factor of safety in line with your adopted piping code?
“It’s not enough to say, “I’ve never had a nozzle problem before” because a nozzle problem, could begin on your next shift. You need to know before start-up that your equipment is fit for purpose; working towards code compliance will help. ”
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HIGH PRESSURE SEALING CODECOMPLIANCE - GLOBAL STANDARDSA major leakage & fire risk exists when the use ofincorrectly specified, non compliant & poorly maintained spray dry nozzle seal gland systems.
Consideration towards global sealing codes for high pressure spray dry nozzle sealing design is essential. These codes prescribe NO GAP seal arrangements to prevent seal extrusion & leakage at drier operating pressures moving above 100 BarG. TYPES OF NOZZLE SEALS Radial Seal - the O-ring is always around the plug. The plug needs room to enter the socket to avoid rubbing damage. This room is what we call ‘gap’.However,thegaprequiredforassemblyisaproblem, since high pressure seals demand no gap. Axial Seal - the O-ring is at the very end of the plug. The plug can have the room it needs to enter the socket thus avoiding rubbing damage, as the seal is at the end. There is NO GAP when the plug is firmly in place. This is ideal for high pressure sealing.PROBLEM Radialsealarrangementsrequireaverytightradialfittocomplywith global sealing standards covering high pressure use. Severe sealing surface damage (rubbing damage) typically results from daily assembly & disassembly of radial seals with the tight fits requiredforcompliance.Evenworse,lessvisibledamagecouldpoint to radial seal face gaps which are only remedied with the use of troublesome & expensive radial seal back-up rings, further complicating sealing problems. Nozzles with excessive seal face gap and / or damaged sealing faces must not be used & immediately replaced with compliant hardware.SOLUTION All these issues can be avoided by using CLICK&DRY™ No Gap Axial seal arrangements Q: Are your seal faces “metal to metal” - No Gap & do they comply to pressure sealing codes? When was your last inspection for seal face damage & hardware compliance?
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Are your seals fit for purpose?
Fig 1: Old Spray Dry Radial Seal Arrangement which require radial assembly gaps. O-ring standards typically depict this radial seal type for operation pressures well below those found most in spray driers.
Oldstylenozzledesignrequiresa joint gap to avoid assembly damage. This can allow seal extrusion & leaks at high pressures.
DETAIL A
DETAIL A
Radial Seal (Expensivetroublesomeback-upringsarerequiredforhighpressure use, with radial seals).
Compliant No join gap
prevents leaks
Seal face protection skirts for EXTRA seal face protection
A
Fig 2: New Spray Dry Axial Seal Arrangement Axial compressive seal is designed for pressures well above typical dryer operating pressures according to O-ring standards.
TRY THE QUICK RADIAL/AXIAL SEAL GAP COMPLIANCE TEST
Body/cap radial seal gap test - measure body/cap bore & plug seal face diameters, if measurements are different, this confirms radial seal face gap. Is this gap being addressed? After radial gap test, perform axial orifice disc gap test. Assemble your wear parts as normal into your nozzle body/cap assembly, but omit all seals. Shake the nozzle assembly. If the internal wear parts rattle inside, it is highly likely you do not have metal to metal axial sealing & leakage gaps are present. The rattle is likely a result of axial gap. Any gap is a problem, any rattle is a problem.Compliant NO GAPhardwareisrequiredbeforefurtheruse.
WARNING - DO NOT PERFORM THIS TEST WITH PRESSURISED LIQUID!
A
PLUG
SOCKET
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“My spray dry nozzles should only be able to be assembled one way!”
CLICK&DRY™
Ease of assembly reduces risk & increases safety!
WEAR PART CONCENTRICITY IS CRITICAL TO CONSISTENT PERFORMANCEWear part concentricity is critical to consistent spray performance by maintaining swirl to orifice alignment.
PROBLEMOldspraydrynozzlesystemsrequireexcessiveclearancesbetween radial faces of wear parts & the internal bores of the cap.Thisgapissowearpartscanberemovedafteruse(andprevent these parts jamming during removal). This design can leadtowearpart(swirltoorifice)eccentricityormovementin relation to cap outlet as the nozzle is assembled & then tightened.
THE RESULT BEING INCONSISTENT SPRAY PERFORMANCE & PRESSURE LOSS!
SOLUTIONThe Easy Out Armour Clasp ensures that perfect concentricity can be achieved between the swirl orifice & nozzle cap outlet which results in consistent spray performance & easy ‘Non-Forced’ wear part extraction - EVERY TIME!
TEST PRESSURES BETWEEN ALL DRIER LANCE SETS WILL ACHIEVE A GREATER BALANCE, DELIVERING MORE EVEN
PERFORMANCE BETWEEN NOZZLES !
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CLICK&DRY™, as well as delivering greater wear part concentricity, eliminates misalignment of wear parts during assembly(EasyOutArmour Clasp model). It also acts as a simple parts remover, removing the need for unnecessary force or press tools acting directly on fragile & costly wear parts. This greatly reduces, if not eliminates, wear part damage.
“My spray dry nozzles should only be able to be assembled one way!”
QUICK WEAR PART CONCENTRICITY TESTPlace your wear parts as normal into the cap housing, shake from side to side or use your finger or other to check for lateral movement. If the wear parts rattle from side to side or move to any small degree, you have a concentricity problem that will adversely effect spray performance. Correct via hardware replacement with wear part clasp concentric holder.
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CLICK&DRY™ Better Concentricity with improved Safety & Quality
PRODUCT BUILD UP & BEARDINGCAN BE GREATLY REDUCEDCLICK&DRY™ introduces safer cap designs to help reduce product build up & scorched particle contamination of powder.
PROBLEMIn many applications this build up or bearding may be due to drier configuration & the use of wider spray angles. Powder formulation & product produced can also greatly contribute to nozzle bearding that occurs. This needs to be reduced & managed to reduce opportunity for fire risk.
SOLUTIONLess build up means less opportunity for fire! With the seal-in-disc™ orifice system, the need for an O-ring groove within the cap is eliminated. This provides a lower outer face profile greatlyreducingbearding(buildup).Removingthegrooveinthecap also produces greater cap strength when under pressure, reducing nozzle pressure stress. The elimination of the O-ring groove within the cap also improves cleaning & hygiene.
Old style cap Vs CLICK&DRY™ Cap bearding comparison
• Reduced bearding• Reduced scorched particles contamination• Reduced fire risk • Easier cleaning
OLD STYLE CAPSHOWING SCORCHED
BUILD UP
CLICK&DRY™ CAPREDUCED BUILD UP IMPROVED QUALITY
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NEW CLICK&DRY™ Seal-In-Disc™ CAP
SEALING IMPROVEMENTS WITHOUT CHANGING
TRADITIONAL WEAR PART GEOMETRY
OLD STYLE WEAKER SEAL IN CAP WITH HEAVY BUILD UP
CLICK&DRY™ Better Concentricity with improved Safety & Quality
Removing the O-ring from the cap allows a lower outer face profile greatly reducing bearding
With the cap O-ring groove removed, this produces a stronger cap when under pressure, reducing nozzle pressure stress. Elimination of the O-ring groove in the cap also improves cap cleaning & hygiene.
NEW
OLD
Vs
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NOZZLE CHECK VALVES REDUCESCORCHED PARTICLE CONTAMINATION & DRIER CLEANING PROBLEMS.A little history, a big advanceThe Drip Pro™ story began over 12 years ago.
PROBLEM A call from a spray drier OEM revealed a problem with nozzle drips which resulted in scorched particle deposits at the fluid bed,compromisingthequalityofthemilkpowder.Thechallengeissued was to develop an anti-drip check valve which would function reliably within the milk fluid path & difficult service conditions encountered. We soon discovered this same problem was extremely common to many other customer’s driers.
SOLUTION TheresultofourworkwastheuniqueDripPro™ patented design, which alleviated these problems of drips & reliability, proving to be a great success. As a result, OEMs set to work converting many existing plants with this first generation valve (GEN-1).Positiveuserfeedbacksetthestagefortheevolution of what has become the industries best performing anti-drip spray dry valve, called the Drip Pro™ Hi-Flo GEN-4. Designed for high solids, viscous products such as nutritionals & others, where longruntimeswithoutblockagewasrequired.
ADVANCING SPRAY DRY NOZZLE
VALVE TECHNOLOGY
Drip Pro™
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Our first valve was the Drip Pro™ GEN-1 valve which was accepted as one of the first spray drier valves in the industry to deliver reliable operation over a full shift run without blockages. Age alone has seen this successful early version typically replaced by later generations of vastly improved valve design - GEN-2, GEN-3 & now GEN-4. CONTACT FACTORY ABOUT CHANGE OUT OPTIONS.
GEN-1small lug(c.2001 now fully superseded)
BIG LUG
NEW HIGH PRESSURE AXIAL SEAL BODY
GEN-4 Latest VersionSuperior high flow, long run performance
The new Drip Pro® Hi-Flo Gen-4 was created to meet the higher productivity demands of the spray dry industry today, not only the demandforhigherflowrates,buttoalsotomeettherequirementsof longer run times. Vastly increased flow efficiency has been achieved with significant improvements in component durability, along with an expanded range of spring opening / closing pressures & seal materials. With larger body / cage lugs & threads, allowing far greater longevity than its predecessor. Upgrading to the new Drip Pro™ Hi-Flo Gen-4 with CLICK&DRY™
will deliver the ultimate in spray drier nozzle technology offering greater improvements in your drier plant performance.
LARGE THREAD CONTINUED FROM GEN 3
NEW HI FLOW CAGE
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“My spray dry nozzles should only be able to be assembled one way!”EASY ASSEMBLY & HANDLING
OF NOZZLES REDUCES LEAKAGE - ASSEMBLY LOGIC
What makes CLICK&DRY™ SYSTEM safer?
PROBLEMLong standing problems inherent with traditional spray dry nozzle designs is opportunity to incorrectly assemble the nozzle. One issue is the inability to see if the orifice O-ring has been inserted after an orifice disc has been installed in the cap. Added to this, regular wear parts & other components can easily be installed upside down, or can become dislodged & misaligned duringtightening.Thisisasignificantproblemforquality&potentialleakage.Mostcurrentnozzlesystemsinuserequirea great deal of assembly skill & the risk of misalignment of components is high, which can result in leakage. If radial seal backupringsareadoptedasrequiredformosthighpressureradial sealing glands, these can be incorrectly installed on the wrong side of the seal or can catch on assembly, compromising the seal before use. Backup rings are also very expensive.
SOLUTIONThe CLICK&DRY™ spray dry nozzle system is the first spray dry nozzle on the market to address these safety issues. Operators can pre-assemble the swirl / orifice cartridge & safely see the orifice O-ring housed in the assembly, before screwing down the cap with assembly Easy Out Armour Clasp technology - featuring assembly logic. Older problematic & complicated radial seals are replaced with full axial compressive seal technology for the ultimate high pressure seal. Pre-assembly technology also allows pre-testing start-up without any internal component movement, which means positive testing - EVERY TIME!
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CLICK&DRY™axialsealdoesnotrequiretroublesome backup rings, it eliminates misalignment of wear partsduringassembly(EasyOutArmourClaspmodel)which can cause leakage & acts as a simple parts remover without damage to wear parts!
“My spray dry nozzles should only be able to be assembled one way!”
CLICK&DRY™
Perfect for pre-assembled nozzle testing prior to start-up!
Click&Dry™
Prevent incorrect assembly, & potential leakage - fool proof operation.
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THREAD DAMAGE IS NOT NORMALImportance of nozzle design to reduce thread damage
Why does the CLICK&DRY™ SYSTEM provide vital thread protection?
PROBLEMMany plants currently operate spray lances with thread systems which are too fine to resist normal impact damage. Fine threads are also more likely to cross thread. Many clearly lack further design considerations which will protect the integrity of the thread system. Such nozzle hardware thread surfaces when externalarefrequentlysubjecttoimpactduringhandling,with the resultant damage compromising assembly & sealing integrity thus leading to leakage. In addition, thread & seal face galling(binding)aproblemfoundonmanycompetitivenozzlesystems,frequentlyrequireexpensiveweldingorreplacementofnozzle bodies due to this cross threading.
SOLUTIONCLICK&DRY™ has been designed with heavy duty female threaded lance fittings which are coarser & more robust, with heavily concealed sealing surfaces which are highly resistant to normal impact damage during lance handling. This improved thread design also extends to the cap itself. The coarser thread type, form & material are designed to match your operating conditions having been developed from over a decade of nozzle spray lance manufacture & research.
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Thread & seal face galling (binding)problemsfoundon typical old style. Nozzle systemsrequireexpensivewelding or replacement of nozzle bodies. If left undetected, this damage can be transferred to all your lances - thus compromising your pressure system & increasing fire risk!
CLICK&DRY™ is designed for longevity. With heavy duty female lance fittings & seal face skirt protection, the coarser threads are highly resistant to impact damage & cross threading.
“Robust design dramatically reduces handling damage of lance hardware!”
CLICK&DRY™
Safer, fit for purpose hardware!
NEW
OLD
Vs
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NOZZLE SEAL FACE DAMAGE CAN BE AVOIDED Importance of nozzle designs to reduce seal face damage “A critical problem with catastrophic results”
PROBLEMMany plants currently operate spray lances with exposed nozzle hardwaresealingsurfaceswhicharefrequentlysubjecttoimpactduring handling, such impact damage can compromise sealing quality&causefailure.Inadditionsealfacegalling(binding)isaproblemfoundonmanycompetitivenozzlesystemsfrequentlyrequireexpensiveweldingorreplacementofnozzlebodiesdueto this excessive seal face damage.
SOLUTIONCLICK&DRY™ has introduced sealing face skirts both on the female lance body & cap. Sealing face skirts are specifically designed to reduce direct impact damage on your all important sealing faces. They are designed to protect the no gap axial sealing system that is making CLICK&DRY™ the name in reliable spray dry nozzle sealing & leakage reduction. These heavily concealed sealing surfaces are highly resistant to normal impact damage during lance handling.
WHAT CONDITION ARE YOUR NOZZLES IN?
Incorrect sealing systems or exposed damaged sealing O-ring groove glands can leak & can cause catastrophic failure
Old, superseded, damaged nozzles
that look like this...
CAN LEAD
TO
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LEAKAGE HAS OCCURRED AT THE REAR OF THIS NOZZLE
SCORCHED PRODUCT
Leakage due to seal damage despite inclusion of back-up ring. Such an assembly is difficult & complex to service correctly on a daily basis. Gland surface damage may have pinched & torn O-ring at assembly.
Mitigating nozzle sealing system failure reduces fire
DAMAGE SEAL GLAND SURFACE
Even without damage, radial sealing standards typically limit such an arrangement to a max. pressure of only 103 BarG.
BACK-UP RING
SEAL DAMAGE
PROBLEMS LIKE THIS?
CLICK&DRY™ SOLUTION . . . seal face skirts
DETAIL A
No join gapprevents leaks
Seal face protection skirts forExtra seal face protection A
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Accessories tailored for field useWEAR PART CONSUMPTION CAN BE SIGNIFICANTLY REDUCED - DELIVERING MAJOR COST REDUCTIONSPremature swirl / orifice damage outside of the drier IS NOT NORMAL!
PROBLEMA majority of old style nozzle systems which were originally designed over 30 years ago to suit smaller spray driers have not advanced at the same pace as the spray drier technology itself. The rigours of modern driers which have a greater number of nozzles operating at higher temperatures and pressures, has meantmorefrequentassembly&disassemblyofnozzlesisrequiredfortheiroperation.Thisoldertechnologyhashighoccurrences of wear part breakages when removing these fragile parts when they are fouled contributing to unnecessary operating costs when it can be avoided.
SOLUTIONThe CLICK&DRY™ nozzle system has been designed to remove the need for direct press force contact when removing fouled wear parts & eliminate the need for inappropriate removal tools which results in high breakages & wear part costs. CLICK&DRY™ utilises patented clasp technology for easy removal of these fragile parts while providing customised fit for purpose tools taking away opportunity for these costly breakages during the extraction process. CLICK&DRY™simplyrequiresnodirectpresscontactwithcarbidepartsforwearpartremoval.Thisequatestomassive operational cost saving with CLICK&DRY™.
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Accessories tailored for field use
1. Place orifice O-ring
P/No. 91007-1 into cap O-ring
groove, at base. Apply a liberal
amount of O-ring lubricant to
the O-ring on installation into its
housing groove to help prevent
dislodgement during assembly.
2. Place orifice disc into cap.
The radiuses side of the disc
orifice should be facing you
when properly positioned.
Disc should sit securely into
position.
5. Cap cross section shows
correct parts assembly.
Note: position of screw pin fully
engaged. You have now inserted
in order... O-ring, orifice disc,
swirl and finally screw pin.
9.
1.
2.
5.
WORLD WIDE PATENTED DESIGN
11.
WORLD WIDE PATENTED DESIGN
O-ring GROOVE in cap
STANDARD DISC
No groove
Click&Dry®
MAXI First Generation System
7. With cap inverted in
orientation shown, use O-ring
lubricant to help adhere O-ring
in place. Fit body O-ring
P/No.91008-1 within O-ring
groove. Ensure proper fit. Keep cap
inverted before assembly to lance
to avoid dislodgement of O-ring.
7.
8.
4. Screw pin can now be
inserted with ‘castellations’
facing into the carrier (4a).
Note: Spanner flats now facing
out. Pin should be screwed to
full thread engagement (4b).
4c. 4b.
4a.
3. Hold Swirl Chamber with swirl
volute facing downward. Keep
cap inverted as shown whilst
placing swirl chamber into cap.
Ensure that it seats evenly hard
up against orifice disc.
3.
4c. Screw pin can be further
‘nipped up’ using hand multi
tool.
6.
6. Turn tightened cap assembly
over and inspect front end face.
Orifice disc should be resting up
hard against inner wall of cap outlet,
without any gaps that might indicate
a loose O-ring, wear parts or
damaged threads preventing proper
assembly. If so check components
and repeat all assembly steps.
10. With cap fully hand tightened
to the body, use the special C&D
multi-tool provided to ‘nip-up’ the
cap ensuring the carrier is fully
engaged and secure.8. Whilst holding the nozzle cap
with the O-ring groove facing
upwards (as shown) and O-ring
in place, cap assembly can
now be carefully hand screwed
‘fully home’ up into the nozzle
lance body without disturbing
the O-ring in preparation for
final ‘nip up’.
NOZZLE ASSEMBLY GUIDE FOR MAXI FIRST GENERATION SYSTEM
O-RING GROOVE IN CAP - NON CLASP SCREW PIN
This guide relates to early First Generation O-ring groove in nozzle cap. To reduce bearding and/or increase operating
pressures please contact us regarding the new SEAL-IN-DISC SYSTEM now available.
WARNING! YOUR NOZZLE PARTS ARE PRECISION HIGH PRESSURE COMPONENTS. THEIR CARE & MAINTENANCE IS CRITICAL TO SAFE
& PROPER OPERATION! WORN & DEFECTIVE PARTS MUST BE REPLACED. REFER NOZZLE WEAR & MAINTENANCE GUIDES - AVAILABLE
ON REQUEST. Following assembly instructions will help deliver significant reductions in damage, increase safety & assist in trouble free operation.
(Refer Nozzle Care & Handling Guide for more specific handling information - available on request)
The information contained in this training manual and the training sessions provided by Spray Nozzle Engineering; are done as a guide
only. Spray Nozzle Engineering is not responsible for any of the information, its implementation or validity to a particular process. If you
are in doubt as to its relations to your application; seek the advice of your Engineering Department or independent source.
CDA3AssHFMiniSept11REV 4
For further Information
1300 Nozzle
www.spraynozzle.com.au
Ensure Lance Body internals
and sealing face are clear
of any, obstruction and
foreign material before
re-assembly. Always “Check
for old seals and O-rings and
remove before re-assembly”.
Use O-ring pick to remove any
old O-rings, prior to cleaning
and re-assembly. Always
replace O-rings and sealing
materials with new replacement
items.11.
BEFORE STARTING!
ENSURE ALL COMPONENTS ARE PROPERLY CLEANED AND
INSPECTED FOR DEFECTS. THE FOLLOWING ARE SOME KEY
POINTS OF CONSIDERATION. . .
ALWAYS USE
Soft Handling BOARD
ALWAYS USE
Soft Handling BASKET
NEVER Scour, scrape or dig to clean nozzles
Avoid metal to metal contact
NOT RECOMMENDED
TECH TIP! Please note: the new Click&Dry design,
has a far superior sealing system when compared to
earlier systems, however you are still required to lubricate
body O-rings before assembly. Apply a liberal amount of
O-ring lubricant to the O-rings on installation into their
respective housing grooves to help prevent dislodgement
during assembly this may also help prevent O-ring pinch
and subsequent damage. Check with your Engineering
Department for suitable O-ring lubricants. Always ensure
used O-rings are removed from nozzle/valve assembly
and accounted for. Always wash nozzle parts in the teflon
lined basket.
The nozzle assembly may be dismantled in the same order, using specialised
tools provided. See training module (1). It is recommended that the swirl/orifice
be removed using the SNE Soft Tool. Nozzle components may now be washed
in accordance with your maintenance procedure. Discard O-rings after each
disassembly and replace with a new set.
DIS-ASSEMBLY TIP
i. ii.
iii.
c.
b.
For Hi-Flo Drip-Pro® Check Valve parts detail refer to
Click & Dry Hi-Flo MINI Exploded Parts and Order Guide
a, b & c. Where optional Drip-Pro Check Valve
is used, always inspect dome seal for damage.
Dome seal is easily replaced and should be
changed regularly. (a) Use thread lock when
re-assembling. Always check with your Engineering
Department for a food approved thread lock material.
(b) C&D multi-tool incorporates a triangular shaped
tool socket to service valve seal. Hold triangular
valve guide in tool and with a small driver inserted
in valve body, twist to loosen or tighten (as shown).
(c) The C&D multi-tool also incorporates a valve
removal driver at its end, push & twist to remove
or insert the valve cage assembly by quarter turn
twist.
OPTIONAL Hi-Flo Drip-Pro® DRIP CONTROL CHECK VALVE TIPS
a.
For components “stuck” in place after use: (i) Place assembled clasp for
dislodgement into special holder with flats aligned as shown. P/No: CD-
MULTITOOL-MINI-BENCHMNT, which must be securely screwed to bench
top. (ii) The Cap orifice should be facing you when properly positioned.
(iii) Finally place special twin handle tool P/No: CD-MULTITOOL-MINI-
BENCH directly over cap with flat aligned and turn in anti-clockwise direction
to loosen.
DISASSEMBLY TIP: CLASP DISLODGEMENT FOR POST RUN ADHESION ISSUE
i. ii.
iii.
IMPORTANT
A soft "push"
with tool is all
that is
required
ASSEMBLY SHEET #1
CLICK&DRY™ is a fully supported product in the field with on-site operator training & comprehensive library of technical support material tailored for field use.
28
Optional ExtrasCLICK&DRY™ SAFETY NOZZLEONE SYSTEM - MANY OPTIONS. Proper handling tools shouldBe provided with your nozzle system.
CLICK&DRY™ One nozzle system & options to suit every drier.
Why you need options.
PROBLEM Traditional nozzle systems can lock you in to technology that is outdated in regards to sealing standards, compliance, pressure integrity&factorsofsafetyrequiredinmodernhighpressuredriers. Including multiple radial seals with exposed O-rings & sealing glands.
SOLUTION The CLICK&DRY™ system has been designed in consultation with industry operators to offer more options. From one innovative safe nozzle body design, you now have the freedom to choose from multiple cap designs, swirl / orifice technology, new Easy OutArmourClasptechnology,directlytargetingpowderqualityvia the only truly concentric wear part system in the market. All of this incorporating the world’s most innovative Drip-Pro™ Hi-Flo Check Valve system available with multiple replaceable soft seal seats. Inclusive is a range of handling tools designed to save you time & money. Offering one of the safest cost saving systems available TODAY!
THE ULTIMATE OPTIONTC Armour™ total wear protection is retrofit to all CLICK&DRY™ maxi hardware
29
CLEANING BASKET& SOFT BOARDSProtects your nozzles from damage during cleaning.
EASY OUT KEYDifficult wear part removal - made easy.
CIP ACCESSORIESCIP caps for both hose & rocket launcher type lance wash systems.
SURFACE TREATMENT Special low profile cap face components with Lustre Polish.
BUMPERProtects your nozzles from damage during cleaning.
ORIFICE GAUGEMeasuring should be part of your pre-runqualitychecking.
O-RING PICKOne easy tool for all O-ring removal replacement operations.
MULTI TOOLOne tool for all operations. Reduces unnecessary damage caused by incorrect tool use.
Optional Extras
METAL DETECTABLE CLEANING AIDSPlastic non-scratchcustom made forCLICK&DRY™
30
THE LARGEST RANGE OF BODY CHOICESAVAILABLE IN THE MARKET TODAY
FOR EVERY DRIER TYPE ALL AVAILABLE WITH DRIP PRO™
ANTI DRIP TECHNOLOGY
Ensure improved product quality, compliance to pressure & sealing standards!
Spray Dry Safety Nozzles
SAFETY & COST BENEFIT INSTANTLY ACHIEVED Adopting the CLICK&DRY™ system delivers dairy sites a state of the art nozzle design, with Design features which improve nozzle seal gland life, reduce the opportunity of handling damage and misalignment during assembly. Most importantly more readily conforms to known sealing standards & conventions for high pressure use, in particular the pressures operated by dairy sites. As such this reduces significantly the risk of leakage & therefore fire, and the resultant potential compromises to safety.
THE LARGEST RANGE OF BODY CHOICESAVAILABLE IN THE MARKET TODAY
FOR EVERY DRIER TYPE ALL AVAILABLE WITH DRIP PRO™
ANTI DRIP TECHNOLOGY
The CLICK&DRY™ System from day 1 you get • increased safety compliance• reduced operating costs• more options from one system• latest technology• increased productivity• continued support & partnership
World wide vendor technical support in respect to operator training & product information including technical literature, user guidelines along with product care & management accessories.
SMARTER DRIER NOZZLES
Spray Dry Safety Nozzles
MELBOURNE, AUSTRALIA 1-8/27 Shearson Cres.
Mentone, Vic. 3194 P +61 (0)3 9583 2368
NEW ZEALAND / PACIFIC RIM 532c Grey Street
Hamilton East, NZ 3216 P +64 (0)7 839 6444
COPYRIGHT © SPRAY NOZZLE ENGINEERING JUNE 2014