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SMARTER DRIER NOZZLES 10 FACTS SPRAY DRIER NOZZLE DESIGN FOR Pressure Code Compliance Spray Performance Product Quality Fire Risk Safety WARNING HIGH PRESSURE LIQUID IN USE WARNING EXPLOSIVE ENVIRONMENT WARNING HIGH TEMPERATURE WARNING COMBUSTIBLE POWDERS
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10 FACTS - Spray Nozzle Engineering...3 10 FACTS Spray Drier Nozzle Design for Pressure Code Compliance Spray Performance Product Quality Fire Risk Safety “ Our intention with this

Jul 17, 2020

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Page 1: 10 FACTS - Spray Nozzle Engineering...3 10 FACTS Spray Drier Nozzle Design for Pressure Code Compliance Spray Performance Product Quality Fire Risk Safety “ Our intention with this

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

Page 2: 10 FACTS - Spray Nozzle Engineering...3 10 FACTS Spray Drier Nozzle Design for Pressure Code Compliance Spray Performance Product Quality Fire Risk Safety “ Our intention with this

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.

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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

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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™

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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.

Page 31: 10 FACTS - Spray Nozzle Engineering...3 10 FACTS Spray Drier Nozzle Design for Pressure Code Compliance Spray Performance Product Quality Fire Risk Safety “ Our intention with this

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

Page 32: 10 FACTS - Spray Nozzle Engineering...3 10 FACTS Spray Drier Nozzle Design for Pressure Code Compliance Spray Performance Product Quality Fire Risk Safety “ Our intention with this

MELBOURNE, AUSTRALIA 1-8/27 Shearson Cres.

Mentone, Vic. 3194 P +61 (0)3 9583 2368

[email protected]

NEW ZEALAND / PACIFIC RIM 532c Grey Street

Hamilton East, NZ 3216 P +64 (0)7 839 6444

[email protected]

COPYRIGHT © SPRAY NOZZLE ENGINEERING JUNE 2014