The FasterBlaster Cleaning System

Transcription

1 The FasterBlaster Cleaning System RBW Enterprises, Inc. 136 Hillwood Circle Newnan, GA Phone: (770)

2 This cost comparison was compiled from information submitted by our customers. Project criteria used to prepare this analysis: Cleaning Project Ground storage tank - 40 high x 150 dia. (exterior surfaces) = 36,000 ft² Cleaning Specifications Commercial Finish - 3 mil Profile Media Hand Blast - Black Beauty - $0.13/lb. - 5 lb / ft² FasterBlaster - S330 Steel Shot with 20% GS-25 Steel Grit - $.57/ lb lbs / ft² Blasting Production * Hand Blast ft²/ hr /6 men Total: 4 hr 2 $12/ hr - 8 hours/ day - 11 days total * FasterBlaster ft²/hr 1.5 $18 / hr (1 Blaster on walls) (1 Blaster and 1 $12/hr helper for the roof )- 6 days total Power Hand Blast cfm Air Compressor FasterBlaster kw Generator (unless plant power is available) * Labor rates shown above do not include overhead and are average hourly pay rates. Rates will vary depending on company, region, unions, etc. The cost analysis below covers approximately 97% of the tank surface. Approximately 3%, which includes pipes, ladders and other cut ins, will have to be completed with at least one hand nozzle and perhaps some small containment. Labor Media Rental Fuel Clean Up Disposal Maintenance Hand Blast (11 Days) 4 Blasters $ Tenders $ 2112 $ ,000 lb Black $ 0.13 / lb $ Delivery $ cfm Compressor For 2 Weeks $ $ 4.00 / gal Fuel for 11 days $ $ 75 / ton Disposal fee $ 6750 Transport/Testing $ 2400 $ / ft² $ 1152 FasterBlaster (6 Days) 1 Blaster (Walls) $ Blaster / 1 Helper (Roof) ---- $ 480 $ 1056 (1) 2000 lb Drum of $ 0.57 / lb $ 1140 (includes delivery) 100 kw Generator For 1 Week $ $ 4.00 / gal Fuel for 6 days $ $75 / ton Disposal fee $ 150 $ 100 $ / ft² $ 540 Total Costs $ 57,190 $ 5,522 Additional Cost Saving Considerations Containment can be a major cost that has not been considered in this analysis. Many projects today require containment. None is required when using the FasterBlaster. Painting can be conducted during the blasting process since there are no dust emissions from the FasterBlaster. Very little blast is lost due to rain. With the time savings advantage of the FasterBlaster, more projects can be completed during the year. Generator rental and fuel cost can often be eliminated if plant power is accessible. Labor and equipment cost for clean up of the hand-blasted disposable waste was not included in this analysis. There is no clean up required with the FasterBlaster operation. 1

3 Features and Services Others Don t Have Wireless Hand-Held Remote Control Operation. Blast Cleans both Vertical & Horizontal (one machine). Blast Cleans Pipe (External & Internal). Blast Cleans in all Directions- Up, Down, Forward, Reverse. (No Turning Around Required) Blasting & Painting Simultaneously. Blast Cleans Internal Walls of Tanks. Remote Controlled Shot Adder. Suction Cup Type Seal. (Zero Emissions) Fixtures for Cleaning all types of Tanks, both Internal and External Surfaces. (Cone, Dome, Knuckle, Floating, Geodesic) C-Frame Fixture for Cleaning below Stairways. Variable Frequency Drive for KleanVac Dust Collector Fan. Automatic Containerized Disposable Waste System. Fits through a 24" Diameter man way. Drive System to move the KleanVac Dust Collector around the tank. Repairable Wear Parts. All Components made in USA. All Components in stock for overnight shipment. Engineering Services for Special Application Fixtures. Engineering Certification on all support fixtures. Video Tutorials on Operation and Maintenance. 2

4 How do we compare? See a Video explanation of the Talking Points TANK Imitated But Never Duplicated See Our Equipment In Operation CLEANING Walls Floors Roofs PIPE CLEANING All sizes See MORE VIDEOS at & Talking Points Video Talking Points Ask our competitors : 1. Do I have to buy an additional machine to clean tank roofs and floors? 2. Does your vertical blast machine do anything other than clean vertical walls? 3. Can your vertical machine clean up and over a dome roof? 4. What is the size and weight of the remote control? How many remotes are required to operate all functions of the machine? 5. Can your vertical machine fit through a 24 diameter manway? Can your vertical machine clean internal walls and floors of tanks? 6. Where are the electrical control panel locations? Are they on the ground for access at all times or on the machine? 7. Can the operator easily pull the dust collector around the tank? Do you offer a drive assist for moving the collector? How do you move the collector? 8. Are the power cables between the machine and the generator furnished with the machine? Are they 300 long? 9. How do you remove spent waste and lead paint from the dust collector? Do you have to handle bags of dust or manually shovel out pans? 10. Do your shot valves require adjustment? Do they have to be closed before shutting down the machine? What do you do if a valve malfunctions? How long does it take to get a replacement? 11. How many hoists are used and how are they synchronized? Are the controls on the ground or on the machine? What happens if one malfunctions? How long would it take to get a replacement? Is there a safety backup system if the hoist gears should fail? 12. Can you paint near the machine while blasting? 13. How do you clean areas under stairways? 14. Does your floor machine blast going forward and backward or do you have to turn the machine around with every pass? Does it use a wireless remote control or do you walk behind the machine to steer? 3

5 (compare these features with other machines on the market) Versatility Blast cleans tank floors, roofs, internal walls, external walls, wind towers, pipe, plate and concrete floors. Blast cleans dome roof and knuckle roof curved areas. Flexibility Blast cleans floors or plate while moving either forward or in reverse. Blast cleans walls while moving both up and down the wall. Blast cleans close to vents, pipes, and other obstructions. Emission Control The suction cup seal allows no emissions; therefore, no containment is required. Painting can be conducted during the blasting operation. This allows more work to be accomplished in less time, lowering cost and increasing profits. Ease of Operation The operator starts the blast and simply drives and steers the machine from a wireless hand held remote control. Light Weight (FasterBlaster16) Great for blast cleaning tank roofs. Easy to transport and maneuver around obstacles. High Power FasterBlaster16-30 HP Blast Motor provides a 16 wide blast pattern. FasterBlaster32 - (2) 30 HP Blast Motors provide a 32 wide blast pattern. Special Blast Wheel Large 16 diameter blast wheel (1 for the FasterBlaster16, 2 for the FasterBlaster32). Increases shot velocity and rebound. Operates with 100% grit (without dumping). Can pick up and reclaim shot left on floor. 4

6 Low Cost Operation 55 gallon drum of steel shot ($ ) cleans approximately 36,000 ft² (a typical 150 diameter x 40 tall tank side-wall and roof at commercial to near white cleaning). No containment required. No clean-up required. Uses electric generator rather than compressed air (about $600.00/ wk. rental). One man operation. Maintenance cost $.01 per ft². 2 to 3 drums (55 gallon) total waste disposal for a typical tank. Production rates equal to 3 to 6 hand blasters. Direct Blast Technology Greater production rates- 700 to 1000 ft² / hour on new steel or painted steel depending on surface conditions, type and thickness of paint and cleaning specifications. Provides Brush Off blast (SSPC-SP 7/ NACE No. 4), Commercial blast cleaning (SSPC-SP 6/ NACE No. 3), Near White metal blast cleaning (SSPC-SP 10/ NACE No. 2) and White metal blast cleaning (SSPC-SP 5/ NACE No. 1). Provides 2 to 5 mil profile depending on the size of steel shot used. No Castings Blades, control cage, impeller and liners can be repaired with stainless or hard face welding rod. Wear components will not shatter if a foreign object goes through the blast wheel. Simple Seals All seals are sheet rubber and can be quickly repaired in the field. No magnetic seals, brushes or special molded seals. Wireless Remote Control Operator can keep the machine running while handling the hoses and adding abrasive. Operators take fewer breaks due to the ease of operation. The FasterBlaster process is truly a one-man operation. Compact Design Breaks down to fit through a 24 diameter tank opening. Break down and reassemble in less than 2 hours. 5

7 All Components are Compatible The FasterBlaster16 and FasterBlaster32 utilize the same KleanVac Dust Collector and electrical panel. Both machines can be used with all Fixtures. Can be purchased without the KleanVac Dust Collector and electrical panel. The same blades, impellers, control cages, liners, drives, hubs, and motors are used on both machines. KleanVac Dust Collector Automatically deposits paint and dust into 55 gal. drum. Eliminates manual handling of lead dust. Incorporates large pneumatic tires for ease of movement. Incorporates a variable speed fan drive. Vacuum can be increased when longer exhaust hoses are required or when blasting heavy weld seams. Vacuum ranges from 40 to 60 of water column (equivalent to 74.7mm to 112.1mm of Hg). Features an automatic filter cleaning system with adjustable timers. Includes 9 fire retardant Torit Ultraweb cartridge filters. Houses the Main Electrical and Remote Control System Full Complement of Attachments Available Pipe Cleaning Attachments. Hoist System for vertical cleaning. Cone Roof Fixture for cleaning all flat, cone, dome or knuckle roof tanks, both internal and external surfaces. Floating Roof Fixture for cleaning open roof tanks, both internal and external walls. C-Frame for cleaning below stairways and other wall obstructions. Shot Adder for adding shot by remote control. Trolley Drive System for blast cleaning internal tank walls. Spare parts kits. 6

8 Services and Support Time Tested System RBW Enterprises, Inc. has been manufacturing portable blast cleaning machines since RBW Enterprises is a family owned and operated business. The company president, Robert Watkin, former vice president of Research & Development for the Wheelabrator Corporation, has over 50 years of blast machine design experience. Over the last several years, this engineering and manufacturing knowledge has been handed down to six family members who manage the daily operations and support the highly skilled manufacturing staff. Mr. Watkin continues his work on developing new and innovative products for the blast cleaning and painting industry. FasterBlasters, by RBW Enterprises, are cleaning tanks, wind towers, plate and pipe in refineries, tank farms, and plants around the world. FasterBlasters are operating in the USA, Canada, Trinidad, Venezuela, Columbia, Panama, Australia, Turkey, Thailand, Netherlands, Nigeria, South Africa, Aruba, Puerto Rico, Jordan, Mexico, Brazil, Ecuador, India, Chile, Jamaica, Saudi Arabia, Guatemala, Argentina, Iraq, Mongolia, Peru, and Curasao. Engineering Services We provide engineering for special fixtures, attachments or material handling systems required for special applications. Customer Support RBW Enterprises is known in the industry for superb customer service and technical support. Technical personnel are on call 24 hours a day, seven days a week. All parts for the FasterBlaster are in stock and can be shipped the same day. Field support and training is available from highly qualified technicians. RBW Enterprises provides a comprehensive Operation, Maintenance and Safety Manual, and a series of training video links covering all aspects of FasterBlaster operation and maintenance. For additional details and specifications, please see the FasterBlaster Videos and Brochures on our web site: www. rbwe.com and our Video Library at 7

9 Shot Blast Machines The FasterBlaster is the only machine on the market that can blast clean both vertical and horizontal surfaces and pipe. The system is used throughout the world for cleaning water tanks, petro chemical tanks, wind tower sections, plate and pipe. The unit has a flat mat seal that creates a suction cup affect against the wall, roof or floor surface. The seal vacuums tightly over weld seals. There are no emissions, therefore, paint can be applied near the operating machine. There is no clean up required and the total disposable waste is a few drums of paint dust, metallic dust, rust, and media fines. The unit is operated by one man from a wireless hand held remote control. The FasterBlaster16 is 30 wide x 60 long x 60 high and weighs 1200 lb The FasterBlaster16 has a 16 wide blast pattern and is used to clean close to obstructions, closer to the ground, enter through small 24 diameter openings with less disassembly and clean roofs where weight is a concern. The FasterBlaster32 is 59 wide x 56 long x 59 high and weighs 2200 lb The FasterBlaster32 provides a 32 blast pattern and is used for the large wide open areas where higher production is needed. Both machines can break down to go through a 24 diameter opening and clean the internal walls of tanks as well as the tank floor. 8

10 Vertical External Wall Cleaning Click the link or Scan for Videos Vertical Blast Cleaning Vertical Blast Cleaning- Domed Roof FasterBlaster 32 FasterBlaster 32 FasterBlaster 16 FasterBlaster 32 FasterBlaster 32 Vertical Internal Wall Cleaning Click the link or Scan for Video Internal Tank Wall Cleaning 9

11 Horizontal External Roof Cleaning Click the Link or Scan for Video Roof and Floor Cleaning Roof and Floor- Spanish Horizontal Internal Floor Cleaning FasterBlaster 32 FasterBlaster 32 FasterBlaster 32 FasterBlaster 16 FasterBlaster 16 FasterBlaster 16 10

12 Painting and Blasting Simultaneously Click the link or Scan for Video Painting and Blasting Painting and Blasting- Spanish The Entire Process- Spanish 11

13 Floating Roof Fixture (Internal Cleaning Adapter) The NEW, Patent Pending, Floating Roof Fixture Internal Cleaning Adapter can be used to support the FasterBlaster to clean both the external and internal vertical surfaces of a floating roof tank. The fixture operates as described on page 19 (as seen in Figure A). Figure B shows the fixture supporting the machine cleaning the internal surface of the wall. The fixture adapter allows the machine to be lifted to the top of the wall, cleaning a greater area. If you currently have our Floating Roof Fixture, it can be easily modified to clean internal surfaces by adding the Internal Floating Roof Adapter shown in Figure C. Pat. 9,599,282 Figure A Figure C Figure B 12

14 Pipe Cleaning Click the Links or Scan for Videos Large Pipe Cleaning Job Site Pipe Cleaning Pipe Cleaning Blasting en Tuberia 13

15 Pipe Cleaning Attachment Options You may already have a way to support the machine and to support, rotate, and move the pipe. An overhead monorail or fork lift can be used to support the machine, or you can purchase the machine support structure shown below. The support structure has hand crank hoists to raise the machine to the proper level for cleaning varied sizes of pipe. The hoists are supported by trolleys which are positioned by ratcheted straps to keep the machine pulled into the proper position against the pipe. If you don t have a pipe conveyance system, drive stands, idler stands, and channel tie braces are available. All stands are self-supporting with the tie channels in place. Each stand supports two solid hard rubber tires which can pivot from 0 to 30 degrees to impart both radial and lineal movement to the pipe. The pipe movement operations are controlled from the wireless hand held remote control. All stands are placed on approximately 15 centers with the machine support frame between the two center stands. This arrangement works well for pipe lengths of 40. Additional stands may be required for shorter or longer pipe sections. Trolleys Hand Crank Hoists Machine Support Structure Ratchet Straps long Channel Stand Braces with bolting pads and hardware (12) required Conveyer Drive Stand (4) Drive Stands are recommended (2) at each end of the machine Idler Stand (2) Idler Stands are recommended (1) at each end of the machine 14

16 Pipe Cleaning Options Small Size Pipe The standard floor and wall seal assembly that comes with the machine can be used to clean large diameter pipe 30 and up. Special seals can be purchased to clean smaller diameter pipe. The standard floor and wall cleaning seal is flat and has the capability of creating a small curvature for cleaning the large pipe. The special seals for smaller pipe have a built in curvature. Special Seals Use Standard Floor and wall seal for 30 and up 8 to 12 pipe seal assembly 12 to 20 pipe seal assembly 20 to 30 pipe seal assembly Very small diameter pipes require a special seal box which houses quick change seals for each pipe diameter processed. The seal box can handle 0.5 to 6 pipe and is made of manganese steel and has replaceable liners and guide funnels for extended wear life. (pipe funnels not shown). Seal Box System for small pipe 0.5 to 6 diameter Small Pipe Box Click the link or Scan for Video 15

17 Pipe Cleaning Machine Support Structures We offer two Machine Support Stands for pipe cleaning. The Driven Machine Support Stand is designed to roll the pipe in place while the machine moves along the length of the pipe. The machine support is driven along a V-rail while the pipe is rolled. This can be used in plants with limited room. The wheels on the drive and idler stands can be adjusted to convey the pipe past the FasterBlaster with our Stationary Machine Support Stand. The speed that the pipe moves past the machine is controlled by the angle of the tires on the drive stands. With both machine support stand systems, the rotation rate of the pipe is adjustable to meet your cleaning requirements. Driven Machine Support Stand for stationary pipe roller stands Stationary Machine Support Stand for use with pipe conveyor system 16

18 Wind Tower Cleaning Click the Link or Scan for Video Internal Pipe Cleaning 48 inch pipe 48 inch pipe 17

19 KleanVac Dust Collector The KleanVac Dust Collector is the heart of the FasterBlaster system. It supports the main electrical panel and provides high vacuum for the FasterBlaster machine. All the paint and dust removed from the surface automatically enters the 55 gallon drum. When the drum is full, it is lowered to the ground by two ratchets and the KleanVac Dust Collector is pulled forward away from the drum. A new drum is attached and the old drum is capped. At the end of the job, the total disposable waste is 2 to 4 drums, depending on the thickness of paint removed and the size of the tank. The unit houses (9) Torit Ultraweb fire retardant cartridge filters that are rated similar to HEPA. The filters are automatically cleaned by an air pulse system that can be adjusted for pulse timing and duration ( (2) cfm air supply is required to pulse the filters). A magnehelix gauge is provided to monitor the condition of the filters. The unit has an air cooler and water extractor to help dry the air supply for the pulse system. The vacuum is provided by a 15 hp variable-frequency fan, which allows for vacuum increase if more than 100 of exhaust hose is used. Large foam-filled tires make it easy to pull the unit around the tank. The machine electrical panel and remote control system is included with each KleanVac Dust Collector. KleanVac pricing varies depending on the electrical system options listed below. The KleanVac, with the silencer, is approximately 5.5 wide x 6.5 long x 6.5 high and weighs approximately 1500 lb. KleanVac Dust Collector and KleanVac Electrical Panel options: 16/32VHP (2) Blast Wheel Operation including vertical, horizontal, and pipe functions. 18