Field Operator Certification
Air Blasters
Lesson Plan
Air Blasters – Lesson Plan
Air Blasters Lesson Plan
Instructor Notes
Lesson Preparation
Review your Lesson Plan materials for this Lesson and become familiar with the content. Consider adding your own plant
specific information where appropriate and/or deleting content that may not apply to your plant.
Review the PowerPoint slides for this Lesson and where appropriate add in your own slides showing specific Air Blasters in your
own plant. Consider having a an actual air blaster or its components in the classroom for clarification.
Review the Learner Guide for this Lesson, paying particular attention to the Troubleshooting and Inspection sections and ensure
that you have your own copy of the Learner Guide. Although the Inspection procedures will not be covered in detail during the
lesson, they need to be review from the Learner Guide, and the participants need to be told that Inspections form part of the on-
the-job (OJT) component.
Print out the required number of copies of the Learner Guide to ensure that each participant receives a copy.
Lesson Equipment & Materials
Air Blasters Lesson Plan
Air Blasters PowerPoint slides 1-26
Air Blasters Learner Guide
Air Blasters Certification Guide
Flipchart easel & paper or whiteboard
Flipchart markers or whiteboard markers
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Air Blasters – Lesson Plan
Notes
This Lesson should take approximately 60 minutes to complete in a standard classroom format
Once you have completed the Lesson, consider taking the participants on a ‘field trip’ in the plant to view and further discuss Air
Blasters in your plant
Remember to use “B” or the period to pause and blackout your PowerPoint slides when you need to spend time on a particular
point. Click on your mouse to re-activate the PowerPoint presentation back to the current slide
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Air Blasters – Lesson Plan
Lesson Objectives
Topic Instructor Activities Graphic/Slide
Have the Lesson Plan introductory slide showing at the beginning of Slide #1
the training session
If this is your first lesson, welcome the class and ensure that an
appropriate introduction of both participants and yourself takes place
Also let participants know approximately how long this lesson will take
to complete (~60 minutes)
Transition to the next slide and review the Lesson Objectives
Objectives Display slide and review lesson objectives Slide #2
1 – 2 mins
Note to participants that this list covers all objectives (both in-class/self-
paced and on-the-job objectives). Note that performing inspections will
be part of the OJT
1. State the purpose of Air Blasters
2. Name the main components of Air Blasters
3. Explain the principle of operation for Air Blasters
4. State the applications for Air Blasters in cement manufacturing
5. Describe the running and static inspections for Air Blasters
6. Describe the troubleshooting for common Air Blasters problems
7. Identify safety hazards associated with the operation of Air Blasters
8. Perform a running and a static inspection on an Air Blasters (OJT)
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Air Blasters – Lesson Plan
Objective 1 – Purpose
Topic Instructor Activities Graphic/Slide
Purpose If your participants are experienced Field Operators, consider asking Slide #3
1 – 2 mins them what the purpose of Air Blasters are and then, using the slide,
reinforce the learning content. Note that the slide shows an Air Blaster
in operation
If your participants are not experienced Field Operators, using the
slide, explain the purpose of Air Blasters
The purpose of the Air Blaster is to remove build up in order to ensure the
proper flow of gases and material
Ask your participants to identify the location of Air Blasters in the
plant
Capture the information on flipchart paper and confirm and complete
as required
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Air Blasters – Lesson Plan
Objective 2 – Components
Topic Instructor Activities Graphic/Slide
Component List Display the graphic of the Air Blaster to identify its’ main components
10 mins and review the list OR
Ask the participants to list the components of the Air Blaster. Write
down the components that are identified on the flipchart or whiteboard
and then review the list using the slide.
NOTE: The Learner Guide lists all the components and also provides Slides #4-8
descriptions of each component. For the purposes of the lesson, do not
review each component in detail; simply present and discuss the
complete list. Give participants a moment to review the list in their
Learner Guides and answer any questions as required.
Air Receiver Tank
Pressure Relief Valve
Pressure Gauge
Isolation Valve
Discharge Pipe
Discharge Nozzles
Valve Body or Conical Head
Piston
Coil Spring
Conical Head Cover Plate
Quick Exhaust Valve
Solenoid Valve
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Air Blasters – Lesson Plan
Objective 3 – Principle of Operation
Topic Instructor Activities Graphic/Slide
Consider having learners explain the principle of operation for an Air
Blaster while you capture their information on flipchart paper.
Supplement the information provided with the content below.
Alternatively, present the information as outlined below using the
appropriate slides
Operation Use the slides to explain the principle of operation for an Air Blaster Slides #9-12
10-15 mins NOTE the following:
Slide 09 shows a Blaster charging sequence
Slide 10 shows the flow of compressed air in the conical
Slide 11 shows a Blaster ready to discharge
Slide 12 shows a firing sequence
Compressed air from the plant’s distribution system is conditioned with
light oil and is then introduced through a solenoid control valve and check
valve into the quick exhaust valve attached to the conical head
The compressed air, in combination with spring pressure, forces the piston
in the quick exhaust valve against its seat
The compressed air then forces its way around the piston and fills the void
space in the conical head
In exactly the same manner as the quick exhaust valve operation, the
compressed air in combination with spring pressure forces the main piston
in the conical head against its seat
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Air Blasters – Lesson Plan
Objective 3 – Principle of Operation
Topic Instructor Activities Graphic/Slide
The compressed air then forces its way around the piston and begins to fill
the air receiver tank
Once the pressure in the receiver tank is equal to that of the supply pressure,
the blaster is ready to discharge
In order to initiate the discharge of the Blaster, the solenoid valve is
automatically or manually activated in order to vent the air under pressure
behind the piston of the quick exhaust valve
Once the air is vented from behind the piston in the quick exhaust valve, it
opens a large path to vent the compressed air from behind the main piston
in the conical head
Once the pressure is evacuated from the conical head, the piston is driven
off its’ seat by the pressure inside the receiver tank
This in turn opens a large path to vent the entire receiver tank through the
discharge pipe
The compressed air directed through the discharge pipe into the build up
enters at a rate faster than the material can absorb
This creates an explosive effect that removes the build up
The duration between the initial triggering and the complete evacuation of
the compressed air in the Blaster is measured in milliseconds
Once the receiver tank is completely exhausted after discharge, the springs
in the conical head and quick exhaust valve force the pistons against their
respective seats and the cycle of filling the reservoir repeats
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Air Blasters – Lesson Plan
Objective 4 – Applications
Topic Instructor Activities Graphic/Slide
Applications NOTE the following: Slides #13-14
1-2 mins
Slide 13 shows a picture of a blaster used in a kiln Riser.
Slide 15 shows a graphic of a blaster used in a clinker cooler
State the following to participants
In cement manufacturing, Air Blasters can be used wherever build up
impedes the flow of material or gases in the process
This includes:
Raw material storage bins
Finished product storage silos
Clinker coolers
Kiln smoke chambers
Cyclone discharge cones and material chutes
Risers of the Preheater
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Air Blasters – Lesson Plan
Objective 5 – Inspections
Topic Instructor Activities Graphic/Slide
Running & Static Notes to Instructor: Slide #15
Inspections
The full inspection procedure will be carried out during the OJT part of this
10-15 mins
training. The section is included to allow a brief discussion of what is
involved in inspecting Air Blasters, both from a running and static
inspection perspective.
Establish a rationale for inspecting equipment if this has not been done
in a previous lesson
Create a series of flipchart pages with the following titles. Running
Inspection
Running Inspection
Static Inspection
Ask participants to close their Learner Guides and brainstorm a list of
inspection points for each type of inspection and record the information
on the flipcharts. Allow ~10 minutes to complete this activity.
Once the lists are completed and have been discussed as a group, ask
participants to review the inspection checklists provided in their
Learner Guides. Allow 5 minutes for this review. Tell participants
that they will be performing full inspections as part of their on-the-job
training and that they will also be tested on their understanding of the
various steps that comprise a full inspection procedure.
Discuss any questions participants have about inspections
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Air Blasters – Lesson Plan
Objective 6 – Troubleshooting
Topic Instructor Activities Graphic/Slide
Troubleshooting Ask participants to review the troubleshooting information their Slide #16
10-15 mins Learner Guides
For the following common problems, ask participants possible reasons
explain the problem and what actions would be required to fix the
problem. Record their information on flipchart paper or on a
whiteboard and supplement as required
Blaster does not charge
Charged Blaster will not fire
Alternatively, you could also have participants divide into groups of 2-3
to complete this activity. For both problems, have each group record
the reason and the action that should be taken to rectify the problem on
flipchart to then be reviewed in plenary session
Once complete, allow participants 10 minutes to review the
Troubleshooting section of their Learner Guides and note to
participants that they will be tested on troubleshooting
Answer any questions that participants may have on troubleshooting
prior to moving to the next topic
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Air Blasters – Lesson Plan
Objective 7 – Safety
Topic Instructor Activities Graphic/Slide
Safety As an interactive class activity, have participants suggest Safety
5 mins Concerns related to this equipment
Have participants write this information in the Safety section of their
Learner Guide
Ensure that the following points have been made and add any other
safety concerns pertinent to your plant operation
The high kinetic energy associated with a Blaster can be fatal for any person Slides #17-18
standing in front of the discharge
Never enter a vessel configured with a blaster/s without properly locking it
out. Lock out must always include:
Isolation from compressed air supply
Blaster receiver tank drained and valve held (locked) in the open
position
Air Blasters very often blast into pressurized vessels with gas temperatures
reaching 1200C. Blow back of high temperature material and gases can
create a serious burn hazard
All surface temperatures of ducts and pipes are very hot
Strictly follow the safety procedures when inspecting and cleaning vessel
internals
Ensure proper personnel protective equipment under all circumstances
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Air Blasters – Lesson Plan
Objective 7 – Safety
Topic Instructor Activities Graphic/Slide
Keep the work area clear of grease, oil, water, and other objects that could
cause a slip or a fall
Report all unsafe conditions or practices immediately
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Air Blasters – Lesson Plan
Lesson Review
Topic Instructor Activities Graphic/Slide
Lesson Review Test for understanding by having participants complete the Review Slides #19-25
10 mins Exercise in their Learner Guide. Ask participants to attempt to
complete the questions without the aid of the information in their
Learner Guides
Review the answers as a class activity and ask participants to provide
answers to the questions. Supplement their answers with the slide as
indicated.
Ask participants to provide answers to the questions
NOTE: Each question is contained on one slide. The answer
information is ‘animated’ on the slide and will be activated as you click
your mouse.
1. What is the purpose of an Air Blaster?
2. List 5 components of an Air Blaster
3. What is the purpose of the spring in the Blaster’s valve body?
4. Where are Air Blasters used in the cement industry?
5. Describe 3 conditions that could explain why a Blaster that is fully charged,
would not fire.
6. Describe 4 running inspection points for an Air Blaster.
7. List 3 safety hazards associated with Air Blasters.
Clarify any misunderstandings with these questions
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Air Blasters – Lesson Plan
Lesson Review
Topic Instructor Activities Graphic/Slide
Summarize the lesson, ask for any final questions and answer as
required
End the lesson
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