_Airdryer

Hkkjr ljdkj jsy ea=ky;

GOVERENMENT OF INDIA

MINISTRY OF RAILWAYS

MAINTENANCE INSTRUCTIONS FOR HEATLESS REGENERATIVE TWIN TOWER TYPE COMPRESSED AIR DRYER FOR DIESEL -ELECTRIC &

ELECTRIC LOCOMOTIVES, EMUs / MEMUs AND DEMUs APPLICATION

Report No. MP.MI-18

REV. - 02, April - 2008

pkyu 'kfDr funs’kky;

vuqla/kku vfHkdYi ,oa~~ ekud laxBu y[kuÅ & 226 011

Motive Power Directorate

RESEARCH DESIGNS & STANDARDS ORGANISATION

LUCKNOW - 226 011

CONTENTS

S.No Title Page No.

1. INTRODUCTION 1

2. SCOPE OF MAINTENANCE INSTRUCTIONS 2

3. DESCRIPTION OF WORKING OF AIR DRYER 4

4. VARIOUS MAKES OF AIR DRYER FOR LOCOMOTIVES 10

5. MAINTENANCE SCHEDULES OF AIR DRYER 10

6. PRECAUTIONS TO BE TAKEN DURING INSTALLATION, MAINTENANCE AND OPERATION OF AIR DRYER

23

7. TROUBLE SHOOTING OF AIR DRYER 23

8. ANNEXURE-I 26

9. ANNEXURE-II 27

10. ANNEXURE-III 28

11. ANNEXURE-IV 39

12. ANNEXURE-V 40

Maintenance Instructions For Heatless Regenerative Twin Tower Type Compressed Air Dryer For Diesel-Electric & Electric Locomotive, EMU/MEMU & DEMU Application

Maintenance Instructions For Heatless Regenerative Twin Tower Type Compressed

Air Dryer For Diesel-Electric & Electric Locomotive, EMU/MEMU & DEMU Application

1. Introduction 1.1 Compressed air is used on Diesel-Electric & Electric locomotives, EMU/MEMU &

DEMU for brake system and operation of other auxiliary devices. The compression cycle of ambient air includes compression in locomotive compressor and then cooling in after cooler. During compression, pressure & temperature of ambient air increases but its relative humidity decreases. However, absolute amount of the moisture present in the air remains same. After compression when the air is cooled in aftercooler, it becomes saturated and condensation takes place. This condensed moisture is drained out from main reservoirs. A major portion of moisture is removed in this process, but water still remains present in the form of vapour in the compressed air. This water vapour condenses in air brake equipment/valves, air pipes and auxiliaries during train operation. The condensation which takes place in air valves and air pipes leads to following problems:- i) Malfunctioning of air valves due to rusting. ii) Sluggish operation of moving parts of the valves. iii) Poor performance of the valves due to washing away of the lubricant. iv) High flow resistance and pre-mature blocking of filters. v) Rusting of air pipes. vi) Poor performance and low life of rubber components of the valves. vii) Sticky and greasy accumulation on the components of the air valve. viii) Freezing of the water droplets when ambient temperature drops below

freezing point. ix) Choking of small chokes and strainer in the valves .

1.2 Condensation of water vapour in brake circuit can be overcome if dew point temperature of compressed air is reduced This can be achieved by reducing moisture content of compressed air by adsorbing the water vapour in air dryers. On Diesel-Electric & Electric locomotives, EMU/MEMU & DEMU heat less regenerative twin tower compressed air dryer is used. This type of air dryers use desiccant to adsorb the moisture. Desiccant used is normally in the form of granules. Each granule of desiccant may be considered as a vast honeycomb of very small pores. These pores give desiccant a very large internal surface area which attracts and absorb moisture. However, after some time, desiccant is completely saturated and no longer capable to adsorb moisture. Therefore, water adsorbed is to be given away from its pores by reactivation. This process is called regeneration. On the heatless air dryer used on the system, regeneration of saturated desiccant is done by drying it by dry air

MP.MI-18 Rev. - 02, April-2008 Page 1 of 40


(regenerative air). For this a small quantity (10 to 20 %) of the air dried by the desiccant is used. Rest of the dried air is used for braking operation.

1.3 The following specifications have been issued for air dryers for different applications

from time to time:

S. No. Specification No. Applications (a) MP.0.0102.01 For diesel locomotives (b) MP.0.0155.01 For electric locomotives (c) MP.0.01.00.06 For diesel & electric locomotives, superseding the above

specification (d) MP.0.01.00.09 For EMUs / MEMUs & DEMUs (e) DLW GM P. L.

No. 17450810 For WDG4 / WDP4 EMD design locomotives

(f) CLW/MS/3/041 For WAG9 / WAP7 / WAP5 locomotives (g) MP.0.01.00.06

(Rev.0.03), March-2007

Diesel-Electric, Electric locomotives (including High HP Dsl- Elec. & Electric locos.), EMUS/ MEMUs & DEMUs (Present specification, superseding all the earlier specifications)

1.4 Maintenance manuals of various makes of air dryer, prepared by respective manufacturers are available. Railways / PUs should insist for supply of maintenance manual with air dryers. As per clause No. 8.1 of combined specification mentioned above the supplier has to supply one maintenance manual with every set of five air dryers.

1.5 Air dryers are being used for last appx. 10 years. Based on the experience gained during this period, these instructions for maintenance of air dryers are being revised to increase awareness about working of air dryer and to bring uniformity in maintenance schedules to be carried out on air dryer.

2. Scope Of Maintenance Instructions

Description of working of air dryer

Various makes of air dryers for locomotives Maintenance schedules of air dryer

Precautions during installation, maintenance and operation of air dryer



Trouble shooting

Testing

This maintenance instruction supersedes earlier maintenance instruction MP.MI-18, Rev. 01, August-2006 for heatless regenerative twin tower type compressed air dryer for diesel/electric locomotive application.



3. Description Of Working Of Air Dryer

There are many manufacturers for heatless regenerative twin tower air dryer. Among various designs, there are some differences in design and features. However basic principle of working of such air dryers remains same. Important components and operation of a typical twin tower heatless regenerative air dryer used on locomotives is described below.

3.1 System Components of a typical Air Dryer 3.1.1 Pre-Coalescer:

A borosilicate or other type of element designed to restrict and collect tiny aerosol contaminants, primarly oil and other contaminants, which may prove detrimental to the successful operation of any form of desiccant.

3.1.2 Desiccant Tower

The desiccant beads, which extract the moisture from the air, are housed in two towers. These are also called desiccant towers.

3.1.3 Pressure Switch An integral pressure sensing device is located internally to control the air drying cycle. The air dryer cycles only when the predetermined pressure is reached. If an emergency arises and air pressure drops below the pre determined level cycling stops immediately and air flows through the air dryers to support the immediate air requirements.

3.1.4 Purge valve

There is one purge valve located at the bottom of each desiccant tower. Alternatively, there is a common purge valve connected to both desiccant towers. Purge valve allows the regenerative air to discharge moisture through the desiccant tower to atmosphere.

3.1.5 Humidity Indicator

A colour indicator is located at each outlet check valve as a visual indication to monitor the condition of air after passing through each desiccant tower. Alternatively, there is a common humidity indicator is located at the outlet of final filter.

3.1.6 Final Filter

This is a unit, which removes any dust generated after the air has passed through the main dryer system. Alternatively, desiccant may be supplied in a fabric cloth bag, which can act as final filter. In such cases, separate final filter will not be required.



3.2 Operation of air dryer (Fig 1)

Compressed air after main reservoir (1) of diesel locomotive (MR-2 in case of electric loco) passes through a pre-coalescer filter (2). This removes significant amount of debris, moisture and oil from the compressed air. After pre-coalescer filter air enters into the actuator (3), which decides the entry of air to either of two desiccant towers (4a and 4b). Position of actuator is controlled by timer unit (5). For example, in a particular cycle, wet air enters from the bottom of the tower (4a) and passes through desiccant bed where moisture is adsorbed by the desiccant. Dry air with dew point less than ambient temperature comes out from the top and finally goes out of dryer to final filter (6). Final filter removes traces of desiccant powder, if any, from the dry air and air then goes to main reservoir-2 (7) of diesel locomotive (MR-3 in case of electric loco).

A small part of the dry air (10-20% of inlet air capacity) is drawn from the dry air outlet of tower (4a) and is passed through regenerative orifice of non-return valve (8) and on to the desiccant bed of the other tower (4b). It removes the moisture collected in the second tower and thus reactivates the desiccant. The moisture laden air is vented through exhaust valve which is also called purge valve (9). Thus in this cycle tower (4a) works as dehydrating tower and tower (4b) works as regenerative tower. After completion of this cycle the working of two towers reverses and now the tower (4a) works as regenerative tower and tower (4b) works as dehydrating tower. In this way two towers alternatively work as dehydrating/regenerative towers. This reversal takes place after a predetermined time period. This is called cycle time of the air dryer. Cycle time of air dryer is normally 1 to 2 minutes.

3.3 Other Modifications

i. Modification in pneumatic pipelines on locomotive to supply dry air to auxiliaries.

ii. Modification of EPG to reduce failure of pressure switch

Change in location of pressure switch Use of improved type of pressure switch on EPG

iii. Changes in electrical circuit of air dryer to incorporate memory feature and to achieve synchronous operation of air dryer fitted on locomotives operating in multiple units.

iv. Removal of by-pass arrangement

Modification Sheet No. MP MOD.BK.-05.27.00 Rev.00 dt. 30 08. 2000 may be referred.



4. VARIOUS MAKES OF AIR DRYER FOR LOCOMOTIVES

Till date, air dryers supplied by M/s SAB WABCO, Harita/Hosur , M/s Stone India Limited, Calcutta and M/s Knorr-Bremse India Limited, Faridabad have been ecommended either for regular use or for extended trials. r

Model numbers of air dryer of the above suppliers are given below:

4.1 D&M (Graham-White) make series 975-123 air dryers supplied by M/s SAB WABCO, Harita/Hosur are being fitted on diesel locomotives. Based on the tests conducted on air dryer in RDSO, a regenerative choke of 0.11" with memory feature has been recommended for diesel locomotives. Earlier on diesel locomotives, air dryers were fitted without memory feature. To provide these locomotives with memory feature, Railways can contact the supplier to supply new printed circuit board (PCB) with memory feature.

D&M (Graham-White) make series 975-124 air dryer with regenerative choke size of 0.0625" with memory feature has been recommended for fitment on electric locomotives. Air dryers already fitted on electric locomotives have memory feature. Therefore, there is no need to change PCB on air dryer already fitted on electric locomotive.

4.2 WABCO vaporid air dryers supplied by M/s Stone India Limited, 16, Taratalla Road,

Calcutta-700 088 have been recommended for use on diesel locomotives.

4.3 Air dryer Model No.LTZW-5000 supplied by M/s Knorr-Bremse India Limited, 14/6 Mathura Road, Faridabad has been recommended for extended trials on diesel locomotives.

Air dryer Model No.LTZW-15.2 supplied by the above firm has been recommended for extended trials on electric locomotives.



Schematic Diagram of FTIL Make Air Dryer



Schematic Diagram of SIL Make Air Dryer



16Knorr-Bremse India, November 2004

Schematic Diagram of Knorr Bramse Make Air Dryer



4. Various Makes Of Air Dryer For Locomotives

The following vendors have approved for supply of air dryer for locomotives conforming to specification no. MP.0.01.00.06 till the date of publication of this maintenance instruction. S.N. Name of Vendor (Designer) & Applications 1. Faiveley Transport India Ltd.(Formerly SAB WABCO), Harita, Hosur

(Graham White) Model no. 975-123 with orifice size 0.11” for all Diesel locomotives including WDG4 and WDP4 and electric locomotives WAG-9,WAP-7 & WAP-5, Model no. 975-129 with orifice size 0.0625” for Electric goods locomotives (excluding WAG-9), Model no. 975-129 with orifice size 0.052” for Electric passenger locomotives (excluding WAP-7 & WAP-5), Model no. 975-124 with orifice size 0.052” for EMU/MEMU& MG DEMU, Model no. 975-124 with orifice size 0.0625” for DEMU.

2. Stone India Ltd., 16, Taratalla Road, Kolkata (Wabtec /Vaporid) Drawing no. 09510102 with orifice size 0.0938” for Diesel locos. Drawing no. 09510101 with orifice size 0.0785” for Electric goods locos. Drawing no. 09510106 with orifice size 0.067” for Electric passenger locos. Drawing no. 09510103 with orifice size 0.052” for EMU/MEMU Drawing no. 09510104 with orifice size 0.0625” for DEMU Drawing no. 09510105 with orifice size 0.089” for ABB locos.

3. Knorr-Bremse India Ltd., 14/6, Mathura Road, Faridabad (Knorr Bremse) Model LTZ 015.2 with orifice size 2 mm for Diesel locomotives Model LTZ 015.2 with orifice size 1.4 mm for Electric locomotives Model LTZ 015.1 with orifice size 1.1 mm for EMU/ MEMUs/ MG-DEMUs Model LTZ 015.2 with orifice size 1.4 mm for DEMUs

5. Maintenance Schedules Of Air Dryer 5.1 Detailed maintenance procedure to be followed for various makes of air dryer is

given in the maintenance manual of respective makes of air dryer. However, important aspects related to installation, periodicity of maintenance schedules and items to be checked in schedules are given below.

5.2 Installation, Pneumatic and Electrical connections of air dryer 5.2.1 As per Clause 7.7 of RDSO Specification no. MP.0.01.00.06, Installation of air dryer

shall be carried out either by supplier or by the purchaser not by any third party. Installation charges should be quoted as an optional item.



The envelope space for air dryer for diesel locos., electric locomotives, EMUs MEMUs and DEMUs the mounting hole dimensions are given in RDSO Specification no. MP.0.01.00.06.

5.2.2 Pneumatic and electrical connections on Diesel loco

Pneumatic and electrical connections of air dryer fitted on diesel locomotives are shown in Drg.No. SK.DP-3348 Alt.1.(Annexure-I) The connections of air dryer electrical junction box are done as under: i) Terminal A (+ve ) - connected to wire No. 13 of loco - For power supply ii) Terminal B (+ve) - connected to wire No. 13 of loco

- For memory iii) Terminal C (-ve) - connected to wire No. 4 of loco

- Negative connection

5.2.3 Pneumatic and electrical connections on Electric loco

Pneumatic and electrical connections of air dryer fitted on electric locomotives are shown in Drg.No. SK.DP-3384 Alt.1 (Annexure-II) The connections of air dryer electrical junction box are done as under: i) Terminal A (+ve ) - connected to wire No. 003 of loco - For power supply ii) Terminal B (+ve) - connected to wire No. 401 of loco

- For memory iii) Terminal C (-ve) - connected to wire No. B-ve of loco

- Negative connection

5.2.4 Pneumatic and electrical connections on DEMUs For pneumatic connections of air dryer fitted on DEMUs & MG-DEMUs, Brake schematic Drg.No. SK.DP-3620 & Drg.No. SK.DP-3636 respectively may be referred. The electrical connections of air dryer are done as under: i) Terminal A (+ve ) - Main +ve Supply ii) Terminal B (+ve) - Compressor (Load/unload signal) +ve Supply

iii) Terminal C (-ve) - Main - ve Supply

5.2.5 Pneumatic and electrical connections on DEMUs

For pneumatic connections of air dryer fitted on EMUs/MEMUs, modification Sheet No. MC/EMU/MSG/DC dt.21.03.2005 may be referred.



The electrical connections of air dryer are done as under: i) Terminal A (+ve ) - Main +ve Supply ii) Terminal B (+ve) - Compressor (Load/unload signal) +ve Supply

iii) Terminal C (-ve) - Main - ve Supply

5.3 Periodicity of maintenance schedules

The maintenance schedules of air dryers should correspond to maintenance schedule of locomotive, which are typically as follows:

(A) For Diesel Locomotives

i) T1 - 20 days ii) M-2 - 60 days

iii) M-4 - 120 days

iv) M-12 - 12 months

v) M-24 - 24 months

vi) M-48 - 48 months

(B) For Electric Locomotives

Schedule Passenger Locomotive

Freight Locomotive

i) Trip

15/20 days 15/20 days

ii) IA 40 days 45 days

iii) IB 80 days 90 days

iv) IC 120 days 135 days

v) AOH 12 months 18 months

vi) IOH 36 months 54 months



(C) For EMU/MEMUs

i) Trip

10 days

ii) IA 45 days

iii) IC 180 days

iv) POH 18 months (D) For DEMUs

i) Trip

7 days

ii) Monthly 1 month

iii) Quarterly 3 months

iv) Half yearly 6 months

v) Eighteen Monthly Schedule

18 months

Note: Maintenance sheds may modify the frequency of above schedules to match their existing schedules.



5.4 Items To Be Checked During Maintenance Schedules (A) For Diesel Locomotives

S.N Items to be checked Remarks

T-1 SCHEDULE 1. Open drain cock of final

filter to drain off any accumulated water content

2. Check the colour of humidity indicator

It indicates condition of air after passing through air dryer. Indication of various colour are as under.

• Blue colour ---- Dryer is performing correctly • Lavender ---- Dryer is suspect - Verify dryer is cycling. - If dryer is cycling correctly and auto drain valve

of main reservoir No.1 is operating correctly, release the loco for service

• White ---- Possible damaged dryer

- Verify dryer is cycling. - Remove humidity indicators and look for

desiccant dust or residue on inside of manifold and humidity indicators.

- If desiccant dust or residue is seen–

Remove dryer for attention. - If no desiccant dust or residue is seen on

inside of manifold- Install new humidity indicators. Again verify dryer is cycling correctly & No.1 main reservoir drain valve is operating correctly

- Release loco for service.

Yellow or Brown colour ----- Damaged dryer -It indicates that desiccant has been

contaminated with oil. Replacement of coalescing element and desiccant is required.

3. Check auto drain of main

reservoir No.1

It should function properly.



4. Check electrical connection of air dryer and their tightness.

M-2 SCHEDULE 1. Repeat all the items of T1

schedule.

2. Check cyclic operation of air dryer.

While the dryer is cycling, there should be a slight and continuous exhaust from the relevant purge valve. After pre-determined cyclic time, exhaust from the purge valve stops and that of the second tower starts exhausting. This cycle should be reversed after cycle time. The cycle timings of various makes of air dryer are as under: FTIL air dryer - 1 minute drying and

-1 minute regeneration • Stone India Ltd. air dryer - - do - Knorr-Bremse air dryer - do –

3. Check Memory Feature When compressor gets unloaded purging of air should stop

and when compressor again gets loaded purging should continue.

4. Examine the drain valve on the sump of pre coalescer

With the dryer operation, the drain valve must expel a short burst of air once a minute (each cycle).

M-4 SCHEDULE

1. Repeat all the items of M-2 schedules.

2. Charge the system from zero pressure and check the dryer does not cycle immediately. Note the pressure when the dryer starts cycling.

Pressure settings of start of cyclic operation are as under: FTIL air dryer ----- 7.0 kg/cm2 SIL air dryer ----- 7.0 kg/cm2 Knorr-Bremse air dryer ----- 4.6 kg/cm2

M-12 SCHEDULE


2. Replace consumables as per respective manufacturer’s recommended replacement kit

Please see Annexure-III for list of items to be replaced. (in case of KB make air dryers no consumables are to be replaced in M-12)



M-24 SCHEDULE


In case of KB make air dryers, please see Annexure III for list of items to be replaced.

2. Clean external muffler connected with purge valves.

Follow the instructions given in maintenance manual of respective manufacturers.

3. Check condition of each pipe assembly and their tightness.

-

M-48 SCHEDULE

1. Overhaul the complete air dryer and change desiccant.

For overhauling follow the instructions given in maintenance manual of respective manufacturers.

2. Replace consumables as per respective manufacturer’s recommended replacement kit.

Please see Annexure-III for list of items to be replaced.

3. Test each air dryer before putting it back in to service.

Schematic diagram of test bench is given in Annexure-IV List of tests to be conducted and format of record to be maintained is given in Annexure V For further details, specification No. MP.0.01.00.06 may be referred.



(B) For Electric Locomotives


TRIP SCHEDULE 1. Open drain cock of final





of main reservoir No.1 is operating correctly, release the loco for service





Remove dryer for attention. - If no desiccant dust or residue is seen

on inside of manifold- Install new humidity indicators. Again verify dryer is cycling correctly & No.1 main reservoir drain valve is operating correctly

- Release loco for service.

Yellow or Brown colour ----- Damaged dryer -It indicates that desiccant has been

contaminated with oil. Replacement of coalescing element and desiccant is required.

3. Check auto drain of main reservoir No.1 & main reservoir No.2





IA/ IB SCHEDULE 1. Repeat all the items of Trip

schedule.



-1 minute regeneration • Stone India Ltd. air dryer - -do- Knorr-Bremse air dryer - 2 minute drying and

2 minute regeneration

3. Check Memory Feature When compressor gets unloaded purging of air should stop and when compressor again gets loaded purging should continue.



IC - SCHEDULE 1. Repeat all the items of

IA/IB schedules.



AOH SCHEDULE 1. Repeat all the items of IC

schedules.


Please see Annexure-III for list of items to be replaced. (in case of KB make air dryers consumables are to be replaced in alternate AOH)






-

IOH SCHEDULE 1. Overhaul the complete air

dryer and change desiccant.For overhauling follow the instructions given in maintenance manual of respective manufacturers.

2. Replace consumables as per respective manufacturer’s recommended replacement kit.


3. Test each air dryer before putting it back in to service.


(C) For EMUs /MEMUs







of main reservoir No.1 is operating correctly, release the EMU/MEMU for service






- If desiccant dust or residue is seen– Remove dryer for attention.

- If no desiccant dust or residue is seen on inside of manifold- Install new humidity indicators. Again verify dryer is cycling correctly & No.1 main reservoir drain valve is operating correctly

- Release EMU/MEMU for service.

Yellow or Brown colour ----- Damaged dryer -It indicates that desiccant has been contaminated with oil. Replacement of coalescing element and desiccant is required.

3. Check auto drain of main reservoir No.1



IA SCHEDULE 1. Repeat all the items of Trip

schedule.



-1 minute regeneration • Stone India Ltd. air dryer - -do- Knorr-Bremse air dryer - 2 minute drying and 2 minute regeneration

3. Check Memory Feature When compressor gets unloaded purging of air should

stop and when compressor again gets loaded purging should continue.



IC SCHEDULE

1. Repeat all the items of IA schedules.





POH SCHEDULE

1. Repeat all the items of IC schedules.






-

Note – (a) Overhaul the complete air

dryer and change desiccant during alternate POH.


(b) Replace consumables as per respective manufacturer’s recommended replacement kit in every alternate POH.


(c) Test each air dryer before putting it back in to service during alternate POH.


(D) For DEMU









of main reservoir No.1 is operating correctly, release the DEMU for service


- Verify dryer is cycling. -Remove humidity indicators and look

for desiccant dust or residue on inside of manifold and humidity indicators.


Remove dryer for attention. - If no desiccant dust or residue is seen on inside of manifold- Install new humidity indicators. Again verify dryer is cycling correctly & No.1 main reservoir drain valve is operating correctly

- Release DEMU for service.

Yellow or Brown colour ----- Damaged dryer -It indicates that desiccant has been contaminated

with oil. Replacement of coalescing element and desiccant is required.

3. Check auto drain of main reservoir No.1



Monthly Schedule

1. Repeat all the items of Trip schedule.


While the dryer is cycling, there should be a slight and continuous exhaust from the relevant purge valve. After pre-determined cyclic time, exhaust from the purge valve stops and that of the second tower starts exhausting. This cycle should be reversed after cycle time. The cycle



timings of various makes of air dryer are as under: FTIL air dryer - 1 minute drying and

-1 minute regeneration • Stone India Ltd. air dryer - -do- Knorr-Bremse air dryer - 2 minute drying and

2 minute regeneration

3. Check Memory Feature When compressor gets unloaded purging of air should stop and when compressor again gets loaded purging should continue.



Quarterly / Half Yearly Schedule 1. Repeat all the items of

Monthly schedules.



Eighteen Monthly Schedule 1. Repeat all the items of

Quarterly/ Half Yearly schedules






-

Note – (a) Overhaul the complete air

dryer and change desiccant during alternate Eighteen Monthly Schedule


(b) Replace consumables as per respective manufacturer’s




recommended replacement kit in every alternate Eighteen Monthly Schedule

(c) Test each air dryer before putting it back in to service during alternate Eighteen Monthly Schedule


6. Precautions To Be Taken During Installation, Maintenance And Operation Of

Air Dryer

6.1 Installation of air dryer shall be carried out either by supplier or by the purchaser not by any third party.

6.2 Air Dryer should be mounted vertically. 6.3 Desiccant material may be hazardous to health. Direct skin contact with desiccant

should be avoided. 6.4 Auto drain valve of main reservoir tanks should be in working order. 6.5 If any welding is to be carried out on underframe, ensure the dryer is electrically

disconnected from the power supply.

6.6 For welding, earthing should not be taken through dryer or near to the dryer. 6.7 On the air dryer, electrical connector has three wires, one for positive, second for

intermittent positive for memory circuit only and third wire is for negative connection. While electrical connections of air dryer are made, care should be taken that these connections are properly done after verifying the inscription on electrical connector of air dryer.

6.8 PCB of air dryer should be isolated when meggering operation is done on Loco./

EMU/MEMU/DEMU 6.9 Proper conduit and safety straps should be provided on all electrical wiring/

connections involved in dryer installation. 7. Trouble Shooting Of Air Dryer

For trouble shooting follow instructions given in maintenance manual of respective manufacturer. However trouble shooting of some of the common problems faced on air dryers are given below :-



S.No. SYMPTOM CORRECTION 1 Dryer not cycling. 1. Make a visual inspection of dryer for damage.

2. Ensure MR air pressure is equivalent to setting pressure of the air dryer.

3. Check supply voltage, it must be in the range of 48-90 V DC for diesel locomotive and 85 to 130 V DC for electric locomotive, EMU/MEMUs & DEMUs.

4. Check electrical connection of air dryer. It should be as per clause5.2. Check circuit board connection.

5. Ensure that solenoid valves are working properly. 6. Inspect control box pressure, check valves, and timer

unit and ensure proper working of check valves, magnet valves

7. Ensure all tubing connections to purge and drain valves for. a) Loose connections. b) Check for blockage inside tubing .

8. Inspect and replace circuit board, if necessary

2 Excessive air discharge during regeneration.

1. Make a visual inspection of dryer for damage. 2. Check outlet valves for debris or damage. 3. Check inlet check valves for debris or damage.

3. Continuous discharge of main reservoir air from pre coalescer drain valve.

1. Make a visual inspection of dryer for damage. 2. Check double seated drain valve seats for debris or

damage. 3. If leakage is occurring for pressure under 70 psi then

check control box pressure check valve.

4 No regenerating air from one or both of the tower purge valves.

1. Make a visual inspection of dryer for damage. 2. Push clean out plunger on and follow instruction given

in maintenance manual.

5. One or both humidity indicators are not of correct colour (indication of proper working)

1. Make a visual inspection of dryer for damage. 2. White Indicators normally turn into proper color after

cycling. 3. Check for dryer cycling operation. 4. Check control box pressure check valve for excessive

leakage from vent hole on cap. 5. Check line power to dryer. 6. Check circuit board. 7. Check circuit board connections..



Annexure I



Annexure II



Annexure-III

1. Recommended Spare Parts List For Air Dryer of M/S FTIL (Graham White Design)

(A) (Kit for Air Dryer fitted on Diesel Locos including WDP4 & WDG4)

Parts to be renewed in M-12 schedule S.N Item FTIL Part No. D & M Part No. Qty

1 Inlet main coalescer kit (AD) 790 0291 65 RK-AB787-W27B 1 2 Kit for final filter 790 0291 25 RK-AB787-W40 1 3 Regenerating orifice kit (AD) 790 0291 11 RK-AB787-W39 1

Parts to be renewed in M-48 schedule

S.N Item FTIL Part No. D & M Part No. Qty

1 Inlet main coalescer kit (AD) 790 0291 65 RK-AB787-W27B 1 2 Kit for final filter 790 0291 25 RK-AB787-W40 1 3 Regenerating orifice kit (AD) 790 0291 11 RK-AB787-W39 1 4 Desiccant canister kit (AD) 790 0291 95 RK-AB787-W44 1 5 Inlet check valve kit (AD) 790 0291 35 RK-AB787-W27A 2 6 Drain valve kit (AD) 790 0291 75 RK-AB787-W28 1 7 Outlet check valve kit (AD) 790 0291 45 RK-AB787-W29 2 8 Purge valve kit (AD) 790 0291 85 RK-AB787-W36 2 9 Solenoid assembly kit (AD) 790 0291 55 RK-AB787-W37 2 10 Compactor assembly kit (AD) 790 0292 05 RK-AB787-W41 2 11 Humidity indicator kit (AD) 790 0291 05 RK-AB787-187 2 12 O-Ring (ID 1.359x width- 0.139) 029 7190 00A AB787-121 8 13 O-Ring (ID 5.234 x width- 0.139) 029 7150 00 AB787-125 4 14 O-Ring (ID 5.984x width- 0.139) 029 7180 00 AB787-173 1 15 O-Ring (ID 1.734 x width- 0.139) 029 7130 00A AB787-188 2 16 Electric box Gasket 029 7120 00 AB787-191 1 17 Tetra seal for drain valve 029 7200 00 AB787-224 1 18 O-Ring (ID 0.674 x width- 0.103) 029 7015 00 AB787-144 1 19 Gasket for Burndy Connector 029 7075 00 AB787-239 1

(B) (Kit for Air Dryer fitted on Electric Locos except 3 phase - WAG-9, WAP-7 &

WAP-5 Locos.) Parts to be renewed in AOH Schedule





Parts to be renewed in IOH schedule

S.N Item FTIL Part No. D & M Part No. Qty 1 Inlet main coalescer kit (AD) 790 0291 65 RK-AB787-W27B 1 2 Kit for final filter 790 0291 25 RK-AB787-W40 1 3 Regenerating orifice kit (AD) 790 0291 11 RK-AB787-W39 1 4 Kit for Desiccant can (Smaller) 790 0291 45 - 1 5 Inlet check valve kit (AD) 790 0291 35 RK-AB787-W27A 2 6 Drain valve kit (AD) 790 0291 75 RK-AB787-W28 1 7 Outlet check valve kit (AD) 790 0291 45 RK-AB787-W29 2 8 Purge valve kit (AD) 790 0291 85 RK-AB787-W36 2 9 Solenoid assembly kit (AD) 790 0291 55 RK-AB787-W37 2 10 Compactor assembly kit (AD) 790 0292 05 RK-AB787-W41 2 11 Humidity indicator kit (AD) 790 0291 05 RK-AB787-187 2 12 O-Ring (ID 1.359x width- 0.139) 029 7190 00A AB787-121 8 13 O-Ring (ID 5.234 x width- 0.139) 029 7150 00 AB787-125 4 14 O-Ring (ID 5.984x width- 0.139) 029 7180 00 AB787-173 1 15 O-Ring (ID 1.734 x width- 0.139) 029 7130 00A AB787-188 2 16 Electric box Gasket 029 7120 00 AB787-191 1 17 Tetra seal for drain valve 029 7200 00 AB787-224 1 18 O-Ring (ID 0.674 x width- 0.103) 029 7015 00 AB787-144 1 19 Gasket for Burndy Connector 029 7075 00 AB787-239 1

(C) (Kit for Air Dryer fitted on 3 phase - WAG-9, WAP-7 & WAP-5 Electric Locos.)

Parts to be renewed in AOH Schedule S.N Item FTIL Part No. D & M Part No. Qty


Parts to be renewed in IOH Schedule


1 Inlet main coalescer kit (AD) 790 0291 65 RK-AB787-W27B 1 2 Kit for final filter 790 0291 25 RK-AB787-W40 1 3 Regenerating orifice kit (AD) 790 0291 11 RK-AB787-W39 1 4 Desiccant canister kit (AD) 790 0291 95 RK-AB787-W44 1 5 Inlet check valve kit (AD) 790 0291 35 RK-AB787-W27A 2 6 Drain valve kit (AD) 790 0291 75 RK-AB787-W28 1 7 Outlet check valve kit (AD) 790 0291 45 RK-AB787-W29 2 8 Purge valve kit (AD) 790 0291 85 RK-AB787-W36 2 9 Solenoid assembly kit (AD) 790 0291 55 RK-AB787-W37 2 10 Compactor assembly kit (AD) 790 0292 05 RK-AB787-W41 2



11 Humidity indicator kit (AD) 790 0291 05 RK-AB787-187 2 12 O-Ring (ID 1.359x width- 0.139) 029 7190 00A AB787-121 8 13 O-Ring (ID 5.234 x width- 0.139) 029 7150 00 AB787-125 4 14 O-Ring (ID 5.984x width- 0.139) 029 7180 00 AB787-173 1 15 O-Ring (ID 1.734 x width- 0.139) 029 7130 00A AB787-188 2 16 Electric box Gasket 029 7120 00 AB787-191 1 17 Tetra seal for drain valve 029 7200 00 AB787-224 1 18 O-Ring (ID 0.674 x width- 0.103) 029 7015 00 AB787-144 1 19 Gasket for Burndy Connector 029 7075 00 AB787-239 1

(D) Kit for Air Dryer fitted on EMU/MEMU & DEMU Application

Parts to be renewed in POH / Eighteen Monthly Schedule



Parts to be renewed in every alternate POH / Eighteen Monthly Schedule S.N Item FTIL Part No. D & M Part No. Qty

1 Inlet main coalescer kit (AD) 790 0291 65 RK-AB787-W27B 1 2 Kit for final filter 790 0291 25 RK-AB787-W40 1 3 Regenerating orifice kit (AD) 790 0291 11 RK-AB787-W39 1 4 Kit for Desiccant can (Smaller) 790 0291 45 - 1 5 Inlet check valve kit (AD) 790 0291 35 RK-AB787-W27A 2 6 Drain valve kit (AD) 790 0291 75 RK-AB787-W28 1 7 Outlet check valve kit (AD) 790 0291 45 RK-AB787-W29 2 8 Purge valve kit (AD) 790 0291 85 RK-AB787-W36 2 9 Solenoid assembly kit (AD) 790 0291 55 RK-AB787-W37 2 10 Compactor assembly kit (AD) 790 0292 05 RK-AB787-W41 2 11 Humidity indicator kit (AD) 790 0291 05 RK-AB787-187 2 12 O-Ring (ID 1.359x width- 0.139) 029 7190 00A AB787-121 8 13 O-Ring (ID 5.234 x width- 0.139) 029 7150 00 AB787-125 4 14 O-Ring (ID 5.984x width- 0.139) 029 7180 00 AB787-173 1 15 O-Ring (ID 1.734 x width- 0.139) 029 7130 00A AB787-188 2 16 Electric box Gasket 029 7120 00 AB787-191 1 17 Tetra seal for drain valve 029 7200 00 AB787-224 1 18 O-Ring (ID 0.674 x width- 0.103) 029 7015 00 AB787-144 1 19 Gasket for Burndy Connector 029 7075 00 AB787-239 1



2. Recommended Spare Parts List For Air Dryer of M/S Knorr Bremse (Knorr Design) (A) (Kit for Air Dryer fitted on Diesel & Electric Locomotives)

Parts to be renewed in M-24 / Alternate AOH schedule

S.N Item Dwg No Qty

1 Final Filter Element I.4.3093 1

Parts to be renewed in M-48 / IOH schedule

S.N Item Part No Qty 1 Desiccant (5.57 Kg/Vessel) 503328 2 POH Kit (55items)

1 Final Filter Element I.4.3093 1 2 Compression Spring B 80465 2 3 Compression Spring C 59204 1 4 Compression Spring B 35531 2 5 Compression Spring B 82679 1 6 Nut B95755/KI 2 7 Washer A33266 2 8 Washer B70469/1/KI 6 9 Round Wire Netting B27807 4 10 Sealing Ring 453783 2 11 Sealing Ring 453790 1 12 Sealing Ring 453807 2 13 Sealing Ring 456999 2 14 O-Ring B24036 2 15 Compression Spring C65798 1 16 Compression Spring B85028 2 17 O-Ring B21928 2 18 O-Ring B21858 6 19 Spring Washer B12 466059 8 20 Hexagon Nut 468086 2 21 Spring Washer B06 466058 2 22 O-Ring A40125/20 2 23 Knorr-K-Ring 454953 2 24 Retaining Ring 467044 2 25 Washer 450864 2 26 O-Ring A40125/13 2 27 O-Ring A52320 1 28 Toothed Ring A62331/2 4 29 O-Ring A91453 2 30 Scraper Ring A97200/5 2



31 O-ring B44910 2 32 Knorr-K-Ring 462422 2 33 Sealing Ring 459633 1 34 O-Ring A79532 2 35 O-Ring B51209 2 36 Venting Valve I46367 1 37 O-Ring A40791 2 38 O-Ring A64261 1 39 O-Ring A83273 1 40 O-Ring B24149 1 41 O-Ring B58177 2 42 Gasket B70667 1 43 Knorr-K-Ring 462615 1 44 Washer 450862 2 45 Locking Ring 466884 4 46 Washer 5.3 462326 3 47 Hexagon Nut 466587 1 48 Locking Ring 468204 3 49 Washer 468646 1 50 Scraper Ring A97200/7 2 51 Knorr-K-Ring 458906 2 52 Retaining Ring 464255 2 53 O-Ring B55436 4 54 Valve Head C87786 2 55 Sealing Ring 466686 2

(B) (Kit for Air Dryer fitted on DEMU’s

Parts to be renewed in Eighteen Monthly Schedule

S.N Item Dwg No Qty


Parts to be renewed in Every Alternate Eighteen Monthly Schedule

S.N Item Part No Qty Desiccant (5.57 Kg/Vessel) 503328 2 POH Kit (56items) 1 Compression Spring B 80465 2 2 Compression Spring C 59204 1 3 Compression Spring B 35531 2 4 Compression Spring B 82679 1 5 Nut B95755/KI 2



6 Washer A33266 2 7 Washer B70469/1/KI 6 8 Round Wire Netting B27807 4 9 Sealing Ring 453783 2 10 Sealing Ring 453790 1 11 Sealing Ring 453807 2 12 Sealing Ring 456999 2 13 O-Ring B24036 2 14 Compression Spring C65798 1 15 Compression Spring B85028 2 16 O-Ring B21928 2 17 O-Ring B21858 6 18 Spring Washer B12 466059 8 19 Hexagon Nut 468086 2 20 Spring Washer B06 466058 2 21 O-Ring A40125/20 2 22 Knorr-K-Ring 454953 2 23 Retaining Ring 467044 2 24 Washer 450864 2 25 O-Ring A40125/13 2 26 O-Ring A52320 1 27 Toothed Ring A62331/2 4 28 O-Ring A91453 2 29 Scraper Ring A97200/5 2 30 O-ring B44910 2 31 Knorr-K-Ring 462422 2 32 Sealing Ring 459633 1 33 O-Ring A79532 2 34 O-Ring B51209 2 35 Venting Valve I46367 1 36 O-Ring A40791 2 37 O-Ring A64261 1 38 O-Ring A83273 1 39 O-Ring B24149 1 40 O-Ring B58177 2 41 Gasket B70667 1 42 Knorr-K-Ring 462615 1 43 Washer 450862 2 44 Locking Ring 466884 4 45 Washer 5.3 462326 3 46 Hexagon Nut 466587 1 47 Locking Ring 468204 3 48 Washer 468646 1 49 Scraper Ring A97200/7 2 50 Knorr-K-Ring 458906 2



51 Retaining Ring 464255 2 52 O-Ring B55436 4 53 Valve Head C87786 2 54 Sealing Ring 466686 2 55 Compression Spring A57201 1 56 Knorr-K-Ring 454931 1

(C) (Kit for Air Dryer fitted on EMU’s/MEMU’s

Parts to be renewed in POH schedule

S.N Item Dwg No. Qty


Parts to be renewed in Every Alternate POH schedule

S.N Item Part No Qty 1 Desiccant (4 Kg/Vessel) 503328 2 POH Kit (48items) 1 Compression Spring B 80465 2 2 Compression Spring C 59204 1 3 Compression Spring B 35531 2 4 Compression Spring B 82679 1 5 Round Wire Netting B27807 4 6 Sealing Ring 453783 2 7 Sealing Ring 453790 1 8 Sealing Ring 453807 2 9 Sealing Ring 456999 2 10 O-Ring B24036 2 11 Compression Spring C65798 1 12 Compression Spring B85028 2 13 O-Ring B21928 2 14 O-Ring B21858 6 15 Spring Washer B12 466059 8 16 Hexagon Nut 468086 2 17 Spring Washer B06 466058 2 18 O-Ring A40125/20 2 19 Knorr-K-Ring 454953 2 20 Retaining Ring 467044 2 21 O-Ring A40125/13 2 22 O-Ring A52320 2 23 Toothed Ring A62331/2 3



24 O-Ring A91453 2 25 Scraper Ring A97200/5 2 26 O-ring B44910 2 27 Knorr-K-Ring 462422 2 28 Sealing Ring 459633 1 29 O-Ring A79532 2 30 O-Ring B51209 2 31 O-Ring A40791 2 32 O-Ring A64261 1 33 O-Ring A83273 1 34 O-Ring B24149 1 35 O-Ring B58177 2 36 Gasket B70667 1 37 Knorr-K-Ring 462615 1 38 Locking Ring 466884 4 39 Locking Ring 468204 3 40 Scraper Ring A97200/7 2 41 Knorr-K-Ring 458906 2 42 Retaining Ring 464255 2 43 O-Ring B55436 4 44 Valve Head C87786 45 Sealing Ring 466686 2 46 Compression Spring A57201 1 47 Knorr-K-Ring 454931 1 48 Toothed Ring A62331/2 1

2



3. Recommended Spare Parts List For Air Dryers of M/s Stone India Limited (Wabtec/Vaporid Design)

(A) (Kit for Air Dryer fitted on Diesel & Electric Locomotives)

Parts to be renewed in M-12 / AOH schedule

S.N Item SIL Part No Qty 1 Filter Coalescing 653298 1 2 Nut 3/8” 16 Hex Lock 569374 1 3 Washer 3/8” lock Self Sealing 6401300001 1 4 O Ring 4.237 I.D 590013 1 5 Kit Humidity Indicator Rebuild 304338 2

3.2 Parts to be renewed in M-48 / IOH schedule

S.N Item SIL Part No Qty

1. Filter Coalescing 653298 1 2. Nut 3/8” 16 Hex Lock 569374 1 3. Washer 3/8” lock Self Sealing 6401300001 1 4. O Ring 4.237 I.D 590013 1 5. Kit Humidity Indicator Rebuild 304338 2 6. O Ring 2” OD 536582 4 7. O Ring 1/2” OD 524612 8 8. Check Valve Seal 653292 4 9. O Ring 1.739 I D 593569 4 10. Gasket Flange 1” 93986 6 11. Gasket Flange 3/8” 93839 3 12. O Ring 4.487 I.D 593572 2 13. O Ring 6” O.D 304493 4 14. Desiccant Element 653510 2 15. Solenoid Valve 653353 2 16. Repair Kit Drain Valve 309112 1 17. Repair Kit Purge Valve 309113 2

(B) (Kit for Air Dryer fitted on DEMU’s)

Parts to be renewed in Eighteen Monthly Schedule




Parts to be renewed in every alternate Eighteen Monthly Schedule

S.N Item SIL Part No Qty

1 Filter Coalescing 653298 1 2 Nut 3/8” 16 Hex Lock 569374 1 3. Washer 3/8” lock Self Sealing 6401300001 1 4 O Ring 4.237 I.D 590013 1 5 Kit Humidity Indicator Rebuild 304338 2 6 O Ring 2” OD 536582 4 7 O Ring 1/2” OD 524612 8 8 Check Valve Seal 653292 4 9 O Ring 1.739 I D 593569 4 10 Gasket Flange 1” 93986 6 11 Gasket Flange 3/8” 93839 3 12 O Ring 4.487 I.D 593572 2 13 O Ring 6” O.D 304493 4 14 Desiccant Element 653510 2 15 Solenoid Valve 653353 2 16 Repair Kit Drain Valve 309112 1 17 Repair Kit Purge Valve 309113 2

(C) (Kit for Air Dryer fitted on EMU’s/MEMU’s)

Parts to be renewed in POH schedule


Parts to be renewed in every alternate POH schedule

S.N Item SIL Part No Qty 1 Filter Coalescing 653298 1 2 Nut 3/8” 16 Hex Lock 569374 1 3. Washer 3/8” lock Self Sealing 6401300001 1 4 O Ring 4.237 I.D 590013 1 5 Kit Humidity Indicator Rebuild 304338 2 6 O Ring 2” OD 536582 4 7 O Ring 1/2” OD 524612 8



8 Check Valve Seal 653292 4 9 O Ring 1.739 I D 593569 4 10 Gasket Flange 1” 93986 6 11 Gasket Flange 3/8” 93839 3 12 O Ring 4.487 I.D 593572 2 13 O Ring 6” O.D 304493 4 14 Desiccant Element 653510 2 15 Solenoid Valve 653353 2 16 Repair Kit Drain Valve 309112 1 17 Repair Kit Purge Valve 309113 2


eatless Regenerative Twin Tower Type Compressed Air Dryer For Diesel-Electric & Electric Locomotive, EMU/MEMU & DEMU Application

Annexure-IV Schematic Diagram of Test Rack for testing of Air Dryer

dT1 P2 T1 P1

MR-1 with auto drain valve

Compressed Air

F-1 Flow Meter

F-2 Flow Meter

Dew PointMeter

to atmosphere MR-2 with auto drain valve

Air Dryer

MP.MI-18 Rev. - 02, April-2008

Legends: F-1 Flow meter up to 6000 l.p.m F-2 Flow meter up to 600 l.p.m T1 Air dryer inlet temperature dT1 Air dryer outlet dew point temperature P1 Inlet pressure Gauge P2 Outlet pressure Gauge

Reference: IS-11989-1986 Specification for compressed air dryers

Maintenance Instructions For H

Page 39of 40


Annexure-V Inspection Report for Air dryer

Air Dryer S.No: Make : Design Air flow rate: 3000 l.p.m for Diesel Locomotives

2000 l.p.m for freight electric locomotive 1500 l.p.m for passenger electric locomotive 1200 l.p.m for EMU/MEMUs 1500 l.p.m for DEMUs

Inlet air pressure: 10 kg/cm2 for Locomotives & 8 kg/cm2 for EMU/MEMUs & DEMUs S.No Description Standards Observation 1 Leakage test

Soap test exterior surface of the air dryer, purge valve and all tube connections

No leakage

2 Drying, and regenerative cycle time.

60+5 seconds

3 Pressure setting at the start of cycling operation of air dyer

7+0.5 kg/cm2 for FTIL& SIL 4.6+0.5 kg/cm2 for KBIL

4 Pressure drop across the unit.

Not more then 3% of working pressure

5 Cyclic operation of air dryer at varying voltage range given below: 48-90 Volt D.C for diesel locomotive 85-130 Volt D.C for Electric locomotive, EMU/MEMUs & DEMUs

Drying, and regenerative time should be FTIL& SIL 60+5 seconds for diesel and electric locomotive application KBIL 60+5 seconds for diesel locomotive application 120+5 seconds for electric locomotives, EMU/MEMUs & DEMUs application

6 Dew Point Depression (Inlet air dryer temperature-Air dryer Outlet dew point temperature)

Minimum 30 0C for nominal flow 3000 l.p.m for Diesel Locomotives 2000 l.p.m for freight electric locomotive 1500 l.p.m for passenger electric locomotive 1200 l.p.m for EMU/MEMUs 1500 l.p.m for DEMUs Minimum 15 0C for the worst case of air flow(6000 l.p.m. for diesel locomotives, 2000 l.p.m for passenger electric locomotives, 3000 l.p.m for freight electric locomotive, 2107 l.p.m.for DEMUs & 1320 lpm for EMU/MEMUs) and ambient temperature (up to 700C)

7 Purge Loss (purge loss measured by flow meter in l.p.m X 100/Design flow in l.p.m)

Maximum 20% at design capacity


Date post:	21-Oct-2015
Category:	Documents
Upload:	fernanguedes2071
View:	204 times
Download:	48 times

_Airdryer

Documents