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Unit #4 Air Dryer

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SPECIFICATION OF DRYER

Compressed Air Dryer

Type-No. 818 WP

Volume Flow (m3/h) CFM 3500 / 2000

Power Consumption total at full load (KW) 6.9

Power Consumption Fan (KW) 0.4

Nominal Current (A) 22.23

Allowable pressure compressed air (Min. / Max) (bar) 02 / 16

Allowable pressure Refrigerant (Min. / Max) (bar) 16 / 20

Weight (kg) 681Refrigerant quantity (kg) 16

Cooling water capacity (m3/h) 2

Cooling water Pressure max. (bar) 10

Cooling water Pressure min. (bar) 2

Vertical Pre cooler

Model AC-N2000-LHType Fixed TB

Air Flow 2000 CFM

Air Pressure 7 kg/cm2G

Air In / Out Temp 60 / 40 Deg.C

Cooling Walter In / Out Temp 38 / 42 Deg.C

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Compressed air and Refrigerant side

exchanger lay out.

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SCHEMATIC DIAGRAM

ACW Inlet

Service Air Inlet

PreAirCooler

ACW Outlet

CCW Inlet

CCW OutletInstrument Air Outlet

Compressed Air Dryer

Moisture Separator

Filter

Moisture Separator

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SCHEMATIC LAYOUT

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SCHEMATIC LAYOUT

ACW inlet to condenser with duplex filter arrangement

Duplex Filter

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SCHEMATIC LAYOUT OF PLATEFORM

Platforms for safe and easy operation of valves

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Operation

1) Switch on the main switch of compressed air dryer after commission or after

long duration of power outage and wait for at least 06 hours to enable a

preheating of the refrigeration compressor.

Starting

2) Ensure to open the CCW inlet and outlet valve of air pre-cooler.

3) Ensure to open the ACW inlet and outlet valve of compressed air dryer by taking

the inlet filter in service.

4) Check for any leakages of ACW / CCW Water.

5) The compressed air dryer is switch ON via operation switch.

6) After approx 05 Min. the compressed air admission is possible by opening the airinlet and outlet valve.

7) Load the compressed air dryer by full opening of inlet and outlet air valve.

8) The temperature display at the switch cabinet indicates the pressure dew point in

operating range of 0 to 4 Deg. Cen.

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Starting

9) Ensure the condensate drain automatically drain the condensate from

compressed air dryer.

10) Ensure the manual condensate drains of pre-cooler and moisture separator

are kept opened.

11) Observe and note down the following parameter during normal operation of

compressed air dryer.a) Pdp from Display unit.

b) Air Inlet / outlet pressure from Display unit / Local Gauges.

c) Air Inlet / outlet Temperature from Display unit / Local Gauges.

d) ACW Inlet temp from Display unit.

e) CCW Inlet / outlet pressure from Local Gauges.

f) CCW Inlet / outlet Temperature from Local Gauges.g) Ensure (Point No.:-09 and 10) i.e., the proper functioning of

condensate drain.

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Stopping

1) Shut the air inlet and outlet valve of compressed air dryer 5 Min. before

the switch off.2) Switch off the compressed air dryer with the operation switch.

3) For longer standstill period of during service, the compressed air dryer is

switched off with the main switch.

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Electronic regulator indication

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Electronic regulator indication

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Electronic regulator indication

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Automatic condensate drain

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Parameter set point

CODE DESCRIPTION SET VALUE

P01 Mode of operation: normal=0 (0 - 4C);summer=1 (2 - 7C) 0

P02Automatic dew point (sets the dew point depending on the ambient temp. at the place

of installation): OFF=0; ON=10

P03External failure system: P03=1(external CA dryer stopping activated for any

failure),P03=0(external CA dryer stopping deactivated for any failure)1

P04 Reference value normal (it can be increased more than 4C but cant be decreased) 4C

P05 Reference value summer (it can be increased more than 8C but can't be decreased) 8C

P06 Failure limit (Dew point too high-it will trip the machine when this temp. crossed) 25C

P07Release of maintenance display (acknowledgement of maintenance interval). During

acknowledgement we have to set the value 0 again from 1.0

P08Acknowledgement of the failures of evaporator sensor. (During acknowledgement we

have to set the value 0 again from 1)0

P09 Acknowledgement of the failures of evaporator sensor. (During acknowledgement wehave to set the value 0 again from 1)

0

P10Acknowledgement of the failures of evaporator sensor. (During acknowledgement we

have to set the value 0 again from 1)0

P11 Acknowledgement of the failures of evaporator sensor 0

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Parameter set point

P12 Sensors not available 0

P13 Sensors not available 0

P14Release of failures :FA( Ambient temp. sensor). During acknowledgement we have

to set the value 0 again from 1.0

P15Release of failures :FC (condensation temp. sensor). During acknowledgement

we have to set the value 0 again from 1.0

P16

Reset switch inside the dryer near the compressor to be pressed forFH (refrigerant

overpressure). Resetting of this code not to be done through the display only the

manual switch inside the dryer to be used.

Reset switch inside the dryer

to be used

P17Release of failures :FE (Failure of heat exchanger). During acknowledgement wehave to set the value 0 again from 1.

0

P18Release of failures :FF (Level sensor of the auto drain valve). During

acknowledgement we have to set the value 0 again from 1.0

P19

Release of failures :FO (Its a pressure sensor which indicates suction pressure

difference of the refrigerant-If the difference is too high that indicates

refrigerant gas leaking). During acknowledgement we have to set the value 0

again from 1.

0

P20Release of failures :EE (External failure due to external factors). During

acknowledgement we have to set the value 0 again from 1.0

P21 Release of failures :Lr ( Lack of refrigerant) 0

P22 SwitchingC=1 ; F=0 1

P23 Deactivation of level sensor:0=deactivate; 1=activate 1

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Parameter set point

P24 Display actual value F1:Inside dew point temp. sensor7C(value showing at

that instance)

P25 Display actual value F2:Inside dew point temp. sensor6C(value showing at

that instance)

P26 Display actual value F3:Inside dew point temp. sensor6C(value showing at

that instance)

P27 Display actual value F4:Inside dew point temp. sensor6C(value showing at

that instance)

P28 Display actual value F5:Dummy DUMMY

P29 Display actual value F6:Dummy DUMMY

P30 Display actual value Ta external sensor(ACW water inlet temp. to the condenser)39C(value showing at

that instance)

P31Display actual value Tc condensation sensor(R134 refrigerant inlet temp. to the

condenser)

45C(value showing at

that instance)

P32 Display actual value To pressure sensor. 3C

P33 Display actual value Ti external sensor(Air inlet temp. to the dryer)36CV(value showing at

that instance)

P34 Relay test 0

P35 Can address 0

P36 switching pressure transmitter: Range will change(6 or 7 value to be set) 6

P37 Deactivation of level sensor:0=deactivate; 1=activate 1

P38 Set point of the no. of times of failure occurred. To be reset after 150 times. 150

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Failure description

Code Failure description Code Failure description

FH Refrigerant overpressure FE Malfunction of heat exchangerEH Electronic failure Lr Lack of refrigerant

H1 Dew point too high SH Overpressure protection

L1 Dew point too low PC Man. Parameter changing

F1 Sensor heat exchanger 1 temp. EL Electronic failure

F6 Sensor heat exchanger 6 temp. ON System switched on

FA Sensor ambient temp. OL Overflow operating hours

FC Sensor condensation temp.

Fo Sensor suction pressure def.

Fi Sensor inlet temp.

FU Failure frequency converter

EE External failure

C1 Failure compressor 1

C2 Failure compressor 2

C3 Failure compressor 3

Co CAN address collision

H2 Inlet temp. too high

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ADP CHECKING

Dew Point Checked on 16.09.2010 and the values of ADP are as (-25Cen.)and PDP are as (+04Cen.)

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ADP CHECKING

Dew Point Checked on 16.09.2010 and the values of ADP are as (-25Cen.)and PDP are as (+04Cen.)

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Dew point conversion graph

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Construction details of dew point apparatus

The outer container constructed by thick glass. The overall tight constructioneliminates possible error in readings due to infiltration of atmospheric moisture.

The inlet and outlet connections are integral parts of the outer container. The

polished cup is positioned inside.

Dew Point Checking

1) The air sample is introduced through the inlet by passing it throughtubing. The tubing should be butted against the inlet port at bottom of dew

point Apparatus.2) Pass a sample flow air through the dew point apparatus. Adjust the flow to

about 5 CFH.

3) Pour acetone (about 2) into the cup. Caution acetone is flammable.

4) After the sample has passed through the apparatus for about five minutes inorder to purge it completely, small amounts of crushed dry ice should be added

to the acetone while stirring constantly with the thermometer.

Dew point apparatus and checking procedure

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5) At the first sign of dew or moisture on the polished surface of cup the

temperature is read from the thermometer. This reading is an accurate

indication of the dew point of the air to be tested. The use of a mixture of

acetone and dry ice in the dew point apparatus makes possible the checking of

dew points as low as -76 C.

Dew point apparatus and checking procedure

http://www.amsystems.co.uk/equivalents/calculate.html

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Dew point apparatus

Thermometer

Dew point apparatus

Flexible tube

Valve

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Compact Design

Low Pressure Drop

Consistent Dew Point

Power Saving

High Quality Finishing

Non-cyclic System

More Reliability

Ease of Installation

Environment Friendly

Reduced Maintenance

SALIENT FEATURES

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THANKS

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