Unit#4 Air Dryer

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    Unit #4 Air Dryer

    1

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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