GEM AIR DRYER
OPERATION & MAINTENANCE
MANUAL
Model
: HOC1003S
Customer
: M/s. ELGI EQUIPEMENTS LTD
Project
: IOTL KORBA
GEM….. The complete solution to your Compressed Air Contamination Problem
FOREWORD
This Manual contains important information for installing, operating,
maintenance and trouble shooting of your GEM Dryer.
The unit has been designed in such a way that it is reliable and
maintenance free. Even then we feel that any machine or equipment has to be understood
and handled with care so that it gives a good service. This manual will help to keep your
dryer in its best condition.
WARRANTY
GEM warrants that all its products will conform to the description thereof
contained in GEM order acknowledgement form including amendments thereto; and that it will
be free from defects under normal use and service in material and workmanship which are not
commercially acceptable. Upon receipt of material within one year from the date of
commissioning or 18 months from the date of supply whichever is earlier with transportation
charges prepaid which GEM’s examination shall disclose to its satisfaction to have been
defective, GEM will at its option:
1. Repair or replace such material; or
2. Issue credit to the original purchase only covering all or part of the purchase
price, as the case may be.
This shall be the buyers and user’s exclusive remedy and in no event shall GEM
be liable for breach of any warranty or negligence of any nature in amount exceeding the price it
received for the item. GEM neither assumes nor authorises any other person to assume for it, any
other liablity of any nature in connection with the sale of said item.
GEM will supply replacement parts during warranty period to the customer on
freight to pay basis against receipt of defective parts on freight paid basis send to our Spares &
Service Division at Coimbatore.
The above warranty shall not apply when:
a. All or any of the chemical and physical characteristics of the environment in which the
product was actually operated (which was required in order to properly select the materials of
construction) was not included with the original order.
b. The environment in which product was operated different from the details of that
environment which were included with the order or recommended by GEM
c. All or any parts of the product design or materials was selected and / or specified by parties
other than GEM or was not approved by GEM
d. In the judgement of GEM the product was subject to misuse, neglect, accident, unauthorised
alternation or was installed in equipment, which was mechanically deficient.
e. The product was improperly installed.
For GEM EQUIPMENTS Limited
TROUBLE SHOOTING
Problems
Cause
Change over failure (4 way No pilot air to control valve
valves)
Air continuously exhausted
in the Solenoid valve
Air Leakage in the Actuator
Excessive Pressure Drop
Solution
Check
Solenoid
valve
operation & vent port
Check & clean distributor
strainer
Check & clean the Solenoid
Valve and replace if
necessary
Check & replace actuator
vane O-ring
Check and replace the filter
elements
Check & replace desiccant
filters
Filter
elements
gets
saturated
Desiccant
enters
after
cooler, air line passage,
filters etc
Poor Dew Point
Inlet Flow rate is high
Check and correct the flow
rate
Inlet pressure is less
Run the unit at rated
pressure
Filters get saturated
Check & replace filter
elements
Desiccant gets spoiled
Replace the desiccant
Continuous air exhaust in Auto Drain Valve failure
Check and clean the
the Moisture separator
Moisture separator ADV
plunger
Check and replace ADV
TIPS FOR SUCCESSFULL OPERATION
1) Do not exceed rated design flow to avoid poor dew point suppression an excessive
“dusting” of the desiccant and pressure drop
2) Do not pass air through the dryer when the timer is not operating as one tower will
remain on stream and become saturated. At this point, all drying will cease. However,
when the timer is re-energized and operating the compressed air flow will be
switched from the tower to tower and complete drying efficiency restored within few
hours.
3) The practical useful service life of an adsorbent desiccant bed is direct function of the
following:
a. Contamination from compressor crankcase oil carry over and other contaminants, such
as gases which might be ingested at the compressor in take.
b. Liquid entrainments in the air stream.
c. Attrition loss due to abrasion of desiccant particles against each other in bed (estimated
at 5% per year). Desiccant replacement is recommended every 24 to 36 months
INSPECTION & MAINTENANCE SCHEDULE
Sl.
No
Inspection
1.
Check
for
Leakage
Pressure Drop
Drain
Check & Clean
Check
the
function
Inspect
&
Replace
Repaint
2.
3.
4.
5.
6.
7.
Filters
PF AF
Valves
M
M
M
M
M
-
Q
M
Towers
&
Desiccant
M
Q
D
Q
-
Q
D
Q
-
Q
W
M
W
Y
M
D
Q
W
D
Y
-
W
Q
-
Y
Y
R
R
R
R
Y
R
R
R
R
-
-
-
-
-
R
R
4WV
Sole
noid
Safe
ty
Elect Adv Cooler
rical
D – Daily
Y – Yearly
W – Weekly
M – Monthly
Q – Quarterly
R – As Required
To claim warranty, the above inspection and maintenance schedule must be strictly
followed. For any doubt or clarification, please consult factory.
GENERAL SERVICE INSTRUCTIONS TO CUSTOMERS
1. Please make service calls only to GEM spares & service division or regional service
centre and give adequate time to arrange service personnel for your call
2. Please inform the serial no of the dryer
3. Please keep available the recommended spares with you prior to calling service
personnel
4. Please assist Gem service personnel for arranging local works & local purchases
5. Please acknowledge every service visit and sign in service reports.
6. In warranty claim, materials have to be sent to Gem spares & service division on
Freight paid basis
7. Warranty of the equipment does not cover the electrical components
8. Please write to us for any assistance in Operation / Service of the equipment
9. Please fix prior appointment for training requirement
LIST OF SPARES FOR 3 YEARS TROUBLE FREE OPERATION
Sl.
No
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
Name of Spare
Pre Filter Cartridge (3 Nos / set)
After Filter Cartridge (3 Nos/set)
220V, 5/2 Solenoid Valve
Pressure Gauge (0-21 Bar), 4”Dial, bottom
entry (H-Guru make)
Temperature Gauge (0-400oC), 4”Dial, back
entry (H-Guru make)
6”-4 way valve
½”GZ-HD Valve
ADV Seal Kit (GZ-HD)
ADV Timer (GZ-HD)
Activated Alumina (1250 Kg/tower)
Qty
Required
3 Set
3 Set
2 No
4 No
Part No
4 No
196902
1 No
2 No
4 No
4 No
1 Lot
272809
128502
10028
120702
902801
195208
195308
111205
101001
For the electrical items likes fuses, contactors, overload relays, lamps etc please refer to
the Wiring Diagram and procure the same locally as per the make provided in the
drawing.
TECHNICAL WRITEUP OF HOC TYPE DRYER
Theory of Operation: - Refer our P & I
HEAT OF COMPRESSION Type Air Dryer is based on the principle of Heated
Regenerative type Adsorption System. The air dryer consists of high quality moisture
adsorbing desiccant (Activated Alumina).
The Air Drying Unit consists of 2 Drying Towers TAD1 & TAD2, a Pre Filter PF,
an After Filter AF and 2 NOS of coolers with moisture separators. The hot air from
the compressor enters the Tower TAD1 through the 4 way valve 4WV1). The hot air
enters the tower from the top and leaves at the bottom. It regenerates the desiccant
and carries the moisture in the form of vapour. The air then enters the heat
exchanger HE and after cooler RAC through the 4 way valve 4WV3 at the bottom.
The tower and cycle time changes in TAD1 & TAD2 through the 4 way valve 4WV2
In the after cooler the temperature of air dropped by the cooling water. The
condensed air with moisture enters the moisture separator, where the condensed
moisture is removed. Moisture separator is fitted with an electronic moisture drain
trap with the bypass arrangement to remove the moisture from moisture separator.
The air then enters the Pre-filter, where the excess moisture and dust are removed.
Pre Filter is fitted with an electronic moisture drain trap which works on frequency of
time set with the bypass arrangement. The dirt and dust content is removed in the
Pre Filter up to 5 micron.
The air then enters the drying tower TAD2 through the 4 way valve 4WV3 at
the bottom. Drying process is from bottom to top. The dry air then passed through
an After Filter (AF) through a Four way valve 4WV2 at the top. In the After Filter AF
the dust and other particles are filtered up to 1 micron. The After filter is provided
with the auto drain valve to remove the dust particles.
The above heating process will continue for 5 hours. After heating for 5 hours
the 4 way valve 4WV1 position will change to divert hot compressed air to
regeneration cooler RAC. Now cool air from RAC will enter TAD 1 from bottom
through The cool air will become hot in the process of cooling the desiccant. Air
enters to heat exchanger HE through 4WV2. Cool air enters tower TAD2 for drying.
The air then enters the drying tower TAD2 through the 4 way valve 4WV3 at the
bottom. Drying process is from bottom to top. The dry air then passed through an
After Filter (AF) through a Four way valve 4WV2 at the top. In the After Filter AF the
dust and other particles are filtered up to 1 micron. The After filter is provided with
the manual drain valve to remove the dust particles. This cooling process will
continuous for 3 hours. At the end of 8 hours (5hrs of heating and 3 hrs of cooling)
the position of valves 4WV1 & 4WV2 will be changed to divert the hot air to TAD2 to
regenerate the desiccant. The regeneration and cooling of TAD2 will take as
mentioned above. This process will be repeated continuously. All the operations of 4
way valves (4WV1, 4WV2 & 4WV3) are automatic and are controlled by PLC timer.
The operations of 4 way valves can be made in manual model also. Both the coolers
are provided with moisture separators for effective removal of moisture.
In each stage Temperature Gauges and pressure gauges are provided to
monitor pressure and temperature of operating air. Appropriate protections such as
Safety valve temperature controller are provided to make the systems run at normal
condition. All the parts are fixed on a rugged frame with all rigid tubing. Air drying
plant is provided with initial fill of desiccant, pressure gauges, temperature gauges,
safety valves, electrical Control panels etc. Surfaces which are exposed above 60
Deg c are insulated in such a way to hold the thermal efficiency of the equipment
and to avoid the thermal heat transformation. In dryer at heating cycle, the air
enters at 160oC inside the TAD1 and comes out at 100oC then the air goes to the
heat exchanger and cools down up to 45oC this air passes through the RAC and
TAD2 and dried air passed out. In dryer at cooling cycle, the air enters to pre cooler
to reduce the temperature at 40-45°C and then passed bottom of tower TAD1 and
passed out through TAD2. This cycle changes after 8hrs frequently.
GEM EQUIPMENTS LTD
SPECIFICATION SHEET-DESICCANT SPEC NO D00545
TYPE, HOC TYPE DRIER
Sheet 1 of 2
Model Code
HOC1003S
Type
Heat of Compression Type
Capacity at Rated Pressure
3
Nm /min
25
Inlet Conditions
2
kg/cm (g)
Inlet Pressure
Inlet Temperature
Relative Humidity
o
C
8
160-180
%
Nm3/min
25
Adsoption cycle
hrs
8
Regeneration Cycle
hrs
8
Heating Cycle
hrs
5
Cooling Cycle
hrs
3
Maximum Capacity
100
Cycle Time
Outlet Condition
Pressure Drop Through Drier at
2
Kg/cm (g)
0.5
maximum flow
Outlet Air Temperature
Outlet Air Pressure
Outlet Air Flow from the Drier
Pressure Dew Point at outlet
Atmospheric Dew Point at outlet
o
C
50 (max)
2
Kg/cm (g)
3
Nm /min
7.5
25
o
C
-15
o
C
-40
Electricals
Input Supply
V / Hz / Ph
Maximum Power
W
230 / 50 / 1
60
Desiccant Chamber
Design Code
IS 2825
Material Code
IS 2002 Gr 2/ SA 516 Gr 70
2
Design Pressure
Kg/cm (g)
10
Hydro Test Pressure
Kg/cm2(g)
15
Corrosion Allowance
mm
1.5
Inside Diameter
mm
0.98
Height of Chamber
mm
1800
Thikness of Sheets used
mm
Radiography
%
Joint Efficiency
8 Shell, 10 Dish
Nil
0.7
Filters
F/DSN/019
Material Code
IS 3589, IS 2062
Diameter x Height
No. of Catridges / rating
mm
12" x 1250mm height
5 Nos / 5 micron rating
Material of Filter Catridge
Polypropylene
No.of Filters
1 Prefilter,1Afterfilter
REV:
01
PREPARED BY:
CHECKED BY:
APPROVED BY:
DATE:
15.01.2013
GEM EQUIPMENTS LTD
SPECIFICATION SHEET-DESICCANT SPEC NO D00545
TYPE, HOC TYPE DRIER
Sheet 2 of 2
Desiccant
Type
Activated Alumina
Size
mm
Expected Life
5 - 8mm
Years
3
Moisture Removed / cycle
Kg
106
Quantity of Desiccant provided /
Kg
1250
m/s
9
Chamber
Linear Velocity Through Pipes
Valves
Type
4 Way Valve (3No)
End Connection
3"NB ANSI Flg
Regenaration Air Flow
Nm3/min
Capacity
25
Source of Regeneration Air
From Compressor
Inlet / Outlet Connection
3"NB ANSI B16.5 Flg
Shipping Details
mm
2500 x 2250 x 3450
Weight of the Dryer
Kg
6000 (approx)
F/DSN/019
Overall Size of the equipment
REV:
01
PREPARED BY:
CHECKED BY:
APPROVED BY:
DATE:
15.01.2013