RfdtypeHydrogendryerOperatingManual

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OPERATIONANDMAINTENANCEMANUAL

REFRIGERATEDTYPEHYDROGEN
GASDRYER

CSB188

CLIENT

M/SBHEL,HARIDWAR

Manufacturer:

M/s.MELLCONENGINEERSPVT.LTD

B297,OKHLAINDUSTRIALAREA
PHASEI,NEWDELHI:110020.

PH.01126816103,26816530,
26811727
FAX.01126816573
EMail:
mellcon@mellcon.com

Website:
www.mellcon.com

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CLIENT

M/sBHEL,HARIDWAR

EQUIPMENT

REFRIGERATEDTYPEHYDROGENGASDRYER

DESIGN, ENGINEERING & CONSTRUCTION

BY
MELLCON ENGINEERS PVT LTD.
YEAR OF MANUFACTURE : 2014
OUR JOB NO. : CSB-188

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CONTENTS

01.INTRODUCTION

02.TECHNICALSPECIFICATIONS

03.PROCESS

04.TESTPROCEDURE

05.SEQUENCEOFOPERATION

06.SAFETYCHECKUP

07.SAFETYDEVICES

08.PLANTSTARTUP

09.TROUBLESHOOTINGCHART

10.GENERALMAINTENANCE

11.TECHNICALINFORMATIONTOREFRIGERATIONENGINEER

12.WARRANTY

13.RECOMMENDEDLISTOFSPAREPARTS

14.SUGGESTEDLOGSHEET

15.DRAWINGS:

(i)P&IDiagram

:CSB188PI
(ii)ControlPanelWiringDiagram
:CSB188CP

16.WARRANTYPOLICY

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INTRODUCTION

These instructions broadly covers the technical data, process flow description and
procedure to befollowedduringstartup,normaloperation,maintenanceandemergency
stopfortherefrigeratedtypehydrogengasdryer.

All information and drawing given with this manualis strictlyconfidentialand are tobe
usedonly forthe purposeofoperationandmaintenanceof thissystem. Theinformation
provided withthismanualisthepropertyofMellconEngineersPvtLtd.Delhiandshould
notbepublicandcopied.

TECHNICALSPECIFICATION

01. DryerCapacity

:40M3/HR

02. InletPressure

:5KG/cm2(g)

03. InletTemperature(Max.)

:60Deg.C.

04. OutletdewpointatlinePr. :(+)35Deg.Catlinepr..

05. PurgeLoss
06. Supplyvoltage

:Nil
:415VAC,3phase,50Hz.

07. Operation

:Automatic

08. Baseframesize

:900mmX850mm

09. Heightfrombase

:2000mm(Approx)

10. Refrigerant

:R134a

(FordetailsreferElectricalDrg.)

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PROCESS

Hydrogen gas saturated with water vapour, enters dryer inlet and is precooled by
outgoing refrigerantineconomiser(precooler),asmoothsurface,nonfoulinggastogas
heat exchanger. Pre cooling removes some of the heat load from the incoming gas
allowing the use of a more efficient refrigeration condensing section. The precooled
gas then passes through a smooth surface, Nonfouling air to refrigerant heat
exchangerChiller(refrigerantevaporator),whereitiscooledto+35degreecentigrade
by giving up heat to refrigeration system. Now the hydrogen gas passes through the
moisture separator, where thewaterisseparatedfromthegasanddischargedregularly
through the auto drain valve. The cold gas then exits at outlet, after it has passed
through the other side ofgas togasheatexchanger,(economiser) whereitis warmed
bythe incoming hot gas.Thisreheatingincreases the gas effectivevolume (enablingit
to do more work ) and prevents pipe sweating downstream. (The dried gas travels
through the activated carbon filter to yours plant ), gas stream does not fallbelowthe
temp. to which itwaschilledinthegastorefrigerantheatexchanger(referredtoasdew
point temp.) and hence no more water vapour will condense into troublesome liquid.
Removing the water allowsyoutokeeppipelines,gastools,valvesandcylinders,spray
guns,pneumaticinstrumentsandanygasoperateddevicecleananddry.
NOTE:
Togetbetterairquality,runtheairdryeratNOLOAdtoachievethedewpoint
of5Deg.C.,thengiveloadtothedryer(Ifchilleristanktype).

TESTPROCEDURE

As per our requirement testing ofequipment we usecompressor for air. For testing its
capacity40 m3/Hr at 60 degreecentigradeitisgoestoheaterof..KWforheatingofair
upto 4060 degreecentigradeand tempwitness through temp indicatorcontrollerafter

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that air goes directly to precooler and from precooler to chiller from where air chilled
through freoncircuit upto35degreecentigrade onthistempairmoisturecondensed
andcomeintothemoistureseparatorfromwhereitisdrained

automatically and manually both after that air comes from moisture separator to
precooler where air heat is removed from precooler and take it to process. Complete
freon circuit functions automatically. Theparametersaretobecheckedasunderasper
yourrequirements.

Temp to be witnessed by tempindicator controllers, locationofTICs as per our

sketch.
Flow rate of air can be checked by anemometer at compressor outlet or
inlet/outletofdryer.
Humidity of air to be checked at compressor outlet and dryer inlet and dryer
outlet (Before connecting of compressor and after connecting of compressor
through humidity indicator at time of starting time of complete systemandafter
completingof4hoursonly).
Cycletimeofoperationandofflinecanbedoneduringtesting.
Calculation of total heat can be done and checked through rate of flow of
compressor and air temp. at inletof dryerand outlet ofdryer (enthalpy inlet air
andoutletairbypsychrometricchart)whichisobservedduringfunctionaltest.

SEQUENCEOFOPERATION

There are two type of starting of control circuit. Oneis remote ON/OFF and secondis
local ON/OFF which is operated by selector switch SW1. BYselecting selector switch
sw 1 on remote mode , control relay CR 3 will be activated only on the command of
GAMP. As per the command of GAMP CR3 will be energize, which will ON thedryer
and lamp indication L5will glowup, which confirm that the dryeris ON.similarlywhen
GAMP signalis notavailable, ControlrelayCR3willdeenergize andselectorswitchat
localmode then it will activated dryerONthrough NC contactof control relayCR3.the
lampindicationL5willglowupandconfirmthatdryerisON.

1. DTC1,DTC2,DTI1&DTI2willbeactive.

CompressorOn/OFFtakesplaceByDTCasperthesettemperature.
DTI1show the dryerinlet temperature ofgas throughsensorwhichismounted
atdryerinlet.

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DTI2show the dryeroutlettemperatureofgasthroughsensorwhichismounted

atdryeroutlet.

2. To control freon discharge pressure, a pressure switch is provided to operate

condenserfanasperpressuresetting.

3. Another selector switch SW2 isprovidedtooperatethedryereitherinautomode

and manual mode. In auto mode the dryer operate with cyclic timer and in
manualmodethedryeroperateswithoutcyclictimer.

In manual mode For manual mode operation, we kept the selector switch
SW2 at manual mode which energizethe control relayCR1and throughcontrol
relay CR1 NO contact which becomes NC now, switch ON thecompressor and
also activate thesolenoidvalveSVandlampindicationL8glowup whichconfirm
thatcompressorisON.
In auto mode For auto mode operation , we kept selector switch on auto
mode. which energizethe cyclic timerCT.andthroughNOcontactofCT,control
relay CR2 will energize and switch ON the compressor. the lamp indication L8
willglowupwhichconfirmthatcompressorisON.

4. HP/LP switch is provided to operate the compressor in required or designed

suction and discharge pressure range. above discharge pressure set pointand
below suction pressure set point HP/LP switch trip the compressor and
respective lamp indication L11 (LP Trip) / L12(HP Trip) will glow up.LP switch
installedin freonsuction line whereasHP switch installed atfreondischargeline
totripcompressoratsetpressure.

5. Underhealthy condition,compressor will beONbyDTandL8willglowup.DT

is delay timer and it is meant for starting the compressor. If the compressor is
being stopped then it will notrestart the compressorbefore 2 minute or any pre
settime.

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SAFETYCHECKUP

DisconnectPowersupplytounitbeforeperforminganyelectricalservicework.
Before working on hydrogen gas side of unit isolate dryer from hydrogen gas
supply by shutting off inlet valves and opening bypass valve (if provided) and
depressuriseunitbyopeningspetcockoncondensatedraintrap.

Donotexceedmaximumhydrogengaspressureratingspecified.
Thedryershouldnotbekeptunderdirectsunlight.
Donotexceedmaximuminletgastempspecified.

SAFETYDEVICES

SPPRTRIP:

ASingle Phase Preventeris mountedintheControlPaneltoprotecttheCompressorin

caseof Phase failure,Phaseunbalance,Phasesequencereversal,Under/HighVoltage
etc. Single Phase Preventer sense negative sequence voltage, supply and trip the
Compressor. When it trips, rectify the fault and reset the Single PhasePreventerand
restartthesystem.

OVERLOADRELAY:

An Over LoadRelayis mountedwith the RefrigerationCompressor contactorto trip

the systemif compressor draws more thanthe specified set current. When ittrips,
wait for few minutes andreset the OLR withresetpushbuttonprovidedontheOLR.
Then restart the system. If still it is tripping then check the Voltage, Compressor
Terminals for any loose connection. Contactor Terminals and Compressor winding.
Rectifytheproblemandrestartthesystem.

OR

AnOver LoadRelayis mountedwith the CondenserFan Contactortotripthesystemif

Fan draws more than the specified setcurrent.Whenittrips, waitfor few minutes and
reset theOLRwith resetpush buttonprovided on the OLR.Then restart thesystem.If
still it is tripping then check the Voltage, Fan Terminals for any loose connection.
ContactorTerminalsandFanmotor.Rectifytheproblemandrestartthesystem.

CAUTION
:
DonotchangethecurrentsettinginOverLoadRelay.

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TEMPERATUREINDICATINGCONTROLLER:

The Temperature Indicating Controller (TIC or DTC) is meant for controlling the Dew
Point temperature. A resistance thermal device type sensor is used for accurate
temperaturecontrolling.

DIGITALTEMPERATUREINDICATOR:

Digital Temperature Indicator (DTC) provided for airinlet &outletline.DTCindicatethe

gasinlet&outlettemperature.

HP/LPSWITCH:

This isacombined High Pressure/LowPressureswitch totripthe systemonabnormal

pressure conditions. If HP trips then check the condenser fan, clean the condenser if
required. Check the choking of dryer. Check the quantity of refrigerant gaschargedif
overchargedreleasetheexcessgasandresettheHP/LP.Thenrestartthesystem.

Similarly if LP trips then check the leakage ofrefrigerantgasand rectifyit. Chargethe

requiredgas.

IMPORTANT:
Donotchangesettings.

PRESSURESWITCH:

Apressureswitch is provided tocontroldischarge pressure bymeansofcontrollingthe

condenserfan. It issensing the dischargepressureandgiving commandto condenser
fantoONorOFF.Thiswillalsosaveenergyduringwinterseason.

IMPORTANT

:
Donotchangesettings.

PLANTSTARTUP

INSTALLATION

ConnecttheHydrogenGasinlet&outlet..

Connect the Electrical connection to the Dryer. Refer attached Control Panel
WiringDiagramfordetails.

MOUNTING

No special foundation is required. However, care should be taken to ensure that the
unitisplacedonlevelsurface.

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PIPING

Hydrogen
gas inletand outlet :Connect hydrogen gaslinesto gas inlet and gasoutlet
locatedandidentifiedonthesideofthecabinet.Pipingandarrangementswouldinclude
inletandoutletvalvesandalsoasuitableairbypassifdesired.

ELECTRICALHOOKUP

IMPORTANT
:Thedryerisdesignedtoruncontinuouslyandmustnotbewiredtocycle
ON and OFF with the air compressor. Dryer compressor can be turn off during
shutdownperiodsbyusingON/OFFswitchonfrontpanel.

NOTE:

The Dryer pressure should not drop below 5 Kg/Cm2(g) as thelowerpressure

degradestheoutletdewpoint.
The inlet temperature should not exceed 60 Deg. C. asthehigher temperature
degradestheoutletdewpoint.
Checkforgasleaksatpipingconnections.
Ensuretheindicatorsandgaugesareoperatingproperly.
Allow the unit to run for several hours. Then check to see if drying is being
accomplished. This can be done by releasing the compressed air from
MoistureSeparatorthroughmanualdraincondensateremovaltrap.

IMPORTANT:
DONOTturnoffpowertounitexceptwhenservicing.

TROUBLESHOOTINGCHART

S.NO NatureofFault

PossibleReason

1.

HPTrip

Condenser fan may not Check the healthiness of

beoperating
fan.

Condenserchoked

ActionTaken

Clean the condenser by

blowingairoverit.

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Setting
may
beendisturbed.

Gasovercharged

Check the quantity of

refrigerant charged and
removetheexcessgas

Ifthem/cisoverload

Check the load and do

theneedful.

Noneoftheabove

Contactthemanufacturer.

2.

LPTrip

Setting may have been Check the setting and

correctitaspermanual.
disturbed.

Any service valve in gas Check the circuit valves

circuit may have been andcorrectthesame.

closed.

Solenoid valve may be Check the solenoid valve

burnt.
in refrigerant circuit and
takecorrectiveaction.

Gasleakedout.

If the m/c is working on Checktheload.

noload.

Noneoftheabove.

contactthemanufacturer.

3.

OLRTrip

Looseconnection

Check the tightness of

eachcables.

Setting
may
beendisturbed.

Singlephasing.

have Check the setting and

correct as per manual
andresetpushbutton.

Check the gas pressure

in the system, if gas is
less rectify the leakage
and charge the required
gas.

have check the setting &rectify

it.

Checkallthreephases.

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If the equipment
runningonoverload.

Noneoftheabove.

contactthemanufacturer.

4.

SPPRTrip

Looseconnection

check the tightness of

eachcables.

Phase sequence may be change the sequence of

changed.
anytwophase.

Noneoftheabove.

is Checktheload.

contactthemanufacturer.

GENERALMAINTENANCE

1. Properly installed and operating, the dryer requires a minimum of care to be

provided for many years ofreliable service. A regularmaintenance program will
add to the life of the dryer and prevents problem with your compressed air
system. Regular maintenance procedures should include daily monitoring of
dryeroperations.

2. On air cooled models, blowing out and cleaning of dirt and dust from the air
cooled refrigeration condensing unit and especially the refrigeration condenser
monthly or as required depending on condition of the area in which dryer is
installed. in exceptionally dirty location, a furnace type filter installation front of
the refrigeration condenser is recommended.It shouldbe keptclean in orderto
maintainfreeairflowacrosscondenser.

3. Do not Tamper with refrigeration section. Settings made at the factory are for
normal conditions. Where conditions are unusual, consult manufacturer's to do
needful.

4. Use stabilized voltage to prevent abnormal electrical component / compressor

failure.

TECHNICALINFORMATIONTOREFRIGERATIONENGINEERS

CLEANING OF CONDENSER (AIR COOLED TYPE) :

It is recommended to
clean the condenser every 13 months dependingupon your site condition.The
dust particles settled inside the finnes of the condenser to be cleaned for

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efficiency improvement. For cleaning blow compressed air at a pressure of12

kg/cm2 through the finnes or spray water jet /soap solution throughthe finnes.
Duringthiscleaningshutdowntheunit&electricalparts.

IMPORTANT:
Wirebrushesorhighpressureair/waterjetsshouldnotbeused.

REFRIGERANTLEAKAGERECTIFICATION: Ifanygasleakageisthereinthe
system proper cooling can not be achieved and suction pressure will showthe
lesser than required. If excess gas is leaked out then lp switch will trip the
system. to rectify the leakage ofthe systemconsult withaqualified refrigeration
engineer.

VACUUM &GAS CHARGING:

Forvacuumandgas charginggoodexperience
isrequired inrefrigeration.Thereforeitisrecommendedtoconsultwithaqualified
refrigerationengineeranduseonlyproperevacuationtechnique.

CAUTION
:Donotoverchargethegasintothesystem,whichmaydamagethe
compressor.

COMPRESSORREPLACEMENT :
Duringcompressor replacement thedryerto
bereplaced andthe wholerefrigerantpipestobeflushed.Thenvacuumandgas
charging is to be done. Therefore it is recommended toconsult withaqualified
refrigerationengineer.

WARRANTY(PLEASEALSOREFERWARRANTYPOLICY)

In order to avail warranty maintenance of log book ismandatory.Non maintenanceof

log book during warranty period shall render the guarantees and warranty of the
equipmentasvoid.

If the equipment is modified , repair or any attachment/accessories is fixed

unauthorisedly,allguaranteesandwarrantyshallbevoid.

RECOMMENDEDSPAREPARTS

FreonDryer
Digitaltemperaturecontroller
Mcontactorforrefrigerationcompressor
HP/LPSwitch

:1NO.
:1NO.
:1NO.
:1NO.

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PressureSwitch
Delaytimer
DrainValve
FreonIndicator
SolenoidValve
CyclicTimer

:1NO.
:1NO.
:1NO.
:1NO.
:1NO.
:1NO.

NOTE
:

At the time of commissioning/ servicing of refrigerated typeair dryer, Please note that
the freongas vacuumpumpand tool &tackle shouldbe arranged by customer onfree
ofcostbasisforourtechnician.

LOGBOOKS

This procedure if adopted andrecorded everyalternatedayoronceaweekwillbevery

useful for maintaining the quality of gas being used and identifying the troubles and
takingpreventivetimelyaction.

MellconEngineersPvtLtd.

ISO DOC. NO.

LOG SHEET OF AIR DRYING PLANT (REFRIGERATED TYPE)

(TO BE FILLED DAILY, AT LEAST TWICE IN A DAY)
Date
&
Time

Remarks :

Air Pressure
(Kg/Cm2 g)
Inlet
Outlet

Air Temperature
(Deg. C.)
Inlet
Outlet

Drain
Valve
(Auto/Manual)

Comp.
Current
(AMPS)

Freon
Pressure
Suct.
Disch.

ME/ISO/08/SV/06
Rev. : 1
Effective : 17/07/2013

Freon Temp.
Suction
TIC-2

Dew Point
Temp. TIC-1
Set.
Actual

MELLCON ENGINEERS PVT. LTD.

NEW DELHI
WARRANTY POLICY
Within the period stipulated above, we expressly guarantee in lieu of any warranty
implied by law to make good any defective parts in the machinery along with complete
consignment of our own manufacture only provided.
01. That the defect develops under proper and normal use as per instructions
laid down by supplier and arises solely from faulty material or workmanship.
02. That the defect does not arise out of damages due to negligence and improper
handling.
03. That the defective part / parts are neither reconditioned nor modified by user
without our consent.
04. The Company shall repair / replace the minor components, jobs at site.
However if the nature of repair becomes beyond control at site then the
equipment shall be sent to our works for repairing. The charges for transport
etc. shall be borne by purchaser.
05. Any electrical parts like MCBs, Contactors, Timers, Lamps, Relays, Solenoid
Coils, Glass Parts, Corrossion & errosion of materials, Rubber parts etc. do not
form a part of warranty.
06. All goods covered under this guarantee are supplied on the conditions that we
shall not be liable for any loss incurred through stoppages or any consequential
damages.
07. Maintenance of Log Book is mandatory. Non maintenance of Log Book during
warranty period shall render the guarantees and warranty of the equipment as
void
08. All our BOPs shall be warranted as per the warranty we receive from our subvendor.
The warranty shall be void if the equipment is mishandled / operated by bypassing the
safeties, misused or unauthoritically modified without written consent of the
manufacturers.