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USER MANUAL
Series HC

Reference No. 145 Final Rev 5

Page 42

September 2004

SECTION 5:

(Continued)

I-R Series HC Theory of Operation Illustration

Legend:

BE = visual moisture indicator

CS = separator

F = filter

FS = float switch

FT = primary float trap

P = pressure gauge

PRV = pressure relief valve

SD = secondary drain

SV = solenoid valve

T = temperature gauge

TW = thermowell

V = valve

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Summary of Contents for HC-239

Page 1: ...E WITH A LUBRICATED COMPRESSOR WILL VOID ALL WARRANTIES AND MAY CAUSE SEVERE DAMAGE Information When making inquiries please provide the following information 1 Equipment Model Number 2 Equipment Serial Number 3 Equipment Operating Pressure 4 Equipment Operating Temperature 5 Approximate time in service 6 Nature of Problem For information parts or service contact your local I In ng ge er rs so ol ...

Page 2: ...without Company s prior written approval The effects of corrosion erosion and normal wear and tear are specifically excluded Performance warranties are limited to those specifically stated within the Company s proposal Unless responsibility for meeting such performance warranties are limited to specified tests the Company s obligation shall be to correct in the manner and for the period of time pr...

Page 3: ...ication 1 4 Product Information 1 4 1 Theory of Operation 1 4 2 Pressure vessel regulations 1 4 3 Airtightness test 1 4 4 Overloading 1 4 5 Technical data sheet 1 4 6 Dryer Flow Capacities 1 4 7 Transport 1 4 8 Storage 1 4 9 Use of an afterfilter SECTION 2 INSTALLATION 2 1 Set up and installation 2 1 1 Mechanical installation 2 1 2 Filter installation 2 1 3 Electrical installation SECTION 3 START ...

Page 4: ... Dewpoint meter maintenance DPDS Option only 4 4 Filters 4 4 1 General comments and use 4 4 2 Function 4 4 3 Assembly and installation 4 4 4 Maintenance 4 4 5 Changing of filter elements 4 4 6 Accessories SECTION 5 SPARE PARTS LIST 5 1 Recommended spares for HC 3 TO HC 239 SECTION 6 TROUBLESHOOTING AND FAULTS 6 1 Introduction 6 2 High Dewpoint 6 3 Fail to shift 6 4 Primary Drain Failure 6 5 Second...

Page 5: ...pany Description 7 2 Material Description 7 3 Ingredients 7 4 Physical Data 7 5 Fire and Explosion Data 7 6 Reactivity Data 7 7 Health Hazard Information 7 8 Spill Leak and Disposal Procedures 7 9 Special Protection Information 7 10 Special Precautions and Comments 7 11 References SECTION 8 AUXILIARY MANUALS DRAWINGS ...

Page 6: ...tions must be followed as written in order to avoid danger and damages which could cause downtime and premature wear and tear on the adsorption dryer In addition to the technical manual and the accident prevention regulations which are valid in the particular location where the dryer is being used the recognized special rules for safe and proper working procedures must also be followed Each person...

Page 7: ...d d accepts no liability for corrosion damage and malfunctions caused by aggressive media Applications other than those mentioned in this manual must be agreed to by I In ng ge er rs so ol ll l R Ra an nd d and confirmed in writing In the interest of further development I In ng ge er rs so ol ll l R Ra an nd d reserves the right to make changes at any time which in keeping with the essential chara...

Page 8: ...egible Advice This sign refers to a procedure or sequence of particular interest or importance All tips must be followed to ensure proper use of this adsorption dryer This dot refers to working or operational steps The steps are to be carried out in the order of their appearance from top to bottom The sign of a hyphen marks enumerations 1 2 2 Safety tips for maintenance inspection and assembly wor...

Page 9: ...ctive goggles and mask when working with the desiccant Advice for protection If desiccant comes into contact with the eyes rinse eyes immediately with large amounts of clear water If the desiccant is spilled clean up with effort to minimize the formation of dust In case of fire there is no restriction on the use of fire extinguishing material A small dust mask must be worn 1 3 PERSONNEL QUALIFICAT...

Page 10: ...gases 1 4 1 Theory of Operation The HC heat of compression dryer uses the hot air from the compressor to regenerate the desiccant Each tower is sized for a minimum of 4 hours online but may be extended by use of the optional DPDS which will allow the dryer to switch towers based on water load rather than time The DPDS Dewpoint Demand System is optional equipment and may or may not be present on yo...

Page 11: ...cted by the inlet 2 way valves into the regenerating tower This hot thirsty air regenerates the bulk of the water from the desiccant The air is then directed into the aftercooler where it is cooled the coalescing separator where liquid water is removed through the drain trap system then into the drying tower where the air is actually dried to its final low dewpoint The heating cycle lasts 90 minut...

Page 12: ...g the hot inlet air directly into the aftercooler separator and drying tower We now begin stripping The stripping phase of regeneration lasts 90 minutes At the beginning of stripping the regenerating tower is depressurized through a muffler During stripping a small adjustable flow of dry air is used to remove the last little bit of moisture from the regenerating tower ...

Page 13: ...ooling At the end of stripping the regenerating tower is repressurized The cooling cycle valves open and cooling begins The cooling cycle lasts 60 minutes During cooling a portion of the dry outlet air is directed into the regenerating tower to reduce the temperature of the bed prior to tower shift ...

Page 14: ... PSIG Operating Temperature Max Min 500 F 20 F Attention Never weld on or alter a pressure vessel in any way 1 4 3 Airtightness test All adsorption dryers are subjected to an airtightness test prior to shipment using compressed air 1 4 4 Overloading Attention Protect the adsorption dryer from overloads The adsorption dryer can become overloaded if The inlet flow is too high The temperature of the ...

Page 15: ...connection 2 NPT 2 NPT 3 FLG 3 FLG FILTER Afterfilter AF 350 AF 550 AF 1000 AF 1000 Voltage 115 1 60 Standard Consult Factory for other voltages Cooling Water GPM 9 16 20 25 Stripping Flow SCFM 6 11 14 17 Cycle time 8 Hour NEMA Cycle 4 Hours drying 4 Hours Regeneration Outlet Dewpoint Variable DPDS Control Adjustable High Humidity Alarm Adjustable Pressure Switch Setpoints 10 PSI Fail to Shift 60 ...

Page 16: ...let connection 3 FLG 4 FLG 4 FLG 6 FLG FILTER Afterfilter AF 1400 AF 2400 AF 3600 AF 7200 Voltage 115 1 60 Standard Consult Factory for other voltages Cooling Water GPM 36 56 80 110 Stripping Flow SCFM 24 38 54 74 Cycle time 8 Hour NEMA Cycle 4 Hours drying 4 Hours Regeneration Outlet Dewpoint Variable DPDS Control Adjustable High Humidity Alarm Adjustable Pressure Switch Setpoint 10 PSI Fail to S...

Page 17: ... connection 6 FLG 6 FLG 8 FLG 8 FLG FILTER Afterfilter AF 7200 AF 7200 AF 7200 AF 10000 Voltage 115 1 60 Standard Consult Factory for other voltages Cooling Water GPM 143 138 172 208 Stripping Flow SCFM 96 122 150 182 Cycle time 8 Hour NEMA Cycle 4 Hours drying 4 Hours Regeneration Outlet Dewpoint Variable DPDS Control Adjustable High Humidity Alarm Adjustable Pressure Switch Setpoint 10 PSI Fail ...

Page 18: ... connection 8 FLG 8 FLG 10 FLG FILTER Afterfilter AF 16000 AF 16000 AF 16000 Voltage 115 1 60 Standard Consult Factory for other voltages Cooling Water GPM 247 289 335 Stripping Flow SCFM 217 254 295 Cycle time 8 Hour NEMA Cycle 4 Hours drying 4 Hours Regeneration Outlet Dewpoint Variable DPDS Control Adjustable High Humidity Alarm Adjustable Pressure Switch Setpoint 10 PSI Fail to Shift 60 PSI In...

Page 19: ...1 7522 7830 8169 8545 HC 103 7909 8273 8664 9101 9474 9884 10339 HC 122 9413 9846 10312 10832 11276 11764 12305 HC 143 11047 11555 12102 12712 13233 13805 14441 HC 166 12812 13401 14035 14743 15347 16011 16748 Note Maximum operating pressure is 150 PSIG higher pressures available as an option Consult factory Minimum Inlet Pressure PSIG 85 90 95 100 105 110 115 Correction Factor 1 15 1 1 1 05 1 96 ...

Page 20: ...gister any damage Shipping damage is not covered by any warranty 1 4 8 Storage If the adsorption dryer is to be stored for a prolonged period of time it should be stored in a dry place preferably indoors protected from the elements including freezing or extremely warm temperatures 1 4 9 Use of a pre and afterfilter Use of a prefilter is not necessary with a heat of compression dryer An afterfilter...

Page 21: ...Since the adsorption dryer has already been completely wired at our factory the customer only has to connect the power supply cable to the terminal strip according to the supplied wiring diagrams Advice Should you still have questions regarding installation you can request installation blueprints separately from I In ng ge er rs so ol ll l R Ra an nd d Davidson NC Warning Use the appropriate load ...

Page 22: ...nt and to prevent contact with hot surfaces Because of vibration during shipping some tube fittings may have loosened therefore inspect all connections and tighten if required Also flange connections may have loosened therefore tighten all flange bolts Ensure that the inlet and outlet connections to and from the I In ng ge er rs so ol ll l R Ra an nd d type HC Dryer are made using the correct rate...

Page 23: ...ated on the filter is followed Ensure that all piping and valves are equivalent or larger in size to the dryer inlet connection Filter Skid with 3 Valve Bypass Installation Filters skid should be located as close to dryer as possible Use the skid bolt holes to secure the assembly Ensure that the skid is located such that the 3 valve bypass will bypass the dryer and filters when in use Check the fl...

Page 24: ... disconnect switch is not provided with the dryer and must be supplied by end user in accordance with the recognized electrical codes Ground the frame of the dryer in accordance with the recognized electrical codes It is recommended that the common alarm relay located in the dryer control panel be connected to the control room or operator station so that an immediate response to the dryer alarm ma...

Page 25: ...let block valve is closed Cooling water is turned on to the aftercooler Slightly open the inlet isolation valve slowly admitting compressed air to the system When full system operating pressure has been reached all connections should be soap bubble tested for leaks Any leaks should be repaired and retested prior to placing the equipment in service If some gas other than the process air will be use...

Page 26: ...nsure dryer is cycling A manual mode is included in the dryer program to allow for fast cycling to verify the operation of the dryer While dryer is in the stripping mode for either chamber the regeneration flow setting should be checked The stripping flow valve should be set at 1 5 turns open at start up and adjusted as necessary to maintain the specified dewpoint The pressure gauge on the regener...

Page 27: ...E Function keys F1 through F4 perform the function displayed on the screen ARROWS ALLOW USER TO SCROLL UP OR DOWN INSIDE OF THE SCREEN LIST SELECTOR AN ARROW ON THE RIGHT SIDE OF THE SCREEN NAMES INDICATES WHICH SCREEN IS BEING SELECTED ENTER SELECTS THE SCREEN IN WHICH THE ARROW IS POINTING AND DISPLAYS THAT SCREEN ...

Page 28: ...wer regenerating is in This will toggle from HEATING to STRIPPING to REPRESSURIZATION to COOLING If the optional dewpoint demand system DPDS is installed you may also see STANDBY below the current tower status The lower left hand corner gives the time remaining in the current regeneration cycle This starts counting down from 240 minutes four hours Note When the dryer is in DPDS Standby the time re...

Page 29: ...lay any and all alarms Alarms are displayed in the order in which they occur for instance the top alarm is always the most recent one When an alarm situation occurs this screen will automatically be displayed When an alarm clears the operator interface will automatically return to the MAIN screen The optional fail to shift alarm comes with an alarm horn The F4 key will allow an operator to disable...

Page 30: ... of 60 seconds When time delay times out if pressure switch PS2 is greater than 10 Fail to Shift alarm 2 2 min De energize SV2 2 Energize SV2 1 Opens V1 15 Closes V2 Heating Right Tower 3 90 min De energize SV2 1 Energize SV2 2 Opens V2 Closes V1 15 Energize SV4 1 Opens V12 Energize SV3 1 Opens V11 Stripping Right Tower 4 180 min De energize SV4 1 Closes V12 Re pressurizing Right Tower When PS3 re...

Page 31: ...elay times out if pressure switch PS2 is greater than 10 Fail to Shift alarm 7 242 min De energize SV2 2 Energize SV2 1 Opens V1 15 Closes V2 Heating Left Tower 8 330 min De energize SV2 1 Energize SV2 2 Opens V2 Closes V1 15 Energize SV4 1 Opens V12 Energize SV3 1 Opens V11 Stripping Left Tower 9 420 min De energize SV4 1 Closes V12 Re pressurizing Left Tower When PS3 reaches setpoint of 60 PSI t...

Page 32: ...t temperature TH1 drops below the setpoint 240 F then Low Regeneration Temperature Alarm 2 At any time during the cycle if the cooler outlet temperature TS1 rises above the setpoint 105 F then High Cooler Outlet Temperature Alarm 3 At any time during the cycle if the dewpoint DPDS rises above the setpoint 20 F for more than five continuous minutes then High Dewpoint Alarm 4 At any time during the ...

Page 33: ...dryer be observed and inspected as often as it is practical the following is a minimum requirement A EVERY 2000 HOURS OR 3 MONTHS 1 Check the inlet air temperature make adjustments if necessary 2 Check the air temperature at intercooler outlet above 100 F means a Increase the cooling water flow b Lower the cooling water temperature c Back flush and thoroughly clean the intercooler to restore effic...

Page 34: ...Months DO NOT REPRESSURIZE DRYER OR RECONNECT POWER TO THE DRYER YET 2 Rebuild the actuators by installing repair kits in the major switching valves V1 V13 and V15 3 Carefully disassemble and clean the solenoid valves in the control group rebuild with new parts only if damage or serious wear is evident 4 Carefully disassemble and clean the 3 way solenoid valve on the separator drain trap 5 Rebuild...

Page 35: ...hrough 9 as outlined in Every 8000 Hours or 12 Months DO NOT REPRESSURIZE DRYER OR RECONNECT POWER TO THE DRYER YET 2 Drain all the desiccant from both vessels through the drain at the bottom of each vessel 3 Refill both vessels with the proper amount of desiccant as noted in the specifications at the front of this manual NOTE Desiccant can be purchased only through Ingersoll Rand distributors aut...

Page 36: ...ter supply as required 4 2 REPLACEMENT DISPOSAL OF THE DESICCANT NOTE Refer to the desiccant MSDS in the appendix of this manual for detailed information regarding material description and ingredients The dryer is filled from the top and emptied from the bottom Refer to the General Arrangement drawing for location of fill and drain ports To drain the desiccant remove the drain plug cover and catch...

Page 37: ...pressed air and other neutral compressed gases This new filtration concept is characterized by high flows at low differential pressure 4 4 2 Function The soiled medium flows through the filter element Series AF from the outside to the inside Solids are filtered out by impact or by the effect of inertia 4 4 3 Assembly and installation Advice The piping system must be cleaned before assembling filte...

Page 38: ...PRESSURIZED Filter elements are to be changed according to the following steps Open the hand hole Loosen and remove the element by hand Install the new element and make sure that the element seats perfectly Re install hand hole cover Elements of the AF series can NOT be cleaned with compressed air 4 4 6 Accessories Advice Pressure differential gauge Indicates the degree to which the elements are s...

Page 39: ... 2 2 38342556 Gasket grafoil 3 150 FF 1 16 4 4 38338893 Switch pressure 30 300 PSIG 1 1 1 1 38338901 Switch pressure 3 30 SPDT for Fail to shift Alarm option 1 1 1 1 38339750 Repair kit actuator CTD S 020 V11 13 1 1 38337937 Repair kit actuator CTD S 030 V11 13 1 1 38339735 Repair kit actuator CTD S 040 V1 10 15 2 2 38337960 Repair kit actuator CTS 050 V12 1 1 38339768 Repair kit ball valve 1 V11 ...

Page 40: ... 2 38338877 Gasket grafoil 12 150 ring 1 16 2 38342564 Gasket grafoil 4 150 FF 1 16 4 4 38338885 Gasket grafoil 6 150 FF 1 16 4 4 38338893 Switch pressure 30 300 PSIG 1 1 1 1 38338901 Switch pressure 3 30 SPDT for Fail to shift Alarm option 1 1 1 1 38339735 Repair kit actuator CTD S 040 V11 13 1 1 38337960 Repair kit actuator CTS 050 V12 1 1 38335634 Repair kit actuator CTS 060 V12 1 1 38338018 Re...

Page 41: ...foil 16 150 ring 1 16 2 2 38338885 Gasket grafoil 6 150 FF 1 16 4 38342572 Gasket grafoil 8 150 FF 1 16 4 4 4 38338893 Switch pressure 30 300 PSIG 1 1 1 1 38338901 Switch pressure 3 30 SPDT for Fail to shift Alarm option 1 1 1 1 38337960 Repair kit actuator CTS 050 V12 1 1 1 1 38335634 Repair kit actuator CTS 060 V22 1 1 1 38337929 Repair kit ball valve 1 V12 1 1 1 38337986 Repair kit butterfly va...

Page 42: ...16 4 4 4 38338893 Switch pressure 30 300 PSIG 1 1 1 1 38338901 Switch pressure 3 30 SPDT for Fail to shift Alarm option 1 1 1 1 38337960 Repair kit actuator CTS 050 V12 1 38335634 Repair kit actuator CTS 060 V22 1 38335634 Repair kit actuator CTS 060 V12 1 1 1 38339693 Repair kit actuator CTS 065 V22 1 1 1 38337929 Repair kit ball valve 1 V12 1 38338018 Repair kit ball valve 2 V12 1 1 1 38338927 R...

Page 43: ...ION 5 Continued I R Series HC Theory of Operation Illustration Legend BE visual moisture indicator CS separator F filter FS float switch FT primary float trap P pressure gauge PRV pressure relief valve SD secondary drain SV solenoid valve T temperature gauge TW thermowell V valve ...

Page 44: ...perature are still within specification 6 2 2 Old Desiccant If the dryer is not able to maintain dewpoint for a sufficiently long period the desiccant may have aged to the point where its capacity is inadequate Replace the desiccant with the appropriate quantity and type of desiccant 6 2 3 Towers Not Reversing Check PLC solenoid valve inlet switching valves and if supplied Dewpoint Demand System m...

Page 45: ...k actuator operation and check for seat wear 6 3 FAIL TO SHIFT 6 3 1 Solenoid Valve Failed To Operate Check electrical connection coil and valve seat 6 3 2 Pilot Air Tubing Leakage Check tubing fittings for leakage 6 3 3 Two way Switching Valve Actuator Leakage A leaking actuator can cause the switching valve to malfunction low pilot pressure due to leakage or solenoid valve failure will cause the...

Page 46: ...mally open solenoid valve Clean repair or replace as necessary 6 5 2 Liquid Level Probe Failure If the PRIMARY DRAIN FAILURE ALARM does not activate after or during failure of the float operated drain check the liquid level probe for proper operation 6 6 SHORT TERM SHUT DOWN Advice The following sequence is to be heeded when switching off the adsorption dryer First close all the shut off valves up...

Page 47: ...A1203 xH20 Other Designation Activated Alumina F 1 F 20 F 200 HF 200 S 100 F 1 E S 100 CG 20 OF 2000 Active bed supports SRU Product Use Absorbent dehydration agent catalyst support 7 3 INGREDIENTS Component by weight typical Occupational Exposure Limits A1203 90 0 95 0 TWA I mg m3 Na20 0 3 0 6 ACGIH TLV Si02 0 01 0 2 Alumina Dust Fe203 0 03 0 1 Total fraction 10 Loss on ignition water 4 0 7 0 PEL...

Page 48: ...emperature NA Freeze Melt Temperature 3700 F 2038 C Vapor Pressure mm NA Vapor Density air 1 NA Evaporation Rate NA Specific Gravity 3 2 Density Loose bulk 39 52 lb ft 3 0 62 0 83 g CM3 Water Solubility Insoluble soluble in concentrated acids and alkalies pH 10 20 slurry solution Color Off white Odor None Odor Threshold ppm NA Coefficient of water oil distribution NA ...

Page 49: ... air None With heat None With strong oxidizers None Non corrosive 7 7 HEALTH HAZARD INFORMATION The desiccant properties of Activated Alumina may cause irritation to the eyes and upper respiratory tract Alumina is a low health risk by inhalation Alumina should be treated as a nuisance dust as specified by the American Conference of Governmental Industrial Hygienists ACGIH According to AIHA Hygieni...

Page 50: ...rol Act Title 40 CFR 710 None of the materials in this mixture are on the EPA list of extremely hazardous substances Section 302 of SARA Aluminum oxide is on the toxic chemical list Section 313 of SARA The reportable chemical substances in this product are regulated by the OSHA Hazard Communication Standard 29 CFR 1910 1200 solely because they are listed by ACGIH However they do not fit any of the...

Page 51: ...USER MANUAL Series HC Reference No 145 Final Rev 5 Page 50 September 2004 SECTION 8 AUXILIARY MANUALS DRAWINGS ...

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