OPERATING & INSTRUCTIONS

MANUAL

UNIT- HEATLESS AIR DRYER

CAPACITY- 3000 CFM

CLIENT:

M/S. ENERMECH PTE LTD.

Supplie d By:

ENGINOX TECHNOLOGIES
305, ROYAL SQUARE, NR. R K HAL,
SCIENCE CITY ROAD,
SOLA, AHMEDABAD
PHONE :- 8000013545
Email :- info@enginoxtech.com

Visit us a t
www.enginoxtech.com
 CONFIDENTIAL
This document is submitted for the exclusive use of M/S. ENERMECH
PTE LTD. On the understanding that the recipient will maintain the
contents confidential.

The document should not be reproduced, distributed or used for any other
purpose other then originally intended, without the written authorization of
M / S. ENGINOX TECHNOLOGIES, AHMEDABAD, INDIA.
 INDEX
SR.NO. PAGE NO.

1) FOREWORD 04

2) GENERAL 05

3) TECHNICAL SPECIFICATIONS 06

4) PROCESS DESCRIPTION 07 TO 10

5) OPERATING INSTRUCTIONS 11

6) TROUBLE SHOOTING 12,13

7) RECOMMENDED LIST OF SPARES 14

8) LIST OF EQUIPMENTS 15 TO 18

9) INSPECTION AND MAINTENANCE 19

10) GUARANTEE CERTIFICATE 20

11) MECHANICAL DRAWING 21TO 28

12) ELECTRICAL DRAWING 28 TO 36

 FOREWORD

This manual summarizes the relevant features of operation and

maintenance of the Air Dryer supplied to M/S. ENERMECH PTE LTD.
This Manual is made for the operating & maintenance personnel who
must adhere to all the instructions, to ensure years of smooth trouble free
operation.

The Adsorbing towers should not be opened and if required, only by

trained personnel.

Whilst the client is free to utilize their own personnel for routine and non-
routine maintenance, we recommend utilization of own Authorized
Services / Agent on a spot or Annul Maintenance Contract basis,
especially after the warranty period.
 GENERAL

• CLIENT : M/S. ENERMECH PTE LTD..

• P.O. NO. : 201301539

• DATE : 04-01-2013

• END USER : M/S. ENERMECH PTE LTD.

• LOCATION : SINGAPORE

• YEAR OF INSTALLATION : 2014

• ENGINOX JOB NO. : 1355

 TECHNICAL SPECIFICATIONS

Type of Dryer : Desiccant Based Heatless type

Fluid to be dried : Compressed Air - Wet
Capacity : 3000 CFM
Operating Pressure : 25Bar-g
Inlet Air Temp. : 40° C Max.
Inlet Flow Rate : 3000 cfm
Design Pressure : 37.5 kg/cm2g
Design Temp. : 65 Deg. C.
Outlet Dew Point of Dry Air : Minus 40°C atm.
Regeneration Method : By dry Product Air
Purge Loss : 8 to 10 %
Cycle Time : 3 Min + 3 Min (Total 6 Min.) OR 4+ 4
Min. (Total 8 Min.) OR 5 + 5 Min.
(Total 10 Min.) OR 6+ 6 Min.
(Total 12 Min.) FOR ADU
Flow direction during Adsorption : Upward
Flow direction during Regeneration : Downward
Inlet and Outlet Connection : 4’’ ANSI 300#
Pressure Drop : 0.5 kg/cm2 g
Operation : Automatic PLC Controlled
 PROCESS DESCRIPTION

A) COMPRESSOR: Compressor sucks the air from atmosphere and

compresses it up to the given / required pressure for air dryer system.
For the reference please refer the operating and maintenance manual
of compressor.

B) SHELL AND TUBE TYPE AIR COOLER : Compressor discharge air

entering into the Shell and Tube type Cooler where it got cooled and
available moisture in air which convert into the condensate and then
this condensate carry by this pressurize air and goes to Moisture
separator.

C) WATER CHILLER: It is provided for to supply the chilled water to the

shell and tube type air cooler please see/refer the manual for
operation and maintenance which is attached with this manual.

D) MOISTURE SEPARATOR: The air which comes from cooler now is

entering into moisture separator where the moisture separated from
the air and drain out through auto drain valve installed at the bottom of
the separator operated atomized frequently and drain out the
moisture.
E) PRE FILTER - A :
Pre-filter is installed for separating the available physical dust particles
present in the wet air. One number of manual drain valve is provided
at the bottom to drain out the condensed moisture and dust particles.

F) ACTIVATED CARBON FILTER :

Now this filtered air passes through the Activated Carbon Filter where
available oil contamination in the air will be removed by this filter.

G) PRE FILTER - B :
Now this air is passing through Pre-filter-2 there might be a little
Carbon dust in the air which needs to be filtered out for making the air
clean. Manual drain valve is provided at the bottom of the pre-filter to
drain out the same. Heavy dust particles filtered in pre filter-1 and rest
particles up to 10 micron filtered in prefilter-2.

H) TWIN TOWER MAIN ADSORPTION SYSTEM:

Main adsorption system consists of two cylindrical adsorbers filled
with desiccant and is provided with filters mesh at bottom and top. At
one time air passes through one adsorber for 5 minutes and total
moisture present in the air is adsorbed by the desiccant.
Simultaneously, the other tower remains under regeneration by
pressure Swing method. The adsorber under regeneration is
 depressurized to atmosphere and then purging of the dessicant takes
place by a small quantity of expanded dry Air. The Adsorption process
takes 04:30 Minutes time and in the rest the purging process takes
00:30 minutes and both the towers are slowly equalized to the same
pressure. (When pressure in both the adsorber is same, changeover
takes place automatically, now the regenerated adsorber comes in
drying mode while the wet adsorber goes under similar regeneration
process.
G) AFTER FILTER:
There might be a little desiccant powder and dust in the dry air
which needs to be filtered out for making the air clean. For further
filtration and removal of any solid particles present in the air, it is
Passes through this filter installed at the outlet of the Dryer. Now
Clean and dry air is available for the system for use.
H) PLC BASED CONTROL PANEL :
The changeover of adsorbers is fully automatic through ON /
OFF Type actuator ball valves operated by instrument air through
Solenoid valves. One number PLC / Sequence Programmer is
Installed which gives the electrical signal to various solenoid and
Accordingly the changeover valves will operate and adsorbers
Changeover takes place.
I) POWER REQUIREMENT:
This Drying unit requires only single phase power supply for
Operating solenoid valves and sequence timer. The Power
Requirement is only 500 – watts (maximum). For chiller pls.
refer The manufacturer’s manual.
 OPERATING INSTRUCTIONS

• Start Up

1. Switch on incoming switch and control supply of dryer and chiller.

2. Switch on the Air Compressor and check for unloading and loading air
pressure.
3. Open Main Air inlet valve to the Plant
4. Wait till you get the required pressure of 10 kg/cm2g in Air dryer
Absorbers.
5. Switch on System On switch.
6. Observe the various pressures.
7. Set the flow as per the requirement.

• Shut Down

1. Close inlet air valve manually and unload the compressor.

2. Switch off air compressor.
3. Switch off system and then control of Air dryer and then Switch off
Water Chiller.
 TROUBLE SHOOTING
Compressed air pressure insufficient
If air pressure is below 10 kg/cm2g then:

¾ Check for leakages

¾ Check for supply of air from the air compressor. Set the loading and
unloading accordingly.
Peak pressure 10 kg/cm2 g in Adsorbers not reached at the end of
adsorption cycle

Causes May be
• Air Supply insufficient
• Leakage may reduce air flow and pressure to ADU tower
• Check the cycle timing
• Choked up filter before air inlet.

Inlet Air temperature is high

• Chiller unit is not on
• Check power supply at chiller unit
• Refer water chiller instruction and operating manual
In Such Case Check

¾ Open air inlet valve to Air Dryer slowly till correct air flow is received.
¾ Check for air source
¾ Check and tighten if any leakages.
¾ Check working of actuator operated ball valves.

Pressure drop through air dryer is maximum

• Check filter element

• Check valves proper opening & closing
• Check for Air inlet pressure

Moisture content in air outlet is beyond required level

• Check air inlet capacity and pressure

• Check air inlet temp.( should be less than 45 deg. C )
• Check cycle timing and valves operation.
• Check the opening of purging valve and should be opened 8 to 10%
 RECOMMENDED LIST OF SPARES

SR.NO. ITEM QTY.

1) Solenoid Valve ¼” BSP 5/2 way 04 Nos.

2) Solenoid Valve ½” BSP 5/2 way 02 No.
3) 2- Way valve seal kit – 100 NB 05 Nos.
4) 2- Way changeover valve – 100 NB 03 Nos.
5) Actuator for 100 NB Valve 03 Nos.
6) 1/2” Manual ball valve 02Nos.
7) 1/2” Needle valve 03 Nos.
8) 100 NB NRV 02 Nos.
9) Sequence Programmer / PLC 01 No.
10) Auto drain valve ½” 01 No.
11) Pressure Gauge ½” (0- 40 kg/cm2) 02 Nos.
12) Filter Element Candle & Cloth 02 Nos. Each
13) Air pressure regulator-½” 01 No.
14) RTD PT-100-12’’ Size 01 No.
15) Safety Valve 40 NB 01 No.
16) DTC (EAPL) 01 No.
17) DPM 01 No.
18) DEWPOINT SENSOR 01 No.
19) FIT 01 No.
 EQUIPMENT DETAILS

1) COOLER:
SIZE 350 X 2500
QUANTITY 01 NO.
MAKE ANEPL

2) MOISTURE SEPERATOR:
SIZE 450 X 750
QUANTITY 01 NO.
MAKE ANEPL

3) ACTIVATED CARBON FILTER:

SIZE 800 X 1300
QUANTITY 01 NO.
MAKE ANEPL

4) PRE FILTER:
SIZE 450 X 1200
TYPE CANDLE
QUANTITY 01 NO.
MAKE ANEPL

5) AFTER FILTER:
SIZE 450 X 1200
QUANTITY 01 NO.
MAKE ANEPL
6) ADU TOWER -1:
SIZE 1650 X 1200
QUANTITY 01 NO.
MAKE ANEPL

7) ADU TOWER – 2:
SIZE 1650 X 1200
QUANTITY 01 NO.
MAKE ANEPL

8) CHANGE OVER VALVES WITH ACTUATOR:

TYPE 2 WAY
SIZE 100 NB
QUANTITY 04 NOS.
MAKE AIRA

10) AUTO DRAIN VALVES:

TYPE 2 WAY
SIZE ½” ON/OFF TYPE
QUANTITY 01 NO.
MAKE RYDER

11) MANUAL DRAIN VALVE:

TYPE 2 WAY THREADED ENDS - F
SIZE ½”
QUANTITY 06 NOS.
MAKE MARCK

12) SOLENOID VALVES:

TYPE 5/2 WAY
SIZE 1/2” BSP
QUANTITY 04 NOS
MAKE ROTEX
13) PRESSURE GUAGE:
TYPE C – BOURDON DIAL
CONNECTION ½” BSP
QUANTITY 05 NOS.
RANGE 0 – 40KG/CM2
MAKE WAREE

14) SAFETY VALVE:

TYPE SPRING LOADED
CONNECTION 1.1/2” BSP
QUANTITY 02 NOS.
MAKE VKE

15) MANUAL VALVE:

TYPE 2 WAY BALL, FLANGE END
SIZE 100 NB
QUANTITY 02 NOS.
MAKE MARCK

16) AIR PRESSURE REGULATOR WITH LUBRICATOR:

TYPE REGULATOR
SIZE ½” (0-28KG/CM2)
QUANTITY 01 NO. EACH
MAKE SEIMAG

17) PLC:
TYPE PROGRAMMABLE
QUANTITY 01 NO.
MODEL MICRO 830
MAKE ALEN BRADELY
18) DTC:
TYPE DIGITAL
QUANTITY 01 NO.
MODEL EX9-2H-U
MAKE EAPL

19) DEW POINT METER AND TRANSMITTER:

TYPE PROGRAMMABLE
QUANTITY 01 NO.
MODEL AI-518
MAKE YUDIAN
MAKE GE – TRANSMITTER

20) FIT:
TYPE DIGITAL
QUANTITY 01 NO.
MODEL 945P
MAKE TUCHCONTROLS
 INSPECTION AND MAINTENANCE

INSPECTION

Filter elements need to be replaced at intervals. Filter drains should be

checked for unhindered drainage at regular intervals.

The Air Dryer should be checked for proper operation regularly.

The following inspection scheduled is recommended:

INTERVAL INSPECTION TYPE

Daily Condensate drainage
Daily Condensate drainage filters
Daily Dry air- flow rate
Daily Dry air- pressure
Daily Dew Point Monitoring

MAINTENANCE

INTERVAL OPERATING MAINTENANCE TYPE

HOURS
Six monthly 2000 Replacing or cleaning of filter element
--- 8000 Inspection of pipe connections and process
valves for any leakages.
 GUARANTEE CERTIFICATE

THIS IS TO CERTIFY THAT THE EQUIPMENT SUPPLIED BY US IS

GUARANTEED AGAINST ANY MANUFACTURING DEFECT FOR 12 MONTHS

FROM THE DATE OF SUPPLY OR COMMISSIONING WHICHEVER IS

EARLIER.

WE HEREBY CONFIRM THAT WE WILL REPAIR/REPLACE THE DEFECTIVE

PART AT OUR COST DURING GUARANTEE PERIOD.

DATE: 19-01-2014

FOR, ENGINOX TECHNOLOGIES

AUTHORISED SIGNATORY