AIR DRYER

INTRODUCTION

NEED OF COMPRESSED AIR:- Compressed air is necessary in

Locomotives and EMUs operation.
Compressed air is used in Locomotive and EMUs for following
operation:-
• Application of Brakes in Locomotives and Trains as well as
EMUs.
• Operation of other auxiliary devices such as pneumatics
valves, electro- pneumatic valves,contactors etc.
 WHAT IS AIR DRYER
• It is a device provided to remove moisture form compressed air in
Locomotives and EMUs.
• Twin Tower Air Dryers have been developed especially to suit
Traction requirements. It is consists of a pair of cylinders containing
desiccants, which extract the water and moisture and ensures
(allows) dry air to pass into the main reservoir and to reach air
operated equipments only clean dry air.
• Water collected is automatically dumped once in each pumping
cycle.
• The noise of the burst of water being discharged can often be
heard at the end of compressor’s pumping cycle.
QUALITY OF COMPRESSED AIR WITHOUT AIR DRYER
AND ITS PROBLEMS

• It is commonly known that atmospheric air always contains water

vapor. As long as the moisture stays in the form of vapor, it is
bound inside the air.
• Only when the saturation limit is exceeded(=100% relative
humidity),is the water precipitated in the form of droplets, fog or
snow.
• The compression cycle of ambient air includes compression in
Locomotive compressor and then cooling in after cooler. During
compression, pressure and temperature of ambient air increases
but its relative humidity decreases. However, absolute amount of
the moisture present in the air remains same.
QUALITY OF COMPRESSED AIR WITHOUT AIR DRYER AND ITS
PROBLEMS

• After compression when the air is cooled in after cooler, it

becomes saturated and condensation takes place. This
condensed moisture is drained out from main reservoirs through
auto drain valves/drain cocks..
• A major portion of moisture is removed in this process, but water
still remains present in the form of vapor in the compressed air.
The water vapor condenses in air brake equipment with water,
oil and dirt.
• These contaminants form the formidable pair of enemies to
compressed air and pneumatic operated valves and contactors
etc and can fail prematurely.
 EFFECT OF CONTAMINATED AIR

The moisture in compressed air systems often causes the

pneumatic equipment to malfunction and wear
prematurely as a result of corrosion and freezing.
The condensation which takes place in air valves and pipes
leads to following problems :-
•Malfunctioning of air valves due to rusting.
•Sluggish operation of moving parts of valves.
•Poor performance of the valves due to washing away of
lubricants.
 EFFECT OF CONTAMINATED AIR

• High flow resistance and pre-mature blocking of filters.

• Rusting of air pipes.
• Poor performance and low life of rubber components of valves.
• Sticky and greasy accumulation on the components of the air
valves.
• Freezing of the water droplets when ambient temperature
drops blow freezing point.
• Choking of small chokes and strainer in the valves.
• The above all problem affects the reliability of Electric
Locos/EMUs.
 EFFECT OF CONTAMINATED AIR

RESULT OF THESE ILL EFFECTS:-

•Malfunctioning ,premature failures of valves inspite of the
anticorrosive treatments given to individual components
during manufacture.
•Compel frequent overhaul and replacements.
•Necessitates inventory build-up and maintenance of spares
•Causes considerable Revenue loss in down time of the
vehicles.
 FORM OF CONTAMINANTS

Water and oil appear in two forms-

• As vapor and
• As liquid particles and aerosols
• When temperature of compressed air is brought down, water and
oil vapors approach saturation limit and begin to condense
forming “FOG” or “MIST”.
• Vapors as long as do not condense are relatively less harmful to
the system.
• It is liquid particles that cause all the problems, presence of water
vapor is generally expressed in terms of relative humidity (RH)
and dew point temperature.
 FILTER VS DRYER

Filter is for entrapping liquid particles form of

contaminants it does not trap vapor passing through.
Air dryer removes vapor contents, thus lowering the dew
point temperature.

Ideal Solution is the combination of both filter and dryer

one to remove liquid / solid particles and the other to trap
vapors.
 As per RDSO,s Combined specification of Air Dryer
for Locomotives- (1) Electric Locos, Diesel Locos,
EMU/MEMU &DEMU Specn.No.
0.01.00.06(Rev.0.03) March 2007,Dated-28.03.2007.

Maintenance Instruction of Air Dryer for Diesel,

Eelectric Locomotives, EMUs/MEMUs/DEMUs
No.MP.MI-18(Rev.02) April2008, Heatless
Regenerative Air Dryer to be fitted in all
Locomotives/EMUs.
 SYSTEM COMPONENTS OF AIR DRYER

Pre-Coalesce:
A borosilicate or other type of element designed to
restrict and collect tiny aerosol contaminants,
primarily oil and other contaminants, which may
prove detrimental to the successful operation of any
form of desiccant.

Technically, an aerosol is a suspension of

fine solid particles or liquid droplets in a
gas. Examples are clouds, and air pollution
such as smog and smoke
PRE-COALESCE
 SYSTEM COMPONENTS OF AIR DRYER

Desiccant Tower
The desiccant beads, which extract the moisture
from the air, are housed in two towers. These are
also called desiccant towers.

Pre-packaged desiccant is most commonly used to

remove excessive humidity that would normally
degrade or even destroy products sensitive to
moisture. Some commonly used desiccants are: silica
gel, activated charcoal, calcium sulfate, calcium
chloride, montmorillonite clay, and molecular sieves.
DESICCANT
TOWER
 SYSTEM COMPONENTS OF AIR DRYER

Pressure Switch
An integral pressure sensing device is located
internally to control the air drying cycle. The air dryer
cycles only when the predetermined pressure is
reached.

If an emergency arises and air pressure drops below

the pre determined level cycling stops immediately
and air flows through the air dryers to support the
immediate air requirements.
 SYSTEM COMPONENTS OF AIR DRYER

PURGE VALVE
There is one purge valve located at the bottom of each
desiccant tower. Alternatively, there is a common purge
valve connected to both desiccant towers. Purge valve
allows the regenerative air to discharge moisture
through the desiccant tower to atmosphere.
 SYSTEM COMPONENTS OF AIR DRYER

HUMIDITY INDICATOR

A color indicator is located at each outlet check valve as a

visual indication to monitor the condition of air after passing
through each desiccant tower. Alternatively, there is a
common humidity indicator is located at the outlet of final
filter.
 SYSTEM COMPONENTS OF AIR DRYER

FINAL FILTER

This is a unit, which removes any dust generated after

the air has passed through the main dryer system.
Alternatively, desiccant may be supplied in a fabric cloth
bag, which can act as final filter. In such cases, separate
final filter will not be required.
 LOCATION OF AIR DRYER IN SYSTEM

It is recommended to be installed after the first main reservoir (in

loco). First MR also act as a water trap because of the sudden
expansion that happens when compressed air charges in.
In addition to the drop in temperature due to the sudden expansion,
the large the surface area of the reservoir offers considerable drop in
temperature thoroughly reducing the dew point.
Dryer immediately after the compressor are more prone to lose their
efficiency sooner than those mounted after the first MR.
The problem surfaces after the wear- out of compressor parts begins
to move oil through sets-in.
Higher the compressor RPM, greater is the oil throw, faster is the
wear-out, which is usual phenomena in any mechanical equipment.
 Isolation of Air Dryer
• This may effect reliability of
valves and seals of pneumatic
system.
•Therefore it would be better
to direct such locomotives to
base shed or nearby shed
where it may be attended.
•To ensure thus, it would be
better to create one display
message to driver as :–
Handle of by pass cock
•In case of air leakage from
air dryer, it is by passed
through a cock which is
provided near the air dryer
and locomotives are in
operation with air dryer in
“AIR DRYER ISOLATED” isolation for not a longtime.
Loco operation may be continued towards base
shed.
KNORR AIR DRYER - CONSTRUCTION
FTIL MAKE AIR DRYER
SIL MAKE AIR DRYER
Knorr-Bremse
 MAJOR FAILURES OF AIR DRIER IN RAILWAYS

• KNORR BREMSE
• PCB FAILURE,
• AIR LEAKAGE FROM DUPLEX PISTON VALVE – VALVE
HEAD
• LOW PRESSURE LEAKAGE DUE TO MAL- OPERATION
OF PRE CONTROL VALVE (DUST)
 Purge Valve Spring
Piston Assembly Fitted with
Valve Head & Spring
 FAILURES OF FTIL AIR DRYER

• PCB FAILURE,
• AIR LEAKAGE FROM TOWER,
• PURGE VALVE SEAT DAMAGE
• DESICCANT FAILURE
• S.S. PIPE CONE & ‘T’ JOINT BROKEN
 ACTION TAKEN BY FTIL
• DEVELOPED MODIFIED PCB WITH AUTO ISOLATION AND TO
WITHSTAND HIGHER SPIKE ENERGY LEVEL. TRIALS AT ELS,
LALLAGUDA & ITARSI ARE UNDER PROGRESS
• DESICCANT FAILURE – PROBLEM WITH ONE BATCH OF SUPPLY
• VALVE SEAT DAMAGE – UNDER INVESTIGATION.
 OPERATION OF AIR DRYER

Compressed air after main reservoir MR-2 passes through a pre-coalesce filter (2). This removes
significant amount of debris, moisture and oil from the compressed air. After pre-coalesce filter
air enters into the ACTUATOR (3), which decides the entry of air to either of two DESICCANT
TOWERS (4A & 4B). Position of actuator is controlled by TIMER UNIT (5).
For example, in a particular cycle, wet air enters from the bottom of the tower (4a) and
passes through desiccant bed where moisture is adsorbed by the desiccant. Dry air with dew
point less than ambient temperature comes out from the top and finally goes out of dryer to
final filter (6). Final filter removes traces of desiccant powder, if any, from the dry air and air
then goes to main reservoir-2(MR-3 in case of electric loco).
A small part of the dry air (10-20% of inlet air capacity) is drawn from the dry air outlet of
tower (4a) and is passed through regenerative orifice of non-return valve (8) and on to the
desiccant bed of the other tower (4b). It removes the moisture collected in the second tower
and thus reactivates the desiccant. The moisture laden air is vented through exhaust valve
which is also called PURGE VALVE (9). Thus in this cycle tower (4a) works as dehydrating tower
and tower (4b) works as regenerative tower.
After completion of this cycle the working of two towers reverses and now the tower (4a)
works as REGENERATIVE TOWER and tower (4b) works as DEHYDRATING TOWER. In this way
two towers alternatively work as dehydrating/regenerative towers. This reversal takes place
after a predetermined time period. This is called CYCLE TIME OF THE AIR DRYER. Cycle time of
air dryer is normally 1 to 2 minutes.
OPERATION OF AIR DRYER
PNEUMATIC AND ELECTRICAL CONNECTIONS ON ELECTRIC LOCO
 INSPECTION SCHEDULES OF AIR DRYER ON ELECTRIC LOCO
TRIP INSPECTION
1. Open drain cock of final filter to drain off any accumulated water content
2. Check the colour of humidity indicator It indicates condition of air after passing
through air dryer. Indication of various colour are as under.
• Blue colour ---- Dryer is performing correctly
• Lavender ---- Dryer is suspect - Verify dryer is cycling. - If dryer is cycling correctly and
auto drain valve of main reservoir No.1 is operating correctly, release the loco for
service
• White ---- Possible damaged dryer
- Verify dryer is cycling.
- Remove humidity indicators and look for desiccant dust or residue
on inside of manifold and humidity indicators.
- If desiccant dust or residue is seen Remove dryer for attention.
- If no desiccant dust or residue is seen on inside of manifold- Install
new humidity indicators. Again verify dryer is cycling correctly & No.1 main reservoir
drain valve is operating correctly Release loco for service.
• Yellow or Brown colour ----- Damaged dryer
-It indicates that desiccant has been contaminated
with oil. Replacement of coalescing element and
desiccant is required.
 INSPECTION SCHEDULES OF AIR DRYER ON ELECTRIC LOCO
3. Check auto drain of main reservoir No.1 & main reservoir No.2
--It should function properly.
4. Check electrical connection of air dryer and their tightness.

IA/ IB SCHEDULE

1. Repeat all the items of Trip schedule.

2. Check cyclic operation of air dryer.

-While the dryer is cycling, there should be a slight and continuous exhaust
from the relevant purge valve. After pre-determined cyclic time, exhaust from the
purge valve stops and that of the second tower starts exhausting. This cycle should
be reversed after cycle time. The cycle timings of various makes of air dryer are as
under:
• FTIL air dryer - 1 minute drying and -1 minute regeneration
• Stone India Ltd. air dryer - -do-
• Knorr-Bremse air dryer - 2 minute drying and 2 minute regeneration

3. Check Memory Feature When compressor gets unloaded purging of air

Should stop and when compressor again gets loaded purging should continue.
 INSPECTION SCHEDULES OF AIR DRYER ON ELECTRIC LOCO
4. Examine the drain valve on the sump of pre coalesce With the
dryer Operation, the drain valve must expel a short burst of air
once a minute (each cycle).

IC - SCHEDULE
1. Repeat all the items of IA/IB schedules.
2. Charge the system from zero pressure and check the dryer
does not cycle immediately. Note the pressure when the
dryer starts cycling.
Pressure settings of start of cyclic operation are as under:
• FTIL air dryer ----- 7.0 kg/cm2
• SIL air dryer ----- 7.0 kg/cm2
• Knorr-Bremse air dryer ----- 4.6 kg/cm2
 INSPECTION SCHEDULES OF AIR DRYER ON ELECTRIC LOCO

AOH SCHEDULE

1. Repeat all the items of IC schedules.

2. Replace consumables as per respective manufacturer’s
recommended replacement Kit
Please see Annexure-III for list of items to be replaced.
(in case of KB make air dryers consumables are to be replaced
in alternate AOH)
3. Clean external muffler connected with purge valves.
Follow the instructions given in maintenance manual of
respective manufacturers.
4. Check condition of each pipe assembly and their tightness.
 INSPECTION SCHEDULES OF AIR DRYER ON ELECTRIC LOCO
IOH SCHEDULE

1. Overhaul the complete air dryer and change desiccant.

For overhauling follow the instructions given in
maintenance manual of respective manufacturers.
2. Replace consumables as per respective manufacturer’s
recommended replacement kit.
Please see Annexure-III for list of items to be replaced.
3. Test each air dryer before putting it back in to service.
Schematic diagram of test bench is given in
Annexure-IV
List of tests to be conducted and format of record to
be maintained is given in Annexure V
 REFERRENCES

RDSO TC NO 108:TEST PROCEDURE FOR TESTING AIR DRYER

RDSO MSG PRESENTATION INMSG2008

AIR DRYER TEST BENCH AT BNDM SHED
AGENDA IN CEE CONFERRENCE JUN2011
• In the existing system the Auto drain valve operates
when the compressors are cut out.
• This is achieved by giving a control supply from RGCP
to "VEAD" coil .
• This control supply should be disconnected . lnstead
we can tap the pneumatic control supply of air dryer,
which has a 2 minute cycle, to operate the Auto Drain
Valve.
• By this Auto Drain Valve shall operate only once in two
minutes .
• Both the Compressors are CUT OUT by RGCP whenever MR
pressure becomes more than 10.5 Kg/sq.cm.ln the air dryer
provided in WAP4/WAG7 , the air dryer continues to perform
its normal cycle of drying and regenerating even when both
the compressors are cutout. Purging takes place during
regeneration cycle .
• After modification when compressors are cut out , both towers
of the air dryer will dehydrate and no purging shall take place.
For this a signal should come from the RGCP whenever the
compressors are cut out. After receiving the signal the air
dryer shall start operating with both towers in dehydrating
mode . A second signal from RGCP when the compressors are
cut in, shall make the air dryer operate in its normal cycle.