Professional Documents
Culture Documents
OPERATION INSTRUCTIONS
SAFETY
Hydrogen dryer is installed in the power plant for eliminating the vapor in hydrogen of
hydrogen cooled generator. It is dangerous during installation and commissioning since
some bare electrical parts are alive and the two drying containers and regeneration
pipeline may be very hot. Hence, there will be serious physical injury or equipment
damage caused by unapproved dismantling of protective cover, unreasonable use,
incorrect operation and maintenance or unsuitable installation.
In order to ensure safety of people and equipment, it is necessary to take the
following measures:
Operate or maintain according to the requirements of operation instructions and
explosion protection regulations after hydrogen charging.
Only qualified personnel are allowable to install and operate the equipment.
The qualified personnel shall be provided with operation instructions or other
instructive documents on the equipment during working at any time, so as to perform
according to the requirements in documents.
Unqualified personnel are strictly prohibited to operate or maintain the equipment or
to work near the equipment.
Note: The operation instructions are subject to change corresponding to product
upgrading without notice.
Version: V4.0-2009.4
CONTENTS
I. Main Technical Parameters .............................................................................................. 3
II. Setting Values and Normal Readings.............................................................................. 4
III. Model Description ........................................................................................................... 5
IV. Working Principles .......................................................................................................... 5
V. Equipment Installation (refer to the attached diagram of installation dimensions) ......... 6
1.
2.
2.
3.
4.
Instructions on keys............................................................................................ 18
2.
3.
4.
2.
3.
4.
5.
6.
Daily:................................................................................................................... 28
2.
Weekly ................................................................................................................ 28
3.
4.
5.
6.
7.
Appendixes:
Common Spares
Table1: Hydrogen dryer performance record table
Table2:Water vapor dewpoint temperature and saturating water vapor content contrast
table
PLC Ladder logic
Temperature controller DTA Operation Instructions
Hydrogen dryer flow diagram
XFG-1F-70-02-001
XFG-1F-70-02-002
VF-2-30-01-001
XFG-1F-80-02-001
XFG-1F-80-03-001
Object
Hydrogen
2.
Working pressure
0.30.6 MPa
3.
Inlet temperature
47
4.
10
5.
-40
6.
100Nm3/h
7.
Heater
1064 W each
8.
Blower
1/2 HP
9.
Desiccant
11. Accessory
4 hours
Cooling time
4 hours
204
Normal reading
8211
Below 38
0.6-0.8Mpa
10.8KPa
Place the hydrogen dryer on a horizontal plane, and secure the four angles with
anchor bolts. All the four angles are provided with mounting holes with diameter of
16mm. Connect the outlet of hydrogen dryer with the hydrogen inlets a and i of
the generator by using DN25 pipeline.
Reserve enough space around the equipment for convenience of access to all the
valves, and reserve a clearance larger than 1.5m above the equipment for
convenience of maintenance for the heater.
DN15 pipeline sends the cooling water to the regenerated cooler. If the user in front
of the control box faces to the dryer, the water flows from right side to the left side.
The water temperature shall be below 38. Otherwise, take remedial measures by
increasing the flow.
Install the compressed air intake line (DN10) for instrument at the left side of the
hydrogen dryer. Keep the compressed air pressure between 0.60.8 MPa.
Prepare pipelines for connection at the replacement inlet valve AA603 on the lower
right side of hydrogen dryer for convenience of carbon dioxide purification,
otherwise, use portable container for purification.
6
The replacement outlet valve AA604 of hydrogen dryer and the outlet valve AA602
of positive-pressure explosion proof will discharge the replaced air to a safe place
through the pipeline for connection.
2)
Failure indication: Line 80 (Terminal X24) and Line 83 (Terminal X27) of the common
end.
Close (N.O. contact close) shows the hydrogen dryer fails.
Disconnected (N.O. contact open) shows the hydrogen dryer is normal.
Power failure: Line 80 (Terminal X24) and Line 85 (Terminal X28) of the common end.
Close (N.O. contact open) shows the power supply of the hydrogen dryer is normal.
Disconnected (N.O. contact open) shows the power of the hydrogen dryer fails.
3)
Analog output
A 420mA analog signal is used for remote transmitting and monitoring the dew
point change at hydrogen inlet and outlet. The contact line is at the back of the
dew point meter.
Turn off the isolating switch of power supply, check whether all the pipes entering the
control box are sealed by using pipe sealing accessories or daub.
2.
Measure the resistances of the two motors and two heaters, record in Table of action
records for the dryer (for reference in future and troubleshooting).
3.
Check to ensure that ventilation of the control box has been completed properly, and
keep the internal ventilation pressure is 10.8KPa (please refer to Chapter VIII
Purification Instructions on Control Box for details.)
4.
Check whether the air in the dryer is replaced by carbon dioxide (CO2).
5.
All the inspection and measurement results are verified and recorded. At this time,
replace CO2 with hydrogen for the hydrogen dryer, increase the pressure to working
value and check whether there is hydrogen leakage.
6.
Check whether each breaker of the motor startup protector is at the mode of open.
8.
Turn on the main power supply and close the switch after the control box and
equipment are checked to be normal (please refer Chapter VIII and Chapter IX for
details of control box gas exchange and equipment replacement).
2.
Check whether the four-way valve can be switched properly, set the operation mode
to be The buttons for test operations and test steps for the hydrogen dryer are
triggered on the interface, turn the Run/Stop switch to Run. Check whether the
dryer is normal at each step with the following procedures. After completion of each
step, set The test step button is triggered to the next step on the interface after 10s.
Step 1: Tower A absorbs moisture
Tower B heats
Tower A heats
Measure and record the amperages for the motors and heaters of the two towers.
4.
XFG-1F dryer, completely automatic, is provided with dual towers and hydrogen
drying system which can operate consecutively. There is a blower towards the
absorption container internally for completion of moisture absorption and
regeneration flow. It working cycle duration includes 8 hours for moisture absorption
and 8 hours for regeneration. In addition, the regeneration process includes 4 hours
for heating and 4 hours for cooling.
The tower starts to absorb moisture, and the regeneration heats. The vapor
Heat
from the heated drier in the regeneration tower will be treated by the cooler and
separator, and the condensed water will be discharged from the drain valve.
After heating for 4 hours, the tower starts to absorb moisture, and the
Cool
regeneration tower cools down, and the heater is switched off. The regeneration flow
will travel through the cooled drier in the tower after heating. After cooling for 4 hours,
the two towers will exchange the working status with the moisture absorption tower in
mode of moisture absorption and the regeneration tower in mode of regeneration.
Continue this cycle hereafter.
5.Once the regeneration tower reaches the given temperature (heating for about 2 hours),
adjust valve AA011 properly for the optimal temperature. The temperature at the
tower outlet shall be 8211, and that inside the tower shall be 16328. After
completion of all adjustments, it takes 15-20 minutes for the equipment to reach a
stable status.
10
6.
. The regeneration flow control valve AA011 is opened at the position of about 11/2
in the factory. It may be necessary to make some adjustments for AA011, so as to
reach a proper regeneration temperature.
A.
B.
B.
The temperature of gas at the regeneration tower outlet may be too high, too low
or normal. This depends on the change of regeneration flow.
B.
The temperature of gas at the cooling outlet will become too high.
C.
7.
In the first steps, the water will be discharge from the drain valve when the
temperature inside the tower reaches 8211.The total displacement depends on
the humidity of hydrogen in the separator and other factors, and the displacement of
the first steps is between 0.57 liters and 1.14 liters. If the drier is very dry during
installation, it is obvious that there is little water discharged at the beginning of
regeneration cycle.
8.
The outlet and inlet of hydrogen dryer without hygrometer are provided with
discoloration indicator of humidity. After completion of the first cycle, the indicator will
be mazarine and it will keep this color in the following working procedures.
11
12
13
2.
Switch the tower to regeneration loop by using "The hydrogen dryer is under test and
the test step button is triggered" on the human-computer interface or by mechanically
turning the four-way valve linkage.
After the four-way valve of the pipeline rotates for 90, make replacement for the
hydrogen dryer according to the instructions in Part 1.
Note: The procedures can be repeated for replacing CO2 with hydrogen.
14
Procedures of troubleshooting
The failures include those of positive pressure, four-way valve, heating and blower
motor of control box. In case of any failure above except positive pressure failure of the
control box, PLC will cut off heating of the heater, so as to ensure operation safety of the
hydrogen dryer.
. Positive pressure failure of control box
Refer to Chapter VIIIThe gas exchange (positive pressure) failure described in
Instructions on Gas Exchange of Electrical Explosion-proof Control Box alarms.
.
Heating failure
KM3 auxiliary point or KM4 auxiliary point of heating contactor KM3 is closed during
normal operation of regeneration heating. It is indicated that the heating contactor is
closed, I0.8 or I0.9 of PLC inputs signals, and the hydrogen dryer runs normally.
In case of over current and short circuit of the heater, there will be no input signal at
the auxiliary point I0.7 of air switch, the failure indicator HL1 will be ON 10 seconds
later, and the failed contact Q0.6 output will be closed.
16
Blower failure
Both the fans of the two towers will run when the equipment operation switch is at
RUN. When the air switch for motor protection is started, the contactor will be
started by the closed motor of the auxiliary point. The auxiliary point of KM1 or KM2
contactor is closed, I0.4 or I0.5 of PLC inputs signals, and the hydrogen dryer runs
normally.
If the motor failures such as over-heating, over-loading, short circuit, under voltage
and phase lacking are detected by the air switch for motor protection, there is no
input signal at I0.4 or I0.5 of PLC for air switch action. The failure indicator HL1 will
be ON 10 seconds after the blower failure timer starts timing, and Q0.6 output of the
defective contact will be closed.
4.
Instructions on keys
Return key ESC: Return to the initial page of system no matter the status of screen.
Left arrow
: Move the modified data bit leftward when modifying the register data, i.e.
to display with blinking display that the data is moved leftward.
Right arrow
: Move the modified data bit rightward when modifying the register data,
i.e. to display with blinking display that the data is moved rightward.
Up arrow
: Turn to the previous page. If it is in mode of data setting, the digit bit will
be increased by 1.
Down arrow
: Turn to the next page. If it is in mode of data setting, the digit bit will be
decreased by 1.
Number keys 0-9 : The modified digit bit is set as the corresponding number in mode
of data setting.
Clear key CLR : Delete the set data in mode of data setting.
Symbolic key +/- : The modified figure is set as a positive or negative number in mode
of data setting.
Alarm key ALM: Enter alarm list page after pressing this key.
Setting key SET: Press this key to start register value modification. The register window
under modification currently is in reverse color, wherein the modified bit is flickering.
Press [SET] again before pressing [ENT] to cancel the current modification operation
and to continue modification for the next register.
Enter ENT: Write the modified data in register and continue to modify the next data
register. Exit the status of modifying the register when the last register on the page is
modified.
2.
System password
18
3.
Line 2
Press SET to set local control / long-range control for the hydrogen dryer.
Line 3
Line 4
Set automatic running / test running mode for the hydrogen dryer.
Line 2
Set step button off / Set step button on (press once for triggering once).
Line 3
Line 2
Line 3
status.
Press
Line 3
4-way valve timer delay: Set the prevalue of 4-way valve failure timer.
Line 3
Tower A heater timer: Set the prevalue for Tower A heating failure timer.
Line 4
Tower A heater timer: Set the prevalue for Tower B heating failure timer.
Tower A blower timer: Set the prevalue for blower failure timer of Tower A.
Line 3
Tower B blower timer: Set the prevalue for blower failure timer of Tower B.
Line 4
19
IN 1
IN 2
IN 3
IN 4
IN 5
IN 6
IN 7
IN 8
IN 9
IN 10
Reserved.
IN 11
Reserved.
IN 12
IN 12
OUT 1
OUT 2
OUT 3
OUT 4
OUT 5
OUT 6
OUT 7
OUT 8
OUT 9
4. Alarm page
4-way valve failure.
C-box pressure failure.
Tower A heating failure.
Tower B heating failure.
Tower A motor failure.
Tower B motor failure.
Call out the alarm page and press ALM directly.
21
22
23
24
Take the pipe plug 7 from the top drain valve, fill water until the water discharges,
and then screw the pipe plug.
Open the drainage section valve AA403 and drainage connection valve AA402. Test
leakage and check the discharging at the final stage of heating.
Note: When cleaning the drain valve, the drainage section valve AA403 and drainage
connection valve AA402 must remain closed or danger may occur if the hydrogen leaks.
Open AA403 and AA402 valves after cleaning (The dryer will be damaged if the drainage
section valve AA403 and drainage connection valve AA402 are closed too long).
25
26
27
Check whether there is alarm of the hydrogen dryer and make records.
2. Weekly
.
When the 4 hour heating period is ending, check whether the temperature at the
heater outlet is 8211 and the temperature in the drying tower is 16328.
Check the drain valve when the 4 hour heating period is ending. Clean this
equipment if necessary.
Make leakage inspection of hydrogen for the whole hydrogen dryer, including all the
electrical connection parts.
Measure the differential pressure at the outlet and inlet of hydrogen dryer, so as to
verify that the hydrogen flows through the dryer.
Check whether the failures of four-way valve, heater, blower and control box
positive pressure can be alarmed normally.
5. Every year
. Check and flush the fin and tube wall around the cooler.
. Check the use conditions of valve diaphragm. Replace it if there is any damage.
. Check the pneumatic solenoid valve, and re-assemble it if it is necessary.
6. Every three years
. Replace the drier.
. Check all the components of hydrogen dryer.
7. Each interruption of running
Make preventative maintenance every day, every week, every three months and every six
months as described above.
28
Warranty period (12 months from the delivery date) The product which is damaged
or can not work normally because of poor production process can be repaired or
changed for free.
2.
As for the failures occur beyond the regulated time of warranty period, we can repair
the equipment at the uses expense.
3.
As for the damage or failure caused by the user and the damage resulted from
illegal operation within the warranty period, we can repair the equipment at the
users expense.
29
Common Spares
Description
Order code
1F23107
1F23108
1F01401
1F05402
1F10403
1F05404
1F05407
1F34501
1F34504
1F34300
1F34150
1F10406
1FB2000
1F3912N
1F36632
1F36634
1F0AA24
Human-computer interface
1FTD220
1F6EP13
1F00VC2
1F0M06C
1F12M5C
1F09M5C
1F01664
1FPT100
1F04848
30
Fuse (FU1FU6)
1F0K1EK
1F0D62P
1FD162P
1F0D22P
Failure indicator
1FBVM4C
1FBD25C
1F0H50G
1F08851
Transformer
1F01064
1F19102
1F20175
31
Date
No
.
Item
Motor resistance
(phase Ato phase B)
Motor resistance
(phase A to phase C)
Motor resistance
(phase B to phase
C)
Motor resistance to
ground (more than
50M)
Heater resistance
(10-12)
Heater current
(about 9A)
Transformer voltage
primary side-415V
Transformer voltage
secondary side,
110V, 220V
10
11
Bed temp.switch
setpoint
(163)
12
13
Tower A
Tower B
32
Tower A
Tower B
Tower A
Tower B
Date
No.
Item
14
Tower pressure
(Mpa)
15
Inlet dewpoint
()
16
Outlet dewpoint
()
17
Condensate
trap water
removal
(L)
Tower A
Tower B
18
19
20
21
22
23
24
25
26
27
28
33
Tower A
Tower B
Tower A
Tower B
Dewpoint
temp.
Dewpoint
temp.
t()
Saturating
water vapor
content
p(g/m3)
Dewpoint
temp.
t()
Saturating
water vapor
content
p(g/m3)
t()
Saturating
water vapor
content
p(g/m3)
-70
0.002793
-40
0.119407
-10
2.140179
-69
0.003323
-39
0.133077
-9
2.329214
-68
0.00417
-38
0.148172
-8
2.533274
-67
0.004274
-37
0.164826
-7
2.753423
-66
0.004971
-36
0.183184
-6
2.990783
-65
0.005636
-35
0.203404
-5
3.246533
-64
0.006490
-34
0.225654
-4
3.521942
-63
0.007379
-33
0.250117
-3
3.818339
-62
0.008450
-32
0.276990
-2
4.137129
-61
0.009647
-31
0.306488
-1
4.479811
-60
0.010999
-30
0.338838
4.8507
-59
0.012526
-29
0.374289
5.1958
-58
0.014247
-28
0.413105
5.5623
-57
0.016184
-27
0.455575
5.9513
-56
0.018364
-26
0.502000
6.3639
-55
0.020813
-25
0.552702
6.8012
-54
0.023561
-24
0.608081
7.2645
-53
0.026641
-23
0.668484
7.7551
-52
0.030090
-22
0.734277
8.2744
-51
0.033948
-21
0.805953
8.8237
-50
0.038259
-20
0.883959
10
9.4045
-49
0.043070
-19
0.968788
10
10.0183
-48
0.048435
-18
1.060958
12
10.6667
-47
0.054410
-17
1.161100
13
11.3513
-46
0.064060
-16
1.269755
14
12.07347
-45
0.068451
-15
1.3875901
15
12.8357
-44
0.076660
-13
1.515293
16
13.6391
-43
0.085768
-13
1.653600
17
14.4857
-42
0.095862
-12
1.803284
18
15.3775
-41
0.107141
-11
1.965283
19
16.3165
34
415