18 - XFG-1 ADSORBENT HYDROGEN DRIER 吸附式氢气干燥器（英文）

XFG-1F ADSORBENT HYDROGEN DDRYER

OPERATION INSTRUCTIONS

United Power Equipment

®

MUDANJIANG UNITED ELECTRICAL EQUIPMENT (CO., LTD)

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.

Installation of mechanical part.............................................................................. 6

2.

Connection of Electrical Elements ....................................................................... 7

VI. Precautions before startup ............................................................................................. 9 VII. Operation Procedures of Equipment Startup .............................................................. 10 VII. Instructions on Gas Exchange of Electrical Explosion-proof Control Box .................. 12 IX. Replacement Procedures (refer to the attached diagram of process flow) ................. 14 X. Instructions on Moisture Absorption, Regeneration and Program Running ................. 15 1.

Instructions on moisture absorption and regeneration ...................................... 15

2.

Program running of programmable logic controller ........................................... 15

3.

Procedures of troubleshooting ........................................................................... 16

4.

Instructions on automatic running and test procedures ..................................... 17

XI. Instructions on Keys and Operation of Human-Computer Interface............................ 18 1.

Instructions on keys............................................................................................ 18

2.

System password ............................................................................................... 18

3.

Display of human-computer interface organization ........................................... 19

4.

Alarm page ......................................................................................................... 21

XII. Maintenance, Removal and Installation of the Equipment Components .................... 22 1.

Replace the alumina drier .................................................................................. 22

2.

Removal of the heater ........................................................................................ 23

3.

Installation of the heater ..................................................................................... 23

4.

Removal of the blower ....................................................................................... 24 1

5.

Installation of the blower .................................................................................... 24

6.

Clean the drain valve ......................................................................................... 25

XIII. Oil-water separator ..................................................................................................... 26 XIV. List of Preventative Maintenance Procedures ........................................................... 28 1.

Daily:................................................................................................................... 28

2.

Weekly ................................................................................................................ 28

3.

Every three months ............................................................................................ 28

4.

Every six months ................................................................................................ 28

5.

Every year .......................................................................................................... 28

6.

Every three years ............................................................................................... 28

7.

Each interruption of running ............................................................................... 28

XV. Precautions of maintenance ....................................................................................... 29 Common Spares ................................................................................................................ 30

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

External dimensions of hydrogen dryer

XFG-1F-70-02-002

External dimensions of water oil separator

VF-2-30-01-001

Electrical schematic diagram of hydrogen dryer

XFG-1F-80-02-001

Electrical wiring diagram of hydrogen dryer

XFG-1F-80-03-001

2

I. Main Technical Parameters 1.

Object

Hydrogen

2.

Working pressure

0.3～0.6 MPa

3.

Inlet temperature

47℃

4.

Inlet dew point (working pressure)

10℃

5.

Outlet dew point (working pressure)

-40℃

6.

Hydrogen treatment capacity

100Nm3/h

7.

Heater

1064 W each

8.

Blower

1/2 HP

9.

Desiccant

(alumina) 23Kg per tower

10. Operation mode

Automatic switching of moisture absorption and regeneration

11. Accessory

Oil extractor (VF-2)

12. Power supply

3-AC415V 50Hz 3KVA

13. Cooling water 14. External dimensions

Flow: 0.5T/H (below 38℃) Pressure: 0.2～0.3MPa 1110mm×884mm×1920mm (hydrogen dryer) 1180mm×600mm×1920mm (oil extractor)

15. Weight (net weight)

650 Kg (hydrogen dryer) 230 Kg (oil extractor)

3

II. Setting Values and Normal Readings Setting of working time Human-computer interface Heating time

4 hours

Cooling time

4 hours

Temperature in regeneration tower CT001 and CT002 Setting value

204 ℃

Normal reading

163℃±28℃ (heating for 2 hours)

Temperature of steam at regeneration tower outlet CT503 Normal reading

82℃±11℃

Temperature of hydrogen in regeneration pipe after cooling CT504 Normal reading

Below 38℃

Pressure of controlled air source Setting value of air source pressure

0.6-0.8Mpa

Setting value of control box pressure

1±0.8KPa

4

III. Model Description X F G—1 F—1 (None) No dew point meter at the hydrogen inlet and outlet. (1) One dew point meter for the hydrogen inlet (2) One dew point meter for the hydrogen outlet and inlet respectively

Applicable to hydrogen cooled generator Serial No. of design Dryer Drying mode-Adsorbent

IV. Working Principles XFG-1F hydrogen dryer is specially used for eliminating the steam in hydrogen of the hydrogen cooled generator. The working principles of XFG-1F hydrogen dryer for drying the hydrogen are to utilize the absorption properties of active alumina to the water molecules. Active alumina is a kind of solid-state desiccant for eliminating the steam in hydrogen of the hydrogen cooled generator. It is implemented by making the hydrogen travel through the absorption tower with alumina of a certain amount. The highly-porous active alumina is provided with large surface area and strong moisture absorption ability. It is adopted as the desiccant for most gas and steam because of its chemical inertness and avirulence. After the alumina is saturated with moisture, eliminate the moister in the desiccant by means of regeneration through heating, so as to recover its moisture absorption ability. At the same time, the performance and efficiency of active alumina is not influenced by regeneration. In the drying tower of the equipment, the buried high-density heater heats the desiccant to evaporate the moisture. At the same time, the steam released from the hydrogen is taken away by the adsorption layer. The desiccant will resume the original characteristics. Then, cool down the hydrogen (containing steam), the condensing water will be discharged through the steam separator. Generally, regeneration for the moisture absorption ability of active alumina can be realized by heating, and this course can be repeated. The equipment is designed with two drying towers, one in moisture absorption mode with the other in regeneration mode. Hence, the absorbent dryer can dry the hydrogen consecutively. During the preset working period, the programmable controller automatically controls the four-way valve by the air valve, and automatically switches the drying tower with saturated desiccant into regeneration mode. At the same time, the drying tower that has completed desiccant regeneration will switch into on-line moisture absorption mode. In this way, automatic switch of equipment is realized. 5

V. Equipment Installation (refer to the attached diagram of installation dimensions) Take care to check whether there is any damage during transportation when receiving XFG-1F hydrogen dryer. If it is true, do not install and contact with the manufacturer immediately. If the equipment is in good conditions, please install according to the installation diagram. 1. Installation of mechanical part The foreign matters or liquid in the hydrogen may enter the absorbent hydrogen dryer, cause pollution of the desiccant and influence the drying effect of equipment. each absorbent hydrogen dryer is provided with a water oil separator for protection and buffering of the hydrogen dryer. Then, the hydrogen will travel through the water oil separator firstly before entering the absorbent hydrogen dryer, so as to filter the foreign matters or liquid in the hydrogen by means of sedimentation in the sedimentation tank and then filter the oil steam in the hydrogen filtering medium tank. In this way, the hydrogen is clean, and the dehumidification effect of the hydrogen dryer desiccant is guaranteed. The water oil separator and the absorbent dryer are installed in the same way. Place the equipment on a horizontal plane, and secure the four angles with anchor bolts. All the four angles herein are provided with mounting holes with diameter of φ16mm.The clearance between the two equipment shall be larger than 1m for convenience of maintenance. Connect the outlet of water oil separator and the inlet of the hydrogen dryer by using DN25 flanged pipeline (since the clearance between the water oil separator and the hydrogen dryer is indefinite, this section exceptional.) Connect the inlet of water oil separator with the hydrogen outlet “g” of generator by using DN25 pipeline. ①.

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 φ16mm. Connect the outlet of hydrogen dryer with the hydrogen inlets “a” and “i” of the generator by using DN25 pipeline.

②.

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.

③.

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.

④.

Install the compressed air intake line (DN10) for instrument at the left side of the hydrogen dryer. Keep the compressed air pressure between 0.6～0.8 MPa.

⑤.

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

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. Connection of Electrical Elements ①. Main power source of electrical XFG-1F is of three phase four wire system,415V, 50Hz and its capacity is 3KVA. The electrical fitting shall be done according to Section 15 Electrical Fitting in Hazardous Area (Colliery Excluded) of GB/T3836.15-2000 Electrical Equipments in Detonating Gas Environment. The blower wheels are specially designed so that the rotating direction of the blower doesn’t matter much for the equipments operation. Therefore， the power phase sequence of the hydrogen dryer may be connected arbitrarily. ②. The hydrogen dryer sends out remote signal for the master-control room. (Refer to the Schematic Diagram of External Terminals) 1)

Remote control Run/Stop command of the hydrogen dryer Press “SET” on the status page of human-computer interface to select remote control of the hydrogen dryer. (Local control of the hydrogen dryer will resume automatically after outage). Run: When Line 100 (Terminal X21) and Line 92 (Terminal X23) of the remote control common end are kept closed, closed Line 100 makes pulses with Line 91, the hydrogen dryer will be put into service by remote control. Stop: When the hydrogen dryer is running, Line 100 (Terminal X21) and Line 92 (Terminal X23) of the remote control common end disconnect short-pulse, the hydrogen dryer stops running.

2)

Remote display hydrogen dryer status indication XFG-1F supplies dry contact for remote display (240VAC/2A, 30VDC/2A). Run indication: Line 80 (Terminal X24) and Line 81 (Terminal X25) of the common end Close (N.O. contact close) remote display shows the hydrogen dryer is running. Disconnected (N.O. contact open) remote display shows the hydrogen dryer is running. Remote indication: Line 80 (Terminal X24) and Line 82 (Terminal X26) of the common end. Close (N.O. contact close) shows the hydrogen dryer is under remote control. Disconnected (N.O. contact open) shows the hydrogen dryer is under local control.

7

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)

Dew point monitoring at hydrogen outlet of the hydrogen dryer (optional) ①.

Adjustable relay output Alarm relay output of dew point setting values at the hydrogen inlet and outlet of rear connection NC and COM (ALARM A) of the hygrometer. Close (N.O. contact close) The dew point of hydrogen inlet or the hydrogen outlet is normal. Disconnected (N.O. contact open) The dew point of hydrogen inlet or hydrogen outlet is higher than the setting value.

②.

Output of failure alarm relay Failure alarm of NC, COM (FAULT) hygrometers with rear connection: Close (N.O. contact close) The hygrometer is normal. Disconnected (N.O. contact open) The hygrometer fails.

③.

Analog output A 4～20mA 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.

8

VI. Precautions before startup 1.

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 1±0.8KPa (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.

Switch all the manual valves to normal operation mode.

AA011—Regeneration control valve—Open 1/2 (refer to the opening of regeneration air flow setting valve) AA403—Discharging & isolating valve—Completely opened AA402—Discharging & communicating valve—Completely opened AA603—Replacement inlet valve—Completely closed and blocked AA604—Replacement outlet valve—Completely closed and blocked 7.

Check whether each breaker of the motor startup protector is at the mode of open.

8.

Ensure that both containers are pressurized.

9

VII. Operation Procedures of Equipment Startup 1.

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

Step 2: Tower A absorbs moisture

Tower B cools down

Step 3: Tower B absorbs moisture

Tower A heats

Step 4: Tower B absorbs moisture

Tower A cools down

It may be necessary to make some adjustments in the fist steps, so as to ensure correctness of switching. Ensure that the hydrogen dryer is set at the mode of Step 1 upon completion of step verification, then set the human-computer interface to be “The hydrogen dryer runs automatically”. 3.

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 82℃±11℃, and that inside the tower shall be 163℃±28℃. After completion of all adjustments, it takes 15-20 minutes for the equipment to reach a stable status. 10

6.

Setting of regeneration flow

①. The regeneration flow control valve AA011 is opened at the position of about 1～1/2 in the factory. It may be necessary to make some adjustments for AA011, so as to reach a proper regeneration temperature. A.

Temperature of gas at regeneration tower outlet: 82℃±11℃

B.

Temperature of gas at cooler outlet: 8℃

C. Temperature inside regeneration tower: 163℃±28℃ If the control valve AA011 is properly set, the temperature of gas at the dryer tower outlet can reach 82℃±11℃ after entering heating step for 2 hours. ②. If the regeneration flow is too low A.

The temperature of gas at the regeneration outlet decreases correspondingly

B.

The temperature of gas at the cooling outlet is normal

C. The temperature in regeneration tower increases Open the control valve AA011 with amplification of 1/8 turning to increase regeneration flow. It needs 15-20 minutes for temperature stabilization before re-adjustment. ③. If the regeneration flow is too high A.

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.

The temperature in regeneration tower becomes too low. Close the control valve AA011 with damping of 1/8 turning to increase regeneration flow. It needs 15-20 minutes for temperature stabilization before re-adjustment. In order to use the dryer with the maximum efficiency, it is necessary to reach a balance of the temperature at regeneration outlet, the temperature of gas at the cooler outlet and the temperature inside the tower of dryer.

7.

In the first steps, the water will be discharge from the drain valve when the temperature inside the tower reaches 82℃±11.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

VII. Instructions on Gas Exchange of Electrical Explosion-proof Control Box Instructions on explosion-proof features According to GB/T3836.1-2000 Electrical Apparatus for Explosive Gas Atmospheres-Part 1: General Requirements and GB/T3836.5-2004 Electrical Apparatus for Explosive Gas Atmosphere—Part 5: Pressurized Enclosures “p”, the electrical explosion-proof control box of hydrogen dryer is designed to be positive pressure protection explosion-proof type “PZ positive pressure” with explosion-proof label of ExPZⅡT4 and explosion-proof certificate number of CJEx07.346.It is admissible to use the electrical explosion-proof control box at positions of Section 2, Class II hazardous locations with explosive gas (H2), i.e. to decrease the hazard classification of control box from Section 2 to nonhazardous positive pressure explosion-proof protection via gas exchange. In normal conditions, the noncombustible instrument air or other suitable inert gas is usually considered to be source of protective gas (take care that there is hazard of asphyxia in case of inert gas. Hence, the user shall attach proper alarm symbols on the control box enclosure. In addition, it is necessary to take corresponding measures for cleaning the inert gas in the control box before opening it). PZ positive-pressure explosion-proof system of electrical explosion-proof control box includes: control box body, relief valve, pressure gauge, outlet valve, alarm labels, differential pressure switch, decompression alarm indicator and remote failure alarm dry contact, one for each. Requirements on gas exchange It is necessary to change air with volume 5 times of that of the electrical explosion-proof control box and to keep the pressure no smaller than 25Pa before energization. Set the flow regulating valve for gas exchange at 175Pa, and open the gas exchange outlet valve completely at the same time, in this way, the generated flow will approach 1.77L/H.The preliminary gas exchange time (minute) is stamped with steel numbers on the gas exchange alarm label of electrical explosion-proof control box door. After ending of the preliminary gas exchange time, close the gas exchange outlet valve, and supply gas continuously to keep the positive pressure of isolating space of the electrical explosion-proof control box at 1±0.8KPa.

12

Operations of gas exchange Take special care that it is prohibited to energize the electrical explosion-proof control box before exchanging gas and pressurizing according to the operation instructions. If gas exchange for the electrical explosion-proof control box is not performed or fails, do not operate the isolating switches and buttons. Only cut off the power at a safe place (remote place), so as to avoid flashover in the unprotected isolating control box. 1. Pressurize at the inlet of relief valve for gas exchange with the maximum gas supply pressure of 1667KPa. 2. Open the gas exchange outlet valve beside the pressure gauge of electrical explosion-proof control box, ensure that the pressure in the control box during gas exchange is no smaller than 25Pa. 3. The gas exchange time for the space of electrical explosion-proof control box is stamped on the alarm label. It is necessary to make gas exchange for the control box with a volume 5 times of that of the control box. 4. After ending of the preliminary gas exchange time, close the gas exchange outlet valve and supply gas continuously, so as to ensure that the positive pressure of the isolating space in the electrical explosion-proof control box is at 1±0.8KPa. 5. Turn on the electrical explosion-proof control box for the hydrogen dryer. Alarm of gas exchange (positive pressure) failures The electrical explosion-proof control box of hydrogen dryer is provided with a differential pressure switch for monitoring the positive pressure. In normal conditions, the positive pressure is higher than the setting value of differential pressure switch, and the alarm relay will send out signals of normal condition upon energization. If the positive pressure decreases to a value lower than the setting value of differential pressure switch, the alarm relay will be de-energized, send out “gas exchange positive pressure failure” locally for alarm with indicator and display on the human-computer interface, and output the dry contact supplied by the user to a remote end. Cut off the power supply of enclosure immediately at a “safe location” (remote place).It is prohibited to operate the buttons or switches. Repeat gas exchange for the electrical explosion-proof control box before re-energization.

13

IX. Replacement Procedures (refer to the attached diagram of process flow) Each power plant shall be provided with a complete system for replacing the generator hydrogen with CO2 or other inert gas. Make gas replacement for the hydrogen dryer before startup or after shutdown of the generator. Method for separate replacement of hydrogen dryer (close the isolating valve between the dryer and generator) 1.

replacement of regeneration loop ①. Convey CO2 to the replacement inlet valve AA603 (with minimum pressure of 2.1 ㎏/cm2; and the maximum pressure of 7.0 ㎏/cm2). ②. Connect the pipeline with the replacement outlet valve AA604 (convey to a safe place). ③. Open the replacement outlet valve AA604 for decompression. Close purification outlet valve after completion of decompression for the equipment. ④. Open the purification inlet valve AA603, pressurize the dryer with CO2 until reaching the minimum pressure of 2．1 ㎏/cm2, then close the replacement inlet valve AA603. ⑤. Open the replacement outlet valve AA604 for decompression of the hydrogen dryer until reaching the pressure value of 0.35 ㎏ /cm2, then close the replacement outlet valve AA604 (avoid the pressure value reaching atmospheric pressure for fear that the oxygen may enters the dryer again). Repeat Step ④ and Step ⑤ for 4 times until the percent of oxygen decreases to be smaller than 0.65%.

2.

Replacement of moisture absorption loop

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

X. Instructions on Moisture Absorption, Regeneration and Program Running 1.

Instructions on moisture absorption and regeneration

It is supposed that Tower A is in mode of moisture absorption and Tower B is in mode of regeneration. Moisture absorption The moist hydrogen from high voltage end flows through the water oil separator. After travelling through AA101 four-way valve at the bottom of dryer, the hydrogen flows to the bottom of dry tower A. Apply pressure to the hydrogen together with the internal blower, so as to dewater the drier. The dry hydrogen will flow back to the low voltage inlet of generator through the upper AA101 four-way valve. Regeneration Apply pressure to the hydrogen with the internal blower to make it rise through the drier being heated by the heater, take away the moisture in the drier (water vapor from heating), make the moist flow pass through the flow control valve AA011. The warm and moist hydrogen flow will continue to pass through the cooler lower than 38℃, then the water vapor will begin to condense. Separate the water from the hydrogen by using a centrifugal steam separator. The separated water will flow to the drain valve by the separation system, and the cooled hydrogen will continue to pass through the four-way valve at the bottom and flows back to the bottom of the container. In this way, the regeneration course is started again there. In normal operation conditions, valve AA403 and valve AA402 are open, valve AA604 and valve AA603 are closed, and valve AA011 is partly closed. The pressure balance pipeline and the four-way valve are connected, so as to ensure that the pressure of the two towers before switching is equal to the pipeline pressure. Valve AA101, a four-way switch valve, is automatically controlled by the pneumatic actuator of hydrogen dryer. 2.

Program running of programmable logic controller

XFG-1F hydrogen dryer is an automatic dual-tower hydrogen drying system which can run continuously. Moisture absorption flow is generated by using the generator fan with the internal blower of the moisture absorption tower. Automatic continuous running is realized by using PLC timed cycle control program. The timed cycle includes 8 hour moisture absorption and 8 hour regeneration of each drying tower. Regeneration includes adjustable 4 hour heating and adjustable 4 hour cooling (the sum of heating and cooling time equals to the exchange working time of moisture absorption tower and the regeneration tower). The designed PLC program for the dryer runs based on four-step cycle. It is supposed that PLC begins to run the first step: Tower A is absorbing moisture and Tower B is heating. The heating control point Q0.1 of PLC output and the solenoid valve control point Q0.8 are alive, PLC output Q0.1 will run to energize KM4 coil, so as to control 15

heating time of Tower B. The temperature controller is used for over-temperature protection during heating. During heating of Tower B, the heating control point Q0.1 will be de-energized when the dryer is stopped or de-energized or fails. Otherwise, Q0.1 must be energized during heating. The aim of heating is to release the moisture caught by the drier during moisture absorption. The flow will pass through the drying layer, condenser, steam separator, etc. The released water vapor will condense and will be discharged through the regeneration system and drain valve. PLC program will enter the second step 4 hours later, i.e. one tower is in mode of moisture absorption, and the other tower is in mode of cooling. At this time, PLC output Q0.1 is de-energized, the heater KM4 stops heating for the heater, the regeneration flow continues to pass through the heated drying layer to cool down the drier. After cooling for 4hours, the working states of the two towers will be switched: Tower B in mode of moisture absorption, Tower A in mode of regeneration. The cycle will be continued until the power of hydrogen dryer is cut off. 3.

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. ①. Positive pressure failure of control box Refer to Chapter VIII—The gas exchange (positive pressure) failure described in Instructions on Gas Exchange of Electrical Explosion-proof Control Box alarms. ②.

Failure of four-way valve Tower A transfer switch contact of switch SQ1 is disconnected when Tower A is in normal operation mode, and Tower B switch contact of switch SQ1 is disconnected when Tower B is in normal working conditions. The switch failure timer starts timing in case of incorrect switch (the transfer switch contact is closed instead of being disconnected), the failure alarm indicator HL1 in ON in 10s and Q0.6 output of failed contact is closed.

③.

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

④.

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.

⑤.

Failure approved shorting stub Failure approved (refer to the schematic diagram) When the shorting stub is disconnected, it can shield the failures of four-way valve, heating and motor. It is mainly used for commissioning and troubleshooting of the equipment. Warning: It is forbidden to adopt this function when the hydrogen dryer can run normally. Otherwise, it may result in abnormal moisture absorption or damage of the hydrogen dryer.

4.

Instructions on automatic running and test procedures The running process of XFG-1F hydrogen dryer is controlled by programmable logic controller (PLC). It is provided with the programs of automatic running test operation for the hydrogen dryer. Test operation of the hydrogen dryer is a tool for commissioning and troubleshooting of the equipment. It is used for controlling the running procedures of hydrogen dryer manually and verifying the correctness of program and equipment running. In case of automatic running mode, it is possible to make the hydrogen dryer enter the next step only when the conditions set according to the regeneration time of the human-computer interface are satisfied. It is necessary to ensure that both the heating and cooling time of regeneration are 4 hours. There is test mode program for convenience of commissioning and maintenance and entering the next step in advance. It is allowable to make the hydrogen dryer enter the next step in advance by over-passing the preset conditions. This function is of great importance and can be used for commissioning and troubleshooting of the equipment. Warning: Take care to use since it is also a strong tool. Be sure what will happen when the hydrogen dryer enter the next step, since all the linkage and protection are over-passed by the commissioning mode. Make sure that it is safe to enter the next step before using this tool. 17

XI. Instructions on Keys and Operation of Human-Computer Interface 1.

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

Open system password before making modification setting. Select operation mode page, press “SET” to enter the page of entering password. Select 1 “Open the password”, press “∧” or “∨” to enter the password 88888888, press “ENT” to confirm. Select 2 “Close the password”. Press “ESC” to exit the system password page.

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3.

Display of human-computer interface organization

Page 1 Status display Line 1

Display that the hydrogen dryer stopped / running / alarming.

Line 2

Press “SET” to set local control / long-range control for the hydrogen dryer.

Line 3

Adsorbing time/heating time/cooling time of Tower A (hour: minute)

Line 4

Adsorbing time/heating time/cooling time of Tower B (hour: minute)

Page 2 Page for setting working mode Line 1

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

Press “SET” to enter password page.

Page 3 Working status reset page Line 1

Display that the hydrogen dryer stopped / running / alarming.

Line 2

Adsorbing (regeneration) of Tower A / Adsorbing (regeneration) of Tower B.

Line 3 status.

Press “

” to restore the heating status/press “

” to restore the cooling

Page 4 Page for setting regeneration time Line 2

Setting of regeneration heating time (hour: minute).

Line 3

Setting of regeneration heating time (hour: minute).

Page 5 PLC failure timer setting 1 Line 2

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.

Page 7 PLC failure timer setting 2 Line 2

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

Press “CLR” to resume factory setting of the parameters.

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Page 8 PLC input point page For example: Indicator 1 is ON: there is input at I 1. Indicator 1 is OFF: there is no input at I 1. IN 0

Run/Stop knob input.

IN 1

Control box differential pressure switch input.

IN 2

Tower A transfer switch input.

IN 3

Tower B transfer switch input.

IN 4

Tower A blower contact input.

IN 5

Tower B blower contact input.

IN 6

Failure alarm allows input.

IN 7

Heating over-current contact input.

IN 8

Tower A heating contact input.

IN 9

Tower B heating contact input.

IN 10

Reserved.

IN 11

Reserved.

IN 12

Remote startup command input.

IN 12

Remote stop command input.

Page 9 PLC point output page For example: Indicator 1 is ON: there is output at Q 1. Indicator 1 is OFF: there is no output at Q 1. OUT 0

Tower A regeneration heating control output.

OUT 1

Tower B regeneration heating control output.

OUT 2

Failure alarm indicator output.

OUT 3

Blower control output.

OUT 4

Display the running output of hydrogen dryer remotely.

OUT 5

Display local/remote control output of the hydrogen dryer remotely.

OUT 6

Display the failure output of hydrogen dryer remotely.

OUT 7

Display power failure output remotely.

OUT 8

Tower A solenoid valve control output.

OUT 9

Tower B solenoid valve control output. 20

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

XII. Maintenance, Removal and Installation of the Equipment Components 1. Replace the alumina drier Every tower of the XFG-1F dryer is equipped with active alumina drier of 23kg, the service time of which, under normal operation condition is 35 years. The service time of drier may be relatively short. When its performance is unacceptable, it is necessary to replace. Replacement steps of the alumina drier: ①. Replace the hydrogen in the equipment. Replace the hydrogen of the dryer by reference to the replacement of the equipment. ②. Remove the thermocouple 8 and heater line 3 from the top. ③. Remove the binding bolt 1 and lift the upper cover 2, disconnect the line between the upper cover connector post and the heater. ④. Clear the drier 4 with reduced performance by vacuum cleaner. ⑤. Take away the heater 5, clear the remaining drier by vacuum cleaner and clean the bottom. ⑥. Put the heater back to the tower. ⑦. Fill new drier into the tower. Be careful not to let the dust of the drier into the tower. ⑧. Replace the flange gasket on the upper cover (10.56 ㎏ /cm2, 260℃ condition must be suitable for hydrogen). ⑨. Connect the heater with the upper cover connector post 3, link with the ground to inspect whether it is short circuit. ⑩. Screw the binding bolt 1, reconnect the heater 3 and thermocouple 8 for installation. 11 . Check for leakage. ○ 12 . Replace the air in the tower and put it to operation. ○

22

2. Removal of the heater ①. Check if the replaced tower is running or stopped for replacement. ②. Remove the thermocouple 8 and heater 3 from the top. ③. Remove the binding bolt 1 and lift the upper cover 2, disconnect the line between the upper cover connector post 3 and the heater. ④. Remove the upper cover 2. ⑤. Remove the drier 4, see “Replacement steps of the alumina drier” for details. ⑥. If there is no drier inside the tower, the heater ⑤ will be easily removed. 3. Installation of the heater ①. Place the heater 5 back to the tower 6 and fill the tower with drier 4. ②. Replace the flange gasket on the upper cover (10.56 ㎏/cm2, 260℃ condition must be suitable for hydrogen). ③. Connect the heater with the upper cover connector post 3, link with the ground to inspect whether it is short circuit. ④. Screw the binding bolt 1. ⑤. Reconnect the heater 3 and thermocouple 8 for installation. ⑥. Check for leakage. ⑦. Replace the air in the tower and put it to operation.

23

4. Removal of the blower ①. Check if the replaced tower is running or stopped for replacement. ②. If the blower is confirmed to be powered off, remove the 3 down leads 5 of the generator. ③. Remove the pipeline connection 6 of the tower bottom and bottom four-way valve. ④. Carefully remove the bottom vessel bolt 3 and move the blower components as a whole downward. Note: Pay special attention when lowering the drier components because the weight of the components is about 56kg. ⑤. Check if the generator 7 and impeller 9 are normal. 5. Installation of the blower ①. Repair and replace the blower components. ②. Replace the flange gasket on the upper cover (10.56 ㎏/cm2, 260℃ condition must be suitable for hydrogen). ③. Place the whole blower components back into the vessel and put on flange gasket, screw the bolt 3. ④. Reconnect the pipeline connection 6 of the tower bottom and bottom four-way valve (replace the flange gasket). ⑤. Reconnect the generator power line 5, make leakage inspection with pressure maintaining. ⑥. Replace the air in the tower and put it to operation.

24

6. Clean the drain valve Clean the drain valve every week at the first two weeks of the equipment operation and later every 3 months. ①.

Before cleaning, close the drainage section valve AA40 and drainage connection valve AA402.

②.

Remove the 4 bolts and active components around the drain valve.

③.

Thoroughly clean the drain valve with detergent and check to make sure that the drainage holes are clear.

④.

Reassemble the drain valve and connect the drainage lines.

⑤.

Take the pipe plug 7 from the top drain valve, fill water until the water discharges, and then screw the pipe plug.

⑥.

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

XIII. Oil-water separator 1. Application of oil-water separator VF-2 oil-water separator is mainly used in generator hydrogen gas drying system to remove oil water, oil steam, dust and impurity in hydrogen gas, protect subsequent hydrogen gas dryer from dust and oil pollution and reduce maintenance work of subsequent hydrogen gas dryer. 2. Structure and function of oil-water separator The oil-water separator mainly consists of settling tank and filtering tank. The hydrogen gas from generator enters into settling tank first; in settling tank, the liquid oil water settles at the bottom under the action of gravity and may be discharged manually by blow-off valve. A small amount of oil steam and hydrogen gas enters into filtering tank and then flows across internal oil steam filtering layer that the extremely strong-absorbability hydrogen gas filtering medium is applied to, and the oil steam, dust and other impurities in hydrogen gas can be removed completely, and moreover, the filtering layer has high porosity and the air resistance is little, so it is easy for hydrogen gas to pass through. It is guaranteed that the hydrogen gas can pass through with a large enough flow under pressure propelling before and after generator fan, and flow into hydrogen gas dryer through pure hydrogen gas outlet after filtering layer. 3. Installation of oil-water separator ①. The weight of VF-2 oil-water separator is 230kg. ②. The oil-water separator is put on the horizontal ground and its four corners are fastened with anchor bolts. ③. The hydrogen gas inlet is at the lower left side of settling tank and the hydrogen gas outlet is at the upper side of filtering tank. ④. The equipment must be connected to the pipeline in front of hydrogen gas dryer inlet. ⑤. No U-bent pipes are allowed between generator and oil-water separator. ⑥. The installation position of oil-water separator must be the lowest point of the whole system.

26

4. Maintenance of oil-water separator Inspect whether oil water remains in settling tank, and if any, the oil water can be discharged to a safe place through pipeline manually by the blow-off valve at the bottom. The service life of hydrogen gas filtering medium in oil steam filtering tank is approx. 1 year and actual service life must be determined according to the flow velocity of hydrogen gas and concentration of oil steam. Replace hydrogen gas filtering medium ①. Isolate the oil-water separator from the hydrogen gas system. ②. Displace the hydrogen gas in oil-water separator up to standard and reduce pressure. ③. Dismount the fastening bolt 1 and flange 2 under oil steam filtering tank and discharge the out-of-service hydrogen gas filtering medium. ④. Replace flange washer (10.56 ㎏ /cm2 condition must be applicable to hydrogen gas) and fastening bolt 1 and shut off the blow-off valve. ⑤. Dismount the inlet fastening bolt 3 and flange 4 above oil steam filtering tank. ⑥. Inject 10kg hydrogen gas filtering medium (1F23108). ⑦. Replace flange washer (10.56 ㎏/cm2 condition must be applicable to hydrogen gas) and resume the flange seal of medium inlet of oil steam filtering tank. ⑧. Inspect the leakage. ⑨. Displace oil-water separator with CO2 and resume the work of oil-water separator in hydrogen gas system.

27

XIV. List of Preventative Maintenance Procedures 1. Daily: ①.

Check whether there is alarm of the hydrogen dryer and make records.

②.

Collect, measure and record the displacement of drain valve.

2. Weekly ①.

When the 4 hour heating period is ending, check whether the temperature at the heater outlet is 82℃±11℃ and the temperature in the drying tower is 163℃±28℃.

②.

Check the dew point at the outlet of hydrogen dryer if possible.

③.

Check the drain valve when the 4 hour heating period is ending. Clean this equipment if necessary.

3. Every three months ①.

Clean the drain valve.

②.

Make leakage inspection of hydrogen for the whole hydrogen dryer, including all the electrical connection parts.

③.

Measure the differential pressure at the outlet and inlet of hydrogen dryer, so as to verify that the hydrogen flows through the dryer.

4. Every six months ①.

Replace the hydrogen filtering medium of steam separator if necessary.

②.

Record the data of hydrogen dryer in the attached list.

③.

Verify whether the four-way valve runs properly.

④.

Check whether the failures of four-way valve, heater, blower and control box positive pressure can be alarmed normally.

5. Every year ①. Check and flush the fin and tube wall around the cooler. ②. Check the use conditions of valve diaphragm. Replace it if there is any damage. ③. Check the pneumatic solenoid valve, and re-assemble it if it is necessary. 6. Every three years ①. Replace the drier. ②. 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

XV. Precautions of maintenance 1.

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 use’s 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 user’s expense.

After-sales telephone: 0453-6596996 6536151 After-sales fax: 0453-6596996 6536151

29

Common Spares Description

Order code

Active alumina (23 ㎏/tower)

1F23107

VF-2 hydrogen filtering medium (10 ㎏)

1F23108

Dual-sleeve ball valve

1F01401

1/2 inch diaphragm valve

1F05402

1 inch diaphragm valve

1F10403

1 inch four-way valve (AA101)

1F05404

Condensing drain valve

1F05407

Pressure gauge of drying tower (CP501—CP502)

1F34501

Positive pressure gauge of control box

1F34504

Dual metal thermometer (CT503)

1F34300

Dual metal thermometer (CT504)

1F34150

Discoloration indicator of humidity (supplied when there is no dew point meter)

1F10406

Compressed air filter

1FB2000

Positive pressure relief valve of control box

1F3912N

Humidity dew point meter

1F36632

Sensor of humidity dew point meter

1F36634

Programmable logic controller

1F0AA24

Human-computer interface

1FTD220

24V switching power supply

1F6EP13

Power load switch

1F00VC2

Motor protector of auxiliary blower

1F0M06C

Regeneration heating contactor (KM3—KM4)

1F12M5C

Contactor of auxiliary blower (KM1—KM2)

1F09M5C

Regeneration heater (1KW, 115V)

1F01664

Temperature controller thermocouple (RTD1—RTD2)

1FPT100

Temperature controller (ST1—ST2)

1F04848 30

Fuse (FU1—FU6)

1F0K1EK

Breaker at the input side of transformer

1F0D62P

Breaker of heating loop at the output side of transformer

1FD162P

Breaker of control loop at the output side of transformer

1F0D22P

Failure indicator

1FBVM4C

Run/Stop selection switch

1FBD25C

Motor of auxiliary blower (415V, 50Hz)

1F0H50G

Five-way two-position solenoid valve

1F08851

Transformer

1F01064

Low-voltage differential switch

1F19102

Explosion-proof traveling switch

1F20175

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Table 1: Hydrogen dryer performance record table

Date

No .

Item

1

Motor resistance (phase Ato phase B)

2

Motor resistance (phase A to phase C)

3

Motor resistance (phase B to phase C)

4

Motor resistance to ground (more than 50MΩ)

5

Heater resistance (10Ω-12Ω)

7

Heater current (about 9A)

8

Transformer voltage primary side-415V

9

Transformer voltage secondary side, 110V, 220V

10

Cooling water outlet temperature (less than 38℃)

11

Bed temp.switch setpoint (163℃)

12

13

Tower A

Tower B

Actual bed temp (163℃±28℃) Reactivation outlet temp. (82℃±11℃)

32

Tower A

Tower B

Tower A

Tower B

Table 1 (continued): Hydrogen dryer performance record table

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

Table 2: Water vapor dewpoint temperature and saturating water vapor content (contrast table)

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

0

4.8507

-59

0.012526

-29

0.374289

1

5.1958

-58

0.014247

-28

0.413105

2

5.5623

-57

0.016184

-27

0.455575

3

5.9513

-56

0.018364

-26

0.502000

4

6.3639

-55

0.020813

-25

0.552702

5

6.8012

-54

0.023561

-24

0.608081

6

7.2645

-53

0.026641

-23

0.668484

7

7.7551

-52

0.030090

-22

0.734277

8

8.2744

-51

0.033948

-21

0.805953

9

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

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415

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