WHITEFIELD EQUIPMENTS PVT' LTD'

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WHITEFIELD EQUIPMENTS PVT. LTD.

• PULSE AIRJET BATCH DRYER
• FOR
• INSULATORS

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MAINTANANCE CUM OPERATION MANUAL

• EQUIPMENT
• PULSE AIRJET BATCH DRYER
• MODEL
• 01-21-SERIES TYPE DM-4
• SIZE
• 11200Lx6600Wx4200Ht
• CAPACITY
• 32MT PER CHARGE
• CUSTOMER
• INSULATORS AND ELECTRICALS COMPANY, MANDIDEEP,
  MP.(NEW PLANT)
• DRYER NUMBER
• D-7, D8 D-9

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EQUIPMENT DETAILS

• The Pulse Air-jet batch dryer manufactured by
  WEPL is a drying chamber fabricated out of Mild
  Steel structurals and Insulated panels made of
  CRCA sheet and Aluminium Sheets with slabs of
  rockwool sandwitched between these sheets. This
  chamber construction is very rugged and provides
  good insulation. Moreover as aluminium is a good
  conductor of heat cooling of the chamber is also
  very fast which helps in making the dryer
  available for loading within a few hours of
  completion of the cycle unlike conventional
  cement walled dryers which take a long time to
  cool after each cycle.
• The dryer is provided with heat exchangers and a
  blower along with necessary ductings to heat the
  chamber and to recirculate the hot air.
• The dryer is also provided with a PULSE AIRJET
  AIR CIRCULATION UNIT (ACU) for circulating the
  air inside the chambers and works on Pulse airjet
  or Intermittent flow principle which is
  considered to be one of the best drying method
  for insulators globally.
• The front side of dryer consists of two large
  doors and a LIFT AND SHIFT type door lifting
  unit to facilitate easy loading and unloading of
  wares using either forklift trucks or pallet
  trucks.
• One motorised threeway valve and two dampers with
  motorised actuators are provided to contorl the
  temperature and humidity inside the dryer. These
  valves and Actuators can be connected to a PID or
  PLC controller to run the dryer using the desired
  pre programmed cycle.

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PARTS LIST

• 1 ) CHAMBER
• 1.0) INSULATED CHAMBER
• 1.1)INSULATED PANELS
• 1.2)LOCKING CHANNELS
• 1.3)DOORS
• 1.4)INSPECTION DOORS
• 2)DUCTINGS
• 2.1)MAIN DUCT
• 2.2)SUCTION DUCT
• 2.3)DISCHARGE DUCT
• 3)HEAT EXCHANGER
• 3.1)HEAT EXCHANGER MS
• 3.2)HEAT EXCHANGER-SS
• 3.3)RADIATOR CHAMBER
• 3.4)CHAMBER BACK COVER

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• 4)DRIVE UNITS
• 5)MOTORS
• 5.1)5 HP MOTOR
• 5.2)0.25HP GEARMOTOR
• 5.3)10 HP MOTOR
• 6)BLOWER
• 7)DOOR LIFTING UNIT
• 7.1)DOOR LIFTING UNT WHEEL
• 7.2)HYDRAULICS FOR LIFTING
• 8)MOTORISED THREE WAY VALVE
• 9)DAMPER

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• 7)DOOR LIFTING UNIT
• 7.1)DOOR LIFTING UNT WHEEL
• 7.2)HYDRAULICS FOR LIFTING
• 8)MOTORISED THREE WAY VALVE
• 9)DAMPER
• 9.1)ACTUATOR
• 9.2)SERVO CONTROLLER
• 10)AIR CIRCULATION UNITS
• 10.1)ACU
• 10.2)CASING
• 10.3)AXIAL FAN

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DETAILS

• 1 ) CHAMBER
• The size of the chamber is 11200mm Length X
  6600mm width X 4200mm Ht.
• 1.0) INSULATED CHAMBER
• The insulated chamber is constructed using mild
  steel channels and insulated panels. The chamber
  comes in a dismantled condition and is assembled
  at site using nuts and bolts.
• 1.1)INSULATED PANELS
• Insulated panels are panels made using aluminium
  sheets,crca sheets and rockwool slabs of density
  48kg/sqm and 75mmthk.The aluminium side will be
  inside the dryer to help avoid corrosion.
• 1.2)LOCKING CHANNELS
• Locking channels are channels formed out of
  aluminium sheets and is used to cover the gap
  betwwen two panels. They are very important as
  they help in retaining heat inside the dryer.
• 1.3)DOORS
• Two big insulated doors of size 2500mm X 4300mm
  are provided on the front of dryer to facilitate
  loading and unloading of wares. The doors are
  operated using the door lifting unit.(ref 7)
• 1.4)INSPECTION DOORS
• An insulated inspection door of size 2000mm X
  1000mm is provided between two main doors. This
  insulated door is hinged and can be opened to
  remove samples in between the drying cycle.
• 1.5)DOOR SEALING
• All the doors are seated on door frames using
  asbestos tape to provide good sealing and
  ensuring no heat loss is taking place.

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• 2)DUCTINGS
• Ductings are fabricated out of crca sheets and
  are either galvanised or painted with heat
  resistant paint. They are used for circulating
  hot air in the chamber.
• 2.1)MAIN DUCT
• Main duct is the duct visible inside the dryer
  with branches projecting to all the ACU cones.
  This duct delivers air from the blower to the
  chamber
• 2.2)DISCHARGE DUCT
• Discharge duct connects the dryer and the blower.
• 2.3)SUCTION DUCT
• Suction duct is used to suck fresh air from
  atmosphere and also to suck the hot air from the
  chamber for recirculation. One damper ie fresh
  air damper is mounted on this duct and the duct
  is also connected to the blower.
• 2.4)BEND DUCT
• Connects suction ducts to blower.
• 2.5)TRANSITION DUCTS
• Connects radiator chamber to discharge duct.

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• 3)HEAT EXCHANGER
• Heat exchanger is of finned tube type and is
  capable of generating heat upto 130 deg celsius
  inside the drying chamber. The input required to
  the heat exchanger is thermic fluid at 250 deg
  celsius.
• 3.1)HEAT EXCHANGER MS
• Two bundles of 36 tubes heat exchanger is fixed
  to the radiator chamber.
• 3.2)HEAT EXCHANGER-SS
• One bundle of 36 tubes heat exchanger is fixed to
  the radiator chamber
• 3.3)RADIATOR CHAMBER
• All the radiators are fixed on this insulated
  chamber which is connected to the blower and
  dryer using ductings.
• 3.4)CHAMBER BACK COVER
• This cover is bolted on the back side of the
  radiator and is used for removing radiators for
  maintanance prposes.

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• 4)DRIVE UNITS
• Drive units are special machine assemblies with
  two concentric shafts rotating in radially
  opposite directions.One shaft is connected to an
  axial fan and and is rotated at RPM upto1400
  using a 5hp motor coupled to the shaft and other
  shaft is connected to the ACU which is rotated at
  1 RPM using a geared motor .
• 5)MOTORS
• 5.1)5 HP MOTOR
• This motor is connected to the axial fan using a
  love joy coupling of size 3dia. The motor is a
  3phase 4 pole squirrelcage induction motor of
  SEIMENS or equivqlent make.
• 5.2)0.25HP GEARMOTOR
• This is a gearbox of model 43.1KH,make ROTOFLEX
  coupled with a 0.25hp SEIMENS or equivalent make
  motor.The gear box is with two stage grease
  filled gearboxes and the output RPM is 3 RPM.
• 5.3)10 HP MOTOR
• This motor is connected to the blower .The motor
  is a 3phase 4 pole squirrelcage induction motor
  of SEIMENS or equivqlent make.
• 6)BLOWER
• The blower is of APCON - Bangalore make and
  capacity is 12000CMH and working condition is
  from 30 deg celsius to 130 deg celsius.

• Bearings for drive Unit
• 6208c3 -4nos
• 6028 -1no
• 6024 - 1no
• Spares for Blower
• 1.Bearing
• 2.Belt

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• 7)DOOR LIFTING UNIT
• Door lifting unit is of LIFT AND SHIFT design and
  is used to open and close the doors of the dryer.
  The unit lifts the door upwards by 50mm from its
  position vertically. The door can then be slided
  along with the lifting unit easily without
  rubbing against the ground and it can be placed
  in front of the other door.
• 7.1)DOOR LIFTING UNT WHEEL
• The wheel is used for sliding the door to any
  position along with the lifting unit. The unit
  consists of two wheels and each wheel has two
  6208 bearings.
• 7.2)HYDRAULICS FOR LIFTING
• The hydraulics for lifting consists of a hand
  pump of Dowty Dynamatic Technologies make and a
  hydraulic cylinder of size 100mm OD,65mm shaft
  and150mm displacement and ½ hydralic hose pipe
  for connecting the cylinder and pump.
• 8)MOTORISED THREE WAY VALVE
• This 2 valve has three ports.One port is
  connected to the main thermic fluid line, one
  port to the radiator and the other port to the
  return line.The motor of this valve is connected
  to the PID or PLC controller which operates the
  valve automatically as per the cycle requirement
  and controls the temperature in the dryer. This
  valve is also provided with a hand wheel which
  can be operated by pressing a small lever near
  the hand wheel and can be used in emergency
  situation.

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• 9)DAMPER
• Two multi louvre dampers are provided for each
  dryer along with motorised actuators.The louvres
  are made of SS304 in order to avoid corrosion as
  it is continuously exposed to humidity and
  temperature. One damper is for exhausting
  humidity and temperature from the drying chamber
  and one damper is for allowing fresh air into the
  chamber through the radiators.
• 9.1)ACTUATOR
• This is a motorised quarter turn actuator used to
  open or close the damper. This actuator is of
  proportionate control type and can be connected
  to a PID or PLC controller. The damper can be
  kept in close, open or any required partially
  open positions.
• 9.2)SERVO CONTROLLER
• This servo controller provided along with the
  damper is to be fitted on the control panel and
  is used to operate the damper manually. It also
  has a digital indicator which shows the position
  of the damper for 0 to 100.
• NB The actuator has to be calibrated after
  connecting to controller.

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• 10)AIR CIRCULATION UNITS
• ACUs are the heart of the pulse airjet driver.
  They are Stainless steel cones with openings on
  two sides and top. The ACU casing is fixed on top
  of the ACU and an axial fan rotates inside the
  ACU. A blast of air escapes from the two openings
  and is intermittently made to fall on the
  insulators from top to bottom.
• 10.1)ACU
• The ACU is of SS 304 construction.
• 10.2)CASING
• The casing is fixed on top of the ACU and an
  axial fan rotates inside the casing.
• 10.3)AXIAL FAN
• The axial fan is made of high quality cast
  aluminium and is dynamically balanced. The
  diameter of the fan is 800mm and capacity is
  25000CMH of air.It is mainly used for circulating
  air inside the chamber.

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SPARES LIST

• 1.) Bearing 6208C3-4nos/Drive unit
• 2.) Bearing 6028 1no/Drive unit
• 3.) Bearing 6024 1no/Drive unit
• 4.)Asbestos tape 75mmX6mm 35mtrs/dryer
• 5.)Silicone sealant GE2000 10 tubes/dryer
• 6.)Sprocket ¾ X 39T- 1no/drive unit with
  suitable bore and counter bore
• 7.)Sprocket ¾ X 13T- I no/drive unit with
  suitable bore and keyway
• 8.)Chain ¾ 2Pkts/Dryer
• 9.)Coupling love-joy 3 Dia with suitable bore
  and keyway.
• 10.)Axial fan dia 800mm, bore 35mm,keyway 8x4,
  dynamically balanced.
• 11.)Motor 5hp,flange mounted 1440 rpm, 4 pole
  3nos/dryer
• 12.)Motor 0.25hp, flange mounted 1440rpm, 4pole
  3nos/dryer.
• 13.) Reduction gear box Rotoflex make Model
  43.1kh.
• 14) V-Belt for Blower- B -150 , 2nos/blower.
• 15.) Plummer block
• 16,) Radiator 36 Tubes,2lakh kcal, 3nos/bundle.

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MAINTANCE

• Maintance is a very important aspect in the pulse
  airjet dryer as the dryers have to run
  continuously for approximately 150 hours every
  cyce and that too at temperatures of upto 130 deg
  celsius. The different types of mainatanance to
  be carried out on the dryer is detailed below.
  Following this procedures will ensure long and
  trouble free running of the dryer.
• Preventive mainatanace
• 1)Daily
• Greasing to be done using High temperature grease
  of synthetic base only. Metal base greases can
  harm the drive units.Use a proper grease gun and
  lubricate the points provided on the drive unit
  above the dryer.
• 2)Weekly
• Check the chain tension and lubricate the chain
  using ordinary grease.The tension can be adjusted
  if necessary.
• Lubricate the links of dampers.
• Lubricate the bearings of the blower.
• Check for any overheating of motors or other
  parts.
• 3)Monthly
• Lubricate the bearings of the drive unit from
  inside the dryer.
• Lubricate the bearings of door lifting unit wheel
  and check the nuts of the wheel for any loosening
  due to vibration. Tighten if loose.
• Check tension of belts of blower and tighten if
  necessary.
• Check antivibration mounts and replace if
  necessary.
• 4)Half Yearly
• Check for any noise from drive units. If there is
  any noise open the bottom and top bearing houing
  and replace the bearings(6208) with good quality
  bearings. Lubricate with high temperature grease.
• Remove radiator back cover,Transition ducts and
  blow the radiators with compreesed air to clean
  the fins of radiator and improve efficiency. Also
  check for any minute leakages.
• Apply silicone sealent on the locking channel
  joints on the interiors of the dryer.
• Replace asbestos tape of front doors .

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• BREAKDOWN MAINTANANCE
• Break down is possible mainly in three parts.
• 1)Drive Unit
• 2)Blowers
• 3)Radiators
• 4)Three way valves

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DRIVE UNIT - REPAIR PROCEDURE

• STEP-1
• Remove the bolts of ACU cone casing and remove
  the cone.
• STEP-2
• Remove the LH threaded nut of main shaft and
  remove the Aluminium axial fan by tapping from
  above using a wooden mallet. This may be
  necessary as the fans tend to get jammed
• STEP-3
• Remove the four M10 bolts of the bottom bearing
  housing.
• STEP-4
• Remove the five HP motor by removing 4 allen
  bolts provided to fix the motor.
• STEP-5
• Remove coupling.
• STEP 6
• Lightly tap on top of the drive shaft. Two
  persons should hold the shaft from inside . The
  shaft will come out from the assy along with
  bottom bearing hsg.