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Summary of Contents for Parker HDK-CNG Series
- Page 1 High-pressure Dryer HDK-CNG 250/250 – 2000/250 Operating manual II 2G IIB T1 Revision 03_2016/ EN...
- Page 2 Declaration of Conformity Parker Hannifin Manufacturing Germany GmbH& Co. KG Gas Separation and Filtration Division EMEA Im Teelbruch 118 D – 45219 Essen Kettwig hereby declares with sole responsibility, that the products High-pressure Dryer Type HDK-CNG 250/250 – 2000/250 Assembly type: assembly acc. to Art. 4 No. 2b,...
- Page 3 Filter Dryer Filter Quantity Allowable Volume Category Module pressure (PS) (PED) HDK-CNG 250/ 250 GH9 1,33 HDK-CNG 750/ 250 GH11 2,09 HDK-CNG1200/ 250 GH11 2,09 HDK-CNG2000/ 250 GH11 2,09 The following standards / technical specifications were used: harmonised standards: DIN EN 12100:2011-3, DIN EN 61000-6-3, DIN EN 61000-6-2, DIN EN 60204-1, DIN EN 13463-1 The following other EC directives were used: ...
- Page 4 Machine passport It is the responsibility of the owner, to enter for the first time any appliance data not stated above, to keep these appliance data up to date. Type designation HDK-CNG__ Order no. Project no. Build no. Vessel no.
- Page 5 Type plate Attach type plate here Note the data on the type plate and keep them complete and always legible. Note: If an acceptance test of the complete system is required in accordance with ATEX, this is a matter for which the operator is responsible.
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Page 6: Table Of Contents
Contents General Information .................... 8 Manufacturer's details ......................8 Details on the dryer ........................ 8 About these operating instructions..................10 About your safety ....................11 Intended use of the dryer ...................... 11 General safety notes ......................12 Signs and hazard areas on the dryer ..................14 Information on inerting the dryer ................... - Page 7 Shutting down and restarting the dryer ............38 Notes for interrupted mains voltage ..................38 Emergency shutdown ......................39 Depressurise the dryer and shut it down ................39 If work is to be carried out on the electrical system .............. 39 Re-start ..........................
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Page 8: General Information
Manufacturer's details General Information Manufacturer's details Name and address Details on the dryer Scope of delivery Dryer, comprising 2 vessels, filled with desiccant 2 prefilter 1 after-filter 1 Water separator Switch cabinet including control 1 Condensate trap ... - Page 9 General Information Notes on accompanying documentation Accompanying documents such as operating instructions for options or related components must always be taken into account. These contain additional information such as in respect of maintenance and are therefore essential for safe operation of the system. Warranty notes In the following cases, the warranty shall be void: ...
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Page 10: About These Operating Instructions
About these operating instructions About these operating instructions These operating instructions contain basic information on the safe use of the dryer. Read these instructions carefully after receiving the dryer. Keep these instructions at an appropriate location so that they can be referred to at a later date. -
Page 11: About Your Safety
About your safety About your safety The dryer has been built in accordance with the state of the art and the recognised technical safety regulations. Nevertheless, there is a risk of personal injury and damage to property when the adsorber is used, if ... -
Page 12: General Safety Notes
General safety notes General safety notes Working with natural gas Natural gas is explosive and toxic. Working with natural gas constitutes a substantial source of hazards to people and the environment. The operator must adopt appropriate safety precautions in respect of these potential hazards. - Page 13 About your safety With ATEX-compliant dryers: — Prior to all work, first cancel the Ex zone (in acc. with the operating instructions of the operator). Then carry out the work. When purifying or drying a critical gas, always pay attention to the hazard notices relating to that gas.
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Page 14: Signs And Hazard Areas On The Dryer
Signs and hazard areas on the dryer Using the heating element As a pressure device prone to overheating, the heating element is subject to special requirements. The operating company must therefore ensure that the requirements stipulated in the Pressure Equipment Directive are observed and applied. -
Page 15: Information On Inerting The Dryer
About your safety Signs and labels The type plates are located on the vessel and on the filters. Note these signs on the dryer. Keep them complete and always legible.Keep them complete and always legible. Information on inerting the dryer Inerting is an explosion prevention measure. -
Page 16: Transportation, Installation And Storage
Information on transportation packaging Transportation, installation and storage Danger due to incorrect transportation! The dryer must be transported by authorised and qualified specialist personnel only. During transportation all applicable national regulations for accident prevention must be complied with. Otherwise there is a risk of personal injury. -
Page 17: Transporting And Installing The Dryer
Transportation, installation and storage Transporting and installing the dryer Requirements for the installation site The conditions at the installation site have a large influence on the functional capability of the dryer and the service life of the drying agent. In order to ensure a mode of operation, which is as continuous as possible, and low maintenance, the installation site must meet the following requirements: ... -
Page 18: Storing The Dryer
Storing the dryer Anchoring the dryer The upright stand profiles of the dryer are provided with pre-drilled anchorage bores. ► Use suitable attachment material to anchor the dryer to the floor. ► In the case of vibrating floors: place the dryer on suitable vibration dampers. Storing the dryer If the dryer is to be stored for an extended period of time, the storage location must meet the following conditions:... -
Page 19: Technical Description
Technical Description Technical Description Layout drawing Front view Controll box Pressure relief heater valve Vessel pressure gauge pressure Check valve gauge Lifting eye vessel plate Vessel Control cabinet Type plate dryer Natural gas outlet After-filter Regeneration gas outlet water seperator Manual drain Natural gas valve... -
Page 20: Function
Function Rear view Connection Safety relief valve Pressure regulator with pressure gauge Heater earth/ground rails Pressure relief valve Natural gas outlet Connection Safety relief valve Rear view Function The dryer dries the natural gas supplied by the compressor and makes it available for industrial use. - Page 21 Technical Description Adsorption Humid natural gas is delivered to the dryer from a compressor. From here, the natural gas flows upwards through the absorption vessel, which is pressurised. In so doing, the drying agent dehumidifies the natural gas. The dry natural gas is directed to the pipework network via the natural gas outlet on the dryer.
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Page 22: Available Options
Available options Available options The following options are available for the dryer: Dewpoint-sensing control Regeneration gas cooler Auxiliary heater Dewpoint-sensing control With a dewpoint-sensing control system, you can operate the dryer in fixed or variable cycles. In the variable cycle, the switchover is effected in relation to the dew point reached and the charging of the drying agent . -
Page 23: Operating And Control Elements
Operating and control elements Operating and control elements Control cabinet Ex d control Control system cabinet Cover with protective glazing Ex e control Control cabinet cabinet control elements Under the control cabinet is a switch box with controls. Using these controls, the dryer can also be controlled in an Ex zone. -
Page 24: Control Unit
Control unit Control unit The dryer control is visible behind the protective glazing. If you will use the keypad of the control unit you must be cancelled the ex-zone before. In an explosion-protected zone of the dryer must be controlled using the controls on the control box (see the following section.) 1 Display 3 Info and Enter keys... - Page 25 Operating and control elements User interface on control Danger! The user interface on the control can only be used when the switch cabinet cover is open. Before disassembly of the cover with protective glazing the Ex zone must be cancelled ! The of each dryer is shown on the status display: Using the keypad, individual menu levels and/or their corresponding sub-menus will be called up.
- Page 26 Control unit ► Select the sub-menu item using arrow keys.. ► To enable the sub-menue press the Enter key. ► Choose the alternative with the arrow keys (the desired alternative must be shown in brackets). ► Confirm input using the Enter key. ►...
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Page 27: Control Elements On The Switch Cabinet
Operating and control elements Control elements on the switch cabinet The dryer can only be controlled in an Ex-protected zone with the controls on the switch cabinet. For this, controls are located under the control switch cabinet. These controls function as follows: ... -
Page 28: Installation
Requirements for installation Installation All work at the pipelines and on the electrical components must be carried out by authorised and suitably qualified technical personnel. As soon as the dryer has been set up at its installation location, you can install the compressed air inlet and outlet lines and make the electrical connection. -
Page 29: Connect Piping
Installation Connect piping In order to ensure that the dryer operates to optimum standards, the dryer must be assembled into the natural gas system free of all stresses. ► Ensure before connection that all inlet and outlet natural gas lines and valves are clean and undamaged. - Page 30 Installing the electrical connection Installing the supply cable The components of the dryer have been connected to the control cabinet at the factory. You only need to connect the control cabinet to the electrical supply cable. ► Ensure that the cross-section of the electrical supply cable corresponds to the power rating of the dryer and the electrical voltage provided by the customer (pay attention to the electrical circuit diagram at the same time).
- Page 31 Installation Connect to earth/ground Earth/ground connection on ATEX-compliant dryers! ATEX-compliant dryers must be earthed/grounded properly. Existing Ex zones near the dryer may need to be cancelled. The earth/ground rails are mounted on the back of the switch cabinet. Here, the dryer is connected to the potential compensation system on the company premises.
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Page 32: Commissioning
Requirements for initial start-up Commissioning On no account place the dryer into service or take the dryer out of service without inerting it beforehand! Together with air, gaseous natural gas can form an explosive gas mixture and therefore poses a considerable danger. An explosive atmosphere can build up especially during commissioning and when replacing the drying agent. -
Page 33: Setting Times Of The Operating Phases
Commissioning Checks before start-up Purge system before start-up! The dryer was subjected at the plant to a leak test using compressed air and is supplied with a positive pressure of +0.5 bar. Prior to commissioning, the dryer must be purged using a suitable medium to remove any residual humidity or oxigen! Warning! Interrupt the start-up procedure if the controller displays an error... -
Page 34: Emergency Shutdown
Emergency shutdown Emergency shutdown In the event of an emergency, shut down the dryer Depressurise the dryer and shut it down as described on page 39. Startup dryer On no account place the dryer into service or take the dryer out of service without inerting it beforehand! Notes for inerting, see page 15. - Page 35 Commissioning Depending on the transportation and storage conditions, the drying agent in the vessels can already be loaded with humidity from the environment. At each first start-up it makes sense therefore to operate the dryer for some time separately from the compressed air system. This causes the drying agent in each vessel to be regenerated repeatedly and thus to be prepared optimally for the take-up of humidity.
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Page 36: Changing Cycle Mode (Optional)
Changing cycle mode (optional) ► With ATEX-compliant dryers: Restore operational potential compensation, check electrical conductivity and document the results. Restart commissioning again. Changing cycle mode (optional) Which cycle modes can I choose? After a successfully concluded initial commissioning process, with the option dewpoint control the dryer must be operated in economy mode (Economy Cycle). -
Page 37: Monitoring Of The Operation
Monitoring of the Operation Monitoring of the Operation The dryer operates fully automatically. However, you should carry out the regular checks described in the Chapter Maintenance and repair of the dryer. Warning of sudden gas escape! During expansion the pressure is relieved suddenly through a restrictor: ... -
Page 38: Shutting Down And Restarting The Dryer
Notes for interrupted mains voltage Shutting down and restarting the dryer In the following cases, the dryer must be fully shut down and depressurised: In the event of an emergency or malfunction For maintenance For disassembly Formation of an explosive gas mixture! ... -
Page 39: Emergency Shutdown
Shutting down and restarting the dryer Emergency shutdown In the event of an emergency, shut down the dryer as described in the next section. Depressurise the dryer and shut it down In order to switch the dryer into a safe state, proceed as described in the next three sections: ►... - Page 40 Re-start If natural gas system and dryer have remained below positive operating pressure ► Ensure that owner-installed natural gas inlet valve is opened. ► Ensure that owner-installed regeneration gas return valve is opened. ► Start program (see section on display elements on page 31 ). The program continues the cycle from the point at which it was interrupted..
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Page 41: Maintenance And Repair Of The Dryer
Maintenance and repair of the dryer Maintenance and repair of the dryer In order to allow maintenance work on the dryer to be carried out efficiently and without danger for maintenance personnel, you should comply with the following instructions. Notes on maintenance Attention! Maintenance tasks may be carried out only by authorised and qualified specialist and approved personnel (e.g. -
Page 42: Regular Maintenance Intervals
Regular maintenance intervals Never use pipes and fittings as steps or holding points! The components might fracture, or the distortions which occur may cause internal damage on the dryer. There is a risk of injury caused by the components slipping, the components breaking off, and by expanding natural gas! ... -
Page 43: Making Preparations
Maintenance and repair of the dryer Maintenance interval Component Maintenance task to be carried Sensor of optional dewpoint- Replace. sensing control system Check valves Clean, replace if necessary. Solenoid valves Valve bodies and purging - clean and replace if ... -
Page 44: Daily Maintenance Tasks
Daily maintenance tasks Daily maintenance tasks Carry out visual and function check on the complete dryer ► Check dryer for external damage or unusual noise generation. ► Duly eliminate any defects found. Clean dryer ATEX-compliant dryers A buildup of dust on the dryer can be dangerous. The dryer must therefore be cleaned regularly. -
Page 45: Weekly Maintenance Tasks
Maintenance and repair of the dryer Replace the safety valve The operator is responsible for the operation and/or maintenance of the safety valve. The nature and scope of maintenance work is determined by local policy and by the type of safety valve installed. Weekly maintenance tasks Check differential pressure on the filters ►... - Page 46 Maintenance work to be completed every 12 months The grounding strap is located behind the switch cabinet and connects all grounding points on the dryer. ► Tighten down these grounding straps regularly and at least once a year. ► The location of the grounding points is shown in the grounding diagram on page 31.
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Page 47: Maintenance Work To Be Completed Every 24 Months
Maintenance and repair of the dryer Clean check valves and replace if necessary Check valves are wearing parts and must therefore be cleaned every 12 months, and replaced if necessary. ► Depressurise the dryer and shut it down (see page 39). ►... - Page 48 Maintenance work to be completed every 24 months Note: For an inspection of the pressure vessels, the drying agent must be removed. For an inspection of the pressure vessels, the drying agent must be removed, as described below. When inspecting the pressure vessel, it is recommended to check the condition of all fittings such as e.g.
- Page 49 Maintenance and repair of the dryer Replace drying agent Never take the dryer out of service without inerting it beforehand. Together with air, natural gas can form an explosive gas mixture and therefore poses a considerable danger. An explosive atmosphere can build up especially when replacing the drying agent.
- Page 50 Maintenance work to be completed every 24 months Add new drying agent. The filling of drying agent in these vessels comprises 3 different layers of drying and cleaning agent. These different layers assure a constant dewpoint. Together with the drying agent, the gaskets and the solids filter in the vessels/hoppers should also be replaced.
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Page 51: Identify And Eliminate Faults
Identify and eliminate faults Identify and eliminate faults Stop condition of dryer In stop condition, the main valves on the dryer are open. When the main valves are open, the dryer is permeated with humid natural gas. This can cause damage to dryer and drying agent. In stop condition, ensure that gas supply is stopped, or that dryer is turned off at the mains isolator switch. - Page 52 Summary of faults Fault Possible cause Remedy dew point Dewpoint not reached Check and if necessary adjust settings Insufficient operating pressure. Increase operating pressure. Differential pressure on the upstream Check differential pressure on the upstream filter, filter is too high. if nec.
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Page 53: Index
Index Index Drying agents storage ..............18 Dust generation ............49 Accident prevention regulations....... 16 Dust mask ..............13 Address, manufacturer ..........8 Dust sieves Adsorption, explanation ........... 21 maintenance interval..........43 Auxiliary heater ............22 Ear protection ............37 Build no. - Page 54 general ..............12 Warning! .............. 10 Noise level ..............56 Safety valves ............. 28, 33 Scope of delivery ............8 Seals maintenance interval ........... 43 Operating instructions Service safe place .............10 Details on~ ............4 safety notes ............11 Shutdown valves ............. 29 Target group ............10 Shutting down ............
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Page 55: Annex With Technical Documentation
Annex with technical documentation Annex with technical documentation This annex comprises the following information and technical documentation: Technical data Replacement and wear parts list Logic control diagram Menu diagram of controller Flow diagram Time diagram of valve setting ... -
Page 56: Technical Data
Technical data Technical data Scope of application Installation location Interior installation, above freezing level, in non-aggressive atmosphere Ambient temperature 25 to 40°C (77 to 104°F) Natural gas inlet temperature 35 to 50°C (95 to 122°F) Operating pressure, maximum 250 bar Return pressure, maximum 20 bar Fluid medium... -
Page 57: Replacement And Wear Parts List
Annex with technical documentation Replacement and wear parts list Note: When exchange or replacement parts are ordered, always state the dryer type and the build no. of the dryer. These data are found on the type plate. First aid kits (for emergency situations) Model Scope of supply Order no. - Page 58 Replacement and wear parts list Additional spare parts Model Scope of supply Amount Order no. Heater ET-HEE65/40NGO-F40380/1KW HDK-CNG 250 HDK-CNG 750 Heater ET-HEE65/40NGO-F40380/2.5 HDK-CNG 1200 Heater ET-HEE65/40NGO-F40380/4KW HDK-CNG 2000 Heater ET-HEE80/40NGO-F40380 Pressure regulator ET-DRM.G10-GHR-J50-C-B9 Condensate drain 11LD/28TG Safety valve ET-VG15/25PS/MS/CNG HDK-CNG Thermometer ET-ITI-MEG/25/VA...
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Page 59: Logic Control Diagram
Annex with technical documentation Logic control diagram Adsorption in B1 and regeneration in B2 Adsorption Regeneration vessel B1 vessel B2 V1 open expansion V4 open max. 5 min Drain V7: heating start heater on alternating ca. 20 min V6 open open 3 sec / closed 30 sec cooling start... - Page 60 Logic control diagram Regeneration in B1 and adsorption in B2 Adsorption Regeneration vessel B2 vessel B1 V2 open expansion V3 open max. 5 min Drain V7: heating start heater on alternating ca. 20 min V6 open open 3 sec / closed 30 sec cooling start heater off...
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Page 61: Menu Diagram Of Controller
Annex with technical documentation Menu diagram of controller HDK-CNG_EN_03_2016... -
Page 62: Flow Diagram
Flow diagram Flow diagram Pos. Designation Pos. Designation prefilter Condensate drain prefilter V8, V9 Condensate valve B1, B2 After-filter Vessel Water separator Pressure reducer V1, V2 Inlet valves Heater V3, V4 Regeneration valves V6, V7 Regeneration valves Optional: Pressure build-up valve Dewpoint sensor V20-V25 Check valves... -
Page 63: Time Diagram For Valve Setting
Annex with technical documentation Time diagram for valve setting HDK-CNG_EN_03_2016... -
Page 64: Dimensional Drawing
Dimensional Drawing Dimensional Drawing Dimensions [mm] Weight Type Connection [kg] HDK-CNG 250 1771 ½ HDK-CNG 750 2110 1139 HDK-CNG 1200 2110 1264 HDK-CNG 2000 2110 1264 1100 HDK-CNG_EN_03_2016...
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