GSI Modular Tower Dryer TM-1008, TM-1010, TM-1012 and TM-1015 Construction Manual PNEG-1708 Date: 08-01-11 PNEG-1708
PNEG-1708 GSI Modular Tower Dryer
Table of Contents Contents Chapter 1 Introduction .......................................................................................................................................... 4 Chapter 2 Safety ..................................................................................................................................................... 5 Safety Guidelines ..................................................................................................................................
1. Introduction READ THIS MANUAL carefully to learn how to properly use and install equipment. Failure to do so could result in personal injury or equipment damage. INSPECT the shipment immediately upon arrival. The customer is responsible for ensuring that all quantities are correct. The customer should report and note any damage or shortage on the bill of lading to justify their claim to the transport company.
2. Safety Safety Guidelines This manual contains information that is important for you, the owner/operator, to know and understand. This information relates to protecting personal safety and preventing equipment problems. It is the responsibility of the owner/operator to inform anyone operating or working in the area of this equipment of these safety guidelines. To help you recognize this information, we use the symbols that are defined below. Please read the manual and pay attention to these sections.
2. Safety General Safety Statement Our foremost concern is your safety and the safety of others associated with tower dryer. This manual is to help you understand safe operating procedures and some problems that may be encountered by the operator and other personnel. As owner and/or operator, you are responsible to know what requirements, hazards and precautions exist and inform all personnel associated with the equipment or in the area. Safety precautions may be required from the personnel.
3. Safety Decals Some of the required safety decals are placed on the dryer before shipping. The remainder are placed on the dryer during electrical installations. The purpose of the safety decals is to immediately alert all personnel to the hazards of an operating dryer. The safety decal does not replace the need for all personnel to know and understand safe dryer operations and requirements. Read the “Dryer Operations and Service Manual”.
3. Safety Decals Safety Decal # DC-GBC-1A Location of Decals English and spanish decals are placed on inside of tower roof access port before shipping. Tower roof access port with decals in place. Rotating flighting will kill or dismember. Flowing material will trap and suffocate. Crusted material will collapse and suffocate. Keep clear of all augers. DO NOT ENTER this bin! If you must enter the bin: 1. Shut off and lock out all power. 2. Use a safety harness and safety line. 3.
3. Safety Decals Safety Decal # DC-1943 Location of Decal On outside of main power box and inside main power box door. Example - Electrical control system HIGH VOLTAGE. HAUTE TENSION. Will cause injury or death. Causera des blessures ou la mort. Lockout power before servicing. Bloquez le courant avant de faire l’entretien.
3. Safety Decals Safety Decals # DC-985, DC-990 and DC-991 Location of Decal Inside main power box door, on same side as main electrical disconnect.
3. Safety Decals Safety Decals # DC-987, DC-988 and DC-989 Location of Decal Inside main power box door, on same side as main electrical disconnect.
3. Safety Decals Safety Decals # DC-1061 and 420-1473-8 Location of Decal On outside of heat module door. WARNING! Flame and pressure beyond door. May cause serious injury. Do not enter when dryer is running.
3. Safety Decals Safety Decals # DC-1063 and DC-1064 Location of Decal On outside of cool module door. WARNING! High speed belt drive operating overhead. Can cause serious injury. Keep head and hands clear. Do not enter when dryer is running. DC-1064 PNEG-1708 GSI Modular Tower Dryer CAUTION! Airborne particles during operation. May impair vision and breathing. Do not enter when dryer is running.
3. Safety Decals Information Decals Nameplate for Main Power Box Location of Decal Inside main power box door, on same side as main electrical disconnect.
4. Dryer Overview and Specifications All models of the GSI Modular Tower Dryer include a base/unload module, a burner/blower module, a roof module and one or more heat modules. Heat modules can be “empty” or with turners based on owner preference. Module 1 on ALL models. NOTE: New dryers ship with corrugated sheets.
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4. Dryer Overview and Specifications Dimensions and Capacities for all Models There are four (4) models of the GSI Modular Tower Dryer. Each model is 10' 10" in diameter. 1. TM-1008 2. TM-1010 3. TM-1012 4.
4. Dryer Overview and Specifications Dimensions - TM-1008 Total weight = 18000 lbs. NOTE: Please refer to Page 51 for individual section weights. Module - 5 Roof module (See Figure 4F on Page 17.) Module - 4 Heat module - w/ turners (See Figure 4C on Page 16.) Module - 3 Heat module - w/ door kit (See Figure 4E on Page 17.) Module - 2 Heat module - burner/blower (See Figure 4B on Page 15.) Module - 1 Base/unload (See Figure 4A on Page 15.
4. Dryer Overview and Specifications Dimensions - TM-1010 Total weight = 21645 lbs. NOTE: Please refer to Page 51 for individual section weights. Module - 6 Roof module (See Figure 4F on Page 17.) Module - 5 Heat module - empty (See Figure 4D on Page 16.) Module - 4 Heat module - w/ turners (See Figure 4C on Page 16.) Module - 3 Heat module - w/ door kit (See Figure 4E on Page 17.) Module - 2 Heat module - burner/blower (See Figure 4B on Page 15.) Module - 1 Base/unload (See Figure 4A on Page 15.
4. Dryer Overview and Specifications Dimensions - TM-1012 Total weight = 23095 lbs. NOTE: Please refer to Page 51 for individual section weights. Module - 7 Roof module (See Figure 4F on Page 17.) Module - 6 Heat module - empty (See Figure 4D on Page 16.) Module - 5 Heat module - w/ turners (See Figure 4C on Page 16.) Module - 4 Heat module - empty (See Figure 4D on Page 16.) Module - 3 Heat module - w/ door kit (See Figure 4E on Page 17.
4. Dryer Overview and Specifications Dimensions - TM-1015 Total weight = 24545 lbs. NOTE: Please refer to Page 51 for individual section weights. Module - 8 Roof module (See Figure 4F on Page 17.) Module - 7 Heat module - empty (See Figure 4D on Page 16.) Module - 6 Heat module - empty (See Figure 4D on Page 16.) Module - 5 Heat module - w/ turners (See Figure 4C on Page 16.) Module - 4 Heat module - empty (See Figure 4D on Page 16.) Module - 3 Heat module - w/ door kit (See Figure 4E on Page 17.
5. Required Tools and Critical Tool Characteristics Equipping the field crew with the right tools is essential for a smooth installation. The GSI Modular Tower Dryer requires a number of standard tools. Please pay particular attention to the following item descriptions as the characteristics of the following tools are extremely important information for proper installation. A comprehensive list of tools required to assemble and install the GSI Modular Tower Dryer is included later in this chapter.
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5. Required Tools and Critical Tool Characteristics 4.
5. Required Tools and Critical Tool Characteristics 5. Laser transit level tool: After placing the unload/base module on the concrete foundation and establishing its proper orientation to other equipment it must be leveled. GSI strongly recommends using a Laser transit leveling tool to level the unit. (See Figure 5E.) If a Laser transit is not available, a carpenter’s level may be used. It is critical to establish the base/unload module as level.
5. Required Tools and Critical Tool Characteristics a. Compression channel: Regardless of what leveling tool is used, the proper reference point for leveling the unload module of the dryer is the Compression Channel and NOT the base/leg plates on the concrete. See Figure 5G for reference. The Compression Channel is the “ledge” around the unload module of the dryer. Use this as the reference point for leveling the unit. Do NOT use base plates/feet to determine whether or not unit is level.
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6. Unloading and Staging the Modules 1. Place modules on ground that is as solid and level as possible. Soft ground/grass will make preparation for installation more difficult. Concrete or gravel ground is preferable for pre-installation work. If no gravel or concrete area is available for staging the modules, consider placing the modules on 2 x 4’s or other blocking material to prevent the modules from sinking into the ground. 2. Place modules next to sequential modules (i.e.
7. Placing and Installing the Base/Unload Module Base/Unload Module Placement Considerations If the concrete foundation is ready and adequately cured, place the base/unload module on it and take careful and complete consideration of the surrounding equipment. Be sure to consider any planned options such as augers and any potential equipment to be added later. 1. Consider the location of the electrical box and control panel.
7. Placing and Installing the Base/Unload Module Figure 7B Consider overhead clearance for the entire height of the dryer. 4. Ladder brackets are not pre-installed on modules. Consider installation location of ladders and brackets. Note that ladder brackets will be offset at each catwalk and will not line up in a straight line. (See Figure 7C.
7. Placing and Installing the Base/Unload Module Securing the Unload Module 1. After determining the orientation of the unload module, use a 1-1/8" drill bit at least 12" long to drill holes for the anchor bolts. NOTE: Anchor bolts are 1" in diameter but the hole for them must be 1-1/8" in diameter to allow for the required epoxy. NOTE: It may be necessary to loosen or remove the bolts on the X-braces to gain easier access to the holes for the anchor bolts.
7. Placing and Installing the Base/Unload Module NOTE: Shims are provided to assist with leveling if necessary. (See Figure 7F.) Figure 7F 3. After drilling the holes, all debris and fine material must be removed from the holes. 4. Use a compressed air hose to blow the dust and debris out. Then, drop anchor bolt in holes to confirm depth is adequate. 5. Once the unit is level, fill anchor bolt holes approximately 1/2" full with the provided epoxy. Press anchor bolts in holes. (See Figure 7G.
8. Assembling Ladders, Platforms and Catwalks Crate as Work Bench Because the base/unload module requires the epoxy to set for a MINIMUM of 4 hours before other modules can be set on top of it, this is an excellent time to begin assembly of the ladders, platforms and catwalks. Once the crate is empty, use a hammer to pound the exposed nails and/or staples back into the frame so that the surface is smooth. The crate makes an excellent work bench for assembling items throughout the installation process.
8. Assembling Ladders, Platforms and Catwalks Installing Outside Ladder with Safety Cage Outside Ladder Bracket Outside ladder brackets are not pre-installed prior to shipping. Pre-assemble safety cages on the ground prior to attaching to the dryer. Top Safety Cage Pre-assemble the top safety cage as follows. (See Figure 8C, Figure 8D below and Figure 8F to Figure 8H on Page 36.) 1. Snug bolt one formed ladder section to two (2) outside ladder stiffeners.
8. Assembling Ladders, Platforms and Catwalks 3. Snug bolt safety cage hoops to safety cage brackets. (See Figure 8E and Figure 8F.) Figure 8E Figure 8F 4. Snug bolt seven (7) vertical supports to safety cage hop halves. (See Figure 8G.) 5. Snug bolt top safety cage assembly to outside ladder brackets. (See Figure 8G.) 6. Tighten all bolts. 7. Use splice plate between ladders sections to connect. (See Figure 8H.
8. Assembling Ladders, Platforms and Catwalks Safety Cage Extensions Install safety cage extensions from top safety cage to bell safety cage just above foundation as follows. Quantity depends upon dryer model. 1. Splice outside ladder stiffeners with ladder stiffener splices. Snug bolt outside ladder stiffeners behind formed ladder sections. (See Figure 8I.) Figure 8I Close Up - Pointing to ladder stiffener splice. Install ladder stiffener splice with four (4) bolts. 2.
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8. Assembling Ladders, Platforms and Catwalks Overview Catwalk and Platform Assembly NOTE: This is a basic overview of the process as it relates to the Modular Tower Dryers and is intended to be a general guide for catwalks and platforms as they are assembled on the GSI Modular Tower Dryer. Catwalk and platform parts are shipped in the shipping crate that accompanies the modules. Assemble all floor planks and kick plates before assembling the dryer or stacking and connecting the modules.
8. Assembling Ladders, Platforms and Catwalks Attaching Catwalks and Platforms to Dryer Modules Catwalks and platforms are attached to the appropriate modules while they are on the ground, before modules are stacked on other modules or lifted into place on the unload module. 5. Remove four (4) bolts per seam on sections to attach catwalk support braces. Be careful not to push bolts back into channel between the screens.
8. Assembling Ladders, Platforms and Catwalks 6. Attach catwalk brackets as shown in Figure 8R. NOTE: All brackets must attach facing/angling the same direction. In the example on the right, all brackets will face to match the bracket being installed. Catwalk bracket Figure 8R Attaching catwalk bracket to dryer module. 7. Assemble catwalk brace/support braces by connecting as shown in Figure 8S and Figure 8T using one nut and one bolt.
8. Assembling Ladders, Platforms and Catwalks 8. Attach catwalk brace to dryer wall using the previously installed catwalk brackets. Catwalk brace attach to outside of bracket. (See Figure 8U.) Tighten fully with impact. Lower arm of catwalk brace connects to top hole of bracket and upper catwalk brace arm connects to top hole of bracket. (See Figure 8U.) In Figure 8U, the catwalk brackets all face bracket and the catwalk brace all face . The catwalk brace attach to the outside of the . 9.
8. Assembling Ladders, Platforms and Catwalks 11. After attaching the catwalk brace to the catwalk brackets on the dryer wall, attach a catwalk transition to the top of each catwalk brace. (See Figure 8X.) IMPORTANT: Note the hole alignment on the catwalk transition. The “five (5) hole” pattern near the center of the transition MUST be oriented so that the center hole is AWAY from the dryer wall. (See Figure 8W and Figure 8X.
8. Assembling Ladders, Platforms and Catwalks 12. Attach catwalk planks (with kick plates attached) to catwalk transitions. 13. There are two (2) planks between catwalk brace. The longer plank with the kick plate goes farther away from the dryer wall with the kick plate on the outside and the shorter plank goes closest to the dryer wall with the kick plate to the inside (to prevent stepping or slipping between the plank and the dryer). (See Figure 8Y.
8. Assembling Ladders, Platforms and Catwalks 14. Install the catwalk plank with the curved kick plate at the stepover point immediate beside ladders. This is an added safety feature to help prevent feet from being wedged between the catwalk and the dryer wall when stepping over or off a ladder. (See Figure 8Z.) This is the stepover section immediately beside a ladder. Use ladder brackets for placement guidance. Stepover section Figure 8Z 15. Stepover kick plates are installed at stepover locations.
8. Assembling Ladders, Platforms and Catwalks Step-in end of platform Closed end of platform Figure 8AB Figure 8AC 16. Attach handrail supports to catwalk brace as shown in Figure 8AD and Figure 8AE. 17. Attach handrails to handrail supports as shown in Figure 8AD and Figure 8AE. Make sure curved side of handrails is to the inside for use. The sharper flat sides should be to the outside.
8. Assembling Ladders, Platforms and Catwalks 18. Connect handrails to the inside of supports as shown in Figure 8AF. Nuts should be to the outside and the curved side of the handrail should be to the inside of the platform or catwalk for use. (See Figure 8AF.) Note handrail orientation. Flat side goes to the outside away from the dryer. Rounded side goes to the inside for hand safety. Outside away from the dryer. (See Figure 8AF.) Also note the placement of connecting handrails to handrail support.
9. Burner/Blower Module - Special Considerations 1. Before lifting and stacking modules, be sure the floor planks are installed for the burner/blower module. These should be factory installed. The burner/blower module contains flooring to support the user when entering the dryer to perform cleaning or maintenance duties. The flooring planks for the burner/blower module are similar to catwalk planks but have “TABS” on the ends to drop into slots in the burner/blower module. (See Figure 9A.
9. Burner/Blower Module - Special Considerations NOTE: The plank nearest the thermistor housing will need to be cut to allow it to drop into place. This should be factory installed. In Figure 9C, the installer is marking the plank so that it can be field cut for proper fit. Figure 9D shows the marks where the plank needs to be cut for proper fit. Note the tabs and slots on burner/blower floor planks. This helps differentiate them from catwalk planks. (See Figure 9C.
9. Burner/Blower Module - Special Considerations Figure 9E shows the field-cut plank installed in the burner/blower module. Note how the cut out now fits around the thermistor. Cut plank Figure 9E Figure 9F shows burner/blower planks installed.
10. Lifting and Stacking the Modules Overview for Safety Before lifting any modules make sure the lifting capacity of the crane is adequate for the total combined weight of the module or modules, as well as any attached accessories such as catwalks, platforms and ladders. • Roof = 2200 lbs. • Turner = 2550 lbs. • Heat = 1450 lbs. • TM-1008 Blower section = 4000 lbs. • TM-1010 Blower section = 4100 lbs. • TM-1012 Blower section = 4200 lbs. • TM-1015 Blower section = 4500 lbs.
10. Lifting and Stacking the Modules The GSI Modular Tower Dryer is designed to maximize safety and minimize assembly time. All models will be assembled in similar fashion by: Lifting the roof module, stacking it on to the dryer module to be directly underneath it and connecting those modules together. Then, the conjoined modules are lifted and stacked on the next highest dryer module and connecting the modules.
PNEG-1708 GSI Modular Tower Dryer Stack and connect Roof to Module 5 Step 1: Stack and connect Roof/5 to Module 4 Step 2: NOTE: If the crane is not sufficient to lift the combined weight of Roof/5/4/3/2 as shown, replace step 4 with connecting Modules 3 and 2, stacking 3/2 on the base and then placing Roof/5/4 on top of Base/2/3. Stack and connect Roof/5/4 to Module 3 Step 3: Stack and connect Roof/5/4/3 to Module 2 Step 4: NOTE: Catwalks, ladders and other accessories not shown for clarity.
Stack and connect Roof to Module 6 Step 1: Stack and connect Roof/6 to Module 5 Step 2: Stack and connect Roof/6/5 to Module 4 Step 3: NOTE: If the crane is not sufficient to lift the combined weight of Roof/6/5/4/3 as shown, replace step 4 with connecting Modules 3 and 2, stacking 3/2 on the base and then placing Roof/6/5/4 on top of base/2/3.
PNEG-1708 GSI Modular Tower Dryer Stack and connect Roof to Module 7 Step 1: Stack and connect Roof/7/6 to Module 5 Stack and connect Roof/7 to Module 6 Step 2: Step 3: Stack and connect Roof/7/6/5 to Module 4 Step 4: NOTE: If the crane is not sufficient to lift the combined weight of Roof/7/6/5/4/3 as shown, replace step 4 with connecting Modules 3 and 2, stacking 3/2 on the base and then placing Roof/7/6/5/4 on top of Base/2/3.
10. Lifting and Stacking the Modules Lifting 1. Use four (4) clevis hooks to connect the crane’s lifting straps to the module. 2. Remember, all modules except the roof, lift from four (4) lift points around the outside of the unit. NOTE: The recommended strap length for lifting is 6' long.
10. Lifting and Stacking the Modules 3. When maneuvering lifted modules across open ground, have personnel beside it to guide it and minimize sway. When lifting the module on top of another module, be sure personnel have hard hats. 4. Carefully lower the module so that the connecting channels of each module are touching and can be connected with nuts and bolts, however, do NOT lower fully at this time. DO NOT REST THE UPPER MODULE(S) ON THE LOWER MODULE(S) AT THIS TIME.
10. Lifting and Stacking the Modules 6. When stacking one module on top of another, be sure to line up ladder brackets. In Figure 10I, ladder brackets are circled. Ladder brackets Figure 10I 7. Installation should proceed with a team of two (2) working to connect the modules from inside of the dryer and two (2) working to connect the modules on the outside of the module. For ease of assembly, place all tools, hardware and step ladders inside the module before stacking another module on top of it.
10. Lifting and Stacking the Modules 8. On all models of the GSI Modular Tower Dryer, the first two (2) connecting seams - between the base/unload module and Module 2 and between Module 2 and Module 3 - require a nut and bolt in EVERY hole of the connecting channel, both INSIDE and OUTSIDE of the dryer. Outside channels - Bolted every other hole Inside channels - Bolted every hole Figure 10K a. For all other connecting seam after/above the first two (2), every other hole may be bolted.
10. Lifting and Stacking the Modules 9. Once all holes (or every other hole based upon which seam of the dryer you are working on at the time) have a nut and bolt installed and are finger tightened, tighten with an electric impact: torque to 45 ft./lbs. NOTE: When installing, in all possible situations, place the impact on the bolt. Do NOT tighten the nut as it will not lock down on the ring. Always tighten the bolt. (See Figure 10M.
10. Lifting and Stacking the Modules 10. To stack additional sections, repeat the process as described above - always remember to line up the ladder brackets on the modules -- and follow the suggested sequence illustrated earlier in this chapter. • Consider the orientation of each module as it pertains to ladders and catwalks before placing it on the module for connection. • Secure the module with clevis hooks and lifting straps. Lift with crane and place on top of next module.
10. Lifting and Stacking the Modules Figure 10P NOTE: It is normal for “dents” or “wrinkles” to appear in the screen during this process of stacking and connecting. Most “dents” and/or “wrinkles” will be eliminated or greatly reduced in the final step of the installation process.
10. Lifting and Stacking the Modules Venturi 3/8" Bolt Burner/blower 3/8" Grill to venturi 5/16" Grill guard Figure 10Q Stiffener Splice Place stiffener splice plate over stiffener at joint of section 1 (base/unload section) and section 2 (burner/blower section). Stiffener splice plate (GT4-5074) 5/16" Bolt 3/8" Bolt Figure 10R NOTE: Seal the upper bolts 5/16" with electrical tape. To avoid drop into the dryer while placing stiffener splice.
11. Electrical Connections Electrical Overview Minimal Connections One of the most beneficial features of GSI Module Tower Dryers is the fact that much of the electrical wiring is done at the plant prior to shipping. This is an advantage for the customer as fewer electrical connections need to be made in field, thereby making is a quicker and safer installation.
11. Electrical Connections Air Switch 1. The air flow sensor connects to the grill guard on the fan with a rubber grommet and feeds through to a connecting point on the outside of the electrical control box, which connects to the sensor on the inside of the control box. (See Figure 11B, Figure 11C below and Figure 11D on Page 66.) Wire clip Air flow sensor Figure 11B 2.
11. Electrical Connections 3. The rubber grommet connects to the air flow sensor inside of the control box. (See Figure 11D.
11. Electrical Connections Flame Sensor and Ignitor Wires (Spark Plug) 1. From inside the burner/blower module, the flame rod wire and the spark plug wire will be passed through these holes as shown in Figure 11F. 2. The flame sensor and ignitor wires connect to the electrical control box. Electrical control box Holes through which flame sensor and ignitor wires will be passed. See close up in Figure 11F on Page 68.
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11. Electrical Connections Bindicator, Outside Overheat and Moisture Sensor The bindicator is mounted on the roof with its wiring running the height of the dryer in conduit and is connected by the customer is the field. (See Figure 11G.) Bindicator Conduit Figure 11G The outside overheat (copper tubing) runs the circumference of the dryer on the roof module. It connects to a junction box with conduit running the height of the dryer and is connected to the control panel by the customer in the field.
11. Electrical Connections Plenum Temperature Plenum temperature is monitored through the wiring in the conduit that runs up through the burner/blower floor. This was referenced in burner/blower module on Page 48, when installing the floor planks in the burner/blower module as it was necessary to cut a floor plank to fit around the conduit. Connecting this is also done in the field by the customer. (See Figure 11I.
12. Gas Pipe Train Overview Gas Pipe Train (Natural or LP) Overview Minimal Connections Another beneficial feature of the GSI Modular Tower Dryer is the fact that the gas pipe train comes pre-fitted and pre-assembled from the factory. This minimizes the connections that need to be made in the field. The result, is a quicker and simpler installation process. Only three (3) connections need to be made in the field to complete the gas train. (See Figure 12B.
12. Gas Pipe Train Overview 1. The largest connecting hose connects inside the dryer for the return to blower. (See Figure 12C.) 3/4" 1" Figure 12C 2. The remaining two (2) connecting hoses are installed inside the dryer as shown. NOTE: All three (3) connecting hoses are pre-sized for correct connections and cannot be connected in the wrong location as a result.
13. Finishing Touches: Removing Wrinkles and Dents from Screens During the installation process it is common for screen to “dent” or “wrinkle” from the pressures and stresses of assembling. Examples of “denting” and “wrinkling” in the screens are circled in the Figure 13A. They are often most visible in bright, reflective sunlight. Removing (or greatly minimizing) these dents and wrinkles is one of the final steps in the installation process. When removing wrinkles, work from the top down. 1.
NOTES 74 PNEG-1708 GSI Modular Tower Dryer
14. Warranty GSI Group, LLC Limited Warranty The GSI Group, LLC (“GSI”) warrants products which it manufactures to be free of defects in materials and workmanship under normal usage and conditions for a period of 12 months after sale to the original end-user or if a foreign sale, 14 months from arrival at port of discharge, whichever is earlier.
This equipment shall be installed in accordance with the current installation codes and applicable regulations, which should be carefully followed in all cases. Authorities having jurisdiction should be consulted before installations are made. GSI Group 1004 E. Illinois St. Assumption, IL 62510-0020 Phone: 1-217-226-4421 Fax: 1-217-226-4420 www.gsiag.
