Tower and T-Series Dryers Vaporizer Installation Manual PNEG-1798 Version: 1.
PNEG-1798 Tower and T-Series Dryers Vaporizer
Table of Contents Contents Chapter 1 Safety .....................................................................................................................................................4 Safety Guidelines .................................................................................................................................. 4 Safety Instructions .................................................................................................................................
1. 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.
1. Safety Safety Instructions Our foremost concern is your safety and the safety of others associated with this equipment. We want to keep you as a customer. 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, it is your responsibility to know what requirements, hazards, and precautions exist, and to inform all personnel associated with the equipment or in the area.
1. Safety Prepare for Emergencies Be prepared if fire starts. Keep a first aid kit and fire extinguisher handy. Keep emergency numbers for doctors, ambulance service, hospital, and fire department near your telephone. Keep Emergency Equipment Quickly Accessible Wear Protective Clothing Wear close-fitting clothing and safety equipment appropriate to the job. Eye Protection Remove all jewelry. Gloves Tie long hair up and back. Wear safety glasses at all times to protect eyes from debris.
2. Decals The GSI recommends you contact your local power company and have a representative survey your dryer installation, so your wiring will be compatible with their system and you will have adequate power supplied to your unit. Safety decals should be read and understood by all people in and around the dryer area. If the following safety decals are not displayed on your dryer or if they are damaged, contact the GSI for replacement: GSI Decals 1004 E. Illinois St. Assumption, IL.
2. Decals HIGH VOLTAGE. Will cause serious injury or death. Lockout power before servicing. DC-1224 DO NOT STAND ON DRUM! Rotating drum will cause serious injury or death. Disconnect power before servicing.
3. Purpose The purpose of this procedure is to provide detailed instructions for the installation and testing of an internal vaporizer coil assembly and its associated piping utilized on GSI or Zimmerman Tower Dryers and the T-Series Dryers that use liquid petroleum (LP) as the main fuel source.
4. Precautions and Limitations 4.1. The installation contractor and its installers shall have experience in properly identifying SCH 80 piping and fittings from SCH 40, cutting, threading and connecting black iron piping used on high pressure (200 PSIG) liquid petroleum (LP) systems. 4.2. Metals with sharp edges are present and installers should be aware of these at all steps during the installation process. 4.3.
5. References 5.1. PNEG-707, Commercial Tower Dryer - GSI Construction Manual 5.2. PNEG-1458, T-Series Tower Dryer - Operation Manual 5.3. PNEG-526, Tower Dryer 2009 - GSI Operation and Service Manual NOTE: The PNEG manuals listed above in Steps 5.1-5.3 are available at the following GSI website link; http://www.grainsystems.com/literature/manuals/conditioning_manuals.php 5.4.
6. Measuring and Special Equipment Required 6.1. Nitrogen gas, large cylinder. 6.2. Regulator, single stage with CGA 580 fitting, nitrogen gas service with gauges. (Must regulate to 200 PSIG - See Page 25.) 6.3. Hose with fittings on each end, high pressure (rated for > 500 PSIG). 6.4. Gauge, pressure (0-300 PSIG) or equivalent digital electronic pressure transducer or pressure transmitter with readout device. 6.5.
7. Procedure 7.1. Dryer Data Information (from its GSI Data Plate) 7.1.1. Record the model # of the dryer on the TD-VIP-01 data sheet. (Hereafter referred to as the data sheet.) 7.1.2. Record the serial # of the dryer on the data sheet. 7.1.3. Record the panel voltage required on the data sheet. 7.1.4. Record the panel current (amperage) on the data sheet. 7.1.5. Record the customer’s name on the data sheet. 7.1.6. Record the dryer location on the data sheet. 7.1.7.
7. Procedure 7.2.4. Verify that there is brass 3/4" manual isolation ball valve in the kit. (See Figure 7B.) (Record this on the data sheet.) Figure 7B 3/4" Manual Isolation Ball Valve 7.2.5. Verify that there is a 3/4" strainer assembly in the kit. (See Figure 7C.) (Record this on the data sheet.
7. Procedure 7.2.6. Verify that there is brass body 3/4" ASCO liquid solenoid valve in the kit. (See Figure 7D.) (Record this on the data sheet.) Figure 7D 3/4" ASCO Liquid Line Solenoid Valve (Normally Closed) 7.2.7. Verify that there is brass 3/4" pressure relief valve and a 3/4" to 1/4" bushing in the kit. (See Figure 7E.) (Record this on the data sheet.
7. Procedure 7.2.8. Verify that there are (2 ea.) 2-1/2" diameter, liquid filled, 0-200 PSIG, 1/4" NPT bottom mount pressure gauges. Gauges will require (2 ea.) 3/4" to 1/4" reducing bushings that are mounted in the 3/4" SCH 80 tees. (See Figure 7F.) (Record this on the data sheet.) Figure 7F Pressure Gauge (0-200 PSIG) 7.2.9. Verify that there are (3 ea.) 3/4" SCH 80 tees for the two (2) pressure gauges and one for the pressure relief valve mounting. (Record this on the data sheet.) 7.2.10.
7. Procedure 7.2.23. Verify that there are vaporizer coil mounting brackets (four (4) pair) in the kit or installed on the coil, if it has been installed at the factory. (See Figure 7G and Figure 7H.) 7G + 7H = 1 pair (Record this on the data sheet.
7. Procedure 7.3. Vaporizer Coil and Piping Installation Information The vaporizer coil is a very heavy piece of equipment; care should be taken in positioning it for mounting and the actual mounting process. The coil consists of four (4) coils with an inlet opening for the liquid propane and an outlet or discharge opening for the ‘vaporized’ heated propane gas.
7. Procedure 7.3.1. Before running any piping, verify that the 2" burner pipe that has been previously installed through the screen window and runs vertically along the outside dryer wall is plumb. This is very important for the keeping the vaporizer piping that will run adjacent to the 2" burner supply line also plumb. This makes for a professional looking installation when all three (3) pipes have been completed.
7. Procedure 7.3.4. The inlet is the bottom of the coil and the outlet is the top, the lines can be crossed over outside the burner can as necessary to get the correct vertical arrangement started downward as soon as reasonably possible with the best positioning possible. There are no set rules or procedure for this, this is a ‘contractor to field run’ item depending on space, fittings and good judgement.
7. Procedure Figure 7M The piping has exited the inside of the burner can to the outside of the assembly structure. These pipes were then crossed at this point due to space and limited access. The 3/4" liquid line is now to the left of the 2" burner line and the 1-1/4" vapor line is to the right of the 2" burner line. 7.3.5. Vaporizer piping (3/4" and 1-1/4") is now run downward toward the window where the 2" burner line exits the dryer.
7. Procedure 7.3.6. Vaporizer piping (3/4" and 1-1/4") continues downward toward the window where the 2" burner line exits the dryer. Make sure to anchor the piping at various locations to prevent piping from moving or creating stress points on fittings due to the vertical hanging weight of this SCH 80 thick walled pipe. U-bolts and uni-strut with clamps are normally used. See Figure 7O, Figure 7P below and Figure 7Q on Page 23 for various anchoring examples.
7. Procedure Figure 7Q Piping Exiting the Window using U-Bolts and Support Brackets 7.3.7. Vaporizer piping (3/4" and 1-1/4") continues downward through the piping window opening and then vertically and in parallel with the 2" burner supply line toward the gas train. 7.3.8. Continue piping (3/4" and 1-1/4") downward to the gas train. Anchor the vertical run piping in at least two (2) locations on the outside of the dryer. Uni-strut and clamps are commonly used for this. 7.3.9.
7.
7. Procedure 7.4. Vaporizer High Pressure Leak Testing Record all steps of this section on the data sheet. Testing Information The vaporizer coil and its associated piping play a vital role in the operation and efficiency of the dryer and a safety concern for those that operate the dryer. Any leaks pose a potential for disaster and inefficient operation. This leak test is a way of identifying leaks, large or small, prior to the initial start-up and operation of the dryer.
7. Procedure ASCO 3/4" liquid valve solenoid. NOTE: The ASCO 3/4" liquid valve is a normally closed (N.C.) valve and it must be ‘energized to open’ for the performance of this test. The valve is activated by 120 volts AC applied to the two (2) red leads coming from the body of the valve. There will actually be three (3) wires on the solenoid, two (2) reds and one green wire. (See Figure 7D on Page 15.
7. Procedure 7.4.16. Verify that the closed 3/4" manual isolation valve is not leaking, by observing that there is still 0 PSIG indicated on the test gauge installed in Step 7.3.11 on Page 23. If there is pressure indicated on the test gauge the manual 3/4" isolation valve will need replaced. Notify the cognizant GSI project manager for the correct valve replacement. Record the pressure reading on the data sheet. 7.4.17.
7. Procedure 7.4.27. Remove the pressure from the vaporizer loop by disconnecting the nitrogen supply hose from the 3/4" manual isolation valve and then slowly opening the valve that has been closed since Step 7.4.21 on Page 27. The test gauge should indicate 0 PSIG when the pressure has been vented. 7.4.28. Close the manual 3/4" liquid line valve and remove any fittings that remain after the nitrogen hose was removed in Step 7.4.27. Record this action on the data sheet. 7.4.29.
8. TD-VIP-01 Data Sheet Selection TD-VIP-01 Data Sheet Dryer Information Data (GSI Data Plate) Step # Information 7.1.1 on Page 13 Model # 7.1.2 on Page 13 Serial # 7.1.3 on Page 13 Panel voltage volts AC 7.1.4 on Page 13 Panel current amps AC 7.1.5 on Page 13 Customer’s name 7.1.6 on Page 13 Dryer location city and state Recorded Data Initials/Date Vaporizer Hardware Verification Data Step # Information 7.2.1 on Page 13 (3 ea.) 21' Lengths of 1-1/4" SCH 80 pipe 7.2.2 on Page 13 (3 ea.
8. TD-VIP-01 Data Sheet Selection Vaporizer Pressure Leak Test Data Step # Information Recorded Data Initials/Date 7.4.1 on Page 25 Bushing installed to accept the 300 PSIG test gauge. 7.4.2 on Page 25 Regulator connected to nitrogen cylinder and handle or knob turned fully CCW. 7.4.3 on Page 25 High pressure hose connected to the regulator. 7.4.4 on Page 25 Hose end connected to the 3/4" manual isolation valve input. 7.4.5 on Page 25 Hose ends tightened at regulator and manual valve. 7.4.
8. TD-VIP-01 Data Sheet Selection Signatures for Completion of Leak Test Test Technician: _______________________________________ Date: _________________ Supervisor: ____________________________________________ Date: _________________ Vaporizer Pressure Leak Test Data (Continued) Step # 7.4.27 on Page 28 Information Recorded Data Initials/Date 1. Disconnect hose at 3/4" manual valve. 1. 1. 2. ‘OPEN’ the valve. 2. 2. 3. Verify 0 PSIG on test gauge. 3. PSIG 3. 7.4.
NOTES 32 PNEG-1798 Tower and T-Series Dryers Vaporizer
9. 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.
