Hydrogen Dryer

LQS-IICSA REFRIGERATING HYDROGEN DRYER

OPERATION MANUAL

LQS-IICSA REFRIGERATING HYDROGEN DRYER OPERATION MANUAL

CONTENTS CLAUSE NO.

DESCRIPTION

PAGE NO.

1.

FOREWORD....................................................................................................................2

2.

TECHNICAL DA DAT TA ....................................... ................... ......................................... ......................................... ......................................... ........................... ......3 3

3.

SPECIFICATIONS............................................................................................................4

4.

INSTALLA INSTALLATION TION AND ADJUSTMENT .......................................... ..................... ........................................... ..................................... ............... 5

5.

GAS DRYER OPERATION OPERATION / SHUT DOWN ........................................ ................... ......................................... ............................. ......... 7

6.

ATTENTION ATTENTION POINTS DURING OPERATION OPERATION AND DAILY DAILY MAINTENANCE.................. MAINTENANCE.................... ..7 7

7.

INPUT METHODS OF PROGRAMM FOR PROGRAMMABLE CONTORLLER.............. 8

8.

OIL REPLACING (DRAIN) METHOD FOR REFRIGERATING REFRIGERATING COMPRESSOR............ COMPRESSOR............10 10

9.

VACUUM VACUUM PUMPING METHODS AND STEPS OF THE REFRIGERATING REFRIGERATING SYSTEM...10 SYSTEM... 10

10.

METHODS AND STEPS FOR CHARGING OR COMPLEMENTING FREON ............... 12

11.

FAULT FAULT ANALYSIS ANALYSIS AND MAINTENANCE OF REFRIGERATING REFRIGERATING SYSTEM ................... 13


CONTENTS CLAUSE NO.

DESCRIPTION

PAGE NO.

1.

FOREWORD....................................................................................................................2

2.

TECHNICAL DA DAT TA ....................................... ................... ......................................... ......................................... ......................................... ........................... ......3 3

3.

SPECIFICATIONS............................................................................................................4

4.

INSTALLA INSTALLATION TION AND ADJUSTMENT .......................................... ..................... ........................................... ..................................... ............... 5

5.

GAS DRYER OPERATION OPERATION / SHUT DOWN ........................................ ................... ......................................... ............................. ......... 7

6.

ATTENTION ATTENTION POINTS DURING OPERATION OPERATION AND DAILY DAILY MAINTENANCE.................. MAINTENANCE.................... ..7 7

7.

INPUT METHODS OF PROGRAMM FOR PROGRAMMABLE CONTORLLER.............. 8

8.

OIL REPLACING (DRAIN) METHOD FOR REFRIGERATING REFRIGERATING COMPRESSOR............ COMPRESSOR............10 10

9.

VACUUM VACUUM PUMPING METHODS AND STEPS OF THE REFRIGERATING REFRIGERATING SYSTEM...10 SYSTEM... 10

10.

METHODS AND STEPS FOR CHARGING OR COMPLEMENTING FREON ............... 12

11.

FAULT FAULT ANALYSIS ANALYSIS AND MAINTENANCE OF REFRIGERATING REFRIGERATING SYSTEM ................... 13


1.

FOREWORD

LQS-IIC Series Refrigerating Hydrogen Dryer (hereinafter referred as to Dryer) is a Kind of main equipment designed for decreasing the hydrogen humidity inside of the hydrogen-inner cooled generator by means of refrigerating, which is one of the main measures to improve the efficiency of the hydrogen inner cooled generator and ensure power plants to be running safely and smoothly. The product is mainly used for drying hydrogen from 200 to 600MW hydrogen inner cooled generator and in the hydrogen generation station. Adopted the programmable controller, LQS-IICSA Programmable Electrical Control System can control the operation of the Dryer by means of the programmer procedure according to the operation conditions. As the AC contactor is replaced by the solid-state relay (SSR), the Dryer has such characteristics as high sensitivity, excellent reliability simple composition and structure and convenient maintenance. Because of SSR applied, there is no contact point in the control section; the device's features are of good explosion-proof with safety and reliability. Since the hot-air defrosting technique with high effect has been adopted in the refrigerating system so that the


2.

TECHNICAL DATA PROGRAMMABLE DESCRIPTION LQS-IICSA Compressor Type

NJ2B4-s

Condensing Mode

water cooled

Raw Cooling Water Flow m e t s y S g n i t a r e g i r f e R

(m 3 /h)

Refrigerating Oil Type Refrigerating Oil Injection Volume Per One

1.7 SUNISO 3GS

(L)

Refrigerant Type

1.1 R12

Refrigerant Injection Quantity Per One

(kg)

6.5

Refrigeration Compressor Capacity

(kW)

3.72

Operation Pressure Motor Power

High Pressure

(MPa)

0.4~1.2

Low Pressure

(MPa)

0~0.2

(kW)

3.0


3.

SPECIFICATIONS

3.1 Device Composition (See Fig. 01) The Dryer is mainly composed three parts: refrigerating system, hydrogen moisture removal system and electrical control system. The refrigerating system consists of a refrigerating compressor unit, a thermal expansion valve and an evaporator. The hydrogen moisture removal system is made up of a heat recovered, two coolers and a water tank. And the electrical control system consists of an electric control box, a defrosting solenoid valve, a temperature controller, a water level controller. 3.2 System Configuration and Operating Principle (See Fig. 02) 3.2.1 Refrigerating System The refrigerating compressor sucks in the low pressure gas of the refrigerant from the evaporator. After compressed, it turns into a high heat and high pressure gas, then comes into the condenser, and makes heat exchanging with air (or water). And then releases the heat refrigerant absorbed in the evaporator and the heat produced by the work done of the compressor. Now the high temperature and high pressure gas has been condensed into liquid refrigerant with high pressure. The high pressure liquid refrigerant, then through the receiver and dry filler after throttling and pressure reducing by a thermal expansion valve, it comes into the evaporator and absorbs the heat of hydrogen in the cooling unit, and makes refrigerant be boiling and evaporate it into gas, which comes into the compressor via the suction pipe and will be compressed by the compressor again. Repeating the process again and again, the heat in hydrogen is absorbed constantly. The temperature of moisture in hydrogen decreases under that of the dew point. The moisture will be


If only Dryer MKG50 works as an operating device, the main power switch (-Q01) of Dryer MKG51 should be putted it turns off and the valve located at inlet of Dryer MKG51 should be turned to close. The Dryer MKG51 is out of service. Press down the buttons of "S.D." and “Defrost” and then press Button “Start”, Dryer MKG50 starts to work as a single device self-cycling operation to remove moisture from hydrogen gas. The protection system of refrigerating module is set a pressure protection, a phase- open protection and an over load protection. The reliable diaphragm solenoid valve should be adopted for defrosting. The water tank is equipped with a water level switch, which the capacity is 14L. When the water volume in the tank reaches to 10L, the level switch is actuated a light signal alarm at local and sent it to remote (dry contact). 4.

INSTALLATION AND ADJUSTMENT

4.1 Installation (See Fig. 03, Fig. 04 and Fig. 05) Before installation, check carefully the moisture device to see if there is any damage caused by the transportation, which could make some influence upon the product performance, if any, solve it in time. Before installation please read this Operation Manual carefully. 4.1.1 The installation ambient conditions should meet the following requirements: 4.1.1.1 Location with good ventilation, clean air with less dust, having neither corrosive gas nor the direct sunlight.


4.1.6 The steel pipe connecting between the generator and the dryer .The U-form bend in the pipe is forbidden, if any, a blow-down valve should be supplied at the lowest point of the bend. 4.1.7 The grounding of the dryer should be reliable when the electric mounting is carried out. 4.2. Adjustment 4.2.1 Preparations before adjustment 4.2.1.1 Check all the connecting nuts of each pipe in the refrigerating system, to see if there is any looseness and check the leakage at all the connectors by means of a halogen leak detector or by suds (Refrigerant R12 has been filled into the condenser before delivery). 4.2.1.2 Check the oil-level through the oil level gauge of the refrigerating compressor. The oil level shouldn't be lower than the “lowest level line” (Refrigerating Oil SUNISO 3GS has been filled into the compressor before delivery). 4.2.1.3 Adjusting the pressure of the pressure controller in the compressor module to 1.5MPa at high pressure and 0-0.02MPa at low pressure (The pressure has been adjusted before delivery). 4.2.1.4 Turn on the inlet/outlet valve of the hydrogen pipe connecting between the dryer and the generator. 4.2.1.5 Anti-clockwise turn fully to open suction valve AA001, discharge valve AA002 and liquid valve AA003 of the refrigerating condenser. The discharge valve AA002 should be returned to close 1/4 to 1/2 circles after fully open.


(e) Press down “S.D.” and “Defrost” buttons. (f) Press down “Start” button, the dryer will carry out both refrigerating and moisture removing. 4.2.2.2 Refrigerating adjustment After running of the device, adjust finally the thermal expansion valve DP101, making sure that the pressure valve of the low pressure gauge of the compressor should be within 0.02-0.1MPa. (After the device running for a space, some frost may appear on the surface of the air intake duct in the front of the snifter valve of the refrigerating compressor). If there is no abnormal event, the device comes into the automatically alternative running status. As 3 UA Thermal Overload Relay (-K03) has a good reliability of differential open-phase protection. If such open-phase takes place, the fault should be removed, and reset manually –K03, the dryer can start again. 5.

GAS DRYER OPERATION / SHUT DOWN

5.1 Starting Up After calibration, the dryer withdraws from running because of other reasons, if it is needed for it to run, the starting up methods and steps are as following. Single device running 5.1.1 First checking all the valves and the power supply according to 4.2.1.4 to 4.2.1.6 of Section 4. 5.1.2 Turn on the power supply of the dryer (“Power" indicator will be lit up)


leak position is in the same place of the leakage position, if any, stop the device and solve it in time, but the open fire is strictly forbidden at that time. 6.1.5 Check frequently the water level through the water level gauge. The volume of the water left cannot be over 2/3 of the height of the water level gauge. The water left should be discharged once a day(Within a few days after the dryer is put into service, or after hydrogen is complemented, there may be much water left, so in creasing the draining times is needed). 6.2 Routine Maintenance for the Refrigerating Compressor CHECKING ITEM

DAILY MONTHLY

YEARLY

REMARKS

Checking the oil volume of the compressor

#

See Para4.2.1.2

Checking High/Low Pressure

#

See Section 2

Abnormal sound by the compressor during operation

#

Hearing

Perfection of the grounding wire Damage of the electric wirings Looseness of the terminals Safety device

#

Visual check

#

Visual check #

Visual & instrumental check


Turn off the power supply of the electric control box first, insert the programmer into the programmable logic controller, then turn on the power supply. 7.2 Program Input Methods First put the toggle switches to the position of PRG.. Program text Input melted 0000 STR 1 Press down STR SHF 1 ENT 0001 OUT 20 Press down OUT SHF 20 ENT 0002 STR 1 Press down SHF 1 ENT 7.3 Program Checking Method Taking the above-said programs as examples, put the toggle switch to position “RUN”, the window will display “0000”. 7.3.1 Press down “NXT”, it will display “0001”, the value of “0000”, now Indicator “STR” is lit up. 7.3.2 Press down “NXT”, it will display “0020” the value of “0001”, now Indicator “OUT” is lit up. 7.3.3 Press down “NXT”, it will display "0001", the value of “0002”, now Indicator “STR” is lit up. If Button “PRV” is pressed again, it will display “0020”, the value of last “0001”, now Indicator “OUT” is lit up. If the content of “0001” is needed to be seen again, press down “SHF”

“1” (or “0001”) and “NXT”, it


Now the changing is completed. 7.5 Clearing All the User Memory Contents Press down CLR, SHF, 348, DEL, and NXT. 7.6 Clearing Method to Cancel the Mal-operation (when “E01” is displayed) Press down CLR.

8.

OIL REPLACING (DRAIN) METHOD FOR REFRIGERATING COMPRESSOR

First of all adjust the pressure controller to make the low pressure be -0.1MPa, then start the compressor and turn the valve rod clockwise to turn off Snifter Valve AA001 of the compressor. When the pointer of the low pressure gauge goes down to the specified limit, the pressure controller comes into operation, the compressor stops working automatically. When the low pressure goes up again, the compressor comes into operation again. In this way, the compressor works intermittently for several times, the low pressure does not go up any move. Then the power supply should be cut off and Discharge Valve AA002 of the compressor should be turned off by means of turning clockwise its valve rod. Screw off the plug of the oil filler hole (or screw off the plug of the discharging hole), charging (or discharging) Oil 3GS to the specified height. (Any other lubricating oil than refrigeration oil is forbidden to be filled in), then tighten the plug wrapped with new adhesive tape to block up the oiling hole. Loosen a little the connector of the piping connecting the high pressure gauge and start the compressor. Put your hand over the loosened connector of the piping of the high pressure gauge, some air drained off should be felt. Once there is no air drained off, fasten the pipe


order to observe if there is any air bubbles in the container. It will be OK if there is no air bubble within 5 minutes. 9.1.1.3 After vacuum pumping, screw in tightly the multipurpose channel cover of Discharge Valve AA002, then the device may be stopped. 9.1.2 Vacuum pumping method when there is some refrigerant in the refrigerating system When there is some refrigerant in the refrigerant storage tank in the compressor module, Charging Valve AA003 and Discharge Vive AA002 should be turned off, the vacuum pumping at low pressure and steps are as following: 9.1.2.1 First of all, screw off the cover connecting the high pressure gauge to the multipurpose channel of Discharge Valve AA002, turn on Snifter Valve AA001. Starting the refrigerating compressor module to carry out vacuum pumping at low-pressure section. 9.1.2.2 When the sound of air exhausted cannot be heard in Discharge Valve AA002, connect a piece of flexible pipe to the multipurpose channel temporarily, the other end of the flexible pipe will be inserted into a container filled with refrigerant in order to observe if there is any air bubbles in the container. It will be OK if there is no air bubbles within 5 minutes. 9.1.2.3 After vacuum pumping, screw in tightly the multipurpose channel cover of Discharge Valve AA002, then the device may be stopped. 9.1.3 Air Exhausting Methods of the Refrigerating System


power of 415VAC, and make the valve be turned on. 9.2.4 Start the vacuum pump for pumping the whole system and when the pressure value on the vacuum meter is less than 0.095MPa, turn the valve rod anticlockwise of Valve AA001 so as to close the multipurpose hole. 9.2.5 Disconnect the vacuum pump and the connecting pipe. Put the nut with washer on the multipurpose hole of Valve AA001 of the compressor then screw it in tightly. 9.2.6 Disconnect the external power of Solenoid Valve AA004 and reset it to the system power supply. When the above-said work is finished, the vacuum pumping is also completed. 10. METHODS AND STEPS FOR CHARGING OR COMPLEMENTING FREON 10.1 Methods and Steps for Charging Freon Freon charging is under such conditions that the vacuum status exists inside of the refrigerating system. The method for Freon charging is as following: 10.1.1 Turn anti-clockwise fully the valve rod of Valve AA001 of the compressor and shut off the multipurpose through hole of Valve AA001. Use the copper pipe mounted with a silica-gel dryer to connect the multipurpose through hole and the nozzle of the Freon cylinder by its both ends respectively. 10.1.2 The Freon cylinder should be put in positive direction on a platform balance so as to weight


10.2.1 Turn on Valve AA001, Valve AA002 and Valve AA003 (Turning anti- clockwise the valve rod, the valve will be turned on). 10.2.2 Screw off the nut of the multipurpose through hole of Valve AA001. Use the copper pipe (or Nylon pipe) mounted a silica gel dryer to connect the multipurpose through hole of Valve AA001 and the nozzle of the Freon cylinder by its both ends respectively (The brand and the type of Freon must be identical with that specified in Operation Manual. The cylinder should be put in positive direction in order to fill the refrigerant vapor in the refrigerating system. The liquid of the refrigerant is absolutely not allowed to be filled in). 10.2.3 Turn on slightly the Freon cylinder and then turn it off immediately and loosen the nut of the multipurpose through hole of Valve AA001 in the compressor, the air will be rid from the pipe by the refrigerant and then tighten the nut. 10.2.4 Turn on the valve of the Freon cylinder (If the cylinder is fully filled with Fron, the valve should be turned on slightly in order to prevent from damaging the cylinder). 10.2.5 Press down Button "S.D." and Button "Start", now the dryer is working. 10.2.6 Turn on clockwise the valve rod of Valve AA001 of the compressor by 1-2 turns; Refrigerant vapor will be sucked slowly by the compressor. 10.2.7 Observe carefully the air intake duct of the compressor, to see if the frost appears on Valve AA001. The Freon cylinder nozzle should be turned off immediately, then turn anti-clockwise the valve rod of Valve AA001 to the end position, shut off the multipurpose through hole, disconnect the


APPENDIX 1: RUN PROGRAM OF LQS-IICSA PROGRAMMABLE 0000 STR 1 0001 OUT 20 0002 STR 1 0003 OUT 17 0004 STR 151 0005 STR 152 0006 STR 142 0007 OR 22 0008 AND STR 0009 OR STR 0010 MCS 0011 STR 5 0012 OR 142 0013 OR CNT 603 0014 OR 22 0015 OUT 155 0016 MCS 0017 STR CNT NOT 602 0018 AND 2 0019 AND 3 0020 OUT 22 0021 STR CNT 601 0022 OUT 156 0023 STR CNT 601 0024 OUT 143 0025 STR 153


0056 STR 151 0057 OUT 25 0058 STR 152 0059 OUT 26 0060 STR 153 0061 AND NOT 23 0062 OUT 27 0063 STR TMR 611 0064 STR NOT 155 0065 OR 374 0066 CNT 601 0067 4 0068 STR TMR NOT 611 0069 AND 155 0070 TMR 611 0071 900 0072 STR TMR 613 0073 STR NOT 156 0074 OR 374 0075 CNT 602 0076 1 0077 STR TMR NOT 613 0078 AND 156 0079 TMR 613 0080 120 0081 STR TMR 615 0082 STR NOT 157 0083 OR 374


APPENDIX 2: LIST OF ELECTRIC COMPONENTS AND PARTS ITEM

Description

FLAG

Specs & Type

Qt'y

1

D.D.Temperature Display

FT001

XMT-102

1

2

Temperature Sensor

FT002

Cu100

1

3

Programmable controller

-U10

SE-11R-EX

1

4

Programmer

-U20

R-21P-EX

1

5

Automatic Circuit Breaker

-Q01

DZ20Y-100/330 30A

1

6

Automatic Circuit Breaker Operating Mechanism

-Q10

7

SSR(Solid State Relay)

-K01

~380/40A

3

8

SSR

-K02

~380/20A

2

9

Cmtroling Transformer

-T01

380V/220V

1

10

Overload Relay

-K03

3UA59/00-1H

1

11

Fuse

-F01~05

RT14-20

5

12

Thin Film ON/OFF Plate

-S41~45

LQS-IIC

1

13

Over Travel Switch

-K10

LX3-11H

1

1

Remarks


APPENDIX 3 Temperature

TABLE OF R12 TEMPERATURE VS SATURATION VAPOR PRESSURE Absolute pressure MPa

Temperature

Absolute pressure MPa

Temperature


-70

0. 0123

-29

0.1047

-3

0. 2791

-68

0. 014

-28

0. 1093

-2

0. 2885

-66

0. 0159

-27

0. 1139

-1

0. 2984

-64

0. 0179

-26

0. 1187

0

0. 3084

-62

0. 0202

-25

0. 1236

+1

0. 3186

-60

0. 0227

-24

0. 1288

+2

0. 3291

-58

0. 0254

-23

0. 1340

+3

0. 3398

-56

0. 0284

-22

0. 1394

+4

0. 3509

-54

0. 0317

-21

0. 1451

+5

0. 3622

-52

0. 0353

-20

0. 1509

+6

0. 3737

-50

0. 0392

-19

0. 1568

+7

0. 3856


Temperature


Temperature


Temperature

(cont. Absolute pressure MPa

+23

0. 6157

+37

0. 8891

+55

1. 3101

+24

0. 6326

+38

0.9108

+60

1. 5171

+25

0. 6507

+39

0. 9344

+65

1.68728

+26

0. 6681

+40

0. 9582

+70

1. 8714

+27

0. 6862

+41

0. 9814

+75

2.0703

+28

0. 7049

+42

1. 005

+80

2. 2792

+29

0. 7239

+43

1. 0301

+85

2. 5108

+30

0. 7249

+44

1. 0548

+90

2. 7545

+31

0. 7627

+45

1. 0803

+95

3. 0156

+32

0.7830

+46

1. 1057

+100

3. 2968

+33

0. 8036

+47

1. 1322

+105

3. 5921


APPENDIX 4: Brief Introduction to SE-11R-EX Programmable Logic Controller (PLC) 1. System Configuration As a kind of industries control device, PLC consists of a CPU, an Input/output interface, system program and user program storage unit. SE-11 series is made up of a PLC with an integrated I/O, the interior of which offers the above-said functions. Fig. 07 is the block diagram of PLC basic units. 2. General Configuration (see diagram as follow) 2.1 State Indicators On the left-up side of the front panel, there are 4 LED state indicators. They are "RUN" "BATT" "CPU" and PWR (power) to indicate the working status of SE-11. 2.1.1 RUN: Green indicator, monitor the working status of CPU. ON: CPU is in user program running status OFF: CPU is in user program not running status 2.1.2 BATT: Red indicator, monitoring the lithium (Li) battery which is used for protecting CMOS RAM to see it is O.K or not. ON: The voltage of Li battery is lower than the voltage that can not preserve the content of the user storage. OFF: Li battery voltage is normal


2.5 Socket on the side plate On the side plate there is a socket with 9 pins, which is used for connecting a communication adapter (E11DM) and it will be a standard RS- 232 or RS-422 communication port and then it can carry out the data communication with a super seat computer or a super seat PC. 2.6 Li (Lithium) Battery The Li (Lithium) battery, which is used as a spare power supply for CMOS RAM memory is mounted under a cover plate of snap-fastener type. During power cut, Li battery is used for maintaining CMOS RAM as follows: 2.6.1 User program in RAM chip 2.6.2 Counting accumulated value of the counter 2.6.3 The status that is needed for power failure memory retention in the stage coils and the internal coils will be effective only when internal Coils 373& 761 are connected by programming. 2.6.4 The contents of Data Register R400-R577 PLC running mode 2.7 Li Battery Replacement The long service time of Li battery is used as a spare one in SE-11PLC. Normally it can be used for more than 5 years. But its life will become shorter when it is used under mal- conditions (such as at high temperature and/or high humidity). When the voltage of the battery is low, it should be replaced as soon as possible (Battery Type: RB-5). At that time the "BATT" indicator on the panel of SE-


ITEM Program capacity Program memory Number points for input and output Stage coils Internal coils Special coils Shift register Timer and counter Drum controller (10000steps) High-speed counter Data register Diagnosing feature

Monitor feature Protection mode Cassette interface

PERFORMANCE PARAMETER LK words CMOS RAM or EPROM EEPROM Input: 15points(4 points may be used software filter) Output: 9points 72 points (32 points with power failure memory retention) 155 points (59 points with power failure memory retention) 18 points 155 points (59 points with power failure memory retention) 20 points counter: 1~9999 timer: 0.1~999.9sec 0.01~99.99sec 20 PCs 2 points, response: 2 KC’s Number of stage setting: 20 steps Total: 184 (include data register and T/C accumulated value register) CPU abnormality, memory abnormality, battery abnormality, grammar error 24 points of I/O display, CPU abnormality, battery abnormality, monitoring by the programmer of multi-point operation, ON/OFF checking, timer/counter accumulated value, register’s data monitoring 4 bits password Interface circuit built in the programmer


APPENDIX 5: Attached Drawing List Fig. 01

FIG.1

LQS-II DRYER STRUCTURE (WATER COOLED)

Fig. 02 Fig. 03 Fig. 04 Fig. 05 Fig. 06 Fig. 07 Fig. 08 Fig. 09

SE-11R-EX INPUT CIRCUIT & WIRING DIAGRAM


FIG. 01

LQS-II DRYER STRUCTURE (WATER COOLED)

23/34


24/34


25/34


26/34


27/34


28/34


29/34


30/34


31/34


32/34


33/34

Hydrogen Dryer

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