Parker HDK-CNG, HDK-CNG 750/250, HDK-CNG 250/250, HDK-CNG 1200/250, HDK-CNG 2000/250 Operating Manual
High-pressure Dryer
HDK-CNG
250/250 – 2000/250
Dokument
-ID: DMN
-HDK
-CNG250
-2000/R0
3
Operating manual
II 2G IIB T1
Revision 03_2016/ EN
Declaration of Conformity
Pressure vessel
Dryer
Quantity
Allowable
pressure (PS)
Volume
[l]
Category
(PED)
Module
HDK-CNG 250 / 250
2
250
8,29
IV
H 1
HDK-CNG 750 / 250
2
250
24,03
IV
H 1
HDK-CNG 1200 / 250
2
250
48,36
IV
H 1
HDK-CNG 2000 / 250
2
250
63,96
IV
H 1
Piping
Dryer
Allowable
pressure (PS)
Dimensions
(DN)
Category
(PED)
Module
HDK-CNG 250 / 250
315
DN15
Art.4.3
Art.4.3
HDK-CNG 750 / 250
315
DN25
Art.4.3
Art.4.4
HDK-CNG 1200 / 250
315
DN25
Art.4.3
Art.4.5
HDK-CNG 2000 / 250
315
DN25
Art.4.3
Art.4.6
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,
which this declaration refers to, conform to Directive 2014/68/EU and were
subjected to a conformity assessment according to Annex III Module H1
The quality control system is monitored by:
Lloyd’s Register Quality Assurance GmbH, Hamburg (code no. 0525).
Mönckebergstraße 27, D - 20095 Hamburg.
The products comply with the 94/9/EG (ATEX) guideline and were subjected to
the conformity assessment after having been classified in this group.
The products were classified as follows: II -/2G IIB T1
Archiving of documents as per 94/9/EG (ATEX) guideline is done by the named
institution EXAM BBG Prüf- und Zertifizier GmbH, Bochum (ID No. 0158).
The assembly consists of pressure appliances according to the classification list
(attached to the technical documentation provided by the manufacturer).
Filter
Dryer
Filter
Quantity
Allowable
pressure (PS)
Volume
[l]
Category
(PED)
Module
HDK-CNG 250/ 250
GH9 3 350
1,33
III
H
HDK-CNG 750/ 250
GH11 3 350
2,09
III
H
HDK-CNG1200/ 250
GH11 3 350
2,09
III
H
HDK-CNG2000/ 250
GH11 3 350
2,09
III
H
Essen,
19.07.2016
Datum / Date
i. V. Dr. Jürgen Timmler
Leiter Technik und Entwicklung /
Manager Engineering and Development
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:
2006/42//EG
2014/30/EU
2014/35/EU
Machine passport
Type designation
HDK-CNG__
Order no.
Project no.
Build no.
Vessel no.
Vessel no.
Year of manufacture
Note:
Further important data on the dryer such as the details on the
permissible operating pressure and the electrical connection are found
on the type plate (for position of the type plate see page 15).
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.
The above-stated appliance data provide for a clear identification of the dryer and
its components, and significantly facilitate any service measures.
Type plate
Attach type plate here
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.
Note the data on the type plate and keep them complete and always legible.
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 ........................................................................................... 15
Transportation, installation and storage ......................................................... 16
Information on transportation packaging ............................................................................... 16
What to do in the case of transport damage occurring? ........................................................ 16
Transporting and installing the dryer ..................................................................................... 17
Installing and anchoring the dryer ......................................................................................... 17
Storing the dryer ................................................................................................................... 18
Technical Description ....................................................................................... 19
Layout drawing ..................................................................................................................... 19
Function ............................................................................................................................... 20
Available options .................................................................................................................. 22
Operating and control elements ...................................................................... 23
Control cabinet ..................................................................................................................... 23
Control unit ........................................................................................................................... 24
Control elements on the switch cabinet ................................................................................ 27
Other display elements ......................................................................................................... 27
Installation .......................................................................................................... 28
Requirements for installation ................................................................................................ 28
Connect piping ..................................................................................................................... 29
Installing the electrical connection ........................................................................................ 29
Commissioning .................................................................................................. 32
Requirements for initial start-up ............................................................................................ 32
Setting times of the operating phases ................................................................................... 33
Emergency shutdown ........................................................................................................... 34
Startup dryer ........................................................................................................................ 34
Changing cycle mode (optional) ........................................................................................... 36
Monitoring of the Operation ............................................................................. 37
With dewpoint-sensing control (optional) ................................................................ .............. 37
6 HDK-CNG_EN_03_2016
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 ................................................................................................................................ 39
Maintenance and repair of the dryer ................................................................ 41
Notes on maintenance ......................................................................................................... 41
Regular maintenance intervals ............................................................................................. 42
Making preparations ............................................................................................................ 43
Daily maintenance tasks ................................................................ ...................................... 44
Weekly maintenance tasks .................................................................................................. 45
Maintenance work to be completed every 12 months........................................................... 45
Maintenance work to be completed every 24 months........................................................... 47
Identify and eliminate faults ............................................................................. 51
Summary of faults ................................................................................................................ 51
Index ................................................................................................................... 53
Annex with technical documentation .............................................................. 55
Technical data ..................................................................................................................... 56
Replacement and wear parts list .......................................................................................... 57
Logic control diagram ........................................................................................................... 59
Menu diagram of controller .................................................................................................. 61
Flow diagram ....................................................................................................................... 62
Time diagram for valve setting ............................................................................................. 63
Dimensional Drawing ........................................................................................................... 64
HDK-CNG_EN_03_2016 7
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
with the option pressure dewpoint control: With pressure dewpoint sensor
ZHM100
with option of regeneration gas cooler
Associated documents
Operating instructions (present)
Technical documentation (see annex)
Circuit diagrams (see separate document)
Operating instructions for installed filters (as a separate document)
8 HDK-CNG_EN_03_2016
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:
If aggressive media in the natural gas and in the environment cause corrosion
damage and functional faults on the dryer.
If the dryer is used without prior approval and confirmation in writing by the
manufacturer for purposes other than those specified in these operating
instructions or contractually agreed.
If preset parameters (e. g. on the control system etc.) are changed without prior
approval and confirmation in writing by the manufacturer.
If the dryer is transported or stored incorrectly.
If the dryer is sited and installed incorrectly.
If the dryer is repaired or maintained incorrectly.
If the dryer is operated by personnel that does not have the requisite
qualifications.
If the limits for maximum pressure supply and maximum gas temperature are
not complied with.
If the data indicated on the type plate are not complied with.
If the environmental conditions defined in the applicable rules for ATEX-
compliant dryers are not complied with.
If modifications are carried out on the dryer, the manufacturer did not approve
that.
In the event of non-compliance the manufacturer will not accept any liability for
any consequential damage whatsoever.
HDK-CNG_EN_03_2016 9
About these operating instructions
This symbol appears beside information relating to explosion protection as
defined in ATEX (94/9/EC).
Note:
These notes provide you with hints and information on the safe and
efficient handling of machines and devices.
Attention!
These safety notes warn against damage to property and help you to
avoid such damage.
Danger!
These danger notes with a grey background warn against personal injury
and/or danger to life and limb; danger notes help you to avoid serious or
life-threatening situations for yourself and/or third parties.
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.
Characters and symbols used
► Work steps that you have to carry out in the sequence stated are marked by
black triangles.
Lists are marked by a small box.
Target group for the present operating instructions
These operating instructions are intended for all persons working on and using
the dryer. We assume that all such persons are specialist personnel, e.g. fitters
or electricians. We presuppose that the personnel has received training in how to
work with natural gas.
Operating instructions: handling
These operating instructions must be continuously available at the site where the
dryer is used. We recommend to prepare a copy and to keep the same in a safe
and freely accessible place next to the dryer. Keep the original document in a
safe place.
10 HDK-CNG_EN_03_2016
About your safety
Note:
For your own safety and to prevent machine damage, please note the
information and safety notes in these operating instructions when
working with the dryer.
ATEX-compliant dryers in acc. with designation CE Ex II 2G must only be used
in Zone 1 and Zone 2 environments.
ATEX-compliant dryers are designed to be electrically conductive. The operator
must ensure that this electrical conductivity is available without restriction. He
must also ensure that this electrical conductivity is not disabled by unsuitable
attachments. Electrical conductivity must be tested after every service
operation, and its full operational capability must be documented.
For filters on ATEX-compliant dryers, only use elements that meet the technical
specification of the manufacturer.
The dryer described here must not be operated using any other medium
than natural gas! The dryer is not designed for other applications.
The dryer must never be used as a climbing aid!
The pipes, valves, etc. have not been designed with this kind of load in
mind. They could fracture, tear off, or become damaged in another way.
This can cause toxic, explosive natural gas to escape and present
substantial hazards to people and the environment.
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
it is operated by non-qualified personnel,
not used within its intended design specifications,
is repaired or maintained incorrectly.
Intended use of the dryer
The dryer is intended solely for the drying of natural gas that is free of aggressive
water, oil, solids and gas constituents. Depending on defined initial conditions, it
dries natural gas for industrial use.
As standard, the dryer is intended to be sited within a building and protected
against the weather.
The dryer may be operated only in accordance with the data on the type plate
and in accordance with the contractual conditions. Non-observance of the data
given there is regarded as improper use.
Warning against misuse
HDK-CNG_EN_03_2016 11
General safety notes
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. Whenever you are working with the dryer, always
follow the safety instructions relating to the handling of natural gas.
Flush the system before commissioning, decommissioning and
maintenance!
The operator must consider these risks and take the necessary safety
measures. When working with the natural gas system, always adhere to
the safety instructions for the handling of natural gas.
General safety notes
Working with natural gas
In the event of an earthquake
An earthquake can cause pipelines to develop leaks, enabling natural gas to
escape. In the event of an earthquake, immediately
► cut off the supply of gas,
► flush the dryer with inert gas,
► ventilate the room thoroughly,
► check dryer and pipework for leaks, and repair them all.
In the event of an escape of natural gas
► Natural gas is toxic and explosive. In the event of an escape of natural gas,
immediately
► put on a protective mask,
► ventilate the room thoroughly and
► stop the gas from escaping immediately.
Personnel qualification
Only authorised and approved specialist personnel (e.g. in acc. with DVGW) may
be tasked with the work on the dryer described in these operating instructions.
Notes on critical gases
All explosive, combustible and toxic gases in Fluid Groups 1 as defined in the
Pressure Equipment Directive are designated as 'critical gases'.
The release of a critical gas can lead to substantial hazards for people and the
environment and must therefore be avoided at all times.
— The operator must install appropriate safety precautions.
— Prior to all work that could lead to a release of critical gases, flush the
affected section of pipework including the dryer and filter with an inert gas.
Then depressurise the dryer and carry out the work.
12 HDK-CNG_EN_03_2016
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.
Avoid the creating of sparks!
An ignition source can arise through the friction caused by emptying and filling
drying and purifying agents. That in turn entails the hazard of sparks being
caused.
For work in Ex-protected rooms, the vessels must all be
earthed/grounded while being filled and emptied.
When emptying, only use Ex-protected suction tools.
When purifying or drying a critical gas, always pay attention to the hazard
notices relating to that gas.
Conversions and modifications
Without prior approval by the manufacturer, no conversions and modifications
must be made to the dryer! Any non-approved modifications may restrict the
operational safety of the dryer and cause damage to property or personal injury.
Notes about the installation location
The ambient conditions at the installation location must comply with the
regulations applicable to ATEX-compliant dryers (94/9/EC) (good ventilation, no
naked flame, smoking ban).
Handling of drying and purifying agents
Under certain circumstances, it can be hazardous to work with the drying agent
involved. Therefore observe the following instructions:
Before changing the drying agent, flush the dryer with inert gas and
depressurised it.
The fresh drying agent can heat up to the evaporation point of water if brought
into contact with water.
When filling and emptying drying agents, wear a dust mask and eye protection!
The old / used drying agent can still contain residual quantities of the product
gas, and may continue to degasify.
When drying agent gets spilled, there is a risk of slipping on the beads of
dessicant.
Notes about safety equipment
The safety equipment used to comply with maximum operating pressure and
permitted fluid temperature must be provided by the operator.
The gas escaping from the safety valve must be directed away appropriately by
the operator and rendered harmless (e.g. gas flare).
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
HDK-CNG_EN_03_2016 13
and by the type of safety valve installed.
Signs and hazard areas on the dryer
Hazard caused by escaping gas!
Never remove any parts of the dryer, or manipulate the same in any way,
for as long as the plant is still pressurised! Sudden escapes of gas can
lead to combustible/flammable atmospheres in the area surrounding the
dryer!
Hazard area
Symbol in
operating
instructions
Warning of escaping natural gas
The high-pressure dryer is operated by natural gas. During all work on the dryer,
note the safety data sheets and safety instructions for working with natural gas.
Warning against overpressure
The entire dryer is under pressure. Before commencing any work, the plant must
be depressurised.
Warning of explosive atmosphere/potentially explosive gas
In a potentially explosive environment, and for the purification of explosive gases,
only use dryers that comply with the corresponding ATEX code. These dryers
must be connected to the customer's own earthing/grounding system (potential
compensation on company premises).
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.
The heating element must only be used for the purpose specified in the data
sheet. The heating element must not be placed into operation before the
operating medium is flowing under operating conditions.
If the heating element is to be placed into storage, it must be stored in a dry
and heated room. The heaters in particular must be protected from moisture.
For this purpose, a drying agent is to be additionally placed in the wiring box
that should be replaced or reconditioned at regular intervals.
The operating company must ensure compliance with the inspection intervals.
Disassembly and disposal
The Ex zone must be cancelled prior to disassembly of the dryer.
Dispose of all parts of the dryer, the drying agent and all other operating in an
environmentally responsible manner and in accordance with the current legal
regulations.
Signs and hazard areas on the dryer
Hazard areas on the dryer
14 HDK-CNG_EN_03_2016
About your safety
Only use suitable tools for working on the system.
Ex-zones are to be cancelled prior to maintenance. Strict compliance with
the operating instructions and the explosion protection documentation is
required for this purpose.
Slowly open the gas inlet valve!
Make sure sudden pressure build-up is avoided! If pressure builds up too
fast, this may cause damage to the dryer. Therefore always open the gas
inlet valve slowly!
Danger!
The system is pressurised during the inerting procedure.
There is a very considerable risk of personal injury, when carrying out
work on the activated and pressurised dryer. Suddenly escaping
compressed air might cause serious injuries.
Never remove any parts of the dryer as long as the unit is pressurised!
Inert the dryer 2x for taking out of service!
The drying agent can still release natural gas after the initial inerting. This
renders a second inerting procedure necessary. The second inerting
operation must not be carried out before at least 10 hours have passed
since the first inerting procedure. This procedure ensures that gas is no
longer bound in the drying agent and cannot be released.
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. It is essential to comply with the
following data and information on inerting. Non-compliance with this information
can result in the formation of a potentially explosive atmosphere inside the dryer,
thus posing considerable danger.
Inerting for taking out of service
The dryer must be completely purged with inert gas at least for two times before
each decommissioning, wherein a time buffer of 10 hours must be maintained
between the purge-processes. This buffer is necessary so that the bounded gas
constituents in the drying agent can outgas. The individual operations are
identical to the inerting activities during the commissioning of the dryer ( see
section Immediately operate dryer in natural gas system ).
HDK-CNG_EN_03_2016 15
Information on transportation packaging
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.
Risk of damage to the dryer when lifting!
The upper pipe bridge is not suitable to safely support the weight of the
dryer. The dryer could be damaged.
Always use eyebolts to lift up the dryer!
Attention!
A damaged dryer must not be taken into operation! Damaged components
may lead to functional faults and possibly cause further damage.
Transportation, installation and storage
Only use suitable and technically perfect lifting gear with a sufficient carrying
capacity.
During transportation the dryer must be carefully secured against falling over.
The manufacturer will not be liable for any damage caused by incorrect storage
or incorrect transportation. Please note therefore the following instructions as well
as the storage instructions on page 18.
Information on transportation packaging
Depending on the type of transportation, the dryer is delivered in different types
of packaging:
All transportation types: the apertures of the dryer are closed off by means of
plugs.
In addition, when transportation is effected by air: the dryer is packaged in a
wooden box.
In addition, when transportation is effected by ship: the dryer is packaged in a
film material and in a wooden box.
If the packaging is undamaged
► The undamaged packaging should be removed only at the final installation
site, as it offers protection against any weather influences.
What to do in the case of transport damage occurring?
► Check whether only the packaging or the dryer itself were damaged.
► When damage occurs, immediately contact the manufacturer to have the
problem examined. You will find the telephone number on page 8.
16 HDK-CNG_EN_03_2016
Transportation, installation and storage
Warning against damage to property!
The dryer is delivered upright on its side on a transportation pallet.
Therefore, always transport the dryer on a lifting or forklift truck.
► Secure the dryer on the lifting or forklift truck against sliding movements.
► Transport the dryer to its installation site.
Danger of tipping over!
The dryer must always be transported upright. However, the center of
gravity of the dryer is high on the unit, so there is a danger of it tipping
over. When attaching lifting gear to the dryer, pay careful attention to its
center of gravity!
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:
The installation site must be located within a building.
The ambient temperature must not drop below +15 °C.
Naked flame and smoking are prohibited at the installation location.
When selecting the installation location, take account of the fact that the noise
emissions of the dryer may briefly rise above 95 dB(A) (further information
about noise emissions can also be found on page 37).
The installation area must be level and firm. It must have the necessary
carrying capacity for the weight of the dryer. The weight of the dryer is
specified in the technical data section of the annex.
The dryer should be installed with sufficient spacing (min. 1 m) at the top,
sides, and rear, in order to be able to carry out maintenance work and change
the drying agent without any hindrances.
If in doubt, the installation site must be inspected by specialists. If you have any
queries in this regard, please contact the manufacturer (for details see page 8).
Transportation using lifting or forklift truck
Installing and anchoring the dryer
Setup
► Remove the packaging of the dryer.
► Hammer a suitable lifting bar around the stand profile and the cross strut.
► Position the dryer to it´s installation site.
HDK-CNG_EN_03_2016 17
Storing the dryer
Note:
If you wish to take the dryer back into service after an extended period
of storage, please proceed as described for its first commissioning and
start-up.
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:
The dryer must not be stored in the open air.
The storage room must be dry.
The storage room must be free from dust or the dryer must be covered by a
protective sheet.
The storage room must have an ambient temperature of at least +1 °C
(33,8 °F).
In order to store the dryer proceed as follows:
► Take dryer out of operation as described on page 39.
► Ensure that the natural gas inlet and outlet valves installed by the operator
are closed, and that the dryer is depressurised.
► Disconnect dryer from the natural gas network.
► Disconnect the dryer from the electrical power supply and all external lines.
► Using plastic film or a similar material, seal the natural gas inlet and outlet
apertures on the dryer to protect the dryer against the ingress of dirt
► If possible cover dryer with a protective sheet.
The dryer can now be stored for long periods.
Store drying agents
► Do not store drying agents in the open air.
► Protect drying agents against humidity.
18 HDK-CNG_EN_03_2016
Technical Description
Front view
Controll box
heater
Pressure relief
valve
Vessel pressure
gauge
pressure
gauge
Check valve
Lifting eye
vessel plate
Vessel
Control
cabinet
Type plate dryer
Natural gas
outlet
After-filter
Regeneration
gas outlet
water
seperator
Manual drain
valve
Natural gas
inlet
autom. drain
prefilter
Condensate
drain
Front view
Technical Description
Layout drawing
HDK-CNG_EN_03_2016 19
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
20 HDK-CNG_EN_03_2016
The dryer dries the natural gas supplied by the compressor and makes it
available for industrial use. Because this is a sealed system, a partial flow
(regeneration gas) is directed back to the compressor inlet.
Installed upstream and downstream filters purify the natural gas directed into the
dryer and/or directed onwards from dryer to consumers.
The two vessels contain an extremely porous drying agent by means of which
humidity is removed from the natural gas and stored just as in a sponge.
To this end, the two vessels alternate between different operating modes. Whilst
in one vessel, natural gas is de-humidified (adsorption), in the other vessel the
humid drying agent is prepared for another charge (regeneration).
These two concurrent states in natural gas treatment are described below.
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