Van Air Systems FD400, FD1600 User Manual

OPERATION AND MAINTENANCE INSTRUCTIONS

FOR

BLAST PAK

PACKAGED COMPRESSED AIR TREATMENT SYSTEM

MODELS: FD-400 through FD-1600

WARNING

DO NOT OPERATE THIS SYSTEM ABOVE MAXIMUM WORKING
PRESSURE (MWP) AND/OR MAXIMUM OPERATING
TEMPERATURE (
PLATE.

THIS ASME CODE VESSEL MUST BE PROTECTED BY A
PRESSURE RELIEF VALVE. Refer to OSHA 1910.169 Par. b,
Sub. Par (3) and ASME Boiler and Pressure Vessel Code,
Section VIII, Division 1, UG-125 through UG-136. Also comply
with all applicable state and local codes.

O

F) SHOWN ON THE VESSEL ASME DATA

JANUARY 2006

P/N 32-0282 rev A

MODEL

FD-400

FD-800
FD-1200
FD-1600

MODEL

FD-400

FD-800
FD-1200
FD-1600

MODEL

FD-400

FD-800
FD-1200
FD-1600

* - ORIGINAL FILL OF DESICCANT SUPPLIED - CUSTOMER TO INSTALL

A

77"

83-3/4"

88"

94-1/2"

REGULATOR SETTING FOR AIR MOTOR

INLET

2" NPT
2-1/2"NPT
2-1/2"NPT

3" NPT

B

49"
54"
60"

71-1/2"

20 PSIG TO GET 1725 RPM
22 PSIG TO GET 1725 RPM
30 PSIG TO GET 1725 RPM
20 PSIG TO GET 1725 RPM

OUTLET

2" NPT

2-1/2"NPT

3" NPT
3" NPT

C

26"
32-7/8"
32-7/8"

43"

WEIGHT

760 lbs

1155 lbs
1525 lbs
1875 lbs

D

58-9/16"

59-1/2"

60"

59-1/8"

DRY-O-LITE

DESICCANT *

E

72-1/8"
78-3/8"
82-5/8"
89-3/8"

400 lbs

500lbs

750 lbs

1000 lbs

DO NOT ATTEMPT TO REMOVE OR REPAIR ANY PART OF THE
SYSTEM UNTIL IT IS COMPLETELY DEPRESSURIZED. SERIOUS
PERSONAL INJURY MAY RESULT IF THIS SAFETY RULE IS
NOT FOLLOWED.

DO NOT WELD, GRIND, OR SAND VESSEL, THIS WILL MAKE
IT UNSAFE TO OPERATE. (Note: Any alteration to the vessel
will void the ASME Code Certification and the warranty.)

INSPECT VESSEL, INSIDE AND OUT, REGULARLY FOR
BULGES, CORROSION, DENTS, GOUGES, LEAKS OR SIGNS
OF FIRE. IF DAMAGED, REMOVE FROM SERVICE
IMMEDIATELY AND NOTIFY YOUR CERTIFYING AUTHORITY.

DO NOT TRY TO TIGHTEN A LEAKING HATCH COVER.
IMMEDIATELY SHUT OFF THE AIR SUPPLY AND
DEPRESSURIZE THE SYSTEM.

DO NOT ATTEMPT TO REMOVE THE HATCH COVER UNTIL
THE SYSTEM IS COMPLETELY DEPRESSURIZED. WHEN
THE VESSEL PRESSURE IS REDUCED TO ZERO, THE
HATCH COVER CAN BE REMOVED BY HAND.

INSTALL A NEW GASKET EVERY TIME THE HATCH COVER
IS REMOVED, OR AT LEAST ONCE PER YEAR. INSPECT
THE COVER AND SEALING SURFACE FOR DAMAGE SUCH
AS CORROSION, CRACKS, OR DISTORTION. IF THERE IS
ANY DAMAGE, REPLACE COVER. REPLACE THE HATCH
COVER EVERY FIVE YEARS REGARDLESS OF CONDITION.
USE VAN AIR AUTHORIZED PARTS ONLY.

DO NOT USE POWER TOOLS OR CHEATER BARS TO
TIGHTEN THE NUT ON THE HATCH COVER. TOO MUCH
FORCE CAN DISTORT THE COVER AND/OR THE GASKET. IF
DAMAGED BY OVERTIGHTENING, THE COVER CAN BLOW
OUT AND CAUSE SERIOUS INJURY. (Note: Tighten the nut
until it is snug. When the vessel is pressurized, the pressure
on the cover will complete the seal.)

THE USE OF CHEMICALS OTHER THAN VAN AIR
DESICCANT WILL VOID THE WARRANTY ON THE BLAST
PAK.

PAGE 1

SECTION 1 DESCRIPTION OF OPERATION

A Blast Pak is a skid mounted system consisting of an air-cooled trim cooler, a single tower dryer with a bed of desiccant tablets and a coarse
afterfilter. Wet warm air enters the trim cooler where it is cooled to a temperature approaching ambient. Water is condensed out during this
cooling process. The saturated air and the liquid water proceed to the inlet of the single tower dryer. The liquid water and any solid particles
present are separated by gravity and fall to the dryer sump area. The process air moves upward through the bed of desiccant tablets which
attract and absorb moisture from the air before it flows through the dryer outlet. The tablets dissolve gradually as they absorb the moisture.
The solution, which consists of dissolved desiccant and water, falls into the sump area at the bottom of the vessel. The dryer must be
drained periodically to remove the accumulated solution. A manual ball valve is supplied for this purpose. A pneumatic drain valve is
available as optional equipment for automatic draining. Likewise, the desiccant in the dryer must be periodically replenished to maintain
performance. The coarse afterfilter is supplied to catch any residuals that may work their way downstream.

SECTION 2 PERFORMANCE

2.1 INLET CONDITIONS

The Blast Paks are rated as follows: 400 SCFM (FD400), 800 SCFM (FD800), 1200 SCFM (FD1200) and 1600 SCFM (FD1600) respectively
at 100 PSIG, 180° F into the trim cooler (sized for 90° F ambient and 10° approach). Approach temperatures will vary with changes to the inlet
conditions (flow, pressure, temperature) and the ambient temperature. The dew point out of the dryer tower is directly related to the inlet
temperature entering the dryer vessel. The lower the inlet temperature, the lower the dew point of the outlet air.

The aftercooler maximum inlet temperature is 250° F. When using DRY-O-LITE desiccant, the inlet temperature to the dryer tower should not
exceed 100° F.

2.2 MAXIMUM CAPACITIES FOR DRYER - SCFM (Nm3/hr)

MODEL

FD-400

FD-800

FD-1200

FD-1600

MAXIMUM
WORKING

PRESSURE

200 PSIG

13.8 Bar

200 PSIG

13.8 Bar

200 PSIG

13.8 Bar

175 PSIG

12.1 Bar

60 PSIG

4.1 Bar

261

419

521

838

782

1256

1042

1675

80 PSIG

5.5 Bar

330

531

661

1062

991

1593

1321

2124

100 PSIG

6.9 Bar

400

643

800

1286

1200

1929

1600

2572

125 PSIG

8.6 Bar

487

783

974

1567

1462

2350

1949

3133

150 PSIG

10.3 Bar

574

923

1149

1847

1723

2770

2297

3694

175 PSIG

12.1 Bar

662

1064

1323

2127

1985

3191

2646

4254

200 PSIG

13.8 Bar

749

1204

1497

2408

2246

3611

-

-

SECTION 3 OPTIONS

3.1 PRESSURE RELIEF VALVE

A 2" NPT coupling is provided on the back of the dryer vessel for
installing the relief valve. A pressure relief valve should be installed to
conform to OSHA safety standards. Refer to OSHA Standard Section

1910.169, paragraph “b”, subparagraph “3” and any other federal, state
or local codes concerning pressure vessels.

See section 6 for recommended relief valves (available from your Van
Air rep.)

3.2 PNEUMATIC DRAIN VALVE (P/N 39-0284)

The 1"NPT drain connection can be fitted with a PDV-500T pneumatic
drain valve for automatic draining of the vessel. Ask your local Van Air
representative for details.

3.3 GAUGE KITS

A 1/2" NPT coupling is provided on the lower front of the dryer for
installing gauges.

See Section 6 for optional gauge kits (available from your Van Air
rep.)

3.4 HIGH LEVEL ALARM (P/N 26-3667)

A 3/4"NPT connection is provided, on the FD800 through FD­1600, for installing a HLA-120 High Level Alarm to alert personnel
that the drain solution in the dryer has reached an unacceptable
level. Ask your local Van Air representative for details.

SECTION 4 OPERATION

4.1 DESICCANT INSTALLATION
IMPORTANT

The Blast Pak is shipped WITHOUT the desiccant installed.
The desiccant MUST BE INSTALLED before using the
system.

THE USE OF CHEMICALS OTHER THAN VAN AIR
DESICCANT WILL VOID THE WARRANTY ON THE DRYER.

The procedure for filling the dryer with desiccant is outlined in
Section 5.6 of this manual.

The Blast Pak is shipped WITHOUT the lubricator oil
installed. The lubricator oil MUST BE INSTALLED before
using the system.

4.3 START UP PROCEDURES

SLOWLY pressurize the air system. Allow some air to bleed
through the manual drain valve. Once the system starts to
pressurize, the manual drain valve can be closed. The Blast Pak
is now in operation.

IMPORTANT

CAUTION

4.2 LUBRICATOR OIL

Check oil level in lubricator regularly and add oil as required.

PAGE 2

Make sure that the Blast Pak is not subjected to sudden
flow surges. Always open the valves slowly to permit
gradual equalization of pressure between the Blast Pak
and the air supply lines.