Betriebsanleitung e

OPERATING INSTRUCTIONS
1 x Helix Dryer BD 600 S File 1, Mechanics
Revision: Sales Order Number: Serial Number: Purchase Order Number:
0 37000881 60001556 I2250
This document must be studied carefully before installation and commissioning of the equipment!
Chapter 1 through 6 of this document were already included with the Installation Information. Within the scope of the order handling, however, additional and more concrete information may have been added. We therefore recommend that you read through these chapters in detail again. Copyright ANDRITZ KMPT GmbH, 20131106. All rights reserved! The copyright in this document is reserved to ANDRITZ KMPT GmbH. This document contains specifications and technical drawings. The document must therefore not be disclosed to third persons neither as a whole nor by extracts or after reproduction.
BD 600 S
OVERALL TABLE OF CONTENTS OF THE OPERATING INSTRUCTIONS
Sales Order No. 37000881, BD 600 S, Serial No. 60001556
File 1 Mechanics
1 2 3 4 5 6 7 8 9 10 11 12 General Technical Description of the Machine Technical Data Safety Instructions Transport, Settingup and Assembly Commissioning and Operation Inspection and Maintenance Trouble Shooting Description of Components Spare Part Stock Separate Manuals Drawings
File 2 Electrical Part

1 2 3 4 5 6 Plant Electric Installation at Helix Dryer Control Cabinet Software Local panel +LP1 Local panel +LP2 4
Quality Documentation
Operating Instructions, revision 0 Sales Order No.: 37000881 Serial No.: 60001556
BD 600 S
Table of contents File Mechanics
1
1.1 1.2
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Contact Persons at ANDRITZ KMPT GmbH . . . . . . . . . . . . . . . . . . . . . . . .
6
6 7
2
2.1 2.2 2.3 2.4
Description of the Dryer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Short Characteristic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Components of the Dryer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Integration in a Process Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9
9 9 10 11
3
3.1 3.2 3.3 3.4 3.5 3.6 3.7 3.8 3.9 3.10
Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Characteristic Data of the Dryer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fields of Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Type plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Vessel and screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Drive for the mixing unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Materials of Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . General Informations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation Details . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Connection list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Utility Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12
12 13 13 14 15 16 17 19 21 23
4
4.1 4.2 4.3 4.4 4.5 4.6 4.7 4.8 4.9 4.10 4.11
Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Proper use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Safety Regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Operation of the Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Operators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Maintenance and Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Monitoring equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inertising . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
24
24 24 24 25 25 26 26 26 27 28 29
BD 600 S
5
5.1 5.2 5.3 5.4 5.5 5.6 5.7
Transport, Settingup and Assembly . . . . . . . . . . . . . . . . . .

General Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Packing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Intermediate Storing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Place of Installation and Required Space . . . . . . . . . . . . . . . . . . . . . . . . . . . Settingup and Assembly Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Guidelines for laying pipes, hose connections and valves . . . . . . . . . . . .
30
30 30 30 31 33 34 37
6
6.1 6.2 6.3 6.4 6.5 6.6 6.7 6.8 6.9 6.10 6.11 6.12
Commissioning and Operation . . . . . . . . . . . . . . . . . . . . . . . .

General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Mechanical Checks before the Test Runs without Product . . . . . . . . . . . . Test Runs without Product . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Commissioning of the Dryer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Adjustments and Settings for Optimizing . . . . . . . . . . . . . . . . . . . . . . . . . . . Shutdown of the Dryer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Opening and closing of vessel / manhole cover . . . . . . . . . . . . . . . . . . . . . Removal of filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Measures before and after extended Shutdown Periods (more than 1 month) ....................................... Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
40
40 41 42 43 46 47 48 50 51 52 53 54
7
7.1 7.2
Inspection and Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . .

General Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
55
55 56
8 9
9.1 9.2 9.3 9.4 9.5 9.6
Trouble shooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Description of Components . . . . . . . . . . . . . . . . . . . . . . . . . . .

Screw locking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation of Sealing Rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Mounting Instructions for Sealing Cord, type DE and DF . . . . . . . . . . . . . Protection of Surfaces of High Quality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0000 Helix Dryer BD 600 S . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1010 Purge gas unit for mechanical seal . . . . . . . . . . . . . . . . . . . . . . . . . . .
58 59
60 65 67 70 71 73
BD 600 S
9.7 9.8 9.9 1810 Vapour filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1820 Blowoff for vapour filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9202 Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76 78 81
10 Spare part stock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10.1 10.2 10.3 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Spare part code ETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Spare part list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
84
84 84 85
11 Drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Separate Manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

12.1 12.2 12.3 12.4 12.5 12.6 12.7 12.8 12.9 Vessel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Mixing unit with drive and sealing unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pressure line accumulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Diaphragm valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Dust filter element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Sample valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pressure filter regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pressure gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Shutoff flap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
86 87
88 89 90 91 92 93 94 95 96 97
12.10 FDACertificates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BD 600 S
1
1.1
General
Preface
These Operating Instructions are divided into chapters which serve both as operation manual and as source for information about the BD 600 S from ANDRITZ KMPT GmbH. These Operating Instructions should be studied and considered in every respect by all persons in charge of the assembly, operation and maintenance of the machine of ANDRITZ KMPT GmbH. The complete Operating Instructions should be always available and accessible at the place of operation. These Operating Instructions contain all information required by yourself and your personnel for the operation of the machine. For this reason it should be studied carefully, understood and respected by all persons concerned. The working instructions and sequences for the installation, commissioning and the maintenance must be followed closely in order to guarantee a reliable and trouble free operation of the machine. The Operating Instructions refer also to the most important details for the special use of the BD 600 S. The thorough knowledge of these Operating Instructions will help you to avoid mistakes at the machine and to arrive at a satisfactory operation. It is important, therefore, that these Operating Instructions be well known to all persons concerned. We recommend that you study these Operating Instructions carefully before commissioning takes place because we shall not be responsible for damages and failures resulting from noncompliance with these Operating Instructions! In case you should face problems we ask you contact our aftersales services or our spare part department or with one of our agencies. We are always at your disposal. We reserve the right of technical revisions of the details and illustrations contained in these Operating Instructions as are required for the improvement of the machine. These Operating Instructions refer exclusively to the machine BD 600 S from ANDRITZ KMPT GmbH. The design of your machine is suitable only for the use specified in Chapter 3 Technical Data. Before using the machine for other applications than agreed upon we recommend you ask the project specialists of ANDRITZ KMPT GmbH for consultation and approval as otherwise the warranty will be void.
BD 600 S
1.2 Contact Persons at ANDRITZ KMPT GmbH
Address:
You can contact us under the following address in Vierkirchen, Germany: ANDRITZ KMPT GmbH Industriestrae 13 85256 Vierkirchen Germany Whenever specific problems arise which are not considered in these Operating Instructions, we ask you to enter into contact with the departments concerned at ANDRITZ KMPT GmbH in Vierkirchen:
Telephone and Fax:
Troubleshooting:

Department Phone 710 531 500 100 730 710 500 103 Telefax 952 750 550 550 150 751 750 550 150 Central office +49 / 81 39 / 8 02 990 Project Management Commissioning AfterSales Service Project and sales Technical design Electrics, control and instrumentation Sale of spare parts mechanical Sale of spare parts electrical
Please find below our Service Hotline for urgent cases. You can reach us around the clock, also at weekends and on public holidays. Phone: +49 / 172 / 8 40 15 32
EMail:
[email protected]
Internet:
www.andritz.com www.kmpt.com
BD 600 S
Our foreign agencies:

Worldwide USA ANDRITZ KMPT GmbH Industriestrae 13 85256 Vierkirchen Deutschland Phone: ANDRITZ KMPT Inc. Florence, KY 41042 USA Fax: 8070 Production Drive +49 / 81 39 / 8 02 99 0 [email protected] www.kmpt.com www.andritz.com Phone: +1 / 859 / 547 1100 Fax: +49 / 81 39 / 8 02 99 952 +1 / 859 / 547 1098 EMail: EMail: [email protected] Internet: Russia India Representation of KMPT AG 190031 St. Petersburg Russia Fax: ANDRITZ KMPT GmbH Liasion Office 304, Dheeraj Kawal Mumbai 400 079 India Fax: ul. Efimova 4a, Lit. A, Office 317 Phone: +7 / 812 / 441 36 73 L.B.S. Marg, Vikhroli (W) +7 / 812 / 441 36 74 EMail: [email protected] Phone: +91 22 25 79 51 34 +91 22 25 79 51 35 EMail: [email protected] China, Shanghai China, Beijing KMPT AG Beijing Representative Office Air China Plaza 2109 36# Xiao Yun Road Chaoyang District 100027 Beijing China P.R. Fax: KMPT Service & Trade (Shanghai) Co., Ltd. Room 310, Tower 6 Taihong, R&D Office Park No. 59 Shennan Road 201108 Shanghai China P.R. Fax: Xinzhuang Industrial Zone Phone: +86 / 10 / 84 47 58 80 EMail: [email protected] +86 / 10 / 84 47 58 83 Phone: +86 / 21 / 3463 5245 or 5246 +86 / 21 / 3463 5244 EMail: [email protected]
BD 600 S
2
2.1
Description of the Dryer

Short Characteristic
The Dryer from ANDRITZ KMPT GmbH is a mixer, dryer, reactor and crystallizer for nonsticky, mostly freeflowing products, that operates in batchwise mode. For the processing of temperaturesusceptible products and the recovery of solvents it can be run under a vacuum. It can also be used for reactions that take place under pressure. In the dryer the mixing and drying takes place under low foreign particle conditions. This ensures a reliable batch identification..
2.2
Components of the Dryer
A Dryer consists essentially of the following componenents (see fig. 1): Heated conical product vessel with spherical lower section and a cover bolted to it Mixing unit with helix, drive unit and sealing unit Product filling at the cover of the vessel (via manhole cover) Product discharge on the bottom of the vessel Support flanges for installation at the building Different nozzles are applied to the vessel depending on the requirements put to the engineering process Filter cartridge protruding into the vessel for the discharge of vapours A heating medium can be used to control the temperature of the conical vessel shell, cover and filter housing The vessel inside can be cleaned by two rotating CIP nozzles
BD 600 S
Vacuum connection Sealing unit Drive unit for helix
Vapour filter Manhole cover Vessel cover
Support flanges
Insulation
Vessel shell
Helix Sample valve Anchor Discharge valve Temperature measurement
Heating medium
Product
Rinsing medium (CIP)
Fig. 1: Schematic Design of a Dryer
2.3
Process
The product enters the conical vessel through the product inlet flange. The helix serves for a permanent mixing of the product. Heating of the vessel causes a drying of the product. You can also take samples through the product sampler. After the process the product leaves the vessel through the discharge valve. Operating Instructions, revision 0 Sales Order No.: 37000881 Serial No.: 60001556
10
BD 600 S
2.4 Integration in a Process Line
The Dryer is mostly combined with Vertical or Horizontal Centrifuges and forms with them a closed system for mechanical and thermic separation.
11
BD 600 S
3
3.1
Technical Data
Characteristic Data of the Dryer

Order Data Plant/Password Customer/Purchaser Machine type NORTEC QUIMICA S.A., Brazil BD 600 S 1 2013 Number of machines Year of manufacture Sales Order No. Serial No. 37000881 60001556 Foundation and connection drawing Drawing Number Item Number Item Number 67000000.507 2915103 PID drawing 00020574 2915103 Number of bill of materials Classification Potentially explosive atmosphere around the dryer Operating Data II 2 G IIB T3 Inside of vessel / process area Operating pressure PS for vessel, max. adm. 1 to +1 bar g Operating temperature TS vor vessel, max. adm. Operating pressure for heating areas, max. adm. Heating medium 15 to +145 C Heating area 1 (vessel shell) 0 to +3 bar g Operating temperature for heating areas, max. adm. 15 to +145 C Steam/Water Heating area 2 (vessel cover and filter housing) Operating pressure for heating areas, max. adm. Heating medium 0 to +3 bar g Operating temperature for heating areas, max. adm. 0 to +80 C Water To be completed by Owner Purchase Order No. Site/building Tag No. I2250 ................................................
12
BD 600 S
3.2 Fields of Application
The Dryer BD 600 S under serial No. 60001556 is suitable exclusively for the drying and mixing of the products specified on the technical data stated on the type plate. The material of construction of the machine is selected considering the properties of the processed product (in particular corrosion). The operating conditions like humidity and temperature can also be of effect on the operation of the machine. Considerable changes of these values must be advised to the manufacturer. Any and all other use is not permissible. The manufacturer will not be liable for damages resulting therefrom but the risk is at the sole responsibility of the owner. These data must be changed only after approval by the manufacturer and revision of the supplier certificate.
3.3
Type plate
13
BD 600 S
3.4 Vessel and screw

Design Basis for design Design data PED 97/23/EG (AD 2000) siehe Kap. 3.1 Vessel Design of vessel: Conical vessel with spherical bottom Vessel height (between inlet flange and outlet flange) Vessel shell wall thickness Cone angle Vessel inner diameter (largest diameter) 1 330 mm 1 462 mm 8 mm 22.5 Design of cover: Dished head, welded to vessel shell Cover wall thickness Total volume of vessel 8 mm 1.1 m3 0.6 m3 Max. adm. feed volume of vessel (usable volume) Possible filling level of usable volume 15 100 % Heat exchanging area (Effective heating area at max. filling volume) Bulk density 3.5 m2 up to 1 200 kg/m3 Heating areas Type of heating zones 1 2 vessel shell double jacket vessel cover and filter housing halb pipe coil (cover) and double jacket (filter housing) 40 dm3 20 dm3 Volume of heating zones 1 2 1 2 vessel shell vessel cover and filter housing vessel shell Heating agent steam / water vessel cover and filter housing water Insulation Type Tightwelded insulation jacket 2.5 mm mineral wool Wall thickness of insulation jacket Material Thickness at least 50 mm Mixing element Helix Type Segmented helix with anchor mixer approx. 1 000 mm 80 mm Length (only mixing elements, without shaft) Shaft diameter Auxiliaries with two CIP nozzles Operating Instructions, revision 0 Sales Order No.: 37000881 Serial No.: 60001556
Vessel
14
BD 600 S
3.5

Drive motor Type 132S IP 55 Enclosure Explosion proof Voltage Power Ex d IIB T4 Gb by thermistors Motor protection 380 V 7.5 kW 60 Hz Frequency Nominal speed at 60 Hz Frequency range 1 760 rpm 660 Hz Frequency converter for drive motor not in scope of supply Type Reduction gear Design Bevel gear SK9042.1AFSH Reduction ratio Oil filling Oil typ 34.39 : 1 6.5 l CLP PG H1 220 First filling Kluebersynth UH16220 5 50 rpm 50 rpm Mixer drive Max. adm. speed range of the mixer drive, adjustable by frequency converter Operating speed at 60 Hz Sense of rotation of the mixer drive (seen from the top) clockwise, conveyance upward
Drive for the mixing unit
15
BD 600 S
3.6 Materials of Construction
Materials Parts in contact with the product Parts not in contact with the product Seals in contact with the product Productwetted screws Sealing unit type sealing rings, productwetted sealing rings, atmospheric Orings, productwetted Surfaces double acting mechanical seal (gas purged) SiC / SiC SiC / C FEPV 316 L (1.4404 / 1.4435 / 1.4401) 304 / 316 L (1.4301 / 1.4404) / Carbon steel painted FEPV, PTFE A470

Surfaces in contact with the product Finish: Ra < 0.8 m + mechanically polished Finish: Ra < 1.6 m + mechanically polished Surfaces not in contact with the product Painting of parts not in contact with product (SS parts are not painted) Primer Thickness 60 m 60 m 60 m SikaCor EGPhosphat (epoxy resin) SikaCor EGPhosphat (epoxy resin) Sika Permacor 2330 (acrylic polyurethane) RAL 7035 (light grey) Intermediate coat Top coat Colour of top coat
Orings inside sealing chamber EPDM
16
BD 600 S
3.7 General Informations

Equipment Machine type Cover BD 600 S bolted to conical vessel, with apparatus flange mechanical (screwed) Manhole cover closure Manhole cover locking Speed monitoring Type by frequency converter Vapour filter Filter bag at the filter socket 1 Number Filter area for each filter element Mesh size Max. temperature Filter material approx. 0.6 m2 max. 130 C 1 m polyester fleece with PTFE membrane to be mounted near to the dryer separate vessel 1 Nitrogen vessel for filter blowoff unit (gas reservoir) Place of installation Type Number Volume, approx. 5 dm3 Design pressure 16 bar g Design temperature Place of installation Number Number 100 C Gas supply unit with monitoring equipment for mechanical seal to be mounted near to the dryer 1 1 Sample valve Actuation Number Type manual Product discharge valve 1 Butterfly valve manual Actuation Temperatures Adm. ambient temperature Design temperature 10 40 C see chapter 3.1 see chapter 3.1 not applicable Max. adm. temperature of the heating medium for vessel Transport Temperature, min. Storage Temperature, min. Storage conditions *) Max. adm. temperature for sterilization **) *) 0 C 0 C Conservation Air sound levels Pressure sound level according to EC machinery directive < 85 dB(A)
17
BD 600 S
*) If the water is removed from the dryer (no water in the heating circuit, inlet and outlet pipes) and the dryer has no temperaturesensitive linings, transport and storage temperatures up to 10C are permissible. **) During sterilization the atmosphere must not be explosive.
18
BD 600 S
3.8 Installation Details
67000000.507
Refer to General Arrangement Drawing:
3.8.1

Total weights, approx. Shipping weight (weight of dryer incl. agitator, drive unit, transport frame but without outlet valve) Operating weight (shipping weight without transport frame, with max. filling, =1.2 assumed for product) 2 000 kg 2 700 kg Catastrophic weight *) (shipping weight without transport frame + totally filled with product, =1.2 assumed) Product outlet valve (butterfly valve) Transport frame 3 350 kg Individual weights, approx. 25 kg 100 kg
Weights
*) The given catastrophic weight includes the weight of the filled vessel but without the weight of the liquid column inside the connected pipe work. This may be considered when doing the construction design of the building.
3.8.2

Dimensions of machine without accessoires, approx. Diameter d Height H Height h Diameter D 1 330 mm 1 836 mm 2 324 mm 870 mm Required space for installation and operation of the machine and for maintenance work, approx. refer to General Arrangement Drawing 67000000.507.
Dimensions
19
BD 600 S
Diameter D Diameter d
Height H
Fig. 2: Dimensions of the dryer
Height h
20
BD 600 S
3.9 Connection list
The following connections can be found at the dryer. Please refer also to the General Arrangement Drawing 67000000.507. Pos. Description Standards Connecting dimensions Remarks
Connections at the vessel N2 N2.1 N3 N3.1 N3.2 N4 N4.1 N4.2 N4.3 N4.4 N8 N9 N10 N11 N12 N13 N14 N15 N16 Agitator nozzle Cleaning of vessel (CIP) Manhole / Filling of vessel Sightglass Sightglass rinsing Filter nozzle (flange at vessel) Gas supply for filter blow off Vacuum connection CIP (Cleaning nozzle) Filter nozzle (top flange) Inlet of heating agent for conical vessel Outlet of heating agent for conical vessel Product outlet Supply of purge gas Sampling valve Inlet of heating agent for vessel cover Outlet of heating agent for vessel cover Measurement of temperature at vessel shell Universal nozzle (flange at vessel) Special flange ISO 228 Zimmerlin type, clap bolts DIN 28120 ISO 228 EN10921 / 01 A ISO 228 EN10921 / 01 A DIN32676, Series A TriClamp EN10921 / 01 A EN10921 / 11 B EN10921 / 11 B EN10921 / 01 A DIN32676, Series A TriClamp Special flange EN10921 / 11 B EN10921 / 11 B Special flange EN10921 / 01 A ISO 2852 ISO 2852 EN10921 / 01 A DIN 28120 DN25 PN10 DN25 PN10 G 3/4 DN200 PN10 2 1 1/2 DN50 PN10 DN50 with pressure transmitter with PT100 G 1/2 400 DN80 G 1/4 DN250 PN10 3/4 DN80 PN10 DN15 DN250 PN10 DN50 PN10 DN50 PN10 DN200 PN16 with valve DN15 with valve N20.1
N16.1 Connection for pressure transmitter N16.2 Connection for nitrogen purge valve N16.3 Nozzle for safety valve N17 Sightglass
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BD 600 S
Pos. Description Standards Connecting dimensions G 1/2 G 1/2 G 1/8 Remarks
Connections at the sealing unit (mechanical seal) N18 (A) Supply of nitrogen ISO 228 ISO 228 ISO 228 N19.1 closed by plug with leckage hose with adapter for hose 10mm N18 with adapter for hose 10mm Connections at the filter blowoff unit N20 Supply of nitrogen ISO 228 ISO 228 G1 G 3/4 N4.1 N20.1 Outlet of nitrogen
N18.1 Outlet (B) N18.2 Leakage control (C) Connections at the purge gas unit N19 Supply of nitrogen
ISO 228 ISO 228
G 1/4 G 1/4
N19.1 Outlet of nitrogen
Each flange is provided with a number of bolt holes which can be divided by four. The bolt holes are arranged symmetrically to the two main axes in such a way that holes do not coincide with the axes.
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BD 600 S
3.10
Pos.
Utility Schedule
Medium Pressure (Overpressure) max. at operation (recommend.) 2 bar 2 bar 34 bar Flowrate max. 9.5 m3/h at operation (recommend.) 8.5 m3/h short pulse short pulse Remarks
Flow rates are partly process dependent. Description
N2.1 N3.2 N4.1 N4.2 N4.3 N8, N9
Cleaning of vessel (CIP) Sightglass rinsing Gas supply for filter blowoff Process outlet / vacuum line Cleaning of filter Supply of heating or cooling agent or air to vessel shell Purge gas inlet
CIP liquid 2.5 bar Nitrogen Nitrogen Gas CIP liquid 2.5 bar Steam; Air; Water Nitrogen 3 bar 3 bar 4.5 bar
connected to vacuum unit 2 bar 3.5 m3/h 3 m3/h max. 145C
connected to heating circuit 1
N11
approx. 1 Nm3/h per 1 m3 filling
flow depends on product Installation of flow meter is necessary
N13, N14
Supply of heating agent to vessel cover and filter housing
Water
3 bar
connected to heating circuit 2
max. 80C
N16.2 Connection for nitrogen purge valve N18 (A) Supply of nitrogen to mechanical seal
Nitrogen
depending on process
Nitrogen
3.5 bar
2.5 bar higher approx. than the pres2 Ndm3/ sure inside the min vessel; Vacuum condition in the vessel: 2.5 bar 3 6 bar 3 4 bar 0.5 Nm3/h
approx. 1 Ndm3/min
N19 N20
Nitrogen inlet at Nitrogen purge gas unit Nitrogen inlet at Nitrogen filter blowoff unit
6 bar 10 bar
intermittent 0.3 Nm3/h
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BD 600 S
4
4.1
4.1.1
Safety Instructions
Symbols
Danger!
This symbol refers to all safety instructions in these Operating Instructions where there is a risk for life and limbs of the persons concerned. Please consider these instructions and proceed with care! The safety instructions shall be made available to all persons concerned. All safety regulations and accident prevention rules in force refer in addition to the instructions contained in these Operating Instructions.
4.1.2
Attention!
This symbol is found in these Operating Instructions wherever special attention should be paid to directions, instructions, specifications and the proper order of work in order to avoid damages to and/or destruction of the machine and/or other plant components.
4.2
Proper use
Proper use means: The machine is suitable exclusively for the drying and mixing of a material. The properties of the mixture given in the contract (e.g. composition, particle size distribution, feed concentration, temperature) must be observed. The values stated in the chapter Technical Data as well as on the type plate must not be exceeded. For machines installed in a potentially explosive atmosphere, the process area must be inertized. Substances that are harmful to health, hazardous and/or toxic substances shall only be processed if a respective hazard assessment and risk assessment have been carried out by the operator prior to the commencement of work. When processing and/or using hazardous media and/or media that are harmful to health the operator shall take measures that rule out any hazard to persons in the event of a leak or opening of the machine. If the residual risk cannot be assessed, substances harmful to health, hazardous and/or toxic substances shall not be processed. The use as specified means also the strict compliance with the Operating Instructions and the assembly and dismantling, commissioning, operation and maintenance instructions. Maintenance and repair work exceeding that described in the Operating Instructions is only to be carried out by the manufacturers personnel or by qualified staff trained by the manufacturer. Any and all other use is not permissible. The manufacturer will not be liable for damages resulting therefrom but the risk is at the sole responsibility of the owner.
4.3
Warranty
Unless otherwise agreed in the contract, during the period of warranty all routine annual and triennial inspection jobs as well as all repair work due to faults are only to be carried out by service staff of ANDRITZ KMPT GmbH. Beyond this, during the period of warranty only original spare parts from ANDRITZ KMPT GmbH are to be installed. Warranty claims shall otherwise become null and void. Operating Instructions, revision 0 Sales Order No.: 37000881 Serial No.: 60001556
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BD 600 S
4.4 Safety Regulations
In any case, local safety regulations and rules for the prevention of accidents in force in the country of the owner are to be considered first! Risks for the life and limbs of the operators may be involved particularly if the machine is run by unskilled personnel, or is used in an improper way or not in accordance with the specifications. The machine and other equipment of the owner may be damaged by the use of the machine by unqualified personnel, in an improper way or for other purposes than specified. Each person, who is concerned in the plant of the owner with dismantling, mounting, commissioning, operation and maintenance of the machine must have read and understood the complete Operating Instructions, especially the chapter Safety. We recommend the owner to confirm this in writing. In addition these persons have to know the relevant Work Safety Regulations. Operating conditions which may result in risks due to improper operation may be caused among others by inadequate or irregular loading, by product buildup or careless setting of the discharge devices. When imbalance is noted for these reasons, the machine must be stopped immediately in any case and the problem eliminated. The safety data sheets of the used agents and utilities must be observed. Suitable protective measures must be taken by the operator where applicable.
4.5
Operation of the Machine
The owner must make sure that the machine will be used only in excellent operating condition at any time. The user must care for cleanliness of and access to the working place at and around the machine by the corresponding instructions and inspections. The machine must be set up to allow a stable operation. The construction company will be fully responsible for the stability of the solid foundation and of the inertia block, if any. Abstain from all work which may affect the safety of the machine. The feed rate of the machine must be absolutely even and constant. Whenever considerable imbalance is noted, the machine must be shut down. A machine which has run at imbalance and was stopped for this reason, must be unloaded and cleaned before restarting it. Machines which are processing inflammable products, must be provided with the suitable equipment to prevent the risk of explosive atmosphere inside which may result in fire, detonation or explosion. The speed of the machine or the feed rate must not be increased above the data in chapter Technical Data unless the supplier of the machine has confirmed this in writing. Unauthorised modifications or changes which may affect the safety of the machine are not allowed. Modifications which may be of effect on the safety of the machine must always have prior approval by ANDRITZ KMPT GmbH and confirmed in writing. The user of the machine must inform the authorities concerned immediately of detonation (breaking, bursting) as well as of explosions of the processed product. Machines which are operating at overpressure above 0.5 barg, must pass the tests specified by the pressure vessel regulations. Operating Instructions, revision 0 Sales Order No.: 37000881 Serial No.: 60001556
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BD 600 S
4.6 Operators
We recommend to the owner to prepare internal instructions considering the qualifications known to him of the personnel in charge and to have the receipt of the Operating Instructions and/or receipt of training/ instruction courses confirmed by writing. The operation, maintenance and repair of the machine must be done only by authorised, qualified and trained personnel. This personnel must receive special instructions regarding the risks involved. Assembly, maintenance, repairs and troubleshooting require technical knowledge and may only be performed by specially trained and authorised specialist staff. Any work on the electrical equipment must be carried out by an electrician in accordance with the regulations of electrical engineering. The owner of the machine shall prepare a manual in the language and makeup suitable for the operator personnel and must make this manual available and accessible to the operator personnel at all times. The operator must guarantee that only authorised persons will work at the machine. The operator must not ascend the machine during operation. The installation of platforms for the operators is recommended. The responsibilities during the assembly, dismantling and reassembly, commissioning, operation and repair must be clearly defined and followed in order to support safety standards by clear competence. The operator agrees to operate the machine only in excellent operating condition. The operators must use the required personal protective clothing (gloves, respirator, suits) considering the risks involved which may be caused by the machine and the processed product, and must use them as required. The owner must instruct the personnel accordingly.
4.7
Inspection
The reliability of the machines shall be inspected at least once yearly in operating condition and at least every three years in disassembled condition. The national and local regulations and all special directions by the trade unions have to be considered by the owner. Our machine components are compatible with these intervals. This is a minimum requirement and the owner is obliged to have the machine inspected in shorter intervals if necessary. It is advisable to duly document the results of the yearly and of the threeyears inspections.
4.8
Maintenance and Assembly
The operator agrees to check the machine at least once each shift for external visible damages and defects, and to advise immediately his observations (including the operating behavior) affecting the safety and to eliminate deficiencies if any. All covers, doors and safety guards must be opened only for routine cleaning and maintenance purposes during inspections and only after the machine has stopped operation. The shutdown procedures stated in these Operating Instructions, must be followed for all assembly and dismantling, commissioning, operation, modification and maintenance work. Whenever maintenance, assembly or dismantling work is done it must be absolutely sure that no explosive atmosphere is existing. Before you start any work at the rotor, all drive motors and control circuits must be dead and locked against unauthorised use. Where frequency controlled motors are installed, the primaryside converter must also be switchedoff. Other power units e.g. control pneumatics for the operation of the valves, pneumatic cylinders, etc., must be deenergized (discharge pressure valve) and must be protected against unauthorised starting (just like the motors). These devices must disconnect the energy supply in a clearly visible and reliable way. Operating Instructions, revision 0 Sales Order No.: 37000881 Serial No.: 60001556
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BD 600 S
Before starting the work at the machine, its drives and optional equipment must be protected by locking against unauthorised operation. This can be done preferably at a local power switch (which is not included in the delivery). All maintenance work at the machine must be done only after the machine is at zerospeed. Protecting guards and devices must be removed only after standstill and locking out of the machine. Doors, guards and covers must be opened only after standstill of the machine and must be installed again immediately after completion of the work. Before starting any work at the open machine, the user shall take the precautions required for the product concerned in order to avoid injuries or health hazards. Before you start any work at the open housing or in the process area, noxious gas or vapours, if any, must be vented, product residues removed and the process area carefully ventilated. When you work at the open process area, all supply and discharge pipes must be closed and secured; the same refers to the inertizing system, if any. Please note that there are not any locking functions in action during the revision resp. test mode of operation which must be used only by authorised persons for testing and adjusting certain functions. For this reason special care must be taken. For work in confined spaces e.g. in the basket, electric devices according to the national safety regulations must be used exclusively (for example: low tension of 42 V according to VDE 0100 in Germany). The lifting appliance crane used for maintenance must meet the weight of the heaviest part to be lifted. The machine must be attached only at the lifting lugs clearly identified. For the assembly and removal of components, special tools and devices provided for this purpose must be used in order to avoid the risk of damages affecting the reliability of the equipment.
4.9
Startup
Before starting the machine after repair, you should see that all protective devices be installed and all doors, guards and covers closed. If the machine is operated in a potentially explosive atmosphere a function test of the repaired or replaced parts must be carried out in a nonexplosive atmosphere before starting the machine. After completion of electric assembly and repair work the provided protection measures (e.g. grounding resistance) must be tested. The owner must take full responsibility. The manufacturer/supplier will not accept any claims unless agreed upon.
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BD 600 S
4.10 Monitoring equipment
For reliable operation of the machine it is necessary for the machine to be operated with monitoring equipment. To this end, the following monitoring equipment must be installed: Pressure and temperature monitoring to keep safely the limits stated on the type plate Locked, separating protective equipment with retention lock mechanism for covers (if covers are bolted and if there is no operational access, the retention lock device is not necessary) Safetyoriented shutdown The information given in the operating instructions of the subassemblies must be observed Requirements due to supply of inert gas (nitrogen or other gases which do not support breathing) to the machine (danger of suffocation) Inert gas which is supplied to the housing seal and to the process housing is also carried to the surrounding area of the machine where operators are located. The user of the machine must take measures in order to avoid a risk for life of the operators mainly to avoid a suffocation of operators. This can be done by avoiding an accumulation of inert gas in the surrounding area of the machine (e.g. by a safe and sufficient ventilation of the area) and/or by installation of gas detectors. Before opening the process housing, the inert gas supply must be reliably shut off, the inert gas must be suck off from the process area and the process area must be carefully ventilated. Moreover, the use of the personal protective equipment and breathing protection may be necessary. Processing harmful and noxious materials Substances that are harmful to health, hazardous and/or toxic substances shall only be processed if a respective hazard assessment and risk assessment have been carried out by the operator prior to the commencement of work. When processing and/or using hazardous media and/or media that are harmful to health the operator shall take measures that rule out any hazard to persons in the event of a leak or opening of the machine. If the residual risk cannot be assessed, substances harmful to health, hazardous and/or toxic substances shall not be processed.
Based on plantspecific and processspecific features (e.g. overpressure, sterilization) additional monitoring and locking installations are required. The safety standard of these monitoring and locking installations must be defined within the scope of a risk analysis carried out by the operator!
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BD 600 S
4.11 Inertising
General
Machines for use in potentially explosive atmospheres must, according to the regulations, only be operated with an inertised process area. The inertising technology must comply with the requirements for the area in which the machine is installed. The machine must therefore not be started up until reliable inertising of the process area has been completed. Moreover, the inertising must prevent a flammable atmosphere from developing inside the machine during the operation. For this purpose nitrogen or a different inert gas must be supplied to the inside of the machine to avoid mixture concentrations which are within an ignition range. In order to obtain the optimum concentration of inert gas, the supply of the inert gas into the machine must be carried out at a place where a uniform distribution of the gas is made possible, to avoid the development of zones which are not affected by the inert gas inflow. The inertising pressure is to be selected in such a way that during the operation there are no zones with a pressure lower than that of the atmosphere. This prevents any unintentional inflow of air into the machine.
Requirements put to inertising

Preflushing: The oxygen content inside the vessel and the downstream connected equipment connected to it during the operation, must be reduced to a value well below the ignition range through the supply of inert gas. For the inside the machine an oxygen content of maximum 1% is usually required. The preflushing is done in the following steps: 1. Evacuate the vessel to approx. 500 mbar abs 2. Purge with nitrogen till atmospheric pressure is obtained 3. If necessary, repeat steps 1 and 2 to receive a further decrease of oxygen in the vessel 4. Purge with nitrogen till a slight overpressure is obtained in the vessel (typically 30 60 mbar g) Release for startup of the machine: The power supply to the machine is not to be switched and the machine started up before completion of the preflushing process and buildup of gauge pressure inside the machine. Monitoring during the operation of the machine: The pressure level in the machine must be maintained throughout the operation in order to adjust a reliable gauge pressure towards the surrounding area (supply of nitrogen when pressure drops; exhaust of gas when pressure increases). The function of the inertising must be monitored by the control and in the case of a failure the machine must be shutdown in a safetyoriented way.
For maintenance work in the machine it must be possible to reliably shut off the nitrogen supply! The nitrogen supply must be shut off only with a standstill machine! In case of plant or power failures, the nitrogen supply still must be present! The plant operator must make sure that all components connected upstream of the machine are included in the inertising process during automatic feed.
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BD 600 S
5
5.1
Transport, Settingup and Assembly

General Instructions
The careful installation is a requirement for the reliable and troublefree operation of the machine. All pipes and connections to the machine must be flexible. We recommend the use of expansion joints, hoses and soft laying of the pipes. Where a filter is included in the delivery, the pure gas pipe should be arranged somewhat downward (by approx. 12%) from the filter to avoid any possible backflow of condensate into the filter.
5.2
Packing
The packing depends on the shipping route and the transportation mode of the machine. The following symbols shall be considered when the machine and the accessories are packed into cases:
Center of gravity
Attach here
This side up
In general the machine is shipped as a complete unit. Protective covers and plugs at openings shall be removed only during the assembly. The contents of the shipment are listed in the packing list. The consignments shall be checked for complete contents upon arrival. Damages in transit and/or missing parts shall be advised immediately in writing.
5.3
Intermediate Storing
When the machine and the accessories are not installed immediately after arrival, the various components shall be stored at a roofed place free of vibration to avoid damages at the bearings. Avoid the ingress of dust and moisture. Under these conditions the machine can be stored for twelve months. Special preserving measures must be taken, however, for protection against high humidity of the air and/or aggressive atmosphere. For this case and for storage times for more than 12 months we recommend you to ask ANDRITZ KMPT GmbH for consultation. Spare roller bearings shall be left in their original packing until just before their installation. Large roller bearings shall be stored in upright position due to the relatively low wall thickness of the races. Operating Instructions, revision 0 Sales Order No.: 37000881 Serial No.: 60001556
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BD 600 S
5.4 Transport
General
Do not damage the accessories when attaching the lifting cables! The tranport weight of the dryer is 2 000 kg. The load capacity of the crane must be suitable for this weight. For handling and shipping lifting lugs are installed at the transport frame as well as at the dryer.
Condition at delivery
The dryer is delivered according to fig.3:
1 transport frame 2 bolting between transport legs and dryer support brackets
Fig. 3: Condition at delivery To transport the whole unit (dryer + transport frame), attach four cables at the four lifting lugs located at the edges of the transport frame.
Only use the lifting lugs at the transport frame to lift the whole unit! Do not use the lifting lugs at top of the vessel to lift the whole unit! Operating Instructions, revision 0 Sales Order No.: 37000881 Serial No.: 60001556
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BD 600 S
Internal transport
For internal transport proceed as follows: Attach two cables at the lifting lugs of the cover (see fig. 4)
Fig. 4: Transport of dryer
Only use the lifting lugs at the cover of the dryer! Do not use the support brackets at the vessel for transport! Lift dryer Remove transport frame (see fig. 3) Transport dryer
The dryer, especially the installed equiupment must not touch the building!
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BD 600 S
5.5 Place of Installation and Required Space
The place of installation must be checked by the owner for suitability (static calculation). The contractors carrying out the job shall bear full responsibility for the stability of the solid foundation, the building and the steel structures.
The foundation and the steel structure respectively must be suitable for the catastrophic weight stated in chapter 3.8! The owner will be fully responsible for the due execution! All inlet and outlet pipes must be designed in such a way that the machine is uncoupled from the surrounding plant. The machine and its complete accessories are not suitable for installation in the open air. The admissible ambient temperature can be seen in chapter 3.7. An operation of the machine in other temperature ranges is not permissible. For transportation of the machine to site a suitable works crane or at least a mobile crane must be available at site. The loads can be seen from the chapter 3.8. For the maintenance work later on a suitable runway rail with trolley of a load capacity corresponding at least to the weight of the complete machine must be provided at adequate elevation (see enclosed General Arrangement Drawing). If the available crane is of lower load capacity it must not be used for transporting the complete machine. In this case the machine can be disassembled and the removed components can be transported separately. The load capacity of the crane must be above the weight of the most heavy item. The installation of the maintenance equipment (e.g. crane, runways, trolleys) in accordance with the General Arrangement Drawing of the order concerned is condition for any supplies or services under warranty by ANDRITZ KMPT GmbH. The required space around the machine for operation and maintenance can be seen from the detailed General Arrangement Drawing referring to your specific order and from chapter 3.8. Adequate space must be be reserved also for the electrical accessories e.g. the local panel.
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BD 600 S
5.6 Settingup and Assembly Procedure
We recommend you urgently to refer to the services of the specialists from ANDRITZ KMPT GmbH for the settingup and a control of the settingup work respectively. For this reason please take up contact with the AfterSales Services (see chap. 1.2).
We shall not accept any claims resulting from improper execution of this work by the owner! The settingup and assembly should be performed in the following order: Tranport the dryer to its place of installation (see chap. 5.4) and insert the dryer from the top into the prepared foundation Align the dryer: A bubble level can be used for alignment which will be placed on a socket for example. Misalignments shall be leveled by shimming at the supporting points Bolt the dryer to the foundation. Ground the dryer (see chap. 5.6.1) Install the product discharge valve, if removed for transport Install the vapour filter, if removed for transport Install the filter blowoff unit near to the dryer and connect it Install the gas supply unit for the mechanical seal near to the dryer and connect it Install additional equipment (rupture disk, pressure and temperature transmitter), see also P&ID 00020xxx Install all other units (such as heating unit, vacuum unit) and ground them Install the heating, nitrogen and other pipes, see also P&ID 00020xxx Wire all installed safety and monitoring instruments, integrate them into the control and check their function If necessary, install further safety instruments in order not to exceed the max. operating parameters (pressure, temperature, filling, see chap. 3). A safe operation of the dryer must be guaranteed.
The operator of the dryer is fully responsible for a safe operation of the dryer! The operator must install adequate monitoring devices to keep safely the max. adm. operating parameters! Check if further guards and safety gates must be installed to protect the operators
If high or low product temperatures appear during the operation protective equipment must be installed around the dryer to avoid a contact with the hot or cold surfaces!
In case of open product supply or product discharge (e.g. product falls onto a conveyor belt), protective equipment must be installed in order to prevent the access of human limbs to the discharge flap or to the discharge screw! Closed product supply or discharge (e.g. racking the product into a barrel): The starting of the dryer and the operation of the supply and discharge flap must be prevented by the control when the closed system is opened and therefore human limbs can reach flaps or the discharge screw (e.g. takingoff the product barrel when changing the barrels at normal operation)! Operating Instructions, revision 0 Sales Order No.: 37000881 Serial No.: 60001556
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BD 600 S
Cable all motors and electric controls (see Electric Documentation) Carry out mechanical checkups before the testrun without product Test the electrical inputs and outputs Install an Emergencystop button at an accessible place and check its function Test the program sequence with all lockings Carry out a testrun without product
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BD 600 S
5.6.1 Cabling of all Motors and of the Electric Control
The electric cabling must be done by .
Check the direction of rotation before taking the electric motors into operation!
5.6.2
Grounding
This grounding symbol is provided at the supporting lug for connection of a ground strap. The position of the grounding symbol is shown on the General Arrangement Drawing. It is left to the operator of the dryer to decide if further earth connections must be added.
5.6.3
Removal of Transport Locks
In order to avoid damages during transport, transport locks might be installed inside the vessel in order to support the agitator. Check the inside of the dryer for these parts and remove them if necessary.
Risk of serious injuries! Drives must be dead and locked against switchingon before you remove the transport protections from the vessel through the manhole! Check the supporting places for damages and inform ANDRITZ KMPT GmbH of damages, if any. Moreover, the mechanical seal has also a transport lock. Screwout the transport lock screws (fixing screws) according to the separate manual of the mechanical seal
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BD 600 S
5.7
5.7.1
Guidelines for laying pipes, hose connections and valves

General
Laying pipes All connecting lines to the machine must be arranged in such a way that there are no forces acting on the connecting flanges of the machine. For this purpose observe the following: Assemble pipes stressfree Lay pipes in such a way that the pipes are supported and do not rest on the connecting flanges. Arrange pipes in such a way that thermal expansions coming from the machine and the pipes do not exert forces on the connecting flanges of the machine. Additionally observe the following: It is recommended to also use expansion joints or hoses, in addition to pipes. To avoid electrostatic charging with machines installed in potentially explosive atmospheres, all connections (hoses, expansion joints) must be electrically conductive. The used pipes and hoses must be designed for the max. permissible pressure and temperature Keep piping as short as possible and lay as straight as possible Keep number of screw connections and flange connections as low as possible Bend pipes as cold as possible
Hot forming leads to scale formation: in event of processed pipe pieces always pickle, neutralize and subsequently flush with oil! Apply corrosion protection after laying pipes! Observe the arrangement of fittings and valves specified by the manufacturer during the installation Open system If an open system is existing, adequate precautions must be taken by the operator in order to prevent the access of human limbs to rotating or moving parts (e.g. installation of install safety barriers, installation of a fence, installation of a down pipe) Closed system If a closed system is existing, the starting of the machine and the operation of the shutoff valves must be prevented by the control when the closed system is opened and therefore human limbs can reach the discharge valve or the other moving parts (e.g. takingoff the product barrel when changing the barrels at normal operation) Maintenance work For maintenance work in the machine all supply lines must be able to be reliably shut off and protected against unauthorized switching on. Couplings If it is necessary to change frequently hose connections during operation, the use of selflocking quick release couplings is recommended in order to avoid leakage. Disassembly work Always make sure that the following conditions apply prior to disassembly work: Pipes are not hot Pipes do not contain media, remove any existing media if necessary Pipes are pressurefree Operating Instructions, revision 0 Sales Order No.: 37000881 Serial No.: 60001556
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BD 600 S
Reassembly work Always observe the following reassembly instructions when carrying out the reassembly of pipes: Tighten screw connections crosswise and tighten to correct torque Check condition of seal; replace if necessary. Always replace hard seals, metalcased seals, and FEPcoated sealing rings Check seals for correct seat After completion of reassembly check for leaks and carry out pressure test, if necessary and flush the pipes to be sure that all hard particulates have been flushed out, dry the pipes, if necessary. Installation examples for hoses Wrong

Correct
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BD 600 S
5.7.2 Machine specific requirements
Inlet pipe arrange the supply tank as close as possible at the machine provide the pipes between supply tank and machine as short as possible no narrow parts permissible arrange the feed valve always at the outlet connection of the supply tank install additional shutoff valve directly at the inlet socket of the machine when operating the machine at vacuum or overpressure CIP pipe (for cleaning of machine) arrange the valve close to the machine care for quick and complete emptying of the pipe Outlet pipe vertical, without narrow parts install additional shutoff valve directly at the outlet socket of the machine when operating the machine at vacuum or overpressure If automatic cleaning of machine is provided, then take care for separation of solids and cleaning liquid. Inert gas pipes / Purge gas pipes / Seal gas pipes Install the inertising / control unit above the machine Provide pipes from the inertising / control unit to the machine without any loops toward the bottom For maintenance work inside the machine it must be possible to reliably shut off the gas supply Nonreturn flaps must be installed in the vertical pipe line Vapour filter pipe Where a vapour filter is included, the pure gas pipe should be arranged somewhat downward (at least 2%) from the filter to avoid any possible backflow of condensate into the filter. Protection against overpressure A bursting disk or a safety valve must be integrated as protection against overpressure. The bursting disk / safety valve is to be dimensioned in compliance with the maximum volumetric flow. As tolerance value for the rupturing pressure we recommend +/ 10%. The max. permissible operating pressure in the process housing is not to be exceeded (refer to chapter 3.7). When the reaction pressure is reached, then the maximum volumetric flow must be discharged in the exhaust air pipe with a pressure loss as close to zero as possible. The loss in pressure must be considered for the design of the overpressure equipment. The exhaust air pipes must not be a danger for the operator or for other persons.
High temperatures as well as emission of hot air can occur at the conical mixer as well as on the peripherical equipment and pipework! Therefore the user of the conical mixer must either ensure that persons / operators have no access to these parts and outlets of the machine or install safety barriers around these parts. This concerns also the product inlet N1. Moreover, if persons / operators have access to large surfaces which can get hot (e.g. the cover of the vessel), the user must install safety barriers to avoid that persons are lying on these surfaces in case of an accident. Operating Instructions, revision 0 Sales Order No.: 37000881 Serial No.: 60001556
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BD 600 S
6
6.1
Commissioning and Operation

General Information
The machines from ANDRITZ KMPT GmbH are highcapacity machines. In order to obtain the optimum capacity from the machine it is absolutely necessary that all processing and mechanical settings be appropriately set. Based on our experience gathered for long years with laboratory tests and commissioning with various products, we most urgently recommend you refer to the services of the personnel of ANDRITZ KMPT GmbH for the commissioning work. On this occasion you will receive additional hints with respect to the operation of the machine in addition to the instructions contained in this manual. Please contact the AfterSales Service of ANDRITZ KMPT GmbH (see chapter 1.2).
Before the commissioning with product it is absolutely necessary that all mechanical checks and inspections before the test runs without product be carried out. The electric program control must be tested in all individual cycles and for the automatic cycle operation. Before starting the batch operation please see that all downstream conveyers like discharge screw, conveyer belt, valve lock, etc. are ready for operation.
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BD 600 S
6.2 Mechanical Checks before the Test Runs without Product
Check the fixing at the foundation Check tight seat of the cover bolts All connections at the Dryer must be soft This means that the piping must be done in such a way that the piping is selfsupported and not supported on the dryer flanges and that thermal expansion of the dryer and of the piping does not produce forces on the dryer flanges. Check vessel inside area for all foreign matter and remove, if any All bearing points must be greased Checks at the gear: Check that the plug screw is replaced by a breather Check the oil level of the gear Before testing the functioning of the motors, close all openings of the vessel and install all covers and safety guards Switchon purge gas supply for the mechanical seal
Never run the dryer without supply of purge gas to the mechanical seal! Switchon the drive motor for testing the direction of rotation of the helix (in clockwise direction seen from top i.e. conveying upward) Actuate the discharge valve for testing the open/closed position of the discharge valve Test the working of all limit switches and sensors Test the speed of the helix; see chapter 3 See if all safety related loops and all monitoring loops are properly installed, check their settings and check their functions; check function of EMERGENCY STOP Check all accessible threaded connections Check all auxiliary equipment Do a pressure / vacuum test of the machine incl. all installed pipework. Take care of the limit values in chap. 3.1 Check the safety instrumens (safety valves, safety temperature limiter) by applying pressure / temperature to them. Take care of the limit values in chap. 3.1. Check also that a safeguard is installed in the heating circuit in order not to exceed the max. heating temperature Check the electric conductivity of all components and check the grounding of the machine Check if the hose connections and hose lengths are suitable and check where the hoses are to be connected
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BD 600 S
6.3 Test Runs without Product
The test runs are carried out to demonstrate the perfect functioning of the dryer. At the same time the program sequence as provided, shall be tested just like the EMERGENCYSTOP functions and all other included locking systems see separate Electrical documentation.
Before takingup the testruns, all mechanical and electrical work must be completed. All openings in the vessel have to be closed! Switchon purge gas supply for the mechanical seal
Never run the dryer without supply of purge gas to the mechanical seal! Testrun the machine at operating speed for approx. 5 to 6 hours
Check the temperature of the drive and sealing unit! Please take up contact with ANDRITZ KMPT GmbH whenever high temperature is noticed. Heatup the vessel; heatingup and cooling rate max. 80 C/h. Avoid big temperature changes during heating/cooling and during rinsing as thermal shock can significantly reduce the working life of the vessel and can also cause permanent deformation at the vessel. It is recommended that a method be used that will allow for the vessel to transition to the new temperature. This can be accomplished by slowly increasing or decreasing the temperature of the heating/cooling and rinsing fluid or by allowing the vessel to return to near ambient temperature before the new fluid is introduced. Check the vessel for uniform heatingup Where steam heating is provided, the condensate must flow off readily
The admissible pressure values for product and heating area according to chapter 3 must not be exceeded! When unusual noise is noted, switchoff the drive immediately, look for the cause and eliminate it! ANDRITZ KMPT GmbH will be always at your disposal for assistance.
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BD 600 S
6.4 Commissioning of the Dryer
Due to the possibility of product or media discharge during the individual process steps operating personnel must wear appropriate personal protection equipment and any constant presence of operating personnel in the vicinity of the vessel / in the room is to be avoided. The use of an oxygen monitor is also recommended! Always observe the respective safety data sheets when using toxic media or media that may be harmful to human health or the environment. It is absolutely necessary that all mechanical tests before the test runs without product be carried out before the commissioning takes place. The electric program control must be tested in all separate steps and during the automatic processing of the cycles. If possible, the program should be processed once without heating, with water for cleaning the vessel and the pipes and for checking the valves and flanged connections for leakage. Before you take up the batch operation it must be sure that all conveying systems downstreams e.g. discharge screw, conveyer belt, rotary lock, etc. are ready for operation.
6.4.1
Process steps
At start up the machine is evacuated and purged with nitrogen by cycle counter. Following a successful inertizing the machine continues under pressure control. Overpressure control for the steps feeding, cooling (optional), discharge and CIP (optional), to maintain the N2 blanket. Vacuum pressure control for the steps drying and cooling (optional). All necessary actuators are switched on and monitored. Start up must be finished before the following steps can be processed batch by batch. The dryer is filled manually at top of dryr, overpressure control is active (optional).
Startup
Feeding
Drying/Mixing
The product is dried by a programmable sequence. The heating/cooling system is active. Vacuum operation is active.
Cooling
The product is cooled by a programmable sequence. The heating/cooling system is active. Optionally vacuum or overpressure control is active.
Discharge
The product is discharged, overpressure control is active (optional).
CIP cleaning
Cleaning in Place: The dryer is cleaned with suitable liquid, overpressure control is active (optional).
Shutdown
The dryer is stopped, the inerting is deactivated.
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BD 600 S
6.4.2 Startup
During startup the machine is set in normal state and prepared for production. Monitoring routines are continuously checking the machine for malfunctions. If there is a fault during startup, the sequence is stopped and shutdown is initiated at once. If the sequence is finished without failures, startup is finished and the control system is set to the state Stand By. Now the machine is ready for production.
6.4.3
Product Feeding
The way of filling the batches into the vessel depends on the type of the product to be mixed/dried. As a consequence the design and the operation of the feeding devices must reply to the processing requirements of the processed product. This dryer can only be filled manually. To fill the dryer, process the following steps:
Manual feeding: During the open vessel, the dryer lost the inert status. The dryer must be switched off. After feeding is finished, the dryer has to be purged again with nitrogen to reach inert status! Adequate precautions must be taken by the operator in order to prevent the risk of injuries for the operating personnel.
All precautions stated in chap. 6.7 must be taken! (For example stopped agitator, nitrogen supply closed, pressureless vessel, ...) Open the manhole cover at the vessel cover Fill in the product
Take care that no foreign parts are in the product when feeding the dryer!
The load stated in chapter 3 must not be exceeded! Close the manhole cover Inert the vessel (see chap. 4.11) and do a leak test Apply the required pressure Start the drive
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BD 600 S
6.4.4 Product Mixing/Drying
Start the mixing unit with filled vessel only with the minmum speed to avoid a damage of the mixing unit! Increase the speed stepwise! The batch sequence and the specific properties of the product are basis for the performance of the mixing/ drying process especially where processes are concerned under high safety conditions.
The conveying by the helix must never be downward! The mixing and drying effect depends on the residence time, the pressure and the temperature. Where a sampling valve is installed, samples can be taken during the processing operation in order to check the condition of the product.
6.4.5
Cooling
The heatedup prodcut can be cooled before discharging (option).
6.4.6
Product Discharge
As soon as the requested mixing and drying effect is obtained the product will be discharged from the vessel through the discharge valve. In general the product will be discharged at atmospheric pressure. Before opening the discharge valve you should ensure that the units downstreams are ready for operation. The discharge in a closed discharge system is recommended in order to prevent the access of human limbs to the discharge valve or to other moving parts. Moreover, nitrogen which is inside the dryer will not be discharged into the place of installation where operators are present (no danger for operators). The agitator must be stopped before product discharge, as the product is discharged into not inertised device.
6.4.7
Shutdown
By Shutdown, the machine is brought to standstill as fast as possible. All parts of the machine are set to their initial position. If standstill is reached and all parts are in secure position, the state shutdown is reached. Shutdown can be initiated by: Usual shutdown by normal finishing the batch being processed by the sequence Stop after batch / discharge or shutting off the dryer by pressing on the button [Shut down] In case of danger shutdown of the dryer by pressing the EMERGENCYSTOP button Shutdown of the dryer due to operation or system failures by the automatic operation of the safety circuit EMERGENCYSTOP
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BD 600 S
6.5 Adjustments and Settings for Optimizing
During the commissioning with product all relevant data shall be recorded and evaluated in order to allow you to set the optimum production conditions. These data are among others: Wet Product: Minimum, average, maximum moisture, particle size, amount each batch, number of admissible batches/load Heating Agent: Temperature, quantity, distribution Speeds: Speed change by frequency controlled drive Residence Time: between the various batches Mixing Time: after filling one batch Drying Program: during batchwise filling, after completed filling Residence Time: after complete filling Properties of the dried and mixed batches (final product) at the end of the processing operation : coarse, fine, granular, powder, free flowing, lumpy, sticky Discharge Method: Helix conveying upward at limited speed Discharge without rotating the Helix Gas Amount: for deodorization Further knowledges gathered in the course of time may result in revision of the original program and of the operating data later on.
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BD 600 S
6.6 Shutdown of the Dryer
For shutting down proceed in the following order: Discharge the dryer Switchoff the heating Switchoff the drives Switchoff all auxiliary equipment Clean the vessel / plant
Opening any lids or covers of the machine requires in any case the measures stated in chap. 6.7!
If high or low product temperatures appear during the operation, the operator must avoid a contact with the hot or cold surfaces!
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BD 600 S
6.7 Opening and closing of vessel / manhole cover
Dont open any covers or lids during the operation of the machine! There may be still rests of product in the vessel at hidden places! Be careful and use safety devices (overgarment, gloves, gasmask etc.), when noxious products are processed!
The local safety and accident preventive rules must be duly considered! This refers above all to the processing of explosive, aggressive and toxic products! Conditions for the opening of the manhole cover / vessel: Remove deposits on the vapour filter by cleaning procedure Clean the vessel inside by the installed rinsing equipment Shutdown the machine (see chap. 6.6) Switchoff all drive elements and control circuits and lock them against unauthorised start. All incoming process valves are closed and reliably secured. All incoming nitrogen valves are closed and reliably secured. The inside of the vessel is empty and vented. (The inside of the vessel must contain no noxious gas or vapours. Therefore the vessel must be reliably ventilated.) The inside of the vessel is pressureless The vessel is cooled down sufficiently (the surface of the dryer is not exceeding handhot temperature) or adequat personal safety equipment is used If necessary, remove the vapour filter
It is absolutely essential to remove the vapour filter in case of processing toxic products! Opening the manhole cover: The personnel should use their personal protective clothing (suits, protective gloves and protective glasses). Open the clamping bolts and open the manhole cover considering the following: All nuts / handles should be opened symmetrically. Cross opening of the bolting arrangement should be used when opening the cover (e.g. North, South, East, West where appropriate). At covers with a swivel hinge, all screws except the two closest to the hinge shall be opened first. Then open the last two screws (if possible, together). Opened lid to be set down securely / carefully, to avoid damage to lid / seal (if possible using a spring loaded locking pin), and to prevent lid falling downwards accidentally causing injury. Measures when the manhole cover is open: Before starting any work at the open vessel, the user shall take the precautions required for the product concerned in order to avoid injuries or health hazards. Before you start any work at the open vessel or in the vessel, noxious gas or vapours, if any, must be vented, product residues removed and the vessel carefully ventilated. Prevent the manhole cover from unintentional closing Operating Instructions, revision 0 Sales Order No.: 37000881 Serial No.: 60001556
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BD 600 S
Closing the manhole cover: In general, the same conditions as for the opening of the vessel Check inside area of vessel for all foreign matter and remove, if any Check the sealing surfaces; clean if necessary Check Oring of the manhole cover for damages and wear; replace if necessary Check condition of clamping bolts Remove the locking of the manhole cover, close manually the manhole cover using the handle and install the clamping bolts Consider the following: Cover has to be closed carefully without force. Look for good centralisation. Ensure that the seal is positioned correctly and that the contact area is clean. Lid and neck should have a little lateral clearance, so that gasket seating did not have metal contact. Centre of lid flange has to enclose the gasket seating of the neck perfectly. Screws / swingpins to be put in the correct position, so that the machined face of sleeves catch to the outside groove of the lid flange. The bolting arrangement must be tightened evenly and to a set torque when using a max. allowable torque procedure in several steps as follows: a) 50% torque b) 80% torque c) Max. torque Please refer to chap. 9.1.1 for the maximum torque for the screws. Cross tightening of the bolting arrangement should be used when applying torque to the nut / handle (e.g. North, South, East, West where appropriate). If covers with a swivel hinge is used, it is necessary to close these two screws at first, which are nearest to the hinge (to avoid bending of the hinge pin). When the hinge is completely in its end position, all other screws can be closed and tightened as described above.
Take care for the correct tightening torque (see chap. 9.1.1)!
Danger! Be careful when closing the manhole cover! Final work: If required, do a leak test
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BD 600 S
6.8
A
Removal of filter
N4.1 N4.3 G C
D E F
Fig. 5: Filter Disassembly Stop machine (refer to chapter 6.6) Check that the conditions as described in chapter 6.7 are existing If necessary, disconnect all pipes and hoses from the cover (A) Remove all fixing bolts (B) and takeoff the cover (A) using the handles Pullout the complete filter unit (C) Cover filter element with a bag or similar Remove the bolting (E, F) Pullout the filter cage (G) Squeeze fastener strap of the filter element by hand and takeoff filter element from fixing ring Reassembly see chapter 12.5 for further information about the filter element Check all sealing rings, replace if necessary Take care that all sealing rings are installed Install new filter or cleaned filter Reassembly takes place in reverse order of disassembly Operating Instructions, revision 0 Sales Order No.: 37000881 Serial No.: 60001556
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BD 600 S
6.9 Cleaning
There may be still rests of product in the vessel at hidden places! Be careful and use safety devices (overgarment, gloves, gasmask etc.), when noxious products are processed! However, the user must define the safety measures that are required for each of the individual product!
Outside cleaning
Do not clean the following elements with steam: Ventilation cage of the motors all electric cables all electric elements
CIP cleaning
CIP nozzles are installed in order to clean the inside of the vessel.
Manual cleaning and inspection

If necessary, a manual cleaning and inspection of the vessel inside can be done after the CIP cleaning. Open the vessel (see chap. 6.7) Check visually if the vessel is in good clean condition Check for damages Remove installed components and clean them separately Clean again the vessel inside Check visually if the vessel inside and outside is in good clean condition Reinstall the cleaned components Tightly close all openings by covers and check that the fixing bolts are firmly tightened
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BD 600 S
6.10 Measures before and after extended Shutdown Periods (more than 1 month)
Max. shutdown period of the dryer is 3 months! Before extended Shutdown Periods Discharge the dryer and clean it Treat the gear according to separate documentation Protect the electric motors against moisture, heat, dust and impacts Protect the bright parts (not stainless steel) of the dryer by Tectyl 506 for example or similar preserving agents After extended Shutdown Periods Remove preservatives from the bright parts Prepare the gear according to separate documentation Prepare couplings according to separate documentation Remove from electric motors all protecting coatings against moisture, heat and impacts
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BD 600 S
6.11 Repair
All spare and wear parts should be on stock at site. Costs incurred by production stops due to missing parts are generally more expensive than the costs by a spare part stock. Bolts damaged by dismantling must be replaced by new ones in same quality (material, solidity) and design.
Before any repair work protect the machine against unauthorized switchingon! Switchoff main switch and remove fusible plugs!
Welding at the machine is not allowed in general!
There is a risk of explosion by welding work at the machine, in particular when explosive products are processed!
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BD 600 S
6.12 Disposal
The individual materials are to be disposed of taking the environmental requirements into account. Particular care has to be taken with parts that contain oil or grease residues.
Incorrect disposal of oil or grease is a threat to the environment and health. Therefore dispose oil and grease in an appropriate way! National laws and regulations as well as the safety data sheets of the manufacturer are to be observed when carrying out any disposal activities.
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BD 600 S
7
7.1
Inspection and Maintenance

General Instructions
Consider safety instructions (see chapter 4) for all maintenance and inspection work. After temporary removal all protection guards and covers must be installed again immediately after completion of the work! Please note that there are not any locking functions in action during the revision resp. test mode of operation which must be used only by authorized persons for testing and adjusting certain functions. For this reason special care must be taken! Before taking up any work in the processing area, special precautions must be taken like the suckingoff of noxious gas and vapors, the use of special protecting clothes and respirators respectively! Failures and troubles caused by inadequate or improper maintenance may result in high repair costs and extended downtimes of the machine. For this reason a regular maintenance will be absolutely necessary. The reliability and the operating time of the machine depend also on a careful maintenance and many other factors more. The following tables show intervals, checks and maintenance instructions for the normal use of the machine. Shorter intervals may be necessary due to varying operating conditions like the processing of abrasive or chemically aggressive products. For this reason the final inspection intervals are to be defined by experience considering your specific operating conditions. It is recommended to carry out a complete review in disassembled condition at least every three years. A review in operating condition should be provided in yearly intervals. Our specialists are always at your disposal for further consultation. The following should be considered in general whenever assembly measures are carried out: 0rings must always be in close contact in their grooves to prevent them from shearingoff All removed components must be handled with care and shall be cleaned carefully before reassembly (storing on a clean surface, protect them against damages, dust, scale, etc.). All removed parts must be reinstalled in their correct position. Specified tightening torques must be considered in any case.
Do not add spring washers where tightening torques are specified for threaded connections! Original parts from ANDRITZ KMPT GmbH shall be used exclusively for the replacement of damaged parts. In case the owner should install other parts than original from ANDRITZ KMPT GmbH (prior to approval by ANDRITZ KMPT GmbH) the warranty of the supplier will be forfeited for damages resulting therefrom.
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BD 600 S

Item Inspection and Maintenance Complete Machine Watch Production quence Notes after 150 h X X X X X daily weekly annual every 3 years 0000 seX X X X Visual check for leakage of machine Unusual noise Unusual vibration Check hoses and expansion joints for mechanical damages X Check accessible boltings X X Check accessible seals replace if for wear necessary Machine name plate available, legible X X X X Check all cables and connections Check the whole machine for wear Check function of safety related loops all Carry out a complete review in disassembled condition Replace all sealings and Orings Clean all parts of the machine X X X Take care for the maintenance intervals of sub supplier components see chapter 12 Check all hoses for leak- replace if age, wear and mechanical necessary damage Replace all hoses due to ageing depending on the field of application and on national and local regulations depending on the field of application and on national and local regulations
7.2
Checklist
56

Item Inspection and Maintenance Vessel Check the cratches vessel Notes after 150 h daily weekly annual every 3 years 0110 for X X X X Check vessel for corrosion and erosion Check inside and outside of vessel for distortions Check sightglass damage HELIX for 0200 Check the helix for wear and marks X Test the rinsing connec- clean if tions and nozzles for clognecessary ging and leakage Check CIP nozzles for wear and damage Check the helix for damages and cracks by dye penetrant examination Vapour filter Clean the vapour filter X X X 1810 depends on product and process depends on product and process Replace the vapour filter All temperature and pressure measurement devices Check function Accessories / Peripheric Equipment X 9999 see chapter 12 and following Maintenance of components according to manual of supplier
BD 600 S
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BD 600 S
8 Trouble shooting
In order to eliminate troubles at site without calling for a specialist from ANDRITZ KMPT GmbH, the following list shows possible troubles (grey), their cause (first column), remedies (second column) along with notes and references (third column).
Should malfunctions occur during the operation of the machine, stop the machine immediately. Do not restart the machine until the fault has been determined and removed! If the machine is operated in an unsatisfactory condition any damage which may occur is excluded from all forms of liability and warranty through ANDRITZ KMPT GmbH.
Refer in any case to the local safety regulations in operation of the dryer in addition to the following instructions! Shut down and switch off the machine in any case before taking up trouble shooting measures! We recommend you urgently to install a local key switch to avoid the risk of unauthorized switchingon of the machine during the execution of repair work or failures! In addition consider the respective safety regulations of the Trade Unions concerned!

Unusual noise in the vessel Foreign matter in the Dryer Shutdown dryer and remove see object 6.6 Inspect sealings chapter Nitrogen pressure decreasing Sealing leakage Improper assembly see chapter 12 Check sealing assembly and adjust Check heating agent temperature High residual moisture Low supply of heating agent Check heating circuit for leakage Check speed of helix Inadequate mixing Consider also the detailed maintenance advices given in the separate manuals in chapter 12 and following!
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BD 600 S
9 Description of Components
This technical description refers essentially to the following information: Function: This paragraph refers to the method of operation and the standard design of the various components. Bill of Materials: This list will give you a complete table of the subassemblies for each component. The various components are marked by position numbers referring to the drawings. Illustration: An assembly drawing is enclosed for each assembly on a separate page. The following should be considered in general whenever assembly measures are carried out: 0rings must always be in close contact in their grooves to prevent them from shearingoff Sealing surfaces must be clean, even and flat; this is especially important for coated surfaces All removed components must be handled with care and shall be cleaned carefully before reassembly (storing on a clean surface, protect them against damages, dust, scale, etc.). All removed parts must be reinstalled in their correct position. All disassembled parts must be checked prior to reassembly. Only reinstall parts and components that are in working order. Always replace defective parts with parts of equal quality. When replacing defective parts you should only use original spare parts from ANDRITZ KMPT GmbH. Only reuse bolts (especially bolts under high stress) that have not undergone elongation, that do not show any necking and that are without excessive deformation under the seating face of the head.
In case the owner should install other parts than original parts from ANDRITZ KMPT GmbH (prior to approval by ANDRITZ KMPT GmbH) the warranty of the supplier will be forfeited for damages resulting therefrom.
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BD 600 S
9.1 Screw locking
All screw joints must be locked. The following rules must be considered: All screw joints (screws, nuts) must be locked with Loctite. It must be used Loctite, type 243 medium or alternatively Loctite, type Hysol M121 HP that is suitable for foodstuff and pharmaceutical applications. The screw joints must be tightened with a tightening torque specified in the following table (see chapter 9.1.1). Exceptions: Where tightening torques are specified in the assembly drawings or in the assembly instructions, a lubricating paste must be applied to these screw joints and then the torque listed in the assembly drawing must be applied to the screw joints. It is recommended to use the lubricating paste from Klueber, type UH1 96402. Screw joints with positivefit locking elements (e.g. locking plate) are not locked with Loctite. However, these screw joints must be tightened with a tightening torque specified in the following table (see chapter 9.1.1). The following screw joints are not locked with Loctite. A lubricating paste instead of Loctite must be applied to these screw joints. It is recommended to use the lubricating paste from Klueber, type UH1 96402: Tension screws for electric motors Fixing screws of peeler knife Screws from M30 Slotted round nuts Pipe and hose connections These screw joints must be also tightened with a tightening torque specified in the following table (see chapter 9.1.1).
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BD 600 S
9.1.1

Dimension Tightening torque MA [Nm] 12.9 16 38 76 8.8 9 10.9 13 32 63 A450 3 6 A470 2.4602 6 15 30 52 M 6 M 8 22 44 76 M 10 M 12 M 16 M 20 M 24 M 30 M 36 M 42 M 48 12 21 53 109 269 521 900 131 325 630 187 364 628 128 248 320 438 764 103 178 355 618 988 1 088 2 170 3 783 6 045 9 109 1 252 2 183 3 488 5 255 1 794 3 128 4 999 7 533 1 221 1 839 1 489 Table: Tightening torques for screws with heads according to DIN 912, 931, 933, 970, 971, etc. Type of screw / nut
Tightening Torques for Screw Joints
Size M16 M16
Tightening torque MA
Collar nuts at manhole cover of vessel Fixing screws and nuts at sightglass of vessel
Table:
60 Nm 60 Nm
Tightening torques for other screws
The torque details specified in the assembly drawings or in the assembly instruction must be considered under all circumstances.
The screw joints with specified torques must not be provided with spring washers!
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BD 600 S
9.1.2 Target
It is necessary to apply lubricating paste during the assembly of a screw connection for the following reasons: To reduce the risk of seizure of the screw connection. To adjust constant friction parameters in order to ensure that the correct preload is applied during the tightening of the screw connection.
Use of lubricating paste
Field of application
Always observe any instructions given in the drawing regarding the use of Loctite or lubricating paste independent of the following chart! Bolts Stainless steel up to M24 Lubricating paste to be used ? yes from M24 yes Small thread reach (< 0.8*diam.) no Base metal up to M24 no From M24 yes
The lubrication of screw connections can be omitted in very soft connections (e.g. with soft seals)!
Notes on application
Generally, the instructions given on the corresponding data sheets are to be observed The lubricating paste used in the factory, Klber, Type UH1 96402, is suitable for foodstuff and pharmaceutical applications The contact surfaces as well as the threads and head contact surfaces must be free from grease and oil and also free from contamination After cleaning, use a brush or a sponge to apply a thin coat of assembly paste to the first thread turns and especially the head contact surface
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BD 600 S
9.1.3 Use of Liquid Plastic (Loctite) for Screw Locking General
Loctite products are liquid singlepack plastic materials for securing, fixing and sealing of metal connections. The chemical conversion into a nearly hard product is achieved by separation from the atmospheric oxygen and upon contact with the metal. After complete hardening the liquid plastic material is of an excellent resistance against water, lubricants, fuel, hydraulic agents and most chemicals except acids and liquors of high concentration.
Field of application
see chapter 9.1!
Application of Loctite
Clean surface by wiping or blowing or preferably by acetone or isoparaffin.
Do not use any drycleaning spirit, nitrolic dilution or similar! As soon as the parts to be connected are completely dry, apply the products as a closed ring on the screw thread Apply on the female thread where blind holes are concerned; otherwise the product will be pushed out by screwingin Tighten the threaded joint by the specified tightening torque and wait for curing time. During the curing time the parts must not be touched and threaded connections not retightened any more.
Curing time

Loctite Product No. Gap in mm (Dd):2 638 270 243 245 max. 0,25 0,05 0,15 0,05 M36 M80 pref. Pressure shearing strength TD in N/mm2 Viscosity in mPas Chemical Basis Hardening 16 30 11 20 6 14 6 14 1500 3000 400 600 th 200 400 th 550 1000 Methacrylatester 3 upon separation from air and contact with metal (anaerobic) 15 30 12 15 30 12 30 60 12 Ready to touch at ambient temp. min. Final stability steel / steel for passive material h 12 5 2 with activator 7471 (T) min Temperature resistant Soluble 30 60 5 30 60 10 20 20 30 35 with activator 7649 (N)min 55 to +100 C difficult difficult difficult difficult th = thixotropic Operating Instructions, revision 0 Sales Order No.: 37000881 Serial No.: 60001556
The curing times can be seen from the following table. They refer always to 20 degree Celsius and usual structural steel.
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BD 600 S
The curing time will be reduced for active metals like brass or copper. The curing time will increase, however, for natural passivated metals (e.g. stainless steel, aluminum) and chemically passivated metals (e.g. cadmiumplated, chromiumplated). At ambient temperatures of 10 15 degree Celsius the hardening will also be slow and the polymerization stops even at approx. 0 degree Celsius. For this reason the use of activator is advisable in these cases and local heating up of the places concerned to 80 120 degree Celsius.
Use of Activators
Use activator type T or N for the types 638, 245, 270 and 243 from Loctite (7471: ref. 168495 / 7649: ref. 168505) Apply activator on connecting part Apply Loctite
Disassembly of a connection secured by Loctite

In case the bolt cannot be unscrewed by wrench, heat the connection up to approx. 200 degree Celsius (e.g. by hot air blower or welding torch) and disassemble immediately because the original resistance is obtained again by cooling down.
Risk of burning by hot metal! Use heat protective gloves! Risk of explosion of flammable mixtures! Check in time if explosive mixture is concerned! Material may be damaged by heating up!
Replacement of Loctite Securing

Remove product residues preferably by wire brush or screw tap
Do not increase thread clearance by cutting! Clean connection. Apply new Loctite.
Stability
The stability of the connection secured by Loctite, is maintained for approx. three years. The pot life of the products is approx. 12 months max. unless otherwise stated elsewhere on the package.
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BD 600 S
9.2 Installation of Sealing Rings
The contact and sealing surfaces must be absolutely smooth and must not show any damages nor contamination. The dimensions and the peaktovalley height of the sealing surfaces must be in strict conformity with the specifications. Rotating sealing surfaces which are finished, must be free of twisting. For seals with sealing edge and sealing lips respectively, the position of the sealing edge must be considered as shown in the corresponding assembly drawing.
Fig. 6: Assembly instruction for seals with sealing edge and lip respectively Use mounting spindle or sleeves where adverse mounting conditions are concerned (see fig. 7)
Fig. 7: Adverse mounting conditions Avoid sharp edges during assembly, cover threads and similar. Expand sealing lips of shaft sealing rings similar Fig. 7 in PTFE materials by hand or soft spindle before assembly. Avoid scratching at the sealing lip Use suitable lubricant before assembly on the sealing ring and the shaft Sealing rings in PTFE material can be expanded easily and formed back again by heating in oil or hot water up to 80 120 degree Celsius. Preform small, inside sealing rings carefully without buckling (see Fig. 8) and install then (see Fig. 9).
Fig. 8: Preformed sealing ring Operating Instructions, revision 0 Sales Order No.: 37000881 Serial No.: 60001556
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BD 600 S
Fig. 9: Assembly of preformed sealing ring Assemble outside sealing, relatively rigid sealing rings by mounting spindle as shown in Fig. 10 and form back by calibrating sleeve as shown in Fig. 11. These tools shall be made in suitable plastic material.
Fig. 10: Use of a mounting spindle
Fig. 11: Use of a sleeve
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BD 600 S
9.3 Mounting Instructions for Sealing Cord, type DE and DF
Structure
The sealing cord contains due to the manufacturing process pure virginal PTFE of stretched fibre structure. However, its surface is soft enough to compensate any unevenness and roughness of the contact surfaces by minimum force. The sealing cord is provided with an adhesive strip to facilitate the fitting operation.
Technical Data
Material Allowed temperature range of use pure virginal PTFE of stretched fibre structure with an adhesive strip to facilitate the fitting operation 240 C to +270 C, for a short time up to +310 C (33 K to 543 K, for a short time up to 583 K)
Chemical resistance Resistant to all media pH 0 to 14, except molten or dissolved alkali metals as well as elementary fluorine at high temperatures and pressures Physiological compatibility Pressure resistance Tensile strength Physiologically compatible at a permanent temperature range of use (260 C) according to BG Nr. 21 up to 250 bar (depending on operating parameters and fitting conditions) approx. 50 N/mm2
All details refer to pressed material.
Fitting operation
Clean the contact surfaces and keep them dry and free of grease Remove covering strip of adhesive strip from sealing cord and glueon the sealing cord starting at a screw hole Cross the two ends at a screw hole and cutoff the sealing cord (see fig. 12)
Fig. 12: Crossing the ends of the sealing cord Operating Instructions, revision 0 Sales Order No.: 37000881 Serial No.: 60001556
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BD 600 S
Additional mounting auxiliaries
Use oblique cutting when lined parts or parts sensitive to tension are mounted (see fig. 13)
1. Clean the contact surfaces and keep them dry and free of grease 2. Remove covering strip of adhesive strip from sealing cord and glueon the sealing cord starting at a screw hole 3. Cut the beginning obliquely, length = approx. two times width
4. Close the sealing ring 5. Glue the end above the beginning piece
6. Cutoff the end in excess flatly by a knife
7. Finished seal with oblique cutting
Fig. 13: Sealing cord with oblique cutting Double the sealing cord when the contact surfaces are irregular or damaged
68
BD 600 S
Install the sealing cord wavelike or install an additional supporting ring resp. to avoid a tilting of the flanges (see fig. 14)
Fig. 14: Wavelike installation of the sealing cord
Dismantling
Remove the sealing cord simply by taking it off.
69
BD 600 S
9.4 Protection of Surfaces of High Quality
Whenever assembly work is carried out at surfaces of high quality, all damages to the surface must be avoided. The following advice is to be considered in this respect: Use only new and suitable tools. Place a protecting support between the surface and the tool. Wrench Support
Fig. 15: Protection of the surface against damages Place a support between the bolt and the tool.
Support
Fig. 16: Protection of the bolt against damages
70
BD 600 S
9.5 0000 Helix Dryer BD 600 S
Drawing No.: 67000000.507 Item No.: 2915103 Revision: 2
9.5.1
Bill of Materials
Item No. Designation 67000000.507 67011000.506 67020000.506 67101000.001 DN200, T 211A 67182000.008 PTFE 67181001.006 TYP 125A FD M12X 35 ISO4017 1.4404 316 / FEP A470 FFKM ISOLAST J9515 DN51 ISO2852 TYP SH, 2 EDELEX 20 DH TR24 ER2AFH70F0 TA50PP 1.4408 PTFE 24V 20W SS 1.4469 316 L 316 L Standard Material
Pos. Quantity
2915103 HELIX DRYER BD 600 S 1 2 2,1 3 5 6 6,1 8 8,1 8,2 1 1 1 1 1 1 1 1 4 1 PC(S). 2906863 VESSEL PC(S). 2906862 MIXING UNIT PC(S). 2913262 PURGE GAS UNIT PC(S). 2717670 SHUTOFF FLAP PC(S). 7008289 BLOW OFF FOR FILTER PC(S). 2718156 FILTER PC(S). 2906897 FILTER CAGE PC(S). 2715853 SAMPLING VALVE PC(S). 0423853 HEXHEAD BOLT PC(S). 2716565 ORING
10
PC(S). 5146451 PRESSURE TRANSMITTER PC(S). 2709049 CLAMP, AC PC(S). 2709048 SEAL PC(S). 5140597 SIGHT GLASS LAMP PC(S). 5145595 TEMPERATURE TRANSMITTER PC(S). 5144412 CLAMP BOLTING 3/4 6MM PTFE PC(S). 2718331 SET OF PLATES PC(S). 2911534 GROUNDING
10,1 1 10,2 1 11 12 1 1
12,1 1 20 21 33 34 35 1 1 1 1 1
99920200.001 8125/20612 8125/10412 DN50 SS SS 316L
PC(S). 5143410 TERMINAL BOX EXI, (236*176*91) PC(S). 5142723 TERMINAL BOX EXE, (170*112*91) PC(S). 5146452 PRESSURE TRANSMITTER
71
BD 600 S
72
BD 600 S
9.6 1010 Purge gas unit for mechanical seal
9.6.1
Bill of Materials
Item No. Designation 2913262 PURGE GAS UNIT 67101000.001 1.4404 Standard Material
Pos. Quantity 1 2 5 1 1 2
PC(S). 2712577 PRESSURE REGULATOR PC(S). 2712578 PRESSURE GAUGE PC(S). 2701820 CLAMP BOLTING
73
BD 600 S
74
BD 600 S
9.6.2 Function
The purge gas unit is used to provide gas to the mechanical seal.
Never run the dryer without supply of purge gas to the mechanical seal! Details on pressure are given in chapter 3.10.
75
BD 600 S
9.7 1810 Vapour filter
N4.1
N4.3
N4.2
76
BD 600 S
9.7.1 Function
The vapors are drawn off via a filter cartridge that projects into the vessel. The cleaning of the filter cartridge takes place using a surge of nitrogen from the receiver. The cleaning interval depends on the dust charge of the vapor and is determined during the commissioning. The removal of the filter is described in chapter 6.8.
77
BD 600 S
9.8 1820 Blowoff for vapour filter
9.8.1
Bill of Materials
Item No. Designation 7008289 BLOW OFF FOR FILTER 67182000.008 Standard Material
Pos. Quantity
1 2 5 6 7
1 1 1 1 1
PC(S). 2707068 PRESSURE LINE ACCUMULATOR PC(S). 2717192 DIAPHRAGM VALVE PC(S). 0478749 LOCKING SCREW PC(S). 0104817 BOLTING PC(S). 0104815 STUD PVDF A470 1.4571 1.4571
78
BD 600 S
79
BD 600 S
9.8.2 Function
The vapors are drawn off via a filter cartridge that projects into the vessel. The cleaning of the filter cartridge takes place using a surge of nitrogen from the receiver. The cleaning interval depends on the dust charge of the vapor and is determined during the commissioning. Besides the interval control a differential pressure dependent cleaning is recommended. The blowoff unit for the vapour filter comprises two units: Nitrogen buffer receiver (1) Diaphragm valve (2) for cleaning the filter cartridge Details on pressure and flow are given in chapter 3.10. The nitrogen buffer receiver has be installed near to the dryer. The nitrogen supply from companys pipe network is connected to nitrogen buffer receiver (1) and the valve outlet connection is connected to the blowoff connection at the vapour filter. In normal position, the diaphragm valve (2) is closed. The nitrogen buffer receiver is filled with nitrogen. When the diaphragm valve (2) is energised, then the valve opens and the nitrogen in the nitrogen buffer receiver (1) is led to the valve outlet connection. This results in a surge of nitrogen to blowoff the vapour filter. The blowoff should be done through cycled opening of the diaphragm valve (2). Blowoff time: approx. 2 sec, afterwards pausing time. During the pausing time, the nitrogen buffer receiver is refilled.
The operator is responsible for the observance of the maximum permissible operating parameters (pressure, temperature)! He must ensure these are observed by installing appropriate safety equipment!
80
BD 600 S
9.9 9202 Grounding
9.9.1
Bill of Materials
Item No. 2911534 2016870 0513098 0464697 0500884 0530364 0533759 Designation GROUNDING GROUNDING PLATE NOTCHED PIN PIN HEX.NUT DISC SERRATED LOCK WASHER 99920200.001 1.4301 1.4303 A470 A470 140 HV A4 A4 Standard Material
Pos. Quantity 1 2 3 4 5 6 1 4 1 3 3 2 PC(S). PC(S). PC(S). PC(S). PC(S). PC(S).
81
BD 600 S
82
BD 600 S
9.9.2 Function
The grounding is provided for potential compensation between the parts connected thereto. At the supporting lug there is one two grounding symbol (1) for connection of an insulated cable. The user must connect here an insulated cable to building.
Take care for right connection of the insulated cable!
83
BD 600 S
10
10.1
Spare part stock

General
The stockkeeping of the most important spare and wear parts at site is condition for the reliability and safe functioning of the machine. For ordering spare parts please refer to the spare part list or our spare part quotations. The assembly drawings stated in the spare part list and the spare part code mentioned below should be used for further information.
The spare part drawings can be found in chapter 9! Warranty will be granted only for the original spare parts of our supply. We would like to point out that the original spares which are not supplied by us, have not been inspected nor released by us. ANDRITZ KMPT GmbH will not accept any liability or warranty for damages caused by the use of parts and accessories other than original. The spare parts of our make or foreign make are often subject to special manufacturing and supply specifications and the spares supplied by us are always of the latest state of art and in conformity with the most recent legal regulations. Sealing rings are subject to natural ageing, thus limiting storage time and service life. The sealing rings supplied by ANDRITZ KMPT GmbH always have a minimum durability of three years. Please advise the following details in your spare part orders: machine sales order number machine type serial number designation of the part item number quantity [ 37000881 ] [ BD 600 S ] [ 60001556 ]
see spare part list
10.2
Spare part code ETS
All items in the spare part list are marked by a code 1 through 4 in the last column called ETS. These codes represent: 1 2 3 4 = = = = wear parts and parts resp. to be replaced for maintenance spare parts of an expected operating time up to 2 years spare parts of an expected operating time above 2 years spare parts, not usually required.
84
BD 600 S
10.3 Spare part list
Further parts list of installed components can be found in chapter 12! Pos. Quantity Item No. Designation 2915103 HELIX DRYER BD 600 S 3 6 8 8,2 1 1 1 1 PC(S). 2717670 SHUTOFF FLAP PC(S). 2718156 FILTER PC(S). 2715853 SAMPLING VALVE PC(S). 2716565 ORING TYP 125A FD 67000000.507 DN200, T 211A 1.4469 PTFE FFKM ISOLAST J9515 DN51 ISO2852 TYP SH, 2 EDELEX 20 DH TR24 ER2AFH70F0 DN50 1.4408 PTFE 24V 20W SS 316L 4 2 2 Standard Material ETS
316 / FEP 4
10
PC(S). 5146451 PRESSURE TRANSMITTER PC(S). 2709049 CLAMP, AC PC(S). 2709048 SEAL PC(S). 5140597 SIGHT GLASS LAMP PC(S). 5145595 TEMPERATURE TRANSMITTER PC(S). 5146452 PRESSURE TRANSMITTER 2913262 PURGE GAS UNIT
4 4 2 4 4 4
10,1 1 10,2 1 11 12 35 1 1 1
67101000.001 1.4404 4 4 67182000.008 PVDF 4
1 2
1 1
PC(S). 2712577 PRESSURE REGULATOR PC(S). 2712578 PRESSURE GAUGE 7008289 BLOW OFF FOR FILTER
PC(S). 2717192 DIAPHRAGM VALVE
85
BD 600 S
11 Drawings
You will find here the following drawings: Item No. 2915103 00020574 Designation GENERAL ARRANGEMENT DRAWING BD 600 S PIPING AND INSTRUMENTATION DIAGRAM (P&ID) Rev. 2 2
67000000.507
86
3
BC) 132
1
)ENT INERTIN>
#an'$% FEED
B)132
!20 (5ar+ 4ro( in$rt$, ,r'(s

B ) 251
8
E & 150
B)251
CIP
&)150
B ) 150
)a1''( @nit
2
2...3 5ar+
B ) 155
B)155
B)150
A!"#PT
C%i$nt
PT 134 A!"#PT C%i$nt P E 134 N2.1
P'r+$ +as 'nit i4 +as %'5ri1at$, s$a%in+

PI
N2
&)130
B ) 130 N1-
#03
T 106
138
N1-.1
B)130
PC)138
N18
E#ER>ENCA )ENT
P)141
3...6 5ar+
BC) B ) 156
B)156
131
N18.2 N18.1
0 5ar+
B)131
P)131 &)140
/ot 0at$r
A!"#PT
C%i$nt
Fi%t$r 5%o0 o44

PI 143
1 B2
B ) 144
PC)143
N20
N20.1
B ) 201
8 O 201
8 C 201
t$a(
N-.1
C
/$atin+ 0at$r
&)200
N8.4 8 O 200 8 C 200 B ) 200 N3.2 N3.1 N3 N4.1 N4.3 N4.2 N2
P E 135 PT 135
B)201
B ) 202
8 O 202
8 C 202
(a=. 3 5ar+ air

N-.2
B)200
N16.1
N16.2
N16.3
B)202 FO
B ) 203 8 O 203 8 C 203
(a=. 3 5ar+ /$atin+ 0at$r

N8.4 TI 207 8 O 207 8 C 207 B ) 207 N13 TT 106
(a=. 3 5ar+ 1oo%in+ 0at$r

N-.3
B)203
B)207
(a=. 3 5ar+
NB ) 208 TT 8 O 208 8 C 208
(a=. 3 5ar+
/ot 0at$r
B
1oo%in+ 0at$r NOTE 7
Insta%% (a=. 1( ,istan1$ to ,ry$r2 (in 1 3 5ar+ 4or $44i1i$nt 5%o0 o44 n$$,$, 2 Ro't$ CIP 3i3$0or; 0it/ 4a%%
N8.2 N8.3 8 O 204 8 C 204 B ) 204
B
N15 TT 103 N-.3
105
B)208
B)204 B)206 FO
B ) 8 O 205 8 C 205 B ) 205 8 O 206 206
N8
N11
N12
T/is ,ra0in+ in1%',in+ a%% t$1/ni1a% ,ata2 is o'r 3ro3$rty. T/$ ,ra0in+ an, any 1o3i$s t/$r$o4 s/a%% 5$ r$t'rn$, on r$6'$st. N$it/$r t/$ ori+ina% ,ra0in+ nor a 1o3y t/$r$o4 s/a%% 5$ ,is1%os$, or 1o(('ni1at$, in any ot/$r 0ay to t/ir, 3arti$s.
(a=. 3 5ar+ air
==== ==== 17.0-.2013 10.06.2013 1-.12.2011
==== ==== Int$rna% #$$tin+ 17t/ o4 $3t$(5$r 2013 Int$rna% #$$tin+ 3r, o4 ?'n$ 2013 First E,ition
==== ==== &'(($% &'(($% Dani$%s
==== ==== B%ass >$+$n4'rtn$r &'(($%
==== ==== )o$+$%$ Dar+$ )*+$%$
3 3 2 1 0
R$:.
&)1-0
8 C 1-0 N10.1
8 C
206
Con,$nsat$
N8.1
4 P'r+$ +as 'nit 4or ,is1/ar+$ :a%:$2 (ay 5$ ,i44$r$nt ,$3$n,in+ on 5ran,
207
(a=. 2 5ar a5o:$ 3r$ss'r$ insi,$ :$ss$%2 5't (in. 3 5ar
B)205
&)102
CD
N10
&) 101
Dat$
D$s1ri3tion<C/an+$s
A't/or
1/$1;$,
a33ro:$,
5 To 5$ insta%%$, a3ro=. 1( a5o:$ s$a%in+ 6 R$%$as$ 4or 4i%%in+ < ,is1/ar+in+ Fs0it1/ 5o= 5y An,rit9D 7 )a%:$s ar$ 0it/o't o3$n<1%os$, si+na%2 'n%$ss s/o0n 8 Insta%% n$ar 4%an+$ N4.2 - Insta%% 3i3in+ ,o0n0ar,s or 0it/ an an+%$ ot/$r0is$ CIP %i6'i, 0i%% ,rain t/$ 3i3in+ B)146 &)146 6
#a1/in$ Ty3$7 i9$7 Nor(7
BD 600 DIN A2 I A!"#PT
D$s1ri3tion7 C'sto($r7 C'sto($r!R$4.7 ANDRIT8!Or,$r7 I,$nt!No.7
P&ID BD stationary NORTEC I!2250 37000881 00020574 Pa+$ 1 4ro( 1
B ) 146
FI 146
Identifikation von Instrumenten / Instrument identifikation F

A C D E F G H Analyse Leitfhigkeit Dichte Elektrische Gre Durchfluss Lnge Hand Anzeige Zeit Stand Feuchte Druck (PD: Differenzdruck) Qualitt Strahlung Drehzahl Temperatur Vibration Gewicht Automatisiert Position
Symbole / Symbols
Handventil manual valve Kompensator compensator
1. Buchstabe / 1. Character
Analysis Conductivity Density Electrical Flow Length Hand Indicating Time Level Moisture Humidity
Pressure (PD: pressure difference)
2. oder 3. Buchstabe / 2. or 3. Charakter

HV
A C D E F
Alarm Regelung Differenz Element
Alarm Controlling Differential Element

XV HV
Handventil stetig einstellbar Regelventil automatisiert Regelventil Druck selbstttig
manual valve continously adjustable control valve automated manual valve pressure self adjustable
Kompenssator mit Schnellkupplung
compensator with quick connector
Anschluss allgemein
general connection
PCV
Anschluss Flansch
connection flange
G H I K L M P Q R S T V W X Z
HV V XV HV
Absperrhandventil
manual isolation valve
E
I K L M P Q R
Anschluss Schnellkupplung
Lokales Instrument Funktion Instrument (Identifikation) Messkreis Funktion, die lokal sicherheitsgerichtet realisiert wird
connection quick connector

local instrument function instrument (identification) Loop-no.
Prozessventil gesteuert
process valve controlled
XX yy
XSV
Magnetventil / Pilotventil
solenoid / pilot valve
local safety function
Rckschlagamatur
non-return valve
Funktion, die in der Steuerung realisiert wird
function made within control unit
Quality Radiation Speed Temperature Vibration Weight Automated Position
Aufzeichnung Schalter / Ein - Aus Transmitter Ventil
Recording Switch / On - Off Transmitter Valve
PSV
berdruck Ventil
Energielos ~ Auf ~ Zu ~ In Position
overpressure valve
without energy ~ open ~ closed ~ stay put
Funktion, die in der Steuerung sicherheitsgerichtet realisiert wird
safety function made within control unit
S T V W X Z
D
KMPT Client
*)NO NC STAY PUT
Liefergrenze
limit of supply
XV
Klappe gesteuert
flap controlled
Klappe manuell
manual flap
Filter allgemein
filter general
Ergnzungsbuchstabe / Additional Character
H L O A
Hoch / Max Niedrig / Min Offen / Ein Zwischenposition
High / Max Low / Min Open / In Intermediate position High High / Max Max Low Low / Min Min Closed / Out
Kerzenfilter
cartridge filter
Berstscheibe
bursting disc
Schauglas
*) wenn nicht angegeben: NC if not indicated: NC
sight glass
HH Hoch Hoch / Max Max LL C Niedrig Niedrig / Min Min Zu / Aus
B
01 29 30 49 50 59 60 69 70 79 80 89 Zentrifuge N2 / Entlftung CIP N2 / HCR Filtration Peripherie Feststoff / Austrag
Messkreis-Nummern / LOOP numbers System Zentrifuge / centrifuge system

Centrifuge N2 / Vent CIP HCR Filtration Periphery Discharge 190 199 Feststoff / Austrag Discharge
B
Dryer N2 / Vent CIP Blow off / Seal --Diese Zeichnung, einschlielich aller technischen Angaben, ist unser Eigentum. Sie ist auf Verlangen, einschlielich angefertigter Kopien zurckzugeben. Sie darf Dritten weder im Orginal, noch in Kopie oder auf eine andere Weise gleich welcher Art - zugnglich gemacht werden. Mitteilung des Inhalts nicht gestattet.
System Trockner / dryer system

101 129 Trockner 130 149 N2 / Entlftung 150 159 CIP 160 169 Abblasen / Dichtung 170 179 --E D C B A
Rev. nderung
xxxx xxxx xxxx xxxx xxxx Datum: Name:

xxxx xxxx xxxx
xxxx xxxx xxxx xxxx xxxx
Datum
Bearbeiter
Datum
Geprft
Bearb.: Gepr.: Freig.: Norm: Format:
xxxx xxxx xxxx
PID System: KMPT-Auftrag: Kunden-Ref.:

Zeichnungsnr.: Zeichnungssachnr.:
xxxx xxxx xxxx

xxxx xxxx
Seite 2 von 2
90 99
Heiz-/Khlaggregat / heating unit

200 249 250 300
VAC-Station / vacuum station
xxxx DIN A2
BD 600 S
12 Separate Manuals
You will find on the next pages the following manuals: No. 1 2 3 4 5 6 7 8 9 10 Item No. Manual 2906863 VESSEL 2906862 MIXING UNIT 2707068 PRESSURE LINE ACCUMULATOR 2717192 DIAPHRAGM VALVE 2718156 DUST FILTER ELEMENT 2715853 SAMPLING VALVE 2712577 PRESSURE FILTER REGULATOR 2712578 PRESSURE GAUGE 2717670 SHUTOFF FLAP FDA certificates Type 67 011000.506 67 020000.506 CRVZS5 690 20D 7205E11/N + 0324 2M1474 41C1050410 Polyester fleece with PTFE membrane, #7025 TYP 125A FD B3000 02BHSD 07 232.30, NG63 0 4 bar DN200, T 211A Tag No. M03, TT108 B2 XSV144 HV101, HV102 PCV138 PI138 HV190 ZSC190
87
BD 600 S
12.1
Vessel
SPECIFICATION ================== Item No.: 2906863
Ausfhrung Konisches Unterteil mit angeschweitem Kugelboden Deckel, verschraubt mit Unterteil Unterteil ist beheizbar mit Doppelmantel und isoliert Deckel ist beheizbar mit Halbrohren und isoliert Filterdom ist beheizbar mit Doppelmantel und isoliert Auslegungsdaten siehe Kapitel 3.3 Auslegungsgrundlage Werkstoff produktberhrt nicht produktberhrt produktberhrte Dichtungen Schrauben Oberflche produktberhrt nicht produktberhrt
Design Conical bottom part with welded on ball part Cover bolted to bottom part Bottom part is heatable by double shell and insulated Cover is heatable by halb pipe coils and insulated Filter dome is heatable by double shell and insulated Design data see chapter 3.3 basis of design Material in contact with prodcut not in contact with prodcut Sealings in contact with product Screws Surface in contact with prodcut not in contact with prodcut Ra <= 0.8 m Ra <= 1.6 m 316L 1.4404 / 316 L / 304 316L / 1.4404 FEPV A470 PED 97 / 23 / EC (AD 2000)
Heiz, Halbrohre, Doppelmantel Halb pipe coils, double jacket
88
BD 600 S
12.2
Mixing unit with drive and sealing unit
SPECIFICATION ================== Item No.: 2906862
Rhrwerk Wendelsegmente mit Ankerrhrer Werkstoff Oberflche, produktberhrt Oberflche, nicht produktberhrt Drehrichtung Durchmesser der Rhrwerkswelle Antriebseinheit Getriebe + Motor Drehzahl Empfohlene Betriebsdrehzahl Motorleistung Werkstoff der Lagerlaterne Dichtungseinheit Gleitringdichtung, doppeltwirkend, gasgeschmiert Werkstoff der Gleitringe, produktberhrt Werkstoff der Gleitringe, atmosphrenseitig Werkstoff der produktberhrten Dichtungen Werkstoff der nichtproduktberhrten Dichtungen Versorgungssystem fr Dichtungseinheit siehe Kap. 9.6 Medium Zubehr mit zwei mitrotierenden CIP Spldsen
Mixing Unit Segmented helix with anchor mixer Material in contact with prodcut not in contact with prodcut Sens of rotation Diameter of agitator shaft Drive Unit Gear + Motor Speed Power of motor Material of bearing housing Sealing Unit Mechanical seal, doubleacting, gas purged Material of seal ring, productwetted Material of seal ring, atmospheric Material of sealings in contact with prodcut Material of sealings not in contact with prodcut Purge unit for sealing unit see chap. 9.6 Media Accessories with two rotating CIP rinsing nozzles Stickstoff / Nitrogen SiC / SiC SiC / C FEPS EPDM 5 50 1/min 7.5 kW / 380 V / 60 Hz / IP55 1.4301 Recommended operating speed 50 1/min (at 60 Hz) 316 L Ra <= 0.8 m Ra <= 1.6 m only clockwise (seen from the top) 80 mm
89
BD 600 S
12.3
Pressure line accumulator
90
BD 600 S
12.4
Diaphragm valve
91
BD 600 S
12.5
Dust filter element
92
BD 600 S
12.6
Sample valve
SPECIFICATION ================== Item No.: 2715853 Type: 125A FD
93
BD 600 S
12.7
Pressure filter regulator
94
BD 600 S
12.8
Pressure gauge
95
BD 600 S
12.9
Shutoff flap
96
BD 600 S
12.10 FDACertificates
FDA certificates can be found in this chapter and also in the other chapters of chapter 12!
12.10.1 List of parts with FDAcertificate

The assembly drawings stated in the list should be used for further information.
The assembly drawings can be found in chapter 9! Pos. Quantity Item No. Designation 67000000.507 67011000.506 see chap. 12.1 see chap. 12.2 see chap. 12.9 PTFE see chap. 12.5 Standard Material FDA certificate
2915103 HELIX DRYER BD 600 S 1 1 PC(S). 2906863 SEALINGS AT VESSEL PC(S). 2906862 SEALINGS AT MIXING UNIT PC(S). 2717670 SHUTOFF FLAP
67020000.506
DN200, T 211A
PC(S). 2718156 FILTER
PC(S). 2715853 SAMPLING VALVE
TYP 125A FD
316 / FEP see chap. 12.6 FFKM ISOLAST J9515 PTFE 2
8,2
PC(S). 2716565 ORING
10,2 1
PC(S). 2709048 SEAL 7008289 BLOW OFF FOR FILTER 67182000.008
PC(S). 2717192 DIAPHRAGM VALVE
PVDF
see chap. 12.4
97
BD 600 S
12.10.2 FDAcertificates
98
BD 600 S
2
99

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OPERATING INSTRUCTIONS

1 x Helix Dryer BD 600 S File 1, Mechanics

Revision: Sales Order Number: Serial Number: Purchase Order Number:

0 37000881 60001556 I2250

File 2 Electrical Part

Description of the Dryer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Transport, Settingup and Assembly . . . . . . . . . . . . . . . . . .

Commissioning and Operation . . . . . . . . . . . . . . . . . . . . . . . .

Inspection and Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . .

Trouble shooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Description of Components . . . . . . . . . . . . . . . . . . . . . . . . . . .

10 Spare part stock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11 Drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Separate Manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Telephone and Fax:

Description of the Dryer

Components of the Dryer

Vapour filter Manhole cover Vessel cover

Helix Sample valve Anchor Discharge valve Temperature measurement

Rinsing medium (CIP)

Fig. 1: Schematic Design of a Dryer

Drive for the mixing unit

Orings inside sealing chamber EPDM

Refer to General Arrangement Drawing:

Fig. 2: Dimensions of the dryer

ISO 228 ISO 228

N19.1 Outlet of nitrogen

Flow rates are partly process dependent. Description

N2.1 N3.2 N4.1 N4.2 N4.3 N8, N9

connected to vacuum unit 2 bar 3.5 m3/h 3 m3/h max. 145C

connected to heating circuit 1

approx. 1 Nm3/h per 1 m3 filling

flow depends on product Installation of flow meter is necessary

Supply of heating agent to vessel cover and filter housing

connected to heating circuit 2

intermittent 0.3 Nm3/h

Operation of the Machine

Maintenance and Assembly

Requirements put to inertising

Transport, Settingup and Assembly

Fig. 4: Transport of dryer

Removal of Transport Locks

Guidelines for laying pipes, hose connections and valves

Commissioning and Operation

The product is discharged, overpressure control is active (optional).

The dryer is stopped, the inerting is deactivated.

The heatedup prodcut can be cooled before discharging (option).

Manual cleaning and inspection

Welding at the machine is not allowed in general!

Inspection and Maintenance

Tightening Torques for Screw Joints

Size M16 M16

Tightening torques for other screws

Use of lubricating paste

see chapter 9.1!

Disassembly of a connection secured by Loctite

Replacement of Loctite Securing

Fig. 10: Use of a mounting spindle

Fig. 11: Use of a sleeve

All details refer to pressed material.

6. Cutoff the end in excess flatly by a knife