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HUMIDIFICATION SYSTEM
MANUAL
SINCE 1961
ement system
nag
c
ma
ified
er t
quality
Quality Policy
UKAS
CORE VALUES
Leading edge innovations
as way of life
CORE PURPOSE
To pioneer innovations by
identifying customer
needs & provide unique
solutions.
Preserves fiber length, improves strength and uniformity and reduces short fiber
content.
Eliminates moisture condensation which is a general problem with all other
moisturisation techniques.
3
4
5
6
Reduces pressing force required to make a bale which reduces strain on bale press
components thus reducing the wear and tear of the components.
Reduces power per bale as dry cotton requires more compression force and more time to
charge and to get Pressed inside the lint box.
Improves lint grade and appearance.
Dry cotton requires additional force to press it into a bale, this additional force causes
excessive tension on the bale ties or strips resulting in breakage of some strips or ties
during storage. Replacing these broken strips is an expensive process and this can also
lead to contamination of lint fiber which reduces the value of the lint cotto
Optimal lint slide capacity and allows correct/Adequate cotton to enter the press
box at each stroke of the tramper and hence correct density bale is obtained.
SYSTEM COMPONENTS
The Humidification system comprises of two important components as described below:
a.
b.
c.
d.
These lint slide are covered with hood arrangement to collect the used humid air and lint flue and return it
to lint flue rising of the battery condenser / Air separator. This is called as recycling of extra humid air
which improves efficiency of fuel consumption.
WORKING PRINCIPLE :
Exposing cotton lint to a stream of warm, humid air is the most effective method of humidifying cotton
gin. Typically, the warm, humid air is generated by a device HUMIDAIRE. This device comprises an air
heater in which oil-fired burner operates with an open flame in the stream of air to be humidified. The
stream of air passes through an air washer chamber in which recirculated water spray scrubs the heated
air, simultaneously cooling the air and evaporating the water. A supply of warm humid air is generated with
o
o
0
0
an air temperature between 120 to 160 F /45 to 70 C Dry bulb temperature and 70 to 100% relative
humidity.
The relative humidity of the air generated by the HUMIDAIRE device is regulated by independent control of
the dry-bulb (air) and wet-bulb (water) temperatures. The closer these two temperature are together, the
higher the relative humidity. Regulating the burner fuel valve controls the dry bulb temperature.
Regulating the butterfly valve for throttling water flow to the spray noozles in the air washer chamber
controls the wet-bulb temperature.
Hot Humid air is inducted in the lint on a lint slide with a set of stainless steel louvers at temperature
o
o
around 45 to 50 C.
Air inlet
screen
Outlet Hood
1
3
2
Breeze Overview
Gins around the world are opening their eyes
to the benefits of conditioning their cotton
with humidified air. The Breeze was designed
for growing gins getting their first taste of
moist air technology.
It has simple and reliable controls that
include graphically labeled selector switches
and a manually operated water valve.
Breeze
UNIT
DESCRIPTION
1
2
3
COLOUR
SMELL
pH VALUE
TURBIDITY
NTU
mg / Ltr
CONDUCTIVITY
ms/cm at 25 C
7
8
9
10
11
12
13
14
mg / Ltr
mg / Ltr as CaCO3
mg / L as Ca
mg / L as Mg
mg / L as Na
mg / L as K
mg / L as Fe
mg / L as Mn
15
CARBONATES
mg / Ltr as CaCO3
16
17
18
19
20
21
22
23
Bi - CARBONATES
SULPHATES
CHLORIDE
NITRATES
PHOSPHATES
FLORIDE
TOTAL SILICA
Oil & Grease
CHEMICAL OXYGEN DEMAND
(COD)
mg / Ltr as CaCO3
mg / L as SO4
mg / L as CL
mg / L as NO3
mg / L as PO4
mg / L as F
mg / L as SiO
mg / L
24
mg / L
REMARK
If Parameters
are not within
this range we
suggest the
customer to
source water in
line with the
parameters
recommended
Sl.
No.
(I)
(ii)
(iii)
Acidity, inorganic
Acidity, total mg of KOH/g, Max
Ash, percent by mass, Max
(iv)
(v)
(vi)
(vii)
(viii)
(ix)
(x)
Nil
To Report
0.01
0.30
48(3)
46
(3)
30C
150C
Not worse
than
No.1
85
95
Nil
Method of Test
P:2
To Report P:2
0.01
P:4/ISO 6245
0.30
P:8/ISO 10370
51(3)
46(3)
3 0C
150C
P:9/ISO 5165
D4737/ISO 4264
P:10/D 5949 or D 5950 or D 5985
Flash point
a) Abel0C
b) Pensky Martens closed cup(5)C,Min
(xi)
(xii)
Requirements
35
66
2.0 to 5.0
0.05
35
0
66C
2.0 to 5.0
24
P:20
P:21
P:25/ISO 3104
P:3
EN 12660
P: or P:32 /
D 4052 /ISO 3675 or
ISO 12185
(xiii)
(xiv)
(xv)
500
350
IP 336 or 4294(9)
ISO 14596 or Iso 8754/ P:83 / D 2785/ D 5433/
D 2622/ D 3120
(xvi)
0.05
-
200
60C
180C
6 0C
180C
24
820-860
820-845
P:110/ D 6371
1.5
25
11
460
460
ISO 12156-1
0.6
0.6
Annex B
IP 391 or EN 1296
RL.28/M
TYPE
OUTPUT (1)
MAX.
MIN.
kW
Mcal/h
kg/h
kW
Mcal/h
kg/h
90-166
76,5-143
7,5-14
Light oil
FUEL
-Net calorific value
kWh/kg
kWh/kg
kg/dm3
-Dersity
0
11.8
10.2(10.200kcal/kg)
0.82-0.85
0
-Viscocity at 20 C
OPERATION
NOZZLE
STANDARD APPLICATIONS
AMBIENT TEMPERATURE
COMBUSTION AIR TEMPERATURE
ELECTRICAL SUPPLY
number
IGNITION TRANSFORMER
delivery (at20 bar)
pressure range
fuel temperature
On-Off (min 1 stop each 24 hours). These burners are also fitted for the
continuous operation, if they are equippedwith the control box LANDIS
type LOK 16.250 A27 (interchangeable with the burner control boc
LANDIS LAL 1025).
Progressive two-stage (modulating by Kit).
1 (nozzle with return)
C
0
C max
v
Hz
rop
w
v
A
ELECTRIC MOTOR
PUMP
663M
166-332
143-286
14-28
V1-V2
L1-L2
kg/h
bar
0
C max
W max
0-40
60
230- +/- 10%
50 - single-phase
2800
300
220/240
2,4
230 V -2X5kV
1,9A - 30ma.
74
10 - 20
60
400
IP 44
dBA
B9/336 - 73/23-96/37-92/42
68
10
2.
3.
4.
5.
6.
7.
8.
9.
10.
11
Lift the Humidifier by means of chain or slings through the hole given on the base frame.
The centre of gravity of Humidifier is behind the base of spray chamber and hence lifting
the Humidifier shall be strictly done from the given holes otherwise the unit will tip over
resulting in damages. Humidifier should be put on foundation bolts on the floor as per
the G.A. Drawing supplied by BSIL. The water level should be checked at the top frame to
ensure that water level is 0-0. If the level is not 0-0 an appropriate packing is to be given
at the base after loosening of nuts and then the nuts shall be tightened.
Assemble careful the lint slid as per the match marking provided.
Assemble the SS arid in the lint slide as of shown in the drawing supplied by BSIL
Lift this lint slide by means of chains or slings and tighten it to the Air-seperator structure at one
O
end & to the Fiber pusher of the bale press at the other end so that the lint slide is at 45
inclination.
Lift the Fan by means of chains or slings and put it on the Foundation Bolts on the floor or
over the structure beneath the lint slide as per the drawing supplied by BSIL. The water
level should be checked at the top frame of the blower to ensure that water level is 0-0 if the
level is not 0-0 an appropriate packing is to be given at base after loosing of unit & then the bolts
shall be tighten.
Connect the Humidaire unit with the Fan by means of 7 connection ducting & Fasteners.
Connect the fan with the lint slide inlet for moist air using 12 connection ductings.
Lift the top hood cover of the lint slide by means of chains and slings & mount over the lint slide.
Match the holes and fasten it by appropriate fasteners.
Connect the recirculation fan with the outlet on the top hood by using 12
connection ductings.
Mount the Kicker roller and adjust for uniform clearances on both sides and tight the
bolts.
BAJAJ STEEL INDUSTRIES LIMITED
IMAMBADA ROAD, NAGPUR- 440 018. INDIA. Tel: +91-712-272 0071 ~ 80 Fax: +91-712-272 8050 / 272 3068
Parameter
Water Reading
To be taken from the water flow meter provided with the system
Diesel Reading
Fuel Pressure
Water Pressure
Air Temp - DB
Air Temp - WB
Rh of Humid air
Air velocity
Re-circualtion Fan
10
To be set at 30 to 60 Lit/Hr
11
Water Temp
12
Diesel Storage
13
Bale Moisture
12
13
14
FAULT
PROBABLE CAUSE
SUGGESTED REMEDY
Adjust or replace
Reset sequence controller
Adjust pressure switch or eliminate over pressure
Reset thermal cut-out
Close all switches - Check connections
Replace
8. Pump jam
9. Defective capacitor
10. Defective motor command control device
11. Defective Sequence Controller
12. Defective Electrical Motor
Replace
Replace
Replace
Replace
Replace
1. Flame Simulation
2. Photo cell short Circuit
3. Missing Phase
4. , Thermal cut-out trips
Adjust
Adjust
Adjust
See nozzle table
Replace
Adjust
15
Adjust or Replace
Replace
10
11
12
Replace or Clean
Suck water from tank bottom with separate pump
Tightened the connections
Feed burner with loop circuit
Increase
Clean
open
Add additive to fuel
Bring to same height as suction pipe
Tighten connection
Replace pump
Adjust head and fan gate
Replace
Clean or Replace
Adjust
Clean, tighten in place or replace
Increase
Adjust head and fan gate
Replace
See nozzle table
Tighten
Clean
Adjust, open air damper
Contact equipment manufacturer
13
14
15
Smoke in flame-DARK
YELLOW
16
17
Clean or Replace
16
PROBABLE CAUSE
POSSIBLE SOLUTIONS
Pump is faulty .
Pump suction filter is choked.
Water pipeline choked.
Water spray nozzles choked.
Replace
Clean
Clean
Clean
No water flow.
Check
Adjust
Adjust
Check and clean
Check and clean
Check and clean
Failure of atomization of
water at the nozzles to
desired droplet size.
Lack of humidification
No water flow
Insufficient air flow .
9
10
Pump reservior
overflowing
Deposition of scales of
Carbon in water
11 Higher moisture
percentage than
desired.
17
A) Fuel Consumption.
Fuel consumption should be checked periodically, as it may change due to change in properties of fuel,
wear of the nozzle etc.
Fuel pump inlet pressure should not be more than 22 kg/cm2 and nozzle return pressure should not be
more or less than 14 Kg/cm2. Ensure that the fuel temperature has been attended ie. 45 Deg C.
B) Purge
Ensure that the purge valve should be opened all the time to purge, minimum
20 ltr of water all the while unit is running. Clean the purge valve and the circulation tank after every 12
Hrs operations.
18
2.
Check the oil level from the oil level indicator in the reduction gear box. The oil of desired
grade shall be filled from time to time. Generally recommended grades for oils is VG-320
or 40. Moreover, oil should be changed in every 60 to 90 days of operation and also while
start of new operational seasons so as to increase the life of gear boxes due to impurities /
dust free oil for better working.
3.
Check proper alignment of drive periodically. This has to be checked at two points viz
level of sprockets on head pulley and gear box shall be straight. The two surfaces of
coupling shall be parallel. This shall be done to avoid any stoppages due to overheating or
change of coupling spider and breakage of chains.
4.
Lubrication of take up studs of kicker roller assembly shall be done with grease or rust
preventive. This will allow easy operation of take up.
5.
It is recommended that water, wet, dust and chaff shall not be permitted to collect
around inlet hood of the humidaire. This shall thus involve good housekeeping at all the
times to enhance the life of machinery.
6.
Check that the chain guard & drive guard has been installed before starting.
Fuel
The burner must be run with the fuel for which it has been preset i.e Diesel. Prior the supplying
fuel of the unit, clean the burner pipes thoroughly; install a filter to prevent the residues. Clean the fuel tank
before cleaning.
Electrical Supply
Make sure that electrical power supply used for connections corresponds to the specifications indicated on
rating plate. Make sure that burner is connected to efficient earth system in compliance with current safety
standards. The electrical system and all cable sections must be adequate to deliver the maximum observed
power value indicated on the rating plate.
19
Use only Industrial water / soft water / treated water as per the instructions mentioned in
this book .
2. Use SS pipes and fittings only .
3. Use only ball valves.
4. Proper supports to pipelines should be given to avoid stress on the valves.
5. Use only Breaded Hose pipes with flanged joints .
6. Fuel piping shall be throughly flushed before connecting to the heater.
7. All the pipelines for water and fuel shall be of standard make and the diameter shall be as
mentioned in our drawings.
8. Good housekeeping shall be followed to avoid any dust or dirt going into the system.
9. Good quality fuel as mentioned in this book shall be used for better results.
10. Cleaning of filter screens , nozzles shall be done periodically for better results .
11. Follow the starting and stopping steps of the Humidifier as mentioned in this book for
better results.
12. Draingae of water shall be done in soaking pits or sewer line.
Don't's 1.
2.
3.
4.
5.
6.
7.
Feed water tank should never be constructed out of cement concrete , as soft water will
absorb calcium and magnesium salts from cement and hardness will insrease.
Use of elbows and bends in supply line .
Use of smaller diameter pipes than as mentioned.
Drainage of water on the floor near to Humidifier.
Inspection glass shall not be removed while the burner is on.
Do not touch the conveying line of the moist air .
Turn on the burner without any fuel or water .
20
21
Shell
Blower
Control Panel
Kicker Roller
Motor
Water Pump
Water Circuit
Fuel Pump
BURNER ASSEMBLY
BURNER ROD, FLAME
HEAD, ELECTRODE,
DIFFUSER PLATE,
PHOTOCELL.
Equipment
SR
Operator
Operator
Operator
Operator
Operator
Operator
Vibration of pump
Leakages from
Piping/valves/Flanges
Operator
Daily
Operator
Daily
Daily
Daily
Daily
Operator
Operator
Operator
Operator
Foundation Bolts
Vibration
IMAMBADA ROAD, NAGPUR- 440 018. INDIA. Tel: +91-712-272 0071 ~ 80 Fax: +91-712-272 8050 / 272 3068
Weekly
Operator
Operator
Operator
Operator
Operator
Operator
Operator
Operator
Weekly
Weekly
Daily
Daily
Daily
Daily
Daily
Operator
Operator
Operator
Operator
Operator
Operator
Daily
Weekly
Weekly
Weekly
Weekly
Weekly
Weekly
Operator
Daily
Operator
Daily
Operator
Damper Screw
Daily
Daily
Daily
Operator
Vibration of Motor
Body cleaning
Vibration of Motor
Sound of Motor
Tightness check of Foundation
Bolts of motor
Body cleaning
Operator
Operator
Operator
Daily
Daily
Daily
Daily
Operator
Daily
Daily
Daily
Daily
Daily
Operator
Daily
Operator
Daily
Weekly
Operator
Daily
Weekly
Operator
Weekly
Operator
Weekly
Daily
FREQUENCY
Operator
Operator
Operator
WORK
DONE BY
Check Point
Operator
On/Off
On/Off
On
Off
Off
On
On
Off
On
Off
Off
Off
Off
Off
Off
Off
Off
Off
On
On/Off
Off
On/Off
On
Off
On
On
Off
On
Off
On
On
Off
Off
On
On/Off
Off
On
Off
Off
Off
Off
Off
Off
MECHANICAL
CONDITION
1
Cleaning by Circulation :
1.Fill the water tank with about 80 liter water. If the water is heated to 50 deg C, better results are
expected.
2.Add 2 to 3 Kg of sulfamic acid powder in 80 liter water.
3.Mix thoroughly the acid powder with water.
4.Remove all the spray nozzles.
5.Switch on the pump and keep the water circulation for 15 minutes.
6.Stop the pump, observe the cleaning efficiency and if required, run the circulation for another
15 minutes. Repeat the same if required.
7.Drain all the water and fill the tank with fresh water and rinse the system thoroughly with fresh
water for 15 minutes by continuously draining the water.
Cleaning by Direct application : (For hard scales which cannot be reached by water spray)
1.Take 5 liters of water at 50 deg C in a bucket.
2.Add 0.5 Kg of sulfamic acid powder in the water.
3.Mix thoroughly.
4.Using a paint brush, apply this mixture directly on the scaling (protect the eyes while doing
this).
5.Apply a liberal quantity until the scaling area is fully wet.
6.Leave it for 4 to 6 hours. Try to remove the scales by using a rubber hammer. If the scales are
hard, apply the mixture again and leave it for 4 more hours.
7.In the remaining quantity of this acid + water mixture, dissolve all the spray nozzles and leave it
for 2 hours.
8.Take out the nozzles and clean them with fresh water and compressed air blast.
9.Wash all the places with fresh water where acid-water mixture was applied.
DO NOT TOUCH THE ACID POWDER WITH BARE HANDS & DO NOT ALLOW CONTACT WITH SKIN & EYES.
WEAR RUBBER GLOVES WHILE DOING DE-SCALING
22
BALE PUSHER
3"
3"
1P
2"
1R
T
ECAF POT
WEIV .H.L
2F
2P
3F
P
1F
ECAF POT
WEIV .H.L
ECAF MOTTOB
"1 EAS
"4/1.1 EAS
ECAF POT
"1 EAS
"4/1.1 EAS
T
WEIV.H.L
1.1
ECAF RAER
P
ROTOM PH 02
DETNUOM EGNALF
1.2
10708
23
L
3.2
DP
AIR SUCTION
DUCTING
HUMIDIFIER
FP
DUCTING
LINT SUCTION
2740
DIESEL
TANK
WATER
TANK
ISMB 150
"A"
ISMB 150
2"
"B"
IMAMBADA ROAD, NAGPUR- 440 018. INDIA. Tel: +91-712-272 0071 ~ 80 Fax: +91-712-272 8050 / 272 3068
2015
8500
PLC
PANEL
1.1/4"
L
2.2
L
2.1
N
TIO
EC DOW
INSPWIN
Code No.
Part Description
Req. Qty
25001288
2 set
25005685
1 No.
25005686
1 No.
25005687
5 Nos.
25005688
5 Nos.
25002128
5 Nos.
25001626
2 Nos.
25001479
1 No.
25005689
2 Nos.
25005690
2 Nos.
25001289
5 Set.
25002160
1 No.
20006291
1 No.
20006290
1 No.
20006288
1 No.
20006287
10 Nos.
16
20006286
5 Nos.
17
20006283
5 Nos.
18
20006282
10 Nos.
19
20006281
2 Nos.
20
20006280
1 No.
21
20006279
1 No.
22
20006277
5 Set.
23
20006289
2 Nos.
24
25005605
5 Set.
8
9
10
11
12
13
14
15
24
25
Ignition Electrodes
Combustion Head
Screw for combustion head adjustment
Photocell
Screw for fixing fan
Servomotor
Side bars
Pump delivery valve (Safety Valve)
Pump delivery valve
Valve on return nozzle
Oil pressure switch
Pump
Plate for passage of hoses & cables
Supplementary air gate valve
Non-Drip nozzle holder
Fan pressure test point.
Mounting flange
Flame stability disc
Flame inspection window
Power switch
Motor contactor
Motor capacitor
Control Box (Sequence Controller)
Terminal Strip
Air gate valve
Pump pressure adjustment
Return oil pressure gauge
Pressure regulator on nozzle return
Extensions for side bars
18
IMAMBADA ROAD, NAGPUR- 440 018. INDIA. Tel: +91-712-272 0071 ~ 80 Fax: +91-712-272 8050 / 272 3068
14
15
17
19
16
90
26
27
28
20
21
11
43
43
9
8
25
32
30
24
12
23
10
13
22
29
31
35
42
38
36
33
34
37
3
4
52
81
70
89
40
41
39
54
55
53
58
56
57
18
71
70
83
82
59
60
51
72
61
44
45
77
73
74
46
69
34
81
63
33
49
78
85
18
77
18
86
87
18
70
76
75
70
80
18
84
67
88
65
64
79
66
68
48
62
50
47
26
27
Description
FAN (Burner Blower)
DRIVE COUPLIGN (Burner blower)
SOUND DAMPING
AIR INTAKE
FUEL PUMP
GRADUATE SECTOR
SPRING
SCREW
LEVER
BEARING
BAR EXTENSION
INSPECTION WINDOW
SCREW
COVER
SCREW
MEMBRAN
MOTOR
SEAL (Fuel Pump)
FLEXIBLE OIL LINE
KEY
MOTOR
BAR
SHORT SHAFT
P.E. CELL
FAIR LEAD
CONTROL BOX
CONTACTOR
CONDENSOR
STARTER
SUPPORT
TRANSFORMER
SWITCH
SUPPORT
NOZZLE HOLDER
FRONT SHIELD
SUPPORT
NUT
H.T. LEAD
ANCHOR PLATE
ELECTRODE
U BOLT
DRIVE DISC (Burner Blower)
SPRING - LEVER
CONTROL DEVICE
FONT PIECE
SR. NO.
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
68
69
70
71
72
73
74
75
76
77
78
79
80
81
82
83
84
85
86
87
88
89
90
Description
SQUARE
SHUTTER
END CONE
FLANGE GASKET
CONNECTOR
DIFFUSER DISC
ANCHOR PLATE
HALF-SHELL
COIL
LEAD
TUBE
TUBE
SHORT SHAFT
LEVER
BEARING
ANCHOR PLATE
CAM ASSEMBLY
STUD
SUPPORT
SERVOMOTOR
CAM HOLDER SHAFT
SEAL
MODULATOR
CONNECTOR
SEAL
SCREW
PRESSURE GAUGE
O-RING
AIR DAMPER ASSEMBLY
TUBE
NIDDLE VALVE
NIDDLE VALVE
CONNECTOR
CONNECTOR
CONNECTOR
CONNECTOR
CONNECTOR
CONNECTOR
PRESSURE SWITCH
SCREW
SEAL
FILTER
CONNECTOR
SPACER
DEGLITCHER
design@blueflames.in
MOODY
INTERNATIONAL
ISO 9001 QMS
quality
UKAS
ement system
nag
c
ma
ified
er t