Dryer Plant Manual (SDS-171)

PLANT MANUAL
For
Fluidized Bed Spray Dryer (FBSD)
Clinet: M/s Hoang Anh Flavors & Food Ingredients.

#22, Road 4, Song Onglon Villas,
Nguyen Van Linh Boulevard, ho Chi Minh City
Vietnam
Year – 2016.
New AVM SYSTECH PVT. LTD.

“AVM HOUSE”, 3B+3Part, 1/3,
Opp. Ador welding Ltd.
D-1 Block, MIDC, Chinchwad, Pune – 411019
Tel: +91-20-20271424/20271425
E-mail: avmtechnologies@vsnl.net
Website: www.avmsystech.co.in
Job No: SDS-171

Operational &Maintenance Manual for Fluidized Bed Spray Drying Plant
INDEX
SECTIONS DESCRIPTION PAGE NO.
1. Brief System Description……………………….……….…2

2. Specifications………………………………….…………5
3. Utility Specifications………………………….………….7
4. Design Conditions…………………………….…………8
5. Bought Out Equipment Specifications………….……….…9
6. Plant Operation………………..……………..….…..….11
7. Nozzle Selection Procedure……………………..………..12
8. Trouble Shooting……………………………..……..…...15
9. Maintenance Schedule…….……………….…..…...……17
10. List Of Recommended Spares………………....….….....…24
11. List Of Drawings & Graphs……...………....….………28
12. List Of Bought Out Equipment Manual………....………29
13. Commissioning Data……………………….......………30
FBSD Operating & Maintenance Manual BSC.DOC Page 1 of 30 Rev: 00

I BRIEF SYSTEM DESCRIPTION
Spray Dryer is designed to produce food flavor powder.
Spray dryer configuration shall be multiple stage spray drying system ( 3 Stage ),
1st product drying stage is carried out in spray chamber where maximum water evaporation
take place , 2nd Stage of product drying is at Internal fluid bed dryer where semi dried
agglomerates gets dried & 3rd Stage of product drying at external fluid bed dryer where
final product has been controlled.
With this configuration of spray dryer it is also possible to produce dust free agglomerates.
Advantage of this configuration over single / 2 stage spray dryer is lower dryer outlet
temperature to achieve desired product moisture, also this configuration is suitable for drying
if products having hygroscopic nature.
Brief System Description is as follows :-
The feed from feed tank is fed to the atomization system through a feed pump.
Liquid shall be atomized with the help of High pressure feed pump and High pressure
nozzles, Single nozzle being used for atomization depend on feed properties and feed rate,
Feed Pump motor is coupled with variable frequency drive, with VFD it is possible to control
feed pressure at nozzle, In turn spray dryer outlet temperature.
Actuated valves are provided for nozzle lance isolation, Nozzle operation can be selected
from PLC / SCADA.
An automatic air flushing arrangement is provided for individual nozzle to flush nozzle lance
& nozzle body to avoid formation of big droplets during shut down / Power failure.
Water tank with actuated valve for feed & water mode isolation is provided. Feed / Water
mode can be selected from PLC / SCADA.
1st Stage Drying -
Liquid atomized particles will come in contact with the hot air entering the spray chamber in
a co-current fashion through an air distributor located on top of spray chamber. The
atomized particles gets instant dried to semi dried state when they are exposed to heat.
Main drying air shall be dehumidified with the help of chilled water and shall be heated to
desire temperature in Electrical air heater using Electrical power as heating media.
Primary & Fine Air filters shall be provided for drying air.
Sufficient pressure relief vents (Rupture discs) shall be provided on Spray chamber to
protect chamber in case of explosion, rupture disc shall have burst sensor which will be
giving signal to PLC to shut down plant.

2nd Stage Drying -
Semi dried particles agglomerate at internal fluid bed (IFBD) provided at the bottom of the
spray chamber. Finer particles through up in the spray chamber where they gets
agglomerates with semi dried particles, Bigger particles kept in fluidization at IFBD where
they get dried.
IFBD Drying air shall be dehumidified with the help of chilled water and shall be heated to
desired temperature using electricity as heating media. Primary & Fine Air filters shall be
provided for FBDI drying air.
3rd Stage Drying -
Product from IFBD is taken in external vibratory fluid bed dryer cum cooler where final drying
of agglomerated product take place, Also the product is cooled down, while product is
passing through fluid bed mechanical de-dusting of product is done i.e. by separating fines
from granular product. Fines are carried back at inlet of main cyclone. Product is discharged
through over weir & rotary air lock valve.
Fluid bed drying and cooling zone air shall be dehumidified with the help of chilled water.
Drying air shall be heated to desired temperature using electricity as heating media.
Primary & Fine Air filters shall be provided for FBD drying & cooling zones.
Sifter -
Vibratory sifter is provided below VFBD to separate out over sized lumps from the product
before product conveying to packing section.
Exhaust air section -
The fines along with exhaust air is conveyed to high efficiency cyclone separators, the fines
are discharged through rotary air lock valves from the bottom of the cyclone and recycled
back to spray chamber on Spray chamber top through pneumatic conveying or discharged
to external fluid bed to mixed with product coming from IFBD.
The exhaust air is further treated in the wet scrubber for scrubbing of fines which are not
separated in cyclone and then vented to the atmosphere with the help of exhaust fan.

CIP System -
CIP system is be provided to wash the plant, CIP system shall be 3 tank, 1st tank for hot
water, 2nd tank for Lay solution & 3rd tank for diluted acid.
CIP of the plant is carried zone by zone for effective cleaning of the equipment, Cleaning
sequence to be arrange in such a way that top most equipment will get washed first followed
by next lowered level equipment.
Plant Operation and Control system –
Entire operation of the Spray Dryer is controlled through PLC / SCADA based Control
system. Necessary Instrumentation also provided for various plant parameters.
PLC / SCADA system shall be designed for automatic and safe operation of the plant; All
parameter shall be controlled from the PLC / SCADA system. PLC will have provision for
Alarm log, Parameter Data logging, Parameter Trends and Report Generation.
MCC panel shall be provided for various plant equipments, Variable frequency drives shall
be provided for all higher rating motors for power saving.

II SPECIFICATIONS
PRODUCT : Food Grade Flavors
CAPACITY
Feed Rate : 52.7 Kg/hr at 50% W/W solid
Evaporation Rate 25 Kg/hr (200°C Inlet & 95°C Outlet Temp)
Product Rate 27.7 Kg/hr
FEED PROPERTIES
Feed Solid Range : 45-55% w/w
Avg. Feed Solids (Design) : 50% w/w
Feed Form : Non Viscous, Free Flowing, Homogenize
Feed Solvent : Water
Feed Temp. : 40 ºC
Feed Density : 1.05 to 1.2
Feed Viscosity :  200 cps at 60 ºC
Feed Nature : Non Corrosive, pH – 6.5 to 7
PRODUCT PROPERTIES
Product Moisture : ≤ 5 % w/w
Product Temperature ( After FBD) : ≤ 32 ° C
Particle Size : Agglomerated powder ( Particle size 50-200µ as
per the sample provided)
OPERATING CONDITIONS
Drying Media : Hot Air
Method of Hot Air Generation : Electric Heater
Utilities Used For Heating : Electricity
Utilities Used For IFBD / FBD Air : Electricity.
Heating
Dryer Inlet Air Temperature : 180° - 240°C
IFBD Inlet Air Temperature : 100-120° C
Dryer Outlet Air Temperature : 85-105 C
FBD ( Heating Zone) Inlet Air : 60-80° C
Temperature
FDB Cooling Zone Air temp. : 24-26° C
MATERIAL OF CONSTRUCTION
Feed Contact Internals : Stainless Steel 316 L
Product Contact Internals : Stainless Steel 316 L / Stainless Steel 316
Hot Air Contact Internals : Stainless Steel 304
Cold Air Contact Internals : Stainless Steel 304
Exhaust Air Contact Internals : Stainless Steel 304
Externals / Stiffeners : Stainless Steel 304

SITE CONDITIONS
Ambient Temperature : Min. : 20C Max. :40C Avg : 30C
Humidity : 80 % RH at Avg. Temp
Altitude : < 300 M From MSL
Installation : Indoor
Area Classification : Non Hazardous / Non Explosive / Non Flameproof

III UTILITY SPECIFICATIONS
Power : Voltage : 380 V / 4 wire / 3 phase Frequency : 50 HZ

Motor List Motor Rating
Supply Air Fan : 1.5 KW
Exhaust Fan : 5.5 KW
IFBD Fan : 1.1 KW
FBD Drying Zone Fan : 0.75 KW
FBD Cooling Zone Fan : 0.75 KW
Feed Tank Agitator : 0.37 KW
Feed Pump : 0.2 KW
Rotary Valve ( FBD) : 0.18 KW
Rotary Valve ( Cyclone) : 0.18 KW
Fines Recycle Blower : 0.75 KW
Scrubber Pump : 2.2 KW
Electric Heater for Main Air : 54.0 KW
Electric Heater for IFBD Air : 12.0 KW
Electric Heater for FBD Drying Air : 3.0 KW
Electric Heater for Air Re-heating : 9.0 KW
Connected Load : 91.48 KW
Consumed Power : 66.00 KW
Chilled Water : Clean filtered at 2 bar g, 5 o C supply and 8 o C return

Normal consumption : 8 m3/hr ( 8 TR)
Hot Water : Clean filtered at 1.5 bar g ( max), 60 o C supply

Normal consumption : 2 m3/hr
Compressed Air : Dry, filtered at 6 bar g, -30 o C dew point

Normal consumption : 10-15 SCFM
Process Water : Clean, Filtered, At 2 kg/ cm2 g

Normal Consumption : 1 –2 LPM
Utilities are specified at average ambient conditions at tolerance of 10%
Utilities are specified at average ambient conditions.

IV DESIGN CONDITIONS
PLANT CAPACITY :
The spray drying plant capacity is defined in terms of water evaporation rate. The plant is
designed to evaporate 25 kg/hr. of water at air inlet temperature of 200°C and air outlet
temperature of 95°C. The actual operating temperature can be selected for the specific
product to be dried, depending on the nature of the product. This may be different than the
designed temperature mentioned above.
At 50 % w/w feed solids & 5 % Product moisture plant will produce 27.5 kg/hr. product
Refer to the water evaporation capacity chart for the actual operating conditions.
The capacity of the dry product depends on the water evaporation rate, its drying behavior
and the solid contents in the feed solution.
Procedure for estimating production rate
Step – I (Ref. Water evaporation capacity chart)
Enter the air inlet temperature on left Y – Axis and the air outlet temperature on the X –
Axis find out point of intersection & move parallel evaporation capacity lines to read
evaporation capacity on right side Y – Axis
Product rate can be estimated from following equations.
Step – II Estimate feed rate ( F )
F = (( 1 –(FS/ PS))^-1) x E
F- Feed rate in kg/h.

E- Evaporation rate in kg/h.
FS – feed solids ( % feed solids / 100)
PS – product solids ( 1- ( % product moisture/100))
Step – III Estimate Product rate ( P)

P= ( F-E )
P- Product rate in kg/h.

F- Feed rate in kg/h.
E- Evaporation rate in kg/h.

V EQUIPMENT SPECIFICATIONS
Specifications sheets for Bought-out Items

Refer specification sheets.
Sr. No. Description of Equipment. Specification Sheet No.
1. Supply Fan Spec. Sheet No: SPC/SDS/171/01 REV. 0

2. Exhaust Fan Spec. Sheet No: SPC/SDS/171/02 REV. 0
3. IFBD Fan Spec. Sheet No: SPC/SDS/171/03 REV. 0
4. FBD Drying Zone Fan Spec. Sheet No: SPC/SDS/171/04 REV. 0
5. FBD Cooling Zone Fan Spec. Sheet No: SPC/SDS/171/05 REV. 0
6. Recycle Fan Spec. Sheet No: SPC/SDS/171/06 REV. 0
7. Main Air Heater. Spec. Sheet No: SPC/SDS/171/07 REV. 0
8. IFBD Air Heater. Spec. Sheet No: SPC/SDS/171/08 REV. 0
9. FBD Air Heater. Spec. Sheet No: SPC/SDS/171/09 REV. 0
10. Air Dehumidifier. Spec. Sheet No: SPC/SDS/171/10 REV. 0
11. Feed Pump. Spec. Sheet No: SPC/SDS/171/11 REV. 0
12. Scrubber Pump. Spec. Sheet No: SPC/SDS/171/12 REV. 0
13. Rotary Airlock Valves Spec. Sheet No: SPC/SDS/171/13 REV. 0
14. Geared Motors for Rotary Valves. Spec. Sheet No: SPC/SDS/171/14 REV. 0
15. Gear Box for Feed Pump. Spec. Sheet No: SPC/SDS/171/15 REV. 0
16. Vibratory Motor Spec. Sheet No: SPC/SDS/171/16 REV. 0
17. Rupture Disc Spec. Sheet No: SPC/SDS/171/17 REV. 0
18. Air Filter Spec. Sheet No: SPC/SDS/171/18 REV. 0
19. Feed Nozzle Spec. Sheet No: SPC/SDS/171/19 REV. 0
20. Scrubber Nozzles Spec. Sheet No: SPC/SDS/171/20 REV. 0
21. CIP Nozzles Spec. Sheet No: SPC/SDS/171/21 REV. 0
22. Demister Pad for Scrubber & Spec. Sheet No: SPC/SDS/171/22 REV. 0
Dehumidifier.
23. Pressure Gauges. Spec. Sheet No: SPC/SDS/171/23 REV. 0
24. Manometers. Spec. Sheet No: SPC/SDS/171/24 REV. 0
25. Temperature Transmitters Spec. Sheet No: SPC/SDS/171/25 REV. 0
26. Pressure Transmitter for Feed Spec. Sheet No: SPC/SDS/171/26 REV. 0
27. Pressure Transmitter for Chamber Spec. Sheet No: SPC/SDS/171/27 REV. 0
28. Differential Pressure Transmitter for Spec. Sheet No: SPC/SDS/171/28 REV. 0
IFBD and VFBD
29. Actuated Ball Valves. Spec. Sheet No: SPC/SDS/171/29 REV. 0
30. Actuated Butterfly Valves. Spec. Sheet No: SPC/SDS/171/30 REV. 0
31. Electromagnetic Hammers. Spec. Sheet No: SPC/SDS/171/31 REV. 0
32. Sequential Timer Spec. Sheet No: SPC/SDS/171/32 REV. 0
33. Thyrister Controller Spec. Sheet No: SPC/SDS/171/33 REV. 0
34. VF Drives Spec. Sheet No: SPC/SDS/171/34 REV. 0
35. Motors Spec. Sheet No: SPC/SDS/171/35 REV. 0
36. MMC Panel. Spec. Sheet No: SPC/SDS/171/36 REV. 0
37. PLC System. Spec. Sheet No: SPC/SDS/171/37 REV. 0
VI PLANT OPERATION
A) Refer Dryer operational manual.
Following are common operational hints for smooth operation / adjustments of plant
parameters.
 Drying of equipment after washing ( After CIP) – After every CIP run / washing of the
plant, ensure that all the equipment are dry, particularly all rotary valves rotors, cyclone
bottom recycle ventury, IFBD discharge duct, Fines recycle line, sifter etc.
After CIP washing, Run supply fans & exhaust fans with pre-define speed (refer FSD
operational manual) for 10 to 15 min & chamber pressure + 25 to 30 mm, then stop the fans
& manually dry the cyclone bottom re-cycle ventury.
Caution – If plant / equipment are not completely dried, it will lead to stick the product
& Jamming / blocking of the system / equipment.
 Control of product moisture contain – Final product moisture can be controlled by

adjusting chamber outlet temperature, Also IFBD bed temp ( which can be controlled by
IFBD air temperature) & FBD drying zone temperature can be adjusted to control moisture
control.
Recommended Temperatures are as follows :-
IFBD bed temperature – 95 to 120 º C.
FBD drying zone temp – 65 to 80 º C.
Caution – Higher FBD drying zone temperature will lead to higher packing
temperature, hence FBD drying temp should be always optimize to get best results.
Coarser particles will require higher outlet / IFBD bed temperature; whereas finer particles
will require lesser outlet / IFBD bed temperature to achieve desired product moisture for a
particular product.
 Coarser Particle Size – For a particular product coarser particle / agglomerates can be
produce, which can be done by selecting proper nozzle combination & atomizing pressure.
Bigger orifice diameter will generally produce coarser particle, higher thickness swirl
chamber will narrow the spray angle, which can be selected to get desired agglomeration in
chamber cone.
Higher IFBD air will help to improve agglomeration. Lower atomizing pressure will produce
coarse particle, Recommended min. pressure 30 barg on feed & maximum pressure-150
barg on feed.
Feed solid contain also will have effect on particle size, higher feed solids will produce
coarse particle & less feed solids will produce finer particle.
Caution – Nozzle combination selection to be done properly, otherwise it will lead to
product deposit in Spray Chamber / IFBD.
 Bulk Density – Bulk density is related to particle size & moisture contain for a particular
product. However same can be slightly adjusted by adjusting Inlet temperature for particular
product operating parameters. Lower inlet temperature will increase bulk density.

VII NOZZLE SELECTION PROCEDURE.
Ranges :
Selection range pressure - Min. 40 barg.
(On feed ) Max. 70 barg.
Selection range angle Min. 75º -

Max. 85º
Some commonly use Nozzles combination are tabulated below,
Orifice
Orifice Core Angle 35 bar 70 bar 100 bar
Diameter
mm No. Size degree LPH LPH LPH
0.71 70 16 79° 26.5 37 43.9
0.73 69 16 80° 27.6 38.5 45.7
0.78 68 16 82° 29.2 40.8 48.4
0.83 66 16 84° 31.4 43.9 52.1
0.71 70 20 76° 32 44.6 52.9
0.73 69 20 76° 33.4 46.5 55.2
0.78 68 20 78° 35.8 50 59.3
0.83 66 20 80° 38.2 53.4 63.4
Note: For more detail please refer Spraying System catalogue.
Effects : Some parameters and their effects on spray are given below.
A Capacity :
The relationship of pressure and flow with a given orifice is:
Q1 (P1)n
---- ~ ------
Q2 (P2)n
To approximate any unknown flow or pressure, use this formula when the other
variables are known. The "n” exponent is used to approximate the ratio of pressure to
flow based on the type of spray pattern.
Low Exponent for All Hollow Cone Nozzles is 0.50

Example:
To determine the flow rate of water for a 1/4SK+SIY69+SKY20 Hollow cone nozzle at 50
bar, consult the performance charts in this catalog.
You will find that:
• The spray angle is 76°
• Flow (Q1) at 70 bar = 46.5 lph
• Pressure (P1) = 70 bar
• Pressure (P2) = 50 bar
• Solving for Q2 = 39.3 lph
Q1
Q2 = -------
(P1/P2)n
46.5
Q2 = --------- = 39.3
0.5
(70 / 50)
B SPECIFIC GRAVITY
All capacity tabulations in this catalog are based on water. Since the specific gravity of a
liquid affects its flow rate, tabulated catalog capacities must be multiplied by the conversion
factor that applies to the specific gravity of the liquid being sprayed as explained below.
Specific gravity is the ratio of the density of a fluid compared to the density of water. The
specific gravity of water is defined as 1. When spraying fluids other than water, specific
gravity must be considered in the flow calculations.
1
Q = Q (water) x
2 1
√SG
• Fluid sprayed is heavier than water and has a specific gravity of 1.2
• Flow of water at 70 bar = 46.5 lpm
• Heavy fluid (Q2) = Q1( water)*1/√ 1.2
Q2 = 39.3 * 1/√ 1.2 = 35.87 lph


C SPRAY DROP SIZE (ATOMIZATION)

Accurate drop size information is an important factor in optimizing spray nozzle
performance, particularly in spray drying.
Drop size refers to the size of the individual spray drops that comprise a nozzle’s spray
pattern. Each spray provides a range of drop sizes; this range is referred to as drop size
distribution. Drop size distribution is dependent on the spray pattern type and varies
significantly from one type to another. The smallest drop sizes are achieved by air
atomizing nozzles while the largest drops are produced by full cone hydraulic spray
nozzles.
Liquid properties, nozzle capacity, spraying pressure and spray angle also affect drop size.
Lower spraying pressures provide larger drop sizes. Conversely, higher spraying pressures
yield smaller drop sizes. Within each type of spray pattern the smallest capacities produce
the smallest spray drops, and the largest capacities produce the largest spray drops.
D VISCOSITY
Absolute (dynamic) viscosity is the property of a liquid which resists change in the shape or
arrangement of its elements during flow. Liquid viscosity is a primary factor affecting spray
pattern formation and, to a lesser degree, capacity. High viscosity liquids – 100 cp or
higher – require a higher minimum pressure to begin formation of a spray pattern and
provide narrower spray angles as compared to those of water.
E TEMPERATURE
The values given in this catalog are based on spraying water at 70°F (21°C). Although
liquid temperature changes do not affect the spray performance of a nozzle, they often
affect viscosity, surface tension and specific gravity which do influence spray nozzle
performance.

VIII TROUBLE SHOOTING
We have summarized below common problems with plant operation.

For trouble shooting of individual bought-out equipments / Instruments refer their manuals.
A For deposit of powder (product) particles in drying chamber, it is advisable to examine

whether the following can be the cause of the problem.
Sr. Causes Remedy

No.
1. The drying chamber has not been Check that after washing, the plant is completely
sufficiently heated before the drying dry and do not start the product until the specified
process was started inlet and outlet temperatures are stable.
2. Drying air quantity is not sufficient. 1. Check inlet air filters are cleaned. If blocked
clean the filters.
2. Check any leakages through system.
3. The quantity of feed too high due to First check the chamber air outlet temperature; it
which drying of feed droplets in should be accordingly to specified value given. If
chamber is not quick enough. it is OK, then we have to control the feed rate i.e.
adjust feed pressure.
4. Leakage at chamber door / sight 1. Tight the Door.

glasses 2. Tight sight glasses.
3. Check gasket of sight glass / door.
4. Remove leakage through rupture disc
5. Nozzle Spray is not proper. 1. Check nozzle spray, (spray can be disturb due
to choking, loose fitting of nozzle component,
leakage through nozzle etc. )
2. Check whether nozzle lance is properly fitted
& orientation is correct.

B In the following section, we have pointed out various operational difficulties and their
remedies:
Sr. Difficulty Remedy

No.
1. Product moisture contents observed is This condition may be because of points 2, 3
higher during operation. below.
Secondly, check that the outlet, FBDI, FBDC
heating temperatures used are the correct one
corresponding to the specified residual moisture
in the product.
(Moisture will be less for higher outlet
temperature).
2. Evaporation capacity reduced There may be reduced drying quantity due to:
1. Air filters are blocked.
2. Excessive air leakages through various flange
joints.
3. Inlet temperature too low.
3. Too low drying inlet air temperature Check following:

1. Heater wire disconnected.
2. Not getting proper Neutral.
3. Heater element damage.
4. Malfunctioning of Temperature Sensor.
4. Too low outlet temperature Check following:

1. Whether feed pressure is correct.
2. Whether leakage through Nozzles.
3. Leakages through system.
5. Too high outlet temperature Check following:

1. Whether feed piping is choked.
2. Whether Nozzle is choked.
3. Whether pump is pumping feed.
4. Feed is available at inlet of feed pump.
6. Too low FBDI / FBDC heating / Check following:

Cooling temperature 1. Heater wire disconnected.
2. Not getting proper Neutral.
3. Heater element damage.
4. Malfunctioning of Temperature Sensor.

IX MAINTENANCE SCHEDULE
A. General Preventive maintenance schedule is mentioned as below, however for

bought-out equipment’s maintenance schedule to follow as per individual
equipment manual.
Sr. Description Cleaning Monthly Half Yearly

No. after every Maintenance Maintenance
batch.
1 Air Filter - -Clean the Filters -Check for any damage, If
necessary Replace the
filter.
2 Supply Blower, - -Check for Fan Vibration -Check Impeller balancing.
FBDI, FBDC & Noise. -Check anti vibration pads,
heating, FBDC -Check suction & if required replaces it.
cooling Blower. discharge bellows. - Check drive motor
-Motor bearing greasing. functionality, electrical
- Check tightness of all connections, winding
bolts, including resistance etc.
foundation bolts.
3 Cold Air Duct - - -Check gaskets for flanges.
4 Air Heater - - - Check for any blockages
in Finns etc.
-Check gaskets.
- Check Heater elements
for any damages by
checking resistance across
the element terminal, If
damage replace the
elements.
-Check insulation.
5 Hot air ducting - - -Check gaskets for flange
joints.
-Check insulation.
6 Air Distributor - - -Check for any blockages in
perforated plate
-Check gaskets for door /
Nozzle lance & fines
recycle mountings.
-Check insulation.

7 Spray Chamber Yes - Check doors / sight -Check insulation / painting

glass gaskets. of MS part
- Check rupture disc for -Check functionality of
leakages. electromagnetic hammers.
- Check pressure - Check hammers electrical
transmitter nozzles for connection & coil.
any blockage.
8 Chamber to Yes -Check hand-hole -Check gaskets for flanges.
Cyclone Ducting gaskets. - Clean CIP Nozzles.
- Check CIP nozzle
gaskets, ‘O’ rings, Spreader
hole blockage, operation of
the CIP nozzle.
- Check CIP hoses for any
leakage.
9 Cyclone Separator Yes -Check hand hole -Check gaskets for flanges.
gaskets. - Clean CIP Nozzles.
- Check CIP nozzle
the CIP nozzle.
leakage.
10 Cyclone Rotary Yes -Check rotary valve oil -Check bearing condition, if
Valve seals, if required replace required replace it.
it. -Lubricate gear box if done
-Check rotary valve for any maintenance.
vibration & noise. -Check Gear box operation
- Check air flushing for any over heating, noise,
arrangement vibration.
functionality. -Check drive motor
- Check tightness of all functionality, electrical
bolts. connections, winding
resistance etc.
11 Fines Recycle -Check Blower for - Painting of MS parts.
Blower Vibration, Noise. - Check bearing condition, if
-Check tightness of all required replace it.
bolts, including - Check Rotor for any wear
foundation bolts. & tear.
- Check functionality of - Check drive motor
NRV & Safety valve. functionality, electrical
connections, winding
resistance etc.

12 Fines Recycle Line Yes - Check leakages -

through joints, if required
replace gaskets.
13 Cyclone to Exhaust Yes -Check hand hole -Check gaskets for flanges.
Fan Ducting gaskets. - Clean CIP Nozzles.
- Check CIP nozzle
the CIP nozzle.
leakage.
14 Exhaust Fan Yes -Check for Blower - Check Impeller balancing.
Vibration, Noise. - Check bearing condition, if
- Lubricate bearings. required replace it.
- Check Belt tension, if - Check anti vibration pads,
required replace belts. if required replace it.
- Check tightness of all - Check belt alignment.
bolts, including - Check drive motor
foundation bolts. functionality, electrical
resistance.
15 Exhaust Fan to Yes -Check hand hole -Check gaskets for flanges.
Scrubber Ducting gaskets. - Clean CIP Nozzles.
- Check CIP nozzle
the CIP nozzle.
leakage.
16 Wet Scrubber Yes - Check gaskets for - Check gaskets for flanges.
Hand hole / sight glass
etc.
- Check rough efficiency
of the scrubbing system
( which can be done by
putting wet white cloth
small piece on exhaust
duct after demister
during running on
product & check color
droplets on cloth)

17 Scrubber line. Yes - Check leakages -Check Scrubber Nozzle for

through flanges, if wear & tear.
required replace
gaskets.
- Check Scrubber
Nozzle for blockage.
18 Scrubber Pump Yes -Check for Pump - Check Impeller for wear &
Vibration, Noise. tear.
- Check bearings - Check shaft seal for
condition. leakage, if required replace
- Check tightness of all it.
bolts, including - Check bearing condition, if
foundation bolts. required replace it.
- Check drive motor
functionality, electrical
resistance.
19 Exhaust Ducting Yes -Check hand hole -Check gaskets for flanges.
gaskets.
20 IFBD Cold & Hot air - - -Check gaskets for flanges.
duct
21 Heaters for IFBI / - - - Check for any blockages
VFBD heating in Finns etc.
-Check gaskets.
- Check Heater elements
for any damages by
checking resistance across
the element terminal, If
damage replace the
elements.
-Check insulation.
22 Fluid Bed Dryer Yes -Check Door / sight -Check gaskets for flanges.
(Internal) IFBD glass gaskets. - Clean CIP Nozzles.
- Check pressure - Check CIP hoses for any
transmitter nozzles for leakage.
any blockage.
- Clean lip type
perforated plate using
SS wire brush.
- Check gland packing
for weir shafts.
23 VFBD Cold & Hot Yes - -Check gaskets for flanges.
air duct

24 Vibratory Fluid Bed Yes -Check Door / sight -Check gaskets for flanges.
Dryer (External) glass gaskets. - Clean CIP Nozzles.
VFBD - Check pressure - Check CIP hoses for any
transmitter nozzles for leakage.
any blockage. - Check vibratory motor
- Clean lip type functionality, electrical
perforated plate using connections, winding
SS wire brush. resistance.
- Check gland packing
for weir shafts.
-Check springs.
25 VFBD Rotary Valve Yes -Check rotary valve oil -Check bearing condition, if
seals, if required replacerequired replace it.
it. -Lubricate gear box if done
-Check rotary valve for any maintenance.
vibration & noise. -Check Gear box operation
- Check air flushing for any overheating, noise,
arrangement vibration.
functionality. -Check drive motor
- Check tightness of all functionality, electrical
bolts. connections, winding
resistance etc.
26 Vibro-Sieves Yes -Check gaskets for deck. -Check Vibratory motor
-Lubricate Vibratory functionality, electrical
motor bearings. connections, winding
-Check springs / bush resistance etc.
etc.
-Check tightness of all
bolts / Clamps.
27 Feed Pump Yes -Check Pump / Gear - Replace Pump Oil.
Box for Vibration, Noise, - Replace gearbox oil.
and Heating etc. - Check Coupling
- Check Lubrication Oil, alignment, if required
if required top-up. replace rubber bushes for
- Check for any oil coupling.
leakage ( Refer - Check drive motor
Hydracell Manual) functionality, electrical
- Check functionality of connections, winding
Non-return valves. resistance.
- Check tightness of all - Check suction &
bolts, including discharge Rubber Hoses, if
foundation bolts. required replace it.
28 Feed Tank Yes. - -

29 Manual Ball Valve -Check for leakages -

through shaft seal,
tighten the locking nut, if
required replace
packing.
- Check for leakage
through Valve seat, if
required replaces it.
30 Actuated ball Yes -Check operation of the - Checking of Solenoid
Valves valve. valve coil. If required
-Check feed back replace it.
signals, if required adjust
feed back limit switch
cams.
- Check for any leakage
through valve seat /
shaft, if required replace.
31 Feed line. Yes -Check leakages -Calibrate pressure gauges.
through flanges, if -Check feed hoses, if
required replace required replace it.
gaskets.
-Check Spray Nozzle for
blockage.
-Check leakages
through Nozzle body,
hose, if required replace.
- Check nozzle
component for any wear
& tear.
32 Instruments - -Clean connection with - Calibration of all
equipments. Instruments.
- Check proper operation
of instruments.
33 Electrical Panels / - -Cleaning of panels with
Motors blower.
-Check overloads
current settings.
-Check timer settings.
-Check functionality of all
electrical components.
-Check & record current
of all equipments,
compare with
commissioning data.

B. LUBRICANTS REQUIRED
For Lubrication schedule refer individual equipment manual.

List of equipment & lubricants specifications are as follows.
Sr. Equipment Lubricant Specification Remark

No.
1. Exhaust Fan Moly coat High Temp Grease /
Refer manufactures
SKF:- LGMT 3IN manual for lubrication
schedule & more grease
options.
2. Rotary valve Geared motor Shell: Cassida Fluid HF 46 Lifelong lubricated, Oil to
Kluber: Klubersynth UH1 6-460 use only maintenance of
Mobil: Glygoyle 460 UH1 gear box is done.
3. Feed Pump Hydra Oil Refer manufactures
manual for Lubricant &
lubrication schedule
4. Feed Pump gear Motor. OKS Make Long Life NLGI 000 Refer manufactures
universal EP grease manual for lubrication
schedule & more Oil
options.
5. Chamber Door bearings Food grade greeses.

X LIST OF RECOMMONDED SPARES
Description Quantity
Inlet Air Filter

1. Pre-filter panels, EU-4, Size:-575X575X50 1 No.
1. Fine-filter panels, EU-7, Size:-610X610X150 1 No.
Dehumidifier Air Heater

1. Heating elements, 750 W, U Tube with Rectangular Finns 15 Nos.
Supply Fan
1. Anti-vibration Pads 1 Set
Main Air Heater

Spray Chamber
1. Gasket for Doors, D Shape 24X 30, 4 Mtr. Long 2 Nos.
2. ‘Y’ Type Bearing, FYTB 20TB, SKF,make 2 Nos.
3. Door Aluminum Hand wheel, AC Size : 8” 2 Nos.
2. Sight glass with ‘C’ gasket & flange gasket 2 Nos.
3. Rupture Disc. 1000 X 500 mm 1 No.
4. Electromagnetic Hammers, Model: AE-EH-50 2 Nos.
Fluid Bed Dryer (Integrated)

1. Gasket for hand holes, Ø150 mm 2 Nos.
2. Sight glass with ‘C’ gasket & flange gasket 1 Set.
3. Gland packing for weir assembly. 1 Set.
IFBD Fan
1. Anti-vibration Pads 1 set.
IFBD Air Heater


Fluid Bed Dryer (External)

1. Gasket for Man hole, Ø400 mm 1 No.
3. Gasket for hand holes, Ø150 mm 1 No.
4. Bellows
a. Product Inlet: Size : 125mm ID X 200mm H X 3 mm (T) 1 No.
b. Product Outlet: Size : 125mm ID X 100mm H X 3 mm (T) 1 No.
c. Hot air Inlet & Outlet: Size : 87mm ID X 200mm H X 3 mm (T) 7 Nos.
5. ‘O’ ring for weir assembly. 2 Nos.
6. Vibratory motor, Make : Sinex, Model No. : EMV- B 4.4/2.8 2 Nos.
7. Springs for FBD, Dia.: 50 mm, Free Length: 141.13 mm 8 Nos.
Rotary Valve for VFBD

1. Bearings 1 Set.
2. Oil Seals 1 Set.
3. End cover ‘O’ ring. 1 Set.
VFBD Drying Zone Fan

1. Anti-vibration Pads 1 Set.
VFBD Cooling Zone Fan

1. Anti-vibration Pads 1 Set.
VFBD Air Heater

Cyclone Separator
1. Gasket for hand holes, Gasket for hand holes, Ø250 mm 1 No.
Rotary Valve for Cyclone

1. Bearings 1 Set.
2. Oil Seals 1 Set.
3. End cover ‘O’ ring. 1 Set.
Fines Recycle Blower

1. Rotor 1 No.
2. Suction & Discharge silencer 1 Set.
Scrubber
1. Gasket for Hand Hole, Gasket for hand holes, Ø150 mm 2 Nos.
3. Scrubber nozzle. Model – 25 SW 49 1 No.

Scrubber Pump
1. Mechanical seal for scrubber pump. 1 No.
2. ‘O’ ring set for pump. 1 Set
3. Impeller for Scrubber Pump 1 No.
4. Pressure Gauge for Scrubber Line. (Range - 0 to 5 kg / cm2) 1 No.
Exhaust Fan
1. Anti-vibration Pads 1 Set
2. V- belts. Size: SPA1700, Make: Feener 2 Nos.
3. Suction bellow, Size: 265mm ID X 150mm H X 3 mm (T) 1 No.
4. Discharge bellow. Size: IS176 X281 & OS256 X361 X 200 L 1 No.
5. Bearings.SKF-2211K 2 Nos.
6. Fan Pulley: 140X2AX38 1 No.
7. Motor Pulley: 180X2AX48 1 No.
Feed Pump
1. Kit designator for Pump. 1 No.
2. Bushes for Coupling. 1 Set.
3. Hose for Pump Suction, Size: 1”X0.5 Mtr, 1 No.
4. Hose for Pump Discharge, Size ½ X1 Mtr. 1 No.
For more detail refer Replacement Parts Kits in Pump manual
Feed Line
1. Pressure Gauge for feed Line. (Range - 0 to 100 kg / cm2) 1 No.
2. Flexible hoses for Nozzle lance, Size: ½”X1.2 Mtr 1 No.
Actuated Valves for Feed Line

1. Solenoid valve coil for Actuated valves, Model: 51424-6-2G+230VAC, 2 Nos.
50 Hz-16
2. Limit switch Box for Actuated valves, Model:- DXLW1A2-4R 2 Nos.
3. Actuator, Model: - ECF63 1 No.
4. Valve Seat / Shaft Seal 1 Set.
Spray Nozzles
1. Spare Orifice for Spray Nozzle (SIY66, SIY68, SIY69 & SIY70) 1 No each.
2. Spare Core size for Spray Nozzle (SKY 16 & SKY 20) 1 No each.
3. Spray Nozzle, Model: 1/4SK
CIP Nozzle
1. Seal kit for Cyclone CIP Nozzle,Size: 2” 6 Nos.
2. Duct cleaning nozzles, Model: EA-2E-220-M2-XC 6 Nos.
3. Chamber cleaning nozzle, Model: EG 2E-800-M2-XF 1 No.
4. Flexible hoses for CIP nozzles 6 Nos.
5. Flexible hose for Chamber CIP nozzle 1 No.
CIP Pump
Note- Refer to pump manufacturer manual for detailed spare list.

Manual Ball Valves

1. Valve Seats 1 No Each type
2. Packing rings for shaft. 1 No Each type
Manual Butterfly Valves

1. Valve Seat for butterfly valve. 1 No Each type
Instruments
1. Manometers (300-0-300) 2 Nos.
2. Temperature Sensors. 200 mm long. (Rang: 0 to 4000C) 1 No.
6. Pressure Transmitter for Chamber, 1 No.
Model: 051CD2A22A1AB4M5D4Q4, Make: Rosemount
7. Pressure Transmitter for Feed, Model: - S-11, Make: - WIKA 1 No.
8. Pressure Transmitter for Feed. Model:-SC504, Make:-Radix 1 No.
9. Thyrister controller, Model: Din-A-Mite C Controller, Make: Watlow 1 No.
10. Hammer timer, Model: ST-6M1, Make: - EAPL 1 No.
PLC System
1. CPU for PLC. 1 No.
2. Digital Input card 8 channel for PLC 1 No.
3. Digital Output card 8 channel for PLC 1 No.
4. Analogue Input Card 2 channel for PLC 1 No.
5. Analogue Output Card 2 channel for PLC 1 No.
6. 24 VDC power supply 1 No.
7. Relay board for digital output 1 No.

XI LIST OF DRAWINGS & GRAPHS
A List of Drawings:-
Sr. No. Description
01 P & I Diagram for Spray Drying Plant

02 P & I Diagram for CIP
03 GA Drawing for Spray Drying Plant
04 Exhaust Fan (ID Fan)
05 Supply Fan (FD Fan)
06 IFBD Fan
07 FBD Drying Fan
08 FBD Cooling Fan
09 Recycle Fan
10 Feed Pump
11 Scrubber Pump
12 Rotary Valves Assembly
13 GA Drawing for Drying Chamber
14 GA Drawing for Cyclone Separator
15 GA Drawing for IFBD
16 GA Drawing for VFBD
17 GA Drawing for Scrubber
18 GA Drawing for Scrubber Tank
19 GA Drawing for Dehumidifier Air Filter
20 GA Drawing for Main Heater
21 GA Drawing for IFBD Heater
22 GA Drawing for VFBD Heater
23 GA Drawing for Dehumidifier Heater
24 GA Drawing for Dehumidifier
12 B) GRAPHS
Sr. No. Description.
01 Evaporation Graphs
02 Production Graphs-
03 Nozzle Selection Chart

XII LIST OF BOUGHT-OUT EQUIPMENT MANUAL
Following Bought-out Items Manuals are attached herewith
Sr. No. Item / Equipment Make
01 Blowers Nadi
02 Recycle Blower Vacunier
03 Feed Pump Wanner / Hydra Cell
04 Scrubber Pump Zeuzer
05 Rotary Valves ACE
06 Geared Motor for Rotary Valves Bonfiglioli Make
07 Gear Box for Feed Pump PBL
08 Air Filters AAF
09 Scrubber Nozzles Shilpa
10 Feed Nozzle Spraying System
11 CIP Nozzles Spray tech
12 Demister Pad Haver
13 Pressure Gauges Pioneer
14 Rupture Disc Fike
15 Temperature Transmitters Baumer
16 Pressure Transmitters Rosemount / Emersion
17 Pressure Transmitters Radix
18 Pressure Transmitters Wika
19 Pneumatic Actuators Rotex
20 Electromagnetic Hammer Ambica
21 Sequential Timer EAPL
22 Thyrister Watlow
23 VF Drives Siemens
24 Vibratory Motor Sinex
25 Electric Motors ABB
26 Panel Wiring Diagram Cotmac
27 PLC Siemens

XIII COMMISSIOING DATA
A) Refer Pre-Commissioning Report.

B) Refer Commissioning PPT for Commissioning Parameters
C) Refer Commissioning PPT for PID Parameters
D) Refer Drive Basic Parameters.
E) Sequential Timer Settings
1) Hammer Sequential Timer On Time: 0.2 sec & Off Time: 10 Sec.

Dryer Plant Manual (SDS-171)

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PLANT MANUAL

Clinet: M/s Hoang Anh Flavors & Food Ingredients.

New AVM SYSTECH PVT. LTD.

Job No: SDS-171

SECTIONS DESCRIPTION PAGE NO.

1. Brief System Description……………………….……….…2

FBSD Operating & Maintenance Manual BSC.DOC Page 1 of 30 Rev: 00

I BRIEF SYSTEM DESCRIPTION

Spray Dryer is designed to produce food flavor powder.

Brief System Description is as follows :-

1st Stage Drying -

FBSD Operating & Maintenance Manual BSC.DOC Page 2 of 30 Rev: 00

2nd Stage Drying -

3rd Stage Drying -

Exhaust air section -

FBSD Operating & Maintenance Manual BSC.DOC Page 3 of 30 Rev: 00

Plant Operation and Control system –

FBSD Operating & Maintenance Manual BSC.DOC Page 4 of 30 Rev: 00

PRODUCT : Food Grade Flavors

FBSD Operating & Maintenance Manual BSC.DOC Page 5 of 30 Rev: 00

FBSD Operating & Maintenance Manual BSC.DOC Page 6 of 30 Rev: 00

III UTILITY SPECIFICATIONS

Power : Voltage : 380 V / 4 wire / 3 phase Frequency : 50 HZ

Chilled Water : Clean filtered at 2 bar g, 5 o C supply and 8 o C return

Hot Water : Clean filtered at 1.5 bar g ( max), 60 o C supply

Compressed Air : Dry, filtered at 6 bar g, -30 o C dew point

Process Water : Clean, Filtered, At 2 kg/ cm2 g

Utilities are specified at average ambient conditions at tolerance of 10%

Utilities are specified at average ambient conditions.

FBSD Operating & Maintenance Manual BSC.DOC Page 7 of 30 Rev: 00

Procedure for estimating production rate

Step – I (Ref. Water evaporation capacity chart)

F- Feed rate in kg/h.

Step – III Estimate Product rate ( P)

P- Product rate in kg/h.

FBSD Operating & Maintenance Manual BSC.DOC Page 8 of 30 Rev: 00

Specifications sheets for Bought-out Items

Sr. No. Description of Equipment. Specification Sheet No.

1. Supply Fan Spec. Sheet No: SPC/SDS/171/01 REV. 0

A) Refer Dryer operational manual.

 Control of product moisture contain – Final product moisture can be controlled by

FBSD Operating & Maintenance Manual BSC.DOC Page 10 of 30 Rev: 00

VII NOZZLE SELECTION PROCEDURE.

Selection range angle Min. 75º -

Note: For more detail please refer Spraying System catalogue.

Low Exponent for All Hollow Cone Nozzles is 0.50

FBSD Operating & Maintenance Manual BSC.DOC Page 11 of 30 Rev: 00

Q2 = 39.3 * 1/√ 1.2 = 35.87 lph

FBSD Operating & Maintenance Manual BSC.DOC Page 12 of 30 Rev: 00

C SPRAY DROP SIZE (ATOMIZATION)

FBSD Operating & Maintenance Manual BSC.DOC Page 13 of 30 Rev: 00

VIII TROUBLE SHOOTING

We have summarized below common problems with plant operation.

A For deposit of powder (product) particles in drying chamber, it is advisable to examine

Sr. Causes Remedy

4. Leakage at chamber door / sight 1. Tight the Door.

FBSD Operating & Maintenance Manual BSC.DOC Page 14 of 30 Rev: 00

Sr. Difficulty Remedy

3. Too low drying inlet air temperature Check following:

4. Too low outlet temperature Check following:

5. Too high outlet temperature Check following:

6. Too low FBDI / FBDC heating / Check following: