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Project Report

Concise and informative document that captures the essential details of a visit. It provides a summary of the purpose and scope of the visit, the individuals or entities visited, and any challenges faced during the visit. The report also outlines any noteworthy achievements or successes and offers recommendations for further action or follow-up. Overall, a visit report serves as a valuable reference tool for future planning and decision-making.
Geelen Counterflow
03/14/2023

Project Report

Concise and informative document that captures the essential details of a visit. It provides a summary of the purpose and scope of the visit, the individuals or entities visited, and any challenges faced during the visit. The report also outlines any noteworthy achievements or successes and offers recommendations for further action or follow-up. Overall, a visit report serves as a valuable reference tool for future planning and decision-making.
Procedure Max Score: 34

    Information

    Visit Purpose

    Customer Info

    Date of Visit

    Goals

    General Information

    Safety

    Safety Guards

    Safety Notes

    Imagenes

    Add or drag pictures

    Assembly

    The dryer will generally be assembled under supervision of Geelen Counterflow. This manual contains general instructions how to assemble and connect electrical devices. The sequence of assembly depends strongly on the local situation. The dryer and cooler should be unloaded from truck or container before the assembly supervisor from Geelen arrives. During the assembly, a forklift truck with a minimal lifting capability of 3 metric tons and long forks should be available. Often parts are lifted in the building via the roof by means of a crane with a maximum load of approximately five metric tons. The dryer will be pre-assembled in modules on the ground, as close as possible to the building in order to avoid transport damage.

    Compress Air

    Compress Air

    Compressed air has to be dry with a minimal pressure of 6 bar and a maximum pressure of 8 bar. The use of lubricated air is advised. For compressed air supply every solenoid valve must be provided with a valve to make the system pressure less. Synthetic air ducts or connections must not be mounted against bin, hood and air ducting. In case of a fire these synthetic ducts can melt.

    • Pass
    • Flag
    • Fail

    Gas Connection

    • GasConnection.PNG

    Rake with torque limiter

    Rake with fixed height (option) The drive of the rotating product distributor/rake is supplied completely pre-assembled.

    Assembly the fram

    The drive of the rotating product distributor/rake is supplied completely pre-assembled.

    Check by turning the drive shaft manually

    • TorqueLimiter.PNG

    Torque limiter

    The torque limiter must be installed according to the diagram below; in case a PLC is used, the second output is used for an input of the PLC generating an alarm

    • TorqueLimiterDiagram.PNG
    • Pass
    • Flag
    • Fail

    Hydraulic Unit

    For transportation reasons the hydraulic unit is supplied separately.

    Dryers

    The support of the dryer’s discharger is fitted with a stationary support for the hydraulic unit. Place the hydraulic unit on the support and secure it with bolts.

    • HUDryers.PNG
    • Pass
    • Flag
    • Fail

    Connections can be made

    Rotating Sensor

    Fixed Position

    In the fixed position the sensor is screwed in a base plate and detects the product level at that particular location.

    • FixPosition.PNG
    • Pass
    • Flag
    • Fail

    Movable Position

    In case of a movable position, different cover plates are used in order to set the height for the level sensor. The plates can be mounted in 4 different ways, every height can be reached:

    • Movable.PNG
    • Pass
    • Flag
    • Fail

    Temperature Probe

    For measuring air temperatures in order to control and monitor the process during product cooling/drying, temperature probes can be installed in the machine and air system.

    PT100 Installation

    • Temperature.PNG
    • Pass
    • Flag
    • Fail

    Preventative Maintenance

    If your equipment is well maintained, it's less likely to breakdown, which leads to increased uptime, more working hours for the equipment, fewer repair costs, and therefore increased revenue.

    Rotary Valve

    Check blades and housing for signs of wear

    • Pass
    • Flag
    • Fail

    Check coupling for friction

    • Pass
    • Flag
    • Fail

    Check oil level of the gearbox

    • Pass
    • Flag
    • Fail

    Replace oil of the gearbox

    • Pass
    • Flag
    • Fail

    Signatures

    Rake with Torque Limiter

    Check cooling air

    • Pass
    • Flag
    • Fail

    Check coupling

    • Pass
    • Flag
    • Fail

    Replace oil of the gearbox

    • Pass
    • Flag
    • Fail

    Check whether paddles of rake and the distributor are adjusted correctly (45°); check leakage gearbox

    • Pass
    • Flag
    • Fail

    Swivel valve discharger

    Check Hydraulic cylinders at each deck.

    • Pass
    • Flag
    • Fail

    Check Oil level and Hydraulic hoses, pipes, connections, etc.

    • Pass
    • Flag
    • Fail

    Check oil colour and filter state

    • Pass
    • Flag
    • Fail

    Check ball-joints at the cylinders and swivel arms on each deck.

    • Pass
    • Flag
    • Fail

    Drain all oil, clean the unit, fill with new oil.

    • Pass
    • Flag
    • Fail

    Replace oil filter

    • Pass
    • Flag
    • Fail

    Bearings

    • Pass
    • Flag
    • Fail

    Commissioning

    All Geelen Counterflow dryers are sold with control systems and commissioning by a Geelen Counterflow engineer. The Geelen Counterflow engineer will start commissioning on site. If for some reason there is no commissioning by a Geelen Counterflow engineer, use the steps mentioned below as a reference.

    Commissioning before trial operation (no power to unit)

    The wiring diagrams are accompanied by a terminal strip which indicates which components must be connected to which terminals. Use this terminal strip to check whether all the terminals in the box are actually and correctly connected.

    • Warn all those present before switching on the power • Switch on all motors in manual mode and check the direction of rotation of the motors. • Check whether the gate opens and closes as described in the relevant section.

    Starting up for the first time (Continuous dryer)

    Before starting up the system, several basic parameters should be set on the machine.

    Adjust the product level sensors to a product layer thickness of 30 – 50 cm. Overflow sensors on each deck prevent overfilling of the decks.

    Product distributor

    In case of a continuous dryer, set the quantity of product to be discharged per unit of time. Set the open and close positions to approximately 25% and 15%. Each discharge should lower the product bed depth with 2-3 cm. It is recommended to use a base setting of 10 seconds between strokes, when starting the machine for the first time.

    Determine the minimum and maximum values to be set as defined for this dryer. Make sure that the product’s fluidization air speed is not reached.

    Set the temperature of the drying air entering the dryer to the value as determined for this project.

    Starting up for the first time (Batch Dryer)

    Before starting up the system, several basic parameters should be set on the machine.

    In case of a batch dryer no level sensors are used for maintaining the product layer thickness, as discharging is controlled by a batch timer. Overflow sensors on each deck prevent overfilling of the decks.

    Adjust the belt distributor, please refer to the corresponding chapter of the manual for instructions.

    In case of a batch dryer, set the residence time of the product on the deck (batch time). Each discharge cycle should completely discharge the product from one deck to the next (or hopper).

    Determine the minimum and maximum values to be set as defined for this dryer. Make sure that the product’s fluidization air speed is not reached.

    Set the temperature of the drying air entering the dryer to the value as determined for this project.

    Verify correct operation of buttons

    Starting (during commissioning)

    Batch dryer basic

    Continous dryer specific

    Press “Stop”. The system should stop

    Manual discharge of gate

    Emptying system

    In case of a batch deck, a deck is emptied automatically.

    Continuous dryer specific

    Spare Parts

    Dryer Gas Burner (Spare Parts)

    Spare Parts Minimum

    Spare Parts Recommended

    Dryer Steam Heater (Spare Parts)

    Spare Parts Minimum

    Spare Parts Recommended

    Field Service Signature

    Click here to sign
Source: Geelen Counterflow (Community Member)

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