t series heatless regenerative compressed air dryer

Certified
Certificate No. FM 589782
T SERIES HEATLESS
REGENERATIVE
COMPRESSED AIR DRYER
T Series Heatless Regenerative
Compressed Air Dryer
Page 2
Table of Contents
T SERIES HEATLESS
Table of Contents
The Need for Dryers
A Message from the Owners
A History of Service
The Sahara Team
A Commitment to Customer Service
A Commitment to Quality
Components / Features / Benefits
The Brains Behind the Dryer
PLC with Allen–Bradley PanelView Component C400 Operator Interface
Optional Dew Point Demand System
Specifications & Dimensions
Theory of Operation
Real World Performance
Upflow Drying/Packed Bed
Heat of Adsorption
Mufflers
Valves
Commitment to Customer Satisfaction
Reference 104pdf
1
2
3
3
3
4
4
5
6
7
7
7
8
9
10
10
10
10
10
11
Acrobat Reader Format 11/2012
T Series Heatless Regenerative
Compressed Air Dryer
Page 3
The Need for Dryers
Compressed air is one of industry’s most important
utilities. Yet without proper air treatment, your
compressed air system cannot deliver its full
potential.
Moisture, dirt, oil; all pollutants, pollutants that
contaminate your process. Frozen air lines,
damaged instruments, product rejects; all
problems caused by air contamination. Downtime,
lost production, lost profits; the cost of air
contamination.
The solution; a systems approach by an
organization dedicated to solving air system
problems one customer at a time.
A Message from the
Owners
“Our father designed our first heatless dryer back
in the 50’s”, says Terry Henderson, President. “I
wanted to take everything we’ve learned in the
past 50 plus years and build the finest possible
heatless dryer. I really believe that our T Series
Heatless gives our customers the best of both
worlds; unparalleled reliability and exceptional
performance.”
“Our strength has always been large, special
custom engineered dryer systems”, said Chuck
Henderson, Vice President. “We didn’t want to just
be another volume manufacturer of heatless
dryers. We had to do something more; something
to give this dryer an edge. I believe our unique
control system and simple, reliable design sets this
dryer apart from all the others.”
SAHARA’S reputation for high quality,
innovative products and customer loyalty
quickly grew. Today, SAHARA is the world
leader in regenerative dryer technology.
Reference 104pdf
Illustration: Joe Henderson, 1957.
A History of Service
SAHARA AIR PRODUCTS, a Division of
Henderson Engineering Co., Inc., was founded in
1957 by Joe Henderson to provide engineered
solutions for air system problems. The first dryer
we ever built was a heatless design way back in
the 50’s. It’s still in service today.
Joe Henderson’s philosophy was to thoroughly
examine the unique requirements of each
customer and to develop the most economical and
reliable system solution for that application. The
trademark of engineered solutions exists at
SAHARA today, as the next generation of
Henderson’s continue the tradition of product
excellence and customer service.
Acrobat Reader Format 11/2012
T Series Heatless Regenerative
Compressed Air Dryer
Page 4
The Sahara Team
A Commitment to
Customer Service
Your SAHARA sales engineer has the expertise to
review your plant air system and design the
optimum engineered solution. This saves you
time and money.
SAHARA products are used throughout the world.
Customers in China, Thailand, Singapore,
Malaysia, Mexico, Canada, Chile, Venezuela,
Argentina, Puerto Rico, Panama, Saudi Arabia,
Kuwait, Bahrain, South Africa, New Zealand,
Australia, England, Italy, Germany, Greece, and
every state in the U.S. successfully operate
SAHARA dryers.
All products are manufactured at the corporate
headquarters in Sandwich, Illinois, 60 miles west of
Chicago. Living and working in the country has
proven to be a tremendous benefit. SAHARA
employees are true team members concerned with
providing our customers with high quality,
responsive service. Because we have very little
turnover, our experience is unmatched.
All SAHARA products are sold with our guarantee
of performance. During commissioning, SAHARA
sales engineers review the complete system and
instruct operators in proper operation. After your
dryer has been installed, our customer service
team maintains regular contact to guarantee
satisfaction.
We understand the difficulties you face every day
trying to keep your plant up and running. We try to
help you do your job better by making sure that
your compressed air system does what it’s
supposed to do; reliably deliver clean, dry air.
We make it easier for you to do your best.
Illustration: Corporate headquarters in Sandwich, IL
The heart of our company has always been
engineering; finding novel solutions to our
customers’ unique applications. We use the most
modern tools available. Drawings are done on
CAD and can be transmitted via email for
immediate customer review and approval. Our
reputation has been built by building dryers
specially designed for each specific application.
We are one of the few dryer manufacturers who
can completely design and fabricate a dryer to
each and every customer’s specifications.
Illustration: CAD system
Visit SAHARA on the Internet at
www.saharahenderson.com
Reference 104pdf
Acrobat Reader Format 11/2012
T Series Heatless Regenerative
Compressed Air Dryer
Page 5
A Commitment to Quality
A total commitment to quality begins with the
desire of every individual to deliver nothing less
than their best. Our team is totally committed to
quality products and customer satisfaction.
Incoming materials are inspected and randomly
tested. All welding is done in strict accordance
with the ASME code. We weld our own pressure
vessels, and we regularly perform radiographic
examination. We can weld exotic materials;
what you want is what we deliver.
Illustration: Pressure vessels
being pressure tested.
Standards constantly evolve. SAHARA meets all
existing quality specifications and is leading the
industry towards the future.
SAHARA is proud to be certified to the
ISO 9001:2008 Quality Management Systems
standards and guidelines.
SAHARA also provides our customers with UL
fabricated electrical panels. We are meeting
standards before they become required practice.
Illustration: Final performance test before shipment.
Reference 104pdf
Innovative technology and quality
engineering; trademarks from SAHARA.
Acrobat Reader Format 11/2012
T Series Heatless Regenerative
Compressed Air Dryer
Page 6
Components / Features / Benefits
Gravity is a powerful force. The T Series dryer has
been specifically designed to fully utilize the force of
gravity to optimize dryer performance. With a wet air
inlet at the bottom of the dryer, water and oil
droplets are concentrated at the bottom of the
desiccant bed. During downflow depressurization
and regeneration, the power of gravity helps pull the
water and oil out of the dryer.
Only two types of switching valves are used. All
valves 2” and smaller are Y angle globe valves with
a diaphragm actuator. This design permits higher
flows at lower pressure drops than any comparable
valve. A separate chamber protects the diaphragm
without disrupting service or removing the valve
from the dryer.
Preformed, stress relieved diaphragms minimize
fatigue, maximize valve responsiveness, and
diaphragm life. Standard valve materials are cast
iron body with stainless steel and brass internals.
Valves 3” and larger are high performance butterfly
valves. A patented axially pliant seat flexes against
the sealing edge of the disc when the valve is
closed. This design assures bubble tight shutoff.
Made of PTFE with a unique pliant membrane, the
bi-directional, self and pressure activated seat
returns to its original shape with every opening of
the valve because the pliant membrane causes
constant restorative forces to act on the seat
member. The eccentrically mounted disc is offset,
which provides for an uninterrupted, 360 seal.
Check valves are one of the biggest problems with
competitive heatless dryers. Our check valves have
several unique features to increase performance
and reliability. Check valves through 2” are a spring
loaded ball cone style valve. This design has the
advantages of bubble tight shutoff and does not
require radial alignment. The straight through design
is streamlined for a minimum change in velocity and
also minimizes pressure drop. Only 2 check valves
provides enhanced reliability and improved
performance.
The spring loading allows for fast sealing. The valve
body is bronze, the ball is glass filled TFE with a 316
stainless steel spring.
Reference 104pdf
Valves 3” and larger are double door spring checks.
This design has a cast iron body with aluminum
internals. The wafer has a silicone seal for
outstanding durability and performance. 304
stainless steel springs provide fast sealing.
Solenoid valves have aluminum bodies with
stainless steel internals. The orifice seat is
machined as part of the body, guaranteeing leakproof internal structure and has a buna seal for
additional protection. The low wattage coil results in
less current drain and is rated for NEMA 4 and by
UL.
Upflow drying design allows the dryer to operate
under adverse, real world conditions. Slugs of water
or oil stay on the bottom of the bed and are easier to
regenerate off. Our unique standpipe design
prevents desiccant fluidization, even under upset
conditions.
Non-lubricated switching valves are proven reliable.
Only 4 switching valves, each controlled by an
independent solenoid. Very few moving parts, very
simple design. Low pressure drop, soft seats, easy
to maintain.
ASME Code pressure vessels are standard.
Pressure gauge on each tower.
Relief valves on each tower.
Fixed orifice purge rate, calibrated for your flow.
Easy to change, impossible to go out of adjustment
or shut-off.
Afterfilter included on Model T-75 (375 SCFM and
smaller). Prefilters and afterfilters mounted on dryer
for nominal charge on all other models.
The mufflers used have been proven by years of
use in thousands of dryers. The muffler design
meets all of the requirements for OSHA regarding
noise control. The muffler is constructed with an
expansion chamber completely free of obstructions
from which the exhaust air, at reduced velocity is
softly dispersed through the openings of the
perforated cylinder wall of the muffler; free of noise
and providing complete protection to personnel from
injurious air blast. Constructed entirely of corrosion
resistant material for maintenance-free performance.
Acrobat Reader Format 11/2012
T Series Heatless Regenerative
Compressed Air Dryer
Page 7
The Brains Behind the Dryer
PLC with Allen–Bradley PanelView
Component C400 Operator Interface
A programmable logic controller with individual
input/output modules controls the dryer’s
operation. The operator interface to this
controller is the Allen-Bradley PanelView
Component C400.
Optional Dew Point Demand System
All of our dryers are designed to operate
economically.
We
realize
that
energy
consumption is a serious concern and have
designed all of our systems to minimize energy
consumption. One of our energy management
devices is the optional Dew Point Demand
System.
The Dew Point Demand System measures the
dew point of the outlet air, overriding the timer,
eliminating unnecessary switching of towers
resulting in considerable savings through
reduction of regeneration cost. Additional
savings can be realized with this system by
reducing wear on component parts, as well as
extending the life of desiccant.
Illustration: PanelView C400 Operator Interface
Housed in a NEMA 4 enclosure (indoor), this
operator interface uses a touch sensitive screen.
All control functions are performed by touching
the appropriate on-screen button or display; to
change screens, modify a setting, or enter a
value.
The Dew Point Demand System utilizes a stateof-the-art SAHARA Moisture Transmitter (SMT)
to accurately measure the actual PRESSURE
DEW POINT the dryer is delivering at all times.
The instrument reads directly to the PLC and is
displayed on the PanelView screen, which
constantly keeps you informed of dryer
performance. An adjustable set point allows you
to set the precise dew point for tower switching.
Tower switching can be activated anywhere
within the broad range of -148°F to +86°F.
Unless otherwise requested, it is factory preset
at -20°F.
The system comes standard with a 4-20 mA
output, which can be connected to a chart
recorder. Alarm contacts are also provided as
standard for audio and visual warning of high
dew point condition.
Illustration: Sahara Moisture Transmitter (SMT)
Reference 104pdf
Acrobat Reader Format 11/2012
T Series Heatless Regenerative
Compressed Air Dryer
Page 8
Specifications & Dimensions
A
B
C
MODEL
SCFM
RATING
@ 120#
SCFM
RATING
@ 100#
SCFM
RATING
@ 80#
INLET /
OUTLET
SIZE
LBS.
DESICCANT/
TOWER
PURGE
RATE
(SCFM)
LENGTH
(INCHES)
(A)
WIDTH
(INCHES)
(B)
HEIGHT
(INCHES)
(C)
WEIGHT
(POUNDS)
T-5
26
23
19
1/4
13.5
3.4
26 ¾
15
65
100
T-10
53
45
37
1/2
27.0
6.8
27 ¼
17
78
200
T-15
79
68
56
3/4
40.5
10.1
28 ½
18
81
320
T-20
106
90
74
3/4
54.0
13.5
28 ½
18
99
395
T-25
132
113
93
1
67.5
16.9
41
23
75
470
T-30
159
135
111
1
81.0
20.3
41 ½
23
84
540
T-40
211
180
149
1 1/2
108.0
27.0
44 ½
24
78 ¾
650
T-50
264
225
186
1 1/2
135.0
33.8
44 ½
24
90 ¼
780
T-75
396
338
279
2
202.5
50.6
51
30
94 ½
880
T-100
528
450
372
2
270.0
67.5
54
30
100 ¾
1000
T-125
661
563
464
2
337.5
84.4
56 ½
30
98
1400
T-150
793
675
557
2
405.0
101.3
59
30
94 ¾
1700
T-200
1057
900
743
3
540.0
135.0
61 ½
42
104 ¾
2000
T-250
1321
1125
929
3
675.0
168.8
66 ¾
44
96 ¾
2900
T-300
1585
1350
1115
3
810.0
202.5
66 ¾
44
107 ¾
3100
T-350
1850
1575
1300
3
945.0
236.3
75 ¾
45
94 ¾
3500
T-400
2114
1800
1486
3
1080.0
270.0
76
47
102
3900
T-500
2642
2250
1858
4
1350.0
337.5
78
44
119 ½
4500
T-600
3171
2700
2229
4
1620.0
405.0
84
56
108 ½
5000
T-700
3699
3150
2601
4
1890.0
472.5
84
56
118 ¼
5500
T-800
4228
3600
2972
4
2160.0
540.0
100
53
109
6500
T-900
4756
4050
3344
6
2430.0
607.5
111 ¼
50
120
7500
T-1000
5285
4500
3715
6
2700.0
675.0
111 ¼
50
127 ¼
8000
SAHARA reserves the right to make changes without notification. Some models not shown. Larger sizes available. Other pressures available.
Metric dimensions available upon request. Ratings are based on 100 PSIG, 100°F.
Reference 104pdf
Acrobat Reader Format 11/2012
T Series Heatless Regenerative
Compressed Air Dryer
Page 9
Theory of Operation
Wet compressed air enters the dryer at the bottom and is directed by non-lubricated switching valves into
the drying tower. The wet air encounters dry desiccant and moisture is transferred from the air to the
desiccant. The direction of air flow during drying is upflow; design of the towers prevents fluidization of
the desiccant. At the top of the dryer, the dry process air is directed to the outlet of the dryer through
check valves. Fifteen percent of the dry air is directed into the regenerating tower where it is
depressurized to atmospheric pressure and is used to regenerate the desiccant. After removing moisture
from the desiccant, the purge air exits the dryer through a muffler and is blown out to atmosphere. After a
preset time or based on the optional dew point system, the dryer will shift towers. At tower shift, the
regenerating tower is gradually repressurized, the switching valves sequentially shift and the offstream
tower is depressurized. Each valve is controlled by an independent solenoid valve.
Illustration: T-150 & Below Heatless Dryer Flow Schematic
Reference 104pdf
Acrobat Reader Format 11/2012
T Series Heatless Regenerative
Compressed Air Dryer
Page 10
Real World Performance
Upflow Drying/Packed Bed
Valves
In the real world, air demand fluctuates. Sometimes
compressors are turned off on Friday. Over the
weekend, your air system loses pressure. Turn on the
compressors Monday morning and the velocity through
a dryer is high enough to pulverize the desiccant.
Competitors tell you to slowly pressurize the system to
avoid desiccant fluidization.
One of the reasons dryers are purchased is to help
pneumatic valves work properly downstream; but what
about the valves on the dryer? They shift every few
minutes and often see wet, oily air. Making the valves
on the dryer perform consistently is one of the toughest
tasks faced by a dryer manufacturer. We use the
knowledge gained during the past 55 years to design
and utilize the most reliable valves possible. In the real
world, we know that components fail; usually on the
weekend when you’ve got much better things planned.
We understand this and designed the T Series to utilize
the most reliable valves on any dryer in the world. High
performance 2-way valves are non-lubricated and
maintenance-free.
At SAHARA, we designed the T Series to operate in the
real world. Packed desiccant beds allow the T to
operate at 0 to 100% flow; full line pressure or no line
pressure. You don’t have a problem downstream
with a T.
Heat of Adsorption
All dryer manufacturers make claims about dryer
efficiency. Everyone talks about the esoteric theories of
heat of adsorption, some even give you obscure
formula. In the real world, what counts is the bottom line
and that’s performance. The T Series gives you the
specified dew point with the minimum amount of purge.
Guaranteed.
Mufflers
Heatless dryers are by nature noisy. Every few minutes,
the valves shift and one tower depressurizes. There’s
no way you can disguise this blast of air. We understand
the concern about noise levels in the workplace and
provide mufflers that are specifically designed for dryer
service. In the real world, mufflers eventually get
clogged up with desiccant dust, reducing the efficiency
of the dryer. The SAHARA T Series is equipped with an
alarm that tells you when to clean the mufflers. You get
better performance and a quieter environment.
Illustration: High performance switching valve.
Reference 104pdf
Acrobat Reader Format 11/2012
T Series Heatless Regenerative
Compressed Air Dryer
Page 11
Commitment to Customer Satisfaction
Since 1957, we have been building dryers and making customers happy.
Our best sales force is our existing customers.
Here’s what they have to say about SAHARA air dryers.
“Approximately 3 years ago, we installed a
Sahara/Henderson heatless dryer sized for 3,000 SCFM.
Since installation, we have had virtually no down time. We
did have one leak in an O-ring and this was promptly
replaced by the local service people. The dryer has a digital
dew point controller which does not allow the dew point of
the air to go above -40F and also controls the units cycle.
From a maintenance standpoint, we appreciate being able
to walk over to the dryer and know exactly how it is
performing because of the digital readout. The unit seems
to be designed with ease of service in mind. It is extremely
sturdy and the workmanship and components appear to be
top quality. Pressure drop is very low, in the 2 psid range.
Should we need another dryer at this facility, I have no
problem recommending the purchase of another Sahara
dryer.” – Supervisor Mechanical Repairs, Utility Company
“In 1996, we replaced our old refrigerant dryer with a new
heatless dryer built by Sahara/Henderson. The old dryer
was incapable of delivering dew point below +40F. In fact,
after we installed a dew point monitor, we often found the
dew points to be +60F or worse. Wet air caused numerous
problems in our distribution system.
The new Sahara/Henderson dryer has worked extremely
well. We still monitor dew point and it has never risen
above -40F. All of our wet air problems have been
eliminated. Additionally, the dryer has not had any serious
failures. During our plant outage, we performed
preventative maintenance on the valves and have not had
any unscheduled shutdowns.
We have recommended the purchase of another
Sahara/Henderson dryer for another location.” – Facilities
Engineer, Automotive Industry
Reference 104pdf
“We used to use refrigerated dryers on our HVAC system.
We had problems with the old fridge dryers. The traps got
plugged up and flooded our air conditioning controls. This
shut down the air conditioning in many of our rooms. We
bought a Sahara heatless dryer rated for 100 scfm. This
dryer works. We haven’t had any problems. It’s one of the
best investments this place has ever made and I’m willing
to tell anybody.” – Maintenance Engineer, Casino
“We purchased a Henderson HL-350 Heatless dryer from
our local compressor distributor about five years ago. It has
worked fine with a couple hours a year minimal
maintenance. Early this year we needed a dryer for another
area and purchased a Henderson T-125 Heatless dryer.
We didn’t expect any problems and have not experienced
any in over eleven months of operation.” – Plant Engineer,
Chemical Company
Acrobat Reader Format 11/2012