M301-016-01 -- On-Board Cleaning Instructions
The Dry System™ supplied by Dry Systems Technologies® consists of a unique patented arrangement of components that provide an explosion proof MSHA approved diesel power package and superior emissions reduction from diesel engines. The system can operate with very minimal maintenance, but requires some attention by the operator to maintain its permissibility and clean exhaust.
The Dry System™ is fitted with a tube-and-shell heat exchanger. It reduces the exhaust temperature from about 950-1150° F in the manifold to a safe temperature of less than 300° F before exhausting to the atmosphere.
Because of the rapid cooling of the exhaust gases inside the heat exchanger, the airborne sub-micron diesel particles agglomerate (cling to each other) and form larger particles. However, some of these particles attach themselves to the cold tube walls, where they accumulate over time. This process is completely normal as part of the operation of the Dry System™, or any system that cools the exhaust gases.
After the particle accumulation has reached a certain thickness, the tubes become partially restricted; and both exhaust backpressure and temperature increase. The exhaust backpressure and the exhaust gas temperature can be monitored on the exhaust-backpressure gauge and the exhaust-temperature gauge which are conveniently mounted in the operator’s compartment.
Once the exhaust backpressure increases, the removal of these internal deposits is necessary to maintain a clean and safe exhaust system. The Dry System™ is equipped with a patented On-board Cleaning System™ that allows removal of the soot deposits while operating the machine. The On-board Cleaning System™ consists of a small water supply bottle, a metered actuator and an injection nozzle. The 1 quart (1 liter) water bottle is located inside the engine compartment, contains several shifts supply and must be filled with clean water (such as bottled water or drinking water) only. The flameproof injection nozzle is located near the inlet of the heat exchanger. A cab mounted valve is all the operator needs to perform the cleaning process while operating the machine.
When activated by the operator with the cab-mounted valve, a very small metered amount of water is injected into the hot exhaust inlet of the heat exchanger. The water flashes into steam and expands to more than 200 times of its original volume. This sudden pressure rise (and not the water itself) causes the soot deposit to dislodge from the tube walls to be carried downstream by the exhaust gas to the particulate filter where it is trapped.
M301-017-01 -- Operating Instructions
The DST Management System™ is designed to be a low maintenance, explosionproof emissions control system. It reduces the diesel particulates by an average of more than 95%, minimizes diesel odor and reduces the carbon monoxide by up to 90%. Concentration and composition on NOx remains nearly unchanged and is a function of the diesel engine design and operation. It is important for the system that performance is properly monitored by the machine operator and that the prescribed basic maintenance procedures are followed.
M301-018-01 -- CO Sampling Insturctions
MSHA requires that the engine-out untreated Carbon Monoxide of all Inby and heavy-duty Outby engines be checked weekly. The test for untreated (engine out) CO emissions is mandatory and will also provide excellent feedback to the mechanic on the engine condition.
CO sampling became a mandatory procedure when MSHA released the new Part 75 regulations. It was introduced to ensure that diesel engines are operated in “as-approved” condition and settings. In most instances when a diesel engine develops a problem, the CO output will increase. Other emissions do not necessarily follow the same trend. Whenever abnormally high CO is observed, an engine problem should be suspected, because CO increases when an engine develops a fault.
CO is an excellent diagnostic tool for the maintenance department to detect engine problems before they lead to failures. It has been used successfully by many mines in a similar way as oil analysis. The main purpose of CO sampling is to minimize exposure of the operator and other personnel to diesel exhaust.
M301-019-01 -- Pre-Operating Instructions
The DST Dry System™ requires very little maintenance, when compared with water scrubbers. The pre-op inspection is required by MSHA to ensure that there is no damage to the DST Dry System™ and all components are properly in place. It is not necessary to perform flushing and refilling of the DST Dry System™. There are no floats or water level sensors that must be checked.
The following form is intended to guide the operator through the walk-around inspection. Please refer also to any machine inspection procedures in the OEM manual, as the following page refers ONLY to the DST Dry System™.
M301-021-01 -- Cooling System Filling Procedure
The DST Dry System™ is fitted with a cooling system that incorporates a surge tank, a recovery bottle, and several vent lines to assure that the system has no trapped air. The system is self purging, once it is filled initially. As with all cooling systems, a mixture of 50% ethylene glycol and 50% treated (clean) water should be used for best performance. Never add untreated mine water to the cooling system. The following is the filling procedure for the system.
M301-022-01 -- Shutdown System Instructions
Compressed air or hydraulic oil may operate the Safety Shutdown system. The components of the Safety Shutdown system are designed to operate with either media. Both systems are fail-safe, that is pressure is required to operate.
The Safety Shutdown System is activated automatically by any one of the following events:
- High Coolant Temperature
- High Exhaust Gas Temperature
- Low Engine Oil Pressure
- Fire Suppression System Activated (Optional for underground metal/non-metal mines)
The following is a description of the system function and instructions for operations.