5672

I N D E X
CHAPTER PAGE NO.

I. II.
DESCRIPTION
Introduction Product gas specification Utilities Requirements Equipment Description 5 Nitrogen Membrane Unit Description Normal start-up and shut-down 9 2 3 4
III. IV.
V. VI. 13 VII. VIII. IX. X. 23 XI. XII. DRAWINGS: 1. 2.
Maintenance of oil filters Important points for Trouble free operation Trouble shooting operations Normal operating parameters Set Points of Instruments Broad Specification of items
16 19 20
24 25
P & I Diagram Power & Control Circuit Drawing
: :
MVS-5977-20719-01 MVS-5977-20720-01
MANUALS:` 1. Air compressor Auto Drain Trap Pressure Switch 36) : : : Atlas Copco Concept Danfoss (KP-
(GA-22)
2. 3. 4.
Pressure Holding Valve
Nirmal
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CHAPTER-I INTRODUCTION
This manual broadly covers the Technical Data, process flow description and procedures to be followed during start up, normal running, automatic trip for the Nitrogen Gas Plant.
All information and drawings given herein are strictly confidential and are to be used only for the sole purpose of operation and maintenance of this unit. All this information is the property of MVS ENGINEERING LIMITED - NEW DELHI and should not be made public or copied.
MVS ENGINEERING LIMITED shall not be responsible for any operation errors claimed to be due to lack of mention in the operation manual.
****************
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CHAPTER - II
Technical SPECIFICATIONS
a)
Capacity:
o Nitrogen gas
50 NM3/hr
b)
Nitrogen outlet condition:
o Oxygen
o Nitrogen
: : :
1% 99% 11 Barg.
o Pressure
****************
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CHAPTER - III
UTILITIES REQUIREMENTS
a) b) c)
Power Supply Connected load Control voltage for Panel : :
400 V AC, 3 phase
22 KWH 230 V AC
****************
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CHAPTER IV
EQUIPMENT DESCRIPTION
1)
AIR COMPRESSOR AND AFTERCOOLER:

a) This is an oil injectory rotary Screw type compressor used to compress atmospheric air up to 13 Barg. For more details please refer Air compressor manual.
b)
Air is cooled in the Air-cooled finned cooler. Air delivered to the PSA unit at 50C max. temp. For more details please refer air compressor manual.
2)
WET AIR RECEIVER:

Incoming compressed air from compressor has some pressure pulsations. To reduce that, an air receiver is installed before air is fed to MEMBRANE UNIT. Condensed
moisture is drained out through Auto Drain Trap/Manual Drain from air receiver bottom. This air receiver holds air at 13kg/cm2g pressure.
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3)
COALESCING FILTERS:
It consists of a pair of coarse & fine filters, which removes oil present in compressed air. Oil separation is done by the filter element which gets choked and saturated after 8 10 months of operation depending on oil load in compressed air. Regular attention is required for proper draining of separated oil and replacement of filter element to avoid any oil carry over to PSA system. These filters reduce oil content in Air up to 0.01 PPM.
4)
ACTIVATED CARBON FILTER:

This is a chemical based filter filled with Activated carbon, which adsorbs fine oil traces which remain in compressed air even after filtered by Coalescing filter. Activated carbon should be replaced every 12-months regularly to avoid any damage of Molecular sieves.
5)
AIR DRYING UNIT:

Air Drying unit is a 2-tower system. The towers are filled with Activated alumina. When adsorption of moisture takes place in one tower under pressure, at the same time desorption of moisture takes place in another tower at a atmospheric pressure. The process is automatically switched from one tower to other tower every 5 minutes. So, you keep getting dry air round the clock. This dry air you shall use as INSTRUMENT Air in your machines.
6)
AIR HEATER BEFORE MEMBRANE UNIT :

Membrane unit needs water droplets free compressed air for good performance. Air coming from Wet air receiver is fully moisture saturated, so, a low capacity electrical heater is provided in compressed air line to heat air to around 45C before entering
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Membrane unit. This high temperature prevents any water droplets going to the Membranes.
7)
DUST FILTER :
Air going to Membrane unit should be very-very pure, free from oil & dust. Oil filters are already provided in compressed air line. To make air dust free, a very fine dust filter of 0.01 micron rating is provided in compressed air line. This makes sure that no pipeline rust or dust particles would reach Membrane unit. Borosilicate glass fibre filter candle. This is special
This filter candle should be de-dusted once in
6-months by reverse compressed air pressure.
8)
MEMBRANE UNIT :
2-Membrane units are provided which are connected in parallel. Each Membrane will produce 25NM3/hr nitrogen of 99% purity. Its working principle is very well explained in Membrane Guide attached in this manual. This should be studied to understand working principle & to obtain best results and long life from the Membranes. In the Membrane unit compressed air is passed through Membrane threads. Oxygen Molecular being smaller in size gets filtered & comes outside the Membrane threads. These Membrane threads are hollow, so Nitrogen keeps flowing inside
hollow tube & comes out from the other end of Membrane tube. Oxygen is vented out continuously from the shell of Membrane unit & it should be taken outside the building through a vent pipeline.
9)
NITROGEN STORAGE TANK :

Nitrogen is produced continuously & is taken to a buffer tank for intermediate storage. From this tank Nitrogen will be used in your packing machines. Nitrogen
production capacity is constant 50NM3/hr.
So, if Nitrogen usage is less, Nitrogen
tank pressure will increase & a pressure switch provided will automatically unload Air compressor. When pressure in Nitrogen tank comes down to 10.5barg Air
compressor will automatically come on load & Nitrogen production will start.
10)
OXYGEN ANALYZER:
To check Nitrogen purity a Portable Oxygen analyzer has been supplied with this gas generator connect sample gas tubing & it starts indicating Nitrogen purity. This
operates by 9-Volts dry cells battery. Its Oxygen range is 0 to 5% Oxygen. It has electro-chemical sensor which is a consumable item. Sensor life is around 12-
months. Once exhausted, it will always show zero reading and that indicates end of senor life. At that time new Oxygen sensor should be replaced. Spare sensor is available from our company and this can be easily replaced at site.
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CHAPTER V
NITROGEN MEMBRANE UNIT DESCRIPTION
1.0) N2 Separator Structure & Nitrogen Gas Generation Principle
As shown in the structure of the N2 Separator in the attached Fig. 1, nitrogen enrichment polyimide hollow fiber membrane developed in-house by our
company are bundled, secured at both ends with a plastic tube sheet and stored in a pipe-shaped vessel. Compressed air entering from the air inlet of the N2 Separator flows into the bore of the polymide hollow fiber membrane. The wall of the hollow fiber separates the oxygen from the compressed air. The oxygen and nitrogen dissolve in the wall from the high pressure side (bore side of the hollow fiber), diffuse through the wall and are desorbed from the low pressure side (shell side of the hollow fiber). Oxygen permeates faster than nitrogen. Therefore the oxygen in the bore of the hollow fiber membrane is gradually removed as it nears the outlet. In other words, nitrogen enriched gas is obtained from the nitrogen gas outlet of the N2 Separator.
2.0) Usage Conditions

a) Pressure (1) Air supply pressure: 3 Barg to 14 Barg (max)
(2) Enriched oxygen outlet pressure: Open to atmospheric pressure (3) Maximum operating pressure: 14 Barg
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(4) Minimum operating pressure:
1 Barg
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b) Temperature (1) Air supply temperature 5 to 60C
(2) Maximum operating environment temperature: 80C c) Allowable pressure difference between inlet and outlet air: 2 Kg/Cm2g
Differential between feed air pressure and product nitrogen pressure should be within 2 Kg/Cm2g to prevent any damage on follow fiber. d) Compressed air characteristics Supply with clean dry air (i) Relative humidity less than 80% (remove moisture with air drier) (ii) Particles and 0.01m mist separator (iii) Residual Oil with 3 m air filter and 0.01 m mist separator. (iv) Hydrocarbons Less than 0.013 mg/Nm3 (0.01 ppm w/w) (remove Hydrocarbons with activated carbon if necessary) Less than 0.01 mg/Nm3(0.008ppm w/w) (Remove oil less than 0.01m (Remove particles with 3 m air filter
3.0) Factors affecting N2 separator performance

4-1. Pressure The greater the pressure, the proportionally larger the increase in the amount generated. The improvement in the recovery rate is good up to 8 Bar, but improves very little if the pressure is raised any higher. 4-2. Temperature
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If solvent or hydrocarbons are present in the atmosphere, the amount dissolved into the hollow fiber membrane decreases as the temperature increases, so the reduction in the separator performance will be small. 4-3. Moisture The water in the fluid will moisten the inner surface of the hollow fiber membrane causing poor permeability and lower performance. If the moisture content is relatively low but this condition is maintained for a long period, or, if the moisture content is high even for a relatively short period, the hollow fiber membrane may be affected.
4-4. Organic solvents & Hydrocarbons Organic solvents & hydrocarbons easily dissolve into the hollow fiber membrane but do not diffuse well and therefore tend to accumulate on fibers. These deposits of solvents and hydrocarbon prevent nitrogen and oxygen from permeating through and thus lower performance.
4.0) System Configuration

An ideal system structure for configuring an N2 separator is shown in the attached diagram.
5.0) Cautions during handling

Observe the following precautions during handling in order to protect the polymide
hollow fiber membrane and plastic tube plate stored in the N2 separator from breaking. (1) Do not drop or subject to mechanical shocks or impacts. (2) Do not subject to sudden heating or cooling. (3) Do not weld (4) Do not disassemble or modify the module. The bundled element inside the container cannot be extracted from the container. (5) Store indoors or similar location until device is to be assembled.
6.0) Cautions during Use

(1) Nitrogen gas may cause an oxygen deficiency, so be sure to comply with the following measures before attempting to use it. Use in a location with good air circulation and ventilation. Vent with fresh air while using the nitrogen gas. Make periodic leak tests of the nitrogen gas piping. (2) Enriched oxygen gas is emitted from the oxygen gas outlet on the N2 separator, so be sure to observe the following points when installing the device. Install at locations away from flammable and inflammable objects. Vent with fresh air during operation of the device.
(3) N2 Separator performance gradually declines over time. When performance drops, the oxygen concentration within the product nitrogen gas gradually rises, so install an alarm and a shut-down device on the equipment.
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(4) Do not inhale the gases (please also see (1) above) except for specific applications, like indoor air-conditioning, where appropriate controls are in place and necessary safety precautions are taken.
(5) The N2 separator was designed solely for the purpose of obtaining enriched nitrogen gas from compressed air. Do not attempt to use it for any other purpose.
7.0) Typical Applications

Laser cutting, tire filing, oil well pressure injection, anti-explosion specifications, soldering irons, plastic molding, indoor air-conditioning ( low oxygen training relaxation).
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CHAPTER VI
NORMAL START-UP AND SHUT-DOWN
A) START-UP PROCEDURE:
1. 2. The area near the unit should be clean. Check that all Electrical connections are o.k. and control panel is getting power supply. 3. Switch 'ON' the Main Switch and control supply switch and accept 'hooter' by push button on the panel. 4. Start Air compressor and maintain wet Air receiver pressure around 13 Kg/cm2g. 5. To start Nitrogen production, make sure that inlet air line valve & isolation valves of both Membrane units are in open position. This will pressurize both Membrane units & Nitrogen production will start & Nitrogen will start going to Storage tank. 6. Now check Nitrogen purity by sample tubing in storage tank. It will take
around 10-minutes to get desired purity. So, during this start-up time Nitrogen may be drained & vented from the bottom drain valve of storage tank. Draining should be continued till Nitrogen purity is achieved in storage tank.
7.
Now you can start using Nitrogen from storage tank.
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B)
NORMAL SHUT-DOWN:
1. 2. Stop Air compressor. Switch off control supply Switch (SW-1) and Main Supply switch to stop Nitrogen unit also.
C)
INDEPENDENT OPERATION OF NITROGEN UNIT :

This unit has facility to be operated totally to produce Nitrogen gas independendetly.
a)
When you want Nitrogen to be produced Air compressor running all air will go to Nitrogen Membrane pressure unit & switch Nitrogen production on Nitrogen tank, will Air
generate.By
Automatic
compressor will keep loading & unloading automatically & Nitrogen production will continue.
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CHAPTER
MAINTENANCE OF OIL FILTERS
Compressed Air to be used in PSA Nitrogen generators and Air Dryers should be oil free. If lubricated screw compressors are used, we provide 3-special filters in
compressed Air line before Membrane Unit to make air oil free.
a)
Coarse Coalescing Oil Filter:

This is Borosilicate filaments filter imported from Zander Germany. This filter removes oil mist coming with compressed Air. Separated oil is to be drained on regular intervals from the bottom drain of this filter. This filter reduces oil level to 0.1 ppm. Without this filter, oil content in Air is around 10-ppm which is highly poisonous to hollow fiber membrane. So this filter is very important.
b)
Fine Coalescing Oil Filter:

This is also identical Borosilicate filaments filter but with fine oil removal capacity. This filters down oil to 0.01 ppm. Fine oil mist gets separated and should be drained out on regular intervals from bottom drain. After this filter oil content in air is around 0.01 ppm.
c)
Activated Carbon Filter:

Air coming out from lubricated compressor has oil, in Liquid form as well as in vapor form due to high temperature of Air. While Liquid oil mist is removed by above 2-filters, but even then oil in vapor form still remains in compressed Air, which is also not desirable as it also affects Membranes life. To remove this oil vapor, an Activated carbon filter is provided as 3rd stage filter and it removes oil vapors completely.
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After these 3-filters the Air becomes absolutely oil free and is as good as air coming from a Non-lubricated compressor. This quality air gives long life of Membrane.
d)
Filters Maintenance:
i) Activated Carbon absorbs oil vapor and becomes saturated gradually. After every 12-months time full quantity should be changed by a new charge. It cannot be regenerated. Its Iodine value is around 1000. ii) Coalescing type coarse filter and Fine filter have special elements on which oil deposits on the outer surface and also oil is trapped by Borosilicate filaments. These filter candles can be easily removed by
opening filter body (without disconnecting filters from the pipelines). Every month once filter elements should be cleaned by Reverse Air pressure. For cleaning, disconnect the filter with flanges from the pipe line and connect the outlet filter flange to any other location of compressed clean Air source in reverse direction. i.e. the outlet port
should be connected to air source and inlet port should be open to atmosphere. Now pass compressed Air through the filter in reverse This exercise will clean the
direction, several times intermittently. choked pores of the filter element.
Now install back the filter at its
location in PSA plant. The candles can be re-used after such cleaning for a maximum life of 8-months operation. After 8-months continuous
running, these candles (also called filter element) should be replaced by new candles. If old candles are used for a longer period, their efficiency deteriorates and oil filtration becomes poor. So never use these filter elements beyond 8-months.
e)
Candle Fixing Inside The Filter:

Follow directions of candle fixing properly so that candle filter element remains in perfect position and No Air escapes without filtration. Also if connection of candle is broken, or candle top surface filter layer is torn off, never use such damaged filter elements any more. There have been instances where
neglecting such damage, people continued using filters and ultimately Membrane got poisoned due to poor oil separation. So never compromise on filter candle replacement expenses as it is still cheaper to replace the candles rather than spending huge money on Membrane replacement.
f)
Feed Air Temperature:

These filters are installed in the line after Air receiver and Air temperature should be maximum 45 C to get good performance of these filters. At higher Air temperature, there would be more oil mist and more oil vapor which these filters will not be able to remove completely. So make sure that compressor After cooler is working efficiently. If After cooler outlet temperature is running high, never run the gas generator to save Molecular Sieves from oil damage.
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CHAPTER VIII
IMPORTANT POINTS FOR TROUBLE FREE OPERATION
1.
Regular periodical maintenance of the Air compressors should be done as per schedule given in Air compressor manual.
2.
Check Auto drain trap of moisture separator is working well and there is no gas leakage. After every 3-4 hours manual drain valve should be opened to drain out left over moisture, if any from moisture separator.
3.
Check and ensure that all valves are opening/closing properly and pressure in both towers goes up to 13 Kg/cm2g and time sequence is correct.
4.
Check and ensure the changeover of working of valves is according to the time cycle.
5. 6. 7.
Filter elements of coalescing filters should be replaced after every 8 months. Activated carbon of the A.C. Filter should be replaced after every 12-month. A log book should be maintained in which all operating parameters should be noted every 2-hours.
**************
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CHAPTER IX
TROUBLE SHOOTING OPERATION
1. Trouble: Air Compressor not starting.
Reasons: a) Some fault with the electrical connection : Check
b) Check Air compressor manual for trouble shooting. c)

Check pressure in Air tank & Nitrogen tank. It both are full pressures, Air compressor will not start.
2.
Trouble: Air Dryer sequence timer not working.
Reasons: a) Air compressor in unloaded condition : Check : Check : Check its Motor rotating.
b) Electrical connection/power supply not OK c) Sequence Timer may be faulty
3.
Trouble: Air Dryer valves not working

Reasons: a) Solenoid valve coil faulty : Check coils & replace, if required. b) Solenoid valve energizing to not releasing air c) Air Dryer timer motor burnt-out, so, no signal to valves : Check sequence timer motor running. : Check & correct : Open Sol. Valve & clean
d) Toggle switch of Air dryer panel might be OFF
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4.
Trouble: Auto drain trap not working. Water coming from Manual drain valve but not from auto drain trap.
Reasons: a) Y-strainer choked b) Drain valve out of order : Clean the Strainer. : Replace the Drain trap.
5.
Trouble:
Reasons: a)
Insufficient N2 flow in Rotameter.
Leakage from some flange in the N2 unit Inlet air valve or Membrane inlet Ball valves might be in closed position Insufficient or low air pressure in Inlet air line before electrical heater Membrane coated with dust or oil contamination
Check leakage from any flanged joint.
b)
Check
c)
Check
d)
: Check pressure drop across Membrane unit
6.
Trouble: coming.
Reasons:
Nitrogen
purity
not
a) Very low pressure in Membrane unit: For good performance minimum pressure should be 7 Kg/cm2 b) Nitrogen flow through Membrane very dry c) Nitrogen temperature very high
: :
Check Check leakages in Nitrogen line. : Check. It should not be more than 50C if ambient temp. high, switch OFF electrical heater.
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7.
Trouble:
Air compressor loading & unloading very fast
Reasons: a) b) Nitrogen consumption very low Faulty unloading system in Air compressor Pressure switch in Nitrogen tank has low set differential : : : Check Check Check & set it right at 2-Bar differential pressure
c)
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CHAPTER X
NORMAL OPERATING PARAMETERS
a) b) e) f) g) h) i)
Wet Air receiver Press. Wet Air Receiver Temp. Membrane unit Heater pressure Heater outlet Air temperature Nitrogen Flow reading N2 Storage Tank press. Oxygen in Nitrogen gas
: : :
13 Kg/cm2g (max) 45C (max.) 13kg/cm2g : : 40 - 50C 50 NM3/hr
: :
11 barg 1%
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CHAPTER
SET POINTS OF INSTRUMENTS
a) b)
High pressure switch in N2 storage tank Low pressure setting of switch in N2 storage tank
: 11.5kg/cm2g : 10.5kg/cm2g
c)
Pressure Holding valve setting at membrane : 11 kg/cm2g unit outlet
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CHAPTER
BROAD SPECIFICATION OF ITEMS
1. Air Compressor:
a) Make b) Model c) Air Capacity d) Motor rating e) Voltage : : : Atlas Copco GA 22 : 22 KW : 400 Volts, 50 c/s 170 M3/hr
2. Air cooler:
a) Type b) Air temp. after cooler : : Fan Type ( NO RADIATOR) 40C (max.)
3. WET Air Receiver:

a) b) c) Size Op. press. Temp. : : : 300 x 1200 (ww) 13 Kg/cm2g 45C (max.)
4. Auto Moisture Drain Trap:

a) b) Make Size : : : Concept 15 NB Solenoid operated, 220 Volts
c) Type
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5.
Fine Oil Filter:

a) Make : : : RAVE A-216 50 NB
b) Model c) Size
7. A C Filter:
a) b) c) Operating pressure MOC Media : : : : : 13 Barg Carbon steel Activated Carbon 300 x 1200 (WW) 170 M3
d) Size e) Air Flow
10. Pressure Holding valve ``````````

a) b) c) Make Set Inlet Press. Size : : : Nirmal 11 kg/cm2g 25 NB
11. Membrane Air Heater:

a) b) c) Type Heat load Outlet Air Temp. : : : Cartridge, Single phase heater 0.5 KW Around 40-50C
12. Membrane N2 Separators:

a) Operating press. b) Model c) Nitrogen Purity d) Nitrogen Capacity f) Inlet Air Quality : : : : 4640 99% 50 NM3/hr : Oil free
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13 Bar
g) No. of Membrane Units
2 Nos.
13. N2 Rotameter:
a) b) c) d) Make Op. press. Flow Range End connection : : : Flow Star 13 Kg/cm2g 7 - 70 NM3/hr : 15 NB, Flanged
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14.
Pressure Holding valve (Nitrogen):

a) b) c) d) Make Set Press. Size flow : : : : Nirmal 13Kg/cm2g 25 NB 50 NM3/hr
15. N2 Storage Tank:

a) b) c) d) Geo. Volume Operating press. MOC Size : : : : 10 M3
11Kg/cm2g Carbon Steel 2000 x 2600 (ww)
17. Dust fitter at Membrane Inlet :

a) Make b) Model c) Size : : RAVE C-216 : 25NB
18. Air Dryer Timer:

a) Make b) Time cycle c) Type : : AG Electronics : 5 + 5 Min.
Motorised, 220 Volts
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19. Safety Valve at Wet Air Receiver: a) Set Pressure b) Size : : 14.3Kg/cm2g 15 NB
20. Safety Valve at N2 Storage Tank:

b) Size a) Set Pressure : : 25 NB 12.3Kg/cm2g
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Operation Manual
NITROGEN PLANT
Client MVS Job No.
: :
M/s Tyre Technocrats India Pvt. Ltd.

5977/ 2011
MVS Engineering Limited

E-24, East of Kailash, New Delhi - 110 065 (India)
Phone No. 91-11-26431908 91-11-26441921 Fax No. 91-11-26464994 91-11-26422654 Email: mvs@mvsengg.com info@mvsengg.com
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PRODUCT GUIDANCE
NITROGEN MEMBRANES
- 33 -

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I N D E X

CHAPTER PAGE NO.

P & I Diagram Power & Control Circuit Drawing

Pressure Holding Valve

Nitrogen outlet condition:

Power Supply Connected load Control voltage for Panel : :

400 V AC, 3 phase

AIR COMPRESSOR AND AFTERCOOLER:

WET AIR RECEIVER:

ACTIVATED CARBON FILTER:

AIR DRYING UNIT:

AIR HEATER BEFORE MEMBRANE UNIT :

This filter candle should be de-dusted once in

6-months by reverse compressed air pressure.

NITROGEN STORAGE TANK :

production capacity is constant 50NM3/hr.

So, if Nitrogen usage is less, Nitrogen

2.0) Usage Conditions

(4) Minimum operating pressure:

b) Temperature (1) Air supply temperature 5 to 60C

3.0) Factors affecting N2 separator performance

4.0) System Configuration

5.0) Cautions during handling

6.0) Cautions during Use

7.0) Typical Applications

Now you can start using Nitrogen from storage tank.

INDEPENDENT OPERATION OF NITROGEN UNIT :

Coarse Coalescing Oil Filter:

Fine Coalescing Oil Filter:

Activated Carbon Filter:

direction, several times intermittently. choked pores of the filter element.

Now install back the filter at its

Candle Fixing Inside The Filter:

Feed Air Temperature:

IMPORTANT POINTS FOR TROUBLE FREE OPERATION

Reasons: a) Some fault with the electrical connection : Check

b) Check Air compressor manual for trouble shooting. c)

Trouble: Air Dryer sequence timer not working.

b) Electrical connection/power supply not OK c) Sequence Timer may be faulty

Trouble: Air Dryer valves not working

d) Toggle switch of Air dryer panel might be OFF

Insufficient N2 flow in Rotameter.

Check leakage from any flanged joint.

: Check pressure drop across Membrane unit

Air compressor loading & unloading very fast

NORMAL OPERATING PARAMETERS

13 Kg/cm2g (max) 45C (max.) 13kg/cm2g : : 40 - 50C 50 NM3/hr

Pressure Holding valve setting at membrane : 11 kg/cm2g unit outlet

3. WET Air Receiver:

4. Auto Moisture Drain Trap:

Fine Oil Filter:

d) Size e) Air Flow

10. Pressure Holding valve ``````````

11. Membrane Air Heater:

12. Membrane N2 Separators:

g) No. of Membrane Units

Pressure Holding valve (Nitrogen):

15. N2 Storage Tank:

11Kg/cm2g Carbon Steel 2000 x 2600 (ww)

17. Dust fitter at Membrane Inlet :

18. Air Dryer Timer:

Motorised, 220 Volts

20. Safety Valve at N2 Storage Tank: