OPERATING & INSTRUCTIONS

M ANUAL
FOR

NITROGEN GENERATION PLANT

(CAPACITY – 400 Nm³/hr. @ 99% PURITY)

CLI EN T:

M/S. ENERMECH PTE LTD.

Supplie d By:

ENGINOX TECHNOLOGIES
305, ROYAL SQUARE, NR. R K HAL,
SCIENCE CITY ROAD,
SOLA, AHMEDABAD
PHONE :- 8000013545
Email :- info@enginoxtech.com

Visit us a t
www.enginoxtech.com

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 CO N FI D EN T I AL

This document is submit ted for the exclusive use of

M / S. ENERMECH PTE LTD. On the understanding that the recipient will maintain
the contents confidential.

The document should not be reproduced, distributed or used for any other purpose
other than originally intended, without the written authorization of
M / S. E N G I N O X T E C H N O L O G I E S

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 I N D EX
SR.N O. PAGE N O.

1) FOREWORD 04

2) GUARANTEE CERTI FICATE 05

3) GENERAL 06

4) TECHNICAL SPECIFICATIONS 07

5) PROCESS DESCRIPTION 0 8 to 1 2

6) ELECTRICAL CONTROL SEQUEN CE 13

7) OPERATING INSTRUCTIONS 1 4 ,1 5

8) CH ECK POINTS 1 6 ,1 7

9) TROUBLE SHOOTING 1 8 ,1 9

10) RECOMMENDED LIST OF SPARES 20

11) EQUI PMENTS & ACCESSORIES DETAI LS 2 1 to 2 3

12) INSPECTION AN D MAINTEN AN CE 24

13) IMPORTANT 25

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 FO R EW O R D

This manual summarizes the relevant features of operation and maintenance of the
Nitrogen plant supplied to M/S. E N E R M E C H P T E L T D .
The Manual is made for the operating & maintenance personnel who must adhere to all
the instructions, to ensure years of smooth trouble free operation.

Topping up of Carbon Molecular Sieves (CMS) may require occasionally. The

PSA, towers should not be opened and if r e quir e d, only by t rained personnel.

Whilst the client is free to utilize their own personnel for routine and non- routine
maintenance, we recommend utilization of our Authorized Services on a spot or Annual
Maintenance Contract basis, especially after the warranty period.

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 GUARANTEE CERTIFICATE

THIS IS TO CERTIFY THAT THE EQUIPMENT SUPPLIED BY US AGAINST YOUR

PO NO . – 3447623 GUARANTEED AGAINST ANY MANUFACTURING DEFECT FOR 12

MONTHS FROM THE DATE OF SUPPLY OR COMMISSIONING WHICH EVER IS EARLIER.

WE HEREBY CONFIRM THAT WE WILL REPAIR / REPLACE THE DEFECTI VE PARTS AT

OUR COST DURING THE GUARANTEE PERIOD.

DATE:

FOR, ENGINOX TECHNOLOGIES

AUTHORISED SIGNATORY

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 GENER AL

 CLIENT : M/S. ENERMECH PTE LTD

 P.O. N O. & DT. : 3447623 Dt. 17/07/2013

 PLANT SUPPLI ED : N ITROGEN GEN ERATION PLANT

 YEAR OF INSTALLATION : 2014

 JOB NO. : 1361

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 T ECH N I CAL SP ECI FI CAT I O N S
 EQUIPMENT
 TOTAL N 2 CAPACI TY
 PURITY AFTER PSA
 PURITY AFTER PSA
 OPERATING CYCLE TIME
 OPERATING TEMPERATURE
 OPERATING PRESSURE
 OUTLET PRESSURE
 OUTLET TEMPERATURE
 COOLING W ATER REQUIREMENT
 POW ER FOR CONTROL PANEL
: NITROGEN GENERATION PLANT
: 400 NM ³ / HR
: 99 % N ITROGEN IN AIR
: 1 % OXYGEN IN N ITROGEN
: 1 + 1 Min. ( Total 2 - Min.) FOR PSA
: 4 0 Deg. C
: 7 .5 Bar g
: 5 .0 TO 5 .5 Bar g
: AMBI ENT
: 1 .0 – 1 .5 N M ³ / Hr AT 3 2 Deg. C Tem p.
: 1 - PHASE - 2 3 0 VOLTS
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 P R O CESS D ESCR I P T I O N

Basic Principle of PSA Nitr oge n Ge ne r a t or : Atmospheric Air Contains 78%

of Nitrogen and 21% of Oxygen. Nitrogen in PSA method is generated by Physical
separation of Oxygen from Atmospheric air. This is done by using a special Molecular
sieve which has selective adsorption affinity for adsorption of oxygen and let the
nitrogen go out. This phenomenon of adsorption of oxygen gas under pressure is
known as Pressure Swing Adsorption i.e.- P.S.A.

Process Steps. (Please r e fe r the P& I dr awing of t h e PSA Pla n t )

1. First the air compressor sucks the air from atmosphere and compresses it to a
pressure of 7.5 BARG.

2. Now this air passes through the activated carbon filter where available oil
contamination in the air will be removed by this filter.

3. Now this air is passing through A ir Receiver and pre- filter there might be a lit t le
carbon dust in the air which needs to be filtered out for making the air clean.

4. Now this air will pass through the PSA module From Air Receiver. I n PSA module the
clean air entering one of tower is allowed to pass through the PSA bed of
chemicals, this adsorption continues for a minute, after a minute the tower got
saturated with oxygen and thus the tower changeover automatically to other tower
for oxygen adsorption and nitrogen generation. The previous tower which is saturated
with oxygen is thus allowed to vent out the oxygen to atmosphere.

5. This process is cyclic and you get a regular supply of nitrogen from either of the
tower which is collected in the surge vessel.

6. The nitrogen is analyzed for its impurity of oxygen by an online oxygen analyzer.

7. I n case the nitrogen is of desired quality then it is allowed to go to Storage Tank.

8. The system is provided with vent valves which do- not allows the nitrogen of
unwanted quality to go for storage and thus use. I t let the impure nitrogen Vent out
t ill the desired purity is achieved.

9. The nitrogen collected in storage tank can be taken for use. Storage tank is provided
with pressure switch, which stop the plant if the pressure is high and restarts the
plant if the pressure goes below the set level.
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Process description in details continued………

ACTIV AT ED CAR BO N FILTER:

Air Received from the Moisture Separator Passes through the Activated carbon filter
where Available oil contamination will be removed by this filter.

AIR R ECEIV ER :
This is same as buffer vessel/ small storage for com pressed dry air for continuous
feed of air to the PSA system and also maintains the pressure pulsation and
supply air at almost constant pressure.

P R E FI LT ER :
Physical dust in the air will be removed by this filter and moisture also. The manual
drain valve is provided at the bottom of the filter to drain out the same regularly.
PSA UNIT :
There are two towers filled with special grade Carbon Molecular Sieves ( CMS) to adsorb
O2 & CO2 present in the air. At the bottom of each tower M. S. perforated plate with 10
mm dish Hole and SS Wire mesh is welded to hold the CMS filled in the tower.
The Carbon Molecular Sieves is being filled up to the straight portion at the top of tower.
The perforated plate facing the bottom & the cover is the top supporting element
while the adsorbent is prevented from flowing out by the wire mesh. The thick layer of
the Coconut fiber mat is packed as the cover to fix the adsorbing bed. The upper
perforated plate com presses adsorbent fill to avoid undesired void. The coconut fiber
mat is squeezed together when the cover is tightened. Cycle time of PSA Unit is one
Minute + one Minute.

N I T R O GEN SU R GE V ESSEL:
Nitrogen from PSA Module will have varying purity depending upon the pressure in the
absorber during the one minute cycle time. This vessel gives product Nitrogen at constant
pressure with constant average gas purity. For analyzing the O2 percentage in the
Nitrogen gas, one sensing point for the sampling is provided on this vessel. One
pressure gauge is also provided on the vessel.

I n Surge Tank, One NRV is fit ted in reverse direction through which some of N2 gas
goes back to PSA towers after the equalization cycle, so that there is drop of 0.2 to 0.5
kg/ cm 2g

Pressure of surge tank. This gas decrease the time required for the pressure rise in
PSA towers, which leads to more production time and better purity of Nitrogen Gas.

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P R I N CI P LE O F O P ER AT I O N O F P SA U N I T :

PSA Nitrogen Generators are based on well proven technology using Carbon Molecular
Sieves (CMS) . CMS is an adsorbent having infinite number of small pores. The diameters
of the “Bottle Necks” are in the same range as those of the molecular.

Thus when CMS is used in the PSA process, an oxygen Molecule having a smaller
diameter than a Nitrogen Molecule into the pores. Therefore, the Nitrogen is recovered
to a high degree while almost all the Oxygen is adsorbed.

O 2 P ER CEN T AN D P P M AN ALY Z ER :
This analyzer is provided to measure O2 percent at surge vessel. I n case of high O2
percent, alarm is provided and it turns gas is vented to atmosphere through 3- way Vent
Valve.

N IT R O GEN FLO W M ET ER :
Flow meter provided at the inlet of the Storage tank to check the quantity of Nitrogen
flow drawn from the Surge Tank.

FLO W CO N T R O L V ALV E ( N EED LE V ALV E) :

I t is a needle valve and is provided to control the flow of Nitrogen precisely.

SAFET Y V ALV E:
I n case pressure in the vessel reaches above the designed pressure, it will start
venting Air/ Nitrogen to atmosphere. I t is for the safety of the unit against over
pressurization.

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BACK P R ESSU R E CO N T R O LLER & FI N AL T H R EE- W AY V EN T V ALV E:
The back pressure controller is installed in outlet line after the surge tank, when the
inlet pressure signal exceed the spring setting, the outlet port of BPC will open and in
case this pressure goes down, it will close the outlet port. The setting of back pressure
controller can be changed by adjusting the bolt provided at the top.
Three- way vent valve is a pneumat ically operated 3- way valve. With no com pressed
air signal, it’s bottom port is open to atmosphere. Thus when the gas generator is started
the gas init ially of low purity will go to atmosphere through this 3- way valve. This
valve close it s bottom port when it gets com pressed air through solenoid valve and
then Nitrogen gas starts going to Nitrogen storage Tank. The solenoid valve will get
energized when the vent push- button is pressed after checking the quality of product
gas for some time.

I n case of any abnormality in the plant, the control valve will open automatically and
the gas will be vented to atmosphere.

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 ELECT R I CAL CO N T R O L SEQ U EN CE

Please refer t o t he enclosed power & control circuit draw ing

(Attached with this manual)

 Check that electrical connections are available and voltage is Correct.

 PSA PLC/ Timer will trip in case of low inlet air pressure, higher inlet air tem p. and
Storage pressure,
Vent Valve will be open in case of; -

 PSA Vent valve open when the purity is higher than the set value in % or PPM
Analyzer

 The PSA Unit valve sequence will not start unless Air Pressure at Air Receiver is
lower than 4.5 Bar g.
 Three- way vent valve will allow the gas to go to the Storage Tank after vent
close.
 PSA valves will operate as per sequence chart.
 Audio- visual alarm will come in case of abnormality on the control panel, as per
detail mentioned in the drawing.

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 O P ER AT I N G I N ST R U CT I O N S
NORMAL START-UP AND SHUT-DOWN:
START-UP PROCEDURE:

1 . The area near the unit should be kept clean.

2 . Check electrical supply are o.k. Control panel is getting energized.

3 . Check the Working of all instruments.

4 . Ensure that drain valves of all equipment’s are closed.

5 . Switch 'ON' the main switch & control supply switch and accept ‘hooter’.

6 . Start the air compressor when the pressure in the air receiver goes around 4.5

bar g valve sequence for PSA Unit will also start.

7 . Observe the operation of the Unit for some time and see that the PSA module is

working all right see for the pressure rise and depressurization of towers taking

place as per the Check points.

8 . Check that minimum pressure in the adsorbing towers of PSA goes to 5.0 bar g

then after charging the PSA unit the pressure will go to Surge tank, when the

pressure reaches to the set value.

9 . Open water line valve for gas cooler and ensure that the water pressure is around

1.5 to 2.0 bar g.

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10. After the pressure in surge tank has reached up to 5.0 bar g, Switch on the PPM

oxygen analyzer.

11. Vent the gas for 5- 10 minutes, through the PSA vent valve. Adjust the Nitrogen

Rota meter for the designed flow. As soon as the Oxygen PPM or % at Surge

Tank reaches within limit s, the Vent Valve will open automatically as per the set

alarm in PPM/ oxygen analyzer now the flow of nitrogen goes to Storage vessel

for further Storage purpose and ahead Process used.

12. Check that all pressure switches / instruments are set as per the instructions

given at the time of commissioning.

NORMAL SHUT DOWN:

Switch off control supply switch and main switch.Don't disturb the setting of Needle

Valves. Stop the supply of water to cooler.

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 CH ECK P O I N T S
 Check/ m a i n t a i n va r ious Pr e ssur e s as below.

 Air Inlet Pressure 7 .5 Bar g

 Peak Pressure in PSA Tower 7 .0 Bar g

 Surge Vessel Pressure 5 .0 to 6 .0 Bar g

 Outlet Pressure a ft e r PSA 5 .0 to 5 .5 Bar g

 Outlet Pressure at storage 5 .0 to 5 .5 Bar g

 PS 1 ( Pressure Switch for Air Inlet ) 4 .5 Bar g

 PS 2 ( Pressure Switch for Gas out le t ) 5 .5 Bar g

 Oxygen Analyzer Alarm 1 - Set Point 1 % for O₂ Analyzer

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IMPORTANT POINTS FOR TROUBLE FREE OPERATION OF THE UNIT:

1. Regular maintenance of the Compressor should be done as per their operating

manual.

2 . Check auto drain trap at bottom of the moisture separator is working well and
there is no water carries over. For this after every 3- 4 hours manual drain
valves should be opened to drain out the moisture, if any.

3 . Check and ensure that all valves of PSA module are opening / closing properly
and minim um pressure in both the PSA Towers goes to 7.0 bar g and t im e
sequence is O.K.

4 . Check and ensure that changeover of towers and working of valves are
according to the time cycle.

5 . Flow of Nitrogen gas to be harmonized to obtain optimum purity and constant

watch should be there on the purity of the product gas.

6 . Check periodically setting of pressure switches, DTC and working of the other
instruments.

7. Back pressure controller function should be observed and checked periodically

so that it always maintains 5. 0to 5.5 Bar g in the surge vessel and 5.0 Bar g in
the Storage Tank

8 . A log book should be maintained in which all operating conditions should be

recorded after regular intervals of 1- hours.

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 T R O U BLE SH O O T I N G
1. Trouble: Com pressed air pressure insufficient:
I f air pressure is below 4.5 bar g then:
Reasons:
- Check any leakages in joints
- Check for supply of air from the air compressor and set the unloading
accordingly

2. Trouble: PSA module sequence programmer not working.

Reasons:

- Electrical supply not there, checks supply.

- PLC may be faulty. If required, replace it .

3. Trouble: PSA module working is erratic.

Reasons:
- PLC signal not o.k.: Check
- Some valve not working properly.

i) Check for instrument air pressure.

ii) Check for Solenoid Valve.
iii) Check for air Signal in the control valves/ Actuators.
I v) Check working of all valves.

4. Peak pressure 7 .0 bar g in PSA tower is not reaches at the end of

Adsorption cycle.

Reasons:
- Leakage m ay reduce air flow to PSA tower
- PLC time cycle disturbed
- Choked up filter before air inlet
I n Such Case Check
- Open air inlet valve to PSA until correct air flow is received
- Check for air source
- Check any leakages in joints

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 - Check working of pilot operated on/ off valves
- Check the working of the dryer and valves sequence and dry air purging.

5. Trouble: PSA Module all right but no pressure in Nitrogen Surge Tank.
Reasons:
- Check the opening of the surge tank inlet valve.
- Drain valve of Nitrogen Surge Tank may be open: Close the valve.
- Pressure indicator not working.

6. Trouble: Gas com position not o.k. a ft e r PSA module.

Reasons:
- Min. tower pressure not 7.0 bars g: check.
- Excessive air flow rate through the towers.
Over loading, check and control supply.
- One of the valves may be faulty: check and rectify the valve.
- Signal from timer may be faulty: check and replace the timer.
- Solenoid valve not working: check & replace.
- Surge Tank pressure should be in between 5.5 to 6.0 bar g.
- Check for leakages in the plant. Note that even slight leakages in the line
cause Considerable change in purity level.
- Ensure plant is operating at designed capacity.

7. Tempe r a t ur e high:
- Check the DTC it is working or not
- Check the set point of temperature as per the limit
- Oxygen content in raw nitrogen is more than 0.1%

Note: Kindly maintain the Air Compressor as per the required parameters.

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 RECOMMENDED LIST OF SPARES

S.N O. I TEM QTY.

1) 2- Way changeover Valve 02 Nos.

2) 3- Way changeover Valve 02 Nos.
3) Valve Seal Kit 02 Nos.
4) Pressure Gauge 03 Nos.
5) Pressures switch 01 No.
6) Filt er Candle 02 Nos.
7) Solenoid Valve 02 Nos.

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 EQ U I P M EN T S & ACCESSO R I ES D ET AI L

ACT I . CAR BO N FI LT ER :
SI ZE 500X1500
MAKE ENGINOX

AI R R ECEI V ER :
SI ZE 1200X1400
MAKE ENGINOX

P R E- FI LT ER :
SI ZE 400X750
MAKE ENGINOX

P SA T O W ER 1 & 2 :
SI ZE 1250X1400
MAKE ENGINOX

SU R GE V ESSEL:
SI ZE 1500X1400
MAKE ENGINOX

CH AN GE O V ER V ALV ES FO R P SA:
TYPE 2 WAY CHANGE OVER VALVE
SI ZE 80 NB
MAKE AIRA

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CH AN GE O V ER V ALV ES:
TYPE 3 WAY CHANGE OVER VALVE
SI ZE 50 NB
MAKE RYDER

SO LEN O I D V A LV ES:
TYPE 3/ 2 WAY
SI ZE ¼ ” BSP
MAKE ROTEX

AI R P R E. R EGU LAT O R W I T H LU BR I CAT O R :

TYPE REGULATOR
SI ZE ½”
MAKE Genatics

R T D:
TYPE PT- 100
SI ZE ½”
MAKE ALTOP

P R ESSU R E GAU GE:

TYPE C – BOURDON DI AL
DI AL SI ZE 4”
CONNECTI ON 3/ 8” BSP
ENTRY BOTTO

SAFET Y V ALV E:
TYPE SPRI NG LOADED
CONNECTI ON 1’’ & 1/ 2” BSP
ENTRY BOTTOM

AU T O D R AI N V ALV E:
TYPE TI MER OPERATED
CONNCETI ON 1/ 2’’
MAKE RYDER

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V EN T V ALV E:
TYPE ON/ OFF
CONNCETI ON 80 NB
MAKE AIRA

BP C:
TYPE BACK PRESSURE CONTROL
SI ZE 2”
MAKE VKE

N RV :
TYPE FLAP TYPE
SI ZE 2”
MAKE ENGINOX

FLO W M ET ER :
TYPE GLASS TUBE
SI ZE 2”
MAKE FLOWTWCH
RANGE 50 TO 500Nm ³ / Hr.

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 I N SP ECT I O N AN D M AI N T EN AN CE
I N SPECTI ON

Filt er elements need to be replaced at intervals. All vessels should be

checked for unhindered drainage at regular intervals.

The following inspection scheduled is recommended:

I N TERVAL I N SPECTI ON TYPE

Daily Condensate drainage
Daily Condensate drainage filters
Daily Residue O2 content
Daily N2 – main flow rate / purge flow rate
Daily N2 – pressure

MAI NTENANCE

I N TERVAL OPERATI N G MAI N TEN AN CE TYPE

HOURS
Quarterly - Calibration of O2- Analyser
Six monthly 2000 Replacing or cleaning of filter element
--- 8000 Inspection of O2- oxygen sensor.
Replacing if required or ordering a
spare cell.
--- 8000 Inspection of pipe connections, j oints
and process valves for leakage

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 I M P O R T AN T

Prior to start of any ma in t e na nce work, please check and ensure that none of
the following conditions could lead to a ha z a r dous situation.

 Pipeline, storage tank and filter housing are pressurized. Relieve pressure during
any maintenance work.

 Pipeline and storage tank contain nitrogen so it created suffocation in breathing!

Hence nitrogen must be vented to the outside.

 PSA- plant can start automatically. Switch off manually if required.

 Control voltage in PSA- control cabinet ( 230 V). Switch off power as relevant key
switch.

Warning and safety M e a sur e s

 Gas discharged is enriched with oxygen concentration ( approx. 31.5 Vol.-% ) . The
PSA- N2- Plant should therefore be vented to the outside of the building away
from areas where flam m ability could cause a concern.

 The product gas has insufficient the oxygen concentration for breathing ( Danger
of Suffocation!). Hence, off spec or used nitrogen must be discharged to the
outside of the plant / enclosed spaces.

 Filters must be replaced regularly as described in the manual.

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