Operating Manual

Hydrogen Plant 250 Nm3/h

No.: 12 31 00722/00

Date: 19.03.2013
Rev.: 0
 If you have technical questions regarding
the hydrogen plant, need the assistance of
a technician or engineer, or wish to order
replacements parts,
please contact:

Mahler AGS GmbH

Inselstrasse 140
D-70327 Stuttgart
Telephone: +49-(711)-87030-0
Telefax: +49-(711)-87030-200
E-Mail: [email protected]
Internet: www.mahler-ags.com

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 Table of Contents

1 Safety............................................................................................. 1-1
1.1 Symbols Used ................................................................................ 1-2
1.2 General notes ................................................................................. 1-5
1.3 Instructions ..................................................................................... 1-5
1.4 Hydrogen plant ............................................................................... 1-6
1.4.1 Safety devices ................................................................................ 1-8
1.4.1.1 Mechanical safety devices.............................................................. 1-8
1.4.1.2 Binary automatic safety devices ..................................................... 1-9
1.4.1.3 Electrical analog automatic safety devices ..................................... 1-9
1.4.1.4 Automatic safety functions of the Step Sequence ........................ 1-11
1.4.1.5 Emergency stop functions ............................................................ 1-12
1.5 Handling hydrogen ....................................................................... 1-13
1.6 Hydrogen properties ..................................................................... 1-14
1.7 Handling natural gas .................................................................... 1-15
1.8 Properties of natural gas .............................................................. 1-15
1.9 Filling materials ............................................................................ 1-16
1.10 Instruments, pipes and vessels .................................................... 1-16
1.11 Safety protection while working at the plant ................................. 1-17
1.12 Alarm plan .................................................................................... 1-18
1.13 Explosion-protected area plan ...................................................... 1-18
1.14 Regulations on safety and prevention of accidents ...................... 1-18

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 Table of Contents

2 Description of the H2-Plant ......................................................... 2-1

2.1 Use ................................................................................................. 2-2
2.2 System specification ....................................................................... 2-3
2.3 Appropriate use .............................................................................. 2-8
2.4 Technical data ................................................................................ 2-9
2.5 Specification of operating media .................................................. 2-11
2.5.1 Natural gas ................................................................................... 2-11
2.5.2 Nitrogen ........................................................................................ 2-11
2.5.3 Instrument air ............................................................................... 2-11
2.5.4 Cooling water ............................................................................... 2-12
2.5.5 Demineralized water ..................................................................... 2-12
2.5.6 Desulphurization catalyst.............................................................. 2-12
2.5.7 Reformer catalyst ......................................................................... 2-12
2.5.8 HT-CO-reactor filling..................................................................... 2-12
2.5.9 Adsorber filling.............................................................................. 2-13

3 Filling Instructions ....................................................................... 3-1

3.1 General notes ................................................................................. 3-2
3.1.1 Desulphurizer: C10201 ................................................................... 3-3
3.1.2 HT-CO-reactor: C 14001 ................................................................ 3-4
3.1.3 Adsorbers: A14110...A14120…A14130…A14140 ......................... 3-5
3.1.4 Reformer Tubes ............................................................................. 3-6
3.1.5 Test of pressure drop of the Reformer Tubes ................................ 3-8

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4 Description of Operating Instruments ........................................ 4-1

4.1 Control Container ........................................................................... 4-2
4.2 Control Cabinet .............................................................................. 4-2
4.2.1 Main Switch .................................................................................... 4-7
4.2.2 EMERGENCY-STOP Pushbutton .................................................. 4-7
4.2.3 Illuminated Pushbutton „Control On“ .............................................. 4-7
4.2.4 Key switches .................................................................................. 4-8
4.2.5 Signal Lamp “COMMON TRIPS” .................................................... 4-8
4.2.6 Signal Lamp “COMMON WARNINGS”........................................... 4-8
4.2.7 Energy Meter .................................................................................. 4-8
4.2.8 Signal Lamps and Maintenance Switches ...................................... 4-8
4.2.9 Burner Control Unit ......................................................................... 4-8
4.2.10 Isolated barrier ............................................................................... 4-8
4.3 UPS ................................................................................................ 4-9
4.4 Process Visualisation and Control Program ................................. 4-10
4.4.1 Overview Window in Visualisation Station.................................... 4-10
4.4.2 Process pictures ........................................................................... 4-12
4.4.3 Faceplates .................................................................................... 4-13
4.4.4 Alarm display ................................................................................ 4-13
4.4.5 Trend window ............................................................................... 4-13
4.4.6 Start and Stop Sequence ............................................................. 4-14
4.4.7 Preconditions to Start up and Shut down the Plant ...................... 4-14
4.4.8 Process Pictures for Plant Configuration ...................................... 4-15
4.4.8.1 Plant Load 4-Bed Operation ......................................................... 4-15
4.4.8.2 K-Parameters ............................................................................... 4-15
4.4.8.3 Compensating Values .................................................................. 4-16
4.4.8.4 PSA Configuration 4-Bed Operation ............................................ 4-16
4.4.8.5 PSA Configuration 3-Bed Operation without A ............................. 4-16
4.4.9 Hardware Monitoring .................................................................... 4-16

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 Table of Contents

5 Start-up.......................................................................................... 5-1
5.1 First start-up ................................................................................... 5-3
5.1.1 Checks ........................................................................................... 5-3
5.1.2 Inerting the plant............................................................................. 5-4
5.1.3 Start-up of the plant systems.......................................................... 5-5
5.1.3.1 Control room and process visualisation system: ............................ 5-5
5.1.3.2 Drainage, venting, shut off valves to atmosphere .......................... 5-5
5.1.3.3 Shut off valves to pressure gauge, shut off valves to transmitter . 5-17
5.1.3.4 Instruments at Orifice measuring ................................................. 5-27
5.1.3.5 Nitrogen ........................................................................................ 5-30
5.1.3.6 Instrument air ............................................................................... 5-31
5.1.3.7 Cooling water, Oil ......................................................................... 5-41
5.1.3.8 Steam for water treatment ............................................................ 5-42
5.1.3.9 Boiler feed water .......................................................................... 5-43
5.1.3.10 Heat recovery steam instruments, Export Steam ......................... 5-46
5.1.3.11 Combustion air ............................................................................. 5-47
5.1.3.12 Burner instruments ....................................................................... 5-52
5.1.3.13 Process steam instruments .......................................................... 5-57
5.1.3.14 Natural gas instruments ............................................................... 5-57
5.1.3.15 Process gas instruments .............................................................. 5-58
5.1.3.16 Instruments to Start-up H2-production ......................................... 5-60
5.2 Starting up the plant in manual mode ........................................... 5-63
5.3 Starting up the plant in automatic mode of operation ................... 5-67
5.4 Operation...................................................................................... 5-68
5.5 Shutdown of the plant in the manual mode of operation .............. 5-68
5.6 Shutdown of the plant in the automatic mode of operation .......... 5-71
5.6.1 Standstill of the plant .................................................................... 5-71
5.7 Start-up in short form.................................................................... 5-72
5.8 Reduction of the reformer catalyst ............................................... 5-72
5.9 Reduction of the CO-catalyst ....................................................... 5-76
5.10 Putting the CO-converter out of operation .................................... 5-79
5.11 Additional information for start-up of the plant............................ 5-Add
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 Table of Contents

6 Maintenance .................................................................................. 6-1

6.1 General Information........................................................................ 6-2
6.2 Maintenance list ............................................................................. 6-3
6.2.1 Desulphurization reactor C10201 ................................................... 6-7
6.2.2 Reformer furnace D13101 .............................................................. 6-7
6.2.3 Reformer tubes............................................................................... 6-8
6.2.4 HT-CO converter ............................................................................ 6-8

7 Trouble Shooting .......................................................................... 7-1

7.1 General information ........................................................................ 7-2
7.2 List of faults .................................................................................... 7-4
7.2.1 Burner faults ................................................................................... 7-4
7.2.2 Reformer pipe faults ....................................................................... 7-4
7.2.3 Stack Faults.................................................................................... 7-5
7.2.4 Trouble Shooting ............................................................................ 7-5
7.3 Index of faults ............................................................................... 7-61

8 Listed Devices and Instruments ................................................. 8-1

9 Classification of Ex-Zone

10 Safety Data Sheet for Catalyst/Filling Material

11 Specification Insulation Vessels/Piping

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 Table of Contents

Attachments
Part 2 Drawings / Material list / P&I diagram

Material list
(List of Instruments and Equipment)
P&I-Diagram 1-27-520949-0
Sheet 1/5 Desulphurization
P&I-Diagram 1-27-520949-0
Sheet 2/5 Heat Recovery Unit
P&I-Diagram 1-27-520949-0
Sheet 3/5 HT-CO-Reactor and Gas Cooling
P&I-Diagram 1-27-520949-0
Sheet.4/5 Gas Cooling and BFW Degasifying
P&I-Diagram 1-27-520949-0
Sheet.5/5 PSA Unit
Drawings / General – and Assembly Drwg.s Part 2

Part 3 Electrical Documentation

Part 4 Pressure Vessels / Safety Valves

Part 5 Skids / Piping / Steel Structure

Part 6 Operating Manual of Sub-Supplier /

Technical Passports of Equipment

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