Revision 00, March 14, 2013.

A.P. Order no. 15844

Containerized Nitrogen
Membrane System

P.O.No. 40-29043-03

Operation &
Maintenance Manual
 Nitrogen Generation System

Preface

1. ADDRESS
Name : AIR PRODUCTS AS

Postal Address : P.O. Box 4103, Kongsgaard

N-4689 Kristiansand S
NORWAY

Street Address : Vige Havnevei 78, 4 etg.

N-4633 Kristiansand S
Norway

Telephone : +47-38 03 99 00
Fax : +47-38 10 01 20

Internet e-mail : [email protected]

WEB-site : http://www.airproducts.no

2. PREFACE
This Operating and Maintenance manual has been specifically designed for
your Nitrogen Generation System. It contains the information necessary for
safe plant operation and maintenance. Efforts have been made to make the
manual brief and well arranged, keeping the operators' need in mind at all
times. The manual is compiled in accordance with EN-NS- 5820, Annex A.

We must stress the importance of being familiar with the section concerning
"Safety Measures". Nitrogen gas is an asphyxiating gas, and all personnel
should know the precautions necessary to prevent accidents.

Finally, we would like to stress the importance of proper training of new

operators, of regular maintenance and of keeping the recommended spare
parts at all times. This constitutes your best guarantee for satisfactory plant
operation.

t:\15844\08 user manual\underlag\15807_frontpage_introduction_manual.doc

 Containerized Nitrogen Membrane System
P.O.No. 40‐29043‐03
Document: 15844‐0808‐001, Rev. 00

Index for Operation &

Maintenance Manual

1. 15844‐0602‐001 DATASHEET

2. 15844‐0605‐001 P & ID

3. 15844‐0607‐001 MSDS

4. 15844‐0608‐001 GENERAL ARRANGEMENT

5. 15844‐0611‐001 E & I BLOCK DIAGRAM

6. 15844‐0616‐001 ALARM LIST

7. 15844‐0616‐003 CONTROL BLOCK & LOGIC DIAGRAM

8. 15844‐0616‐005 VISUAL DISPLAY UNIT GRAPHICS

9. 15844‐0619‐001 PROCESS DESCRIPTION

10. 15844‐0700‐001 PACKING, PRESERVATION AND TRANSPORTATION INSTRUCTIONS

11. 15844‐0807‐001 OPERATING SPARE PARTS AND MAINTENANCE SCHEDULE

12. 15844‐0805‐001 OPERATING AND MAINTENANCE INSTRUCTIONS

4+A1

SUPPLIERS FRONT SHEET (FOR A4/A3 DOCUMENTS ONLY)

SUPPLIER NAME AIR PRODUCTS AS

PURCHASE ORDER No. 40-29043-03

DOCUMENT
15844-0602-001_r01__Package Data Sheet
TITLE

TOTAL NO. OF PAGES

(including front sheet)
4
SUPPLIERS ORDER No 15844
SUPPLIERS
SUPPLIERS OWN DOCUMENT NUMBER DATE SUPPLIERS APPROVAL SIGNATURE
REVISION
15844-
3 10.01.13 VØ
2 13.09.12 VØ
1 11.09.12 VØ

SUPPLIER DOCUMENT REVIEW

BP BERAU LTD
NA 1 Reviewed and NO COMMENTS. Work may proceed.

Revise and resubmit. Work may proceed subject to incorporation PACKAGE CONTAINERIZED NITROGEN
NA 2 of changes indicated.
DESCRIPTION
MEMBRANE SYSTEM
PROJECT
NA 3
Revise and resubmit. Work may not proceed.
NUMBER 4800016254

TAG No.
NA
4 No further review required.

SHEET 1 OF 4

BP DOCUMENT NUMBER
Signature: Date:01.1
Vidar Østerberg 0.2012
0163-FMM-M-DSH-001
Print Name:
 Containerized N2 Membrane System
PO: 40-29043-03

APAS project no.: 15844

Nitrogen Production Unit Datasheet Page 2 of 4
04 For Construction SGN VØ 14.01.13
03 For Approval VØ KS 10.01.13
02 For Approval VØ KS 13.09.12
01 For Approval VØ KS 06.09.12 Manufacturer: Air Products AS
Description Prep. Check Date Doc. id: 15844-0602-001

1. PLANT SPECIFICATION DATA FOR ONE X 100% Capacity System

1 System Type: PRISM® Nitrogen Generator

2 Operating Principle: Air Separation Membrane Technology
3 Membrane Module Type: PA6050‐N1‐8B‐G2 (6" membrane)
1.1. Scope of Supply
Scope Of Supply: Item
1 Compressor Package No
2 Feed Air Buffer Tank No
3 APAS 15844 Nitrogen Generator Yes
4 LCP-5.1 Local Control Panel Yes
5 HCP-5.2 Heater Control Yes
6 AIT-8.50 Oxygen Analyser Yes
7 Junction Box Interface No
8 Inert Gas Receiver No
9 Interconnection Piping No

1 Area Location: Outdoor / Indoor Outdoor

2 Area Classification: Nonhazardous Area
3 Ambient Data: Atmosphere Coastal
4 Temperature ( min / max ) °C 0 / 35
5 Humidity (max) % 100 @ 35°C
6 Design Pressure (mech. ) Kg/cm² 28.14417 (27.6barg)
7 Design Temperature (mech.) °C -29/82

2. PERFORMANCE DATA
2.1. Nitrogen Capacity
PROCESS DATA
1 Nitrogen Capacity Nm3/h 4831(3000SCFM) 3301 (2050 SCFM) 1691 (1050 SCFM)
@ 5 vol% O2 @ 3 vol% O2 * @ 1 vol% O2 *
2 Outlet Temperature: °C 30
3 Outlet Pressure kg/cm²g 23 (22,6 barg)
4 Water Dew Point at atmospheric pressure °C -40
NOTE: * non contractual data

3. UTILITY REQUIREMENTS
3.1. Feed Air Requirements

1 Feed Air Consumption (at 25 kg/cm²g feed pressure and 45°C temp. at Nm³/h Mode 1: 11053 (6863 SCFM)
skid inlet ) Mode 2: 7570 (4700 SCFM)
Mode 3: 5798 (3600 SCFM)
2 Feed Air Pressure at Skid Edge: Max. kg/cm²g -
3 Normal kg/cm²g 25 (24,5barg)
4 Min kg/cm²g -
5 Process Design Value kg/cm²g 25 (24,5barg)

6 Feed Air Quality At Skid Edge: Oil Content ppm <0,1 ppmv
7 Solid Particle Size above 5 micron % 98 removed
8 Particle Concentration (max) micron 1
 Containerized N2 Membrane System
PO: 40-29043-03

APAS project no.: 15844

Nitrogen Production Unit Datasheet Page 3 of 4
04 For Construction SGN VØ 14.01.13
03 For Approval VØ KS 10.01.13
02 For Approval VØ KS 13.09.12
01 For Approval VØ KS 06.09.12 Manufacturer: Air Products AS
Description Prep. Check Date Doc. id: 15844-0602-001

9 Feed Air Temp. At Skid Edge: Max. °C 50

10 Min °C 45
11 Design Value for Heater °C 45
12 Feed Air Dew point at operating pressure °C 100% Saturated
3.2. Electrical/Instrument power Supply Requirements.
1 Electrical Heater 400V 50Hz 3 ph (3 wire) kW 60
2 Instrumentation, 24VDC kW 0,5
NOTE:

4. DESIGN, CODES AND CERTIFICATIONS

4.1. Third Party Inspection
1 Certifying Authorities (IIA) N/A
NOTE:

4.2. Design Codes

1 Feed Air Heater ASME VIII, Div.1 (Non U-Stamp)
2 Feed Air Filter ASME VIII, Div.1 (Non U-Stamp)
3 Membrane Modules Air Product Standard, Un coded vessel
4 Feed air, Product and Off-spec Nitrogen pipelines ASME B31.3/ANSI B16.5
5 Feed air and Product manifolds/lines inside Membrane Module Cabinet Air Products Standard: Instrument pipe tubing &
fittings.
6 Carbon bed NA
7 Container DNV2.7-1
8 Control Panel and Instrumentation Nonhazardous area
9 Heater Control Panel Nonhazardous area
10
NOTE:

5. ALARM LIST
Alarm Sensor Type Alarm Monitoring Sensor set point Remarks
Tag. no
1 See P&ID for details
6. MATERIALS OF CONSTRUCTION
6.1. Piping
1 Feed Air Piping-Upstream Membrane Separators. NORSOK ANSI B31.3/ANSI B36.19/B16.5/B16.9
Class BS20
2 Nitrogen Piping-Downstream Membrane Separators. NORSOK ANSI B31.3/ANSI B36.19/B16.5/B16.9
Class BS20
3 Permeate vent Flange NORSOK ANSI B31.3/ANSI B36.19/B16.5/B16.9
Class BS20
4 Feed air Manifold / Nitrogen Manifold for Membrane 316 SS Manifolds with Instrument fittings for
Module inter connection inside Cabinets connection of membranes
6.2. Valves
1 Needle Valves Stainless Steel N/A
2 Carbon Steel NA
3 Ball Valves Stainless Steel PI 6D/BS5351-A182F316/AISI 316
4 Carbon Steel NA
5 Globe Valves 316 SS NA
6 Check Valves Stainless Steel 316 SS
7 Control valve Stainless Steel 316 SS (Masonilan)
 Containerized N2 Membrane System
PO: 40-29043-03

APAS project no.: 15844

Nitrogen Production Unit Datasheet Page 4 of 4
04 For Construction SGN VØ 14.01.13
03 For Approval VØ KS 10.01.13
02 For Approval VØ KS 13.09.12
01 For Approval VØ KS 06.09.12 Manufacturer: Air Products AS
Description Prep. Check Date Doc. id: 15844-0602-001

6.3. Other Equipment

1 Feed Air Heater Vessel Stainless Steel ASTM AISI 316/36L
2 Feed Air Filter Vessel Stainless Steel ASTM AISI 316/36L
3 Membrane Separator Module Pressurised part Aluminum AL
4 Non-pressurized part Aluminum AL
7. NOZZLE /CONNECTION SCHEDULE
1 Terminal Point Description Size Rating End
2 TP-1 Feed Air Inlet 6” 300# ANSI B16.5
3 TP-2 Nitrogen Outlet 4” 300# ANSI B16.5
4 TP-4 Off Spec Outlet 4” 300# ANSI B16.5
5 TP-4 A/B Permeate Outlet approx. 1,1m² -- --
8. SURFACE TREATMENT AND PAINTING
1 Feed Air Filter Stainless Steel Uncoated, 10% X-RAY BW. 100% DPI
2 Feed Air Heater Stainless Steel Uncoated, 10% X-RAY BW. 100% DPI
3 Membrane Modules AL Uncoated
4 Piping ( Tubing, Fittings) Stainless Steel Uncoated, 10% X-RAY BW. 100% DPI
5 Container inside CS Doc: 15844-0902-001/Doc: 0163-FMM-Q-PRO-001
6 Container outside CS Doc: 15844-0902-001/Doc: 0163-FMM-Q-PRO-001
9. WEIGHT AND DIMENSIONS
9.1. Weight
1 Nitrogen Generator Package Dry kg 10000
2 Operation kg 10000
3 Max maintenance weight kg 70
9.2. Dimensions (Overall Size)
1 Nitrogen Generator Package (L x W x H) 6058 x 2438 x 2735
Material Safety Data Sheet
Version 1.6 MSDS Number 300000000099
Revision Date 07/20/2004 Print Date 02/07/2011

1. PRODUCT AND COMPANY IDENTIFICATION

Product name : Nitrogen

Chemical formula : N2

Synonyms : Nitrogen, Nitrogen gas, Gaseous Nitrogen, GAN

Product Use Description : General Industrial

Company : Air Products and Chemicals,Inc

7201 Hamilton Blvd.
Allentown, PA 18195-1501

Telephone : 800-345-3148

Emergency telephone number : 800-523-9374 USA

+1 610 481 7711 International

2. COMPOSITION/INFORMATION ON INGREDIENTS

Components CAS Number Concentration

(Volume)
Nitrogen 7727-37-9 100 %

Concentration is nominal. For the exact product composition, please refer to Air Products technical
specifications.

3. HAZARDS IDENTIFICATION

Emergency Overview
High pressure gas.
Can cause rapid suffocation.
Self contained breathing apparatus (SCBA) may be required.

Potential Health Effects

Inhalation : In high concentrations may cause asphyxiation. Asphyxiation may bring about
unconsciousness without warning and so rapidly that victim may be unable to
protect themselves.

Eye contact : No adverse effect.

Skin contact : No adverse effect.

Ingestion : Ingestion is not considered a potential route of exposure.

Chronic Health Hazard : Not applicable.

Exposure Guidelines

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Air Products and Chemicals,Inc Nitrogen
 Material Safety Data Sheet
Version 1.6 MSDS Number 300000000099
Revision Date 07/20/2004 Print Date 02/07/2011

Primary Routes of Entry : Inhalation

Target Organs : None known.

Symptoms : Exposure to oxygen deficient atmosphere may cause the following symptoms:
Dizziness. Salivation. Nausea. Vomiting. Loss of mobility/consciousness.

Aggravated Medical Condition

None.

Environmental Effects
Not harmful.

4. FIRST AID MEASURES

General advice : Remove victim to uncontaminated area wearing self contained breathing
apparatus. Keep victim warm and rested. Call a doctor. Apply artificial
respiration if breathing stopped.

Eye contact : Not applicable.

Skin contact : Not applicable.

Ingestion : Ingestion is not considered a potential route of exposure.

Inhalation : Remove to fresh air. If breathing has stopped or is labored, give assisted
respirations. Supplemental oxygen may be indicated. If the heart has stopped,
trained personnel should begin cardiopulmonary resuscitation immediately. In
case of shortness of breath, give oxygen.

5. FIRE-FIGHTING MEASURES

Suitable extinguishing media : All known extinguishing media can be used.

Specific hazards : Upon exposure to intense heat or flame, cylinder will vent rapidly and or rupture
violently. Product is nonflammable and does not support combustion. Move
away from container and cool with water from a protected position. Keep
containers and surroundings cool with water spray.

Special protective equipment : Wear self contained breathing apparatus for fire fighting if necessary.
for fire-fighters

6. ACCIDENTAL RELEASE MEASURES

Personal precautions : Evacuate personnel to safe areas. Wear self-contained breathing apparatus
when entering area unless atmosphere is proved to be safe. Monitor oxygen
level. Ventilate the area.

Environmental precautions : Do not discharge into any place where its accumulation could be dangerous.
Prevent further leakage or spillage if safe to do so.

2/7
Air Products and Chemicals,Inc Nitrogen
 Material Safety Data Sheet
Version 1.6 MSDS Number 300000000099
Revision Date 07/20/2004 Print Date 02/07/2011

Methods for cleaning up : Ventilate the area.

Additional advice : If possible, stop flow of product. Increase ventilation to the release area and
monitor oxygen level. If leak is from cylinder or cylinder valve, call the Air
Products emergency telephone number. If the leak is in the user's system,
close the cylinder valve, safely vent the pressure, and purge with an inert gas
before attempting repairs.

7. HANDLING AND STORAGE

Handling
Protect cylinders from physical damage; do not drag, roll, slide or drop. Do not allow storage area temperature
to exceed 50°C (122°F). Only experienced and proper ly instructed persons should handle compressed gases.
Before using the product, determine its identity by reading the label. Know and understand the properties and
hazards of the product before use. When doubt exists as to the correct handling procedure for a particular gas,
contact the supplier. Do not remove or deface labels provided by the supplier for the identification of the cylinder
contents. When moving cylinders, even for short distances, use a cart (trolley, hand truck, etc.) designed to
transport cylinders. Leave valve protection caps in place until the container has been secured against either a
wall or bench or placed in a container stand and is ready for use. Use an adjustable strap wrench to remove
over-tight or rusted caps. Before connecting the container, check the complete gas system for suitability,
particularly for pressure rating and materials. Before connecting the container for use, ensure that back feed
from the system into the container is prevented. Ensure the complete gas system is compatible for pressure
rating and materials of construction. Ensure the complete gas system has been checked for leaks before use.
Employ suitable pressure regulating devices on all containers when the gas is being emitted to systems with
lower pressure rating than that of the container. Never insert an object (e.g. wrench, screwdriver, pry bar, etc.)
into valve cap openings. Doing so may damage valve, causing a leak to occur. Open valve slowly. If user
experiences any difficulty operating cylinder valve discontinue use and contact supplier. Close container valve
after each use and when empty, even if still connected to equipment. Never attempt to repair or modify
container valves or safety relief devices. Damaged valves should be reported immediately to the supplier. Close
valve after each use and when empty. Replace outlet caps or plugs and container caps as soon as container is
disconnected from equipment. Do not subject containers to abnormal mechanical shocks which may cause
damage to their valve or safety devices. Never attempt to lift a cylinder by its valve protection cap or guard. Do
not use containers as rollers or supports or for any other purpose than to contain the gas as supplied. Never
strike an arc on a compressed gas cylinder or make a cylinder a part of an electrical circuit. Do not smoke while
handling product or cylinders. Never re-compress a gas or a gas mixture without first consulting the supplier.
Never attempt to transfer gases from one cylinder/container to another. Always use backflow protective device
in piping. When returning cylinder install valve outlet cap or plug leak tight. Never use direct flame or electrical
heating devices to raise the pressure of a container. Containers should not be subjected to temperatures above
50°C (122°F). Prolonged periods of cold temperature below -30°C (-20°F) should be avoided.

Storage
Full containers should be stored so that oldest stock is used first. Containers should be stored in a purpose build
compound which should be well ventilated, preferably in the open air. Stored containers should be periodically
checked for general condition and leakage. Observe all regulations and local requirements regarding storage of
containers. Protect containers stored in the open against rusting and extremes of weather. Containers should
not be stored in conditions likely to encourage corrosion. Containers should be stored in the vertical position and
properly secured to prevent toppling. The container valves should be tightly closed and where appropriate valve
outlets should be capped or plugged. Container valve guards or caps should be in place. Keep containers tightly
closed in a cool, well-ventilated place. Store containers in location free from fire risk and away from sources of
heat and ignition. Full and empty cylinders should be segregated. Do not allow storage temperature to exceed
50°C (122°F). Return empty containers in a timely m anner.

3/7
Air Products and Chemicals,Inc Nitrogen
 Material Safety Data Sheet
Version 1.6 MSDS Number 300000000099
Revision Date 07/20/2004 Print Date 02/07/2011

Technical measures/Precautions
Containers should be segregated in the storage area according to the various categories (e.g. flammable, toxic,
etc.) and in accordance with local regulations. Keep away from combustible material.

8. EXPOSURE CONTROLS / PERSONAL PROTECTION

Engineering measures
Provide natural or mechanical ventilation to prevent oxygen deficient atmospheres below 19.5% oxygen.

Personal protective equipment

Respiratory protection : Self contained breathing apparatus (SCBA) or positive pressure airline with
mask are to be used in oxygen-deficient atmosphere. Air purifying respirators
will not provide protection. Users of breathing apparatus must be trained.

Hand protection : Sturdy work gloves are recommended for handling cylinders.
The breakthrough time of the selected glove(s) must be greater than the
intended use period.

Eye protection : Safety glasses recommended when handling cylinders.

Skin and body protection : Safety shoes are recommended when handling cylinders.

Special instructions for : Ensure adequate ventilation, especially in confined areas.

protection and hygiene

Remarks : Simple asphyxiant.

9. PHYSICAL AND CHEMICAL PROPERTIES

Form : Compressed gas.

Color : Colorless gas

Odor : No odor warning properties.

Molecular Weight : 28 g/mol

Relative vapor density : 0.97 (air = 1)

Density : 0.075 lb/ft3 (0.0012 g/cm3) at 70 °F (21 °C)

Note: (as vapor)

Specific Volume : 13.80 ft3/lb (0.8615 m3/kg) at 70 °F (21 °C)

Boiling point/range : -321 °F (-196 °C)

Critical temperature : -233 °F (-147 °C)

Melting point/range : -346 °F (-210 °C)

4/7
Air Products and Chemicals,Inc Nitrogen
 Material Safety Data Sheet
Version 1.6 MSDS Number 300000000099
Revision Date 07/20/2004 Print Date 02/07/2011

Water solubility : 0.02 g/l

10. STABILITY AND REACTIVITY

Stability : Stable under normal conditions.

Hazardous decomposition : None.

products

11. TOXICOLOGICAL INFORMATION

Acute Health Hazard

Ingestion : No data is available on the product itself.

Inhalation : No data is available on the product itself.

Skin. : No data is available on the product itself.

12. ECOLOGICAL INFORMATION

Ecotoxicity effects
Aquatic toxicity : No data is available on the product itself.

Toxicity to other organisms : No data available.

Persistence and degradability

Mobility : No data available.

Bioaccumulation : No data is available on the product itself.

Further information
No ecological damage caused by this product.

13. DISPOSAL CONSIDERATIONS

Waste from residues / unused : Contact supplier if guidance is required. Return unused product in orginal
products cylinder to supplier.

Contaminated packaging : Return cylinder to supplier.

14. TRANSPORT INFORMATION

CFR
Proper shipping name : Nitrogen, compressed
Class : 2.2

5/7
Air Products and Chemicals,Inc Nitrogen
 Material Safety Data Sheet
Version 1.6 MSDS Number 300000000099
Revision Date 07/20/2004 Print Date 02/07/2011

UN/ID No. : UN1066

IATA
Proper shipping name : Nitrogen, compressed
Class : 2.2
UN/ID No. : UN1066

IMDG
Proper shipping name : NITROGEN, COMPRESSED
Class : 2.2
UN/ID No. : UN1066

CTC
Proper shipping name : NITROGEN, COMPRESSED
Class : 2.2
UN/ID No. : UN1066

Further Information
Avoid transport on vehicles where the load space is not separated from the driver's compartment. Ensure vehicle
driver is aware of the potential hazards of the load and knows what to do in the event of an accident or an
emergency.

15. REGULATORY INFORMATION

OSHA Hazard Communication Standard (29 CFR 1910.1200) Hazard Class(es)

Compressed Gas.

Country Regulatory list Notification

USA TSCA Included on Inventory.
EU EINECS Included on Inventory.
Canada DSL Included on Inventory.
Australia AICS Included on Inventory.
South Korea ECL Included on Inventory.
China SEPA Included on Inventory.
Philippines PICCS Included on Inventory.
Japan ENCS Included on Inventory.

EPA SARA Title III Section 312 (40 CFR 370) Hazard Classification:
Sudden Release of Pressure Hazard.

US. California Safe Drinking Water & Toxic Enforcement Act (Proposition 65)
This product does not contain any chemicals known to State of California to cause cancer, birth defects or any other
harm.

16. OTHER INFORMATION

NFPA Rating

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Air Products and Chemicals,Inc Nitrogen
 Material Safety Data Sheet
Version 1.6 MSDS Number 300000000099
Revision Date 07/20/2004 Print Date 02/07/2011

Health : 0
Fire : 0
Instability : 0
Special : SA

HMIS Rating
Health : 0
Flammability : 0
Physical hazard : 3

Prepared by : Air Products and Chemicals, Inc. Global EH&S Product Safety Department

For additional information, please visit our Product Stewardship web site at
http//www.airproducts.com/productstewardship/

7/7
Air Products and Chemicals,Inc Nitrogen
 12 11 10 9 8 7 6 5 4 3 2 1
PROPRIETARY NOTICE: THIS DOCUMENT AND INFORMATION HEREIN IS THE PROPERTY OF
AIR PRODUCTS AS, NORWAY (APAS), AND MUST BE KEPT CONFIDENTIAL AND NOT DISCLOSED
WITHOUT APAS AGREEMENT, NOR USED, IN WHOLE OR IN PART, WITHOUT THEWRITTEN PERMISSION
WEIGHT & OVERALL DIMENSION
OF APAS. APAS AUTHORIZES THE NECESSARY AND REASONABLE USE OF THIS DOCUMENT, AND THE DRY/ OPERATION WEIGHT 11000 kg
H INFORMATION HEREIN, SOLELY FOR THE EVALUATION, INSTALLATION, OPERATION AND MAINTENANCE H
OVERALL SIZE (L x W x H) 6058 x 2438 x 2735 mm
OF THE SYSTEMS. NO OTHER USE IS AUTHORIZED
D D MAX. MAINTENANCE WEIGHT 67 kg (ELECTRIC PRE-HEATER)

= C.O.G.
C.O.G.
CONDITION MAX. WEIGHT
X Y Z
DRY/ OPERATION 11000 kg 3050 mm 1120 mm 1320 mm

WARNING
G G

2735
HATCH TO BE
REMOVED
BEFORE
START-UP

C.O.G.: Z1324,6

DATUM LINE
DATUM LINE
DATUM LINE
C.O.G.: X3044,4 C.O.G.: Y1120,4

F F
6058 2438

RIGHT END VIEW ELEVATION VIEW LEFT END VIEW

ACCESS DOOR TRAIL

C B

E E
1200

AIR PREHEATER
REMOVAL AREA
(INSIDE CONTAINER)

E E
D D
4838

2438

F F

C A AREA REQUIERED
A C
1200

FOR OPERATION

1200 6058 1200

3D-VIEW
(NOT IN SCALE)
8458
MEMBRANE COMPARTMENT DOOR;
C DOOR TRAIL. MAINTENANCE PURPOSE ONLY.

PLAN VIEW
B B B

COMPANY : CONTRACTOR : VENDOR :

NOTED :
1) ALL DIMENSIONS ARE IN mm UNLESS OTHERWISE NOTED. BP BERAU, Ltd PT.FAJAR MAS MURNI
2) SEE SHEET NO.2 AND 3 FOR ADDITIONAL VIEWS AND FOOTPRINT.
3) OPERATION AREA (DOTTED AREA): REQUIRED FOR DAILY INSPECTION, BUSINESS DEVELOPMENT DIVISION
DRAWING NO. :
ENGINEERING PROCUREMENT & CONTRACTING GROUP
MAINTENANCE AND OPERATION. 15844-0608-001
4) ALL TOLERANCES IN ACCORDANCE WITH NS-EN 1993 GRADE B.
PROJECT : TITLE :
NITROGEN MEMBRANE SYSTEM
GENERAL ARRANGEMENT DRAWING
2 01 0163-FMM-R-PID-001 P & ID CONTAINERIZED NIRTOGEN
1 01 0163-FMM-M-DSH-001 PACKAGE DATA SHEET 00 04.10.12 ISSUED FOR APPROVAL JFS VØ MEMBRANE SYSTEM & BOOSTER SCALE SIZE SHEET DRAWING NO. REV
A COMPRESSOR PACKAGES A
NO. REV DRAWING NO TITLE
REV DATE DESCRIPTION 1:25 A1 1 OF 3 0163-FMM-M-GAR-002 00
REFERENCE DRAWING AP FMM BP
12 11 10 9 8 7 6 5 4 3 2 1
 12 11 10 9 8 7 6 5 4 3 2 1
PROPRIETARY NOTICE: THIS DOCUMENT AND INFORMATION HEREIN IS THE PROPERTY OF
AIR PRODUCTS AS, NORWAY (APAS), AND MUST BE KEPT CONFIDENTIAL AND NOT DISCLOSED NOZZLE SCHEDULE
WITHOUT APAS AGREEMENT, NOR USED, IN WHOLE OR IN PART, WITHOUT THEWRITTEN PERMISSION
TP DIM CONNECTION SERVICE
OF APAS. APAS AUTHORIZES THE NECESSARY AND REASONABLE USE OF THIS DOCUMENT, AND THE
H INFORMATION HEREIN, SOLELY FOR THE EVALUATION, INSTALLATION, OPERATION AND MAINTENANCE N1 6" (DN150) ASME B16.5 #300 RF FEED AIR INLET H
OF THE SYSTEMS. NO OTHER USE IS AUTHORIZED N2 4" (DN100) ASME B16.5 #300 RF NITROGEN OUTLET
N3 1" (DN25) NPT (F); ASME B16.11 #3000 OPEN DRAIN OUTLET
N4 1" (DN25) NPT (F); ASME B16.11 #3000 INSTRUMENT AIR SUPPLY

ALARM BEACON;
XI-5.52 EQUIPMENT DESCRIPTION
TAG.NO. DESCRIPTION
XV-8.31 ON/OFF FEED AIR INLET VALVE
XV-8.55A ON/OFF NITROGEN OUTLET VALVE
XV-8.55B ON/OFF NITROGEN VENT VALVE
FV-8.54 FLOW CONTROL VALVE
WS-8.11 WATER SEPARATOR
F-8.13/14 PARTICLE/ COALESCING FILTER
G H-8.15 AIR PREHEATER G

AT SAFE LOCATION
PERMEATE/ VENT
MS-8.18 MEMBRANE SEPARATORS

TO AMBIENT AIR
PERMEATE/
VENT LOUVRE

TP
N2
250

TP
N4
250

POWER SUPPLY TP
PUT-THROUGH ENTRY N1
250

F TP F
N3
220

LIMIT SWITCH;
500 300 2614
ZSC-8.10

TP TP TP TP VIEW B-B ( 1 : 20 )
N4 N2 N1 N3 (OMITTED FOR CLEARITY; ROTATED 90° CW)
POWER SUPPLY
PUT-THROUGH ENTRY

VIEW A-A ( 1 : 20 )
(OMITTED FOR CLEARITY)

E E

PDT XV
8.32 8.55A

TT
8.39

XV-8.55B FV-8.54
D D

SILENCER
MS-8.18
MS-8.18

WS-8.11
F-8.14

F-8.13
MS-8.18

XV-8.31
NV-8.56
XV-8.55A

LCV-8.36
LCV-8.37
LCV-8.38
C C

VIEW D-D ( 1 : 20 )
(OMITTED FOR CLEARITY) SECTION E-E ( 1 : 20 )
(ROTATED 180°)

B B

COMPANY : CONTRACTOR : VENDOR :

NOTED :
BP BERAU, Ltd PT.FAJAR MAS MURNI
BUSINESS DEVELOPMENT DIVISION
DRAWING NO. :
ENGINEERING PROCUREMENT & CONTRACTING GROUP
15844-0608-001
PROJECT : TITLE :
NITROGEN MEMBRANE SYSTEM
GENERAL ARRANGEMENT DRAWING
2 01 0163-FMM-R-PID-001 P & ID CONTAINERIZED NIRTOGEN
1 01 0163-FMM-M-DSH-001 PACKAGE DATA SHEET 00 04.10.12 ISSUED FOR APPROVAL JFS VØ MEMBRANE SYSTEM & BOOSTER SCALE SIZE SHEET DRAWING NO. REV
A COMPRESSOR PACKAGES A
NO. REV DRAWING NO TITLE
REV DATE DESCRIPTION 1:25 A1 2 OF 3 0163-FMM-M-GAR-002 00
REFERENCE DRAWING AP FMM BP
12 11 10 9 8 7 6 5 4 3 2 1
 12 11 10 9 8 7 6 5 4 3 2 1
PROPRIETARY NOTICE: THIS DOCUMENT AND INFORMATION HEREIN IS THE PROPERTY OF
AIR PRODUCTS AS, NORWAY (APAS), AND MUST BE KEPT CONFIDENTIAL AND NOT DISCLOSED NOZZLE SCHEDULE
WITHOUT APAS AGREEMENT, NOR USED, IN WHOLE OR IN PART, WITHOUT THEWRITTEN PERMISSION
TP DIM CONNECTION SERVICE
OF APAS. APAS AUTHORIZES THE NECESSARY AND REASONABLE USE OF THIS DOCUMENT, AND THE
H INFORMATION HEREIN, SOLELY FOR THE EVALUATION, INSTALLATION, OPERATION AND MAINTENANCE N1 6" (DN150) ASME B16.5 #300 RF FEED AIR INLET H
OF THE SYSTEMS. NO OTHER USE IS AUTHORIZED N2 4" (DN100) ASME B16.5 #300 RF NITROGEN OUTLET
N3 1" (DN25) NPT (F); ASME B16.11 #3000 OPEN DRAIN OUTLET
N4 1" (DN25) NPT (F); ASME B16.11 #3000 INSTRUMENT AIR SUPPLY

EQUIPMENT DESCRIPTION
TAG.NO. DESCRIPTION
XV-8.31 ON/OFF FEED AIR INLET VALVE
XV-8.55A ON/OFF NITROGEN OUTLET VALVE
XV-8.55B ON/OFF NITROGEN VENT VALVE
FV-8.54 FLOW CONTROL VALVE
XV
8.55B WS-8.11 WATER SEPARATOR
FV-8.54
F-8.13/14 PARTICLE/ COALESCING FILTER
XV-8.55B
G H-8.15 AIR PREHEATER G
FE-8.54 XV-8.55A MS-8.18 MEMBRANE SEPARATORS
NOTE:
PANEL 5.1-HMI TO BE DEMOUNTED

H-8.15
5.1
BEFORE AIR PREHEATER H-8.15 IS
HMI
REMOVED FOR INSPECTION.

SILENCER

SILENCER
MS-8.18

MS-8.18

XV-8.31
NV-8.56
LCP-5.1 HCP-5.2

TP
N2

250
AIT-8.50
TP
F N4 F

250
TP

LCV-8.36
N1

250
TP
LOCAL N3

220
DRAIN

SECTION F-F ( 1 : 20 ) VIEW C-C ( 1 : 20 )

(OMITTED FOR CLEARITY; ROTATED 90° CCW)

E E

D D

C C

B B

COMPANY : CONTRACTOR : VENDOR :

NOTED :
BP BERAU, Ltd PT.FAJAR MAS MURNI
BUSINESS DEVELOPMENT DIVISION
DRAWING NO. :
ENGINEERING PROCUREMENT & CONTRACTING GROUP
15844-0608-001
PROJECT : TITLE :
NITROGEN MEMBRANE SYSTEM
GENERAL ARRANGEMENT DRAWING
2 01 0163-FMM-R-PID-001 P & ID CONTAINERIZED NIRTOGEN
1 01 0163-FMM-M-DSH-001 PACKAGE DATA SHEET 00 04.10.12 ISSUED FOR APPROVAL JFS VØ MEMBRANE SYSTEM & BOOSTER SCALE SIZE SHEET DRAWING NO. REV
A COMPRESSOR PACKAGES A
NO. REV DRAWING NO TITLE
REV DATE DESCRIPTION 1:25 A1 3 OF 3 0163-FMM-M-GAR-002 00
REFERENCE DRAWING AP FMM BP
12 11 10 9 8 7 6 5 4 3 2 1
 SUPPLIERS FRONT SHEET (FOR A4/A3 DOCUMENTS ONLY)

SUPPLIER NAME AIR PRODUCTS AS

PURCHASE ORDER No. 40-29043-03

DOCUMENT
Alarm List
TITLE

TOTAL NO. OF PAGES

(including front sheet)

SUPPLIERS ORDER No 15844

SUPPLIERS
SUPPLIERS OWN DOCUMENT NUMBER DATE SUPPLIERS APPROVAL SIGNATURE
REVISION
15844-0616-001 1 28.01.13 TE

SUPPLIER DOCUMENT REVIEW

BP BERAU LTD
NA 1 Reviewed and NO COMMENTS. Work may proceed.

Revise and resubmit. Work may proceed subject to incorporation PACKAGE CONTAINERIZED NITROGEN
NA 2 of changes indicated.
DESCRIPTION
MEMBRANE SYSTEM
PROJECT
NA 3
Revise and resubmit. Work may not proceed.
NUMBER 4800016254

TAG No.
NA 4
No further review required.

SHEET 1 OF 3

BP DOCUMENT NUMBER
Signature: TE Date:28.01.13
0163-FMM-F-IND-001
Print Name:
 Doc. No.: 15844-0616-001

Alarm List – Nitrogen Production Unit Page 2 of 3

APAS Ref.: 15844

Customer.: PT Fajar Mas Murni (FMM) / BP Indonesia
01 Re-issued for approval TE VØ 28.01.13 Req. / P.O. No.:
00 Issued for Construction GL RH 06.09.12 Project: Tangguh Lang Facility
Rev Description Prep. Chk. Date Yard / Hull No.: Nitrgen Membrane System

Sensor Type
Alarm Alarm Location of Sensor Alarm Alarm in Panel Shut
ID Monitoring Sensor Range Setting 5.1 CA Down Remarks
Diff. pressure transmitter
PDAH- Feed air filter 0,611
Feed air filter package X General delay 30 sec.
8.32 diff. press. high kg/cm2
0-800 mbar
Level switch
Water separator
LA-8.36 Water separator WS-8.11 N/A X SD1 * * SD after 5 minutes
drain failure
N/A
Level switch
Feed air filter
LA-8.37 1st feed air filter F-8.13 N/A X SD1 * * SD after 5 minutes
drain failure
N/A
Level switch
Feed air filter
LA-8.38 2nd feed air filter F-8.14 N/A X SD1 * * SD after 5 minutes
drain failure
N/A
Temperature transmitter
Feed air temp.
TAH-8.39 Feed air inlet line 60 °C X
high
0-100°C
Temperature transmitter Indicates heater failure.
TDAL- Heater temp.
Up-/down stream heater 3 °C X SD1 Start-up delay 3 min.
8.39 rise low
0-100°C Optional dt-temp reg. included
Safety thermostat
Heater Repeated to UCP as XA-8.15
TAH-8.40 Feed air heater 175 °C X
overtemp. “Heater Fault”
5-215 °C
Temperature transmitter
Separator feed
TAL-8.42 Membrane feed air line 45 °C X Start-up delay 3 min.
temp. low
0-100°C
Temperature transmitter
Separator feed
TAH-8.42 Membrane feed air line 65 °C X
temp. high
0-100°C
Temperature transmitter
TAHH- Separator feed
Membrane feed air line 70 °C X SD1
8.43 temp. high high
0-100°C
Pressure transmitter
Separator feed 20,39
PAL-8.45 Membrane feed air line X Start-up delay 2 min.
pressure low kg/cm2
0-40 barg
Separator feed Pressure transmitter
PALL- 10,19
pressure low Membrane feed air line X SD3 Start-up delay 2 min.
8.45 kg/cm2
low 0-40 barg
Oxygen analyser
Oxygen content
AAH-8.50 N2 product line 5,5% X Start-up delay 5-10 min.
high
0-25 vol.% O2
Oxygen analyser
AAHH- Oxygen content
N2 product line 6,0% X SD2 Start-up delay 5-10 min.
8.50 high high
0-25 vol.% O2
Emergency stop button
Open
UA-5.32 Emergency stop Panel 5.1 X SD1
contact
N/A
Proximate Limit Switch
Permeate Vent Closed
ZAC-8.10 Permeate vent Hatch X SD1
Hatch Closed Hatch
N/A

Shut down
SD-1 Shutdown of complete system SD-3 De-energize of feed air heater CA Common Alarm
SD-2 Closure of N2 discharge valve
 Doc. No.: 15844-0616-001

Alarm List – Nitrogen Production Unit Page 3 of 3

Sensor Type
Alarm Alarm Location of Sensor Alarm Alarm in Panel Shut
ID Monitoring Sensor Range Setting 5.1 CA Down Remarks
PLC/Alarm relay
Any
XA-5.40 Common alarm Panel 5.1 X (SD1) SD if caused by a SD alarm
alarm
N/A
PLC
Self
XA-5.41 PLC failure Panel 5.1 X (SD1) SD if caused by a SD alarm
diagn.
N/A
PLC
Com. error – Com.
XA-5.42 Panel 5.1 X (SD1) SD if caused by a SD alarm
Displays Error
N/A

Test performed by Test witnessed by

…..…….. …………………………................. …………………………......

Test Date (Air Products A/S Representative) (Customer Representative)

Shut down
SD-1 Shutdown of complete system SD-3 De-energize of feed air heater CA Common Alarm
SD-2 Closure of N2 discharge valve
 SUPPLIERS FRONT SHEET (FOR A4/A3 DOCUMENTS ONLY)

SUPPLIER NAME AIR PRODUCTS AS

PURCHASE ORDER No. 40-29043-03

DOCUMENT
Visual Display Unit GrapVOcs
TITLE

TOTAL NO. OF PAGES

(including front sheet)

SUPPLIERS ORDER No 15844

SUPPLIERS
SUPPLIERS OWN DOCUMENT NUMBER DATE SUPPLIERS APPROVAL SIGNATURE
REVISION
15844-0616-005 1 11.02.13 TE

SUPPLIER DOCUMENT REVIEW

BP BERAU LTD
NA 1 Reviewed and NO COMMENTS. Work may proceed.

Revise and resubmit. Work may proceed subject to incorporation PACKAGE CONTAINERIZED NITROGEN
NA 2 of changes indicated.
DESCRIPTION
MEMBRANE SYSTEM
PROJECT
NA 3
Revise and resubmit. Work may not proceed.
NUMBER 4800016254

TAG No.
NA 4
No further review required.

SHEET 1 OF 8

BP DOCUMENT NUMBER
Signature: Trond Egeland Date:11.02.13
0163-FMM-I-ESP-001
Print Name:
 15844-0616-005

Visual Display Unit Graphics

Siemens OP 177B 6” Touch terminal.

Main View:

This is the screen that will be displayed when powering up.

Here you find information how to contact Air Products. You will also see the time and date.
In the bottom you find buttons to maneuver into the other screens and start/stop of system.
 15844-0616-005

Visual Display Unit Graphics

Nitrogen Generator:

This screen gives you an overview of the nitrogen system. All measured values and alarms will be
indicated.
You are able to start and stop the system and make selection of oxygen content (select buttons). You
will also find information if emergency stop have been activated, if the permeate hatch are closed.
At next screen we have used the same tagging as at the P&ID.
 15844-0616-005

Visual Display Unit Graphics

 15844-0616-005

Visual Display Unit Graphics

Controller Parameters:

This screen are used to change controller parameters. You need to login to get access to input field.
Login user: APAS Login password: 47004700
 15844-0616-005

Visual Display Unit Graphics

Alarm Settings:
 15844-0616-005

Visual Display Unit Graphics

The screens are showing you alarm limits used. If you need to change an alarm limit you need to
login.
 15844-0616-005

Visual Display Unit Graphics

Alarm List:

This screen will list alarms with the newest at top. To acknowledge the alarm you press this button.
 SUPPLIERS FRONT SHEET (FOR A4/A3 DOCUMENTS ONLY)

SUPPLIER NAME AIR PRODUCTS AS

PURCHASE ORDER No. 40-29043-03

DOCUMENT
15844-0619-001_r00_Process Description
TITLE

TOTAL NO. OF PAGES

(including front sheet)
4
SUPPLIERS ORDER No 15844
SUPPLIERS
SUPPLIERS OWN DOCUMENT NUMBER DATE SUPPLIERS APPROVAL SIGNATURE
REVISION
15844-0619-001

1 18.09.12 VØ

SUPPLIER DOCUMENT REVIEW

BP BERAU LTD
NA 1 Reviewed and NO COMMENTS. Work may proceed.

Revise and resubmit. Work may proceed subject to incorporation PACKAGE CONTAINERIZED NITROGEN
NA
2 of changes indicated.
DESCRIPTION
MEMBRANE SYSTEM
PROJECT
NA 3
Revise and resubmit. Work may not proceed.
NUMBER 4800016254

TAG No.
NA 4
No further review required.

SHEET 1 OF 4

BP DOCUMENT NUMBER
Signature: Date:18.0
Vidar Østerberg 9.12
0163-FMM-R-MAN-001
Print Name:
 Doc. No.: 15844-0619-001

Process and Functional Description

APAS Ref.: 15844

P.O. No.: 40-29043-03
Item: CONTAINERIZED NITROGEN
MEMBRANE SYSTEM
00 Issued for approval VØ KS 18.09.12 Tag no.: --
Rev Description Prep. Chk. Date Serial no.: --

1. PREFACE

This document covers the process and functional description of the Containerized Nitrogen Membrane System

The Containerized Nitrogen Membrane System utilises membrane separation from compressed air, and is designed for unattended operation.

2. REFERENCE DRAWINGS AND DOCUMENTS

Reference is made to following documents for more details:

P&ID 15844-0605-001
Cable Block Diagram 15844-0611-001
Alarm and Trip Schedule 15844-0616-001
Control Block & Logic Diagram 15844-0616-003
General Arrangement Drawing 15844-0608-001
General Performance Data 15844-0602-001

3. ABBREVATION USED

Explanations of abbreviations given in the text below are as follows:

ESD - Emergency Shut Down

DCS - Distributed Control System
HCP - Heater Control Panel
UCP - Unit Control Panel
PLC - Programmable Logic Controller

4. SAFETY ASPECTS

Nitrogen is a non-toxic but asphyxiating inert gas of slightly lower density than air.

Exposure to an atmosphere with a low concentration of oxygen does not necessarily produce recognisable symptoms before
unconsciousness occurs. The onset of brain damage and risk of death can follow within a few minutes. If the oxygen deficiency is not
sufficient to cause unconsciousness, the mind is liable to become apathetic and complacent, and even if these symptoms are noticed and
escape is attempted, physical exertion will aggravate the weakness of both the mind and the body. It is therefore necessary to ventilate the
space entered thoroughly, so that no pockets of oxygen low atmosphere remain. When testing for entry, reading of 21% oxygen is required.
Consequently, product outlet, and product vent pipe should be piped to safe area.

5. SYSTEM DESCRIPTION

The Containerized Nitrogen Membrane System consisting of one processing skid, comprising of the following components:

• 1 x 100% Air Inlet Filter Package (F-8.12, F-8.13 and F-8.14).

• 1 x 100% Air Pre-Heater (H-8.15) with Heater Control Panels (HCP-5.2).
• 1 x 100% Membrane Separator Unit (MS-8.18) installed for air separation.
• Nitrogen Generator Off-spec Vent Silencer
• Piping and valves.

Page 2 of 4
 Doc. No.: 15844-0619-001

Process and Functional Description

6. LOCAL CONTROL PANEL

Start-up, control and shut down are done from Local Operator Panel 5.1-HMI.

For further details, see document and “Control Block & Logic Diagram”.
See “Alarm and Trip Schedule” for shut-down functions, alarm interlock functions, all alarm settings, controller settings and alarm override
settings.

7. BASIC PRINCIPLE OF MEMBRANE BASED NITROGEN GENERATION

The membranes are formed into hollow fibres to obtain maximum membrane surface per unit of volume (see picture below). Compressed
and filtered air is fed to the bore side of a hollow fibre bundle enclosed in a pressure vessel, which geometrically is arranged the same way
as a shell and tube heat exchanger. As the air flows along the bore side of the fibres, O2, CO2 and H2O (vapour) contained in the air,
permeate faster than nitrogen through the fibre wall to the low pressure side. The result is that the concentration of nitrogen gas is increasing
through the length of the fibres or the membrane module itself. In other words, quite pure nitrogen exits at the end of the hollow fibres.

Many parameters must be considered when designing a membrane separation system. Three of the more important ones are the driving
force (or the differential partial pressure) across the membranes, the length of time the gases are exposed to the membrane surface, and the
membrane area. In practice this means the feed air pressure, the feed flow rate and the module size respectively.

8. FUNCTIONAL DESCRIPTION

The package is fed with dry instrument air from oil lubricated compressors outside Air Products scope of supply.

In principle higher inlet pressure will give higher product capacity at the same maximum oxygen content. The pressure variation must not be
abruptly but rather smoothly (about 2 minutes from minimum to maximum value) to ensure that the control loops will work satisfactorily.

A pneumatic operated ball valve (XV-8.31) located at package feed air inlet is used for start/stop and shutdown. This valve is controlled by
LCP.

Page 3 of 4
 Doc. No.: 15844-0619-001

Process and Functional Description

The feed air flows through Air Inlet Filter Package to remove solid particles down to 0.01 micron. A differential pressure transmitter (PDT-
8.32) monitors the filters pressure drop, and will warn the operator in case of high diff. pressure.

Then the air flows through the Air Pre-Heater that is provided to heat the air to a specified temperature. This will vaporize oil or water that
might come from the compressors. This will also keep a constant temperature to the membranes, regardless of the varying inlet
temperature, and ensure a stable nitrogen production.

Start/stop and control of the heater is done by PLC located in LCP, using temperature controller TIC-8.42 to ensure that the power
modulation is done properly. This is to ensure a constant temperature. In case of ESD or process shut-down HCP will be tripped from LCP.

The air temperature downstream the heater is monitored by a temperature transmitter (TT-8.42). The PLC supply 4-20mA control signal for
heater regulation to the HCP. HCP contain a thyristor unit that turns the power on/off in pulses - modulating the pulse width.

Air Pre-Heater H-8.15 is equipped with internal temp switch TSHH-8.40 hardwired to HCP. This temp switch monitors the heating element
skin temperature and will shut the heater down. The function is to safeguard the heater from overheating in case of little- or no flow through
the heater. After activation of TSHH a manual reset is required prior to re-start.

Pre-alarms for membrane separators high and low feed air temperature, are initiated by TIC-8.42.

To prevent any overheating (accumulation of heat) in the heater shell, and hence activation of heater high temp shutdown, a low-low
pressure alarm PT-8.45 downstream the electrical heater will be activated. This will disable the temp controller TIC-8.42. Heater power will
automatically be turned on once the feed pressure returns above the low low alarm setting.

A low pressure pre-alarm will warn the operator prior to low-low alarm and de-energizing of the heater.

The membrane separators are separating the air into one products stream (reduced oxygen) and one permeate stream (increased oxygen).

The membrane separators are protected from high temperature by temperature transmitter TT-8.42. This transmitter is connected to LCP,
and will cut the heaters power supply through main contactor in HCP. In addition package feed air supply is shut byXV-8.31, product
discharge shut by XV-8.55A and product vent valve open XV-8.55B. The system will de-pressurize through membrane separators permeate
ports and N2 vent off-spec line to ambient air.

Nitrogen flow is monitored and limited by PLC flow controller FIC-8.54, which regulates control valve FCV-8.54 to keep a constant flow rate
and hence give approximately stable product purity based on the set point given. The set point is given by the mathematical equation below,
where the signal from the pressure transmitter PT-8.45 upstream the membranes is incorporated. The higher the skid inlet pressure is, the
higher the nitrogen flow rate will be at the same purity. The calculated set point is then compared with the actual monitored flow rate
produced by the flow element FE-8.54 and flow transmitter FT-8.54. Any offset will then activate the flow control valve FCV-8.54 to new
position. Controller input signal from FT-8.54 is pressure compensated by pressure transmitter PI-8.45.

If the demand for nitrogen gas is smaller than the flow controller set point, the control valve will gradually open until it reaches 100% open. In
this condition the consumption or product output is dependent upon the consumer pressure (backpressure). When the consumption
increases and reaches the controller set point the valve will start throttling. The flow control loop limits the product flow rate not to exceed the
generator contractual capacity; hence product purity is maintained within its specification. The unit has a 100% turndown.
The set point of the flow controller (FIC-8.54) is calculated from following equation (see Control Block & Logic Diagram A and B value):

Setpoint = A x PPI-8.45 – B

PPI-8.45 is the signal from the pressure transmitter (PT-8.45) in the units of Barg. The set points are given in SCFM. Fine tuning will be done
during commissioning.
The nitrogen product is sampled to measure and indicate the purity by the oxygen analyser (AIT-8.50).
Should the oxygen content rise above High Alarm, a pre-alarm will be initiated by AAH-8.50. If the oxygen content continues to rise, High-
High Alarm (AAHH-8.50) will be initiated. This alarm causes the delivery valve (XV-8.55A) to close and vent valve (XV-8.55B) to open such
that product discharge is shut, and product vented to ambient air. The oxygen content must be below High-High Alarm limit (AAHH-8.50)
before nitrogen gas again is routed to consumers.

High oxygen content is normally caused by too high product flow, too low separator feed pressure or too low separator feed temperature.
It is recommended that the analyser is checked for correct calibration as per maintenance schedule. For this purpose use instrument air and
this will give a reading of 20.9 vol. % oxygen (span calibration).

Page 4 of 4
 SUPPLIERS FRONT SHEET (FOR A4/A3 DOCUMENTS ONLY)

SUPPLIER NAME AIR PRODUCTS AS

PURCHASE ORDER No. 40-29043-03

DOCUMENT
15844-0700-001_r00_Packaging and preservation
TITLE instructions

TOTAL NO. OF PAGES

(including front sheet)
4
SUPPLIERS ORDER No 15844
SUPPLIERS
SUPPLIERS OWN DOCUMENT NUMBER DATE SUPPLIERS APPROVAL SIGNATURE
REVISION
15844-0700-001

1 13.09.12 VØ

SUPPLIER DOCUMENT REVIEW

BP BERAU LTD
NA 1 Reviewed and NO COMMENTS. Work may proceed.

Revise and resubmit. Work may proceed subject to incorporation PACKAGE CONTAINERIZED NITROGEN
NA
2 of changes indicated.
DESCRIPTION
MEMBRANE SYSTEM
PROJECT
NA 3
Revise and resubmit. Work may not proceed.
NUMBER 4800016254

TAG No.
NA 4
No further review required.

SHEET 1 OF 4

BP DOCUMENT NUMBER
Signature: Date:13.0
Vidar Østerberg 9.12
0163-FMM-S-PRO-001
Print Name:
Lift package onto the transport and secure. Remove the lifting equipment from the
package and secure to the transport.

When unloading, same procedure. Ensure then after unloading, the packages are
adequately supported on a plane surface and that the lifting equipment is stored
safely.

2.2 Protection and packing.

All internal and external surfaces of the equipment are throughly cleaned, rust free
and piping/equipment purged with nitrogen. All piping, valves, junction boxes etc.
are moustly of AISI 316/316L material.

All open flanges/interconnections flanges are blanked with plastic cover. Seals and
protection not to be removed before interface piping connections are ready to be
connected.

2.3 Marking.

Shipping marks on opposite sides of container.

Equipment is identified by equipment tag.no.

3.0 Procedure for preservation/storage of units at site.

3.1 Unpacking/preservation of nitrogen generation packages.

The protection cover to be removed at time for installation. Do not remove blanks
installed on tie-in flanges. This activity to take place just prior to connection of
piping to skids.

Upon receipt of the goods, it is assumed it will be subject to visual inspection and
control. In case of any shortage or damage to the goods, Air Products to be
contacted immidiately. Air Products will inform relevant concerned parties as to
corrective action to be taken.

All painting to be checked for damage, touch up if required.

All bolts to be checked, and that no equipment/parts has loosened during the
transport.

If any requirements for preservation after installation due to long term storage at
site, contact Air Products for re- preservation.

4
 TABLE OF CONTENTS

PACKING, PRESERVATION AND TRANSPORTATION

INSTRUCTIONS

Page

1.0 Introduction 3

2.0 Procedure for packing and marking of units 3

3.0 Procedure for preservation/storage of units at site 4

2
1.0 Introduction

This document covers the packing, preservation and transportation procedures for
the Containerized Nitrogen Membrane System

Document and drawing references:

- General arrangement drawing, 15844-0608-001
- P & ID, 15844-0605-001
- Packing and shipping list

For final dimensions and weights, see packing and shipping list.

Expected/Estimated overall transport dimensions are:

Containerized Nitrogen Membrane System

Qty: 1

Dimension: 6058 X 2438 X 2735 (LxWxH)

Weight: 10 000 kg

2.0 Procedure for packing and marking of units.

Following procedures to be performed before transportation

• Make sure system is completely free from liquid oil and water by opening all
drain valves.
• Mount transport hatch on enriched oxygen outlet

2.1 Package design- Nitrogen Generators

Ref. General arrangement drawing, 15844-0608-001

The Nitrogen Production Unit are skid containerized with lifting arrangement on
top of the skid unit.

One set of lifting slings are provided with the units. Lifting and transport is based
upon use of the certified lifting slings.

Lifting and transportation :

Ensure that the crane to be used for lifting has sufficient capacity for the lift
required by checking the safe working load marked on the lifting equipment. Check
and carry out a thorough visual inspection of all lifting components before lifting the
package.

3
 SUPPLIERS FRONT SHEET (FOR A4/A3 DOCUMENTS ONLY)

SUPPLIER NAME AIR PRODUCTS AS

PURCHASE ORDER No. 40-29043-03

DOCUMENT
15844-0700-002_r00_Transportation instructions
TITLE

TOTAL NO. OF PAGES

(including front sheet)
4
SUPPLIERS ORDER No 15844
SUPPLIERS
SUPPLIERS OWN DOCUMENT NUMBER DATE SUPPLIERS APPROVAL SIGNATURE
REVISION
15844-0700-002

1 25.10.12 VØ

SUPPLIER DOCUMENT REVIEW

BP BERAU LTD
NA 1 Reviewed and NO COMMENTS. Work may proceed.

Revise and resubmit. Work may proceed subject to incorporation PACKAGE CONTAINERIZED NITROGEN
NA
2 of changes indicated.
DESCRIPTION
MEMBRANE SYSTEM
PROJECT
NA 3
Revise and resubmit. Work may not proceed.
NUMBER 4800016254

TAG No.
NA 4
No further review required.

SHEET 1 OF 4

BP DOCUMENT NUMBER
Signature: Vidar Østerberg Date:25.10.2012
0163-FMM-S-PRO-002
Print Name:
 TABLE OF CONTENTS

TRANSPORTATION INSTRUCTIONS

Page

1.0 Introduction 2

2.0 Lifting and transportation Procedure 3,4

2
1.0 Introduction

This document covers the packing, preservation and transportation procedures for
the Containerized Nitrogen Membrane System

Document and drawing references:

- General arrangement drawing, 15844-0608-001
- P & ID, 15844-0605-001
- Packing and shipping list

For final dimensions and weights, see packing and shipping list.

Expected/Estimated overall transport dimensions are:

Containerized Nitrogen Membrane System

Qty: 1

Dimension: 6058 X 2438 X 2735 (LxWxH)

Weight: 10 000 kg

2.0 Procedure for Lifting and transportation

Following procedures to be performed before transportation

• Make sure system is completely free from liquid oil and water by opening all
drain valves.
• Mount transport hatch on enriched oxygen outlet

2.1 Package design- Nitrogen Generators

Ref. General arrangement drawing, 15844-0608-001

The Containerized Nitrogen Membrane System are skid containerized with lifting
arrangement on top of the skid unit.

One set of lifting slings are provided with the units. Lifting and transport is based
upon use of the certified lifting slings.

3
Lifting and transportation :

Ensure that the crane to be used for lifting has sufficient capacity for the lift
required by checking the safe working load marked on the lifting equipment. Check
and carry out a thorough visual inspection of all lifting components before lifting the
package.

Lift package onto the transport and secure. Remove the lifting equipment from the
package and secure to the transport.

When unloading, same procedure. Ensure then after unloading, the packages are
adequately supported on a plane surface and that the lifting equipment is stored
safely.

4
 Containerized Nitrogen Membrane System
P.O.No. 40-29043-03
Document: 15844-0807-001, Rev. 00

1. OPERATING SPARE PARTS AND MAINTENANCE

SCHEDULE

See manual for operation and maintenance of specific parts.

1.1 SPECIAL TOOLS & LIFTING EQUIPMENT

There are no requirements for special tools on this package. No components require special lifting
devices.

1.2 INSPECTION AND MAINTENANCE SCHEDULE

The instructions here provided are for routine maintenance and inspection only. Overhaul
maintenance instructions are given in the respective vendor manuals.
1) Every 10min 4) Monthly 7) Every 2 years
2) Daily 5) Every 6 months 8) Every 4 years
3) Weekly 6) Every 12 months 9) Every 5 years
1 2 3 4 5 6 7 8 9 Note
Check manual drain valve for F-8.05 X 1
Check operation of electric heater X 2
Check sample flow oxygen- analyser X 3
Check oxygen content in product X 4
Check drain system from filter package X 5
Run N2 system minimum 45 minutes continuous X
Check span calibration of oxygen analyser X 6
Check oxygen content high and high-high alarm X
Check system for leakage X 7
Inspect all electrical panels X
Replace filter elements (including F-8.15) X 8
Check all alarm functions X 9
Check/tighten electrical connections X
Check/tighten bolts and nuts X
Replacement of O2-sensor (Draeger) X 10
Replace solenoid valves X
Replace non return valves X
PLC battery X
Check control valve X
Check XV-valves/actuators X
Check orifice X
Transmitters PT/TT X
Indicators PI/TI X
Replace all relays X
Replace O2 analyzer X
Internal inspection, pressure test and re- X
 Containerized Nitrogen Membrane System
P.O.No. 40-29043-03
Document: 15844-0807-001, Rev. 00

certification of all vessels

NOTE: Only recommended maintenance schedule and spare parts provided by Air Products AS
will provide full warranty.

NOTES:

1. Check that filter bowl is free from water at regular basis. Change filter element according to
schedule.
2. Check that electrical heater is working correctly during operation. The electric heater outlet
temperature shall be at least 5°C higher than inlet temperature. The system will automatically shut
down (TDAL-8.39) when temperature difference is equal or lower than 5 °C. If operating at lower
delta T across the el. heater oil may condensate and hence gradually damaging the membrane
bundles.
3. Check the sample flow of the oxygen analyser by checking the sample flow indicator
4. If the nitrogen purity deviates from design, change Oxygen Regulator Set-points.
5. Check that drain water/oil are coming out to the bilge system. Replace filter-elements if necessary.

NOTE: The amount of condensate to be drained is larger in warmer areas than in colder due to
increased temperature and relative humidity.

6. Test the oxygen content high alarm and change over function.
7. See attachment for simplified procedure.
8. Oil carry over may deteriorate the membranes. Change filters according to schedule, or when
pressure differential switch PDT-8.32 is giving warning when running. See attachment for
simplified procedure.
9. Check all alarm functions by simulating malfunctions of the system
10. Check the span point calibration of the oxygen analyser

Please contact Air Products AS office for operating spare packages.

1.2.1 Repairs and Modifications

Contact Air Products AS.

2. ATTACHMENT

2.1 SPARE PARTS ENQUIRY FORM

2.2 CALIBRATION O2 ANALYSER

2.3 REPLACE FILTER ELEMENTS

 Containerized Nitrogen Membrane System
P.O.No. 40-29043-03
Document: 15844-0807-001, Rev. 00

SPARE PARTS INQUIRY FORM

AIR PRODUCTS PROJECT NUMBER

SHIPYARD AND HULL NUMBER
VESSEL / PLATFORM / SITE NAME

APAS
Component Tag
Item Quantity Part Description
number Number
Ref. P&ID

CLIENT NAME AND ADDRESS

Company ________________________________________________
Contact person ________________________________________________
Telephone ________________________________________________
Telefax ________________________________________________
E-mail ________________________________________________
Delivery address ________________________________________________
 Containerized Nitrogen Membrane System
P.O.No. 40-29043-03
Document: 15844-0805-001, Rev. 00
OPERATING AND MAINTENANCE INSTRUCTIONS

1. INTRODUCTION ....................................................................................................... 2

2. RISK AND RISK REDUCTION .................................................................................. 2

3. SAFETY MEASURES ................................................................................................ 2

4. REFERENCE DOCUMENTS .................................................................................... 3

5. OPERATING INSTRUCTIONS .................................................................................. 3

5.1 Normal Start Up ......................................................................................................... 3
5.2 Normal Shut Down ..................................................................................................... 4

6. FAULT FINDINGS ..................................................................................................... 4

6.1 Feed Air Filter Drain Failure (LA-8.36, LA-8.37, LA-8.38) ......................................... 4
6.2 Diff. Pressure Transmitter (PDAH-8.32 across coalescing filters) ............................. 4
6.3 Temp. Element (TSHH-8.40 internal of Air Preheater H-8.15) .................................. 5
6.4 Feed Air Temperature Alarms (TAH/L-8.42) .............................................................. 5
6.5 Feed Air Temperature Alarm (TAHH-8.43) ................................................................ 5
6.6 Feed Air Temp Rise Low Across Pre Heater (TDAL-8.39) ........................................ 6
6.7 Membrane Separator Feed Air Pressure Too Low (PAL/PALL-8.45) ........................ 6
6.8 Oxygen Content Alarms (AAH/AAHH-8.50) ............................................................... 6

7. MAINTENANCE INSTRUCTION ............................................................................... 7

7.1 PRISM ® Membrane Separator, MS-8.18 ................................................................. 7
7.2 Particle/Coalescing Filters, F-8.13, F-8.14 ................................................................ 8
7.3 Feed Air Electric Inlet Heater, H-5511A ..................................................................... 8
7.4 Oxygen Analyser, AIT-8.50 ........................................................................................ 9
7.5 Instrumentation .......................................................................................................... 9
7.6 Maintenance Schedule / Inspection Period ............................................................... 9

8. EQUIPMENT DATA / SUBVENDORS INSTRUCTIONS & OPERATION AND

MAINTENANCE MANUAL ......................................................................................... 9

Page 1 of 9
 Containerized Nitrogen Membrane System
P.O.No. 40-29043-03
Document: 15844-0805-001, Rev. 00
1. INTRODUCTION

This procedure contains the normal start-up, shutdown, fault findings, and maintenance
descriptions of the Containerized Nitrogen Membrane System.

2. RISK AND RISK REDUCTION

• Always when operating the unit the operator should wear eye protection for safety,
and also hearing protection depending of the surroundings of the Nitrogen
Production Unit. The unit itself generates only low sound pressure levels when in
normal operation.
• The unit is designed for easy operation with operator controls at normal heights to
minimize stress on workers. Also the unit contains no movable or rotating parts that
could represent dangers to the workers.
• The normal internal pressure of the system is below the mechanical design
pressure of all the associated parts of the system. The contained volumes are
relatively small, so there is no danger associated with this part of the process. But
workers are encouraged to use at least eye protection while working on the
system. Users of the nitrogen unit must make sure that inlet pressure does not
exceed design pressure.
• The unit contains nitrogen gas, which does not support life. Any leakages should
be corrected.
• Special attention with regard to lifting, are the heater, filter housings and the flow-
regulating valve.
• All the transmitters, the solenoid valves and solenoids operate on 24V DC which is
non-harmful to people. The heater operates on 415-440V AC and special
precautions should be made prior to maintenance. The main switch, for the 415-
440V AC going to the heater, should be switched off to prevent any accidents if
work is to be performed on the heater.

3. SAFETY MEASURES

Nitrogen is a non-toxic but asphyxiating inert gas of slightly lower density than air.
Exposure to an atmosphere with a low concentration of oxygen does not necessarily
produce recognisable symptoms before unconsciousness occurs. The onset of brain
damage and risk of death can follow within a few minutes. If the oxygen deficiency is not
sufficient to cause unconsciousness, the mind is liable to become apathetic and
complacent, and even if these symptoms are noticed and escape is attempted, physical
exertion will aggravate the weakness of both the mind and the body. It is therefore
necessary to ventilate any confined area where nitrogen gas has been used. When testing
for entry, reading of 21% oxygen is required. Consequently, product outlets should be
piped to safe area if hazardous situation may occur.
The enriched oxygen permeate local vents (see Piping & Instrument Diagram: 15807-
0605-001) are exposed direct to ambient air and mixed with air to normal concentration of
21 vol% from oxygen content of about 34 vol%. Asphyxiating problems do not arise from
exposure of permeate vent due to high oxygen content in any case.
When system is running off-specification i.e. nitrogen gas flows to ambient air, via
silencer, it will be mixed with the enriched oxygen permeate in the membrane section, and
reach composition as in normal air before exiting the vent.
The Prism® Nitrogen System is under pressure during operation. Do not disconnect
equipment/pipelines before the system is de-pressurized.

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 Containerized Nitrogen Membrane System
P.O.No. 40-29043-03
Document: 15844-0805-001, Rev. 00
4. REFERENCE DOCUMENTS

Prior to the start-up of the unit it is assumed that documents referred to below have been
followed and completed:

Functional Test / Pre-Commissioning / Commissioning & Initial Start-Up Procedure:

15844-902-502.

Documents listed below shall be used as reference in connection with following

description:

Datasheet: 15844-0602-001
P & ID: 15844-0605-001
E&I Block Diagram: 15844-0611-001
Site Acceptance, Commissioning and Performance Test Procedure: 15844-0902-503
Control Block & Logic Diagram: 15844-0616-003
Visual Display Unit Graphics: 15844-0616-005
Process Description: 15844-0619-001

5. OPERATING INSTRUCTIONS

5.1 Normal Start Up

¾ Make sure the transport hatch for the enriched air vent outlet is removed.
¾ Inlet pressure must not under any circumstances exceed design pressure of
Nitrogen Generator. Safety measures must be installed upstream Nitrogen
Generator.

The Start Up of the Nitrogen Production Unit is done from Local Control Panel (LCP) as
detailed described in Chapter 6 in Process Description 15807-0619-001.
The detail description of Operator Terminal installed in local control panel and how it is
operated to start and stop the unit is given in document Visual Display Unit Graphics
15844-0616-005 and will therefore not be repeated here.
The Nitrogen Production Unit is designed for automatic, unattended operation. Prior to
start up one should ensure that all manual valves are in the correct positions and that
electrical power is available for heater, and controls. Also ensure that feed air
pressure/flow is available before start up. It is assumed that actions described in Sections
above are completed.
Once the Nitrogen Production Unit is started from local control panel the feed air inlet
valve XV-8.31 will start to open and pressurise the unit while the valves XV-8.55A and XV-
8.55B will stay in the position such that the nitrogen gas flows to ambient air (off. Spec.). It
will take some time to reach the operating temperature of the membranes of
approximately 60°C depending on ambient condition (approx 20 minutes). This means
that the unit capacity will not be reached before stable temperature has been achieved.
The purity (oxygen content) will however reach design value quite soon (5-10 minutes)
since oxygen analyser is part of the product control loop (see Process Description 15807-
0619-001 for detail description). During start up time the flow rate will gradually increase
at about constant purity until design capacity is reached.
Make sure that the other process parameters like feed air pressure, Electric Heater outlet
temperature and product pressure are at expected values (see Site
Acceptance/Performance Test Procedure: 15844-0902-503 for specified values). If
necessary, adjust the feed air skid inlet pressure (outside scope of supply).

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 Containerized Nitrogen Membrane System
P.O.No. 40-29043-03
Document: 15844-0805-001, Rev. 00
The flow controller set point is a function of the membrane inlet pressure (see Process
Description: 15844-0619-001 for detail description).
The unit is now on-stream and produces nitrogen to consumer(s).

5.2 Normal Shut Down

The detail description of Operator Terminal installed in local control panel and how it is
operated to start and stop the unit is given in document Visual Display Unit Graphics:
15844-0616-005 and will therefore not be repeated here.

In the event of a shutdown (done from Local Control Panel 5.1) the following will occur:
The Electric Heater H-8.15 will shut down and the feed air inlet valve XV-8.31 will close,
while on/off valves XV-8.55A and XV-8.55B will be repositioned such that the nitrogen gas
flows to ambient air. The unit will then be depressurised to ambient air to off spec vent
and via membrane cabinets.

6. FAULT FINDINGS

6.1 Feed Air Filter Drain Failure (LA-8.36, LA-8.37, LA-8.38)

Condition: Feed air filter liquid level exceed set point

Possible Cause Remedy
ƒ Drain unit dirty or clogged ƒ Clean units or operate manual 2-3
times.
ƒ Water drain unit is ƒ If malfunctioning clean drain unit or
malfunctioning change drain unit.

Condition: False Alarm Signal

Possible Cause Remedy
ƒ NA ƒ NA

6.2 Diff. Pressure Transmitter (PDAH-8.32 across coalescing filters)

Condition: Pressure drop across filters bed exceeds set-point defined.

Possible Cause Remedy
ƒ Filter element “saturated” ƒ Shut down the process train
with solid particles and and check / replace
liquid.
ƒ Instrument isolation valve ƒ Check
throttled/closed

Condition: False Alarm Signal

Possible Cause Remedy
ƒ Incorrect settings of alarm ƒ Check / adjust set-points
limit
ƒ Check, calibrate
ƒ Transmitter out of
calibration

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 Containerized Nitrogen Membrane System
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Document: 15844-0805-001, Rev. 00
6.3 Temp. Element (TSHH-8.40 internal of Air Preheater H-8.15)

Condition: Element surface temp. in electric heater exceeds set-point defined). Manually
resetting of heater J.B.
Possible Cause Remedy
ƒ Thyristor Unit failure ƒ Check / replace Thyristor
unit
ƒ Temp. controller TIC-8.42 ƒ Check controller for correct
malfunction operation/repair/replace
(see chapter for sub
vendor instructions)

Condition: False Alarm Signal

Possible Cause Remedy
ƒ Temperature transmitter failure ƒ Check / repair temperature
Transmitter

6.4 Feed Air Temperature Alarms (TAH/L-8.42)

Condition: Separator feed air temperature exceeds set-points defined

Possible Cause Remedy
ƒ Power failure ƒ Check, repair
ƒ Temp. controller TIC-8.42 set- ƒ Check / adjust set-point in Operator
point too high Terminal in LCP.
ƒ Thyristor Unit failure ƒ Check / repair/ replace Thyristor Unit.

Condition: False alarm signal.

Possible Cause Remedy
ƒ Transmitter out of calibration ƒ Compare indicators with temperature
transmitter. Calibrate if necessary
(see sub vendor instruction).

6.5 Feed Air Temperature Alarm (TAHH-8.43)

Condition: Separator feed air temperature exceeds set-points defined

Possible Cause Remedy
ƒ Power failure ƒ Check, repair
ƒ Temp. controller TIC-8.42 set- ƒ Check / adjust set-point in Operator
point too high Terminal in LCP.
ƒ Thyristor Unit failure ƒ Check / repair/ replace Thyristor Unit.

Condition: False alarm signal.

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 Containerized Nitrogen Membrane System
P.O.No. 40-29043-03
Document: 15844-0805-001, Rev. 00
Possible Cause Remedy
ƒ Transmitter out of calibration ƒ Compare indicators with temperature
transmitter. Calibrate if necessary
(see sub vendor instruction).
6.6 Feed Air Temp Rise Low Across Pre Heater (TDAL-8.39)

Condition: Heater diff temperature too low according to set point

Possible Cause Remedy
ƒ Heater malfunction ƒ Check fuses / Thyristor Unit and
Temperature controllers for correct
operation

Condition: False Alarm Signal

Possible Cause Remedy
ƒ Temperature transmitter ƒ Check and repair/calibrate
malfunction

6.7 Membrane Separator Feed Air Pressure Too Low (PAL/PALL-8.45)

Condition: Feed air pressure lower than set point

Possible Cause Remedy
ƒ Compressor pressure settings ƒ Adjust compressor outlet pressure
to low
ƒ Leakage in system ƒ Check for leakages

Condition: False Alarm Signal

Possible Cause Remedy
ƒ Pressure transmitter ƒ Check and repair/calibrate according to
malfunction description in sub vendor Manual

6.8 Oxygen Content Alarms (AAH/AAHH-8.50)

Condition: Oxygen Content exceeds set-points defined.

Possible Cause Remedy
ƒ Membrane separator temperature ƒ Check controller TIC-8.42 for
too low correct set-point.
ƒ Check heater for correct
operation (power failure, fuse
failure, Thyristor Unit failure)
ƒ Nitrogen flow too high ƒ Reduce set point of flow
controller FIC-8.54. Contact
vendor for information.

Condition: False alarm signal

Possible Cause Remedy

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 Containerized Nitrogen Membrane System
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Document: 15844-0805-001, Rev. 00

ƒ Sample flow to oxygen analyser is ƒ Adjust sample flow FI-8.50. Check

too low setting of pressure control valve PCV-
8.50 and reading of analyser’s internal
flow meter.
ƒ Analyser is out of calibration ƒ Check analyser calibration

7. MAINTENANCE INSTRUCTION

The maintenance and inspection work of the Nitrogen Generator Unit during operation
is quite simple, since unit has no moving or rotating parts.
Nitrogen production is based upon Permea’s PRISM ® Membrane separators, and
designed to supply 3000 SCFH of nitrogen with a maximum oxygen content of 5.0vol%.
The Nitrogen Generator Unit is a built into two different sections, one Process Section
and one Membrane Section. The former skid consists of feed air treatment, product
measurements, instrumentation and control while the other consists of membranes.
For detailed information for the various components (instruments, filters, valves etc.)
see Chapter 8 – Equipment Data / Sub vendors Instructions & Operation and
Maintenance Manual.

WARNING: During any maintenance routine, all safety precautions are to be

observed most rigidly. Suitable warning signs are to be put up when
maintenance is being carried out to avoid the possibility of accidental
or unauthorized operation of the plant.

The main components are as follow:

PRISM ® Membrane Separator, MS-8.18.

Feed Air Water Separator, WS-8.11
Particle/Coalescing Filters, F-8.13 and F-8.14
Air Preheater, H-8.15
Silencer for venting product outside specification.
Oxygen Analyzers, AIT-8.50
Control Valve, FV-8.54
All necessary piping and valves
All necessary instrumentation and electrical equipment
Local Control Panel 5.1

7.1 PRISM ® Membrane Separator, MS-8.18

The process of producing gaseous nitrogen by air separation in hollow fibres polymer
membranes is based on selective permeation of the constituent gases in air. Oxygen,
carbon dioxide and water vapour permeate faster through the membranes than
nitrogen.
There is no maintenance requirement on the membrane separators. The installed
oxygen analyser will give status of the generated gas.

NOTE. Significant liquid oil and solid particles carry over from Particle/Coalescing
Filters F-8.13 & F-8.14 may permanently reduce the membrane capacities. It is

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 Containerized Nitrogen Membrane System
P.O.No. 40-29043-03
Document: 15844-0805-001, Rev. 00
therefore important to keep the filter element replacement schedule. Compressed air
(outside Air Products’ scope of supply) is supplied from oil lubricated machines so
liquid oil will be present in the feed air.

7.2 Particle/Coalescing Filters, F-8.13, F-8.14

Use detail drawing of Particle/Coalescing Filter 15807-0608-301 for reference.

Maintenance and inspection of the inlet filters are important. Clogged elements will
reduce the membrane separators operating feed air pressure, and therefore decrease
the nitrogen production. Additionally, clogged filter element may collapse due to the
high diff. pressure and led to un-filtered air being fed into the membrane separators.
This could deactivate membrane area of the separators and therefore reduce the
nitrogen capacity of the Nitrogen Gas Generator Package. These filters will also
remove oil from inlet air, oil carryover can lead to reduced lifetime of the membranes.

Recommended inspection interval:

Every 7 day:
- Check filter diff. pressure by. max pressure drop is 60m mbar (warning alarm only).
If the diff. pressure indicator (PDIT-8.32) shows an abnormal low value
(< 200 mbar) the filter element may be damaged and has to be inspected and
perhaps replaced.
Apart from above abnormal operating conditions the filter elements should be
replaced every 6 months.

When the filter elements (6 in each vessel) shall be replaced following procedure
should be followed:

• Shut down Nitrogen Generator Unit and make sure that the unit is depressurized
(described above) before the maintenance work starts.
• Make sure that all filter elements with model number APAS88-PF are available for
filter vessel F-8.13 and ditto with model number APAS88-AF are available for filter
vessel F-8.14.
• Disconnect drain pots LCV-8.37 and LCV-8.38.
• Disconnect the vessel bottom head of F-8.13 and F-8.14, and move aside.
• Unscrew with clock direction element for element with handcraft. If this is not possible
use suitable tool.
• Then take the new elements one by one and add Rocol Foodlube universal grease or
similar to the O-ring.
• Connect the new element such that one steel rod (inside of the vessel) is entering the
centre of the element. The rod is treaded at the end which shall enter bottom of the
element. Tightened just with handcraft.
• Install all elements as described above and reconnect bottom heads, drain pots and
pipe.
• Then start unit as required.

7.3 Feed Air Electric Inlet Heater, H-5511A

The feed air heater is powered by 415-400V AC. Special care should be taken when
working on live equipment becomes necessary.

Ref. Chapter 8. Equipment Data/Sub Vendors Instruction & Operation and

Maintenance Manuals.

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 Containerized Nitrogen Membrane System
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Document: 15844-0805-001, Rev. 00

7.4 Oxygen Analyser, AIT-8.50

Weekly: Check the analyser calibration.

Check the analyser calibration.
• Select “Calibrate sensor” sub menu then select “span” Then
apply span gas (Instrument air) by turning the sample selector
valve located near the analyser to the "span" position
(instrument air is now led to the analyser). Wait for measured
value to be stabilized. Adjust to 20.9 vol% O2 if wrong reading.
Confirm decision with “Yes”.
• Then apply sample gas by turning the sample selector valve to
the sample position
• Wait until measured value is outside alarm range and confirm
with “Yes”.

7.5 Instrumentation

For detailed maintenance instructions (instruments, valves etc.) see Ref. Equipment
Data/Sub Vendors Instruction & Operation and Maintenance Manual (Sub-Vendors
Catalogue Information).

7.6 Maintenance Schedule / Inspection Period

See document Operating Spare Parts 15807-0807-001 for inspection and maintenance
schedule.

8. EQUIPMENT DATA / SUBVENDORS INSTRUCTIONS & OPERATION AND

MAINTENANCE MANUAL

The following equipment is included in this chapter.

• Control Valve (Valve, Actuator and Instrument Supply Pressure Regulator)

• Oxygen Analyser
• Heater Element
• Compact Flow Meter
• Pressure Transmitter
• Temperature Transmitter
• Level Switch
• On-off Valve (Valve and Actuator)
• Thyristor

Page 9 of 9