-1-

INDEX

CHAPTER DESCRIPTION PAGE NO.

1. Introduction 3

2. Technical Specification 4

3. Equipment Description 5

4. PLC Write-up 10

5. Normal start-up and shut-down. 14

6. Normal Operating Parameters 15

7. Important points for trouble free 16

Operation

8. Trouble shooting operations 17

9. Maintenance of Oil Filters 21

10. Set Point of Instruments 24

11. Log Sheet for Nitrogen Plant 25

12. Broad Specification of Items. 26

DRAWINGS

1. P & I Diagram : MVS-5939-20322-00

2. Power & Control Circuit : MVS-5939-20323-02

3. Sequence Chart for PSA Unit : MVS–5939–20503-00

4. Sequence Chart for Deoxo Unit : MVS-5939-20504-00

5. Sequence Chart for Nitrogen Dryer : MVS-5939-20505-00

\\nldfbs01\userprofile$\RDPUserDesktop\sumanths\Desktop\Nitrogen Manual.doc
 -2-

MANUALS & CATALOGUES

1. Percentage Oxygen Analyzer : Nucon (4326)

2. Trace Oxygen Analyzer : Nucon (4316)

3. Pressure Holding Valve (Nitrogen) : Nirmal

4. Pressure Reducing Valve (Ammonia) : Nirmal

5. Level Switch (Liquifant FTL 20) : E&H

6. Temperature Indicating Controller : Radix (TC-96)

-------x-------x-------

\\nldfbs01\userprofile$\RDPUserDesktop\sumanths\Desktop\Nitrogen Manual.doc
 -3-
CHAPTER - 1

INTRODUCTION

This manual broadly covers the Technical Data, process flow

description and procedures to be followed during start up, normal
running, automatic trip for the Nitrogen Gas Plant.

All information and drawings given herein are strictly

confidential and are to be used only for the sole purpose of
operation and maintenance of this unit. All this information is
the property of MVS ENGINEERING LIMITED - NEW DELHI and should not
be made public or copied.

MVS ENGINEERING LIMITED shall not be responsible for any

operational errors claimed to be due to lack of information in the
operation manual.

-------x------x------

\\nldfbs01\userprofile$\RDPUserDesktop\sumanths\Desktop\Nitrogen Manual.doc
 -4-

CHAPTER - 2

TECHNICAL SPECIFICATION

2.1 PRODUCT GAS SPECIFICATION :

a) Capacity (Nitrogen Gas) : 230 NM3/hr

b) Composition(Nitrogen Gas) :

Oxygen : 1 PPM
Hydrogen : 2 PPM
Nitrogen : Balance

c) Dew Point (Atm.) : (-) 60° C

d) Nitrogen Pressure : 5.5 Kg/cm2g

2.2 UTILITIES CONSUMPTION :

a) Power Supply : 415 V AC, 3 Phase, 50 Hz

b) Connected Electrical Load : 25 KW

c) Chilled water : 1.5 M3/hr at

2 kg/cm2g pressure
and 6°C(max.) temp.

d) Cooling water : 2 M3/hr at

2 kg/cm2g pressure
and 32°C(max.) temp.

e) Hydrogen Gas : 2.5 NM3/hr at

6.5 kg/cm2g pressure

-------x------x------

\\nldfbs01\userprofile$\RDPUserDesktop\sumanths\Desktop\Nitrogen Manual.doc
 -5-

CHAPTER - 3

EQUIPMENT DESCRIPTION

Please refer P&I Drawing No. MVS-5939-20322-00

A) CHILLED WATER COOLER :

Compressed Air supplied from your Air Compressor at 7.5 Kg/cm2g is

cooled to below 20 deg.C temperature in a Chilled water cooler.
This is a Shell & Tube type heat exchanger where compressed air
flows through shell and chilled water flows through tubes.

B) AIR RECEIVER :

An air receiver is installed before compressed air is fed in to

the system. Condensed Moisture is also drained out here by Auto
Drain Trap & Manual Drain. It is important to check proper
moisture draining by opening of manual valves at least twice in a
shift. A low pressure switch and a high water level switch are
mounted on the Air Receiver to stop the time sequence and to give
alarm.

C) COALESCING FILTER :

It consists of a pair of coarse and fine filters, which removes

oil present in compressed air. Coarse and Fine filters are
installed after the Air Receiver. Oil separation is done by the
filter element which gets choked / saturated during operation
depending on oil load in compressed air. Regular attention is
required for proper draining of separated oil and replacement of
filter element to avoid any oil carry over to PSA system. The
filter element of these filters should be replaced every 6-8
months to avoid any oil carry over to the PSA system.

\\nldfbs01\userprofile$\RDPUserDesktop\sumanths\Desktop\Nitrogen Manual.doc
 -6-
D) AC FILTER :

This is a desiccant based filter having a Activated Carbon fabric

filter element which adsorbs fine oil traces which remain in
compressed air even after filtered by coalescing filters. Filter
element of this filter should be replaced every 6-8 months
regularly to avoid any damage of molecular sieves.

E) PSA UNIT :

There are two towers filled with special grade Carbon

Molecular sieves (CMS) to adsorb O2, CO2 & moisture present in
air. At the bottom of each tower M.S. Perforated plate with 8 mm
dia hole and SS wire mesh is welded to hold activated alumina and
CMS in the tower. Just above the plate, the ceramic balls are
spread to act as a holding bed for activated alumina. Alumina is
used to remove remaining moisture of air entering CMS bed.
Dry air is also used to operate the actuators and valves.

Above alumina, CMS is filled. The perforated plate and wire mesh
cover the CMS bed and the adsorbent is prevented from flowing out.
A 25 mm thick coconut fibre mat is provided at the top of CMS bed.
Coconut fiber mat is squeezed when the top flange cover is
tightened.

Each tower has air inlet valves (V1 & V2) at bottom, product
valves (V7 & V8) at top and exhaust outlet valves (V3 & V4) at
the bottom. Besides these valves, a valve V5, at the bottom
and a valve V6, at the top are installed for equalization of
pressure in both towers, before change-over.

F) NITROGEN SURGE VESSEL:

Nitrogen from PSA Module will have varying purity, depending

upon the pressure in the adsorber during the cycle time. This
vessel gives product Nitrogen at constant pressure with constant
average gas purity. For analysing the O2 percentage in the
Nitrogen gas, one needle valve for sampling is provided on this
vessel.
From Surge Vessel, some of Nitrogen gas goes back to PSA towers
after the change-over, so that there is drop of around 0.5

\\nldfbs01\userprofile$\RDPUserDesktop\sumanths\Desktop\Nitrogen Manual.doc
 -7-
kg/cm2g pressure of surge vessel. This back-flow of gas
decreases the time required for the pressure rise in PSA towers,
which leads to more production time, and better purity of Nitrogen
Gas.

G) PERCENTAGE OXYGEN ANALYZER

This is an on-line, digital, percentage Oxygen Analyzer, which

monitors continuously Oxygen content in raw Nitrogen gas in surge

vessel. A filter cum pressure regulator is fitted on the sample

line to reduce sample gas pressure. In case of high oxygen

percentage, Hydrogen shut off valve closes and gives audio visual

alarm.

H) DE-OXO UNIT:

To remove oxygen gas present as impurity in Nitrogen gas De-Oxo

unit is installed. This is a twin tower system. Both towers are
filled with catalyst and fitted with ‘U’ tube heaters. Valve
operation is automatic through the PLC. In De-Oxo Tower, oxygen
gas present as impurity in Nitrogen gas is removed by catalyst.
Hydrogen gas supplied from the cylinders are used for regeneration
of catalyst.

I) DE-OXO COOLER:

Hot Nitrogen gas after the De-oxo Unit is cooled to ambient

temperature by the cooler. This cooler is shell & tube type, in
which water is in tube side and gas passes through the
shell.

J) DEOXO MOISTURE SEPARATOR :

The moisture in the gas gets condensed in De-oxo After Cooler &
drained at moisture separator through Auto Drain Trap fitted at
the bottom. It is important to check proper moisture draining by
opening of manual valves at least twice in a shift. A high water
level switch is mounted on the moisture separator to give alarm.

\\nldfbs01\userprofile$\RDPUserDesktop\sumanths\Desktop\Nitrogen Manual.doc
 -8-

K) TRACE OXYGEN ANALYZER :

This is an on-line PPM Oxygen Analyzer which monitors continuously

Oxygen content in Nitrogen gas and gives digital display. A
filter cum pressure regulator is fitted on the sample line to
reduce sample gas pressure. Solenoid valves provided at Inlet and
outlet, isolate the sensor when analyzer is switched off. In case
of high Oxygen PPM it gives alarm and opens the 3-way Vent Valve
to start venting.

L) GAS DRYING UNIT :

To remove moisture from product gas a heated type gas dryer is

installed. This is a twin tower system in which one tower is in
drying operation while the other tower is under regeneration
simultaneously. The tower changeover is automatic through PLC
with a fixed time cycle of (6+6) hours. Each tower has two valves,
one at the Inlet and another at exhaust. There is one Non-return
valve at the top in product line. Purge line is provided at the
top of Dryer tower. A small quantity of dry gas passes through the
tower under regeneration to make the bed of tower dry before it
comes in line again. Same process is repeated in the other tower
also. For the opening/closing time of different valves, the time
cycle of the dryer (attached with this manual) can be referred.

Both the Drying Towers are provided with Regeneration Heaters of

7.5 KW rating in each tower . During regeneration cycle, the purge
Gas gets heated upto 200°C and picks up adsorbed moisture from the
desiccant bed and vent out. This heating goes on up to 2 hours and
after that, heaters are switched off automatically and cooling of
the bed starts.

Before the changeover from one tower to another, equalization of

pressure in both the drying towers takes place.

\\nldfbs01\userprofile$\RDPUserDesktop\sumanths\Desktop\Nitrogen Manual.doc
 -9-

M) PRESSURE HOLDING VALVE (PHV):

The PHV is provided after the drying unit. When the inlet
pressure signal increases to exceed the spring setting,
the outlet port of valve will open and in case this
pressure goes down, the regulator will close the outlet port.
This would always maintain 5.5 kg/cm2g minimum pressure at
the dryer. The setting of PHV can be changed by adjusting the
bolt provided at the top.

N) 3-WAY VENT VALVE:

3-way vent valve after PHV is a pneumatic operated 3-way valve.

When there is no instrument air signal, its bottom port is open to
atmosphere. Thus when the gas generator is started the gas,
initially of low purity will be vented to atmosphere through this
3-way valve. This valve closes its bottom port when it gets
compressed air through solenoid valve. The solenoid valve will get
energized when Nitrogen purity is OK and Vent valve is switched
‘ON’. In case of any abnormality in the plant, the 3-way vent
valve bottom port will open automatically and the gas will be
vented to atmosphere

-------x------x------

\\nldfbs01\userprofile$\RDPUserDesktop\sumanths\Desktop\Nitrogen Manual.doc
 - 10 -

CHAPTER - 4

PLC Write-up

 Please refer Power & Control Circuit Drawing No. MVS-5939-

20323-00

1) Outputs Q 0.0, Q 0.1, Q 0.2, (R1 to R3) for PSA Valves shall
be available as per sequence chart MVS-5939-20503-00, if
following inputs are available :

a) I 0.0 – (d1) LPS at Chilled water line

b) I 0.1 – (d2) LPS at Air Receiver
c) I 0.2 – (d3) Water Level Switch (Air Receiver)
d) I 0.4 – (d5) LPS Cooling water line (De-oxo cooler)
e) I 1.0 – (d9) HPS at N2 Outlet

2) Output Q 0.3 (R4) for Air Inlet Valve and N2 Dryer Exhaust
shall be available, whenever following inputs become
available :

a) I 0.0 – (d1) LPS at Chilled water line

b) I 0.1 – (d2) LPS at Air Receiver
c) I 0.2 – (d3) Water Level Switch (Air Receiver)
d) I 0.4 – (d5) LPS Cooling water line (De-oxo Cooler)
e) I 1.0 – (d9) HPS at N2 Outlet

3) Output Q 0.4 (R5) for Instrument Air valve shall be available

for 2-minutes, if following Inputs are available :

a) I 0.0 – (d1) LPS at Chilled water line

b) I 0.1 – (d2) LPS at Air Receiver
c) I 0.2 – (d3) Water Level Switch (Air Receiver)
d) I 0.4 – (d5) LPS Cooling water line (De-oxo cooler)
e) I 1.0 – (d9) HPS at N2 Outlet

\\nldfbs01\userprofile$\RDPUserDesktop\sumanths\Desktop\Nitrogen Manual.doc
 - 11 -

4) Output Q 0.5 (R6) for Surge vessel outlet Valve shall be

available after 5-minutes, whenever following inputs become
available :

a) I 0.0 – (d1) LPS at Chilled water line

b) I 0.1 – (d2) LPS at Air Receiver
c) I 0.2 – (d3) Water Level Switch (Air Receiver)
d) I 0.4 – (d5) LPS Cooling water line (De-oxo cooler)
e) I 1.0 – (d9) HPS at N2 Outlet

5) Output Q 0.6 (R7) for Hydrogen Shut-Off Valve shall be

available, if following outputs and inputs are available :

a) Q 0.5 – (R6) for Surge Vessel outlet valve

b) I 0.7 – (d8) LPS at N2 Dryer Outlet
c) I 1.2 – (d11) De-Oxo Tower-I Middle Temp. High
d) I 1.4 – (d13) De-Oxo Tower-II Middle Temp. High
e) I 1.7 – (d16) Oxygen Percentage High
f) I 0.4 – (d5) LPS at Deoxo After cooler water line

6)Output Q 0.7 (R8) for Vent Valve shall be available, if

following outputs/inputs are available :

a)Q 0.5 – (R6) for Surge Vessel outlet valve

b)I 2.0 – (d17) Oxygen PPM high
c)I 2.1 – (SW-4) Vent valve close / open Switch is ‘On’
d)I 1.2 – (d11) Deoxo Tower-I Middle Temp. High
e)I 1.4 – (d13) Deoxo Tower-II Middle Temp. High

\\nldfbs01\userprofile$\RDPUserDesktop\sumanths\Desktop\Nitrogen Manual.doc
 - 12 -

7) Outputs Q 1.0 to Q 1.3 (R9 to R12) for De-Oxo Valves shall

be available as per sequence chart MVS-5939-20504-00, if
following inputs are available :

a) I 0.0 – (d1) LPS at chilled water line

b) I 0.1 – (d2) LPS at Air Receiver
c) I 0.2 – (d3) Water Level Switch (Air Receiver)
d) I 0.4 – (d5) LPS Cooling water line (Deoxo cooler)
e) I 1.0 – (d9) HPS at N2 Outlet

8)Output Q 1.4 (R14) for De-oxo Tower-I Heater (H1) will be

available, if following Inputs are available :

a) I 1.1 – (d10) De-oxo Tower-I Top Temp. High

b) I 1.2 – (d11) De-oxo Tower-I Middle Temp. High

9)Output Q 1.5 (R15) for De-oxo Tower-II Heater (H2) will be

available, if following Inputs are available :

a) I 1.3 – (d12) De-oxo Tower Tower-II Top Temp. High

b) I 1.4 – (d13) De-oxo Tower Tower-II Middle Temp. High

10)Outputs Q 1.6, Q 1.7, Q 2.0, Q 2.1, Q 2.2, Q 2.3 (R15 to

R20) for N2 Dryer Valves & Heaters shall be available as per
sequence chart MVS-5939-20505-00, if following inputs are
available :

a) I 0.1 – (d1) LPS at Chilled water line

b) I 0.2 – (d2) LPS at Air Receiver
c) I 0.3 – (d3) Water Level Switch (Air Receiver)
d) I 0.4 – (d5) LPS Cooling water line (Deoxo cooler)
e) I 1.0 – (d9) HPS at N2 Outlet

\\nldfbs01\userprofile$\RDPUserDesktop\sumanths\Desktop\Nitrogen Manual.doc
 - 13 -

11)Besides the Sequence Chart Timing Output Q 2.2 (R19) for N2

Dryer Heater (H3) shall not be available, if following inputs
are not available :

a)I 0.5 – (d6) HPS at N2 Drying Tower-I

b)I 0.7 – (d8) LPS at N2 Dryer Outlet
c) I 1.5 – (d14) N2 Drying Tower-I Temp. High

12)Besides the Sequence Chart Timing Output Q 2.3 (R20) for N2

Dryer Heater (H4) shall not be available, if following inputs
are not available :

A)I 0.6 – (d7) HPS at N2 Drying Tower-II

b)I 0.7 – (d8) LPS at N2 Dryer Outlet
c) I 1.6 – (d16) N2 Drying Tower-II Temp. High

-----x-----x-----

\\nldfbs01\userprofile$\RDPUserDesktop\sumanths\Desktop\Nitrogen Manual.doc
 - 14 -

CHAPTER - 5

NORMAL START-UP AND SHUT-DOWN

NORMAL START-UP :

1. Area near the unit should be clean.

2. Ensure that drain valves of all equipments are closed.

3. Switch 'ON' the main switch & control supply switch.

4. Open chilled water and cooling water supply and return valves.
5. Start your Air compressor and open Air inlet valve.
6. As soon as the Air receiver pressure will reach 6 kg/cm2g,
time cycle of PSA unit, De-oxo unit and Nitrogen Dryer unit
will start.

7. After 5-minutes Surge Vessel outlet valve will open. Adjust

Nitrogen flow with the globe valve provided before the Rota
Meter.

8. Switch ‘ON’ Percentage Oxygen Analyzer

9. Open Hydrogen inlet valve and adjust pressure if required.

10. Adjust Hydrogen gas flow with the Needle valve provided

before the Rota Meter.

11. Switch ‘ON’ the Trace oxygen Analyzer.

12. When Nitrogen Purity becomes OK, Switch ‘ON’ Vent Valve
Switch. Now Nitrogen gas will start going to your system.

NORMAL SHUT-DOWN :

1. Switch ‘OFF’ and Trace & Percentage oxygen analyzers.

2. Close Hydrogen inlet valve.
3. Stop Air compressor and Close Air inlet valve..

-------x------x------

\\nldfbs01\userprofile$\RDPUserDesktop\sumanths\Desktop\Nitrogen Manual.doc
 - 15 -

CHAPER-6

NORMAL OPERATING PARAMETERS

1) Cooling water pressure : 2 - 4 Kg/cm2g

2) Air Receiver Press. : 7.5 Kg/cm2g

3) Air Receiver Temp. : 25°C (max.)

4) Instrument Air Header pressure : 6 to 7 Kg/cm2g

5) Instrument Air Regulator Press. : 5 Kg/cm2g

6) PSA Tower press. : 7 Kg/Cm2g

7) N2 surge vessel press. : 6.5-7 kg/cm2g
8) Oxygen percentage in N2
Surge vessel : 0-1%
9) Hydrogen Pressure after
press. Regulator : 6.5 Kg/cm2g

10) Nitrogen Flow : 250 NM3/hr

11) Hydrogen Flow : 2.5 NM3/hr

12) Deoxo Tower Pressure : 5.5 Kg/cm2g

13) De-oxo Tower Temp. : 50-200°C (Normal)

250°C (max.)
14) De-oxo Moisture separator temp. : 40°C (max)

15) N2 Drying Tower Pressure : 5.5 Kg/cm2g

(during Drying cycle)

16) N2 Drying Tower Pressure

(during Regeneration cycle) : 0.2 kg/Cm2g (max.)

17) N2 Drying Tower Bottom Temp.

(during heating cycle) : 200°C (max)

18) N2 Drying Tower Top Temp.

(during heating cycle) : 120°C (max)

19) N2 Drying tower temp : 70°C (max)

(during cooling cycle)

20) Oxygen PPM in Nitrogen gas : 1 ppm

21) Dew Point of Nitrogen gas : (-) 60˚ C

--------x--------x--------

\\nldfbs01\userprofile$\RDPUserDesktop\sumanths\Desktop\Nitrogen Manual.doc
 - 16 -

CHAPTER - 7

IMPORTANT POINTS FOR TROUBLE FREE

OPERATION

1. Check auto drain traps provided with Air receiver and Moisture
separator are working well and there is no water carry over.
For this after every 3-4 hours manual drain valves should
be opened to drain out condensed moisture, if any.

2. Check and ensure that all valves of PSA module are

opening/closing properly and pressure in both PSA Towers
goes up to 7 kg/cm2g.

3. Check and ensure the changeover of towers and working of

valves are according to the time cycle.

4. Time and operating sequence of Drying unit valves and heaters

to be checked once in a shift.

5. Flow of Nitrogen and Hydrogen gases 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 switch, Temp. controller

and working of the other instruments.

7. Pressure Holding Valve function should be observed and checked

periodically so that it always maintains 5.5 kg/cm2g Pressure in
the Drying Tower.

8. Topping up of PSA Towers should be done half yearly.

9. Filter element of Coarse, fine & AC filters should be replaced

half yearly.

10. A log book should be maintained in which all operating

conditions should be recorded after regular intervals of
2-hours.

-------x------x------

\\nldfbs01\userprofile$\RDPUserDesktop\sumanths\Desktop\Nitrogen Manual.doc
 - 17 -

CHAPTER - 8

TROUBLE SHOOTING OPERATIONS

1. Trouble : PSA unit/De-oxo Unit/Drying unit sequence

not working.

Reasons :

a) Chilled water pressure low : Check

b) Cooling water pressure low : Check
c) Air receiver pressure low : Check
d) Air receiver water level high : Check
e) N2 outlet Pressure high : Check

2. Trouble : PSA unit working is erratic.

Reasons :

a) Signal from the PLC not OK : check.

b) Some valve not working properly : check.
c) Instrument Air Pressure not sufficient : Check Pressure
Regulator setting
d) Solenoid valve faulty : rectify/replace it.
e)

-
3. Trouble : Auto drain trap not working. Water coming from
manual drain valve but not from auto drain trap.

Reasons :

a) Y-strainer might have been chocked : Clean the strainer.

b) Drain valve out of order : rectify/ replace it.

\\nldfbs01\userprofile$\RDPUserDesktop\sumanths\Desktop\Nitrogen Manual.doc
 - 18 -

4. Trouble : PSA module alright but no pressure in the Nitrogen

Surge Vessel.

Reasons :

a) Automatic Valve on the product gas line from the PSA

module is not opening : check & rectify the valve.

b) Drain Valve of Nitrogen Surge vessel may be open : close

the valve.

c) Pressure indicator not working : Rectify it.

5. Trouble : Oxygen percentage high / Deoxo Temp. high

Reasons :

a) Air Receiver temp. high : Check chilled water flow/press./

temp.
b) PSA tower pressure not going up to 7 kg/cm2g : check.

c) Excessive Nitrogen flow rate through the Rota meter.

: check and reduce Nitrogen flow.

d) One of the PSA valves may be faulty : check and rectify

the valve.

e) Signal from PLC to PSA valve may be faulty : check and

rectify.

f) Solenoid valve not working : rectify/replace.

6. Trouble : Enough Hydrogen gas is not coming to Rotameter.

Reasons :

a) Low Hydrogen flow rate : Increase Hydrogen flow rate.

b) Hydrogen Shut-off valve closed : Please refer point No.7

c) Leakage in pipe line carrying Hydrogen gas : Check all

the joints and tighten them properly.

c) Choking somewhere in the system : Check

\\nldfbs01\userprofile$\RDPUserDesktop\sumanths\Desktop\Nitrogen Manual.doc
 - 19 -

7. Trouble : Hydrogen shut-0ff valve doesn’t open

Reasons :

a) N2 Surge Vessel Outlet valve closed : Check, it will open

after 5-minutes, when PSA cycle starts.

b) N2 Dryer outlet pressure low : Check

c) Cooling Water pressure low : Check

d) De-oxo Tower Temp. high : Check

e) Oxygen percentage high in surge vessel : Please refer

point No. 5

8. Trouble : Nitrogen Dryer working is erratic

Reasons :

a) PLC may be faulty : check & replace.

b) Valve not functioning : check
c) Instrument air signal not available : check
d) Solenoid valve defective : check & replace.

9. Trouble : Working pressure of Drying Unit is less than

5 kg/cm2g.

Reasons :

a) The Rotameter adjusting valve may be closed.

b) Pressure Holding Valve Malfunctioning : check the

setting.

c) Any of the Dryer Inlet valves leaking : check &

rectify.

d) Non-Return valve at the Dryer's outlet

malfunctioning : Check & replace it.

\\nldfbs01\userprofile$\RDPUserDesktop\sumanths\Desktop\Nitrogen Manual.doc
 - 20 -

10. Trouble: Oxygen PPM High in Product Gas

Reasons:
a) Flow of Hydrogen gas is not sufficient, so Deoxo Unit
will not remove all Oxygen : Check and increase Hydrogen
gas flow.
b) Excessive Nitrogen flow rate : check
c) Oxygen percentage high in surge vessel : Please refer
point No. 5
d) Activity of Deoxo catalyst may be deteriorated : check &
replace the catalyst. If PPM Oxygen does not come down even
after increasing Hydrogen- gas flow.

11. Trouble : Vent valve not closing

Reasons :

a) N2 Surge Vessel Outlet valve closed : Check, it will open

after 5-minutes, when PSA cycle starts.

b) De-oxo Tower Temp. high : Check

c) Oxygen PPM is high : Check
d) Vent Valve switch is ‘OFF’ : Check

-------x------x------

\\nldfbs01\userprofile$\RDPUserDesktop\sumanths\Desktop\Nitrogen Manual.doc
 - 21 -
CHAPTER 9

MAINTENANCE OF OIL FILTERS

Compressed Air to be used in PSA Nitrogen generators should be oil

free. We provide 3-special filters in compressed Air line before
Molecular sieves unit to make air oil free.

a) Coarse Coalescing Oil Filter :

This is Borosilicate fiber filter. This filter removes thick

oil mist coming with compressed Air. Separated oil is to be
drained on regular intervals from the bottom drain of this
filter. This filter reduces oil level to 0.1 ppm. Without
this filter, oil content in Air is around 10-ppm which is
highly poisonous to Molecular sieves. So this filter is very
important. Life of Filter element is around 6-months.

b) Fine Coalescing Oil Filter :

This is also identical Borosilicate filaments filter but with

fine oil removal capacity. This filters down oil to 0.01
ppm. Fine oil mist gets separated and should be drained out
on regular intervals from bottom drain. After this filter
oil content in air is around 0.01 ppm. Life of this filter
element is around 6-months.

c) Activated Carbon Filter:

Air coming out from lubricated compressor has oil, in Liquid

form as well as in vapor form due to high temperature of Air.
While Liquid oil mist is removed by above 2-filters, but even
then oil in vapor form still remains in compressed Air, which
is also not desirable as it also affects Molecular sieves
life. To remove this oil vapor, an Activated carbon fabric
filter is provided as 3rd stage filter and it removes oil
vapors completely. The life of this filter element is around
6-months.

\\nldfbs01\userprofile$\RDPUserDesktop\sumanths\Desktop\Nitrogen Manual.doc
 - 22 -

After these 3-filters the Air becomes oil free and is as good
as air coming from a Non-lubricated compressor. This quality
air gives long life of Molecular sieves.

d) Filters Maintenance:

i) Filter element of Activated Carbon Filter absorbs oil

vapor and becomes saturated gradually. After every 6-
months time filter element should be changed by a new
one. It cannot be regenerated.

ii) Coalescing type coarse filter and Fine filter have

special elements on which oil deposits on the outer
surface and also oil is trapped by Borosilicate
filaments. These filter candles can be easily removed
by opening filter body (without disconnecting filters
from the pipelines). Filter elements must be replaced
at the end of its service life. If old filter elements
are used for a longer period, their efficiency
deteriorates and oil filtration becomes poor. So never
use these filter elements beyond its service life.

e) Candle Fixing Inside The Filter:

Follow directions of candle fixing properly so that candle

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

\\nldfbs01\userprofile$\RDPUserDesktop\sumanths\Desktop\Nitrogen Manual.doc
 - 23 -

f) Feed Air Temperature:

These filters are installed in the line after Air receiver

and Air temperature should be maximum 25º C to get good
performance of these filters. At higher Air temperature,
there would be more oil mist and more oil vapor which these
filters will not be able to remove completely. So make sure
that Chilled water cooler is working efficiently, Chilled
water supply temperature is maximum 6º C and Air receiver
temperature is maximum 25º C. If Air temperature is running
high, never run the gas generator to save Molecular Sieves
from oil poisoning.

-------x------x------

\\nldfbs01\userprofile$\RDPUserDesktop\sumanths\Desktop\Nitrogen Manual.doc
 - 24 -

CHAPTER - 10

SET POINTS OF INSTRUMENTS

1) Low Pressure Switch at Chilled water line : 1 Kg/Cm2g

2) Low Pressure Switch at Air Receiver : 6 Kg/Cm2g

3) Instrument Air Press. Regulator outlet press.: 5 Kg/cm2g

4) Percentage Oxygen Analyzer (High O2 %) : 1.3%

5) Hydrogen Pressure Regulator outlet press. : 6.5 Kg/cm2g

6) Low Pressure Switch at Cooling water line : 1 Kg/Cm2g

7) Temp. controller at Deoxo Towers I&II Top : 250ºC

(TIC – 1&3)
8) Temp. controller at Deoxo Towers I&II Middle : 100ºC
(TIC – 2&4)
9) Temp. controller at Drying Towers I & II : 180ºC
(TIC – 5&6)

10) High press. switch at Drying Towers I & II : 1 Kg/cm2g

11) Low pressure switch at N2 Dryer outlet : 4.5 Kg/cm2g

12) Pressure Holding valve at N2 dryer outlet : 6 Kg/cm2g

13) Trace Oxygen Analyzer (High o2 PPM) : 20 PPM

14) High pressure switch after Vent Valve : 5.5 Kg/cm2g

------x------x------

\\nldfbs01\userprofile$\RDPUserDesktop\sumanths\Desktop\Nitrogen Manual.doc
 - 25 -
CHAPTER - 11

LOG SHEET FOR NITROGEN PLANT

Date :

Time
S. No. Parameters Unit
1 Chilled water pressure Kg/cm2g

2 Cooling water pressure Kg/cm2g

3 Hydrogen Pr. after Pr. Regulator Kg/cm2g

4 Air Receiver Pressure Kg/cm2g

5 Air Receiver Temp. ˚C

6 Moisture draining from Air Receiver OK/Not OK

7 Instrument Air Header Pressure Kg/cm2g

8 Instrument Air Regulator Pressure Kg/cm2g

9 PSA Tower Pressure Kg/cm2g

10 N2 Surge Vessel Pressure Kg/cm2g

11 Oxygen Percentage %

12 Nitrogen Flow NM3/hr

13 Hydrogen Flow NM3/hr

14 De-oxo Tower-I Pressure Kg/cm2g

15 De-oxo Tower-I Top Temp. (TIC-1) ˚C

16 De-oxo Tower-I Middle Temp. (TIC-2) ˚C

17 De-oxo Tower-II Pressure Kg/cm2g

18 De-oxo Tower-II Top Temp. (TIC-3) ˚C

19 De-oxo Tower-II Middle Temp. (TIC-4) ˚C

20 Moisture Separator Temp. ˚C

21 Moisture draining from Moisture OK/ Not OK

Separator
22 Oxygen PPM PPM

23 Drying Tower-I Pressure Kg/cm2g

24 Drying Tower-I Top Temp. ˚C

25 Drying Tower -I Bottom Temp. (TIC-5) ˚C

26 Drying Tower-II Press. Kg/cm2g

27 Drying Tower -II Top Temp. ˚C

28 Drying Tower-II Bottom Temp. (TIC-6) ˚C

\\nldfbs01\userprofile$\RDPUserDesktop\sumanths\Desktop\Nitrogen Manual.doc
 - 26 -
CHAPTER - 12

BROAD SPECIFICATION OF ITEMS

1. Air Receiver:

a) Size : 1200 Dia x 1400 WW

b) MOC : Carbon Steel
c) Working Pressure: 7.5 Kg/cm2g

2. PSA Tower:

a) Size : 1100 Dia x 1400 WW

b) MOC : Carbon Steel
c) Working Pressure: 7.5 Kg/cm2g.
d) Type : Composite Bed (Bottom-Alumina
Top- CMS)

3. N2 Surge Vessel:

a) Size : 1800 Dia x 1750 WW

b) MOC : Carbon Steel
c) Working Pressure: 7 kg/Cm2g

4. Deoxo Towers:

a) Size : 250 Dia x 1150 WW

b) MOC : Carbon Steel
c) Working Pressure: 5.5 Kg/Cm2g

5. Heater for De-oxo Tower:

a) Type : U-tube
b) Size : 1350 mm Long
c) Rating : 4.5 KW / tower (3x1.5 KW)

6. N2 Drying Towers:

a) Size : 400 Dia x 1300 WW

b) MOC : Carbon Steel
c) Working Pressure: 5.5 Kg/ cm2g

\\nldfbs01\userprofile$\RDPUserDesktop\sumanths\Desktop\Nitrogen Manual.doc
 - 27 -

7. Regeneration Heater for N2 Dryer:

a) Type : U-tube
b) Size : 1350 mm Long
c) Rating : 7.5 KW / tower (6x1.25 KW)

8. Deoxo Moisture Separator:

a) Size : 300 dia x 1200 WW

b) MOC : Carbon Steel
c) Working Pressure: 5.5 Kg/cm2g

9. Chilled Water Cooler:

a) Type : Shell & Tube

b) Shell : 8” Dia.
c) Tube : 4 feet long, copper
d) Shell Side : Air
e) Tube Side : Chilled Water.
f) Installation : Vertical

10. De-oxo Cooler:

a) Type : Shell & Tube

b) Shell : 6” dia
c) Tube : 4 feet long, copper
d) Shell side : Nitrogen
e) Tube Side : Cooling water
f) Installation: Vertical

11. Percentage Oxygen Analyzer:

a) Make : Nucon
b) Model : 4326
c) Range : 0 – 30 %
d) Sensor : B1 (Electrochemical)

12. Trace Oxygen Analyzer:

a) Make : Nucon
b) Model : 4316
c) Range : 0 – 1999 PPM
d) Sensor : B2 (Electrochemical)

\\nldfbs01\userprofile$\RDPUserDesktop\sumanths\Desktop\Nitrogen Manual.doc
 - 28 -

13. PSA Valves:

a) Make : GEMU
b) Type : Angle valve, Double acting
c) Size : 50 NB (8 Nos.)

14. Deoxo Valves:

a) Make : GEMU
b) Type : Angle valve, Double Acting
c) Size : 50 NB (6 Nos.)
25 NB (5 Nos.)

15. Dryer Valves:

a) Make : GEMU
b) Type : Angle valve, Double Acting
c) Size : 50 NB (2 Nos.)
25 NB (2 Nos.)

16. Surge Vessel Outlet Valves:

a) Type : Pneumatic Valve, Dome design, 2-way
b) Size : 50 NB

17. Hydrogen shut-off Valves:

a) Type : Pneumatic Valve, Dome design, 2-way

b) Size : 15 NB

18. Air inlet Valve:

a) Type : Pneumatic Valve, Dome design, 2-way
b) Size : 50 NB

19. Instrument Air Valve:

a) Type : Pneumatic Valve, Dome design, 2-way
b) Size : 15 NB

\\nldfbs01\userprofile$\RDPUserDesktop\sumanths\Desktop\Nitrogen Manual.doc
 - 29 -

20. 3-Way Vent Valve:

a) Type : Pneumatic Valve, Dome design, 3-way
b) Size : 50 NB

21. Pressure Holding Valve (at N2 Dryer Outlet):

a) Make : Nirmal
b) Size : 50 NB
c) Set Pressure: 5.5 kg/ cm2g
d) Flow : 230 NM3/hr.
e) Service : Nitrogen

22. Safety Valve (at Hydrogen Inlet):

a) Make : Diamond
a) Size : 15 NB
b) Set Pressure : 7.15 Kg/cm2g

23. Safety Valve (at Air Receiver):

a) Make : Tyco
b) Size : 50 NB
c) Set pressure : 8.25 Kg/cm2g

24. Safety Valve (at N2 Surge Vessel):

a) Make : Tyco
b) Size : 25 NB
c) Set pressure : 7.7 Kg/cm2g

25. Solenoid Valve:

a) Make : Rotex
b) Voltage : 220 V AC
c) Type : 1/4”, 2-way (3 Nos.)
: ¼”, 3-way (5 Nos.)
: ¼”, 5/2-way Namur (23 Nos.)

\\nldfbs01\userprofile$\RDPUserDesktop\sumanths\Desktop\Nitrogen Manual.doc
 - 30 -

26. Auto Drain Trap:

a) Make : Concept
b) Model : Smart Drain
c) Type : Solenoid operated
d) Size : 15 NB
e) Water drain
capacity : 50 ltrs./ hr
f) Quantity : 2 Nos.

27. Low Pressure Switch (at Chilled Water Line):

a) Make : Danfoss
b) Model : RT-110

28. Low Pressure Switch (at Cooling Water Line):

a) Make : Danfoss
b) Model : RT-110

29. Low Pressure Switch (at Air Receiver):

a) Make : Danfoss
b) Model : KP-35

30. Low Pressure Switch (at Hydrogen Inlet):

a) Make : Danfoss
b) Model : KP-35

31. Low Pressure. Switch (at Dryer outlet):

a) Make : Danfoss
b) Model : KP-35

32. High Pressure. Switch (at Drying Tower exhaust line):

a) Make : Danfoss
b) Model : KP-35

\\nldfbs01\userprofile$\RDPUserDesktop\sumanths\Desktop\Nitrogen Manual.doc
 - 31 -

33. High Pressure. Switch (after Vent Valve ):

a) Make : Danfoss
b) Model : KP-35

34. Thermocouple (for Deoxo Tower, and N2 Dryer):

a) Make : Radix
b) Type : K (Chromel/Alumel)
c) Op. Temp. : 300 oC (Max)
d) Length : 8”

35. Temperature Controller (at Deoxo Tower, at N2 Dryer):

a) Make : Radix
b) Model : TC-96
c) Input : Thermocouple "K" type
d) Range : 0 – 3000C

36. Nitrogen Rotameter:

a) Make : Flow Star

b) Type : Acrylic Body
c) End Connection : 50 NB
d) Operating Pr. : 7 kg/cm2g
e) Range : 35 to 350 NM3/hr

37. Hydrogen Rotameter:

a) Make : Flow Star

b) Type : Acrylic Body
c) End Connection : 15 NB
d) Operating Pr. : 6.5 kg/cm2g
e) Range : 0.4 – 4 NM3/hr

\\nldfbs01\userprofile$\RDPUserDesktop\sumanths\Desktop\Nitrogen Manual.doc
 - 32 -
38. Coarse Filter :
a) Make : Rave
b) Model : A-1200
c) Line size : 80 NB
d) Element life : 6 months (approx.)

39. Fine Filter :

a) Make : Rave
b) Model : C-1200
c) Line size : 80 NB
d) Element life : 6 months (approx.)

40. AC Filter:
a) Make : Rave
b) Model : D-1200
c) Line size : 80 NB
d) Element life : 6 months (approx.)

41. Level Swtich:

a) Make : E & H
b) Model : Liquifant FTL 2o
b) Proecss conn. : ½” NPT
c) Voltage : 220 V AC

42. PLC:
a) Make : Siemens
b) Model : S7-200 (CPU-226)
c) Inputs : 24 Nos.
d) Outputs : 24 Nos.

43. Annunciator:
a) Make : Minilec
b) Model : MBAS-0600
c) Windows : 12 Nos.
d) Voltage : 220 V AC

-------x------x------

\\nldfbs01\userprofile$\RDPUserDesktop\sumanths\Desktop\Nitrogen Manual.doc
 - 33 -

Operation Manual

NITROGEN PLANT

Client : M/s. NOCIL Limited

MVS Job No. : 5939 / 2011

M VS
E N G IN E E R IN G L T D .

MVS Engineering Limited

E-24, East of Kailash, New Delhi - 110 065 (India)

Phone No. 91-11-26431908 Fax No. 91-11-26464994 Email : [email protected]

91-11-26441921 91-11-26422654 [email protected]

\\nldfbs01\userprofile$\RDPUserDesktop\sumanths\Desktop\Nitrogen Manual.doc