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enraf 1200-5-10 CM Instruction Manual

Nitrogen generator
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INSTRUCTION MANUAL
NITROGEN GENERATOR
GENERAL INFORMATION
MEM :
1200
- 5
- 10
CM

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Summary of Contents for enraf 1200-5-10 CM

  • Page 1 INSTRUCTION MANUAL NITROGEN GENERATOR GENERAL INFORMATION MEM : 1200 - 10...
  • Page 2 This publication is to be used for the standard model of the machine of the type given on the cover page. Enraf Smit Gas Systems cannot be held responsible for any damage resulting from the application of this publication to the version actually delivered to you.
  • Page 3 INSTRUCTION MANUAL NITROGEN (GAS) GENERATOR Type: MEM 1200 - 5 - 10 CM Order number: 042.11.1.9121 Manufacturing number: 04421 Year of construction: 2005 Customer: China Changjiang National Shipping Group Ref. Customer: ECTEC-P03201-021 Yard number: Hull no. QS20030401 (chemical tanker)
  • Page 4 : 19121 ORDER NR How to use this manual This manual contains: • the user manual, • the partslist, • flow diagrams, dimensional drawings and electrical drawings, • original manufacture documentation (OEM-documentation). The partslist, flow diagrams, dimensional drawings and electrical drawings are included after 10 of this user manual.

  • Page 5: Table Of Contents

    : 19121 ORDER NR TABLE OF CONTENTS GENERAL .................................. 6 ..........................6 UARANTEE AND ERVICING ........................... 7 ENERAL SAFETY INSTRUCTIONS ..........................8 ERMEATE OXYGEN STREAM & ..................8 AFETY INSTRUCTIONS FOR PERATING MAINTENANCE ............................9 AFETY COMPONENTS INSTALLATION ............................... 10 ..........................

  • Page 6: General

    Natural wear and tear and any damage due to neglectable operation and maintenance are excluded. As far as the above-mentioned special conditions are not applicable, our normal guarantee terms according to the 'General conditions of Sale and delivery of Enraf Smit Gas Systems are in force. Rev. x Date. x-xx-xxxx...

  • Page 7: General Safety Instructions

    : 19121 ORDER NR General safety instructions INERTGAS STREAM THIS PLANT IS DESIGNED TO PRODUCE HIGH PURITY NITROGEN (95-99.5 %) AT NORMAL AIR CONDITIONS OF 78% NITROGEN AND 20.8% OXYGEN (1% ARGON). NITROGEN IS A COLOURLESS, ODOURLESS GAS THAT IS VERY DANGEROUS FOR LIFE. IF RELEASED IN AN UNVENTILATED AREA, IT WILL DISPLACE THE OXYGEN AND CAN CAUSE INJURY OR DEATH.

  • Page 8: Permeate / Oxygen Stream

    : 19121 ORDER NR Permeate / oxygen stream The vent waste gas (permeate) out of the system is oxygen enriched; it typically contains 30% oxygen but can be as high as 45% oxygen. While oxygen will not burn, oxygen concentrations above 25% will support combustion of other materials much more readily than air.

  • Page 9: Safety Components

    : 19121 ORDER NR Safety components The installation has the following safety components to switch off in case of an emergency: - EMERGENCY STOP pushbutton at the right side of the local control panel. - EMERGENCY STOP pushbutton on cargo control room panel, or elsewhere outside the machinery space The installation has all kinds of safety devices that switch off the unit if it exceeds the safe working range.

  • Page 10: Installation

    : 19121 ORDER NR INSTALLATION Installation instructions Carefully read the cautions and instructions before installing the equipment: Remove all packing material carefully. The Nitrogen (gas) installations are delivered on foundation frames; on behalf of transport, the installation is divided or parts are disassembled that are delivered separately, depending on the dimensions.
  • Page 11 : 19121 ORDER NR 15. The compressed air supply may contain rests of lubricating oil but restricted to a quantity of 3 mg/m3. (Free air delivery). THE LUBRICATION OIL MUST BE OF TYPE PAO (Poly-Alpha-Olefin), Synthetic screw compressor oil. 16. All blow-off piping indicated on the drawings must be led to the "outside". 17.

  • Page 12: Storage Instructions

    Ambient temperature should not be below 5 ° C and above +50 ° C. During transportation, severe shocks or vibrations should be prevented. All equipment is packed by Enraf Smit Gas Systems and suitable for storage under above- mentioned conditions. If equipment, such as blowers, is stored for a period longer than 12 months, it may be required to check the lubrication.

  • Page 13: Membrane Instructions

    : 19121 ORDER NR MEMBRANE INSTRUCTIONS The fibres inside the membrane bundles are very sensitive to liquid water, oil and particles. Please pay good attention to the following: Storage instruction: minimum temperature 5° C ; Optimum temperature 25° C (+/- 5° ); Maximum temperature 50°...

  • Page 14: Technical Description

    TECHNICAL DESCRIPTION GENERAL The nitrogen (gas) systems, supplied by Enraf Smit Gas Systems , consist of 2 identical air compressors, one common air treatment skid and one common membrane bundle skid. Further many items are supplied as loose item, to be mounted by the shipyard.

  • Page 15: Filtration System (Air Treatment)

    : 19121 ORDER NR Well functioning of this heater is very important to achieve air with humidity less than 70%, because otherwise the carbon bed filter will absorb water particles. The carbon is more susceptible to water then to oil vapour, so after absorbing lots of water, the carbon is not able anymore to absorb the oil vapour If the activated carbon ones get wet, it is strictly recommended to renew the carbon and to check the temperature increase by the heater.

  • Page 16: Membrane Bundle

    : 19121 ORDER NR 5.1.6 Membrane bundle Separation of nitrogen and oxygen occurs in the membrane modules, where the compressed air flows into hollow fibres. The faster gases (oxygen, water, and carbon dioxide) permeate through the fibre walls. This wet and oxygen-enriched flow (permeate) is expelled from the module and directed to the permeate discharge and is to be vented to a safe area (outside).

  • Page 17: Deck Pressure Control And Nitrogen Delivery To Deck

    : 19121 ORDER NR 5.1.9 Deck pressure control and nitrogen delivery to deck This system is connected to a deck main. The system is suitable to produce nitrogen with an oxygen content of 5% or less. (Oxygen level is normally set at 5% but is changeable by changing the setpoint at the oxygen controller.

  • Page 18: Technical Specification

    : 19121 ORDER NR Note: Ship may have additional safety devices, but this is outside the scope of supply and responsibility of Enraf Smit Gas Systems. Technical specification 5.2.1 Design basis The design of the installation has been based and calculated on the following principles: The unit is designed and will be built in accordance with the regulations of IMO and the rules of the classification society, based on UMS unless otherwise required.

  • Page 19: Nitrogen (Gas) Specification

    : 19121 ORDER NR 5.2.2 Nitrogen (gas) specification Capacity 1200 nm /h * (2 compressors in operation) Discharge pressure min. 10 bar(g) Typical gas composition (on dry basis) Oxygen better than 5 vol. % Nitrogen + Argon + Ar balance 60 °C Temperature max.

  • Page 20: Operating Instructions

    The complete generator is controlled by the PLC. The PLC program is no part of this manual since the program details are not required for installation or operation of this system. However in case there might be problems or questions, please contact Enraf Smit Gas Systems , for further assistance.

  • Page 21: Switching On

    : 19121 ORDER NR - Other panels : Equipment such as a compressor is equipped with starter panels comprising motor starters and some basic indications. For more details about the control panels, please refer to the electrical diagrams at Chapter 10.1. SWITCHING ON 6.3.1 Nitrogen (gas) production About 2 hours before unit start-up.
  • Page 22 : 19121 ORDER NR After acknowledgement and reset it is possible to start the compressor again. 4. Select running mode : - Nitrogen to cargo with no tankfilling - Nitrogen to cargo with tankfilling - Automatic tankfilling Explanation for above selections. The total system is designed and build, based on energy saving operation.
  • Page 23 : 19121 ORDER NR 10. It is possible to start or stop one of the compressors during running of the system. 11. The heater will be energised immediately after signal “on-load” of one of the compressors is detected. The heater will try to reach the operating temperature of about 52° C. A minimum temperature rise by the heater is required.

  • Page 24: Normal Stop

    : 19121 ORDER NR NORMAL STOP 1. Push the start/stop delivery button on the CCRP to stop the delivery and turn the mode switch to “Nitrogen to cargo with no tankfilling” Production of nitrogen is not stopped but no gas is led to deck or to the storage tank, even if the oxygen level is within range.

  • Page 25: First Start-Up During Commissioning

    : 19121 ORDER NR FIRST START-UP DURING COMMISSIONING 6.6.1 General for commissioning Documents required: - Electrical diagrams. - P&ID’s. - Detailed description. - Test protocol, showing the required settings. If the assembly of the equipment has been completed and all solenoid valves, limit switches, temperature measurement devices, pressure measurement devices, and heaters are cabled, the commissioning activities can be started.

  • Page 26: Failures

    -high' and 'O -low' are mounted in the local panel and adjusted in the Enraf Smit Gas Systems works. In section 7.2 a trouble chart is given in which all failures that are indicated on the control panels, plus some general generator failures, are mentioned.
  • Page 27 : 19121 ORDER NR Suppliers manual. Membranes polluted. Valves at the inlet / outlet of each membrane not fully opened. Operating temperature of the membranes too low; wait for 15 min. (the process flow will warm the system) Optimum temperature is between 45- 52 degrees Celsius. Heater failure;...
  • Page 28 : 19121 ORDER NR Compressor won’t start Compressor is not in standby mode; check if errors are indicated on the display of compressor. In case of an error try to reset it by pressing the “0” stop button (see compressor manual in chapter 11l) power failure has occurred;...

  • Page 29: Maintenance

    : 19121 ORDER NR MAINTENANCE Before operating the unit, read the SAFETY INSTRUCTIONS. General maintenance instructions Next page(s) include the maintenance schedule for the installation. The detailed instructions for maintenance and repair of equipment can be found in the instruction manuals of the sub-suppliers. Because maintenance greatly depends on the operating conditions, the maintenance intervals might have to be shortened or extended due to these conditions.

  • Page 30: Maintenance List

    : 19121 ORDER NR Maintenance list Table 8-2a Maintenance table every 250 hrs. Interval: Component: Maintenance Remarks: Description Every 250 -analyser (5300) Check ‘zero’ and Opsis manual hours: ‘span” calibration or renew (average every 4 years) Differential pressure indication on top If red than renew Zander manual.

  • Page 31: Lubricating Schedule

    : 19121 ORDER NR Next open blow-down valve (2510) of the carbon bed filter(s) carefully and blow-down for about 1 minute to remove all possible dust from the system! (The compressor will switch to load again during blow-down). After this, reset override of solenoid valve 2700 and open inlet valves of membranes. Table 8-2c As per sub-supplier indicated schedule or at least ones a year.

  • Page 33: Test Protocol

    : 19121 ORDER NR TEST PROTOCOL List of documentation: Doc. no. Title BGS19121/3-1E Test protocol Rev. x Date. x-xx-xxxx Name: GLI...

  • Page 34: Documentation

    : 19121 ORDER NR DOCUMENTATION Process drawings List of documentation: Dwg. no. Title PL19121 Partslist 19121-025 Alarm & Safety table 19121001 Flow diagram Nitrogen Generator SSYMX005 Code Symbols Rev. x Date. x-xx-xxxx Name: GLI...

  • Page 35: Plant Dimensional Drawings

    : 19121 ORDER NR Plant dimensional drawings List of documentation: Dwg. no. Title 19121648 Dimensional drawing screw compressor 19121649 Dimensional drawing membrane skid Rev. x Date. x-xx-xxxx Name: GLI...

  • Page 36: Electrical Documentation

    : 19121 ORDER NR Electrical documentation List of documentation: Dwg. no. Title 19121-802 Local Control Panel generator 19121-803 Cargo Control Room Panel 19121-804 Bridge Panel 19121-805 Engine Room Panel 19121-8xx Page overview + wiring regulations and terminal definitions Rev. x Date. x-xx-xxxx Name: GLI...

  • Page 37: Sub-Supplier Documentation

    : 19121 ORDER NR SUB-SUPPLIER DOCUMENTATION Enclosures (in alphabetical order): List of documentation: Enclosures (in alphabetical order): Supplier Description - Induction motors 185 KW AIR TORQUE - Air torque manual ARI-Armaturen - ARI 470 - DP 33 / 34 / 35 Beko - Bekomat 14 Danfoss...
  • Page 38 : 19121 ORDER NR Enraf Smit Gas Systems St. Huberstraat 10 6531 LB Nijmegen P.O. Box 6664 6503 GD Nijmegen The Netherlands tel.: +31 (0)24 35 23 100 fax: +31 (0)24 35 64 995 E-mail: aftersales@smitgas.nl www.smitgas.com Rev. x Date. x-xx-xxxx...

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