INSTRUCTION MANUAL

INERTGAS GENERATOR

GENERAL INFORMATION
Series MEM

 2012 All rights reserved. No part of this publication may be copied or published by means of printing, photocopying, microfilm or otherwise without prior written consent of the manufacturer. This restriction also applies to the corresponding drawings and diagrams.

INSTRUCTION MANUAL INERTGAS GENERATOR Series Gln

Type:

Smit Gas MEM 500 3 8 CM

Order number:

061.11.1.9372

Manufacturing number:

06672

Year of construction:

2006

Customer:

AMCO Compressoren B.V.

Ref. Customer:

M/T. DURICHA

Yard number:

Hull No. 548

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How to use this manual This manual contains: the user manual, the parts list, flow diagrams, dimensional drawings and electrical drawings, original manufacture documentation (OEM- documentation). The parts list, flow diagrams, dimensional drawings and electrical drawings are included after chapter 8 of this user manual. The OEM documentation is inserted after the electrical drawings. The OEM documentation is inserted in alphabetical order after there respective alphabetically indexed tabs. If there are two or more suppliers after a index tab, they are separated with a coloured sheet. Two or more manuals of the same supplier are not separated.

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TABLE OF CONTENTS
1 GENERAL................................................................................................................................................................ 6 1.1 GUARANTEE AND SERVICING ............................................................................................................................. 6 1.2 SAFETY INSTRUCTIONS....................................................................................................................................... 7 1.2.1. Nitrogen stream........................................................................................................................................ 7 1.2.2. Permeate / Oxygen stream ....................................................................................................................... 8 1.2.3. Operating & maintenance ........................................................................................................................ 8 1.3 SAFETY COMPONENTS ........................................................................................................................................ 8 2 INSTALLATION & STORAGE ............................................................................................................................ 9 2.1 2.2 3 INSTALLATION INSTRUCTIONS ............................................................................................................................ 9 MEMBRANE INSTRUCTIONS .............................................................................................................................. 10

TECHNICAL DESCRIPTION............................................................................................................................. 11 3.1 GENERAL ......................................................................................................................................................... 11 3.2 PROCESS DESCRIPTION ..................................................................................................................................... 11 3.2.1 General ....................................................................................................................................................... 11 3.2.2 Feed air system ........................................................................................................................................... 11 3.2.3 Filtration system ......................................................................................................................................... 11 3.2.4 Heater system.............................................................................................................................................. 12 3.2.5 Feed air Controls........................................................................................................................................ 12 3.2.6 Membrane bundle ....................................................................................................................................... 12 3.2.7 Nitrogen Supply system............................................................................................................................... 12 3.3 TECHNICAL SPECIFICATION .............................................................................................................................. 12 3.3.1 Design basis................................................................................................................................................ 12 3.3.2 Nitrogen gas specification .......................................................................................................................... 13 3.3.3 Utilities ....................................................................................................................................................... 13

OPERATING INSTRUCTIONS.......................................................................................................................... 14 4.1 4.2 4.3 GENERAL ......................................................................................................................................................... 14 SWITCHING ON ................................................................................................................................................. 14 SWITCHING OFF ................................................................................................................................................ 14

TROUBLE SHOOTING ....................................................................................................................................... 15 5.1 FAILURES ......................................................................................................................................................... 15

TROUBLE CHART .............................................................................................................................................. 16 6.1 6.2 POSSIBLE CAUSES AND REMEDIES .................................................................................................................... 16 TROUBLE CHART .............................................................................................................................................. 16

MAINTENANCE................................................................................................................................................... 18 GENERAL MAINTENANCE INSTRUCTIONS ....................................................................................................................... 18 MAINTENANCE TABLE ................................................................................................................................................... 18

8 9 10 11 12

TEST PROTOCOL ................................................................................................................................................. 2 PROCESS ................................................................................................................................................................. 3 DIMENSIONAL .................................................................................................................................................. 4 ELECTRIC .......................................................................................................................................................... 5 DOCUMENTATION .......................................................................................................................................... 6

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1 1.1

GENERAL Guarantee and Servicing

c. In order to save time, we will first give instructions by telex or cable to solve the problem. If this attempt is not successful, we are prepared to send one of our specialists.

Our guarantee covers all defects due to our faults, such as wrong design, defective material and defective workmanship, but not those occurred through overload, deterioration, faulty use, negligence, freezing (see chpt II), external damage, accidents or similar causes. Under this guarantee we are held to remedy any defects of the plant or any part of it and to replace the defective parts. N.B.: - For an extensive survey concerning our guarantees, please consult our "CONDITIONS OF SALE AND DELIVERY" enclosed. - With respect to the above we take it for granted that small repairs can be done by the engineers on site, for which it will be necessary that a certain set of spare parts is stored. - If any trouble will occur, the procedure will be as follows: a. The engineers on site will try to solve the problem in accordance with the instructions given in the maintenance and instruction manuals. If this effort has no success, a message with as much information as possible will be sent to

d.

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 Alfa Laval Aalborg Nijmegen B.V.' are in force.

b.

Alfa Laval Aalborg Nijmegen B.V. St. Hubertusstraat 10 6531 LB Nijmegen The Netherlands P.O. Box 6664 6503 GD Nijmegen The Netherlands Tel.: +31 24 35 23 100 Fax: +31 24 35 23 177 E-mail: inertgasaftersales.nijmegen@alfalaval.com

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1.2
1.2.1.

Safety instructions
Nitrogen stream

Caution: This plant is designed to produce high purity nitrogen (95 - 99.5%) at normal air conditions of 78% nitrogen and 20.8% (1% is argon) oxygen. 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. A general indication about the effects and symptoms in case of low oxygen content is given below: Nitrogen is asphyxiant. Before entering an enclosed or poorly ventilated area containing a nitrogen generator or transmission equipment and piping, follow all established safety precautions and procedures. Product gas with 5% or less oxygen content represents an extreme asphyxiation hazard when not handled properly. Product gas should not be vented or otherwise discharged except through the normal piping system. Appropriate signs should be placed in the area of the nitrogen system warning of the hazard. The enriched nitrogen stream will not support life and it must be used and treated accordingly.

Oxygen content
15-19%

Effects and symptoms

Decreased ability to work strenuously. May impair the coordination. Respiration increase with exertion, increase of pulse rate, impaired co-ordination, reception and judgement affected.
Respiration further increases in rate and depth, poor judgement, blueness of lips.

12-14%

10-12%

8-10%

Mental failure, fainting, unconsciousness, ashen face, blueness of lips, nausea and vomit. 8 minutes exposure: fatal; 6 minutes exposure: 50% fatal; 45 minutes exposure recovery with treatment. Coma in 40 seconds, convulsions, respiration ceased or death. Note: oxygen contents indicated by volume percentage at atmospheric pressure.

9- 8%

4- 6%

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1.2.2.

Permeate / Oxygen stream

Failure to heed any of these warnings can cause serious injury or death.
After complete shutdown of the system, including power supply, the system remains pressurised! Depressurise the complete system manually if required and take care that all nitrogen is led to the outside!

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. For example, materials that smoulder in air could burn fiercely in this atmosphere. It is imperative that vent gas is discharged only in well-ventilated and safe areas. If the unit is located in an air tight or poorly ventilated room, the permeate stream should be piped to a ventilated atmosphere for release. Piping of the enriched nitrogen stream and the oxygen enriched air stream to areas of high air circulation is recommended. Consult your own safety personnel for local, state and federal procedures or regulations.
1.2.3. Operating & maintenance

This equipment must be operated by qualified personal that has been trained to work on this type of equipment. Before operating this equipment read the following notes: Do not operate this equipment without all guards in place and properly adjusted. Do not operate this unit in a manner for which it was not designed. Do not remove any of the protective devices or render them inactive. When doing any service work or maintenance work on the feed air system, be absolutely sure the equipment is locked out and all internal pressure is relieved. Do not enter any cargo space and/or tank before the oxygen content in these spaces is measured and found sufficient to guarantee that these places are not filled with inert gasses or other gasses then air!

This packaged equipment is a piece of machinery that inherently has many possible hazards. There are systems that operate under pressure, at extreme temperatures, at high speeds and at high voltages. Before doing any maintenance read the following instructions: before doing any maintenance to the electrical installation, be certain that the electrical supply has been switched off by the main switch; Do not remove parts from pressure containing systems without relieving pressure first.
At no time the unit should be energised and started in hazardous environments;

1.3

Safety components

The installation has the following safety components to switch off in case of an emergency: - EMERGENCY STOP pushbutton on local control panel, - EMERGENCY STOP pushbutton on compressor panel, The installation has all kinds of safety devices that switch off the unit if it exceeds the safe working range.

spill of oil (fuel or lubrication) may cause slipperiness or fire damages;

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9.

2 2.1

INSTALLATION & STORAGE Installation instructions

Make sure, that no condensate can flow back to the nitrogen unit!

Carefully read the cautions and instructions before installing the equipment: 1. No special foundations are required to carry the weight of the nitrogen unit. Anchoring is dependent on customers requirements, but is not required for unit vibration. One metre on the front side and a meter clearance on both sides should be maintained of the nitrogen generator unit for access. The interconnecting piping shall be blown free of debris or contaminants prior to connecting to the nitrogen generator. Any cutting oil or other contaminants shall be washed and/or wiped from piping, prior to connection into the system. Pipe dope should not be employed in making connections in the feed air piping system. Solvents present in the pipe dope may impair the membrane performance. Only use pipe tape during assembly. The drains from the moisture separator filters will contain condensed water and some oil only and should be properly disposed of. The drain piping should be free of blockage and should allow the operator to check, that the fluid is actually draining, i.e. drain piping set into an open bell-shaped drain connection. This fluid should not be drained onto the floor or slab. It should be noted that the pressure of the condensate from the equipment is 7 to 12 bar(g) blowing down to atmospheric pressure. The maximum back-pressure on permeate outlet port shall not exceed 0.02 bar(g). See also the enclosed sheet of installation instructions for the permeate line. The customer shall ensure that the nitrogen product line cannot be over pressurised by downstream conditions. 9
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2.2

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 condition: minimum temperature 5 C; optimum temperature 25 C (+/- 5); maximum temperature 60 C.

Damaged membrane bundles due to lack of maintenance or wrong operation of the system are not the responsibility of Alfa Laval Aalborg Nijmegen B.V.

Process condition: Maximum operating pressure 13 bar(g) Maximum working temp. 55 C Liquid water: Liquid water entering or condensing inside the membrane bundles will decrease the capacity of the bundles dramatically. Purging of dry air through the bundles will remove the water afterwards, but this will take a very long time! Oil/particles: Oil and particles entering the membrane bundle will damage the bundle permanently and should be avoided under all circumstances! Only PAO type lubrication oil shall be used in the screw compressor. The life time of the membrane will be reduced if this is not done. The nitrogen generator is equipped with several provisions to avoid exceeding any of above-mentioned process condition. The user shall operate the unit according the instructions given in this manual and carry out maintenance as instructed. The unit shall not be stored in direct sunlight, as radiant energy will raise the effective storage temperature.

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3 3.1

TECHNICAL DESCRIPTION General

their own controls. The feed air compressor is described in the sub-suppliers manual.

3.2.3 Filtration system

An inert gas system contains standard the following equipment:
1) A 100% feed air screw compressor equipped with local control panel and motor starters

2)

Nitrogen generators Heater - Filter(s) - Membrane bundle(s) - Local control room panel (LCRP) - Oxygen analyser - Other valves and instrumentation

3.2

Process description

3.2.1 General
The complete system can be divided into several sub-systems. The following paragraphs describe the functions of these sub-systems. The P&ID drawing(s) of the nitrogen generator give(s) a good overview of the complete installation. Please refer also to these documents for the under mentioned tag numbers.

The filtration system guarantees an acceptable feed air quality. Micro filters (2200 and 2300) filter out any particles in the feed air stream. Active carbon bed filter (2600) takes out any oil remaining and thus prevents oil carry over to the membrane bundles. The inlet air to the carbon bed filter should never be wet as then the carbon will adsorb water instead of oil vapour. The carbon cannot be regenerated from water and should be replaced. By opening valve 2610 and 2820 it can be checked if water is coming. If the carbon filter is not operating properly the membranes will be damaged. Micro filter 2800 removes any solids from the feed air stream what could come from the carbon filter. NOTE: Check regular, if the time settings are set correctly to drain all the water (otherwise water can flow from the separator up-stream of the system and eventually reach the membrane!).

3.2.2 Feed air system

The feed air system ensures a supply of feed air under working pressure. The ambient air is taken in the Feed Air compressor. After compression a water-cooled after-cooler installed on the compressor cools down the air. The compressed air is saturated with water. A pre heater (2100) is installed to make the air under saturated before it comes to the filters. It is most important that this heater is in operation any time, as the carbon filter will not adsorb oil in case the heater is not in operation, and as a consequence the membranes will be damaged by oil. To guarantee this heating a delta T switch is installed (2115) The screw type compressor operate independent from the N2 system and have
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3.2.4 Heater system

The function of electrical heater 2900 is to warm up the feed air to the required membrane operating temperature. It is controlled by 2915 and 2920 and is protected against overheating by safety thermostat 2910 (inside the junction box of the heater). If the air temperature fed to the membranes exceeds the setpoint of temperature switch 2950, the nitrogen generator will be switched-off.

3.2.7 Nitrogen Supply system

The function of the pressure control valve (PCV-4020) is to keep the oxygen contents in the nitrogen gas flow to the desired value. A controller (5320) controls the position of valve 4020. The controller takes action if there is a difference between the set value and the measured value of oxygen and dewpoint. Oxygen: The measured O2 value comes from the oxygen analyser 5310. The sample gas goes via a selection valve 5009 and via a pressure reducing valve (5100) to the cell (5300) of the O2-analyser (5310) and will then be vented to atmosphere (ventilated area). The sample airflow to the cell can be set with flowmeter 5200. The selection valve 5010 can be used for calibration too if another position is selected. For a detailed description of the oxygen analyser, see sub-suppliers documentation. When the purity of the produced nitrogen is according specification or better, the delivery/purge valve (4200/4300) will switch and the nitrogen product will be directed to delivery. If the oxygen level in the nitrogen outlet exceeds the alarm setting of the oxygen analyser (5310), the delivery/purge valve (4200/4300) will switch in blow-off position.

3.2.5 Feed air Controls

If the compressed air pressure to the nitrogen system drops below the setpoint of pressure switch 2050, the nitrogen generator will be switched-off. To prevent a pressure shock to the membranes and filters, valve 2700 will open slowly. Solenoid 2730 is fed with system air by pressure control valve 2710 and operates pneumatic valve 2700 via an adjustable restriction 2720. The output of valve 2710 is also used as instrument air supply for the purge/delivery valve (4200/4300) and other devices requiring system air. For visual indication of temperature and pressure, some pressure indicators and temperature indicators are installed.

3.2.6 Membrane bundle

Separation of nitrogen and oxygen occurs in the membrane modules, where the compressed air flows into the hollow fibres, the faster gases (oxygen, water, carbon dioxide) permeate through the fibre walls and this permeate stream is collected at reduced pressure. The flow of permeate is expelled from the module. This oxygen-enriched flow is directed to the permeate discharge and is to be vented to a safe area. See also Membrane instructions, 2.2.

3.3

Technical specification

3.3.1 Design basis

The layout of the installation has been calculated and based upon the following criteria: the unit is designed and will be built in accordance with the regulations of IMO and the rules of the applicable classification society; shipboard use, indoor erection; Ambient temperature max 45 C Nitrogen gas capacity and composition, calculated with combustion air of +25 C and 80% relative humidity at atmospheric
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pressure and with an average cooling water temperature of 25 C; pressures mentioned are effective working pressures (5% tolerance); Use of PAO type lubrication oil in compressor temperature tolerances 1 C; quantities tolerance 3%; electrical supply voltage tolerance +10% / 15%;

3.3.2 Nitrogen gas specification

Capacity:
500 Nm3/h at 5 % O2

Discharge pressure Typical gas composition Oxygen (O2) Nitrogen + Argon (N2 + Ar) Temperature Dewpoint

7 bar(g)

< 5 vol.% balance max. 50 C 65 C *

*: After expansion to atmospheric pressure.

3.3.3 Utilities
Feed air: Temperature max. 45 C Pressure max. 8.7 bar(g) Consumption (each compressor) abt. 1340 Nm3/h Oil content: max. 5 ppm Electricity: Power supply Control supply by internal transformer Control system Heater 2100 400V, 3ph, 50Hz 220V, 1ph, 50Hz 1 3 kW kW

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OPERATING INSTRUCTIONS

Before operating the unit, read chapter 1.

off-load mode and eventually turn down. Only in case of a long period of standstill, handle as follows: 2. Shutdown compressor(s)

4.1

General

The complete generator is controlled by relays. In case there might be problems or questions, please contact Alfa Laval Aalborg Nijmegen B.V. , for further assistance. For more details about the control panels, please refer to the electrical diagrams).

4.2

Switching on

To start the generator, go true the following steps: 1. Check if the cooling air/water supply to the compressor is correct. 2. Press the reset button and release and check if no yellow lamp lights. 3. Push start-button of compressor and release. 4. Check if compressor indicates ready to start (green lamp lights up) If not refer to Trouble shooting, 5. Now the compressor is ready to start delivery of compressed air to the nitrogen system. For further starting sequence points go to local control panel of nitrogen system 5. Check if mimic indicates Ready to start. 6. Start the generator(s) by pushing the start button and release. 7. The first 3 minutes after starting the generator is started any high oxygen alarm is suppressed and the nitrogen cant be delivered to deck. The nitrogen will only be used for tank filling provided that the oxygen level in the produced nitrogen must be according the chosen level. The delivery switch must be set to automatic.

4.3

Switching off

In case of a normal shutdown handle as follows: 1. Push the stop button Closing of valve 2700 stops the generators. The compressor(s) will run for a short while in
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5 5.1
-

TROUBLE SHOOTING Failures

In case of a failure, an audible alarm is given and a failure indicating signal lamp lights up (blinking). After pushing the ACKNOWLEDGEMENT button on the panels, the audible alarm is switched off, but the signal lamp remains lightened (steady). After eliminating the cause of the failure, the installation has to be reset by pushing the RESET button on the local control panel. Next, the generator can be restarted. The setting of all safety devices is given in the test-protocol. In 6 a trouble chart is given in which all failures that are indicated on the control panels, plus some general generator failures, are mentioned. For specific failures in operation of the various accessories belonging to the installation, the manufacturers instructions have to be consulted. In the trouble chart, one column is named C.o.F., which means Consequences of failures.

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6 6.1

TROUBLE CHART Possible causes and remedies

Alarm Cause Too low feed air pressure from feed air system (PIZA 2050) Heater failure (TZA 2110 high) Heater failure, protection by safety thermostat (TZA 2910) Feed air temperature to membrane bundles to high (TZA 2950) Too low purity of the produced nitrogen (QIA 5310) O2 analyser (5310) must be calibrated or sensor (5300) replaced Effect / Remedy Shut-down Check feed air Shut-down Check heater Shut-down Check heater Shut-down Check heater and feed air temperature Delivery/purge valve (4200/4300) in purge position See trouble shooting Delivery/purge valve (4200/4300) in purge position

Feed air failure

Heater air temperature high Heater temperature high Temperature high

Oxygen high

Check calibration

6.2

Trouble chart
Possible cause and remedy: - Feed air pressure too low. - Modulating controller settings not correctly. - Membrane polluted (water in membrane will cause a temporary decrease of capacity, particles can damage the membrane permanent!). - Carbon filter bed saturated by water or oil: replace carbon - Setpoint of controller too low or too high (see setting in Test protocol). - Valves of membranes valves (3040, 3020) not full opened - Operating temperature of the membranes too low - Wrong lubrication oil used (should be PAO type)

Trouble: Capacity too low: Purity not acc. spec:

Oxygen content too high / low:

- Setpoint of valve 4020 not correctly. Re-adjust (see setting in test protocol). 16

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- Oxygen analyser error. Check calibration. - Check settings of the oxygen analyser (low oxygen alarm is not in use!). - Check capacity / pressure feed air

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MAINTENANCE

General maintenance instructions

Because maintenance very much depends on the operating conditions, the maintenance intervals might have to be shortened or extended. This is to operator's experience.

Before removing any accessory out of or from service piping, be certain that the relevant isolating valves have been closed and the pressures released (if applicable). The detailed instructions for maintenance and repair of equipment can be found in the instruction manuals of the sub-suppliers.

Maintenance table
ITEM: Water separator: MAINTENANCE: Clean drain 2011 yearly. REMARKS: Check function of the Automatic drain regularly.

Pre-/microfilters:

Replace filter elements every 2000 running hours. Calibrate every week NEW CARBON FILLING EVERY 1500 RUNNING HOURS. No maintenance required.

Check pressure drop over filters regularly. See the instruction manual After renewing carbon filling, open valve 2610 and blow-off carbon dust out of filter. Capacity too low: *) -Water or particles have entered membrane bundle. -Oil has damaged the membrane bundle.

Oxygen (O2-analyser): Carbon bed filter:

Membrane bundle:

*) under normal operating conditions.

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TEST PROTOCOL

Test protocol 19372

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PROCESS
Partslist Flow diagram Flow diagram Nitrogen generator

19372PL 19372001

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10

DIMENSIONAL
Pressure transmitter Dim. Drw. assembly membrane Non return valve

19372575 19372649 19372862

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ELECTRIC
Electrical key diagrams

19372-802

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DOCUMENTATION
1. DANFOSS Instructions RT 101 Instructions RT 116 4 th Generation pneumatic actuators Oxygen analyser manual type BA 1000 Temperature transmitter type TMT 187 Controller KS 40 Controller KS 90 Control valve Type 470 Positioner PS2 Installation and Maintenance Instructions ecodrain G2 - G19, Planning-, Installation-, Operating Instruction

2. AIRTORQUE 3. BUHLER 4. ENDRESS & Hauser 5. PMA

6. ECONOSTO 7. SIEMENS 8. ZANDER

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Alfa Laval Aalborg Nijmegen B.V. St. Hubertusstraat 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 23 177 E-mail: inertgasaftersales.nijmegen@alfalaval.com www.alfalaval.com
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