enraf 1200-5-10 CM User manual

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

© Enraf Smit Gas Systems
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 Enraf Smit Gas Systems. This restriction also applies to the
corresponding drawings and diagrams.
The information given in this document has been collected for the general convenience of our clients. It has
been based on general data pertaining to construction material properties and working methods known to us
at the time of issue of the document and is therefore subject at any time to change or amendment. The right
to change or amend is hereby expressly reserved. The instructions in this publication only serve as a
guideline for installation, use and maintenance of the machine mentioned on the cover page of this
document.
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.
This publication has been written with great care. However, Enraf Smit Gas Systems cannot be held
responsible, either for any errors occurring in this publication or for their consequences.

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)

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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.
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 G UARANTEE AND S ERVICING ................................................................................................................................. 6
1.2 G ENERAL SAFETY INSTRUCTIONS ........................................................................................................................... 7
1.3 P ERMEATE / OXYGEN STREAM ................................................................................................................................ 8
1.4 S AFETY INSTRUCTIONS FOR O PERATING & MAINTENANCE ......................................................................................... 8
1.5 S AFETY COMPONENTS ........................................................................................................................................... 9
2 INSTALLATION ....................................................................................................................................................... 10
2.1 I NSTALLATION INSTRUCTIONS ............................................................................................................................... 10
3 STORAGE INSTRUCTIONS.................................................................................................................................... 12
3.1 G ENERAL STORAGE INSTRUCTIONS ....................................................................................................................... 12
3.2 S TORAGE INSTRUCTIONS FOR THE CONSTRUCTION PERIOD ..................................................................................... 12
4 MEMBRANE INSTRUCTIONS................................................................................................................................. 13
5 TECHNICAL DESCRIPTION ................................................................................................................................... 14
5.1 P ROCESS DESCRIPTION ....................................................................................................................................... 14
5.1.1 General........................................................................................................................................................ 14
5.1.2 Feed air system........................................................................................................................................... 14
5.1.3 Filtration system (air treatment)................................................................................................................... 15
5.1.4 Heating system............................................................................................................................................ 15
5.1.5 Feed air controls.......................................................................................................................................... 15
5.1.6 Membrane bundle........................................................................................................................................ 16
5.1.7 Oxygen control system................................................................................................................................ 16
5.1.8 Nitrogen supply to storage tank................................................................................................................... 16
5.1.9 Deck pressure control and nitrogen delivery to deck ................................................................................... 17
5.2 T ECHNICAL SPECIFICATION .................................................................................................................................. 18
5.2.1 Design basis................................................................................................................................................ 18
5.2.2 Nitrogen (gas) specification ......................................................................................................................... 19
5.2.3 Utilities......................................................................................................................................................... 19
6 OPERATING INSTRUCTIONS ................................................................................................................................ 20
6.1 G ENERAL OPERATING NOTES ............................................................................................................................... 20
6.2 CONTROL PANELS ........................................................................................................................................ 20
6.3 SWITCHING ON.............................................................................................................................................. 21
6.3.1 Nitrogen (gas) production ............................................................................................................................ 21
6.4 NORMAL STOP............................................................................................................................................... 24
6.5 C HECKS DURING OPERATION ................................................................................................................................ 24
6.6 FIRST START-UP DURING COMMISSIONING .............................................................................................. 25
6.6.1 General for commissioning.......................................................................................................................... 25
6.6.2 General actions ........................................................................................................................................... 25
6.7 F AILURES .......................................................................................................................................................... 26
6.8 T ROUBLE CHART ................................................................................................................................................. 26
7 MAINTENANCE ....................................................................................................................................................... 29
7.1 G ENERAL MAINTENANCE INSTRUCTIONS ................................................................................................................ 29
7.2 M AINTENANCE LIST ............................................................................................................................................. 30
7.3 L UBRICATING SCHEDULE ...................................................................................................................................... 31
8 TEST PROTOCOL ................................................................................................................................................... 33
9 DOCUMENTATION.................................................................................................................................................. 34
9.1 P ROCESS DRAWINGS .......................................................................................................................................... 34
9.2 P LANT DIMENSIONAL DRAWINGS ........................................................................................................................... 35
9.3 E LECTRICAL DOCUMENTATION .............................................................................................................................. 36
10 SUB-SUPPLIER DOCUMENTATION.................................................................................................................. 37

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1 GENERAL
1.1 Guarantee and Servicing
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 chapter VII), 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".
- 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.
b. If this effort has no success, a message with as much information as possible will be
sent to
Enraf Smit Gas Systems
Service Department,
St. Hubertusstraat 10
6531 LB Nijmegen
P.O. Box 6664
6503 GD NIJMEGEN
The Netherlands
Tel.: [phone]
Fax: [phone]
E-mail: [e-mail]
c. In order to save time, we will first give instructions by telex, telefax, or e-mail to solve
the problem.
d. If this attempt is not successful, we are prepared to send one of our specialists.
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.

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1.2 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. A GENERAL INDICATION ABOUT THE EFFECTS AND SYMPTOMS IN CASE OF LOW
OXYGEN CONTENT IS GIVEN BELOW:
OXYGEN CONTENT EFFECTS AND SYMPTOMS
(% BY VOLUME) (AT ATMOSPHERIC PRESSURE)
15-19% DECREASED ABILITY TO WORK STRENUOUSLY. MAY IMPAIR
THE COORDINATION.
12-14% RESPIRATIONS INCREASE WITH EXERTION, INCREASE OF
PULSE RATE, IMPAIRED COORDINATION, RECEPTION AND
JUDGEMENT AFFECTED.
10-12% RESPIRATION FURTHER INCREASES IN RATE AND DEPTH;
POOR JUDGEMENT, BLUENESS OF LIPS.
8-10% MENTAL FAILURE, FAINTING, UNCONSCIOUSNESS, ASHEN
FACE, BLUENESS OF LIPS, NAUSEA AND VOMIT.
9- 8% 8 MINUTES EXPOSURE: FATAL; 6 MINUTES EXPOSURE: 50%
FATAL; 4-5 MINUTES EXPOSURE RECOVERY WITH
TREATMENT.
4- 6% COMA IN 40 SECONDS, CONVULSIONS, RESPIRATION
CEASES; DEATH.
CAUTION:
NITROGEN IS AN ASPHYXIANT. BEFORE ENTERING AN ENCLOSED OR POORLY
VENTILATED AREA CONTAINING AN 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.
PURGING OF NITROGEN TO AREAS OF HIGH AIR CIRCULATION IS RECOMMENDED.
CONSULT YOUR OWN SAFETY PERSONNEL FOR LOCAL, STATE AND FEDERAL
PROCEDURES OR REGULATIONS.

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1.3 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.
For example, materials that smoulder in air burn fiercely in this atmosphere. It is imperative that
vent gas is discharged only in well-ventilated and safe area. If the unit is located in a poorly
ventilated room, the stream of permeate 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.
1.4 Safety instructions for Operating & maintenance
This packaged equipment is a piece of machinery that inherently has many possible hazards.
There are systems that operate under pressure, at extreme temperatures and at high voltages
Operating the equipment in excess of the conditions set forth in the Sales Contract and
the Technical Specification will subject it to stresses and strains that it was not designed to
withstand.
Carefully read the cautions and instructions before starting the equipment or doing any
maintenance.
1. Before doing any maintenance to the electrical installation, be certain that the electrical supply
has been switched off by the main switch.
2. Before doing any maintenance to the equipment, be sure that all pressures of the entire
system have been vented.
After complete shutdown of the system, including power supply, the system remains
pressurised! De-pressurise the complete system manually (if required) and take care
that all nitrogen is led to outside!
3. When operating the equipment, do not exceed the rated capacities, pressures or temperatures
or act otherwise than laid down in these instructions and the sub-contractors manuals.
4. At no time the unit should be energised and started in hazardous environments.
5. Spilling oil may cause slipperiness or fire damages.
(Example : oil of oil lubrication screw compressors)
6. Do not operated the unit without all guards in place and properly adjusted or in a way it was
not design for.
7.. Failure to heed any of these warnings can cause serious injury or death.
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!

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1.5 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.

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2 INSTALLATION
2.1 Installation instructions
Carefully read the cautions and instructions before installing the equipment:
1. Remove all packing material carefully.
2. 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.
3. No special foundations are required to carry the weight of the nitrogen unit.
4. Anchoring is dependent on customers’ requirements, but is not required for unit vibration.
5. The interconnecting piping shall be blown free of debris or contaminants prior to connecting to
the nitrogen generator.
Any cutting oil or other contamination’s shall be washed and/or wiped from piping.
6. Pipe dope should not be employed in making connections in the feed air piping systems.
Solvents present in the pipe dope may impair the membrane performance.
Only use pipe tape during assembly.
7. The diameters of the piping, to which the supply, vent, discharge and distribution lines on
board must be connected, are indicated on the diagrams and drawings (Process
documentation and dimensional drawings). In case a big pressure drop will occur in the pipe
system, these lines should be of an extra ample design. When choosing the pipe diameters,
the capacities and pressures mentioned in the technical specification should be considered.
8. The drain 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. The fluid should not be drained on the floor or slab. It should be
noted that the pressure of the condensate from the equipment is 7 - 10 bar (g) blowing down
to atmospheric pressure.
9. If more than one generator is placed on a ship, each generator must be provided with its own
fittings, such as shut-off valves, filters, reducing valves etc in the various supply and discharge
lines. This in order to be able to guarantee an independent operation of each generator.
10. The MAXIMUM back-pressure on permeate outlet port shall not exceed 0.02 bar (g).
11. The customer shall ensure that the nitrogen product line cannot be over-pressurised by down-
stream conditions.
12. Make sure that no condensate can flow back to the nitrogen unit!
13. No rain or water from the outside may find its way into the venting and aerating pipes.
14. The supplied compressed air should be as constant as possible, this means of constant
pressure and temperature.

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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. When the generator including compressor, is erected in a room specially meant for it, there
has to be a forced purge of air to discharge the heat developed; a fan must be fitted in the
discharge canal.
18. The nitrogen generator is equipped with a Zirconia type of O
2
-analyser. This item contains no
moving or rotating parts and ship movements or vibrations will have no effect. The O
2
measurement and the O
2
-sensor will last for many years. The only attention this analyser
requires is regular calibration. Calibration requires a calibration nitrogen gas bottle including
pressure-reducing set. A nitrogen cylinder must be on board of the ship, close to the O
2
-
analyser.
19. The wiring of the auxiliary (control) current part is performed according to the X-wiring
principle, which means that the wires are running at the rear side of the mounting plates. The
internal wiring is of the required flexible type for shipboard use. All connections are made with
wire connectors.
20. The entrance of the main supply cables can be made on a suitable place on the starter panel.
The electrical connections (cables) between the terminal boxes, other electrical parts and the
panels must be laid alongside the ship's steel structure. These cables should be laid during
erection on board
.

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3 STORAGE INSTRUCTIONS
3.1 General storage instructions
The equipment must be stored at a clean and dry place, protected against weather and moisture.
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. If necessary, it must be replaced.
3.2 Storage instructions for the construction period
With the construction period Enraf Smit Gas Systems means:
”The period between removing the packaging material, the installation of the equipment into the
ship (or into a segment of the ship) and the commissioning of the complete ship”.
During this construction period of the ship the equipment must be stored according to the General
storage instructions mentioned above.
Great care must be taken to protect the equipment against damages while working in the
surrounding area of the equipment.
Special care must be taken to protect the equipment from sparks when welding near to the
equipment.

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4 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°C (max. 55°C for limited time)
Process conditions: maximum operating pressure 14 bar (g)
Maximum working temperature 52°C (continuously)
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 bundles
permanently and should be avoided under all circumstances!
Only PAO type lubrication oil shall be used in oil lubricated screw
compressor.
The lifetime of the membrane will be reduces if this is not done.
The nitrogen generator is equipped with several provisions to avoid exceeding any of above
mentioned process conditions.
The user shall operate the units according the instructions given in this manual and carry out
(preventive)maintenance as instructed.
The unit shall not be stored in direct sunlight, as radiant energy will raise the effective storage
temperature.
DAMAGED MEMBRANE BUNDLES DUE TO LACK OF MAINTENANCE OR WRONG
OPERATION OF THE SYSTEM ARE NOT THE RESPONSIBILITY OF SMIT GAS
SYSTEMS B.V.

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5 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.
Before the compressed air will enter a membrane bundle, additional air treatment is required to
reach the optimum inlet conditions.
The next process description and the P&ID’s (chapter 10) will give a good overview of the
complete installation. Please also refer to the P&ID for the under mentioned tag numbers.
5.1 Process description
5.1.1 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 (19121001) of the nitrogen generator system give a good overview of the
complete installation. Please refer also to these documents for the under mentioned tag numbers.
Depending on the running mode or requested capacity, four compressors are allowed to run. The
ship crew will select the number of compressors by starting the required compressors, based on
the required nitrogen capacity.
It is recommended to select the required number of compressors based on the running hours, to
get equal maintenance intervals for each compressor.
Each compressor operates independent from the N2 system and has its own controls.
(See TMC compressor M160-13 EWNA of the sub-suppliers documentation).
5.1.2 Feed air system
The feed air system ensures a supply of feed air under working pressure. Two- (2) large size feed
air compressors that supply air to a filtration line take in ambient air under working pressure.
The compressors are of oil lubricated type. The oil used should be of PAO type only!
The compressed air is cooled down to a temperature level of max. 45°C, by an after-cooler
at the outlet of each compressor. The after-cooler uses fresh water and is designed for a constant
cooling water temperature of 36°C.
A lower cooling water temperature can cause less nitrogen capacity. A higher temperature can
cause problems with oil vapour removal and possible damage of the membranes.
The compressed air leaving the compressors will be saturated with water vapour.
A pre-heater (2100) is installed to make the air under-saturated before it comes into the filters
(control of temperature via Solid State relays).
This heater also brings the compressed air to the optimum operation temperature for air
separation.

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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. (> 5°C)
5.1.3 Filtration system (air treatment)
The filtration system guarantees an acceptable feed air quality.
Water particles will be separated from the air at the inlet of the air treatment skid. Micro-filters
(2200 & 2300) upstream the carbon bed filter (2600), filter out any particles in the feed air stream.
The active carbon bed filter takes out any oil remaining and thus prevents oil carry over to the
membrane bundles.
A micro-filter downstream the carbon bed filter removes any from the feed air stream what could
come from the carbon filter.
The water separator and the filters upstream the carbon bed filter are provided with level controlled
automatic drain valves. Possible water droplets, removed from the compressed air will be drained
and in case of a clogged/blocked drain line an alarm will be given, shutting down the unit.
NOTE:
Each automatic drain valve (2011) is provided with a test button. Check regularly!
5.1.4 Heating system
The function of electrical heater (2100) upstream the carbon bed filter is to warm up the feed air to
the required membrane operating temperature and to reduce the relative humidity level of the
compressed air. The heater outlet temperature is controlled by a controller (2125), inside the local
control panel.
The heater elements are protected against overheating by an internal safety thermostat inside the
junction box of the heater.
If the air temperature fed to the membranes exceeds the limit, measured directly upstream the
membranes (TZA 2930), the nitrogen generator will be switched-off/shut down to protect the fibre
material of the membranes.
5.1.5 Feed air controls
If the compressed air pressure, measured at the inlet of the treatment skid drops below the
setpoint of pressure switch 2050, the nitrogen generator will be switched-off, to avoid high element
temperature of the heater.
A low temperature current switch, installed over the heater (XZA 2127), detects a too low
temperature rise, to prevent that too wet air will enter the carbon bed filter.
To prevent a pressure shock to the membranes and filters, valve 2700 will open slowly after first
compressor start-up. Solenoid 2730 is fed with system air and operates pneumatic valve 2700 via
an adjustable restriction 2720.
The system air is also used as working air for actuation of the purge, delivery valve (4200, 4300)
and other devices on deck, requiring system air. The system air (Ship air supply), supplied by
the ship is expected to be dry and clean. A low-pressure switch safeguards the system air
pressure.
For visual indication of temperature and pressure, some pressure indicators and temperature
indicators are installed.

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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).
5.1.7 Oxygen control system
The function of the pressure control valve (CV-4020), which are mounted as close as possible to
the outlet of the air treatment skid, have to keep the oxygen contents in the nitrogen flow produces
at the desired value. A controller (5320) controls the position of both valve, and thus the pressures
upstream of the control valve. Both valves will operate at split-range operation to have the
best control at any possible nitrogen capacity.
The controller takes action if there is a difference between the set value and the measured value.
The measured value comes from the oxygen analyser 5310. The sample gas goes via a flexible
hose and via a pressure reducing valve (5100) to the probe (5300) of the O
2
-analyser (5310) and
will then
be vented to atmosphere (ventilated area). The sample airflow to the cell can be set with
flowmeter 5200.
On right side of the local panel a selection switch is mounted, which can be rotated to the right
position for sampling, calibration and testing of the analyser.
For a detailed description of the oxygen analyser, see sub-suppliers documentation of OPSIS.
When the purity of the produced nitrogen is according specification or better, the system can be
switches to delivery and the nitrogen produced will be directed to deck and/or the nitrogen
produced can be stored in the nitrogen storage tank at a maximum nitrogen pressure of 10 bar (g).
If the oxygen level in the nitrogen outlet exceeds the alarm setting of the oxygen analyser (5310),
the purge valve opens, after which the delivery/supply valve closes.
5.1.8 Nitrogen supply to storage tank
The nitrogen produced can be supplied to deck and/or supplied to a storage tank. This selection is
to be made from the CCRP.
Inside the storage tank a maximum pressure of 10 bar(g) can reached. When storage tank is
selected only, the operator is able to start all compressors, but normally one compressor is
enough. The surplus of N2 not able to flow into the storage tank otherwise will be
blow-off via the purge outlet.
When the maximum set pressure at the storage tank is detected, the unit will switch to blow-off
position. First after detecting low pressure inside the storage tank, the unit will fill-up again the
storage tank.
After start-up and immediately after reach of the required oxygen level, nitrogen will be supplied to
the tank and at high tank pressure the unit will switch to blow-off. Now, first after detecting low
tank pressure, the unit switch starts tank filling again. (So at start-up, the tank will be filled from
any storage tank pressure.)
!
It is up to the operator to stop the unit when not necessary anymore, however if a lot of
nitrogen is consumed from the storage tank within a limited, it is advised to keep the unit
running to avoid a high number of starts/stops.

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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. The Alarms however will be kept at the 5% level.)
The nitrogen capacity needs to be chosen by the plant operator and is based on the off-loading
capacity of the cargo pumps and the number of pumps. The nitrogen capacity is selected by
selecting a number of feed air compressors. Each additional compressor will result in about 25%
more nitrogen flow.
Each compressor is selected in such a way, that the total compressed air production will be used
for separation by a set of membranes, when producing nitrogen with max. 5% oxygen.
At reduced oxygen setpoint, the nitrogen flow will decrease, which is causing over capacity of the
compressors. The over-capacity will be blown-off to a maximum of 1 compressor.
If the air capacity is still too much, compressors will go to off-load one by one and stop after 20
minutes running in off-load operation.
The arrangement of valve 7300, 7100 and 7200 work as “Double Block & Bleed” to prevent back
flow of a hydrocarbon-nitrogen mixture to the nitrogen generator room (safe area).
Additionally an excess gas valve is installed upstream the block & bleed valves. The excess valve
is designed for blowing of the capacity of one set of membrane bundles.
The open and close position of this valve is indicated on the CCRP. If the light for close is off it
is indicated that there is a certain over-capacity in the nitrogen production.
If the open position is indicated, the operator is advised to switch-off one of the compressors.
The controller mounted in the CCRP (8515) controls the excess gas valve. The setpoint is set just
below the maximum deck main line pressure.
A deck transmitter panel takes care of transmission of the deck pressure signals of the deck-main
to the Cargo Control Room.
The standard sequence for the safety of the tanks is:
1. Pre-alarm at CCRP (or ship's systems). Personnel will take actions to prevent alarms and/or
shutdown.
A high alarm indicates over-capacity in the nitrogen production with fully opened excess gas
valve. When doing nothing the deck pressure high alarm will be activated and the nitrogen
system will switch to blow-off.
A low deck pressure alarm indicates an over-capacity in the cargo-pump capacity.
It advised to switch-off a number of cargo pumps or to start an additional compressor/
membrane set, to fit in with the pump capacity.
2. The “low-low” deck pressure alarm from N2 generator will shutdown cargo-pumps.
3. Differential pressure sensing. If the deck main line pressure becomes higher than the nitrogen
supply pressure, during nitrogen delivery, an alarm will be generated at the CCRP, meaning
that a risk of back flow or a mixture of hydrocarbon/nitrogen can be expected.
This however is a situation that never will occur, except when all other safety and valve position
checks will be absent.

ORDER NR : 19121
Rev. x Date. x-xx-xxxx Name: GLI
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Note: Ship may have additional safety devices, but this is outside the scope of supply and
responsibility of Enraf Smit Gas Systems.
5.2 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.
- Shipboard use, indoor erection. Also OCIMF will be followed for block & bleed systems.
- N
2
gas capacity based on the specified O
2
percentage (see II.1.) in the N
2
and calculated
with ambient air of 25°C and 80% RH
- Voltage tolerances: - 15% / + 10%.
- Capacity tolerances: +/- 3%
- Tolerances on quality percentage +/- 0.01%
- Max air temperature for membrane inlet 55 °.
- Max air pressure compressor discharge 13.5 bar(g)
- Electric motors switched star/delta.
- Process safeguarded by several protecting devices.
- Control voltage 220V - 60Hz.
- Interconnecting flanges will be according DIN
- The arrangement is designed in such a way that the whole unit requires minimum space.
- The membrane unit and compressor can be mounted directly on a flat horizontal floor.
Compressors need flexibles for connecting points
- Max. ambient conditions 45 °C - 90% RH
- Lubrication oil used for screw compressor(s) need be of PAO type (included in scope of
supply)
- Bundles precautions: bundle should be kept frost-free any time, bundle never should come
in contact with any solvent (Loctite not to be used close to fibres). Gas that will be supplied
to the fibre to be oil free and dry (no condense). Lubrication oil used in compressors to be
PAO type only.

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Rev. x Date. x-xx-xxxx Name: GLI
19
5.2.2 Nitrogen (gas) specification
Capacity N2 max 1200 nm
3
/h * (2 compressors in operation)
Discharge pressure min. 10 bar(g)
Typical gas composition (on dry basis)
Oxygen O
2
better than 5 vol. %
Nitrogen + Argon N
2
+ Ar balance
Temperature max. 60 °C
Dewpoint minus -60°C after expansion to atmospheric pressure
5.2.3 Utilities
Feed air
Temperature max. 45 °C
Pressure atmospheric
Consumption max. 2450 Nm
3
/h (0°C, P= atmospheric)
Electricity
Power supply 440V, 3ph, 60Hz
Control supply 220V, 1ph, 60Hz
Power Rating
Compressor 2x185 kW
Control system 3 kW
Heater 2100 10 kW
Cooling water
Quality freshwater, (mesh size 3 mm)
Supply pressure between 2-4 bar (g)
Outlet pressure atmospheric
Inlet temperature constant 36 °C
Consumption (each compressor) 5 m
3
/h (based on 36°C inlet)
Noise level
Noise produced by compressor: abt. 80 dB(A) measured at 1 metre distance in free
field.

ORDER NR : 19121
Rev. x Date. x-xx-xxxx Name: GLI
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6 OPERATING INSTRUCTIONS
Before operating the unit, read the SAFETY INSTRUCTIONS.
6.1 General operating notes
THIS PACKAGED EQUIPMENT IS A PIECE OF MACHINERY THAT INHERENTLY HAS MANY
POSSIBLE HAZARDS. THERE ARE SYSTEMS THAT OPERATE UNDER PRESSURE, AT HIGH
TEMPERATURES AND AT HIGH VOLTAGES.
THIS EQUIPMENT MUST BE OPERATED BY QUALIFIED PERSONNEL WHO HAVE BEEN
TRAINED TO WORK ON THIS TYPE OF EQUIPMENT.
- DO NOT REMOVE PARTS FROM PRESSURE CONTAINING SYSTEMS WITHOUT
RELIEVING PRESSURE FIRST.
- 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.
- THERE ARE PARTS OF THIS EQUIPMENT WHICH CAN CAUSE ELECTRICAL SHOCK.
- DO NOT REMOVE ANY OF THE PROTECTIVE DEVICES OR RENDER THEM INACTIVE.
- WHEN DOING ANY SERVICE WORK OR MAINTENANCE WORK ON THE UNIT(S), BE
ABSOLUTELY SURE THE EQUIPMENT IS LOCKED OUT AND ALL INTERNAL
PRESSURE IS RELIEVED.
- FAILURE TO HEED ANY OF THESE WARNINGS CAN CAUSE SERIOUS INJURY OR
DEATH.
After opening the hand valves for all utilities, doing the necessary checks and start-up the cooling-
water supply, the generator can be started by one single button.
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.
6.2 CONTROL PANELS
The nitrogen gas system comprises several control panels:
- Local Control Panel (LCRP) : This is the main control panel of the nitrogen system from
which the generators can be operated.
The panel is mounted on the air treatment / filter skid.
-Cargo Control Room Panel (CCRP) : From this panel the nitrogen delivery valve can be
operated and the deck line main pressure is controlled. In
fact this panel is the interface between the nitrogen
generators and the cargo tanks