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INSTRUCTION MANUAL

NITROGEN GENERATOR

GENERAL INFORMATION

MEM :

1200

- 5

- 10

CM

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Summary of Contents for 1200-5-10 CM

Page 1: ...INSTRUCTION MANUAL NITROGEN GENERATOR GENERAL INFORMATION MEM 1200 5 10 CM ...

Page 2: ...ument 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 ...

Page 3: ...NERATOR 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: ...e 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...

Page 5: ... 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 TECHNICAL 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 GENERAL OPERATING NOTES 20 6 2 CONTROL PANELS 20 6 3 SWITCHING ON 21 6 3 1 Nitrogen gas production 21 6 4 NORMAL STO...

Page 6: ...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 ...

Page 7: ... 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 EQ...

Page 8: ...ill 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 ...

Page 9: ...ents 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: ... 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 ch...

Page 11: ... have no effect The O2 measurement and the O2 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 O2 analyser 19 The wiring of the auxiliary control current part is performed according to the X wiring princ...

Page 12: ... 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 shi...

Page 13: ...rwards 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 ex...

Page 14: ...mpressors 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 suppl...

Page 15: ...ical 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 ...

Page 16: ...ppliers 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 ana...

Page 17: ... 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 val...

Page 18: ...ances 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 an...

Page 19: ...5 2 3 Utilities Feed air Temperature max 45 C Pressure atmospheric Consumption max 2450 Nm3 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 Consump...

Page 20: ...SOLUTELY 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 ma...

Page 21: ...e or locally 1 Check if the cooling water supply pump s for the compressors is are running Open all valves in the cooling water supply and in the discharge line of the compressor A compressor only can be started from the LCRP if the selected compressor is switched on by switching on the main switch at the compressor panel 2 The selection for local or remote operation is done on both LCRP Local Con...

Page 22: ...ceptable alarm at this stage first start could be a low low low pressure of deck main pressure or low tank pressure Further all alarms must be off Check if the purge valve is open and the delivery valve is closed All compressors must be stopped Otherwise the program will not allow you to start 7 Check if compressor belonging to the selection indicate standby If not refer to the sub supplier docume...

Page 23: ...e stopped and the system waits until the oxygen is corrected In the meantime all N2 produced will be purged The system automatically switches to delivery again if the oxygen content is below the setpoint again It is also possible to fill the nitrogen storage tank during delivery to deck Therefore the mode Nitrogen to cargo with tankfilling needs to be selected If the tank is not full indicated on ...

Page 24: ...l compressors ADDITIONAL IN CASE A LONG PERIOD OF STANDSTILL IS EXPECTED 3 Drain possible condensate from the condensate drains before all pressure us released from the unit Close the storage tank inlet valve 4 Do not switch off the electric supply if the unit will be used regularly as these is required for the oxygen analyser no heating up time at next start up f the electric supply is switched o...

Page 25: ...ve manually and build up pressure 8 Open all other instrument block valves if applicable 9 Check all piping connections for leakage 10 Close the inlet valve to stop the compressed air supply 10 Test the automatic drain valves one by one 11 Open the carbon bed vessel blow down valve very slowly and blow off the air Possible carbon dust will blow out Keep open until all pressure is released from the...

Page 26: ...ng to the installation the manufacturers instructions in chapter 11 have to be consulted In the trouble chart one column is named C o F which means Consequences of Failures The figures indicated are explained in section 7 3 6 8 Trouble chart In the next table most common problems failure are explained and mostly a simply remedy is given to solve the problem If this guide does not enable you to do ...

Page 27: ... should be not in operation is not closed System won t start No power supply take care of sufficient power supply Start request not answered with release by the power management system Compressor failure see compressor won t start and or temperature to high Alarm indicating see Cause Effect chart Chapter 10 4 for solving Selections made are not possible re select and wait for indication of system ...

Page 28: ...em not yet stabilised wait for 5 min Wrong setting pressure controller 8530 readjust according sub suppliers manual Chapter 11 and settings of test protocol Wrong setting alarm levels re adjust according test protocol settings and sub suppliers manual Compressor temperature to high non or not enough flow of compressor cooling medium open valves in cooling medium supply and discharge line Cooling m...

Page 29: ...als 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 This is to the operator s experience Before removing any accessory out of or from piping be certain that the relevant isolating valves have been closed and the pressure released if applicable In case of a longer stand stil...

Page 30: ...nual Automatic drain valves Test clean drain lines if necessary Bekomat manuals Table 8 2b Maintenance table 1500 running hours Interval Component Maintenance Description Remarks Every 1200 running hours Pre micro filter elements Renew Zander manual Activated carbon Renew 750 kg REMARK After renewing activated carbon first close membrane inlet valves 3020 and override solenoid 2730 at the slow ope...

Page 31: ... membranes Table 8 2c As per sub supplier indicated schedule or at least ones a year SEE TMC MANUAL Chapter 11 Interval Component TMC compressor Maintenance Description Remarks Compressor oil Oil filter Oil separator cartridge Valve seals other seals diaphragms Renew or clean TMC manual 7 3 Lubricating schedule Interval Component Maintenance Description Remarks Every 750 running hours Compressor m...

Page 32: ......

Page 33: ...ORDER NR 19121 Rev x Date x xx xxxx Name GLI 33 8 TEST PROTOCOL List of documentation No Doc no Title 1 BGS19121 3 1E Test protocol ...

Page 34: ...x Date x xx xxxx Name GLI 34 9 DOCUMENTATION 9 1 Process drawings List of documentation No Dwg no Title 1 PL19121 Partslist 2 19121 025 Alarm Safety table 3 19121001 Flow diagram Nitrogen Generator 4 SSYMX005 Code Symbols ...

Page 35: ...R NR 19121 Rev x Date x xx xxxx Name GLI 35 9 2 Plant dimensional drawings List of documentation No Dwg no Title 1 19121648 Dimensional drawing screw compressor 2 19121649 Dimensional drawing membrane skid ...

Page 36: ...ical documentation List of documentation No Dwg no Title 1 19121 802 Local Control Panel generator 2 19121 803 Cargo Control Room Panel 3 19121 804 Bridge Panel 4 19121 805 Engine Room Panel 5 19121 8xx Page overview wiring regulations and terminal definitions ...

Page 37: ...witch RT 101 6 Endress Hauser Temperature transmitter M TR12 7 Fisher Pressure reducer 67C 8 Opsis Oxygen monitor model 0 2000 Oxygen probe model OM10 STD 9 PCC User manual 10 PMA KS30 operation instructions KS90 operation instructions KS 3930 AB operation instructions 11 RHPS Pressure regulator type BRSF 16 Pressure regulating series RSH 15 series 12 Siemens Sipart PS2 6DR5xxxxx 13 Hiross Pressur...

Page 38: ...x Date x xx xxxx Name GLI 38 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 ...

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