OPERATION & MAINTENANCE MANUAL

FOR SANGHI-ORG OXYGEN / NITROGEN

GAS PLANT

PLANT CAPACITY 200 / 300

SANGHI ORGANIZATION
1-2, TURF VIEW, SETH MOTILAL G. SANGHI MARG,
OPP. NEHRU CENTRE, WORLI, MUMBAI – 400 018

TEL NO. : 2494 5464 (12 LINES), FAX NO. : (91-22) 2494 7052

E-MAIL : [email protected]
Website :http://www.sanghioverseas.com

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I. PLANT SPECIFICATIONS

1. Production Capacity - The plant is very versatile and can be set for a cycle to produce any one of
the following alternatives:

OXYGEN PRODUCTION NITROGEN PRODUCTION

Alternative Gas Gas Product Gas Quantity Gas Product

Quantity Purity Purity Purity Purity
1. Sanghi-Org 200 200 Cu.m./hr 99.5% 150 Kg/cm2 * 700 Cu.m./hr 99.2% 0.1 Kg/cm2
1A Sanghi-Org 200 180 Cu.m./hr 99.5% 150 kg/cm2 * 400 Cu.m./hr 99.9% 0.1 kg/cm2
2. Sanghi-Org 300 300 Cu.m./hr 99.5% 150 kg/cm2 *1300 Cu.m./hr 99.2% 0.1 kg/cm2
2A Sanghi-Org 300 240 Cu.m./hr 99.5% 150 kg/cm2 *700 Cu.M./hr 99.9% 0.1 kg/cm2

* About 400 M3/hr of Nitrogen will be used for regeneration of dryers.

** About 600 M3/hr of Nitrogen will be used for regeneration of dryers.

The above product capacities are based on ambient conditions of 15°C . Temperature, 760 mm. of Hg
Pressure and 50% relative humidity and 0.03% of carbon dioxide in Atmospheric Air.

2. Other Specifications SANGHI-ORG 200 SANGHI-ORG 300

Air Pressure (Starting) 55 kgs/cm2 55 kgs/cm2

Air Pressure (Normal – Operation) 36 kg/cm2 36 kg/cm2
Starting Time (After Defrost) 5 Hours 5 Hours
Starting Time (For Short Stop) 1 Hour 1 Hour
Defrosting Time 8 Hours 8 Hours
Defrosting Cycle at Normal Conditions 12 Months 12 Months
Cylinder filling Manifold Connections 2 X 24 Nos. 2 X 40 Nos.
Cooling Water Requirement 50 Cu.M./hr 70 Cu.M./hr
Inlet Cooling Water Temperature 25 Deg °C 25 Deg °C
Total Weight (About) 40 tons 45 tons
Assembly Height 10.5 Mtrs. 10.5 Mtrs.
Max. Roof Height 12 Mtrs. 12 Mtrs.
Area Required 40 X 80 Mtrs. 40 X 80 Mtrs.
Air Input 1000 Cu.m./hr 1500 Cu.m./hr
Power Supply Required 440 Vlts. 440 Vlts.
& 230 Vlts. 230 Vlts.
50 Htz. 50 Htz.

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3.Power Requirement SANGHI-ORG 200 CU.M./HR SANGHI-ORG 300 CU.M./HR

H.P. K.W. H.P. K.W.

Air Compressor 350 225 530 410

Drier Heater 40 32 50 36
Expansion Engine 40 30 40 30
L O Pump 7.5 5 7.5 5
Nitrogen gas blower - - - -
Defrost heater (Off Load) 8 12 18 12
Cooling Water Pump 7.5 x 2 5x2 18 12
Cooling Tower 7.5 5.63 10 7.5
Chilling Unit 10 7.5 10 7.5
Circulating water pump 3.5 2 3.5 2
Total Connected load 492.5 337.13 687 510

Plus Lighting Load = Say 30 KW/ 40 HP. Plus Lighting Load = Say 30 KW/40 HP.

D.G. SET REQUIRED CAPACITY TO BE INSTALLED FOR RUNNING OUR PLANT.

For SANGHI ORG - 200 550 KVA.

For SANGHI ORG -300 725 KVA.

II. INFORMATIVE ENCLOSURES

COMPOSITION OF ATMOSPHERE
CONSTITUENT % VOLUME VPM
WATER VAPOURS VARIABLE -
DRY AIR 100 -
NITROGEN 78.084 + 0.004 -
OXYGEN 20.948 + 0.002 -
ARGON 0.934 + 0.001 9340
CARBON DIOXIDE 0.0315 + 0.001 315
NEON (4.818 + 0.004) X 10 -3 48.18
HELIUM (5.24 + 0.05) X 10 -4 5.24
KRYPTON (1.14 + 0.001) X 10 -4 1.14
XENON (8.7 + 0.1) X 10 -6 0.087
METHANE 1.5 X 10 -4 1.5
HYDROGEN 5 X 10 -5 0.5
NITROUS OXIDE 3 X 10 -5 0.3
CARBON MONOXIDE 1.2 X 10 -5 0.12
AMMONIA 1 X 10 -6 0.01
NITRIC OXIDE 1 X 10 -7 0.001
SULPHUR OXIDE 2 X 10 -6 0.0002
HYDROGEN SULPHIDE 2 X 10 -8 0.0002
OZONE VARIABLE -

(REFERENCE : EVOLUTION OF ATMOSPHERE BY WALKER.)

III. MAJOR COMPONENTS AND DETAILS

(Figures in bracket are for 300 Cu.m/hr. Oxygen plant)

Page 3
1. Air Suction Filter : Dry type - woolen pad inserted between mesh.

2. Air Compressor : Four stage Horizontal - Reciprocating Type with its

accessories - approximately to deliver 931 CM/hr
(1380CM/hr) at 60 Kgf/cm2

3. Air compressor Motor : With Pulley and belt guard.

H.P. : 350 (530), KW : 225 (410)
Volts : 440, Amps : 450 Max (690 max.)

4. Moisture Separator : Shell-Dgn. Pr. 60 kgf/cm2 Hyd.T.Pr. 90 kgf/cm2

5. Evaporation Side : Shell side - Dgn. Pr. 0.2 kgf/cm2 Hyd.T.Pr.0.25

kgf/cm2 Max. Temp. 35 ° C. Tube side - Dgn.
Pr.60 kgf./cm2 Hyd. . Pr. 78 kgf./cm2. Max.
temp 35 °C.

6. Chilling Unit with chilled : 10(15) Ton Capacity operating range is 6 ° C to

10 °C Water coil tank and water temperature
Circulating pump

7. Moisture Separator : Shell-Dgn. Pr.60 kgs./cm2 Hyd. T.Pr.90kgs/cm2

8. Oil Absorber : (Packed with activated Carbon and two filters

provided in inlet and outlet) Dgn. Pr. 60 kgs./cm2
Hyd. T. Pr. 90 kgs./cm2

9. Molecular Sieve Drier : (Refer Molecular Sieve Drier Chapter)

Dgn. Pr. 60 kgs./cm2 hyd. T. Pr. 90 kgs./cm2
Max. Dgn. Temp 400 ° C

10. Drier Heater : (Refer Molecular Sieve Drier Chapter)

Dgn. Pr. 0.5 kgs./ cm2 Pn. T. Pr. 0.6 kgs/cm2
Max. Dgn Temp. 400 ° C

11. Regeneration : (Refer Molecular Sieve Drier Chapters)

Nitrogen Blower

12. Drier Control panel : 440 Volts, 13.5 KW, 45 Amps. (36 KW, 80 Amps)

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13. Cold Box consisting of : (a) Heat Exchanger No.1
(b) Heat Exchanger No. 2
(c) Lower Column
(d) Upper Column
(e) Main condenser.
(f) Accessories

14. Expansion Engine : Refer Chapter on Expansion Engine

15. Liquid Oxygen Pump : Refer Chapter on L.O. Pump

16. Product filling manifold : A - SANGHI-ORG 200-2 Nos. for 24 cylinders each

with pig tail connection. Dgn. Pr. 160 kgs./cm2 and

6 cylinder buffer manifold.

B - SANGHI-ORG-200-2 Nos. for 40 cylinders each

with pig tail connection Dgn. Pr. 160 kgs./cm2 and 6
cylinder buffer manifold.

17. Inter-Connecting : A per our standard layout this does not include the
piping & Valves compressor drain, water pipelines,
pipe fittings, valves etc.

ABBREVIATIONS

Dgn. Pr. - Design Pressure Hyd. T. Pr. - Hydraulic Test pressure.

Pn. T. - Pneumatic Test pressure Temp. - Temperature.

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 IV. GENERAL BASIC PRINCIPLES

Air is a mechanical mixture of Oxygen and nitrogen and its physical properties lie between the two but
closer to those of Nitrogen. In its normal atmospheric condition, air is a colourless, odourless gas. Air
which is normally in gaseous state can be liquefied as steam from gaseous state can be condensed to liquid
state.

The Plant manufactured by us have operating pressure of 40 Kg/cm2. this is achieved with the
incorporation of Expansion Engine along with Joule - Thompsons expansion valve.

1.1 Air is sucked into Air compressor via suction Air filter (1) Drawing No.1 where dust particles are
removed. The Air filter fitted on Air compressor should be 100 Meter away from the Acetylene
Plant, if Acetylene Plant is installed on the same premises or near by. Please refer compressor
Manual provided by Air compressor manufacturer for Air compressor.

1.2 Air can be compressed to max 60 Kg/cm2 (40 to 35 Kg/cm2 in normal running condition) and passed
through cascade cooler. (3) The lubricant which is mixed in Air during the compression is
also get cooled in Cascade Cooler (5) where it gets cooled to about 20 Deg.C. This cooler is an
elliptical tank having two compartments. In each compartments there is a pipe coil that is
interconnected. The coils are half submerged in water in the tank. Dry Nitrogen bubbles through
this water are get moisturized. As the water vaporizes it requires latent heat, which is absorbed
from water itself. Thus water gets cooled and in turn the air in the pipe also gets cooled. The
condensed water is removed in moisture separators. This is drained once in an hour. The
separation of moisture helps in getting effective through put. The Compressor Condensate, if not
drained periodically can cause hammering and damage to the compressor.

1.3 The air from moisture separators than passes to cooling coil in the chilling coil tank. (6) which is
having chilled water at a temperature of 6 ° C to 10 ,° C. This chilling of water is done with the
help of chilling unit (7). In the chilling tank coil the moisture entrapped in the air further gets
condensed which is separated in the form of moisture from the moisture separator (8) and is
drained once in an hour. The separation of moisture is carried out in different stages so that the
air entering in the molecular sieve has minimum moisture level. Better adsorption of Co2 can
take place in the molecular sieve battery, if the moisture content is low in air.

1.4 The air will then pass through carbon filter separator packed with Activated Carbon. Here the oil
vapour carried over from air compressor will be removed. If this oil vapour is not removed
sufficiently, due to spent carbon or due to high temperature of process air, the oil vapour will
damage the molecular sieves. To obtain a long life of molecular sieve ensure that carbon filter is
well maintained. (A sample of Carbon beads may be taken out from Carbon Filter once in six
months checked and should be checked)

1.5 The Air cooled in chilling unit should be between 6 ° c to 10 ° c for better adsorption of carbon
dioxide in the molecular sieve .The chilled Air then passes through Molecular Sieve Drier
unit (12). This unit have two Vessels when one is on line and other is on Reactivation . The
regeneration cycle of drier is 8 to 10 hrs ( approx)

1.6 The cooled Dried Air is passed through Dust Filter (14) (Hard compressed ceramic filter) where
small dust particles are arrested.

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 1.7 The Dust, Moisture and Oil free cooled Air is passed finally into cold Box (15) which consists of
Heat Exchanger 1&2, Lower column, Upper Column, Condenser. etc

1.8 The Air is passed through Heat Exchanger 1 where Air is cooled to –100 Deg.C by the incoming
Oxygen & Nitrogen gas.

1.9 The air will then be bifurcated into two streams. The main air stream, will enter Expansion
Engine (16) at 40 kgs./cm2 and will be expanded to 5 kgs./cm2 and – 150 °C. The rest of the air
will pass through Heat Exchanger No. 2 to be cooled to about - 140 °C to - 155 °C by the
outgoing Oxygen and Nitrogen. This air will then be expanded by an Expansion Valve R1 to
form liquid air. Both the air streams will now enter into a buffer vessel and then to the bottom
portion of the lower Column (C-13).

1.10 As the air enters the Lower Column, after the Expansion Engine and after Air Expansion valve
R1, part of this air condenses into liquid and falls at the bottom of the column. This liquid is
about 35% to 40% Oxygen and 60% to 65% Nitrogen and is usually called the ‘Rich Liquid’
(RL).

1.11 A part of the air in this Column evaporates and rises to the top of the Column touching the
Condenser, which is colder than the Lower Column. As this air touches the Condenser, it
condenses into a liquid on top of the Lower Column. This liquid is generally 96% to 99%
Nitrogen and being poor in Oxygen, is called “Poor Liquid” (PL). The pressure in the lower
column is between 4.7 Kg/cm2 to 5.2 Kg/cm2. in the normal operating condition.

1.12 Final separation of the 2 traction is achieved in the Upper Column Both the Poor liquid and the
Rich Liquid are carried into the Upper Column by two Expansion valves and the pressure, drops
from 5 kgs./cm2 in the lower column to 0.5 kgs./cm2 in the upper column. This Rich Liquid
enters the middle of the Upper Column and as it flows down, Nitrogen evaporates and Oxygen
continues as liquid. The Liquid Nitrogen (poor Liquid) enters the top of the upper column and as
if flows down the column, it comes in contact with any evaporating Oxygen and condenses the
same into a liquid, while the nitrogen itself becomes a Gas as it is more volatile. This process
takes place in each tray. The entire gaseous Nitrogen is piped out from the top of the upper
column through the Heat Exchangers. Similarly the liquid Oxygen at the bottom of the
condenser is carried away to a liquid Oxygen pump from which it is compressed and
again passed through the Heat Exchanger into the Gas Cylinders. As the Liquid Oxygen
travels through the Heat Exchangers, it evaporates into the gaseous Oxygen giving up its cold to
the incoming air.

Generally the purity of Oxygen will be 99.5% and Nitrogen about 96%, when the plant is
operated exclusively for Oxygen production. If Nitrogen is also required, a part of the RL vapor
(Mixture gas) is bled out from the center of the Upper column. By doing so, waste Nitrogen
purity will gradually increase to 99.5% and the Oxygen production will fall. The Nitrogen so
produced can be compressed by means of a standard Nitrogen Compressor. Liquid N2 production
can also be possible at 0.5 kg/cm2 pressure (Please refer chapter on simultaneous Oxygen &
Nitrogen Production). This system is provided to the customer on demand. The normal ASU has
no liquid nitrogen drawal facility.

Page 7
 The plant operation should be such that it is not too cold or too warm. If the cold box is too cold,
the Nitrogen will condense and mix with Liquid Oxygen and the Oxygen purity will fall. If the
plant is too warm the Oxygen will evaporate with the Nitrogen, and the quantity of Oxygen
produced will go down substantially and the waste Nitrogen will carry more and more of Oxygen.
To obtain optimum result of the plant, therefore, check the purity of the waste Nitrogen which
should not fall below 98% to 99%.

1.13 When the plant works continuously for a few months, it tends to accumulate Carbon Dioxide and
Moisture in its internal parts. These are to be removed once in about 4 – 6 months. For details,
refer Chapter on Defrosting of plant.

Similarly LO. Pump alone can be defrosted in case of trouble in pumping (Refer LO. Pump
chapter)

It is advised to give Carbon Tetra Chloride wash to the Cold Box equipment once in two years when
Acetylene contamination in Liquid Oxygen exceeds 2.0 PPM (may be checked and confirm after carrying
out spot acetylene test) to ensure protection against Hydro Carbon contamination in heat exchanger tubes
and top and bottom column trays.

Before starting plant, it is generally defrosted and blown out. Then the cooling/starting is done which will
take about 8 hours. When the plant stops for short intervals, the plant need not be defrosted, but all the Cold
line valves are to be closed to prevent moisture from entering the Cold Box

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V. VALVE INDEX AND NOMENCLATURE

Sr. No. Valve Nomenclature Valve No. Types

1. Main Air Expansion R1 Expansion
2. R.L. Expansion R2 Expansion
3. P.L. Expansion R3 Expansion
4. Air Bye - Pass R4 Expansion
5. P.L. Expansion to Buffer valve R5 Expansion
6. Liquid N2 production valve R-6 Cryogenic
7. Oxygen vent valve R-7 Cryogenic
8. Oxygen Pump feed valve R-8 Cryogenic
9. P.L. Vapour Vent from buffer R-11 Cryogenic
10. L. Nitrogen pump vent valve R-10 Cryogenic
11. L. Nitrogen feed valve R-9 Cryogenic

AIR VALVES

1. Moisture Separators Drain A1 Blow Off

2. Main Line air Blow off A2 Blow Off
3. Main line air valve A3 H.P. Globe
4. Moisture separator Drain A4 Blow Off
5. Oil Trace drain valve A5 Blow Off
6. Mol. Sieve Drier ‘A’ Air inlet A6 H.P. Globe
7. Mol. Sieve Drier ‘B air inlet A7 H.P. Globe
8. Mol. Sieve Drier ‘A’ air outlet A8 H.P. Globe
9. Mol. Sieve Drier ’B’ air outlet A9 H.P. Globe
10. Molecular sieve Drier ‘A’ Pressurising A10 Needle valve
valve
11. Molecular Sieve Drier ‘B’ pressurising A11 Needle valve
valve
12. Molecular sieve drier depressurising A12 Needle valve
13. Air filter after drier drain valve A13 Blow Off
14. Air inlet to main exchanger 1 A14 H.P. Globe
15. Air inlet to mix exchanger in cold box A15 H.P. Globe
16. Air inlet to Expansion Engine A16 Cryogenic
17. Air outlet to Expansion Engine A17 Cryogenic
18. Defrost Main air inlet A18 ¾” H.P. Globe
19. Cylinder gas inlet for defrost A19 Cylinder valve
20. Defrost air in Lower column A20 G.M. Globe
21. Defrost air in Upper column A21 G.M. Globe
22. Defrost Air L.O. Pump A22 1” H.P. Globe
23. Air Regeneration for Mol. Battery A23 1” H.P. Globe
24. Air inlet N2 Exchanger A24 Manifold
25. Air inlet O2 Exchanger A25 Manifold
26. Air inlet O2 L.P. Exchanger A26 Manifold

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NITROGEN VALVES

1. Main Nitrogen out from cold Box to ATM. N-1 Gate/ Butterfly
2. Nitrogen out from Evaporation cooler N-2 Gate/ Butterfly
3. Nitrogen inlet to Regeneration Heater N-3 Gate /Butterfly
4. Molecular Sieve Drier ‘A’ N2 inlet N-4 H.P. Globe
5. Mol. Sieve Drier ‘B’ N2 inlet N-5 H.P. Globe
6. Mol. Sieve Drier ‘A’ N2 inlet N-6 H.P. Globe
7. Mol. Sieve Drier ‘B’ N2 Outlet N-7 H.P. Globe
8. N2 purge for Expansion Engine N-8 G.M. Gate
9. N2 Purge for L.O. Pump N-9 G.M. Gate
10. Nitrogen Purge for L.N. Pump N-10 G.M. Gate
11. Mix. Gas out cold box N-11 G.M. Globe

OXYGEN VALVES.

1. High pressure vent valve from cold box OP-1 Manifold

2. High pressure filling valve from cold box OP-2 Manifold
3. Manifold ‘A’ isolation valve OP-3 Manifold
4. Manifold ‘B’ isolation valve OP-4 Manifold
5. Buffer Manifold Isolation valve OP-5 Manifold

NITROGEN VALVE OPTION

1. High pressure vent valve from cold box NP-1 Manifold

2. High pressure filling valve from cold box NP-2 Manifold
3. Manifold ‘A’ isolation valve NP-3 Manifold
4. Manifold ‘B’ isolation valve NP-4 Manifold
5. Buffer manifold isolation valve NP-5 Manifold

DRAIN VALVE

1 Air Drain from Distributor after H.E. 1 D-1 Blow off.

2. Air Drain before R1 Expansion valve D-2 Blow off.
3. Defrost out of L.O. Pump D-3 Blow off.
4. Lower Pressure column Drain valve D-4 Safety valve
5. Buffer manifold isolation valve D-5 Blow off.
6. Main condensor Drain valve D-6 Safety valve
7. Main Condensor Drain D-7 Blow off.
8. Liquid Oxygen Pump Drain D-8 Blow off.
9. Rare Gases purge out D-9 Blow off.
10. L.N. Pump Drain D-10 Blow off.
11. Defrost out L.N. Pump D-11 Blow off.

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ANALYSIS VALVE

1. Mix Gas analysis S-1 Sampling valve

2. R.L. Analysis S-2 Sampling valve
3. Condensor gas analysis S-3 Sampling valve
4. Condensor liquid analysis S-4 Sampling valve
5. Oxygen analysis before sub cooler S-5 Sampling valve
6. Oxygen analysis before pump S-6 Sampling valve
7. P.L. Analysis bottom column S-7 Sampling valve
8. Waste Nitrogen analysis T.C. S-8 Sampling valve
9. Waste Nitrogen analysis after H.E.-1 S-9 Sampling valve
10. L.N. analysis buffer S-10 Sampling valve
11. P.L. analysis after R3 valve S-11 Sampling valve
12. L.N. analysis before pump S-12 Sampling valve

PRESSURE GAUGE & INSTRUMENT ISOLATION VALVES

1. Air pressure Gauge before H.E. (P1) VP-1 Needle

2. Air pressure gauge before R1 (P2) VP-2 Needle
3. L.C.T. Pressure gauge (P3) VP-3 Needle
4. Pressure gauge (P4) VP-4 Needle
5. U.C.T. Pressure gauge (P-5) VP-5 Needle
6. U.C.B. Pressure gauge (P6) VP-6 Needle
7. Oxygen Pressure gauge after H.E. 1 (P8) VP-8 Needle
8. Nitrogen Pressure Gauge after H.E.1(P10) VP-10 Needle
9. Air inlet gauge Expansion Engine (P11) VP-11 Needle
10. Air Outlet gauge Expansion Engine (P12) VP-12 Needle
11. Liquid Nitrogen Buffer Pressure gauge VP-13 Needle
(P13)
12. Waste Nitrogen after H.E. 1 (P14) VP-14 Needle
13. Air pr. before moisture separator gauge VP-15 Needle
(P15)
14 Mol. Sieve Drier ‘A’ Pressure gauge (P16) VP-16 Needle
15 Mol. Sieve Drier ‘B’ Pressure gauge (P17) VP-17 Needle
16 O2 Buffer manifold ‘A’ pressure gauge VP-18 Needle
(P18)
17 O2 Buffer manifold ‘B’ pressure gauge VP-19 Needle
(P19)
18 O2 pressure gauge before isolation valve VP-20 Needle
(P20)
19 N2 Buffer manifold pressure gauge (P21) VP-21 Needle
20 N2 pressure gauge isolation valve (P22) VP-22 Needle
21 N2 pressure gauge manifold ‘A’ (P23) Needle
22 N2 pressure gauge manifold ‘B’ (P24) Needle
23. Defrost air pressure gauge (P25) VP-25 Needle
24. Regeneration N2 pressure gauge (P26) VP-26 Needle
25. Expansion Oil pressure gauge (P27) VP-27 Cock
26. L O Pump Oil pressure gauge (P28) VP-28 Cock
27 L.N. Pump Oil pressure gauge (P29) VP-29 Cock

Page 11
LIQUID LEVEL ISOLATION VALVE

1. LC / Liquid level LP. Isolation RL VL-1 Needle

2. LC/ Liquid level H.P. isolation RL VL-2 Needle
3. LC / Liquid level Bye pass RL VL-3 Needle
4. LC / PL Liquid level L.P. isolation VL-4 Needle
5. LC / PL liquid level bye pass VL-5 Needle
6. LC / PL Liquid level bye pass VL-6 Needle
7. Nitrogen Buffer liquid level L.P. isolation VL-7 Needle
8. Nitrogen Buffer liquid level H.P. isolation VL-8 Needle
9. Nitrogen Buffer liquid level Bye pass VL-9 Needle
10. Condensor liquid level L.P. isolation VL-10 Needle
11. Condensor liquid level H.P. isolation VL-11 Needle
12. Condensor liquid level Bye Pass VL-12 Needle

LEVEL GAUGES

1. Lower Column RL L-1 DP Manometer (P)

2. Nitrogen Buffer vessel L-3 DP Manometer (P)
3. Liquid Oxygen L-2 DP Manometer (P)

OTHER VALVES

1. Upper Column Safety S-1 Safety

2. Lower Column Safety S-2 -
3. High Pressure Oxygen Safety S-3 -
4. Defrost Air Safety S-4 -
5 High Pressure Air Safety S-5 -

Page 12
VI. INSTRUMENTS INDEX AND NOMENCLATURE

PRESSURE GAUGES

Sr. No Pressure Gauge Pressure Type

Nomenclature (Oil Free) Gauge No.
1. Air Pressure before H.E.1 P-1 Panel mounted Back connection

2. Air Pressure before R1 P-2 “

3. C. Pressure Top P-3 “

4. L.C. Pressure Bottom P-4 “

5. U.C. Pressure Top P-5 “

6. U.C. Pressure Bottom P-6 “

7. O2 filling pressure P-8 “

8. N2 filling pressure P-10 “

9. Air inlet pressure Expansion Engine P-11 “

10. Air outlet pressure Expansion Engine P-12 “

11. L.N. Buffer pressure P-13 “

12. Waste N2 pressure After H.E.1 P-14 “

13. Air pressure before moisture P-15 “

separator Bottom connection

14. Molecular Sieve drier ‘A’ pressure P-16 “

15. Molecular Sieve drier ‘B’ pressure P-17 “

16. O2 buffer manifold ‘A’ Pressure P-18 “

17. O2 buffer manifold ‘B’ Pressure P-19 “

18. O2 pressure before isolation valve P-20 “

19. Nitrogen buffer manifold pressure P-21 “

20. Nitrogen pressure isolation valve P-22 “

Page 13
21. Nitrogen manifold ‘A’ pressure P-23 “

22. Nitrogen manifold ‘B’ pressure P-24 “

23. Defrost Air Pressure P-25 “

24. Regeneration Nitrogen pressure P-26 “

25. Expansion Engine Oil Pressure P-27 “

26. L.O. Pump Oil Pressure P-28 “

27. L.N. Pump Oil Pressure P-29 “

28. Oxygen Buffer manifold P-30 “

pressure

TEMPERATURE INDICATORS.

S.No. Temperature Indicator

Nomenclature No. Type

1. Air in Expansion Engine T-1 Panel PT-100

2. Air Out Expansion Engine T-2 -
3. Air before R1 T-3 -
4. Air In Heat Exchanger 1. T-4 -
5. Nitrogen Out Heat Exchanger 1. T-5 -
6. Expanded Air entering Lower Column T-6 -
7. Air Out Mixture Exchanger T-7 -
8. Defrost Air Upper Column inlet T-8 -
9. Defrost Air Out De. Heater T-9 Dial
10. Regeneration N2 out from Mol. Sieve Drier ‘A’ T-10 Dial
or Mol. Sieve Drier ‘B’
11. Regeneration N2 in to Mol. Sieve Drier ‘A’ or T-11 PT 100
Mol. Sieve Drier ‘B’

LEVEL GAUGES

S.NO LEVEL GAUGE NOMENCLATURE NO. TYPE

1. Lower Column RL L-1 Panel DP Manometer

2. Upper Column L.O. L-2 -

Page 14
VII. DEFROSTING OF PLANT

Despite air purification by Molecular Sieve, some amount of water vapour and Carbon dioxide will get past
the Molecular sieve Driers and enter the Cold Box. In due course, any Carbon Dioxide or water vapor that
gets pass through the Molecular sieve driers will be deposited as solid carbon dioxide (Dry ice-Sublimation
temperature of - 80 ° C) or ice (water ice freezing temperature 0°C) within the walls of Tubes of Heat
Exchanger, inside the valves, Expansion Valve. L.O. Pump filter and inside the holes in sieve trays. These
solid deposits will restrict the flow of air and will be evidenced by gradual increasing difference between
Air Compressor discharge pressure P-4 and Air Pressure P-1 before R1, in case of excess carbon dioxide
the L.O. Pump suction Filter will get choked. Other symptoms of frosting are fluctuations of pressure and
an increasing difficulty in maintaining the required purity and rate of production. Ultimately the pipes
become so restricted that even when the compressor is working at its rated pressure and flow, the amount of
air that can enter the plant is not sufficient to maintain production and purity. When the above occurs, the
plant must be defrosted which is the process of melting out all of these accumulated deposits.

A COMPLETE DEFROST OF PLANT

1. Initially drain all the liquid from the plant through D-1, D-2, D-5, D-6, D-7, D-8, D-9 & D-10.

2. Check before defrosting that any one of the Molecular Sieve Driers A or B is completely
reactivated. This reactivated drier ‘A’ or ‘B’ should be kept as standby for final cooling and
production of plant after defrost. The other spent drier is to be used for complete defrosting.

3. Then keep the following valves setting (Assume Drier ‘A’ is ready).

(a) Valves closes.

R1, A3, A5, A7, A9, A14, A19,

N2, N4, N5, N6, N7, N8, N9, N10.

O3, O5,

(b) Valves Open

A1, A2, A4, A6, A8, A13 A16, A17, A18,

A20, A 21.

N1, N11

OP-1, OP-2

D1, D2, D3, D4, D5, D6, D7, D8, D9, D10 & D11.

Page 15
 and blinds of 3 way level gauge valves.

VL1, VL2, VL3, VL4, VL5 , VL6, VL10, VL11 & VL12.

R4, R2, R3.

4. In Expansion Engine, lift the inlet and outlet valve push rod by a lever. Place a metallic piece of
about 4 mm thickness in between pestle plunger and push rod. Or remove the valve cap and
remove both the ball valves, (this will allow proper flow of air for defrosting) then refit the valve
cap.

5. Start the air compressor after ensuring cooling water circulation as per air compressor
manual and adjust air pressure to about 30 kgs./cm2 initially by closing compressor
drain valves and valves A1, A2,A13. Adjust air pressure by A1. Start chilled water and
circulating pump and start the chilling unit to bring the water temperature 6 to 8 ° C.

6. Gradually open air inlet to defrost heater valve A 18 watching pressure in P-05. The pressure
should not be more than 0.5 kgs./cm2.

7. Check flow of air in all drain valves D1 to D11 and also after Nitrogen-vent.

8. After about 1/2-1 hour switch on the defrost Air Heater T9 and watch temperature of air, after
Heat, it should not exceed 65 ° C, under any circumstances. This is very important.

9. Check outlet temperature at all defrost outlets. They should be hand warm to a temperature of
about 35 ° C to 40 ° C. The process of defrost may take approximately 6 to 8 hours.

10. After the outlet air all points are hand-warm Switch off the defrost heater.

11. After about 6 to 8 hours, close Defrost Air inlet valve A.18. Open air drains A1 and A2.

12. Stop air compressor. Depressurise all lines and vessels and close all valves of the plant.

13. Do not over heat the plant. If you do so the soldering in the cold box may melt and result in the
total destruction of the cold box.

VIII. START UP AFTER DEFROST.

1. Ensure availability of electricity at normal voltage and enough water level in cooling Towers. &
Tanks. Check oil levels of all running machinery’s are normal. [440 Volts at 50 HZ].

2. Start cooling water circulation pump for Air compressor and ensure continuous water flow at all
outlets.

3. Start chilling coil circulation pump and start the chilling unit to bring the water temperature to
6 C to 8 ° C.

Page 16
4. Rotate flywheel of all machinery’s by hand at least one turn for free rotation. Ensure Expansion
Engine in-let valve A 13 is closed and the 4mm packing on the tappet is removed ball valve
assembly is fitted back.

5. Keep the following valve setting : (Assume drier ‘A’ on line)

VALVES OPEN :

A-1, A-2, A-5, A-14,

N-1, N-3, N-6, N-8, N-9, N-10,

D-1, D-2.

R-2 and R-3 to be kept 10 turns open and open R-4 valves 5 turns.

VALVES CLOSE :

R-1, A-3, A-4, A-6, A-7, A-8, A-9, A-10, A-11, A-12, A-13, A-15,

A-16, A-17, A-18, A-19,

N-2, N-4, N-5, N-7,

O-1, O-2, O-3, O-5, O-6,

Drain valves D-3 & D6.

All pressure gauge isolation valves should be kept slightly open

Level Gauge isolation Valves are to be kept closed.

6. Start the Air Compressor as per Compressor Manual. After attaining full speed, close the
inter-stage separator drain valves, Close A-2 completely. Close A-1 partially, watching air
pressure in P-4, to be about 40 kgs./cm2. Ensure that oil feed to each cylinder is as prescribed in
Compressor Manual. If oil is fed more than required, it will form hydrocarbons and cause
explosion of distillation column. Excess air temperature in cylinders also can cause hydrocarbon
formation.

7. Gradually pressurize Molecular sieve Drier, which is ready for operation (Assume ‘A’)
through valve A3, gradually watching P-5. When P-5 is almost near P-4, open air inlet
to Drier A-3. Sudden pressurizing and depressurizing molecular sieve pellets become powder
and its life will reduce, hence the operation should be gradual.

Page 17
 8. Now air is ready to be admitted to cold box. Open A-11, slowly watching P-1 pressure. Now air
will be blown through drains D-1 and D-2, Blow the air lines a few times by closing and opening
A-11.

9. Similarly blow Mixed Air Line by opening and Closing A-12.

10. There after close A-11, A-12, D-1, and D-2.

11. Now again open A-11 slowly watching Air pressure in P-1, After pressurizing, open A-11
fully.

12. Now the expansion engine should be started electrically. Keep the inlet valve hydraulic system
lever in ‘stop’ position. Oil pressure in P-15 should be at least 1.2 kgs/cm2. Then release all air
locks in hydraulic system. Keep the inlet cam in ‘7th’ position. Bring the inlet valve hydraulic
lever to run position. Now both inlet and outlet valve pestles should work. Open the air inlet
valve A-13, slowly watching P-7 and P-8 pressure gauges. Then A-13 should be opened fully.

13. The lower column pressure P-2 also will go up. During initial start up, the lower column pressure
will be about 2 to 3 kgs./cm2 in P-2 and 0.4 to 0.5 kgs./cm2 in P-3, upper column pressure.

14. After reaching a steady upper column pressure in P-3, regeneration Gas Blower (for 60/80
NM3/hr Plant) should be switched on to regenerate the line drier, After checking drier cycles,
heating should be started.

15. Then Nitrogen to the evaporation cooler should be admitted by opening valve N-2. Valve N-1
must be closed watching upper column pressure, If there is excess water in evaporation cooler, it
will generate a back pressure on upper column P-3, which should not exceed 0.5 kgs./cm2,.
Ensure that Nitrogen pipe just dips into water in the evaporator cooler.

16. Now watch air pressure in P-1,P-2,P-3 and P-4. They should be steady. Slowly increase air
pressure in P-4 by closing A-1 gradually, so that, discharge pressure in P-4, is about 55 to 57
kgs./cm2. Take care that P-2 and P-3 does not go up. Also watch warmth of expansion engine
cylinder if new piston rings have been used. If it is warm, reduce air pressure slightly, and flew
Nitrogen to cool the Cylinder or cool it with Blower or whatever is the excess air being bled
through A2 valve can be utilised for cooling the engine cylinder

17. start cooling. After about 2.1/2 to 3 hours T-1 will reach -90 ° C and T-2 will reach - 140 ° C.
When T-2 Temperature comes to -120 ° C start closing R-4 valve, and fully close it when T-2
Temperature is -140 ° C

18. By now, we would have advanced the Expansion Engine Cam position from 7 to about 5 or 4
depending upon the increase in air pressure in P-2 and P-3, when we reduce Cam position, the
inlet pressure will go up and the outlet pressure will come down and vice versa. In higher cam
position, more air will be handled by Expansion Engine but the temperature drop will be less
and vice-versa. When starting the plant, even when the expansion machine is operated in Cam 7,
the pressure will be very high . The pressure at P-1 will be high (50 kgs./cm2) as the warm air
volume is large. As air contracts due to cooling after the first heat exchanger the pressure at P-1

Page 18
 will drop gradually and the Cam position are adjusted to make it gradually. maintain a high P-1
pressure. After about five hours operation, the liquid will appear in Lower Column
and P-1 pressure will continue to drop. The Cams are then shifted opposition
3,2...etc., to adjust to sustain high pressure at P-1 and obtain maximum purity, hence the plant
is sufficiently cool. 19. When T-1 is -90 ° C to -100 ° C and when T-2 is -140 ° C Open R-1
valve slightly. Then watch T-3 temperature. This will start cooling down.

19 When T-3 temperature before R1 reaches -140 ° C/-150 ° C. Open R1 slightly more without
upsetting T3. Half an hour after this, liquid air will start forming in Lower column. In the recent
oxygen plants T6 temperature point has been provided at the air entry point to the bottom
column. When the Temperature is -174 ° C rich liquid appears in the bottom column.

20. Now level gauge L1 of lower column should be lined up. Slowly open VL 17 and VL 18
simultaneously and close VL 19. Level will start to rise in L1

21. 1 hour or 1.1/2 hours after this, liquid oxygen will start forming in Main condenser.

22. Now line up Upper column level gauge (L2) by opening VL 20 and VL 21 gradually at
the same time and close VL 22. The level of Liquid Oxygen will start increasing.

23. It is a good practice to drain a little amount ( about 10 cm of R.L and L.O). Initially to flush
Lines by opening D4 and D5.

24. When Upper Column level in L2 has increased to about 50 cms. Setting R-2 and R-3 valves. The
Controlling should be such that due the Level will fall down and again rise to say about 1cm.

25. When R-2 is about 2 turns open and R-3 is about 1 turn open. Check the Oxygen purity by orset
apparatus by collecting sample from D-11 valve.

26. Oxygen purity should be more that 99% before starting production. As per I S I the product is
Oxygen when purity of Oxygen about 99 %.

27. To increase Oxygen purity, R-2 is to be slightly closed.

28. After attaining good Oxygen purity and having good level, open Oxygen valve O2 and then O-1
valve gradually. Now Liquid Oxygen is allowed to enter L.O. pump. Keep watch on pressure P3.

WARNING-- Since the pump jacket is warm, Large entry of Oxygen in the pump will vaporise
liquid Oxygen and increase the P3 pressure.

29. When level has again risen after a drop, we are ready to start L.O. pump

30. Open valve O-4 and close valve O-3.

31. Before starting L.O. pump, check free rotation by hand. Clean the L.O. Pump piston with C.T.C.

32. Start the L.O. Pump and check oil pressure for crank lubrication in P-16 pressure gauge it should

be about 0.70 kgs./cm2.

33. Now check for flow Oxygen in vent O-4.

Page 19
34. Then open O-3,O-5,O-6 and loosen all bull nose connections to cylinders. Close O-4. Now,
product Oxygen lines will be purged.

35. There after close O-4, O-5, O-6 and tighten bull nose connection. Keep Open cylinder valves.
Individual connection valves. Now buffer manifold cylinders will be filled.

36. Once buffer manifold cylinders are filled, upto 140 kgs./cm2, filling in main manifold lines can
be started.

37. Rate of production can be checked by time taken for filling a set of known capacity
cylinders.

Note : R-4 valve has been provided to reduce the cooling time of the plant after defrost and long shutdown
of above 4 to 6 hrs depending upon the duration of the stoppage time it should be so opened that the
bottom column pressure remains at 2 to 3 kg/cm2 this valve should be fully closed when T-2 temperature
reaches -140 ° C to -150 ° C.

IX. START UP AFTER SHORT SHUT DOWN

1 When plant is stopped for short time, either due to electricity or Maintenance or cooling water
failure, the start up is not very lengthy as earlier.

2. Keep the following starting conditions : (Assume Drier ‘A’ on line)

VALVES OPEN :

A-3, A-6, A-8, A-14,

N-1, N-3, N-5, N-7, N-8.

O-1, O-2, O-4, R2 and R3 Turns open or as per condition of the plant duration of stoppage hours.

VALVES CLOSE :

R1, A-2, A-4, A-5, A-7, A-9, A-10, A-11, A-12, A-13, A-15, A-16, A-17,
A-18, A-19, A-20, A-21, A-22, A-23, A-24, A-25, A-26.

N-5, N-7,

Drain valve D-1 to D-5.

All pressure gauge isolation valves should be slightly opened and level gauge bypass valves are to
be opened.

3. Start the air compressor after ensuring cooling water supply. Close inter-stage drain valves and
adjust air pressure in P-02 to about 40 kgs./cm2 by valve A1.

Page 20
 4. Pressurize drier which was on operation (Assume ‘A’ by opening A-3) After pressurizing open
A-3 fully.

5. After pressurizing Drier, gradually open A-11 and pressurize Heat Exchanger watching
P-02 pressure. After pressurizing open A-14 completely.

6. Start Expansion Engine. Set hydraulic system and pressure properly. Keep cam around 3-4
position. Open air inlet valve A-16.

7. Watch P-1, P-2, P-3 P-4, P-5 &P-6 pressure. When pressure are normal start drier
regeneration and Nitrogen blower, Start drier heater if required.

8. Admit Nitrogen to evaporation cooler by opening N2 and closing N1.

9. Watch temperature T-1 and T-2 when they are -100 ° C/ -90 ° C and -140 ° C
respectively open R-1 valve.

10. Control R-2 and R-3 valves watching Upper Column level in L-2 .This should be done gradually.

11. Check Oxygen purity after setting R-1, R-2, R-3 valves and Expansion Engine cam
setting are complete.

12. When purity is normal then cool the L.O Pump about half an hour. Start L.O. Pump. Keep the
pump discharge pressure to about 50 kgs/cm2, this is done by controlling the R-7 & R-8 valve.
Start filling cylinders as mentioned earlier.

X. NORMAL RUNNING OF PLANT.

In the operation of any Oxygen plant, it is better not to disturb operation much. Normal operation of plant is
best known by experience in individual plants. However, the following are guidelines.

Air Compressor liner-stage separator drains and moisture separator drains are to be opened and closed,
every hour, to let out condensed moisture. All readings should be noted in a prescribed Log Sheet. A format
of the same is enclosed with the manual. Molecular sieve Drier heating and Cooling cycles are to be taken
care (Refer MS Drier Chapter.)

The Manual for Operation & Maintenance of Air compressor is supplied by Air Compressor Manufacturer
separately. Please ensure the running of Air Compressor as per their Manual. Please ensure that oil
pressure switch is operational.

The rare gas vent valve D-7 should be kept slightly open to allow non-condensed rare gases to escape from
Lower Column. It is better to be bubbled through water kept in bottles of through a small . It should be
approx. 120 bubbles per minute.

Page 21
After starting the plant, the air pressure is to be brought down slowly to about 35 to 40 kgs./cm2, by further
opening R-1 or by bringing up the inlet cam position of Expansion Engine to 3 or 2, from 1. This will
increase production slightly. However, the upper column level .L-2 and purities should be maintained. The
plant can be maintained steadily if the upper column liquid level, column pressure, air pressure are
maintained properly. Every half an hour product Oxygen purity should be checked by drawing sample gas
from D-11.

If any hydrocarbon (Particularly Acetylene) is present, in the atmospheric air, or is found due to excessive
heating of the air compressor oil, the Acetylene will settle as solid crystal, in the condenser. Acetylene
crystals in liquid Oxygen can explode spontaneously, causing serious accidents. Therefore, once in 8 hours,
liquid Oxygen and liquid air should be drained little, in order to avoid accumulation of Acetylene. Excess
presence of Acetylene in liquid Oxygen can cause explosion. In 5-litres of liquid Oxygen , presence of
more than 5 milligrams of Acetylene (C2H2) or 200 mgs, of other Hydrocarbons are hazardous. Analysis
for presence of Acetylene is explained separately and analysis should be done in each shift. In any case the
Acetylene content should not be more than 2 P.P.M., if it is above 2 ppm then immediately stop the Plant
and put for defrosting.

If Acetylene is found to be present, the liquid is to be drained to reduce contamination. If Acetylene still
persists in the Liquid Oxygen, the Plant must be stopped immediately. All liquid should be drained and the
plant should be defrosted.

The standard operating conditions are the following, but they differ from plant to plant
P-1 40-45 kgs./cm2 T-1 -100 ° C to -110 ° C
P-2 4.8 kgs./cm2 T-2 -158 ° C to -168 ° C
P-3 0.5 kgs./cm2 T-3 -150 ° C to -155 ° C
P-9 60 -65 kgs./cm2 T-4 +25° C to +15 ° C
P-4 42-47 kgs./cm2 T-5 +22 ° C to +10 ° C
P-13 0.5 kgs./cm2 T-6 -174 ° C to -180 ° C
P-14 0.2 kgs./cm2 T-7 -150 ° C to -125 ° C
L-1 50-100 mms T-8 -80 ° C to -110 ° C
L-2 360-500mms.
Exp. Engine inlet cam - 1 to 3.
R-1 valve - 0/4 to -0/6
R-2 valve - 1/10, 2
R-3 valve - 0/4 to 0/10 .

If liquid levels drop and if the plant is getting warmed up, throttle R-1 valve and bring down Expansion
Engine Cam position to increase cold production. When cam position is brought down from upper number
to lower number, the air inlet pressure will go up and outlet pressure will come down. The air throughout
will also come down. Therefore, temperature drop across Expansion Engine will go up. Similarly, if inlet
cam number is brought up to higher number, air inlet pressure will come down and outlet pressure will go
up. Air throughout will go up but temperature drop across Expansion Engine will be less.

The purity of Oxygen should always be maintained. To increase Oxygen purity, the plant can be slightly
warmed up or R-2 can be slightly closed. When upper column level is constant the purity also will be
constant

Page 22
Cylinder filling should be checked. There should not be any gas leaks. Avoid using oily waste or oil in
filling procedure. Change cylinder valves if found contaminated with oil or grease.

Water level should be maintained just to deep N2 pipe in Evaporation cooler.

XI. SIMULTANEOUS OXYGEN & NITROGEN PRODUCTION.

To get simultaneous Oxygen and Nitrogen production, gradually open mixed Gas Outlet valve to half turn.
Mixed air valve should be gradually opened to half turn, watch temperature T-7 and it should be around
-150 ° C to -160 ° C. Adjust poor Liquid. (Lower column Nitrogen) purity by closing R-3 valve, to just
about half turn open. The lower column Nitrogen purity should be about 99% to 99.5%.

After about 1/2 hour, the upper column Nitrogen purity will increase. Keep checking Oxygen purity also. If
Oxygen Purity is dropping, close R-2 valve slightly. The Oxygen production will drop down by about 6 to
10 M3/hr. The mixed gas flow should be maintained to about 12 to 40 M3/hr.

During defrosting, Mixed gas line and air line also should be defrosted.

XII. PLANT SHUT DOWN

Plant can be shut down under various circumstances. Therefore the same is instructed under different
categories such as,

(a) Normal (planned) Shut Down.

(b) Emergency Shut Down in case of power failure, cooling water failure or Air Compressor
trouble or any other running machinery failure and
(c) Shut down in case of only Expansion Engine failure.

(a) NORMAL PLANNED SHUT DOWN

1. Stop Oxygen Cylinder filling when a particular batch is over and vent Oxygen Close
valves. O-3, O-5, O-6 and Open O-4 valve.
2. Stop L.O. Pump and close O-1 and O-2 valves. Drain liquid Oxygen through D6 valve
3. Open Nitrogen vent N-1 and then close N-2.
4. Stop drier heater and Nitrogen blower.(Nitrogen blower not required in 100 m3/hr ).

5. Reduce air pressure by opening A-1 by about 1/2 to 1 turn.

6. Close A-13 and stop Expansion Engine.
7. Close A-11 air inlet valve.
8. Close drier air inlet and outlet valve.
9. Open all separator drains and inter stage drains of air compressor.
10. Stop the Air Compressor.
11. When Air Pressure in P-1 come down close R-1 valve and isolate level gauges valves
VL-17, VL-18, VL-20 and VL-21 open VL-19 and VL-22.
12. Stop cooling water circulation after 15 minutes.

Page 23
(b) EMERGENCY SHUT DOWN

1. Stop Drier Heater and Nitrogen Blower

2. Open valve N-1 and close N-2.
3. Stop Expansion Engine Electrically and bring hydraulic system lever to stop position.
Open A-1 valve.
4. Stop L.O Pump electrically and close O-3 and open O-4.
5. Open air drain valves A-1 and A-2 stop air compressor.
6. Close valves A-11, A-13, R-1, Drier Air valves, O-5, O-6 Level Gauge valves.
7. R-2 & R-3 valves should not be closed & N-1 valve should be open.

(c) SHUT DOWN IN CASE OF TROUBLE IN EXPANSION ENGINE

1. Open Air drain valve A-1, by one turn.

2. Stop drier heater and Nitrogen blower.
3. Open N-1 and close N-2.
4. Stop L.O. Pump electrically.
5. Expansion Engine inlet valve hydraulic system lever is to be brought to stop position.
6. Stop Expansion Engine electrically.
7. Watch air pressure not to exceed limits
8. Close R-1 valve.
9. In case of short maintenance A-11 and Drier Air Valves need not be closed and air
compressor can be kept running. Otherwise they are to be shut.

XIII. MOLECULAR SIEVE DRIERS

TECHNICAL DATA SANGHI ORG 200 SANGHI ORG 300

Type of Adsorbent Molecular Sieve Type 13-X Molecular Sieve Type 13-X
Quantity of Molecular sieve 165 kgs. per each drier + 20kg 430 kg + 20kg Alumina
Alumina Quantity of 931 M3/hr for 8 hours 1380 M3/hr. for 8 to 10 hrs.
Air handled
Heating time 2 ½ Hours 2.1/2 - 3 hours
Cooling time 5 ½ hours 5 ½ hours
Change over time 1.1/2 hours 1.1/2 hours
Heating Inlet temp Min. 280 ° C. to Min 280 ° C to
Max 350 ° C Max 350 ° C

Heating Outlet temp Min 110 ° C to Min 110 ° C to

Max 140 ° C. Max 140 ° C.

Cooling outlet temp. Min 30 ° C to Min 30 ° C to

Max 40 ° C. Max 40 ° C.

Main air inlet temp Min 8 ° C to Max 10 ° C Min 8° C to Max10 °C

Air pressure Min 35 kgs/cm2 to Min 35 kgs./cm2 to

Max 60 kgs./cm2 Max 60 kgs./cm2

Page 24
Max. permissible carbon in 0.03% 0.03%
atm. air. 50% to 70% relative 50% to 70% relative in
humidity at 15 ° C humidity at 15 ° C

Heater capacity 27 KW 30 KW

Heater Voltage supply 440 V. + 5% 440 V. + 5%

Heater Individual ammeter 53 amps each 60 amps each

reading

Blower Motor H.P. Not required Not required

Blower Power supply 440 V. + 5%

Blower pressure

Nitrogen pressure 0.2 to 0.3 kgs/cm2 0.16 to 0.3 kgs./cm2

DESCRIPTION :

Each vessels of the molecular Battery is filled with Molecular sieve of 1.5/3 mm Type 13-X. As the process
air passes through the Molecular Sieve the Molecular sieve will adsorb water vapour and Carbon dioxide
[CO2] from the air. After some 8-10 hours, the Molecular sieve becomes saturated and it will have to be
regenerated.

If hot Nitrogen air at low pressure passed through the saturated molecular sieve, the Molecular Sieve will
discharge the CO2 and water vapour and is ready for use again. The adsorbing capacity of the Molecular
Sieve drops rapidly if the process air is warm. Therefore, ensure that the compressed air entering into the
Molecular Sieve is below 10 ° C and that the Molecular Sieve is thoroughly cooled after regeneration,
before the process air is passed through it again.

REGENERATION :

The waste Nitrogen from the Cold Box is passed through an Electrical Heater of about 13.5/18 KW and
then passed through the vessel to be regenerated. The Temperature at the inlet of the vessel will rise
rapidly, while the outlet temperature will rise very slowly. If the inlet temperature exceeds 320 ° C the
heater must be put off and put on again (Automatic Temp. indicator controller is provided). When the outlet
temperature reaches 100 ° C (for about 2 to 2.1/2 hour) the Molecular Sieve is regenerated. This process is
known as the heating cycle, which will take 2 to 2.1/2 hours. At this stage, the heater must put off, but the
cold Nitrogen will continue to pass through the vessel cooling the Molecular Sieve. This process is known
as the cooling cycle which will last about 4 to 5 hours. After cooling, the vessel is ready for use when
required for purifying the process air.

Molecular Sieve is a very expensive material, and should be carefully used. The following will ensure its
long life.

Page 25
(a) Oil vapour will destroy the Molecular Sieve and therefore ensure that the carbon filter is in good
condition and the process air is as cool as possible, that maximum oil and moisture condenses out
before the air enters the vessel. Maintain air inlet temperature to the molecular sieve battery
between 6 ° C to 10 ° C. Inspect the Activated Carbon in Carbon filter at an interval of Six
months and replaced it with fresh one if found necessary contamination of in it

(b) While changing from one vessel to the other, pressurise the vessel very slowly, by opening the
valve A-7 or A-8. It may take half an hour for the vessel to pressurise. If the main valves are
opened rapidly, the Molecular Sieve may break up, due to high pressure air propelling the
Molecular Sieve in the vessel.

(c) When charging fresh Molecular Sieve, lower the same through a pipe, so that it does not break
on falling at the bottom.

Most of the plant operating problems are caused by the carry over of CO2 into the cold box and its
blocking the Heat Exchanger, Satisfactory working of the Molecular Sieve drier will avert all these
problems. Therefore, maintain and operate this equipment carefully.

The drier valve seats should be in perfect condition and if the air passes through valve seat both production
of plant and regeneration of driers will be effected

IMPORTANT :

The heater should immediately be shut down either in case of plant shut down or Expansion Engine
shut down. Otherwise, water and water vapour will be drawn from Evaporation Cooler by the
Blower and will flood the Heater and the drier with water.

1 DRIER CHANGE OVER

When cooling is complete, the regenerated drier is to be lined up, as the other drier would have become
saturated by now, First, the Nitrogen blower is to be switched off. The Nitrogen valves of regenerated drier
are to be closed. Then the regenerated drier will first be pressurized through pressuring valve. The
pressurizing should not be sudden neither it should done with main air inlet valve. The molecular sieve
pallets will get disintegrated soon if pressurizing and depressurizing is sudden.

After pressurizing open air inlet valve completely. Open air outlet valve gradually, watching the outlet air
temperature. This temperature will initially go up and thereafter will cool down. Then open the outlet valve
completely. Start closing the outlet valve of the drier on line, taking care of common air outlet temperature.
Then close air outlet and inlet valves of drier which was on line tightly. Depressurize the drier by
depressurizing valve. The depressurizing of the Drier is also done by opening valve A-7 or A-8 and A-9 .
It may take half an hour for the Drier to depressurize. Then open the Nitrogen Valves of the drier to be
regenerated. Start the Nitrogen blower. Check flow of gas at the regeneration Nitrogen vent. Then switch
on the drier heater for starting heating cycle of drier. Check for proper performance of drier heater.

Page 26
 DRIER CHANGE OVER (IN SHORT).

Imagine No.1 drier is ready after regeneration. (in case of No.2 Drier adjust the valves given in brackets.)

1. Stop Nitrogen Blower.

2. Close N-5 and N-7 (N-4 & N-6)
3. Close A-10 and Open A-11 and A-9.
4. Watch P-17 to increase gradually for 1/2 an hour. (P-16)
. When P-17 and P-16 are almost equal, open A-9 (A-8)
6. Close A-6, A-8 and A-11.
7. Open A-12 slowly, watch T-4 (A-6)
8. After 15 minutes open A-12 fully and start closing (A-6, A-8)
A-6 slowly
9. After 15 minutes close A-6 and A-8 completely (A-6, A-3)
10. Open A-7 and A-9 (A-6, A-8)
11. P-16 will come down. (P-17)
12. When P-16 reads minimum, open N-4 & N-6. (P-17, N-5, N-7)
13. Start Nitrogen Blower
14. Start Drier Heater and watch T-11.

REPLACEMENT OF MOLECULAR SIEVE.

Molecular Sieve is to be replaced if :
(a) It becomes powder.
(b) If it gets contaminated by oil or oil vapour.
(c) If it looses its adsorption capacity.

The above will be known by frequent checking of Cold Box Equipment. To change Molecular Sieve, open
the top and bottom flanges of drier vessel. Remove the filter at the bottom. Collect the old Molecular Sieve,
which will fall down. Clean the filters, blow the drier vessel Fit the bottom filter, charge about 3 kgs. (10
kgs) of Alumina. Then charge Molecular Sieve Type 13X, size 3 mm, about 100 kgs in 80 Cu.m/hr & 150
kgs in 100 Cu.m/hr O2 plant. The Molecular Sieve should be sieved and be free of all smaller size particles.
It is better to charge through a long funnel so that molecular sieve does not fall with a force and break.
Charging is normally done by hand. When level of Molecular sieve is just at the domed portion fill with 10
kg alumina. Fit the top filter after cleaning . There should be 1” gap between Aluminia & Filter.

XIV. EXPANSION ENGINE :

TECHNICAL DATA SANGHI ORG 200 SANGHI ORG 300

Type of Expansion Engine SEM 0.5/1 SEM 0.5/1

No. of Cylinders 2 2
Diameter of cylinder bore 80mm 80 mm
Piston stroke 125 mm 125 mm
Speed 210 RPM. 210 RPM.
Inlet air pressure 60 kgs./cm2 60 kgs./cm2
Outlet air pressure 5 kgs./cm2 5 kgs./cm2

Throughput volume at 60 kgs./cm2 560 NM3/hr 828 NM3/hr

Page 27
and 8 ° C (about)

Throughput volume at 50 kgs./cm2 400-560 NM3/hr 550-830 NM3/hr.

and -75 ° C (about)

Inlet valve opening time cam setting 8 8

positions

Power required or supplied 30 KW 30 KW

Piston head clearance 1.2 + 0.2 mm 1.2 + 0.2 mm
Inlet valve pestal clearance 0.4 to 0.5 mm 0.4 to 0.5 mm
Outlet valve pestal clearance 0.3 to 0.4 mm. 0.3 to 0.4 mm

DESCRIPTION :

The Expansion Engine is a vertical single-acting reciprocating type engine. This produces the cold required
for operating the plant. The high pressure air enters through inlet valve at the start of downward stroke of
the piston. On further downward motion, the inlet valve closes and entrapped air expands. During upward
stroke, outlet valve remains open and inlet valve remains closed.

Therefore, in downward stroke air enters the cylinder and expands, In the upward stroke the expanded air is
pushed outside. The electric motor is used initially to start the machine. Thereafter the engine is moved by
the air pressure itself and during which time, the engine motor retains the speed by acting as a brake. Since
work is done by air in rotating the flywheel. It loses its heat content (enthalpy) . Thus the air gets cooled.
This cooling is more than that of an expansion in an expansion valve.

An elementary factor for function of Expansion Engine is to use dry and Carbon Di-Oxide free air, as
otherwise, ice and dry ice will form on valve seats, causing malfunctioning. Dry ice entering the cylinder
will damage PTFE piston rings and score the liner.

The approximate temperature drop across Expansion Engine is 50 to 70 ° C depending upon inlet air
pressure, temperature and inlet cam position.

The Expansion Engine can be considered as three major units :

(a) the drive unit

(b) the cylinder unit for air expansion and
(c) the hydraulic system for operating the valves.(inlet & outlet ball valves.)

The drive unit is similar to any reciprocating machine with usual parts, such as, crank case, crankshaft,
connecting rod, crosshead, etc. The Expansion Engine has an extended crankshaft to enable to
accommodate the cam. The moving parts are lubricated through a hole in crankshaft . Oil scrapper rings are
provided to prevent oil escape to cylinder unit.

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The cylinder unit handling process air consists of cylinder, piston, inlet and outlet isolation valves,
assemblies. The ball valves are actuated mechanically by push rod as per the timing transmitted by the cam.
The push rods are housed in stuffing box to avoid air leakage and is actuated by the hydraulic system.

The hydraulic system is the control system. As per schematic sketch enclosed the hydraulic oil is fed by a
pump to (a) Pressurised Oil container for valve actuation (b) to lubricate crankshaft and drive unit parts,
and (c) to lubricate the roller holders. The pressure at P-5 should be 1.5 to 2 kgs./cm2 and can be adjusted
by a valve mounted on the pump. The oil specification should be viscosity 6.5 ° C and specific Gravity 0.9
kgs./cm2. Flash point of at least + 175 ° C solidifying point of atleast -5 ° C . This requires an addition of
Silicon De-foaming Agent of 1-2 drops per liter of oil. Recommended oil is ENKLO-68 or equivalent.

Oil from pressurised oil container is fed to two control oil push pumps for inlet and outlet. The outlet valve
cam rigid with one cam position creates a to-and-fro motion on the roller holder of the push pump . This
motion is received by the pistons of the push pump and develops an oil pressure pulsation. This pulsation is
transmitted to valve piston though a piping. The piston in valve pestal again transmits the pressure
pulsation into a mechanical to and fro motion . As the piston of valve pestal is in line with the push rod, the
ball valves are operated. Similarly, the inlet valve push pumps operates the inlet ball valve as per the cam
setting. The inlet valve cam has 8 different cam setting and the required cam setting is set by the selector
arrangement.

TO CHANGE CAM POSITION :

(a) release locking device of cam setting
(b) change cam position by turning cam selector wheel
(c) Check cam position by noting the pointer on cam number
(d) lock cam setting device by tightening lock handle on cam selector. The effects of different cam
setting is mentioned in the plant start up procedure.

The Expansion Engine inlet ball valve is brought to close position by bypassing oil pressure pulsation /
displacement from inlet push pump to pressurised oil container by an unloaded valve or by solenoid valve
electrically operates.

There are air release valve at each valve pestal. During initial start up, air should be released : (a) at air
released plug of oil pressure container (b) at oil pressure gauge valve VP-15 and (c) at air release valves of
valve pestales. There should be no leaks in hydraulic system for best performance of engine.

SAFETY :

If the power supply to the Expansion Engine should fail, there would be no breaking of the engine speed,
which will rise rapidly. To prevent such contingencies, the following two safety features have been
provided

Page 29
(a) If the power supply fails, a solenoid valve will operate in oil system, closing the inlet valve to the
Expansion Engine.

(b) A lever load/unload valve is provided in the Expansion Engine, which can be operated by hand.
This too will close the air entry to the engine and can be operated by the operator when required.

(c) Release of pestal of inlet ball valve can be used for controlling the speed.

A safety valve (bursting disc) is provided in the air outlet line before air out isolation valve A.

This safety is set to blow at 8 kgs./cm2.

Nitrogen purge is provided in distance place below cylinder and in valve pestal housing to prevent
atmospheric moist air to form ice on colder parts.

Page 30
OPERATION :

(A) Start Up :

1. Check oil level in crank case, cam case and pressure oil container.
2. Open air outlet valve, Nitrogen purge valve and oil feed valve to control push pumps.
3. Start the motor and check direction of rotation.
4. Observe oil pressure and release air locks.
5. Check outlet valve lifting and inlet valve.
6. Open air inlet isolation valve slowly.

(B) Normal run :

1. Check for oil levels, oil pressure, oil leaks, air lock in oil system and mal-function of
hydraulic system and set right.
2. Check if valve lifting is normal
3. If stuffing box of valve push rods are leaking the same should be attended..
4. Avoid temperatures less than -165 ° C
5. Check that the cooling is proper by observing temperatures T1 & T2.
6. Change inlet valve cam position. If necessary, as detailed in plant start up.

(C) Shut Down :

1. Unload inlet valve pestal by operating load/Unload valve in hydraulic system.

2. Stop Motor.
3. Close air inlet valve.

MAINTENANCE :

(a) Changing of piston Rings :

Normally the Expansion Engine piston Rings wear out in about 3 to 4 month’s time. They have to be
changed. The rings wearing out can be noticed by excessive air leak, at the bottom of Engine Cylinder. If
the cover plate of the distance piece is removed the leak can be felt.

Isolate Engine by closing the main inlet and outlet isolation valves (A-13 & A-14) . Open the cylinder head
on top of the Engine. Remove the oil scraper rings. Its housing is to be dismantled from the crank case, and
is to be kept lifted up. Rotated the fly wheel to attain top dead center. Remove the stud nuts of the piston
rod bottom mounting flange. Hold the piston in position by lever and rotate the flywheel, so that the cross
head gets disconnected from piston rod. Unscrew the piston rod mounting flange from piston and also
remove the oil scraper housing. Now, the piston can be lifted up from the top by using eye-bolt threaded to
the top of the piston. The piston rings and the guide rings are to be changed if worm out. While placing the
new rings, take care that the play between but joints of a ring is about 0.4 to 0.5 mm. The ring gaps are to
be staggered at 120 °C. Now the piston with piston rings should be inserted in a false liner provided for
the purpose of maintenance. This liner with piston ring assembly inside is to be placed on top of cylinder,
such that, the liner is in line with the cylinder. Now push the piston rod along with the rings, so that, the
rings slide from the liner to main, cylinder. without distortion or expansion. After the piston has been
pushed completely inside the main cylinder, the liner provided for the purpose of ring insertion is to
removed.

Page 31
Insert the scrapper ring housing inside the piston rod and then thread in the mounting flange on the piston.
Tight the flange with stud bolts of the cross head. Fix the oil scrapper ring housing and oil scraper ring

Rotate the flywheel and check for free rotation. Place the small place of lead on top of the piston and fix the
cylinder head. Now rotate the flywheel for atleast two rotations. Remove the cylinder head, check the
thickness of lead which indicates the head end clearance. This should be above 1 mm, and less than 2 mm

(b) Valve maintenance :

The inlet and outlet ball valve should be maintained properly for efficient performance of the Expansion
Engine. The valves can be opened by opening the Cap, nut of the press screw. Then loosen the press screw.
Remove the valve top block by unscrewing. The ball valve assembly can now be taken out by using a small
eye-bolt. The ball valve assembly is to be dismantled & checked for spring tension, for no scratches either
on the ball or on the ball seat. Reassemble the valve after cleaning with C.T.C. The whole assembly can be
assembled in the manner it was opened.

The clearance between the valve hydraulic pestle and the push rod of the ball valve should be such that it
has 0.4 mm to 0.5mm in inlet and 0.3mm to 0.5 mm in outlet. To check the same, remove the spring in the
ball valve assembly and fix a solid wooden piece and tighten the valve assembly. Also tighten the valve top
block. Using a lever, lift the push rod, Measure the clearance between the push rod and piston of the
hydraulic valve pestal, using a feeler gauge. To vary the clearance the checknut of the screw on the top to
the piston of the hydraulic valve pestle is to be loosened. Then either by tightening the screw or loosening
the screw, the clearance can be varied. After setting the clearance, the checknut of the screw is to be
tightened. After every maintenance of the ball valves. It is better to check the clearance of the push rod

Also ensure that the ball valve assembly is leak proof from the ball and the seat. If the leakage is observed
then the ball seat should be lapped properly to ensure that it is leak proof.

CAUTION:- Please do C.T.C. wash of the components before taking it for assembly.

Page 32
XV. LIQUID OXYGEN PUMP.

TECHNICAL DATA SANGHI-ORG-200 SANGHI ORG-300

Type of pump IL / IK / 100 / 26 IL / IK / 100 / 30

Number of cylinders 1 1
Cylinder diameter 26 mm 30 mm
Piston stroke 100 mm 100 mm
Speed 125/150 RPM. 125/150 RPM.
Suction pressure 0.5 kgs./cm2 0.5 kgs./cm2
Discharge pressure (final max) 165 kgs./cm2 165 kgs./cm2
Operating Temperature -183 ° C -183 ° C
Normal delivery 200 to 220 NM3/hr 300 to 350 NM3/hr
Driving capacity required 7.5 H.P / 5 KW 7.5 H.P./ 5 KW.

MOTOR.

(1) DESCRIPTION

The liquid Oxygen pump is a single stage, single acting piston pump. It is used for filling Oxygen into
cylinders upto a pressure of 165 kgs./cm2

The pump is designed for assembly in air separation unit. It works by pumping liquid Oxygen and
gasifying the same in Heat Exchangers for final filling as gas in cylinders. Control of liquid feed is not
necessary, because the pump is designed in accordance with the plant size and the liquid produced is
constantly pumped off.

The drive unit is similar to any reciprocating machine with the crankshaft, fly wheel connecting rod, cross
head etc.

The liquid Oxygen pump consists of a stainless steel liner with liquid inlet and evaporated gas outlet port.
There are no valves on these ports and are closed by the piston itself on the pressure stroke. The third
outlet is the main discharge outlet with the two non-return ball valves. The two ball valves remain firmly
closed during suction stroke, due to high pressure in partly filled cylinders. To ensure that these valves are
fully closed, a positive pressure of about 60 kgs./cm2 must be maintained on it. When a fresh batch of
cylinders in taken for filling, open the manifold valve slowly or use a spare batch of cylinders to ensure
positive pressure on these valves. Most malfunctions of the pump are due to these valves not closing
properly.

When the pump is operated Liquid Oxygen from the Main condenser enters the outer jacket of the pump.
Some of this liquid evaporates due to heat produced in pumping and the vapour is passed out through the
upper port back into the upper column as gas. The main stream of Liquid Oxygen is taken into the pump
cylinder and compressed out by the piston in the pressure stroke. This high pressure liquid Oxygen passes
through two non-return valves into the heat exchangers and then to the cylinder in filling rack.

Page 33
If the Molecular Sieve is not functioning properly, some Carbon Dioxide as dry ice will travel to the L.O.
pump inlet where a filter is provided. The solid Co2 may block the filter and the pump will not operate
efficiently.

In such an even the L P Pump should be defrosted. This way the solid Carbon Dioxide will be removed
and the pump will now work satisfactorily unless there is a continuous carry over of CO2 Drain a little L O
in a double glass vessel and check again light. If the Liquid is turbid there are CO2 crystals, in it if it is
clear the fault is elsewhere.

LUBRICATION.

Before starting the crank case is to be filled with oil two thirds (2/3) of oil level gauge though the breather
in the back side. The oil specifications are : Viscosity 6.5 Engine at +50 ° C. Specific gravity 0.91
kgs./cm2, Flash point +175 ° C and solidification point Max. 0 ° C. The oil is to be changed in 1000 hours.
Recommended oil is ENKLO - 68 or equivalent.

Oil is sucked from crank case through Magnetic Mesh Filter by gear oil pump, which is directly driven by
crank shaft. There is a pressure regulating valve in the pump. The pressurised oil enters a pressurised
chamber and enters oil hole drilled through crank shaft, big end bearing connecting rod cross head pin and
cross head. An oil pressure gauge, P-16 is provided which should normally be 0.5 to 1 kg/cm2.

The end bearing of crank shaft or the two roller bearings are lubricated by splash of oil by the crank shaft.
To avoid any escape of lubricating oil oiling the piston rod, rubber ‘O’ ring is provided around the piston
rod. This ‘O’ ring is held in position by a cover plate at front side (Piston end side) of crank case.

In spite of this precaution oil wetting of piston rod is to be checked often. Remove oil film if any by
spraying Carbon Tetrachloride. Any escape of oil from drive unit to pump side should immediately be
attended to. As a precaution, before the pump, the piston rod should be cleaned with CTC (Carbon
Tetrachloride).

OPERATION

1. Open return Oxygen gas vent (0-2) gradually, watching upper column P-3 pressure.
2. Open Liquid Oxygen inlet valve 0-1 gradually. The level in upper column L-2, will fall
down initially and then wait till it again builds up.
3. Check for liquid-flow by opening valve D-6.
4. Open valve 0-4 and close 0-3.
5. Check free rotation of fly wheel by hand. Clean L.O. Pump piston with CTC. Open Nitrogen
purge for stuffing box.
6. Start L.O. Pump Motor. Check for right direction of rotation. It should be anticlockwise when
viewed, from flywheel side.
7. Oil pressure P-16 should build upto 1.0 kgs./cm2, If not release air through pressure Gauge valve
P-16.

Page 34
8. Check for flow of Oxygen in vent after 0-4.
9. Open 0-3, 0-5, 0-6 and loosen all ball nose connection and purge the product Oxygen.
10. Thereafter close 0-4, then close 0-5 and 0-6 and tighten bull noose connections.
In buffer manifold, keep open cylinder valves, individual connection valves, Now fill
buffer manifold cylinders. Thereafter change over to filling manifold.

During normal run, check for any gland leaks of liquid Oxygen in the piston rod of stuffing box asbestos
packing are to be changed.

CAUTION

Always keep the L .O. Pump parts of pump unit free from oil and grease. Refer chapter on safety.

SHUT DOWN AND DEFROST

1. To stop L.O. Pump stop the motor electrically.

2. Close valves 0-1, 0-2, 0-3, 0-5, 0-6 and open 0-4.
3. Open liquid Drain valve D-6 and drain liquid oxygen.
4. Open defrost outlet valve of L.O. Pump D-3.
5. Open Defrost Air inlet to pump A-19.
6. Defrost air is to be drawn from process air through A-15 and watch pressure at P-13 to
be less than 0.5kgs./cm2.
7. L.O. Pump can be defrosted even when the plant is in operation.
8. Check for flow of air at D-3 and D-6.
9. After 15 minutes, switch on heater to maintain maximum of 65 ° C
10. When outlet air is hand warm defrosting is complete and switch off the Defrost
Heater.
11. Close valve A-15, A-19, D-3 and D-6.

MAINTENANCE :

(A) FILTER.

Remove Cold Cover plate on right side in L.O. Pump Housing. Remove slag wool/Perlite powder. The
filter and cover can be removed by opening is outer nut. An insert made of wire mesh or high pressure
sintered bronze is fixed inside. It can be cleaned by initial blowing with High Pressure Nitrogen CTC
washing and again blowing with Nitrogen. While fixing back make sure there are no gas leaks, by
conducting a pressure test.

(B) CYLINDER PISTON AND PISTON RINGS.

The inside liner can be remove along with piston rod and rings. Detach piston rod from cross head by
opening cross head cap remove. Remove stuffing box cover nut, internal ring and packings. Remove non-
return valve on pump end side and cap nut. Clean oil from piston pull out inside liner with a small puller.
The liner with piston rod will come out.

Page 35
Remove piston rod from liner and inspect piston rings. There are four sets of Teflon rings and one guide
ring. If the rings are damaged, replace them. Clean all parts with CTC. Fix new Teflon asbestos rope of
3mm. O.D., around liner, push piston rod with rings inside liner. They should not be cut by port holes in
to-and-for motion. Insert the assembly as it was removed connect piston rod to cross head. Check head end
clearance of pump to be not less than 1mm. Fix cap removed on pump end. Assemble stuffing box with
new graphite impregnated asbestos packing PTFE square rope cut in the form of rings.

XVI. SAFETY PRECAUTION FOR AIR SEPARATION PLANTS

All personnel being employed for work in connection with Oxygen / Rich Air should be cautioned
concerning the hazards involved and precaution to be observed.

Oil grease or similar substances must not be allowed to come into contact with compressed oxygen or
Liquid Oxygen. Contact of these substances with Oxygen may result in an explosion .personnel working in
an area of possible Oxygen concentration, such as near an Oxygen vent or a Liquid Oxygen spillage, or in a
trench where Oxygen see page and concentration might occur, must ensure that their clothing is free from
contamination Oxygen before lighting a cigarette or approaching a naked flame. It is essential that the
clothes be aired for at least 15 minutes before approaching a flame after any such contamination.

The following precautions must be strictly observed at all times.

1. Thoroughly wash all Oxygen fittings, valves and parts with clean (TCE) Trichloro Ethylene or
Carbon tetra chloride (CTC) before installation. Never use petrol, Kerosene or other Hydrocarbon
solvents for this purpose. All tubing, lines, valves etc. to the used in Oxygen service, must be of
an approved type and must be thoroughly degreased and blown out with clean oil-free
compressed air or Nitrogen before being placed in service.

2. Do not permit the release of Acetylene or other flammable gases in the vicinity of the plant air
intake. A concentration of Acetylene exceeding 5 parts per million (5 ppm) in liquid Oxygen may
explode with extreme violence. The plant is equipped with absorbers which give protection
against accidental contamination, strict supervision is essential to minimise the possibility of
contamination.

3. The plant and the plant vicinity must kept clean and free obstructions at all times. Any oil leaks
with in the plant surrounding must be rectified without delay. Oil spillage must be cleaned up
immediately using rag and carbon Tetra Chloride of TCE.

4. Do not lubricate Oxygen valves, regulators, gauges or fittings with oil or grease.

5. Ensure that insulation removed from Air separator jacket is not contaminated with oil or other
inflammable materials. Personnel carrying out maintenance on the Air Separation plant
equipment must wear overalls and their hands and tools must be free of oil. This ensures that the
insulation and equipment within the jacket is not contaminated with, oil. Should contamination
take place the effected material must be discarded and replaced by clean new material.

Page 36
6. Do not fasten electric conduits to the plant or its pipelines.

7. Do not use Oxygen as a substitute for compressed air, spark present in an atmosphere of Oxygen
will immediately burst into flame.

8. Do not fill any container or pipe line with Oxygen unless it has thoroughly been degreased

9. When discharging Liquid Oxygen, rich liquid from drains, valves or pipe lines, open valves
slowly to avoid the possibility of being splashed. In particular ensure that liquid does not run into
shoes or gloves. Contact with liquid oxygen, rich liquid will cause frostbite evidenced by
whiteness and numbness of the skin. The affected parts must be bathed at once in cold (not hot)
water seek medical attention immediately.

10. Do not breath cold Oxygen vapour. The temperature of the vapour raising from liquid oxygen is
approximately -180 ° C. A deep breath of vapour at this temperature can result in frostbitten
lungs with resultant serious illness and permanent disability or death .

11. Do not experiment with Liquid Oxygen by putting solids or liquids into it for the purpose of
watching the effect of the cold liquid. The object placed in the Oxygen may catch fire or explode.

12. Do not pour liquid Oxygen on the floor of the shop or around any object that can catch fire. As
the liquid Oxygen vaporises, the cold vapours may be swept along with ground into contact with
combustible material. The whole floor of an office is known to have caught fire when Oxygen
vapours contacted a lighted cigarette butt. Spillage of liquid oxygen must be avoid especially in
the vicinity of lubricated machinery, asphalt paving, concrete surface containing bitumen joints
or where the liquid oxygen can flow into drains or sewers.

13. Do not use any pipe jointing on Oxygen pipe threads except the jointing approved for Oxygen
service. Ordinary pipe jointing contains grease as a lubricant and will catch fire.

14. Compressor and Expander lubricating oil consumption must be regularly checked. Any
excessive consumption must be investigated immediately and the cause should be rectified.

15. The Cold Box atmosphere must be checked at least once in a week. If local frost spots occur or in
liquid level is unaccountably lost in the plant, and if any check indicates Oxygen concentration
above 21% immediate action should be taken to locate and rectify the leaks.

16. The use of flame (e.g. for welding or cutting) in the immediate vicinity the Air Separation plant
or Oxygen piping must be permitted only when the plant has been shut down and defrosted and
when the Oxygen content of the air within the equipment concerned does not exceed the
atmospheric normal of 21%.

17. Do not attempt repairs until all pressure is released from the section to be dismantled.

Page 37
18. Remember that pressure alone is not dangerous. A Boiler at 0.7 kgs./cm2g. may be more
destructive in the event of an explosion than a small container at 220 kgs./cm2
owing to the greater mass of metal involved. In general, fluid at high pressure and
moving at a high velocity are the most dangerous.

19. Use a face shield or chemical-type safety goggles when using Oxygen or Nitrogen test set to
prevent possible injury to the operator in the event of a blow-back of the reagent.

XVII. OXYGEN TEST SET

The purity of Oxygen product is determined in an Orsat Apparatus. The purity of Oxygen to
the tune of 99% and above only is called the product Oxygen.

TEST APPARATUS :-

The test apparatus required for this should be as per sketch enclosed. figure .

Pure chemicals and distilled water shall be employed in tests.

REAGENTS :-

I. Copper wire.

II Ammonia solution :- Dissolve 550 gm of ammonium chloride (NH4C1) in 1085 ml. of distilled
water and to this solution add 917 ml. of ammonium hydroxide solution (sq.gr. 0.90)

PROCEDURE :-

Invert the copper wire container C , remove the bung and fill it with copper wire in spiral or
other form. Then fill it with ammonia solution and replace the bung. Return C to upright
position. Pour the ammonia solution into the leveling tube A until it is about three quarters full.
Then operate the three way cock E and H so that burette B is in communication with the
atmosphere through inlet F , and by raising leveling tube A , completely fill burette B. Keeping
A raised, turn E so that B is in communication with C , and allow the solution to pass into
C Until D is half full.

Close E , lower A and operate E to draw gas from C into B. close E when capillary of E is
full of liquid. Raise A and operate E to expel gas from B to the atmosphere through F, closing
E when the capillary H is full of liquid, fill the lute G with a head of about 50 mm of water and
connect F with sample gas and purge the gas from the lute G. Draw in the sample through F
(taking care that no air is sucked in through F during this operation). Until the liquid level in B
is at the zero mark and is at the same level with that in A. Pass the gas into C by suitably
operating the cock E , and raising A . Shake thoroughly and then draw back the unabsorbed
gas into B by lowering A and operating the cock E, until a little solution from the capillary
trickles down into B in order to ensure that the capillary in the plug of cock E is filled with
liquid before leveling up and reading the volume of the gas. Repeat the process a
number of times until no further absorption takes place.

Page 38
 RENEWAL OF SOLUTION :-

When the solution is spent, close E , remove the bung from C and drain out the solution from C
and D. Invert C and fill it with fresh solution. Replace the bung and set C and D in proper
place and in upright position. Now add fresh solution to the partially spent solution of A and
repeat the process as indicated in the procedure.

The percentage of Oxygen can be directly read from the graduated burette.

XVIII. NITROGEN TEST SET

The purity of Nitrogen product is determined in an Orsat Apparatus. The purity of Nitrogen to the tune of
99% and above only is called the product Nitrogen .

APPARATUS :-

The assembly of apparatus shall be as shown in Figure.

I Pyrogallol Solution : Dissolve 350 g of pyrogallol in 1000 ml of water. Keep the stock
solution in amber coloured bottles.

II Potassium Hydroxide solution : Dissolve 1000 g of potassium hydroxide in 1000 ml of

water.

NOTE :- Alkali purified by alcohol should not be used since solution evolve some carbon monoxide.

Page 39
PROCEDURE :-

Pour 140 ml of pyrogallol solution and 100 ml of potassium hydroxide solution into Woulfe’s bottle A
through its opening F. Immediately after introducing the solutions, close the opening with rubber bung and
shake the bottle to mix the solutions. Having charged bottle A with the solution, fill measuring burette C
with water by raising leveling bottle D, closing one way tap G and turning three way tap E, to position.

When the water in the burette reaches the zero mark, turn three way tap F to position I and replace bottle D
in set.

The burette C shall be capable of measuring to an accuracy of 0.05 ml

Open one-way tap G and lower bottle D to draw the liquid into absorption pipette B from bottle A. When
burette C becomes full gas, close one-way tap G and turn three-way tap F to position 2 and raise bottle D
until burette C is full of water again. Turn three-way tap F to position I and repeat the foregoing operation
until the level of the solution reaches mark L. Perfect control of the level may be obtained by raising or
lowering bottle D slowly.

Close tap G and finally expel any gas from burette C and turn tap F to position I.

Connect the supply of gas to inlet of a three-way tap F, the tap being in position 2, purge the inlet tube with
the sample and then turn tap F to position 2. Bring the level of water in bottle D in line with graduation
mark 100 on burette C. Turn tap F to position 3 and raise water bottle D to expel all the gas to atmosphere.
Again turn tap F to position 2 and lower water bottle D in line graduation mark 100 on burette C. Repeat
this process of purring burette C and the manifold connection up to G and F once again.

Turn tap F to position I again. Allow water to drain down the sides of burette C and read the volume
keeping water level same in burette C and bottle D. Open tap G, and raise bottle D until burette C is just
full of water. close tap G, replace bottle D in set and leave gas to be tested in absorption pipette B for a few
minutes so that oxygen and other active contaminants are absorbed from it.

Open tap G and lower bottle D until the level of the solution again reaches mark L. To ensure complete
absorption, raise the bottle again until burette C is full of water, close tap G, replace bottle D in set for
another few minutes. Open tap G, and lower bottle D until the level of the solution again reaches mark L.
Close tap G and finally allow water to drain in the burette C and read the volume of gas, keeping the water
level same in C and D.

XIX. ACETYLENE SPOT TEST

INTRODUCTION

In the operation of air separation plants, trace quantities of certain gaseous contamination’s can pass
through the Heat Exchangers and the distillation column and accumulated in the liquid Oxygen within the
condenser. The source of these contaminants is generally the air fed in to the plant or to a minor degree, the
cracking of lubricating oil in the Air Compressor cylinders.

Acetylene is a contaminate of liquid Oxygen which becomes dangerous if the quality present exceeds two
parts per million. The danger of an excessive concentration of Acetylene can be prevented by use of clean
air and by the correct operation and maintenance of the Air Compressor.

Page 40
OPERATING SUPPLIES :

The following chemicals are required for the Acetylene spot check. The quantities stated are sufficient to
permit 5 tests per day for period of 150 days.

Concentrated Ammonium Hydroxide (Specific gravity 0.9) : 1.4 lit.

Soluble Starch : 30 gms
Hydroxylamine Hydrochloride : 500 gms
Copper Sulphate : 250 gms
Distilled water : 11 Lit.

DESCRIPTION :

The test equipment complete a one-litre silvered-glass, Dewar Flask which is used to obtain and hold liquid
Oxygen sample a rack for five eight-inch pyrex test tubes each calibrated at 3,10 and 20 cc. levels, a test-
tube holder and a dropping bottle by which Hydroxylamine Hydrochloride drops may be added to the test
tube in use. Also included in the equipment are two reagent bottles for storage of the Acetylene test
solution, a test solution addition bottle to enable addition reagent to the test, and a colour standards and
rack.

TEST FREQUENCY :

The frequency of testing for trace of acetylene will largely depend on the location of the plant with respect
to sources of contamination, the greater the chance of Acetylene contamination the greater the need for
frequent testing.

On initial start-up, the test should be carried out at least every 4 hours. The test results must be recorded.
After tests have been carried out for several month, the records must be close examined to determine the
average Acetylene contaminate leveling the product liquid Oxygen if the level has remained at a steady low
average. (below 0.25 ppm. Acetylene the period of test may be extended to 24 hours, if fluctuations in the
levels are noted, the test must continue of 4 hours periods.

TEST PROCEDURE :

The Acetylene content of the liquid Oxygen is determined from the colour intensity produced by a
chemical reaction with the Acetylene. The residue remaining just before the evaporation of the final traces
of liquid Oxygen sample is reacted with an Acetylene test solution. A reddish colour resulting from this
reaction indicates an Acetylene concentration in the liquid Oxygen.

Proceed as follows :

1 Open valve D-5 and purge the sample line before taking a liquid Oxygen sample. Precool the
Dewar Flash by filling with liquid Oxygen from the sample line. Allow to stand for about one
minute. Discard contents of flask and refill from sample.

2 Precool a clean test tube by filling it with liquid Oxygen from the Dewar Flask. Allow the tube to
cool and the discard the contents. Use a clamp to hold the test tube to prevent contact with the
fingers. Refill the test tube to the 20 cc mark with liquid oxygen from the flask.

3 Allow the oxygen to evaporate from the tube without agitating the tube. Immediately before the
last drop of liquid oxygen evaporates, add Acetylene test solution to the test tube until the 3 cc.
mark is reached. Close the test tube with a finger and warm the solution by holding the tube in

Page 41
 the hand. Add exactly 12 drops of the Hyroxylamine Hydrochloride solution to eliminate the blue
colour of the Acetylene test solution and allow the colour reaction to proceed for approximately
one minute.

The appearance of a reddish colour in the sample. In the test tube indicates the presence of Acetylene. To
determine the approximate Acetylene concentration present in the sample, compare the colour developed
against the colour standards. The two colour standards 0.25 and 1.0 ppm., are for tests that are carried out
using a 20 cc. sample. In the event that the test indicates contamination exceeding 0.25 ppm, repeat the test
using a 10 cc. sample in place of the 20 cc. sample normally taken. A colour intensity equal to 0.25 ppm.
in the 20 cc. sample will indicate 0.5 ppm. in the 10 cc. sample. Similarly the same procedure enable
the 1 ppm. colour standards to be used to determine a 2 ppm. concentration.

WARNING.

ACETYLENE CONCENTRATIONS OF 2 PPM OR HIGHER ARE DANGEROUS STOP THE PLANT

IMMEDIATELY AND PROCEED AS DETAILED BELOW TO AVOID POSSIBLE INJURY TO
PERSONNEL AND DAMAGE TO EQUIPMENT

PREPARATION OF SOLUTIONS AND COLOUR STANDARDS.

ACETYLENE TEST SOLUTION :

Prepare the test solution as follows:

1. Add one gram of soluble starch to 10 cc. of distilled water and stir into a thin paste. Pour the
paste into a vessel containing 20 cc. of boiling distilled water. Stir the solution and allow to cool.

2. Dissolve 5 grams of Copper Sulphate (CuSO4 5H2O) in approximately 500 cc. of distilled water
in a one-litre flask.

3. Add 50 cc. of concentrated Ammonium Hydroxide (26.4% NH3, specific gravity 0.900 at
60 ° F.) to the copper sulphate solution.

4. Add the prepared starch solution to the Cooper Ammonia solution and dilute to the one litre
mark with distilled water. Store in glass bottle.

NOTE :

The Acetylene test solution has a deep blue colour.

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Preparing Hydroxyiamine Hydrochloride Solution :

Add 2 cc concentrated Hydrochloride acid (37.7 NCL, specific gravity 1.191 at 60 ° F) to 150 cc of
distilled water contained in a beaker. Add the following and stir until dissolved.

Cobaltous Chloride Hexahydrate CoCL2, 6H2O - 10.00 gms

Cupric Sulphate Pentahydrate CuSo4,5H2O - 2.00 gms.

Ferric Chloride Hexahydrate FeCL3,6H2O - 0.30 gms.

Transfer all of the solution to a 200 cc. Flask and make up to 200 cc. with distilled water and shake well.
Tube 15 cc of this solution to a test tube and seal the tube. The colour and colour intensity when viewed
from the side of the tube against a white back ground should be equivalent to that produced by liquid
Oxygen containing 1 ppm, Acetylene when tested in accordance with the procedure described.

0.25 ppm. Colour Standard :

The solution is as for the 1 ppm standard except that the quantities of chemicals used is as follows :

Cobaltous Chloride Pentahydrates CoCL2,6H2O - 1.90 gms.

Cupric Sulphate Pentahydrate CuSO4,5H2O - 1.30 gms.

Ferric Chloride Hexahydrate FeCL3,6H2O - 0.20 gms.

The colour and colour intensity of the solution when viewed from the side of tube against a white
background is essentially equivalent to that produced by liquid Oxygen containing 0.25 ppm. acetylene
when tested in accordance with the procedure, detailed.

TEST SET PART LIST.

The test apparatus comprises of the following :

DESCRIPTION QTY. REQUIRED

1. Dewar Flask, one litre thermos. 1

2. Test Tube rack. 1
3. Test Tube Holder. 1
4. Test Tubes, Pyres, 8 in. x 5/8 in. graduated 3 cc. 10 cc. & 20 cc. 5
5. Dropper bottle, 4 oz, Polyethylene with dropper. 1
6. Reagent bottle, 16 oz, narrow-mouth, storage. 2
7. Carrying case 1
8. Reagent bottle, 16 oz, polyethylene for test solution addition 1
9. Colour standards 0.25 ppm, and 10 ppm. 2

Page 43
 ACTION IN THE EVENT OF ACETYLENE CONTAMINATION

1. Contamination less than 0.5 ppm.

The plant may continue to be operated normally.

2. Contamination greater than 0.5 ppm but less than 2 ppm

The plant may continue to be operated but the source of contamination must be
ascertained and eliminated and the following action must be taken to reduce the level of
contamination in the condenser.

Operate the plant at the maximum liquid production rate and as quickly as it is produced,
withdraw liquid oxygen from the condenser through drain valve D-5. Dispose off the
contaminated Liquid Oxygen . Continue thus until the contamination is less than 0.5 ppm.

3. Contamination greater than 2 ppm.

If the maximum operating limit of 2 ppm. is reached the plant must be shut down immediately
drain off and dispose of all Liquid Oxygen from valves (D4,D5 & D6) and defrost the plant.
The source of contamination must be ascertained and eliminated before the plant is again started.

XX. AIR PRODUCTS - A THERMODYNAMIC VIEW

OXYGEN NITROGEN ARGON

Chem. Formula O2 N2 A
Molecular Wt. 32 28 40
Colour of Liquid Light Blue Colour less -
Boiling Point ° C -183 -196 -185.7
Freezing point ° C -218 -210 -189
Critical Temp ° C -119 -147 -122
Critical pressure (kg/cm2) 50 34 48
S.G. Liquid at B.P. 1.14 0.808 1.402
Sp. heat (gas) Cal/gm ° C 0.258 0.237 0.125
Latent heat of vaporisation (cal/gm)51 47.7 40
% by Vol. in air 20.99 78.03 0.93

NOTE : From the above table we note that the freezing point of Argon is -189 ° C. Which lies between the
boiling points of Oxygen and Nitrogen. Thus there is danger of Argon freezing if the temperature controls
in rectification column are not strictly maintained. All argon manufacturing units should bear in mind the
importance of this.

Page 44
 PROCESS PARAMETERS

PRESSURE Kg/cm2 Bar Atmosphere Pounds/ Sq.In mm ofmeter

(Lbs/In2) Mercury
Water
(Hg.)
Kg/cm2 1 0.98 0.986 14.223 736 10

Bar 1.02 1.00 0.987 14.5 750 10.2

Atmosphere 1.033 1.013 1 14.7 760 10.33
Lbs. / In2 0.07 0.069 0.068 1.0 51.7 0.702
MM of Hg. 0.0014 0.00133 0.00132 0.019 1 0.0136
Meters of water 0.01 0.098 0.097 1.425 73.6 1

VACUUM

Pa=Fg+1 Atmosphere where

a = absolute g = gauge

where Vaccume is sub-atmosphere pressure

Vaccumes are measured in mm of Hg. or Micron.

1 atmosphere = 760 mm Hg
1 mm hg = 1000 microns Hg.
1 Microns hg = 0.001 mm of Hg.

TEMPERATURES :

° K = ° C+273
° C = (° F-32) x 5/9
° F = (° C x 9/5) + 32

FLOW RATES :

Cmh Cfh Cfm

Cmh 1 35.32 0.589

Cfh 0.0283 1 0.0166
Cfm 1.699 60 1

PURITY :
100% = 1000000 = 10 EXP 6 PPM
10% = 100000 = 10 EXP 5 PPM
1% = 10000 = 10 EXP 4 PPM
0.1% = 1000 = 10 EXP 3 PPM
0.01% = 100 = 10 EXP 2 PPM
0.001% = 10 = 10 PPM
0.0001%= 1 = 1 PPM

Page 45
SIMULTANEOUS OXYGEN & NITROGEN WITH LIOUID PUMPS

The following procedures are adopted for simultaneous Oxygen Nitrogen production.

A combination of production of 70% Oxygen and 30% Nitrogen at an O2 purity of 99.6 and Nitrogen
production of 99.99% can be obtained from the 100 Cu.m./hr plant.

This combination has been best suited as the Nitrogen gas demand as compared to Oxygen is normally not
in the market except in some special area where the demand for Nitrogen may be more.

In case for the simultaneous Oxygen Nitrogen production. The R3 valve in the column panel is throttle
gradually and purity after the R3 valve, analysis point D12 is constantly monitored when the purity in the
D12 analysis point starts showing 0.00% R5 valve is opened slowly i.e. 0/2 turns to collect liquid
Nitrogen in Liquid Nitrogen Buffer vessel. After 15 minutes to 20 minutes the L3 H P isolation valve & L3
L P isolation valve is opened and bye-pass valve is closed to check the level of liquid Nitrogen in Liquid
Nitrogen Buffer vessel. The purity of Oxygen is monitored continuously and Oxygen purity will be
improved from 99.5% to 99.6% in due course. Liquid Nitrogen isolation valve to liquid Nitrogen pump NI
and Nitrogen vapour vent valve from pump N2 are opened when the liquid Nitrogen level reaches 360 mm
in the liquid level gauges to cool down the Nitrogen pump. After 15 minutes to 25 minutes, Liquid

Nitrogen pump is started to fill the Nitrogen cylinders of manifold, keeping monitoring the Oxygen purity,
Nitrogen purity, condensor, Oxygen Liquid Level, the Buffer Liquid Nitrogen level. The Air inlet valve
tot he Nitrogen Heat Exchanger is opened at the same time when Liquid Nitrogen pump is started, so as to
maintain the Air temp. outlet from N2 Heat Exchanger from – 136 deg C. to – 140 deg.C. and Air inlet to
N2 Exchanger from 4 deg.C. to 8 deg.C.

Before filling in the cylinders the Nitrogen gas should be purged in the manifold so that the purity in the
cylinders do not drop.

Also the Nitrogen cylinders should be examined properly for proper purity if the Nitrogen cylinder purity is
less than it should be flushed with Nitrogen gas and then the Nitrogen should be filled in the cylinders.

Page 46
 ADDITIONAL PRODUCTION FACILITIES IN 100 CU.M./HR OXYGEN PLANT

Ultra purity Nitrogen production

The process of setting the valve and preparation for Nitrogen pump remains the same. For getting the Ultra
purity the R3 valve should be further controlled and the R2 valve should be opened slightly to maintained
the bottom column pressure.

Also the high pressure air and the expansion engine cam should also be adjusted so that the basic
temperature parameter required for the thermodynamic balance in the heat exchanger is maintained. The
plant would take some time to come into ppm range may be about 1 to 2 hours before the plant gets
stabilized for filling.

Hence for getting the ppm production the process should be gradual and in order to avoid production loss
product like O2 and Nitrogen can be filled. The fine turning of this can be best experienced during the
plant operation.

For getting full 100% N2 Production of ppm range, the Oxygen production will have to be fully stopped.

The cylinder preparation for ppm grade Nitrogen in cylinder is a must. The cylinder should be properly
vacuuminized with proper vacuum pump before it is put in the cylinder manifold.

Number of purges of ppm N2 will also be required to get proper grade of Nitrogen.

Page 47
EXPANSION ENGINE :

TECHNICAL DATA SANGHI-ORG 200

Type of Expansion Engine SEM 0.5/1

No. of Cylinders 2
Diameter of cylinder bore 80mm
Piston stroke 125 mm
Speed 210 RPM.
Inlet air pressure 0 kgs./cm2
Outlet air pressure 5 kgs./cm2
Throughput volume at 60 kgs./cm2 60 NM3/hr
and 8 ° C (about)
Throughput volume at 50 kgs./cm2 00-560 NM3/hr
and -75 ° C (about)
Inlet valve opening time cam setting 8
positions
Power required or supplied 30 KW
Piston head clearance 1.2 + 0.2 mm
Inlet valve pestal clearance 0.4 to 0.5 mm
Outlet valve pestal clearance 0.3 to 0.4 mm.

Page 48
 LIQUID OXYGEN PRODUCTION

The liquid Oxygen production can be produced from this Model OG 200 plant upto 100 Ltrs/hr
simultaneous with gaseous Oxygen production through liquid oxygen pump. This Liquid Oxygen can be
transferred directly from condenser of ASU (Column) to VIST (VACUUM INSULATED STORAGE
TANK) or to small container (Liquid storage container).

MODE OF OPERATION DURING LIQUID OXYGEN PRODUCTION

The plant may be operated for liquid oxygen production by slightly change in valve operation.
We have provided following Extra valves for operation of liquid oxygen production.

R2 - R/L valve provided in normal plant for bottom column to top column.
R6 - Another R/L valve provided extra in addition to R2 from Bottom
column to Top Column.
R12 - Liquid Oxygen production valve.
R5 - Another extra P/L valve provided in addition to R3 from P/L bath to
Liquid Nitrogen Buffer Vessel.
R7 - Liquid Nitrogen production valve.

The liquid oxygen withdrawn from column as product (Liquid Oxygen) cold taken out directly from
condenser is compensated by increasing the high pressure of the column by suitable adjustment either by
closing valve R1 or inlet cam of Expansion Engine (from higher ride (7,6,5,.....3,2.....) by monitoring
T1,T2, T3. Temperature R/L valve R2 which is normal gaseous oxygen production is in operation is to be
operated slightly and to be closed slowly i.e. in 10 minutes and the same time R6 is to be opened slowly.

Considering the rate of production of the gaseous oxygen as 100 M3/hr. Gradually change from R2 valve
to R6 valve and duration will be one hour to one and half an hour such that plant cold condition could not
be destablized. Now the O1 valve of the pump should be gradually closed in such a fashion that the
production of the gaseous oxygen in around 70-80 M3/hr. This normally is achieved in one or two changes
of oxygen cylinder filling. During this time the liquid level in the condenser will raise. The level of the
liquid oxygen in the condenser during the oxygen gas production should be noted. During the liquid
oxygen simultaneous production, the production valve to be gradually opened so that the liquid in the
condenser is slightly above the actual level of the condenser during gas production cycle.

Handling of Liquid Oxygen / Liquid Nitrogen.

The cryogenics liquid oxygen, liquid Nitrogen have different boiling points at different pressures and are
between 140 Deg.C to 195Deg.C cold burns could cause painful blisters, also vapour of this liquid if
inhaled could be injurious to the health.

If a person seems to become dizzy or loses consciousness while working with liquid nitrogen oxygen,
argon move to a well ventilated area immediately. If breathing has stopped apply artificial respiration. If
breathing is difficult, give oxygen. Keep warm and at rest. If exposed to liquid or cold gas restore tissue to
normal body temperature 37 Deg.C as rapidly as possible, followed by protections of the injured tissue
from further damage and infection. Remove or loosen clothing that might constrict blood circulation to the
frozen area. Rapid warming of the effected part is best achieved by using water be over 44 Deg.C nor
should the frozen part be rubbed either before or after rewarming. The patient should neither smoke, nor
drink alcohol.

Page 49
 LIQUID NITROGEN PRODUCTION

The liquid nitrogen production can be produced from this model OG-200 plant upto 100 ltrs/hr,
simultaneously with gaseous oxygen production through liquid nitrogen production. The liquid nitrogen
can be transferred directly from bottom P/L bath of ASU (Column) to VIST (Vacuum Insulated Storage
Tank) or to small container (Liquid Storage Container). There is always evaporation losses during the
transfer of liquid from column (ASU) to VIST and it varies from 60% to 80% depending upon,

 Length of transfer (decantation) pipe (Distance between ASU (Column) to VIST).

 Diameter of Pipe.
 Insulation of pipe.
 Rate of production i.e. volume of liquid handled.
 Vacuum insulation of VIST.
 Rate of pressure building up inside the container (VIST) or small container due to normal
ambient temperature. (It is preferred to have small quantity of liquid inside the VIST or in small
container such that vaporization loss can be minimized.)

MODE OF OPERATION DURING LIQUID NITROGEN PRODUCTION

The plant may be operated for liquid nitrogen production by slight change in valve operation. We have
provided following extra valves for operation of liquid nitrogen production.

R3 - P/L valve provided in noraml plant from P/L bath (lower column of ASU
to top column).

R5 - Liquid Nitrogen production valve from P/L bath to liquid nitrogen buffer
Vessel.

L3 - Liquid level gauges for measuring liquid level in liquid nitrogen buffer vessel.

R7 - Liquid nitrogen production valve.

D12 - Analysis point for checking purity.

QUALITY / PURITY OF NITROGEN

1. Commercial Grade Nitrogen Purity 99.0% to 99.9% (i.e. 10000 PPM to 1000 PPM)
2. High Purity Grade Nitrogen purity from 99.9% to 99.99% (i.e. 1000 PPM to 100 PPM).
3. Ultra High Purity Grade Nitrogen Purity from 99.99% to 99.9998% (i.e. 100 PPM to 2PPM).

COMMERCIAL GRADE NITROGEN PRODUCTION

Nitrogen production of this grade can be achieved in normal operation and can be produced without any
change in mode of operation of the plant. The purity of nitrogen is checked from analysis point D12 and
then R5 valve is opened slowly 0-2 turns to collect liquid Nitrogen in liquid nitrogen buffer vessel and at
the same time R3 valve is closed slowly 0-2 turns. The liquid nitrogen production valve is opened
accordingly as per requirement of production i.e. 100 Ltrs/hr.

Page 50
 HIGH PURITY GRADE & ULTRA HIGH PURITY GRADE LIQUID NITROGEN
PRODUCTION.

The Ultra high purity grade liquid nitrogen production can be produced from this model OG-200. The
liquid nitrogen purity is checked from analysed point D-12 & is continuously monitored. The liquid
nitrogen purity is improved from 99.9% (1000 PPM) towards 2 PPM by gradually closing the R3 (P/L)
valve in the column. First of all if the position of R3 valve is 0-6 (180 Deg. Or half open) liquid nitrogen
purity is 99.9% (1000 PPM) then it is closed from 0-6 to 0-5 and purity is checked from analysis point D12
after 15 minutes. Gradually closing the R3 valve slowly and monitoring the purity from analysis point D12
& when purity starts showing 10 PPM 0.00% R5 vale is opened slowly i.e. 0-2 turns to collect liquid
nitrogen in liquid nitrogen buffer vessel. After 15-20 minutes the L3 HP isolation valve and L3 LP
isolation valve is opened and L3bypass valve is closed to check the level of liquid nitrogen in liquid
nitrogen buffer vessel.

The purity of oxygen is monitored continuously and oxygen purity will be improved 99.5% to 99.6% in due
course. After ascertaining the liquid level in L3 liquid level gauge above 480mm (water gauge) the
respective liquid Nitrogen production valve R7 or inlet valve to the liquid nitrogen pump is opened upto get
100 ltrs./hr liquid nitrogen production and rest gaseous oxygen production through liquid oxygen pump.

Handling of Liquid Oxygen / Liquid Nitrogen.

The cryogenics liquid oxygen, liquid Nitrogen have different boiling points at different pressures and are
between 140 Deg.C to 195Deg.C cold burns could cause painful blisters, also vapour of this liquid if
inhaled could be injurious to the health.

If a person seems to become dizzy or loses consciousness while working with liquid nitrogen oxygen,
argon move to a well ventilated area immediately. If breathing has stopped apply artificial respiration. If
breathing is difficult, give oxygen. Keep warm and at rest. If exposed to liquid or cold gas restore tissue to
normal body temperature 37 Deg.C as rapidly as possible, followed by protections of the injured tissue
from further damage and infection. Remove or loosen clothing that might constrict blood circulation to the
frozen area. Rapid warming of the effected part is best achieved by using water be over 44 Deg.C nor
should the frozen part be rubbed either before or after rewarming. The patient should neither smoke, nor
drink alcohol.

Page 51