715 Complete Manual

Operating Manual
Nitrogen-Generation Plant 220 Nm3/h

Type N2-PSA-220/1,0
Job-No.:
1122 0 0715/00
Projekt-Name /
Job Name
Projekt-Nr./ Job
No.
WALCOT III
69842
Pos.- / Item No.
4500Benennung / Title
Req.
M-076
Nitrogen Generation Plant

Operating Manual
Registrier-Nr. / Registration No.
69842-4500-K626-0001
Date:18.11.2011
Rev.:0
Bl. / Sh.
1/Rev.
If you have technical questions regarding

the nitrogen plant, need the assistance of
a technician or engineer, or wish to order
spare parts please contact:
Mahler AGS GmbH
Insel Strasse 140
D-70327 Stuttgart
Telephone:
+49-(0)711-87030-0
Telefax:
+49-(0)711-87030-200
E-Mail:
info@mahler-ags.com
Internet:
www.mahler-ags.com
0-2
Table of Contents
Safety
Technical Specification
Description of the Plant
Initial Start-Up of the Plant
Standard Startup
Shut-Down of the Plant
Service and Maintenance
Attachments
Mechanical Documentation .................................. File 2
Electrical Documentation ..................................... File 3
Additional Documentation .................................... File 4
0-3
Safety
Safety
1-2
1.1
Symbols Used
1-2
1.2
General notes
1-4
1.3
Instructions
1-4
1.4
Safety devices
1-6
1.4.1
Mechanical safety devices
1-6
1.4.2
Binary automatic safety devices
1-6
1.4.3
Electrical analog automatic safety devices
1-7
1.4.4
Emergency stop functions
1-8
1.5
Filling materials
1-8
1.6
Instruments, pipes and vessels
1-8
1.7
Safety protection while working at the plant
1-9
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Safety
1 Safety
1.1 Symbols Used

Symbols used in these operating instructions should especially be paid
attention to. All operators should be informed about the safety
instructions.
These safety instructions are particularly important for them and they
must be strictly observed.
This symbol warns of hazardous situations.
Injury to persons included.
This symbol points out the possibility of considerable damage to the
plant and control software.
Injury to persons included.
This symbol indicates that work must be carried out only by authorized
skilled electricians.
This symbol warns of possibility of touching hot surfaces or possibility of
hot gas escaping.
This symbol warns of danger caused by flammable materials in rooms
(ex.: stock rooms or cabinets with flammable content) or flammable
materials in different vessels, machines, etc.
This symbol indicates a dangerous situation requiring definite rules of
action. If not observed, consequences can be heavy damage to
persons and property.
No fire, open light and smoking.

No kind of work producing sparks e. g. welding, grinding, parting or
cutting.
Following potential ignition sources should not be generated or put in
close proximity to the area marked with this sign:
Open flames and hot gases
(ex.: candles, matches, weld spitting, weld sparks, glowing charcoal or
tobacco).
Heated / hot surfaces
(ex.: radiators, heating plates, incandescent lamps, motor casings,
exhausters).
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Safety
Frictional heat (ex.: overheated bearings).

Mechanically generated sparks
(ex.: stone, concrete and metal sparks produced by grinding, cut-off
grinding or hammering).
If such kind of work must be fulfilled in marked areas, special safety
measures should be taken beforehand.
Warning of explosive atmosphere.
All potential ignition sources (ex.: open fire, hot thermal sources, not
explosion-protected electrical devices) must be removed out of
explosive areas (EX-areas).
No welding, cutting or grinding.
In explosive atmosphere, only electrical devices corresponding to
definite conformity-classes of atmosphere and possessing the required
protection can be used.
Material marked with this symbol can cause death or considerable

health damage if swallowed, inhaled or in touch with skin. Nearly all
poisonous materials evolve poisonous gases if they are inflamed or if
they decompose under the influence of temperature. Some poisonous
materials have additional dangerous properties, ex. flammability.
This symbol indicates the necessity of ear protection!
This symbol indicates that plant operation generates noise with a level
detrimental to health.
This symbol indicates the danger of amputation of extremities.
This symbol indicates the danger of squeezing extremities.
+
N2-PSA-220/1,0
This symbol points out useful advices to improve the performance and
reliability of the plant or control software.
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Safety
1.2 General notes

This plant is manufactured in accordance with the rules for prevention
of accidents in force at the moment.
Each modification of the original state of the plant without prior consent
of Mahler AGS is not admissible. Only original spare parts should be
employed.
The design, installation and operation concepts of this plant are based
on general and special safety regulations, norms and recommendations
of the German engineer association DIN, VDE, IEC.
Read these operating instructions through and pay attention to the
documentation included in the appendix, particularly to manufacturers
operating and safety instructions enclosed.
1.3 Instructions
For the sake of your safety, please strictly observe all instructions,
placards, forbidding or warning signs, notices and instruction plates.
Observe the enclosed operating and safety instructions.
Inform yourself of accident-prevention rules concerning the employed
technical equipment and operation processes.
Observe the operating and safety instructions of the appendix!

The plant can be operated only by authorized, trained personnel.
Fire protection should correspond to local regulations (fire extinguisher
in close proximity and easy accessible).
No smoking or open fire in close proximity to the plant (forbidding
signs).
Inform your superior about all changes concerning the plant, control and
indication devices which possibly can impair the safety of the plant.
Dont demount safety devices.
They are intended for your safety.
This also means that safety devices should not be put out of operation.
The function of safety devices should regularly be checked by the user!
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Safety
Works connected with electrical equipment of the plant ought to be

carried out by authorized skilled electricians. While completing electrical
works, power supply must be interrupted and secured against restarting. The plant must be operated only in a faultless condition.
Vessels containing compressed gases must be inspected in according
to national codes and regulations by authorized specialists.
Works on pipelines, instruments and vessels are to be carried out by
authorized skilled personnel. It must be assured that the plant is un
pressurized and cooled to the ambient air temperature.
If irregularities in comparison to normal operation are registered, shut
down the plant and contact Mahler AGS!
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Safety
1.4 Safety devices

1.4.1 Mechanical safety devices
Safety valves against overpressure in the piping system and vessels
The plant is protected against harmful overpressure. Overpressure is
discharged to atmosphere.
Non-return valves
Non-return valves are designed to prevent the return flow.
Emergency stop buttons
Emergency stop buttons are to be actuated manually. They should be
actuated only in extraordinary cases.
1.4.2 Binary automatic safety devices

Pressure switches
Pressure switches protect the plant against too high and/or too low
pressure.
Temperature switches
Temperature switches protect the plant against too high and/or too low
temperature.
Level switches
Level switches protect the plant against too high and/or too low level.
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Safety
1.4.3 Electrical analog automatic safety devices

F-controllers with limit values (flow)
Flow controllers regulate the quantity according to the specified set and
limit value. If the flow value is lower or higher than the adjusted limit
value, alarms will be enabled or the plant will be tripped. It depends on
the specification in PLC-program. The limit and set values are adjusted
in the controller or they are defined as K-factors (constant factors).
P-controllers with limit values (pressure)
Pressure controllers regulate the pressure in a plant section according
to the specified set or limit value. If the pressure value is lower or higher
than the adjusted limit value, alarms will be enabled or the plant will be
tripped. It depends on the specification in PLC-program. The limit or set
values are adjusted in the controller or they are defined as K-factors
(constant factors).
T-controllers with limit values (temperature)
Temperature controllers regulate the temperature in a plant section
according to the specified set or limit value. If the temperature value is
lower or higher than the adjusted limit value, alarms will be enabled or
the plant will be tripped. It depends on the specification in PLCprogram. The limit or set values are adjusted in the controller or they
are defined as K-factors (constant factors).
L-controllers with limit values (level)
Level controllers regulate the level in the heat-recovery system,
deaerator and knockout drum according to the specified set or limit
value. If the level is lower or higher than the adjusted limit, alarms will
be enabled or the plant will be tripped. It depends on the specification in
PLC-program. The limit or set values are adjusted in the controller or
they are defined as K-factors (constant factors).
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Safety
1.4.4 Emergency stop functions

Emergency stop functions are safety functions to be applied in a
situation which requires urgent action. They are to prevent damages to
persons, equipment and buildings. To enable this function, the
emergency stop button must be pushed. The crude hydrogen
compressor, all motors and the PSA-cycle (all valves closed) is stopped
immediately.
In case of emergency stop or similar shutdown, the control program
keeps running. All values are indicated by the process visualisation
system.
1.5 Filling materials

While handling filling materials, the personnel must use the
corresponding protection for respiratory organs and skin (mouth and
nose protection, hand guard etc.).
1.6 Instruments, pipes and vessels

Open slowly locking devices that can be operated manually.
Do not touch hot pipes of the plant : HAZARD OF BURN! Protective
shoes, hand guard and protective goggles are to be used when fulfilling
all kinds of work concerning the plant.
The outlet nitrogen has a too low oxygen concentration for respiration.
That is why near the openings of vessels there is HAZARD OF
SUFFOCATION! The same when you bend down to vessels. If they are
installed in closed rooms, a proper ventilation and venting should be
provided.
To prevent the hazard of suffocation, pay particular attention to the
following:
The outlet air ought to be conveyed to the atmosphere.
Safety, blow-off and decompression equipment is to be installed in safe
places where persons or property are not endangered by outlet gases.
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Safety
1.7 Safety protection while working at the plant

Hazard of fire:
No kind of work generating sparks ought to be carried out as for
example welding, grinding, splitting or cutting at the plant.
Following potential ignition sources cannot be generated or placed in
close proximity to the areas marked with safety signs:
open flames and hot gases
warmed / hot surfaces
frictional heat
mechanically produced sparks
Danger of injury by pressure
A sudden expansion of a gaseous medium (air, nitrogen etc.) can cause
severe injuries (ex. loss of visual faculty) or death. To prevent such
accidents, pipes and pressurized components are to be shut off, the
whole system must be decompressed before the pressurized parts or
their joints can be opened, loosened or removed. Protective goggles
are absolutely necessary during this kind of work!
Danger by moving machine components
Moving machine components can cause injuries up to the loss of
extremities and death (by cutting, hitting, sticking, squeezing, spilling
liquids, getting tangled etc.)
To prevent such accidents, stop the plant (its components, machines
etc.) and switch off the voltage supply before starting any kind of work
at the plant. All safety requirements must be met. Make sure that the
plant cannot be restarted during this work. Lock the plant to prevent
restarting.
Temperature
A sudden escape of hot gases or liquids as well as hot surfaces can
cause severe injuries or death.
To prevent such accidents, observe the safety instructions and mind
particularly that:
Any work on the pipes or machines can be started only when the
system/plant has been stopped; pipes, media and surfaces cooled;
pressure removed.
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2-2
2.1
General Information
2-2
2.2
Process Data
2-2
2.2.1
Nitrogen Product
2-2
2.2.2
Power Consumption
2-3
2.2.3
Compressed air for PSA-feed
2-3
2.2.4
Instrument air
2-3
2.2.5
Chilled water
2-3
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2 Technical Specification
2.1 General Information

Plant type:
N2 - PSA 220/1,0
Plant no.
1122 0 0715 / 00
Ambient conditions:
Ambient temperature (min. / design / max.):
0 / 20 / 48 C
Ambient design pressure:
980 mbar
Relative humidity (min. / max.):
30 / 70 %
2.2 Process Data

2.2.1 Nitrogen Product
Capacity:
220 Nm3/h
Purity:
N2 + Ar
99 % by vol.
Impurities:
O2
1,0 % by vol.
CO2
5 ppm
H2O
Dewpoint - 40C at 1013 mbar.
Pressure downstream N2-PSA:
approx. 6,5 bar(g)
Product pressure downstream

pressure control unit:
6 bar(g)
Product temperature:
approx. ambient temperature
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2.2.2 Power Consumption

Control cabinet:
2 kW
230 V, 50 Hz
2.2.3 Compressed air for PSA-feed

Flow:
average 650 Nm3/h
Pressure (min. / max.):
7,5 / 9,5 bar(g)
Temperature:
max. 40 C
Dew point:
approx. + 4C (at 9,5 barg)
2.2.4 Instrument air

Flow:
approx. 6 Nm3/h
Pressure:
min 6 bar(g)
2.2.5 Chilled water

Flow:
approx. 1,5 m3/h
Pressure (min. / max.):
2,5 / 5 bar(g)
Temperature inlet:
max. 7 C
Temperature outlet:
12 C
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Description of the plant
3-2
3.1
General Description
3-2
3.2
Process Description
3-2
3.2.1
Process Air
3-3
3.2.2
Adsorption Process
3-3
3.2.3
Regeneration Process
3-4
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3 Description of the plant
3.1 General Description

Plant type:
N2 - PSA 220/1,0
Plant no.
1122 0 0715 / 00
In this plant nitrogen is produced from atmospherical compressed air by

Pressure-Swing-Adsorption at carbon molecular sieves.
Capacity of the plant:
220 Nm3/ h nitrogen
Residual oxygen:
max. 1,0 % by vol.
See: Technical Data
3.2 Process Description

The nitrogen product with a purity of min. 99,9 % by vol. is generated from air
by adsorptive air separation on a carbon-molecular sieves (CMS), the process
is called Pressure Swing Adsorption (PSA). The oxygen from the process air is
adsorbed on the molecular sieve and the nitrogen, with a residual content of
max. 1,0% oxygen, is available as product gas.
As the adsorption capacity of the molecular sieve is limited, and in order to
reach an almost continuous nitrogen production, two adsorption vessels, filled
with molecular sieve, are used (Adsorber 4500-R11 and 4500-R12).
Due to the pressure swing adsorption principle only one adsorber is used each
time for the adsorptive air separation = adsorption (nitrogen production). At the
same time the second adsorber is regenerated by pressure reduction, i.e. relief
to the atmosphere pressure (desorption).
Before the switch-over of the adsorbers, a pressure equalization is conducted
by the inlet and outlet valves of the two adsorbers. Thereafter the switch-over
takes place, i.e. the regenerated adsorber is switched over to adsorption =
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nitrogen production and the oxygen-charged adsorber is regenerated.

The produced nitrogen flows via the adjustment valves to a buffer vessel
4500-V11. Thereby a continuous nitrogen production is guaranteed for the
consumer.
For the control and supervision of the adsorption process, sample gas is taken
downstream the buffer vessel 4500-V11 and the residual oxygen-content in the
nitrogen is measured and controlled by an oxygen analyzer.
The switch-over of the adsorbers is effected by a pre-programmed cycle: i.e. the
switch-over of adsorber 4500-R11 and adsorber 4500-R12 to the adsorption is
conducted each time after approx. 60 sec., in order to switch each adsorber to
adsorption or desorption in a two-minutes-cycle.
3.2.1 Process Air

The process air required for the generation of nitrogen is supplied at battery
limits at a pressure of 7,5 9,5 bar(g).
For the adsorption process for the generation of nitrogen the process air must
be:
a. mechanically clean and free from oil
b. the content of moisture = dew point max. +3 +5 C (at 9,5 barg).
The process-air is cooled to approx. 20 C with the chilled water cooler 3.03.
3.2.2 Adsorption Process

The process air flows to adsorber 4500-R11 or adsorber 4500-R12 for nitrogen
production. For example: Adsorber 4500-R11 on nitrogen production: The
process air reaches via butterfly valve XV00-55 the adsorber 4500-R11 through
the bottom and flows through the molecular sieve bed. During this process, the
oxygen-content of the process air is adsorbed on the molecular sieve.
The nitrogen product gas flows via the outlet- valve XV00-53 to the buffer
4500-V11. A feedback line equipped with a check valve 4.25 is installed in
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parallel to the adjusting valve 4.22. The feedback line has the task to reach
more quickly the operation pressure in the respective adsorption vessel after
the pressure equalization between adsorber 4500-R11 and adsorber 4500-R12
by nitrogen flow from the N2-buffer 4500-V11 to the adsorber.
Downstream buffer 4500-V11 measuring gas is taken via solenoid valve
XV00-64 for the oxygen analyzer QT00-56. Via a limit-value contact the release
to the consumer or to athmosphere is switched. If the O2-content of the product
gas exceeds the upper limit, the plant switches after 5 sec. to athmosphere, i.e.
valve XV00-62 to the storage closes and valve XV00-63 opens to atmosphere
via silencer 4500-S11. When the O2- content reaches again the positive range,
the switch-over to the storage (consumer) follows automatically. Should the limit
value (O2-content) not fall below the upper limit again after 4 minutes, the plant
is going to be shut-down.
See: chapter 7 = safety devices: " oxygen analyzer alarms "
The pressure of the plant is controlled to approx. 7 bar(g) by means of the
pressure control valve PC00-58. The nitrogen flow rate of the plant is regulated
by means of the flow control valve FC00-52.
Downstream the PSA-unit a N2-storage tank 4500-V12 (Volume 20 m3) is
installed. The product pressure at battery limits is controlled with the pressure
controller PC00-96 to approx. 6 bar(g).
3.2.3 Regeneration Process

Parallel to the adsorption process in adsorber 4500-R11, adsorber 4500-R12 is
regenerated:
Butterfly valve XV00-58 to atmosphere opens. Gas from Adsorber 4500-R12,
which is at the start of the regeneration process at a pressure of approx. 3,5
bar(g), is now released to atmosphere. By means of this relief, the oxygen taken
up by the molecular sieve is removed from the molecular sieve and released to
the atmosphere through silencer 4500-S11.
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Initial Start Up of the Plant
Initial Start-up of the Plant
4
4.1
4-2
Final inspection of the assembly
4-2
4.1.1
Check the power supplies
4-2
4.1.2
Pipe-connection lines
4-2
4.1.3
PSA- Adsorber 4500-R11 / 4500-R12
4-3
4.1.4
Process air supply
4-3
4.2
Preparations for the Initial start-up
4-3
4.2.1
Open shut-off - / adjusting valves:
4-3
4.2.2
Starting of the control cabinet
4-4
4.3
Start-up of the plant
4-5
4.4
Adjustment of the plant parameters
4-6
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4 Initial Start-up of the Plant

4.1 Final inspection of the assembly
Preparation and control for initial start-up
4.1.1 Check the power supplies
electric mains to the switch cabinet PSA plant
= 230 Volt ; 50 Hz
connection: switch cabinet PSA plant Signals (X5; X59) extern
DCS
connection: switch cabinet PSA plant collective alarms extern DCS
by profibus
4.1.2 Pipe-connection lines
Process air
Battery limits --- inlet PSA- plant

- Chilled water cooler 3.03
- Outlet safety valve PSV00-89 to silencer 4500-S11
PSA-skid N2 - buffer
= N2- buffer 4500-V12
- safety valve PSV00-85 and PSV00-86 (waste gas pipe to
atmosphere)
- pressure gauge PI00-61
- temperature gauge TI00-65
Nitrogen
Instrument air
pressure switches PSHL00-62 and PAL00-63

pressure transmitter PIR00-64
pressure control valve PC00-96
strainer 7.25
valves 7.16; 7.19; 7.23; 7.24; 7.26, 7.27
= Check pressure at PI00-67: approx 6 bar

= Place all hand switches at the control solenoid valves of the
switch-over valves to operating position
Cooling water
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cooling unit Heat exchanger 3.03
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4.1.3 PSA- Adsorber 4500-R11 / 4500-R12

The PSA- Adsorbers have to be filled completely according the
filling list onside with adsorber agent ( CMS ) !
See: chapter 7 = point 7.3 Filling instructions / filling list /
filling report
4.1.4 Process air supply

Check pressures:
-
PI00-51: 7,5 9,5 bar(g)
PI00-52: approx. 7,5 bar (g)
4.2 Preparations for the Initial start-up

4.2.1 Open shut-off - / adjusting valves:
open completely
globe valve
3.09 / 3.12 process air inlet plant
open completely
globe valves
7.05 / 7.06 / 7.16 / 7.23 / 7.24 / 7.26

nitrogen outlet plant
open
valve with regulating cone
3.06 *
air inlet
open
4.22 *
nitrogen outlet adsorber
open
7.54 *
outlet plant
open
7.09 *
to atmosphere
open
Pressure control valve
PC00-51 * air pressure
open
PC00-58 * plant pressure
open
Flow control valve
FC00-52 * flow rate
open
PC00-96 * product pressure

* Adjust when plant is in operation
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4.2.2
Starting of the control cabinet
Information
The control of the complete plant is effected by means of an electronically
programmable logical control = PLC, type: S7 CPU314, which is installed in the
control cabinet.
In the front is installed an Operator Panel (OP) MP277.
See additional documentation in File 3.
The program is stored on a memory card.
All operation elements for the individual switching on- and operation phases are
installed on the front side of the control cabinet.
Signal lights (front side of control cabinet )
Green =
operational function
Red
failure signal ( flashing light )
1.
Switch-on main switch
2.
Release EMERGENY-OFF switch
3.
Switch on control = press button " control on

lamp: control on = ON
4.
Acknowledge failure signal !

= press button acknowledge at the MP277
horn + failure lights = OFF
Should there still be a failure, the corresponding failure message is shown
on the MP277.
Find out the reason for the failure and eliminate it = After acknowledge all
fault-messages the failure light will switch OFF
5.
Lamp test: press button lamp test at the MP277

All lamps = ON = o.k
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4.3 Start-up of the plant
Information:
The start-up procedure can be seen also in the function chart:
See Operating Manual File 3: Electrical Documentation
1.
Lamp: plant on = ON ( flashing light = enable for start-up )

Press button: Plant Start
Lamp: Plant Start = ON
( in the start switch )
Lamp: Plant on = ON ( turns from flashing light into permanent

light )
2.
Sequence steps
>> PSA-cycle will be switched on (switch-over valves)
>> valve XV00-63 opens to atmosphere
The process air, compressed to approx. 8 bar(g) flows to the PSA-unit =
adsorber 4500-R11 or adsorber 4500-R12 = nitrogen generation.
The generated nitrogen flows through valve XV00-53 / XV00-54 to the
nitrogen buffer 4500-V11. Downstream the buffer the nitrogen flow is
adjusted by control valve FC00-52. The pressure is adjusted by control
valve PC00-58. Nitrogen flows through valve XV00-63 and the adjusting
valve 7.09 to the silencer 4500-S11 and then to the atmosphere.
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4.4 Adjustment of the plant parameters

The generated nitrogen flows now via switch-over valve XV00-63 and adjusting
valve 7.09 to the atmosphere
1.
Control the oxygen value

Indication on the display of the oxygen analyzer
The O2 - value should amount to approx. 1,0 % by vol.
2.
" Calibrate the oxygen analyzer

See therefor: operating manual " AMS ":
See Operating Manual File 3 (Electrical Documentation)
After the calibration of the oxygen analyzer, switch again to O2 - measuring
in the product gas.
Sample gas flows through the solenoid valve XV00-64 to the O2 - analyzer.
Check O2 - value !
3.
Adjust the pressure of the plant

Pressure control valve PC00-58 = approx. 6,5 bar (g)
Check: pressure gauge: PI00-57 (N2 - buffer 4500-V11).
4.
Adjust the capacity (flow rate nitrogen) of the plant

Flow control valve FC00-52
= approx. 220 Nm3/ h
Check: pressure in the storage vessel 4500-V12.

5.
Correct the adjustments: pressure / flow rate

The adjustments must always be conducted under observation of the oxygen
value (approx. 1,0 % by vol.)
N2- PSA- Station
Regulating valve 4.22 outlet N2- adsorber*
Pressure controller PC00-58 downstream 4500-V11
= approx. 6,5 bar (g)
Flow control valve
FC00-52
= approx. 220 Nm3/h
Regulating valve
7.54*
Regulating valve
7.09*
* datas will be filled in on site during commissioning

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6.
Check:
Pressures / flow rate / temperatures
Pressures:
-
Adsorber 4500-R11 (PI00-55) or
Adsorber 4500-R12 (PI00-56)
Adsorption:
approx. 7,5 bar(g)
Pressure equalization:
approx. 4,0 bar(g)
Buffer vessel 4500-V11 (PI00-57): approx. 6,5 bar(g)
O2-content product gas QT00-51
< 1,0 Vol.%
Now the nitrogen supply can be switched-over to consumer (storage vessel

4500-V12)
Check measured values at all indicating devices

( pressures / temperatures etc.)
Check the O2- content at the O2- analyzer
The initial start-up is finished now.
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Standard Start-Up
Standard start-up
5-2
5.1
Preconditions for start-up of the N2 - PSA plant
5-2
5.2
Start-up of the PSA plant
5-3
N2-PSA-220/1,0
Walcot III 112200715/00
715E005
5-1
Standard Start-Up
5 Standard start-up
5.1 Preconditions for start-up of the N2 - PSA plant
All adjusting valves within the plant are on operating position
(see also: chapter 4 = Initial start-up)
Main switch is switched on
EMERGENCY-OFF SWITCH is released
Control voltage is switched on = lamp: " control on " = ON
No failure signal ( red signal lamps are off )
In case of failure signal = acknowledgement ( acknowledge switch)
O2 - analyzer is switched on = see Display
Chilled water circuit is switched on
Process air at battery limits is available
Lamp: " plant Start " = flashing light = release for start-up ( in the Start switch )
>> See plant sequence in operation panel
Preconditions for Start-up of the N2 - PSA plant are fulfilled.
N2-PSA-220/1,0
Walcot III 112200715/00
715E005
5-2
Standard Start-Up
5.2
Start-up of the PSA plant
Press Button: " plant Start !

Message: " plant on
turns from flashing light into permanent light
Chilled water circuit in Operation

PSA-cycle on: switch-over valves start to switch
Solenoid valve XV00-64 sample gas to O2- analyzer opens
Solenoid valves XV00-80 and XV00-81 sample gas to dew-point analyzer opens
The produced nitrogen flows now via valve XV00-63 to the atmosphere.
Message: " gas to atmosphere
= ON
Correct the adjustments: pressure / flow rate

The corrections must always be effected under observation of the oxygen value (value:
approx. 1,0 % by vol.)
The adjustment of the N2- PSA- plant in the Test - Phase is finished now .
Now it can be switched-over to the consumer ( storage vessel)
When the O2-value is within the specified range = 1,0 % by vol., the switch-over to the
consumer is effected automatically
>> valve XV00-62 opens
= message: gas to consumer = ON
>> valve XV00-63 closes
= message: gas to atmosphere = OFF
The generated nitrogen flows now via valve XV00-62 to the consumer
Check measured values at all indicating devices
Pressures / temperatures etc. and the O2- value at the analyzer
N2-PSA-220/1,0
Walcot III 112200715/00
715E005
5-3
Shut-down of the plant
6-2
6.1
Standard shut-down (for a short period)
6-2
6.2
Shut-down for a longer period
6-2
6.3
Plant STOP in case of EMERGENCY
6-3
6.4
Automatical shut-off
6-3
N2-PSA-220/1,0
Walcot III 112200715/00
715E006
6-1
6 Shut-down of the plant

6.1 Standard shut-down (for a short period)
Plant stop = press button plant stop
The plant shuts-down.
Shut-down program for N2- adsorber:

Valves XV00-53 + XV00-54, XV00-55 + XV00-56, XV00-59 + XV00-60 close.
Butterfly valves XV00-57 + XV00-58 open.
N2- adsorbers 4500-R11 + 4500-R12 get released (to atmosphere).
After 3 min. butterfly valves XV00-57 + XV00-58 will also be closed.
6.2 Shut-down for a longer period

Plant stop = press button plant stop
The plant shuts-down.
Shut-down program for N2- adsorber:

Valves XV00-53 + XV00-54, XV00-55 + XV00-56, XV00-59 + XV00-60 close.
Butterfly valves XV00-57 + XV00-58 open.
N2- adsorber 4500-R11 + 4500-R12 get released ( to atmosphere ).
After 3 min. butterfly valves XV00-57 + XV00-58 will also be closed.
Switch-off main-switch
N2-PSA-220/1,0
Walcot III 112200715/00
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6-2
6.3 Plant STOP in case of EMERGENCY

Attention !
The EMERGENY-STOP- button may only be actuated in case of danger !
Switching the " Emergency stop ":

Control voltage = off
Lamp: " Control on " = off
PSA- Plant stops, all valves close
Release EMRGENCY / OFF
6.4 Automatical shut-off

Automatic shut-off in case of failures:
See alarm and fuction list, electrical documentation
N2-PSA-220/1,0
Walcot III 112200715/00
715E006
6-3
Service and Maintanance
7-2
7.1
General Information
7-2
7.2
General Service Note
7-2
7.3
Filling Instructions for the N2-PSA Adsorber Vessels
7-4
7.3.1
Information
7-4
7.3.2
Initial Filling with Adsorption Agent (N2-CMS)
7-5
ANNEX
Filling report / filling instruction
Filling list
N2-PSA-220/1,0
Walcot III 112200715/00
715E007
7-1
7 Service and Maintanance

7.1 General Information
Precondition for a perfect operation of the plant is, that it will be operated correctly
and maintained frequently. By this an optimal operation performance and lifetime of
the complete plant can be achieved.
The experience has shown that it is advisable to keep an operation- and
maintenance book about the operation data (at least once per day) and the executed
maintenance works. These records give important information and data for necessary
controls resp. maintenance works.
In case of deviations a control has to be effected immediately: recognition of the
cause and elimination of the failure.
Maintenance- and Repair Works must only be executed by the respective technical
personnel and in presence of the factory security officer. All maintenance works must
be recorded in a maintenance book (see above) and the be evaluated.
This way secures a control over the maintenance intervals resp. deviations. This is
also important for the storage of spare parts.
All instructions for the maintenance in the separate operating instructions of the
individual aggregates and valves have to be considered and observed on principal.
7.2 General Service Note

1.
Ball valves
Ball valves require - to a large extent - no maintenance. We recommend to
check the tightness in regular intervals. In case of leaks, the ball valves
have to be exchanged
2.
Valves
Check regularly on tightness. In case of leaks, tighten the gland or
exchange it
3.
Gas pressure Controllers

Gas pressure controllers should be checked approx. every 6 months, on:
-- tightness towards the outside
-- reliability of the adjusted control pressure
N2-PSA-220/1,0
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7-2
-- tightness inside in case of zero-consumption.

Once a year the gas pressure controllers should be dismounted, cleaned
and the interior parts should be subject to a visual inspection. Any
damaged or worn parts should be exchanged
4.
Solenoid Valves
Every three months the solenoid valve actuators should be checked on
tightness and firm seat. In case of damages, the solenoid valve should be
exchanged and, if necessary, sent to the supplier for repair. Do not carry
out yourself any repair work at site - explosion hazard!
5.
Pneumatic Setting Valves

Every three months the tightness should be checked; where necessary,
renew gasket.
Check also the basic adjustment and the firm seat of the mounted setting
regulator - if necessary readjust. About once a year the filter inserts of the
instrument air station at the setting regulators should be exchanged.
6.
Safety Valves
Those valves should be lifted up about twice a year and then checked on
tightness. In case of leaks they should be exchanged.
7.
Pressure Vessels
After 10 years of operation, an inspection of the interior parts - on possible
corrosion or cracks - is necessary. Furthermore, the Acceptance Test
should be renewed after this period of time in presence of the local
Technical Authorities.
8.
Measuring Instruments
Check regularly on tightness, see whether connections are firmly
tightened, check working order. Exchange them in case of irregularities.
9.
Control Cabinet
The cable connections should be checked once a year: are they still firm,
perhaps they need tightening.
In case that any instruments are damaged, they should be exchanged - do
not carry out yourself any repair work.
10.
Analyzers
Maintenance in accordance with the recommendations and instructions of
the manufacturer can be found in the Documentation Part 4
(Documentation sub-supplier).
11.
PSA - Adsorber 4500-R11 / 4500-R12

If the efficiency of the adsorption agent ( N2- CMS ) decreases, it should
be exchanged.
N2-PSA-220/1,0
Walcot III 112200715/00
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7-3
7.3 Filling Instructions for the N2-PSA Adsorber Vessels

7.3.1 Information
Should the adsorbers be filled at site (place of installation), the filling of the adsorbers
has to be effected according to the filling instructions !
This applies also when the adsorption agent has to be replaced because it became
inactive.
The adsorption agent (N2 - CMS) will be delivered in synthetic canisters.
Content: approx. 41 kg / canister.
Attention: The canisters are vacuum-tightly closed ! Please storage in a
warehouse !
To guarantee smooth operation of the adsorber later on, the adsorption agent has to
be tightly fixed in each vessel, and, taking into consideration ist hygroscopic
characteristics, it has to be protected against humidity.
Therefore the following points should be strictly observed during storage, filling and
erection:
1.
The adsorption agent has to be stored in a dry, closed room. On arrival the
transport vessels have to be checked on whether they are tightly closed.
2.
Before filling-in the adsorption agent, please check whether the inserts are
undamaged ( spec. wire cloth ).
The inside of the vessel must be clean and absolutely dry.
Close the nozzle of the pressure gauge with steel wool.
Dismount the piping with the switch-overvalves on the adsorbers (at the
top) !
Release and remove the filling flanges of the adsorbers!
Remark :
As the CMS has to be filled in through the nozzle (at the top of the adsorber), an
appropriate platform should be installed around the adsorbers.
Oberserve the regulations for prevention of accidents !
N2-PSA-220/1,0
Walcot III 112200715/00
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7-4
Wear a dust mask during the filling process !
7.3.2 Initial Filling with Adsorption Agent (N2-CMS)

Filling Procedure
For details see filling report (enclosure I) and filling list
(enclosure II).
Mark the CMS - cannisters according to the numbers of
the filling list (see enclosure II)!
Arrange the CMS-canisters according to the numbers: 1
- X and place them near to the adsorber vessels !
Adsorber 4500-R11 = No.: 1 / 1 ; 1 / 2 ; 1 / 3 ; etc.
Adsorber 4500-R12 = No.: 2 / 1 ; 2 / 2 ; 2 / 3 ; etc.
Reason: the relative volume of the adsorption agents is
different.
For example: RV = 2,4 and 2,15
the CMS with the higher RV-number is to be filled-in
first ( therefore the numbering: determination of order).
Attention:
Open and fill in always only one canister !
Open the sealing cover and cut up the vacuum protective
foil.
Reason:
The CMS can no more be stored in the opened
canisters.
Air and moisture would penetrate and the CMS would
become i n a c t i v e !
Fill the canisters into the adsorber 4500-R11 / 4500R12 according to the consecutive numbers.
The adsorbers have to be topped up to the limit
mark as per enclosure I.
The CMS has now to be compressed by means of

a vibrator !
The compression with the vibrator has only to be
N2-PSA-220/1,0
Walcot III 112200715/00
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7-5
stopped, when no more CMS slides into the nozzle,

i.e. when no more compression is recognizable.
After that the adsorbers are to be filled up to the
LIMIT - filling height mark as per enclosure I.
LIMIT - filling height mark as per enclosure I is the
end of the cylindrical wall of the adsorbers.
If required, compress again and top up up to the
LIMIT.
The adsorbers have now to be topped up with
ceramic balls.
a. Insert the synthetic net on the filled-in CMS in
the adsorbers.
b. Fill-in the ceramic balls.
c. Close the synthetic net in an overlapping manner.
Insert the filter pad ( 1 coco-mat) into the nozzle of
the vessel.
To the upper edge leave approx. 20 mm free space !
All residues of the adsorption agent have to be
removed from the gasket surfaces of the vessel
flanges.
The gaskets have to be cleaned and greased with
graphite.
Slowly put back again the lid together with the
perforated-plate.
Now press the lid tightly onto the vessel with screw
clamps up to the point where the flanges can be
tightened with the vessel screws.
Fix tightly the lid with the screws.
The filling process is finished now.
Those steps should be carried out without any long
interruptions to avoid that the adsorption agent is
unnecessarily exposed to atmospheric humidity!
Remount the pipes and switch-over valves.
During the subsequent erection of the adsorber, all
inlets and outlets of the adsorber have to be
equipped with filter sealing disks.
The adsorbers are now ready for operation!
N2-PSA-220/1,0
Walcot III 112200715/00
715E007
7-6
Important Notes
Mark the numbers of the filled-in canisters in the filling
list.
Should there remain any CMS, only originally closed
canisters can be stored and used for future filling.
Enter the number of the filled-in canisters into the filling
report.
For example:
10 canisters + approx. 5 kg CMS
= 10 x 41 kg + 5 kg = 415 kg CMS
The filled-in quantities of Adsorber 4500-R11 and

4500-R12 should be preferably the same.
Fill in the filling report + filling list (with the entered
filling data) in the operating instructions = enclosures I
and II.
Remark:
When the adsorption agent has to be replaced, the
used adsorption agent is to be evacuated by means of
an evacuating device.
The new filling has again to be carried out according
to the filling instructions!
The disposal of the inactive CMS has to carried out
in accordance to the local regulations.
N2-PSA-220/1,0
Walcot III 112200715/00
715E007
7-7
Filling Report
N2 - PSA- Adsorber
Plant:
N2 - PSA- 220/1,0
Plant no: 1122 0 0715
Project:
Walcot III
Adsorber 4500-R11 and 4500-R12 mit CMS entsprechend der Fll-Liste gefllt.
Adsorber 4500-R11 and 4500-R12 filling with CMS according to the Filling list
Fll-Menge / Filling rate :
Adsorber 4500-R11 = Canister no.: 1 - ... = ............ kg
I Total = ............... kg
Adsorber 4500-R12 = Canister no.: 1 - ... = ............ kg
I
durch: / through : Fa. .............................................................. + Mahler AGS: .................
Ort / Place : ...............................
Datum / Date :
.........................
-- blind flange
-- metal ring with coco mat
A
ceramic balls in synthetic bag
Keramikkugeln im Synthetiksack
no. X
welding
Schweinaht
limit
Filling procedure:
CMS
Canister
No.: 1 - X
no.3
1. Canister no. 1 - x filling in to H ;

vibration ramming with vibrator ( compressed )
2. adsdorber filling up to H
and ramming again to limit
3. syntetic fibre bag inserted
4. ceramic balls filling in
5. syntetic fibre bag close
6. adsdorber close with blind flange A
Fllvorgang:
1. Kanister Nr. 1 - x einfllen bis H
Verdichten mit dem Betonrttler
2. Adsdorber wieder auffllen H
und wieder verdichten bis limit
3. Syntetiksack einlegen
4. Keramikkugeln einfllen
5. Syntetiksack verschlieen
6. Adsdorber mit Blindflansch A verschlieen
no.2
no.1
Drahtgewbe / wire cloth
gewlbtes Lochblech / curved disc
Blechscheibe / metal disc
Mahler AGS GmbH
D - 70327 Stuttgart
Inselstrasse 140
Sortierliste
Mahler AGS GmbH
Nr.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
2,15
2,20
Enclosure II /SE/EB/CMSF
CMS-F
Plant:
N2-PSA 220 / 1,0
N2-PSA-Adsorber
Plant no.:
Project :
1122 0 0715
Walcot III
Date:
2,25
2,30
2,35
2,40
2,45
2,50
1 von 1
Customer:
Mahler AGS Job No.:
Revision:
Date:
WALCOT III
112200 715
1
07-11-2011
TABLE OF CONTENTS
Page 1 of 1
715-Materialliste-Rev.1
Customer:
Mahler AGS Job No.:
Revision:
Date:
WALCOT III
112200 715
1
07-11-2011
LIST OF PRESSURE VESSELS / MAJOR EQUIPMENT

TAG No.
Description
Manufacturer
Material
Shell
3.03
Medium
Tube
Shell
Design pressure
Tube
Design temperature
Volume
Shell
Tube
Shell
Tube
bar(g)
bar(g)
m3
Outer
Heat exchanging
diameter
area
capacity
mm
m2
kW
90
8,9 kW
1,5 m/h
Process Air Cooler
Hiross
WFN013
P265GH
copper
chilled water
process air
16
10
3,3 Ltr
1,5 Ltr
4500-R11
21.01
Adsorber
Clauss
P265GH
Ambient Air /
Nitrogen
40 (8)
-10 / 50
800
4500-R12
21.02
Adsorber
Clauss
P265GH
Ambient Air /
Nitrogen
40 (8)
-10 / 50
800
Blow Off Silencer

80 dB(A)
Wilhelm
S235JRG
waste gas;
O2, N2
-10 / +100
2,5/ 4m
height
630
Buffer Vessel
Lohenner
P265GH
Nitrogen
13
-10 / +50
1500
Buffer Vessel
Lohenner
P265GH
Nitrogen
13
-10 / +100
20
2200
4500-S11
21.06
4500-V11
7.01
4500-V12
7.02
Page 1 of 1
Customer:
Mahler AGS Job No.:
Revision:
Date:
WALCOT III
112200 715
1
07-11-2011
MACHINERY LIST
TAG No.
Description /
Equipment
Type
Manufacturer
Material
Equipment
Design
Medium
Capacity
Rated
TAG No.
Motor
Pressure
Temperature
Motor Power
bar(g)
kW
Page 1 of 1
Remarks
Customer:
Mahler AGS Job No.:
Revision:
Date:
WALCOT III
112200 715
1
07-11-2011
MOTOR LIST
TAG No.
Motor
Description
Manufacturer
Motor
Type
Rated
Shaft
Power
Power Current
kW
kW
Rated
Page 1 of 1
Rated
Voltage
Frequ. Protection
Speed
RPM
Class
V
Hz
IP
Iso
Ex
Class Protection
Start
Remarks
control
EEx-
Customer:
Mahler AGS Job No.:
Revision:
Date:
WALCOT III
112200 715
1
07-11-2011
LIST OF VALVES WITH ACTUATOR

TAG No.
Description
Manufacturer
Type
DN
PN
Medium
Material
body
VX00-54
21.11
Shut-off valve
Gem
514 40D
1 9 51 2
G
1,5"
10
Nitrogen
XV00-51
21.22
Shut-off valve
Gem
514 25D
1 9 51 2
G 1" 10
Nitrogen
XV0052
21.23
Shut-off valve
Gem
514 25D
1 9 51 2
G 1" 10
Nitrogen
XV00-53
21.10
Shut-off valve
Gem
514 40D
1 9 51 2
G
1,5"
Nitrogen
XV00-55
21.12
Shut-off
butterfly vlave
Gefa
Gem
HG1.6666
TG
50
25 Process Air
XV00-56
21.13
Shut-off
butterfly vlave
Gefa
Gem
HG1.6666
TG
50
XV00-57
21.14
Shut-off
butterfly vlave
Gefa
Gem
HG1.6666
TG
XV00-58
21.15
Shut-off
butterfly vlave
Gefa
Gem
XV00-59
21.16
Shut-off valve
Gem
kvs-
Actuator Faile safe
value Type / Size position
CC499K,
red brass,
PTFE,
CC499K,
red brass,
PTFE,
CC499K,
red brass,
PTFE,
CC499K,
red brass,
PTFE,
Solenoid
valve
Positioner /
Additional
Pres. reducer equipment
US
UV /PC
Protection
Electr.
Ex
data
type 2
120mm
NC
8357 6M 114
21230 50
type 2
120mm
NC
8357 6M 114
21230 50
type 2
120mm
NC
8357 6M 114
21230 50
type 2
120mm
NC
8357 6M 114
21230 50
stainless
steel, PTFE
APM
4,5SR, F10
NC
8357 6M 114
21230 50
25 Process Air
stainless
steel, PTFE
APM
4,5SR, F10
NC
8357 6M 114
21230 50
80
25 Waste Gas
stainless
steel, PTFE
APM
3,5DA, F07
8458 6M 114
21230 50
HG1.6666
TG
80
25 Waste Gas
stainless
steel, PTFE
APM
3,5DA, F07
8458 6M 114
21230 50
514 40D
1 9 51 2
G
1,5"
CC499K,
red brass,
PTFE
type 2
120mm
NC
8357 6M 114
21230 50
10
10
Nitrogen
Page 1 of 2
230V
50Hz
4,9 VA
230V
50Hz
4,9 VA
230V
50Hz
4,9 VA
230V
50Hz
4,9 VA
230V
50Hz
4,9 VA
230V
50Hz
4,9 VA
230V
50Hz
4,9 VA
230V
50Hz
4,9 VA
230V
50Hz
4,9 VA
Customer:
Mahler AGS Job No.:
Revision:
Date:
WALCOT III
112200 715
1
07-11-2011
LIST OF VALVES WITH ACTUATOR

TAG No.
Description
Manufacturer
Type
DN
PN
Medium
Material
body
XV00-60
21.17
Shut-off valve
Gem
514 40D
1 9 51 2
G
1,5"
10
Nitrogen
XV00-62
7.12
Shut-off valve
Gem
514 40D
1 9 51 2
G
1,5"
10
Nitrogen
Product
XV00-63
7.13
Shut-off valve
Gem
514 40D
1 9 51 2
G
1,5"
10
Nitrogen
to atm
XV00-64
12.09
Solenoid Valve
Nitrogen
Product
( O2 )
XV00-72
8.25
Shut-off valve
Buschjost
83040
20
16
chilled
water
XV00-80
18.25.1
Solenoid Valve
XV00-81
18.25.2
Solenoid Valve
Nitrogen
Product
( H2O )
Nitrogen
Product
( H2O )
kvs-
Actuator Faile safe
value Type / Size position
CC499K,
red brass,
PTFE,
CC499K,
red brass,
PTFE,
CC499K,
red brass,
PTFE,
Solenoid
valve
Positioner /
Additional
Pres. reducer equipment
US
UV /PC
Protection
Electr.
Ex
data
230V
50Hz
4,9 VA
230V
50Hz
4,9 VA
230V
50Hz
4,9 VA
type 2
120mm
NC
8357 6M 114
21230 50
type 2
120mm
NC
8357 6M 114
21230 50
type 2
120mm
NC
8357 6M 114
21230 50
NC
for more
details Edocu
steel cast
5,8
NC
230V
50Hz
20 VA
NC
NC
Page 2 of 2
for more
details Edocu
for more
details Edocu
Customer:
Mahler AGS Job No.:
Revision:
Date:
WALCOT III
112200 715
1
07-11-2011
LIST OF MANUAL VALVES

TAG No.
12.11
12.12
21.25
21.30
21.41.1
21.42.1
21.43.3
21.44.3
3.06
3.09
3.12
3.14
3.16
Description
Manufacturer
Type
DN
PN
equipment
Nitrogen
JS 1049
APZ EN10204 3.1
1/2"
10
drain
waste gas
brass
G1/2"
400
Nitrogen
1.4571
G1/2"
400
Nitrogen
1.4571
100
Natural Gas
1.4571
G1/2"
400
Natural Gas
1.4571
40
16
Process Air
JS 1049
40
16
Process Air
cast iron
40
16
Process Air
cast iron
40
16
Process Air
JS 1049
APZ EN10204 3.1
40
16
Process Air
JS 1049
APZ EN10204 3.1
G1/2"
70
Ball valve
Riegler
390.03
G1/2"
70
Shut-off valve
Ari
FABA-Plus, straight through,

Type 2204600250G1
40
Ball valve
MAGS
standard
Pressure gauge valve
Schneider AS
Schneider AS
Three valve manifold
Schneider AS
Schneider AS
Shut-off valve
Ari
Ball valve
BEE
Ball valve
BEE
Shut-off valve
Ari
Shut-off valve
Ari
Page 1 of 3
body
16
390.03
S004.16.200
clamp socket plug
Type 2204600500G1
71MS-40-16-F-E-R27-0
certificate 10204-3.1
71MS-40-16-F-E-R27-0
Type 2204600500G1
Type 2204600500G1
Additional
1.4401
1.4408
1.4401
1.4408
Riegler
S341.36.210
Material
Instrument Air
to O2 analyser
Nitrogen
to O2 analyser
Ball valve
S004.16.200
clamp socket plug
S004.16.200
clamp socket plug
Medium
for manometer
PI00-55
for manometer
PI00-56
for dp transmitter
PDIRAHL00-55
for dp transmitter
PDIRAHL00-56
APZ EN10204 3.1
gasket set E
PTFE-GF & -FKM
gasket set E
PTFE-GF & -FKM
Customer:
Mahler AGS Job No.:
Revision:
Date:
WALCOT III
112200 715
1
07-11-2011

TAG No.
3.19
3.40.1
3.41.1
4.22
7.03
7.05
7.06
7.09
7.16
7.19
7.23
7.24
7.26
Description
Manufacturer
Ball valve
BEE
Schneider AS
Schneider AS
Shut-off valve
Ari
Ball valve
BEE
Ball valve
BEE
Ball valve
BEE
Shut-off valve
Ari
Ball valve
BEE
Ball valve
BEE
Ball valve
BEE
Ball valve
BEE
Ball valve
BEE
Type
DN
71MS-25-16-F-E-R27-0
S004.16.200
clamp socket plug
S004.16.200
clamp socket plug
Type 2204600400G1
71MS-25-16-F-E-R27-0
71MS-40-16-F-E-R27-0
71MS-40-16-F-E-R27-0
Type 5504600400G1 O2-version
71MS-40-16-F-E-R27-0
71MS-25-16-F-E-R27-0
71MS-40-16-F-E-R27-0
71MS-40-16-F-E-R27-0
71MS-40-16-F-E-R27-0
Page 2 of 3
PN
Medium
Material
Additional
body
equipment
25
16
drain
process air
cast iron
G1/2"
400
Process Air
1.4571
G1/2"
400
Process Air
1.4571
40
16
Nitrogen
JS 1049
25
16
drain N2
4500-V11
cast iron
40
16
Nitrogen
cast iron
40
16
Nitrogen
cast iron
40
16
Waste Gas
1.4408
40
16
Nitrogen
cast iron
25
16
drain N2
4500-V12
cast iron
40
16
Nitrogen
cast iron
40
16
Nitrogen
cast iron
40
16
Nitrogen
cast iron
gasket set E
PTFE-GF & -FKM
for manometer
PI00-51
for manometer
PI00-52
APZ EN10204 3.1
gasket set E
PTFE-GF & -FKM
gasket set E, PTFEGF & -FKM
gasket set E
PTFE-GF & -FKM
APZ EN10204 3.1
O2 Version QA026
gasket set E
PTFE-GF & -FKM
gasket set E
PTFE-GF & -FKM
gasket set E
PTFE-GF & -FKM
gasket set E
PTFE-GF & -FKM
gasket set E
PTFE-GF & -FKM
Customer:
Mahler AGS Job No.:
Revision:
Date:
WALCOT III
112200 715
1
07-11-2011

TAG No.
7.27
7.41.1
7.42.1
7.45.1
7.48.2
7.54
8.26
8.27
9.00
9.02
9.03
9.04.1
9.08
Description
Manufacturer
Ball valve
BEE
Schneider AS
Schneider AS
Schneider AS
Manometer double valve
Schneider
Shut-off valve
Ari
Shut-off valve
Ari
Ball valve
BEE
Ball valve
BEE
Ball valve
BEE
Ball valve
BEE
Schneider AS
Ball valve
Riegler
Type
DN
71MS-40-16-F-E-R27-0
S004.16.200
clamp socket plug
S004.16.200
clamp socket plug
S004.16.200
clamp socket plug
S004.60.200
clamp socket plug
Type 2204600400G1
Type 2204600200G1
71MS-20-16-F-E-R27-0
71MS-25-16-F-E-R27-0
71MS-25-16-F-E-R27-0
71MS-25-16-F-E-R27-0
S004.16.200
clamp socket plug
390.03
Page 3 of 3
PN
Medium
Material
Additional
body
equipment
gasket set E
PTFE-GF & -FKM
for manometer
PI00-57
for manometer
PI00-60
for manometer
PI00-61
for press. transm.
PIR00-64
40
16
Nitrogen
cast iron
G1/2"
400
Nitrogen
1.4571
G1/2"
400
Nitrogen
1.4571
G1/2"
400
Nitrogen
1.4571
G1/2"
100
Sauerstoff
1.4571
40
16
Nitrogen
JS 1049
APZ EN10204 3.1
20
16
chilled water
JS 1049
APZ EN10204 3.1
20
16
chilled water
cast iron
25
16
instrument air
cast iron
25
16
instrument air
cast iron
25
16
instrument air
cast iron
G1/2"
400
Instrument Air
1.4571
G1/2"
70
Instrument Air
drain
1.4401
1.4408
gasket set E
PTFE-GF & -FKM
gasket set E
PTFE-GF & -FKM
gasket set E
PTFE-GF & -FKM
gasket set E
PTFE-GF & -FKM
for manometer
PI00-67
Customer:
Mahler AGS Job No.:
Revision:
Date:
WALCOT III
112200 715
1
07-11-2011
LIST OF ELECTRICAL INSTRUMENTATION

TAG No.
FAL00-51
8.29
PAL00-63
7.47
PDIRAHL
00-55
21.43
PDIRAHL
00-56
21.44
PIR00.64
7.48
PSAL00-53
3.44
PSHL00-62
7.46
TIS00-55
3.56
Description
Manufacturer
Type
Medium
Adjusted
Process
Protection
Electr.
range
connection
Ex
data
Remarks
Flow meter
Krohne
DW182
chilled water
250 - 2000
Ltr / h
DN15 / PN40
no
reed contact
switch
Pressure switch
Pinter
Manocomb
MO111B-026-CAO
Nitrogen Product
0-10 bar
G1/2"
Eexi
micro switch
Pressure Difference
Transmiter
Emerson
2051CD3A02A1BHJB1I1D
4Q4
Nitrogen
-600 up to 600
mbar
M20x1,5
ATEX
HART
dp adsorber bed
Pressure Difference
Transmiter
Emerson
2051CD3A02A1BHJB1I1D
4Q4
Nitrogen
-600 up to 600
mbar
M20x1,5
ATEX
HART
dp adsorber bed
Pressure Transmiter
Emerson
2088G2S22B2M7Q4
Nitrogen
0 - 10 bar
M20x1,5
ATEX
HART
with local display
Pressure switch
Pinter
Process Air
0-10 bar
G1/2"
Eexi
micro switch
Pressure switch
Pinter
Nitrogen Product
0-10 bar
G1/2"
Eexi
micro switch
Temperature switch
Wika
Process Air
0 60C
G1/2 B
Ex II 2 GD
contact standard
Manocomb
MO111B-026-CAO
Manocomb
MO131B-026-CAO
A5501-S-C1C-GDB100G1-Z3Z
fluid filled, 300mm
Page 1 of 1
process data:
1500 Ltr / h
1x switch
gold contactor
1x switch
gold contactor
2x switch
gold contactor
thermowell /
NG160
Customer:
Mahler AGS Job No.:
Revision:
Date:
WALCOT III
112200 715
1
07-11-2011
LIST OF LOCAL INSTRUMENTATION

TAG No.
FI00-53
4.27
FI00-57
21.24
PDI00-59
7.32
PI00-51
3.40
PI00-52
3.41
PI00-55
21.41
PI00-56
21.42
PI00-57
7.41
PI00-60
7.42
PI00-61
7.45
PI00-67
9.04
TI00-53
3.53
TI00-54
3.55
Description
Manufacturer
Flow meter
Krohne
Flow meter
Krohne
Pressure difference
Manometer
Zander
Pressure gauge
Wika
Pressure gauge
Wika
Pressure gauge
Wika
Pressure gauge
Wika
Pressure gauge
Wika
Pressure gauge
Wika
Pressure gauge
Wika
Pressure gauge
Wika
Temperature gauge
Wika
Temperature gauge
Wika
Type
Medium
H250 RR M9, ss
flow left to right
H250 RR M9, ss
flow upwards
standard version
233.55-E-BG410Z-GD-UZHZCZZ-ZZZ
fluid filled
fluid filled
fluid filled
fluid filled
fluid filled
fluid filled
fluid filled
fluid filled
A5501-S-C1C-GD-B100G1-ZZZ
fluid filled, 100mm
fluid filled, 100mm
Page 1 of 2
Measuring
Process
Remarks
range
connection
Nitrogen
28 - 280 Nm/h
DN40 PN40
Nitrogen
5 - 50 Nm/h
DN25 PN40
Nitrogen
Process Air
0 - 10 bar(g)
G1/2 B
100 / 316L / SS
Process Air
0 - 10 bar(g)
G1/2 B
100 / 316L / SS
Nitrogen
0 - 10 bar(g)
G1/2 B
100 / 316L / SS
Nitrogen
0 - 10 bar(g)
G1/2 B
100 / 316L / SS
Nitrogen
0 - 10 bar(g)
G1/2 B
100 / 316L / SS
Nitrogen
0 - 10 bar(g)
G1/2 B
100 / 316L / SS
Nitrogen
0 - 10 bar(g)
G1/2 B
100 / 316L / SS
Instrument Air
0 - 10 bar(g)
G1/2 B
100 / 316L / SS
Process Air
0 60C
G1/2 B
thermowell / NG160
Process Air
0 60C
G1/2 B
thermowell / NG160
Working conditions:
6,5bar(g), 30C
Working conditions:
7,0bar(g), 30C
to check filter
7.30
Customer:
Mahler AGS Job No.:
Revision:
Date:
WALCOT III
112200 715
1
07-11-2011
LIST OF LOCAL INSTRUMENTATION

TAG No.
TI00-57
8.83
TI00-65
7.51
Description
Manufacturer
Temperature gauge
Wika
Temperature gauge
Wika
Type
Medium
A5501-S-CBB-GD-B100G1-ZZZ
fluid filled, 100mm
fluid filled, 300mm
Page 2 of 2
Measuring
Process
Remarks
range
connection
Chilled Water
-20 60C
G1/2 B
thermowell / NG160
Nitrogen
0 60C
G1/2 B
thermowell / NG160
Customer:
Mahler AGS Job No.:
Revision:
Date:
WALCOT III
112200 715
1
07-11-2011
LIST OF MEASURING ORIFICES

TAG No.
Description
Manufacturer
DN
Material
PN
Pipe
Medium
Nom. density
Orifice
kg / Nm3
Page 1 of 1
Measuring
Differential
Working
Working
range
pressure
pressure
temperature
mbar
bar(g)
Customer:
Mahler AGS Job No.:
Revision:
Date:
WALCOT III
112200 715
1
07-11-2011
LIST OF SAFETY VALVES

TAG No.
Description
Manufacturer
Type
Material
Medium
body
Inlet
Set
pressure
Outlet
Certified
DN
PN
Facing
DN
PN
Facing
flow
bar(g)
PSV00-85
7.15
Safety Valve
Leser
4331.4044
GGG40 / .7043
Nitrogen
10
40
16
B1
40
16
B1
PSV00-86
7.15.1
Safety Valve
Leser
4331.4044
GGG40 / .7043
Nitrogen
10
40
16
B1
40
16
B1
PSV00-89
3.17
Safety Valve
Leser
4331.4024
GGG40 / .7043
Process Air
10
25
16
B1
25
16
B1
PSV00-93
8.28
Safety Valve
Leser
4373.2604
1.4104 / 430
chilled water
10
G1/2"
16
G1/2"
16
Page 1 of 1
certificates
3.1 material
3.2 pressure
certificates
3.1 material
3.2 pressure
certificates
3.1 material
3.2 pressure
certificates
3.1 material
3.2 pressure
Customer:
Mahler AGS Job No.:
Revision:
Date:
WALCOT III
112200 715
1
07-11-2011
LIST OF PIPING COMPONENTS

TAG No.
21.03.1
21.03.1
3.10
4.25
7.25
7.30
7.55
9.04
FC00-52
4.26
FO-00-70
21.05.1
FO-00-71
21.05.1
PC00-51
3.11
Description
Manufacturer
Type
DN
PN
Medium
Material
Remarks
Flow Deflector
Clauss
perforated cone plate
80
10
Waste Gas
steel
noise reduction, flow correction
Flow Deflector
Clauss
perforated cone plate
80
10
Waste Gas
steel
noise reduction, flow correction
Strainer
Ari
230500050G1
diagonal flow
50
25
Nitrogen Product
JS1049
with fine and std sieve (0,25mm)

APZ EN10204 3.1
Check Valve
Gestra
RK 86
40
6-40
Nitrogen Product
1.4317 / SS
EPDM, 5mbar spring
Strainer
Ari
230500040G1
diagonal flow
40
25
Nitrogen Product
JS1049
Gas Filter
Zander
GL12VLDH
G1,5"
16
Nitrogen Product
Check Valve
Gestra
RK 86
40
6-40
Nitrogen Product
1.4317 / SS
EPDM, 5mbar spring
Check Valve
Riegler
220.05-ES
G 1"
40
Nitrogen Product
stainless steel,
FKM
for PC00-66, dp 200mbar
Flow Control Valve
Samson
type 42-36
2423, 2426
32
16
Nitrogen Product
EN-JL1040,
EPDM
3.1 certificates for material & function

Kvs 16, Cv 20
Aperture Plate
Clauss
restrictor
40
10
Nitrogen
brass
for adsorber refilling
Aperture Plate
Clauss
restrictor
40
10
Nitrogen
brass
for adsorber refilling
Pressure Relief Valve
Samson
type 41-23
2412, 2413
50
16
Process Air
EN-JL1040,
EPDM

Kvs 32, Cv 37
Page 1 of 2
with fine and std sieve (0,25mm)

APZ EN10204 3.1
99,95% >3m filter element 1/3050
with different pressure manometer
Customer:
Mahler AGS Job No.:
Revision:
Date:
WALCOT III
112200 715
1
07-11-2011
LIST OF PIPING COMPONENTS

TAG No.
Description
Manufacturer
Type
DN
PN
Medium
Material
Remarks
PC00-58
4.24
Samson
type 41-73
2417, 2413
32
16
Nitrogen Product
EN-JL1040,
EPDM

Kvs 16, Cv 20
PC00-66
9.01
Pressure Filter Reducer
Riegler
Standard 678.43K
G 1"
16
Instrument Air
main supply
polycarbonat cap
0,5-10 bar, 40m, 6bar(g)
PC00-96
7.17
Samson
type 41-23
2412, 2413
40
16
Nitrogen Product
EN-JL1040,
EPDM

Kvs 16, Cv 20
Page 2 of 2
Customer:
Mahler AGS Job No.:
Revision:
Date:
WALCOT III
112200 715
1
07-11-2011
LIST OF FILLING MATERIALS

TAG No.
21.00
21.03
21.04
Description
Manufacturer
Type
Amount
Remarks
Carbon Molecular Sieve
Mahler AGS
F5
1312 kg
filling 656 kg each adsorber
Ceramic Balls
Mahler AGS
ceramic balls 3/4"
10 bags
each 50 ltr (30kg)
filling finish for adsorber bed 21.00
cocos matte
Mahler AGS
2 pc
eac adsorber one piece
Page 1 of 1
Customer:
Mahler AGS Job No.:
Revision:
Date:
WALCOT III
112200 715
1
07-11-2011
LIST OF BURNERS
TAG No.
Description
Manufacturer
Type
Capacity
Fuel
Page 1 of 1
Remarks
nom.
max.
kW
kW
Customer:
Mahler AGS Job No.:
Revision:
Date:
WALCOT III
112200 715
1
07-11-2011
LIST OF MISCELLANEOUS COMPONENTS

TAG No.
Description
Manufacturer
Type
Quantity
Dimensions
Remarks
Concrete shaker
Vibratec
230V / 50Hz
1 pc
80 x 80 x 15 cm
30 kg
for densifying of melecular sieve

during filling procedure (commissioning)
Flow control dew ponit nanalyser
Krohne
details see electric documetation
Oxygen Analyser
AMS
Dew Point Analyser
Mitchell
FAL00-65
18.25.3
QIRSAH
00-51
12.00
QIRSAH
00-56
18.225
Page 1 of 1

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Operating Manual

Nitrogen-Generation Plant 220 Nm3/h

Pos.- / Item No.

Nitrogen Generation Plant

If you have technical questions regarding

Description of the Plant

Initial Start-Up of the Plant

Shut-Down of the Plant

Service and Maintenance

Mechanical safety devices

Binary automatic safety devices

Electrical analog automatic safety devices

Emergency stop functions

Instruments, pipes and vessels

Safety protection while working at the plant

Walcot III 112200715/00

1.1 Symbols Used

No fire, open light and smoking.

Walcot III 112200715/00

Frictional heat (ex.: overheated bearings).

Material marked with this symbol can cause death or considerable

Walcot III 112200715/00

1.2 General notes

Observe the operating and safety instructions of the appendix!

Walcot III 112200715/00

Works connected with electrical equipment of the plant ought to be

Walcot III 112200715/00

1.4 Safety devices

1.4.2 Binary automatic safety devices

Walcot III 112200715/00

1.4.3 Electrical analog automatic safety devices

Walcot III 112200715/00

1.4.4 Emergency stop functions

1.5 Filling materials

1.6 Instruments, pipes and vessels

Walcot III 112200715/00

1.7 Safety protection while working at the plant

Walcot III 112200715/00

Compressed air for PSA-feed

Walcot III 112200715/00

2.1 General Information

Ambient design pressure:

Relative humidity (min. / max.):

2.2 Process Data

Dewpoint - 40C at 1013 mbar.

Pressure downstream N2-PSA:

approx. 6,5 bar(g)

Product pressure downstream

approx. ambient temperature

Walcot III 112200715/00

2.2.2 Power Consumption

2.2.3 Compressed air for PSA-feed

average 650 Nm3/h

Pressure (min. / max.):

7,5 / 9,5 bar(g)

approx. + 4C (at 9,5 barg)

2.2.4 Instrument air

2.2.5 Chilled water

approx. 1,5 m3/h

Pressure (min. / max.):

Walcot III 112200715/00

Description of the plant

Walcot III 112200715/00

3 Description of the plant