Operation Material 2016

GAS INTEGRATED MANAGEMENT SYSTEM Doc. Ref.
:
BUSINESS SUPPORT DEPARTMENT Training Section
Training & Development Section 01-Jun-2016

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Operation Material
Operation Material
PLANT AREA
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GAS INTEGRATED MANAGEMENT SYSTEM Doc. Ref.:

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Review Of Progression Level 1 By Tutors.

Before starting the training session of progression level 2 Tutors should briefly review
progression level 1 material with the help of following topics discussions.
1- What are products of ASU plants and how GAS as company is distributing it
products to customers?
2- Why filtration process required in process plants?
3- How Air Separation Plants feed filtration is carried out?
4- Why compression process is required for ASUs process plant.
5- What type of compressors used for compression in GAS?
6- How pre-cooling process is functioning in ASU process plant?
7- How many systems of feed purification are applied in GAS ASUs?
8- What is the function of turbine in ASU process plant?
9- What methodologies are used in GAS to utilize turbine power as get generated?
10- How cool down process of feed air in ASU process plant is vital important?
11- What type equipments are installed in GAS ASU plant for feed cool down?
12- How distillation takes place in distillation column?
13- What are main parts of column?
14- Why liquid storage is required with ASU plants in GAS?
15- What type of liquid storages are available in GAS?
16- How many type of GAS compressions are for industrial gases?
17- What type of liquid pump are available with GAS plants?
18- How Liquid product transportation is carried out in GAS?
19- How GAS employee will report road tanker hazard from field?
20- How field operator will do his 1st visit to plant area?
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Plant Safety
Note. Plant safety notes are provided in progression level 1 for awareness.
OXYGEN SYSTEM HAZARDS.

All information based on Air Product oxygen hazards training session material.
Oxidation term very commonly used to explain oxygen reaction with metals and oxide of
metal get develop. Ferrous/ ferric oxide are 2 oxides of iron and common name is RUST.
Other oxidizers are:-
1-Flourine.
2-Chlorine.
3-Nitrous Oxides (N2O4 or NO2)
All these chemical reactions of elements is named as oxidation.
As ASU process is basically to produce oxygen. Nitrogen as gas /liquid is also available on
plant site. Plant area can have following atmospheric conditions:-
1-Oxygen enrichment. If concentration of oxygen get increase to 23.5% due

to any reason like gas venting or LOX leakage, Area
oxygen enrichment must be declared for
precautionary measurements.
2- Fire Hazard. If oxygen concentration get increase in between 23.5
to 40% fire hazard risks need to treat as important
one in area.
3-Discussion. If oxygen concentration get increase above 40% and
less than 80% a detail discussion should be carried
out to do analysis of related hazards.
4-Pure Oxygen. If concentration of oxygen in plant atmosphere get
increase above 80% it will treated as pure oxygen and
all hazards related to pure oxygen will be considered.
5-Oxygen deficiency. If concentration of oxygen get decrease to 19.5% due
to any reason like nitrogen gas venting or LIN
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leakage, Area oxygen deficiency must be declared for

precautionary measurements.
Filtration
Why do we need filtration?
In ASU process filtration is needed to protect air compressors and working stream
pipeline from any foreign particles that lead to damage or blockage to the system.
If there is no filter installed on process pipeline, during long run of operation a lot of
unwanted impurities will move with the feed to the system causing damage the
equipment and blocked the system.
All type of air filters performance is effected by DUST and Moisture . Special
attention is recommended during stormy and humid conditions of atmosphare.
Air Filter Environment and Safe Operation
Vacuum
The down streamside of the air filter leads to the suction conditions of the air.
compressor operates at a slight vacuum head pressure. Operator will suffer from this
vacuum effect during doing internal inspection. All safety measures should be observed
when filter internal inspection in required.
Operating Conditions
Fuel Operated equipment should not be allowed near the air filter area to
avoid potential accumulation of organic compounds in the process leading to
potential explosion in clod box. All these areas must be marked clearly.
Change filters
If the standby filter is available than change over can be done such
as lube oil filters.
If There is NO standby filter than filter elements should only be changed when the plant or
equipment is shutdown.
Confined space Entry:-

MAC air filter consider as a Confined space, Confined space entry procedure shall be follow.
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Environmental Aspect.
Filter elements is to be disposed in accordance with Environmental Management System
(GIMS).
Other Industrial Filters
1-Oil filter:
An oil filter is provided to remove impurities and contaminants from re-
circulating lube oil supply for rotating part of machines or an equipments
hydraulic oil (Jacking oil) as it get return back from gear box after lubrication.
Two oil filters are provided to kept one in operation and one in standby to run
the equipments continuously during filter cleaning.
Oil filter operational limitations:-

As soon as pressure difference of both oil streams get increase to 0.8 ~ 1.0
kg/cm2, Filter element should be changed over to stand by one. Pressure
difference is calculated as under:-
P1 Oil pressure before oil filter.
P2 Oil pressure after oil filter.
DP P1-P2
Oil Filter Changeover

Mostly Lube oil filter equipped with three way valves which maintain always
one filter on line and other one on standby condition.
NOTE: For change over follow the vendor procedure.
Oil filter are provided with proper access to remove filter mesh for cleaning or
replacement.
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Figures below for oil filter cartridge:-
Add Synthetic type filter
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Water Filter/ strainers:

A water filter removes impurities from water by means of a fine physical mesh
filter or strainer These impurities can be due to chemical process or a
biological process in the water or pipeline corrosion/erosion .
Differential pressure gauge always installed across the filter or strainer, if the
P increases to the required limit Process flow and pressure will change, in such
situation equipment must be change over and replace or clean the filter
cartridge / strainer by mechanical.
Figures below give different shapes of water strainers.
Types of Filters / Strainers:
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Strainers can be classified into two main types according to their body
configuration named as Y-Type and the Basket Type but still there are some
other types such as Backwashing Type FILTER.
Backwashing type Filters / Strainers

Reverse the direction of flow through the screen. A set of valves is changed
over so that water is directed across the screen in the reverse direction and
out through a flush valve. The fluid dislodges any debris entrained in the
screen and carries it out in the backwash fluid to a waste drain.
SW system at the inlet of Plate Heat Exchangers and DCACs water outlet
streams are some time provided with back flush or back wash type water
Filter / Strainers.
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D-Temporary strainers
Temporary strainers are designed for protection of equipment and
instrumentation during start-up periods. The strainer is usually installed
between a set of flanges for an initial period after a new plant has been
erected. Installation of a spool piece equal or more than the length of the
strainer is recommended for easy installation or removal of strainer.
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Compression
Compression term is simply increasing gas pressure. In molecular terms, increased
pressure will cause molecules hitting the sides of an enclosed space more frequently.
This can be achieved by
forcing a given volume of molecules to occupy a smaller volume
increasing the temperature so that molecular motion is increased.
increasing Kinetic energy so that molecular motion is increased.
Many type of compressors are used in process industry. In ASU process only
Reciprocating or centrifugal compressors are used depending upon nature of process
and capacity of plant. In Tonnage plant centrifugal compressors are preferred.
NOTE: GAS YANBU AND JUBAIL HAVE ALL CENTRIFUGAL PROCESS

COMPRESSORES.
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ASU process is based on free air as raw material and table below provide air features.
Table below will provide contaminants availability in free air AFTER FILTER.
NAME CHEM CONC. IN FREEZING NORMAL CRITICAL CRITICALP MOLECULAR

CALSY AIR % RESS. WEIGHT
MBOL POINT oC B.P. Co TEMP. Co KG/CM2 g/mole
PRODUCTS GROUP
oxygen O2 20.95 -218 -183 -118 51.3 32
NITROGEN N2 78.113 -210 -196 -147 34.6 28
Argon Ar 0.931 -189 -186 -122 49.6 40
Krypton Kr 0.0001 -157 -153 -64 56.0 83.8
Xenon Xe 0.000009 -112 -107 17 60.1 131
Neon Ne 0.0018 -249 --246 -229 28.13 20
Helium He 0.0005 -272 -269 -268 2.335 2
Hydrogen H2 0.00002 -259 -254 240 13.4 1----2
BLOCKING MATERIAL FOR PHE

Water H2O Up to 4-5 0 100 374 225.7 18.016
Nitrous Oxide NO -163.3 -152.0 -94.0 67.2 30.008
Hydroch. acid -114.3 -85.0 +51..4 85.7 36.465
Hydrogen Sulf H2S -85.5 -60.4 +100.4 91.937 34.082
Sulferr dioxide -75.5 -10.0 +157.7 80.22 64.066
Carbon dioxide CO2 0.035 -56.5 -78.5 +31.0 75.3 44.011
Ammonia NH3 -77.7 -33.4 +132.4 115.2 17.032
Nitrous Oxide N2O -90.8 -88.7 +36.5.4 74.1 44.016
HYDROCARBONS EXPLOSIVE ELEMENTS

Methane CH4 -182.5 -161.5 -82.5 47.12 16.043
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Ethane C2H6 -183.3 -88.6 +32.1 49.8 30.070
Ethylene C2H4 -165.5 -103.9 +9.6 52.6 28.054
Acetylene C2H2 -81.5 -83.6 +36.0 64.0 26.038
Propane C3H8 -187.8 -42.3 +96.8 43.4 44.097
Propylene C3H6 -185.4 -47.7 +92.1 46.6 42.081
Others H/ C HnCn ---- ----- ------ ------- --------
As air get free from dust and enter to compressor for process of compression, Different
type of compressors are used for compression. Common type of compressors are :-
1-Centrifugal compressor.
2-Reciprocating compressor.
1-Centrifugal compressor.
Centrifugal compressor are available in a no. of varieties. The selection of compressor
depends upon process requirement. As air is ASU feed, commonly compressor is
named as air compressor. Air compressors are commonly in multi stage construction .
In GAS for ASU process 3 stage, 4 stage and 5 stage air compressors are in service.
Why Centrifugal Compressor preferred for ASU process:-

In these days ASU s are supplying gases to industries and industrial demands are
varying in low or high on regular basis. Centrifugal compressor have features to
regulate feed air within certain range supports to process to produce gases as needed.
This is why centrifugal compressors are preferred for ASU process.
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Centrifugal air compressor have following parts:-

1-Inlet Guide van.
2-Stage Impellor.
3-Stage casing diffuser.
4-Stage Casing.
5-Inter stage Heat Exchanger or Cooler.
6-Gear Box.
7-Lube. Oil system.
8-Electric Motor.
9-Antisurge control system.
10- Field information transfer instrument,(PTs, TTs, LTs, FTs, and PDTs)
1-Inlet Guide van.

Dust free air from air filter enters to air compressor 1st stage impellor after passing
through inlet guide van. Guide van opening will control air flow through centrifugal air
compressor. Inlet guide vane also helps to provide angle of inlet to impellor. All guide
vanes are operated by an electro-pneumatic operated actuator designed to operate
guide vane. It can be diaphragm type or on DP basis operation type.
Figures below for guide vanes as provided in systems:-
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Guide vane in close position
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Guide vane in open position.
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2-Impellor
Compressor impellor is mounted on shaft and housed in stage casing.
As impellor size goes bigger, Kinetic energy impart to air molecules get also high. In
other words discharge pressure of stage will be high.
Figure below for open end

compressor impellor.
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3-Casing diffuser:-
Diffuser is a stationary part of the Centrifugal compressor which is placed inside the
casing where it divert air to casing which is released from the impellor outlet.
Figure below for casing diffusers:
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4-Casing:-
Stage casing is an important unit of
compressor. It is supported on gear box housing. It

provide support to compressor inlet guide vane,
Stage diffuser and housing to impellor. Stage casing provides air inlet port to
compressor stage and also provide port with direction to deliver compressed air to
heat exchanger. Main function of casing is to occupy compressed air after diffuser as it
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get diverted to change kinetic energy of compressed air to potential energy. As a result
compressed air will get high pressure air before it get enter to heat exchanger.
In compressors stage casing is commonly made of good grade of steel to with stand
pressure, temperature and low erosion rate.
Compressor can have no. of stages depending upon process requirement. Normally
one impellor is housed in casing but some time more than one impellor can also be
housed in one stage casing.
Single stage compressor as nitrogen compressor.
Compressor casings supported on gear box.
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5-Inter stage Heat Exchanger or Cooler.
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As air Leaves from impellor, it got high molecule velocity. In stage casing kinetic energy
get transfer:-
1-To potential energy of air gases molecules in form of pressure of air.
2-To raise temperature of air gases molecules.
As air temperature get increase, Air gases molecule get apart from each other, Mass
flow of gases get low. To improve mass flow of gases it is essential to cool down air
gases to possible low temperature before it get enter to next compression stage.
Heat Exchanger in between the stages known as inter stage cooler and another heat
exchanger after final stage known as after cooler.
Commonly shell and tube type Heat Exchangers are arranged with compressors as
inter stage coolers.
Some time air is passing from shell side and some time cooling media is passing from
shell side. Assignment of flows depends upon duty of heat exchanger.
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Figure below for heat exchanger:-
U- Tube heat Exchanger
As steam traces in compressed air after compression will pass through heat exchanger
and get change to water and will get collected in basement of heat exchanger. This
water formation is called as condensate. Condensate formation rate depends upon
Humidity level of atmosphere. It is very important to remove condensate from heat
exchanger on regular basis to have good performance of heat exchanger. High level of
condensate in heat exchanger will have adverse effect on heat exchanger in heat
transfer process.
High level of condensate in heat exchanger will reduce air passage for air and can lead
air compressor to operate in surge area.
As air will undergo compression process and moisture will continue to knock out in
heat exchangers. Very small amount of moisture in form of steam will be available in
compressor final discharge flow.
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Air compressor all inter stage coolers are provided moisture drain trap to remove
condensate on regular basis.
Moisture drain trap functional layout diagram is as under:-
HEAT EXCHANGER
Moisture drain trap are arranges in GAS with air compressor Heat exchanger
(Intercoolers).
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6-Gear Box.
Gear box is an important structural part of an air compressor. It provides
support to all bearings, compressor seal system and casings of all stages. It
provide housing to speed up gear system as get arranged. (Bull Gear and Pinion
Gears)
BULL GEAR
Bull gear is a main driving gear that is bigger in size which is directly connected
with the driving motor shaft and used to increase the speed of the driven
Pinions gear.
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PINION GEARS
Pinion gears are a small gears mounted on a impellor shaft driven by Bull gear
to increase the RPM of each stage. They are different in size and RPM.
All these gears are HELICAL GEARS. See fig below:-
1ST AND 2ND STAGE SHAFT RPM. 5460 PINION 1 (Variable)
3RD STAGE SHAFT RPM. 8600 (PINION 2(Variable)
BULL GEAR SPEED RPM 1200 (MAIN MOTOR)
Bearings for stage shaft/bull gear.

Compressor shafts are normally supported by bearings to minimize friction between
two touching surfaces. These bearings are mostly GENERAL BEARINGS. Improved form
of general bearings are now in the form of PAD BEARINGS. In pad bearings in touch
area is reduced by using advance technology. There are 6 bearings in MAC to support 3
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shafts. AS there are 3 stages in MAC, one free end of shaft is provided with THRUST
BEARING to equalize axial thrust of 3rd stage. All bearings are lubricated with
recommended grade of oil. Bearing body is provided with temperature and vibration
measuring probes Vibration measuring probes are provided at X-AXIS and Y-AXIS
level.
Radial / Thrust bearings and seal on shaft
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7-Lube. Oil system.

Oil is used for lubrication of machine parts those comes in contact with each other
during power transfer for one to another and to keep parts in their position during
time of motion. Different types and graded oil are used for this purpose. Oil circulation
to parts is on cont. bases. One oil pump is running cont. and second one is kept in
stand by potion to take action as soon as low pressure alarm get activated. Oil pumps
are named as under:-
1-Main oil pump mostly screw oil pump coupled with main bull to
have a positive drive all time.
2-Aux. oil pump is a gear type pump driven by an electric motor on

low pressure alarm activation bases.
Oil get return back to oil reservoir with some seal gas as get leakage
to oil . oil in reservoir is make free of gas by extraction process of
gas. To extract this seal gas and oil vapors mist exhaust fan is
running on cont. bases. Oil demister is provided to minimize oil
droplets carry over to vent.
Main oil pump and Aux. oil pump outlets are joint in one header to
divert oil to oil cooler before returning it to machine for lubrication.
Required oil pressure for system is controlled a PCV valve placed on
this header.
Oil temperature is controlled by a TCV or TIC type valve by bypassing

oil flow across oil cooler.
Two oil filter elements are provided in parallel to each other so that
one stay in service all time and second element is kept in stand by
position for change over when ever DP of filter get increase to limit.
Oil temperature in oil reservoir is controlled by an electric heater.
Electric heater will come in service if oil temperature get drop below
20Co.
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Lube. Oil system arrangements for MAC.
Emergency Oil Reservoir

In some plants both lube oil pumps are operated by electric motor. In case of power
failure no oil supply to machine can cause damage to machine parts. To maintain oil
supply to machine as it is still in rotation, Emergency lube. Oil reservoir is provided in
system.
If one oil pump is driven by compressor main gear box, after power failure it takes
time to become in standstill position. Therefore oil supply to all parts continue without
any delay. Emergency lube. Oil reservoir is not provided in system.
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OIL / GAS SEAL

Oil is a poison for ASU process. Under no circumstances oil should get in touch
with process feed. Labyrinth gas seal system is provided to avoid mixing of oil
with gas, Labyrinth seal normally have 3 chambers. 1st chamber is rich in oil
vapors. 3rd chamber is pressurized with seal gas and 2nd chamber gets leakage of
seal gas and oil vapors. This mixture is removed continuously to avoid over
pressurizing from this chamber by vent arrangement. Sometime this vent is kept
at control pressure to minimize seal gas vent losses.
NOTE: NITROGEN IS MOST COMMONLY RECOMMENDED AS SEAL

GAS IN COMPRESSORS. DRY AIR FREE OFF MOISTURE CAN
REPLACE GAN.
FIG. BELOW FOR LABYRINTH SEAL.
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8-Primover.
Type of drivers.
1- Electric motor.
2- Steam Turbine.
3- Diesel engine.
Types of electric motors

Commonly there are 2 types of motors are available for service.
1. Induction Electric Motors.
2. Synchronies type electric motor.
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1- Induction Electric Motors.

These motors are consuming a very high power for startup torque and electrical
supply system will get over load for short time. Induction motor normally consume
6 to 8 time of it max. power consumption in startup torque. This power
consumption will be only for 30-40 seconds.
2- Synchronies type electric motor.

This type of motor takes longer time to acquire normal rotating RPMs. Power
consumption during start up is too low and power consumption increases as
rotations of motor increases and motor will consume power up to 30% of its
max. power consumption to acquire synchronies RPMs. It can take 2-3 min.
A complete soft start up system will help to carry out

motor start up.
Main compressors motors ( MAC / BAC / NCP) are normally high tension
motors with supply voltage as 13.8KV.
Motors Cooling Media:

There are two types of motors:
1. Water cool type
2. Air cool type.
Figure below for electric motor of Main Air Compressor.
Water cool type Motor.
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NOTE: Add Jubail (PH-2) Air cool type motor

picture.
1-EXCITER
Excitation system is provided with motor to run it at synchronized speed.
Exciter is provided at Non drive end (NDE) of motor shaft. Its working helps to
improve power factor of motor. For such motors power factor is 1.0 .
MOTOR COUPLING SYSTEM.

Motor and gear box are connected with a flexible shaft coupling system to
transfer motor power to bull gear of gear box.
Failures in this system are:-
1- Shearing of coupling bolts at motor drive end.

2- Shearing of coupling bolts at gear box drive end.
3- Failure of shaft due to deformation
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4- Failure of shaft due to misalignment.
9-Antisurge control system.

PRESSURE FLOW CONTROL
Rotary compressors are very sensitive in relation of pressure and flow
Of gas through machine. If pressure get high and flow of gas through
compressor get drop below certain level, compressor behavior goes in
unstable condition. This unsafe operation is called as SURGE AREA.
If a compressor continue to run in this operating zoon (Surging)
compressor component can be affected and machine may trip.
To run the compressor safely Anti Surge system has been provided.
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surge controller fig. is below for view:-
FIG NO.1
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FIG.NO.2
This controller is programmed to control operation of Anti Surge valve
at outlet of compressor to vent out gas to reduce outlet pressure. As a
result gas flow through compressor will increase and operation will be
in safe area. This controller is providing following information as guide
line to operator as under. All data information guide line are numbered
as under for easy understanding in fig 2.
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Anti surge controller Legend

1-Top legend plate indicating name of equipment being parameter.
2-Code letter display is indicating digital display values of parametric Controller
3-Selector switch for digital display is used to change display for No.2
4-Digital display field where all data get display during formatting and monitoring
5- Index for code letters indicating AUTO/MAN operation mode.
6-Decimal indication.
7-Four digit display.
8-Analog display, Actual value by RED light / Set point value by GREEN light.
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9-Raise /lower keys for set points and parameter. These both keys
whenever pushed together will RESET controller ERROR function.
10-Set point selection (I/E Key) (can be disabled)
11-Status display.
12-AUTO/MAN transfer key.
13-Raise or lower key for output variable (MV). To close valve on MAN.
Quickly.
14-Lower legend plate.
15-Handle for removal.
16-Module locking screw (E).
17-Output variable display.
18-Multi function key(F-Key).
Selector switch for digital display

This display indicates different letters X, W. Y ,A, YH, T, F ,,,,,,,,,.Operator must
understand functional meanings of these letters. Meanings are as under:-
X- Actual value of variable get develop after parameters calculation.
W-Response line position at that time.
A-Actual output of controller for valve position.
YH- Max. output permitted by operator.
F- Frequency of power supply.
T- Temperature at measuring point.
P- Pressure used for reference calculation.
Pre Cooling & Air Purification

Purification is required to remove impurities such as water, carbon dioxide, Sulfur dioxide,
Nitrous oxide and hydrocarbons from the feed air before cryogenic distillation can take place.
If not removed, impurities can cause blockage of cryogenic equipment.
Direct Contact Air Cooler /Trickling Cooler

(DCAC /Tr. cooler).
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The trickling cooler Or Direct Contact Air Cooler is a vertical, cylindrical vessel
containing trays or packing OR pall/Beta rings built up to various heights. process air
enters from the bottom. A demister is built in before the air outlet at the top. Cooling
down of process air after the air compressor prior to enter mole sieve. The air is
cooled down by contact with water over trays and packing rings in lower portion of
vessel. In upper zones of vessel the air is further cooled down by contact with chilled
water . The demister sieve serves to remove any drops of water still contained in the
cooled air stream. The warm water collects at the bottom of the vessel. The direct
cooler cools and washes air by direct contact with cooling water.
Differential Pressure
DCAC and EV. Cooler are provided with demister pads to hold water droplets carry
over to streams. It helps to minimize cooling water losses. As water carry over
generates scaling, demister pads will get chock and air passing will get channel
passages and water carry over with stream will increase.
Water carry over with stream will effect purification of Mol sieve and RHEs PHE.
PDI is provided to measure differential pressure across demister pads / packing in
DCAC and EV. Coolers.
Field operator is required to check PDIs regularly for preventive measures.
Level Control
For DCAC / Ev. Cooler Level control system (LIC) is provided to operate the equipment
safely. Alarms, Level switches and Interlocks system also provided with LOW/ LO
LO/HI/ HI HI to take action or shut down the equipments in safe mode.
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Paul rings are made of poly propylene and Beta rings are made of stainless
steel material.
Evaporating Cooler Introduction. (EV. COOLER)
The evaporating cooler cools the water against a flow of dry gas, normally pure
nitrogen and waste nitrogen but gas stream is replaced by wet air after DCAC
during plant start up. The water flows down wards through the packing from
top of the vessel and comes into contact with the rising dry gases. As a result
water is cooled down and collect at the bottom of vessel which is pumped to
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DCAC cooler. During the process humid gases leaving from the top of the
evaporating coolers
General Water pump change over.

Note: Follow operation Pump change over procedure
ALL EQUIPMENTS ARE ON REMOT START/SHUT DOWN

OPERATIONAL STATUS.
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Water treatment.
Cooling water supplies to DCAC /EV. Cooler are arranged on following basis:-
1- Chemically treated cooling water from cooling water header. (Sami close
circuit)
2- Process / potable water supply to EV. Cooler to maintain level (Close
circuit).
In close circuit system as process or potable water is supplied to EV. Cooler to

make up level, independent area water treatment is implemented to reduce
corrosion rate of Pre-purification unit. Different type of chemicals are
recommended by consultants depending upon nature of water during
recirculation process as follow.
System Treatment Application (Function) Product Name
Cooling Water 1.Corrosion , Scale Inhibitor, 1.HYDREX 2857 / 2910

DCAC (OPEN) Dispersant and pH control
2.Biocide
2.HYDREX 7918 /7310
3.Caustic Soda 49%
3.Caustic Soda 49%
Field operator must be made aware of nature of water treatment and

associated hazards from chemicals.
Chemicals handling and maintain chemicals MSDS

Records.
As chemical handlings are dangerous, Operator should read MSDS for material
Carefully and understand NFPA poster placed on chemicals storage container .
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If NFPA poster not available on site must be asked to arrange it.
Back flush Filter

In some plants DCAC and EV. Cooler water flow stream is provided with back flush type
stream filter. As all structure work is made of steel and corrosion will cause blockage in
drains and accumulation of sludge will be in EV. Cooler basement. As filter will have
regular back flushing, will help to keep system operation trouble free for longer time.
Drain Trap / Catch pot systems
As feed air is leaving DCAC / Trickling cooler after getting cool down with direct contact
with water. Air is carrying water vapours according to saturation point at gas
temperature. These vapours get change to water droplets during moving to next
purification unit. On Some plants DCAC outlet lines are provided with purge bottles
named as Catch Pot. Moisture drain traps are arranged with Catch Pot to remove water
condensate on regular basis. Drain traps bypass system is also provided to operate in
case malfunctioning of normal system .
Condensate level awareness to DCS operator is provided through level transmeter
reading.
Field operator have to check system functioning minimum twice in shift.
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Trickling/EV Cooler Safety operation

and Environmental Hazards
Isolate individual equipment safely during Normal operation /shutdown
A- DCAC cooler
As DCAC cooler is a confine space vessel as no direct cross ventilation of air is
possible. For isolation all confine space PTW requirements should get fulfilled.
B- EV. Cooler.
As EV. Cooler is a confine space vessel as no direct cross ventilation of air is possible.
For isolation all confine space PTW requirements should get fulfilled.
C- DCAC / Ev, Cooler pumps.

DCAC and EV. Cooler water pumps are required for maintenance and complete
procedure of lock out /tag out (LOTO) must get implemented and followed
procedure for safe hand over of equipment.
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Potential Hazards:
There are no major hazards associated with normal operation of the direct contact air
cooler and EV. cooler. The following potential hazards exist during maintenance.
1. Hazard caused by the fact that the direct cooler operates under pressure.
2. Asphyxiation.
Before maintenance, take the following safety precautions:

a) Isolate and depressurize all equipment before working on the direct cooler.
b) Check the oxygen content before entering the direct cooler vessel.
Entering the direct cooler /EV cooler vessel:

The direct cooler /EV cooler pipe work must be positively isolated with a blank or
spade before entering the direct cooler vessel.
Preparation for maintenance:
When preparing to maintain the direct cooler, ensure that:
1. A permit to work is obtained.
2. A confined entry certificate is obtained if working inside the cooler.
PPE for maintenance:

When performing maintenance on the cooler, you must wear the following personal
protective equipment:
Gloves
Eye protection
Air Purification
Contents of blocking material in feed air get reduce to minimum but not get
completely remove. Presence of these elements in feed air will block main heat
exchanger in HRS. only. Therefore complete removal of blocking material is
essential for smooth continuous plant operation. Different methods are used to
remove these impurities as under:-
In GAS 2 type of purification units are arranged as under:-
1- Mole sieve 2 beds arranged to remove Blocking and explosive group

elements.
2- RHE Heat exchanger type purification units to remove Blocking and
explosive group elements.
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Normally there are Two mole sieve vessels / Two banks of RHE are arranged with
every plant. One MS bed/ One bank of RHE stay in service for specified designed time
period and other under goes regeneration process.
MOLECULAR SIEVE: STAGE

This document will provide you the basic information regarding the molsieve
dryer construction, operation and function. Also it will facilitate with necessary
terminology associated with it operation. Trouble shooting and operational
problems will be also available for reference and help whenever required.
This document is self develop based on information from vendor (LINDE), for
reference LINDE MANUAL also can be considered.
FUNCTION OF UNIT
Compressed air after compressor is used as process feed. Process feed is
cooled down in process air cooler (PAC) with direct contact of water streams.
This feed air is enrich in unwanted impurities of the process these impurities
are:
1. Water Vapors
2. Carbon Dioxide
3. Oxides of Sulphar and Nitrogen.
4. Hydrocarbons
All these impurities are harmful for ASU operation as all these will get solidify
in heat exchanger and will block the feed air passage. To remove these
impurities and to keep ASU in continue operation. Two bed molsieve dryer is
arrange before heat exchanger. One bed stay in operation for specified time
while the other under goes the operation of regeneration so that it can be
switch to service at the end of cycle of operation.
These dryers or Mole Sieves are named as:
1. WEP Warn End Purifier
2. FEP Front End Purifier
3. PPU Pre-Purification Unit
4. MS-UNIT Mole sieve unit
NOTE: In GAS mol sieve term is used for all warm end purifiers/
driers.
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These molsieve dryers are arranged in horizontal or vertical positions

depending upon design matters. Size of dryer bed depends upon
process flow of air.
Figure below for horizontal layout of bed.
Figure below for vertical layout of bed.
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UNIT CONSTRUCTION
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The unit consists of two vessels made of mild steel and installed in horizontal
or vertical position. Inside the vessel a bed is arranged to support the
adsorbents layers those will be spread for the purposed of it function. Vessel is
provided with ports to allow the entry/exit of gases and for the entry of human
being for examination from top and bottom of grid. Also a port is provided to
remove the condensate during operation of service and regeneration. Air inlet
ports are provided with baffle plates to distribute the air gas uniformly. This
also avoids the direct hitting of air to bed from down side. Normal / Maple
butterfly types valves are provided in system to perform all necessary activities.
(See attached diagram 1A/B)
FLOW THROUGH SYSTEM
There are only three types of flows through the system are under:
1. Process Feed Air (wet air enters from
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bottom)
2. Regeneration gas 1. Waste Nitrogen

2. Dry Air
(Dry hot gas from top)
3. Impurities 1-Water Vapors

2-Carbon Dioxide and other
oxides
3-Hydrocarbons
ADSORBANDS SPECIFICATION
There are no. of types of absorbent are arranged in layer wise over the bed.
These are:
1. Inert ceramic ball

ceramic balls
2. Moisture absorbent silica
alumina
3. CO2 and hydrocarbon
absorbent mole sieve
beads ( 13 X )
4. CAX To remove CO2 and
N2 O
5. LMSK Mixture in powder
form. To adsorb
hydrocarbons.
WHAT ARE ADSORBENDS

INNERT CERAMIC BALL
Inert ceramic ball are ceramic balls with a size of 5-7mm in dia. These helps to
minimize water vapours flow toward alumina and also help to improve gas
distribution.
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SILICA ALUMINA
This is compound of silica and aluminum oxide that have a great efficiency to
absorb and release water vapors. They are in size 2-5 mm in dia.
Silica Gel :-
Silica gel is also used for low temperature ( cryogenic temperature -150 C )
adsorption of hydrocarbons and carbon dioxide.
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Molecular sieve 13X
It is used to adsorb the traces of carbon dioxide (CO) and some of other
hydrocarbon available in feed air. It is most commonly named with its grain
size a 13x or 16x. This is a compound of sodium aluminum silicate and also
known as ziolite. Sometimes it is also compound of different oxide bonded
together.
4-CAX ( AP. Plants)

Molecular sieve type 13X is used for combined N2O and CO2 removal. CAX is more
effective for removing CO2 than 13X but its adsorption capacity is affected by water.
Unwanted elements are removed from a feed air stream by a temperature swing
adsorption using a first adsorbent such as alumina to adsorb water, a second adsorbent
such as 13X to adsorb carbon dioxide and third adsorbent such as binder less calcium
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exchanged X zeolite (CAX) to adsorb nitrous oxide and optionally ethylene, prior to
cryogenic separation of the purified air stream.
Internal arrangements of vertical molsieve bed.
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Molsieve system layout
Molsieve beds are laid in horizontal or vertical position as designed by plant supplier.
As purification process is continuous process and changeover of beds takes place after
specified time period. To do smooth changeover of beds, beds are equipped with
butterfly type valve to change flow direction.. Depressurizing and pressurizing valves are
control valves and operate as programmed.
Molsieve purification process under goes following steps:-
1- Prepare for depressurizing.

2- Depressurizing step.
3- Prepare for heating step.
4- Heating step.
5- Prepare for cooling step.
6- Cooling step
7- Prepare for pressurizing step.
8- Pressurizing step.
9- Prepare for parallel operation step.
10- Parallel operation step.
In some plants operation, every step is delayed for specified time to confirm that bed
have acquired safe operational conditions before advancing to next step. This time
period is named as Prepare For Next Step.
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Molsieve Layout In Vertical Position
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Molsieve Layout In Horizental Position
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Molsieve Beds valve operation

Molsieve beds inlet , outlet and other valves are operating according to logic as
programmed, these valves can be open or closed by force during shut down.
These absorbents provided have certain capacity of adsorption. Total air flow quantity
should not increased calculated design quantity.
NOTE: Flow verses pressure chart is provided by vendor for consideration.
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OPERATIONAL LIMITATION
As the absorbents have certain adsorption capacity, so the beds are regenerated after
specified time of operation. This is why two beds are required for continue smooth
operation. One bed stays in operational service while the second one undergoes
regeneration process to make the beads activated. Operation cycle can be varied not
to exceed the specified capacity of the beads. All plants have different duration of
time of bed in operation.
REGENERATION
Regeneration term is used to reactivate the beads after service. Thermal swing
process is used to reactivate the beads. Waste nitrogen or dry air is used in reverse
direction of process flow in hot condition (about 200~207C or as advised by vender)
for certain time to damp heat to remove all impurities adsorbed by adsorbent. The
adsorbents are then cooled down to certain temperature before taking in service to
the that bed.
BAKING
Baking is also regeneration process of adsorbents but in this case hot flow is
continuously passed through adsorbents till the inlet and outlet temperature become
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equal. Baking process carried out during initial commissioning of Mole Sieve or CO2 /
Moisture breakthrough .
Note: To facilitate during operational process all necessary areas are provided with
temperature, pressure and differential pressure indicator. These are listed below:
1-Temperature element in process air common header.
2-temperature element on inlet line to individual bed.
3-Temperature element on outlet line of individual bed.
4-Pressure elements on outlet of individual bed.
5-Differential pressure element across individual bed.
REGENERATION FACILITY
To provide the necessary heat energy to reactivate adsorbents regeneration heaters
are provided. To make the heating process more reliable more than one heaters
are arranged in heating system. Some time a heat accumulator is also associated
with heater that stores heat during cooling, pressurizing and depressurizing cycle of
operation and release heat during heating cycle with dry gas flow. Heater provided
work on following basis.
Electric heater can have only one heating element and heater is coming in service
during Heating cycle only.
Electric heater have 3 heating elements. 2 heating elements come in service on 100%
load fully or gradually and 3rd element can share heating to meet heat transfer
requirement. Heater element No. 2 and 3 are of same power to do inter change
whenever required.
Some time heaters are having 3 bundles of heating elements. All 3 will be in service
and Outlet temperature will be controlled by controller output by controlling heater
power.
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Some time heater outlet temperature is controlled by regulating flow through heater/
A flow controller is provided on heater inlet line.
Heater protection :-
For heater elements protection, all elements are provided with 2 sets of RTDs to
Provide temperature signal to DCS system and to electric supply breaker.
Electric heater can get trip from DCS signal which can be reset from DCS
Heater trip due to hardwire trip interlock then breaker will be Rest from substation.
Heater trips are also assigned to low gas flow through heater. As low flow will result
high element temperature can cause damage to element in long run.
In heaters gas outlet high temperature is also interlocked to trip heater power to safe
it. Temperature range assigned varies from one unit to another.
Molecular Sieve vessel Entry requirements Safety
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Operators and maintenance staff should not enter a vessel containing molecular sieve
without the correct PPE, as the sieve will continue to "breathe" contaminants after
depressurization.
Permit to work shall be issued.

Enclosed vessel entry certificate, and confined space
Entry record should be available at sight and controlled.
All required PPEs shall be made available.
Any other forms as required.
Conditions to be maintained before Entry:
Vessel shall be at ambient temperature,

Ensure vessel is positively isolated (Spaded)
Fully depressurized
Fully ventilated
Gas test shall be carried out accordingly
Entry record should be available at sight and controlled
RHE (Reversible Heat Exchanger)

RHE is a critical purifying unit (Need special care) because it is working as a
purifier and main heat exchanger.
Feed air after DCAC is saturated with water vapors and all other impurities at
temperature of 25 to 30oC will enter to heat exchanger from warm end and will
leave heat exchanger at temperature of -171 to -174oC from cold end.
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Flow reversal between feed air and WN is necessary at 10 -12 minutes interval
of time to prevent build up of ice from water vapors and carbon dioxide
deposits on exchanger surface in the high pressure air stream. In reverse
process the deposits are evaporated by low pressure WN. Reverse process is
achieved by reversing (or changeover) valves piped into the warm end of the
exchanger.
Changeover of streams is called switching over processes. As RHE switching

over starts, CO2 and ice deposits get blown off process due to sudden
depressurizing process of stream. Deposits left on plate surface are evaporated
by WN flow due to dryness of gas.
R. Heat air flow will leave Heat exchanger from middle point at temperature of
-80 to -100oC for Expansion Turbine inlet flow. Plant will have 2 banks of RHEs
for continuous and smooth operation. Both banks will have equal no. of heat
exchangers. Nos. of heat exchangers depends upon capacity of the plant.
Process air will leave heat exchanger at temperature of -171 to -173oC with
dew point >-80oC and free off Hydrocarbons
RHE Heat exchanger follow schematic diagram:-
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COLD END
Warm End
Flow direction through RHEs is controlled by switching valves position provided at

warm end of heat exchangers. Flow direction in bank changes as timer assigned. Timer
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is adjustable/variable depends on operator observations and conclusions. Measure of

differential pressure across RHEs blocks will help operator to do proper decision.
Differential Pressure (DP)

Differential pressure across RHEs is a measure of performance of heat exchange
between streams. As wet air is entering to RHEs . stream paths will get block. Regular
monitoring of DP is recommended.
Different types of manometers and DPI indicators are equipped with RHEs cold box
for monitoring purpose. At present pressure differential transmitters and indicators
are in service.
Liquid manometer for DP. Pressure differential gauge
Differential Pressure Manometer
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Thawing process of RHE.

Thawing, deriming or defrosting term is used to remove solidified and unwanted
materials from ASU cold operated equipments. RHEs demands for thawing process
very frequently even plant shut down for hours. To perform thawing process for RHEs
GAN is passed through RHEs from warm end to cold end to remove deposits of
blocking materials. Thawing process is continued till required dew point get achieved.
SEQUENCE MODE SELECTOR:
This switch has 3 positions.
Auto: Position keeps the cycle to automatic change over.
Semi Auto: Any delay to switching valve open / close or feed back failure set the
switch to semi auto. Which be changeover back to auto position when situation is
normalize.
Manual: Sequence can be manage on manual regardless auto change over which
is prohibited.
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RHEs Safe operation and Environmental Hazards

.
Potential Hazards:
The following potential hazards exist during operation.
1- Hazard caused by the fact that the RHE operates under pressure.
2- System operates with Waste Nitrogen.
3- Asphyxiation due to WN leakage.
4- Asphyxiation due to nitrogen leakage from instrument valves.
Before entering to switching valves room, Cross ventilate the area and use sniffer to
ensure presence of oxygen is 21%.
Hazards of Noise:
System generates heavy sound due to sudden depressurizing of air stream during
changeover. Ear protective MUFFs must be use prior to entering the area.
Preparation for maintenance:

When preparing for maintain , ensure that:
1- A permit to work is obtained.
2- System is not in operation.
3- System is completely depressurized.
5- A confined entry certificate is obtained if working inside the RHE switching
valve room.
PPE for maintenance:

When performing maintenance on the RHEs , you must wear all required personal
protective equipment.
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Process Feed Air Contents

Table below will provide contaminants availability in free air after
MOLSIEVE AND RHE.

NAME CHEM CONC. IN FREEZING NORMAL CRITICAL CRITICALP MOLECULAR
CALSY AIR % RESS. WEIGHT
MBOL POINT oC B.P. Co TEMP. Co KG/CM2 g/mole
PRODUCTS GROUP
oxygen O2 20.95 -218 -183 -118 51.3 32
NITROGEN N2 78.113 -210 -196 -147 34.6 28
Argon Ar 0.931 -189 -186 -122 49.6 40
Krypton Kr 0.0001 -157 -153 -64 56.0 83.8
Xenon Xe 0.000009 -112 -107 17 60.1 131
Neon Ne 0.0018 -249 --246 -229 28.13 20
Helium He 0.0005 -272 -269 -268 2.335 2
Hydrogen H2 0.00002 -259 -254 240 13.4 1----2

Methane CH4 0% -182.5 -161.5 -82.5 47.12 16.043
adsorption
Ethane C2H6 0% -183.3 -88.6 +32.1 49.8 30.070

adsorption
Ethylene C2H4 45% -165.5 -103.9 +9.6 52.6 28.054
adsorption
Acetylene C2H2 0% -81.5 -83.6 +36.0 64.0 26.038
adsorption
Propane C3H8 34% -187.8 -42.3 +96.8 43.4 44.097
adsorption
Propylene C3H6 0% -185.4 -47.7 +92.1 46.6 42.081
adsorption
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Hydrocarbons contents will reduce up to certain level depending

upon nature of H/Cs and adsorption capacity of absorbents.
OFF SPECIFICATION FEED AIR

GAS ASUs are getting surrounded by Petrochemical plant, these plants can release any
type of hydrocarbon based gas from their process or from process pipeline as leakage.
As all release gases from plants are uncontrolled, will effect ASU feed quality directly.
Air purification units provided with ASUs can remove a small portion of hydrocarbons
gases and remaining will get pass to MHE and distillation column . Finally hydrocarbon
will get accumulated in reboiler and condenser sump and can lead to Plant explosion.
Note: Field operator duty is to monitor atmospheric conditions closely and do

communication with DCS operator /shift supervisor to take necessary action to
improve hazard operation conditions.
HYDROCARBON ANALYSERS
Hydrogen carbons are main source of ignition/explosion if ignition Supporters are
available. Ignition support agent is OXYGEN. Therefore A mixture of Hydrocarbon and
oxygen can cause explosion if conditions Of explosion get achieved. These condition
are:-
1-Concentration of Hydrocarbon mixture with LEL range:
For example: 4% acetylene, 96% oxygen, Static charge Can develop
explosion.
2- Concentration of Hydrocarbon mixture with UEL range:
For Example: 96% acetylene, 4% oxygen, Static charge, Can develop
explosion.
ALL HYDROCARBONS MIXTURES HAVE THEIR OWN

LIMITS.NO COMMON LIMIT IS REFERED.
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TABLE BELOW FOR LEL/HEL FOR DIFFERENT HYDROCARBONS.
Diethyl ether 1.9% 36%

Diesel fuel 0.6% 7.5%
Gasoline 1.4% 7.6%
Hexane 1.1% 7.5%
Heptane 1.05% 6.7%
Hydrogen 4% 75%
Hydrogen sulfide 4.3% 46%
Kerosene 0.6% 4.9%
Methane 5.0% 15%
Octane 1% 7%
Pentane 1.5% 7.8%
Propane 2.1% 9.5%
Propylene 2.0% 11.1%
Styrene 1.1% 6.1%
Toluene 1.2% 7.1%
Xylene 1.0% 7.0%
To do analysis of hydrocarbons different type of analyzers are used.

These are named as:-
1-Methane base analyzer.
2-Individual & Total hydrocarbon base. (Gas Chromatograph)
3-Total hydrocarbon analyzer.
Routine Mole Sieve area checks of field operator:-

Field operator has to do following checks in area as regular basis :-
1- As all area pipeline are processing pressurized air. Check air leakage in area.
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2- Check all pipeline insulation is ok as air in process at low temperature.

3- All valves are operating freely.
4- Instrument air pressure in area is above low pressure limit (>3.5 kg/cm 2).
5- Drain traps are functioning well.
6- All heaters insulation is in good condition.
7- All measuring instruments are functioning well.
RHEs Area
1- Check that both doors of switching room are open for cross ventilation of air.
2- Check sound level inside switching room after stream changeover .It will help
to analyze leakage from valves,
3- Check Oxygen concentration before entering inside switching room.
4- Check GAN/instrument air line to valves for leakage and damage of tubes.
5- Check condition of below off silencer and water drain.
6- Check W/N pressure to Ev, Cooler to analyze demister conditions.
AIR BOOSTER COMPRESSOR

Air booster Compressor is used to produce high pressure of dry air. Air Booster
Compressors in GAS ASU process are 4 or 5 Stages. These booster compressors are
capable to deliver dry air pressure up to 60 kg/cm2. High pressure air is using for
Expansion Turbine and JT Expansion Valve to produce cooling as per Joule Thomson
theory ( if a gas is compressed and expanded cooling will be produced).
Dry air booster compressor all construction is similar to main air compressor.
Following are the construction Feature of BAC:
1- As dry air is feed stock, No suction filter is provided at inlet of compressor.
2- As dry air is feed of booster compressor, No drain traps provided in between

inter stage coolers.
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3- After cooler arranged at outlet of final stage.
4- In some booster compressor heat exchanger is provided at inlet stream for heat
exchange with final discharge flow of booster compressor from after cooler to
improve temperature of stream flow before entry to heat exchanger.
5- Balance gas is withdrawn from stage casing and routed back to inlet of
compressor.
6- Oil Seal gas is arranged internally. In some booster compressors additional

external oil seal (IA) supply is also arranged.
NOTE:- Never ever try to start booster air compressor lube Oil system if
seal gas supply is not available.
Balance Seal Gas

As air or gas is passing over impellor blades and leave impellor outer tip with good
kinetic energy. Max.gas get diverted to diffuser and transferred to stage outlet for
process. A small amount of gas get escape to back side of impellor as space is available
and will continue to build pressure on impellor plan surface. As in booster compressor
two stages impellors are arranged on one shaft, back pressure on impellor will
develop axial displacement and impellor can touch to casing of stage. As result of high
axial displacement booster compressor will trip. To have smooth booster compressor
operation axial movements of shaft should be minimized. Therefore gas accumulation
on impellor back should be minimized by extraction process.
Air or gas extracted from impellor back was processed before entry to booster,
extracted gas can be diverted to booster inlet for re-processing under control of
pressure because seal gas supply to labyrinth seal is also provided from balance gas.
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Figures below for balance gas seal

extraction from stages. 3rd stage
4th stage
Process Air distribution:

Purified dry Air after Mole Sieve distributed as under:-
1- Dry air to MHE (Main heat exchanger)
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2- Dry air to Booster compressor (BAC)

3- Low or medium pressure dry air to expansion turbine booster compressor.
All dry air distribution is designed to meet ASU process requirements.
ASU process demands cooling to liquefy gases for fraction distillation of air.
Liquefaction temperatures of main air components are too low. Therefore intense
cooling is required to liquefy the Air.
To produce cooling JOULE THOMSON theory is applied. Theory states that:-

WHEN EVER A GAS IS COMPRESSED AND THEN EXPANDED COOLING WILL BE
PRODUCED.
Production of cooling is directly proportional to drop in pressure. It means high

pressure is required to have batter cooling for system.
To produce cooling 2 methodologies are used in GAS

1- Expansion Turbine and Dense fluid Expander.
2-Expansion Valve (JT valve)
Expansion Turbine is main cooling producer unit in ASU process. These turbines are
operated with medium or high pressure of air depending upon need of cooling in
process. As turbine utilized pressure energy to run and produced work force, this
work force used to run the following:
1- Booster compressor coupled to same shaft.

2- Blower coupled to same shaft.
3- Power generator coupled to turbine through step down gear box.
EXPANSION TURBINE
Expansion turbine air or gas will enter to turbine impellor at medium or high pressure
and will leave impellor from center at low pressure and at low temperature. As a
result work force energy will be produced.
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As air or gas enters at outer edge of impellor and leaves from inner edge of impellor,
Turbine is named as centripetal turbine. In GAS all turbines are centripetal

turbines. (Centripetal force moves an object towards center of rotation)
Below is connectional layout of expansion turbine and booster compressor on one

shaft.
Turbine types:-
1-Blower/Booster Loaded Expander
This turbine is basically reaction turbine in which large portion of the

expansion occurs in the blades of the wheel. It has two sections, Casing and
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Impellor. Casing is that section which contains stationary nozzle and the
Impellor consist of blades mounted on it. When the air expands in a nozzle its
pressure decreases and velocity increases when this high-velocity air strikes on
the blade it runs the Impellor and produces mechanical power. Nozzles are
additionally equipped to vary the nozzle area and can expand air effectively .
Nozzle areas are selected to increase the cold generation.
Mechanical power produced by turbine is consumed by booster compressor to

raise pressure of dry air routes to turbine inlet or by blower to apply brake to
turbine.
2-Generator Loaded Expander
Expansion Turbine work force energy can be utilize to run Generator to produce
power 4.16 KV which is connected to power bus bar in substation.
3-Dense Fluid Expander (DFE) & Dense Liquid Expander

(DLE)
DFE is cryogenic turbine. Turbine inlet temperature is in cryogenic temperature

range, Inlet pressure of turbine is maintained at a level where gas stay as gas.
Commonly inlet temperature is -171 to -173oC and pressure is kept at +52 ~ 75
kg/cm2 (above critical temperature/pressure). As dry air expands in impellor
blades, produces cooling and convert to liquid from gas. DFE work force energy
can be utilize to run Generator to produce power 4.16 KV which is connected to
power bus bar in substation.
DFE turbine constructional layout can be horizontal or

vertical .
Parts Of Expansion Turbine

1- Inlet Strainer
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As dry air is coming after molsieve. It get purified and get cool down to -115 to
-125oC before entering to expansion turbine. Some traces of blocking materials
like dust, CO2 , NH3 N2O and hydrocarbons can pass through molsieve. These
elements can get solidifies as air get cool down in main heat exchanger . If
these solidified tiny particles passed over high speed rotating impellor van , will
develop erosion in rotor vans and also these small particles (ice, CO2 or dust)
can cause severe erosion of the nozzles and wheel blade tips. This will reduce
life of rotor and IGV. A fine metallic Mesh filter is arranged at inlet of turbine to
minimize entry of solidified ice particles.
Figure below for inlet filter.
2-Inlet Guide Nozzles
Nozzles are usually variable and used to control the throughput for the turbine.
Their function is to convert some of the pressure energy into kinetic energy or
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work force energy. There is a pressure drop across the nozzles which causes an
increase in the gas velocity and a decrease in the gas pressure, Because of the
high velocity.
Gas passage through nozzle and way it is diverted to Impellor blade at inlet of
Impellor blade. Number of IGV nozzles depends upon the number of blades on
Impellor. Nozzles position is controlled by an actuator to meet through put or
flow of turbine.
Figure indicates that no. of nozzles of guide van are equal to no. of blades on
rotor/impellor.
Expansion Turbine Deriming:

Cryogenic Air Turbine normally demands for deriming after certain length of operation
time due to blockage of inlet strainer. To do deriming of turbine complete isolation is
required. In turbine layout all provisions are provided. NANUAL isolation valves are
provided at inlet and outlet of turbine. One operational shut off valve is provided in air
inlet line to have isolation if required.
To do deriming of turbine dry air or nitrogen gas is recommended to pass in reverse

direction of normal process flow.
Deriming of turbine is carried out during plant shut down, or for plant cold standby
position or plant shutdown for more than 4 Hrs or
required to hand over to maintenance for some
job.
Turbine casings
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Turbine casing is main component to provide support to IGV, impellor housing and
IGV actuator.
Figures below provide views of turbine casings.
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Impellor
Impellor is main part of turbine where expansion takes place and gas pressure energy
get change to kinetic energy and due to rotation of impellor kinetic energy get transfer
to shaft of turbine. As shaft of turbine will rotate and other couple equipment will
utilize energy.
Figure below for impellor of Turbine.
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Shaft Gas Seal

Shaft seals are arranged on shaft to minimize creep of cold or oil mist vapors along
with shaft and approach to other media flow. Cold creep will damage shaft and also
damage lube Oil properties. Cold creep also can damage to shaft bearing.
To avoid these happening Labyrinth gas seals are arranged in ET/ DFE systems.
Compressed dry air or Nitrogen is used as sealing media. Seal gas pressures and flow
are adjusted according to the requirement.
Seal gas vent is restricted with control valve to maintain seal gas pressure.
Figure below for seal gas arrangement.
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LABYRINTH SEAL
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Diffuser:
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In practice, the gas leaving the wheel still has some kinetic energy. The outlet
diffuser is designed to convert this energy kinetic energy to pressure head of
gas. There will be pressure increase between the wheel outlet and the outlet
of the turbine. Diffuser will help to minimize turbulence in air stream flow after
turbine casings.
Lube oil system:-

The function of lube oil system is to provide forced feed cooled and clean oil to
turbine bearings and reduction gearbox and generator bearings if provided..
Lube Oil System Description
The system consists of the following components mounted on a common skid.
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1-Lube oil reservoir
2-Electrical motor-driven oil pumps. Sometime motor driven pump is stand by
pump.
3-Primary gearbox-driven oil pump as main oil pump.
4-Dual oil filters.
5- Oil cooler .
6-Pressure relief valves, pressure and temperature control valves, and
miscellaneous other valves.
7-Reservoir mist exhaust fan.
8-Local gauges and transmitters.
9-Seal gas vent silencer.
10-Emergency Oil Reservoir
Figure below for oil system of expansion Turbines
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Function of all equipments already explained in

progression level 1 document. Please refer to if
needed.
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Emergency Lube oil system.

Emergency lube oil storage tanks are provided with some equipments to meet
requirements of oil lubrication during emergency shutdown of equipment or total
power failure. Tanks make oil supply due to:-
1- System pressurized with dry air or GAN.
2- Tank located at quite height to supply oil by gravity.
Below is schematic diagram for pressurized system.
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If main oil pump is operated by main gear box Bull gear, oil pump will take enough
time to become stand still due to heavy mass rotation. As result oil supply to
equipment will drop gradually and stand by pump will be in operation on time.
Emergency oil tank is omitted from these equipment.
Oil Shaft Seal System

Oil can move along shaft and can reach to area where turbine body components are at
cryogenic temperature.oil will get solidify and will damage to rotating parts.
If oil reach to feed flow , it can reach to column will create operational hazards and can
lead to ASU explosion.
To have safe operation of expansion turbine, oil seal on shaft is provided to avoid oil
movement towards process feed flows.
Normal dry air or Nitrogen gas is used as sealing media.

Schematic diagram of oil shaft seal is as under:-
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Gear Box
refer to air compressor
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Bull gear type gear box. Planetary reduction

gear box
Prepare after Maintenance

handed over:
1-Follow all vendors instructions for each particular equipment and procedures
2-Pump is lined up as per start up check list
ATTENTION:-Operator have to check dew point from turbine body drain and it
should be less than -40oC.
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Prepare DFE For Startup

Follow to following line as pre start up preparation guide line :-
1-All PTWs get close and housekeeping of area carried put.
2-Lube oil system get normalize .
3-Main oil pump and AUX. lube oil pumps get primed.
1- Seal gas system normalized.
2- Instrument air supply to all controllers get normalized.
3- DFE get derimed and dew point of DFE machine is less than -40o C.
4- Insulation of equipment is completed.
Prepare for cool down/ start up:-

Follow these guide lines to prepare DFE for start up:-
1- Check and confirm dew point of DFE pipeline and body.
2- Cool down DFE very slowly as recommended by vender.
3- After cool down properly , commission DFE & close all drain, than inform DCS.
Area checks for field operator.

Field operator have to do regular field area checks for followings,
1-check area housekeeping is maintained.
2-oil Tank levels are ok.
3-No oil spillage or leakage in area.
4-emergency oil tanks levels are ok.
5-emergency oil tanks GAN pressure is being maintained.
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6-Seal gas vent is free of ice and blockage.

7-No cold patch on cold box and surroundings.
8-All instrument are functioning freely.
9-all control valves are operating trouble free and on cold patch on valves.
10-check oil conditions in storage, it should be free of cold effects and in normal color.
11-PSVs should be free of ice patches.
Gaseous Oxygen Production:-

Gaseous Oxygen as gas is produced from lower part of low pressure column just upper
part of condenser. Oxygen purity is 99.6 % to 99.8 % . Gas production pressure ex.
Column is 0.6 to 0.7 kg/cm2. Gaseous oxygen will pass through fin type Plate heat
exchangers and will leave cold box from warm end of heat exchanger at pressure of
0.30 to 0.35kg/cm2 .
Oxygen Compression by compressor

To supply gaseous oxygen to customers, it is compressed by multi stage centrifugal
oxygen compressors to maintain pipeline pressure.
ASU that produce oxygen as gas is named as Oxygen gas plant.

ASU that produce oxygen as liquid is named as Oxygen liquid
plant.
INTERNAL COMPRESSION
Oxygen as liquid is produced from lower part of low pressure column in condenser.
Oxygen purity is 99.6 % to 99.8 % . Liquid oxygen production pressure outlet of
Column is 0.6 to 0.7 kg/cm2.. Liquid oxygen will get pressurize to customer header
pressure by internal compression pump. Compressed liquid will pass through fin type
Plate heat exchangers and will leave cold box from warm end of heat exchanger at
supply header pressure . pressure of oxygen gas is 30 to 32kg/cm 2 . As liquid oxygen
get compressed and vaporized in plate heat exchanger, compression is named as
internal compression. Liquid oxygen pump is named as internal compression pump.
Suction pressure of LOX I C Pump is 2.0 to 2.4 kg/cm2 base on condenser level.In order
to evaporate and warm up the compressed liquid a counter current stream of Air with
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higher pressure than the required liquid pressure is required due to thermodynamic
reasons. With this method a complex external Oxygen compression is no long
required, thus plant operation and maintenance has become considerably easier and
more reliable. Furthermore the risk of dangerous hydrocarbons enrichment in the
condenser is avoided because liquid oxygen is permanently withdrawn from
condenser. Pumped liquid and evaporated in the heat exchanger saves power and
reduce maintenance cost of oxygen compressors, Compared by external compression
system.
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Liquid pump term is used for pumps used to transfer liquid product under controlled
operating conditions. These operating conditions are:-
1-Working temperature
2-Seal gas system
3-Net positive suction head
4-Pump discharge flow
5-Pump discharge pressure
Structure of pump depends upon requirement of discharge pressure and flow. LOX I C
pump can be a single stage or multi stage pumps.
Cryogenic Liquid Pumps:-

1- To transfer liquid oxygen to main plate heat exchanger.
2- To Transfer liquid oxygen/ nitrogen to backup vaporizer.
3- To transfer liquid oxygen / nitrogen to HP Vacuum Insulated
Evaporators with atmosphere vaporizers.
4- To transfer liquid oxygen / nitrogen to road tankers (Vacuum Insulated
Tankers) for filling.
5- To re-circulate liquid oxygen from condenser to condenser for H/C
recovery system.
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In GAS liquid pumps are arranged with cryogenic liquid storage tanks and with
distillation column and are routed to meet ASU process requirements.
Types Of Pumps
Following types of cryogenic liquid pumps are used :-
1- Centrifugal liquid pumps.
2- Reciprocating liquid pumps.
Centrifugal Cryogenic Liquid Pump

Centrifugal cryogenic pumps are available in GAS in following layouts:-
1- Centrifugal pump in horizontal layout.
2- Centrifugal pump in vertical layout.
Seal Gas Arrangement.

Seal is a media provided between to surfaces to stop transfer of one media to another
media. In cryogenic Liquid pumps sealing media is dry gas nitrogen as recommended
by pump venders. In cryogenic pump seal is provided to stop leakage of :-
1- Liquid from pump casing to motor side along shaft.
2- Cold creep of liquid along shaft.
Labyrinth gas seal is arrange in pump construction to provide services to minimize

both media leakage.
Nitrogen as dry gas is recommended for sealing media. Nitrogen gas for seal gas is
normally drawn from nitrogen customer header and step down to required pressure
by pressure control valve. This is to ensure that seal gas will be available at required
pressure all time.
Liquid/gas pressure at sealing point is measured and named as REFERENCE PRESSURE.
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Seal gas pressure is always maintained more than reference pressure. Additional
pressure valves are determined according to nature of leaking material.
Figure below for systematic flow diagram of seal gas.
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Seal gas flow control is based on reference pressure that operates pressure differential
controller to regulate seal gas flow.
Reference pressure and seal gas pressure are indicated on a pressure PDI gauge. Red
pointer indicates reference pressure and black pointer indicates actual seal gas
pressure. Seal gas streams are named as:-
Stream A Seal gas at motor bearing.

Stream B Seal gas supply to pump shaft.
Stream C Seal gas pressure at pump shaft
Stream D Seal gas reference pressure.
Stream E Seal gas supply in case of
Standstill sealing system.
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STANDSTILL SEAL IS PROVIDED IN SEFCO LOX/ LIN BACK UP PUMPS

As pump is running, all parts are getting enough energy to be in warm condition.
When pump is in standstill position cool can reach to motor bearing. To minimize cool
transfer to bearing standstill gas seal is provided through a solenoid valve that
get energize as soon as pump get stop.
In these days LINDE and AIR PRODUCT (AP) plant providers companies are providing
I.C / Back up pumps as multi stage vertical pumps. These pumps are having electric
motors named as :-
1- Motor with variable speed.
2- High speed / Slow roll of motor at about 55% speed.
NOTE: Pumps running with slow roll, standstill seal is not require.
Cryogenic vertical pumps

As pump and motor are located at quite distance, pump shaft is supported by bearing.
Pump is provided with two seals as under:-
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1- Nitrogen gas seal for support bearing.
2- Labyrinth gas seal for pump casing.
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Labyrinth type seal gas system is provided with pump to minimize cold travel to
Seal gas media. Gas nitrogen

Normal flow of seal 17.0 m3/hr.
Labyrinth seal gas temp. 0---50oC
Low temperature alarm -75oC
Low Low temperature alarm -120oC
Difference of pressure (Pi-P ref) 0.1 to 0.2kg/cm2
Difference of pressure (Pref-Ps.out) 0.1 to 0.2kg/cm2

Difference of pressure (Pi-P ref) alarm low at 0.04 kg/cm2
Trip at 0.0 kg/cm
Bearing retainer chamber press. 0.1 to 0.2 kg/cm2
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Cold box purge press. 0.1 to 0.2 kg/cm2
These pressure adjustment are made by adjusting regulators and

Flo outlet valves.
Normal cool down time is preferred to 2 to 3 hrs so that all parts
must get cool down fully.
Figure below for sealing system of vertical pump.
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Motor for Liquid Pumps
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All liquid pumps in ASUs

are operated by an
induction motor. Sometime
These motors are operated directly on designed RPM and sometime these derives are
getting through motor drive control unit. Motor drive control unit will change motor
speed to meet customer requirement.
Motors operate as under:-

1-Variable speed in 2 steps only as High speed and Slow roll.
2-Variable speed as required by process by changing Voltage/ Frequency
(VVVF)Variable volt variable frequency .
Liquid pumps motor power supply voltage are 460V and can vary depending upon
motor power and nature of motor duty.
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LOX I.C Pump Operation and control

As LOX I.C pump discharge flow will pass through main heat exchanger, get vaporized
and join the main GOX header.
Customer GOX supply varied time to time so that LOX I C pump discharge pressure
controller and down stream Flow controller will maintain pump discharge flow and
pressure accordingly.
As I.C pump smooth operation is required for proper functioning of main heat
exchanger.
Following process controls are provided for LOX I.C. pump.

1- Vent for GOX. At heat exchanger outlet to vent gas as pressure increases.
2- LOX I.C pump outlet recycle valves HIC/ PIC are provided to control the load on
main heat exchanger and LOX I.C pump.
3- Stand by pump keep running on Slow roll, it can loaded up any time in case of
running pump trip. .
4- Some Pump casing temperature is provided to restrict pump start up if pump

casing temperature is not at liquid temperature. It will help to safe labyrinth
seal from damage.
5- Motor over load protection provided to safe motor from over load operation.
6- Motor operation protected against motor bearing temperature and vibration of

shaft hi - hi.
7- Motor Stator and Winding temperature hi hi alarm is provided, It will safe

motor from internal short circuit of rotor and stator.
8- Shaft and Seal temperature LO LO will trip motor to protect motor from cold
creep.
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LOX I.C pump deriming.

LOX I.C PUMP is taking liquid supply from condenser where liquid oxygen temperature is
-179oC. Number of hydrocarbons present in feed stock after molsieve will get solidify at
liquid oxygen temperature in condenser. These solidified hydrocarbons will continue to
move in liquid oxygen due to turbulence flow and lighter will float on LOX surface in
condenser.
Solidified hydrocarbons in LOX will reach to LOX I.C. pump inlet strainer. As a result pump
inlet strainer will get chock after certain period of time. Strainer chockage will be
indicated by DP local gauge / transmitter OR by pump performance. To do cleaning of
strainer, deriming of Lox I.C pump is recommended.
Follow to Deriming guideline below:-

1- change over LOX I.C pump to stand by pump.
2-confirm pump working conditions from DCS operator.
3-coordinate with DCS operator to shut down required LOX I.C pump.
4-Isolate power for motor and do lockout/tag out.
5-Isolate I.C pump and do valves chain lock.
6-Drain all liquid from LOX I.C pump pipeline and body.
7-Start deriming of pump with GAN or dry air can be used if GAN is not available.
8-Check dew point from pump body drain before starting cool down.
For detail procedure follow to SOP of GAS for LOX I.C pumps deriming.
Prepare lOX I.C Pump for Operation:-

To prepare LOX I.C pump for operation, Follow the below guideline and also follow
to standard operating procedure (SOP) of GAS. for LOX I.C pumps cool down.
1- Check and confirm that all PTW get close and lock out/tag out get
removed.
2- Check area housekeeping get complete.
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3- LOX I.C pump insulation packed properly and cold box closed and
cold box GAN purge commission.
4- Check dew point from LOX I.C pump casing blow. It must be less
than -40oC.
5- Follow LOX I.C pump cool down procedure as SOP of gas. cooling
rate should be slow so that all pump parts get cool down properly
6- Inform to DCS operator before Start LOX I.C pump from field
switch on slow roll.
7- Keep pump running condition on slow roll for hours to ensure all
pump parts get proper cool down and check pump for any
abnormality or leakage.
Routine Area Checks.

As LOX I.C pump is operating at cryogenic temperature. Cold box area
routine checks will be require for following:-
1- Check cold box for any cold patch.
2- Check cold box purge GAN flow is ok.
3- Check any abnormal sound in LOX I.C. pump area.
4- Check LOX I.C. pump seal gas system is working well.
5- Check DP of LOX I.C. pump inlet strainer if provided.
6- Check LOX I.C. pump inlet and discharge pressures.
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Main Plate Heat Exchanger.

ASU process plants are having plate heat exchanger to cool down process
air at different pressures . Heat exchange process takes place between gas
to gas and between gas to liquid. These heat exchanger are commonly
named as main heat exchangers.
These heat exchangers are grouped as under:-
1-Heat transfer between gas to gas or liquid to gas
named as main heat Exchangers and are called as MHE
2-Heat transfer between gas to liquids are commonly
named as sub coolers or super cooler.
All these heat exchangers are made from aluminum metal due to good
heat transfer quality. A number of streams are pass through each block of
heat exchanger, Some streams are high pressure and some are low
pressure.
As feed air comes out from main heat exchanger cold end. It is in form of
mist very near to have state of change to get liquefied.
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Figures below for ASUs Main heat exchangers.
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Heat exchangers can get damage due to thermal shocks if DT during

operation is kept high. Recommended DT between streams are 3 to 5oC.
It is very important to maintain DT of streams during plant warm or cold
start up.
Special care should be taken during injecting LOX to heat exchanger after
taking I.C. pump in service. During deriming or start up of the plant warm
up or cool down rate should not be more than -30oC.
In Sub cooler or super cooler liquids before entering to LP column are

further chilled by outgoing GAN/WN from LP column. .
In Supper cooler DT between streams should not exceed > 3 to 5oC
Process Technology
All element have three state as mention below:-
1-SOLID state.
2-LIQUID state.
3-GASEOUS state.
To deal these change of state following terms are used.
1-Boiling Point. A temperature at which an element/compound will have

change of state from solid to liquid or from liquid to gas.
2-Freezing Point. A temperature at which an element/compound will
have change of state from liquid to solid or from gas to
solid . (Sublimation process)
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3-Critical Press. There are specific pressure points for all liquids/liquid
mixtures and gases to have change of state. If pressure is
increased above this specified point, change of state will
not take place even temperature is raised or reduced to
any level. This specific pressure is call CRITICAL PRESSURE
Pressure have a very important effect on boiling point of

an element/compound. Boiling point will increase if
liquid surface pressure is increased and it will decrease if
liquid surface pressure is decreased. Keeping in view of
this property effect, water can boil at room temperature
under vacuum and water will not change to steam even
temperature get raise to 580oC at pressure of 1700PSI.
(water in nuclear reactor for power plants).
4-Critical Temp. A temperature at critical pressure where change in state

will take place is called as critical Temperature.
5-Flash Point. Flash point term is also used to indicate boiling point of a
element in liquid state.
Figure blow for critical temperature-pressure for Oxygen, Nitrogen and

Argon
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It is very important for everyone dealing with ASU process to understand

contents of blow graph and table to know properties of elements liquid at
certain temperature and pressure.
Distillation
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Distillation is a method of separating mixture ingredients based on

difference in their volatilities in the boiling liquid mixture. Distillation is a
unit operation process or a physical separation process. This separation do
not have chemical reaction. Distillation process using several vaporization
and several condensation.
GAS maintained High product purity at the outlet of distillation column.
Gas ASU plants are mainly produce industrial gases.

These gases are :-
1- Oxygen Liquid or Gas
2- Nitrogen Liquid or Gas
3- Argon Liquid
4- Krypton Liquid
5- Xenon Liquid
These gases are accepted for commercial use . For example steel mill and
petrochemicals plants uses high purity Oxygen purity for their process and Nitrogen
gas is used for plant purging and blanketing or sometime in the process and at GAS it is
used for emergency instrument gas supply.
In rectification feed air achieve following parameters:-
1- Cool down in heat exchanger as gas to its liquefaction
Temperature.
2-Feed air get partially liquefied
Distillation of feed air starts as air get into distillation column. Mostly all feed air is
entering to lower column from lower portion of column. In some plants expansion
Turbine discharge flow is directed to low pressure column. Sieve trays arrangement
starts from upper level of air pipeline to pressure column. Sieve trays are arranged in
bundles ( As required to meet design requirements, bundle can have any numbers of
trays).
Feed air will start liquefaction if temperature and pressure conditions get satisfied.
Normally pressure column temperature in bottom is -173 to -174oC and pressure varies
from 4.0 to 5.5 kg/cm2. Temperature at upper part of pressure column is -177 to
o
-179 C and pressure varies as DP of pressure column.
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Liquid rich in oxygen ( Rich Liquid RL ) will get collected in bottom of pressure column
or in sump and nitrogen gas vapors will evolve upward . Nitrogen vapors will change
to pure nitrogen gas or liquid after heat exchange with LOX in reboiler. Pure LIN or
GAN as product can be collected from upper part of pressure column.
Figures for distillation column.
ASU Column
Column is cylindrical in shape. There are three parts of air distillation column.
These are named as :-
1-Lower column or high pressure column.
2-Upper column or low pressure column.
3-Condenser.
1- Pressure Column. It is lower part of column and working pressure varies
from 4.0 to 5.4 kg/cm2. Gases and liquids temperatures
varies from -174 to -172oC at bottom of column .
Temperature at top end of pressure column varies from
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-179 to -181oC depending upon column working pressure

conditions.
HP Column Sump. Extreme lower portion of pressure column is called as

sump and it always accumulate liquid air or Rich liquid.
2-Lower pressure column Upper portion of column is named as low pressure

Column because working pressure of column varies from
3500 to 7500 mm WC . Gases and liquid temperatures
varies from -180 to -179oC in bottom of LP column.
Temperature at top end of low pressure column varies
from -194 to -192oC depending upon column working
pressure conditions.
3-Condenser. Lower most part of low pressure column is named as
condenser because it contain Reboiler and hold liquid
Oxygen in the sump.
Reboiler. Rebiler produces liquid nitrogen after condensing

nitrogen gas vapors by boiling of liquid oxygen. This
condensed Nitrogen vapor named Reflux play important
rule in function of both LP & HP columns.
Sieve Tray. A Type of tray with very small holes that holds liquid on it
in column for distillation.
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Types of columns.
Distillation columns are named according to internal construction as under:-
A- Distillation methodology.
1- Sieve tray column.
2- Pack distillation column.
3- Bubble cap distillation column.
B- Liquid level control methodology.

1- Liquid over flow from sieve tray.
2- Side weir level control down fall from tray.
3- Center weir level control down fall from tray.
Sieve Tray Of Column.

Sieve trays are simply metal plates normally made of aluminum or copper with large
number of holes in them. Size of hole is less than capillary size of liquid to be kept on
surface of sieve. Vapors can pass straight upward through the liquid on the plate.
Number of sieve trays in a column depends upon air flow to be processed and type of
distillation in column. More number of trays will help to control quality of produts.
As sieve trays are made of thin metal sheets . care will be required to avoid
followings:-
1- Sudden drop of pressure in column.
2- High cool down rate during plant start up.
3- High liquid holding on stay due to over design feed processing.
4- Rapid rate of loading and unloading of plant.
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Sieve trays layout in column.
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Pack distillation column.

Pack column is now a days coming in cryogenic industrial application widely. Column
heat transfer system is similar to plate heat exchanger. Liquid and vapors have direct
contact for a long time for heat exchange to perform distillation.
The packing used in cryogenic plants is like honeycombed sections having several light
sheets of stainless steel or aluminium rigid together.
The big advantage of packed columns is their low pressure drop and consequently a
low plant power consumption as compared to conventional sieve tray columns.
Because of advantage of low pressure drop is more critical at lower pressures.
In figure below left side view shows how streams inter act in pack column.
Vapors passing behavior through liquid on sieve tray.
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Compression of pack column and sieve tray column
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Packed Distillation Columns
L iq u id in le t in to p r e - d is tr ib u to r
E le m e n t d is tr ib u to r
L o c a tin g g r id
S t r u c tu r e d p a c k in g
F e e d in le t in to r in g c h a n n e l
S u p p o r t g r id
V a n e c o lle c to r
E le m e n t d is tr ib u to r w ith
p r e - d is tr ib u to r
B e d lim ite r
R a n d o m p a c k in g
S u p p o r t p la te
G a s in le t s y s te m
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Liquids Distributors.
Liquid distributors are used to give a uniform spread of liquid over the top surface of
the packed bed whilst permitting the passage of vapor through the distributor.
The quality of liquid distribution is of vital importance and any design and installation
should ensure equal distribution over the whole surface of the packing. A distributor is
required at every feed and product off take point and in argon columns between
sections of packing.
A liquid collection header is required for every liquid distributor to ensure uniform and
correctly distribution of liquid.
Two principle types of distributor are used
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1- chimney type 2- channel type
Bubble cap tray column.

A bubble cap
tray has riser or
chimney fitted
over each hole,
and a cap that
covers the riser.
The cap is
mounted so
that there is a
space between
riser and cap to
allow the
passage of
vapors. Vapors
rises through
the chimney and is directed downward by the cap, finally discharging through slots in
the cap and finally bubbling through the liquid on the tray.
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High Pressure and Low pressure column arrangements as under.
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Commonly this column arrangements are named as double

column.
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Low pressure column

Low pressure column is located on top of pressure column with built in reboiler in
condenser unit. It is named as low pressure due to low pressure working conditions.
Normally highest column pressure is at top of condenser and it varies from 0.3 to 0.7
kg/cm2. This wide variation is due to internal structure of column.
Low pressure column have two types of internal structures as under:-
1- Sieve trays column.
2- Packed coulmn .
Low
pressure Packed Column
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Low Pressure Column Construction.

Commonly low pressure column are sieve tray type with side or central fall weir.
With developments of new technology low pressure columns are now a days are in
pack system arrangements.
Gases properties at 1
bar(Atms)
Freezing Gas density Liquid density
Boiling point (c) point (c) ( kg/m3) ( kg/m3)
Oxygen -183 -218 1.354 1139
Nitrogen -196 -210 1.185 810
Argon -186 -189 1.691 1394
Gases properties at pressure/Low pressure column working conditions.
Name of element Boiling point at 1 atm. Boiling point at 5 atm.

Press. Press.
Water 100oC 152oC
Nitrogen -196oC -179oC
Oxygen -183oC -164oC
Argon -186oC -167oC
Air -194oC -177oC
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As quality of liquid on every tray is different, therefore different quality products can be
withdrawn from column. These products are:-
1- Crude oxygen with purity of 98 to 99.9%concentration.
2- Crude Argon with 88 to 90% oxygen.
3- Waste Nitrogen with 2 to 25% oxygen concentration.
4- Gaseous nitrogen with ppm oxygen concentration.
Analysis Equipments
In GAS all analyzers are measuring oxygen in as product or as impurity with different
range of measurement. Every equipment is measuring with in specified range of
analysis.
Three type of analyzers are in service in gas as under:-
1- Paramagnetic analyzer for Oxygen concentration.(For Oxygen)
2- Zirconium Oxide analyzer for oxygen concentration.(For Waste Gas)
3- Micro fuel oxygen concentration analyzer.( For Pure Nitrogen)
Oxygen analyzer.
In GAS all higher oxygen concentration analyzers are paramagnetic type analyzers.
These analyzers are working on paramagnetic properties of oxygen. This property
enables oxygen to get attracted toward magnetic field. See below self explained
working principle of instrument.
PRINCIPLE OF MEASUREMENT
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In the cell, two glass spheres filled with nitrogen gas are suspended with strong metal.
At first, the spheres are kept in balance in an inhomogeneous magnetic field. When
oxygen molecules having a large magnetic susceptibility flow there, the molecules are
pulled toward the stronger magnetic field zone and the spheres are moved away
from the zone. The resulting deviation of the spheres is detected with the light source,
reflecting mirror and light receiving element, and a current is flowed through the
feedback loop to control so that the spheres can return to the initial balanced state.
The current flowing through the feedback loop is proportional to oxygen
concentration. Thus, oxygen concentration is converted into an electric signal. Electric
signal is converted to display for indication of results.
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Zirconium Oxide Oxygen analyzer
zirconium-oxide-based oxygen analyzer uses an advanced zirconium oxide sensor in

combination with a new manifold assembly to ensure leak-free integrity and accurate
measurement of oxygen content from percent levels to less than 0.1 ppm. In Gas
these analyzers are used for waste nitrogen and rich liquid sample gases analysis.
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Micro Fuel Oxygen Analyzers

Micro fuel analyzers are used for traces oxygen analysis from products. These
analyzers have analytic cell based on Sodium Hydroxide or Potassium hydroxide
electrolytic material. The active components of the Micro-Fuel Cell are a cathode, an
anode, and the 15% aqueous KOH/NAOH electrolyte in which they are immersed. The
cell converts the energy from a chemical reaction into an electrical current in an
external electrical circuit. Its action is similar to that of a battery. The production of
electric signal depends upon impurity of oxygen in sample.
The sample gas diffuses through the Teflon membrane. Any oxygen in the sample gas is
reduced on the surface of the cathode by the following HALF REACTION:
O2 + 2H2O + 4e 4OH (cathode)
(Four electrons combine with one oxygen moleculein the presence of water from
the electrolyteto produce four hydroxyl ions.)
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When the oxygen is reduced at the cathode, lead is simultaneously oxidized at the
anode by the following HALF REACTION:
Pb + 2OH Pb+2 + H2O + 2e (anode)

(Two electrons are transferred for each atom of lead that is oxidized.
Therefore it takes two of the above anode reactions to balance one cathode
reaction and transfer four electrons.)
The electrons released at the surface of the anode flow to the cathode
surface when an external electrical path is provided. The
current is
proportional to the amount of oxygen reaching the cathode. It is
measured and used to determine the oxygen concentration in the gas mixture.
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Reboiler
A tubular/fin plate heat exchanger placed at the bottom of low pressure distillation
column or stripper to supply necessary column vapors or heat. (Reboiler at the
bottom of upper column which is also a condenser for lower column
Condenser:
The main purpose of condenser is liquefaction of gas accompanied by

the evaporation of a liquid to maintain the rectification in the columns.
There are several types of condensers:
A) Bath Condenser:
B a th C o n d e n s e r
GOX
- u s e d f o r o n e - s t o r ie d c o n d e n s e r s
GOX
LO X LO X
- lo n g o p e r a t io n e x p e r ie n c e
PGAN
- n a t u r a l L O X c ir c u la t io n
- n o o x y g e n p ip e w o r k o n t h e c o n d e n s e r
LO X LO X - f it f o r A S U 's w it h lo w p r e s s u r e G O X -
p ro d u c t
PGAN
Top of
P re s s u r e c o lu m n
L O X r in s in g lin e
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B) Down flow Condenser:
D o w n F lo w C o n d e n s e r LOX
- u s e d in s te a d o f tw o -s to rie d o r
PGAN
m o r e -s to rie d b a th c o n d e n s e r s
- no condenser vessel
- L O X - r e c y c l e p u m p f o r r e f l u x is n e c e s s a r y
P L IN - o x y g e n p ip e w o r k is n e c e s s a r y
- f i t f o r A S U 's w i t h in t e r n a l L O X c o m p r e s s i o n
G O X+LO X
- f it f o r la r g e s iz e A S U 's
P L IN - e n e r g y s a v i n g s o lu t io n
PGAN Top of
P r e s s u r e c o lu m n
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C) Combi Condenser:
C om bi C ondenser
L O X fr o m L o w p r e s s u r e c o lu m n
- C o m b in a t io n o f b a t h c o n d e n s e r p lu s
d o w n f lo w c o n d e n s e r
PGAN
- n o o x y g e n p ip e w o r k
- n o L O X - r e c y c le p u m p in c o n n e c t io n
P L IN
w it h K r /X e - p r o d u c t io n
G O X+LO X G O X+LO X
G O X +LO X G O X +LO X - L O X - r e c y c le p u m p f o r r e f lu x is n e c e s s a r y
PGAN
w it h o u t K r /X e - p r o d u c t io n
P L IN - f it f o r A S U 's w it h in t e r n a l L O X c o m p r e s s io n
P L IN - f it f o r la r g e s iz e A S U 's
PGAN Top of
LOX P r e s s u r e c u lu m n
L O X p r o d u c t f o r t h e in t e r n a l
c o m p r e s s io n
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D) Multi stage Bath Condenser (Cascade):
The multi stage bath condenser has the advantages

of a normal bath condenser as e.g. natural LOX
circulation
On the evaporation side, due to many stages, the

liquid level in one stage is small; therefore energy
efficiency is good.
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Figure below for condenser and Reboiler as in cold box.
Condenser / Reboiler
Hazard Operation
As feed stock of ASU process plant is AIR and sucked from atmosphere. Atmospheric
conditions varies from location to location for contaminations of hydrocarbons.
Hydrocarbons are extremely dangerous for ASU operation as all will get accumulate in
low pressure column lower portion and finally will reach to condenser and reboiler.
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Liquefaction and solidification temperatures of all hydrocarbons are very close to

liquefaction temperature of oxygen. As ASU process pressure ex. Booster is supporting
to all hydrocarbons to pass through main heat exchanger and approach to distillation
column .
Table for hydrocarbons elements properties.

Element symb Freezing Boiling Critical Critical Molecular
ol Point oC Point oC Temp oC Press Weight
kg/cm2
Methane CH4 -182.5 -161.5 -82.5 47.12 16.043
Ethane C2H6 -183.3 -88.6 +32.1 49.8 30.070
Ethylene C2H4 -165.5 -103.9 +9.6 52.6 28.054
Acetylene C2H2 -81.5 -83.6 +36.0 64.0 26.038
Propane C3H8 -187.8 -42.3 +96.8 43.4 44.097
Propylene C3H6 -185.4 -47.7 +92.1 46.6 42.081
All informations below based on Air Products

(ASU Vender) handout document.
Special Hazards of Specific Contaminants
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Four contaminants deserve special monitoring due to their specific hazards:-
Hydrogen carbons are main source of ignition/explosion if ignition Supporters are

available. Ignition support agent is OXYGEN. Therefore A mixture of Hydrocarbon and
oxygen can cause explosion if conditions Of explosion get achieved. These condition
are:-
1-Concentration of Hydrocarbon mixture with MIN. hydrocarbon
Named as LEL limit range e.g. 4% acetylene + 96% oxygen +Temp.
Can develop explosion.
2- Concentration of Hydrocarbon mixture with Max. hydrocarbon
Named as HEL limit range. e. g 96% acetylene + 4% oxygen +Temp.
Can develop explosion.
ALL HYDROCARBONS MIXTURES HAVE THEIR OWN

LIMITS. NO COMMON LIMIT IS REFERED.
Acetylene (C2H2) Acetylene is only slightly soluble in LOX. At typical

reboiler conditions, a solid will precipitate out of solution if the concentration exceeds
about 4 ppm. Solid acetylene is shock sensitive, and requires only a slight
amount of energy to ignite. Fortunately.
The adsorbents within Mole Sieve remove 100% of
the acetylene from the air to eliminate the
explosion hazard in the ASU,s.
In reversing heat exchanger plants (REVEX), acetylene enters the cold box, and
must be removed by a combination of liquid phase adsorption( Circulating adsorbers)
and LOX purge.
Total Hydrocarbon Analyzer
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Typical hydrocarbon analyzer

Analyzer sampling systematic flow diagram.
_________________ SAMPLE TO 3AI 2615
Dry air Ex M.S

From AI2615 SAMPLE TO AI 2620
TREATED DRY AIR

FROM AD 004
Hydrogen + Helium gas mixture
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Field Operator Routine Activities In Cold Box Area.

AS distillation column is housed in cold box due to operating temperature range, it is
very important to do regular monitoring for followings.
1- Location of all control valves hand valve in area.

2- Location of all analyzers APs in field area with description.
3- Location of all measuring Points in field area with description.
4- Instrument air supply sources to all controllers in area.
5- GAN purge to cold box and flows of different parts of cold box.
6- Corrosion and erosion to cold box structure.
7- Cold patches developments to cold box.
8- Insulation levels in all parts of cold box.
9- Wind sack location and physical condition.
10- Jib crane working condition to be maintained with help of
maintenance section.
11- Have confident awareness of products outlets pipelines from cold box.
12- Have confident awareness of drainage outlets pipelines from coldbox.
13- Liquid disposals systems arranged with cold box and its safe
operation.
14- Confident awareness to do safe isolation of coldbox if required.
15- Confident awareness how to normalize coldbox isolation after
maintenance turnaround.
Products From ASU Coldbox:-

Following products are collected from ASUs.:-
1- Gaseous oxygen as product at low pressure.

2- Gaseous Nitrogen as product at low pressure.
3- Gaseous Nitrogen as product at medium pressure.
4- Liquid nitrogen as product at low pressure.
5- Liquid nitrogen as product at medium pressure.
6- Liquid oxygen as product at low pressure.
7- Gaseous oxygen product at high pressure by I.C system.
8- Feed stock for rare gases AR/KR/XE production at low pressure.
All gaseous products are directed to compressors for gas compressor to meet customer
supply requirement. Nitrogen supply pressure is maintained at 11.5 kg/cm 2. And
gaseous oxygen pressure in maintained at 32 kg/cm2 (can vary as per customer
demand).
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Rare Gases Recovery

Rare gas term is used for elements of table 8 in periodic table. These are:-
1- Helium
2- Neon
3- Argon
4- Krypton
5- Xenon
Product Oxygen Gases Compression

Oxygen is produced from ASU process as gas from low pressure column with quality of
99.6 to 99.8% oxygen. Product pressure ex column is about 0.6 kg/cm 2and
temperature is about -180oC. Gaseous oxygen have heat exchange with feed air and
other streams and leave coldbox at temperature of 15 to 20oC. Gaseous oxygen is
compressed by oxygen compressors to meet to customer supply pressure
requirements. Following types of compressors are used for oxygen gas compression:-
1- Reciprocating Oxygen Gas Compressors.
2- Centrifugal Oxygen Gas Compressors.
In GAS only centrifugal oxygen compressors are used for oxygen gas compression.
These oxygen compressors are operating with ASUs as under:-
1- ASU 21 oxygen compressor 21K002.
2- ASU22 oxygen compressor 22K002
3- ASU 31 Oxygen compressors 32K002 A / B
The OG Compressor is probably main equipment and the most important equipment
on the site, Oxygen gas supply to customer will be impossible without this equipment
from these ASUs as product pressure is too low.
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As OG Compressor is also the consumer of electricity on the air separation plant, so it

is important to maximize performance of equipment. Poor Performance means
increased running costs, particularly for electricity supply, and these can be significant.
Poor operation can also lead to failure of the OG Compressor, which will be costly.
The following factors of the OG Compressor operation can be consider during

deteriorated performance:-
1-High ambient temperature.

2-High-pressure drop across the inlet air filter.
3-Deterioration of components, such as impeller and inlet valve, due to dust or
particles entering the machine.
4-Poor cooling due to:
A-Fouling of coolers.
B-High cooling water temperature.
C-Low cooling water pressure.
5-Poor calibration of control instruments
6-Losses due to:
A- Excessive high Leaking from seals
B- Excessive Leaking from vent valve
Oxygen Compressor Data
Gas handled : Dry Oxygen

Type : Centrifugal
Capacity Flow Nm3/H : 17,500 ~ 18,750
LP Suction Pressure Kg/cm2 : 0.272 ~ 0.375
LP Suction Temperature Max. oC : 47 and R.H = 0%
HP Suction Pressure Kg/cm2 : 13.7
HP Suction Temperature Max. oC : 47 and R.H = 0%
Discharge Pressure Kg/cm2 : 25.3 ~ 29.88
Speed RPM : 14856
B.H.P Required (K.W) : 2730 ~ 2864
L.P Stages/Impeller :5
H.P Stages/Impeller :3
Shaft Seal : Nitrogen Gas
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Start up / Shut Down Purge Gas : Nitrogen Gas
Construction:
The compressor unit consists of two casing namely low-pressure casing and high-
pressure casing.
Low /High -pressure casing is made of suit able material specifications and having 5
stages with built in / after stage intercooler. Low pressure casing is housing 3 stages
and further every stage is having more than one impellor. For example ASU 21 /22
oxygen compressor 1 /2 /3 stages have 2 impellors in each stage and High pressure
casing for 4 / 5 stages have 3 impellors in each stage.
All stage impellors are close impellors to minimise gas losses from stage outlet nozzles.
Low and High-pressure inter stage coolers are also made of suit able material
recommended for oxygen service. Interstage coolers are arranged in 2 constructional
way as under:-
1- Shell and tube type interstage cooler for every stage.
2- Parallel side build cooler for LP stage only and HP stage with shell and tube
type interstage coolers.
OG Compressor is driven by an electrical motor through a speed up gear box, which

increases the speed from 1800 rpm to speed required to impellors to deliver gas to
header to meet customer header pressure requirements .
Oxygen compressor all stages are having same speed as both stage shafts are coupled
together.
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Compressor construction consists of the casing in 2 halves, Impellors, impeller shafts,

Gas seal sections and the bearings section to support stage shafts. Gas seal port vents
are provided to every gas seal to do seal vent analysis if required.
Gas System:-
Oxygen as gas is produced from distillation column. Product gas pressure is about
0.65kg/cm2 and temperature of gas is -180oC. After heat exchange in cold box with air
streams, oxygen at pressure of 0.45 to 0.5 kg/cm2 and temperature about 20oC will
leave cold box. Oxygen product flow if measured by Restricted Orifice placed in
product line. Product line pressure is control by pressure control valve by venting of
gas. Manual valves are provided to isolate ASU unit if required.
Figure below for oxygen gas production layout ex. Cold box.
Gas system At Oxygen Compressor Inlet.
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Low pressure oxygen as gas will enter to compressor suction. Compressor suction line
is provided with shut off valve. This valve is ON/OFF type valve and will get fully close
if any malfunction or unsafe operation detected by process control.
XV PV
Emergency nitrogen supply to compressor will commission from customer header

through pressure control valve to safe compressor in case any trouble like high
discharge temperature or high high vibration alarm get activated.
Oxygen compressor will run on nitrogen cycle. Inlet shut off valve and discharge valve
to customer will get close and vent valve will get open.
Oxygen compressor recycle valve is functioning in 2 cases:-
1- Suction flow is low and compressor operation enters in surge area.
2- Customer demand get low and discharge pressure get high.
As differential pressure across valve is high, valve operation creates lot of noise and it
makes unsafe entry to compressor housing without proper safety gears.
Oxygen compressor is housed in flame proof housing to minimise damage risk in case
compressor get fire. Secondly this housing also serve as acoustic housing to reduce
sound level of compressor area.
Gas Inlet Filter:-
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A fine mesh metallic filter is provided at inlet of compressor to avoid any hard particle
entry to impellor. As hard particle will generate friction in gas passage and atmosphere
is rich in oxygen will get fire immediately. Regular cleaning is recommended for this
filter. Dry Gas Fiter for compressors
Oxygen Compressor casings

Oxygen compressors are having 2 halves split casings for low/high pressure casings as
uner in figures.
ASU 21/22 oxygen compressor low / high pressure casings.
ASU 31 oxygen compressor low / high pressure casings.
Compressor Impellors
As suction pressure of
oxygen varies from 2500 to
3500 mmWc and discharge
pressure of compressors
varies from 28.0 to 32.0 kg / cm2.
Oxygen compression is
carried out in nos. of stages.
Oxygen compressors are
5 stage compressors
and further every stage is
having more than one
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impellor as arranged internally. All these impellors are close impellor as shown in
figure below.
ASU 21 / 22 oxygen compressors are having 2 impellors in each stage in Low pressure
casing and 3 impellors in each stage of high pressure casing.
Lube Oil System

To provide cooled and filtered oil to the bearings and gear mesh, a forced feed
lubrication system is arranged. Some compressors have both motor driven oil pumps
and some compressors lube oil supply is through an Auxiliary Oil Pump and shaft
driven pump. The system consists of a storage tank, two oil filters, cooler, and an oil
mist exhaust fan.
The main pump is driven through the low speed gear shaft, while the auxiliary one is
separate motor driven which can be start/stop on DCS.
Pumps draw oil from reservoir and pump to a pressure up to 2.5 kg/Cm2 cool down in
oil cooler than passes through the filter before entering to the bearing and gear box
for lubrication. A thermostatic mixing valve is also provided which mix the oil from the
pump and the cooler outlet to maintain an oil temperature as recommended by
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venders. During cold operation this valve restricts the oil through the cooler to raise
the oil temperature quickly. As well as, an oil heater system is also provided in the
reservoir which maintain the reservoir temperature >20 oC . If the heater on Auto ON
position heater will be ON/OFF automatically according to the temperature set value.
Emergency oil supply tank is arranged with compressor having both oil pump on
electric motor drive. Oil tank is located at suitable height to maintain oil pressure to
compressor rotating shaft bearings for some time as Aux. lube oil pump will be in
operation as soon as low pressure alarm get activated.
The auxiliary pump provides the oil during start up till main pump discharge pressure
reached to required pressure than pump will stop automatically.
During operation if the oil pressure dropped due to any reason to pre set value. @nd
or Aux. oil pump will start automatically to avoid compressor train shutdown.
Auxiliary oil pump start automatically, and oil pressure is not controlled above preset
pressure value, compressor will trip.
Oil is supplied to the following parts of the compressor:
Each bearing of the compressor / motor.

Gears mesh tooth surface and bearing of speed up gear.
After the lubrication/cooling of the all bearings / gear mesh etc, oil re3turn
back to the reservoir and this cycle continuous.
The two notch type clean able filters are provided to clean the oil supply before going
to the bearings and gear box and motor bearings.
The notch filter is as type having a three-way cock valve. During normal operation One
filter is in service and other always in standby ready for service, If the D.P across the
filter reaches to max.1.0 kg/Cm2. changeover the filter to clean one. When switching
over one filter element to other care to be taken that the filter element taking in
operation is filled up with oil before Starting the handle switching over to stand by
element. Always do slowly transfer of handle simply in the opposite position.
Without having filled up the new one element, a pressure drop could be caused which
could lead to a shutdown of the compressor.
Figure below for lube oil system.
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Shaft Gas Seal System:-

A three-chamber labyrinth seal system with buffer gas is used for sealing the shaft. The
working principle of a labyrinth seal is the successive reduction of process oxygen gas
pressure from one end and buffer gas opposite end to a pressure almost equivalent to
atmospheric through consecutive steps of the seal, resulting leakage flow through seal
becomes very small.
A three chamber are namely as Oxygen gas chamber, oxygen / nitrogen mixture
exhaust and equalizing chamber, and nitrogen gas as a seal /buffer gas chamber.
Nitrogen gas is injected into the seal gas feeding chamber through pressure control
system with reference to pressure extracted from the equalizing chamber.
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The exhaust chamber is located in between the seal feeding and equalizing chamber,
from where the leakage of oxygen is concluded based on gas analysis. Regular analysis
of gas vent will help to monitor performance of gas seal system.
In the equalizing chamber leaked oxygen gas is collected. So the pressure of leakage
gas, which is collected in equalizing chamber, will be almost equal to suction pressure,
which works as a reference pressure to PCV for buffer gas.
Oil Seal:-
Another labyrinth seal also provided to stop oil traveling to the gas side, this labyrinth
is placed in between shaft seal and bearings housing. N2 gas from seal gas control
system is supplied to this seal to avoid oil to mix with oxygen gas.
Labyrinth seal are made of light alloy or material resistance to oxygen corrosion and
having less hardness than that of the shaft to avoid any change to the shaft in the
event of a any accidental contact.
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Oxygen Compressor Control System:-

As oxygen compressor is centrifugal compressor. Compressor operational range is
limited by the surge limit. If the compressor is required to supply less oxygen gas at
high discharge pressure than corresponding to this limit, the flow through the
compressor becomes unstable and the compressor start to surge. Flow rate and
discharge pressure collapse suddenly and rise again in rapid succession causing a
bombing noise, called surging. This is a serious operation of machine and can cause
severe damage to compressor and even compressor can have explosion due to sudden
rise in gas temperature.
In order to avoid surging an anti surge control system is provided which keeps the
compressor flow rate at the admissible value by opening an anti surge valve . The gas
in excess from plant for oxygen compressor requirement escapes through the product
valve to the atmosphere, so that compressor continue to work in the stable range at
the right side of the surge limits, even if only a small gas quantity is delivered to
customers header.
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Every centrifugal compressor has got a curved called Surge Curve whose shape
depends on a number of mechanical and aerodynamic factors. Surge curve is traces
out experimentally; it separates the machine-operating range into two areas.
Stable operating area
Unstable operating area where surge takes place leading to a heavy mechanical
damage. Possible damages caused by surging can be:
1-Thrust bearing failure.
2-Rubbing of labyrinth strips causing higher clearances and consequently
higher leakages/thrust forces.
3-Rubbing of impellers blades.
4-Failure of blading on axial compressor due to overstress / overheating.
5-Damage on suction filter, silencer, process armature etc.
To avoid surging anti surge system is provided which has been programmed in DCS
panel at control room.
Anti surge valve will be operated at low flow as calculated by programmed formula
and high discharge pressure to save the compressor from surging.
Flow Switch:
Low low switches will shutdown the compressors as final

protection device for surge detection.
Vibrations:-
Bentley Nevada system 3300 is provided to indicate all the shaft vibration of the
compressors shaft. An electric Signal from Bently Nevada monitor comes to DCS for
vibration monitoring.
ALERT and DANGER alarms setting also provided which can be seen by pushing alert
and danger push button for each vibration indicator on monitor panel.
Oxygen Compressor Start up Operation:-
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As oxygen compressor discharge flow is connected to customer header. It is extremely

important to confirm gas analysis as compressor outlet before introducing oxygen flow
from compressor to customer header. Oxygen compressor start up is performed in 2
modes as under:-
1- Oxygen compressor start up after maintenance job.
2- Oxygen compressor start up after unit shutdown.
1- Oxygen compressor start up after maintenance job.

As maintenance tools can have traces of oil and those traces of oil can cover
compressor rotating parts (Impellor) or stationary part (Casing). Presence of oil traces
in oxygen rich atmosphere can lead to fire in compressor. To avoid such accidents,
oxygen compressor start up is recommended on gaseous Nitrogen mode. Oxygen
compressor should run for 30 to 40 min. with nitrogen as suction gas media. Small
amount of gas from compressor discharge end is vented out to ensure cleanliness
operation of compressor get complete. Oxygen compressor will continue to run with
safe openings of recycle valves.
Oxygen gas is introduced to compressor gradually and finally compressor get fully inlet
flow media as oxygen gas.
Gas analysis will be conducted from compressor outlet before connecting to customer
supply header. At latest practice compressors are provided with discharge product
analysis confirmation to open discharge valve to header.
2-Oxygen compressor start up after unit shutdown.

ASU 21 /22 oxygen compressors are having common suction header, if one ASU is in
operation, Both compressors are pressurized and system is holding product quality.
If both ASU 21 /22 are shutdown and oxygen compressor header tie in valve is closed,
oxygen compressor will be purged from respective unit to get product purity at
compressor discharge end after low and high pressure purging.
Safe compressor start up practice is observed in ASU 31 oxygen compressors. Oxygen

compressor is get start up on nitrogen mode and oxygen inlet valve will open only
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after motor get its normal running speed as motor is induction motor. Nitrogen
injection valve will get close gradually and oxygen inlet valve will open gradually. Vent
valve to atmosphere will remain open till product quality get confirm and main
discharge valve opening permitted by interlock reset.
Oxygen Compressor Safe operation and

Environmental:-
Explanation of signs and references
Do not start any job in compressor housing before taking gas test of atmosphere in
oxygen compressor housing by gas sniffer. Do gas test on regular basis.
Personnel Safety.
When starting a oxygen compressor on nitrogen mode, the number of personnel in

the area should be avoided as area can have oxygen deficiency due to leakage.
Work Safety Sign:-

Safety related to person and work practice signs are placed in area with all description
of work safety measures to avoid injuries and deadly dangers. These instructions are
contained in compressor operation manual (OM).
Please follow this instruction, proceed with caution, especially in the described
situation, and follow to all work safety measures on to other users.
To be observed are not only the safety instruction included in this OM, but also the
General safety Measures for the prevention of accidents should be followed.
Caution Sign.
Some safe work practice signs are explained in operation manual of compressor OM,
those have to be especially considered, So that work instruction, safety measures and
Proper guideline are correctly followed, In order to avoid damages and destruction of
machines and / or other components.
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Work Safety Measures

The following work safety, measures are to be strictly followed:
1-The compressor is constructed on sound engineering practices and safe to

operate it. However, it can be dangerous when improperly handled.
2-Everyone engaged with assembly, disassembly , as well as commissioning
and maintenance (supervision, repair works, maintenance) of the
compressor must first read and understand the complete operation
manual, especially the chapter Safety. It is recommended to let this be
confirmed in writing.
3-The compressor is exclusively intended for the compression of oxygen gases
described in the technical data for a period of 100,000 running hours. Further
applications are considered improper, which means that the manufacturers
will treat it as inadequate use, and the user solely assumes the
responsibility.
4-In order to use equipment properly, it is necessary to observe the
manufacturers assembly, disassembly, and commissioning operation
instructions and maintenance conditions.
5-Unauthorized modifications of the compressor operations are forbidden.
The manufacturer will not be liable for any damage resulting from such
changes.
6-Only original spare parts should be used.
7-The responsibilities at the assembly, disassembly, commissioning and
maintenance works must be clearly determined and strictly observed, in
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order to avoid misunderstandings regarding competences in safety matters.

8-The delivered tools must be used in all assembly, disassembly work.
9-Any operation that could endanger the compressor must be avoided.
10-The user must also assume the responsibility of making sure that only
authorized and specially trained personnel operate the oxygen compressor.
11-The operator is obliged to inform manufacturer about the changes arisen in
the compressor that could endanger the installation.
12-It is the users responsibility to keep the compressor in perfect condition.
13-Information and regular supervision should be documented. Cleanliness
and functionality of all equipment in the compressor area should be
properly monitored and documented.
14-The maintenance works in the compressor plant must be basically
performed only when the machine are not in operation.
15-Only specially trained personnel should perform work in electrical,
pneumatic and hydraulic equipment.
16-Before performing any work in the oxygen compressor it is necessary to
secure its driving and any additional equipment from unintentional
switching in.
17-Safety devices should be removed only when the compressors is at

standstill and the equipment is locked out /tagged out.
18-Before starting after maintenance works it is necessary to check if all safety
devices have been installed.
19-The normal load capacity of the lifting appliance to be used must at least
confirm with the weight of the part to be lifted.
20-Parts to be lifted should only be suspended by using the foreseen lifting
lugs or trunions.
21-The users must secure that the operators wear the mandatory clothings
specified for this job.
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Nitrogen Gas Compression

Nitrogen gas is produced from ASU process plants with 2 production pressures as
under :-
1- Low pressure gaseous nitrogen production from low pressure column.

2- Medium pressure gaseous nitrogen production from high pressure column.
Nitrogen gas purity is maintained at two levels:-
1- In Gas Jubail area gaseous nitrogen purity is maintain at less than 10 ppm.
2-In Gas Yanbu area gaseous nitrogen purity is maintained at less than 5 ppm.
Nitrogen compressors are provided to compress nitrogen gas to deliver to customer at

11.5 kg/cm2 pressure.
To compress nitrogen gas two type of centrifugal compressors are available.
1- Multistage nitrogen compressors. (Low pressure GAN)

2- Single stage nitrogen compressor. (Medium pressure GAN)
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Nitrogen compressor operation.

Nitrogen compressor takes suction from low pressure column as it get
warm up in main heat exchanger with incoming feed air stream. GAN
Pressure at inlet of compressor 1st stage varies from 500 to 1000 mmWc.
GAN compressor each stage pressure data:-
After 1st stage. 0.6 to 0.7 kg/cm2.
After 2nd stage. 2.4 to 2.7 kg/cm2.
After 3rd stage. 5.9 to 6.2 kg/cm2.
After 4th stage. 11.8 to 12.2 kg/cm2.
In some ASUs medium pressure nitrogen as gas is produced. GAN pressure

after main heat exchanger is monitored as 3.7 to 4.5 kg/cm2. As this
pressure is more than 2nd stage discharge pressure and approaching to 3rd
stage discharge pressure range, A single stage design parameter can support
to build compressor discharge pressure up to 12.0kg/cm2. Single stage
nitrogen compressors are provided with ASUs producing medium pressure
Nitrogen as product.
Single Stage Nitrogen Compressor:-

Single stage nitrogen compressor takes suction from high pressure column
as it get warm up in main heat exchanger with incoming feed air stream.
GAN. Pressure at inlet of compressor 1st stage varies from3. 5 to 4.5 kg/cm2.
Single stage compressor will deliver GAN to header at customer required
pressure11.5 kg/cm2.
3- Reciprocating Nitrogen Compressors.

In GAS Jubail 2 Nitrogen reciprocating compressors are functioning to
compress nitrogen gas from 6.0kg /cm2 pressure to 12.0 kg / cm2 in single
stroke. Compressor stages are places in V shape. Cooling water is used to cool
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down stages during compression process. These compressors are named as

single stage double acting compressor. Compressor technical data is as under:-
1-Suction pressure. 5.8 to 6.5 Kg / cm2
2-Discharge Pressure. 11.5 to 12.0 kg / cm2
3-Max. Compression flow 5000m3/ Hr.
4-Motor power 0.5MWH
Multistage nitrogen compressors.

All multi stage nitrogen compressors in GAS are 4 stage compressor having following
construction and layout arrangements.
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1-Compressor casing and stages.

2-Inlet guide van.
3-Speed up gear box.
4-inter stage cooler.
5-Lube oil system for lubrication .
6-Seal gas system.
7-Balance gas system
8-Anti surge control system.
9- HT Electric motor
1-Compressor
casing and
stages.
Compressor Casing (Each stage) provide housing for impellor, diffuser, IGV and
inlet /outlet port of gas. commonly it is made of steel or alloy steel depending upon
nature of duty. In multi stage compressors stage casings are located in line of pinion
shaft as power to impellor will be provided by pinion shaft and are mounted on
gearbox frame structure.
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2-Inlet guide van.

Guide van is located at inlet of first stage and it regulate flow through compressor to
meet customer demand. It is an electro-Pneumatic operated valve.
Figure below for guide van of nitrogen compressor
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3-Speed up gear box:-

To import necessary centrifugal force to gas molecules, Impellor of stage needs high
rotation. As electric motor have 1800rpm. A speed up gear is arranged to provide
necessary rotational force to impellor. Main parts of gear box are:-
1-Bull Gear. 2- Pinion gears. 3-Shaft Bearings, 4-Gas seal system.
5-Lube. Oil system.
6-Temp. and Vib.
Monitoring
instruments.
4-Inter stage / After coolers:-

Shell and tube type inter stage /After coolers are arranged as interstage coolers to cool
down nitrogen gas after every stage. Chemical treated cooling water is used as cooling
media. Cooling water is circulating on shell side of all cooler.
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5-Lube oil system for lubrication .

All rotating and reciprocating equipments needs lube Oil supply to minimize friction
between metal surfaces. Nitrogen compressor have six bearings in gear box and two
bearings of electric motor. A complete lube Oil system is arranged with nitrogen
compressor for lubrication of all parts Lube oil system is provided with two types of oil
pumps as under:-
1- Screw / Gear type oil pump directly powered from bull gear of gear box.
2- Electric motor driven oil pumps functioning as stand by pump or main oil
pumps if gear box pump not available.
Oil supply system is also provided with emergency lube oil supply arrangements with
some of nitrogen compressors if gear box pump not available .
All nitrogen compressors having main oil pumps driven by bull gear of gear box do not
have emergency lube. Oil supply system.
6-Seal gas system.

Oil free nitrogen gas supply to customer is only possible if proper shaft gas labyrinth
seal system is provided. Seal gas supply is arrange as under:-
1-Nitrogen gas supply to seal system from external source.
2-Nitrogen gas supply to seal from internal source (Balance seal).
7-Balance gas system
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As balance gas is collected from back side of impellor to minimize axial thrust on
impellor. This balance gas is also used as internal seal gas source. For external seal gas
source nitrogen supply from seal gas header is arranged to maintain all time seal gas to
nitrogen compressors.
Balance gas pressure helps to maintain shaft seal gas pressure for internally build seal
gas systems
4TH STAGE BALANCER

GAS
3RD STAGE BALANCE

GAS
2ND STAGE BALANCE

GAS
GAN TO
SECTION
GAN FROM SEAL

HEADER
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8. Anti-surge control system

Centrifugal compressor can surge due to low flow through the compressor with high
discharge pressure.
Due to Surge compressor will suffers from unstable operation behavior resulting
damage of structure due to high vibration or axial displacement. This unstable
operation of centrifugal compressor is called surge.
To avoid unstable operation of centrifugal compressor an anti surge control system is
provided. System helps to improve gas flow through compressor either by venting
product to atmosphere or recycle to suction line. Usually all products and processed
flows are send back to suction line to minimize losses.
Figure below of anti surge controller.
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ADD ANTISURGE LOOP DIAGRAM
Flow oriented anti-surge control system
Surge line Graph:-
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9-
Electric Motor Drive.

In GAS all plants compressors run by Electric motor accept PH-6 run by steam
turbines.
Storage Area
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In GAS all ASUs products are being delivered to customers directly. No buffer storage
zoon is provided in system to supply gases to customer in case of plant shutdown for
some time.
Liquids products is stored in designated tanks to vapourise it to meet customers

diamonds and to supply liquid to internal / external customers.
As products liquids temperatures are too low, Specially designed storage vessels are
required to hold products in liquids form. GAS have storage for following products:-
1- Liquid Oxygen storage tank.
2- Liquid Nitrogen storage tank.
3- Liquid Argon storage tank.
All liquids storage tanks are double walled tanks and insulated to maintain inner tank
working temperature. Inner tanks working temperatures are in range of cryogenic
temperatures, Storage tanks are named as cryogenic storage.
Liquid storage tanks are of two types as under:-
1- Low pressure storage tanks.
2- High pressure storage tanks.
In GAS both type of storage facilities are in service for following services:-
1- Low pressure Tanks to store liquid products from plant in bulk

quantity to serve as main storage of liquid products
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2- High pressure storage vessels are having max. capacity of 40Tons

and are directly coupled with vapouriser. These storages are named
as VIEs (vacuum insolated evaporators). Refilling of HP. Tanks will
be carried out as soon as low level alarm get activated on MAN
/AUTO operational basis to keep tank ready to supply liquid to
vapouriser whenever it is required.
1-LOW PRESSURE
ATMOSPHERIC
TANKS:
The LIN/LOX/LAR produced from Plants are directly stored in low-pressure

atmospheric tanks.
LOX/LIN products diversion to tanks are controlled depending upon empty spaces
available in tank and its utility.
The LIN /LOX stored in atmospheric tanks, are vaporized to supply customer at
high pressure through LIN/LOX back up pumps and high pressure VIEs when
plants do not have sufficient product to meet customer requirements, due to plant
emergencies or plants shutdown.
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Road tankers are filled through low / high pressure pumps to supply
LIN/LOX/LAR liquid to customers.
Storage product quality is continuously analyzed and maintain to avoid any risk of
contamination with LIN/LOX/LAR products while leaving plant to the storage.
Figure below for Internal low pressure double walled tank:
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TECHNICAL DATA for Liquid TankS.

Product Service : Liquid.
Tank Capacity : Variable MT / LIN
Design Temperature Inner Tank. : -196o C
Design Temperature Outer Tank : 37.8 C
Test Pressure inner Tank : 0.1275kg/cm2
Design Pressure Inner Tank : 0.102 kg/cm2
Outer Tank purge pressure : 0.0051kg/cm2
Internal Tank Sheet Material : Ni-steel
Outer Tank Sheet Material : Carbon Steel
Space Insulation type : Perlite
Low Pressure Tank CONSTRUCTION
In all plants low pressure cryogenic liquid storage tanks are provided to store liquid as
product.. Max. working pressure of tanks is 0.08 kg/cm2 or 800mmwc.
Tank test pressure is 0.1223kg/cm2 or 1223mmwc.
Tanks basements are made of concrete in two layers. About 2m space is provided for
cross ventilation to sweep out cooling from bottom of tanks if cold patch appeared on
bottom ring.
Liquid storage tanks are designed to withstand with high wind pressure.
Design Wind speed. 160km/Hrs.
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NEVER REMOVE VALVE KEY FROM VALVE AND

NEVER ISOLATE BOTH PSVs TOGATHER.
Emergency shut off valve are provided to isolate tank in case of any type of
emergency. Emergency shut off valves are Electro pneumatic type on some tanks and
on some tanks these valves are only electric operated. All valves are source (IA /
Power )failure close type valves. Breathers are provided to break through vacuum if
get develop in inner or outer space of tanks.
Inner Tank pressure Build up Control

Tanks inside pressure build up controllers is provided which will vaporized liquid to
maintain inner tank pressure 0.07 kg/cm2 in case of pressure dropped due to excessive
withdraw of liquid or PSV,S get open.
Pressure build vaporizers which is taken from the bottom of the tanks and enter to the
top of the tanks in form of cold vapor after passing through LIN/LOX or atmospheric
vaporizers..
Tanks Level Control System

Two level transmitters are provided to read tanks liquid levels based on differential
pressure . Also positive displacement level indicator is provided called ENRAF meter.
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Emergency Tanks Isolation

Emergency push button for LIN/LOX are provided to the Tanks internal valves and
backup system in case of any emergency.
Tanks isolation can be performed from field or from control room depending upon
field situation This isolation process can be performed for individual storage system,
individual shut Off valve isolation and common for whole storage area shutdown.
Normalize Tanks Isolation
These internal shut off valves can be RESET by Push button operation from field if shut
off valves are electro pneumatic type. System needs reset by key operation from field
cabin. Before resetting shut off valves operated emergency switch must be normalize
otherwise system will not be Reset.
In some LOX/LIN storage tanks emergency shut off valves resetting is performed by
MANNUAL operation. Electric supply to electromagnetic solenoid valve is normally
380V. Operator should observe extra care during valve resetting operation.
NORMALISE LIN/LOX TANKS SYSTEM

LIN tank declared emergency shutdown and isolated by DCS operator. Field operator
undergo following procedure to normalize it :-
1- Field operator has to visit area immediately and confirm to DCS operator about area
situation.
2-Field operator to confirm from DCS operator about ES. Get operated.
3-DCS will confirm ES. Number get operated.
4-Field operator will visit ES in field and release it.
5-Field DCS operator confirm to Field operator that ES is normalized and then field
operator will open EM. Shut off valves by push buttons one by one.
6-Field operator will confirm from DCS operator about status of valves that all get
open or not.
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7-Field operator will reset all the pumps from substation panel.
8-Field operator will reset LIN backup pumps A/B by putting the field switches to OFF
position then put on Ready position and some pumps needs to confirm that back up
pumps cooling fans are in operation.
9-Confirm with DCS operator that area get normalized.
Field operator has to check area again for any abnormality.
Mannual Resetting Of Valves.

In some LOX/LIN storage tanks emergency shut off valves resetting is performed by
MANNUAL operation as follow.
1- Ensure electric supply source to solenoid valves available. ( Help from

electrical department).
2- Operator have to locate himself safely.
3- Raise valve actuator with full manpower up above man height suddenly
to pass rope knot through solenoid valve to open the valve.
4- Listen a sound tick/click from solenoid valve.
5- Return back manual cap of valve.
6- Check/ confirm liquid flow from tank outlet line below valve.
Emergency Vents Outer shell

Outer shells of tanks are provided with a manhole type PSV valve to protect
tanks from high-pressure damage as tanks shell space is under purging with
nitrogen gas and shell design pressure is too low..
GAN Purge Supply to Tank
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GAN is supplies to the annular space of the tanks to keep Perlite powder always dry
with a local flow indicator to ensure always availability of purge gas to the tanks. GAN
supply to purge line is arranged from GAN main header.
Operator Safety:-
Tank storage area have bulk LIN/LOX storage, Area can have oxygen deficiency or
enrichment due to leakage /spillage of liquid . For employees safety areas are
provided with local area analysis equipments to warn out all concerns in area. A
siren will get activate and a area light will start blinking as soon as area get
deficiency or enrichment of oxygen in area.
All personnel those are in the area of the tank, as a minimum, should review the
following documents for awareness of personals physical hazard:
1. OSHA 29CFR 1910.1200

2. AGGIH Threshold Limit Values and Biological Exposure indices
3. MSDS for stored product.
Before product is introduced into tank, the GAS should develop procedures to cover
spillage, traffic, visitors, maintenance, emergency evacuation and fire fighting, etc. if
emergency get develop in the storage area.
ALL THE PERSONS IN THE AREA OF THE

TANK SHOULD BE AWARE ABOUT THE
POSSIBLE HAZARDS AND TRAINED IN
EMERGENCY PROCEDURES.
2-High Pressure Liquid Storage Tank

High pressure tanks are provided in Lox/ Lin storage areas for following services:-
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1- To store liquid at high pressure to supply it to vapouriser as needed.

2- To Supply liquid Product to transport tankers under pressure.
Construction Of Tank:
These tanks are normally double wall tanks. Internal tank is high pressure tank made
of alloy steel suitable for cryogenic temperature operation. Outer shell is made of
carbon steel and space between two shells is filled with insulation material and after
that insulation filling performance is further enhanced by vacuum as vacuum is also
non conductor of heat media.
Based on construction and duty performed these high pressure tanks are named as
VIEs (Vacuum insulated evaporator)

High pressure in tank is maintained by pressure control system as high pressure liquid
evaporator provided with tank.
High pressure in tank is controlled by venting gas from tank or by release of gas from
pressure safety valve.
Liquid transfer pumps are used to fill high pressure tanks from low pressure tanks or
bulk storage tanks.
In GAS these tanks are in operation with following high pressure services.
1-OX high pressure tank with design pressure of 40 kg/cm 2 and operating
pressure of 32-34 kg/cm2.
2-LIN high pressure tank with design pressure of 16 Kg/cm2 and operating
pressure of 13 kg/cm2
Very regular vacuum monitoring is recommended for VIEs to maintain insulation level.
Vacuum insulation level is measured in TORS and max. is 3.8.
Field operator have to check area regularly for any abnormality like leakage from
isolation valves, PSVs and control valves.
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High Pressure LIQUID TANK.
Liquid Oxygen / Nitrogen

Vapourisers
All GAS plants are delivering products to
customer headers directly from cold boxes or
from product compression compressors, no
buffer storage available in system for supply
of gases in case plant or equipment
shutdown. Liquid oxygen and liquid nitrogen
vapouriser serves to provide buffer storage
service to customer header. In GAS three
types of vapouriser are in operation. These
are named as:-
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1- Seawater LOX /LIN plate vapouriser.
2- Atmospheric LOX /LIN Fin plate Vapouriser.
3-Shell and tube type LOX /LIN vapouriser.
Figures below for these vapouriser/ evaporators
Shell And Tube Type Evapor. Plate Type Evapor.
Atmospheric Vaporizers
Seawater LOX /LIN

Plate Vapouriser.
In this vapouriser hot seawater is used as
hot media to vapourise LOX /LIN in
vapouriser. Hot seawater is supplied from
outlet of seawater coolers and in case of
plant shutdown seawater is used as hot
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media. LOX / LIN supply to vapouriser are arranged from LOX /Lin high pressure tanks.
Both liquid flows are in counter directions. Sea water is distributed from top of
vapouriser and get collected in pit for further disposal to sea.
Number of plates in vapouriser depends upon quantity of liquid required

to vapourise.
Plates of vapouriser are made of Aluminum due to good heat exchange.
2-Atmospheric LOX /LIN Fin plate Vapouriser.

A lot of heat energy from SUN is available in natural atmosphere space. This heat
energy is utilized to vapourise LOX /Lin in fin type tube heat exchangers. LOX/LIN are
supplied to vapouriser from high pressure tanks/liquid pumps. One vapouriser system
can have no. of vapouriser units. 75% of vapouriser units are kept in normal operation
when ever service required and 25% units are kept in stand by defrost mode to
remove ice deposits from vapouriser fins plates. In case vapouriser outlet
temperatures are observed low, power drafts of air are arranged to enhance heat
transfer level in system.
Nos. of vapouriser units in system depends upon quantity of liquid to vapourise.
Advantage of atmospheric vapouriser are hot media supply free of cost and
disadvantages of atmospheric vapouriser are that surrounding areas are getting heavy
fog in summer and dense fog in winter season.
3-Shell and tube type LOX /LIN vapouriser.

These vapouriser are using sea water as hot media to vapourise LOX/ LIN to gas.
Supply of seawater to vapouriser depends upon its availability. High pressure liquid
from liquid backup pumps are directed to tube side of vapouriser and hot media SW is
flowing on shell side of vapouriser.
As seawater is corrosive in nature, alloy metals like Monel metal is used for vapouriser
construction. Vapouriser size and seawater flows depends upon quantity of liquid to
be vaporized
Liquid pumps
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Liquid pumps used to transfer liquid product under controlled operating conditions to
LIN/LOX vaporizers and to fill LIN/LOX /LAR road tankers. These operating conditions
are:-
1-Working temperature
2-Seal gas system
3-Net positive suction head
4-Pump discharge flow
5-Pump discharge pressure
Structure of pump depends upon requirement of discharge pressure and flow. If

pressure / flow is low, single stage pump can meet requirement. Otherwise multi stage
pumps are recommended.
Figures below for different types of liquid pumps available in

GAS:-
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Four types of Liquid pumps are available as under:-

1- Liquid pump as LOX I / C pump.
2- Liquid pump as back up pump.
3- Liquid pump as liquid transfer pump ( Tanker filling pump).
Liquid Pumps Deriming.

Liquid pumps are taking cryogenic liquid from liquid storage tanks . To do cleaning of
strainer & to do any Maintenance job pumps must be derime up to warm
temperature before handed over to maintenance.
Deriming of liquid pumps also recommended as pump maintenance get
complete to remove moisture from pump casing and pipeline.
Follow to following lines as guideline or follow to GAS SOP:-

1-coordinate with DCS operator to start deriming of required pump.
2-Isolate power for motor and do lockout/tag out if required.
3-Isolate and drain all liquid from the pump body and pipeline.
4-Start deriming of pump with GAN as preferred gas or dry air can be used if GAN Is Not
available.
For detail procedure follow to SOP of GAS for liquid pumps

deriming.
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Prepare Liquid Pump for Service.

In GAS liquid pumps are located in 2 physical positions as under:-
1-Liquid pump housed in cold box.
2-Liquid pump located open to atmosphere .
To prepare Liquid pump for operation, Follow following guideline and also follow
to standard operating procedure (SOP) of GAS for liquid pumps cool down.
1- Check and confirm that all PTW get close and lock out/tag out get
removed.
2- Check area housekeeping get complete.
3- Liquid pump cold box insulation packed properly and cold box
closed if provided. Cold box GAN purge must be open before cool
down.
4- Check dew point from liquid pump casing / pipeline blows, It must
be less than -45oC.
5- Follow to liquid pumps cool down procedure as SOP of gas, cooling
rate should be slow so that all pump parts get cool down properly,
wait till all pump casing and pipe lines get heavy ice coating.
6- Inform to DCS operator before Start liquid pump from field switch.
Cryogenic Liquid Tankers ( CT /VIT)_.

A cryogenic liquid tanker is used to transfer Cryogenic liquid from one place to other.
It is consist of storage tank, operation cabinet, cryogenic liquid pump and tanker head.
The storage tank which is double walled vacuum insulated vessel having little
evaporation loss and highly reliable for safe transportation of cryogenic liquids. These
tanker are used sometime for storing of liquefied argon/oxygen/nitrogen. As tanker
vessel is vacuum insulated , it is also named as VIT.
These tankers are of different capacities. Tanker are designed for low pressure
2.5kg/cm2 and high pressure from 18 to 25 kg/cm2.
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High pressure tankers are used to do liquid decanting to customer VIEs without pump.
Low pressure inner tank vessel tankers are provided with liquid pumps to transfer
liquid from Tanker to customer VIEs. Tankers Liquid pumps are capable to deliver liquid
to customer VIEs up to 18 kg/cm2 pressure.
A skilled and qualified tanker operator required for safe

operation of liquid pump.
TANKER PURGING FOR CONVERSION

Tanker conversion some time is unavoidable due to shortage of tankers this
conversion may be from LOX to LIN to LAR & vice versa.
Follow the detail SOP for reference.
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Liquid Transfer From Tanker:-

Liquid transfer from road tanker is carried out in two ways:-
1- Transfer of liquid from tanker to VIE by pressure difference.
2- Transfer of liquid from tanker by liquid pump to VIE ( force transfer)
Usually transfer of liquid to customer VIEs is termed as DECANDING.
To do transfer of liquid by difference of pressure high pressure liquid transfer tankers
are used. Liquid surface is pressurized by vapours. Liquid is vaporized in liquid
evaporator equipped to tanker construction. Liquid to evaporator is supplied from
tanker drain line or from liquid pump discharge line if liquid pump provided. Liquid
transfer rate depend entirely on performance of pressure build liquid evaporator.
Liquid transfer rate is too slow.
To meet customer high pressure demand in VIEs liquid transporting tankers are
provided with liquid transfer pumps. These pumps can deliver liquid to customer VIEs.
Against working pressure up to 18 kg/cm2.
A qualified tanker operator is recommended to operate liquid pump on customer site.
Receiving Customer Tanker For Liquid Supply

Customer Tankers are visiting to GAS plant sites to collect liquid oxygen, liquid
nitrogen and liquid argon products. It is extremely important to check tanker for
followings before placing tanker on site for filling:-
1- Tanker physically do not any defect of engine, trolley and VIT.

2- Use proper Cryogenic PPE.
3- Weigh the tanker before and after filling.
4- Tanker should by specified & labeled for certain product fillings.
5- Tanker valve cabin is equipped with GAS standard analyzer sample
point and do analysis before and after filling.
6- Tanker do not have dual Liquid filling connection.
7- All Valves in cabin of LOX tanker are free of oil service.
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8- Tanker liquid level gauge is in proper function.

9- Different liquids ( LOX, LIN, LAR) contents table is available in cabin.
10- Hose pipes are free of oil for LOX service.
11- Tanker operator must use all Tools suitable for cryogenic LOX or LIN
liquid services.
12- Tanker operator must own all safety gears suitable for cryogenic liquids
handlings.
Note: Operator should do practice to place tankers for

filling with reasonable distance between tanker engine
and oxygen vapors vent if LOX Filling in progress.
Electricity And Drives

Main source of power in GAS is electricity. Electricity supply is received from SECECO/
Marafaq in Jubail / Yanbu. High tension supply is received as 230 or 115KV.
In Gas following voltage drives are provided with equipments:-
Jubail Area
1- ASU 31/41/51/71 Main air compressor drives 13.8KV
2- ASU 41/51/71 Booster compressor drives 13.8KV
3- All Nitrogen compressor with capacity of 50000Nm3/Hr. 13.8KV.
4- All Nitrogen compressor with capacity > 50000Nm3/Hr. 4.16 KV
5- ASU 21/22 Main air compressor. 6.6KV
6- All Oxygen compressors. 4.16KV.
7- All Chilling units CW and SW pumps. 4.16KV
8- All other motors and heaters power supply varies from 380 to 560volts.
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9- All chemical dozing pumps power supply varies from 110to 220 volts.
Yanbu Area
1- ASU 32/42/52 main air compressor drives 13.8KV
2- ASU 32/42/52 booster compressor drives 13.8KV
3- All Nitrogen compressor with capacity of 50000Nm3/Hr. 13.8KV.
4- All chilling units CW and SW pumps. 4.16KV
5- All other motors and heaters supply varies from 480 to 600 volts.
6- All chemical dozing pumps power supply varies from 110to 230 volts
Two type of electric motors are in service in GAS as under:-

1- Induction electric motors.
2- Synchronies electric motors.
1-Induction electric motors.

An induction motor is a type of alternating current motor where power is supplied to
the rotor by means of electromagnetic induction.
Main parts of induction motor are:-

1- Stator . 2- Rotor.
3-Winding armature. 4-Side covers with bearings.
5-End cooling fan. 6-Termination Box.
2-Synchronies Electric Motor.
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Alternative current as it passes through stator winding produce EMF field in motor
rotor and stator . Magnetic field will force motor rotor to rotate as result of repulsion
and attraction of magnetic pools.
These motors are equipped with power factor correction mechanism known as excitation
system. As motor power factor is less than 1 due to Cos . Excitation system will improve
power factor and approach to 1.
Electric motors are cooled down in 2 ways as under:-
1- Air cooled electric motors.

2- Water jacket cooled electric motors.
Air cooled electric motors are of 2 types as under:-
1- Motor stator cooled by external draft of air.

2- Motor stator cooled by internal draft of air.
In these days electric motors stator cooled with external draft of air are preferred as these
motors are treated as water proof as water will not enter in motor even it get in water.
Electric Motor Soft Starter

All high tension and high power motor s are started through soft starter. This system
provide electric motor a variable alternative current frequency.
Power is supplied under controlled monitoring system. Electric motor will start with
normal operating voltage and frequency of 15Hz.
Motor rotor will start rotation with slow rotation and rotor rotation will increase as
power supply frequency will increase. Normally it takes 2 min. to achieve normal
frequency of 60 Hz. M
Motor will achieve its max. speed called as synchronized speed. System will confirm all
informations before shifting power supply from main power supply breaker.
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As power supply to motor will get consume very gradually, no power impact will be
observed on main power supply grid. This system will help to avoid limitations on nos.
of starts of motor in 24Hrs.
Process Instrumentation:-
To have a smooth plant process it is very important to maintain certain parameters of
processing raw material to acquire product on specification. These basic parameters
are:-
1- Level of liquids in different parts of plant equipment (L).
2- Pressure of processing media stream in different locations (P).
3- Temperature of processing media streams in different locations (T).
4- Flow of processing media in different streams of process in plant (F).
5- Differential pressure in streams across equipments (PD).
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To measure all these parameters standard practice instrument are installed in plant
layout on stream as routed and as required basis.
1-LEVEL
Basically level is measured on differential measurement of head pressures as under:-
1- Total head pressure -----------HT
2- Vapor head pressure-------H
3- Net level head -------------HN
HN = HT - H
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Two sampling tubes provides parameters

to differential measuring equipment that
finally indicates net values of liquid level.
HT Sampling tube is named as (+) Positive
line.
H Vapor pressure sampling line is named
as (-) negative line.
To measure liquid levels in different
locations in plant area, following equipment are installed:-
1- Level gauge on site.
2- Level Transmitter to communicate to DCS Panel.
3- Level switch to act directly to safe process and equipment.
Level Gauge.
Level glass gauges are provided in field to indicate levels of pits and tanks. These glass
gauges are graduated with scale to measure levels.
With the development of digital display systems, in these days digital level indicator
are provided in plants on site. These helps to minimise error in data recording.
Figures below for level gauge s,
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Float type level indicator

To have positive level position in any vessel or pit, float type level indicators and
transmitters are provided in field. These are pneumatic and electro-pneumatic type.
Figure below for float type level indicators:-
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Pneumatic Level indicators.

Some time nature of fluid in tank or pit is not supporting to conventional level
indication system. Pneumatic level measuring system is applied in such situation. In
this system compressed dry gas is pushed through a tube up to bottom of pit or tank
and gas pressure required to generate bubble is measure and calibrated in term of
head of liquid to measure level of liquid.
Figure below for pneumatic level indicator.
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Level Transmitters and controllers

Level transmitters are instruments that deliver level conditions in the form of digital
signal to control panel via field junction box. Control panel can be of DCS type or
conventional analog type.
There are 2 types of transmitters available in field. One type is box type to send only
electric signal and 2nd is window type provide display of data in field and serves as
field gauge.
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Figure below for window type transmitter.
2-Pressure
Pressure is force to drive process media from one place to another place. It is
measured in different units of measurements as under:-
1- MKS system. Meter , Kilogram, Second system.
2- CGS system Centimeter, Gram, Second system.
3- FPS System Foot, Pound, Second System.
4- SI System Meter. Newton, second.
Basic measuring tool is pressure gauge. Pressure gauges are available to measure
pressure in all standards. Pressure is measured in 2 scales as positive or negative .
Negative pressure is measured in term of water column height and noted as WC with
measuring unit. For example 10mmWC .
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Pressure gauges
Pressure gauges are used to measure wide range of Positive / Negative pressures.
Dial type gauge provided with needle to indicate pressure value of stream at any
location.
To have accurate values of data, Now digital display type pressure gauges are also
available on plant site. These are also equally used to measure Positive / Negative
pressures.
Figures below for pressure gauges.
Pressure Transmitters
Pressure transmitters provides services to transfer pressure data equivalent electric
signal to control panel via field junction box.
Different type of transmitters are available for service. Window type transmeters
provide service of gauge also as data can be read in field.
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Figures below for pressure transmeters .
3-Temperature
Degree of hotness or coldness of a fluid media is measured in terms of temperature.
Following measuring scales are used in normal practice:-
1- Degree centigrade. oC 0 o C as water freezing point.
2- Degree Fahrenheit oF 32o F as water freezing point.
o
3- Degree Absolute. A 273.2o C as water freezing point.
o
4- Degree Kelvin K 273.2o C as water freezing point.
o
5- Degree Rankin R 492oF as water freezing point.
All these temperature scales are transferable to each other by applying equivalent
scale conversion equations as under:-
o
C = (oF - 32) / 9/5.
o o
A/K = C + 273.2
o o
R = F + 460
To measure temperature following equipments are used in GAS.
1- Temperature gauge.
2- Thermocouple.
3- Resistance temperature detector (RTD)
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4- Infrared temperature detector.

5- Radiation Pyrometer temperature detector.
1-Temperature Gauge
Commonly used equipment for measuring

temperature in a wide range and available both in dial and digital display. Figures
below for temperature gauges.
2-Thermocouple:-
It is used to measure temperature in a wide range. It is working on principle as under:
The junction between two metals generates a voltage which is a function of
temperature. Thermocouples depend on this feedback effect. Although almost any
two types of metal can be used to make a thermocouple, a number of standard types
are used because they possess predictable output voltages and large temperature
gradients. The diagram below shows a K type thermocouple, which is the most
popular:
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In GAS thermocouples are used in different plants for temperature measuring

element. Electric signal is routed to control panel via field junction box.
Figures below for thermocouples.
3-Resistance Temperature Detector (RTD).

RTDs are used to measure wide range of temperatures for very low and for high
temperature as possible in field. Instrument works on comparison principle. One metal
resistance is treated as standard and second metal resistance will change with
temperature. Change in electric resistance is compared with standard metal resistance
measure in term of temperature.
Standard metal usually is considered as platinum.
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Figures below for RTDs arrangement.
4-Radiation Pyrometers:-
If working temperature of object is too high and human reach is unsafe, radiation
pyrometer type instruments are used to measure temperature. Pyrometer is working
on electric signal principle as under:-
A pyrometer for estimating the temperature of distant sources of heat; radiation is

focused on a thermo junction connected in circuit with a galvanometer. Thermo
junction will generate electric signal based on reception of heat radiation rays and
arrange galvanometer will display it in form of temperature.
Figure below provide working principle of instrument.
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4-Flow Of Stream.
Every process
demands specified
amount of feedstock
to produce specified
amounts of
products. To supply
specified amount of
feedstock, standard
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measuring instruments and systems are applied. Flow of fluid through a pipe is
function of followings:-
1- Area of pipe. (A)
2- Pressure of flow media. (P)
3- Velocity of flow media. (V)
F = PAV
There are several types of flow measurement devices. Commonly used devices in gas
are:-
1- Venturi Tube meter.
2- Orifice plate meter.
3- Pitote tube meter.
4- Ultrasound flow sensor meter.
5- Positive Displacement Flow meter.
Control Valves
Control valves are valves used to control conditions such as flow, pressure,
temperature, and liquid level by fully or partially opening or closing in response to
signals received from controllers that compare a the set point" to a "process
variable" and operate the control valve accordingly.
Dry instrument air or nitrogen is recommended for supply of air to control valves.
Supply pressure to valve is maintained in between 3.5 to 5.0 kg / cm 2. As observed
from control valve behavior, if supply pressure get drop below 3.5 kg/cm2 could be
malfunctioning.
Self control valve
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Self control valves are provided in the plant to maintain the required stable upstream
or downstream pressure. These valves are usually used to maintain the pressure with
small flow rate.
These type of valves are diaphragm type operated valves. One side of diaphragm is
provided with spring force to move spindle and other side of diaphragm is provided
with a pressure force of fluid (gas or Liquid ) needs control of operating parameters.
As soon as pressure drops in upstream / downstream of valve, self controlled valve
will operate to compensate it. No control system required to assist valve functioning.
The set value of controller is adjusted by the spring tension.
Figure below for self control valve.
Control loop
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A control loop consists of the following three parts:-

1- Measurement by a Transmitter connected to the process,
2- Feed back to controller element,
3- Action through signal convertor ("actuator") such as a control valve
Some control loops work in cascaded control, ( It refers to a control system involving
two or more controllers. One instrument measure a process variable (as temperature
or pressure) and resets a second process condition (as flow) through another
controller and so produce signals used by other controllers or use signals created by
other controllers. For example, suppose a water tank is used to supply water for
several parts of a plant and it is necessary to control the tank level at a constant
value. Tank level control valve opening will send 2nd control signal to consumers
points to monitor consumption with reference to tank level.
Measuring data, processing the data from feedback information and finally making a
control action to operate the valve. These three functions make up what is known as a
control loop.
Figure below for heating process loop
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Gases Volume conversion Table

OXYGEN NITROGEN
Units
US US
Kg Ton Nm3 Liters Kg Ton Nm3 Liters
Gallon Gallon
Kg 1.0 0.001 0.700 0.2315 0.8765 1.0 0.001 0.800 0.326 1.237
Ton 1000 1.0 700 232.4 879 1000 1.0 800 328.6 1,244.0
Nm3 1.4285 0.0014 1.0 0.3205 1.2558 1.2500 0.0013 1.0 0.4106 1.5552
Gallon 4.321 0.0043 3.120 1.0 3.78531 3.059 0.0030 2.435 1.0 3.7853
Liter 1.1416 0.00126 0.7963 0.2642 1.0 0.80829 0.00089 0.6430 0.26417 1.0
ARGON HYDROGEN
US US
Kg Ton Nm3 Liters Kg Ton Nm3 Liters
Gallon Gallon
1.0 0.001 0.5603 0.1896 0.7178 1.0 0.001 11.124 3.7236 14.0949
1000 1.0 560.3 189.8 718 1000 1.0 10,092 3,378 12,787
1.7847 0.0018 1.0 0.3387 1.2815 0.0898 0.000099 1.0 0.3346 1.2671
5.2743 0.0053 2.952 1.0 3.78531 0.26857 0.00029 2.9881 1.0 3.78531
1.393 0.0013 0.7803 0.26417 1.0 0.07094 0.000078 0.78919 0.26417 1.0
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Rare Gases Volume conversion Table

KRYPTON/XENON
1 Nm3 = 3.940 Kg
1 Nm3 = 1000 N Liters
1 Kg = 0.2538 Nm3
1 Ton = 253.8 Nm3

1Ton = 1000 Kg
1 Kg = 0.001 Ton
1 Kg = 253.8 Liter
1 Liter = 0.00394 Kg
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GAS INTEGRATED MANAGEMENT SYSTEM Doc. Ref.

Training & Development Section 01-Jun-2016

Training & Development Section 01-Jun-2016

Review Of Progression Level 1 By Tutors.

2- Why filtration process required in process plants?

3- How Air Separation Plants feed filtration is carried out?

4- Why compression process is required for ASUs process plant.

5- What type of compressors used for compression in GAS?

6- How pre-cooling process is functioning in ASU process plant?

7- How many systems of feed purification are applied in GAS ASUs?

8- What is the function of turbine in ASU process plant?

12- How distillation takes place in distillation column?

13- What are main parts of column?

14- Why liquid storage is required with ASU plants in GAS?

15- What type of liquid storages are available in GAS?

18- How Liquid product transportation is carried out in GAS?

Training & Development Section 01-Jun-2016

OXYGEN SYSTEM HAZARDS.

1-Oxygen enrichment. If concentration of oxygen get increase to 23.5% due

Training & Development Section 01-Jun-2016

leakage, Area oxygen deficiency must be declared for

Air Filter Environment and Safe Operation

Confined space Entry:-

Training & Development Section 01-Jun-2016

Other Industrial Filters

Oil filter operational limitations:-

Oil Filter Changeover

Training & Development Section 01-Jun-2016

Figures below for oil filter cartridge:-

Add Synthetic type filter

Training & Development Section 01-Jun-2016

Water Filter/ strainers:

Figures below give different shapes of water strainers.

Types of Filters / Strainers:

Training & Development Section 01-Jun-2016

Backwashing type Filters / Strainers

Training & Development Section 01-Jun-2016

Training & Development Section 01-Jun-2016

This can be achieved by

forcing a given volume of molecules to occupy a smaller volume

increasing the temperature so that molecular motion is increased.

increasing Kinetic energy so that molecular motion is increased.

NOTE: GAS YANBU AND JUBAIL HAVE ALL CENTRIFUGAL PROCESS

Training & Development Section 01-Jun-2016

NAME CHEM CONC. IN FREEZING NORMAL CRITICAL CRITICALP MOLECULAR

NITROGEN N2 78.113 -210 -196 -147 34.6 28

Argon Ar 0.931 -189 -186 -122 49.6 40

Krypton Kr 0.0001 -157 -153 -64 56.0 83.8

Xenon Xe 0.000009 -112 -107 17 60.1 131

Neon Ne 0.0018 -249 --246 -229 28.13 20

Helium He 0.0005 -272 -269 -268 2.335 2

Hydrogen H2 0.00002 -259 -254 240 13.4 1----2

BLOCKING MATERIAL FOR PHE

Nitrous Oxide NO -163.3 -152.0 -94.0 67.2 30.008

Hydroch. acid -114.3 -85.0 +51..4 85.7 36.465

Hydrogen Sulf H2S -85.5 -60.4 +100.4 91.937 34.082

Sulferr dioxide -75.5 -10.0 +157.7 80.22 64.066

Carbon dioxide CO2 0.035 -56.5 -78.5 +31.0 75.3 44.011

Ammonia NH3 -77.7 -33.4 +132.4 115.2 17.032

Nitrous Oxide N2O -90.8 -88.7 +36.5.4 74.1 44.016

HYDROCARBONS EXPLOSIVE ELEMENTS

Training & Development Section 01-Jun-2016

Ethane C2H6 -183.3 -88.6 +32.1 49.8 30.070

Ethylene C2H4 -165.5 -103.9 +9.6 52.6 28.054