TAL NIS PRO MAN 0001 - 01 - Manual de Op y Manto

PROYECTO DE MODERNIZACIÓN REFINERÍA TALARA PROYECTO: TAL
UNIDADES AUXILIARES Y TRABAJOS COMPLEMENTARIOS
MANUAL DE OPERACIÓN Y MANTENIMIENTO

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N° DOCUMENTO: TAL-NIS-PRO-MAN-0001 REV. 01 FECHA: 22/11/2019
HOJA DE CONTROL DE REVISIONES

DOCUMENTO PRINCIPAL
REV. FECHA DESCRIPCIÓN COMENTARIOS
00 11/09/2019 Emisión para Diseño
01 22/11/2019 Emisión para Construcción
ANEXOS
CÓDIGO DESCRIPCIÓN REV.
FORMATOS
PREPARADO: REVISADO: APROBADO:

Marco La Barrera Brenner Silva Ángel Agudo
Este documento contiene información privada y no puede ser duplicado, modificado o divulgado a terceros sin el consentimiento escrito de COBRA SCL. La
única copia controlada de este documento está en el Sistema Informático de Gestión Documental de COBRA SCL.

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ÍNDICE
1. INTRODUCCIÓN....................................................................................................5
1.1. ALCANCE ..............................................................................................................5
1.2. DEFINICIONES ......................................................................................................5
1.3. DOCUMENTOS DE REFERENCIA .............................................................................6
2. BASES DE DISEÑO .................................................................................................8
2.1. GENERALIDADES ..................................................................................................9
2.2. ALIMENTACION A LA UNIDAD Y CARACTERIZACION DE MATERIAS PRIMAS ......... 10
2.3. CAPACIDAD DE LA UNIDAD ................................................................................. 10
2.4. MODOS DE OPERACIÓN DE LA UNIDAD .............................................................. 17
2.5. ESPECIFICACIONES DE LOS PRODUCTOS .............................................................. 18
2.6. CONDICIONES EN LÍMITES DE BATERÍA ............................................................... 18
2.7. CONDICIONES DE LOS SERVICIOS AUXILIARES ..................................................... 19
2.8. CATALIZADORES Y PRODUCTOS QUIMICOS ......................................................... 19
2.9. MATERIALES DE CONSTRUCCIÓN ........................................................................ 19
2.10. VIDA ÚTIL Y DISPONIBILIDAD .............................................................................. 20
2.11. AMBIENTE .......................................................................................................... 20
3. DESCRIPCIÓN GENERAL DEL PROCESO ................................................................ 20
4. DESCRIPCIÓN DE LA UNIDAD .............................................................................. 22
4.1. DESCRIPCIÓN DE LA UNIDAD .............................................................................. 22
4.2. DIAGRAMAS DE FLUJO ....................................................................................... 28
4.3. CONDICIONES DE OPERACIÓN ............................................................................ 44
4.4. FILOSOFÍA DE CONTROL...................................................................................... 50
4.5. LISTA DE EQUIPOS ............................................................................................ 117
5. PREPARACIÓN PARA LA PUESTA EN MARCHA ................................................... 127
5.1. GENERAL .......................................................................................................... 127
5.2. INSPECCION DE EQUIPOS Y DE LA UNIDAD........................................................ 129
5.3. PRECOMISIONADO ........................................................................................... 136
5.4. COMISIONADO Y OPERACIONES PRELIMINARES ............................................... 140
6. PRIMERA PUESTA EN MARCHA ......................................................................... 140

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6.1. INTRODUCCIÓN ................................................................................................ 140

6.2. CRONOLOGÍA DE LA PUESTA EN MARCHA......................................................... 141
7. OPERACIÓN DE LA UNIDAD .............................................................................. 142
7.1. RESUMEN DE LAS CONDICIONES DE OPERACIÓN .............................................. 142
7.2. BALANCE DE SERVICIOS .................................................................................... 142
7.3. LISTA DE EFLUENTES ......................................................................................... 148
7.4. LISTA DE QUIMICOS Y CATALIZADORES............................................................. 152
7.5. LISTA DE INTERCONEXIONES............................................................................. 161
7.6. LISTA DE ALARMAS Y PUNTOS DE AJUSTE ......................................................... 168
7.7. SUMARIO DE ALIVIOS ....................................................................................... 178
8. PARADA Y REARRANQUE DE LA UNIDAD .......................................................... 184
8.1. PROCEDIMIENTO DE PARADA NORMAL DE LA PLANTA ..................................... 184
8.2. REARRANQUE DE LA UNIDAD LUEGO DE UNA PARADA CORTA ......................... 185
8.3. PARADAS DE EMERGENCIA ............................................................................... 185
8.4. PARADAS AUTOMATICAS DE EMERGENCIA ....................................................... 186
9. CONTROL ANALÍTICO ....................................................................................... 186
10. ENCLAVAMIENTOS DE EMERGENCIA ................................................................ 186
10.1. MATRIZ CAUSA-EFECTO .................................................................................... 186
11. MANTENIMIENTO ............................................................................................ 211
11.1. INSTRUCCIONES GENERALES DE MANTENIMIENTO ........................................... 211
11.2. MANTENIMIENTO DE INSTRUMENTOS ............................................................. 214
11.3. MANTENIMIENTO DE EQUIPOS DINAMICOS ..................................................... 217
11.4. MANTENIMIENTO DE EQUIPOS MAYORES Y EQUIPOS PAQUETE PRINCIPALES... 219
12. SEGURIDAD ...................................................................................................... 236
12.1. RECOMENDACIONES DE SEGURIDAD ................................................................ 236
12.2. LUCHA CONTRA INCENDIOS .............................................................................. 238
12.3. SUSTANCIAS Y MATERIALES – HOJAS DE DATOS DE SEGURIDAD DE MATERIALES
(MSDS) ............................................................................................................. 239
12.4. PRIMEROS AUXILIOS ........................................................................................ 271
12.5. RIESGOS DE SOBREPRESIÓN Y VACÍO ................................................................ 271
12.6. LISTA DE SUSTANCIAS PELIGROSAS ................................................................... 271

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13. DIAGRAMAS..................................................................................................... 274

13.1. DIAGRAMA GENERAL DE LA UNIDAD ................................................................ 274
13.2. DIAGRAMAS DE TUBERÍA E INSTRUMENTACIÓN ............................................... 274
13.3. PLOT PLAN ....................................................................................................... 274
14. APÉNDICES ....................................................................................................... 313
14.1. RECOMENDACIONES DEL ESTUDIO DE HAZOP ................................................... 313
14.2. MANUALES DE OPERACIÓN DE AIR LIQUIDE...................................................... 317

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1. INTRODUCCIÓN
El presente documento recopila las guías y procedimientos operativos relacionados con
los procesos de comisionado, arranque, operación normal y operaciones especiales
(como las paradas programadas y parada de emergencia) de la unidad de Nitrogeno para
Inertización (Nitrogen Inertization System) – NIS a ser construida en el marco del proyecto
“Unidades Auxiliares y Trabajos Complementarios” (UA&TC), el cual hace parte de la
ejecución del “Proyecto Modernización de la Refinería Talara” (PMRT), en Perú.
Este documento debe ser leído en conjunción con las descripciones de proceso e
instrucciones de operación de las unidades paquete suministradas por Air Liquide
Engineering & Construction (ALE).
1.1. ALCANCE
Se incluyen a continuación las instrucciones y guías operacionales para el comisionado,
arranque, operación normal y parada programada y de emergencias de la unidad NIS,
diseñada para la producción de nitrógeno requerido en la Refinería TALARA.
1.2. DEFINICIONES
 PROYECTO: Proyecto de Modernización Refinería TALARA / Unidades Auxiliares y
Trabajos Complementarios (también identificado como UA&TC)
 EMPLEADOR: significa:
a) La persona nombrada como EMPLEADOR en este Contrato;
b) Los sucesores legales y cesionarios/novados legítimos del EMPLEADOR en el
Contrato; y
c) Toda persona que se convierta en Parte del presente en sustitución o
conjuntamente con el EMPLEADOR y los sucesores legales y cesionarios/novados
legítimos de dicha persona en el Contrato.
Para fines prácticos PETROLEOS DEL PERÚ – PETROPERÚ S.A. (también identificado
como “PP”)
 REPRESENTANTE DEL EMPLEADOR (PMC): Se refiere al PMC o a la persona nombrada

por el EMPLEADOR en el Contrato o designada de manera periódica por el
EMPLEADOR conforme a la Su cláusula 3.1 [Representante del EMPLEADOR] para que
actúe en representación del EMPLEADOR.
 CONTRATISTA: Significa la o las personas designadas como contratistas en el presente
Contrato e incluye a su o sus derechohabientes y cesionarios legítimos.
Para fines prácticos, aquel designado por PETROPERÚ como empresa adjudicataria
del Contrato para la ejecución del Proyecto de Modernización Refinería TALARA /

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Unidades Auxiliares y Trabajos Complementarios, CONSORCIO COBRA SCL UA&TC

(también identificado como COBRA SCL) o cualquiera de sus afiliadas, representantes
autorizados o sucesoras)
 PROVEEDOR DE PROCESOS: Significa las personas jurídicas que ha suscrito contratos
con el EMPLEADOR para elaborar las licencias de procesos.
 DISEÑO FEED: Se refiere al diseño de ingeniería básica extendida llevado a cabo por
parte de Técnicas Reunidas bajo el Contrato FEED EPC.
 EPC: (Engineering, Procurement & Construction) Fase de Ingeniería Detallada,
Adquisiciones y Construcción (incluye las actividades de Pre-Comisionado/Pruebas,
Comisionado, Puesta en Servicio y Pruebas de Garantía)
 ESPECIFICACIONES GENERALES DE LOS TRABAJOS A REALIZAR (MJS: Master Job
Specifications) Se refiere al documento que se adjunta como Anexo 2 al Contrato
considerando cualquier adenda y modificaciones que se haga a dicho documento
conforme al Contrato.
 VENDEDOR/VENDOR: Cualquier Proveedor y/o Fabricante de Equipo o Sistemas,
contratado por el CONTRATISTA.
 SUBCONTRATISTA: Significa (i) toda persona nombrada en el Contrato como
subcontratista, (ii) toda persona nombrada como subcontratista bien sea
directamente por el CONTRATISTA o a un nivel inferior (incluyendo cualquier
subcontratista o proveedor de Materiales) para una parte de los Trabajos, y (iii) los
sucesores legales de cualquiera de lo anterior.
 NIS: (Nitrogen Inertization System) Unidad de Nitrógeno para Inertización.
1.3. DOCUMENTOS DE REFERENCIA

 571780-PP-COBRA-CNT-0001 Anx2 Contrato de Ingeniería, Procura y
Construcción de las Unidades Auxiliares y
Trabajos Complementarios Proyecto de
Modernización Refinería Talara Petróleo
del Perú – PETROPERÚ Especificaciones
Generales de los Trabajos a Realizar (MJS)
Rev. 02 [1]
 TAL-GEN-ENG-DBD-001 Bases Generales de Diseño Rev. 06 [2]
 PP-02070-I-302 Health, Safety and Environmental
(HSE)Requirements for Suppliers and
Subcontractors [3]
 LEY N° 26221 Ley Orgánica que norma las Actividades
de Hidrocarburos en Territorio Nacional
[4]

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 D.S. 051-1993-EM Decreto Supremo N°051-1993-EM –

Reglamento de Normas para la
Hidrocarburos [5]
Reglamento de Seguridad para el
Almacenamiento de Hidrocarburos [6]
 D.S. 036-2003-EM Decreto Supremo N°036-2003-EM
Modifican el Reglamento de Seguridad
para el Almacenamiento de
Hidrocarburos, aprobado por D.S. 052-
1993-EM [7]
 D.S. 085-2003-PCM Decreto Supremo N°085-2003-PCM-
Reglamento de Estándares Nacionales
de Calidad Ambiental para Ruido [8]
Modifican el Reglamento de Servicios y
Concesiones Postales [9]
Modifican el Reglamento de Normas
para la Refinación y Procesamiento de
Hidrocarburos, aprobado por Decreto
Supremo N°051-93-EM [10]
 D.S. 014-2010-MINAM Decreto Supremo N°014-2010-MINAM
Aprueban los Límites Máximos
Permisibles para las Emisiones Gaseosas y
de Partículas de las Actividades del Sub-
sector de Hidrocarburos [11]
 D.S. No. 015-2006-EM Reglamento para la protección
Ambiental en las actividades de
hidrocarburos 2006 [12]
 TAL-NIS-PRO-DBD-0001 Bases Generales de Diseño Rev. 01 [13]
 V-TAL-MEC-0001-OC-04-NIS-Z-001-0035 Operating Manual [14]
-0186
 TAL-NIS-PRO-PFD-0001 PFD Planta de Nitrógeno Rev. 03 [15]
 TAL-NIS-INS-MCE-0001 Matriz Causa y efecto Rev. 01 [16]
 TAL-NIS-PRO-PID-0001/0004 Diagramas de Tubería e instrumentación
Rev. 03 [17]
 TAL-NIS-PRO-LIS-0001 Lista de Equipos Rev. 00 [18]

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 TAL-NIS-PRO-HMB-0001 Balances de Materia y Energía Rev. 02[19]

 TAL-NIS-PRO-BLD-0001 Diagrama General de la Unidad Rev. 03
[20]
 TAL-NIS-PRO-SPE-0002 Hojas de seguridad de los Materiales
Rev. 00 [21]
 TAL-NIS-SCI-STU-0001 Reporte Estudio Sist. Contraincendio
Rev.01 [22]
 TAL-NIS- PRO-SPE-0002 Hoja de seguridad de los materiales
Rev. 00 [23]
 TAL-NIS-PRO-LIS-0003 Lista de interconexiones – TIE – INS
Rev. 03[24]
 TAL-NIS-PRO-REP-0005 Sumario de alívios Rev. 02 [25]
 TAL-NIS-PRO-MSD-0001 Diagrama de materiales. Planta de
Nitrógeno Rev. 01 [26]
 TAL-NIS-PRO-LIS-0007 Lista de sustancias peligrosas Rev. 01 [27]
 TAL-NIS-PNG-LAY-0001 Planta de Nitrógeno – implantación de
la Unidad Rev. 02 [28]
 TAL-GEN-PRO-REP-1001-01 Reporte Hazop / SIL unidades paquetes-
Nis Rev. 00 [29]
 TAL-GEN-PRO-REP-1001-04 Informe del estudio Hazop/SIL unidades
paquete – NIS: compresor de aire y
turbina de expansión Rev. 00 [30]
 V-TAL-MEC-0001-OC-04-NIS-Z-001-0052 Process Description [31]
 V-TAL-MEC-0001-OC-04-NIS-Z-001-0077 Completed lubricant and Adsorbents charts
[32]
 V-TAL-MEC-0001-OC-04-NIS-Z-001-0076 Chemical and Consumibles List [33]
 V-TAL-MEC-0001-OC-04-NIS-Z-001- P&ID’s [34]
0011-0256
 V-TAL-MEC-0001-OC-04-NIS-Z-001-0160 RANGE ALARMS AND THRESHOLD LIST -RAT
LIST [35]
 V-TAL-MEC-0001-OC-04-NIS-Z-001-0053 Effluent List [36]
2. BASES DE DISEÑO
Este capítulo cubre las bases de diseño de proceso de la unidad de producción de
nitrógeno, incluyendo capaciad, especificaciones de los productos, condiciones de límite
de batería y otros requerimientos.

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2.1. GENERALIDADES
CONDICIONES DEL SITIO
Para las condiciones del sitio referirse al Anexo 1 del documento TAL-GEN-ENG-DBD-001
Rev 06 [2].
UNIDADES DE MEDIDA
Las unidades de medida para el Proyecto corresponden al Sistema Internacional de
Unidades; sin embargo, para volumen y flujo de líquidos se utilizarán también Barriles
(Bbl) y Barriles por día (BPD). Para medidas de presión se podrán utilizar kilogramos por
centímetro cuadrado (kg/cm2) y libras por pulgada cuadrada (psi). Para energía y
propiedades calóricas se podrán utilizar calorías (cal)
Tabla 1 - Unidades de Medida

Area [m2]
Capacidad calorífica [kcal/kg °C]
Concentración en peso [wt%] [ppmwt]
Concentración en volumen [mole %], [ppmv]
Conductividad térmica [W/m °C]
Coeficiente de transferencia de calor [kcal/h m2 °C]
Corriente eléctrica [A]
Densidad [kg/m3]
Diámetro (Tuberías y accesorios) [inch]
Energía térmica [Gcal/h]
Energía [kcal]
Entalpía [kcal/kg]
Factor de ensuciamiento [(m2 °C h)/kcal]
Flujo (Gas) [Nm3/h (0°C, 14.7 psia)], [MMSCFD (15°C, 14.7 psia)]
Flujo (Líquido) [kg/h], [m3/h], [BPSD]
Frecuencia eléctrica [Hz]
Flujo (Vapor) [kg/h]
Intensidad del sonido [dBA]
Longitud [m] [mm]
Peso, masa [kg]
Potencia [Gcal/h], [kW]
Presión [kg/cm2 g], [psig], [mmWG]
Temperatura [°C]
Tensión eléctrica [V]
Tensión superficial [Dynes/cm]
Trabajo [kWh]
Vacío [mmHg abs]
Velocidad [m/s]
Velocidad de rotación [RPM]

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Viscosidad [cP]
Volumen [m3], [BLs]
2.2. ALIMENTACION A LA UNIDAD Y CARACTERIZACION DE MATERIAS PRIMAS

Este sistema utiliza aire del ambiente como materia prima para la producción de
nitrógeno.
La calidad del aire de alimentación a la unidad será la composición típica del aire del
medio ambiente en una refinería cerca del mar y debe cumplir con los parámetros de
calidad requeridos por la legislación peruana. Ver Ref. No. [2].
2.3. CAPACIDAD DE LA UNIDAD

Capacidad de planta de separación criogénica
La planta de separación criogénica deberá cubrir los requerimientos de nitrógeno gaseoso
continuo de las nuevas unidades del proyecto y producir nitrógeno con las
especificaciones de calidad indicadas en la sección 2.5. de este documento.
Según lo anterior, se proporcionará una planta modular de separación criogénica para
cubrir la siguiente capacidad:
• Caudal normal: 3627 Sm3 / h.
• Caudal de diseño: 3900 Sm3 / h.
Los consumidores de nitrógeno en las unidades de proceso están divididos en tres
categorías:
1. Flujo requerido para la operación normal y flujo constante (continuo)
2. Nitrógeno requerido durante el arranque, apagado, regeneración y secado, etc., que
están sujetos a variaciones significativas pero pueden considerarse eventos
programados y por esa razón no pueden considerarse simultáneamente (picos
programados).
3. Nitrógeno requerido en situaciones de emergencia para equipos al aire libre, durante
su cierre, para diluir los flujos de salida que pueden contener hidrógeno e
hidrocarburos, etc. (picos no programados). Estos eventos no programados están
sujetos a variaciones significativas y no son necesariamente simultáneos. En general,
ocurren durante un período límite y pueden ser aditivos con el uso continuo o el
consumo máximo esperado.
La siguiente tabla muestra la demanda de nitrógeno de cada unidad de proceso:
Tabla 2 - Consumo de nitrógeno en Unidades de proceso. Ver referencia [13]

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Consumo de Nitrógeno (Sm3/h)

Máximo Pico no Pico
Unidades Normal normal programado programado
Unidad de destilación 0 (367) (367) -
primaria (DP1)
Unidad de craqueo 438 (724) (851) (1428)
catalítico (FCC/RG1)
Unidad de destilación al 0 (1096) (1296) -
vacío III (DV3)
Unidad de recuperación
2 (288) (290) (1520)
de gas II (RG2, área DV3)
Unidad de recuperación
de gas II (RG2)
5 (384) (415) (600)
Unidad de tratamiento
de GLP (TGL)
Unidad de Flexicoking 2632 (5338) (5393) (13039)
(FCK)
Unidad de flexicoking 0 (148) (163) -
(FCK - Coque húmedo)
Unidad de
hidrotratamiento de 4 (290) (294) (5070)
gasolina (FCC, HTF)
Unidad de reformado
catalítico (RCA)
Unidad de 20 (362) (843) (4466)
hidrotratamiento de
nafta (HTN)
Unidad de
hidrotratamiento diésel 16 (302) (321) (3042)
(HTD)
Unidad de Amina (AM2)
Unidad de aguas agrias 36 (218) (2200) (200)
(WS2)
Unidad de Producción y
Purificación de 92 (192) (275) (2700)
Hidrógeno (PHP)
Planta de ácido sulfúrico 0 (286) (343) -
(WSA)
Planta de tratamiento
cáustico de queroseno 0 (143) (143) -
(TKT)
Unidad de disolventes 0 (143) (143) -
(TNS, existente)

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Unidad de oxidación 43 43 (194) -
cáustica gastada (OX)
(5918) (5973) (13039)
3288
TOTAL (Ver Nota 1) (Ver Nota 2) (Ver Nota 3)
Notas:
* Los valores informados entre "()" indican consumos intermitentes.
1. Se consideran los consumos continuos normales de las unidades más la purga del
reactor FCK y el precalentador COS (2706 Sm3 / h). Otros consumos normales
máximos se consideran intermitentes y son inferiores al valor total indicado.
2. Se consideran los consumos continuos normales de las unidades más el consumo
máximo de FCK, incluida la purga del reactor FCK y el precalentador COS. Otros
picos no programados se consideran intermitentes y son inferiores al valor total
indicado.
3. Se considera el mayor valor como pico máximo programado, que es el arranque
de la Unidad FCK.
Los consumos de nitrógeno de las unidades de servicios industriales y áreas de
almacenamiento corresponden a los consumos de la unidad de agua de enfriamiento,
sistema de teas, sistema de almacenamiento, unidad de blending de productos y
exportación (TKS) y los máximos consumos intermitentes debido al uso del nitrógeno
como respaldo al sistema de aire de instrumentos.
El consumo de nitrógeno en los nuevos tanques de almacenamiento se divide en tres
categorías:
• Flujo de nitrógeno requerido durante la operación normal basado en el flujo de salida
normal de los tanques (flujo normal continuo). El tanque TKS-T-005 considera un flujo de
salida normal, sin embargo, el resto de los tanques no consideran flujos de salida
continuos debido a que sus movimientos son solo programados.
• Nitrógeno requerido durante la operación basado en la salida máxima de líquido del
tanque (pico programado).
• Nitrógeno requerido debido a la contracción del líquido o condensación de los vapores
causada por una disminución repentina de la temperatura (aspiración térmica del aire).
No es necesario suministrar nitrógeno a los tanques de almacenamiento existentes
(biodiesel, Turbo A1, solventes 1 y 3), de acuerdo con lo especificado en las Bases de
diseño fuera de las instalaciones y los balances de servicios industriales correspondientes.
Sin embargo, se considera el consumo de nitrógeno del tanque ASC-T-002.

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El consumo de nitrógeno para las unidades de servicios industriales y los tanques de

almacenamiento se muestra en la siguiente tabla:
Tabla 3 - Consumo de nitrógeno en unidades de servicios industriales y almacenamiento [13]

Unidad de aire (8430)
0 (6598) -
comprimido (PAR) (ver Nota 3)
Unidad de combustibles 0 (286) (286) -
(SCR)
Sistema de antorchas 9 (430) (430) -
(FB2 - "Zona Antorchas")
(FB2 - "Zona Norte")
(FB2 - "Zona Sur")
Sistema de antorchas
(FB2 - "Zona Recip. 0 (143) (143) -
Antorchas")
Unidad de recuperación - - - -
de condensado (RCO)
Unidad de tratamiento - - - -
de agua (STA)
Unidad cáustica (CAF) 0 (286) (286) -
Instalaciones de
distribución de ácido - - - -
sulfúrico (AST)
Unidad de
almacenamiento (TKS - 0 (143) (143) -
Noroeste)
Unidad de
Suroeste)
Unidad de
Aceite caliente)
Muelle (MU1) 0 (150) (150) -
Muelle (MU2) 0 (143) (143) -
(157)
Interconexión (INT) 0 0 0
(ver Nota 1)

PÁGINA 14 DE 556

Sistema de generación 0 (286) (286) -
de vapor (SGV)
Unidad de recuperación - - - -
de condensado (RCO)
Cogeneración (GE) 0 0 (286)
Planta de aguas
residuales (WWS) /
15 0 (286) 20
Planta de agua sanitaria
(SA2)
Almacenamiento de
ácido sulfúrico (ASC) /
(594) (1782)
Tanques de ácido 0 -
(ver Nota 2) (ver Nota 4)
sulfúrico (ASC-T-001A / B
como ASC-T-002 )
Sistema de agua de mar
y sistema de
101 (387) (387) -
refrigeración (SWC /
CWC)
Sistema Slops (SLP) 0 (143) (147) 0
(6937) (8769)
339 (157)
TOTAL (ver Nota 5) (ver Nota 6)
Notas:
* Los valores informados entre "()" indican consumos intermitentes.
1. Pico requerido para la purga / inertización del sistema de antorcha.
2. El valor informado solo considera uno de los tanques A o B.
3. Máxima demanda para respaldo del sistema de aire de instrumentos en caso de
baja-baja presión en el cabezal de distribución de aire.
4. Consumos por efecto térmico. Se incluye el consumo de todos los tanques AST (T-
001A, T-001B y T-002).
5. Se consideran los consumos normales más el mayor consumo normal máximo
intermitente (339 + 6598 = 6937 Sm3 / h).
6. Se consideran los consumos normales más el pico no programado intermitente
más grande (339 + 8430 = 8769 Sm3 / h).

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Capacidad de almacenamiento de nitrógeno líquido

Según los consumos continuos y máximos de nitrógeno indicados en las secciones 2.3.1.
de este documento. La capacidad requerida del sistema de almacenamiento de nitrógeno
líquido se determina en función de los siguientes escenarios:
• Dos (2) días de consumo normal de todas las unidades, en caso de cierre de la planta de
separación criogénica.
• Ocho (8) horas de consumo intermitente en el arranque de la Unidad Flexicoking (FCK)
(pico programado), más ocho (8) horas de los consumos intermitentes debido a picos no
programados solo de las unidades de proceso (no se incluyen las Unidades RG2, FCK, RCA
y WS2), y una (1) hora de aspiración térmica de nitrógeno, en caso de disminución
repentina de la temperatura.
• Dos (2) días para la inertización o gas de cobertura de tanques basado en el flujo máximo
de salida de los tanques (efecto de respiración del tanque por movimiento de líquidos),
más el consumo continuo del paquete de aceite caliente (TKS-Z-001) y del tanque de
residuos de vacío (TKS-T-005) , y el pico máximo programado entre los tanques de ácido
sulfúrico (ASC-T-001A / B) y el consumo del tanque ASC-T-002.
• Tres (3) horas de aspiración térmica de nitrógeno en tanques debido a una disminución
repentina de la temperatura (efecto térmico).
• Respaldo del sistema de aire de instrumentos durante 30 minutos, para lograr un
apagado seguro en caso de falla en ese sistema.
El volumen de nitrógeno total requerido se determinará para cubrir el escenario de mayor
demanda.
A continuación se presenta la capacidad estimada de almacenamiento de nitrógeno para
cada escenario:

PÁGINA 16 DE 556
Tabla 4. Volumen de Nitrógeno líquido requerido
Volumen de Nitrógeno (m3)

Escenario Descripción
Pico programado
Normal
(Ver Nota 1)
A Apagado de plantas criogénicas 170477 250
Arranque de la FCK, consumos
B intermitentes e inhalación 135099 198
térmica de tanques
Gas de cobertura por
C movimiento de líquidos en 29118 43
tanques.
Gas de cobertura por
D 3601 5
respiración térmica en tanques
Respaldo del sistema de aire de
E 4215 (2) 6
instrumentos
Notas:
(1) El volumen de nitrógeno líquido se ha calculado considerando una densidad de 1.185
kg / m3 y una relación líquido / gas de 1 m3 liq. / 682 m3 de gas.
(2) El Sistema de Aire de Instrumentos (PAR) considera una demanda máxima de 8430
Sm3 / h, durante esta contingencia, en caso de baja – baja presión en el cabezal de
distribución del PAR.
El volumen neto de líquido requerido en el sistema de almacenamiento, considerando el
escenario A de la Tabla 4, es de 250 m3. Además, se supone que este volumen representa
el 92% de la capacidad del nuevo sistema, es decir, el volumen bruto requerido es de 280
m3.
El Nitrógeno líquido, LIN, se producirá en la planta criogénica y se almacenará a
condiciones criogénicas. Sin embargo, se consideran conexiones para recibir el nitrógeno
líquido por camiones de 11000 gal (42 m3) durante un día, en casos de mantenimiento,
de arranque o parada de la planta criogénica. Por esta razón, el plot plan considerará el
espacio suficiente para manejar los camiones de descarga, durante los períodos de alta
demanda de LIN, principalmente durante el arranque de las unidades de alto consumo.
Capacidad de Vaporización de Nitrógeno

Para estimar la capacidad requerida del sistema de vaporización de nitrógeno líquido, se
consideran los mismos escenarios que para el diseño del sistema de almacenamiento,
calculando el caudal máximo en una hora.
A continuación se presentan los caudales de nitrógeno utilizados para el diseño de los
vaporizadores:

PÁGINA 17 DE 556
Tabla 5 - Capacidad requerida para vaporización de Nitrógeno líquido

Caso
Escenario Descripción (Ver Nota 1) Diseño(Sm3/h)
Normal (Sm3/h)
(Ver Nota 2)
A Apagado de plantas criogénicas 3627 3900
Arranque de FCK, consumos intermitentes
B - 17100
e inhalación térmica de tanques
Gas de cobertura por movimiento de
C - 610
líquidos en tanques.
Gas de cobertura por respiración térmica
D - 1200
en tanques
Respaldo del sistema de aire de
E - 8430
instrumentos
Notas:
1. Para la descripción del escenario, ver numeral 2.3.2. del presente documento
2. Los caudales se estimaron tomando los volúmenes indicados en la tabla 5
divididos por la duración del evento.
La capacidad de vaporización requerida es:
• Mínimo: 610 Sm3 / h.
• Máximo: 17100 Sm3 / h.
• Diseño: 18756 Sm3 / h.
La configuración del sistema de vaporización hace parte del alcance del proveedor del
paquete, cumpliendo con los caudales mínimos y máximos requeridos.
La capacidad mínima del sistema de vaporización LIN será de 610 Sm3 / h, que
corresponde al caudal mínimo requerido por la refinería. Esta carga se probará por un
mínimo de 24 horas, y durante este período, los productos se mantendrán en
especificación, cubiertos por las garantías de calidad y funcionamiento.
2.4. MODOS DE OPERACIÓN DE LA UNIDAD

El sistema de producción de nitrógeno gaseoso (tipo de unidad criogénica) garantizará los
requisitos normales y continuos.
La unidad funcionará en 2 modos, modo de gas completo (GAN) y modo de líquido
máximo (GAN/LIN). De acuerdo con esto, la Unidad criogénica podrá realizar la siguiente
producción:
Tabla 6. Modos de operación de la NIS
Modo 100% GAN Modo Máximo LIN
Nitrógeno
Sm3/h kg/día Sm3/h kg/día
GAN 3900 (1) 110770 3627 (2) 100829
LIN 0 0 (Ver Notas 3,4) 9089

PÁGINA 18 DE 556
Notas:
1. Producción máxima disponible. Capacidad de diseño.
2. Capacidad normal de acuerdo con los consumos esperados de la refinería.
3. Producción máxima de líquido equivalente al sobre diseño del sistema (10% del
consumo normal de nitrógeno de las unidades de proceso según la referencia [2]).
0.56 m3 / h de Nitrógeno líquido equivalente a 320 Sm3 / h de Nitrógeno
vaporizado.
2.5. ESPECIFICACIONES DE LOS PRODUCTOS

La calidad requerida de nitrógeno, tanto para gas como para líquido, es:
Tabla 7 - Calidad de Nitrógeno requerido (Gas o líquido).

Propiedades Pureza
N2 99.9 – 99.99%
O2 <10 ppm Vol.
Punto de rocío H2O a presión de
< -40°C
funcionamiento normal
Las siguientes unidades requieren alta pureza de nitrógeno: Unidad Flexicoking (FCK),
Unidad de Producción y Purificación de Hidrógeno (PHP), Unidad de Craqueo Catalítico
(FCC) y Unidad de Reformador Catalítico (RCA), de acuerdo con los documentos de los
proveedors:
• FCK: EMRE “Instrucciones generales y cuestionario de información” Rev.2 (4 de agosto
de 2010),
• PHP: Trabajo S-01642 Doc. P40001 Haldor Topsoe Design Basis Rev.1 (23 de mayo de
2018), recibida el 27 de julio de 2018,
• FCC: UOP 959563-A.4-BEDQ Rev.01 (6 de enero de 2012).
• RCA: Axens 04041_RCA_1PB_Rev0 (25 de junio de 2010).
El contenido de oxígeno reportado es equivalente al máximo típico para una unidad
criogénica a la pureza requerida, encontrando que este valor es más bajo que el requerido
en las unidades FCK, PHP, FCC y RCA.
2.6. CONDICIONES EN LÍMITES DE BATERÍA

La siguiente tabla muestra las condiciones para el suministro de nitrógeno en el límite de
batería:

PÁGINA 19 DE 556
Tabla 8 - Condiciones para el suministro de nitrógeno en el límite de batería

Condición Temperatura (°C) Presión (kg/cm2g)
Mínimo - 7.9
Normal Ambiente 8 (3)
Máximo - 9.8
Diseño (1, 2) (Min /
12.8 / 93 10.5
Max)
Notas:
1. El rango de temperatura de diseño y la presión de diseño estarán garantizados por
el proveedor del paquete NIS-Z-001 en líneas de gas y nitrógeno líquido
vaporizado.
2. La temperatura de diseño y la presión dentro del sistema son definidas por el
proveedor del paquete NIS-Z-001.
3. La presión de entrega desde el paquete NIS-Z-001 puede estar entre 8 y 9 kg /
cm2g para la corriente de GAN.
4. Para las condiciones de presión en los usuarios B.L ver Anexo en la Ref. No. [2]
2.7. CONDICIONES DE LOS SERVICIOS AUXILIARES

Las condiciones han sido tomadas del documento TAL-GEN-ENG-DBD-001, Bases Generales de
Diseño, que incluye todas las condiciones de sitio.
2.8. CATALIZADORES Y PRODUCTOS QUIMICOS

En el proceso no se utilizan catalizadores, sin embargo, las características de los productos
químicos asociados a la unidad se encuentran en los documentos Lista de Químicos y
Consumibles, V-TAL-MEC-0001-OC-04-NIS-Z-001-0076, y Tabla de Lubricantes y adsorbentes,
V-TAL-MEC-0001-OC-04-NIS-Z-001-0077.
2.9. MATERIALES DE CONSTRUCCIÓN

El material de construcción del sistema de distribución se basa en el caso más
desfavorable y 40 años de vida útil mínima requerida como caso restrictivo.
Sin embargo, la selección de materiales dentro del paquete NIS-Z-001 está dentro del
alcance del proveedor.

PÁGINA 20 DE 556
2.10. VIDA ÚTIL Y DISPONIBILIDAD

La Unidad NIS operará con un factor de servicio de 0.95 (es decir, se estima que la unidad
está en funcionamiento 8320 horas / año); con 4 años, como mínimo, de operación
ininterrumpida entre cambios importantes o inspecciones generales.
El paquete completo de nitrógeno, incluidos los auxiliares, debe diseñarse, fabricarse,
transportarse e instalarse para lograr una vida útil mínima de 40 años, considerando
factores de seguridad, condiciones climáticas, etc.
2.11. AMBIENTE
Emisiones gaseosas
No se esperan emisiones gaseosas, excepto nitrógeno producido o manejo de aire
comprimido en la Unidad NIS. Sin embargo, las emisiones a la atmósfera deberán cumplir
con lo indicado en el numeral 3 de la Ref. No. [2]. Para detalle de los efluentes de la unidad
NIS, referirse al documento V-TAL-MEC-0001-OC-04-NIS-Z-001-0053.
Efluentes líquidos
Los condensados retirados de los compresores de aire, los desagües del sistema de agua
de refrigeración y otros desagües de equipos se enviarán al Sistema de Alcantarillado de
Agua Aceitosa (OWS).
Ruido
El compresor de aire y el sistema de expansión de nitrógeno de la unidad deben
especificarse cumpliendo con los requisitos indicados en la legislación peruana (Ref. No.
[8]). Si es necesario, se proporcionará un sistema de protección acústica.
Residuos sólidos
El desecante gastado del sistema de purificación y secado de aire debe eliminarse de
manera segura y no contaminante, siguiendo la legislación peruana (Ref. [12]).
3. DESCRIPCIÓN GENERAL DEL PROCESO

La Refinería existente de Talara no tiene una Unidad de Nitrógeno para Inertización (NIS),
sin embargo, el diseño de las nuevas unidades de proceso PMRT, instalaciones de proceso
y almacenamiento existentes, lo requieren como medio de inertización (cobertura o
purga) en los casos donde no se puede usar gas natural o gas de refinería. Además, este
nuevo sistema se considerará como respaldo de la unidad de aire de instrumentos de la
refinería.

PÁGINA 21 DE 556
El sistema de producción de nitrógeno gaseoso será del tipo de nitrógeno criogénico de

alta pureza (HPN) debido a los requerimientos de alta pureza de algunos consumidores
finales (99.9 - 99.99%, según el anexo de la Ref. No. [2]).
El siguiente diagrama muestra la tecnología más conveniente desde un punto de vista
económico, de acuerdo con la pureza de nitrógeno y el caudal requeridos.
Figura 1 - Distribución económica de los procesos de producción de nitrógeno. Tomado de

documento V-TAL-MEC-0001-OC-04-NIS-Z-001-0052
El proceso de separación criogénica de nitrógeno divide el aire mediante rectificación o

destilación, utilizando diferentes temperaturas de evaporación de los componentes del
aire, en varias secciones que se suministran en módulos.
La planta criogénica consta de una sección caliente o “extremo caliente” (con un
compresor de aire, enfriador, prefiltros y una unidad de purificación y secado de aire), y
una sección fría o “caja fría” (con una columna de rectificación, intercambiadores de calor,
y sistema de expansión) que es donde realmente ocurre el proceso de fraccionamiento
de aire.
Además, el sistema de producción de nitrógeno gaseoso (GAN) (planta criogénica) se
integrará automáticamente con el sistema de almacenamiento y vaporización de
nitrógeno líquido (LIN).
Los sistemas de producción, almacenamiento y vaporización de nitrógeno se consideran
un paquete.
El LIN se produce en la cámara fría de la misma planta criogénica que podrá producir
continuamente GAN requerido por las unidades de proceso y servicios.
El sistema de almacenamiento LIN se alimentará directamente de la planta criogénica con
nitrógeno de alta pureza (99,99%), o de una fuente externa (de camiones).

PÁGINA 22 DE 556
El líquido almacenado se vaporizará cuando sea necesario, para cubrir los picos que
suceden según la demanda (operación normal de la planta criogénica), como respaldo
para los requisitos de operación intermitente.
Un sistema de control de presión detecta la demanda de nitrógeno gaseoso y regula el
flujo de gas en la tubería del usuario final para mantener una presión de línea actual.
El siguiente esquema presenta una referencia para el Sistema de Inertización de
Nitrógeno (NIS):
Figura 2 - Esquema de referencia. Unidad de Nitrógeno para Inertización (NIS).
4. DESCRIPCIÓN DE LA UNIDAD
4.1. DESCRIPCIÓN DE LA UNIDAD
El proceso se basa en la destilación fraccionada del aire a temperatura criogénica en una sola
columna según el siguiente esquema:

PÁGINA 23 DE 556
Figura 3. Esquema de producción de la unidad de nitrógeno para inertización
La siguiente descripción del proceso se basa en el PFD del proveedor (V-TAL-MEC-0001-

OC-04-NIS-Z-001-0010):
 Compresor de aire y unidad de purificación.
 Caja fría
 LIN almacenamiento y vaporización
Compresión de aire
Después de la filtración (en un filtro de caída de baja presión), el aire se comprime en un
compresor centrifugo de 3 etapas C01. Este lleva el aire a la presión requerida, que es la
presión final de suministro de nitrógeno más la caída de presión del sistema. Después de
cada etapa de compresión, el aire pasa a través de un intercambiador de calor enfriado
por agua para reducir su temperatura.
El compresor es totalmente autónomo (sistema de lubricación, filtración, y lazos de
control dedicados). Se instalan válvulas en cada enfriador en el lado del agua para ajustar
el flujo y, por lo tanto, ajustar la temperatura de salida del agua a su valor operativo. El
flujo de aire hacia el proceso aguas abajo se controla actuando sobre la persiana de
entrada de aire al compresor (Inlet Guide Vanes).
Para proteger la máquina, el compresor de aire tiene su propio sistema antisurge para
lograr el flujo de aire mínimo requerido a través de la máquina.
En la salida de la tercera etapa, el aire comprimido pasa a través de un enfriador final para
disminuir su temperatura y su humedad. El enfriador final está equipado con una trampa
de agua para eliminar automáticamente el agua condensada. Posteriormente el aire va al
sistema de purificación.

PÁGINA 24 DE 556
Sistema de purificación de aire

Aguas abajo del enfriador final, el aire comprimido se envía al sistema de purificación de
aire. Este sistema de purificación está compuesto por dos adsorbedores (recipientes a
presión) R01 y R02 para eliminar el vapor de agua y el dióxido de carbono.
Cada uno de ellos está lleno de:
 Alúmina para eliminar el vapor de agua
 Tamiz molecular para eliminar el dióxido de carbono y algunos hidrocarburos.
Está previsto que uno de los dos recipientes está en funcionamiento, mientras que el otro
se reactiva con el gas residual que sale de la caja fría para tener un flujo continuo de aire
hacia el proceso.
El ciclo de los adsorbedores es el siguiente:
Tabla 9 - Fases de operación de los adsorbedores

(R01) (R02)
Fases de operación Fases de operación
Despresurización a presión casi
atmosférica
Fase de calentamiento del gas de
regeneración libre de H2O y CO2 en la
entrada de R02
Fase de adsorción para eliminar H2O y Fase de enfriamiento del gas de
CO2 del aire comprimido antes de ir a la regeneración libre de H2O y CO2 en la
caja fría entrada de R02
Represurización a la presión de adsorción
Operación paralela con R02 Operación paralela con R01
Despresurización a presión casi
atmosférica
Fase de calentamiento del gas de
entrada de R01
Fase de adsorción para eliminar H2O y
Fase de enfriamiento del gas de
CO2 del aire comprimido antes de ir a la
caja fría
entrada de R01
Represurización a la presión de adsorción
Operación paralela con R02 Operación paralela con R01

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Figura 4 - Comportamiento de la presión en los adsorbedores
Durante la fase de calentamiento, el calentador 810-X-001-E01 calienta el gas de

regeneración y la temperatura se controla encendiendo y apagando el calentador para
mantener su temperatura de salida.
El gas residual utilizado para la reactivación está disponible en exceso. Parte de él se
ventila directamente (silenciador S04), y el resto pasa por los adsorbentes R01 y R02
actualmente en modo de reactivación antes de que también se ventile a la atmósfera. Por
lo tanto, el flujo de regeneración se controla manteniendo la presión actuando sobre la
válvula de ventilación. El operador puede ajustar el punto de ajuste de este controlador
(el valor se proporcionará en el arranque), teniendo en cuenta los otros parámetros de
reactivación (tiempo de calentamiento y temperatura).
En la salida del sistema de purificación de aire, el aire está libre de H2O y CO2.
Para asegurarse de que la purificación del aire funciona bien, se realiza un monitoreo
continuo del CO2 con un analizador de CO2. Solo se monitorea el CO2, ya que será el
primer elemento en avanzar en caso de mal funcionamiento del sistema. El agua no puede
pasar ya que la alúmina y el tamiz molecular lo detienen y su capacidad de adsorción en
el tamiz molecular es mayor que la del CO2.
Caja fría: separación del aire (GAN / LIN y producción fría)

El aire comprimido, libre de agua y dióxido de carbono, se enfría, cerca de su punto de
rocío, en el intercambiador de calor E01, con nitrógeno puro frío y gas residual.

PÁGINA 26 DE 556
El aire, enfriado, se inyecta en el fondo de la columna K01 para producir nitrógeno puro
por destilación. El reflujo líquido en la columna se garantiza mediante la condensación de
nitrógeno puro en el vapocondensador E02.
La columna tiene tres salidas de proceso:
 Línea de producción de nitrógeno gaseoso en la parte superior de la columna de
destilación (GAN)
 Línea de producción de nitrógeno líquido en la parte superior de la columna de
destilación (LIN)
 Línea de líquido rico en la parte inferior de la columna de destilación (LR)
Línea de producción de GAN

La producción de GAN está controlada por dos bucles de control.
 Un controlador de presión mantiene una presión constante en el punto de entrega
de la planta.
 Un controlador de velocidad de flujo limita el flujo de producción de GAN a un
valor establecido. Este valor se establecerá correctamente para mantener la
pureza (cuanto mayor sea el flujo, menor será la pureza GAN).
El contenido de oxígeno en la producción de GAN y LIN se verifica mediante un analizador
de O2. En caso de alto contenido de O2, la válvula de producción GAN & LIN se cerrará
para evitar el envío a la red de productos con especificaciones inferiores. Entonces la GAN
se ventilará a la atmósfera.
La pureza de GAN es una consecuencia de los parámetros operativos. En caso de baja
pureza la acción principal sería reducir la producción de GAN o aumentar el flujo de aire
si es posible.
Línea de producción de LIN

El nitrógeno líquido puro se extrae de la parte superior de la columna y se pone a
disposición en la caja fría que está conectada a los depósitos de nitrógeno líquido.
En caso de requerimiento de producción de LIN, la producción en frío debe maximizarse
para producir tanto frío como sea posible. El operador deberá ajustar manualmente la
turbina de expansión IGV para maximizar la producción de frío. Se obtiene una producción
óptima en frío cuando la válvula de derivación está casi cerrada.
Luego, la producción de LIN se ajusta según el nivel de líquido en la parte inferior de la
columna.

PÁGINA 27 DE 556
Línea de líquido
El líquido rico se gasta desde el fondo de la columna 810-X-002-C01 hacia el condensador
E02 que está a una presión más baja. Luego, se vaporiza (contra la condensación del
nitrógeno gaseoso puro). El gas resultante se llama oxígeno residual o gas residual. Por
razones de seguridad y funcionamiento correcto del condensador, el nivel de líquido rico
debe mantenerse al 100% de inmersión del condensador.
Además, el líquido rico en el condensador se extrae del fondo del vaporizador mediante
una purga cíclica para evitar la acumulación de hidrocarburos en el vaporizador. Se
requiere una purga mínima del 0.2% del flujo de aire entrante. La válvula de purga es una
válvula ON / OFF. Para lograr el caudal deseado, se abre periódicamente (1 hora para ser
ajustado durante el arranque) por una duración predefinida.
Se instala un analizador de trazas totales de hidrocarburos, CnHm, (principalmente etano
y propano) para analizar el drenaje de líquido rico y evitar la acumulación de CnHm en el
vaporizador. En caso de alto contenido de hidrocarburos, la purga debe aumentarse para
mantener aceptable el nivel de hidrocarburos.
Después de la vaporización, el gas residual se envía al intercambiador de calor principal
E01, se calienta parcialmente y luego se envía a la turbina de expansión para proporcionar
la refrigeración requerida a la planta. La presión de entrada de la turbina de expansión se
controla mediante un controlador de presión que actúa sobre el bypass de la turbina de
expansión y la presión de suministro se controla mediante otro controlador de presión
(ventilación directa de gas residual).
Después de la expansión, el gas residual se calienta en el intercambiador de calor E01.
Luego puede usarse como gas residual para la reactivación de materiales adsorbentes.
Sistema de respaldo de GAN, almacenamiento de LIN

El sistema de respaldo LIN se basa en el control de presión. Sin embargo, existe la
posibilidad de llenado del tanque de almacenamiento por medio de camiones,
simultáneamente con el despacho de nitrógeno líquido hacia los vaporizadores.
El almacenamiento LIN (V50) tendrá puntos de ajuste de presión ajustables
independientes para mantener la presión en él.
Si la presión en el almacenamiento de LIN disminuye bajo la presión establecida, la válvula
que va a la bobina de acumulación de presión de LIN se abrirá para vaporizar algo de LIN
en GAN y mantener la presión.
El almacenamiento de LIN está equipado con una válvula de ventilación que se abre si la
presión aumenta, antes de que se abran las válvulas de seguridad. Estas válvulas de
seguridad en los recipientes están duplicadas, lo que permite extraer una válvula de
seguridad para mantenimiento / prueba sin pérdida de LIN.
Para mantener una alta presión en el LIN, hay una bomba LIN (P51-) conectada a la línea
de producción y al tanque LIN.

PÁGINA 28 DE 556
Si la presión de la red GAN es menor que el punto de ajuste de presión, la válvula de

derivación del LIN se cerrará para entregar el LIN al vaporizador ambiental y así mantener
la presión en este.
Los vaporizadores LIN ambientales se calientan naturalmente por el aire ambiente y
vaporizarán el nitrógeno líquido. Los dos conjuntos se instalan con el interruptor de la
válvula para tener uno en funcionamiento mientras que el otro está debajo de la
derivación para eliminar el hielo que se ha acumulado durante la vaporización de LIN. El
cambio de un vaporizador ambiental a otro se realizará automáticamente en una base de
temporizador.
Aguas abajo del vaporizador atmosférico, hay un calentador de ajuste GAN, lo que
garantiza que el suministro de temperatura al cliente sea superior a 10 °C,
independientemente de las condiciones ambientales. Este calentador se controla en
modo ENCENDIDO / APAGADO.
4.2. DIAGRAMAS DE FLUJO

A continuación, se presentan los diagramas de flujo de proceso de la unidad, TAL-NIS-PRO-
PFD-0001, diagramas de flujo del paquete NIS-Z-001 suministrados por el proveedor, así como
el balance de materia y energía, TAL-NIS-PRO-HMB-0001.
PROYECTO MODERNIZACIÓN REFINERÍA TALARA
PFD PLANTA DE NITRÓGENO
TAL-NIS-PRO-PFD-0001 1 1 03
PROYECTO: TAL
PROYECTO DE MODERNIZACIÓN REFINERÍA TALARA
PÁGINA 1 DE 8
BALANCES DE MATERIA Y ENERGÍA
N° DOCUMENTO: TAL-NIS-PRO-HMB-0001 REV. 02

FECHA: 14/12/2018

DOCUMENTO PRINCIPAL
00 13/07/2018 Emisión para Revisión
01 28/09/2018 Emisión Incluidos Comentarios
ANEXOS
FORMATOS
Alberto Pan Sergio Téllez Ángel Agudo
Este documento contiene información privada y no puede ser duplicado, modificado o divulgado a terceros sin el consentimiento escrito de
COBRA SCL. La única copia controlada de este documento está en el Sistema Informático de Gestión Documental de COBRA SCL.
PROYECTO: TAL
PÁGINA 2 DE 8

FECHA: 14/12/2018
ÍNDICE
1. OBJETO ..............................................................................................................3
2. ALCANCE ............................................................................................................3
3. DEFINICIONES .....................................................................................................3
4. DOCUMENTOS DE REFERENCIA............................................................................4
5. BALANCE DE MATERIA ........................................................................................4
PROYECTO: TAL
PÁGINA 3 DE 8

FECHA: 14/12/2018
1. OBJETO
El propósito de este documento es presentar los balances de materia y energía de los casos
de operación de la nueva planta de producción de nitrógeno (NIS), como parte del proyecto
“Unidades Auxiliares y Trabajos Complementarios” (UA&TC), el cual hace parte de la
ejecución del “Proyecto Modernización de la Refinería Talara” (PMRT), en Perú.
2. ALCANCE
Este documento contiene el balance de materia y energía de las corrientes de nitrógeno
gaseoso producido y nitrógeno vaporizado del sistema de almacenamiento. Este balance de
materia y energía se desarrolla utilizando hoja de cálculo (Excel) y el simulador Aspen HYSYS
V9® para obtener las propiedades de dichas corrientes.
Se excluyen las corrientes de servicios y líneas que operan solamente durante el arranque.
La información contenida en el presente documento se corresponde con los números de
corrientes identificados en el diagrama de flujo de proceso TAL-NIS-PRO-PFD-0001 - PFD
Planta de Nitrógeno, Rev 02.
3. DEFINICIONES
• PROYECTO: Proyecto de Modernización Refinería TALARA / Unidades Auxiliares y
• EMPLEADOR: significa:
b) Los sucesores legales y cesionarios/novados legítimos del EMPLEADOR en el
Contrato; y
c) Toda persona que se convierta en Parte del presente en sustitución o
conjuntamente con el EMPLEADOR y los sucesores legales y cesionarios/novados
legítimos de dicha persona en el Contrato
Para fines prácticos PETROLEOS DEL PERÚ – PETROPERÚ S.A. (también identificado
como “PP”)
• REPRESENTANTE DEL EMPLEADOR (PMC): Se refiere al PMC o a la persona nombrada
por el EMPLEADOR en el Contrato o designada de manera periódica por el EMPLEADOR
conforme a la Subcláusula 3.1 [Representante del EMPLEADOR] para que actúe en
representación del EMPLEADOR.
• CONTRATISTA: Significa la o las personas designadas como contratistas en el presente
Para fines prácticos, aquel designado por PETROPERÚ como empresa adjudicataria del
Contrato para la ejecución del Proyecto de Modernización Refinería TALARA / Unidades
Auxiliares y Trabajos Complementarios, CONSORCIO COBRA SCL UA&TC (también
PROYECTO: TAL
PÁGINA 4 DE 8

FECHA: 14/12/2018
identificado como COBRA SCL) o cualquiera de sus afiliadas, representantes autorizados

o sucesoras)
• LICENCIANTE DE PROCESOS: Significa las personas jurídicas que ha suscrito contratos
con el EMPLEADOR para elaborar las licencias de procesos.
• DISEÑO FEED: Se refiere al diseño de ingeniería básica extendida llevado a cabo por
parte de Técnicas Reunidas bajo el Contrato FEED EPC.
• EPC: (Engineering, Procurement & Construction) Fase de Ingeniería Detallada,
Adquisiciones y Construcción (incluye las actividades de Pre-Comisionado/Pruebas,
• ESPECIFICACIONES GENERALES DE LOS TRABAJOS A REALIZAR (MJS: Master Job
• VENDEDOR/VENDOR: Cualquier Proveedor y/o Fabricante de Equipo o Sistemas,
• SUBCONTRATISTA: Significa (i) toda persona nombrada en el Contrato como
subcontratista, (ii) toda persona nombrada como subcontratista bien sea directamente
por el CONTRATISTA o a un nivel inferior (incluyendo cualquier subcontratista o
proveedor de Materiales) para una parte de los Trabajos, y (iii) los sucesores legales de
cualquiera de lo anterior.
4. DOCUMENTOS DE REFERENCIA
• TAL-NIS-PRO-PFD-0001 PFD Planta de Nitrógeno, Rev. 02
• TAL-NIS-PRO-SPE-Z001 Especificación Técnica de Procesos de la Planta N2,
Rev. 01
5. BALANCE DE MATERIA
La información presentada en las siguientes tablas se corresponde con los números de
corrientes identificados en el diagrama de flujo de proceso TAL-NIS-PRO-PFD-0001 - PFD
Planta de Nitrógeno, Rev 02.
A continuación, se presentan los balances de materia de cada una de las corrientes
anteriores, para el suministro normal de nitrógeno gaseoso (GAN) producido por la NIS
(Corriente No. 1) y para la capacidad de vaporización máxima requerida de nitrógeno líquido
(LIN) (Corriente No. 2). En operación normal, la Corriente No. 2 normalmente no tiene flujo
(NNF).
Para mayor información sobre la operación de la NIS, referirse al documento TAL-NIS-PRO-
SPE-Z001 - Especificación Técnica de Procesos de la Planta N2, Rev 01.
PROYECTO: TAL
PÁGINA 5 DE 8

FECHA: 14/12/2018
CORRIENTE No. 1 (SUMINISTRO NORMAL GAN)

Temperatura 32.2 °C Fase Vapor
Presión 9 kg/cm2 g Fracción de vapor (base masa) 100 %
Flujo másico 4300 kg/h Entalpía 4890 kcal/h
Flujo molar 154 kmol/h Poder calorífico inferior, LHV 0 kcal/kg
Peso molecular 28.01 kg/kmol Poder calorífico superior, HHV 0 kcal/kg
Fase Vapor
Flujo másico 4300 kg/h Densidad 10.90 kg/m3
Flujo molar 154 kmol/h Viscosidad 0.019 cP
Flujo volumétrico
3627 Sm3/h Conductividad térmica 0.023 kcal/m∙h∙°C
estándar
Flujo volumétrico 395 m3/h Capacidad calorífica 0.253 kcal/kg∙°C
Peso molecular 28.01 kg/kmol Entalpía 31.86 kcal/kmol
Cp/Cv 1.416
Compresibilidad 0.997
Gravedad específica (aire) 0.967
Composición
Componente % peso kg/h % Molar kmol/h
Nitrógeno 99.99 4299.6 100.00 154
Oxígeno 10 ppm 0.004 0 0
CORRIENTE No. 2 (SUMINISTRO MÁXIMO LIN)

Flujo molar 723.6 kmol/h Poder calorífico inferior, LHV 0 kcal/kg
Fase Vapor
Flujo molar 723.6 kmol/h Viscosidad 0.019 cP
Flujo volumétrico
estándar
Cp/Cv 1.415
Composición
PROYECTO: TAL
PÁGINA 6 DE 8

FECHA: 14/12/2018
CORRIENTE No. 2 (SUMINISTRO MÁXIMO LIN)

Nitrógeno 99.99 20267.98 100.00 723.6
A continuación, se presentan los balances de materia de cada una de las corrientes

anteriores, bajo las condiciones de diseño de la planta.
CORRIENTE No. 1 (CAPACIDAD DE DISEÑO GAN)

Fase Vapor
Flujo volumétrico
estándar
Cp/Cv 1.416
Composición
Nitrógeno 99.99 4622.5 100.00 165
CORRIENTE No. 2 (CAPACIDAD DE DISEÑO LIN)

Fracción de vapor (base
Presión 8 kg/cm2 g 100 %
masa)
Poder calorífico inferior,
Flujo molar 793.7 kmol/h 0 kcal/kg
LHV
Poder calorífico superior,
Peso molecular 28.01 kg/kmol 0 kcal/kg
HHV
Fase Vapor
PROYECTO: TAL
PÁGINA 7 DE 8

FECHA: 14/12/2018
CORRIENTE No. 2 (CAPACIDAD DE DISEÑO LIN)

Flujo molar 793.7 kmol/h Viscosidad 0.019 cP
Flujo volumétrico
estándar
Cp/Cv 1.415
Composición
Nitrógeno 99.99 22228 99.99 793.6
Oxígeno 10 ppm 0.22 0 0.01
Las corrientes 3 y 4 corresponden al consumo de agua de enfriamiento esperado bajo las

condiciones de diseño de la Planta de Nitrógeno, a las condiciones normales de suministro
de agua de enfriamiento. El consumo real y condiciones de retorno en operación normal
(producción de GAN), será confirmado en el desarrollo de la ingeniería, con base en la
información del vendedor de la Planta de Nitrógeno.
CORRIENTE No. 3
Temperatura 24 °C Fase Líquido
Presión 5.6 kg/cm2 g Fracción de vapor (base masa) 0 %
Flujo másico 189506 kg/h Entalpía -832.04 Gcal/h
Fase Líquida
Flujo volumétrico
189.9 Sm3/h Conductividad térmica 0.524 kcal/m∙h∙°C
estándar
Flujo volumétrico 190 m3/h Entalpía -68136 kcal/kmol
Peso molecular 18.02 kg/kmol Capacidad calorífica 0.999 kcal/kg∙°C
Tensión superficial 72.27 dyn/cm
Gravedad específica 0.997
Composición
Agua 100 220000 100.00 12212
PROYECTO: TAL
PÁGINA 8 DE 8

FECHA: 14/12/2018
CORRIENTE No. 4
Temperatura 37 °C Fase Líquido
Presión 4.9 kg/cm2 g Fracción de vapor (base masa) 0 %
Flujo másico 189506 kg/h Entalpía -829.74 Gcal/h
Fase Líquida
Flujo volumétrico
189.8 Sm3/h Conductividad térmica 0.534 kcal/m∙h∙°C
estándar
Flujo volumétrico 190.6 m3/h Entalpía -67956 kcal/kmol
Peso molecular 18.02 kg/kmol Capacidad calorífica 0.999 kcal/kg∙°C
Tensión superficial 70.54 dyn/cm
Gravedad específica 0.994
Composición
Agua 100 220000 100.00 12212
PROYECTO DE MODERNIZACIÓN
REFINERIA TALARA
DOCUMENT CODE / CODIGO: PURCHARSE ORDER/ORDEN DE COMPRA N°
V-TAL-MEC-0001-OC-04-NIS-Z-001-0010 TAL-NIS-MEC-0001-OC-04
EQUIPMENTS / EQUIPOS (TAGS) N°: CODE VENDOR / CODIGO DE DOCUMENTO DEL VENDOR:
NIS-Z-001 57506-60-01-PR-013100
VENDOR NAME / NOMBRE DEL VENDOR:
Air Liquide
DOCUMENT TITTLE / TITULO DEL DOCUMENTO:
Combined PFD
DATE OF REVIEW: FECHA DE REVISIÓN: REV.:
20/03/2019 00
10
14
13
16
15
12
11
2
9
4
6
1
7
3
A
A
B
B
C
C
D
D
E
E
F
F
EQUIPMENT TAGS
TAG ALE TAG PETROPERU DESCRIPTION
C01 NIS-K-001 MAIN AIR COMPRESSOR FLUID CODES
G R01 NIS-R-001 AIR PURIFICATION VESSEL CODE ALE CODE PETROPERU DESCRIPTION
G
R02 NIS-R-002 AIR PURIFICATION VESSEL AW / AD UA INDUSTRIAL AIR ( AIRE DE PLANTA)
E08 NIS-E-008 REGENERATION HEATER AG PA PROCESS AIR, OIL FREE (AIRE DE PROCESO LIBRE DE ACEITE)
S04 NIS-SL-004 WASTE GAS VENT SILENCER WO ATM WASTE OXYGEN
E01 NIS-E-001 MAIN HEAT EXCHANGER WO SV SAFETY VALVE DISCHARGE LINE (DESCARGA DESD E VALVULA DE ALIVIO)
E02 NIS-E-002 MAIN VAPORIZER IA IA INSTRUMENT AIR (AIRE DE INSTRUMENTOS)
K01 NIS-C-001 HP COLUMN
H
H
LIN NI NITROGEN LIQUID (NITROGENO)
ET01 NIS-X-001 EXPANSION TURBINE
GAN NI NITROGEN GAS (NITROGENO)
E080 NIS-E-003 LIQ. DISPOSAL VAPORIZER WL
NIS-SL-002 NITROGEN SILENCER NOD WASTE CRYOGENIC LIQUID
S02
DERIME HEATER LR P RICH LIQUID
E81 NIS-E-009
V50 NIS-T-050 LIN STORAGE CWS CWS COOLING WATER SUPPLY (SUMINISTRO DE AGUA DE ENFRIAMIENTO)
LIN VAPORIZER CWR CWR COOLING WATER RETURN (RETORNO DE AGUA DE ENFRIAMIENTO)
E51/1/2/3/4 NIS-E-004/005/006/007 - LS LOW PRESSURE STEAM (VAPOR DE BAJA PRESION)
I F01 NIS-F-001
I
AIR FILTER
C01.S NIS-SL-001 BLOW OFF SILENCER IG INSTRUMENT GAS
V50E NIS-E-010 WW WASTE WATER
LIN PRESSURE BUILDING COIL
J
J
E&C FRANCE NUMBER PETROPERU NUMBER DESIGNATION

57506-01-PR-013001 V-TAL-MEC-0001-OC-04-NIS-Z-001-0252 TAG & CODE EQUIVALENCES
57506-01-PR-013010 V-TAL-MEC-0001-OC-04-NIS-Z-001-0002 COMPRESSION AND PURIFICATION
K
K
57506-01-PR-013050 V-TAL-MEC-0001-OC-04-NIS-Z-001-0003 COLD BOX
57506-01-PR-013071 V-TAL-MEC-0001-OC-04-NIS-Z-001-0004 LIQUID NITROGEN STORAGE AND VAPORIZATION
57506-01-PR-013083 V-TAL-MEC-0001-OC-04-NIS-Z-001-0007 WATER NETWORK
57506-01-PR-013100 V-TAL-MEC-0001-OC-04-NIS-Z-001-0010 PFD COMBINED
L
L
M
N
N
Copyright Air Liquide/all rights PROYECTO MODERNIZACIÓN REFINERÍA TALARA

reserved. This print is the
property of L'Air Liquide and UNIDADES AUXILIARES Y TRABAJOS COMPLEMENTARIOS
contains valuable confidential
information. No part of this print
O
O
may be reproduced, copied, lent
or disposed of, directly or
TALARA NIS 6
indirectly, nor used for any other

purpose than that for wich it is 01 15/03/2019 ISSUED FOR REVISION E.RODRIGUES F.STEULET F.STAINE TAG AND CODE EQUIVALENCES
specifically furnished. This print
A0 - DS.122.07.03
05/10/2018 ISSUED FOR REVISION E.RODRIGUES F.STEULET F.STAINE
is lent subject to return on 0
FORMATO: PROY. NUM: 57506 PROCESS FLOW DIAGRAM
P demand. A
P
27/09/2018 PRELIMINARY ISSUE E.RODRIGUES F.STEULET F.STAINE
ESCALA: PLANO CLIENTE Nº PLANO AL Nº PAG. REV.
NOTAS GENERALES NOTAS PLANO REF N° PLANOS DE REFERENCIA N° REV. FECHA DESCRIPCIÓN DE LA EMISIÓN ELAB. REV. APR. V-TAL-MEC-0001-OC-04-NIS-Z-001-0252 60-01-PR-013001 1 DE 5 01
16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
10
14
13
16
15
12
11
2
9
4
6
1
7
3
A
A
B
B
10" 10"WO06 10"
SAFE AREA
PSV
S04 PIC PSHH
8" 10"WO05 WO FROM E01

C 28 60-01-PR-013050
C
6"
PDSLL PDI
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HIC
D
D
TI TSHH
ASHH
3"
8"
AI
CO2
8"AG06
108 AG TO E01
60-01-PR-013050
E
E
1 1/2"
8" 8"WO09
PSV
PI
8"WO09A 8"WO09B
F
F
1 1/2"IA01 IA TO UTILITIES
8"
8"
2" 2"
01
PI PDI PI
G
R01 R02
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PDI PDI
H
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TI TI 01
8"WO06
4"WO12
8"WO07A 8"WO07B
I 1"AD05 AD TO ET01 DERIMING
I
3"WO12A 3"WO12B 60-01-PR-013050
01
8" 8"
TP
05
1"IA07 2" IA FROM CUSTOMER
J
J
8"
FROM FIC E01 (AG INLET) 1/2"IG03 IA TO ET01 SEAL GAS

4" 3"
60-01-PR-013050 60-01-PR-013050
FO
2"AG06 AG TO COLD BOX DERIMING
PDI 01 60-01-PR-013050
K F01
K
TI TSHH
HIC
18"AW05 16" TO BE CLARIFIED
PDI C01
PI PSHH
M
PDSHH
L
L
SAFE AREA
8"AG05
01 AC
6"
6"
CWS FROM CUSTOMER 8" C01.S

6"AW02
60-01-PR-013083
CWR TO CUSTOMER 8" PSV
M
M
60-01-PR-013083
8"AW01
101
AIR FILTER MAIN AIR COMPRESSOR BLOW OFF SILENCER AIR PURIFICATION VESSEL AIR PURIFICATION VESSEL REGENERATION HEATER WASTE GAS VENT SILENCER
N
N
F01 C01 C01.S R02 R01 E08 S04

O
O
TALARA NIS 6

purpose than that for wich it is 01 15/03/2019 ISSUED FOR REVISION E.RODRIGUES F.STEULET F.STAINE COMPRESSION AND PURIFICATION
A0 - DS.122.07.03
05/10/2018 ISSUED FOR REVISION E.RODRIGUES F.STEULET F.STAINE
is lent subject to return on 0
P demand. A
P
16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
10
14
13
16
15
12
11
2
9
4
5
6
1
7
3
A
A
FROM E51
60-01-PR-013071
B
6"GAN06 3"
S02 PSV
TSLL ASHH
PI TI FIC FIC PIC PI AI

TP
03 O2 TRACES PSV
C GAN TO CUSTOMER 6"GAN04 6"GAN02
42
C
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01
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D
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60-01-PR-013010 28 HCV
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1 CH4 1/2"LR04
60-01-PR-013010
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F 4"GAN01
F
3/4"LIN03
3/4"LIN01 3/4"LIN03 LIN TO STORAGE AREA
60-01-PR-013071
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HS
G
E01
6"WO02
PIC HS
3"
H
H TSHH
TSHH
1" TI
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2"AD02 2"AG06 AG FROM R01/R02
HS CWS/CWR 60-01-PR-013010
60-01-PR013083
1/2"
I
I
PDI
1"
1 1/2"CWS
DOET01 PDSLL
1 1/2"CWR
6"
ET01
1/2"
OIL 6"WO01
BRAKE
1/2"WO03
J
J
SIC
6"AG08
TSLL
K01
01
1/2"LR05 LSHH LIC
TI
HIC
K
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60-01-PR-013071 HS
8"WO03
3"LR01
IA FROM R01/R02 1/2"IG03 4"GAN01

60-01-PR-013010
E80
1/2"
L
L
AD FROM R01/R02 1"AD05
60-01-PR-013010 01
2"WL01
2"IA08 1/2" IA FROM NETWORK
M
NITROGEN SILENCER EXPANSION TURBINE MAIN HEAT EXCHANGER MAIN VAPORIZER HP COLUMN DERIME HEATER LIQ. DISPOSAL VAPORIZER
N
S02 ET01 E01 E02 K01 E81 E80
N

O
O
TALARA NIS 6

purpose than that for wich it is 01 15/03/2019 ISSUED FOR REVISION E.RODRIGUES F.STEULET F.STAINE COLD BOX
A0 - DS.122.07.03
ISSUED FOR REVISION E.RODRIGUES F.STEULET F.STAINE
is lent subject to return on 0 05/10/2018
P demand. A
P
16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
10
14
13
16
15
12
11
2
9
4
5
6
1
7
3
A
A
B
B
HS 2x100%
01 PSV
C
TRUCK 3"
UNLOADING
LI LSHH
V50E 3"
D V50 PSH/L
PSHH PIC
D
E51.1 TO O2 ANALYZER
60-01-PR-013050
E
E
TSLL
HS 01
PSV TIC PIC
FIC AP
1002 TP
04
O2 TRACES
LIN FROM COLD BOX
3/4"LIN03 3/4"LIN04 3/4"LIN100 6"LIN160 3" 6" 8"GAN160 GAN TO CUSTOMER
60-01-PR-013050 160
MINI NOTE 1
1/2"
F
HS
TO PIT
G
E51.2
G
3"
8"
6"
01
3" 6"
H
H
E51.3
PSV
I
3" 6" 1/2"IG03 GAN TO ET01 SEAL GAS
60-01-013050
01
E51.4
J
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01
3" 6"
K
K
L
L
M
LIN PRESSURE BUILDING COIL LIN STORAGE
LIN VAPORIZER LIN VAPORIZER LIN VAPORIZER LIN VAPORIZER
V50E V50
N
N
E51.1 E51.2 E51.3 E51.4
Copyright Air Liquide/all rights 1. CONTROL SELECTION PROYECTO MODERNIZACIÓN REFINERÍA TALARA
O
O
TALARA NIS 6

purpose than that for wich it is 01 15/03/2019 ISSUED FOR REVISION E.RODRIGUES F.STEULET F.STAINE LIN STORAGE AND VAPORIZATION
A0 - DS.122.07.03
P demand. A
P
16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
10
14
13
16
15
12
11
2
8
9
4
5
6
1
7
3
A
A
B
B
C
C
D
D
01
TP
02
8"CWS 8"CWS CWS FROM CUSTOMER
3"CWS
8"CWS
E
E
MAIN AIR
01 COMPRESSOR TURBINE OIL
C01 SYSTEM ET01
3"CWR
8"CWR
F
F
01
TP
01
8"CWR 8"CWR CWR TO CUSTOMER
G
H
H
I
J
J
K
L
L
M
N
N

O
O
TALARA NIS 6

purpose than that for wich it is 01 15/03/2019 ISSUED FOR REVISION E.RODRIGUES F.STEULET F.STAINE WATER NETWORK
A0 - DS.122.07.03
P demand. A
P
16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1

PÁGINA 44 DE 556
4.3. CONDICIONES DE OPERACIÓN

Debido a que las condiciones de operación de la unidad son de la responsabilidad del
proveedor de la misma, para consultarlas, debe observarse el balance de materia y
energía del proveedor para cada uno de los equipos de proceso, V-TAL-MEC-0001-OC-04-
NIS-Z-001-0009, el cual se adjunta a continuación.
REFINERIA TALARA
CODE VENDOR / CODIGO DE DOCUMENTO DEL

EQUIPMENTS / EQUIPOS (TAGS) N°:
VENDOR:
NIS-Z-001 57506-60-01-PR-013204
Air Liquide
Material Balance
04/04/2019
15/07/2019 01
Air Liquide Confidential Information
This print is the property of L’Air Liquide S.A. or its (direct and indirect) affiliates or subsidiaries and contains valuable confidential information.
Derived from G-TPL-13-0-1, Rev.0, Issued date: 04-Aug-14 ●CONFIDENTIAL Copyright and all other rights in this print are expressly reserved. No part of this print may be disclosed by the intended recipient to a third
party, reproduced, copied, lent, or disposed of, directly or indirectly, nor used for any purpose other than that for which it is expressly
Rev. 0A furnished. This print is lent subject to return on demand.
AL_CRYO_PROCESS_DS_TEMPALTE_MATERIAL_BALANCE
39
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Case-Name:
XXX
X
Ref. ID
Design LIN
TALARA NIS
Project Name
Design GAN
4
3
Page
1
1
XX
57506
Revision
Project No.
Process
Material Balance
Process Data Sheet
XXX
Document No.
Modifications
Printed by / date / time:

57506-60-01-PR-013204
RNETW
/
2 / 4
Page / of
10/07/19
/
1
Line revised under Rev. No.
12:41
Revision
Process
Process Data Sheet
Copyright and all other rights in this print are expressly reserved. No part of this print may be disclosed by the intended recipient to a third
Material Balance
01 Case name Design GAN

02 Stream Number 1 28 42
Description Dry air from
03 purification vessel
Waste oxygen from GAN from E01 to
R01/R02 to main
E01 to E08 customer
04 heat exchanger
E01
05 Phase Vapour Vapour Vapour
06 Pressure kg/ cm2 (abs) 10.52 1.35 10.28
07 Temperature °C 41 37 37
08 Nm3/h 9470 5759 3 692
furnished. This print is lent subject to return on demand.
Norm. vol. flow

09 Sm3/h 10011 6088 3903
10 Vapour fraction mol % 100% 100% 100%
11 Component mol %
12 N2 78.11% 64.21% 99.99%
13 Ar 0.93% 1.51% 0.01%
14 O2 20.96% 34.28% 0.00%
15 Molecular weight 29 30 28
16 Enthalpie kcal/h 1276283 778940 486700
17
18
19
20
21 Stream Number 101 108 160 (1) 1
Description Air from
22 Waste oxygen from
compressor C01 to GAN from E51 to
E08 to purification
purification vessel customer
23 vessels R1/R2.
R01/R02.
●CONFIDENTIAL

27 Nm3/h 9663 4000 3 689
Norm. vol. flow
28 Sm3/h 10215 4228 3900
30 Component mol %
31 N2 78.11% 64.21% 99.99%
32 Ar 0.93% 1.51% 0.01%
33 O2 20.96% 34.28% 0.00%
35 Enthalpie kcal/h 1266479 682373 479731
36
37
38
39
Notes: Normal conditions refers to T= 273.15 K and P = 1.03323 kg/cm 2 abs

Standard conditions refers to T= 288.75 K and P = 1.03323 kg/cm 2 abs
(1) The flow indicated in the Heat and Material Balance corresponds to the GAN operation mode, for the 1
GAN/LIN operation mode the capacity is 3550 Sm 3/h GAN and 320 Sm3/h LIN
Derived from G-TPL-13-0-1, Rev.0, Issued date: 04-Aug-14
Client Project Name Client Project Number Client Document Number

X XX XXX Line revised under Rev. No.
Project Name Project No. Document No. Page / of Revision

Rev. 0A
TALARA NIS 57506 57506-60-01-PR-013204 3 / 4 1

Case-Name: XXX Printed by / date / time: RNETW / 10/07/19 / 12:41
Process
Process Data Sheet
Copyright and all other rights in this print are expressly reserved. No part of this print may be disclosed by the intended recipient to a third
Material Balance
01 Case name Design LIN

02 Stream Number 1 28 42 30 1
Description Dry air from
03 purification vessel
Waste oxygen from GAN from E01 to
R01/R02 to main LIN from K01 to V51
E01 to E08 customer
04 heat exchanger 1
E01
05 Phase Vapour Vapour Vapour Liquid 1
06 Pressure kg/ cm2 (abs) 10.51 1.36 10.28 10.36 1
07 Temperature °C 41 39 39 -169 1
08 Nm3/h 9700 6015 3 360 305 1
furnished. This print is lent subject to return on demand.
Norm. vol. flow

09 Sm3/h 10254 6359 3552 322 1
10 Vapour fraction mol % 100% 100% 100% 0% 1
11 Component mol %
12 N2 78.11% 64.92% 99.99% 99.99% 1
13 Ar 0.93% 1.49% 0.01% 0.01% 1
14 O2 20.96% 33.59% 0.00% 0.00% 1
15 Molecular weight 29 30 28 28 1
16 Enthalpie kcal/h 1307287 816671 444889 5190 1
17
18
19
20
21 Stream Number 101 108 160 (1) 1
Description Air from
22 Waste oxygen from
compressor C01 to GAN from E51 to
E08 to purification
purification vessel customer
23 vessels R1/R2.
R01/R02.
●CONFIDENTIAL

27 Nm3/h 9896 4000 3 689
Norm. vol. flow
28 Sm3/h 10461 4228 3900
30 Component mol %
31 N2 78.11% 64.92% 99.99%
32 Ar 0.93% 1.49% 0.01%
33 O2 20.96% 33.59% 0.00%
35 Enthalpie kcal/h 1297017 682363 479731
36
37
38
39
Notes: Normal conditions refers to T= 273.15 K and P = 1.03323 kg/cm 2 abs

Standard conditions refers to T= 288.75 K and P = 1.03323 kg/cm 2 abs
(1) The flow indicated in the Heat and Material Balance corresponds to the GAN operation mode, for the 1
Derived from G-TPL-13-0-1, Rev.0, Issued date: 04-Aug-14
GAN/LIN operation mode the capacity is 3550 Sm 3/h GAN and 320 Sm3/h LIN
Client Project Name Client Project Number Client Document Number

X XX XXX Line revised under Rev. No.
Project Name Project No. Document No. Page / of Revision

Rev. 0A
TALARA NIS 57506 57506-60-01-PR-013204 4 / 4 1

Case-Name: XXX Printed by / date / time: RNETW / 10/07/19 / 12:41

PÁGINA 50 DE 556
4.4. FILOSOFÍA DE CONTROL

La filosofía de Operación y Control ha sido desarrollada en un documento detallado, V-TAL-
MEC-0001-OC-04-NIS-Z-001-0173 suministrada por el proveedor de la unidad (ALE) , el
cual se adjunta a continuación.
REFINERIA TALARA
NIS-Z-001 57506-60-01-PR-013902
Air Liquide
Operation and Control Philosophy
13/09/2019 04
PROJECT NBR: C.57506 013-902
Rev. 04
NAME : TALARA NIS Page 1 of 65
CONTROL STRATEGY
COVER PAGE
Rev Date Prepared by Approved by Revision

0 21/12/2018 M. ATAM Preliminary Revision (excluded back-up
system)
1 01/02/2019 C. BECKER Initial issue
2 29/04/2019 C. BECKER Issued for review
5
DISCLAIMER
The information contained in this document has been prepared by L’Air Liquide S.A. and/or its controlled subsidiaries (“Air
Liquide”), exclusively for their use, and is Air Liquide property. Air Liquide believes the information is current and accurate,
but circumstances may warrant additional requirements or procedures. This document is subject to periodic review and
users are cautioned to obtain the latest edition.
Air Liquide makes no representations or warranties to third parties as to the quality, accuracy or completeness of information
contained in this document and EXPRESSLY DISCLAIMS ALL WARRANTIES, INCLUDING, BUT NOT LIMITED TO, THE
WARRANTY OF MERCHANTABILITY AND THE WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE.
No part of this document may be copied or otherwise shown or disclosed to third parties without the prior consent of Air
Liquide.
Unauthorized use of this document by any third Party, including Air Liquide contractors and subcontractors, shall be at such
Party’s own risk, and Air Liquide assumes no liability in connection with information contained herein. Air Liquide disclaims
any liability for any damage suffered by any company or person as a result of or in connection with the use, application or
implementation of the information contained herein or any part thereof. The benefit of this disclaimer shall inure to Air Liquide
and its affiliates.
This document should not be confused with federal, state, provincial, or municipal specifications or regulations, insurance
requirements or national safety codes.
This document is issued and administered by the Air Liquide Engineering Standards
Department.
Paper copies of this document are considered to be “uncontrolled” and users should
always check for the most recent revision.
DISCLAIMER: Prior to using this document, all individuals must refer to the Disclaimer on the first page of this document.
PROJECT NBR: C.57506 013-902
Rev. 04
CONTROL STRATEGY
TABLE OF CONTENTS
1 REFERENCE DOCUMENTS LIST 4

2 ABBREVIATIONS AND GENERAL NOTES 5
3 GENERAL DESCRIPTION 7
3.1 PROCESS DESCRIPTION: 7
3.1.1 WARM PART 7
3.1.2 COLD PART (Air separation) 8
3.2 OPERATION MODES: 8
3.2.1 Start up: 8
3.2.2 GAN only: 8
3.2.3 GAN and LIN: 8
3.2.4 Air purification Exceptional Reactivation: 8
3.2.5 Cold box deriming: 8
3.2.6 LIN Storage and Vaporization: 9
3.3 Control Loop List 10
3.4 Air Purification unit timers 11
4 CONTROL DESCRIPTION 11
4.1 Unit Control Objective 11
4.2 Unit Control Strategy 12
5 DETAILED CONTROL NARRATIVES: 13
5.1 AIR COMPRESSOR 13
5.1.1 MAIN AND AUXILIARY OIL PUMP 13
5.1.2 OIL HEATER 13
5.1.3 AIR FILTER FAN 13
5.1.4 COMPESSOR READY TO START 14
5.1.5 COMPRESSOR START/STOP 14
5.1.6 COMPRESSOR LOAD/UNLOAD 15
5.1.7 COMPRESSOR ANTI-SURGE 15
5.2 AIR PURIFICATION UNIT 17
5.2.1 AIR PURIFICATION SEQUENCE 17
5.2.2 ADSORBERS PRESSURIZATION: KY230 22
5.2.3 WASTE GAS TEMPERATURE CONTROL: TX233 24
5.2.4 COLD BOX BYPASS CONTROL: HIC240 26
5.2.5 REGENERATION PRESSURE CONTROL: PIC261 27
5.2.6 CO2 ANALYZER: AI242 29
5.2.7 INSTRUMENT AIR PRODUCTION IN 86: 31
5.2.8 EXCEPTIONAL REGENERATION 33
5.3 AIR SEPARATION UNIT 34
5.3.1 GASEOUS NITROGEN PRODUCTION FLOW CONTROL: FIC615A/FIC615B: 34
5.3.2 GASEOUS NITROGEN PRESSURE CONTROL: PIC615 / PIC640 37
5.3.3 AIR FLOW TO COLD BOX: FIC630/HIC630 39
5.3.4 TURBINE INLET GUIDE VANES CONTROL: HIC608 / SIC675 42
5.3.5 LIN PRODUCTION CONTROL: LIC602 44
5.3.6 COLUMN PURGE: KV623 / IN15 46
PROJECT NBR: C.57506 013-902
Rev. 04
CONTROL STRATEGY
5.3.7 VAPORIZER CONDENSER SUBMERGENCE CONTROL: LIC614 47

5.3.8 VAPORIZER CONDENSER HYDROCARBON PURGE: KV603 / IN 29 50
5.3.9 OIL HEATER TEMPERATURE CONTROL: TSL/TSH690 52
5.3.10 OXYGEN ANALYZER: AI618 53
5.3.11 HYDROCARBONS ANALYZER: AI684 55
5.3.12 DERIMING OF THE COLD BOX 57
5.4 NITROGEN LIQUID STORAGE AND VAPORIZATION 58
5.4.1 STORAGE PRESSURE CONTROL: PIC 821B and PSL/PSH 821A: 58
5.4.2 NITROGEN VAPORIZER PRESSURE CONTROL: PIC 971 60
5.4.4 NITROGEN VAPORIZER FLOW CONTROL: FIC 971 62
5.4.5 NITROGEN VAPORIZER TEMPERATURE CONTROL: TIC 974 64
PROJECT NBR: C.57506 013-902
Rev. 04
CONTROL STRATEGY
1 REFERENCE DOCUMENTS LIST

P&ID:
 C57506-60-01-PR-014001: P&ID Index
 C57506-60-01-PR-014002: Symbols & Schematic – Piping Symbols 1 / 2
 C57506-60-01-PR-014003: Symbols & Schematic – Piping Symbols 2 / 2
 C57506-60-01-PR-014004: Symbols & Schematic – Instrumentation Symbols 1 / 2
 C57506-60-01-PR-014005: Symbols & Schematic – Instrumentation Symbols 2 / 2
 C57506-60-01-PR-014010: Air Compression
 C57506-60-01-PR-014030: Air Purification Vessels R01/R02
 C57506-60-01-PR-014031: Air Purification Regeneration Heater E08
 C57506-60-01-PR-014060: Main Exchanger E01 & Expansion Turbine ET01.1/2
 C57506-60-01-PR-014070: MP Column K01 & Cryogenic Liquid Disposal Vaporizer E80
 C57506-60-01-PR-014106: LIN Storage V51 (IN/OUT)
 C57506-60-01-PR-014107: LIN Storage V51
 C57506-60-01-PR-014200: Instrument Air & Derime
 C57506-60-01-PR-014640: Air Expansion Turbine
Causes and effects:

 C57506-60-01-PR-013901
PROJECT NBR: C.57506 013-902
Rev. 04
CONTROL STRATEGY
2 ABBREVIATIONS AND GENERAL NOTES
Abbreviations Designations Definitions

2oo3 Voting (2 out of 3) Voting is a method to reduce spurious alarms or dormant
failure. A two-out of “n” system requires “n” sensors; at
least two sensors shall be taken into account to activate
an alarm or a trip.
2oo3 voting system mode means that two sensor signals
are required to involve an action.
AI Analog Input
AO Analog Output
BPCS Basic Process Control System ISA-S5.1 definition:
A system that, while being functionally integrated,
consists of subsystems that may be physically separate
and remotely located from one another.
DCS Distributed Control System
DI Digital Input
Direct Direct Controller Acting Measurement increasing gives controller output signal
increasing
DO Digital Output
EIS Equipment Important for
Safety
ESD Emergency Shutdown
FAT Factory Acceptance Test
HMI Human/Machine Interface A system that provides operator interface to all BPCS (or
PLC) screen displays functions for command and data
entry, along with screen pointer manipulation and control.
I/O Inputs/Outputs
IEC International Electrotechnical
Commission
IEEE Institute of Electrical and
Electronic Engineers
ISA Instrument Society of America American standard related to instrumentation
ISO International Standard
Organization
LED Light Emitting Diode
MCC Motor Control Center
MOS Maintenance Override Switch
MTBF Mean Time Between Failure
MTTR Mean Time To Repair
PROJECT NBR: C.57506 013-902
Rev. 04
CONTROL STRATEGY
Abbreviations Designations Definitions

NC Normally Closed (Contact) Contact is closed when not activated (Logic status=1).
Contact is opened when activated (Logic status=0)
NO Normally Opened (Contact) Contact is opened when not activated (Logic status=0)
Contact is closed when activated (Logic status=1)
OOS Operating Override Switch Override (safety by-pass) usually used for start-up
PC Personal Computer
PID Proportional, Integral, Controller parameters
Derivative
PLC Programmable Logic ISA-S5.1 definition:
Controller A controller, usually with multiple inputs and outputs, that
contains an alterable program.
PRM Plant Resource Manager
Reverse Reverse controller acting Measurement increasing gives controller output signal
decreasing
RSP Remote Set Point (cascade, Set point coming from another controller. This set point
etc.) mode is also called “cascade” mode.
RTD Resistance Temperature
Device
SAT Site Acceptance Test
SGS Safeguarding System Safety system that monitors primary process signals to
initiate alarms and shutdown safety functions and
safeguard the unit.
SIS Safety Instrumentation
System
SIL Safety Integrity Level
SP Set Point
Tracking Set Point Tracking Tracking of the local set point (LSP) to the process value
(PV=measure). It shall be configured to obtain seamless
transfer when shifting controller from manual to auto
mode
Output Tracking Backtracking of the remote set point (RSP) in a cascade
control loop. It shall be configured on the secondary
controller to obtain smooth changeover from manual/auto
mode to remote mode.
UPS Uninterruptible Power Supply Means which allow the electrical back-up in case of main
power supply failure
V AC Volt Alternating Current
V DC Volt Direct Current
VDU Video Display Unit.
PROJECT NBR: C.57506 013-902
Rev. 04
CONTROL STRATEGY
3 GENERAL DESCRIPTION
3.1 PROCESS DESCRIPTION:
3.1.1 WARM PART

First, the air goes to the purification unit.
The water vapor and carbon dioxide and heavy hydrocarbons contained in the compressed air are adsorbed
on activated alumina and molecular sieve.
The purification unit consists mainly in two vessels (R01 and R02). One is in adsorption phase, while the
other is regenerated by counter current circulation of waste gas, returning from the air separation unit.
Each adsorber is automatically sequenced through the following steps:
- Isobaric air purification near the air compressor discharge pressure.
- Depressurization near atmospheric pressure.
- Reactivation of the adsorbent by waste gas circulation in counter current.
- Pressurization near air compressor discharge pressure using purified gas supplied by the other vessel.
PROJECT NBR: C.57506 013-902
Rev. 04
CONTROL STRATEGY
3.1.2 COLD PART (Air separation)

Air is separated into pure nitrogen and waste gas by simple rectification at cryogenic temperature.
The compressed and purified air is cooled down, near its dew point, in heat exchanger (E01), against cold
pure nitrogen and waste gas.
The air is injected in the distillation column (K01). The air is separated into pure nitrogen at the top, and
oxygen rich liquid at the bottom.
The oxygen rich liquid is expanded and sent to the vaporizer (E02).
In the two vaporizers, it is vaporized against a fraction of the pure gaseous nitrogen coming from the top of
the column (K01). This condensed nitrogen is used as reflux for the column.
After vaporization in (E02), the oxygen rich gas is sent to the main heat exchanger (E01), partly warmed up
and then sent to the expansion turbine in order to provide the required refrigeration to the plant. After
expansion the waste gas is heated up in the exchanger and then used for the regeneration of the air
purification.
The pure gaseous nitrogen is withdrawn from the top of the column (K01), and heated up in heat exchanger
(E01).
The pure liquid nitrogen is withdrawn from the top of the column (K01) and is made available at a connection
on the cold box.
3.2 OPERATION MODES:

3.2.1 Start up:
The start up of the plant consists in bringing the plant under normal operation conditions. In this operational
mode: the objective is eventually to bring the plant under cold conditions and to build up the liquid levels
before looking for good Nitrogen purity conditions. The unit is considered “ready to produce” when the
oxygen content in the nitrogen is less than the “ready to start condition” for GAN production.
3.2.2 GAN only:

In this mode, the plant produces only Gaseous Nitrogen under the required purity.
3.2.3 GAN and LIN:

In this mode, the plant produces Liquid Nitrogen and Gaseous Nitrogen. If no Gaseous Nitrogen is
consumed by the network, it would be vented out to atmosphere automatically (see 5.3.1): Liquid Nitrogen
Production only is not possible to fill the storage.
3.2.4 Air purification Exceptional Reactivation:

Exceptional Maintenance operation consists in removing at high temperature the impurities of the adsorbing
beds.
This operation is done the plant being stopped and manually by the operator.
3.2.5 Cold box deriming:

Exceptional Maintenance operation consists in drying up the cold box (all cryogenic liquids being drained
before). This operation is done manually by the operator.
PROJECT NBR: C.57506 013-902
Rev. 04
CONTROL STRATEGY
3.2.6 LIN Storage and Vaporization:

A simultaneous filling & withdrawal of the storage is possible only in case of truck’s filling.
3.2.6.1 Filling
The duration of the complete filling of tank (filled by the NGS) will be approximately five weeks duration.
The operator have to manually start the storage filling which open the inlet valve and set the pressure.
The pressure set-point of the tank being filled-up by the NGS should be decreased to facilitate the liquid
transfer (around 1kg/cm² less).
The filling could be stopped automatically by the high level of the storage.
3.2.6.2 Back-Up
The pressure set-point of the tank (stand-by and ready for vaporization) shall be set approximately at
8.5kg/cm². The network pressure controller should be slightly lower than the NGS production pressure.
NGS has the priority on the backup vaporizer (out of scope).
The vaporization system starts automatically when the pressure network decreases and NGS shutdown.
PROJECT NBR: C.57506 013-902
Rev. 04
CONTROL STRATEGY
3.3 Control Loop List
Manipulated Typical Set Point

Tag Controlled Value Normal Position
Value Value
Auto – Local (forced
Regeneration Gas
PIC261 PV261 0.32kg/cm² jump at absorber switch-
Pressure
over)
10000Sm3/h in GAN
run
FIC630 Cold Box Air Flow FV106 Auto – Remote
10250Sm3/h in LIN
run
3900Sm3/h in GAN
GAN production flow ( to Auto – Local in GAN run
FIC615A FV615A run
network ) Auto – Local in LIN run
3550Sm3/h in LIN run
GAN production flow ( to
FIC615B FV615B 97 % of SP(FIC615A) Auto – Remote
vent )
100% Submersion
LIC614 E02 bath level LV614 Auto – Local
minimum
PIC615 GAN pressure PIC640_SP 9.25kg/cm² Auto – Local
PIC640 E02 pressure PV640 4.82kg/cm² Auto – Remote
Manu – Local in GAN
ET01 Turbine IGV
HIC608 HV608 45% run
position1
Remote 100% in LIN run
ET01 Turbine speed
SIC675 HV608 34400rpm Auto – Local
limiter
Manu 0% (forced
LIC602 LIN production LV452 30% closed) in GAN run
Auto – Local in LIN run
3.4kg/cm² in Filling
mode
PIC821B V50 pressure PV821B Auto – Remote
8.5kg/cm² in Backup
mode
PIC971 GAN network pressure PV971A/B 8.25kg/cm² Auto – Local
FIC971 GAN network flow PV971A/B 3690Sm3/h Auto – Local
TIC974 GAN network temperature PV971A/B 13°C Auto – Local
1
: To manage K01 column level
PROJECT NBR: C.57506 013-902
Rev. 04
CONTROL STRATEGY
3.4 Air Purification unit timers

All process timers useful for the sequence described in §5.2.1 are listed below:
Step Tagname description duration

- Z Adsorption cycle 150 min
2 and 10 Depressurization preset
Timer_Si 9.7 min
time
4 and 12 Timer_Si Heating preset time 34 min
5 and 13 Timer_Si Cooling preset time 76 min
7 and 15 Timer_Si Pressurization preset time 15.4 min
9 and 16 Timer_Si Parallel preset time calculated
i: Step number
Timer_S9 = Z – (Timer_S2 + Timer_S4 + Timer_S5 + Timer_S7 + 60s)
Timer_S16 = Z – (Timer_S10 + Timer_S12 + Timer_S13 + Timer_S15 + 60s)
4 CONTROL DESCRIPTION
4.1 Unit Control Objective
The operator starts the NGS manually. When the normal levels of liquids are reached, the interlocks of the
unit can be reset and activated. When Nitrogen purity is under the ready to start condition, the operator
chooses the production mode (GAN only or LIN and GAN) with the production selector HS602S, the GAN
set point FX615S and the unit can deliver to the network.
PROJECT NBR: C.57506 013-902
Rev. 04
CONTROL STRATEGY
4.2 Unit Control Strategy

The scheme below shows links between sub-functions due to interlocks.
S: Shutdown
U: Unload
PROJECT NBR: C.57506 013-902
Rev. 04
CONTROL STRATEGY
5 DETAILED CONTROL NARRATIVES:
5.1 AIR COMPRESSOR

5.1.1 MAIN AND AUXILIARY OIL PUMP
The Main Oil pump (MOP) is derived by compressor. The compressor needs at least 25 seconds as
acceleration time, and 35 seconds for the main oil pump to establish adequate oil pressure. If after this
delay, the oil pressure is not sufficient, the auxiliary oil pump could start automatically on oil pressure low
(OPT).
The auxiliary oil pump (AOP) must be in operation before compressor C01 start-up in order to reach and
maintain the minimum lube oil temperature on compressor bearings (34°C).
The auxiliary oil pump stops automatically 1 minute after the compressor has been started.
The auxiliary oil pump restarts automatically in case of compressor shutdown (normal stop or trip) and
remain running for hot start availability, while the compressor is energized.
The trip function provides a start permissive interlock and shutdown to the auxiliary oil pump. If the auxiliary
oil pump is already stopped, you cannot start it, and if the auxiliary oil pump is running, the PLC stops it
immediately.
The auxiliary oil pump start-up is interlocked by the lube oil tank level low (LOLS). Until the oil level on the
tank is less than 20% the pump can’t start.
At initial start-up the auxiliary oil pump must be started manually from PLC. Then the PLC logic provides
automatic start-stop when the oil pressure decreases or when the compressor stops.
5.1.2 OIL HEATER
The oil heater (OHR) must be in operation before compressor start-up in order to warm the oil in the tank.
The oil heater operation is interlocked by the oil tank level alarm low (LOLS). This alarm function provides
a start permissive interlock and shutdown to the oil heater. If the level inside the tank is less than 50% the
oil heater cannot operate. If the oil heater is already stopped, you cannot start it, and if the oil heater is
running, the PLC stops it immediately.
The normal operation of the oil heater is controlled by a temperature control (OTS). Two temperature
setpoint are provided on PLC to control the oil heater operation, a low setpoint to start it, and the high
setpoint to stop it.
A very high heating element temperature shutdowns directly the heater.
5.1.3 AIR FILTER FAN
The filter fan F01 is a 2-stages inlet filter.

The first stage filter elements can be changed while the compressor is running. The second stage elements
can only be changed when the compressor is stopped.
PROJECT NBR: C.57506 013-902
Rev. 04
CONTROL STRATEGY
5.1.4 COMPESSOR READY TO START
The compressor C01 is ready to start if all the trip functions have been reset, if the 3 minutes restart time is
completed, the main motor is available, the lube oil temperature is greater than 34°C, and the compressor
is stopped.
Operation procedure to reset all trip functions:
The level on the oil tank must be greater than 50% in order to have the oil heater in operation to warm the
oil in the tank.
The instrument air must be available to reach the minimum seal air pressure (SAPT) in order to be able to
start the auxiliary oil pump (AOP).
The auxiliary oil pump must be in operation in order to reach the nominal lube oil pressure and warm the oil
on the compressor bearings. The IGV shall be fully closed and blow-off valve UCV fully open.
Every time that the compressor stops, a 3 minutes timer is enabled to prevent the immediately restart of
the compressor. This function is provided, to prevent a possible start-up of the compressor if the main motor
is not completely run-out.
5.1.5 COMPRESSOR START/STOP
When the compressor C01 is ready to start and selected in local mode operation, it can be started from
compressor skid local panel by local start push button.
When the compressor is ready to start and selected in remote mode operation, it can be started from PLC
by remote start command.
When the running feedback contact has been received the compressor is running.
When the compressor is stopped the IGV valve is fully closed and the blow-off valve UCV is fully open.
When the compressor starts the IGV valve opens at the minimum pre-defined percentage value in unload
condition.
The blow-off valve still remains fully open.
After a time of 1 minute, during which compressor acceleration is accomplished and main oil pump (MOP)
is successfully derived by compressor, the auxiliary oil pump (AOP) stops and the compressor LOAD
automatically after 17 seconds in AUTOLOAD mode.
In local mode operation, the compressor can be stopped from compressor skid local panel by local stop
push button.
In remote mode operation, the compressor can be stopped from PLC by stop command.
When the compressor stops, the auxiliary oil pump restart immediately and the IGV valve closes. The blow-
off valve UCV is fully opened by automatic action.
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CONTROL STRATEGY
5.1.6 COMPRESSOR LOAD/UNLOAD
When the compressor C01 is running more than 17 seconds and selected in local mode operation, it can
be loaded from compressor skid local panel by local start push button.
The inlet cold box flow is controlled by FIC 630 acting on the inlet guide vanes (IGV). The objective of this
controller is to maintain a constant flow to cold box and adapt IGV opening to production needs.
The blow-off valve ensures minimum flow through the compressor and its safe operation in all conditions
and so that the compressor does not operate in surge conditions which is detrimental to the machine.
Anti-surge controller opens blow-off valve during unstable situations and prevents the machine from
approaching its maximum admissible pressure. The set point must to be set under the PSV 105 value.
5.1.7 COMPRESSOR ANTI-SURGE
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CONTROL STRATEGY
Legend:
- (A): Air Pressure Set point
- (B): Surge Limit (Control Line)
- (C): Minimum Stable Operating Range
- (D): Surge Point
- (E): Minimum Flow
- (F): Maximum Stable Operating Range
- (H): Surge Line Bias
- (I): Surge Line
- (J): Pressure Cap Level
After the PLC is commanded to load, the compressor pressurizes the air system. Once Air Pressure Set
point (A) is achieved, the IGV throttles the airflow into the compressor to maintain the desired compressor
system pressure. As long as the process demand for compressed air remains at or below the full capacity
of the compressor, the IGV will automatically open and close to allow the correct airflow through the
compressor required to satisfy the Air Pressure Set.
Since the constant pressure control method has the characteristic of never unloading the compressor, it is
possible to maintain a uniform compressor discharge pressure while satisfying any process demand. The
modulating blow off valve UCV will remain closed so long as the process requirement is above the surge
limit (B) of the compressor or the pressure rises above the pressure cap level (J). If the process demand
falls below the minimum stable operating range (C) of the compressor, the modulating blow off valve will
open and close as required to vent excess compressor capacity. The process of coordinating the positions
of both the IGV and modulating UCV ensures the sum of the airflow delivered to the process and venting
to atmosphere will always be equal to (or greater than) the compressor’s minimum stable operating point.
A pressure cap set point is used to temporarily limit the discharge pressure if there is process disturbance.
The pressure cap limit does not protect equipment and pipe limitations. The pressure cap is used to limit
pressure excursions to the process. If the discharge pressure rises above the pressure cap level (J), the
blow off valve will open to attempt to bring the pressure down to the set point level.
The PLC uses this blow-off type control to protect the compressor from surging during periods of low
process demand. If the compressor operating parameters should approach the surge point (D), the control
system will transmit a signal to open the modulating blow off valve in order to maintain an air flow through
the compressor that is above the surge limit. This is the Minimum Flow (E). The PLC based on the machine
discharge pressure and the slope of the surge limit continuously calculates the Minimum Flow.
The surge limit line is determined when the machine is commissioned by performing two surge tests. The
pressure and flow are determined experimentally at a given pressure. This pressure and flow are entered
as Surge Press 1 and Surge Flow 1. A second surge test is performed at a lower pressure producing Surge
Press 2 and Surge Flow 2 set points. Given these two points, the PLC calculates the surge limit line as a
straight linear line. The Surge Line bias (H) is added to provide a small safety margin from the true machine
surge points to control to. The surge line bias is set to 5% but is field adjustable in the PLC depending on
process demands.
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CONTROL STRATEGY
5.2 AIR PURIFICATION UNIT

5.2.1 AIR PURIFICATION SEQUENCE
5.2.1.1 Objective:
The goal of the air purification stage is to remove from the compressed air the components (water, dioxide
carbon, hydrocarbons…) which are present in the air and which could accumulate at cryogenic temperature
and produce perturbation on the process.
5.2.1.2 Functional description:

The purification of the air is done thanks to two vessels containing alumina bed and molecular sieve bed.
These two vessels are used successively: when a vessel is in use, the other is in a regeneration phase.
The air purification process is completely sequential and a set of valves permits the flow of air from the
compressor to the cold box (purification) or flow of oxygen enriched gas (waste gas) from the cold box to
the vent (regeneration).
5.2.1.3 Operational aspects:

5.2.1.3.1 Operational modes
There are two operating modes:
• “Automatic mode”, each purification step is automatically activated when the last step is complete;
• “Manual mode”, the transition of all steps requires the validation of the user.
• “Exceptional regeneration”: usable only for maintenance when the unit is stopped; to activate this
mode, use the button HS200E when you are in manual mode (Not HL 200A). Please refer to 5.2.8
for more details on the exceptional regeneration.
In automatic sequence, timers are used for each step and have constant time duration. The timer settings
are based on the worst design case for the air purification unit to guarantee that the sequence will switch in
time to regeneration before saturation has been reached.
In manual mode, the operator should use the button HS200B to go to next step when all conditions are
fulfilled (HL 200B is ON).
The two operating modes can be selected at any time by the operator by the hand switch HS200A on the
HMI.
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5.2.1.3.2 Start-up
The adsorbers’ pressurization must be done carefully so as not to disperse the alumina and molecular sieve
beds. To manage this specific step, please refer to the air flow control §5.3.3.
You should select the on line vessel with HS 200S and initialize the sequence with the button HS 200I.
5.2.1.3.3 Normal Steady State

The following paragraph will describe the different steps of one of the two purification vessel R01 or R02.
The sequence (cf. Figure 1) is strictly identical for the two vessels and fully automatic. The complete cycle
includes, for each vessel, adsorption and reactivation steps 11 to 18 for the first vessel (steps 19 to 26 for
the second).
A typical value is between 120 to 150 minutes for a complete cycle on each vessel (refer to table 3.4).
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Figure 1
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The duration of the regeneration is equal to the purification period. It means that the two sequences of the
two vessel are shifted by half the total duration of a cycle, that means R02 is “on line” following step 1, R01
is reactivated during step steps 11 to 19, and R01 is “on line” following step 19, R02 is reactivated during
step 19 to 26.
The table below permits to see the state of the valves during all the air purification cycle.
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
KV230 C C C C C C O O C C C C C C O O
KV210 C C C C C C C O O O O O O O O O
KV220 O O O O O O O O C C C C C C C O
KV215 C C O O O C C C C C C C C C C C
KV225 C C C C C C C C C C O O O C C C
KV216 C O C C C C C C C C C C C C C C
KV226 C C C C C C C C C O C C C C C C
Timer 20s S1 20s S4 S5 20s S7 S8 20s S10 20s S12 S13 20s S15 S16
Table 1
C: Closed
O: Open
5.2.1.3.4 Fallback Strategy

In case of trouble, the operator could decide to put in manual mode with HS200A and use the button
HS200B to go to next step manually or HS200C to override conditions and go to the next step without
condition.
5.2.1.3.5 Shutdown / Abnormal conditions

The shutdown causes are listed in the document 013-901 Causes and effects.
If an alarm occurs on the HMI and you have 15 minutes to try to correct the problem and acknowledge
through the button HS200D to reset the fault.
Event: Action Operator Action

Heat peak missing (UA 213A and UA
Alarm only Increase heating time
223A)
Cooling too long (UA 213B and UA
Alarm only Decrease heating time
223B)
5.2.1.3.6 Interfaces with other Control or Safeguarding Functions

N/A
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CONTROL STRATEGY
5.2.1.4 Design and Implementation Aspects:

5.2.1.4.1 Calculations
N/A
5.2.1.4.2 Initializations
At the first start-up, the operator should initialize the sequence (HS 200I) and select the vessel 1 or 2 with
HS 200S.
5.2.1.4.3 Special Considerations

In manual mode (not HS200A), the operator should use the button HS200B to go to the next step. A
dedicated view indicates to the operator the transition and the on going step. The sequence in manual mode
is the same than previously.
5.2.1.4.4 Implementation Details

Refer to functional diagrams
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5.2.2 ADSORBERS PRESSURIZATION: KY230

5.2.2.1 Objective:
Before the end of the adsorption cycle, and after the regeneration of the vessel, the pressure should be
balanced between the vessels. This operation will be done automatically during the sequence at the step
“PRESSURIZATION” (Step 17 or 25). This step is important to avoid disturbances on the distillation process
and insure a continuous air flow to the cold box. Furthermore, to avoid fluidization of the molecular sieve,
the pressurization should be controlled.

A “3 step ramp” controller KY230 manages the opening of the valve KV230 during the step 17 or 25 of the
purification sequence. This specific controller is defined by 3 times and 3 opening values to establish the
following opening curve.
Parameters Ix and Tx are set by the start-up specialist during the commissioning.
In the example below, during the first step of 160 seconds the valve will ramp from 0% to 50%; during the
second step of 180 seconds, the valve will ramp from 50 to 70%.
Controllers Action Final Element / Fail position

KY230 DIRECT KV230 / FC
This control is in automatic only during the pressurization phase of the sequence (step 17 or 25).
In all the other case, this control is switched off.
No manual intervention is required in this sequence
5.2.2.3.2 Start-up
N/A
N/A
PROJECT NBR: C.57506 013-902
Rev. 04
CONTROL STRATEGY

Malfunction Automatic Action Operator Action
Check KV230 / Increase or decrease the
See IN 4 Sequence stop
pressurization time
N/A
N/A

N/A
N/A
N/A
Refer to the functional diagram.
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CONTROL STRATEGY
5.2.3 WASTE GAS TEMPERATURE CONTROL: TX233

5.2.3.1 Objective:
To regenerate correctly the adsorbers, the waste gas from the distillation column should be warmed up to
reach the minimum required temperature. This temperature should be maintained during all the heating
phase for each adsorber.
Air
Vessel 1
Heating Cooling
pressure
Adsorption time
Regeneration
WN2
Vessel 2
Heating Cooling
pressure
time
Air

The temperature (TI233) at the delivery of the electrical heater E08 is maintained by temperature
transmitter. The electrical heater is composed of 2 circuits; the first heater supplies continuously 2/3 of the
power (always ON when heating is required) and the second (supplies 1/3 of power) is switched ON and
OFF, according to the delivery temperature.

TX233 DIRECT EY238B/US238B / FC
This control is in automatic only during the heating phase of the sequence.
In all the other case, this control is switched off.
The operator has only access to the temperature set point and the duration of the heating step. No manual
intervention is required in this sequence
5.2.3.3.2 Start-up
N/A
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CONTROL STRATEGY

N/A
TI233 faulty
No heating; alarm Check faulty thermocouple
thermocouple
N/A
N/A

N/A
N/A
This controller is discrete hysteresis controller.
Refer to the functional diagram.
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5.2.4 COLD BOX BYPASS CONTROL: HIC240

5.2.4.1 Objective:
The purpose of this loop is to let the Air Purification Unit work while the Cold Box is shut down or not running
(i.e. no flow going to the cold box and no flow coming back). Indeed, some flow is needed for the
regeneration of the adsorber beds. This bypass would allow a substitution to the Waste Oxygen that
normally comes from the Cold Box.
This loop is fully manual. The control of the valve has to be done by the operator around 40%, only during
start up or exceptional regeneration of the adsorber beds.

HIC240 DIRECT HV240 / FC

N/A
5.2.4.3.2 Start-up
Once the unit is pressurized, the regeneration cycle has to be started or resumed. For that purpose, the
flow through the heater shall not be in low alarm. The alarm can be cleared opening the bypass valve to
feed the heater with some air.
In normal operation, this valve shall be fully closed by the interlock IN 4.
N/A
When the Air purification shuts down this valve is automatically closed.
N/A
N/A
N/A
N/A
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5.2.5 REGENERATION PRESSURE CONTROL: PIC261

5.2.5.1 Objective:
The waste oxygen that comes back from the Cold Box is either vented out to the atmosphere, either sent
to the air purification unit in order to regenerate the adsorbing beds. The PIC261 adjusts the pressure for
the regeneration heater so that during the regeneration steps (blowing, heating, cooling steps) enough flow
is sent to the heater and the purification vessel to perform the regeneration properly.
The operator gives a set point to the controller from the HMI. The set point is defined by the process
calculation to obtain enough flow to the vessel during the regeneration. The pressure of the waste oxygen
downstream the expansion turbine will then be controlled by adjusting the opening of the valve PV261.
This control shall always remain in automatic mode.
Note that this pressure is the discharge pressure of the expansion turbine. If this pressure is decreased,
maintaining the inlet pressure of the turbine constant, the expansion will be pre-dominant. As a
consequence, the speed of the turbine should increase and its discharge temperature should decrease.

PIC261 DIRECT PV261 / FC

N/A
5.2.5.3.2 Start-up
This controller should be in automatic from the start up of the APU.
This controller should be in automatic from the start up of the APU.
Malfunction Automatic Action
Operator Action
Check faulty transmitter
Freeze the controller Eventually adjust opening of the valve to the flow
PT261 faulty
output at last good PV going through the heater in case the regeneration
transmitter
Value is going on / check the speed of the turbine
otherwise.

This controller is switched in automatic mode when the cold box is stopped (IN 5).
In case of very high pressure PAHH 261, the unit is stopped. You should check the valve PV261 and the
controller settings PIC261.
N/A
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CONTROL STRATEGY

N/A
N/A
This controller will have a specific output depending on the step of the Air Purification Unit cycle:
• During regeneration steps (blowing, heating and cooling steps) most of the flow goes to the
regeneration heater: the vent valve PV261 tends to close. At the beginning of the blowing step, the
controller will be “helped” to close the valve by a jump of a given value adjustable by the engineer
(value to be set at start up, around 20%). This action enables to force the flow to the heater and
adsorbing vessel and limiting the pressure fluctuation.
• During switching steps (isolation LP, pressurization, parallel, isolation HP steps) most of the flow is
vented out to the atmosphere: the vent valve PV261 tends to open. At the isolation Low Pressure
step, the controller will be “helped” to open the valve by a jump of a given value adjustable by the
engineer. This action enables to force the flow to the vent and limiting the pressure perturbation.

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CONTROL STRATEGY
5.2.6 CO2 ANALYZER: AI242

5.2.6.1 Objective:
Avoiding breakthrough of CO2 content downstream of the purification unit.
A CO2 breakthrough may also indicate breakthrough of other impurities, such as hydrocarbons. The ingress
of these impurities into the cold box may lead to plugging of passages of vaporizers and accumulations of
hydrocarbons which may in turn result in local or even major explosions
Bed Height
t = 100 min
Adsorbed
quantity
t = 20 min
0
500 400 300 200 100 0 0 1 2 3 4 5
CO2 (ppm) Adsorbed quantity
Molecular sieve will be more and more saturated by the CO2 during the adsorption phase. If the CO2 goes
to the exchanger and cold box, there will be some CO2 ice plugs inside.

An analyzer installed on the purification skid monitors the CO2 value all the time (at each step of the
sequence).
An alarm is activated if the level reaches 1 ppm. The purification (IN 4) is stopped if the level reaches 3 ppm
during 15 minutes.

None

When the analyzer is in calibration mode (HL242), the alarm and trip are inhibited during this manual
operation.
5.2.6.3.2 Start-up
The analyzer should be calibrated before the start-up of the unit.

No calibration alarm (HL242)
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CONTROL STRATEGY

AI242 faulty Check faulty transmitter
Alarm on the HMI
signal Eventually make a new calibration (over range)

If the level of CO2 reaches 3 ppm during 15 minutes, the purification unit is stopped (Refer to IN 4 in 013-
901) and of course the cold box. In the operation manual, it is recommended to realize an exceptional
regeneration.
An increase of the pressure difference between PT202 and PT615 could be a good indication of the
plugging of the exchanger and or the column. In this case, refer to the operation manual to make a complete
deriming of the unit.

N/A
N/A
N/A
N/A
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CONTROL STRATEGY
5.2.7 INSTRUMENT AIR PRODUCTION IN 86:

5.2.7.1 Objective:
Each Nitrogen generation unit is able to produce its instrument air thanks to the air purification module. Until
the unit is not started or in case of troubles, the unit needs to have a backup air instrumentation feed. The
selection between each feed is made by this function.

A pressure transmitter monitors the air instrument network. When the pressure PT050 is under the minimum
value of 4.6kg/cm², the valve PY053 opens and the PY052 closed.
When the purification is started, the unit produces enough air and the valve PY053 close automatically
when the pressure reaches 5.1kg/cm².

None

N/A
5.2.7.3.2 Start-up
The valve PY053 is open and the PY052 is closed until the start up of the purification module. An alarm on
the HMI is activated
The valve PY053 is closed and the PY052 is open; no alarm on the system.

PT050 faulty
Alarm Check faulty transmitter.
transmitter

N/A

N/A
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CONTROL STRATEGY

N/A
N/A
N/A
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5.2.8 EXCEPTIONAL REGENERATION

The exceptional regeneration of the APU adsorbers consists of stopping the NGS and “overheating” the
adsorbent bed with a flow of low pressure air heated to a temperature of 290°C. This is done to remove
hydrocarbons and water which could have been accumulated in the molecular sieve and alumina beds
during normal operation.
The normal period between consecutive Exceptional Regenerations is 3 years but shall be done
immediately in case of repetitive CO2 breakthroughs. If the exceptional regeneration is not done, the
performance of the APU would reduce leading to off-specification air feeding the Cold Box. This would
eventually lead to unsafe operating conditions.
Exceptional regeneration is done to maintain the performance of the Cold Box and keep the operating
parameters close to the design values.
It has to be done thoroughly to ensure a complete regeneration of the adsorbent bed.
The exceptional regeneration is done with process air taken from the other adsorbent bed, using the bypass
valve HV240. Both adsorbent beds have to be exceptionally regenerated in succession.
The air purification unit will run normally with a low flow value (specified in the operating manual) and a
different set point for the electrical heater.
T (°C)
PHASE 1 PHASE 2 PHASE 3 PHASE 4

≈2h ≈2-3h ≈6-9h ≈4-6h
The details of the procedure are indicated in the Operating Manual.
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5.3 AIR SEPARATION UNIT
5.3.1 GASEOUS NITROGEN PRODUCTION FLOW CONTROL: FIC615A/FIC615B:

5.3.1.1 Objective:
The flow produced by the unit (measured across FE615) shall be as constant as possible. Indeed, variations
on the production flow can upset the purity of the gas.
The cold box flexibility is 50% of the cold box design flow, meaning that if the demand of Gaseous Nitrogen
flow is below 50% of the design of the unit, the rest of the flow shall be vented out through FV615B.
Otherwise, between 50% and 100% of the design, the process can be optimized (reducing air consumption).
This optimization is done through the GAN request FX615S. See details in § 5.3.1.4.1.
By default, the unit is in “GAN PRODUCTION” mode until the selector for the LIN mode (HS602S) is off. To
energize the solenoid FY615A please refer to IN 21 for the ready to start condition. The production is started
by the button HSH615 on the HMI.
The FIC615A controls the flow FXI615 acting on the production valve FV615A. The controller is to be
switched in “AUTO” by the operator. If the “GAN PRODUCTION” mode cannot be switched on, the output
of the controller is forced at 0% (valve closed).
The controller is to be switched in “REMOTE” by the operator. In that case, the set point of the controller is
the “GAN REQUEST” given by the operator.
The FIC615B is controlling the flow FXI615 acting on the vent valve FV615B.
The controller is switched in “AUTO” by the operator. The controller is switched in “REMOTE” by activating
the “GAN PRODUCTION” on. In this case the set point given to the controller FIC615B is the “GAN
REQUEST” FX615S minus a dead band given by the operator (~3% of the GAN set point). This prevents
the flow from decreasing too much when the production decreases.

FIC615A REVERSE FV615A / FC
FIC615B DIRECT FV615B / FC

Note that the GAN flow available is different when producing LIN.
5.3.1.3.2 Start-up
In order to set the GAN production, the purity has to be good. If the purity is not good, the flow shall be
vented out through FV615B. The flow controller FIC615B can be set in auto at the minimum turndown value.
The air flow can be the full design (100% of the nominal air flow) in order to be in excess of Nitrogen in the
column.
Once the good purity is reached, “GAN PRODUCTION” HSH615 can be started and the production valve
FV615A would be ramp up slowly automatically until to reach the controller set point. The vent valve should
PROJECT NBR: C.57506 013-902
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CONTROL STRATEGY
be closing slowly automatically in the same way. If more flow is needed, increase the “GAN REQUEST”
FX615S slowly.

Although the column can adapt to the low consumption conditions (turn down capacity of the plant), the
reaction of the column is slow (a few minutes). When consumption profiles are unpredictable, it is best to
vent temporarily the excess GAN rather than to change all distillation parameters.
The Gaseous Nitrogen flow shall not be lower than the minimum turndown value.

Freeze the controller Check faulty transmitter
FT615 faulty
output at last good PV Eventually adjust opening of the valve to the
transmitter
Value pressure of the unit.
Freeze the controller
PT615 faulty Eventually adjust opening of the valve to the
output at last good PV
transmitter orifice plate transmitter value comparing it to the
Value
previous values.
TT615 faulty
output at last good PV Check faulty PT100
PT100
Value

N/A
N/A
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CONTROL STRATEGY

Calculation of the corrected flow from orifice plate FE615, air inlet temperature TI615 and Inlet pressure
PT615:
PI + atm T0
FXI = K ⋅ ⋅ ⋅ FT
P0 TI + 273.15
K,T0, P0: constants defined by process.
FXI is the corrected flow FXI615

PI is the pressure of the GAN produced PT615
TI is the temperature of the GAN produced TI615
Calculation of the remote set point of the flow controller in GAN mode:
FIC 615 A _ RSP = FXI × EXTRACTION _ RATIO
FIC 615 B _ RSP = FIC 615 A _ SP − DEAD _ BAND
FIC 615 A _ RSP = Remote set point of the controller FIC615A

FIC 615 B _ RSP = Remote set point of the controller FIC615B
EXTRACTION RATIO = Capacity of the column to extract the Nitrogen
DEAD_BAND = gap between the set points of production flow controller and vent flow controller (~3% of
the GAN set point).
N/A
N/A
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5.3.2 GASEOUS NITROGEN PRESSURE CONTROL: PIC615 / PIC640

5.3.2.1 Objective:
This function enables to deliver the nitrogen at the desired pressure.
A decrease in pressure in the vaporizer E02 is directly related with a decrease in Gaseous Nitrogen
production pressure through the condenser vaporizer efficiency (linked to the temperature difference).
The GAN pressure is controlled by the PIC615 adjusting the set point of the PIC640 to control the opening
of the turbine by-pass valve PV640. This control has a direct effect on the pressure in the vaporizer E02.
If the pressure PT615 decreases, the PIC615 increases the set point of PIC640. This reduces the opening
of the by-pass valve PV640 and so to increase the vaporizer pressure PT640 for a fixed Inlet Guide Vane
of the turbine.
In the opposite way, if the pressure PT615 increases, the PIC615 decreases the set point of PIC640. This
will increase the opening of the by-pass valve PV640 and to reduce the vaporizer pressure PT640.

PIC615 REVERSE Set Point of the PIC640 / last value
PIC640 DIRECT PV640 / FC

N/A
5.3.2.3.2 Start-up
Before the cold box start-up, the plant operator must check that the PIC640 is in auto mode with the correct
set point (Typical remote set point = 4.4kg/cm²).

During the normal steady state, the controller PIC615 described above is in automatic mode, whereas the
PIC640 is in automatic and remote mode.
The opening of the by-pass valve PV640 should be between 10% and 90%.
PROJECT NBR: C.57506 013-902
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CONTROL STRATEGY

PT615 faulty
output at last good PV Check faulty transmitter
transmitter
Value
PT640 faulty
output at last good PV Check faulty transmitter
transmitter
Value
When the output of the controller PIC640 reaches 0%, it means it can’t maintain the vaporizer pressure
E02. To solve this problem, it’s possible, either to reduce the opening of the expander inlet guide vanes or
to reduce the set point of the controller PIC640.
When the output of the controller PIC640 reaches 100%, it means it can’t control the vaporizer pressure
E02. To solve this problem, it’s possible, either to increase the opening of the expander inlet guide vanes
or to increase the set point of the controller PIC640.
After a shutdown of the cold box, the controller PIC640 is maintained in automatic with the last set point
value. The pressure in the vaporizer is controlled to restart the cold box quicker.
The solenoids PY640 and KY651 are not energized as long as the temperature probe TT625 reads a lower
value than -20°C. As the valve PV640 is failure closed, it would close.

N/A

N/A
The set point of the controller PIC640 should be in the predefined range.

To avoid bump or bad adjustments, the rate of PIC615’s output should be set at the same value than the
integral time of the PID controller PIC640.

PROJECT NBR: C.57506 013-902
Rev. 04
CONTROL STRATEGY
5.3.3 AIR FLOW TO COLD BOX: FIC630/HIC630

5.3.3.1 Objective:
The objective is to maintain a steady distillation flow despite the possible upsets within the process. The
control of the air flow is made acting on the inlet valve of the air purification unit.
In parallel, when the air is supplied by an air network, we should avoid a too high pressure in the air
purification.
The amount of Nitrogen available for production depends directly on the amount of air entering the unit. In
order to maintain this air flow constant the flow controller will adjust the flow valve opening according to the
flow entering the cold box. The set point can be locally given by the operator. It can also be remotely
calculated according to the “GAN request” given by the operator FX615S.

FIC630 REVERSE FV630A/B / FC
HIC630 DIRECT FV630A/B / FC
The air flow to the cold box is corrected with pressure and temperature measures to have a flow value in
Nm3/h from an orifice plate.
To limit and control manually the IGV opening the HIC630 controller will be used. The lowest value between
both controllers is selected to be applied to the valve FV630.

A switch on the HMI (HS602S) shall enable the operator to select either of the two production modes. They
will change the remote set point given to the flow controller.
5.3.3.3.2 Start-up
To slowly pressurize the unit, the HIC630 will ramp up slowly his set point from 0 to IGV nominal position.
This will enable to avoid critical speeds and attrition in the adsorber beds. The flow can then be increase
slowly to achieve the design flow.
Once the unit has reached its design, the flow controller can be set in remote control. Its set point would be
calculated to be optimized to the “GAN request” (FX615S) given by the operator.

During normal steady state, the controller FIC630 described above is in AUTO/REMOTE.
PROJECT NBR: C.57506 013-902
Rev. 04
CONTROL STRATEGY

FT630 faulty
transmitter
Value
previous values.
TT630 faulty
output at last good PV Check faulty PT100
PT100
Value

Upon shutdown of the Cold Box IN 5 the output of the controller FIC630 is forced to minimum opening
(typical: 15-20%).
If the valve is a 100% opened and that the nominal flow is not reached, the operator shall check the pressure
map of the system: there might be a blocking point in the process.

Calculation of the remote set point is made in § 5.3.1.
PROJECT NBR: C.57506 013-902
Rev. 04
CONTROL STRATEGY

Calculation of the corrected flow from orifice plate FE630, air inlet temperature TI630 and Inlet pressure
PT202:
PI + atm T0
FXI = K ⋅ ⋅ ⋅ FT
P0 TI + 273.15

PI is the pressure of the air PT202
TI is the temperature of the air TI630
Calculation of the remote set point of the flow controller in LIN mode:
SP615S
FIC630 _ RSP =
Extraction _ RatioLIN _ mod e
FIC 630 _ RSP = Remote set point of the controller FIC630
SP615S = GAN requested by the operator FX615S
N/A
A selector HY630 will automatically apply the lowest outlet of both controllers.

Refer to functional diagram
PROJECT NBR: C.57506 013-902
Rev. 04
CONTROL STRATEGY
5.3.4 TURBINE INLET GUIDE VANES CONTROL: HIC608 / SIC675

5.3.4.1 Objective:
The turbine produces the cold for the thermal balance of the unit. This cold production is a direct function
of the flow of the turbine and this flow could be manipulated by the inlet guide vane (IGV) FV608. To optimize
this cold production, the operator should tune manually the valve on oil brake FCV672 (manual valve). This
operation is done at the first start-up only.
To protect the machine against high speed, a speed controller will limit the risk of trip by limiting the IGV
position.
When you need more cold production, you should increase the flow through the turbine with the HIC608
which will increase the liquid in the column.
In the other side, when you increase the flow, you could increase the speed of the turbine. The speed
controller SIC675 will decrease the IGV when the speed will became too high. A low selector HY608 will
manage this selection (low pass-band)

HIC608 DIRECT FV608 / FC
SIC675 REVERSE FV608 / FC

Both controllers should be in automatic mode.
5.3.4.3.2 Start-up
The speed controller SIC675 should be in automatic.
The operator should increase manually the IGV through the HIC608 in manual mode or in automatic with
the ramp.
During the first start-up, the oil brake could be set manually by the valve FCV672 (manual valve) to
maximize the liquid production.

SIC675 should be in automatic..
PROJECT NBR: C.57506 013-902
Rev. 04
CONTROL STRATEGY

ST675 faulty The controller output at
Check faulty transmitter.
transmitter 0%; Trip turbine
5.3.4.3.5
The turbine will be tripped in case of very low or very high speed.
Refer to IN 11 in causes and effects documents 013-901.
If the level decreases too much (LAL602) you should maximize the IGV position with the HIC608.

N/A

N/A
The set point of the speed controller will be tuned on-site between the nominal speed value and alarm
value.

The low selector HY608 enables to select the minimum value from controller and manual value.

PROJECT NBR: C.57506 013-902
Rev. 04
CONTROL STRATEGY
5.3.5 LIN PRODUCTION CONTROL: LIC602

5.3.5.1 Objective:
The objective of this loop is to produce liquid nitrogen without bringing any disturbance to the plant. Only
the excess liquid produced will be produced to the storage and the unit should continue to produce some
GAN to assure the purity.
This controller is active when the plant is switched on ‘LIN run” from the HMI by the operator through
HS602S. It will adjust the level in the sump of the distillation column K01 acting on the outlet LIN pump
valve LV602.
Note that the level that is controlled is the sump of the distillation column K01 and that the production takes
place on top of the column just below the condenser E02. This implies a dead time on the response of the
loop. The controller shall have a fairly low speed/sensitivity.

LIC602 DIRECT LV602 / FC

This control is only used in LIN production mode.
The cold production from the turbine shall be maximized: the IGV of the turbine can be opened until the
opening of by pass valve PV640 is around 10% to maintain the pressure control PIC640 effective.
5.3.5.3.2 Start-up
During start up of the plant, this control shall not be used.
By switching the unit under “LIN Production” mode, the system will first purge the production line opening
the valve KV633 for a given time. Then it will set the level controller LIC602 in automatic. The operator has
to make sure that the set point is correct.

The level at the sump of K01 is disturbed by the Hydrocarbon purge sequence (refer to IN 29 and KV603).

Freeze the controller output at last
LT602 faulty Check faulty transmitter to restart
good PV Value
transmitter the unit
The unit shuts down
5.3.5.3.5
When the unit shuts down, the controller is forced in manual and the output is set at 0%.
PROJECT NBR: C.57506 013-902
Rev. 04
CONTROL STRATEGY

N/A
N/A
The controller would keep the last set point given by the operator.

N/A
PROJECT NBR: C.57506 013-902
Rev. 04
CONTROL STRATEGY
5.3.6 COLUMN PURGE: KV623 / IN15

5.3.6.1 Objective:
The objective of this valve is to drain all liquid manually for maintenance reason through HS623 or to reduce
the level of the column LI602.
This function could be useful to restart the unit (no LAH602)
The operator can open the purge valve manually from the HMI but the system would close it automatically
after a time delay (10 min).
If the level in the column K01 reaches the high switch level (LSH602), the valve will be opened until the
level decreased under the switch.

None DIRECT KV623 / FC
N/A
5.3.6.3.2 Start-up
This valve should be closed.
This valve should be closed.
N/A
After a shutdown of the plant, a lot of liquid accumulates at the sump of distillation column. As a
consequence, the purge valve is most likely going to be opened manually by the operator.
N/A
N/A
N/A
N/A
PROJECT NBR: C.57506 013-902
Rev. 04
CONTROL STRATEGY
5.3.7 VAPORIZER CONDENSER SUBMERGENCE CONTROL: LIC614

5.3.7.1 Objective:
The term "bath-type vaporizer" defines any exchanger of air separation units immersed in liquid containing
more than 30 % of oxygen. The hydrocarbons in solution with the oxygen into the passages concentrate
progressively, as an increasing part of oxygen is vaporized. In such case, deposits of solid hydrocarbons
may build up in the passages. When the liquid level of the bath is below a specific level, the liquid vaporizes
completely as it flows up the passages. This phenomenon is called "dry vaporization" and should be avoided
as much as possible.
W a s te G a s
V a p o r iz e d R ic h L iq u id
TOTAL
LT
614 IM M E R S IO N
E02 LT
EXCH ANGER 601
R IC H L IQ U ID
BATH
L IN =
G AN GAN
L IN R e f lu x
OUTPUT
OUTPUT R ic h L iq u id
R ic h D r a in
H liq
y d ruo id
ca rb o n
t o K V 6 0 3 v a lv e
As the liquid level increases, not all of the liquid oxygen vaporizes as it flows up the passage and thus liquid
recirculation sets in once again.
Bath-type vaporizers must be immersed 100%, i.e. the liquid level of the bath must reach the upper end of
the vaporizer.
Special attention should be paid to the liquid level LI614 in the bath type vaporizer E02 and the hydrocarbon
deconcentration valve KV603 (refer to §5.3.8) because a malfunction can have serious consequences (risks
of explosion).
PROJECT NBR: C.57506 013-902
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CONTROL STRATEGY

To maintain the level in the vaporizer condenser, the rich liquid flow from the column will be manipulated
by the level controller LIC614.

LIC614 DIRECT LV614 / FC

N/A
5.3.7.3.2 Start-up
The controller will be let in manual mode 100% (full opening of the rich liquid valve) at least during warm
start-up and until liquid level will reach the nominal values (100% more or less).
The cold box is off and the operation override (OOS) for the trip is on (HL 600).

The 100% immersion of the core can be easily and periodically checked, by opening the corresponding
valve (VE02A). The follow up of liquid at this gauge level gives the evidence that the core is fully immersed;
refer to the operation manual to have this procedure.
In this condition the set point of LIC614 controller should be always set to 100% and in automatic local
mode.
The cold box is on and the operation override (OOS) for the trip is off (HL 600).

LT614 faulty Check faulty transmitter and adjust the opening
Value
transmitter of the valve manually to maintain the level
Trip after one hour
delay

A low level threshold corresponding to a 90 % immersion of the core activates an alarm alerting the operator.
One solution is to increase the liquid production by acting on the turbine (see §5.3.4).
A very low level threshold corresponding to 80 % immersion of the core induces, after a sixty (60) minutes
period, the shutdown of the installation (IN 5).
This safety protection is override during the start-up and automatically reset when the cold box is on (HL
600).

N/A
PROJECT NBR: C.57506 013-902
Rev. 04
CONTROL STRATEGY

N/A
N/A

LI614 is calibrated so that it displays the submergence of E02 exchanger body between 70% and 130%.
100% corresponds to the total immersion of the exchanger body and 0% would correspond to the bottom
of the exchanger body.
The settings (maximum range in kg/cm²) of the transmitter LT614 should be in accordance with the initial
design. It is recommended to lock the parameters of this transmitter.
In case of modification, the immersion test enables to check plugs and bad ranges.
The controller is paused at its last value during the activation of purge (opening of KV603)

PROJECT NBR: C.57506 013-902
Rev. 04
CONTROL STRATEGY
5.3.8 VAPORIZER CONDENSER HYDROCARBON PURGE: KV603 / IN 29

5.3.8.1 Objective:
The heat exchanger E02 is a bath type vaporizer. The liquid that is vaporized is rich in oxygen (~40%).
Some hydrocarbons contained in the air can pass through the air purification unit and end up in this bath.
The concentration of these hydrocarbons is to be avoided anytime. If their concentration is too high, a risk
of explosion is taken.
In order to decrease the hydrocarbon concentration in the vaporization bath, a purge sequence is carried
periodically (typically every one hour). A rich liquid amount corresponding to a minimum of 0.2% of the total
incoming air flow has to be purged from the sump of the vaporizer E02. This amount of rich liquid
corresponds to a target level difference during the purge sequence.
At the beginning of the purge sequence, the system records the current level in the column (LI614) and
opens the drain valve KV603. The system closes the valve when:
1. The minimum delay (10minutes) and the targeted level difference (5%) are reached,
2. Or if the maximum duration (20 minutes) is reached,,
3. Or if the low level alarm in the column is activated LAL602.
A successful purge is counted only in the first case.

A counter of successful purges over a sliding period of 24 hours (FX603) is implemented in the system.

This function is used in GAN and in LIN/GAN production mode.
5.3.8.3.2 Start-up
Upon first start-up or after a shut-down of the unit, the purge sequences and the automatic shutdown are
automatically deactivated in order to allow unit start-up.
The sequence is automatically activated when the cold box is activated HL 615.

Sequence always on when the production cold box is activated HL 615.

The button HS603 on the HMI enables to start manually the purge described below. The successful purges
counter could increase by this way.
PROJECT NBR: C.57506 013-902
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CONTROL STRATEGY

An alarm FXAL603 occurs if the counter decreases under the alarm value (typically 22 successful purges
per 24 hours).
If this counter reaches trip value FXALL603 (typically 20 successful purges per 24 hours) continuously
during 24 hours, the unit is shut down.
An indication of the time remaining before the trip KI603 is displayed on the HMI. Furthermore, the alarm
FXALL603 is automatically reactivated every hour to remind the operator that he should purge manually
through the button HS603 and try to increase the counter.
The following curve describes the purge behavior:

N/A
N/A
The timer in the purge sequence is tuned upon the start up of the plant.
When the purge sequence is on going, the level controller LIC614 is frozen (paused) at its last position.
PROJECT NBR: C.57506 013-902
Rev. 04
CONTROL STRATEGY
5.3.9 OIL HEATER TEMPERATURE CONTROL: TSL/TSH690

5.3.9.1 Objective:
To guarantee a good lubrication, the oil temperature should be maintained at a nominal value defined by
the supplier.
The lube oil tank is equipped with an electrical heater controlled by the temperature TI690. When the
temperature is below a threshold, the heater starts and it stops when this temperature decreases under this
value minus a hysteresis.

TSL690 DIRECT EY690 / FC
TSH690 DIRECT NO EY690 / FC

N/A
5.3.9.3.2 Start-up
This control should be always on during operation and start at least half an hour before the turbine start-up.
The heater starts and stops automatically at a frequency depending of the external condition.
N/A
N/A
N/A
N/A
The set point value is given by the turbine’s supplier.
N/A
Refer to functional diagram
PROJECT NBR: C.57506 013-902
Rev. 04
CONTROL STRATEGY
5.3.10 OXYGEN ANALYZER: AI618

5.3.10.1 Objective:
To control the quality of the nitrogen produce by the generator, the easiest way is to measure the oxygen
content in the nitrogen.
An analyzer AI618 is connected to the system through analog signal.
A low value (not ASH 618) is used for the ready to start conditions in the production interlock IN19 and IN
21: You should reach a minimum purity during a certain period of time (3 minutes) to obtain the condition
to start the production (GAN or LIN).

none

N/A
5.3.10.3.2 Start-up
Function not use

The value is under the high alarm ASH 618.

AI618 faulty Check faulty transmitter and calibrate eventually
Production is stopped
transmitter the analyzer

A very high level on this analyzer AAHH 618 would stops the nitrogen production (IN19 and IN 21 refer to
document 013-901).

N/A
PROJECT NBR: C.57506 013-902
Rev. 04
CONTROL STRATEGY

N/A
N/A

This analyzer should be calibrated manually before the start-up of the unit.

PROJECT NBR: C.57506 013-902
Rev. 04
CONTROL STRATEGY
5.3.11 HYDROCARBONS ANALYZER: AI684

5.3.11.1 Objective:
In addition to the hydrocarbon “deconcentration”, a specific device to sample the liquid is installed on the
vaporizer sump: the “vapoflash”. In this device, a portion of liquid is vaporized. This system is designed to
provide a representative proportion of components existing in the liquid of the vaporizer sump.

A specific analyzer dedicated for this device is installed to monitor the hydrocarbons in the rich liquid bath.

None
The alarm AAH684 (125ppm) indicates to the operator that he should purge manually with HS603 to try to
reduce the content in the bath. If this content reaches the high value continuously during 24 hours, then the
unit is stopped (IN 60)
N/A
5.3.11.3.2 Start-up
N/A

No calibration

AI684 faulty
Alarm Check faulty transmitter
signal

N/A

N/A
PROJECT NBR: C.57506 013-902
Rev. 04
CONTROL STRATEGY

N/A
N/A

The analyzer should be calibrated before the start-up of the unit.
During operation and calibration, this analyzer uses hydrogen. If there is problem with this gas supply, the
analyzer is in failure.

PROJECT NBR: C.57506 013-902
Rev. 04
CONTROL STRATEGY
5.3.12 DERIMING OF THE COLD BOX

5.3.12.1 Objective:
The deriming operation consists in taking the Cold Box out of production and heating it to atmospheric
temperature. This is done to melt or vaporize the Water, CO2, and other ambient air molecules, that tend
to build up on the internal surfaces of the column, exchanger and piping within the cold box during normal
operation.
The normal period between 2 consecutive cold box deriming is 3 years. If deriming is not done, this layer
would build up and could clog the different process equipments of the cold box, like heat exchangers,
distillation column, turbine, valves and instrumentation. Deriming is also necessary to ensure the safe
operation of the plant.
Deriming is done to maintain the performance of the Cold Box and keep the operating parameters close to
the design values
Deriming has to be done thoroughly to ensure a complete heat up of the cold box.

Deriming is done by taking dry air from the Air Purification Unit (APU) and passing it through the process
stream. In addition a separate flow of air is heated in the deriming heater E80 and passed to the condenser
in the distillation column to speed this part of the process.
The details of the procedure are given in the Operating Manual.

The heater is locked off when the cold box is off (IN 5) and the control is fully manual.
Refer to the functional diagrams
PROJECT NBR: C.57506 013-902
Rev. 04
CONTROL STRATEGY
5.4 NITROGEN LIQUID STORAGE AND VAPORIZATION

5.4.1 STORAGE PRESSURE CONTROL: PIC 821B and PSL/PSH 821A:
5.4.1.1 Objective:
The pressure inside the liquid nitrogen tank should be controlled during the filling and for normal operation
as backup of the production unit.

When the liquid is consumed by the vaporization system, the level inside the storage will decrease and
consequently the pressure too.
To maintain the pressure, a small amount of liquid is vaporized in the Pressure Built-Up (V50E) and injected
at the top of the tank to increase the pressure. The V50E inlet valve PV 821A opens by a low pressure
threshold (PSL 821A) and closes by a high pressure threshold (PSH 821A).
To facilitate the filling of the storage, the pressure should be lower than the NGS. To decrease the pressure,
the vent valve PV 821B should be opened by the controller PIC 821B.
During the filling, the liquid arrives at the top of the storage (gaseous phase) that increase the pressure.
The first controller (PSL/PSH 821A) enables to maintain the minimum pressure and the second one (PIC
821B) to limit it and to avoid or limit the opening of pressure safety valve.

PIC 821B REVERSE PV 821B / FC
PSL/PSH
DIRECT PV 821A / FC
821A

The operational modes are the following:
• “Filling”: To fill the liquid nitrogen tank from the NGS (Nitrogen Generator System), the liquid
storage inlet should be opened HV 813A. The storage is not available for vaporization to customer
and the outlet valves must to be closed PV 971A/B.
• “Back-Up”: The storage is considered full, the liquid outlet valves PV 971A/B can be opened. The
storage is not available for the filling and the inlet HV 813A is closed.
The pressure set-point of the tank shall be set approximately 0.5kg/cm² above the normal network pressure
(adjustable value). The network pressure controller should be lower than the NGS production pressure.
NGS has the priority on the backup vaporizer.
PROJECT NBR: C.57506 013-902
Rev. 04
CONTROL STRATEGY
5.4.1.3.2 Start-up
N/A
Controller should be in automatic mode with appropriate set point.

Freeze controllers
PT 821B faulty Eventually adjust opening of the valve PV 821B
outputs at last good PV
transmitter manually to avoid PSV opening or low delivery
value
pressure

In case of high high pressure, the system switches automatically the controller PIC 821B in manual mode
with an opening at 100%.
On storage trip PLC 61, the inlet valve HV 813A is closed (refer to document causes & effects).

N/A
None
N/A

The storage filling during the vaporization is allowed only with a truck (PV821C).

Refer to the document functional diagrams
PROJECT NBR: C.57506 013-902
Rev. 04
CONTROL STRATEGY
5.4.2 NITROGEN VAPORIZER PRESSURE CONTROL: PIC 971

5.4.2.1 Objective:
The system should be able to supply gaseous nitrogen when the pressure decreases in the nitrogen
network. The vaporization will be driven by the customer demand which produce a pressure decreasing in
the network.

The controller PIC971 acts on vaporizer inlet valves PV971A/B. When the network pressure PI971
decreases, the controller PIC971 opens the PV971A/B to increase the liquid quality brought to the vaporizer.
This controller is set in automatic mode when the vaporization system starts on operator demand or a low
pressure network (PAL971) or NGS GAN production shutdown (IN 21).

PV 971A/ FC
PIC 971 DIRECT
PV 971B /FC

A split range function is used on PV971A/B.
Typical control used is:
- When the low selector outlet value (PY971A) is between 0 and 50%, it corresponds to 0-100% on
PV971A
- When the low selector outlet value (PY971A) is between 50 and 100%, it corresponds to 0-100%
on PV971B
5.4.2.3.2 Start-up
This controller is in automatic.


Freeze controllers
PT 971 faulty
outputs at last good PV Check faulty transmitter
transmitter
value

In case of trip IN65.1, the controllers PIC971 is forced in manual mode at 0%.

N/A
PROJECT NBR: C.57506 013-902
Rev. 04
CONTROL STRATEGY

None
N/A

N/A

PROJECT NBR: C.57506 013-902
Rev. 04
CONTROL STRATEGY
5.4.4 NITROGEN VAPORIZER FLOW CONTROL: FIC 971

5.4.4.1 Objective:
The flow controller is used for peak shaving control to limit the customer consumption and avoid a pressure
drop on customer network.

The controller FIC971 acts on vaporizer inlet valves PV971A/B via a low selector to limit the opening of both
valves.

PV 971A/ FC
FIC 971 REVERSE
PV 971B /FC

NA
5.4.4.3.2 Start-up


FT971 faulty
transmitter
Value
previous values.
TE974B faulty
output at last good PV Check faulty PT100.
PT100
Value

N/A
N/A
PROJECT NBR: C.57506 013-902
Rev. 04
CONTROL STRATEGY

Calculation of the corrected flow from orifice plate FE971, air inlet temperature TI974B and Inlet pressure
PT971:
PI + atm T0
FXI = K ⋅ ⋅ ⋅ FT
P0 TI + 273.15

PI is the pressure of the GAN produced PT971
TI is the temperature of the GAN produced TI974B
N/A
N/A
PROJECT NBR: C.57506 013-902
Rev. 04
CONTROL STRATEGY
5.4.5 NITROGEN VAPORIZER TEMPERATURE CONTROL: TIC 974

5.4.5.1 Objective:
To limit and avoid low temperature of the vaporized nitrogen sent to the customer network, the temperature
should be controlled to avoid low gas temperature.

To avoid low temperature, a temperature controller TIC974 is used via a low selector on PV971A/B to limit
the opening of both valves.
In order to avoid a trip on low temperature at the outlet of the vaporizer E51 (TALL974) in case of vaporizer
overloading, the temperature TI974A is used by the controller TIC974 to limit the opening of the inlet valves
PV971A/B with a low pass band (P974).

PV 971A/ FC
TIC 974 REVERSE
PV 971B/ FC

NA
5.4.5.3.2 Start-up


Freeze controllers
TE 974A faulty
outputs at last good PV Check faulty PT100
PT100
value

In case of trip IN65.1, the controller TIC974 is forced in manual mode at 0%.

N/A
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CONTROL STRATEGY

None
N/A

N/A


PÁGINA 117 DE 556
4.5. LISTA DE EQUIPOS

El listado detallado de equipos se encuentra en el documento TAL-NIS-PRO-LIS-0001, Ref. [18],
Lista de Equipos, el cual se adjunta a continuación.
PROYECTO DE MODERNIZACIÓN REFINERÍA TALARA UNIDADES
PROYECTO: TAL
AUXILIARES Y TRABAJOS COMPLEMENTARIOS
PÁGINA 1 DE 5 .
LISTA DE EQUIPOS
N° DOCUMENTO: TAL-NIS-PRO-LIS-0001 REV. 00 FECHA: 14/06/2019
LISTA DE EQUIPOS
DOCUMENTO PRINCIPAL
REV. FECHA DESCRIPCION COMENTARIOS
00 14/06/2019 Emisión Para Diseño
ANEXOS
FORMATOS
PREPARADO REVISADO APROBADO
Alberto Pan Brenner Silva Ángel Agudo
única copia controlada de este doc. está en el Sist. Informático de Gestión Documental de COBRA SCL.
PROYECTO: TAL
PÁGINA 2 DE 5 .
LISTA DE EQUIPOS
ÍNDICE
1. OBJETO 3
2. ALCANCE 3
3. DEFINICIONES 3
4. CONTENIDO 4
PROYECTO: TAL
PÁGINA 3 DE 5 .
LISTA DE EQUIPOS
1. OBJETO
El objeto de este documento es presentar la lista de equipos de la Unidad de Nitrógeno para Inertización
(NIS), a ser instalada para el proyecto "Unidades Auxiliares y Trabajos Complementarios, UA&C, que
completa la ejecución del proyecto "Modernización de la Refinería Talara", PMRT, de Petroperú, en Talara,
Perú.
2. ALCANCE
Esta lista presenta los equipos de la Unidad de producción de Nitrógeno para Inertización, la cual se
compone de la "Planta de Nitrogeno" suministrada por un proveedor especializado como unidad paquete,
y los equipos/lineas y requerimientos auxiliares a ser instalados como complemento para garantizar la
operación de la misma.
3. DEFINICIONES
• PROYECTO: Proyecto de Modernización Refinería TALARA / Unidades Auxiliares y Trabajos

Complementarios (también identificado como UA&TC)
b) Los sucesores legales y cesionarios/novados legítimos del EMPLEADOR en el Contrato; y
c) Toda persona que se convierta en Parte del presente en sustitución o conjuntamente con el EMPLEADOR
y los sucesores legales y cesionarios/novados legítimos de dicha persona en el Contrato
Para fines prácticos PETROLEOS DEL PERÚ – PETROPERÚ S.A. (también identificado como “PP”)
• REPRESENTANTE DEL EMPLEADOR (PMC): Se refiere al PMC o a la persona nombrada por el EMPLEADOR
en el Contrato o designada de manera periódica por el EMPLEADOR conforme a la Subcláusula 3.1
[Representante del EMPLEADOR] para que actúe en representación del EMPLEADOR.
• CONTRATISTA: Significa la o las personas designadas como contratistas en el presente Contrato e incluye
a su o sus derechohabientes y cesionarios legítimos.
Para fines prácticos, aquel designado por PETROPERÚ como empresa adjudicataria del Contrato para la
ejecución del Proyecto de Modernización Refinería TALARA / Unidades Auxiliares y Trabajos
Complementarios, CONSORCIO COBRA SCL UA&TC (también identificado como COBRA SCL) o cualquiera de
sus afiliadas, representantes autorizados o sucesoras)
• LICENCIANTE DE PROCESOS: Significa las personas jurídicas que ha suscrito contratos con el EMPLEADOR
para elaborar las licencias de procesos.
• DISEÑO FEED: Se refiere al diseño de ingeniería básica extendida llevado a cabo por parte de Técnicas
Reunidas bajo el Contrato FEED EPC.
• EPC: (Engineering, Procurement & Construction) Fase de Ingeniería Detallada, Adquisiciones y
Construcción (incluye las actividades de Pre-Comisionado/Pruebas, Comisionado, Puesta en Servicio y
Pruebas de Garantía)
Este documento contiene información privada y no puede ser duplicado, modificado o divulgado a terceros sin el consentimiento escrito de COBRA SCL. La única copia
controlada de este documento está en el Sistema Informático de Gestión Documental de COBRA SCL.
PROYECTO: TAL
PÁGINA 4 DE 5 .
LISTA DE EQUIPOS
• ESPECIFICACIONES GENERALES DE LOS TRABAJOS A REALIZAR (MJS: Master Job Specifications) Se

refiere al documento que se adjunta como Anexo 2 al Contrato considerando cualquier adenda y
modificaciones que se haga a dicho documento conforme al Contrato.
• VENDEDOR/VENDOR: Cualquier Proveedor y/o Fabricante de Equipo o Sistemas, contratado por el
CONTRATISTA.
• SUBCONTRATISTA: Significa (i) toda persona nombrada en el Contrato como subcontratista, (ii) toda
persona nombrada como subcontratista bien sea directamente por el CONTRATISTA o a un nivel inferior
(incluyendo cualquier subcontratista o proveedor de Materiales) para una parte de los Trabajos, y (iii) los
4. CONTENIDO
Ver tabla a partir de la siguiente página.
NOTAS
1. Eliminada.
2. Capacidad de producción:
3
-Modo GAN: 3900 Sm /h
3 3
-Modo LIN: Nitrógeno gaseoso 3550 Sm /h, Nitrógeno líquido (a almacenamiento) 320 Sm /h
3
-Capacidad de Vaporización: 18756 Sm /h
3. Para información detallada de los equipos que componen la planta referirse al documento: V-TAL-MEC-
0001-OC-04-NIS-Z-001-0001.
4. Nitrógeno de Pureza entre 99.9 y 99.99%, contenido de O2 menor a 10 ppm (v/v), Dew point menor a
-40°C.
5. Condiciones del nitrógeno gaseoso en el B.L. de la unidad NIS.
6. Aislamiento térmico para equipos que operan a condiciones criogénicas.
Este documento contiene información privada y no puede ser duplicado, modificado o divulgado a terceros sin el consentimiento escrito de COBRA SCL. La única
copia controlada de este documento está en el Sistema Informático de Gestión Documental de COBRA SCL.
PROYECTO: TAL
PÁGINA 5 DE 5 .
LISTA DE EQUIPOS
Materiales de Recipiente/Intercambiador
Potencia
Longitud
Condiciones de Operación Condiciones de Diseño Capacidad y/o Tamaño Misceláneos Aislamiento
Nominal
Construcción Dimensiones Carcasa
Paquete
Peso P&ID
Pintura
Descripción
REV
TAG Tubos/ Temp. [ºC] Pres. [kg/cm2g] Temp. [ºC] Pres. [kg/cm2g] Intercambiador Altura Notas
Equipo Caudal Alt. Difer. Diam. T—T Vol. No.
Total
Carcasa Camisa/ Tubos/ Tubos/ Tubos/ Tubos/ 3 Area Calor Int. 3
Lechos/
Lechos
Tipo
Espesor
[mm]
[kg] N°
Carcasa Carcasa Carcasa Carcasa [m /h] [m] [mm] [mm] [m ] Platos
Impulsor Camisa Camisa Camisa Camisa [m]
2
[m ] [Gcalh/hr] (kW) [m]
3690
3
Nm /h /
TAL-NIS-PRO-
01 NIS-Z-001 PLANTA N2 32 (5) 8 (5) 93/-10 (5) 10,5/FV (5) 3900 C (2) (3)
3
PID-0001
Sm /h
(2)
Este documento contiene información privada y no puede ser duplicado, modificado o divulgado a terceros sin el consentimiento escrito de COBRA SCL. La única copia controlada de este doc. está en el Sist. Informático de Gestión Documental de COBRA SCL.
REFINERIA TALARA
NIS-Z-001 57506-60-01-EM-012001
Air Liquide
Main equipment list
26/07/2019 02
FORM
57506-60-01-EM-012001
MAIN EQUIPMENT LIST

Rev. 2
Project or Proposal Number C57506

Project Name TALARA NIS
PROJECT APPROVALS
Rev Date Prepared By Approved By Revision

0 22-oct-18 M. ATAM J. LEGRAND Initial issue
1 05-mars-19 M. ATAM Updated with new information
2 25-juil-19 M. ATAM M. PAILLET Updated with new information from suppliers & client
Table of Revisions
Section Description
E-FRM-14-1-3, Rev C Page 2 of 4

FORM
57506-60-01-EM-012001
MAIN EQUIPMENT LIST (INCLUDES EXHAUSTIVE LIST OF PRESSURE VESSELS)

Rev. 2
Project or Proposal Number C57506
Main Dimension (for transport)

ALE Design
Design
Equipment PetroPeru P&ID document Oxygen Pressure
Rev. Designation Fluid Code Temperatur Width-W Weight (kg) total for transport Remarks MDR Doc No:
Number Number number code service PS Lenght L Height H
e TS °C DIA-D
number kg/cm2,g (mm) (mm)
(mm)
2 C01 NIS-K-001 Main Air Compressor 14010 611 AW No 12,23 -10 / 65 2203 TBD 3180 17 000 V-TAL-MEC-0001-OC-
04-NIS-Z-001-0228
2 R01/R02 NIS-D-001 / Air purification vessels 352 AW No 12,23 300 3810 7500 4800 29 000 Delivered as a skid with V-TAL-MEC-0001-OC-
NIS-D-002 piping and valves 04-NIS-Z-001-0224
2 E08 NIS-E-008 Regeneration Heater 362 WO YES 6,11 400 480 3489 636 550 It will not be transported, V-TAL-MEC-0001-OC-
it is included inside 04-NIS-Z-001-0232
purification skid.
2 S04 NIS-SL-004 Waste Gas Vent Silencer 373A WO YES ATM 0 / 300 970 2800 79 It will not be transported, V-TAL-MEC-0001-OC-
purification skid.
2 E01 NIS-E-001 Main exchanger 311 AG YES 6,11 / -196/65 2003 1992 5784 2 540 It will not be transported, V-TAL-MEC-0001-OC-
GAN 12,23 it is included inside Cold 04-NIS-Z-001-0216
WO-MP Box.
WO-BP
2 E02 NIS-E-002 Main vaporizer 312 GAN Yes 6,11 / -196/65 1310 3040 1170 700 It will not be transported, V-TAL-MEC-0001-OC-
12,23 it is included inside Cold 04-NIS-Z-001-0218
Box.
2 K01 NIS-C-001 HP Column 321 GAN + W Yes 6,11 / -196/65 1050 9985 4 270 It will not be transported, V-TAL-MEC-0001-OC-
Box.
2 ET01 NIS-X-001 Expansion turbine 651 WO Yes 6,11 / -196/65 1046 2102 2000 1 350 It will not be transported, V-TAL-MEC-0001-OC-
Box.
2 E80 NIS-E-007 Liquid Disposal Vaporizer 315 WL Yes ATM -168 1125 1000 6000 658 V-TAL-MEC-0001-OC-
04-NIS-Z-001-0238
2 S02 NIS-SL-002 Nitrogen Silencer 373b GAN No Atm -10 / 65 810 1672 37 It will not be transported, V-TAL-MEC-0001-OC-
it is included inside Cold 04-NIS-Z-001-0241
Box.
2 E81 NIS-E-009 Derime heater 362B AD No 12,23 -10 / 65 226 1200 90 It will not be transported, V-TAL-MEC-0001-OC-
purification skid.
2 V50 NIS-T-050 Liquid Nitrogen Storage 332 LIN No 14,27 -196/65 5100 24600 5206 109180 V50E is a part of the V50 V-TAL-MEC-0001-OC-
storage 04-NIS-Z-001-0222
2 E51.1/2/3/4 NIS-E- Liquid Nitrogen Vaporizers 316B LIN + GAN No 12,23 -196 / 65 2900 2900 12000 9000 V-TAL-MEC-0001-OC-
003/004/005/ 04-NIS-Z-001-0236
006
*This document is giving only general information about main equipment. For detailed information please refer to Manufacturer Data Records of related equipment.

Short instructions for the use of the standard Main Equipment list.
1 General:
This project document should be issued at the beginning of the project with information at least for
these columns : Equipment number, Designation, Fluid code, Oxygen service, PS and TS.
It should be revised and issued after each PID revision.
The document must be given to all specialists to ensure a perfect conformity between the main
equipment list and the equipment specifications (in particular for the PS/TS values).
Dimensions and weight have to be filled in for transport purpose, lifting and erection purpose,for
data informations,
"European Regulation" columns can be replaced by other country regulation,
When finalized, this document must be given to the client with the Technical documentation
2 Multiple users:
This document is used by different project's specialists and therefore we have indicated which
specialist is responsible for each information :
2.A. The cells coloured in blue are under the responsibility of the Project Engineer.
2.B. The cells coloured in yellow are under the responsibility of the system specialist; this specialist
should at least be consulted for any question concerning PS/TS.
2.C The cells coloured in orange are under the responsibility of the pressure vessel specialist.


PÁGINA 127 DE 556
5. PREPARACIÓN PARA LA PUESTA EN MARCHA

5.1. GENERAL
Las actividades que se llevan a cabo después del montaje mecánico (culminación
mecánica) de la planta consisten en una serie de diversas comprobaciones, inspecciones
y pruebas que se ejecutan para declararla como lista para la admisión de carga.
Se trata de garantizar que cada pieza del equipo de la refinería de nueva construcción se
haya instalado correctamente de acuerdo con los planos de ingeniería y que opere de
acuerdo con las condiciones de diseño.
Los objetivos de estas verificaciones son dejar la planta para hacer el arranque de manera
segura y sin problemas y establecer un período de arranque hasta la consecución del
estado estacionario lo más corto posible.
Las actividades que se llevan a cabo al final de la Construcción se dividen en dos fases,
Pre-comisionado y Comisionado.
El término Pre-comisionado por lo general se refiere a todas las inspecciones y pruebas a
realizar, en una planta / unidad, después de la construcción mecánica (culminación
mecánica) en "condiciones estáticas". Esto significa que las inspecciones y pruebas se
realizan, mientras que la planta / unidad está en unas “condiciones estáticas” sin
energizar.
El término Comisionado, en general, se refiere a todas las inspecciones y pruebas a
realizar al final de la etapa de precomisionado, en una planta / unidad y / o parte de una
planta/ unidad, en "condiciones dinámicas". Esto significa que las inspecciones y pruebas
se llevan a cabo, por medio de fluidos auxiliares, tales como: agua, aire, vapor, etc., una
vez que la planta / unidad está en un estado energizado.
CRONOLOGÍA DE LAS OPERACIONES

Las operaciones de Precomisionado y Comisionado se llevan a cabo de forma secuencial,
como a continuación se indica, de tal manera que, una vez que todos los pasos han sido
cumplimentados, las Unidades / plantas pueden alcanzar el estado de Listo para la
admisión de carga.
La secuencia de las actividades principales es la siguiente:
Actividades de precomisionado:
 Pruebas hidráulicas.
 Flushing, soplado y drenaje (de las líneas de proceso).
 Preparación de los servicios.
 Reinstalación de los instrumentos (FT, válvulas de control…)

PÁGINA 128 DE 556
 Precomisionado de equipos eléctricos y energización.

 Inspección y pruebas de la instrumentación (lazos de control, DCS, ESD ...)
 Comprobación de la unidad, inspección de los recipientes.
 Cierre de los man way (reactores, recipientes, etc…)
 Período de adaptación de las bombas.
Actividades de Comisionado:
 Carga de los adsorbentes.
 Limpieza química de las líneas y equipos.
 Tratamiento químico (desengrasado) de líneas.
 Prueba de fugas y de estanqueidad.
 Purga de nitrógeno y de inertización.
 Pruebas funcionales del DCS.
 Pruebas de lógica de protección y seguridad (ESD).
RESPONSABILIDAD DEL PROVEEDOR DEL PAQUETE

Es parte de la labor del proveedor de este paquete llevar a cabo el recorrido por la planta
para verificar que los componentes principales se han instalado según sus
requerimientos.
El equipo de puesta en marcha del proveedor generalmente está presente en dos
momentos
 Hacia la finalización de la Construcción. El equipo de puesta en marcha debe disponer
de tiempo suficiente para inspeccionar la Unidad antes de la CULMINACIÓN
MECÁNICA de la misma.
 Cuando finalizan las actividades de Precomisionado, una vez que la Unidad se declara
"LISTA PARA ARRANQUE", es decir, que está lista para iniciar con las actividades de
Comisionado.
No entra dentro de las responsabilidades del proveedor del Proceso el suministrar
instrucciones relativas a las actividades de Precomisionado.
En este apartado se definen las obligaciones del proveedor respecto a las actividades de
comisionado. En algunos casos, el proveedor sólo es testigo de que la actividad se
desarrolle de acuerdo con los procedimientos adecuados, sin impedir la ejecución
satisfactoria de las operaciones de puesta en marcha. En otros casos, el proveedor revisa
los resultados de pruebas y/o proporciona instrucciones que deben seguirse
estrictamente (requerimientos especiales, secado de la unidad, carga de catalizador).

PÁGINA 129 DE 556
Ambas operaciones de Precomisionado y Comisionado deben realizarse de acuerdo con

las instrucciones de los fabricantes de los equipos, así como las normas y procedimientos
pertinentes.
Una buena planificación y ejecución de las actividades de precomisionado y comisionado
generalmente conllevan a una rápida y exitosa puesta en marcha.
En este sentido, se recomienda que el/los representante/s del proveedor esté/n
presente/s durante el desarrollo de los siguientes trabajos:
Inspección de la Unidad (participación obligatoria desde el primer día de revisión de la
unidad e inspección de equipos).
Pruebas de estanqueidad (la presencia del proveedor es opcional y limitada a ser testigo
de la operación).
Para la programación de la ingeniería, el plazo mencionado debe coincidir con el final del
comisionado de los servicios (disponibilidad de los sistemas de servicios) y la terminación
del comisionado de la unidad (lavado con agua, pruebas hidráulicas, etc.).
5.2. INSPECCION DE EQUIPOS Y DE LA UNIDAD

La inspección de los equipos se deberá realizar de acuerdo con lo establecido en los planes
de inspección correspondientes, incluyendo: inspecciones en fábrica, inspecciones en
sitio, inspecciones finales de montaje, antes de expedir los certificados de liberación de
cada uno de los equipos. Será responsabilidad del CONTRATISTA correspondiente el
cumplimiento de los procedimientos desarrollados para tal fin.
Se deberá desarrollar un protocolo de revisión de los equipos una vez montados, y de los
internos instalados en cada uno de los mismos, de igual manera, será necesario realizar,
como parte del proceso de inspección de la planta, la comprobación de P&IDs, la
comprobación de válvulas tanto de bloqueo como de control y de seguridad, y la
generación de los comentarios a la documentación correspondiente para la generación
de los diagramas as-built de la planta.
En la medida en la que se vaya emitiendo los certificados de terminación mecánica, se
podrá comenzar con el proceso de precomisionado de la misma.
INSPECCIÓN DE EQUIPOS
General
El proveedor de la unidad paquete debe garantizar la inspección de equipos la cual puede
llevarse a cabo en varias fases.
 En los talleres del fabricante.
 En el sitio, antes de la carga de adsorbentes y / o antes de la culminación mecánica
(otros depósitos).

PÁGINA 130 DE 556
 Durante y, al final de la carga de adsorbentes, por ejemplo en los pasos de hombre

entre secciones.
La inspección en taller es opcional dependiendo de la complejidad de los internos y, la
criticidad de los elementos a inspeccionar.
Las inspecciones en el sitio, antes de y durante la carga de los adsorbentes son
obligatorias, incluso aunque la inspección en taller haya sido presenciada por un
representante del proveedor y, hubiera resultado satisfactoria.
Alcance de la inspección
Los equipos a ser inspeccionados son los siguientes:
 Adsorbedores
 Todos los separadores y recipientes.
El equipo se inspecciona conforme a las especificaciones, planos y recomendaciones de
construcción del fabricante. El especialista de puesta en marcha emitirá, si fuera
necesario, una lista con los trabajos correctivos necesarios.
A continuación se incluye una lista típica, pero no exhaustiva, de los elementos a
comprobar:
 Elevación de equipos
 Revestimiento de equipos.
 Bandejas: número, tipo, separación, nivel, sello de líquido, altura del vertedero,
orificios de drenaje, soportes, etc…
 Distribuidores: ubicación, alineación, tamaño
 Toberas: localización y clasificación de las bridas y revestimiento
 Demisters: tamaño, materiales y soportes
 Termopozos: localización y libraje nominal y cara de la brida.
 Instrumentos de nivel.
 Limpieza.
Precaución:
Antes de entrar en un recipiente se deben tener en cuenta las medidas de seguridad de
la refinería. Normalmente se incluyen las siguientes:
 Muestreo del recipiente por la presencia de vapores tóxicos y verificar la

concentración de oxígeno (obligatorio 21%).
 Proveerse del alumbrado correcto y la plataforma de acceso.

PÁGINA 131 DE 556
 Llevar aparato de respiración asistida si se estima necesario.

 Llevar arnés de seguridad y proveerse de asistencia fuera del recipiente. No entrar en
recipientes sin vigilancia en el exterior.
Trabajos de preparación de la inspección

A continuación se incluye la descripción del trabajo de preparación para permitir el acceso
a los internos:
Adsorbedor: Aislados por bridas ciegas de cualquier fuente potencialmente peligrosa
(flare, Fuel Gas, hidrógeno, N2, productos químicos, HC ...). Bocas de hombre abiertas y
atmósfera respirable para permitir, la primera inspección del estado de la pared del
equipo y, una segunda inspección después del montaje de los internos (sin bocas de
hombre internas).
Recipientes y Tanques: Aislados por bridas ciegas, de cualquier fuente potencialmente
peligrosa (flare, Fuel Gas, hidrógeno, N2, productos químicos, HC...). Bocas de hombre y,
conductos de ventilación abiertos, atmósfera respirable. Elementos internos
ensamblados.
Inspección de Internos de Equipos

En las últimas etapas de la fase de construcción, los internos de los recipientes necesitan
ser cuidadosamente revisados. El primer chequeo se realiza basados en los planos
producidos durante la ingeniería de detalle, pero se necesitan revisiones adicionales para
garantizar que el equipo, y en última instancia la unidad, funcionarán como está previsto.
Las comprobaciones finales de los internos de los recipientes se deben hacer antes de
retirar el acceso a los mismos. Adicionalmente a la inspección continua que se realiza
durante la fase que asegura que los componentes internos están diseñados e instalados
adecuadamente, se necesitan realizar estas últimas comprobaciones para asegurarse de
que el equipo está listo para funcionar.
Como ejemplo, se debe verificar que los ciegos temporales utilizados en los distribuidores
de las columnas para su protección, sean removidos y última las juntas finales instaladas.
Lonas, mantas ignífugas, o tapones utilizados para recoger los desechos de construcción
de tuberías deben ser removidos, o las líneas no serán capaces de hacer circular la
cantidad de fluido previsto.
Montaje e inspección de los internos de adsorbedores

Se recomienda ensamblar los internos y tenerlos inspeccionados tan pronto como sea
posible para ejecutar cualquier ajuste sin retrasar la planificación de arranque.

PÁGINA 132 DE 556
Para la inspección de los ítems internos se debe referir a los planos de detalle de los
mismos.
 Instalar el colector de salida en el fondo del adsorbedor. Si aplica verifique el tamaño
de luz de malla, la correcta soldadura del sello y el apriete de sus piezas.
 Disposición en campo de los termopozos. Verifique la localización de los mismos.
 Chequeo del difusor de la alimentación.
 Verificación de plato anillos y boquillas de inyección.
INSPECCIÓN DE LA UNIDAD
Antes del comienzo de cualquier actividad de precomisionado se debe recorrer toda la
planta (“Walk Through”). Puede realizarse antes de la culminación mecánica de la Unidad.
Este recorrido tiene como objetivo verificar la conformidad de la unidad para acometer
las actividades de precomisionado y consiste principalmente en las siguientes actividades
(aunque sin limitarse a las mismas):
Comprobación de P&IDS
A su llegada, el proveedor del equipo llevará a cabo una revisión de la Unidad “as built”
frente a los requerimientos expresados por el dueño. Esta revisión se hará principalmente
en las tuberías, instrumentos y dispositivos de seguridad. La localización de los
instrumentos, válvulas (incluyendo las válvulas de corte especiales, puntos de conexión,
etc.), cuando el proveedor haya emitido una recomendación especial, será revisada para
satisfacer dicha recomendación. De ser necesario, se llevarán a cabo trabajos correctivos.
La verificación de los P&ID consiste, pero no se limita, a lo siguiente:
 Comprobar que el ruteo de las tuberías de proceso y de servicios se ajusta al flujo
de proceso deseado.
 Verificar que toda la instrumentación se ha instalado correctamente.
 Verificar la orientación de las válvulas check y de globo.
 Verificar que las pendientes de las líneas son correctas respecto a lo representado.
 Verificar que todo el traceado de vapor y el aislamiento se han instalado de
acuerdo a lo requerido.
 Verificar que los filtros temporales / filtros permanentes, así como los discos
ciegos están en su lugar.
 Verificar que todas las trampas de vapor están instaladas correctamente.
 Verificar que las sujeciones de las tuberías y los apoyos están correctamente
instalados y anclados o guiados según sea necesario.
 Verificar que los equipos están correctamente conectados a tierra eléctricamente.

PÁGINA 133 DE 556
 Verificar la accesibilidad equipos y espacio libre para la expansión de tuberías.

 Verificar los requisitos generales de seguridad.
 Se debe verificar la instalación del seguro de válvulas (CSO, CSC, LO, LC).
Las anotaciones de todas las deficiencias o faltas deberán ser registradas y resueltas antes
del inicio de cualquier actividad de precomisionado y comisionado.
Revisión de la operatividad
Consiste en evaluar la posibilidad de realizar todas las operaciones requeridas para el
comisionado, puesta en marcha y parada. Se centra principalmente en el acceso a los
instrumentos y válvulas (incluyendo venteos, drenajes), a las bocas de hombre, a los
discos reversibles y a las partes del equipo que requieren ser extraídas. Se revisa la
correcta configuración de las líneas de puesta en marcha y de presurización, así como el
impacto de los dispositivos de seguridad en las operaciones de puesta en marcha.
Revisión de instrumentos
A. Antes del arranque de la unidad, todos los instrumentos deben haber sido
comprobados con respecto a:
 Etiquetado adecuado.
 Ubicación apropiada en el proceso.
 Montaje correcto.
 Rango de trabajo en consonancia con las condiciones de funcionamiento.
 Calibración.
 Tamaño del orificio de caudal, los coeficientes, la orientación con respecto al
sentido de flujo.
 Los instrumentos de nivel serán calibrados, usando la densidad de diseño del
líquido.
 Integridad del cableado del instrumento, polaridad y toma de tierra.
B. Comprobación de alarmas
Asegúrese de que se acciona la luz correspondiente o una alarma audible en la sala de
control cuando se genera una alarma en un dispositivo.

PÁGINA 134 DE 556
C. Válvulas
Las válvulas de control se desmontan durante las operaciones de limpieza. Se comprobará
la limpieza de los asientos y, que el tapón o bola se pueden mover libremente.
Compruebe el movimiento de las válvulas y su respuesta a la señal del controlador.
Cuando todos los instrumentos se han comprobado de forma individual, y todas sus
direcciones se han verificado en el DCS, entonces puede comenzar la comprobación de
lazos.
Cada acción automática, ya sea vinculada al proceso o al equipo, también se comprobará
por separado.
A continuación se muestra lo referente a la comprobación de válvulas.
Comprobación de válvulas manuales:

 Comprobar que las válvulas están instaladas en el sentido correcto de flujo.
 Comprobar que la manija de la válvula está bien orientada y accesible.
Para los tipos de válvula en los que es importante que no queden líquidos
atrapados, comprobar que la orientación de la válvula es correcta.
 Comprobar que las válvulas tienen el libraje de presión adecuado.
 Comprobar que la válvula puede ser completamente abierta/cerrada sin
demasiado esfuerzo.
 Comprobar todas las juntas.
 Dejar las válvulas en posición cerrada.
Comprobar las válvulas de control:

 Comprobar que la válvula está instalada en el sentido correcto del flujo.
 Comprobar la posición segura de la válvula a fallo de aire.
 Comprobar la posición de la válvula (stroke) a 0, 25, 50, 75, 100% de
apertura. Comprobar ambas posiciones desde apertura a cierre y desde
cierre a apertura. Si se instala, comprobar el posicionador y su
correspondiente señal/lectura en DCS durante la prueba.
 Comprobar que la válvula opera suavemente y sin tirones.

PÁGINA 135 DE 556
Comprobación de válvulas solenoides:

 Comprobar la posición de fallo seguro a fallo de energía.
 Comprobar que los indicadores de posición (si los hay) funcionen.
 Comprobar que la válvula opera suavemente y sin tirones.
 Medir el tiempo de movimiento hasta la apertura total y ajustar el actuador
si es necesario.
Comprobación de válvulas de no-retorno:

 Comprobar que la orientación es correcta para el tipo particular de válvula
de no-retorno.
 Comprobar que todos los dispositivos internos de anti-retorno no están
atascados en una posición y se mueven suavemente.
Comprobación de válvulas de seguridad:

 Comprobar que la válvula ha sido probada y calibrada en taller y que se ha
emitido un certificado válido.
 Comprobar (si es necesario) que el sello está intacto y que la etiqueta es
correcta.
 Comprobar que los dispositivos de protección (como discos de ruptura,
aislamiento, traceado) están instalados correctamente.
 Comprobar la orientación de las tuberías y salida son correctas.
 Comprobar que hay agujeros de drenaje (si aplican) y que están abiertos.

PÁGINA 136 DE 556
D. Revisión de los instrumentos de seguridad
El proceso incluye una serie de dispositivos de seguridad específicos referidos como

enclavamientos de seguridad - Interlock Safety (IS) que se implementan en el sistema de
parada de emergencia – Emergency Shutdown System (ESD). Estos dispositivos están
diseñados, ya sea para proteger la unidad contra el mal funcionamiento o, para cumplir
con las medidas de seguridad.
El Interlock Safety (IS) se compone de sistemas independientes que, en caso de eventos
pre-definidos y, potencialmente peligrosos, desencadenan diversas acciones tales como:
 La (s) válvula (s) van a su posición de fallo (FC-fail close, FO-fail open o FL-fail last)
 Parada de equipos (bombas, compresores, hornos, calentadores eléctricos, etc.)
para aliviar el riesgo.
Los detalles de los Interlocks Safety se dan en el Capítulo 10 de este manual
“ENCLAVAMIENTOS DE EMERGENCIA”. Deben ser leídos atentamente y comprendidos
por los operadores.
Las pruebas de estos dispositivos deberán ser presenciadas por representantes del
proveedor y, habrá que hacer trabajos correctivos hasta que la operación sea totalmente
satisfactoria.
Los principios de estas comprobaciones son los siguientes:
 Una señal simulada de defecto del sensor primario se introduce en el sistema y se
comprobará la salida de la señal resultante a las válvulas o equipos.
 Siempre que sea posible, se observará el resultado final de la salida de la señal,
como el fallo real de la válvula o, parada de la máquina.
 En definitiva, durante los siguientes procedimientos de operación, debe realizarse
una verdadera prueba que requiere que las máquinas funcionen.
A lo largo de este ejercicio, se comprobará la posición física real de las válvulas o estado
de las máquinas con las indicaciones que se muestren en la sala de control.
La comprobación de válvulas motorizadas es parte de la misma tarea. Incluye:
 Una prueba en el sitio de la apertura / cierre de la válvula ante la señal de entrada.
 Una verificación de la información presentada en la sala de control y, una
comprobación del comando de la sala de control.
5.3. PRECOMISIONADO
Una vez que se ha certificado la terminación mecánica de los diferentes componentes de
la unidad, se puede dar inicio a la fase de precomisionado. El objetivo de estas actividades
es optimizar los tiempos de alistamiento y puesta en marcha de los sistemas.

PÁGINA 137 DE 556
En este manual se describen algunos procedimientos preliminares de precomisionado y

alistamiento; sin embargo, debe prestarse atención especial a los procedimientos
específicos definidos en los manuales de operación y mantenimiento específicos de los
equipos, suministrados por los fabricantes.
A continuación, se listan las principales actividades involucradas en el precomisionado de
la Planta que son aplicables a esta unidad. Dependiendo del sistema o sistemas a
precomisionar, se deben preparar una descripción detallada de cada una de estas
actividades.
 Energización del sistema eléctrico.
 Limpieza y pasivación de los sistemas de agua de enfriamiento.
 Puesta en servicio de los sistemas de agua de enfriamiento.
 Lavado con agua de los diferentes circuitos de la unidad.
 Soplado con aire de instrumentos o N2 de la red de aire de instrumentos.
 Instalación de válvulas de control, elementos de flujo e instrumentación en
general en las líneas post-lavado.
 Prueba de hermeticidad a la presión de operación en las secciones de la unidad.
Revisión de instalaciones eléctricas

Antes de la energización de los sistemas eléctricos es importante realizar las siguientes
verificaciones y chequeos:
 Verificar que todos los equipos eléctricos han sido instalados de acuerdo con los
códigos aplicables, las buenas prácticas de instalación y las instrucciones del
fabricante.
 Verificar que todos los cables están adecuadamente soportados y protegidos.
 Verificar que todos los cables en las cajas de paso y terminales están
adecuadamente marcados.
 Revisar que los prensaestopas en los cables y los sellos de las cajas están
adecuadamente instalados.
 Determinar la continuidad en las conexiones del sistema de tierra y la resistividad
a tierra.
 Chequear el aislamiento eléctrico de cables y equipos mediante un
megaohmímetro y de acuerdo con las instrucciones del fabricante.
 Chequear por medio de lámpara o zumbador de prueba la correcta conexión de
los circuitos de potencia y control.
 Revisar que la potencia de los fusibles corresponda con los sistemas a proteger.

PÁGINA 138 DE 556
Revisión de arreglo de equipos y tuberías

Antes de cualquier prueba, debe asegurarse que las tuberías, equipos, válvulas e
instrumentos están correctamente instalados de acuerdo con los PID´s y los planos
mecánicos correspondientes.
Debe prestarse especial cuidado a la revisión de internos en los recipientes y termopozos.
Pruebas de presión
Todos los recipientes y líneas a presión deben ser probados hidrostáticamente,
preferiblemente con agua desmineralizada o, en todo caso, con agua libre de cloruros.
En el caso de los recipientes a presión que han sido probados hidrostáticamente en
fábrica, y cuentan con el certificado correspondiente, solo serán probados nuevamente
luego del montaje si es requerido específicamente por las autoridades, o si resulta
práctico involucrarlos en la prueba de circuitos de tubería.
Las pruebas hidrostáticas deberán ser realizadas antes de la instalación de aislamientos
térmicos a efectos de detectar aún pequeñas fugas. Las válvulas de seguridad, válvulas de
control y orificios de restricción deberán ser removidos o aislados para las pruebas.
Limpieza de líneas y equipos

Las líneas y equipos deben ser limpiados con barrido con agua y posterior soplado con
aire o vapor.
Los elementos de flujo, placas de restricción y válvulas de control o de seguridad no
deberán ser instalados hasta que termine el proceso de limpieza de líneas y equipos. En
caso de ser necesario, estos elementos deberán ser reemplazados por carretes
temporales para facilitar las operaciones de limpieza. Las conexiones de instrumentos
deberán ser desconectadas, así como las conexiones a bombas y compresores.
Las tuberías de instrumentos deberán ser sopladas con aire de instrumentos o nitrógeno.
Las líneas de proceso deberán ser sopladas con vapor o aire, o barridas con agua a una
velocidad igual o mayor a la condición operativa del sistema (rv2 entre 1 y 1,5 veces). Las
líneas y equipos con refractario interno no deberán ser barridas con agua o vapor. Las
tuberías de proceso de alta temperatura deberán ser barridas con vapor y luego con aire.
El lavado de circuitos que involucran equipos mayores deberá hacerse de la siguiente
manera:
Intercambiadores de calor: La conexión de entrada debe estar abierta y se

debe instalar una platina ciega contra la brida
del equipo.

PÁGINA 139 DE 556
Separadores con tapa bridada: La tapa y la malla demister, si la hay, deben ser
retiradas.
Separadores La tapa del paso de hombre debe ser retirada.
Los equipos deben ser limpiados manualmente antes de la limpieza en línea. Los pasos de
hombre y bridas abiertas deberán ser cerrados luego de la limpieza en línea para
proseguir con el resto del circuito.
Después del soplado con vapor, las líneas y equipos deberán se secados mediante barrido
con aire o con nitrógeno para evitar corrosión.
Una vez terminada la operación de limpieza de líneas, todas las conexiones temporales o
intermedias, y las platinas ciegas deben ser retiradas, y las conexiones normales
aseguradas.
Los adsorbedores y otros recipientes a presión deberán ser internamente revisados para
retirar cualquier material extraño que pudiese causar taponamientos en la operación.
Luego, todos los internos deben ser adecuadamente instalados.
Chequeo de instrumentación
Se debe asegurar que todas las platinas de orificio están instaladas en la dirección
correcta, se deben realizar pruebas de banco de calibración, continuidad de señales, etc.
Antes de la instalación de instrumentos
Una vez energizada la unidad y habilitado el suministro de aire de instrumentos deben
realizarse las pruebas de cada instrumento como sigue:
 Desconectar la conexión al proceso.
 Establecer una señal de proceso simulada al instrumento.
 Chequear el funcionamiento del instrumento al 0% - 25% - 50% - 75% - 100% de
la señal de proceso.
 Chequear todos los componentes individuales del lazo incluyendo la acción de la
válvula de control del lazo en caso de falla de aire.
 Chequear la funcionalidad del lazo completo.
 Diligenciar un certificado de prueba de cada lazo.
 Chequear cada interlock de seguridad. Verifique las alarmas individualmente y las
acciones de seguridad relacionadas (cierre/apertura de válvulas, parada de
motores, etc.).
Todas las válvulas deben ser inspeccionadas para asegurar que han sido debidamente
empacadas y preservadas y que operan adecuadamente. Una vez instaladas, se debe

PÁGINA 140 DE 556
verificar que la dirección de flujo es correcta. Las válvulas deben dejarse en posición de
falla.
Todas las válvulas de seguridad deben ser calibradas y certificadas en el taller antes de su
instalación.
Revisión de equipo rotativo

Todos los equipos rotativos de la Planta deben ser revisados de acuerdo con los
protocolos definidos por el fabricante. Estos protocolos deben cubrir como mínimo los
siguientes puntos:
 Alineamiento del conjunto máquina-motor.
 Dirección de rotación.
 Alineamiento de tubería.
 Revisión de los sistemas de lubricación, sello y enfriamiento.
 Revisión de las conexiones eléctricas.
 Revisión del panel local de instrumentos cuando aplique.
 Revisión de filtro de aire.
 Procedimiento de carga del desecante de adsorbedores.
 Revisión internos de la caja fría y columna.
5.4. COMISIONADO Y OPERACIONES PRELIMINARES

Para el comisionado de las diferentes secciones de esta unidad se deben seguir las
indicaciones dadas en el manual de operación entregado por el fabricante de esta unidad
paquete, Ref [37].
6. PRIMERA PUESTA EN MARCHA
6.1. INTRODUCCIÓN
Este capítulo describe los procedimientos para el arranque seguro de la Unidad. De
manera general, los procedimientos descritos aplican tanto para el primer arranque luego
del precomisionado y comisionado de la instalación, como para el arranque posterior a
una inspección general o parcial de la unidad. En donde existan particularidades que
apliquen solamente al arranque inicial, serán indicadas.
Previo al inicio de operaciones en cualquier sección de la unidad, es imprescindible que
todas las personas involucradas estén familiarizadas con las regulaciones, precauciones y

PÁGINA 141 DE 556
procedimientos de seguridad de la instalación, incluyendo la localización de los equipos

de seguridad y contra incendio, los controles y procedimientos de emergencia, las rutas
de escape y puntos de encuentro, al igual que deben conocer los límites de diseño y
ventanas operativas de los equipos y los riesgos y precauciones de seguridad requeridas.
Es importante establecer un programa de reentrenamiento periódico del personal de
operaciones en los procedimientos de emergencia que asegure que estos procedimientos
son conocidos y entendidos. Este manual y los documentos complementarios no
reemplazan la formación y entrenamiento.
Es igualmente importante establecer una bitácora de Planta en la cual se registren todos
los incidentes y actividades, así como los datos de operación relevantes durante el
proceso de arranque de la Planta. El análisis de este registro permitirá determinar si se
requiere alguna acción correctiva para mantener la operación segura y eficiente de la
Unidad.
Antes del inicio de operaciones en la Planta deberán asegurarse los siguientes puntos:
 Todos los procedimientos preliminares de preparación para arranque, indicados
por el fabricante de la unidad, han sido completados.
 Los servicios industriales están disponibles.
 Las bridas ciegas temporales o de mantenimiento han sido retiradas o cambiadas
de posición.
 Las bridas ciegas permanentes están instaladas.
 Los empaques temporales han sido cambiados por empaques definitivos.
 Los resortes en soportes y ganchos de amarre de tuberías están correctamente
colocados.
 La posición en frío de los soportes deslizantes ha sido registrada.
 Las válvulas están en la posición correcta.
 Los sistemas de control operativos, equipos de telecomunicaciones y de seguridad
están habilitados y disponibles.
 Los enfriadores con agua han sido llenados y disponen de circulación de agua de
enfriamiento.
6.2. CRONOLOGÍA DE LA PUESTA EN MARCHA

Los pasos para el arranque de la Unidad son los siguientes:
1. Arranque y verificación de los servicios industriales como aire y agua de
enfriamiento, vapor, agua de proceso, agua potable y sistema contra incendio.
2. Asegurar que se mantiene comunicación activa entre las unidades afectadas por
el arranque de esta unidad.

PÁGINA 142 DE 556
3. Alineamiento de la red de distribución de nitrógeno a la planta.

4. Arranque de la unidad de generación de nitrógeno para inertización.
Los pasos a seguir para el arranque del sistema de producción de nitrógeno están
indicados en el manual de operación entregado por el proveedor de esta unidad. Ref [14].
7. OPERACIÓN DE LA UNIDAD
7.1. RESUMEN DE LAS CONDICIONES DE OPERACIÓN
En este capítulo se revisan los principales parámetros y procedimientos operativos para
asegurar una operación estable y continua de la Planta.
El personal de operaciones debe supervisar permanentemente la operación y asegurarse
que todos los parámetros se mantienen dentro de las ventanas operativas definidas en el
manual de operación de la unidad de generación de nitrógeno entregado por el
fabricante.
Debe definirse un Plan de Confiabilidad que contenga todas las rutinas y procedimientos
de mantenimiento primario, preventivo y por condición, así como los planes de
inspección en operación, y debe asegurarse que tanto los operadores como el personal
de mantenimiento están familiarizados con el mismo y realizan las tareas allí definidas.
Las condiciones de operación de la Planta deben mantenerse tan estables como sea
posible. Cambios abruptos en condiciones de proceso pueden conllevar inestabilidad en
la operación con consecuentes pérdidas en la producción o afectación a los catalizadores
y al equipo. Para mayor información referirse al manual de operación del proveedor V-
TAL-MEC-0001-OC-04-NIS-Z-001-0040_00.
7.2. BALANCE DE SERVICIOS

El balance general de servicios se presenta a continuación, documento Informe de
Disponibilidad de Servicios, TAL-NIS-PRO-REP-0002.
PROYECTO: TAL
PÁGINA 1 DE 5 .
INFORME DE DISPONIBILIDAD DE SERVICIOS
N° DOCUMENTO: TAL-NIS-PRO-REP-0002 REV. 02 FECHA: 21/06/2019
DOCUMENTO PRINCIPAL
REV. FECHA DESCRIPCION COMENTARIOS
01 10/12/2018 Emisión Para Construcción
01 21/06/2019 Emisión Para Construcción
ANEXOS
FORMATOS

LÍDER PROCESO COORDINADOR INGENIERÍA GERENTE INGENIERÍA
Tamara Salazar Frank Chanchanya Alberto Pan
PROYECTO: TAL
PÁGINA 2 DE 5 .
ÍNDICE
1. OBJETO 3
2. ALCANCE 3
3. DEFINICIONES 3
4. CONTENIDO 4
5. NOTAS 4
PROYECTO: TAL
PÁGINA 3 DE 5 .
1. OBJETO
El objeto de este documento es presentar la lista de los requerimientos de sistemas auxiliares que
suministran servicios a la unidad de nitrógeno para inertización, NIS, a ser instalada como parte del
proyecto “Unidades Auxiliares y Trabajos Complementarios” (UA&TC), que completa la ejecución del
“Proyecto Modernización de la Refinería Talara” (PMRT), en Perú.
2. ALCANCE
Esta lista presenta los consumos de los diferentes servicios de la unidad de nitrógeno para inertización,
NIS, para la estimacion de los balances globales de la refinería.
3. DEFINICIONES

c) Toda persona que se convierta en Parte del presente en sustitución o conjuntamente con el
EMPLEADOR y los sucesores legales y cesionarios/novados legítimos de dicha persona en el Contrato
• REPRESENTANTE DEL EMPLEADOR (PMC): Se refiere al PMC o a la persona nombrada por el
EMPLEADOR en el Contrato o designada de manera periódica por el EMPLEADOR conforme a la
Subcláusula 3.1 [Representante del EMPLEADOR] para que actúe en representación del EMPLEADOR.
• CONTRATISTA: Significa la o las personas designadas como contratistas en el presente Contrato e
incluye a su o sus derechohabientes y cesionarios legítimos.
Complementarios, CONSORCIO COBRA SCL UA&TC (también identificado como COBRA SCL) o cualquiera
de sus afiliadas, representantes autorizados o sucesoras)
• LICENCIANTE DE PROCESOS: Significa las personas jurídicas que ha suscrito contratos con el
EMPLEADOR para elaborar las licencias de procesos.
PROYECTO: TAL
PÁGINA 4 DE 5 .

CONTRATISTA.
4. CONTENIDO
5. NOTAS
1 Consumo intermitente correspondiente a 1 estación de servicio.

2 El consumo de aire de instrumentos de respaldo para operaciones de arranque y parada (cuando el
compresor de aire está parado), incluye el consumo de los instrumentos fuera de la Unidad. Durante
operación normal, el aire de instrumentos se suministrará desde la unidad de purificación de aire.
3 Deleted
4 Vapor sobrecalentado
5 Vapor saturado
6 * Significa pico intermitente. - (Signo negativo) significa cantidades producidas.
PROYECTO DE MODERNIZACIÓN REFINERÍA TALARA UNIDADES AUXILIARES Y TRABAJOS COMPLEMENTARIOS PROYECTO: TAL
INFORME DE DISPONIBILIDAD DE SERVICIOS PÁGINA 5 DE 5
PERDIDAS
FLUIDOS FLUIDOS FLUIDOS
BALANCE DE AGUA BALANCE DE VAPOR Y CONDENSADO COMBUSTIBLES
Potenci GASEOSOS ENFRIAM. CALENT.
Rev. Equipo Servicio a Req. HS MS LS (1) CW NOTAS
RW PGW DW PW HHBW HCC HC MCC MC LCC LC NG FG IA (2) UA
(kW) (4) (5) (4) (5) (4) (5) DT DT
3 3 3 3 3
m /h m /h m /h m /h kg/h kg/h kg/h kg/h kg/h kg/h kg/h kg/h kg/h kg/h kg/h kg/h kg/h kg/h Nm3/h Nm3/h Nm3/h Nm3/h m3/h °C m /h °C
02 NIS-Z-001 Planta de Nitrógeno 1716 - - - - - - - - - - - - - - - - - - - - 50 - 158 10 - -
Estaciones de Servicio - 2.5* - - - - - - - 62.5* - - - - - - - - - - - 201* - - - - 1, 6
02 Ducha Lavojos 5.0* 6
TOTAL 1716 0 2.5* 0 5.0* 0 0 0 0 0 62.5 0 0 0 0 0 0 0 0 0 0 50 201* 158 02

PÁGINA 148 DE 556
7.3. LISTA DE EFLUENTES

Para información del documento Lista de Efluentes, suministrado por el proveedor
referirse a V-TAL-MEC-0001-OC-04-NIS-Z-001-0053, mostrado a continuación.

PÁGINA 152 DE 556
7.4. LISTA DE QUIMICOS Y CATALIZADORES

Un listado general de las características de los adsorbentes y lubricantes asociados a la
unidad se encuentran en los documentos Chemical and Consumibles List y Completed
lubricant and Adsorbents charts, V-TAL-MEC-0001-OC-04-NIS-Z-001-0076/0077,
presentado a continuación.
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PÁGINA 161 DE 556
7.5. LISTA DE INTERCONEXIONES

A continuación, se presenta el documento Lista de Tie-ins, TAL-NIS-PRO-LIS-0003. En el cual
se detallan los puntos de interconexión.
PROYECTO: TAL
LISTA DE INTERCONEXIONES - TIE-INS

PÁGINA 1 DE 6 .
DOCUMENTO PRINCIPAL
01 26/03/2019 Emisión para Construcción Revisión General
ANEXOS
REFERENCIAS
PROYECTO: TAL

PÁGINA 2 DE 6 .
ÍNDICE
1. OBJETO 3
2. ALCANCE 3
3. DEFINICIONES 3
4. CONTENIDO 4
5. NOTAS 4
PROYECTO: TAL

PÁGINA 3 DE 6 .
1. OBJETO
Este documento presenta el lisado de puntos de interconexión de los sistemas de proceso (Nitrógeno) y
servicios industriales de la unidad de inertización con nitrógeno, NIS, a ser instalada como parte del
proyecto "Unidades Auxiliares y Trabajos Complementarios (UA&TC)" de la Modernización de la
Refinería Talara (PMRT).
2. ALCANCE
Esta lista es conformada por la información proporcionada en los diagramas de tubería e

instrumentación, siguiendo los citerios de asignación de alcances estipulados en el párrafo 9.9, Anexo 2
"MJS" parte B.
3. DEFINICIONES

EMPLEADOR y los sucesores legales y cesionarios/novados legítimos de dicha persona en el Contrato
Subcláusula 3.1 [Representante del EMPLEADOR] para que actúe en representación del EMPLEADOR.
• CONTRATISTA: Significa la o las personas designadas como contratistas en el presente Contrato e
incluye a su o sus derechohabientes y cesionarios legítimos.
Complementarios, CONSORCIO COBRA SCL UA&TC (también identificado como COBRA SCL) o cualquiera
de sus afiliadas, representantes autorizados o sucesoras)
PROYECTO: TAL

PÁGINA 4 DE 6 .

CONTRATISTA.
4. CONTENIDO

5. NOTAS
1. Consumo discontinuo
2. Condiciones de operación y diseño definidas según el documento anexo "Bases Generales de Diseño"
TAL-GEN-ENG-DBD-001 ultima revisión y “Bases de diseño de Proceso" TAL-NIS-PRO-DBD-0001 última
revisión.
3. Doc. referencia: TAL-NIS-PRO-REP-0002 Rev.01 "Informe de Disponibilidad de Servicios"
4. Clase definida para servicio contra incendio en material HDPE
5. El flujo máximo de nitrógeno, corresponde a la máxima capacidad de vaporización de la planta para el
Nitrógeno líquido almacenado en los recipientes de la misma.
6. Eliminada
7. Eliminada
8. Flujo total requerido del escenario contra incendio a ser suministrado por las dos líneas
simultáneamente.
9. Línea existente OSBL en 10", línea interna de la planta en 8", se instalará reducción en el L.B.
10. Eliminada
11. Flujo minimo corresponde al (30%) del valor normal
12. Flujo minimo corresponde al (50%) del valor normal
13. Referirse a los documentos: V-TAL-MEC-0001-OC-04-NIS-Z-001-0011-0256
14. De acuerdo con Balance de Materia y Energía No.TAL-NIS-PRO-HMB-0001 ultima revisión
15. Información de acuerdo a lo indicado por Air Liquide
16. Eliminada
17. Modo de operación GAN
18. Modo de operación LIN
19. Todas las líneas identificadas como INT, a ser instaladas por otros.
20. Referirse al documento: V-TAL-MEC-0001-OC-04-NIS-Z-001-0033
21. Drenajes a ser ruteados en campo hacia el sistema de OWS.
22. Flujo mínimo corresponde a la capacidad mínima requerida de vaporización de la planta de
Nitrógeno.
LISTA DE INTERCONEXIONES - TIE-INS PÁGINA 5 DE 6 .
N° DOCUMENTO: TAL-NIS-PRO-LIS-0003 FECHA: 08/11/2019
CAUDAL, kg/h
LÍNEA DE INTERCONEXIÓN/INTERFAZ CONDICIONES DE OPERACIÓN (2) CONDICIONES DE DISEÑO (2)
N° SERVICIO PIF NÚMERO DE LÍNEA P&ID OBSERVACIONES
(19)
MÍNIMO NORMAL MÁXIMO PRESIÓN, kg/cm2g TEMPERATURA, °C PRESIÓN, kg/cm2g TEMPERATURA, °C
47282 157612 157612 5,6 24 13,3 70

01 Agua de Enfriamiento (Suministro) PIF2T-02.030.00 8"-CWS-NIS-00201-A21F-N TAL-NIS-PRO-PID-0002 8''-CWS-INT-02014-A21F-N
(11) (15) (15) 03
03
47282 157612 157612 2,5 37 13,3 70

02 Agua de Enfriamiento (Retorno) PIF2T-02.029.00 8"-CWR-NIS-00401-A21F-N TAL-NIS-PRO-PID-0002 8"-CWR-INT-02014-A21F-N
(11) (15) (15)
03 03
38.9 64.8 64.8 7,2 36 10,5 100

03 Aire de Instrumentos PIF2T-02.062.00 2"-IA-NIS-00201-C21F-N TAL-NIS-PRO-PID-0002 2"-IA-INT-02029-C21F-N
(12) (1) (3) (1) (3)
03
155.94 259.9 259.9 8 40 10,5 100

04 Aire de Planta PIF2T-02.119.00 2"-UA-NIS-00201-A21F-N TAL-NIS-PRO-PID-0002 2"-UA-INT-02002-A21F-N
(12) (1) (3) (1) (3)
03
2496 4992 4992 4,9 20-24 10,5 60

05 Agua Potable PIF2T-02.103.00 2"-PW-NIS-00201-C21F-N TAL-NIS-PRO-PID-0002 2"-PW-INT-02036-C21F-N
(12) (3) (3)
03
723 4300 20270 8 32 10.5 93

06 Nitrógeno PIF2T-02.075.00 8"-NI-NIS-00101-A21F-N TAL-NIS-PRO-PID-0002 10"-NI-INT-02001-A21F-N (5)(9)
(22) (14) (14)
03
1248 2495 2495 3,5 20-24 6,4 60

07 Agua de Procesos II PIF2T-02.091.00 2"-PGW-NIS-00201-A21F-N TAL-NIS-PRO-PID-0002 2"-PGW-INT-02033-A21F-N
(12) (1)(3) (1)(3)
03
31.25 62.5 62.5 3,3 160 10.5/FV 250

08 Vapor de Baja Presión PIF2T-02.069.00 2"-LS-NIS-00201-A21F-H TAL-NIS-PRO-PID-0002 2"-LS-INT-02027-A21F-H
(12) (3) (3)
03
170344 227125 12,0 25 16 70

09 Agua Contra Incendio PIF2T-02.042.01 8"-FW-NIS-00105-PE0F40T-N TAL-NIS-SCI-PID-0001 8"-FW-FWS-01341-FG033T-N 170344 (4)
(1) (8)
03
170344 227125 12,0 25 16 70

10 Agua Contra Incendio PIF2T-02.042.00 8"-FW-NIS-00104-PE0F40T-N TAL-NIS-SCI-PID-0001 8"-FW-FWS-01345-FG033T-N 170344 (4)
(1) (8)
03
11
12
13
14
15
16
17
18
19
20
21
22
Notas:
Ver notas en página 4
Leyenda
PIF: Punto de Interfaz
LISTA DE INTERCONEXIONES - TIE-INS PÁGINA 6 DE 6 .
N° DOCUMENTO: TAL-NIS-PRO-LIS-0003 FECHA: 08/11/2019
CAUDAL, kg/h CONDICIONES DE OPERACIÓN CONDICIONES DE DISEÑO

N° SERVICIO TIEIN NÚMERO DE LÍNEA P&ID ORIGEN DESTINO OBSERVACIONES
MÍNIMO NORMAL MÁXIMO PRESIÓN, kg/cm2g TEMPERATURA, °C PRESIÓN, kg/cm2g TEMPERATURA, °C
8"CWR 47282 157605 157605 2,5 37 13,3 70

01 Agua de enfriamiento (retorno) TAL-NIS-001 8"-CWR-NIS-00101-A21F-N TAL-NIS-PRO-PID-0001 8"-CWR-NIS-00101-A21F-N
(13) (11) (15) (15)
8"CWS 47282 157605 157605 5,6 24 13,3 70

02 Agua de enfriamiento (suministro) TA-NIS-002 8"-CWS-NIS-00101-A21F-N TAL-NIS-PRO-PID-0001 8"-CWS-NIS-00101-A21F-N
(13) (11) (15) (15)
03 Drenajes (21)
03
04 ELIMINADO
8"GAN160 723 8 32 10.5 93

05 Nitrógeno Líquido Vaporizado TAL-NIS-007 8"-NI-NIS-00104-A21F-N TAL-NIS-PRO-PID-0001 8"-NI-NIS-00104-A21F-N 20270 (14) 22230 (14) (5)(18)
(13) (22)
1"IA07 38.9 64.8 64.8 7,2 36 10,5 100

06 Aire de intrumentos TAL-NIS-013 2"-IA-NIS-00101-C21F-N TAL-NIS-PRO-PID-0001 2"-IA-NIS-00101-C21F-N
(13) (13) (1) (3) (1) (3)
6"GAN04 8 32 10.5 93
07 Nitrógeno Gaseoso TAL-NIS-014 6"-NI-NIS-00102-A21F-N TAL-NIS-PRO-PID-0001 6"-NI-NIS-00102-A21F-N - 4300 (14) 4623 (14) (5)(17)
(13)
08
09
10
11
12
13
14
15
16
17
18
19
20
21
22
Notas:
Ver notas en página 4

PÁGINA 168 DE 556
7.6. LISTA DE ALARMAS Y PUNTOS DE AJUSTE

Para referirse a los puntos de alarma se debe consultar el documento del proveedor, Range,
Alarms and Threshold list (RAT list), V-TAL-MEC-0001-OC-04-NIS-Z-001-0160.
REFINERIA TALARA
NIS-Z-001 57506-60-01-IN-801005
Air Liquide
Range, Alarms and Threshold list (RAT list)
13/09/2019 02
57, avenue carnot Job nbr : C.57506 Document number
94500 Champigny-sur-Marne Name : TALARA NIS
(FRANCE) Type : APSA L4 C57506-60-01-IN-801005
ALARMS & TRIPS SETTINGS : FRONT PAGE
Qnom FT_615 FT_630 FT_917A FT_917A FT_917B

min max
Notes (1): Calculation for flow elements : Q= 3901 10250 3559 17098 610
P0 in kg/cm² abs, T0 in °K, DP in kg/cm² K= 20615 47531 47991 47643 2717
P, Patm in kg/cm², T in °C P= 9.220 9.568 8.149 8.149 8.149
Patm = 1.0279 1.0279 1.0279 1.0279 1.0279
P0 = 10.248 10.596 9.177 9.177 9.177
T0 = 310.15 313.85 304.15 304.15 304.15
P + Patm T0 T= 37 40.7 31 31 31
Q=K ∆P 273,15 = 273.15 273.15 273.15 273.15 273.15
P0 T + 27315
.
DP = 0.0358 0.0465 0.0055 0.1288 0.0504
Qmax FT_615 FT_630 FT_917A FT_917A FT_917B

min max
Q max = 4610 12576 18587 20213 1052
K= 20615 47531 47991 47643 2717
P= 9.2201 9.5681 8.1491 8.1491 8.1491
Patm = 1.0279 1.0279 1.0279 1.0279 1.0279
P0 = 10.248 10.596 9.177 9.177 9.177
T0 = 310.15 313.85 304.15 304.15 304.15
T= 37 40.7 31 31 31
273,15 = 273.15 273.15 273.15 273.15 273.15
DP max = 0.05 0.07 0.15 0.18 0.15
Revision DATE BY VISA DATE CHECKED VISA Page

00 29-avr-19 C. BECKER
01 13-août-19 C. BECKER 1
02 13-sept-19 C. BECKER
CONTROLLER SETTINGS (only for information)
TAG ACTIONS DIRECTION SET POINT REMARKS

P I D Local Remote
PIC_261 0.05 15 0 Direct 0.32 No

LIC_602 0.5 15 0 Reverse 42.8 No
LIC_614 1 15 0 Reverse 100 No
FIC_615A 0.01 35 0 Reverse 3900 GAN Request
FIC_615B 0.02 30 0 Reverse 3800 FIC_615A - DB
PIC_615 0.01 50 0 Reverse 9.25 No
FIC_630 0.05 40 0 Reverse 10250 Air Request
PIC_640 4 2 0 Direct 4.82 PIC_615
SIC_675 0.005 70 0 Reverse 34400 No
PIC_821B 0.01 15 0 Reverse 3.4 / 8.5 No
PIC_971 0.01 15 0 Direct 8.25 No
FIC_971 0.01 30 0 Reverse 3690 No
TIC_974 1 50 0 Reverse 13 No
Notes: All set point, parameters and alarms limits will be adjusted during commissionning

PLC DATA LIST : AIR COMPRESSOR
TAG RANGE UNIT LIMITS AND SET POINT FLOW CALCULATION (1)
Min Max LL L SP H HH P0 T0 ∆P max K
VI_101 -635 635 µm 1 3

PDI_101 0 62.5 mbar 2.5
II_101 0 500 A 38.4 211.3
PI_105 0 10.3 bar
VXI_111 0 125 µm 25.4 33.02
VYI_111 0 125 µm 25.4 33.02
TI_112A/B -17.4 204.4 °C 110 121
PI_115 0 1.03 bar 0.17
VXI_121 0 125 µm 25.4 33.02
VYI_121 0 125 µm 25.4 33.02
TI_122A/B -17.4 204.4 °C 110 121
TI_126 -50 250 °C 38 41
VXI_131 0 125 µm 25.4 33.02
VYI_131 0 125 µm 25.4 33.02
TI_132A/B -17.4 204.4 °C 110 121
TI_136 -50 250 °C 38 41
VXI_141 0 125 µm 25.4 33.02
VYI_141 0 125 µm 25.4 33.02
TI_142A/B -17.4 204.4 °C 110 121
VXI_191A/B 0 200 µm 85 100
VXI_192A/B 0 200 µm 85 100
TI_192 -17.4 204.4 °C 95 105
TI_193 -17.4 204.4 °C 95 105
TI_194 -17.4 204.4 °C 145 155
PI_186 0 2.07 bar 1.03 1.45
TI_186 -50 250 °C
PDI_188 0 3.45 bar 1.24
X : To Be Defined

PLC DATA LIST : AIR PURIFICATION
PI_202 0 12.23 kg/cm² 7.34 9.38 11.5

PDX_202A 0 12.23 kg/cm² 0.3
PDX_202B 0 12.23 kg/cm² 0.3
TI_203 -50 300 °C 29 32.5 34.5
PI_212 0 12.23 kg/cm² 0.3
PDX_212 0 12.23 kg/cm² 0.3
TI_213 -50 300 °C 40 50
PI_222 0 12.23 kg/cm² 0.3
PDX_222 0 12.23 kg/cm² 0.3
TI_223 -50 300 °C 40 50
TI_233 0 350 °C 60 100 300
PDI_234 0 0.01 kg/cm² 0.0033 0.0068 0.009
AI_242 0 20 ppm CO2 1 3
PI_261 0 6.11 kg/cm² 0.32 0.5 0.6
X : To Be Defined

PLC DATA LIST : COLD BOX N2
LT_601 0 0.26 kg/cm²

LI_601 0 100 % 66 72 78 93.3 96.7
LT_602 0 0.06 kg/cm²
LI_602 0 100 % 20 42.8 75 80
TI_608 -200 50 °C -182 -180 30
LT_614 0 0.09 kg/cm²
LI_614 70 130 % 80 90 100 110
TI_615 -50 100 °C 0 5
PI_615 0 12.23 kg/cm² 8.25 9.25 10.25
FT_615 0 0.05 kg/cm² 10.248 310.15 0.05 20615
FI_615 0 4651 Sm3/h 3900
PI_616 0 12.23 kg/cm² 8.25 10.25
AI_618 0 20 ppm 5 10
AI_684A 0 500 ppm 125 480
AI_684B 0 50 ppm 5 33
TI_625 -50 100 °C 0 5
TI_630 -50 100 °C 55 60
FT_630 0 0.07 kg/cm² 10.596 313.85 0.07 47531
FI_630 0 12686 Sm3/h 10250
PI_630 0 12.23 kg/cm²
PI_640 0 6.11 kg/cm² 3.3 4.82 5.3
X : To Be Defined

PLC DATA LIST : TURBINE
PDI_670 0 2.04 kg/cm² 0.102 0.357 0.612

TI_671 0 100 °C 75 85
PI_672 0 16.32 kg/cm² 6.63 7.14 8.16
VXI_673 0 100 µm 25 30 35
SI_675 0 50000 rpm 5000 5250 34400 40100 41600
PDI_691 0 2.04 kg/cm² 0.51 1.02
X : To Be Defined

PLC DATA LIST : BACKUP
PI_821A 0 12.23 kg/cm² SP - 0.5 3.4/8.5 SP + 0.5 11.5

PI_821B 0 12.23 kg/cm² 9.5 11.5
LIT_822 X X kg/cm²
LI_822 0 100 % 15 90 95
PI_971 0 10.5 kg/cm² 8 8.25 9.5
FIT_971A1 0 0.15 kg/cm² 9.177 304.15 0.15 47991
FI_971A1 0 20086 Sm3/h
FIT_971A2 0 0.18 kg/cm² 9.177 304.15 0.18 47643
FI_971A2 0 20086 Sm3/h
FIT_971B 0 0.15 kg/cm² 9.177 304.15 0.15 2717
FI_971B 0 1057 Sm3/h
TI_974A -50 100 °C 0 5 13
TI_974B -50 100 °C 0 5
X : To Be Defined

PLC DATA LIST : UTILITIES
PI_050 0 7.13 kg/cm2 4.6 6.12

TI_095 -50 300 °C 62 65
PDI_095 0 0.05 kg/cm2 0.017 0.034
X : To Be Defined


PÁGINA 178 DE 556
7.7. SUMARIO DE ALIVIOS

A continuación, se presenta el documento Sumario de Alivios, TAL-NIS-PRO-REP-0005
UNIDADES AUXILIARES Y TRABAJOS PROYECTO: TAL
COMPLEMENTARIOS
SUMARIO DE ALIVIOS PÁGINA 1 DE 5
SUMARIO DE ALIVIOS
DOCUMENTO PRINCIPAL
ANEXOS
FORMATOS
COMPLEMENTARIOS
ÍNDICE
1. OBJETO 3
2. ALCANCE 3
3. DEFINICIONES 3
4. CONTENIDO 4
Este documento contiene información privada y no puede ser duplicado, modificado o divulgado a terceros sin el consentimiento escrito de COBRA
SCL. La única copia controlada de este documento está en el Sistema Informático de Gestión Documental de COBRA SCL.
COMPLEMENTARIOS
1. OBJETO
El objeto de este documento es presentar el sumario de alivios de la unidad de inertización de

nitrógeno (NIS), a ser instalada como parte del proyecto "Unidades Auxiliares y Trabajos
Complementarios" (UA&TC), que completa la ejecución del "Proyecto Modernización de la
Refinería Talara" (PMRT), en Perú.
2. ALCANCE
Se presenta el sumario de alivios de la unidad NIS identificando las causas y condiciones

correspondientes.
3. DEFINICIONES

EMPLEADOR y los sucesores legales y cesionarios/novados legítimos de dicha persona en el
Contrato
Subcláusula 3.1 [Representante del EMPLEADOR] para que actúe en representación del
EMPLEADOR.
Para fines prácticos, aquel designado por PETROPERÚ como empresa adjudicataria del Contrato
para la ejecución del Proyecto de Modernización Refinería TALARA / Unidades Auxiliares y
Trabajos Complementarios, CONSORCIO COBRA SCL UA&TC (también identificado como COBRA
SCL) o cualquiera de sus afiliadas, representantes autorizados o sucesoras)
• DISEÑO FEED: Se refiere al diseño de ingeniería básica extendida llevado a cabo por parte de
Técnicas Reunidas bajo el Contrato FEED EPC.
Construcción (incluye las actividades de Pre-Comisionado/Pruebas, Comisionado, Puesta en
Servicio y Pruebas de Garantía)
COMPLEMENTARIOS

Specifications) Se refiere al documento que se adjunta como Anexo 2 al Contrato considerando
cualquier adenda y modificaciones que se haga a dicho documento conforme al Contrato.
• VENDEDOR/VENDOR: Cualquier Proveedor y/o Fabricante de Equipo o Sistemas, contratado
por el CONTRATISTA.
• SUBCONTRATISTA: Significa (i) toda persona nombrada en el Contrato como subcontratista,
(ii) toda persona nombrada como subcontratista bien sea directamente por el CONTRATISTA o a
un nivel inferior (incluyendo cualquier subcontratista o proveedor de Materiales) para una
parte de los Trabajos, y (iii) los sucesores legales de cualquiera de lo anterior.
4. CONTENIDO
PROYECTO: TAL

Causas de Relevo
Presión de Ajuste
Otras Causas (Como se Especifica) P&ID
A Falla de Agua de Enfriamiento A Falla de Energía Eléctrica Fuego
Líquido Vapor
REV
TAG Equipo Protegido Destino Notas

T. Ajuste
[kg/cm2g] Fase Caudal MW T. Ajuste Fase Caudal MW T. Ajuste Fase Caudal MW T. Ajuste Caudal Densidad Caudal MW Descripción N°
[ºC]
[L / V] [kg/h] Sp. Gr. [ºC] [L / V] [kg/h] Sp. Gr. [ºC] [L / V] [kg/h] Sp. Gr. [ºC] [kg/h] [kg/m3] [kg/h] Sp. Gr.
NIS-PSV- Drenajes de aguas TAL-NIS-PRO-PID-
02 8”-CWR-NIS-00101-A21F-N 13.3 444 986.8 60 Expansión Térmica (1)
00101 aceitosas 0001
18441 V-TAL-MEC-0001-OC-
02 NIS-PSV-105 NIS-K-001 Atmósfera 12.23 27
Sm3/h 04-NIS-Z-001-0016
6066 V-TAL-MEC-0001-OC-
02 NIS-PSV-257 NIS-E-008 Atmósfera 6.11 41
Sm3/h 04-NIS-Z-001-0255
11935 V-TAL-MEC-0001-OC-
02 NIS-PSV-610 NIE-E-001 Atmósfera 6.11 41
Sm3/h 04-NIS-Z-001-0021
15697 V-TAL-MEC-0001-OC-
02 NIS-PSV-615 NIS-E-001 Atmósfera 10.5 38
Sm3/h 04-NIS-Z-001-0021
239 V-TAL-MEC-0001-OC-
02 NIS-TSV-620 NIS-C-001 Atmósfera 12.23 41
Sm3/h 04-NIS-Z-001-0023
V-TAL-MEC-0001-OC-
NIS-TSV-630 NIS-C-001 2"-WL-01-A045 14.27 (2)
02
04-NIS-Z-001-0023
1435 V-TAL-MEC-0001-OC-
02 NIS-TSV-813 NIS-T-050 Atmósfera 14.27 -170
sm3/h 04-NIS-Z-001-0025
1915 V-TAL-MEC-0001-OC-
02 NIS-PSV-821 NIS-T-050 Atmósfera 15.29 -159
Sm3/h 04-NIS-Z-001-0026
1435 V-TAL-MEC-0001-OC-
02 NIS-TSV-821A NIS-T-050 Atmósfera 15.29 -170
sm3/h 04-NIS-Z-001-0026
02 NIS-TSV-821B NIS-T-050 Atmósfera 14.27 -126
Sm3/h 04-NIS-Z-001-0026
2460 V-TAL-MEC-0001-OC-
02 NIS-TSV-821C NIS-T-050 Atmósfera 30.59 -170
Sm3/h 04-NIS-Z-001-0026
7585 V-TAL-MEC-0001-OC-
02 NIS-PSV-810A NIS-T-050 Atmósfera 14.27 -126
Sm3/h 04-NIS-Z-001-0026
7585 V-TAL-MEC-0001-OC-
02 NIS-PSV-810B NIS-T-050 Atmósfera 14.27 -126
Sm3/h 04-NIS-Z-001-0026
1435 V-TAL-MEC-0001-OC-
02 NIS-TSV-970 NIS-E-004/005/006/007 Atmósfera 14.27 -170
Sm3/h 04-NIS-Z-001-0256
24221 V-TAL-MEC-0001-OC-
02 NIS-PSV-974 NIS-E-004/005/006/008 Atmósfera 10.5 31
Sm3/h 04-NIS-Z-001-0256
02 NIS-PSV-984 NIS-E-004/005/006/009 Atmósfera 7.13 31
Sm3/h 04-NIS-Z-001-0256
02 NIS-PSV-054 NIS-R-001/002 Atmósfera 7.13 41
Sm3/h 04-NIS-Z-001-0028
V-TAL-MEC-0001-OC-
02 NIS-PSE-821A NIS-T-050 Atmósfera 13214 -126
04-NIS-Z-001-0026
V-TAL-MEC-0001-OC-
02 NIS-PSE-821B NIS-T-050 Atmósfera 13214 -126
04-NIS-Z-001-0026
V-TAL-MEC-0001-OC-
02 NIS-PSE-823 NIS-T-050 Atmósfera (2)
04-NIS-Z-001-0026
97254 V-TAL-MEC-0001-OC-
02 NIS-PSE-822 NIS-T-050 Atmósfera 32
Sm3/h 04-NIS-Z-001-0026
NOTAS GENERALES:
1. La temperatura de ajuste corresponde al valor máximo que el sistema puede alcanzar por radiación solar. En caso de bloqueo en la línea, la temperatura de disparo de la PSV está en el rango de 38°C-60°C.
2. Las condiciones de relevo deben ser definidas por el vendedor de la unidad NIS
3. Eliminada

PÁGINA 184 DE 556
8. PARADA Y REARRANQUE DE LA UNIDAD

Los procedimientos y las acciones operativas necesarias para una parada controlada, total
o parcial de esta unidad dependerán de circunstancias particulares como la duración
esperada de la parada de unidad, el propósito de la parada o los equipos que serán
inspeccionados o intervenidos. En este capítulo se presentan guías generales para la
parada de los sistemas de la unidad de tal manera que durante la planeación de la parada
se pueda establecer el procedimiento adecuado según las circunstancias particulares
arriba mencionadas.
Esta unidad está diseñada para operar de manera continua por largos períodos; todo el
equipo crítico dispone de unidades en stand-by de manera que una falla o un trabajo de
mantenimiento en una de las unidades pueda ser llevado a cabo sin afectar la operación
de la unidad. La operación continua de la unidad asegura que los adsorbentes se
mantienen en su estado activo y disminuye la afectación mecánica a los equipos asociada
con cambios importantes en temperatura y presión.
Durante una parada controlada se puede alcanzar el punto de disparo de interlocks de los
sistemas de seguridad (ESD) o control (DCS), por lo que se debe prever la deshabilitación
de estor interruptores para evitar una parada de emergencia.
De igual manera que en el procedimiento de arranque, para el proceso de parada deberán
seguirse de manera estricta los procedimientos entregados por el fabricante de la unidad.
La parada de la unidad puede ocurrir por cualquiera de los siguientes iniciadores:
 Parada por falla interna de cualquiera de sus componentes
 Parada de emergencia de la planta
 Parada voluntaria mediante el botón de parada (solamente en posición
“MANUAL”)
8.1. PROCEDIMIENTO DE PARADA NORMAL DE LA PLANTA

Teniendo en cuenta que este es un servicio industrial de la refinería, el procedimiento de
parada de la unidad deberá coordinarse con la parada de otras secciones de la planta. Sin
embargo, para la programación de paradas cortas se debe tener en cuenta que el sistema
de nitrógeno de respaldo esté operando correctamente y que se tiene suficiente
nitrógeno líquido para operar durante el período de tiempo en que la planta esté parada.
Una vez parada la unidad se debe chequear que, todas las válvulas de control y on/off
hayan alcanzado la posición segura. Precauciones especiales se deben tener en cuenta si
la parada se extiende por encima de 48 horas. En este caso se recomienda drenar la
unidad de los fluidos criogénicos antes de iniciar un nuevo arranque.
El paso a paso para la parada de la unidad se encuentra indicado en el manual de
operación entregado por el fabricante.

PÁGINA 185 DE 556
8.2. REARRANQUE DE LA UNIDAD LUEGO DE UNA PARADA CORTA

El proceso de arranque de la unidad luego de una parada corta difiere de manera
importante de una arrancada normal luego de un mantenimiento prolongado. El
arranque después de una parada corta considera que la columna está presurizada y la
planta está fría.
Para las acciones que se deben tomar para el arranque con la fría referirse al manual de
operación donde se describe el paso a paso para el arranque de la planta fría.
8.3. PARADAS DE EMERGENCIA

GENERAL
Esta Unidad está equipada con una serie de controles de parada de emergencia, que en
caso de un fallo importante, automáticamente la llevan a una situación segura. Las
acciones de las paradas de emergencia se deben dirigir a proteger el personal y el daño
de los equipos.
La protección del personal y los equipos es resultado de:
 Buen conocimiento por parte del personal de los procedimientos de operación y
parada seguros.
 Cumplimiento de las normas de seguridad en la construcción de la planta p. ej.
distancias de seguridad, orientación adecuada, etc...
 La instalación de dispositivos adecuados de detección de fuego y gas y equipos de
protección contra-incendio.
 Conocimientos adecuados de seguridad y procedimientos de entrenamiento para
el operador.
Los siguientes apartados de esta sección del Manual, cubren todas aquellas situaciones
que los operadores pueden tener que afrontar durante el funcionamiento de la Unidad.
Todo el personal de operación debe estudiar y entender perfectamente los pasos a seguir
en estas situaciones antes de poner en marcha la Unidad.
Muchas de estas situaciones están controladas por sistemas de parada automática. Estos
sistemas deben estar siempre operativos, los procedimiento de by-pass deben ser
minimizados, por ejemplo, únicamente durante arranque y periodos transitorios.
PÉRDIDA DE AGUA DE ENFRIAMIENTO

En caso de falla total de agua de enfriamiento, la unidad debe ser parada inmediatamente
en vez de esperar a que el compresor se dispare por alta carga o alta temperatura de
descarga.

PÁGINA 186 DE 556
FALLA ELÉCTRICA
En este caso se activan los interlocks de seguridad de los equipos principales que paran
todos los equipos eléctricos en la unidad tales como compresores, turbina, calentadores
y bombas, como está indicado en el manual de operación de la unidad entregado por el
fabricante.
Si la falla de energía eléctrica es corta se debe proceder con el arranque de la planta en
frio como está indicado en el manual de operación de la unidad entregado por el
fabricante.
FALLA DE AIRE DE INSTRUMENTOS

Las válvulas se llevan a su posición segura, de acuerdo a la especificación falla abierta o
falla cerrada.
Ante la falla de aire de instrumentos el operador deberá verificar el funcionamiento de
los equipos rotativos de la unidad para no afectar la integridad mecánica de los mismos.
La pérdida de presión de aire de instrumentos es generalmente lenta y hay tiempo para
proceder con una parada corta/ standby. Si el suministro de aire se recupera en pocos
minutos, la Unidad/sección puede volver rápidamente a las condiciones iniciales.
8.4. PARADAS AUTOMATICAS DE EMERGENCIA

Las paradas asociados a la unidad de generación de nitrógeno se encuentran descritas en
el manual de operación de la unidad, V-TAL-MEC-0001-OC-04-NIS-Z-001-0045.
9. CONTROL ANALÍTICO
En caso de requerirse de pruebas de calidad o monitoreo referirse al manual de operación
de la unidad entregado por el fabricante, V-TAL-MEC-0001-OC-04-NIS-Z-001-0173.
10. ENCLAVAMIENTOS DE EMERGENCIA

La descripción de los enclavamientos de emergencia de la unidad paquete se encuentran
descritos en los documentos entregados por el fabricante.
10.1. MATRIZ CAUSA-EFECTO

Los interbloqueos internos de la unidad de generación de nitrógeno deberán ser
consultados en el documento de matriz causa – efecto de la unidad entregado por el
proveedor, el cual se presenta a continuación.
PROYECTO: TAL
PÁGINA 1 DE 24 .
MATRIZ CAUSA Y EFECTO
N° DOCUMENTO: TAL-NIS-INS-MCE-0001 REV. 01 FECHA: 18/07/2019
DOCUMENTO PRINCIPAL
01 18/07/2019 Emisión Para Construcción Revisión General
ANEXOS
FORMATOS

LÍDER INSTRUMENTACIÓN Y
COORDINADOR INGENIERÍA GERENTE INGENIERÍA
AUTOMATIZACIÓN
Rafael Migueles Frank Chanchanya Marco La Barrera
PROYECTO: TAL
PÁGINA 2 DE 24 .
ÍNDICE
1. OBJETO 3
2. ALCANCE 3
3. DEFINICIONES 3
4. CONTENIDO 4
PROYECTO: TAL
PÁGINA 3 DE 24 .
1. OBJETO
El objeto de este documento es presentar la matriz causa efecto de la Unidad de Inertización de

Nitrógeno (NIS), el cual hace parte del proyecto “Unidades Auxiliares y Trabajos
Complementarios” (de ahora en adelante UA&TC) que completa la ejecución del proyecto
“Modernización de la Refinería Talara” (de ahora en adelante PMRT).
2. ALCANCE
Esta documento presenta la matriz causa efecto de la Planta de producción de Nitrógeno NIS-Z-
001.
3. DEFINICIONES

EMPLEADOR y los sucesores legales y cesionarios/novados legítimos de dicha persona en el
Contrato
Subcláusula 3.1 [Representante del EMPLEADOR] para que actúe en representación del
EMPLEADOR.
Para fines prácticos, aquel designado por PETROPERÚ como empresa adjudicataria del Contrato
para la ejecución del Proyecto de Modernización Refinería TALARA / Unidades Auxiliares y
Trabajos Complementarios, CONSORCIO COBRA SCL UA&TC (también identificado como COBRA
SCL) o cualquiera de sus afiliadas, representantes autorizados o sucesoras)
• DISEÑO FEED: Se refiere al diseño de ingeniería básica extendida llevado a cabo por parte de
Técnicas Reunidas bajo el Contrato FEED EPC.
Construcción (incluye las actividades de Pre-Comisionado/Pruebas, Comisionado, Puesta en
Servicio y Pruebas de Garantía)
PROYECTO: TAL
PÁGINA 4 DE 24 .

Specifications) Se refiere al documento que se adjunta como Anexo 2 al Contrato considerando
cualquier adenda y modificaciones que se haga a dicho documento conforme al Contrato.
• VENDEDOR/VENDOR: Cualquier Proveedor y/o Fabricante de Equipo o Sistemas, contratado
por el CONTRATISTA.
• SUBCONTRATISTA: Significa (i) toda persona nombrada en el Contrato como subcontratista, (ii)
toda persona nombrada como subcontratista bien sea directamente por el CONTRATISTA o a un
nivel inferior (incluyendo cualquier subcontratista o proveedor de Materiales) para una parte de
los Trabajos, y (iii) los sucesores legales de cualquiera de lo anterior.
4. CONTENIDO
REFINERIA TALARA
V-TAL-MEC-0001-OC-04-NIS-Z-001-0183
NIS-Z-001 57506-60-01-PR-013901
Air Liquide
Logic Diagrams (Interlock and Safety)
29/04/2019 01
Job nbr. : C.57506 Doc No. : 013-901
Rev. 01
Project name : TALARA NIS Page 1 of 19
CAUSES AND EFFECTS
COVER PAGE

00 01/02/2019 C. BECKER Initial issue / For information
01 29/04/2019 C. BECKER Updated After Customer Comments
This document is issued and administered by the AIR LIQUIDE Engineering. Paper copies of this document are considered to be
“uncontrolled” and users should always check for the most recent revision.
Job nbr. : C.57506 Doc No. : 013-901
Rev. 01
CAUSES AND EFFECTS
TABLE OF CONTENTS
1. SHUT-DOWN SYSTEM ................................................................................................................................................. 3
2. UNIT CONTROL STRATEGY ..................................................................................................................................... 4
3. UNIT TRIP: INTERLOCK I60 ...................................................................................................................................... 5
4. AIR PURIFICATION UNIT: INTERLOCK I04 ......................................................................................................... 6
5. AIR SEPARATION UNIT: INTERLOCK I05 ............................................................................................................. 7
6. EXPANDER: INTERLOCK I11 .................................................................................................................................... 8
7. CONDENSER PURGE: INTERLOCK I29 ................................................................................................................ 11
8. K01 PURGE: INTERLOCK I15 .................................................................................................................................. 12
9. LIN PRODUCTION: INTERLOCK I19 ..................................................................................................................... 13
10. MP GAN PRODUCTION: INTERLOCK I21 ........................................................................................................ 14
11. DERIMING HEATER: INTERLOCK I86 ............................................................................................................. 15
12. INSTRUMENT AIR: INTERLOCK I88 ................................................................................................................. 16
13. LIN STORAGE: INTERLOCK I61 ......................................................................................................................... 17
14. LIN VAPORIZATION: INTERLOCK I65 ............................................................................................................. 19
Job nbr. : C.57506 Doc No. : 013-901
Rev. 01
CAUSES AND EFFECTS
1. SHUT-DOWN SYSTEM
The main goal of this drawing is to define the principles for a safe stopping of the unit (partial or total) when a
defect occurs, and precise conditions allowing the start of the unit and the follow up actions to be done.
The unit is split into in different functional modules (process subunit, machines,...)
For each module, the drawing shows :
The conditions allowing the start of the module (READY TO START) these conditions are linked with an "AND"
logic function. All the conditions have to be satisfied to allow the start of the unit.
If the module is running, the conditions can disappear; they have no action on the module.
The inputs stopping the module (SHUTDOWN) come either from a shutdown set point (pressure, temperature,
level, analysis, speed, vibration ...) or from the state of another module (serial shutdown). These inputs are linked
by an "OR" logic function, so any input stops the module.
The actions following the start of the module (ON).
The actions following the stop of the module (OFF).
For each condition and action the drawing shows :
The time delay (time necessary or not during which the condition or the state of the module has to be satisfied to
be taken in account).
The pulse time (the condition or the action is pulsed or not, in the first case the condition or the action is taken in
account after it occurs only during the pulse time, in the second case continuously when it occurs).
A module output is acting on a machine or a valve or switching the controller output from production to blow-off
valve, or acting on another module. In this case the module is sending downward and upward defects or
conditions to the other modules controlling a machine or a valve in all the cases, the start of the module is made
by an operator pushbutton If the ready to start conditions are satisfied, and if there is no shutdown.
The stop of the module is made by a defect occuring, or by an operator pushbutton.
Job nbr. : C.57506 Doc No. : 013-901
Rev. 01
CAUSES AND EFFECTS
2. UNIT CONTROL STRATEGY

The scheme below shows links between sub-functions due to interlocks.
Job nbr. : C.57506 Doc No. : 013-901
Rev. 01
CAUSES AND EFFECTS
3. UNIT TRIP: INTERLOCK I60
SHUTDOWN
CAUSES ACTIONS
DESCRIPTION TAG DELAY PULSE TYPE FUNCTION DELAY PULSE DESCRIPTION TAG
AIR COMPRESSOR - SHUTDOWN I01 2S SHUTDOWN - C01 I01
AIR PURIFICATION - SHUTDOWN I04 15 MIN SHUTDOWN - AIR PURIFICATION CYCLE I04
REGENERATION OXYGEN ENRICHED WASTE TSALL

5S 2S SHUTDOWN - COLD BOX I05
- TEMPERATURE SAFETY SWITCH 625
EMMERGENCY SHUTDOWN Y20 HA Y20 SHUTDOWN - TURBINE I11
INLET GASEOUS AIR - TEMPERATURE TAHH

30S 10 MIN 2S E02 LEVEL CONTROL IN MANUAL 0 % LIC 614
ALARM HIGH HIGH 203
REGENERATION OXYGEN ENRICHED WASTE PAHH

30S INSUFFICIENT DRAIN IN INHIBITION I29
- PRESSURE ALARM HIGH HIGH 261
COLD BOX - SHUTDOWN I05 2S
CONDENSER PURGE – FXALL 603 I29 2S
E02 COLUMN EXCHANGER - CNHM ALARM AAHH

24H
ANALYSIS HIGH HIGH 684A
E02 COLUMN EXCHANGER - CNHM ALARM AAHH

24H
ANALYSIS HIGH HIGH 684B
OR AND
INLET GASEOUS AIR - TEMPERATURE TAHH
60S
ALARM HIGH HIGH 630
E02 COLUMN EXCHANGER - CNHM ALARM AA

24H
OPEN LOOP 684A
E02 COLUMN EXCHANGER - CNHM ALARM AA

24H
OPEN LOOP 684B
INLET GASEOUS AIR - TEMPERATURE

TA 203 30S
ALARM OPEN LOOP
REGENERATION OXYGEN ENRICHED WASTE

PA 261 30S
- PRESSURE ALARM OPEN LOOP
INLET GASEOUS AIR - TEMPERATURE

TA 630 60S
ALARM OPEN LOOP
INLET AIR TO R01 R02 PRESSURE ALARM PAHH

30S
HIGH HIGH 202
STOP
2S
OPERATOR VALIDATION STOP COMMAND UNIT
Job nbr. : C.57506 Doc No. : 013-901
Rev. 01
CAUSES AND EFFECTS
4. AIR PURIFICATION UNIT: INTERLOCK I04
SHUTDOWN
CAUSES ACTIONS
OUTLET GASEOUS AIR TO COLD BOX - CO2

AAHH 242 15 MIN 15 MIN 2S UNIT I60
ANALYSER ALARM HIGH HIGH
TSAHH
2S CLOSE PURIFICATION BYPASS VALVE (0%) HIC 240
TEMPERATURE HEATER E08 ALARM HIGH 238A
2S DERIMING I86
UNIT TRIP I60 2S 2S INSTRUMENT AIR PRODUCTION I88
HEATER E08 - FLOW RATE ALARM OPEN

PDA 234 15 MIN
LOOP OR AND
TSAHH
TEMPERATURE HEATER E08 ALARM HIGH 238B
AIR PURIFICATION IN MANUAL MODE HS 200A 15 MIN
OUTLET GASEOUS AIR TO COLD BOX - CO2

AA 242 15 MIN
ANALYSER ALARM OPEN LOOP
MANUAL MODE
CAUSES ACTIONS
ADSORBER R01 - DIFFERENTIAL PRESSURE

UA 202A AIR PURIFICATION IN MANUAL MODE HS 200A
ALARM LOW
ADSORBER R02 - DIFFERENTIAL PRESSURE

UA 202B
ADSORBER LOW
ADSORBER R01 - DEPRESSURISATION

UA 212A
ALARM TOO LONG
ADSORBER R01 - PRESSURISATION ALARM

UA 212B
TOO LONG
OR AND
ADSORBER R02 - DEPRESSURISATION
UA 222A
ALARM TOO LONG
ADSORBER R02 - PRESSURISATION ALARM

UA 222B
TOO LONG
E08 START HEATING FAULT UA 233A
E08 STOP HEATING FAULT UA 233B
HEATER E08 - FLOW RATE ALARM LOW PDALL

15MIN
LOW 234
AUTOMATIC MODE
CAUSES ACTIONS
AIR PURIFICATION - NOT SHUTDOWN I04 AIR PURIFICATION IN AUTO MODE HS 200A
AIR PURIFICATION - NOT INITIALISATION HS 200I OR AND
OPERATOR VALIDATION AUTO HSH 200A
Job nbr. : C.57506 Doc No. : 013-901
Rev. 01
CAUSES AND EFFECTS
5. AIR SEPARATION UNIT: INTERLOCK I05
SHUTDOWN
CAUSES ACTIONS
LAHH CLOSE GAN PRODUCTION VALVE IA FV

K01 COLUMN - LEVEL ALARM HIGH HIGH 602 SUPPLY 615A
CONTROL GAN TO ATMOSPHERE IN FIC

LA 602 30 S 2S
K01 COLUMN - OPEN LOOP TRANSMITTER MANUAL 0% 615B
TURBINE BYPASS PRESSURE CONTROL IN

I60 30 S 2S
UNIT - SHUTDOWN AUTOMATIC MODE PIC 640
E02 COLUMN EXCHANGER - LEVEL ALARM LAHH

2S
HIGH HIGH 601 LEVEL CONTROL IN AUTOMATIC MODE LIC 614
LALL
601
60 MIN 2S
E02 COLUMN EXCHANGER - LEVEL ALARM AND HL CONTROLER IN MANUAL MODE X%
LOW LOW 615A (MINIMUM POSITION) FIC 630
LALL
614
60 MIN 2S
E02 EXCHANGER SUBMERGENCE - LEVEL AND HL
ALARM LOW LOW 615A OR AND SHUTDOWN – UNIT I60
E02 EXCHANGER SUBMERGENCE - OPEN WASTE PRESSURE CONTROL IN

LA 601 60 MIN 2S 2S
LOOP TRANSMITTER AUTOMATIC MODE PIC 261
E02 EXCHANGER SUBMERGENCE - OPEN

LA 614 60 MIN 2S
LOOP TRANSMITTER SHUTDOWN - GAN PRODUCTION I21
OUTLET GASEOUS NITROGEN PRODUCTION TALL

5S 2S
- TEMPERATURE ALARM LOW LOW 615 SHUTDOWN - LIN PRODUCTION I19
WASTE OXYGEN - TEMPERATURE ALARM TALL

5S 2S
LOW LOW 6215 SHUTDOWN - CONDENSER PURGE I29
OUTLET GASEOUS NITROGEN PRODUCTION

TA 615 5S
- TEMPERATURE ALARM OPEN LOOP
WASTE OXYGEN - TEMPERATURE ALARM

TA 625 5S
OPEN LOOP
COLD BOX EMERGENCY SHUTDOWN HA_Y60
READY TO START
CAUSES ACTIONS
E02 COLUMN EXCHANGER – NOT LEVEL

LAL 601 COLD BOX ON HL 600
ALARM LOW
K01 COLUMN – NOT LEVEL ALARM LOW LAL 602 5 MIN

AND AND
E02 EXCHANGER SUBMERGENCE - NOT
LAL 614
LEVEL ALARM LOW
HSH
OPERATOR VALIDATION: START COLD BOX 2S
600
Job nbr. : C.57506 Doc No. : 013-901
Rev. 01
CAUSES AND EFFECTS
6. EXPANDER: INTERLOCK I11
ET01 - READY TO START I11

CONDITIONS ACTIONS
LAH READY TO START CONDITIONS (OPENING

I11
K01 COLUMN - NOT LEVEL ALARM HIGH 602 OF INLET VALVE POSSIBLE)
ET01 TURBINE – OIL - NOT PRESSURE PAL

ALARM LOW 672
ET01 TURBINE – SEAL GAS – NOT

PDAL
DIFFERENTIAL PRESSURE ALARM LOW
670
SWITCH
ET01 TURBINE – OIL PUMP – NOT LEVEL LSAL AND AND

ALARM LOW SWITCH 687
ET01 - TURBINE ISOLATING VALVE – CLOSE KV 651
ZSL
ET01 TURBINE – INLET GUIDE VALVE CLOSE 608
ET01 TURBINE – DERIMING OFF HL 652
ET01 TURBINE – NOT TRIP I11
ET01 – BACKUP SEAL GAS

CONDITIONS ACTIONS
ET01 TURBINE – SEAL GAS – DIFFERENTIAL PDAL OPEN BLOCK AND BLEED VALVE HY
PRESSURE ALARM LOW 670 SOLENOID ACTIVATED 985A
OPEN BLOCK AND BLEED VALVE HY

AND AND
SOLENOID ACTIVATED 985B
CLOSE BLOCK AND BLEED VALVE HY

SOLENOID DESACTIVATED 985C
Job nbr. : C.57506 Doc No. : 013-901
Rev. 01
CAUSES AND EFFECTS
ET01 – SHUTDOWN I11

CAUSES ACTIONS
ET01 TURBINE – SEAL GAS – DIFFERENTIAL PDALL

2S CLOSE TURBINE INLET VALVE KV 651
PRESSURE ALARM LOW LOW 670
ET01 TURBINE - SPEED ALARM HIGH HIGH SAHH 675 10S 2S CLOSE IGV (0%) HIC 608
ET01 TURBINE - SPEED ALARM SWITCH SSAHH

HIGH HIGH 675
ET01 TURBINE – SPEED ALARM LOW LOW UA 651 10S
ET01 TURBINE – SPEED ALARM SWITCH SSALL

2S
LOW LOW 675
ET01 TURBINE – OIL RETURN TEMPERATURE

TAHH 671
HIGH HIGH
ET01 TURBINE – OIL – PRESSURE SWITCH PSALL

ALARM LOW LOW 672
ET01 TURBINE – OIL – PRESSURE ALARM

PALL 672
LOW LOW
ET01 TURBINE – VIBRATION ALARM HIGH VXAHH 30S

HIGH 673
ET01 TURBINE – OIL PUMP ON/OFF NO EL 680

OR AND
COLD BOX EMERGENCY SWITCH HA Y60
OUTLET TURBINE - TEMPERATURE ALARM

TALL 608
LOW LOW
UNIT – SHUTDOWN I60 2S
ET01 TURBINE – SPEED ALARM OPEN LOOP SA 675 5S
ET01 TURBINE – OIL RETURN ALARM OPEN 5S

TA 671
LOOP
OUTLET TURBINE – TEMPERATURE ALARM

TA 608 5S
OPEN LOOP
ET01 TURBINE – VIBRATION ALARM OPEN

VXA 673 5S
LOOP
ET01 TURBINE – SEAL GAS – DIFFERENTIAL

PDA 670 5S
PRESSURE ALARM OPEN LOOP
ET01 TURBINE – OIL – PRESSURE ALARM

PA 672 5S
OPEN LOOP
ET01 TURBINE – EMERGENCY STOP HA 600
Job nbr. : C.57506 Doc No. : 013-901
Rev. 01
CAUSES AND EFFECTS
OIL PUMP ET01.P1 SHUTDOWN

CAUSES ACTIONS
DISCREPANCY EA 680 5S STOP OIL PUMP EY 680
PDALL
670 OR AND
ET01 TURBINE - SEAL GAS -– DIFFERENTIAL
AND
PRESSURE LOW LOW
SALL
675
OIL PUMP - READY TO START I11

CONDITIONS ACTIONS
ET01 TURBINE - SEAL GAS - NOT PDAL

START OIL PUMP EY 680
DIFFERENTIAL PRESSURE LOW 670
ET01 TURBINE – OIL PUMP – NOT LEVEL LSAL

SWITCH ALARM LOW 687
AND AND
HSH
2S
OPERATOR START 680
HEATER OIL TANK TEMPERATURE ALARM TSH

SWITCH HIGH 690
TURBINE DERIMING
CONDITIONS ACTIONS
ET01 TURBINE - OIL PUMP ON EL 680

AND AND TURBINE DERIMING ON HL 652
HSH
OPERATOR START DERIMING 2S
652
Job nbr. : C.57506 Doc No. : 013-901
Rev. 01
CAUSES AND EFFECTS
7. CONDENSER PURGE: INTERLOCK I29
READY TO START
CONDITIONS ACTIONS
COLD BOX - IN SERVICE HL 600 START AUTOMATIC DRAIN SEQUENCE FX 603
LAH
OVERALL LEVEL HIGH 601
AND AND
OUTLET TURBINE - TEMPERATURE ALARM TALL
2MIN
LOW LOW 608
HSH
OPERATOR START PURGE 603
STOP
CONDITIONS ACTIONS
OUTLET GASEOUS NITROGEN PRODUCTION

HL 615
VALVE OPEN STOP AUTOMATIC DRAIN SEQUENCE FX 603
AND AND
SUBMERGENCE LEVEL LOW LAL 614
COLD BOX - SHUTDOWN I05
SHUTDOWN
CAUSES ACTIONS
FXALL
INSUFFICIENT DRAIN LAST 24H 24H 2S 2S UNIT TRIP I60
603
Job nbr. : C.57506 Doc No. : 013-901
Rev. 01
CAUSES AND EFFECTS
8. K01 PURGE: INTERLOCK I15
OPEN
CONDITIONS ACTIONS
LXSH
2S
K01 LEVEL HIGH LIMIT 602 OPEN K01 DRAIN VALVE KV 623
AND AND
CLOSE
CONDITIONS ACTIONS
LXSL
2S
K01 LEVEL LOW LIMIT 602 CLOSE K01 DRAIN VALVE KV 623
AND AND
Job nbr. : C.57506 Doc No. : 013-901
Rev. 01
CAUSES AND EFFECTS
9. LIN PRODUCTION: INTERLOCK I19
READY TO START
CONDITIONS ACTIONS
AUTHORIZATION TO OPEN PRODUCTION

HSH
OPERATOR START PRODUCTION 2S 30S VALVE LY602
602
SOLENOID ENERGIZED
HL
GAN PRODUCTION ON 30S OPEN LIN PURGE KV633
615A
ET01 TURBINE – INLET VALVE OPENED KV 651 30S 2S COLUMN LEVEL CONTROL IN AUTOMATIC LIC602
AND AND
HS
LIQUID PRODUCTION SELECTOR
602S
NO
NOT HIGH OXYGEN CONTENT ASH 60 S
618
ANALYSER NOT IN CALIBRATION HS 618 60 S
SHUTDOWN
CAUSES ACTIONS
OUTLET GASEOUS NITROGEN PRODUCTION AAHH

– O2 ALARM ANALYSIS HIGH HIGH 618 CLOSE – LIN PRODUCTION VALVE LY602
COLD BOX - SHUTDOWN I05 30S OPEN – LIN PURGE KV633
OR AND HY
I11
ET01 TURBINE – SHUTDOWN CLOSE – LIN STORAGE INLET VALVE 813A
ET01 TURBINE – INLET VALVE CLOSED KV 651
LIN STORAGE – SHUTDOWN I61 2S
Job nbr. : C.57506 Doc No. : 013-901
Rev. 01
CAUSES AND EFFECTS
10. MP GAN PRODUCTION: INTERLOCK I21
READY TO START – PRODUCTION

CONDITIONS ACTIONS
HSH OPEN - GAN PRODUCTION VALVE IA FY

OPERATOR START PRODUCTION 2S
615 SUPPLY 615A
NOT HS
GAN SELECTOR CLOSE – LIN PRODUCTION VALVE HY 602
602S
AND AND
NO
NOT HIGH OXYGEN CONTENT ASH 3MIN
618
COLD BOX - IN SERVICE HL 600 60 S
SHUTDOWN
CAUSES ACTIONS
OUTLET GASEOUS NITROGEN PRODUCTION AAHH CLOSE - GAN PRODUCTION VALVE IA FY

60S 2S
- O2 ALARM ANALYSIS HIGH HIGH 618 SUPPLY 615A
OR AND FIC
I05 2S PUT FLOW CONTROLER IN MANUAL 0%
COLD BOX - SHUTDOWN 615A/B
ANALYSER SIGNAL OPEN LOOP AA 618 60S 2S 2S START VAPORIZATION SYSTEM I65
Job nbr. : C.57506 Doc No. : 013-901
Rev. 01
CAUSES AND EFFECTS
11. DERIMING HEATER: INTERLOCK I86
SHUTDOWN
CAUSES ACTIONS
DISCREPANCY EA 093 STOP DERIMING HEATER EY 093
ELECTRICAL FAULT UA 093
TAHH
HIGH HIGH PIN TEMPERATURE
093
PDALL
LOW LOW DIFFERENTIAL PRESSURE
095
OR AND
HIGH TEMPERATURE AT OUTLET OF TSH
DERIMING HEATER 095
COLD BOX ON HL 600
HSL
OPERATOR STOP DERIMING
093
READY TO START
CONDITIONS ACTIONS
NOT
COLD BOX OFF START DERIMING HEATER EY 093
HL 600
AND AND
HSH
OPERATOR START DERIMING 2S
093
Job nbr. : C.57506 Doc No. : 013-901
Rev. 01
CAUSES AND EFFECTS
12. INSTRUMENT AIR: INTERLOCK I88
SHUTDOWN
CAUSES ACTIONS
PAL
LOW INSTRUMENT AIR PRESSURE 5S OPENING OF BACK UP INSTRUMENT AIR PY051
050
OR AND
CLOSING OF BACK UP IA VENT VALVE PY052
ET01 TURBINE – SEAL GAS – NOT PDAL

AND AND OPENING OF BACK UP INSTRUMENT AIR PY055
DIFFERENTIAL PRESSURE ALARM LOW 670
READY TO START
CONDITIONS ACTIONS
NOT
INSTRUMENT AIR PRESSURE NOT LOW PAL 5S CLOSING OF BACK UP INSTRUMENT AIR PY051
050
AND AND
PI212
AIR PURIFICATION UNIT PRESSURIZED OPENING OF BACK UP IA VENT VALVE PY052
PI222
ET01 TURBINE – SEAL GAS – DIFFERENTIAL PDAL

AND AND CLOSING OF BACK UP INSTRUMENT AIR PY055
PRESSURE ALARM LOW 670
Job nbr. : C.57506 Doc No. : 013-901
Rev. 01
CAUSES AND EFFECTS
13. LIN STORAGE: INTERLOCK I61
SHUTDOWN
CAUSES ACTIONS
V50 LIN STORAGE – LEVEL ALARM HIGH LAHH CLOSE INLET VALVE HY
2S
HIGH 822 SOLENOID DESACTIVATED 813A
LA
V50 LIN STORAGE – LEVEL ALARM OPEN 822 CLOSE PBUC VALVE PY
5S
LOOP AND PRESSURE ALARM OPEN LOOP AND PA SOLENOID DESACTIVATED 821A
821
V50 LIN STORAGE – PRESSURE ALARM HIGH PAHH

2S OR AND
HIGH 821
HS
V50 CONTROL ROOM EMERGENCY STOP
821A
HS
V50 LOCAL EMERGENCY STOP
821B
INLET VALVE (HV 813A) CLOSING

CAUSES ACTIONS
HSL CLOSE INLET VALVE HY

OPERATOR CLOSE COMMAND 2S
813A SOLENOID DESACTIVATED 813A
LAH
V50 LIN STORAGE – LEVEL ALARM HIGH
822 OR AND
LIN STORAGE SHUTDOWN I61
LIN PRODUCTION SHUTDOWN I19
Job nbr. : C.57506 Doc No. : 013-901
Rev. 01
CAUSES AND EFFECTS
PBUC VALVE (PV 821A) CLOSING

CAUSES ACTIONS
PSH CLOSE PBUC VALVE PY

LIN STORAGE HIGH PRESSURE 2S OR AND 2S
PBUC VALVE (PV 821A) OPENING

CAUSES ACTIONS
PSL OPEN PBUC VALVE PY

LIN STORAGE LOW PRESSURE 2S OR AND 2S
OUTLET VALVE (HV 870) OPENING

CONDITIONS ACTIONS
NO HY
LIN STORAGE INLET VALVE NOT OPENED PERMISSIVE TO OPEN OUTLET VALVE HV 870
813A
AND AND
Job nbr. : C.57506 Doc No. : 013-901
Rev. 01
CAUSES AND EFFECTS
14. LIN VAPORIZATION: INTERLOCK IN I65
SHUTDOWN
CAUSES ACTIONS
E51 LIN VAPORIZER – 1 OUT OF 2 TALL CLOSE INLET VALVE PY

TEMPERATURE ALARM LOW LOW 974 SOLENOID DESACTIVATED 971A
E51 LIN VAPORIZER – 1 OUT OF 2 TA CLOSE INLET VALVE PY

5S
TEMPERATURE ALARM OPEN LOOP 974 SOLENOID DESACTIVATED 971B
NETWORK PRESSURE CONTROL

PIC 971
IN MANU 0%
NETWORK FLOW CONTROL IN MANU 0% FIC 971

OR AND
NETWORK TEMPERATURE CONTROL
TIC 974
IN MANU 0%
CLOSE TURBINE BACKUP SEAL GAS HY

DBB VALVE 985A
CLOSE TURBINE BACKUP SEAL GAS HY

DBB VALVE 985B
OPEN TURBINE BACKUP SEAL GAS HY

DBB VENT VALVE 985C
START
CAUSES ACTIONS
PAL OPEN INLET VALVE PY

NETWORK PRESSURE ALARM LOW 2S 2S
971 SOLENOID ACTIVATED 971A
OPEN INLET VALVE PY

I21 2S
GAN PRODUCTION - SHUTDOWN SOLENOID ACTIVATED 971B
ET01 TURBINE – SEAL GAS PRESSURE PDAL NETWORK PRESSURE CONTROL

2S 2S PIC 971
ALARM LOW 670 IN AUTO
HSH
OPERATOR START COMMAND 2S 2S NETWORK FLOW CONTROL IN AUTO FIC 971
971
OR AND
NETWORK TEMPERATURE CONTROL
TIC 974
IN AUTO%
PDAL OPEN TURBINE BACKUP SEAL GAS HY

670 DBB VALVE 985A
PDAL OPEN TURBINE BACKUP SEAL GAS HY

670 DBB VALVE 985B
PDAL CLOSE TURBINE BACKUP SEAL GAS HY

670 DBB VENT VALVE 985C

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11. MANTENIMIENTO
Este capítulo cubre las instrucciones generales para el mantenimiento de la Unidad tanto
en operación como los planes de inspección e intervención con parada de Planta.
El mantenimiento en plantas industriales busca mantener los equipos y sistemas
disponibles para operar, evitar el deterioro prematuro, y restablecer los equipos a la
condición de funcionamiento, a un costo razonable.
La confiabilidad se define como la probabilidad de que un sistema, equipo, o dispositivo
cumpla su función(es) para la cual fue adquirido durante un periodo de tiempo
establecido bajo condiciones operacionales preestablecidas en el diseño.
11.1. INSTRUCCIONES GENERALES DE MANTENIMIENTO

Tradicionalmente, se han distinguido 5 tipos de mantenimiento, que se diferencian entre
sí por el carácter de las tareas que incluyen, así como por las herramientas y metodologías
empleadas para la definición de los planes de intervención.
Mantenimiento correctivo
Es el conjunto de tareas destinadas a corregir los defectos que se van presentando en los
distintos equipos y que son comunicados al departamento de mantenimiento por los
usuarios de los mismos. No es objeto de planeación; sobreviene como consecuencia de la
necesidad de reparar una avería imprevista o por una condición imperativa que debe ser
subsanada sin espera (problemas de seguridad, de contaminación, de aplicación de
normas legales, etc.) y usualmente se atiende con criterio de emergencia.
Al tratarse de urgencias, el mantenimiento correctivo en muchas ocasiones no permite
un análisis exhaustivo de las fallas; igualmente, su ejecución puede trastornar los planes
de mantenimiento programados o generar sobrecostos por horas extras al personal de
mantenimiento de la refinería, así como la necesidad de mantener stocks de seguridad
de partes y repuestos o planes de contingencia en suministro.
Mantenimiento preventivo
Es el mantenimiento que tiene por misión prevenir la ocurrencia de fallas y mantener un
nivel de servicio determinado en los equipos, programando las intervenciones de sus
puntos vulnerables en el momento más oportuno. Suele tener un carácter sistemático
basado en rutinas programadas en el tiempo, sin esperar a que el equipo presente alguna
sintomatología que permita anticipar algún problema.
Por ser parte de un plan de mantenimiento, permite programar las intervenciones sin
afectar el plan de producción de la refinería; asimismo, es posible prever los
requerimientos de personal, partes y repuestos evitando sobrecargas en el plan de
personal, exceso de inventarios en almacén y compras de emergencia.

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Mantenimiento predictivo
Es el que persigue conocer e informar permanentemente del estado y operatividad de las
instalaciones mediante el conocimiento de los valores de determinadas variables,
representativas de tal estado y operatividad. Para aplicar este mantenimiento, es
necesario identificar variables físicas (temperatura, vibración, consumo de energía, etc.)
cuyas variaciones son indicativo de procesos de deterioro en curso que pueden derivar
en daños al equipo. La definición de las intervenciones requeridas involucra metodologías
analíticas y conocimientos técnicos avanzados.
Frente a la estrategia de mantenimiento preventivo, el mantenimiento predictivo genera
ahorros al optimizar la utilización de los equipos y permitir programar la intervención en
el momento justo antes de que se presente la falla. Permite también realimentar el
programa preventivo ajustando la frecuencia de intervención de los equipos de acuerdo
con la curva de desgaste específica en el servicio.
Mantenimiento Cero Horas (Overhaul)

Es el conjunto de tareas cuyo objetivo es intervenir los equipos a intervalos programados
bien antes de que aparezca ningún fallo, bien cuando la fiabilidad del equipo ha
disminuido apreciablemente de manera que resulta arriesgado hacer previsiones sobre
su capacidad productiva. Se busca reemplazar o reparar todos los elementos sometidos
a desgaste de manera que el equipo quede en su condición original, a Cero horas de
operación.
Mantenimiento en operación o Cuidado básico de los equipos

Es el mantenimiento básico de un equipo realizado por los usuarios del equipo. Consiste
en una serie de tareas elementales (tomas de datos, inspecciones visuales, limpieza,
lubricación, reapriete de tornillos) para las que no es necesario una formación
especializada, y que forman parte de la rutina diaria del personal a cargo de la operación.
Este tipo de mantenimiento permite atender y corregir de la manera más oportuna las
desviaciones que pueden derivar en daño a los equipos, y genera sentido de pertenencia
en el operador respecto a los equipos y la Planta al involucrarlo directamente en la gestión
de confiabilidad.
Las novedades detectadas durante la ejecución de las rutinas de cuidado básico de los
equipos son un elemento importante en el análisis y actualización de los planes de
mantenimiento preventivo de la Planta.
Ventanas operativas de integridad

El régimen de operación de los equipos tiene un efecto determinante en la integridad y
la vida útil. Desde el diseño, cada componente está intencionado para trabajar dentro de

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un rango determinado en sus parámetros críticos, a efectos de obtener el desempeño

esperado. En caso de que se excedan los límites de esta ventana segura de operación, los
equipos o componentes estarán sujetos a condiciones que exceden sus parámetros de
diseño y estarán en riesgo de falla.
Figura 5 - Ventana operativa de integridad
Las ventanas operativas de integridad deben definirse para todos los parámetros que
puedan afectar la confiabilidad o la integridad de los equipos o componentes de la Planta.
Parámetros químicos como pH, contenido de agua, contenido de agentes agresivos
(azufre, oxígeno, cloruros, etc.), o físicos como presión absoluta, presión diferencial,
temperatura, ratas de calentamiento o enfriamiento, entre otros deben ser considerados
para definir los límites de operación estable y las ventanas operativas de integridad como
se muestra en la Figura 5.
Las ventanas operativas de integridad deben ser clasificadas de acuerdo al riesgo que su
violación puede representar para la integridad de los equipos o componentes. Esta
clasificación establece las prioridades de notificación al operador, incluyendo alarmas o
acciones automáticas de emergencia.
El historial de las ventanas operativas de integridad es importante en el análisis de falla
de los equipos y en la definición de los planes de intervención.
Para la definición de las Ventanas Operativas de Integridad para cada equipo de la Planta
debe consultarse la información de diseño y el Manual de Operación suministrados por
los fabricantes de los equipos.

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Sistema de gestión de activos

La Gestión de Activos se define según como el conjunto de actividades y prácticas
coordinadas y sistemáticas por medio de las cuales una organización maneja de manera
óptima y sustentable sus activos y sistemas de activos, su desempeño, riesgo y gastos a
lo largo de sus ciclos de vida, con el fin de lograr su plan estratégico organizacional.
El ciclo de vida abarca desde la concepción de un activo hasta la desincorporación y/o
renovación, pasando por el diseño, construcción, puesta en marcha, operación,
mantenimiento y mejoramiento.
El termino optimización se refiere a la mejor relación de costos, riesgos y beneficios.
Un sistema de gestión se refiere a la manera en que se especifican, controlan las prácticas
requeridas para cumplir con los planes organizacionales y normalmente se basan en
círculo de la calidad: Planificar, Hacer, Verificar y Actuar.
Como parte del Sistema de Gestión se establece la manera de llevar a terreno de manera
auditable las aspiraciones de la gerencia corporativa, convirtiendo las políticas,
estrategias, objetivos y finalmente planes con acciones específicas sobre las personas con
las competencias, responsabilidades y autoridades requeridas.
De esta manera el sistema de gestión de mantenimiento es un mecanismo muy valioso
para asegurar que los principios de planificación total del ciclo de vida, gestión de riesgo,
costo/beneficio, enfoque al cliente, sustentabilidad, etc. sean realmente implementados
dentro del trabajo diario de implementación de proyectos de capital, operaciones,
mantenimiento, etc.
11.2. MANTENIMIENTO DE INSTRUMENTOS

La tipología de la instrumentación instalada en la Planta no difiere significativamente de
aquella instalada en otras plantas de la refinería, y el programa de mantenimiento, salvo
procedimientos especiales definidos por los proveedores, los cuales deben ser
consultados en los manuales de operación y mantenimiento suministrados por los
fabricantes, es definido por los departamentos de confiabilidad y de Planeación del
Mantenimiento de la refinería.
La instrumentación asociada a lazos críticos de seguridad de la Planta cuenta con
Interruptores de Bloqueo para Mantenimiento (Maintenance Override Switches – MOS)
los cuales permiten adelantar revisión, ajuste, reparación o cambio sin afectar la
operación de la unidad. Estas intervenciones deben surtir un estricto protocolo de
seguridad coordinado entre operaciones y mantenimiento, con un monitoreo especial de
las variables operativas para evitar activación del lazo de interbloqueo intervenido y
afectación a la producción.

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En la Tabla 10 se presentan las tareas típicas de mantenimiento de la instrumentación de

la refinería. Este listado no reemplaza el plan de mantenimiento indicado por los
fabricantes
Tabla 10 - Tareas típicas de inspección y mantenimiento de la instrumentación
INSTRUMENTO ACCIONES TÍPICAS DE INSPECCIÓN/MANTENIMIENTO
ANALIZADORES, DETECTORES - Verificación condiciones de trabajo (presión, flujo,
temperatura, sistemas de filtrado, etc.)
- Verificación sistema coalescente (extracción de agua)
- Verificación sistema de frío
- Correcto envío del efluente
EQUIPOS DE SISTEMA - Comprobar tensiones de alimentación
CONTROL DISTRIBUÍDO - Comprobar tarjetas convertidoras A/D y D/A
- Comprobar tarjetas salida
- Comprobar estaciones de operación.
- Comprobar rizado fuentes de alimentación
- Comprobar resistencia de tierra
INTERRUPTORES DE ALARMA - Cambio de membrana
O CORTE - Cambio de fuelle
- Limpieza de contactos
- Cambio de ampolla de mercurio
- Cambio de microinterruptor
- Cambio de flotador
ACTUADORES ELÉCTRICOS - Comprobar estanqueidad en las tapas
- Comprobar autodiagnóstico
- Comprobar alimentación
- Comprobar engrase
- Comprobar carrera
EQUIPOS DE MONITOREO DE - Cambio de sonda
MÁQUINAS - Comprobar estado cableado y aislamiento
- Calibrar sensor de proximidad
- Revisar señal en campo / monitor
MANÓMETROS MECÁNICOS - Reemplazo
- Calibración con patrón de presión
- Cambio de elementos (cristal,. bourdon, etc)
TERMOPARES - Sustitución de termopar
- Comprobar conexionado en cabeza del termopar
TERMORESISTENCIAS - Comprobar señalización en panel con generador de Milivoltios
- Contrastar con patrón de temperatura en taller
INDICADORES VISUALES DE - Cambio de cristales
NIVEL - Cambio de juntas
- Limpieza de cristales
- Cambio de láminas en mica
CONVERTIDORES - Comprobación conversión P/I
- Comprobación conversión I/P

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INSTRUMENTO ACCIONES TÍPICAS DE INSPECCIÓN/MANTENIMIENTO

- Limpieza relé-tobera
TRANSMISORES PRESIÓN, - Comprobar alimentación

PRESIÓN DIFERENCIAL, - Verificar calibración en 5 puntos
TEMPERATURA - Comprobar cero estático
- Reponer sellos
VÁLVULAS SOLENOIDE - Cambio de bobina
- Limpieza
- Activar/desactivar solenoide
- Comprobar visualización en pantalla PLC
VÁLVULAS AUTOMÁTICAS - Cambio obturador
- Cambio asiento
- Cambio empaquetadura
- Prueba estanqueidad
- Comprobación carrera
- Calibración
DETECTOR DE LLAMA - Prueba de funcionamiento
- Limpieza y revisión de lente y detector
- Cambio de óptica
- Comprobar estanqueidad en la junta de la tapa
VÁLVULAS DE SEGURIDAD - Desmontaje, inspección, limpieza y reparación/sustitución de
partes.
- Lapeado de área de sello.
- Ensamblaje
- Prueba y calibración del disparo en banco de pruebas.
- Prueba de estanqueidad (fugas al 90% Pset)

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11.3. MANTENIMIENTO DE EQUIPOS DINAMICOS

Los planes y los procedimientos de mantenimiento del equipo rotativo de la Planta deben
ceñirse estrictamente a las indicaciones suministradas por los fabricantes en los Manuales
de Operación y Mantenimiento ; desviaciones de lo indicado por los fabricantes pueden
conllevar pérdida de las garantías y afectación de la integridad y la vida útil de los equipos.
Bombas
Los servicios de bombeo de régimen continuo cuentan con un conjunto bomba-motor
principal y uno auxiliar, lo que permite la rotación de los mismos durante la operación de
la Planta, y la intervención por mantenimiento en caso de ser requerido.
Cuidado básico de las bombas

El monitoreo continuo del equipo rotativo por parte del operador es decisivo en la
detección temprana de anomalías que pueden conducir a fallas. Durante las rondas
operativas, el operador debe observar cuidadosamente el desempeño del equipo y las
variables operacionales. Este monitoreo le permitirá detectar posibles comportamientos
anormales cuyo origen y tratamiento deberá ser definido por el técnico de confiabilidad.
Entre las señales y/o parámetros que debe observar el operador están:
 Temperatura del aceite lubricante o del agua de refrigeración: Un aumento en la
temperatura del aceite saliendo de los cojinetes, o del agua de refrigeración en el
retorno puede significar problemas mecánicos en el equipo.
 Estado del aceite: La presencia de partículas en suspensión en el aceite o
depositadas en los filtros es indicio de desgaste de los materiales. Igualmente, la
contaminación del aceite con agua o la turbidez excesiva pueden afectar la función
lubricante.
 Nivel de aceite: La pérdida excesiva de aceite lubricante es indicio de anomalías
en el circuito que deben ser corregidas.
 Nivel/Presión de sello: Los sistemas de sello que trabajan con fluido barrera
disponen de medición de parámetros que permiten determinar la falla de los
sellos primarios de los equipos, y programar la intervención antes de que se
presenten fugas al exterior.
 Monitoreo del ruido: Dado que el operador es quien mejor conoce el
comportamiento normal de los equipos, un cambio en el ruido característico
durante la operación puede ser fácilmente detectado, lo que le permitirá tomar
acciones oportunas en caso de que se concluya que el origen del problema pueda
estar asociado a desviaciones de las ventanas operativas (ej. cavitación), o alertar
al personal técnico de confiabilidad para adelantar análisis de mayor profundidad,
conducentes a determinar las causas de la desviación.

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Intervenciones de mantenimiento en las bombas

Tal como fue indicado anteriormente, la intervención por mantenimiento en los equipos
debe seguir de manera estricta las indicaciones y procedimientos definidos por los
fabricantes. En esta sección se presentan las tareas típicas de mantenimiento para las
tipologías de equipos instalados en la Planta.
Tabla 11 - Tareas típicas de inspección y mantenimiento de los equipos de bombeo

EQUIPO ACCIONES TÍPICAS DE INSPECCIÓN/MANTENIMIENTO
BOMBAS CENTRÍFUGAS - Reparación de sellos mecánicos
- Cambio de rodamientos
- Limpieza de filtros
- Engrase
- Revisar circuitos de refrigeración
- Alineación y balanceo
- Preventivo según condición
BOMBAS DE Bombas Reciprocantes:
DESPLAZAMIENTO - Reparación de válvulas
POSITIVO - Cambio de membrana
- Empaquetaduras
- Preventivo engrase
Bombas de tornillo:
- Cambio de rodamientos
- Reparación de cierres mecánicos
- Engrase
- Limpieza de filtros
Compresores
Los compresores son máquinas de un nivel de complejidad alto y su operación, cuidado
básico y mantenimiento demandan especial conocimiento y entrenamiento del personal
de operaciones y mantenimiento a cargo, así como un estricto cumplimiento de las
ventanas operativas y los planes de inspección y mantenimiento definidos por los
fabricantes.
Intervenciones de mantenimiento en los compresores

No existen planes de intervención “típicas” para los compresores, y para este propósito
es preciso remitirse a los manuales de operación y mantenimiento de los fabricantes de
cada máquina.

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11.4. MANTENIMIENTO DE EQUIPOS MAYORES Y EQUIPOS PAQUETE PRINCIPALES

Los planes de mantenimiento del equipo estático deberán ser definidos mediante una
estrategia integrada de gerenciamiento del riesgo que involucra:
 Definición / selección de los equipos que deben ser inspeccionados
 Inspección inicial del equipo antes del arranque inicial
 Primera inspección luego de la entrada en operación
 Programa de mantenimiento regular. Definición de intervalos de inspección.
 Alcance de la inspección
En el enfoque de Gerenciamiento del Riesgo, la inspección del equipo es una de las áreas
de acción para el dueño del activo. Deben igualmente considerarse acciones en
mantenimiento preventivo, muestreo de materiales, pruebas de presión, seguimiento
estricto de las ventanas operativas y entrenamiento al personal, entre otras.
Definición del Plan de Inspección
Selección de los equipos que deben ser inspeccionados

El Plan de Inspección de la Planta debe cubrir todos los elementos de seguridad
dispuestos en la Unidad, así como los recipientes y equipos a presión y tuberías en los
cuales un defecto puede conducir a la liberación no controlada de energía contenida que
pueda constituir un riesgo importante para las personas, el ambiente, la instalación o la
producción.
La determinación de la frecuencia, profundidad y naturaleza de las inspecciones de los
equipos, se requerirá disponer de la siguiente información:
 Posibles mecanismos y tasas de deterioro en relación con la duración del servicio.
 Sitios que pueden ser particularmente susceptibles a deterioro o falla
 Posibles tipos de defectos o degradación.
 Tolerancia de la pieza a defectos o degradación.
 Probabilidad de falla en operación.
 Modo de falla probable.
 Consecuencias de la falla.
 La clasificación del riesgo.

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Inspección Línea Base antes del arranque inicial

En plantas nuevas, una vez terminado el montaje mecánico y las etapas de
precomisionamiento y comisionamiento, se debe adelantar una inspección inicial que
asegure que todo el equipo está en condición satisfactoria para la operación, y que provea
información útil como base para posteriores inspecciones. Para este propósito también
deben considerarse los resultados de las pruebas e inspecciones realizadas durante el
diseño y fabricación de los equipos.
La inspección de línea base se refiere a un programa de inspección ejecutado bajo la
responsabilidad del grupo de inspección del propietario después de que se entregue el
activo. Los resultados de la inspección deben ser medibles y de suficiente confianza para
una evaluación oportuna y para compararlos con los documentos de calidad de
fabricación y los hallazgos que se encuentren en las inspecciones futuras.
Cuando se habla de cualquier equipo o tubería en operación en una planta, hay ciertas
propiedades clave que deben controlarse, incluidos, entre otros, sus materiales de
construcción, su diseño y espesor instalado, y su revestimiento o aislamiento.
A continuación, se presentan cada una de estas propiedades con mayor detalle para ver
la practicidad de verificarlas en las primeras etapas de la operación de la planta.
• Verificación de los materiales de construcción

Se debe crear una lista de equipos críticos según su impacto en la seguridad como el
primer elemento para priorizar y verificar en un programa de inspección de línea base. Lo
primero que se debe verificar es que se hayan instalado los materiales de construcción
correctos tanto para los equipos como para las tuberías. Esto incluye la verificación de
actividades como tratamiento térmico, controles de chequeo, controles de perfil de
soldadura, según lo dictado por la criticidad inicial o la evaluación RBI.
La tubería es típicamente más vulnerable a las discrepancias de materiales y
ocasionalmente ocurre por error. Por lo tanto, se debe inspeccionar el sistema de tuberías
para verificar que se usaron los materiales correctos en todo momento, tomando un
muestreo aleatorio. Se puede usar el análisis basado en el riesgo para identificar los
circuitos de mayor preocupación y / o utilizar métodos estadísticos para determinar un
tamaño de muestra representativo para satisfacer el nivel de confianza requerido.
Al revisar los sistemas de tuberías para una correcta instalación del material, las tuberías
de bajo diámetro y alto riesgo no deben ignorarse o considerarse de baja prioridad solo
porque son pequeñas. La identificación positiva del material (PMI) se debe realizar
durante la inspección de la línea base. También es importante que los Informes de no
conformidad se recopilen, registren y evalúen durante la construcción de la planta.

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• Espesor de diseño versus espesor instalado

Es importante verificar que el espesor de la tubería esté en línea con las especificaciones
de diseño. Se debe mantener un registro de cualquier no conformidad para una
planificación y resolución efectivas. Se debe dar prioridad a los sistemas de tuberías
críticos para la seguridad y deben ser los primeros cuando se verifican los espesores
durante una inspección de línea base. Es una verificación importante cuando se calculan
las velocidades de corrosión, ya que los espesores nominales pueden ser inexactos
cuando se comparan con las inspecciones de espesores subsiguientes y producen
velocidades de corrosión inexactas.
El código de inspección en servicio API 510 de recipientes a presión menciona en su
numeral 6.2.1 Instalación de equipos, que los recipientes de presión deberán ser
inspeccionados por un inspector al momento de la instalación. El propósito de esta
inspección es verificar que el equipo es seguro para operar, que no hayan ocurrido daños
inaceptables durante su transporte al lugar de instalación, y para iniciar los registros en
planta de inspección del equipo. Esta inspección también proporciona una oportunidad
para recopilar la información deseada de partida y obtener las lecturas iniciales de
espesor en los CML (Condition Monitoring Locations) designados.
El código de inspección en servicio de tuberías de proceso API 570 menciona en su
numeral 6.2, Las tuberías deben inspeccionarse de acuerdo con el código de construcción
al momento de la instalación. El propósito de la inspección durante instalación es verificar
que la tubería esté limpia y segura para la operación, e iniciar los registros de inspección
de la planta para los sistemas de tubería. Esta inspección de la instalación debe
documentar las mediciones de espesor de la línea de base que se utilizarán como lecturas
de espesores iniciales para los cálculos de velocidad de corrosión en lugar de los datos de
espesor nominal y mínimo en las especificaciones, las hojas de datos/dibujos de diseño.
Esto también facilitará la creación de un cálculo preciso de la velocidad de corrosión
después de que se registren las primeras mediciones de espesor en servicio.
El API 580 menciona que una fuente potencial de dispersión y error en el análisis, y es la
suposición sobre la historia del equipo. Por ejemplo, si la inspección de la línea base no
se realizó o documentó, el espesor nominal puede ser usado como espesor original. Esta
suposición puede afectar significativamente la velocidad de corrosión inicialmente
calculada en la vida del equipo. El efecto puede ser enmascarar una velocidad de
corrosión o inflar una velocidad de corrosión que realmente es baja. Una situación similar
se da cuando la vida útil remanente de un equipo, con una velocidad de corrosión alta
requiere inspección con mayor frecuencia de inspección. El error de medición puede
resultar en que la velocidad de corrosión aparece calculado artificialmente alta o baja. Es
importante entender que los supuestos que hacen tienen impacto potencial sobre el
cálculo del riesgo.

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• Apropiada instalación de pintura y aislamiento térmico

El último parámetro que debe verificarse en un programa de inspección de línea base es
la condición de la pintura y el aislamiento de los equipos y las tuberías. La aplicación o
instalación inadecuada y la mala calidad de los materiales pueden ser costosos cuando se
trata de recubrimientos y aislamientos. Los problemas incluyen, pero no se limitan a,
aislamiento térmico de baja calidad (resultados en pérdidas de energía y en la calidad del
producto y la confiabilidad del equipo), deterioro del metal principal, corrosión
atmosférica y corrosión bajo aislamiento (CUI), así como agrietamiento bajo aislamiento.
Aunque la pintura y el aislamiento se pueden inspeccionar visualmente, se recomienda
una inspección adicional. Ensayos no destructivos, como la termografía infrarroja, puede
evaluar la eficacia del aislamiento según las especificaciones. También es una buena
inversión realizar un trabajo eficaz de inspección de revestimiento, QA / QC, que incluye
medir el espesor del revestimiento, la preparación de la superficie, las condiciones
atmosféricas durante la aplicación, el curado adecuado y los perfiles de superficie según
las especificaciones. Una buena calidad de recubrimiento protege el equipo contra la
corrosión atmosférica y CUI.
Una vez que se realizan las inspecciones de línea base, todas las recomendaciones deben
documentarse, compilarse y presentarse al equipo de administración para su revisión
inmediata y se debe desarrollar un plan de remediación, según sea necesario. Una
inspección de línea base efectiva puede ahorrar millones al proporcionar información
precisa de la línea base para futuras comparaciones y prevenir incidentes de seguridad
causados por descuidos críticos durante la fase de construcción, incluida la instalación
incorrecta del material, espesores más delgados de lo esperado y un revestimiento y
aislamiento de los equipos de baja calidad.
Primera inspección luego de la entrada en operación

La primera inspección luego de la entrada en servicio de la Planta es determinante para
el establecimiento de la línea base de la condición de los equipos. Una inspección
temprana puede detectar inicios de falla o deterioro resultante de un diseño inadecuado,
fallas en fabricación no detectadas durante las inspecciones, o condiciones de operación
diferentes a las de diseño. Esta inspección provee información específica de enorme valor
para el análisis de riesgos que soporta la filosofía de confiabilidad. Es práctica normal en
algunas autoridades la aprobación de los análisis de riesgos solamente después de que se
haya realizado la primera inspección luego de la entrada en operación.
El período para la primera inspección después de la entrada en operación debe estar
definido en el Plan de Confiabilidad, y en todo caso, no debería exceder de 24 meses de
operación. Para la definición de este tiempo deben considerarse los siguientes aspectos:
 Los resultados generales y el nivel de conformidad alcanzado en la inspección
inicial del equipo antes del arranque inicial.

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 El grado de certidumbre en relación con las condiciones reales de operación del

equipo.
 El nivel de tolerancia al riesgo en caso de fallas en diseño o fabricación.
El nivel de riesgo asociado a las fallas potenciales de los equipos permite establecer la
prioridad para la inspección de cada equipo lo que podría permitir, dependiendo de la
flexibilidad del diseño y el impacto en la operación, escalonar la primera inspección
después del arranque inicial. Aún si hay equipos nominalmente idénticos y sometidos a
condiciones similares de operación, deben ser tratados como elementos individuales e
independientes e inspeccionados sin excepción.
Intervalos de inspección
No existe un intervalo predefinido para la inspección de equipos; esta definición debe ser
realizada por un equipo técnico competente y experimentado y con base en información
relevante. Es posible que haya equipos o partes de equipos o de la Planta que requieran
intervalos de inspección diferentes.
Así mismo, la definición de los intervalos de inspección debe armonizarse con aspectos
operacionales de la Unidad como los ciclos de los catalizadores, o de la refinería como la
disponibilidad de materia prima, el manejo de productos o los planes de inspección de
otras unidades relacionadas.
La definición del intervalo de inspección debe estar encaminada a asegurar la posibilidad
de identificar en forma temprana cualquier deterioro o mal funcionamiento que pueda
afectar la integridad del activo y la operación segura del sistema. Las consecuencias de la
falla de equipos y sistemas ya ha sido considerada en la definición de los equipos a
inspeccionar de acuerdo con lo indicado en el numeral 11.4.1.1, por lo que para la
definición de los intervalos se consulta información complementaria relevante como:
 Recomendaciones del fabricante.
 Registros de seguridad, edad e historial del equipo o sistema.
 Información genérica existente sobre sistemas similares.
 Régimen de operación previsto, incluyendo calidad de los fluidos.
 Normas y estándares de la refinería.
 Requisitos legales.
Alcance de la inspección
La inspección de equipos es costosa y la definición del alcance se convierte en un tema
relevante de decisión técnico-gerencial. Es preciso determinar si los riesgos a la integridad

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de un componente, equipo o sistema son generales (corrosión generalizada) o muy

particulares de componentes o equipos específicos.
Puntos con alta probabilidad de falla como soldaduras, zonas de alto stress, soportes de
equipos, superficies expuestas a fuego, entre otras deben ser incluidas en el Plan de
Inspección. El equipo técnico a cargo de la definición del Plan de Inspección debe generar
una prioridad para inspección de soldaduras considerando, entre otros, os siguientes
aspectos:
 Sitio de ejecución (taller/campo).
 Stress.
 Condiciones del servicio.
 Función de la junta en la estructura / equipo.
 Consecuencias en el evento de falla.
 Grado de incertidumbre de la información base analizada.
Metodologías de inspección local y Ensayos No Destructivos - NDT

A continuación se describen los principales métodos de inspección y ensayos no
destructivos para la determinación de defectos en los equipos estáticos.
Inspección Visual
Con o sin la ayuda de elementos ópticos, la inspección visual se hace con el objeto de
determinar grietas sobre la superficie del material. Existen ayudas ópticas que mejoran
de manera importante la calidad del diagnóstico, desde una lupa manual hasta
endoscopios de fibra óptica para la inspección de áreas de acceso restringido. La
efectividad de la técnica es fuertemente dependiente del nivel de luz disponible.
Normalmente se emplea como técnica de inspección preliminar o complementaria con
otras metodologías.
Prueba de Líquidos Penetrantes

En la prueba de Líquidos Penetrantes se aplica una tinta penetrante sobre la superficie a
inspeccionar. El líquido penetra en las grietas del material por capilaridad. La aplicación
de un revelador extrae el líquido de la grieta dejando una huella en la superficie del
material.
Es una prueba rápida, de fácil aplicación y bajo costo; sin embargo, es limitada a
superficies limpias de materiales no porosos y solamente puede detectar grietas abiertas
a la superficie del metal, y no puede detectar grietas parantes en el material.

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Inspección con Partículas Magnéticas

El material es magnetizado y luego cubierto por una capa de líquido con partículas de
limadura de hierro en suspensión. Si el material está sano, las líneas de flujo de material
magnético se verán perfectamente alineadas. Al encontrar una grieta, los campos
magnéticos se distorsionan haciendo que las líneas de flujo rodeen el defecto
evidenciándolo.
Este método es solamente aplicable a materiales que puedan ser magnetizados, y solo
aplica para la detección de defectos superficiales.
Inspección con corrientes de Eddy

Una bobina energizada se coloca cerca al elemento a analizar. La corriente en la bobina
genera corrientes circulantes de Eddy sobre la superficie del material y estas a su turno
afectan la corriente en la bobina por inducción mutua. Los defectos superficiales en el
material afectan la magnitud de las corrientes de Eddy por lo que pueden ser detectados
al medir los cambios eléctricos en la bobina excitadora.
Es un método de muy alta precisión en la detección de defectos, pero igualmente sensible
a indicaciones espurias por variaciones en la permeabilidad del material especialmente
en cercanías a las soldaduras, o por muy alta rugosidad del material. Adicionalmente, solo
puede ser aplicado a materiales electro-conductores, y requiere una alta experticia para
su aplicación e interpretación.
Radiografía
Para esta prueba, se bombardea el material con una haz de rayos X o rayos gama, con una
película fotográfica en el lado contrario a la fuente de la radiación, lo que genera una
película del material examinado. Para los rayos X se utiliza una fuente entre 20 kV y 20
MV de potencia. Para la radiación gama se utilizan isótopos radioactivos como cobalto-
60 o iridio-192.
Aunque la sensibilidad de la radiación gama es inferior a la obtenida con rayos X, la
portabilidad de los equipos requeridos la hace más atractiva para los trabajos de campo.
El método presenta algunas limitaciones en detección sobre superficies planas cuando las
grietas no están orientadas paralelamente al haz incidente. Tampoco puede determinar
defectos pasantes en el material. La radiación en el área es una de las principales
desventajas.

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Ultrasonido
Para este método se analiza el material con una probeta emisora de sonido de alta
frecuencia (en el rango de MHz), conectada a un osciloscopio. La captura del eco permite
determinar la localización y tamaño del defecto en el material.
La mayoría de los materiales de grano fino pueden ser analizados con esta técnica, incluso
hasta espesores bastante grandes. En contraste, materiales de grano grueso como el
acero austenítico pueden ser muy difíciles de analizar mediante ultrasonido.
El método presenta muy buena sensibilidad para la detección y dimensionamiento de
defectos, lo que la hace una de las metodologías más poderosas para el análisis no
destructivo de materiales. Sin embargo, requiere considerable experticia del inspector
para la calibración y operación del equipo, y para la interpretación de los resultados.
Esta técnica también es útil en la medición de espesores de material para determinación
de la vida residual en elementos sometidos a corrosión/erosión; sin embargo, en
espesores de soldadura menores a 5 mm la medición resulta difícil e imprecisa, al igual
que la medición en materiales de grano grueso, como las piezas de fundición y soldaduras
de acero inoxidable austenítico.
En la Tabla 12 se indican las metodologías de ensayo más comunes para la detección de
defectos superficiales en láminas de aceros ferríticos y austeníticos, y en la Tabla 13 se
presentan las metodologías para la inspección de soldaduras en los mismos materiales.
Tabla 12 - Metodologías de inspección y Ensayos No Destructivos para detectar

defectos superficiales en equipos
Inspección Prueba de Inspección por Inspección por
Visual Líquidos Partículas corrientes de
Penetrantes Magnéticas Eddy
Aceros Ferríticos    *
Aceros Austeníticos    *
Tabla 13 - Métodos para detección de defectos internos en soldaduras
Espesor del material base (t), mm
t≤8 8 < t ≤ 40 t > 40
Radiografía / Ultrasonido / Ultrasonido /
Soldadura ferrítica a tope
Ultrasonido Radiografía Radiografía
Soldadura ferrítica en Ultrasonido / Ultrasonido / Ultrasonido /

filete Radiografía Radiografía Radiografía
Soldadura austenítica a Radiografía / Radiografía /

Radiografía
tope Ultrasonido Ultrasonido

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Espesor del material base (t), mm

t≤8 8 < t ≤ 40 t > 40
Soldadura austenítica en Ultrasonido / Ultrasonido / Ultrasonido /
filete Radiografía Radiografía Radiografía
En la Tabla 14 se muestra la capacidad de los principales métodos de ensayo no

destructivo en la detección y dimensionamiento de defectos y espesores de materiales.
Tabla 14 - Capacidad de los métodos de ensayo no destructivo en la detección y

dimensionamiento de defectos y espesores de materiales
Inspecci Líquidos Partículas Corrient Radiograf Ultrasoni
ón Visual Penetrant Magnétic es de ía do
es as Eddy
Grietas
superficiales *    * 
Grietas
internas * 
Imperfeccion
Capacidad de es * 
detección Escoria
remanente  
Porosidad /
Vacíos  
Corrosión /
Erosión   
Localización
del defecto      
Longitud de
la grieta      
Capacidad de
Profundidad
dimensionamie
nto
de la grieta * 
Espesor del
material *  
Espesor del
aislamiento  
Mecanismos de Daño
Los siguientes son los principales mecanismos de daño objeto de estudio en la inspección
del equipo estático:

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Fragilización por Fase Sigma: Formación de una fase metalúrgica conocida como fase
sigma que puede resultar en una pérdida de tenacidad a la fractura como resultado de
exposición a alta temperatura.
Creep: Deformación plástica progresiva de un material sometido a un esfuerzo constante.
Se da a altas temperaturas y depende del tiempo. Involucra el desarrollo de vacíos a límite
de grano, los cuales coalescen para formar microgrietas, que a su vez se interconectan
para formar macrogrietas.
Ampollamiento por hidrógeno: El mecanismo de daño consiste en que el hidrógeno
atómico producido en la superficie del acero penetra en el material y se sitúa en los
lugares más susceptibles como, interfaces, inclusiones, carburos, cavidades, límites de
grano, ocasionando un aumento de la presión interna y una descohesión de los granos y
finalmente la aparición de fisuras.
Ataque por Hidrógeno a Alta Temperatura (HTHA): Es la reducción de resistencia y
ductilidad del material por reacción a alta temperatura del hidrogeno absorbido con
carburos del material, resultando en descarburación y fisuramiento interno.
Agrietamiento Inducido por hidrógeno (HIC): Es la fase en la cual las grietas internas
conectan las ampollas de hidrogeno adyacentes en diferentes planos del material.
Oxidación a Alta Temperatura: El oxígeno reacciona con el acero a alta temperatura
convirtiendo el metal en oxido.
Corrosión Bajo Esfuerzo (SCC): Es la acción combinada de un medio corrosivo y los
esfuerzos mecánicos produciendo agrietamiento del material, que puede ser
transgranular o intergranular. El esfuerzo involucrado puede ser residual o aplicado y la
corrosión generalmente es localizada.
Carburización: El carbono es absorbido en el material a temperaturas elevadas mientras
está en contacto con un ambiente carburante.
Corrosión Microbiólogica (MIC – Microbiologically Induced Corrosion): Es una forma de
corrosión causada por organismos vivos como bacterias, asociado usualmente a
ambientes acuosos.
Corrosión por Agua de Enfriamiento: Es una corrosión generalizada o localizada causada
por sales disueltas, gases, compuestos orgánicos o actividad microbiológica. Puede
resultar en diferentes formas de daño incluyendo corrosión general, picado (pitting), MIC,
SCC y ensuciamiento.
Corrosión Atmosférica: Es una forma de corrosión que se produce a partir de la humedad
asociada con las condiciones atmosféricas. Los ambientes marinos e industriales húmedos
y contaminados, son los más severos.
Inspección Basada en Riesgo (RBI)

El RBI es un instrumento dinámico que puede ofrecer evaluaciones de riesgos actuales y
proyectadas a futuro, basadas en datos y conocimientos en el momento de la evaluación.

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El API RP 580 proporciona el marco básico, los elementos y los requisitos para desarrollar
e implementar un programa RBI para los equipos y líneas de proceso. RP 580 está
destinado a complementar los códigos de inspección existentes (API 510, API 570 y API
653) relacionados con el aumento o la disminución de las frecuencias de inspección. Estos
códigos de inspección tienen disposiciones que permiten un análisis RBI para establecer
planes de inspección para equipos estáticos en la industria de refinación y petroquímica.
El RP 580 también proporciona disposiciones de las evaluaciones de RBI durante la fase
de diseño de los nuevos proyectos y puede beneficiar a los propietarios / operadores
durante la instalación, después del inicio, y la primer parada de planta e inspección.
Es importante mantener y actualizar el programa RBI para garantizar que la inspección
más reciente, la información del proceso y mantenimiento sean incluidas. Los resultados
de las inspecciones, los cambios en las condiciones del proceso y la aplicación de prácticas
de mantenimiento pueden tener efectos significativos sobre los riesgos, y por
consiguiente sobre el plan de inspección y puede provocar la necesidad de realizar una
nueva evaluación.
RBI tiene un enfoque de trabajo en equipo por lo cual requiere de la recopilación de datos
de diversas fuentes, análisis especializados, tales como el análisis de riesgo, análisis
financiero, estudios de riesgos realizados e incorporados en la operación, los materiales
y la ingeniería de corrosión, ingeniera de Proceso, la ingeniería mecánica y
mantenimiento, la inspección, etc. seguido de la toma de decisiones de gestión de riesgos.
Beneficios de un RBI
A continuación se enumeran los principales beneficios de implementar la metodología de
inspección basada en Riesgos (RBI)
 Base de datos iniciales del RBI para la gestión del ciclo de vida de los equipos.
Las evaluaciones de RBI durante la fase de ingeniería, procura y construcción (EPC)
proporcionarán a los propietarios / operadores una base de datos de RBI para el ciclo de
vida de la planta, que se puede actualizar en el futuro después de los estudios de línea
base se actualicen mediante las inspecciones por ejemplo en las paradas de planta.
El mejor enfoque para una mayor confianza en la inspección y la integridad de los activos
a largo plazo es realizar inspecciones de línea base al recibir un activo.
 Estimaciones de las velocidades de corrosión.

Como RBI requiere calcular las velocidades de corrosión para diferentes mecanismos de
adelgazamiento según API 581, estas velocidades de corrosión calculadas durante la fase
EPC brindan a los ingenieros de corrosión una buena idea acerca de los sistemas críticos
con altas ratas de corrosión esperadas durante el primer ciclo de operación. Se
recomienda prestar más atención a estos sistemas críticos durante la operación. La

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identificación de los mecanismos de daños en esta etapa proporciona orientación sobre

dónde colocar las CML (ubicaciones de monitoreo de condición) para las mediciones de
referencia y las inspecciones posteriores.
 Auditoria de los materiales de construcción.

Como la evaluación de riesgos requiere el cálculo de la probabilidad de falla para todos
los mecanismos de corrosión y daño durante el estudio, los componentes con servicio de
hidrocarburos tóxicos y / o inflamables que tienen altas velocidades de corrosión
calculadas, susceptibilidad al fisuramiento o a daños metalúrgicos pueden aparecer como
elementos de alto riesgo en la matriz de riesgo. La identificación de los elementos de alto
riesgo y sus factores de riesgo es extremadamente valiosa durante la fase de diseño del
proyecto. Brinda oportunidades para que los propietarios / usuarios evalúen las opciones
de materiales, comparando el costo del equipo hecho de varios materiales versus el nivel
esperado de confiabilidad, consecuencia de fallas y riesgos en cualquier período de
tiempo.
En la tubería se puede usar el análisis basado en el riesgo para identificar los circuitos de
mayor preocupación y / o utilizar métodos estadísticos para determinar un tamaño de
muestra representativo para satisfacer el nivel de confianza requerido para satisfacer el
requisito de riesgo.
 Identificación de información faltante.

Las evaluaciones de RBI requieren la revisión y la población de datos de ingeniería de
diferentes documentos tales como; especificaciones de materiales, hojas de instrucciones
de seguridad para elementos críticos de tuberías y equipos, P & ID, planos de construcción
general y hojas de especificaciones de ingeniería. Esto será útil para identificar las brechas
en los datos, como los valores faltantes en los documentos, las especificaciones
incorrectas, los documentos faltantes requeridos y los datos inconsistentes en los
diferentes documentos, y ofrecer a los propietarios / usuarios la oportunidad de resaltar
estas brechas frente al EPC para los proyectos en curso.
 Optimización de las inspecciones en servicio (onstream).

Las evaluaciones de RBI definen niveles de riesgo para los componentes bajo evaluación
y puede identificar y establecer un programa de inspección optimizado en servicio de
diferentes niveles de riesgo para los diferentes activos. En lugar de establecer los CML de
una manera convencional para toda la planta, se pueden utilizar niveles de riesgo y
establecer criterios para la cantidad de CML que se agregarán para diferentes tipos de
equipos, tuberías, tanques, etc. Esta optimización puede ahorrar una gran cantidad de
tiempo y costo del estudio de la línea base y para la gestión continua del ciclo de vida de
la instalación.

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 Inspecciones y ensayos
Los resultados de RBI pueden proporcionar, las áreas objetivo o los puntos de enfoque a
los inspectores durante las actividades iniciales de planeación de las inspecciones y
ensayos de las nuevas instalaciones. Los planes de inspección generados por las
evaluaciones de RBI marcarán claramente los elementos de alto riesgo y pueden ser
utilizados por los diferentes departamentos como inspección, mantenimiento,
planeación etc. dentro de una organización para planificar mejor las actividades de
inspecciones y ensayos ya que los controladores de riesgo están claramente identificados
en su gestión. Esta puede ser una de las herramientas proactivas utilizadas durante la fase
de planificación, beneficiosa para la gestión de recursos.
 Enfoque en Integridad Mecánica

El proceso de RBI se centra en mantener la integridad mecánica de elementos del equipo
de presión y minimizar el riesgo de pérdida de contención debido al deterioro. Por lo
general, las evaluaciones de riesgo del PHA (Process Hazards Analysis) se centran en el
diseño de la unidad de procesos y prácticas de operación y de su adecuación, dada la
unidad de las condiciones de funcionamiento actuales o previstas. RBI complementa el
PHA, centrándose en los mecanismos de integridad mecánica de daños relacionados con
la gestión de riesgos y mediante la inspección. RBI, además, es complementario a los
programas del RCM en el que ambos programas se centran en la comprensión de los
modos de fallo, su direccionamiento a los modos y por lo tanto la mejora de la fiabilidad
de los equipos e instalaciones de proceso.
 Optimización de la Inspección
Cuando el riesgo asociado con distintos equipos que se determina y la eficacia relativa de
las diferentes técnicas de inspección y vigilancia del proceso para reducir el riesgo se
estima o se cuantifica, existe información fiable para la planificación, optimización y
ejecución de un programa RBI.
La Figura 6 se presentan las curvas estilizadas que muestra la reducción en el riesgo de
que se pueda esperar cuando el grado y la frecuencia de la inspección se incrementan. La
curva superior representa un programa de inspección típico. Donde no hay inspección,
puede haber un mayor nivel de riesgo, como se indica en el eje y en la figura. Con una
inversión inicial en las actividades de inspección, el riesgo en general, se reduce
significativamente. Se alcanza un punto donde la actividad de inspección adicional
comienza a mostrar un rendimiento decreciente y, eventualmente, puede producir muy
poca reducción adicional del riesgo. Si la inspección se aplica demasiada, el nivel de riesgo
aún puede subir. Esto se debe a las inspecciones invasivas que en determinados casos
causan un deterioro adicional (por ejemplo, la entrada de humedad en los equipos
susceptibles a los ácidos politiónicos, daños durante la inspección a las capas protectoras

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o capas de fibra de vidrio). Esta situación se representa por la línea de puntos al final de
la curva superior.
Un completo programa RBI proporciona una metodología coherente para evaluar la
combinación óptima de métodos y frecuencias de inspección. Cada método de inspección
disponibles pueden ser analizados y su eficacia relativa para reducir la probabilidad de
fallo puede ser estimado. Teniendo en cuenta esta información y el costo de cada
procedimiento, un programa de optimización se puede desarrollar. La clave para el
desarrollo de este procedimiento es la posibilidad de evaluar el riesgo asociado a cada
elemento del equipo y luego para determinar las técnicas de inspección más adecuados
para esta sección del equipo. Un resultado conceptual de esta metodología se ilustra por
la curva inferior de la Figura 6. La curva inferior indica que con la aplicación de un
programa RBI eficaz, menores riesgos se pueden lograr con el mismo nivel de actividad
de inspección. Esto es así porque, a través de RBI, las actividades de inspección se centran
en los elementos de mayor riesgo y lejos de los componentes de menor riesgo.
Como se muestra en la Figura 6, el riesgo no puede reducirse a cero únicamente por los
esfuerzos de inspección. Los factores de riesgo residual para la pérdida de contención
incluyen, pero no se limitan a cuestiones tales como:
- Error humano,
- Desastres naturales,
- Acontecimientos externos (colisiones o caída de objetos),
- Efectos secundarios de las unidades cercanas,
- Efectos indirectos de los equipos asociados en la misma unidad,
- Actos deliberados (sabotaje),
- Limitaciones fundamentales de los métodos de inspección,
- Errores de diseño,
- Desconocimiento o mecanismos de daños que no anticiparon.

PÁGINA 233 DE 556
Figura 6 - Gestión del Riesgo mediante RBI
• Ayuda a gestionar los riesgos operativos

La integridad mecánica y el rendimiento funcional de los equipos dependen de la
adecuación del equipo para operar de manera segura y fiable en las condiciones de
operaciones normales y anormales (disturbios) a los que está expuesto el equipo. En la
realización de una evaluación RBI, la susceptibilidad de los equipos a los daños por uno o
más mecanismos (corrosión, fatiga, agrietamiento) está establecida. La susceptibilidad de
cada elemento del equipo debe estar claramente definida para las condiciones de
funcionamiento actuales y proyectadas, incluyendo factores tales como:
- Funcionamiento normal
- Condiciones de disturbio,
- Puesta en marcha y parada
- Reposo o fuera de servicio en tiempo
- Parada de emergencia y la posterior puesta en marcha.
- Variables de proceso que deben ser considerados para cada condición de operación
- Fluido de proceso, los contaminantes y componentes agresivos
- Presiones, incluidas las condiciones cíclicas y temporales;
- Temperaturas, incluidas las condiciones cíclicas y temporales
- Rangos de flujo
- Tiempo de corrida operacional entre paradas programadas.

PÁGINA 234 DE 556
 Gestión de Riesgos a través de la inspección.

El objetivo de RBI es dirigir el proceso de decisión de la Gerencia para priorizar los recursos
y así gestionar el riesgo. Inspección influye en la incertidumbre de los riesgos asociados a
los equipos a presión sobre todo por mejorar el conocimiento del estado de deterioro.
Aunque la inspección no reduce el riesgo directamente, es una actividad de gestión que
puede conducir a la reducción del riesgo. La inspección en servicio se ocupa
principalmente de la detección y el seguimiento de su deterioro.
 Uso de RBI para establecer planes de inspección y Prioridades

El principal producto del esfuerzo RBI debe ser un plan de inspección para cada elemento
de equipos evaluados. RBI es un proceso lógico y estructurado para planificar y evaluar
las actividades de inspección de equipos a presión. El plan de inspección debe detallar el
riesgo sin mitigación relacionado con la operación actual. Para los riesgos considerados
inaceptables, el plan debe contener las medidas de mitigación que se recomiendan para
reducir el riesgo sin mitigar a niveles aceptables.
Para los componentes del equipo, donde la inspección es un medio costo-efectivo de la
gestión de riesgos, los planes deben describir el tipo, alcance y oportunidad de la
inspección. La clasificación de los equipos por el nivel de riesgo sin mitigar permite a los
usuarios asignar prioridades y el nivel del riesgo sin mitigar se debe utilizar para evaluar
la urgencia para realizar la inspección.
Reevaluación de un RBI
La reevaluación de un RBI se debe dar en los siguientes casos:
 Después de Cambios Significativos

Puede ser deseable llevar a cabo una reevaluación RBI después de cambios significativos
en las condiciones del proceso, que incluya la revisión de los mecanismos de daño, ratas
y severidades o las premisas del RBI. Personal calificado debe evaluar cada cambio
significativo para determinar el potencial de un cambio en el riesgo.
 Después de un período de tiempo determinado

A pesar de que cambios significativos que no se hayan ocurrido, con el tiempo muchos
pequeños cambios pueden ocurrir y acumulativamente causar cambios significativos en
la evaluación RBI. Los usuarios deben establecer plazos máximos predeterminados para
las evaluaciones posteriores. Los códigos que rigen la inspección ( API 510, API 570 y API
653) y reglamentos legales, si los hay, deben ser revisados en este contexto.

PÁGINA 235 DE 556
 Después de la implementación de estrategias de mitigación de riesgos

Una vez que una estrategia de mitigación se implemente, es prudente determinar la
eficacia de la estrategia en la reducción del riesgo a un nivel aceptable. Esto debería
reflejarse en una nueva evaluación del riesgo y la actualización adecuada en la
documentación.
 Antes y Después de una Parada de Planta (Turnarounds) de Mantenimiento

Como parte de la planificación de una parada de planta de mantenimiento, por lo general
es útil llevar a cabo una reevaluación RBI. Esto puede convertirse en un primer paso en la
planificación de la recuperación para asegurar que el esfuerzo de trabajo se centra en los
equipos de mayor riesgo y en las asuntos que puedan afectar a la capacidad de alcanzar
las premisas del tiempo de operación de una manera segura, económica y ambiental.
Dado que un gran número de inspección, reparación y modificaciones se realizan durante
una parada de planta de mantenimiento, puede ser útil actualizar la evaluación poco
después del cambio para reflejar los niveles de riesgo nuevos.
Entregables del RBI

Los siguientes son los entregables de un RBI:
 Evaluación de riesgo:
Para cada uno de los equipos y lazos de corrosión, la evaluación de riesgo incluye nivel de
riesgo actual del equipo y su proyección en el tiempo, mecanismos de daño que afectan
al equipo o lazos de corrosión y próxima fecha de inspección. Adicionalmente un resumen
de la información general de cada equipo.
La evaluación de riesgo se realiza bajo la matriz de API 581, la cual es una matriz
cuantitativa con sus propias escalas de probabilidad de falla, consecuencia y umbrales de
riesgo ya definidas en el estándar. Se puede hacer un escalamiento de la matriz del API
versus la matriz de la empresa, con el fin de proponer una sensibilización de los resultados
de la evaluación de riesgo versus la gestión de riesgo de la empresa.
 Plan de inspección detallado:

Para inspección interna e inspección externa, los documentos incluyen las técnicas de
inspección, los puntos a inspeccionar, la extensión de técnica y la capacidad de detectar
y dimensionar cada uno de los mecanismos de daño.

PÁGINA 236 DE 556
12. SEGURIDAD
12.1. RECOMENDACIONES DE SEGURIDAD
Por su ubicación dentro de la refinería, la Planta de Producción de nitrógeno - NIS
comparte los mismos riesgos generales de la instalación, y el personal asignado a la
operación y el mantenimiento debe observar las normas de HSE establecidas por
PETROPERÚ.
Este capítulo describe los riesgos específicos asociados con los procesos y productos
involucrados en los procesos de producción y purificación de nitrógeno. Es muy
importante que el personal esté familiarizado con los riesgos de la operación y
mantenimiento de la planta, y con las características y los riesgos asociados al manejo de
los químicos presentes.
La seguridad en las actividades de operación y mantenimiento de la planta es
responsabilidad del operador/dueño de la misma. Se considera que la instalación de la
planta se ha realizado bajo criterio de diseño seguro. Así mismo, las actividades de
operación y mantenimiento se basan en la aplicación de procedimientos de ejecución
totalmente seguros. Sin embargo, es conveniente tener en cuenta que se maneja
nitrógeno que puro, de no tomarse las debidas precauciones para su manejo y operación
pueden causar problemas a la salud del personal.
Los procedimientos y prácticas propias de seguridad de PETROPERÚ deben seguirse en
todo momento. La información y lineamientos indicados en esta sección son
suministrados como suplementos a los procedimientos locales de seguridad y no para
suplantarlos.
El campo de la seguridad cubre una amplia variedad de tópicos, desde el combate de
incendios hasta el manejo de químicos-tóxicos. El conocimiento de la seguridad en la
planta es imperativo. El cuerpo directivo de la planta deberá implementar las medidas
necesarias para lograr una operación y manejo seguro de la planta, tomando en cuenta
las recomendaciones de los grupos de profesionales, asegurando el cumplimiento de las
regulaciones y lineamientos de la autoridad o del gobierno. Esta sección no puede cubrir
cada faceta de lo expuesto. No se trata de negar la importancia de la seguridad, tan sólo
se supone que cada planta debe desarrollar su propio método coordinado de
implementación de procedimientos seguros, apropiados y actualizados, así como el
manejo de emergencias.
Tres conceptos importantes para una operación segura son:
A) CONOCIMIENTO
El conocimiento no es automático, debe ser aprendido. El tiempo y esfuerzo invertido en
adquirirlo será recompensado muchas veces por los problemas y accidentes evitados.
Una parte importante del conocimiento es la comunicación. Los accidentes tienen mucho

PÁGINA 237 DE 556
menos oportunidad de ocurrir si cada uno sabe que trabajo se está desarrollando. Las
líneas de comunicación deben estar bien establecidas, no dejarlas a la ocasión. Esto
también aplica al personal que entre y salga de la unidad. Al entrar a la unidad, el personal
deberá reportarse al cuarto de control para informar al personal de operación apropiado
de su presencia en la unidad. Antes de salir de la unidad, se volverán a reportar para
informarles acerca de su salida.
Además, se deberán seguir todos los procedimientos de obtención de permisos de trabajo
en la planta. Los permisos son emitidos para asegurar que los procedimientos de
seguridad sean los apropiados y para informar a todo el personal involucrado acerca del
trabajo que se va a realizar.
B) PREPARACIÓN.
Es otra parte importante de la seguridad. Esto incluye la planeación de emergencias y la
práctica de maniobras. Es responsabilidad de cada operador estar completamente
familiarizado con todos los equipos y procedimientos de emergencia.
C) SENTIDO COMÚN.
Es quizá el más relevante de todos los factores de seguridad. No puede ser olvidado
cuando se tiene prisa para acabar un trabajo o cuando se está a cargo de un problema. El
error humano es la causa de muchos accidentes. El detenerse brevemente para pensar
acerca de una acción y sus posibles consecuencias, ayudará a evitar muchos de estos
problemas.
Practique la seguridad en apego a procedimientos y prácticas de trabajo con sentido
común debidamente probados. Piense en la seguridad. Cuando surjan dudas, extreme sus
precauciones y obtenga asistencia o consejos apropiados.
TOXICIDAD DE QUÍMICOS Y CATALIZADORES
GASES TÓXICOS
En la operación de la Unidad puede estar presente normalmente el nitrógeno. Son gases
que al estar concentrados pueden generar asfixia por la ausencia de oxígeno.
ALTA O BAJA TEMPERATURA

La compresión de aire contempla altas temperaturas a la descarga de compresor , por lo
que el personal de operaciones y mantenimiento debe tomar las protecciones necesarias
para evitar accidentes con quemaduras.
Los equipos y líneas con temperaturas superficiales superiores a 60°C están protegidos
con aislamiento térmico para protección personal.

PÁGINA 238 DE 556
La parte criogénica de la unidad presenta bajas temperaturas, las cuales pueden causar
daños al personal de operaciones y mantenimiento, por esta razón se deben tomar las
precauciones necesarias para evitar accidentes por quemaduras por bajas temperaturas.
12.2. LUCHA CONTRA INCENDIOS

Los sistemas contra incendio de la planta han sido definidos con base en los estudios
requeridos de protección y el cumplimiento de las normas asociadas. Los documentos
detallados del sistema se relacionan a continuación:
 Reporte estudio Sistema Contraincendio TAL-NIS-SCI-STU-0001 Rev.01
 Memoria De Cálculo Sistema Contra Incendio (Hidráulico), TAL-NIS-SCI-MEM-0001
Rev.01
En el presente capítulo se encuentra una descripción general de los equipos de lucha
contra incendios instalados con base en los estudios realizados específicamente para esta
planta.
DEFINICIÓN DE LOS ESCENARIOS DE INCENDIO

Como descrito en el documento TAL-NIS-FGS-PHI-0001 “Filosofía Operación y Control SCI
y de Fuego y Gas”, la planta de nitrógeno no contará con la presencia de fluidos
inflamables o combustibles, ya que consistirá en una planta de fraccionamiento de aire
para obtener nitrógeno y oxígeno, por lo que no se esperan escenarios de incendio dentro
de la misma. Sin embargo, debido que es posible que se vea afectada por la radiación
proveniente de incendios en plantas o edificios aledaños, es necesaria la instalación de
hidrantes e hidrantes/monitores de agua alrededor de la misma para asegurar cualquier
necesidad de enfriamiento que sea evidenciada en un caso de emergencia.
Es por ello, que el escenario de incendio definido para la planta se basará en un incendio
externo, que haga necesaria la utilización de al menos 2 fuentes de agua contra incendio
desde dos equipos dispuestos en lados opuestos de la planta (hidrantes de agua o
hidrantes/monitores de agua), para asegurar un enfriamiento uniforme de la misma.
CÁLCULO DE LA DEMANDA DE AGUA CONTRA INCENDIO

La Tabla 15 , se muestra el resumen de los resultados obtenidos en el cálculo de la
demanda de agua contra incendio para la planta de nitrógeno. Cabe resaltar que, han sido
consideradas las premisas enunciadas a continuación:
 El enfriamiento con agua contra incendio se llevará a cabo por medio de la utilización
de mangueras contra incendio conectadas a los hidrantes de agua o
hidrantes/monitores de agua que serán instalados alrededor de la planta.

PÁGINA 239 DE 556
 La aplicación de agua contra incendio se realizará desde dos lugares diferentes de la

planta, para asegurar un enfriamiento uniforme de los equipos.
 El flujo a través de cada conexión de manguera será de 113.6 m3/h.
Tabla 25 - Demanda de Agua Contra Incendio
Aplicación de Agua Contra Incendio
Flujo de Agua a través Flujo de Agua a través Demanda de Agua
Escenario de Incendio de Hidrante o de Hidrante o Contra Incendio
Hidrante/Monitor de Hidrante/Monitor de (m3/h)
Agua 1 (m3/h) Agua 2 (m3/h)
Fuego exterior a la
planta con afectación a
56.8 56.8 113.6
equipos por radicación
(Nota 1)
Nota 1: Aunque se considera la aplicación de agua para enfriamiento desde 2 equipos
contra incendio, la planta podrá ser protegida utilizando cualquiera de los 4 equipos contra
incendio dispuestos para ello alrededor de la misma (2 hidrantes de agua y 2
hidrantes/monitores de agua). Dependiendo de la localización de incendio externo, el
personal de la brigada deberá decidir cuál será la mejor estrategia de enfriamiento a
utilizar.
CONCLUSIONES DEL ESTUDIO CONTRAINCENDIO

 Debido a que la planta de producción de nitrógeno es una planta de bajo riesgo de
incendio, la protección contra incendio se llevará a cabo por medio de la conexión de
mangueras contra incendio a hidrantes de agua localizados alrededor de la planta.
 La demanda de agua contra incendio para la planta de nitrógeno es de 1893 L/min, la
cual será provista a través de 2 corrientes de agua provenientes desde lados
diferentes de la planta.
12.3. SUSTANCIAS Y MATERIALES – HOJAS DE DATOS DE SEGURIDAD DE MATERIALES

(MSDS)
A continuación, se adjunta el documento Hojas de Seguridad de los Materiales,
TAL-NIS-PRO-SPE-0002, donde se describen los riesgos asociados a cada uno de los
materiales que se manejan en la planta NIS.
PROYECTO: TAL
PÁGINA 1 DE 31
HOJAS DE SEGURIDAD DE LOS MATERIALES
N° DOCUMENTO: TAL-NIS-PRO-SPE-0002 REV. 01

FECHA: 31/10/2019

DOCUMENTO PRINCIPAL
ANEXOS
FORMATOS

Tamara Salazar Frank Canchanya Marco La Barrera
COBRA SCL. La única copia controlada de este doc. está en el Sist. Informático de Gestión Documental de COBRA SCL.
PROYECTO: TAL
PÁGINA 2 DE 31

FECHA: 31/10/2019
ÍNDICE
1. OBJETO ................................................................................................................. 3
2. ALCANCE............................................................................................................... 3
3. DEFINICIONES ....................................................................................................... 3
4. HOJAS DE SEGURIDAD........................................................................................... 4
4.1. HOJA DE SEGURIDAD NITRÓGENO LIQUIDO REFRIGERADO .................................... 5
4.2. HOJA DE SEGURIDAD NITRÓGENO GASEOSO ....................................................... 15
4.3. HOJA DE SEGURIDAD ALUMINA........................................................................... 25
PROYECTO: TAL
PÁGINA 3 DE 31

FECHA: 31/10/2019
1. OBJETO
El objeto de este documento es presentar las hojas de seguridad de los materiales de la
unidad de inertización de nitrógeno (NIS), a ser instalada como parte del proyecto "Unidades
Auxiliares y Trabajos Complementarios" (UA&TC), que completa la ejecución del "Proyecto
Modernización de la Refinería Talara" (PMRT), en Perú.
2. ALCANCE
Se presentan las hojas de seguridad con el fin de indicar las particularidades y propiedades
de las sustancias presentes en la planta de nitrógeno (NIS), además de tener las instrucciones
detalladas para su manejo y reducir los riesgos laborales y medioambientales.
3. DEFINICIONES
• PROYECTO: Proyecto de Modernización Refinería TALARA / Unidades Auxiliares y
b) Los sucesores legales y cesionarios /novados legítimos del EMPLEADOR en el
Contrato;
y
c) Toda persona que se convierta en Parte del presente en sustitución o conjuntamente
con el EMPLEADOR y los sucesores legales y cesionarios/novados legítimos de dicha
persona en el Contrato
Para fines prácticos PETROLEOS DEL PERÚ – PETROPERÚ S.A. (también identificado como
“PP”)
• REPRESENTANTE DEL EMPLEADOR (PMC): Se refiere al PMC o a la persona nombrada por

el EMPLEADOR en el Contrato o designada de manera periódica por el EMPLEADOR
conforme a la Subcláusula 3.1 [Representante del EMPLEADOR] para que actúe en
representación del EMPLEADOR.
Para fines prácticos, aquel designado por PETROPERÚ como empresa adjudicataria del
Contrato para la ejecución del Proyecto de Modernización Refinería TALARA / Unidades
Auxiliares y Trabajos Complementarios, CONSORCIO COBRA SCL UA&TC (también
PROYECTO: TAL
PÁGINA 4 DE 31

FECHA: 31/10/2019
identificado como COBRA SCL) o cualquiera de sus afiliadas, representantes autorizados

o sucesoras)
• LICENCIANTE DE PROCESOS: Significa las personas jurídicas que ha suscrito contratos con
el EMPLEADOR para elaborar las licencias de procesos.
• DISEÑO FEED: Se refiere al diseño de ingeniería básica extendida llevado a cabo por parte
de Técnicas Reunidas bajo el Contrato FEED EPC.
• EPC: (Engineering, Procurement & Construction) Fase de Ingeniería Detallada,
Adquisiciones y Construcción (incluye actividades de Pre-Comisionado/Pruebas,
• VENDEDOR/VENDOR: Cualquier Proveedor y/o Fabricante de Equipo o Sistemas,
• SUBCONTRATISTA: Significa (i) toda persona nombrada en el Contrato como
subcontratista, (ii) toda persona nombrada como subcontratista bien sea directamente
por el CONTRATISTA o a un nivel inferior (incluyendo cualquier subcontratista o
proveedor de Materiales) para una parte de los Trabajos, y (iii) los sucesores legales de
cualquiera de lo anterior.
4. HOJAS DE SEGURIDAD
Ver hojas de seguridad a partir de la siguiente página.1
1
La información de los adsorbedores y asilamientos se encuentra en HOLD hasta tanto, el proveedor de los
equipos confirme dicha información.
PROYECTO: TAL
PÁGINA 5 DE 31

FECHA: 31/10/2019
4.1. HOJA DE SEGURIDAD NITRÓGENO LIQUIDO REFRIGERADO
Página : 1 de 9
C
B
FICHA DE DATOS DE SEGURIDAD Edición revisada (*) Nº : 6
Fecha : 18 / 5 / 2016
Reemplaza : 10 / 2 / 2015
Nitrógeno Líquido Refrigerado / Lasal™ 2001 Líquido 089B-1

Refrigerado
n
ó2.2 : Gases no
inflamables, no tóxicos
Atención
«
M
SECCIÓN 1. Identificación de la sustancia o la mezcla y de la sociedad o la empresa
1.1. Identificador del producto

Nombre comercial : Nitrógeno Líquido Refrigerado / Lasal™ 2001 Líquido Refrigerado
Número de la Ficha de Datos de : 089B-1
Seguridad
Descripción Química : Nitrógeno (Líquido)
N° CAS :7727-37-9
N° EC :231-783-9
N° índice :---
Número de registro : Figura en la lista del Anexo IV / V de REACH, exento de solicitud de registro.
Fórmula química : N2
1.2. Usos pertinentes identificados de la sustancia o de la mezcla y usos desaconsejados
Usos aplicables identificados : Industrial y profesional.Llevar a cabo evaluación de riesgo antes de usar.
Usado para la fabricación de componentes electrónicos/fotovoltaicos.
Gas de ensayo / gas de calibrado. Purgado. Uso en laboratorio.
Gas de proteccion en procesos de soldadura.
Gas purgante, gas disolvente, gas inertizante.
Para mayor información sobre su uso contactar con el suministrador.
Usos desaconsejados : Sin datos disponibles.
1.3. Datos del proveedor de la ficha de datos de seguridad
Identificación de la Compañía (*) : AL AIR LIQUIDE ESPAÑA S.A.
Pº DE LA CASTELLANA , 79
28046 MADRID ( ESPAÑA )
E-mail:[email protected]
www.airliquide.es
Dirección e-mail (persona competente) : [email protected]
1.4. Teléfono de emergencia
Teléfono de emergencia [24h] : : +34 91 502 9300
SECCIÓN 2. Identificación de los peligros
2.1. Clasificación de la sustancia o de la mezcla

Clase y categoría de riesgo, Código de Normativa CE 1272/2008 (CLP)
• Peligros físicos : Gases a presión - Gases licuados refrigerados - Atención - (CLP : Press. Gas Ref. Liq.) -
H281
2.2. Elementos de la etiqueta
Normativa de Etiquetado CE 1272/2008 (CLP)
AL AIR LIQUIDE ESPAÑA S.A.

Pº DE LA CASTELLANA , 79 28046 MADRID ( ESPAÑA )
www.airliquide.es
Página : 2 de 9
C
B
Fecha : 18 / 5 / 2016
Reemplaza : 10 / 2 / 2015

Refrigerado
SECCIÓN 2. Identificación de los peligros /...
«
M
• Pictogramas de peligro
• Código de pictogramas de peligro : GHS04

• Palabra de advertencia : Atención
• Indicación de peligro : H281 - Contiene un gas refrigerado; puede provocar quemaduras o lesiones criogénicas.
• Consejos de prudencia
- Prevención : P282 - Llevar guantes que aíslen del frío/gafas/máscara.
- Respuesta : P336+P315 - Descongele las partes heladas con agua tibia. No frote la zona afectada.
Consulte a un médico inmediatamente.
- Almacenamiento : P403 - Almacenar en un lugar bien ventilado.
2.3. Otros peligros
: Asfixiante a altas concentraciones.
SECCIÓN 3. Composición/información sobre los componentes
3.1. Sustancia / Mezcla

Sustancia.
N° CAS
Nombre del componente Contenido N° EC Clasificación(DSD) Clasificación(CLP)
N° índice
Nº de Registro
Nitrógeno (Líquido) : 100 % 7727-37-9 No clasificado (DSD) Press. Gas Ref. Liq. (H281)
231-783-9
-----
*1
No contiene otros componentes o impurezas que puedan influir en la clasificación del producto.
* 1: Figura en la lista del Anexo IV / V de REACH, exento de solicitud de registro.
* 2: No ha expirado el plazo límite de solicitud de registro.
* 3: No exige su registro.Sustancias fabricadas o importadas<1t/y.
Texto completo de Frases-R, véase capítulo 16. Texto completo de declaraciones-H, véase capítulo 16.
Para saber la composición exacta del producto consultar las especificaciones técnicas de Air Liquide.
SECCIÓN 4. Primeros auxilios
4.1. Descripción de los primeros auxilios

- Inhalación : Retirar a la víctima a un área no contaminada llevando colocado el equipo de respiración
autónoma. Mantener a la víctima caliente y en reposo. Llamar al doctor. Aplicar la respiración
artificial en caso de parada respiratoria.
- Contacto con la piel : En caso de congelación rociar con agua durante 15 minutos. Aplicar un vendaje estéril.
Obtener asistencia médica.
- Contacto con los ojos : Lavar inmediatamente los ojos con agua durante, al menos, 15 minutos.
- Ingestión : La ingestión no está considerada como una vía potencial de exposición.
4.2. Principales síntomas y efectos, agudos y retardados
: A elevadas concentraciones puede causar asfixia. Los síntomas pueden incluir pérdida de la
consciencia o de la movilidad. La víctima puede no haberse dado cuenta de la asfixia.
Para mas información, ver la Sección 11.
4.3. Indicación de toda atención médica y de los tratamientos especiales que deban dispensarse
inmediatamente
: Ninguno.

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SECCIÓN 5. Medidas de lucha contra incendios
5.1. Medios de extinción

- Medios de extinción adecuados : Agua en spray o en nebulizador.
- Medios de extinción inadecuados : No usar agua a presión para extinguirlo.
5.2. Peligros específicos derivados de la sustancia o la mezcla
Peligros específicos : La exposición al fuego puede causar la rotura o explosión de los recipientes.
Productos de combustión peligrosos : Ninguno.
5.3. Recomendaciones para el personal de lucha contra incendios
Métodos específicos : Desplazar los envases lejos del área del fuego si ello se puede hacer sin riesgo.
Utilizar medidas de control de incendios apropiadas con el incendio circundante. La
exposición de los envases de gas al fuego y al calor pueden provocar su ruptura. Enfriar los
envases dañados con chorro de agua pulverizada desde una posición protegida. No vaciar el
agua contaminada por el fuego en los desagües.
Si es posible, detener la fuga de producto.
En caso de fuga no rociar agua sobre el recipiente. Utilizar el agua para contener el fuego en
el área circundante, desde un lugar protegido.
Usar agua en spray o en nebulizador para disipar humos de incendios.
Equipo de protección especial para : Utilizar equipos de respiración autónoma de presión positiva (ERA).
extinción de incendios Vestimenta y equipo de protección estandard (aparato de respiración autónoma) para
bomberos.
Norma UNE-EN 137: Máscara de cara completa que incluya un aparato de respiración
autónomo de aire comprimido en circuito abierto.
Norma UNE-EN 469: Vestimenta protectora para bomberos.
Norma UNE-EN 659: Guantes de protección para bomberos.
SECCIÓN 6. Medidas en caso de vertido accidental
6.1. Precauciones personales, equipo de protección y procedimientos de emergencia

: Intentar parar la fuga.
Utilizar equipos de respiración autónoma cuando entren en el área a menos que esté probado
que la atmósfera es segura.
Evacuar el área.
Usar ropa de protección.
Asegurar la adecuada ventilación de aire.
Prevenir la entrada en alcantarillas, sótanos, fosos de trabajo o en cualquier otro lugar donde
la acumulación pueda ser peligrosa.
Actuar de acuerdo con el plan de emergencia local.
Mantenerse encontra del viento.
6.2. Precauciones relativas al medio ambiente
6.3. Métodos y material de contención y de limpieza
: Las fugas de líquido pueden producir fragilidad en materiales estructurales.
Ventilar la zona.
6.4. Referencia a otras secciones
: Para más información sobre control frente a la exposición, protección personal o
consideraciones de eliminación, ver también las Secciones 8 y 13.

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SECCIÓN 7. Manipulación y almacenamiento
7.1. Precauciones para una manipulación segura

Uso seguro del producto : Sólo personas experimentadas y debidamente entrenadas deben manejar gases sometidos a
presión.
La sustancia debe ser manipulada de acuerdo con los procedimientos de buena higiene
industrial y seguridad.
Utilizar sólo equipo específicamente apropiado para este producto y para su presión y
temperatura de suministro, en caso de duda contacte con su suministrador.
No fumar cuando se manipule el producto.
Comprobar que el conjunto del sistema de gas ha sido, o es con regularidad, revisado antes
de usarse respecto a la posibilidad de fugas.
Considerar los instrumentos de reducción de la presión en las instalaciones de gas.
No respirar el gas.
Evitar la eliminación del producto a la atmósfera.
Manipulación segura del envase del : Solicitar del suministrador las instrucciones de manipulación de los envases.
gas Debe prevenirse la filtración de agua al interior del recipiente.
No permitir el retroceso hacia el interior del recipiente.
Nunca intentar reparar o modificar las válvulas de las botellas o los mecanismos de
seguridad.
Las válvulas que están dañadas deben ser inmediatamente comunicadas al suministrador.
Mantener los accesorios de la válvula libres de contaminantes, especialmente aceites y agua.
Reponer la tulipa de la válvula si es facilitada por el suministrador , siempre que el envase
esté desconectado del equipo.
Cierre la válvula del envase despues de su uso y cuando se quede vacío, incluso si aún está
conectado al equipo.
No utilizar nunca mecanismos con llamas o de calentamiento eléctrico para elevar la presión
del envase.
7.2. Condiciones de almacenamiento seguro, incluidas posibles incompatibilidades
: Observar todas las regulaciones y los requerimientos locales relativos al almacenamiento de
las botellas.
Mantener el contenedor por debajo de 50°C, en un lugar bien ventilado. Los envases deben
de ser almacenados en posición vertical y debidamente asegurados para evitar su caída. Los
envases almacenados deben ser comprobados periódicamente respecto a su estado general
y a posibles fugas . Las protecciones de las válvulas y las tulipas deben estar siempre
colocadas. Almacenar los envases en un lugar libre de riesgo y lejos de fuentes de calor e
ignición.
Los envases no deben ser almacenados en condiciones que favorezcan la corrosión .
Mantener alejado de materiales combustibles.
7.3. Usos específicos finales
: Ninguno.
SECCIÓN 8. Controles de exposición/protección individual
8.1. Parámetros de control

DNEL: Nivel de efectos no derivados (
trabajadores)
: Sin datos disponibles.
PNEC: Concentración prevista sin
efectos
8.2. Controles de la exposición
8.2.1. Controles técnicos apropiados : Los sistemas sujetos a presión deben ser regularmente comprobados respecto a fugas.
Deben usarse detectores de oxígeno cuando pueden ser emitidos gases asfixiantes.
Proporcionar ventilación adecuada, general y local, a los gases de escape.
Considerar un sistema de permisos de trabajo p.ej para trabajos de mantenimiento.
8.2.2. Equipo de protección personal : Sólo los EPI que cumplan los estandares recomendados por las normas EN-UNE/ISO deben
seleccionarse.
Un análisis de riesgos debe ser realizado y formalizado en cada área de trabajo para evaluar
los riesgos relacionados con el uso del producto y para determinar el EPI que corresponde a
un riesgo relevante. Estas recomendaciones deben ser tenidas en cuenta.

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SECCIÓN 8. Controles de exposición/protección individual /...
Proteger los ojos, cara y piel de las salpicaduras de líquido.

• Protección para el ojo/cara : Usar gafas cerradas sobre los ojos y protector para la cara al hacer trasvases o al efectuar
desconexiones.
Usar gafas de seguridad con protecciones laterales.
Norma UNE-EN 166: Protección para los ojos.
• Protección para la piel
- Protección de las manos : Usar guantes de trabajo al manejar envases de gases.
Norma EN-UNE 388: Guantes que protegen contra riesgos mecánicos.
- Otras : Usar zapatos de seguridad mientras se manejan envases.
Norma ISO 20345: Equipos de protección personal, zapatos de seguridad.
• Protección de las vías respiratorias : Un aparato de respiración asistida (SCBA) o una máscara con una vía de aire a presión
tienen que usarse en atmósferas con insuficiente oxígeno.
Los usuarios de los aparatos de respiración deben ser entrenados.
• Peligros térmicos : Standard EN 511- Guantes aislantes del frio.
Usar guantes que aislen del frio al hacer trasvases o al efectuar desconexiones.
9 = >
Protección personal
8.2.3. Controles de exposición : No necesaria.

medioambiental
SECCIÓN 9. Propiedades físicas y químicas
9.1. Información sobre propiedades físicas y químicas básicas

Apariencia
Estado físico a 20°C / 101.3kPa : Gas.
Color : Líquido incoloro.
Olor : Sin olor que advierta de sus propiedades.
Umbral olfativo : El umbral de olor es subjetiva e inadecuado para advertir de sobreexposición.
Valor de pH : No aplica.
Masa molecular [g/mol] : 28
Punto de fusión [°C] : -210
Punto de ebullición [°C] : -196
Temperatura crítica [°C] : -147
Punto de inflamación [°C] : No es aplicable a gases ni a mezcla de gases.
Velocidad de evaporación (éter=1) : No es aplicable a gases ni a mezcla de gases.
Rango de inflamabilidad [% de : No inflamable.
volumen en aire]
Presión de vapor [20°C] : No aplica.
Densidad relativa del gas (aire=1) : 0.97
Densidad relativa del líquido (agua=1) : 0.8
Solubilidad en agua [mg/l] : 20
Coeficiente de reparto n-octanol/agua [ : No es aplicable a gases inorganicos.
log Kow]
Temperatura de auto-inflamación [°C] : No aplica.
Viscosidad a 20°C [mPa.s] : No aplica.
Propiedades explosivas : No aplica.
Propiedades comburentes : Ninguno.
9.2. Información adicional

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SECCIÓN 9. Propiedades físicas y químicas /...
Otros datos : El vapor es mas pesado que el aire. Puede acumularse en espacios confinados,
particularmente al nivel del suelo o en sótanos.
SECCIÓN 10. Estabilidad y reactividad
10.1. Reactividad
: Sin riesgo de reactividad salvo lo expresado en la sub-sección más adelante.
10.2. Estabilidad química
: Estable en condiciones normales.
10.3. Posibilidad de reacciones peligrosas
: Ninguno.
10.4. Condiciones que deben evitarse
: Ninguno en las condiciones de manejo y almacenamiento recomendados (ver sección 7).
10.5. Materiales incompatibles
: Aceros no resistentes a bajas temperaturas. Las fugas de líquido pueden producir fragilidad
en materiales estructurales.
Para información complementaria sobre su compatibilidad referirse a la Norma ISO 11114.
10.6. Productos de descomposición peligrosos
: Ninguno.
SECCIÓN 11. Información toxicológica
11.1. Información sobre los efectos toxicológicos

Toxicidad aguda : No se conocen los efectos toxicológicos de este producto.
Corrosión o irritación cutánea : Se desconocen los efectos de este producto.
Lesiones o irritación ocular graves : Se desconocen los efectos de este producto.
Sensibilización respiratoria o cutánea : Se desconocen los efectos de este producto.
Carcinogénesis : Se desconocen los efectos de este producto.
Mutagenicidad : Se desconocen los efectos de este producto.
Toxicidad para la reproducción : Se desconocen los efectos de este producto.
Toxicidad específica en determinados : Se desconocen los efectos de este producto.
órganos (STOT) – exposición única
órganos (STOT) – exposición repetida
Peligro de aspiración : No es aplicable a gases ni a mezcla de gases.
SECCIÓN 12. Información ecológica
12.1. Toxicidad
Evaluación : No se conocen daños ecológicos causados por este producto.
12.2. Persistencia y degradabilidad
12.3. Potencial de bioacumulación
12.4. Movilidad en el suelo

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SECCIÓN 12. Información ecológica /...
12.5. Resultados de la valoración PBT y mPmB

: No se clasifica como PBT o vPvB.
12.6. Otros efectos adversos
: Puede causar hielo que dañe a la vegetación.
Efectos sobre la capa de ozono : Ninguno.
Produce efectos en el calentamiento : Ninguno.
global
SECCIÓN 13. Consideraciones relativas a la eliminación
13.1. Métodos para el tratamiento de residuos

: Puede ser liberado a la atmósfera en un lugar bien ventilado.
No descargar dentro de ningún lugar donde su acumulación pudiera ser peligrosa.
Consulte el código de prácticas de EIGA Doc 30 "Eliminación de gases", se puede
descargar en http://www.eiga.org, para obtener mayor información sobre métodos más
adecuados de eliminación.
Consulte al proveedor acerca de posibles recomendaciones específicas.
Lista de residuos peligrosos : 16 05 05: Envases de gases a presión distintos de los mencionados en 16 05 04.
13.2. Informacíones complementarias
: Ninguno.
SECCIÓN 14. Información relativa al transporte
14.1. Número ONU

Número ONU : 1977
n
ó
Etiquetado según ADR, IMDG, IATA
: 2.2 : Gases no inflamables, no tóxicos

14.2. Designación oficial de transporte de las Naciones Unidas
Transporte por carretera/ferrocarril ( : NITRÓGENO LÍQUIDO REFRIGERADO
ADR/RID)
Transporte por aire (ICAO-TI / IATA- : NITROGEN, REFRIGERATED LIQUID
DGR)
Transporte por mar (IMDG) : NITROGEN, REFRIGERATED LIQUID
14.3. Clase(s) de peligro para el transporte
Transporte por carretera/ferrocarril (ADR/RID)
Clase : 2
Código de clasificacion : 3A
H.I. n° : 22
Restricciones en Túnel : C/E : Paso prohibido por túneles de la categoría C y D cuando las mercancías son
transportadas en cisternas. Paso prohibido por túneles de la categoría E.
µ
“
’
‘
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SECCIÓN 14. Información relativa al transporte /...
Transporte por aire (ICAO-TI / IATA-DGR)

Clase/División (Riesgo/s Subsidiarios) : 2.2
Transporte por mar (IMDG)
Instrucciones de Emergencia (EmS) - : F-C
Incendio.
Instrucciones de Emergencia (EmS) - : S-V
Derrames
14.4. Grupo de embalaje
Transporte por carretera/ferrocarril ( : No aplica.
ADR/RID)
Transporte por aire (ICAO-TI / IATA- : No aplica.
DGR)
Transporte por mar (IMDG) : No aplica.
14.5. Peligros de contaminación
Transporte por carretera/ferrocarril ( : Ninguno.
ADR/RID)
Transporte por aire (ICAO-TI / IATA- : Ninguno.
DGR)
Transporte por mar (IMDG) : Ninguno.
14.6 Precauciones particulares para los usuarios
Packing Instruction(s)
Transporte por carretera/ferrocarril ( : P203
ADR/RID)
Transporte por aire (ICAO-TI / IATA-
DGR)
Avión de carga y pasajeros : Permitido.
Instrucción de embalaje- Avion de : 202
pasaje y carga
Avion de carga solo : Permitido.
carga solo
Transporte por mar (IMDG) : P203
Precauciones particulares para los : Evitar el transporte en los vehículos donde el espacio de la carga no esté separado del
usuarios compartimiento del conductor.
Asegurar que el conductor está enterado de los riesgos potenciales de la carga y que conoce
que hacer en caso de un accidente o de una emergencia.
Antes de transportar las botellas :
- Asegurarse de que los recipientes están bien fijados.
- Asegurarse que las válvulas de las botellas están cerradas y no fugan.
- Asegurarse que el tapón del acoplamiento de la válvula (cuando exista) está
adecuadamente apretado.
- Asegurarse que la caperuza de la válvula o la tulipa, (cuando exista), está adecuadamente
apretada.
- Asegurar una ventilación adecuada.
14.7. Transporte de granel según anexo II del tratado MARPOL 73/78 y según código IBC
Transporte de granel según anexo II : No aplica.
del tratado MARPOL 73/78 y según
código IBC

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SECCIÓN 15. Información reglamentaria
15.1. Reglamentación y legislación en materia de seguridad, salud y medio ambiente específicas para la
sustancia o la mezcla
Legislación UE
Restricciones : Ninguno.
Seveso directiva 96/82/EC : No esta cubierto.
Legislación Nacional
Legislación Nacional (texto) : Asegúrese que se cumplen las normativas nacionales y locales.
15.2. Evaluación de la seguridad química
: Un CSA (Análisis de seguridad química) no tiene que ser realizado para este producto.
SECCIÓN 16. Otra información
Enumeración de los cambios : Hoja de datos de seguridad revisada de acuerdo con la regulación de la Comisión (UE) Nº
2015/830. Cambios (*)
Consejos relativos a la formación : El riesgo de asfixia es a menudo despreciado y debe ser recalcado durante la formación de
los operarios.
Recipiente a presión.
Informacíon adicional : La presente Ficha de Datos de Seguridad está establecida de acuerdo con las Directivas
Europeas en vigor .
Cambios por revisión - Ver : *
Producto informacíon : Ver ficha técnica del producto para informaciones más detalladas.
Fuente de los datos utilizados : Base de datos EIGA.
Lista del texto completo de : H281 - Contiene un gas refrigerado; puede provocar quemaduras o lesiones criogénicas.
declaraciones-H en la sección 3.
Nota : El contenido y el formato de esta ficha de seguridad se ajustan a los
Reglamentos (CE) Nº453/2010. y (CE) CLP 1278/2008
RENUNCIA DE RESPONSABILIDAD : Los detalles dados son ciertos y correctos en el momento de llevarse este documento a
impresión. A pesar de que durante la preparación de este documento se ha tomado especial
cuidado, no se acepta ninguna responsabilidad por las lesiones o los daños resultantes.
Antes de utilizar el producto en un nuevo proceso o experimento, debe llevarse a cabo un
estudio completo de seguridad y de compatibilidad de los materiales.
RENUNCIA DE RESPONSABILIDAD La información en esta Ficha de Seguridad fue obtenida de fuentes que creemos son
fidedignas. Sin embargo, la información se proporciona sin ninguna garantía, expresa o implícita en cuanto a su exactitud. Las
condiciones o métodos de manejo, almacenamiento, uso o eliminación del producto están más allá de nuestro control y
posiblemente también más allá de nuestro conocimiento. Por esta y otras razones, no asumimos ninguna responsabilidad y
descartamos cualquier responsabilidad por pérdida, daño o gastos ocasionados por o de cualquier manera relacionados con el
manejo, almacenamiento, uso o eliminación del producto. Esta Ficha de Seguridad fue preparada y debe ser usada sólo para
este producto. Si el producto es usado como un componente de otro producto, es posible que esta información de Seguridad no
sea aplicable.
Fin del documento

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4.2. HOJA DE SEGURIDAD NITRÓGENO GASEOSO
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Nitrógeno / Cool N2 089A-1
n
ó2.2 : Gases no
inflamables, no tóxicos
Atención
«
M
SECCIÓN 1. Identificación de la sustancia o la mezcla y de la sociedad o la empresa
1.1. Identificador del producto

Nombre comercial : Nitrógeno / Cool N2
Número de la Ficha de Datos de : 089A-1
Seguridad
Descripción Química : Nitrógeno
N° CAS :7727-37-9
N° EC :231-783-9
N° índice :---
Número de registro : Figura en la lista del Anexo IV / V de REACH, exento de solicitud de registro.
Fórmula química : N2
1.2. Usos pertinentes identificados de la sustancia o de la mezcla y usos desaconsejados
Usos aplicables identificados : Industrial y profesional.Llevar a cabo evaluación de riesgo antes de usar.
Gas de ensayo / gas de calibrado. Purgado. Uso en laboratorio.
Gas de proteccion en procesos de soldadura.
Usado para la fabricación de componentes electrónicos/fotovoltaicos.
Gas purgante, gas disolvente, gas inertizante.
Para mayor información sobre su uso contactar con el suministrador.
Usos desaconsejados : Sin datos disponibles.
1.3. Datos del proveedor de la ficha de datos de seguridad
Identificación de la Compañía (*) : AL AIR LIQUIDE ESPAÑA S.A.
Pº DE LA CASTELLANA , 79
28046 MADRID ( ESPAÑA )
www.airliquide.es
Dirección e-mail (persona competente) : [email protected]
1.4. Teléfono de emergencia
Teléfono de emergencia [24h] : : +34 91 502 9300
SECCIÓN 2. Identificación de los peligros
2.1. Clasificación de la sustancia o de la mezcla

Clase y categoría de riesgo, Código de Normativa CE 1272/2008 (CLP)
• Peligros físicos : Gases a presión - Gases comprimidos - Atención - (CLP : Press. Gas Comp.) - H280
2.2. Elementos de la etiqueta
Normativa de Etiquetado CE 1272/2008 (CLP)

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SECCIÓN 2. Identificación de los peligros /...
«
M
• Pictogramas de peligro
• Código de pictogramas de peligro : GHS04

• Palabra de advertencia : Atención
• Indicación de peligro : H280 - Contiene gas a presión; peligro de explosión en caso de calentamiento.
• Consejos de prudencia
- Almacenamiento : P403 - Almacenar en un lugar bien ventilado.
2.3. Otros peligros
: Asfixiante a altas concentraciones.
SECCIÓN 3. Composición/información sobre los componentes
3.1. Sustancia / Mezcla

Sustancia.
N° CAS
Nombre del componente Contenido N° EC Clasificación(DSD) Clasificación(CLP)
N° índice
Nº de Registro
Nitrógeno : 100 % 7727-37-9 No clasificado (DSD) Press. Gas Comp. (H280)
231-783-9
-----
*1
No contiene otros componentes o impurezas que puedan influir en la clasificación del producto.
* 1: Figura en la lista del Anexo IV / V de REACH, exento de solicitud de registro.
* 2: No ha expirado el plazo límite de solicitud de registro.
* 3: No exige su registro.Sustancias fabricadas o importadas<1t/y.
Texto completo de Frases-R, véase capítulo 16. Texto completo de declaraciones-H, véase capítulo 16.
Para saber la composición exacta del producto consultar las especificaciones técnicas de Air Liquide.
SECCIÓN 4. Primeros auxilios
4.1. Descripción de los primeros auxilios

- Inhalación : Retirar a la víctima a un área no contaminada llevando colocado el equipo de respiración
autónoma. Mantener a la víctima caliente y en reposo. Llamar al doctor. Aplicar la respiración
artificial en caso de parada respiratoria.
- Contacto con la piel : No se esperan efectos adversos de este producto.
- Contacto con los ojos : No se esperan efectos adversos de este producto.
- Ingestión : La ingestión no está considerada como una vía potencial de exposición.
4.2. Principales síntomas y efectos, agudos y retardados
: A elevadas concentraciones puede causar asfixia. Los síntomas pueden incluir pérdida de la
consciencia o de la movilidad. La víctima puede no haberse dado cuenta de la asfixia.
Para mas información, ver la Sección 11.
4.3. Indicación de toda atención médica y de los tratamientos especiales que deban dispensarse
inmediatamente
: Ninguno.

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SECCIÓN 5. Medidas de lucha contra incendios
5.1. Medios de extinción

- Medios de extinción adecuados : Agua en spray o en nebulizador.
- Medios de extinción inadecuados : No usar agua a presión para extinguirlo.
5.2. Peligros específicos derivados de la sustancia o la mezcla
Peligros específicos : La exposición al fuego puede causar la rotura o explosión de los recipientes.
Productos de combustión peligrosos : Ninguno.
5.3. Recomendaciones para el personal de lucha contra incendios
Métodos específicos : Desplazar los envases lejos del área del fuego si ello se puede hacer sin riesgo.
Si es posible, detener la fuga de producto.
Utilizar medidas de control de incendios apropiadas con el incendio circundante. La
exposición de los envases de gas al fuego y al calor pueden provocar su ruptura. Enfriar los
envases dañados con chorro de agua pulverizada desde una posición protegida. No vaciar el
agua contaminada por el fuego en los desagües.
Usar agua en spray o en nebulizador para disipar humos de incendios.
Equipo de protección especial para : Utilizar equipos de respiración autónoma de presión positiva (ERA).
extinción de incendios Vestimenta y equipo de protección estandard (aparato de respiración autónoma) para
bomberos.
Norma UNE-EN 469: Vestimenta protectora para bomberos.
Norma UNE-EN 659: Guantes de protección para bomberos.
SECCIÓN 6. Medidas en caso de vertido accidental
6.1. Precauciones personales, equipo de protección y procedimientos de emergencia

Evacuar el área.
Utilizar equipos de respiración autónoma cuando entren en el área a menos que esté probado
que la atmósfera es segura.
Asegurar la adecuada ventilación de aire.
Actuar de acuerdo con el plan de emergencia local.
Mantenerse encontra del viento.
6.2. Precauciones relativas al medio ambiente
6.3. Métodos y material de contención y de limpieza
: Ventilar la zona.
6.4. Referencia a otras secciones
: Para más información sobre control frente a la exposición, protección personal o
consideraciones de eliminación, ver también las Secciones 8 y 13.
SECCIÓN 7. Manipulación y almacenamiento
7.1. Precauciones para una manipulación segura

Uso seguro del producto : Sólo personas experimentadas y debidamente entrenadas deben manejar gases sometidos a
presión.
La sustancia debe ser manipulada de acuerdo con los procedimientos de buena higiene
industrial y seguridad.
Utilizar sólo equipo específicamente apropiado para este producto y para su presión y
temperatura de suministro, en caso de duda contacte con su suministrador.
No fumar cuando se manipule el producto.
Comprobar que el conjunto del sistema de gas ha sido, o es con regularidad, revisado antes
de usarse respecto a la posibilidad de fugas.
Considerar los instrumentos de reducción de la presión en las instalaciones de gas.
No respirar el gas.
Evitar la eliminación del producto a la atmósfera.

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SECCIÓN 7. Manipulación y almacenamiento /...
Manipulación segura del envase del : Solicitar del suministrador las instrucciones de manipulación de los envases.
gas Debe prevenirse la filtración de agua al interior del recipiente.
No permitir el retroceso hacia el interior del recipiente.
Proteger las botellas de los daños materiales, no arrastrar,ni rodar, deslizar o dejar caer.
Si mueve botellas, incluso en pequeños recorridos, use una carretilla (mecánica, manual,etc)
diseñada para transportar botellas.
Mantener colocada la protección ( tulipa ) de la válvula hasta que el envase quede fijo contra
una pared, un banco o situado en una plataforma, y ya dispuesto para su uso.
Si el usuario aprecia cualquier problema en una válvula de una botella en uso, cierre el
envase y contacte al suministrador.
Nunca intentar reparar o modificar las válvulas de las botellas o los mecanismos de
seguridad.
Las válvulas que están dañadas deben ser inmediatamente comunicadas al suministrador.
Mantener los accesorios de la válvula libres de contaminantes, especialmente aceites y agua.
Reponer la tulipa de la válvula si es facilitada por el suministrador , siempre que el envase
esté desconectado del equipo.
Cierre la válvula del envase despues de su uso y cuando se quede vacío, incluso si aún está
conectado al equipo.
No intentar nunca trasvasar gases de una botella/envase a otro.
No utilizar nunca mecanismos con llamas o de calentamiento eléctrico para elevar la presión
del envase.
No quitar ni desfigurar las etiquetas facilitadas por el suministrador para identificar el
contenido de las botellas .
7.2. Condiciones de almacenamiento seguro, incluidas posibles incompatibilidades
: Observar todas las regulaciones y los requerimientos locales relativos al almacenamiento de
las botellas.
Mantener el contenedor por debajo de 50°C, en un lugar bien ventilado. Los envases deben
de ser almacenados en posición vertical y debidamente asegurados para evitar su caída. Los
envases almacenados deben ser comprobados periódicamente respecto a su estado general
y a posibles fugas . Las protecciones de las válvulas y las tulipas deben estar siempre
colocadas. Almacenar los envases en un lugar libre de riesgo y lejos de fuentes de calor e
ignición.
Los envases no deben ser almacenados en condiciones que favorezcan la corrosión .
Mantener alejado de materiales combustibles.
7.3. Usos específicos finales
: Ninguno.
SECCIÓN 8. Controles de exposición/protección individual
8.1. Parámetros de control

DNEL: Nivel de efectos no derivados (
trabajadores)
PNEC: Concentración prevista sin
efectos
8.2. Controles de la exposición
8.2.1. Controles técnicos apropiados : Los sistemas sujetos a presión deben ser regularmente comprobados respecto a fugas.
Deben usarse detectores de oxígeno cuando pueden ser emitidos gases asfixiantes.
Proporcionar ventilación adecuada, general y local, a los gases de escape.
Considerar un sistema de permisos de trabajo p.ej para trabajos de mantenimiento.
8.2.2. Equipo de protección personal : Sólo los EPI que cumplan los estandares recomendados por las normas EN-UNE/ISO deben
seleccionarse.
Un análisis de riesgos debe ser realizado y formalizado en cada área de trabajo para evaluar
los riesgos relacionados con el uso del producto y para determinar el EPI que corresponde a
un riesgo relevante. Estas recomendaciones deben ser tenidas en cuenta.
• Protección para el ojo/cara : Usar gafas de seguridad con protecciones laterales.
Norma UNE-EN 166: Protección para los ojos.

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SECCIÓN 8. Controles de exposición/protección individual /...
• Protección para la piel

- Protección de las manos : Usar guantes de trabajo al manejar envases de gases.
Norma EN-UNE 388: Guantes que protegen contra riesgos mecánicos.
- Otras : Usar zapatos de seguridad mientras se manejan envases.
Norma ISO 20345: Equipos de protección personal, zapatos de seguridad.
• Protección de las vías respiratorias : Un aparato de respiración asistida (SCBA) o una máscara con una vía de aire a presión
tienen que usarse en atmósferas con insuficiente oxígeno.
• Peligros térmicos : No necesaria.
= > 8
Protección personal
8.2.3. Controles de exposición : No necesaria.

medioambiental
SECCIÓN 9. Propiedades físicas y químicas
9.1. Información sobre propiedades físicas y químicas básicas

Apariencia
Estado físico a 20°C / 101.3kPa : Gas.
Color : Incoloro.
Olor : Sin olor que advierta de sus propiedades.
Umbral olfativo : El umbral de olor es subjetiva e inadecuado para advertir de sobreexposición.
Valor de pH : Sin datos disponibles.
Masa molecular [g/mol] : 28
Punto de fusión [°C] : -210
Punto de ebullición [°C] : -196
Temperatura crítica [°C] : -147
Punto de inflamación [°C] : No es aplicable a gases ni a mezcla de gases.
Velocidad de evaporación (éter=1) : No es aplicable a gases ni a mezcla de gases.
Rango de inflamabilidad [% de : No inflamable.
volumen en aire]
Presión de vapor [20°C] : No aplica.
Densidad relativa del gas (aire=1) : 0.97
Densidad relativa del líquido (agua=1) : No aplica.
Solubilidad en agua [mg/l] : 20
Coeficiente de reparto n-octanol/agua [ : No es aplicable a gases inorganicos.
log Kow]
Temperatura de auto-inflamación [°C] : No aplica.
Viscosidad a 20°C [mPa.s] : No aplica.
Propiedades explosivas : No aplica.
Propiedades comburentes : Ninguno.
9.2. Información adicional
Otros datos : Ninguno.

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SECCIÓN 10. Estabilidad y reactividad
10.1. Reactividad
: Sin riesgo de reactividad salvo lo expresado en la sub-sección más adelante.
10.2. Estabilidad química
: Estable en condiciones normales.
10.3. Posibilidad de reacciones peligrosas
: Ninguno.
10.4. Condiciones que deben evitarse
: Ninguno en las condiciones de manejo y almacenamiento recomendados (ver sección 7).
10.5. Materiales incompatibles
: Ninguno.
Para información complementaria sobre su compatibilidad referirse a la Norma ISO 11114.
10.6. Productos de descomposición peligrosos
: Ninguno.
SECCIÓN 11. Información toxicológica
11.1. Información sobre los efectos toxicológicos

Toxicidad aguda : No se conocen los efectos toxicológicos de este producto.
Corrosión o irritación cutánea : Se desconocen los efectos de este producto.
Lesiones o irritación ocular graves : Se desconocen los efectos de este producto.
Sensibilización respiratoria o cutánea : Se desconocen los efectos de este producto.
Carcinogénesis : Se desconocen los efectos de este producto.
Mutagenicidad : Se desconocen los efectos de este producto.
Toxicidad para la reproducción : Se desconocen los efectos de este producto.
órganos (STOT) – exposición única
órganos (STOT) – exposición repetida
Peligro de aspiración : No es aplicable a gases ni a mezcla de gases.
SECCIÓN 12. Información ecológica
12.1. Toxicidad
12.2. Persistencia y degradabilidad
12.3. Potencial de bioacumulación
12.4. Movilidad en el suelo
12.5. Resultados de la valoración PBT y mPmB
: No se clasifica como PBT o vPvB.
12.6. Otros efectos adversos
Efectos sobre la capa de ozono : Ninguno.

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SECCIÓN 12. Información ecológica /...
Produce efectos en el calentamiento : Ninguno.

global
SECCIÓN 13. Consideraciones relativas a la eliminación
13.1. Métodos para el tratamiento de residuos

: Puede ser liberado a la atmósfera en un lugar bien ventilado.
No descargar dentro de ningún lugar donde su acumulación pudiera ser peligrosa.
Consulte al proveedor acerca de posibles recomendaciones específicas.
Consulte el código de prácticas de EIGA Doc 30 "Eliminación de gases", se puede
descargar en http://www.eiga.org, para obtener mayor información sobre métodos más
adecuados de eliminación.
Contactar con el suministrador si se necesita orientación.
Lista de residuos peligrosos : 16 05 05: Envases de gases a presión distintos de los mencionados en 16 05 04.
13.2. Informacíones complementarias
: Ninguno.
SECCIÓN 14. Información relativa al transporte
14.1. Número ONU

Número ONU : 1066
n
ó
Etiquetado según ADR, IMDG, IATA
: 2.2 : Gases no inflamables, no tóxicos

14.2. Designación oficial de transporte de las Naciones Unidas
Transporte por carretera/ferrocarril ( : NITRÓGENO COMPRIMIDO
ADR/RID)
Transporte por aire (ICAO-TI / IATA- : NITROGEN, COMPRESSED
DGR)
Transporte por mar (IMDG) : NITROGEN, COMPRESSED
14.3. Clase(s) de peligro para el transporte
Transporte por carretera/ferrocarril (ADR/RID)
Clase : 2
Código de clasificacion : 1A
H.I. n° : 20
Restricciones en Túnel : E : Paso prohibido por túneles de la categoría E.
Transporte por aire (ICAO-TI / IATA-DGR)

•
»
“
’
”
‘
Transporte por mar (IMDG)
Instrucciones de Emergencia (EmS) - : F-C
Incendio.

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SECCIÓN 14. Información relativa al transporte /...
Instrucciones de Emergencia (EmS) - : S-V

Derrames
14.4. Grupo de embalaje
Transporte por carretera/ferrocarril ( : No aplica.
ADR/RID)
Transporte por aire (ICAO-TI / IATA- : No aplica.
DGR)
Transporte por mar (IMDG) : No aplica.
14.5. Peligros de contaminación
Transporte por carretera/ferrocarril ( : Ninguno.
ADR/RID)
Transporte por aire (ICAO-TI / IATA- : Ninguno.
DGR)
Transporte por mar (IMDG) : Ninguno.
14.6 Precauciones particulares para los usuarios
Packing Instruction(s)
Transporte por carretera/ferrocarril ( : P200
ADR/RID)
Transporte por aire (ICAO-TI / IATA-
DGR)
Avión de carga y pasajeros : Permitido.
pasaje y carga
Avion de carga solo : Permitido.
carga solo
Transporte por mar (IMDG) : P200
Precauciones particulares para los : Evitar el transporte en los vehículos donde el espacio de la carga no esté separado del
usuarios compartimiento del conductor.
Asegurar que el conductor está enterado de los riesgos potenciales de la carga y que conoce
que hacer en caso de un accidente o de una emergencia.
Antes de transportar las botellas :
- Asegurarse de que los recipientes están bien fijados.
- Asegurarse que las válvulas de las botellas están cerradas y no fugan.
- Asegurarse que el tapón del acoplamiento de la válvula (cuando exista) está
adecuadamente apretado.
- Asegurarse que la caperuza de la válvula o la tulipa, (cuando exista), está adecuadamente
apretada.
- Asegurar una ventilación adecuada.
14.7. Transporte de granel según anexo II del tratado MARPOL 73/78 y según código IBC
Transporte de granel según anexo II : No aplica.
del tratado MARPOL 73/78 y según
código IBC

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SECCIÓN 15. Información reglamentaria
15.1. Reglamentación y legislación en materia de seguridad, salud y medio ambiente específicas para la
sustancia o la mezcla
Legislación UE
Restricciones : Ninguno.
Seveso directiva 96/82/EC : No esta cubierto.
Legislación Nacional
Legislación Nacional (texto) : Asegúrese que se cumplen las normativas nacionales y locales.
15.2. Evaluación de la seguridad química
: Un CSA (Análisis de seguridad química) no tiene que ser realizado para este producto.
SECCIÓN 16. Otra información
Enumeración de los cambios : Hoja de datos de seguridad revisada de acuerdo con la regulación de la Comisión (UE) Nº
2015/830. Cambios (*)
Consejos relativos a la formación : El riesgo de asfixia es a menudo despreciado y debe ser recalcado durante la formación de
los operarios.
Recipiente a presión.
No respirar los gases.
Los usuarios de los aparatos de respiración deben ser entrenados.
Informacíon adicional : La presente Ficha de Datos de Seguridad está establecida de acuerdo con las Directivas
Europeas en vigor .
Cambios por revisión - Ver : *
Producto informacíon : Ver ficha técnica del producto para informaciones más detalladas.
Fuente de los datos utilizados : Base de datos EIGA.
Lista del texto completo de : H280 - Contiene gas a presión; peligro de explosión en caso de calentamiento.
declaraciones-H en la sección 3.
Nota : El contenido y el formato de esta ficha de seguridad se ajustan a los
Reglamentos (CE) Nº453/2010. y (CE) CLP 1278/2008
RENUNCIA DE RESPONSABILIDAD : A pesar de que durante la preparación de este documento se ha tomado especial cuidado, no
se acepta ninguna responsabilidad por las lesiones o los daños resultantes.
Los detalles dados son ciertos y correctos en el momento de llevarse este documento a
impresión. Antes de utilizar el producto en un nuevo proceso o experimento, debe llevarse a
cabo un estudio completo de seguridad y de compatibilidad de los materiales.
RENUNCIA DE RESPONSABILIDAD La información en esta Ficha de Seguridad fue obtenida de fuentes que creemos son
fidedignas. Sin embargo, la información se proporciona sin ninguna garantía, expresa o implícita en cuanto a su exactitud. Las
condiciones o métodos de manejo, almacenamiento, uso o eliminación del producto están más allá de nuestro control y
posiblemente también más allá de nuestro conocimiento. Por esta y otras razones, no asumimos ninguna responsabilidad y
descartamos cualquier responsabilidad por pérdida, daño o gastos ocasionados por o de cualquier manera relacionados con el
manejo, almacenamiento, uso o eliminación del producto. Esta Ficha de Seguridad fue preparada y debe ser usada sólo para
este producto. Si el producto es usado como un componente de otro producto, es posible que esta información de Seguridad no
sea aplicable.
Fin del documento

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PROYECTO: TAL
PÁGINA 25 DE 31

FECHA: 31/10/2019
4.3. HOJA DE SEGURIDAD ALUMINA
Section 01 - Product And Company Identification
Product Identifier Activated Alumina
Other Means of Identification Activated alumina grade A and AA, aluminum oxide, alumina dessicant, catalyst alumina,
adsorbent alumina.
Product Use and Restrictions on Catalyst support, desiccant, absorbent, adsorbent.

Use
Initial Supplier Identifier ClearTech Industries Inc.

1500 Quebec Avenue
Saskatoon, SK. Canada
S7K 1V7
Prepared By ClearTech Industries Inc. Technical Writer

Phone: 1 (800) 387-7503
24-Hour Emergency Phone Phone: 1 (306) 664 – 2522

Section 02 - Hazard Identification
GHS-Classification
This product has been assessed in accordance with the Hazardous Products Regulations and is not classified as a hazardous
substance or mixture.
Section 03 - Composition / Information on Ingredients
Chemical Name CAS Number Weight % Unique Identifiers

Aluminum Oxide 1344-28-1 93-95%
Section 04 - First Aid Measures
Inhalation If symptoms are experienced, remove victim to fresh air. Give artificial respiration only if
breathing has stopped, if breathing is difficult give oxygen. Seek medical attention.
Skin Contact / Absorption Remove contaminated clothing. Wash affected area with soap and water. If irritation
persists, seek medical attention.
Eye Contact Flush immediately with lukewarm, gently flowing water for at least 30 minutes while
forcibly holding the eyelids open to ensure complete irrigation of the eye tissue. If irritation
persists, seek medical attention.
Ingestion Have victim rinse mouth with water. Do not induce vomiting. Seek medical attention.
Additional Information Call physician if symptoms persists.
Section 05 - Fire Fighting Measures
Suitable Extinguishing Media Use extinguishing agent suitable for surrounding fire.
Page 1 of 6
Unsuitable Extinguishing Media Not Available
Specific Hazards Arising From the Not Available

Chemical
Special Protective Equipment and Wear NIOSH-approved self-contained breathing apparatus and protective gear.
Precautions for Fire-Fighters
Further Information Note that product can build up a static charge when subjected to friction from conveying,
mixing or other movements.
Section 06 - Accidental Release Measures
Personal Precautions / Protective Wear appropriate personal protective equipment. Ventilate area. Only enter area with
Equipment / Emergency PPE. Stop or reduce leak if safe to do so. Flush with water to remove any residue.
Procedures
Environmental Precautions Prevent material from entering sewers.
Methods and Materials for Avoid generation of dust. Sweep spilled product and place in suitable, labelled containers
Containment and Cleaning Up for proper disposal.
Section 07 - Handling and Storage

Precautions for Safe Handling Use proper equipment for lifting and transporting all containers. Use sensible industrial
hygiene and housekeeping practices. Wash thoroughly after handling. Avoid all situations
that could lead to harmful exposure.
Conditions for Safe Storage Store in a well ventilated area away from incompatible materials. It is good practice to keep
containers closed when not in use.
Incompatibilities Halocarbons, chlorine trifluoride, ethylene oxide, oxygen difluoride, vinyl acetate.
Section 08 - Exposure Controls and Personal Protection

Exposure Limit(s)
Component Regulation Type of Listing Value
3
Aluminum Oxide ACGIH TLV-TWA 1 mg/m
3
OSHA PEL-T-TWA 15 mg/m
Engineering Control(s)
Ventilation Requirements Mechanical ventilation (dilution or local exhaust), process or personnel enclosure and
control of process conditions must be provided in accordance with all fire codes and
regulatory requirements. Supply sufficient replacement air to make up for air removed by
exhaust systems.
Other Emergency shower and eyewash must be available and tested in accordance with
regulations and be in close proximity.
Protective Equipment
Eyes/Face Chemical safety glasses should be worn while product is being handled.
Hand Protection No specific requirement, but it is good practice to prevent skin contact by wearing
impervious gloves of chemical resistance.
Skin and Body Protection No specific requirement, but it is good practice to prevent skin contact by wearing body
suits, aprons and/or coveralls while product is being handled.
Page 2 of 6
Respiratory Protection Where an inhalation risk exists, wear a class P1 (particulate) respirator.
Thermal Hazards Not Available
Section 09 - Physical and Chemical Properties

Appearance
Physical State Powder, granules
Colour White
Odour Odourless
Odour Threshold Not Applicable
Property
pH Not Applicable
Melting Point/Freezing Point 2050°C
Initial Boiling Point and Boiling 2980°C

Range
Flash Point Not Applicable
Evaporation Rate Not Applicable
Flammability Non-flammable
Upper Flammable Limit Not Applicable
Lower Flammable Limit Not Applicable
o
Vapour Pressure (mm Hg, 20 C) Not Applicable
Vapour Density (Air=1) Not Applicable
Relative Density Not Available
Solubility(ies) Insoluble in water.

Slightly soluble in alkalis and acids; insoluble in organic solvents.
Partition Coefficient: n- Not Applicable

octanol/water
Auto-ignition Temperature Not Applicable
Decomposition Temperature Not Available
Viscosity Not Applicable
Explosive Properties None
Specific Gravity (Water=1) 3.97
% Volatiles by Volume Not Applicable
Page 3 of 6
Formula Al2O3
Molecular Weight 101.96
Section 10 - Stability and Reactivity
Reactivity Not Available
Stability Normally stable.

Possibility of Hazardous None known.
Reactions
Conditions to Avoid Generation of dust, moisture.
Incompatible Materials Halocarbons, chlorine trifluoride, ethylene oxide, oxygen difluoride, vinyl acetate.
Hazardous Decomposition None reported.
Products
Section 11 - Toxicological Information
Acute Toxicity
Component Oral LD50 Dermal LD50 Inhalation LC50

Aluminum Oxide 2,000 mg/kg (rat) Not Available Not Available
Chronic Toxicity – Carcinogenicity

Component IARC
Aluminum Oxide Not known to be a carcinogen.
Skin Corrosion/Irritation Prolonged or repeated exposure may cause irritation due to mechanical action.
Ingestion Low toxicity. Ingestion of large doses may cause nausea, vomiting and irritation of the
gastrointestinal tract.
Inhalation Generation of dust may cause irritation to the respiratory tract.
Serious Eye Damage/Irritation May cause mild irritation with symptoms of lacrimation, pain, redness and conjunctivits.
Respiratory or Skin Sensitization Not Available
Germ Cell Mutagenicity Not known to by mutagenic.
Reproductive Toxicity Not known to cause reproductive toxicity.
STOT-Single Exposure May cause irritation to the respiratory tract.
STOT-Repeated Exposure Not Available
Aspiration Hazard Not Available
Synergistic Materials Not Available
Section 12 – Ecological Information

Ecotoxicity
Component Toxicity to Algae Toxicity to Fish Toxicity to Daphnia and
Other Aquatic Invertebrates
Aluminum Oxide Not Available Not Available Not Available
Page 4 of 6
Biodegradability Not Available
Bioaccumulation Not Available
Mobility Not Available
Other Adverse Effects No effects expected from insoluble product as insolubility leads to non-bioavailability.
Section 13 – Disposal Considerations
Waste From Residues/Unused Dispose in accordance with all federal, provincial, and/or local regulations including the
Products Canadian Environmental Protection Act.
Contaminated Packaging Dispose in accordance with all federal, provincial, and/or local regulations including the
Canadian Environmental Protection Act.
Section 14 – Transport Information
UN Number Not Regulated
UN Proper Shipping Name Not Regulated
Transport Hazard Class(es) Not Regulated
Packaging Group Not Regulated
Environmental Hazards Not listed as a marine pollutant under Canadian TDG Regulations, schedule III.
Special Precautions Not Available
Transport in Bulk Not Available
TDG
Other Secure containers (full and/or empty) with suitable hold down devises during shipment and
ensure all caps, valves, or closures are secured in the closed position.
TDG PRODUCT CLASSIFICATION: This product has been classified on the preparation date specified at section 14 of this
MSDS / SDS, for transportation in accordance with the requirements of part 2 of the Transportation of Dangerous Goods
Regulations. If applicable, testing and/or published test data regarding the classification of this product are listed in the
references at section 16 of this MSDS / SDS.
Section 15 – Regulatory Information
NOTE: THE PRODUCT LISTED ON THIS SDS HAS BEEN CLASSIFIED IN ACCORDANCE WITH THE HAZARD CRITERIA OF
THE CANADIAN CONTROLLED PRODUCTS REGULATIONS. THIS SDS CONTAINS ALL INFORMATION REQUIRED BY
THOSE REGULATIONS.
Section 16 – Other Information
Preparation Date August 10, 2016
Note: The responsibility to provide a safe workplace remains with the user. The user should consider the health hazards and
safety information contained herein as a guide and should take those precautions required in an individual operation to instruct
employees and develop work practice procedures for a safe work environment. The information contained herein is, to the best of
our knowledge and belief, accurate. However, since the conditions of handling and use are beyond our control, we make no
guarantee of results, and assume no liability for damages incurred by the use of this material. It is the responsibility of the user to
comply with all applicable laws and regulations.
Attention: Receiver of the chemical goods / SDS coordinator
As part of our commitment to the Canadian Association of Chemical Distributors (CACD) Responsible Distribution ® initiative,
ClearTech Industries Inc. and its associated companies require, as a condition of sale, that you forward the attached Safety Data
Sheet(s) to all affected employees, customers, and end-users. ClearTech will send any available supplementary handling, health,
and safety information to you at your request.
Page 5 of 6
If you have any questions or concerns please call our customer service center.
References:
1) CHEMINFO
2) eChemPortal
3) TOXNET
4) Transportation of Dangerous Goods Canada
5) HSDB
6) ECHA
ClearTech Industries Inc. - Locations

Corporate Head Office: 1500 Quebec Avenue, Saskatoon, SK, S7K 1V7
Phone: 1(306) 664 – 2522
Fax: 1(888) 281-8109
www.cleartech.ca
24 Hour Emergency Number - All Locations – 1(306) 664-2522
Page 6 of 6

PÁGINA 271 DE 556
12.4. PRIMEROS AUXILIOS

ASFIXIA O DESCARGA ELÉCTRICA
Siempre que haya duda de la inocuidad de una atmósfera gaseosa, utilizar el equipo
adecuado de respiración. Conocer el tratamiento correcto de primeros auxilios a víctimas
de asfixia, que se pueden resumir en:
 Trasladar a la víctima a una zona de aire puro. Mantenerla caliente y acompañada.
 Aplicar la respiración artificial hasta que recupere la respiración espontánea.
 Avisar inmediatamente a un médico, pero sin retrasar la aplicación de la
respiración artificial.
 Administrar oxígeno cualquiera que sea la gravedad del caso.
 Mantener a la víctima tumbada con la cabeza baja hasta la llegada del médico.
En el apartado 12.3 anterior se describen también los primeros auxilios y prevenciones
referentes al manejo de productos tóxicos.
12.5. RIESGOS DE SOBREPRESIÓN Y VACÍO

La sobrepresión en los equipos puede producirse por muchas razones. La principal es que
se produzca una descompensación de caudal tanto de materia como de calor en uno o
más equipos. Las válvulas de seguridad se han instalado después de estudiar
cuidadosamente las posibles fuentes de sobrepresión.
Todos los equipos de la Unidad están diseñados para una presión algo más alta que la
esperada en condiciones de operación normal. Se han previsto válvulas de seguridad para
hacer frente a las posibles contingencias de sobrepresión. Debe prestarse atención a las
válvulas abiertas o cerradas con sello, identificadas como CSO y CSC o como LO y LC en
los P&ID's de la Unidad, con objeto de no dejar desprotegido ningún sistema. Estas
válvulas sólo podrán operarse bajo la supervisión de personal autorizado.
Durante las operaciones de purga con vapor o drenaje de agua es importante dejar un
venteo abierto para reemplazar con aire el vapor que condensa o el agua que se drena.
Si el recipiente está libre de hidrocarburos y se produce vacío, abrir todos los venteos y
drenajes y dejar que entre aire. Ahora bien, si en un recipiente que contiene
hidrocarburos se produce vacío, NO ABRIR LOS VENTEOS, YA QUE SE PUEDE PRODUCIR
MEZCLA EXPLOSIVA. Más bien introducir vapor o nitrógeno para romper el vacío.
12.6. LISTA DE SUSTANCIAS PELIGROSAS

Se adjunta lista de sustancias peligrosas de la unidad, TAL-NIS-PRO-LIS-0007.
PROYECTO: TAL
LISTA DE SUSTANCIAS PELIGROSAS PÁGINA 1 DE 2
LISTA DE SUSTANCIAS PELIGROSAS
DOCUMENTO PRINCIPAL
ANEXOS
FORMATOS

Tamara Salazar Enry Luna Alberto Pan
PROYECTO: TAL
LISTA DE SUSTANCIAS PELIGROSAS PÁGINA 2 DE 2
SUSTANCIA VOLATILIDAD
TEMP. DE PUNTO DE
PUNTO DE DENSIDAD PESO
ESTADO@ LIE/LSE DENSIDAD DEL PRESION DE AUTO- INFLAMA-
MOLECU-LAR
REV.
EBULLICIÓN @ RELATIVO AL OBSERVACIONES

N°.
DESCRIPCIÓN COMPOSICIÓN (%mol) 20°C (1) LIQUIDO @ 20°C VAPOR @ 20°C IGNICIÓN CIÓN
Patm AIRE
3 2
Vol. % kg/m kg/cm °C °C kg/kgmol °C
A pesar de no ser combustible, se lista este fluido porque

1 Nitrógeno N2: 100 G - - - - 0.97 - 28 - su liberación súbita en un área cerrada puede causar
daños a la salud por deficiencia de oxígeno
NOTAS:
1 Estado Líquido: L, Estado Gaseoso: G
2 La MSDS del Nitrógeno se encuentra incluida dentro del documento TAL-NIS-PRO-SPE-0001 "Hoja de Seguridad de los Materiales", y deberá ser completada por el vendedor del paquete NIS-Z-001 durante el desarrollo de la ingeniería de detalle.

PÁGINA 274 DE 556
13. DIAGRAMAS
En este capítulo se presentan, como referencia para la lectura y comprensión del Manual
de Operación, los siguientes diagramas de la Planta:
13.1. DIAGRAMA GENERAL DE LA UNIDAD

TAL-NIS-PRO-BLD-0001 DIAGRAMA GENERAL DE LA UNIDAD
13.2. DIAGRAMAS DE TUBERÍA E INSTRUMENTACIÓN

TAL-NIS-PRO-PID-0001 P&ID PLANTA DE PRODUCCIÓN DE
NITRÓGENO
TAL-NIS-PRO-PID-0002 P&ID LÍNEAS DE INTERCONEXIÓN DE
PROCESOS Y SERVICIOS
TAL-NIS-PRO-PID-0003 P&ID CABEZALES DE AGUA Y VAPOR
TAL-NIS-PRO-PID-0004 P&ID CABEZALES DE AGUA DE ENFRIAMIENTO
Y AIRE
V-TAL-MEC-0001-OC-04-NIS-Z-001- P&ID’s AIR LIQUIDE
0011-0256
13.3. PLOT PLAN

TAL-NIS-PNG-LAY-0001 PLANTA DE NITRÓGENO - IMPLANTACION DE
LA UNIDAD
LINEAS DE SERVICIOS AUXILIARES
CWR AGUA DE ENFRIAMIENTO (RETORNO)

CWS AGUA DE ENFRIAMIENTO (SUMINISTRO)
LEYENDA
SISTEMA DE PRODUCCIÓN DE NITRÓGENO
NIS-Z-001 PLANTA DE NITRÓGENO
NITRÓGENO
CWS
157605 kg/h (3) 4300 kg/h A USUARIOS
158 m³/h 3627 Sm³/h

03
CWR
157605 kg/h (3)
SISTEMA DE PRODUCCIÓN
158.6 m³/h DE NITRÓGENO
03
AIRE
ATMOSFÉRICO (1)
12499 kg/h 20270 kg/h (2)

10215 Sm³/h 17100 Sm³/h

03
DIAGRAMA GENERAL DE LA UNIDAD
TAL-NIS-PRO-BLD-0001 1 1 03
H G F E D C B A
NIS-Z-001
PLANTA N2 (NOTA 12)
DP/DT: 10.5 kg/cm²g / 93.0 °C
OP/OT: 8 kg/cm²g / 32.0 °C
MDMT: -10.0 °C
TAL TAL
NIS 013 NIS 014
AIRE DE INSTRUMENTOS NITRÓGENO
1640 2"-IA-NIS-00101-C21F-N 6"-NI-NIS-00102-A21F-N 2
2 1877 Z-001-0028 1882 Z-001-0021
IA 2" NOTA 9
HACIA CABEZAL DE DE SISTEMA DE 6" SPE
TAL-NIS-PRO-PID-0004 DISTRIBUCION DE AIRE PRODUCCION DE GAN
NOTA 9 00101
NIS-Z-001
NOTAS 5, 7, 11
TAL
NIS 007
NITRÓGENO NITROGENO
ENFRIAMIENTO
DE ENFRIAMIENTO
DESDE CABEZAL DE
RETORNO DE AGUA DE
RETORNO DE AGUA
1879
8"-NI-NIS-00104-A21F-N 8"-NI-NIS-00101-A21F-N
04 1881 Z-001-0256 1888 TAL-NIS-PRO-PID-0002
NOTA 10
DISTRIBUCION DE AGUA DE
DE VAPORIZADORES DE LIN 8" A L.B
SPE
Z-001-0029
SUMINISTRO DE AGUA
NOTA 10
3 3
Z-001-0029
HACIA CABEZAL DE
ENFRIAMIENTO
DE ENFRIAMIENTO
00102
1880
8" 8"
TAL TAL
NIS 001 NIS 002
TIT TI
00101 00101
SET @=13.3kg/cm²g 1-1/2"
1" D 2"
PSV
8"-CWR-NIS-00101-A21F-N
+
1:500 00101
2"-SV-NIS-00101-A21F-N
1"-CWR-NIS-00102-A21F-N
4 4
8"-CWS-NIS-00101-A21F-N
MIN.
LEGIBLE
3/4"
OWS
1:500
1"
CSO 8"
FP NO
NOTA 4
8"-CWR-NIS-00401-A21F-N
TAL-NIS-PRO-PID-0004
CWR
CWS
1642
1641
5 5
12. LAS CONDICIONES REPORTADAS CORRESPONDEN A LAS CONDICIONES DE ENTREGA DE

NITROGENO. PARA CONDICIONES DEL PAQUETE NIS REFERIRSE A
V-TAL-MEC-0001-OC-04-NIS-Z-001-0011-0082/0057/0078/0104/0056/0064/0111/0116.
1. ELIMINADA.
Este Documento contiene A- PARA CONSULTAR LA SIMBOLOGIA GENERAL DEL PROYECTO
VER DIAGRAMAS Nº TAL-GEN-PRO-PID-0001-0008-03. 2. ELIMINADA. PROYECTO MODERNIZACIÓN REFINERÍA TALARA
información privada y no B- TODOS LOS TAGS DE INSTRUMENTOS VAN PRECEDIDOS 3. ELIMINADA.
puede ser duplicado, POR EL CODIGO NIS. 4. VALVULA CSO DEBE SER INSTALADA CON EL VASTAGO ORIENTADO HORIZONTALMENTE. UNIDADES AUXILIARES Y TRABAJOS COMPLEMENTARIOS
G- PARA CONEXIONES EN LA INTERFASE TUBERIA- 5. LA MEDICION DEL CAUDAL DE NITROGENO GASEOSO Y LIQUIDO VAPORIZADO CONSUMIDOS
modificado o divulgado a INSTRUMENTOS REFERIRSE A TAL-GEN-PNG-TYP-0001. SERA REALIZADA DENTRO DE LA PLANTA N2 NIS-Z-001 CON SEÑALES Y 04 08/11/2019 Emisión para Construcción T.S.R F.C.Q M.L.C
6
terceros sin el H- PARA DETALLES DE VENTEOS Y DRENAJES DE
INSTRUMENTOS REFERIRSE A TAL-GEN-INS-TYP-0001.
CONTADORES EN LA SALA DE CONTROL.
6. ELIMINADA.
03 08/07/2019 Emisión para Construcción T.S.R. F.C.Q A.P.G
P&ID PLANTA DE PRODUCCIÓN DE
consentimiento escrito de 7. PARA DETALLES DE LA UNIDAD NIS REFERIRSE A 6
NITROGENO
I- PARA VALORES DE SET POINTS DE LAS ALARMAS REFERIRSE
COBRA SCL. La única A V-TAL-MEC-0001-OC-04-NIS-Z-001-0160. V-TAL-MEC-0001-OC-04-NIS-Z-001-0016/0018/0255/0021/0023/0025/0026/0028/0029/0256.
8. ELIMINADA. 02 27/02/2019 Emisión para Construcción T.S.R. E.L.C. A.P.G
copia Controlada de este 9. NITROGENO GASEOSO.
Documento está en el 10. NITROGENO LIQUIDO VAPORIZADO DE ALMACENAMIENTO.
11. TODOS LOS CODIGOS DE PID DEL PROVEEDOR VAN ANTECEDIDOS POR: 01 28/09/2018 Emisión para Diseño incluido comentarios de PP/CPT y HTAS T.S.R. E.L.C. A.P.G
Sistema Informático de V-TAL-MEC-0001-OC-04-NIS. FORMATO: PROY. NUM:
Gestión Documental de A1 TAL
TAL-NIS-PRO-PFD-0001 PFD PLANTA DE NITROGENO 00 13/07/2018 Emisión para Aprobación T.S.R. E.L.C. A.P.G
COBRA SCL. ESCALA: PLANO CLIENTE Nº PAG. REV.
NOTAS GENERALES NOTAS PLANO REF N° PLANOS DE REFERENCIA N° REV. FECHA DESCRIPCIÓN DE LA EMISIÓN ELAB. REV. APR. 1:SIN TAL-NIS-PRO-PID-0001 1 DE 1 04
H G F E D C B A
H G F E D C B A
L.B.
INT NIS
MIN. 1
NITROGENO NITROGENO
10"-NI-INT-02001-A21F-N 8"-NI-NIS-00101-A21F-N
02070-INT-PRO-PID-002-13 3523 TAL-NIS-PRO-PID-0001 1888
10"x8" 8" 8" 8"
NO 3/4" NO DESDE NIS-Z-001
PIF
04
2T-02.075.00
PIF
04
2T-02.069.00
VAPOR DE BAJA PRESIÓN VAPOR DE BAJA PRESION

2"-LS-INT-02027-A21F-H 2"-LS-NIS-00201-A21F-H
3580 02070-INT-PRO-PID-002-7 1644 TAL-NIS-PRO-PID-0003
2" 2" 2"
NO 3/4" NO 3/4" HACIA USUARIOS
1" 1"
NC 3/4" NC
2
2
PIF
04
2T-02.119.00
AIRE DE PLANTA AIRE DE PLANTA

2"-UA-INT-02002-A21F-N 2"-UA-NIS-00201-A21F-N
2" 2" 2"
NO 3/4" NO HACIA USUARIOS
04 MIN
PIF
2T-02.062.00 04
AIRE DE INSTRUMENTOS AIRE DE INSTRUMENTOS

2"-IA-INT-02029-C21F-N 2"-IA-NIS-00201-C21F-N
2" 2" 2"
04
3 MIN 3
PIF
04
2T-02.029.00
AGUA DE ENFRIAMIENTO AGUA DE ENFRIAMIENTO
(RETORNO) (RETORNO)
8"-CWR-INT-02014-A21F-N 8"-CWR-NIS-00401-A21F-N
02070-INT-PRO-PID-002-19 3604 TAL-NIS-PRO-PID-0004 1647
8" 8" 8"
NO 3/4" NO DESDE CABEZAL
04
MIN
PIF
2T-02.030.00 04
AGUA DE ENFRIAMIENTO AGUA DE ENFRIAMIENTO

(SUMINISTRO) (SUMINISTRO)
8"-CWS-INT-02014-A21F-N 8"-CWS-NIS-00201-A21F-N
4 3604 02070-INT-PRO-PID-002-19 1648 TAL-NIS-PRO-PID-0004 4
8" 8" 8"
04
MIN
PIF
04
2T-02.103.00
AGUA POTABLE AGUA POTABLE

2"-PW-INT-02036-C21F-N 2"-PW-NIS-00201-C21F-N
2" 2" 2"
MIN.
PIF
2T-02.091.00 04
5 5
AGUA PROCESOS II AGUA DE PROCESOS II

2"-PGW-INT-02033-A21F-N 2"-PGW-NIS-00201-A21F-N
2" 2" 2"
MIN.
04
Este Documento contiene A- PARA CONSULTAR LA SIMBOLOGIA GENERAL DEL PROYECTO

VER DIAGRAMAS N° TAL-GEN-PRO-PID-0001-0008-03. PROYECTO MODERNIZACIÓN REFINERÍA TALARA
información privada y no
puede ser duplicado,
B- TODOS LOS TAGS DE INSTRUMENTOS VAN PRECEDIDOS
POR EL CODIGO NIS. UNIDADES AUXILIARES Y TRABAJOS COMPLEMENTARIOS
C. LAS VÁLVULAS DE DRENAJE, VENTEO, BY-PASS O SISTEMAS
modificado o divulgado a DE ARRANQUE DEBEN ESTAR EN POSICIÓN 04 08/11/2019 Emisión para Construcción T.S.R F.C.Q M.L.C
6
terceros sin el NORMALMENTE CERRADA.
P&ID LINEAS DE INTERCONEXION DE
consentimiento escrito de 6
COBRA SCL. La única PROCESOS Y SERVICIOS
copia Controlada de este 02 27/02/2019 Emisión para Construcción T.S.R. E.L.C. A.P.G
Documento está en el
01 28/09/2018 Emisión para Diseño incluido comentarios de PP/CPT y HTAS T.S.R. E.L.C. A.P.G
Sistema Informático de FORMATO: PROY. NUM:
H G F E D C B A
H G F E D C B A
TI
PI
00301
00301 04
04
FI
PIT PG 00301
TIT 1
00301 00304 00301 MIN.
AGUA POTABLE 3/4" 3/4" 1-1/2" 1"

FIT 2"-PW-NIS-00201-C21F-N
1649 TAL-NIS-PRO-PID-0002 +
00301
4"x2" 4"x2"
MIN.
DESDE L.B.
2"
NO
2"-PW-NIS-00301-C21F-N
2"
NO COBRA 2
2 TI VENDOR
MIN.
PI
00302
00302
NIS-DS-001
EMERGENCIA
DUCHAS DE
NOTAS 3, 4
FI
1890
PG PIT TG TIT 00302
00305 00302 00304 00302 MIN.
AGUA DE PROCESOS II 3/4" 3/4" 1-1/2" 1-1/2" 1"

FIT 2"-PGW-NIS-00201-A21F-N
MIN.
00302 3/4"
DESDE L.B. 4"x2" 4"x2"
NO
3/4"-PGW-NIS-00301-A21F-N
FQI FI
NIS-ES-001
DETALLE "1"
NOTA 5
00303 00303
1887
3 3
DETALLE "1"
NIS-ES-001
TI
1886
PI
3/4"-LS-NIS-00301-A21F-H
00303
00303
FIT
PG PIT 00303
TG TIT
00306 00303
00305 00303 MIN.
1/2" 1/2"
3/4" 3/4" 3/4"
MIN.
VAPOR DE BAJA PRESIÓN 1-1/2" 1-1/2" 1"
2"-LS-NIS-00201-A21F-H NO
1644 TAL-NIS-PRO-PID-0002
DESDE L.B. 4"x2" 4"x2" SPE
04
00305
2" 3/4"-LS-NIS-00302-A21F-H NO 3/4"-OWS-NIS-00301-A21F-P
T
3/4" 3/4" NOTA 6
3/4"
4 4
I
04 O D
V
OWS
DETALLE "1"
ESTACIÓN DE SERVICIO
LS PGW UA
3/4" 3/4"
5 5
SPE SPE
00301 00302
Este Documento contiene A- PARA CONSULTAR LA SIMBOLOGIA GENERAL DEL

PROYECTO, VER DIAGRAMA
1. ELIMINADA.
2. ELIMINADA. PROYECTO MODERNIZACIÓN REFINERÍA TALARA
información privada y no Nº TAL-GEN-PRO-PID-0001-0008-03. 3. LA DUCHA LAVAOJOS DEBE SER INSTALADA A NO MAS, DE 15 m DE LA UNIDAD.
puede ser duplicado, B- TODOS LOS TAGS DE INSTRUMENTOS VAN PRECEDIDOS 4. PARA DETALLES DE DUCHAS DE EMERGENCIA REFERIRSE A TAL-GEN-SCI-DTS-1008. UNIDADES AUXILIARES Y TRABAJOS COMPLEMENTARIOS
POR EL CODIGO NIS. 5. PARA UBICACION DE LA ESTACION DE SERVICIO REFERIRSE A TAL-GEN-PNG-STD-1001
modificado o divulgado a C. LAS VÁLVULAS DE DRENAJE, VENTEO, BY-PASS O SISTEMAS SECCION 9.8. 04 08/11/2019 Emisión para Construcción T.S.R F.C.Q M.L.C
terceros sin el DE ARRANQUE DEBEN ESTAR EN POSICIÓN 6. PROPORCIONAR FILTRO INTEGRADO A LA TRAMPA DE VAPOR. CUANDO LA DISTANCIA
6
consentimiento escrito de
NORMALMENTE CERRADA.
G- PARA CONEXIONES EN LA INTERFASE TUBERIA-
ENTRE LA BOTA DE CONDENSADO Y LA TRAMPA SEA MAYOR A 5M, SE REQUIERE VALVULA
DE AISLAMIENTO ADICIONAL. 03 08/07/2019 Emisión para Construcción T.S.R. F.C.Q A.P.G P&ID CABEZALES DE AGUA Y VAPOR 6
COBRA SCL. La única INSTRUMENTOS REFERIRSE A TAL-GEN-PNG-TYP-0001. 04
copia Controlada de este
H- PARA DETALLES DE VENTEOS Y DRENAJES DE 02 27/02/2019 Emisión para Construcción T.S.R. E.L.C. A.P.G
H G F E D C B A
H G F E D C B A
NIS-ES-001
DETALLE "1"
1892
NOTA 3
3/4"-UA-NIS-00401-A21F-N
PI
00401
1
04 FI
PG PIT 00401
00405 00401
MIN.
3/4"
NO
3/4" 3/4"
MIN.
AIRE DE PLANTA 1"
FIT 2"-UA-NIS-00201-A21F-N
00401
DESDE L.B.
NIS-Z-001
1640
NOTA 2 DETALLE "1"
ESTACIÓN DE SERVICIO
2"-IA-NIS-00101-C21F-N
PI
00402
L LS PGW UA
FI
3/4"
PG PIT 00402 2
2
00406 00402 NOTA 1 MIN.
2" 1" 04
04 NO NC SPE
3/4" 3/4"
MIN.
MIN.
AIRE DE INSTRUMENTOS 1"
FIT 2"-IA-NIS-00201-C21F-N
1646 TAL-NIS-PRO-PID-0002 + 00401
00402
DESDE L.B.
NIS-Z-001
1642
PI
TI 00404
00401
TG TIT
PG
00407
PIT
00404
VER DETALLE "2"
04 AP.C
DETALLE "2" 3
00403 00401 00401

AGUA DE ENFRIAMIENTO
(RETORNO) 3/4" 3/4" TIPO C
1-1/2" 1-1/2" 8"-CWR-NIS-00401-A21F-N MUESTRA LIQUIDA NO PELIGROSA Y A BAJA TEMPERATURA
TAL-NIS-PRO-PID-0002 1647 (TEMPERATURA <50°C)
HACIA L.B.
LINEA DE SUMINISTRO DE MUESTRA
3/4"
3/4"
NIS-Z-001
1641
LINEA DE PROCESO
MIN.
LINEA DE LIQUIDO FRIO
8"-CWS-NIS-00101-A21F-N
4" NOTA 4
FQI FI NC
PI 3/4"
00403 00403
00403 TI
00402 3/4"x1/2"
4 FIT 4
PIT PG 1/2"
MIN.
00403 MIN.
00403 00408 TG TIT
00404 00402 8"
NO 1/2" 3/4" FL
AGUA DE ENFRIAMIENTO 1/2" 1/2" 3/4"x1/2"
(SUMINISTRO) 3/4" 3/4"
1-1/2" 1-1/2" 8"-CWS-NIS-00201-A21F-N 1/2"x1/4"
MIN.
1648 TAL-NIS-PRO-PID-0002 I D
O R LINEA A FLARE
DESDE L.B. V
4"
1/4"
1/4" NIPPLE 04
NOTA 5
OWS
NOTA 6
PISO O PLATAFORMA OWS
5 5
TIPO C MUESTRA LIQUIDA NO PELIGROSA Y A BAJA TEMPERATURA

CONEXION DE MUESTREO DIBUJO Nº LINEA DE PROCESO Nº LINEA DE MUESTREO Nº LINEA FLARE Nº / DIBUJO OWS DOBLE BLOQUEO
TAL-NIS-AP-00401 TAL-NIS-PRO-PID-0001 8''-CWR-NIS-00401-A21F-N 3/4''-CWR-NIS-00402-A21F-N NO REQUIRE NO REQUIRE 3/4"-OWS-NIS-00401-A21F-N NO
Este Documento contiene A- PARA CONSULTAR LA SIMBOLOGIA GENERAL DEL

PROYECTO VER DIAGRAMAS Nº
1. TÍPICO A SER CONECTADO EN LA PARTE SUPERIOR DEL CABEZAL, LOCALIZAR CADA 6-8m.
2. PAL-00402= 6.0 Kg/cm²g. PROYECTO MODERNIZACIÓN REFINERÍA TALARA
información privada y no 3. PARA UBICACION DE LA ESTACION DE SERVICIO REFERIRSE A TAL-GEN-PNG-STD-1001
puede ser duplicado,
TAL-GEN-PRO-PID-0001-0008-03.
B- TODOS LOS TAGS DE INSTRUMENTOS VAN PRECEDIDOS SECCION 9.8. UNIDADES AUXILIARES Y TRABAJOS COMPLEMENTARIOS
POR EL CODIGO NIS. 4. TOMA DE LA CONEXIÓN DE MUESTRO DESDE LÍNEA HORIZONTAL SUPERIOR
modificado o divulgado a C. LAS VÁLVULAS DE DRENAJE, VENTEO, BY-PASS O SISTEMAS 5. TODAS LAS TERMINACIONES ABIERTAS DE LAS CONEXIONES DE MUESTREO SERÁN 04 04 08/11/2019 Emisión para Construcción T.S.R F.C.Q M.L.C
6
terceros sin el DE ARRANQUE DEBEN ESTAR EN POSICIÓN
NORMALMENTE CERRADA.
BISELADAS EN UN ANGULO DE 45° CON UNA EXTENSIÓN MÍNIMA DE 75 mm.
6. SE REQUIERE ESPACIO PARA PERMITIR LA UBICACIÓN DE LOS CONTENEDORES DE
P&ID CABEZALES DE AGUA
consentimiento escrito de 6
ENFRIAMIENTO Y AIRE
G- PARA CONEXIONES EN LA INTERFASE TUBERIA- MUESTRAS SIN DERRAMAR EL CONTENIDO. ALTURA DE UNA BOTELLA TÍPICA DE 0.95l: 210 mm.
COBRA SCL. La única INSTRUMENTOS REFERIRSE A TAL-GEN-PNG-TYP-0001.
copia Controlada de este
H- PARA DETALLES DE VENTEOS Y DRENAJES DE 02 27/02/2019 Emisión para Construcción T.S.R. E.L.C. A.P.G
H G F E D C B A
REFINERIA TALARA
V-TAL-MEC-0001-OC-04-NIS-Z-001-0072
NIS-Z-001 57506-001-611520
AIR LIQUIDE NIS
NIS-K-001 Compressor Cross sectional and assembly drawings (with part list)
PID Index
27/07/2019
20/03/2019 00
02
FLUID CODES EQUIPMENT TAGS
TAG ALE TAG PETROPERU DESCRIPTION
CODE ALE CODE PETROPERU DESCRIPTION Main Air Compressor
C01 NIS-K-001
AW/AD UA Industrial air (Aire de planta)
R01 NIS-R-001 Air Purification Vessel
AG PA Process air, oil free (Aire de proceso libre de aceite)
R02 NIS-R-002 Air Purification Vessel
WO ATM Waste Oxygen
E08 NIS-E-008 Regeneration Heater
Safety valve discharge line
WO SV S04 NIS-SL-004 Waste Gas Vent Silencer
E01 NIS-E-001 Main Heat Exchanger
IA IA Instrument air (Aire de instrumentos)
E02 NIS-E-002 Main Vaporizer
LIN NI HP Column
K01 NIS-C-001
GAN NI NIS-X-001 Expansion Turbine
ET01
Waste Cryogenic Liquid E80 NIS-E-003 Liq. Disposal Vaporizer
WL NOD
S02 NIS-SL-002 Nitrogen Silencer
LR P Rich Liquid Derime Heater
E81 NIS-E-009
Cooling Water Supply LIN Storage
CWS CWS V50 NIS-T-050
(Suministro de agua de enfriamiento)
E51/1/2/3/4 NIS-E-004/005/006/007 LIN Vaporizer
Cooling Water Return F01 NIS-F-001 Air Filter
CWR CWR (Retorno de agua de enfriamiento)
C01.S NIS-SL-001 Blow Off Silencer
- LS V50E NIS-E-010 LIN Pressure Building Coil
IG Instrument Gas 02
WW WW Waste Water
E&C FRANCE NUMBER PETROPERU NUMBER DESIGNATION

57506-60-01-PR-014001 V-TAL-MEC-0001-OC-04-NIS-Z-001-0011 P&ID INDEX
57506-60-01-PR-014002 V-TAL-MEC-0001-OC-04-NIS-Z-001-0012 P&ID LEGEND EQUIPMENT SYMBOLS
57506-60-01-PR-014003 V-TAL-MEC-0001-OC-04-NIS-Z-001-0013 P&ID LEGEND INSTRUMENT SYMBOLS
57506-60-01-PR-014004 V-TAL-MEC-0001-OC-04-NIS-Z-001-0014 P&ID LEGEND PIPING SYMBOLS
57506-60-01-PR-014010 V-TAL-MEC-0001-OC-04-NIS-Z-001-0016 AIR FILTER AND AIR COMPRESSOR
57506-60-01-PR-014030 V-TAL-MEC-0001-OC-04-NIS-Z-001-0018 AIR PURIFICATION VESSEL
57506-60-01-PR-014031 V-TAL-MEC-0001-OC-04-NIS-Z-001-0255 REACTIVATION HEATER E08
57506-60-01-PR-014060 V-TAL-MEC-0001-OC-04-NIS-Z-001-0021 MAIN HEAT EXCHANGER & EXPANSION TURBINE 02
57506-60-01-PR-014070 V-TAL-MEC-0001-OC-04-NIS-Z-001-0023 HP COLUMN / MAIN VAPORIZER
57506-60-01-PR-014106 V-TAL-MEC-0001-OC-04-NIS-Z-001-0025 LIQUID NITROGEN STORAGE INTERFACE
57506-60-01-PR-014107 V-TAL-MEC-0001-OC-04-NIS-Z-001-0026 LIQUID NITROGEN STORAGE
57506-60-01-PR-014166 V-TAL-MEC-0001-OC-04-NIS-Z-001-0256 LIQUID NITROGEN VAPORIZER E51
57506-60-01-PR-014200 V-TAL-MEC-0001-OC-04-NIS-Z-001-0028 INSTRUMENT AIR AND DERIME
57506-60-01-PR-014210 V-TAL-MEC-0001-OC-04-NIS-Z-001-0029 COOLING WATER
57506-60-01-PR-014300 V-TAL-MEC-0001-OC-04-NIS-Z-001-0032 P&ID COMBINED
TALARA PSA
P&IDs INDEX
P&ID INDEX
V-TAL-MEC-0001-OC-04-NIS-Z-001-0011 57506-60-01-PR-014001 1
REFINERIA TALARA
V-TAL-MEC-0001-OC-04-NIS-Z-001-0072
NIS-Z-001 57506-001-611520
AIR LIQUIDE NIS
NIS-K-001 Compressor PID

Cross sectional
Legend and assembly
Equipment Symbols drawings (with part list)
27/07/2019
20/03/2019 00
02
EQUIPMENT IDENTIFICATION CRUSHER MILL SHAPING &FORMING EQP SEPARATORS HEAT TRANSFER EQUIPMENT
............................ .......... .......... .......... ..... ..........
EQUIPMENT IDENTIFICATION EXAMPLE : P01A

.........................
MAIN EQP MAIN EQP MAIN EQP

CODE SEQ. NO SUFFIX CRUSHER, MILL, PELLETIZING TABLE, IMPACT SEPARATOR, WET SCRUBBER,
GENERAL GENERAL NEW SEPARATOR GENERAL GENERAL AIR COOLER AIR-COOLED FINNED AIR-COOLED FINNED FIRE FIRING BURNER,
P 01 A
FLARE FOR
.......... .......... .......... .......... .......... .......... .......... TUBE HEAT EXCHANGER TUBE HEAT EXCHANGER BOX GENERAL
GASES
.......... .......... .......... ..........
..........
FILTER SCREENING EQP CENTRIFUGE
..... ..... .....
P 1 DIGIT MAIN EQUIPMENT CODE

1 DIGIT ..........
01 2 DIGITS MAIN EQUIPMENT SEQUENCE NUMBER 01 TO 99

2 DIGITS .....
A 2 DIGITS MAX. (7 DIGITS FOR PFD) MAIN EQUIPMENT SUFFIX ELECTRICAL

................... PLATE ELECTRICAL BAYONET INTERNAL HEATING INTERNAL SINGLE EFFECT SPRAY
2 DIGITS MAX (.....................) SCREEN, SCREENING CENTRIFUGE, HEATER
GAS FILTER, CARTRIDGE FILTRATION LIQUID FILTER, FILTER PREHEATER HEATER OR COOLING COIL EXCHANGER EVAPORATOR DESUPERHEATER
EQUIPMENT, CENTRIFUGING
AIR FILTER, FILTER EQUIPMENT GENERAL PRESS ..........
SCREENING MACHINE MACHINE, .......... .......... .......... .......... .......... ..........
GENERAL
.......... .......... .......... .......... .......... GENERAL
..........
..........
ANCILLARY/SUB/PACKAGE UNIT EQUIPMENT IDENTIFICATION EXAMPLE : 70C01AE01A

......................... DRIVERS
.....
MAIN EQP MAIN EQP MAIN EQP A/S/P A/S/P A/S/P FINNED TUBE FINNED TUBE
DOUBLE-PIPE
CODE SEQ. NO SUFFIX EQP CODE SEQ. NO SUFFIX HEAT EXCHANGER HEAT EXCHANGER
HEAT EXCHANGER
C 01 A E 01 A .......... ..........
..........
ELECTRIC ELECTRIC MOTOR ELECTRIC MOTOR ELECTRIC MOTOR, POWER GENERATOR, PRIME MOVER EXPANDER
GENERATOR FOR ALTERNATING FOR DIRECT GENERAL ROTATING-TYPE OPERATING BY ..........
C 1 DIGIT MAIN EQUIPMENT CODE .......... CURRENT, BUTTOM CURRENT, BUTTOM GENERATOR, BUTTOM EXPANSION OF
..........
1 DIGIT ........... .......... .......... .......... THE WORKING FLUID SHELL & TUBE SHELL & TUBE SHELL & TUBE
PLATE HEAT PLATE HEAT
.......... HEAT EXCHANGER HEAT EXCHANGER HEAT EXCHANGER
EXCHANGER EXCHANGER
01 2 DIGITS MAIN EQUIPMENT SEQUENCE NUMBER 01 TO 99 WITH FIXED CUBE SHEETS WITH FLOATING HEAD WITH U-TUBE
2 DIGITS ........... .......... ..........
DRYER MIXER AGITATOR .......... .......... ..........
A 2 DIGITS MAX. (7 DIGITS FOR PFD) MAIN EQUIPMENT SUFFIX
...........
..... ..... .....
2 DIGITS MAX. (.....................)
E 1 DIGIT ANCILLARY/SUB/PACKAGE UNIT

1 DIGIT EQUIPMENT CODE
..........
01 2 DIGITS ANCILLARY/SUB/PACKAGE UNIT

2 DIGITS 01 TO 99
EQUIPMENT SEQUENCE NUMBER
..... HEAT EXCHANGER HEAT EXCHANGER SPIRAL-TYPE
WITH CROSSING OF FLOW WITHOUT CROSSING OF HEAT
A 2 DIGITS MAX. ANCILLARY/SUB/PACKAGE UNIT (CIRCULAR SIZE) FLOW (CIRCULAR SIZE) EXCHANGER
2 DIGITS MAX. EQUIPMENT SUFFIX AGITATOR, PROPELLER
DRYER GENERAL KNEADER, GENERAL MIXER, GENERAL SILENCER STATIC MIXER .......... .......... ..........
............................. .......... .......... .......... .......... .......... GENERAL AGITATOR
COOLING TOWER
.......... ..........
(AERO) STACK
.......... ..........
TRANSPORTATION
.....
PUMPS MISCELLANEOUS - NOZZLES AND CONNECTIONS FOR EQUIPMENTS INSULATION FOR EQUIPMENTS
..... DIVERS - RACCORDEMENT SUR EQUIPEMENTS ..........
FLANGED NOZZLE INSTRUMENT
H
RACCORDEMENT A BRIDE CONNECTION ATMOSPHERIC VENT
MISE A L'ATMOSPHERE INSULATION, INSULATION FOR
RACCORDEMENT GENERAL PUMP/COMPRESSOR
H
FLANGED NOZZLE INSTRUMENTATION ...................... ......................
CENTRIFUGAL DIAPHRAGM EJECTOR ELECTRO- GEAR INCLINED ARCHIMEDAN WITH BLIND
CRANE TRUCK HOIST ROAD TANKER TANK TRUCK HAND HOLE ...................... ......................
RACCORDEMENT A BRIDE
PUMP PUMP PUMP MECHANICAL PUMP PUMP SCREW PUMP
.......... .......... .......... .......... AVEC BRIDE PLEINE PASSAGE DE MAIN
.......... .......... .......... .......... .......... ..........
BUTT WELD CONNECTION MAN HOLE INSULATION FOR
CONVEYING EQUIPMENT
RACCORDEMENT SOUDE TROU D'HOMME COLD BOX/CASING
..... ......................
......................
JET LIQUID PUMP, LUBRICANT OSCILLATING POSITIVE POSITIVE TEMA SHELL & TUBE
PUMP GENERAL PUMP DISPLACEMENT DISPLACEMENT DISPLACEMENT .....
PUMP PUMP PUMP, GENERAL
.......... .......... ..........
.......... .......... ..........
FRONT END TEMA SHELL REAR END REAR END

BELT CONVEYOR, CHAIN CONVEYOR, BELT EJECTOR, BUCKET POCKET CONTINUOUS CONVEYOR,
TYPE A TYPE E TYPE L TYPE U
GENERAL GENERAL TRUCK ELEVATOR ELEVATOR GENERAL
.......... .......... .......... ..........
.......... .......... .......... .......... .......... ..........
RECIPROCATING ROTARY LOBE JET SCREW SUMP WATER

PISTON PUMP PUMP PUMP PUMP PUMP PUMP FRONT END TEMA SHELL REAR END REAR END
.......... .......... .......... .......... .......... .......... TYPE B TYPE F TYPE M TYPE W
.......... .......... .......... ..........
COMPRESSORS, FANS
..... FRONT END TEMA SHELL REAR END
REVERSIBLE CONTINUOUS TROUGHED CHAIN SCREW CONVEYOR, VIBRATING CONVEYOR, VIBRATING CONVEYOR VIBRATING CONVEYOR
TYPE C TYPE G TYPE N
CONVEYOR CONVEYOR GENERAL GENERAL WITH END-DRIVE WITH TWIN-DRIVE
.......... .......... .......... TEMA SHELL
.......... .......... .......... .......... .......... ..........
TYPE K
..........
OTHER EQUIPMENT FRONT END TEMA SHELL REAR END
..... TYPE D TYPE H TYPE P
CENTRIFUGAL COMPRESSOR, EJECTOR LIQUID-RING PISTON PISTON DIAPHRAGM
.......... .......... ..........
COMPRESSOR VACUUM PUMP, COMPRESSOR, COMPRESSOR, COMPRESSOR, COMPRESSOR,
GENERAL EJECTOR VACUUM LIQUID-RING PISTON VACUUM DIAPHRAGM
..........
.......... PUMP VACUUM PUMP PUMP VACUUM PUMP
.......... .......... .......... .......... FRONT END TEMA SHELL REAR END
REVFEEDER ROTARY GATE VALVE LOCK PENDULUM ROTARY TELESCOP DISTRIBUTION MIXING NOZZLE TYPE N TYPE J TYPE R
FOR SOLIDS, VALVE FOR LARGE .......... FLAP TABLE .......... DEVICE FOR FLUIDS .......... .......... .......... ..........
GENERAL PIPES SPRAY NOZZLE
.......... .......... ..........
.......... .......... ..........
ROOTS-TYPE ROTARY COMPR. SCREW SL VANE-TYPE STAGE OF TURBOCOMPRESSOR, FRONT END TEMA SHELL REAR END
COMPRESSOR, POSITIVE COMPRESSOR ROT. COMPRESSOR, COMPRESSOR TURBOVACUUM PUMP TYPE Q TYPE V TYPE S
ROTARY LABE DISPLACEMENT SLIDING .......... .......... ..........
.......... .......... ..........
VACUUM PUMP TYPE ROTARY VANE-TYPE ROT.
.......... VACUUM PUMP VACUUM PUMP
.......... .......... WEIGHING LOT, BARREL, GAS SACK EJECTOR IN-LINE SILENCER LOCAL PIT PULSATION
EQUIPMENT, DRUM CYLINDER .......... .......... .......... .......... DAMPENER TEMA SHELL REAR END
GENERAL TYPE X TYPE T
.......... .......... ..........
.......... ..........
..........
FAN GENERAL EXHAUST FAN
.......... ..........
LEGEND EQUIPMENT SYMBOLS
REFINERIA TALARA
V-TAL-MEC-0001-OC-04-NIS-Z-001-0072
NIS-Z-001 57506-001-611520
AIR LIQUIDE NIS
NIS-K-001 Compressor Cross sectional

PID Legend andSymbols
Piping assembly drawings (with part list)
27/07/2019
20/03/2019 00
02
D'UTILISATION
S
R
P&IDs
LEGEND INSTRUMENT SYMBOLS
REFINERIA TALARA
V-TAL-MEC-0001-OC-04-NIS-Z-001-0072
NIS-Z-001 57506-001-611520
AIR LIQUIDE NIS

PID Legend and assembly
Instrument Symbolsdrawings (with part list)
27/07/2019
20/03/2019 00
02
P&ID
LEGEND PIPING SYMBOLS
REFINERIA TALARA
V-TAL-MEC-0001-OC-04-NIS-Z-001-0072
NIS-Z-001 57506-001-611520
AIR LIQUIDE NIS

PID Air and
Filter and Air assembly drawings (with part list)
Compressor
27/07/2019
20/03/2019 00
02
HOLDS :
DESCRIPTION DISCIPLINE
A
A PIPING LINE AND VALVES DIAMETER SYSTEM /
TO BE CONFIRMED SUPPLIER
02 "
IN
1
IN
C01.S
1
TRIP
ALARM
START/STOP
1
UA UA EL
1 102A 103A 101A
PDIT
F01 101
ATM
"
AT ATM TO
SAFE LOCATION
VPDIT101A
(EH3G50)
US US ES EY "
AIR FILTER " " " 102A 103A 101A 100A F ALE
1
SP = 12.23 kg/cm2 g
7Lb A PSV
PV
FO
// // 105 "
105
C57506-001-611200
//
//
//
//
//
//
02
C01
// // //
//
ANTI-SURGE IA
CONTROL
FV
06007 60-01-PR-014060 " CVAW02A
106
FROM FIC-630
"
AIR COMPRESSOR B 5V
01001 60-01-PR-014030
" VAW02A AW TO R01/R02
20009 60-01-PR-014200 L7 (CA2D53)
IA FROM NETWORK VIA12A
(EH3E50) 1
C57506-001-611200
"
- 2"-OWS-NIS-00101-A21F-N
"
21001 60-01-PR-014210 O 02
CWS FROM NETWORK VCWS01A LSHH LSHH TAL NIS
" (CA2D50) 107B 003
" 107A
60-01-PR-014210 01002 N A
CWR TO NETWORK VCWR01A
(CA2D50)
LAHH LAHH
107A 107B
2oo2
LY
107
IN 02
1
C01
OWS TO CLIENT
1878
EQUIPMENT NAME MAIN AIR COMPRESSOR
FLUID (PATH) [SUC] AW [DISC]

02
PS (kg/cm2 g) ATM 12.23
-10 / 65 -10 / 65
* DRAINS MUST BE INSTALLED AT EACH LOW POINT ON WET 1. SUPPLIED IN LOOSE BY COMPRESSOR VENDOR
AIR PIPELINES.
* DRAINS MUST BE INSTALLED AT EACH LOW POINT AND

VENTS AT EACH HIGH POINT ON COOLING WATER PIPELINES.
V-TAL-MEC-0001-OC-04-NIS-Z-001-0014 LEGEND PIPING SYMBOLS
V-TAL-MEC-0001-OC-04-NIS-Z-001-0013 LEGEND INSTRUMENT SYMBOLS
V-TAL-MEC-0001-OC-04-NIS-Z-001-0012 LEGEND EQUIPMENT SYMBOLS AIR FILTER AND AIR COMPRESSOR
V-TAL-MEC-0001-OC-04-NIS-Z-001-0011 P&ID INDEX
REFINERIA TALARA
V-TAL-MEC-0001-OC-04-NIS-Z-001-0072
NIS-Z-001 57506-001-611520
AIR LIQUIDE NIS
NIS-K-001 Compressor Cross

PIDsectional and assembly
Air Purification Vessel drawings (with part list)
27/07/2019
20/03/2019 00
02
REFINERIA TALARA
V-TAL-MEC-0001-OC-04-NIS-Z-001-0072
NIS-Z-001 57506-001-611520
AIR LIQUIDE NIS
NIS-K-001 Compressor
PID MainCross sectional and
Heat Exchanger assemblyTurbine
& Expansion drawings (with part list)
27/07/2019
20/03/2019 00
02
REFINERIA TALARA
V-TAL-MEC-0001-OC-04-NIS-Z-001-0072
NIS-Z-001 57506-001-611520
AIR LIQUIDE NIS
NIS-K-001 CompressorPID
Cross sectional
HP Column and Vaporizer
/ Main assembly drawings (with part list)
27/07/2019
20/03/2019 00
02
REFINERIA TALARA
V-TAL-MEC-0001-OC-04-NIS-Z-001-0072
NIS-Z-001 57506-001-611520
AIR LIQUIDE NIS
NIS-K-001 CompressorPID
Cross sectional
Liquid Nitrogenand assembly
storage drawings (with part list)
interface
27/07/2019
20/03/2019 00
02
REFINERIA TALARA
V-TAL-MEC-0001-OC-04-NIS-Z-001-0072
NIS-Z-001 57506-001-611520
AIR LIQUIDE NIS

PID Liquid and assembly
Nitrogen Storage drawings (with part list)
27/07/2019
20/03/2019 00
02
// // IA
//
//
//
// //
// //
AT ATM TO 2"
SAFE LOCATION
FC
PV
821B
AT ATM TO
SAFE LOCATION
SP = 14.27 kg/cm2 g AT ATM TO AT ATM TO

SAFE LOCATION SAFE LOCATION
1/2"
TSV
2"
821B
02
1 1
4"
4"
1/2"
SP = 14.27 kg/cm2 g SP = 14.27 kg/cm2 g
PSV PSV
X"
X"
SP = HOLD 810A 810B SP = HOLD
PSE PSE
ATM ATM
X"
X"
821A 2 821B
V20
DR3A DR3B
3"
3"
3"
3"
X" 1/8" 3" IR 3" 1/8"
V V V
V21 V6 V7
3"
2"
AT ATM TO 1
SAFE LOCATION
SP = 15.29 kg/cm2 g
" PSV 02
821
3"
X"
IN IN
// // // // // // // // // // // // // // // // // // // // // // // // // // // // // // // // // // // // // // // // // // // // // // // // // // // // // // // // // // // // // 65 61
3" 3"
//
SP = HOLD
//
//
AT ATM TO
W21 SAFE LOCATION PSE
//
//
822 02
//
150 lbs
//
//
DR2 1oo2
//
W2
300 lbs HH
H
PIC PY
//
//
821B 821
//
X"
//
SP = 30.59 kg/cm2 g
//
TP09
//
TSV
//
HH
//
PI SH/H
821C
//
//
821A L ALE F
//
SL
//
V50E
//
3"
//
//
//
1/2"
1/2"
//
Nx
Nx
//
RS
//
HH
//
PI PIT PIT LI LIT LI H IN

61
V50
//
821 821B 821A 821 822 822

L
//
RE
3"
3" X" 1/2" 02

"
02
3 SP = HOLD Nx
Nx
Nx
Nx
FC RI
PSE
3"
SP = 15.29 kg/cm2 g PV 823

P
TSV TP10 821C ATM X"

ZAL ZSL
821A 821A 821A 02 DR1
TP11
PV
FC
// //
821A
WCV1
VV2
1/8"
//
300 lbs
1/2"
1/2"
W41
1/2"
S
150 lbs C3 VV1 3
W10
3"
//
PY
W8
821A
IA W11
LOCAL PIT 1
"
V50 V50E
20008 60-01-PR-014200
1 EQUIPMENT NAME LIN STORAGE LIN PRESSURE BUILD-UP COIL

IA FROM NETWORK
FLUID (PATH) LIN / GAN LIN / GAN

4
02
2 02
PS (kg/cm2 g) 14.27 + HH
-196 / 65
15.29
-196 / 65
LOCAL PIT 1
1. SPECIFIED BY ALE.
2. AT NORMAL RUNNING, BOTH SAFETY VALVES MUST BE IN
OPERATION. IT MUST BE IMPOSSIBLE TO ISOLATE BOTH
SAFETY VALVES SIMULTANEOUSLY.
- MECHANICAL INTERLOCKED.
3. VALVE IS USED FOR START-UP ONLY AND SHALL BE
PLUGGED DURING NORMAL OPERATION. V-TAL-MEC-0001-OC-04-NIS-Z-001-0014 LEGEND PIPING SYMBOLS
4. SAFE LOCATION PIT AREA SHALL BE VISIBLE AND
LOCATED AT 3M MAX FROM TRUCK LOADING AREA.
V-TAL-MEC-0001-OC-04-NIS-Z-001-0012 LEGEND EQUIPMENT SYMBOLS LIQUID NITROGEN STORAGE
REFINERIA TALARA
NIS-Z-001 57506-60-01-PR-014200
Air Liquide
PID Cooling Water
20/03/2019 00
20008 60-01-PR-014107
20009 60-01-PR-014010
IA TO C01 COMPRESSOR
VIA107A IA TO V50
WITHIN SKID
WARM SKID
(FD5A50X)
" "
SPARE SPARE
VIA12C VIA107L
(BD5F52) (BD5F52)
60-01-PR-014010 VIA107K 60-01-PR-014166

VIA12B (BD5F52)
(BD5F52)
VIA107J 60-01-PR-014166
IN (BD5F52)
88
1 VIA107H 60-01-PR-014166
(BD5F52)
IN
2"-IA-NIS-00101-C21F-N
FO
88
S
VIA107G 60-01-PR-014166
TP05 1 IN 01 (BD5F52)
88
S 1
60-01-PR-014166
" " VIA107F
877 TAL-NIS-PRO-PID-0001 AT ATM TO (BD5F52)
SAFE LOCATION
IA FROM CUSTOMER VIA07A H 60-01-PR-014107
(FD5A50X) " VIA107E
(BD5F52)
TO PY-821A
SP = 7.13 kg/cm2 g
01
L 01
C ALE PSV VIA107D
(BD5F52)
054 TO HY-813B
(DD5A50X)
CVIA01B
VIA107B
VIA107C
(BD5F52)
60-01-PR-014106 COLD BOX
VPIT050A
(EH5G50)
(BD5F52)
01
1/2
"
WITHIN SKID
"
7Lb 5V "
(FD5A50X)
(BD5F52)
(BD5F52)
(BD5F52)
(BD5F52)
(BD5F52)
(BD5F52)
(BD5F52)
(BD5F52)
(BD5F52)
(BD5F52)
(BD5F52)
(FD5A50X)
VIA02G
VIA02C
VIA02D
VIA02H
VIA02A
VIA02B
VIA05A
VIA02E
VIA02K
VIA02F
VIA02J
VIA02I
VIA08A
01
SPARE
SPARE
" " "
03101 60-01-PR-014031
AG FROM R01/R02 CVIA01A
(BD5F52)
(BD5F52)
(BD5F52)
(BD5F52)
(BD5F52)
(BD5F52)
(BD5F52)
(BD5F52)
(BD5F52)
(BD5F52)
(BD5F52)
(BD5F52)
VIA001I
VIA01G
VIA01C
VIA01D
VIA01H
VIA01B
VIA01E
VIA01K
VIA01A
VIA01F
VIA01L
VIA01J
(DD5A50X)
60-01-PR-014060
60-01-PR-014060
60-01-PR-014060
60-01-PR-014060
60-01-PR-014070
60-01-PR-014070
60-01-PR-014070
60-01-PR-014070
60-01-PR-014070
(FD5A50X)
SP= 6.11 kg/cm2 g

VIA01R
SPARE
SPARE
SPARE
(FD5A50X)
VAD05A
(DD5A50X)
TO KY-226
TO HV-240
60-01-PR-014030
60-01-PR-014030
60-01-PR-014030
60-01-PR-014030
60-01-PR-014031
60-01-PR-014031
TO KY-220O/F
TO KY-225O/F
CVIA01C
"
VAD05B
(FD5A50X)
BLDAD05A
(R821)
HH
H
L
LL
V V
(EH5E50)
(EH5E50)
VAD01B
VAD02A
BLDAG02A
(R8211)
" "
03002 60-01-PR-014030
IA TO COLD BOX VENTILATION

7Lb 9C 5S 5S
60-01-PR-014070 20007
AG FROM R01 / R02 VAD01A STRAD01A
(FD5A50X) (R851)
01
01
E81
WITHIN SKID
WARM SKID E81
IA TO E80
IG TO ET01 SEAL GAS
AD TO E02
AD TO ET01
60-01-PR-014070 20006
60-01-PR-014060 20001
60-01-PR-014070 20003
60-01-PR-014060 20004
EQUIPMENT NAME DERIME HEATER
FLUID (PATH) AD
PS (kg/cm2 g) 12.23
-10 / 65

V-TAL-MEC-0001-OC-04-NIS-Z-001-0012 LEGEND EQUIPMENT SYMBOLS INSTRUMENT AIR AND DERIME
REFINERIA TALARA
NIS-Z-001 57506-60-01-PR-014211
Air Liquide
PID Derime
20/03/2019 00
01
C ALE
TP02
8"-CWS-NIS-00101-A21F-N "
880 TAL-NIS-PRO-PID-0001
CWS FROM CUSTOMER
01
TP01
8"-CWR-NIS-00101-A21F-N "
879
CWR TO CUSTOMER
01
CWS TO ET01
CWS TO C01
60-01-PR-014060 21003
60-01-PR-014010 21001
06004 60-01-PR-014060
01002 60-01-PR-014010
CWR FROM ET01
CWR FROM C01
* DRAINS MUST BE INSTALLED AT EACH LOW POINT AND

VENTS AT EACH HIGH POINT ON COOLING WATER PIPELINES.

V-TAL-MEC-0001-OC-04-NIS-Z-001-0012 LEGEND EQUIPMENT SYMBOLS COOLING WATER
REFINERIA TALARA
NIS-X-001 57506-003-651200
Air Liquide
PID Expansion Turbine process & seal gas circuit
17/06/2019 01
H G F E D C B A
DIRECT
TRIP T
PDALL
SAHH
PDAHH T I2
SAH VAHH TAHH
T
A T T I1
PDAH
VAH TAH
A I1 T A A A
SALL PDAL
ZLL
3 3 3 3 3 3 3 3 1
4-20mA
4-20mA
DRTD
SSHH SSH SSL SSLL
"C"
675 675 675 675
PDIT ZSH ZSL PP PI ST VXT PDIT

691 651 651 691 670 A 675 673  670 A PI
R 1 670 B
"B"
(SEE NOTE 4) PCV
KY 670 B
651 S CV
"C" "A" "A" 670 B
CV F V
670 A 670 670
J AUXILIARY SEAL GAS
ANNEX PLATE
PDCV LO
NOTE : SEAL GAS SOURCE MUST BE SECURED
670 A BY CUSTOMER IN ORDER TO PROVIDE
FCV-5 ENOUGH SEAL GAS PRESSURE FOR ANY 2
2
CASE OF OPERATION AS SOON AS 02
PROCESS ENTERS THE EXPANDER CASING
 7  V
PROCESS GAS IN PP
(SEE NOTE 2) 672 E
672
PIT
011-F-1 KV A 672
4-20mA
3 A I1
651 PAL
CRYOSTAR
7 V
PROCESS GAS OUT CUSTOMER SE
(SEE NOTE 3)
EXPANDER 675 672 D
(SEE NOTE 5)
B 2 PI
672
IGV
S  V
PSLL
PP 672 B 3
692 672 C
1 PSLL
672 A 3 T DIRECT TRIP
3 I 5
PALL
3
VXE
DRAIN
673
HEATER TRIP
3 1
CONTROL THERMOSTAT
TE
3 ZI 671
I1 ZSL 608
3 608
ZLL
OIL FILTER OIL FILTER

FY
"B" 021-F-7A 021-F-7B
608
4mA=CLOSED ; 20mA=OPEN
VENT VENT
CONTROL SIGNAL PCV
DRAIN DRAIN
672 PDI PDI
4 - 20 mA
672 A 672 B
IGV ACTUATOR
001-FV-9
MAIN
TI OIL PUMP DRAIN DRAIN
MOTOR
671 001-M-6
4 4
BREATHER AND
FILLER FILTER
021-F-5
OIL COOLER
091-E-6
LI OIL WATER
LSL VENT VENT
697
687
TSL
I2 3 TI OIL TANK
TLL
690
690 021-TK-5 TI
672
TSH OIL HEATER
CONTROL THERMOSTAT FOR OIL HEATER 3 021-H-5 CRYOSTAR
690 V V
V-5
POWER 672 A 672 B TCV
3 672 CUSTOMER
TAH L OIL
DRAIN
WATER
DRAIN
SAFETY THERMOSTAT WITH TSHH MAIN
HEATER TRIP A 3 OIL PUMP
LOCAL MANUAL RESET 690 021-P-6
POWER
P O
VAZ DOS
SANTOS
B G3160-03 Template updated according to Customer's comments JLP MSr AVs 15.04.19
Arlindo
2019.04.15
16:45:30
3 3
+02'00'
5 A G3160-02 Updated as per customer comments ACM MSr AVs 06.03.19 5

A LAL WATER OUT WATER IN 0 Original issue JLP MSr AVs 11.01.19
I2 I3
Rev Rev No Issue / Description Author Checked Approved Date
Document No 57506-003-651200 Language EN
Work Order kg/mm Page
ECO 120 1
FIH99 1
P & I Diagram Drawing No. Scale
of
Size
ALEC - TANARA NIS 704233315 % A0
Copyright Air Liquide/all NOTE 1 : All alarms and trip are turbine start interlock
rights reserved. This print is
NOTE 2 : When QCV is not installed directly on expander inlet casing,
1 Piped into annex plate
2 Speed probe with 25.0m cable
the property of L'Air Liquide
and contains valuable
it shall not be installed at a distance greater than 10 times
3 Direct wired by Customer
expander diameter.
confidential information. No Wired into Speed & interface box
part of this print may be NOTE 3 : Straight pipe run (free of any component) of minimum 4 01
6 reproduced, copied, lent or
disposed of, directly or
3 times diameters shall be installed at expander outlet. 5 Vibration probe whit 9.0m cable
00
ISSUED FOR REVIEW
TALARA NIS 6
NOTE 4 : Instrumentation for differential pressure across conical strainer 6 Wired into Junction Box ISSUED FOR REVIEW
indirectly, nor used for any is not provided in the base scope of Cryostar. It can be supplied
PID Expansion Turbine process & seal gas circuit
Counter falnge supplied with bolts, nuts & B 16.04.19 N° G3160-03 Template updated according to Customer's comments JLP MSr AVs
other purpose than that for in option. Cryostar requests High alarm 1 & High High trip on 7 gasket by Cryostar
wich it is specifically differential pressure across strainer.
Supplied loose A 06.03.19 N° G3160-02 Updated as per Customer comments ACm MSr AVs
furnished. This print is lent FORMATO: PROY. NUM:
subject to return on NOTE 5 : Process isolation valve at expander outlet to be supplied by
Symbols according to ANSI/ISA-S5.1-1984(R1986) 704149000 Symbols & Abbreviations according to Cryostar Standard Drawing A1 57506
demand. Cusrtomer. & ANSI/ISA-S5.3-1983
0 11.01.19 Original issue JLP MSr AVs
ESCALA: PLANO CLIENTE Nº PLANO AL N° PAG. REV.
NOTAS GENERALES NOTAS PLANO REF N° PLANOS DE REFERENCIA N° REV. FECHA DESCRIPCIÓN DE LA EMISIÓN ELAB. REV. APR. N/A 57506-003-651200 DE B
H G F E D C B A 01
REFINERIA TALARA
V-TAL-MEC-0001-OC-04-NIS-Z-001-0072
NIS-Z-001 57506-001-611520
AIR LIQUIDE NIS
NIS-K-001 Compressor Cross sectional and

PID Reactivation assembly
Heater E08 drawings (with part list)
27/07/2019
20/03/2019 00
02
REFINERIA TALARA
V-TAL-MEC-0001-OC-04-NIS-Z-001-0072
NIS-Z-001 57506-001-611520
AIR LIQUIDE NIS

PID Liquid andVaporizer
Nitrogen assembly drawings (with part list)
E51
27/07/2019
20/03/2019 00
02
FCK START UP
SPL SPL 1oo2

IN TY
02 65
974
PY PY
971B 971A P,T
f(x)
FIC FX
971A 971A2
02 2 SPL
AT ATM TO SPL
SPL SAFE LOCATION P,T
TIC TI f(x)
IN 974A
H
65 L 974B L FX PIC
" LL LL
SP = 14.27 kg/cm2 g TP12 ZAL SP= 10.5 kg/cm2 g 971A1 971

L
TSV 971B PSV AP

PY
970 974 618B 10603 60-01-PR-014060
971B S ALE C
SPL SPL SP = 1.01 kg/cm2 g TO AY-618
TE TE PIT
//
E51.1 974A 974B
FIT FIT PCV
971 02
//
ZSL 618B 02
//
IA 971A1 971A2
//
02 971B
(FD5F50X)
VPIT971A
(EH5G50)
//
VAP618B
TAL NIS
3/4
3/4
1/2
007
1/2
LOCAL PIT 2
//
MINI
(EH5G50)
(EH5G50)
VFE971B
VFE971A
// //
2% // // //
1/2
1/2
" " " " " 8"-NI-NIS-00104-M11F-N
"
10601 60-01-PR-014106 1881 TAL-NIS-PRO-PID-0001
5V FC " 5V 9C 9C VGAN160A 7E 7R 7Lb
LIN FROM V50 CVGAN160A VGAN160B GAN TO CUSTOMER
(MS) FE (DB5D51X) (MS )
PV
1 971A
971B
28 D MIN 7 D MIN
SP = 5.91 kg/cm2 g
E51.2 AT ATM TO PCV
SAFE LOCATION 984
"
02
SPL
IN " " 3
65 02
5V
"
ZAL
SP= 7.13 kg/cm2 g PSV
971A 984
PY IA
971A S VGAN160C 7E VGAN160D
(FD5A50X) FE (FD5A50X)
//
//
971B
E51.3 02 IN
//
ZSL
//
IA 65
S
PERFORMANCE
//
971A
//
//
HY
//
// //
IN 985A HV
FC
// // // // //
65 985A
" " ZAL
FC " ZAL ZSL
985C HY
PV 985A 985A
985C S
971A
CVGAN093A
(DD5A50X)
// IA
//
ZSL
//
985C
"
E51.4
MINI
AT ATM TO
SAFE LOCATION "
FO IA
HV
" 985C
"
//
IN
65
//
02 HY
985B HV
FC
// //
985B
02
ZAL ZSL
985B 985B
"
09702 60-01-PR-014060
GAN TO ET01 SEAL GAS
E51
EQUIPMENT NAME LIN VAPORIZER
FLUID (PATH) LIN / GAN
PS (kg/cm2 g) 10.5
-196 / 65
1. TEMPERATURE PROBES TO BE PLACED AT A

DISTANCE OF 3 TIMES THE PIPE DIAMETER (AT
LEAST 0.5M) DOWNSTREAM THE COMMON HEADER
2. SPLIT RANGE FUNCTION

3. USED ONLY FOR PERFORMANCE TEST FOR FLOW OF V-TAL-MEC-0001-OC-04-NIS-Z-001-0014 LEGEND PIPING SYMBOLS
610 Nm3/h
V-TAL-MEC-0001-OC-04-NIS-Z-001-0012 LEGEND EQUIPMENT SYMBOLS LIQUID NITROGEN VAPORIZER E51
REFINERIA TALARA
CODE VENDOR / CODIGO DE DOCUMENTO DEL

EQUIPMENTS / EQUIPOS (TAGS) N°:
VENDOR:
NIS-Z-001 57506-60-01-PR-014200
Air Liquide
PID Instrument Air and Derime
DATE OF REVIEW: FECHA DE REVISIÓN:
23/11/2018 00
20008 60-01-PR-014107
20009 60-01-PR-014010
IA TO C01 COMPRESSOR
TO V50
WITHIN SKID
WARM SKID
IA
(FD5A50X)
"
VIA107A
"
SPARE SPARE
VIA01P VIA107L
(BD5F52) (BD5F52)
PID number and line 60-01-PR-014010 VIA107K

(BD5F52)
60-01-PR-014166
VIA01N
number must be (BD5F52)
60-01-PR-014166
indicated
VIA107J
IN (BD5F52)
88
1 VIA107H 60-01-PR-014166
(BD5F52)
IN
FO
88
S
VIA107G 60-01-PR-014166
TP05 1 IN
88 (BD5F52)
S 1
60-01-PR-014166
" " " VIA107F
AT ATM TO (BD5F52)
FC SAFE LOCATION
IA FROM CUSTOMER VIA07A H 60-01-PR-014107
(FD5A50X) " VIA107E
(BD5F52)
SP = 7.13 kg/cm2 g TO PY-821A
L
C ALE PSV VIA107D
(BD5F52)
054 TO HY-813
(DD5A50X)
CVIA01B
A
VIA107B
(BD5F52)
VIA107C
(BD5F52)
60-01-PR-014106
COLD BOX HOLDS :
DESCRIPTION DISCIPLINE
B
"
WITHIN SKID
"
A SAFETY VALVE PROCESS
SIZING
7Lb 5V
(FD5A50X)
B PIPING ARRANGEMENT INSTALLATION
(BD5F52)
(BD5F52)
(BD5F52)
(BD5F52)
(BD5F52)
(BD5F52)
(BD5F52)
(BD5F52)
(BD5F52)
(BD5F52)
(BD5F52)
(FD5A50X)
VIA02G
VIA02C
VIA02D
VIA02H
VIA02A
VIA02B
VIA05A
VIA02E
VIA02K
VIA02F
VIA02J
VIA02I
VIA08A
B
SPARE
SPARE
" " "
03101 60-01-PR-014031
AG FROM R01/R02 CVIA01A
(BD5F52)
(BD5F52)
(BD5F52)
(BD5F52)
(BD5F52)
(BD5F52)
(BD5F52)
(BD5F52)
(BD5F52)
(BD5F52)
(BD5F52)
(BD5F52)
VIA001I
VIA01G
VIA01C
VIA01D
VIA01H
VIA01A
VIA01B
VIA01E
VIA01K
VIA01F
VIA01L
VIA01J
(DD5A50X)
60-01-PR-014060
60-01-PR-014060
60-01-PR-014060
60-01-PR-014060
60-01-PR-014070
60-01-PR-014070
60-01-PR-014070
60-01-PR-014070
60-01-PR-014070
(FD5A50X)
SP= 6.11 kg/cm2 g

VIA01R
SPARE
SPARE
SPARE
(FD5A50X)
VAD05A
(DD5A50X)
TO KY-226
TO HV-240
60-01-PR-014030
60-01-PR-014030
60-01-PR-014030
60-01-PR-014030
60-01-PR-014031
60-01-PR-014031
CVIA01C
TO KY-220O/F
TO KY-225O/F
"
VAD05B
(FD5A50X)
BLDAD05A
(R821)
HH
H
L
LL
V V
(EH5E50)
(EH5E50)
VAD01B
VAD02A
BLDAG02A
(R8211)
" "
03002 60-01-PR-014030
IA TO COLD BOX VENTILATION

7Lb 9C 5S 5S
60-01-PR-014070 20007
AG FROM R01 / R02 VAD01A STRAD01A CH
(FD5A50X) (R851)
CH
E81
WITHIN SKID
WARM SKID E81
IA TO E80
IG TO ET01 SEAL GAS
AD TO E02
AD TO ET01
20006
60-01-PR-014060 20001
60-01-PR-014070 20003
60-01-PR-014060 20004
EQUIPMENT NAME DERIME HEATER
60-01-PR-014070
FLUID (PATH) AD
PS (kg/cm2 g) 12.23
-20 / 65
* EXCEPT FOR ANALYSIS POINTS, ALL INSTRUMENTATION

ASSEMBLIES, MOUNTED ON PIPING OR EQUIPMENT, IN AIR
LIQUIDE SCOPE OF STUDY MUST FOLLOW CPY-EP-14-4-2 BY
DISREGARDING ROOT VALVES AND CONSIDERING A SW-SCRD
THREADOLET FOR FITTING.
APPROVAL INSTRUMENT AIR AND DERIME
60-01-PR-014200 13
V-TAL-MEC-0001-OC-04-NIS-Z-001-0257
· UNIDADES AUXILIARES Y TRABAJOS COMPLEMENTARIOS
·
·
PLANTA DE NITRÓGENO -
· IMPLANTACIÓN DE LA UNIDAD
TAL-NIS-PNG-LAY-0001 1 1 02

PÁGINA 313 DE 556
14. APÉNDICES
Se incluyen los siguientes apéndices, complementarios a la lectura del Manual de
Operación y Mantenimiento de la Unidad:
14.1. RECOMENDACIONES DEL ESTUDIO DE HAZOP

A continuación se relacionan las acciones derivadas de los estudios Hazop de Ingeniería:
 REPORTE HAZOP / SIL UNIDADES PAQUETES - NIS, TAL-GEN-PRO-REP-1001-01
 INFORME DEL ESTUDIO HAZOP/SIL UNIDADES PAQUETE – NIS: COMPRESOR DE
AIRE Y TURBINA DE EXPANSIÓN, TAL-GEN-PRO-REP-1001-04.
REPORTE HAZOP / SIL UNIDADES PAQUETES - NIS PÁGINA 25 DE 72
N° DOCUMENTO: TAL-GEN-PRO-REP-1001 A REV. 00 FECHA: 16/09/2019
6.3 ACCIONES DE SEGUIMIENTO DE LAS RECOMENDACIONES
A continuación, se muestra la tabla de seguimiento de las recomendaciones del estudio HAZOP & SIL:
No. PARÁMETRO
ESTATUS DE LA
RECOMEN EVALUADO CAUSA (2) CONSECUENCIA (3) RECOMENDACIÓN (4) REFERENCIA RESPONSBALE SOLUCIÓN ACORDADA FASE DE CIERRE FECHA
RECOMENDACIÓN
DACIÓN : (1)
R1 MENOS FLUJO 1.4.2. Fallo del compresor C- 1.4.2.1. No aire a la Unidad NIS. Evaluar opciones alternativas de suministro de CPT/PP y COBRA La capacidad de
01 Baja Presión en el sistema. Paro Nitrógeno a la Refinería en caso de Paro de SCL almacenamiento de
de Planta Unidad NIS. respaldo fue definida
por PetroPerú en las
Bases de Diseño. Una
acción complementaria
para atacar la causa es
la inclusión de un
compresor de respaldo.
A revisar por GM
R2 OTRA 1.10.2. Lógica de control del 1.10.2.1 Durante la Verificar las alarmas generadas en caso de CPT/PP y COBRA
COMPOSICIÓN paquete no funciona regeneración. Baja calidad de la funcionamiento inadecuado de la lógica de SCL
adecuadamente Regeneración. Bajo purificación control. Garantizar que estas alarmas se
del producto. Riesgo de muestren en el P&ID
taponamiento en el área de
destilación.
R3 MENOS FLUJO 2.4.1. Fallo mecánico de 2.4.1.1. No posibilidad de enfriar Evaluar en el Hazop de la Turbina, la severidad y CPT/PP y COBRA
turbina. E-01. Paro de la Unidad NIS. la afectación al sistema en caso de paro de SCL
turbina.
R4 MÁS NIVEL 3.1.1. Fallo de Lazo de 3.1.1.2. Alto Nivel y arrastre de Validar las protecciones internas de la turbina COBRA SCL
Control LIC-614, abriendo LV- líquido hacia el circuito ET-01. para garantizar que estén acordes al escenario,
614 Daño de turbina y línea aguas en caso positivo se considera un SIL final NR.
abajo del E-01. Pérdida de
producción de Nitrógeno.
R5 NO/MENOS 3.3.6. HV-813B abierta 3.3.6.1.Pérdida de producción Garantizar la descarga segura de la línea de la COBRA SCL
FLUJO cuando requiere estar de Nitrógeno líquido hacia HV-813B a un lugar seguro (Ejemplo Local PIT,
cerrada Spillage Area. E-80) y asegurar la pendiente continua de esta
línea hacia el PIT
R6 NO/MENOS 3.3.6. HV-813B abierta 3.3.6.1.Pérdida de producción Evaluar la posibilidad de instalar un Limit Switch COBRA SCL
FLUJO cuando requiere estar de Nitrógeno líquido hacia en la válvula HV-813B
cerrada Spillage Area.
Este documento contiene información privada y no puede ser duplicado, modificado o divulgado a terceros sin el consentimiento escrito de COBRA SCL. La única copia controlada de este documento está en el Sistema Informático de Gestión Documental de COBRA SCL.
REPORTE HAZOP / SIL UNIDADES PAQUETES - NIS PÁGINA 26 DE 72
N° DOCUMENTO: TAL-GEN-PRO-REP-1001 A REV. 00 FECHA: 16/09/2019
No. PARÁMETRO
ESTATUS DE LA
RECOMEN EVALUADO CAUSA (2) CONSECUENCIA (3) RECOMENDACIÓN (4) REFERENCIA RESPONSBALE SOLUCIÓN ACORDADA FASE DE CIERRE FECHA
RECOMENDACIÓN
DACIÓN : (1)
R7 MÁS FLUJO 3.4.2. Fallo de Lazo de 3.4.2.2. Posible baja Estudiar la posibilidad de incluir una protección COBRA SCL Se hizo cambio de
control FIC-615A abre FV- temperatura en los equipos en la extra para proteger la tubería de Nitrógeno material en el tramo de
615A línea aguas abajo del equipo E- aguas abajo de la NIS en caso de baja interconexión del
01, con posibles daños en el temperatura en este sistema. paquete con la línea
equipo. Pérdida de producción externa.
de Nitrógeno. Air Liquide debe definir
la mínima temperatura
que puede alcanzar el
nitrógeno en el punto
de tie-in durante la
condición indicada
(Falla abierta de FV-
615A)
R8 MENOS NIVEL 4.2.1. No posibilidad de 4.2.1.1. No producción de Garantizar que la operación simultánea en el COBRA SCL
llenado de V-50 durante la Nitrógeno. Parada de Planta Tanque V-50 de llenado y vaporización es
Vaporización a Planta posible.
cuando no haya producción
de Nitrógeno.
R9 FLUJO 4.5.1. PV-821C abierta 4.5.1.1. Riesgo de Nitrógeno Gas Implementar en la línea de descarga de COBRA SCL Air Liquide debe revisar
INVERSO durante proceso de hacia la atmósfera. Riesgo de cisternas hacia V-50 alguna de las alternativas la configuración y
conexión de mangueras. anoxia durante descarga de reflejadas en la GP aplicable para este caso, operabilidad del
cisterna hacia V-50 al sistema tomando en cuenta las válvulas aguas arriba de sistema de descargue
con afectación al personal. la PV821C. de cisternas para
prevenir el riesgo de
fuga de nitrógeno al
momento de hacer la
conexión del
carrotanque debido a
apertura automática de
PV-821C
R10 FLUJO 4.5.1. PV-821C abierta 4.5.1.1. Riesgo de Nitrógeno Gas Evaluar la posibilidad de implementar un COBRA SCL
INVERSO durante proceso de hacia la atmósfera. Riesgo de indicador de posición local en la PV-821C
conexión de mangueras. anoxia durante descarga de
cisterna hacia V-50 al sistema
con afectación al personal.
Notas:
(1) Desviación de la intención del diseño Líder de Seguridad
(2) Origen de las desviaciones o formas en las que puede ocurrir
(3) Resultado de la Desviación Líder del estudio
(4) Recomendaciones para cambios de diseño, procedimientos o para estudios posteriores
PÁGINA 29 DE 71
INFORME DEL ESTUDIO HAZOP/SIL UNIDADES PAQUETE –
NIS: COMPRESOR DE AIRE Y TURBINA DE EXPANSIÓN FECHA: 13/08/2019
N° DOCUMENTO: TAL-GEN-PRO-REP-1001-04 REV. 00
10.4 ACCIONES DE SEGUIMIENTO DE LAS RECOMENDACIONES
A continuación, se muestra la tabla de seguimiento de las recomendaciones del estudio HAZOP & SIL:
PARÁMETRO
No. RECOMENDACIÓN: CAUSA (2) CONSECUENCIA (3) RECOMENDACIÓN (4) REFERENCIA RESPONSABLE SOLUCIÓN ACORDADA FASE DE CIERRE FECHA ESTATUS DE LA RECOMENDACIÓN
EVALUADO (1)
1.10.2.1. Fuga de aire comprimido hacía el circuito de Instalar un sistema de

1.10.2. Rotura de tubos en aguas de refrigeración. Posible contaminación del agua detección y eliminación de
intercooler de alta presión. de enfriamiento. aire a la salida de agua de
R1 OTRA COMPOSICIÓN COBRA-SCL
1.10.3. Rotura de tubos en 1.10.3.1. Fuga de aire comprimido hacía el circuito de refrigeración de los
aftercooler. aguas de refrigeración. Posible contaminación del agua intercooler de alta presión y
de enfriamiento. aftercooler.
Asegurar que la ronda
periódica del operador
incluye la inspección del
2.10.1.2. Rebose del tanque de
2.10.1.2.1. Cubeto de retención y sistema de recogida cubeto de retención de aceite
R2 OTRA COMPOSICIÓN aceite lubricante con derrame y COBRA-SCL
de aguas aceitosas. y el nivel del tanque de aceite
posible impacto ambiental.
LG-180 e incluir en la
documentación
correspondiente.
Instalar un filtro redundante
con 11-F-01 para evitar el
3.3.3. Obstrucción del filtro 11-F-
R3 MENOS FLUJO 3.3.3.1. Pérdida de la producción de nitrógeno. paro de la turbina durante su COBRA-SCL
01.
limpieza. Ver Parking Lot Nota
19.
4.3.1. Fallo de la bomba de aceite Instalar una bomba en espera
4.3.1.2. Pérdida de producción.
MENOS FLUJO 021-P-6. en el circuito de lubricación
R4 4.11.1.1. Paro de la bomba de aceite. Pérdida de COBRA-SCL
FALLO SERVICIOS 4.11.1. Fallo de suministro de la turbina. Ver nota 13 del
lubricación a la turbina. Daños a la turbina.
eléctrico parking lot.
Instalar toma muestras en
tubería de retorno de agua de
4.10.1. Rotura de tubo en 4.10.1.1. Contaminación de agua de refrigeración con refrigeración de enfriador de
R5 OTRA COMPOSICIÓN COBRA-SCL
enfriador 091-E-06. aceite. aceite 091-E-06 (será
instalado fuera de la unidad
paquete).
Implementar alimentación
4.11.1. Fallo de suministro 4.11.1.1. Paro de la bomba de aceite. Pérdida de eléctrica de bomba en espera
R6 FALLO SERVICIOS COBRA-SCL
eléctrico. lubricación a la turbina. Daños a la turbina. desde fuente eléctrica
confiable o instalar Rundown.
Instalar una válvula check
5.5.1. Corte de suministro de gas 5.5.1.1. Posible contaminación del circuito de gas de
R7 FLUJO INVERSO adicional disímil en la línea de COBRA-SCL
de sello. sello.
suministro de gas de sello.
Evaluar la instalación de un
6.3.2. Fallo cerrando la válvula 6.3.2.1. Riesgo de atmósfera explosiva por ingreso de
R8 MENOS FLUJO disparo del compresor por COBRA-SCL
PCV-115 aceite en el circuito de nitrógeno.
baja presión de gas de sello.
Instalar doble válvula check

6.5.1. Corte de suministro de gas 6.5.1.1. Posible contaminación del circuito de gas de
R9 FLUJO INVERSO disímiles en la línea de COBRA-SCL
de sello. sello.
suministro de gas de sello.
Notas:
(1) Desviación de la intencion del diseño
Líder de Seguridad
(2) Origen de las desviaciones o formas en las que puede ocurrir
(3) Resultado de la Desviación

Líder del estudio
(4) Recomendaciones para cambios de diseño, procedimientos o para estudios posteriores

PÁGINA 317 DE 556
14.2. MANUALES DE OPERACIÓN DE AIR LIQUIDE

A continuación se relacionan los manuales de operación suministrados por Air Liquide
para la unidad paquete.
 OPERATING MANUALS, V-TAL-MEC-0001-OC-04-NIS-Z-001-0035
REFINERIA TALARA
NIS-Z-001 57506-60-01-PR-019001
Air Liquide
Operating Manual - Foreword
06/08/2019 00
Document N°.
57506-60-01-PR-019001
OPERATING MANUAL
Rev 0
Page 1 of 5
OPERATING MANUAL - FOREWORD - INTRODUCTION
COVER PAGE

0 01/08/2019 M. ATAM M. PAILLET RFR – Complete, ready for review
Project Number C57506

Project Name APSA L – TALARA NIS
Table of Revisions
Section Description
This document is administered by the Air Liquide Engineering Standards Department.

Paper copies of this document are considered to be “uncontrolled” and users should always check
for the most recent revision.
E-TPL-10-10-1 – rev A
Document N°.
57506-60-01-PR-019001
OPERATING MANUAL
Rev 0
Page 2 of 5
TABLE OF CONTENTS
TABLE OF CONTENTS 2
AIR LIQUIDE DISCLAIMER 3
1 INTRODUCTION 4
2 AIR LIQUIDE PROPERTY 4
3 FIELD OF APPLICATION 4
E-TPL-10-10-1 – rev A
Document N°.
57506-60-01-PR-019001
OPERATING MANUAL
Rev 0
Page 3 of 5
AIR LIQUIDE DISCLAIMER
The operating manual was written in English, for any translation of this document, the English version should be the
reference document.
The information contained in this document has been prepared for use for an Air Separation Unit designed by Air
Liquide Engineering (“Air Liquide”) and is based on technical information and experience currently available to Air
Liquide as of the original issue date of this manual. Air Liquide believes that the information contained in this document
is true and correct and that the document suitably addresses the matter to witch it relates. Air Liquide makes no
guarantee to third parties of the performance and assumes no liability or responsibility in connection with the
information or recommendations contained in the operating manual. Moreover, it should not be assumed that
recognized practice, test or safety procedure or method, precaution, equipment or device is contained within, or that
abnormal or unusual circumstances may not warrant or suggest further requirements or additional procedure.
This operating manual is intended to facilitate familiarisation with the ASU and its application for the intended purpose
as specified in the contract. Use for the intended purpose shall also include compliance with the specified operating
data indicated in the operating instructions (data sheets), as well as the inspection and overhaul conditions given in this
operating manual or in the relevant equipment operating manual.
Air Liquide makes no representations or warranties as to the completeness of this document and EXPRESSLY
DISCLAIMS ALL WARRANTIES INCLUDING BUT NOT LIMITED TO, THE WARRANTY OF THE
MERCHANTABILITY AND THE WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE OTHER THAN THE
INTENTED PURPOSE AS SPECIFIED IN THE CONTRAT.
Air Liquide makes no representation or warranty with respect to the accuracy of the information or with respect to the
suitability of the use of such information outside Air Liquide, nor does Air Liquide assume responsibility for any injury or
damage which may result, directly or indirectly, from the use of such information.
E-TPL-10-10-1 – rev A
Document N°.
57506-60-01-PR-019001
OPERATING MANUAL
Rev 0
Page 4 of 5
1 INTRODUCTION
Air Liquide advises you to read completely these instructions.

This Operating manual is written for personnel operating the Air Liquide ASU for Petro Peru Refinery at Talara in Perou,
Project Number C57506 and Project Name APSA L – TALARA NIS.
The purpose of this document is to give a consistent overview of the ASU in order to facilitate the understanding and
the communication between all specialists. The operating instructions must be read and applied by all individuals
responsible for operating the ASU, even if you are fully familiar with the principles of operation and safe practices for
this equipment before taking up their duties. Only personnel who have received appropriate training or familiarization
are allowed to operate the ASU
This manual includes descriptions, instructions and guidelines for commissioning, start-up, operation and shutdown of
the ASU. However, regarding commissioning, start-up, operation and shutdown of equipment, reference should be
made to the relevant description and instructions from the equipment supplier. These instructions are not intended to
cover all details or variations in equipment, or to provide for every contingency connected with the installation,
replacement and maintenance of the ASU. If more information is desired, if any instruction is unclear, or if problems
arise which are not covered herein, contact your Air Liquide representative for clarification.
This document is issued at different revision and users are cautioned to obtain the latest edition.
2 AIR LIQUIDE PROPERTY
This document is the property of:

AIR LIQUIDE GLOBAL E&C SOLUTIONS FRANCE S.A.
57 Avenue Carnot 94500 Champigny (France)
This document contains proprietary information which is the exclusive property of Air Liquide. It must not be
reproduced, copied, lent or otherwise disposed of, directly or indirectly, nor used for any purpose other than assessing
its merits without the written consent of Air Liquide.
3 FIELD OF APPLICATION
This operating manual contains important information on how to operate the ASU properly and safely. However, this
manual is no substitute for on-the job training for operating personnel when the ASU is running. If required Air Liquide
can provide all necessary training for this purpose on a contractual basis.
E-TPL-10-10-1 – rev A
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OPERATING MANUAL
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Page 5 of 5
Prior to start-up, it is recommended that all the components of the equipment supplied be inspected and adjusted, to
prevent any incident that may occur due to casual erection methods, or result from exposure to bad weather. Read and
fully understand the safety precautions listed in this manual and equipment documentation supplied, before attempting
operation or maintenance.
Proper and safe operation and maintenance of the ASU is subject to an adequate level of qualification and experience
of the personnel in charge.
AIR LIQUIDE shall not assume liability and responsibility as a result of:
Operating errors, unsuitable treatment of the Unit, negligence, omissions, mishandling and misunderstanding by
operating personnel.
Integration of ASU within downstream or upstream processes which could induce abnormal transitory phases.
Operating conditions not in compliance with the conditions of design defined in the contract and which could
affect or damage:
Proper and safe operation of the plant
Personnel safety
Equipment protection
Environmental preservation
Use of this manual for equipment not mentioned in this manual.
No modification shall be made to the plant, equipment, control systems, process descriptions and operating procedures
without authorization from Air Liquide Engineering. In the event of unauthorized modification, Air Liquide Engineering
disclaims all liability as to the consequences to the unit or any personal injury.
In few chapters certain process values are included for the purpose of making explanation clearer. All the operating
values indicated in the operating manual, are preliminary and are likely to be adjusted as of the reception of the final
manual (Rev n°2). In case of not reception of the final manual six months after the end of the starting period, the “as
started manual” (Rev n° 1) will be taken as official reference.
This manual shall be supplemented by the manual supplied by each equipment supplier. In case of discrepancy
between Air Liquide manual and an equipment operating manual, the operating manual for the relevant equipment shall
prevail.
The ASU shall only be operated within the operating data specified in the contract.
The operating instructions shall be supplemented by existing laws, operating and environmental permit, norms, rules
and regulations.
This manual must be available on the site at all times.
E-TPL-10-10-1 – rev A
REFINERIA TALARA
NIS-Z-001 57506-60-01-PR-019A011
Air Liquide
Operating Manual - Summary

Operating Manual - Table of Content
06/08/2019 00
Doc No.
57506-60-01-PR-019A011
OPERATING MANUAL
Rev .0
Page 1 of 2
OPERATING MANUAL - VOLUME A – SECTION A-01 – TABLE OF CONTENT
COVER PAGE


Table of Revisions
Section Description
E-TPL-10-10-4, Rev. C
Doc No.
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OPERATING MANUAL
Rev .0
Page 2 of 2
OPERATING MANUAL - VOLUME A – SECTION A-01 – TABLE OF CONTENT
APSA L OPERATING MANUAL
1 SECTION 0 FOREWORD
2 SECTION 1 TABLE OF CONTENTS
3 SECTION 2 SAFETY AND ENVIRONMENT
4 SECTION 3 THEORETICAL ELEMENTS
5 SECTION 5 MAINTENANCE
E-TPL-10-10-4, Rev. C
REFINERIA TALARA
NIS-Z-001 57506-60-01-PR-019A021
Air Liquide
Operating Manual - Personal Safety
06/08/2019 00
Doc No.
57506-60-01-PR-019A021
OPERATING MANUAL
Rev. 0
Page 1 of 35
OPERATING MANUAL - VOLUME A – SECTION A-02 - PERSONAL SAFETY
COVER PAGE


Table of Revisions
Section Description
E-TPL-10-10-3, Rev. C
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TABLE OF CONTENTS
COVER PAGE...................................................................................................................................... 1
TABLE OF CONTENTS ....................................................................................................................... 2
INTRODUCTION .................................................................................................................................. 3
1 COMMON INDUSTRIAL HAZARDS PREVENTION .................................................................... 3
1.1 The Working Permit .................................................................................................................................3
1.2 Personal safety equipment ......................................................................................................................5
1.3 Personal safety recommendations ..........................................................................................................5
1.4 First Aid – Emergency and Evacuation Plan ...........................................................................................7
1.5 Safety Showers and Eyewash Stations ..................................................................................................8
2 THE HAZARDS LINKED TO THE GASES ................................................................................... 8
2.1 Toxicity ....................................................................................................................................................8
2.2 Explosion or rapid burning.......................................................................................................................9
2.3 Asphyxiation ..........................................................................................................................................10
2.4 Pressure ................................................................................................................................................11
2.5 Hot temperatures ...................................................................................................................................12
2.6 Prevention knowledge ...........................................................................................................................13
3 THE HAZARDS LINKED TO COLD TEMPERATURE ............................................................... 14
3.1 Causes and effects ................................................................................................................................14
3.2 In case of accident ................................................................................................................................14
3.3 Prevention .............................................................................................................................................15
4 THE HAZARDS LINKED TO THE CONFINED AREA ................................................................ 16
4.1 Definition................................................................................................................................................16
4.2 Work in a box insulated with perlite .......................................................................................................17
4.3 Operating in a box insulated with rock-wool..........................................................................................18
4.4 Work in an adsorber or close to adsorbing material .............................................................................18
4.5 Implementation of the pre-entry procedure ...........................................................................................18
4.6 Safety equipment ..................................................................................................................................21
5 OTHER HAZARDS LINKED TO AN ASU OPERATION ............................................................ 22
5.1 Noise .....................................................................................................................................................22
5.2 Gas Cylinders handling .........................................................................................................................22
6 RESTRICTIVE AREA ................................................................................................................. 23
7 SAFETY DATA BASE ................................................................................................................ 25
7.1 Summary liquid knowledge ...................................................................................................................25
7.2 Summary gases knowledge ..................................................................................................................26
7.3 Fire extinguishing methods and devices ...............................................................................................26
8 MANUFACTURER SAFETY DATA SHEETS OF CHEMICAL PRODUCTS AND SUBSTANCES
IN USE IN AN ASU ............................................................................................................................ 28
8.1 Products used within the installation .....................................................................................................28
8.2 Products produced by the ASU .............................................................................................................28
8.3 How to interpret MSDS information sheets ...........................................................................................29
CASING – CONFINED SPACE .......................................................................................................... 32
8.4 Summary of the risks involved in the different areas ............................................................................34
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INTRODUCTION
An ASU is a complex plant producing gas (N2, O2, AR…) and associated cryogenic liquids, these products
being either at extremely high or low temperature as well as extremely high pressure.
All personal including subcontractors working in the plant shall receive the safety information included in this
document and understand it.
When several firms are used as subcontractors to perform at the same time one operation or several operations
that might interfere, a meeting aiming to work out the prevention safety measures related to the concerned
operation must be organized.
The common industrial hazards are mainly linked to:
• Personal safety equipment
• Usual hazardous works
The hazards on cryogenic air separation unit are mainly linked to:
• Processed gas
• Cold
• Work in confined space
• Hydrocarbons in the air (Developed in the Process Safety section)
• Restrictive area
Operators are strongly requested to take the here below mentioned recommendations into consideration, since
the hazards that are here evoked may lead, if the necessary precautions are not taken, to serious damages to
the plants and also to injuries and even fatalities to people.
Complementary information are given in Volume B section « SAFETY/ ENVIRONMENT »
1 COMMON INDUSTRIAL HAZARDS PREVENTION
1.1 The Working Permit

As a rule, the work permit procedure must be widely implemented for any work in the plant:
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WORK PERMIT N°
JOB DESCRIPTION
CONCERNED EQUIPMENT : ----------------------------------------------------- ZONE : ------------------------------------------------
CONFINED AREA : Yes No If answer is YES apply Pre-Entry Permit
JOB : ------------------------------------------------------------------------------------------------------------------------------------------------------------------
----------------------------------------------------------------------------------------------------------------------------------------------------------------
PERSON in CHARGE of the JOB : Name : ------------------------------------------------------- Company : ----------------------------------
WORK PERMIT VALIDITY : From (day / time) : ------------------------------------------------------ To (day / time) -----------------------------
A. - NEARBY COACTIVITIES (example : welders above, Painters below, Traffic ...) - DESCRIBE :
----------------------------------------------------------------------------------------------------------------------------------------------------------------------
POTENTIAL HAZARDS
B. - FLUIDS : Gas Liquid Others Which ones : -----------------------------------------------------
Related Hazards : Anoxia Toxicity Overoxygenation Inflammation Hot Work

Heat Cold Pressure Flames / sparks (A)
Electricity Corrosive Others
C. - JOB’S SPECIFIC HAZARD : Height Digging Lifting Fire Flames / sparks
Noise Electricity Rotating / moving parts Others
D. - OTHERS : -----------------------------------------------------------------------------------------------------------------------------------------------------------
(A) Apply Fire Permit
Drain Depressurization Locking out (B) Nitrogen blowing Steam blowing Analysis
PREVENTION
Air ventilation Deriming Signposting Barricades Cordoning Protective screen

Scaffolds Watchman Signalman Extinguisher Fire Hose Nets
OTHERS : ----------------------------------------------------------------------------------------------------------------------------------------------------------------
PERSON in CHARGE of the IMPLEMENTATION of PRECAUTION MEANS : -----------------------------------------------------------------------
(B) apply Lock out procedure
Hard hat Goggles Safety boots Hearing protection Harness

P.P.E.
Breathing apparatus anti-dust mask gloves Analyzer
OTHERS : ----------------------------------------------------------------------------------------------------------------------------------------------------------------
Prior to work Work achieved

SIGNATURES
NAME COMPANY
Date / time Date / time
Person in charge of the job
AL/DI Site Manager
Site Safety Manager
ADDITIONAL PROCEDURES to be APPLIED :

Detailed Work procedure Lockout procedure Fire permit Pre-entry permit
Others :
Contacts in case of accidents : NAME : Phone nr :

NAME : Phone nr :
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1.2 Personal safety equipment
The workers must be fitted with the necessary personal safety equipment. Any safety equipment, whether
collective or personal, must comply with existing standard and country regulation.
Hard hats for head protection. Safety shoes
Safety glasses for eyes

protection and adequate face
shields for specific hazards such Safety mitten or gloves for
as: chipping, acid work, welding, hand protection.
molten metal, other risks of the
same kind.
Personnel when exposed to Safety belt or harness

any hazard to ears must wear complying with existing standard
ear protective devices. or (and) country regulation.
Clean work clothes; fire-

retardant clothes are
Protective masks with suitable
recommended when working in
filter when exposed to any
area where hazard of oxygen
hazard to the lungs caused by:
enriched atmosphere or
harmful fumes and gases, spray
presence of flammable product
painting, excess dust, other
exist. Other adequate protective
risks of the same kind.
clothing will be worn in case of
exposure to specific hazards.
1.3 Personal safety recommendations

Work at high For such works specific equipment must be implemented such as scaffoldings, safety harness,
level or vessel life lines and other adequate devices to prevent workers from falling (such devices must comply
with the existing standards and (or) country regulations).
Particular precautions must be taken to prevent any piece from falling from elevated locations
down to lower levels and to protect people working at lower levels.
It must be reminded that a ladder is not convenient base to perform any work. If ladder is used,
it must comply with existing standard and (or) country regulation and be in good condition.
Digging Work That induces risks of underground networks (pipeline, electrical wires...) break and of fall in the
excavation. Piping drawings must be carefully studied before operation in order to locate the
underground pipelines or network and care must be taken for digging close to pipes. Shoring is
required for deep trenches with vertical walls. Adequate signalling and protection devices must
be installed to prevent people from falling in the excavation.
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Hoisting and Any operation must be studied in details, particularly when the piece to be handled is heavy or
handling large, in order to make sure that adequate vehicle is used, necessary room for crane is
equipment available, and to prevent any damage, especially to people, that could result of the fall of the
load. Whether specialist must make sure of the proper condition of the vehicle used, or the
evidence of the proper conditions (according to country regulation), as technical visit
certificates, must be available.
Only trained, qualified and authorized persons may operate lifting or handling vehicles. Some
operation may require the permanent presence of a signalman.
Traffic Adequate measures must be taken to arrange a circulation schema in the plant site in order to
avoid collisions between vehicles. For instance, sign posting may be installed in order to direct,
depending on the operation performed, trucks, car, handling vehicles and pedestrians.
STOP
Employees must be aware of the hazards involved in working with electricity. Only trained,
Electricity qualified and authorized employees may work on electrical installations.
Appropriate equipment’s must be used and must be in good condition (grounded or equipped
with double insulation).
If work is to be performed on electrical equipment, work procedures must be applied and
special safety equipment must be used. The electrical lock out/tag-out is an essential,
obligatory safety procedure. It involves disconnecting the equipment from any possible source
of power (electrical, mechanical).
Use adequate sign posting and other means to inform people working on site that work in
being performed.
Machines Since machines include moving parts, any work on them obviously induce a hazard. In
addition some of them, as gas compressors, present other risks that are related to high
temperature and pressure. The protection devices installed on the machines must be kept in
place or replaced when damaged. Any intervention on the machine must be undertaken
following the needed procedures that are work permit, electrical and mechanical lockout. Use
adequate sign posting and other means to inform people working on site that work in being
performed.
Working on Any work on a pipe must perform following the work permit procedure. The part to be worked
piping or at must be properly isolated (double block and bleed, blind flange...) and the means used
vessel locked out. In case the part on which the work is performed is used to flow hazardous product,
adequate blowing and analysis must be done to ensure the absence of remaining product.
Welding Electric arc and oxy-acetylene welding must be performed by qualified and authorized welders
only. Welders must wear the adequate equipment. When welding in confined area, particular
precautions must be taken (procedure to be followed, analysis to be performed...).
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Sources of
radioactivity When such a method is used (particularly when verifying the quality of stainless steel
welding), a controlled zone must be set and properly signalled. A procedure must be worked
out to ensure that no one remains inside controlled zone at the time the specialists for
radiography work.
Prohibition to smoke on the site and prohibition of open flames
Prohibition of use of cell telephone and Walky Talkies near the electronics components (in
particular in control room, near the cupboards systems, in the instrumentation modules....)
because of the possible electromagnetic disturbances
1.4 First Aid – Emergency and Evacuation Plan

First Aid
Considering the risks involved in the operation of the plant, appropriate first aid kit should be available and easily
accessible at any time by the personal.
Unless a first aid room and a qualified attendant are close at hand and prepared to render first aid to employees
on behalf of the employer, the employer shall furnish a first aid kit for the employees. The first aid kit shall
include at list all materials necessary to treat hot and cold burns, electrical shocks, and eyewash as well as usual
kits.
The contents of the kit should be adapted to the size of the plant, when larger operations or multiple operations
are being conducted at the same location, employers should determine the need for additional first aid kits at the
site, additional types of first aid equipment and supplies and additional quantities and types of supplies and
equipment in the first aid kits.
In a similar fashion, employers who have unique or changing first-aid needs in their workplace may need to
enhance their first-aid kits. Consultation from the local Fire/Rescue Department, appropriate medical
professional, or local emergency room may be helpful to employers in these circumstances. By assessing the
specific needs of their workplace, employers can ensure that reasonably anticipated supplies are available.
Employers should assess the specific needs of their site periodically and augment the first aid kit appropriately.
If it is reasonably anticipated employees will be exposed to blood or other potentially infectious materials while
using first-aid supplies, employers should provide personal protective equipment (PPE). Appropriate PPE
includes gloves, gowns, face shields, masks and eye protection
At least one employee per shift shall be qualified to administer first aid to the injured.
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The contents of such kit shall contain a sufficient quantity of at least the following types of items:
• Gauze roller bandages,
• Gauze compresse bandages,
• Adhesive bandages,
• Triangular bandage,
• Antiseptic applicators
• Burn dressing,
• Eye dressing,
1.5 Safety Showers and Eyewash Stations
Safety showers and eyewash stations shall be located within buildings and other process areas where there is a
hazard of chemical or cryogenic spillage or splashes. They shall be located as close as practical to the hazards
identified. They shall be self contained and supplied with potable water at ambient temperature. They should be
tested and maintained periodically.
1.5.1 Emergency Plan
In case of emergency, an adequate emergency plan should be put in place in accordance with local regulation.
1.5.2 Evacuation Plan
An adequate evacuation plan shall be put in place to evacuate all personnel from the facility to a safe location in
case of major incident in accordance with local regulation.
2 THE HAZARDS LINKED TO THE GASES
2.1 Toxicity
A gas is toxic when it can cause, even for very low quantities, a poisoning of human body.
Although the main liquids and gases processed in an air separation unit are not toxic, some toxic
products may be used for the operation of auxiliary equipment’s. Those equipment’s are mainly:
• Cooling units using ammonia

• Water treatment station
In case neighbouring factories are possible sources of toxic emissions that might, according to
atmospheric conditions and particularly the wind direction, reach the air separation unit site,
adequate safety equipment’s must be available.
Poisoning effects can be very fast for big quantities breathed causing a fast death or very slow for
little quantities. Every little dizzy-turn must be taken into account.
More important the quantity is, more serious the effects are.
Effects depend on the quality of each gas.
Effects are particularly insidious for gas without color or odor.
It's absolutely imperative to systematically check atmosphere of contaminable zones.
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2.2 Explosion or rapid burning
There are two possible causes:
Presence of flammable gas in air
Oxygen enriched atmosphere (More than 21 % of oxygen)
In case of an oxygen enriched atmosphere, the combustive product is in big quantity,
certain material normally regarded as being non-flammable in the air become flammable
(grease, asphaltic bitumen, oil...).
In this case also, a spark, a flame, a shock, a friction is enough to cause burning. The
phenomenon is linked to concentrations ratio of combustible and combustive, and to a
fortuitous event which cause ignition.
The explosive regarded zone must be periodically checked.
Tools, clothes, place design will be chosen to prevent any hazard.
Concerned zones or operations on an air separation plant:
The hazard of combustion or explosion exists in any place where, due to accidental or
unexpected event or to the performance of an improper operation, atmosphere may be
oxygen enriched.
As a rule, specific precautions must be taken when work is undertaken in the vicinity of:
• Liquid oxygen filling station
• Oxygen compressor
It's very important to • Oxygen expansion valve station
keep in mind that
explosion is a violent • Oxygen metering station liquid or gaseous oxygen vent
phenomenon causing
every time serious
Particular environmental conditions, such as wind direction and strength, may induce
damages. oxygen enriched atmosphere on areas which may be considered far enough of the
source of hazard.
Flammable products used or stored on site may of course be an other source of
combustion, as oil and grease. Lubricants used for oxygen use must comply with Air
Liquide recommendations.
Hydrogen is sometimes used for crude argon epuration. The risk due to the presence of
this gas is therefore present on the warm argon purification unit and may even spread to
the cold argon purification equipment.
Before any work is undertaken on a location where such a risk exists, the work permit
procedure must be applied.
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2.3 Asphyxiation
Asphyxiation is a lack of oxygen in the body. It occurs when air is replaced by a gas
containing not enough oxygen under an assimilable form by the human body:
DANGER BEGINS WHEN O2 CONTENT IS LESS THAN 18 %.
There are two kinds of asphyxiation:
• Sudden asphyxiation:
For very low oxygen content (less than 6 %), the victim falls down immediately. Death
can occur within a few minutes.
• Slow asphyxiation:
It occurs slowly either by slow decreasing of oxygen content or during the victims
presence in a lightly under oxygenated atmosphere.
Concerned zones or operations on an air separation plant:
Any confined area or insufficiently ventilated place where Nitrogen or Argon is likely to be
present:
• Inner and outer cold box .
• In case any closure device is removed or not tight, nitrogen may flow out, building up
an asphyxiant area close to the opening or leakage.
• In the interspace of nitrogen, oxygen and argon storage tanks since there are
permanently blown with nitrogen.
• In any room in which equipment operate using inert gases (analysers rooms or
cabinets, control room...).
• In any place where air may be replaced by nitrogen or argon (control room,
workshop...).
• In trenches or low points (sewers, pits...).
• When using cryogenic liquids (nitrogen, argon...).
• When using by mistake nitrogen instead of air for breathing equipment.
• In rooms where a fixed fire extinction system is installed, when either halon or CO2 is
used as an extinguisher agent, since in case of functioning of the system, the oxygen
content will decrease down to until hazardous values.
• In the vessels of the purification unit where, even after an air blowing has been
performed, nitrogen may desorbe off the adsorbent beds at a later stage.
• Use of instrument air as a breathing gas in confined spaces (control room, vessel,
etc.), in case when instrument air system is backed-up by a nitrogen network.
Particular note related to instrument fluid:
As a rule instrument fluid in normal operation is taken from air process circuit
downstream the front end purification unit. When this instrument air is potentially
backed–up by nitrogen, it must be permanently treated as being nitrogen with
regards to the risk of anoxia. The symbol used on relevant drawings to identify the
related lines is IG (Instrument Gas). Operations teams should identify these lines with
dedicated signposting/stickers as per the applicable local codes.
Specific tagging and procedures should be implemented by the operations teams to
forbid the use of connection points potentially let or made free. It is strongly
recommended to remove such a connection point is it exists
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2.4 Pressure
The risk inherent in pressure vessels systems from the quantity of stored energy used
to pressurize the fluids contained. This energy may be considerable!
In the case of a rupture, this energy will cause a sudden expansion of the fluid:
• Leak and bursting
• Explosion
PRECAUTIONS:
Certain safety measures must be followed to the letter in order to limit the hazards of
pressure:
• When systems are being designed, the regulations in effect must be respected.
You must comply with the instructions provided in the pressure vessel construction
codes. Systems and equipment under pressure must be inspected before the first
start-up and then periodically as indicated by law. Equipment under pressure must
be checked on a regular basis for strength and leaks.
• Safety devices must be installed for use when normal operation conditions are
exceeded (ex: bursting disks, safety valves, buckling rods, cut-off and lock-out
devices controlled by temperature or pressure, measurement and regulation
devices...).
• The pressure gauges installed on the equipment under pressure are used to
measure the internal pressure. The reading on the pressure gauge must always be
at 0 before you can start any work on the equipment.
• Operating procedures have been developed to eliminate the hazards of pressure.
They must be followed to the letter. One particularly important procedure is the lock-
out / tag-out procedure for gases.
• Changes to pressure vessels are prohibited unless done in accordance with the
rules: design and construction in accordance with standards, periodic tests.
• Finally, everyone must immediately report any defect or anomaly noted on a device,
pipe or safety device to his immediate superior so that measures can immediately
be taken to correct the problem. Considering the hazards of pressure, reporting is
the duty of each and every one of us.
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2.5 Hot temperatures

The risk inherent to hot temperature is that some piping of the plant can reach temperature higher
than 150°C or more, causing severe burns. Such high temperature can be reached on the
following items:
• the regeneration system including the regeneration heater and the associated piping
• The compressors casing and associated piping
• The vaporisation systems
• The steam piping when existing
PRECAUTIONS:
Certain safety measures must be followed to the letter in order to limit the hazards
of high temperature:
• When systems are being designed, the regulations in effect must be respected.
You must comply with the instructions provided in the pressure vessel construction
codes. Systems and equipment under pressure must be inspected before the first
start-up and then periodically as indicated by law. Equipment under pressure must
be checked on a regular basis for strength and leaks.
• Safety devices must be installed for use when normal operation conditions are
exceeded (ex: bursting disks, safety valves, buckling rods, cut-off and lock-out
devices controlled by temperature or pressure, measurement and regulation devices...).
• The pressure gauges installed on the equipment under pressure are used to
measure the internal pressure. The reading on the pressure gauge must always be
at 0 before you can start any work on the equipment.
• Operating procedures have been developed to eliminate the hazards of pressure.
They must be followed to the letter. One particularly important procedure is the lock-
out / tag-out procedure for gases.
• Changes to pressure vessels are prohibited unless done in accordance with the
rules: design and construction in accordance with standards, periodic tests.
• Finally, everyone must immediately report any defect or anomaly noted on a device,
pipe or safety device to his immediate superior so that measures can immediately be
taken to correct the problem. Considering the hazards of high temperature, reporting is the
duty of each and every one of us.
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2.6 Prevention knowledge

Any hazard considered (toxicity, explosion, asphyxiation), the main rule is the Areas considered as dangerous:
knowledge of atmosphere composition where it is necessary to work or to stay.
• With difficult access (so,
Measurements can be made: difficult to evacuate) because
of small exits (man hole) or
• Continuously
exits position (height...).
• Periodically
• With closed area even
• Or just when there is a particular danger (with portable analysers) ventilated because
accumulation in corners
Neutralization the risk source: (analyser panels, caskets,
Pipes will be cleaned of their pollutant gas. holes, sewers, ground with pit
(gas heavier than air), ceilings
For toxic or asphyxiating gas, blowing with air up to safety quantity particular to (gas lighter than air, etc.).
each gas.
• With cul-de-sac (sewers, pits,
For flammable or combustive gas, blowing with nitrogen up to safety quantities gutters, containers...).
particular to each gas and, afterwards, blowing with air to have a breathable
atmosphere (between 18 % and 23 % oxygen). • In open air, near a gas source
(nitrogen drying outlet...)
After these cleanings, atmosphere will be checked as noted above
where atmosphere can be very
(continuously when performing tasks or periodically after blowing and before
polluted.
any work).
• Places regarded as non
Case of work to be done on only one part of the plant:
dangerous but linked with
This part will be isolated with blind flanges or by pipes disconnected from the dangerous places by piping
polluted part. Nota: An isolating valve or a control valve is not of absolute (sewer...).
security.
Adequate safety means supply:
Implementation of procedures for
• Safety guards far enough from the dangerous zone but near enough to work in vessels, tanks and other
watch workers. confined space:
• Special safety material: special kind of extinguisher for each kind of hazard (See section work in confined
(Carbon dioxide, water spray...) automatic showers, gas mask adapted to space)
concerned gas, autonomous mask etc.). Specific Protection Devices:
• Information and training of people likely to work on polluted areas. (See section work in confined
• Use of adequate tools (antiburning lamp, bronze tools (anti-sparks) free of space)
oil and clean).
Generally on a plant:
• Clear signalling of hazardous zones (use barricades, sign posting...),
• Adequate bans (prohibited to smoke, to come in, to make fire),
• Cleanliness (no materials on the ground, no oil pool, no oily rags...),
• Availability of adequate help and safety equipment.
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3 THE HAZARDS LINKED TO COLD TEMPERATURE

ALWAYS REMEMBER that a liquefied gas concentrates in a
small volume big amount of matter.
Therefore, the characteristics and particularly the hazards are
amplified in the liquid.
3.1 Causes and effects
Causes Effects
Causes linked to the cryogenic liquid hazards during plant Every skin touch with liquefied gas or materials at the
operation: temperature range of liquefied gas causes serious
frostbite, similar to burn. The touch gives a sensation of
• Every cryogenic liquid handling, sticking to the material.
• Container transport, • Skin can be damaged by a very cold atmosphere,
• Work on cryogenic pumps, • Lungs can be damaged by breathing in a very cold
• Voluntary purges (even with evaporating devices), atmosphere,
• Plant cold test without insulation, • The lower the temperature is, the longer touch or
the presence is, the more serious effects are.
• Tasks executed in a zone where there are non
insulated pipes, A serious effect is hypothermia (body temperature
decreasing), which can cause death.
• Cryogenic liquids on the ground.
Accidental causes:
• Cryogenic liquid safety valve opening,
• Leak on flanges, valves (packing...),
• Not well dried pipes bursting,
• Piping collapse due to ice accumulation (during rain or
fire fighting).
3.2 In case of accident

• Remove any cloth embarrassing blood circulation in the frost bitten zone.
• Water the frost bitten part with water at about +20°C for at least 15mn.
• Call for emergency or safety brigade in order to make the victim be transferred to the adequate care center
(hospital or infirmary).
After cold atmosphere breathing:
• Bring the victim to a warmed room (be careful not to place the victim directly in a hot atmosphere).
• In case of dizzy-turn, bring the victim to a hospital or infirmary (don't forget that hypothermia can cause
death).
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Frostbites are often painless at the beginning. This may
lead to estimate the injury less serious that actually is.
3.3 Prevention
Gloves
Safety shoes
(leather...)
Special clothes
Safety
in case of
glasses
spray
• Don’t touch cold material or liable to be cold (vessels, pipes and liquid itself!).
• Don’t stay in a cold atmosphere (plant cold test, quantity of cryogenic liquid evaporating after fall on the
ground...).
• Don’t walk in a zone where cryogenic liquid has flown on the ground (fog caused by cold hides cryogenic
liquid pools).
• Be careful, the liquid can freeze and make the zone slippery.
• Don’t purge voluntarily cryogenic liquids on the ground.
• Take care of wet clothes, pockets, shoes (trousers over the boots), gloves which can be filled with liquid
spray.
Particular precaution linked to liquid oxygen:
Always remember that purging liquid oxygen

aground may lead to immediate explosion if the
covering ground matter is combustible.
Be careful with:
• Purge on asphaltic bitumen, on sand etc.,
• Contact with rust, paper,
• Permeation with porous materials (wood, tissues etc.).
Requirements:
• No handling near flammable materials (ground and walls also),
• No storage of volatile materials or flammable materials near oxygen tanks or oxygen vents,
• Provide good ventilation of liquid oxygen storage areas (if possible in open air),
• Proscribe low points (sewers, pits...),
• Install extinguishing devices (sprayed water extinguishers...),
• Requirements for gaseous oxygen hazards and cryogenic liquid handling are also applicable.
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4 THE HAZARDS LINKED TO THE CONFINED AREA
4.1 Definition
A closed or open volume, located above or below ground level, in which the natural permutation of the air inside
with the atmosphere is diminished.
Closed confined spaces
Open confined spaces
(relatively tight and difficult access due to the
(with relatively free and easy access)
narrowness of the openings)
Trenches, shafts, manholes, tunnels, piping, pipe- Cold boxes, casings: pumps, valves, cold
lines, sewers, pits, retention basins, air intake for exchangers -reservoirs, tanks, absorbers, cooling
venting inert gases, water/nitrogen towers, ... towers, heat exchangers, boilers, furnaces, ...
The atmosphere, as one enters in the confined area is unknown and has to be checked.
Generally, any work on an installation, which has already been operating, is hazardous and the surrounding
atmosphere always has to be checked, before entering it.
It is hazardous to enter into a confined area because it may contain a dangerous atmosphere (toxic gas or
suffocating gas) or an explosive atmosphere.
Inventory of Risks
SUFFOCATION
Risk of being buried, drowned in perlite, inert gases (argon, nitrogen,...)
POISONING
Presence of waste or of toxic gases (CO2, CO, Ammoniac, Chlorine,

Phosgene...), Presence of solvents
EXPLOSION-FIRE
Inflammation of vapours or particles (sparks, hot points)
CHEMICAL
Presence of chemical substances: burning due to inhalation
ELECTRICAL
Presence of electrical current, static electricity
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RADIOACTIVE
Presence of radioactive sources
Intervention on a piece of equipment in running mode, uninformed personnel

MECHANICAL (faulty instructions, lack of blind flange, lack of knowledge about pressure
variations between different circuits), mechanical weaknesses in the
equipment used for the intervention (scaffolding, tunnel,...)
Medically unfit (claustrophobia, vertigo,...), fatigue, anoxia, physical condition

PHYSIOLOGICAL
NOTE: The workers’ PHYSIOLOGICAL and PHYSICAL FITNESS is a
PHYSICAL
preponderant element to be taken into account when undertaking work.
Example of Accidents
OPERATIONS CONSEQUENCES
Injection of gaseous nitrogen into a distillation column by a

Operator feels unwell when working to
bleed pipe which has defective sealing in the coupling
improve tightness (immediate first-aid)
device
Check on the penetration of a weld on a pipe of large A welder and foreman found asphyxiated by
diameter argon (death)
A subcontractor found unconscious in the

A washing tower repainted on the inside
tower (death)
Two labourers intoxicated by H2S naturally

Removal of molecular sieve from a bottle of a drying unit desorbed of the sieve in the truck the sieve
had been poured
High CO content in the bottle when CO

Activated carbon filling of a PSA adsorber
naturally desorbed from the activated carbon
4.2 Work in a box insulated with perlite

(Cold box, exchanger box)
Perlite is a hydrated silicate pre-submitted to an expansion by thermal treatment. Perlite is extremely light and
fluid. Falling in perlite causes death because one literally drowns and dies of stifling.
It is a highly irritant material, which has to be handled with gloves, protecting glasses and breathing masks or
autonomous breathing apparatus.
Work in a perlite box insulated with perlite should be done if the following conditions are fulfilled:
• Scaffolding around the work area.
• All the workers have to be equipped with a security harness linked to a stable point strong enough to carry
the worker. The rope shall be short enough to avoid falling in the perlite below the working spot.
• Workers shall be supervised, permanently by other workers, observing the scene from a place out of the
dangerous zone.
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• Every worker shall wear glasses, gloves and a dust-protecting breathing mask.
Caution:
In the case of a complete removal of the perlite in a box, before entering it, it is compulsory to make sure that no
accumulation spot exists.
An old perlite, carrying damp, is more compact and has a more important mass. Perlite could be retained in the
upper section by other devices and collapse under a slight action.
Even the devices can be broken by this accumulation, especially when the perlite is old and damped.
4.3 Operating in a box insulated with rock-wool

(Cold tank, exchangers box, pumps casing, turbines casing)
The rock-wool is a highly itching material, which requires to be handled with gloves, glasses and autonomous
dust protecting breathing masks.
Caution:
Any work on an installation only accessibly through a tunnel, is highly dangerous, because of the risk of
collapsing.
This work is very hazardous and should be avoided. However, if no other possibility exists, it has to be prepared
with great care, making sure that all the security instructions are followed.
The tunnel has to be backed-up strongly enough, in order to allow it to support the upper weight.
Of course, the workers operating in it, have to be equipped with a harness, linked to a rope attached somewhere
out of the tank and being easily accessible.
The staff entering the dangerous area shall be supervised by people staying out of the tank but near enough to
be able to rescue (fainting by lack of air or heat).
The tunnel shall be enough ventilated in order to ensure a sufficient exchange of breathable air.
4.4 Work in an adsorber or close to adsorbing material

Any work performed inside an adsorber is highly dangerous for taking place inside a confined space. All general
hazards linked to performing work in such places designated as confined spaces have to be taken into account
and the pre-entry procedure must be implemented. There is a further specific hazard associated with the
handling and transfer of adsorbing materials, which have the ability such a material to release products that have
been previously adsorbed. The desorbed products may include, according to composition of fluid processed
through the adsorber, hazardous contaminants, which can seriously injure people by asphyxiation, intoxication or
fire.
The main safety measures that should be taken to control these risks are listed here below:
• Material Safety Data Sheet of the material should be looked at and relevant manufacturer recommendations
taken into account.
• Hazards during handling and transfer of material should be identified through job safety analysis. This
analysis should include the risks described above and include the risk of desorption of hazardous material.
• The pre-entry procedure and work permit should clearly describe the hazards and define the safety measures
to be implemented and the protection equipment required prior to any work.
• The hazards and safety measures should be explained to all personnel involved in the work.
4.5 Implementation of the pre-entry procedure
IT IS FORBIDDEN TO ENTER INTO A CONFINED SPACE WITHOUT FIRST HAVING

ASCERTAINED THE RISKS AND SET OUT THE PRECAUTIONARY MEASURES TO BE
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The pre-entry procedure must at least stress the following points.
No. : Date :
Establishment: Installation: Equipment:

ACTIVITY
Type of Work:
yes no yes no yes no

- LACK OF OXYGEN - STATIC ELECTRICITY - GAS POCKET
- OVER OXYGENATION - DESORPTION of MATERIAL - LACK OF VENTILATION
- TOXICITY - PRESSURE - DEFECTIVE SEALING
- PRESENCE OF NON BREATHABLE GAS - TEMPERATURE - MECANICAL SYSTEM
RISKS
- INFLAMMABLE PARTICLES - SAFETY DEVICE

- PRESENCE OFSOLVENTS - WORK WITH HOT POINTS - PHYSIOLOGICALLY FIT
- PRESENCE OF LIQUIDS - FALLS FROM HEIGHTS - MEANS OF COMMUNICATION
- DROWNING - SPARKS - ...
- BEING BURIED - PRODUCT INLET - ...
- EXPLOSION
- PROCEDURE FOR CONFINED SPACES - INERTING THE CONTAINER (*) - PERMANENT MONITORING
- PROCEDURE FOR LOCKING - ELIMINATION OF DANGEROUS - TRAINED SUBCONTRACTORS
- DRAINING MATTER - REMOVAL OF SOURCES OF
PREVENTIVE MEASURES
- DEPRESSURIZATION - OBLIGATORY VENTILATION IGNITION

- ISOLATING FLUID INLETS - BREATHABLE AIR INTRODUCED - FIRE JET PIPE
- ELECTRICAL ISOLATION - ANALYSIS OF THE ATMOSPHERE - VISUAL INFORMATION
- SAFETY LABELS OXYGEN - PHYSICAL FITNESS
- RINSING WITH WATER / SOLVENT INFLAMMABLE SUBSTANCES - PHYSIOLOGICAL FITNESS
- OBTAINING AN AMBIANT TEMPERATURE TOXIC SUBSTANCES - ...
- CONTINUOUS ANALYSIS - ...
- ZONE CORDONED OFF (*) see overleaf
- WARNING NOTICES
REMARKS:
BOTTLES OF OXYGEN SCAFOLDING FACE MASK

PORTABLE(s) ANALYSER(s) LIFELINE SAFETY LIGHTING
FIXED ANALYSER(s) NACELLE DIFFERENTIELCIRCUIT BREAKER(30 mA)
PROTECTION
EXPLOSIMETER HELMET RADIOPHONE (EXPLOSION PROOF)

BREATHING APPARATUS GLOVES EXTINGUISHERTYPE : ........................
HARNESS GOGGLES
ROPE EAR PROTECTIONS
LADDER SPECIAL CLOTHING
- GAS TO BE ANALYSED 02 H2 CO CH4 ................. .................
- ALARM THRESHHOLD 19 % - 23 % 1% 50 ppm 1,25 % ................. .................
ANALYSYS
- ANALYSIS PRIOR TO ENTRY .......... % .......... % .......... ppm .......... % ................. .................
- ANALYSED EVERY : ......... min. ......... min ......... min ......... min ......... min ......... min
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CAN WORK BEGIN yes no
AUTHORISATION DELIVERED BY : ................................................ POSITION HELD: ................................ SIGNATURE :
AUTHORIZATION
PERSON IN CHARGE OF THE WORK : ............................................................................................................ SIGNATURE :

PERSON MONITORING THE WORK : .............................................................................................................. SIGNATURE :
PERSON(s) CARRYING OUT THE WORK : ..................................................................................................... SIGNATURE :
AUTHORISED FROM (Date / time) until (date / time)
START OF WORK : END OF WORK :
FINISHED WORK INSPECTED BY : SIGNATURE :
IN CONFORMITY NON CONFORMITY
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4.6 Safety equipment

Consideration shall be given to specifying that the following be worn by men entering the tank:
• Protective clothing
• Eye protection
• Breathing equipment
• Safety harness with line fastened outside of tank
Additional Safety Equipment may include:
• A ladder of adequate length, secured if possible at the top and equipped with non-slip feet at the bottom.
• An air mover capable of providing adequate and continuous fresh air supply.
• A portable alarm horn, possibly compressed gas operated, to summon help by the safety watcher.
• Unless there are persons nearby who are trained to administer artificial respiration, resuscitation equipment
should be available for emergencies in addition to the self-contained breathing apparatus with which it is
mandatory that the safety watcher be provided.
• Where exit from a tank is made vertically through a manhole opening or where vertical ascent is required from a
confined space, a tripod, block and rope may be needed, particularly for removal of an incapacitated worker.
Breathing apparatus:
Toxic atmospheres:
Use only gas masks with special cartridge adapted to the gas concerned (don't forget to change the cartridge when
polluted) or autonomous masks called Self Contained Breathing Apparatus (feed with pure air coming from non
polluted area).
Watch out! Paper masks can not stop toxic gases!
• Asphyxiating atmosphere:
Use only Self Contained Breathing Apparatus (SCBA) with adequate capacity (20 to 45 minutes or more) shall
be used.
Watch out! Filtering cartridge of gas masks can not compensate lack of oxygen!
• Flammable atmosphere:
The protective devices will be included in room design and will be preventive devices.
The phenomenon is sudden; there is no effective protection for people in case of explosion. It will be necessary
to prohibit coming in the polluted zone.
To prevent clothes fire, use cotton clothes (no synthetic tissues or wool because of the electrostatic
phenomenon and rapid burning with sticking to the skin...). After a stay in oxygen enriched atmosphere or after
be sprayed with liquid oxygen, it's absolutely necessary to take a shower to prevent electrostatic sparks
(synthetic tissues or wool...) and to remove all polluted clothes far away from any heat source (people smoking
for example...).
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Never use the word «air» when referring to «oxygen»

Fatal mistake have occurred when people who were accustomed to
the use of the term «air» when referring to «oxygen» were given
oxygen when air was required for ventilation.
5 OTHER HAZARDS LINKED TO AN ASU OPERATION
5.1 Noise
Several equipments in the plant are noisy. These equipments are typically all the rotating machines (compressors,
pumps, fans…) but also vents during start-up and shut down. Even if the installation is design to limit the noise
impact to regulatory levels, the noise should be taken into consideration during operation.
Noise causes damage which most people are unaware of since it occurs little by little over many years.
This type of damage is irreversible since noise destroys the inner hair cells in the ear. This damage is irreparable
since the cells are dead.
Repeated exposure to noise can result in serious deafness
Working with noise can also cause other problems which are every bit as serious (20% more fatigue is enormous!).
These other problems can lead to accidents.
The easiest and most effective solution is to have the person who is exposed to noise wear hearing protection. In
fact, it is difficult and even impossible to eliminate noise from our facilities, even if we try to decrease the noise level.
Hearing protection, even bottom of the line devices, can easily decrease noise levels by 15 decibels.
Noise is dangerous as soon as it reaches 80 decibels. Air Liquide suggests that employees wear hearing protection
as soon as noise levels reach 80 decibels and that such protection should be obligatory as of 90 decibels.
5.2 Gas Cylinders handling

Different types of gas cylinders are used in an ASU mainly for gas sampling and calibration of analysers. In addition
to the hazard of the gas itself, several safety rules shall be followed with gas cylinders.
Gas cylinders must be:
• Secured in upright position. They must never be stored laying down!
• Stored outdoors and segregated (combustible, oxidizing, neutral and toxic) to avoid any grouping of
incompatible gases together.
• Stored away for hot sources and flames.
• Returned empty with the valve closed and the cap secured.
• Filled only by a certified Air Liquide supplier.
• Transported only in a specially fitted and ventilated vehicles.
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In addition:
• The local regulation concerning the quantity stored shall be strictly followed.
• Clearly identify the gases (label or tags with composition).
• Never tamper with connectors and distribution networks.
6 RESTRICTIVE AREA
Several areas in the plant should be considered as restricted areas. The restricted areas are
not limited to the confined spaces but also to some other dangerous and hazardous area
spaces, (often open spaces) because of the significant risks (explosion, burns,
asphyxiation…) involved in this area.
These areas are:
• Electrical room (Does not exist)
• Instrumentation Cabinets (known as “modins»)
• Compressor’s air filter
• Oxygen blockhouses and compressor houses (Does not exist)
• Cold box and cold box casings
• Storage tanks retention pits
Electrical room
Due to the electrical hazard, the access to the electrical room shall be restricted to competent electrical
personnel trained to electrical hazard. Authorization merely proves that the person has been given specific
training in the hazards of electricity, in the procedure to be followed based on his level of authorization, and in
the measures to be taken in case of accident.
Such authorization comes from the employer. Authorization is required for any work on electrical facilities.
There are different levels of authorization, based on the hazards present and work performed.
Instrumentation cabinets
Due to the electrical hazard the access to the electrical room shall be restricted to competent electrical
personnel. In addition, some Instrumentation cabinets contain gas analyzers. The atmosphere control and alarm
system should be strictly checked before access to an Instrumentation cabinet. Access should be strictly
forbidden while the red flashing beacon is on.
Air filter house
Due to the hot air and blast hazard in case of surging of the air compressor, the access to the air filter house
shall be locked and strictly forbidden during running of the air compressor. Any maintenance in the Air filter
house shall be preceded by a work permit procedure.
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Oxygen blockhouse and compressor houses
Due to the explosion hazard in the oxygen blockhouse and compressor houses, the access to the blockhouse
and compressor house be locked and strictly forbidden during operation of the oxygen piping or equipment. Any
maintenance in the Air filter house shall be preceded by a work permit procedure.
Cold Boxes and cold box casings
The Cold boxes and casings contain the equipment needed to separate gases. Due to the cold temperature, the
nitrogen, the perlite and the rockwool hazard in the cold box and the associated casings, the access to cold
boxes and casing shall be strictly forbidden during operation of the ASU.
Confined Space permits shall be put in place before any operation. Cold boxes are constantly ventilated with
nitrogen and to enter them in operation means death.
Three precautions must be taken before any work is done on a cold box to eliminate any possibility of
asphyxiation:
• The nitrogen supply must be locked out and tagged out,
• The oxygen level in the cold box or the adjacent casings must be measured on an ongoing basis,
• If necessary, the area must be ventilated with fresh air.
Some cold boxes are insulated with rock wool and others are insulated with perlite. The perlite-insulated cold
boxes are very dangerous because perlite is so fluid that someone falling into it can drown.
It is mandatory to take specific precautions when filling or emptying cold boxes containing perlite:
• A co-worker must be present at all times to supervise the work from outside the hazard zone,
• Oxygen levels must be measured,
• A harness must be worn,
• A dust mask must be worn.
• Wrap-around goggles and gloves must be worn.
WARNING: perlite is very abrasive and is irritating to the eyes and respiratory membranes.
Storage Tank Retention Pits
Access to the storage retention pits shall be strictly forbidden during operation of the LOX, LIN and LAR storages
tanks.
Spillage or purging of liquefied gas in the pit can be hazardous: cryogenic fog can form when systems are
vented, in the event of leaks, or when there are high concentrations in the atmosphere.
Cryogenic fog can hide several hazards:
• First, as in the case of any fog, you can't see objects which might cause falls or blows if you bump into them,
• Second, puddles of cryogenic liquids can cause serious burns to the feet. As they warm up, these puddles
form black ice which can cause slips and falls.
• Finally, when there is a large concentration of the gas in the air, you will encounter the hazards specific to
the gas: an oxygen-rich atmosphere in the case of oxygen, lack of oxygen in the case of nitrogen, etc.
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7 SAFETY DATA BASE
7.1 Summary liquid knowledge

Precautions for Actions in case of
Product Characteristics Hazards
handling accident
• Dew point at Combustion DANGER >24%O2 Same as for GOX plus :
Liquid atmospheric press.
• Accelerate vigorously Same as for GOX plus : In case of skin frostbite
Oxygen • 183°C
any combustion. • Use of adequate gloves, • Water the frost-bitten
(O2) • Density/water of LOX:
1,1(spread aground) • Any contact with goggles, safety shoes. part for more than 15mn
LOX Color of LOX :blue combustible (oil, • Don’t stay in cold • Don’t undress.
light grease) may induce an atmosphere. • Don’t touch the frost-
• 1 liter of LOX explosion.
• Don’t walk in cryogenic bitten part.
vaporises into about Frostbite fog.
800 litters of GOX • Call for medical
• Similar to burn. Gravity • Don’t purge LOX on assistance
of frostbite are often ground made with
undervalued. combustible material (i.e.
Fall macadam).
• Due to fog resulting of • Make sure of safety
LOX leakage or vent. release valve presence
Explosion on capacity (vessel, pipe)
where liquid may be
• Due to vaporisation of enclosed.
enclosed liquid
• Dew point at Breathing DANGER <18%O2 Same as for GAN plus :

Liquid atmospheric press. • Asphyxiation Same as for GAN plus : In case of skin frostbite
Nitrogen
(N2) • 196°C Frostbite • Use of adequate gloves, • Water the frost-bitten
• Density/water of LIN: • Similar to burn. Gravity goggles, safety shoes. part for more than 15
LIN 0,8 (spread aground) of frostbite are often • Don’t stay in cold mn
Colorless undervalued. atmosphere. • Don’t undress.
• 1 liter of LIN vaporises Fall • Don’t walk in cryogenic • Don’t touch the frost-
into about 650 litters • Due to fog resulting of fog. bitten part.
of GAN LOX leakage or vent. • Make sure of safety • Call for medical
Explosion release valve presence assistance
• Due to vaporisation of on capacity (vessel, pipe
enclosed liquid ) where liquid may be
enclosed.
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7.2 Summary gases knowledge

Actions in case of
GASES Characteristics Hazards Precautions for handling
accident
Oxygen • Prevention of leakage. Alert.
Oxidizing gas. Combustion
(O2) • Protect. Don’t become
• Analyse of atmosphere
• From 25 % O2 in air, the second victim.
GOX • Support and • accelerated combustion • DANGER>24% O2 • Watering in case of fire
accelerate • From 30 % vigorous • Avoid work in over- is the more efficient
combustion. combustion enriched atmosphere. mean.
• From 50 % • First aid to burnt
• Procedure, work
• Density/air at ambient instantaneous person:
permit, fire permit.
temperature: 1,1 combustion, explosion. • Remove the victim
• Training of personnel. outside the hazardous
• Colourless Breathing
• Use clean clothes, no area
• Tasteless • Possible cramps, grease nor oil, anti • Water the burnt part for
• Odourless nausea, dizzies...when spark tools, equipment more than 15mn
breathing a mixture with must be for «oxygen • Don’t undress.
more than 75 % O2. use». • Call for medical
• Watering systems assistance
immediately available.
Nitrogen • Inert gas. Breathing • Prevention of leakage. • Alert
(N2) • Asphyxiation • Analyse of atmosphere: • Remove the victim
• Does not support life DANGER< 18% O2 outside the hazardous
GAN • Density / air at (leave the place) area (rescuer equipped
ambient temperature: • Procedure, work permit with self contained
0,97 • Training. breathing apparatus).
• Colourless • Equipment for
• Apply resuscitation
resuscitation available.
• Tasteless methods.
• Self contained
• Odourless breathing apparatus • Call for medical
available. assistance.
Instrument • Inert gas. Breathing • Prevention of leakage. • Alert
Gas • Asphyxiation • Analyze of atmosphere: • Remove the victim
(Air/N2) • Does not support life DANGER< 18% O2 outside the hazardous
• Density / air at (leave the place) area (rescuer equipped
IG ambient temperature: • Procedure, work permit with self contained
1/ 0,97 • Training. breathing apparatus).
• Colourless • Equipment for
• Apply resuscitation
• Tasteless resuscitation available.
methods.
• Self contained
• Odourless breathing apparatus • Call for medical
available. assistance.
7.3 Fire extinguishing methods and devices

Fire extinguishers shall be available in different locations of the plant. They should be easily reachable at all time
without obstructing the walkways and access. They will be maintained with full load according to local regulation.
Extinguishers shall be recharged or replaced immediately after use.
In addition fire hose and hydrants shall be maintained in good working condition and periodically controlled
according to local regulation. In service hose shall be inspected and service tested at least annually. Testing
shall include the followings:
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• Acceptance (proof) hydrotesting
• Visual examination for the following:
• Cuts at band clamps
• Coupling slippage or noticeable wear
• Loose cover
• Bulges on soft spot
• Weathering
• Kinking
• Physical damage to end connections.
Extinguishing
Kinds Products Methods Remarks
devices
Wood, Coal Cooling Water stream or spray
Solids Fires Plants Smothering With or without additive
Inhibition Powder "ABC"
Papers, Tissues, Plastics
Smothering Proof liquids , Foam
Particularly flammable liquids: In case of flowing:
Inhibition Powder
Liquefiable Carbon sulfur, Methylene oxide, - close valves
Smothering Carbon dioxide
Ethylene, Propane. -dam with sand or earth
Methanol, Ethanol, Propane Powder
Solids Flammable water mixable liquids Inhibition Carbon dioxide
for example Ether. Smothering Anti-alcohol, Foam
Flammable liquids : Gasoline for Inhibition Powder, Carbon dioxide
Liquids
cars, planes, etc... Smothering Foam, Water
Heavier flammable liquids Cooling Sprayed water without additive
Fires Gas oil, Fuel oil, Inhibition Foam powder
Crude oil Smothering Carbon dioxide
Flammable liquids with boiling Sprayed water with or without
point over 100C Cooling additive
Oils, asphalt, bitumen Inhibition Foam powder
liquefiable solids grease Smothering Carbon dioxide
Paraffins
Methane, Ethane Stop the flow If not possible, leave it
Gas fires Propane, Acetylene Powder burning and protect
Hydrogen etc …. Inhibition Carbon dioxide other equipment
Aluminium Smothering Special powder
Metal fires Magnesium Inhibition Special liquid, dry sand graphite.
Sodium, potassium.... Heavy oil.
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8 MANUFACTURER SAFETY DATA SHEETS OF CHEMICAL PRODUCTS AND

SUBSTANCES IN USE IN AN ASU
The risk due to chemical products and substances shall always be taken into consideration for the risk
evaluation before maintenance operation or handling of these products.
It is recommended to read carefully the MSDS (Manufacturer Safety Data Sheet), the instructions note and tags
of all products before any operation.
The most common risks involved by these products can be either:
• Intoxication
• Hot or cold Burns
• Skin or eyes rash
• Respiratory infections
• Skin or respiratory allergies
• Cancers
In addition some of those products can as well cause fires and explosions.
The products involved in an ASU shall be divided in two categories:
• Product used within the installation
• Products produced by the ASU
8.1 Products used within the installation

These products are mainly the following ones. You will find attached the corresponding MSDS (Manufacturer
Safety Data Sheet). It is the responsibility of the Operating Management to keep those MSDS up-dated.
• Rockwool for casing insulation,
• Rockwool for piping insulation,
• Perlite for Cold Box insulation,
• Foamglass for piping and tanks insulation,
• Molecular sieve for dessication bottles,
• Alumina for dessication bottles,
• Lubrification oil for compressors,
• Frigorific fluid for Frigorific Group,
• Chemical treatment products for Water treatment,
8.2 Products produced by the ASU

These products are the result of the operation of the plant.
• Compressed air
• Air (refrigerated)
• Nitrogen
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• Nitrogen ( refrigerated )
• Oxygen
• Oxygen ( refrigerated )
The MSDS gives all the information regarding the product and hazard, emergency, handling and storage,
exposure control and personal protection ecological ,disposal and transportation considerations.
8.3 How to interpret MSDS information sheets

The following provides some guidance on the interpretation of MSDS. These sheets may at first seem
complicated and difficult to understand, but they are a reliable source of the data you need to handle chemicals
safely.
Here above the explanation of the different sections into which MSDS are generally divided, using portions of a
sheet provided by a commercial supplier.
1 Identification of substance
Section 1 gives details of the company issuing the data sheet....
.... and, often, emergency call-out information.
2 Composition / Data on components

The second section identifies the material, and gives the CAS and other registry numbers.
3 Hazards identification
The third section summarizes the major hazards associated with use of the chemical. The R and S codes in this
section are followed by explanatory text.
4 First aid measures

The fourth section outlines first aid measures
5 Fire fighting measures

Section 5 covers fire fighting and protective equipment.
6 Accidental release measures

Section 6 outlines the procedures to be followed in case of accidental release of the chemical, including
methods to be used to clean up spills. Note that these measures are unlikely to be sufficiently detailed if the
chemical is particularly hazardous, and local procedures should be drawn up to supplement what is given in the
MSDS.
7 Handling and storage

Section 7 is self-explanatory. This is an important section, sometimes overlooked by those using chemicals in
the laboratory. It contains information about the possible formation of peroxides in storage, flammability,
explosive risks, etc. Pay particular attention to the possible need for flammable storage cabinets, explosion-
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proof fridges, and also the need to avoid storage near incompatible chemicals.
8 Exposure controls and personal protection

Section 8 provides information on regulatory standards for exposure; in other words, the maximum permitted
concentration of the material in the environment to which you are allowed to be exposed. It also usually contains
information on suitable types of PPE (personal protective equipment)
9 Physical and chemical properties:

Section 9 is self-explanatory.
10 Stability and reactivity

The next section is also largely self-explanatory.
11 Toxicological information
Section 11 outlines the risks to which you may be exposed when using the chemical. It is therefore a section of
crucial importance!
The acute toxicity gives an indication of the kind of quantities of the chemical, which may cause immediate
damage to health if swallowed, inhaled or absorbed through the skin.
There follows a section, which gives, often in some detail, an indication of the health effects, which may be
attributable to this chemical. This section should be read particularly carefully, since the range of health effects
may be broad, and may include carcinogenic or sensitizer effects.
Chemical sensitisation, for example by platinum compounds, is a potentially debilitating problem. Pay particular
attention to any information, which may suggest that the chemical is a sensitiser.
Here we find details of the possible long-term effects of exposure to the chemical.
For this chemical there now follow important comments regarding the carcinogenicity. The acronyms such as
IARC refer to regulatory or health agencies.
12 Ecological information
Section 12 is largely self-explanatory
13 Disposal considerations
Section 13, which deals with disposal, is often not sufficiently detailed for you to be able to undertake disposal
yourself. If you need to dispose of the chemical after use, ensure that you know how to do this safely.
14 Transport information
Section 14 gives transport information, generally as a list of codes indicating the dangers associated with the
chemical (flammable, radioactive, very toxic, etc) and the type of transport, which may be used. There are
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usually UN hazard codes given in this section.
15 Regulations
Section 15 lists the hazard codes, which indicate the principle hazards, associated with the chemical and the
precautions, which should be taken when working with it.
16 Other information
Finally, a section of an additional information, such as the name of the person preparing the data sheet, a list of
references from which data have been drawn, disclaimers, etc.
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SAFETY RULES
CASING – CONFINED SPACE
Risks :
• Inflammation
• Burns by projection, burns by fire
• Oxygen enriched atmosphere
• Oxygen deficient atmosphere, asphyxiation, anoxia
• Dust or burying in mineral wool or perlite
Measures to respect:
ACCESS FORBIDDEN TO NON-AUTORISED PERSONNEL
• No open flame
• Wear clean clothes and gloves without grease and oil
• Use degreasing and lubricating agents approved for oxygen service
• For intervention :
WORK PERMIT and CONFINED SPACE PERMIT

MANDATORY IN CASE OF INTERVENTION
Wear adapted Personnel Protective Equipment ( gloves, goggles, masks, overall… )

Lock out nitrogen ventilation inlet
Lock out fluids circulation, purge lines when possible
Lock out electrical and control supplies
Open all manholes
Ventilate abundantly the casing
Analyse atmosphere quality before entrance
Control permanently oxygen rate during intervention
Plan emergency rescue organisation in case of accident
Insure permanent watch of the intervention
• In case of accident :
Implement rescue means ( extinguishers, breathing apparatus, …)
Bring back the victim to safe area
Alert emergency services
Additional Measures :
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DANGER OF ASPHYXIATION
DANGER OXYGENE
DANGER
CONFINED SPACE
DANGER OF COLD
DANGER OF IRRITATION
NO OPEN FLAME
ACCESS FORBIDDEN
WHITOUT AUTORISATION
WORK PERMIT AND LOCK OUT

MANDATORY PRIOR ENTRANCE
DISCLAIMER : These Safety Rules are not exhaustive and can not be substituted to specialities specific procedures and
local applicable regulation.
In case of further information or question, please contact Air Liquide Engineering.
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OPERATING MANUAL – VOLUME A – SECTION A-02 – PERSONAL SAFETY
8.4 Summary of the risks involved in the different areas
Liquid oxygen
Liquid oxygen
Cooling water
Compressors
Liquid argon
storage tank
storage tank
storage tank
vaporization
vaporization
water tower
Absorbers
treatment
Electrical
Air water
Cold box
Nitrogen
nitrogen
nitrogen
system
system
Heater
Drains
/argon
Liquid
Liquid
Water
tower
tower
room
PROHIBITIONS OBLIGATIONS
access under storages portable analyzer
blockhouses
Asphyxiation X X X X X X X X X X X X zones marked out by chains
ARI if needed
red & white
oil portable analyzer
greasy substances fire permit
Oxidizing X X X X X X X smoke ventilation of clothing after
open flame work
smoke portable analyzer
open flame fire permit
Explosion X X X X X cell phone & Walky Talkies clothing in Nomexdes
after work
smoke portable analyzer

Flammable X X X X X open flame fire permit
clean work clothes

Toxic & Irritant X X X X X X entry to unauthorized person face protection
gloves
clean work clothes
safety mask
Cryogenic burn X X X X X X X X X gloves
Temperature prtotection of hot parts

burn X X X X X X X X X gloves
Protection of revolving
Revolving
machines X X X X X parts
gloves
periodical inspection of
Pressure X X X X X X X X X X the material
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OPERATING MANUAL – VOLUME A – SECTION A-02 – PERSONAL SAFETY
Liquid oxygen
Liquid oxygen
Cooling water
Compressors
Liquid argon
storage tank
storage tank
storage tank
vaporization
vaporization
water tower
Absorbers
treatment
Electrical
Air water
Cold box
Nitrogen
nitrogen
nitrogen
system
system
Heater
Drains
/argon
Liquid
Liquid
Water
tower
tower
room
PROHIBITIONS OBLIGATIONS
working permit,
Electricity X X X X X X X X according to the type of
intervention
cleaning of the ground

Slipping ground X X X X X X X X X X salting of icy parts
Drowning X X X X paid attention
Noise X X X X ear protection
E-TPL-10-10-3, Rev. C
REFINERIA TALARA
NIS-Z-001 57506-60-01-PR-019A022
Air Liquide
Operating Manual - Process Safety
06/08/2019 00
Doc No.
57506-60-01-PR-019A022
OPERATING MANUAL Rev 0
Page 1 of 24
OPERATING MANUAL - VOLUME A – SECTION A-02 – SAFETY

PROCESS SAFETY
COVER PAGE


Table of Revisions
Section Description
DISCLAIMER
The information contained in this document has been prepared by L’Air Liquide S.A. and/or its controlled subsidiaries (“Air Liquide”), exclusively for their use, and is Air Liquide property. Air
Liquide believes the information is current and accurate, but circumstances may warrant additional requirements or procedures. This document is subject to periodic review and users are
cautioned to obtain the latest edition.
Air Liquide makes no representations or warranties to third parties as to the quality, accuracy or completeness of information contained in this document and EXPRESSLY DISCLAIMS ALL
WARRANTIES, INCLUDING, BUT NOT LIMITED TO, THE WARRANTY OF MERCHANTABILITY AND THE WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE.
No part of this document may be copied or otherwise shown or disclosed to third parties without the prior consent of Air Liquide.
Unauthorized use of this document by any third Party, including Air Liquide contractors and subcontractors, shall be at such Party’s own risk, and Air Liquide assumes no liability in connection
with information contained herein. Air Liquide disclaims any liability for any damage suffered by any company or person as a result of or in connection with the use, application or implementation
of the information contained herein or any part thereof. The benefit of this disclaimer shall inure to Air Liquide and its affiliates.
This document should not be confused with federal, state, provincial, or municipal specifications or regulations, insurance requirements or national safety codes.

Paper copies of this document are considered to be “uncontrolled” and users should always check for the most recent revision.
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PROCESS SAFETY
TABLE OF CONTENTS
1 INTRODUCTION 3
2 AIR SOURCE 3
3 AIR COMPRESSOR 4
4 AIR PRECOOLING 8
5 PURIFICATION UNIT 8
6 MAIN HEAT EXCHANGER 10
7 COLD POWER- LIQUID ASSIST ERROR! BOOKMARK NOT DEFINED.
8 DISTILLATION COLUMN 14
9 DECONCENTRATION PURGE 17
10 CONTAMINANT ANALYSIS 17
11 OXYGEN PURITY 18
12 DEAD ENDS 19
13 GASEOUS OXYGEN PIPING AND COMPRESSORS 19
14 STORAGE TANKS 21
15 VAPORIZATION SYSTEM 23
16 IMPORTANT ELEMENT FOR SAFETY 24
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PROCESS SAFETY
1 INTRODUCTION
The present section aims to inform the operation teams about main hazards inherent to typical process equipments
of an Air Separation Unit, on how such hazards are typically taken into account at design phase and on additional
measures that should be taken by the operation team during work or operation to ensure the safe operation of the
concerned equipments.
This section does not deal either with usual industrial hazards related to fluids characteristics or the physical
parameters such as pressure, temperature or flow, nor with the risks for the operators to work in usual industrial
area environment. The section “Personnel Safety” of this operating manual provides information on these subjects.
The mentioned hazards are based on AIR LIQUIDE knowledge at the date of issuance of this operating manual.
Therefore the scenarios considered here after are not exhaustive.
It is of utmost importance that the equipment be operated according to descriptions and instructions given in other
sections of this operating manual and in the documentation of equipment suppliers. Furthermore, a detailed risk
analysis should be undertaken by the operation teams before performing any work or operation on any equipment or
part of the facility in order to assess all the risks the intervening people are likely to face during the performance of
such a particular work or operation.
2 AIR SOURCE
A major hazard for Air separation unit is the introduction in the equipment, particularly in the distillation column, of an
abnormally high amount of contaminants.The introduction of large quantities of hydrocarbons and other
contaminants into the plant always represents a risk, regardless of the protection devices implemented in the design
and operation.
For this reason, it is necessary to detect when such a condition arises.
The air is supplied to the Air Separation unit through one (or several) compressor which takes the air from the local
area. It is therefore essential to maintain a good awareness of the current environment surrounding the plant.
Information and events to aware of should include:
• A list of nearby plant complexes liable to release significant quantities of contaminants (for example:
ammonia, chlorine, H2, CO, hydrocarbons, ...) into the air during normal operation, or in the case of mal-
operation or accident
• the distance between these potential sources and the air separation plant air intake, as well as their
relative heights
• the local atmospheric condition (the instantaneous wind direction and speed should be made available in
the control room)
• the presence in air of haze (suspension in the atmosphere of particle matters, including aerosols, in
sufficient concentration to cause visible consequences such as light attenuation, visual range reduction,
or giving the sky an appearance of opalescence )
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PROCESS SAFETY
3 AIR COMPRESSOR
3.1 Particles stoppage at the compressor suction
3.1.1 Dust stoppage

The filtering system at the suction of the feed air compressor is designed according to the existing local situation and
particularly the amount and kind of particles present in ambient air.
This filtering system must be kept in good conditions to prevent dust from entering the unit since dust passing
through the machine could lead to damages to the wheels of the rotor and to foul the inter-stages coolers and to
plug the after coolers drains.
Additional specific filtrations may be required in case of the presence of particular contaminants ( Acid vapor, Haze)
The pressure difference measured at this filtering system is a good indication of the fouling condition.
In case modification are performed on this filtering system one should make sure that no gap between the filters and
the supporting structure or filter casing creates by pass of the filters.
3.1.2 Haze stoppage

Haze which currently results form fires of vegetation (e.g.; forest, bushes) can be more or less rich in organic
compounds that are potentially dangerous for ASU. The particles composing the haze are extremely small ((less
than 1µm) and therefore not stopped by typical dust filters. As a result they can concentrate in locations of the
distillation columns and form with oxygen flammable mixtures.
Normal atmosphere contains up to 50 µg/m3 of aerosols. A haze with 125 µg/m3 is already considered as very
unusual (1 day per year or less in most areas). As a rule of thumb, a haze containing 250 µg/m3 of particles would
result in a visibility of less than 50 meters.
Air containing more than 125 µg/m3 of organic aerosols shall be considered as polluted.
Haze can be more or less rich in organic compounds that are potentially dangerous for ASU. It is difficult to
determine the proportion of organic compounds in haze, therefore unless it can be demonstrated otherwise,
haze shall be considered as containing 100% organic compounds.
For location where Haze formation is likely to occur, dedicated filtration may be required based on area historical
data on haze likelihood. The following procedure describes the “subject to haze risk” classification of an ASU and
the instructions to control the risk:
3.1.2.1 Haze risk assessment

The holder of the ASU shall assess whether it is located in an area subject to haze pollution risk, by checking this
with the nearest weather station. There may be other sources of information in regions where haze pollution is
relatively frequent and these shall be used as required.
The result of such assessment is the classification of the unit as “subject to haze risk” or as “not subject to haze
risk”.
A review of local history of haze events at least for the past 4 years (or more if data available) shall be performed.
Such study shall be done based on the mass balance of the organic compounds in haze, estimated from
data published or given by weather stations or other sources of information. Data shall permit to estimate
the duration and the level of haze events:
o Pollution level (µg/Nm3): average concentration in organic based haze (organic compounds)
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o Duration of haze based on historical haze events

If haze data is not available, the study shall be done by researching past events recorded by local
authorities related to haze with potential organic compounds (forest fires, but also by oil well fires, dump
site fire, field burning, war zone fires…) and which have affected the visibility for duration of 1-day time. In
case data or event records are not available, the assumption shall be that no haze event has occurred.
An ASU shall be preventively qualified as “subject to haze risk”, if it is not equipped with an HEPA filter with
characteristics defined in Annex 1 and if the region1 of the facility has experienced in the past 4 years (or more if
data available) pollution of air by haze up to 125 µg/m3 for more than 1 day. If the concentration data is not
recorded, every event for which the visibility has been significantly affected for duration of 1-day time shall be taken
into account.
3.1.2.2 Instructions for ASU “not subject to haze risk”

Every 3 years, each ASU “not subject to haze risk” shall be assessed, to determine if the ASU shall be reclassified
or not as “subject to haze risk”
In case of haze events, as per criteria in §3.1.2.1:
All instructions described for ASU “subject of haze risk” in §3.1.2.3 will be applied,
The ASU is automatically reclassified as “subject to haze risk”.
3.1.2.3 Instructions for ASU “subject to haze risk”

A - Filtration
The efficiency of the existing filtration upstream the air compressor(s), including sub-micron particles (% of sub-
micron particles stopped by the filter), given by the technical documentation of the supplier shall be verified, and
compare it to the classical filtration criteria described in Annex 1.
If the existing filtration is less efficient than the classical filtration, the installation of a classical filtration shall be
evaluated with the Design Authority.
B - Monitoring the air filter operation
Monitor the pressure drop of the air filter and store the historical trend between two successive filter changes. The
information is relevant as an indicator of haze event and/or of its significance.
C - Haze level monitoring
The facility shall be organized to obtain the information, upon demand, on the mass concentration of organic
aerosols in air. Source of information on haze level can be:
Direct measurement in air by the facility or by a local laboratory. The measurement can be done by the
beta-attenuation method.
Local air quality information delivered by local authorities, by the local weather services, or by other
sources.
The Facility Manager shall verify the availability of such information.
D - Equivalent Cumulated Duration of Operation under haze conditions
1 The investigation shall take into account the area or the region of the ASU, typically 50-100 km radius, but also the wind
direction and the geographical configuration that could increase the radius
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From collected data, the Equivalent Cumulated Duration of Operation under haze conditions in days (DH) shall be
calculated, yearly as a minimum and after each haze event, with the following formula:
DH = ∑ Di x Ci
Where:
Di is the duration of each recorded haze event (i.e. > 125 µg/Nm3). Days (Di) may need to be split in, half-
days or hours if there are significant changes in pollution level during the period.
Ci is the “accumulation coefficient” based on the level of pollution during each recorded event determined
with respect to air pollution given by the following table.
Average pollution level < 125 µg/m3 125 – 249 µg/m3 > 250 µg/m3
Accumulation coefficient (Ci) 0 0.5 1
Such DH2 indicator allows estimating the equivalent number of days when organic compounds have entered an ASU
at the compressor intake in quantities higher than 250 µg/m3 of organic aerosols.
If a HEPA filter with characteristics defined in Annex 1 is installed, Ci=0 regardless the pollution level
E - Maximum allowable duration of operation under haze conditions
The Maximum Allowable Equivalent Cumulated Duration of Operation under haze conditions (DHmax) is 90
days .3
Such maximum durations are given for the entire life of the unit4 or since the last organic removal by solvent wash. If
a HEPA filtration has been installed and designed with filtration class as per Annex 1, there are no restrictions for
operation.
F - Actions in case of haze events
In case of haze in the geographical area of the facility (even if not reaching the ASU), personnel must anticipate and
be prepared to execute the related SOPs describing the following actions:
Obtain information on the haze (origin, type);
If possible, determine the content of organic compounds in the haze. If not possible, it shall be considered
as containing 100% organic compound (as per §3.1.2);
If possible, obtain from the local weather services the estimated duration of the haze;
Check wind direction and climatic conditions.
2 Such indicator shall include all historical events from start-up of the ASU (or from the last organic compounds removal by
solvent wash). In case of historical pollution events by haze, the equivalent pollution shall be estimated in terms of duration and
pollution level.
3 Tests have shown that aerosols present in the liquid oxygen bath of a bath vaporizer that is correctly submerged have little
chance of reaching the vaporized phase; they deposit on all wetted surfaces.
4 Deriming is not efficient. Contrary to classical impurities (H2O, CO2, hydrocarbons below C4) that are volatile enough to be
totally eliminated by the periodical derime of the unit, hydrocarbon aerosols are heavy components and stay where they were
trapped.
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If, by judgement based on the above information on the haze in the geographical area or from the possible analysis
of the haze at the ASU site, the haze is considered to reach a significant pollution level (> 125 µg/m3) at the air inlet
of the ASU, the following actions shall be performed:
Reduce air flow to the minimum;
If possible, shutdown preventively the ASU instead of running the plant in haze conditions (for examples:
shutdown the liquid producing ASU, shutdown the ASU part of pipeline system that could be backed-up
by other ASUs not concerned by the event);
Increment the DH indicator defined in §3.1.2.3.D
If the DH indicator (Equivalent Cumulated Duration of Operation under haze conditions) has reached the
DHmax value given in §3.1.2.3.E, operation shall be discontinued until HEPA filters are installed or until
the unit is solvent-washed.
ANY MODIFICATION ON THE FILTRATION SYSTEM MUST BE SUBMITTED TO THE DESIGN AUTORITHY
APPROVAL
G - Organic compounds removal by solvent wash

Solvent wash is an exceptional and critical operation used to remove organic compound. Due to the related safety
concerns, the solvent shall be chosen and procedure shall be prepared and implemented with the approval and the
supervision of the Air Liquide Engineering division and the Design Authority involved in the cold box process design
(if different).
Following a thorough organic compound removal by solvent wash, the Equivalent Cumulated Duration of Operation
under haze conditions is reset to zero.
A solvent wash shall only be used to allow the subsidiary to operate the ASU until HEPA filtration can be installed.
A presence of haze in ambient air will be visually detected (e.g.; light attenuation, visual range reduction, sky with an
appearance of opalescence). If such a presence is detected while the plant is in operation and if a dedicated filter is
not installed, Air Liquide Engineering must be contacted for delivery of adequate recommendation.
3.2 Contamination that may occur from the machine

Regardless of the contamination level of the area surrounding the plant:
• no additive should be present in the water used in line rotor cleaning system when such a system is
recommended by the machine supplier.
• the absence of leakages form the inter-stage coolers must be periodically checked to order to avoid the
contamination of air by treated water which could induce damages ( corrosion, deposits) to the rotor and
the downstream pipes and equipment.
3.3 Removal of condensed water

Checking of the proper operation of the drainers
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• To avoid damages to the rotor and bad general operation ( surging)

• To avoid sending large amount of liquid water downstream in the process
4 AIR PRECOOLING
Not applicable for this project
5 PURIFICATION UNIT
5.1 Example of arrangement

Heater
Air to
Waste Nitrogen OFF
Cold Box
V5 V6
V3 V4
V11
R01 R02
high pressure in service
isolation
Air Event
V7 V8
V9 V10
V1 V2
Air
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5.2 Important parameters for Process Safety
5.2.1 CO2 content in the air stream to the cold box

By measuring the CO2 content at the outlet of the adsorber vessels the proper operation of the front-end purification
is verified.
Complete retention of CO2 at the front-end purification is of vital importance for the unit, for CO2 having a solubility of
only 4.5 ppm in liquid oxygen at -181°C it immediately forms deposits and may clog very rapidly the main exchanger
and the vaporizer.
• Quality of the adsorption
A good adsorption of the contaminants is achieved when the following parameters comply with the
design:
- quality of adsorbent beds: alumina and molecular sieve. Only material approved by Air Liquide
should be used
- the air flow : the adsorption capacity of the alumina and molecular sieve is based on the maximum
design air flow.
- The air pressure: this pressure is normally set by the process control.
- the air inlet temperature: the inlet temperature set the water content in the air entering the
purification unit since the water is saturated. The inlet temperature should not exceed the design
temperature to prevent exceeding the capacity of the alumina to adsorb water which would result in
polluting the molecular sieve with water.
- Duration of the adsorbtion phase
• Quality of the reactivation of the adsorbents
A good reactivation of the adsorbents is achieved when the following parameters comply with the design:
- regeneration flow
- heating temperature
- duration of the heating phase
Temperature
Heating
temperature
Inlet
Temperature
Outlet
Cold Hot Temperature
desorption desorption
Heat Peak
Regeneration
gas
temperature
Tim
Heating Cooling e
The observance of a “heat peak” (see outlet temperature curve here above) means that the
desorption has been properly completed.
Accidental presence of water in the molecular sieve reduces the CO2 adsorption capacity of the
sieve; In some cases, molecular sieve CO2 adsorption capacity may be recovered by an
"exceptional regeneration" at high temperature (over 250°C), performed according a specific
procedure.
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Exceptional procedure requires stopping the plant for several days.

• Particular Hazard during maintenance
One should keep in mind that any maintenance performed inside a vessel filled with any adsorbant, or
any operation of replacement of adsorbent may expose the intervening personnel to breathe or be in
contact with hazardous products that may be naturally desorbed from the adsorbents. Personnel may
face to immediate risk of being asphyxiated or intoxicated.
• Protection means supplied at design:
- measurement of regeneration flow with alarm and blocking of the heating phase timer in case of low
regeneration flow
- measurement of heating temperature with alarm and blocking of the heating phase timer in case of
low heating temperature
- no switch to cooling phase before the completion of design heating time through control command
system programming
• Preventive action to be performed during operation:
- periodical checks of the proper operation of concerned loops ( calibration of instruments)
- Frequent check on corresponding trends
- Implementation of adequate operating procedure in case of activation of the step by step operation
- Implementation of work permit procedure and pre-entry permit for any work perform close to or in
contact with adsorbent material. The recommendation of the dedicated Material Safety Data Sheets
(supplied by the manufacturer) will be taken into account for this purpose.
5.2.2 Temperature of air at the outlet of the FEP
The temperature at the outlet of the front air purification should remain below a maximum temperature (typically
65°C) in order to avoid altering the mechanical properties of the aluminum alloys or producing excessive thermal
stress on the main exchanger of the cold box is avoided. That is why one should make sure that the cooling phase
of the FEP sequence is completed before the switching of bottles. During normal operation, the programming of the
supplied control command system take this condition into account. It may occur that a step by step manual operation
of the FEP be required. This is a situation when the risk of mistake is high.
The potential consequences of a too high temperature at the outlet of the FEP are:
- upset of the distillation column due to excessive heat entered into the cold box
- damage to the main exchanger due to excessive mechanical/thermal on welds and structures.
• Protection means supplied at design:

- Temperature measurement with alarm set point and trip set point. To exceed the trip set point leads
to automatically shut down the Air Separation Unit
• Preventive action to be performed during operation:
- Periodical verification of the proper operation of the loop and the interlock
- Frequent checks of the temperature trend
- Implementation of adequate operating procedure in case of activation of the step by step operation
6 MAIN HEAT EXCHANGER
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6.1 Arrangement
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6.2 Air Feed temperature
As explain in Purification Unit section, too high air inlet temperature, resulting of an improper operation of the
FEP could lead to damage the main exchanger. A temperature measurement is supplied on this line in order to
prevent such damages.
Protection supplied at design (same than at section 5):

- Temperature measurement with alarm set point and trip set point.
- Interlock to trip the plant if the trip set point is exceeded
Preventive action to be performed during operation

- Periodical verification of the proper operation of the corresponding loop and interlock
- Frequent checks of the temperature trend
6.3 Temperature at warm end
If the heat exchange in the main exchanger is not properly balanced, a situation which may arise during
particular transient phases or improper operation, the temperature difference between entering and outgoing fluids
increases. The temperature of outgoing fluids happen to reach, in such a specific circumstances, may reach
temperature below 0°C. Depending on which material they are made of, the concerned pipes may be embrittled and
broken due to the combined effect of low temperature and pressure.
Such an event would induce a serious hazard for people who may be present in the surrounding of the
break, due to splinters casting and fluid release, and of course would make the plant unavailable for several days or
weeks.
Protection means supplied at design:

- Temperature measurement with a low alarm and a trip set points. Any temperature lower than the trip set
point leads to automatically shut down the Air Separation Unit. The interlock is active either permanently or
during transient phases depending on the fluid characteristics
Preventive action to be performed during operation:

- Periodical verification of the proper operation of the loop and the interlock
- Frequent checks of the temperature trends
- Compliance with operating conditions specified at design
- Compliance with the start up procedure of this operating manual
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6.4 Pressures of outgoing fluids

The main heat exchanger is designed for both a maximum working pressure. On the Nitrogen generation package,
all the pressures inside the cold box are derived from the air feed and consequently to the gaseous nitrogen
production, so these are the two values which have to be monitored. Therefore, one should take care of keeping the
pressure of fluids at design values.

- Pressure measurement with low pressure alarm set point

- Periodical verification of the proper operation of the corresponding loops
- Frequent checks of the pressure trends
- Compliance with operating conditions specified at design
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7 DISTILLATION COLUMN
7.1 Schematic arrangement
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7.2 Level in the sump of the medium pressure column

The level in the sump of the medium pressure column must be sufficient in order to prevent disturbing the liquid flow
sent to the downstream equipments (Low pressure column or Argon column) and must no be too high to avoid any
risk to damage the distillation packing of the column. These potential damages may be caused by the bursts of liquid
pushed by the gaseous air stream.
The plant must not be started up or must be shut down if the level is too high.
7.2.1 Protection means supplied at design:

• Level measurement with a low level alarm set point, a high level alarm set point and a very high trip set
point.
7.2.2 Preventive action to be performed during operation:

• Periodical verification of the proper operation of the corresponding loop and interlock and calibration of
the level transmitter
7.3 Level in the bath type vaporizer (Main vaporizer E02)

The concentration of solid or liquid impurities in rich liquid or liquid oxygen baths may induce very serious
explosions.
Maintaining the core completely and permanently submerged will ensure a proper recirculation of the liquid and
therefore that the hydrocarbon concentration in the bath is homogenous, and avoids local concentrations which may
exceed the solubility and / or explosivity limits.
When the liquid level of the bath is below a specific level, the liquid vaporizes completely as it flows up the
passages. This phenomenon is called "dry vaporization". In this case, the contaminants likely present in air stay in
the passages instead of being removed at the upper part of the exchanger and locally concentrate in the passages.
In such case, deposits of solid hydrocarbons may build up in the passages leading, depending on the contaminants
characteristics, to a dangerous situation.

• Overall measurement with a low level set point giving an alarm is the level decrease down 90% of the
core submergence, and a very low level set point which automatically trips the plant is the level
decreases down 80% of the vaporizer core after a 60mn period.
• Operating level measurement with a set point ensuring the full submergence of the core, a low level set
point giving an alarm is the level decrease down 90% of the core submergence, and a very low level set
point which automatically trips the plant is the level decreases down 80% of the vaporizer core after a
60mn period.
• A level gauge located slightly above the top of the vaporizer core for the verification of the proper
calibration of the level transmitters

the level transmitters.
• Periodical verification of the proper calibration of the level transmitters by performing the gauge test
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• Frequent verification of the proper operation of the level transmitter by comparison between the
indications of the two transmitters
7.4 High level in the bath type vaporizer

A too high level in a bath type vaporizer may result in damages to the equipment installed above or downstream.

• Overall measurement with an alarm high level set point and a trip set point which activates the automatic
plant shut down if exceeded.

the level transmitters.
• Periodical verification of the proper calibration of the level transmitters by performing the gauge test
7.5 Management of hydrocarbon hazard during transient phases
7.5.1 Shutdown phase

When the unit is shut down, the gaseous flows discontinue. The liquid contained in the trays or packings drain to the
low points of the column, making the vaporizer level increase significantly.
• Cold standby - Short duration (less than 48 hours)
Control of the liquid level at the vaporizer:
If a liquid nitrogen assist system exists, the vaporizer level and the levels of the capacities in which a
liquid rich in oxygen is stored, must be maintained at normal values. It is important to monitor the
temperatures at the warm end of the main exchanger, in order to ensure that they do not fall below the
low temperature limit.
If that operation is not possible and the level decreases until attaining an 80 % immersion of the core,
drain all liquids of the unit.
• Cold standby - Long duration (more than 48 hours)

If shutdown is scheduled to exceed 48 hours, it is recommended to drain all liquids
• Cold start up (presence of liquid in the unit)
- with liquid nitrogen assist system
During start-up, keep the liquid level of the vaporizer at normal operating level with the aid of the
liquid nitrogen assist system.
- without possibility of liquid nitrogen assist system
It is probable that the liquid level decreases to a very low value, until the vaporizer is deactivated.
The time during which the unit is run with a very low level should be limited by:
using the full refrigerating capacity available
feeding the unit with only the appropriate quantity of air required to keep up the pressures.
Before the normal operating level (complete immersion of the vaporizer) is reached the oxygen purity
should be as low as possible, in order to limit the hazards during the start-up phase. For this purpose, the
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gaseous oxygen outlet, if existing, must be widely opened, while the openings of the gaseous and liquid
nitrogen outlet valves must be reduced at maximum.
From units with internal compression (LOX vaporized under pressure), the oxygen is extracted by starting
the pumps. In terms of “frigories”, that purge is compensated by the corresponding liquefied air.
Monitor the impurities, if an adequate analyzer is available.
• Warm startup (without liquid in the unit)
The precautions to be taken during warm startup are the same as for cold startup, since concentration of
dangerous materials is only possible when the first liquids appear. These liquids vaporize partially under
the effect of the progressive cool down of the unit or when the vaporizer starts operating.
8 DECONCENTRATION PURGE
The method for mandatory deconcentration of impurities believed to be present in air and that are not completely
removed by front-end purification is a continuous LOX purge. This purge is achieved by withdrawing liquid oxygen
out of the system.
The LOX purge is the only mean that provide a full efficiency to deconcentrate the contaminants whatever they are.
The plant must not be operated without this purge.
8.1 Protection means supplied at design:

• Measurement of the purge with a low flow alarm an a low flow trip function. The plant is automatically shut
down is the purge has been detected below the very low flow limit during a certain period of time.
8.2 Preventive action to be performed during operation:

the flow transmitters.
• Follow up of the contaminant analyzer ( when foreseen at design) in order to verify the efficiency of the
deconcentration purge.
9 CONTAMINANT ANALYSIS
9.1 Analysis during normal operation

Depending on the environmental condition and the type of process used, analysis of the contaminants contents must
be required. Thresholds are defined for each contaminant.
9.1.1 Preventive action to be performed during operation :

Action to be taken in situations between 1st Step threshold and 2nd Step threshold
When a 1st Step threshold is exceeded, an alarm is activated. At that signal, corrective measures must be taken, to
avoid exceeding the 2nd Step threshold. IF THE ALARM EXCEEDS 2ND TRESHOLD
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Diagnosis :
Confirm the validity of the analysis - Inquire about atmospheric conditions and their forecast evolution - Determine
the possible cause of pollution. Examples:
• -acetylene cylinder close to the air intake
• -discharge of pollutants (ethane, ethylene, propane, etc…) of a nearby facility
• -nearby road paving
• -trucks with engines running parking close to the air compressor suction
• -generator set exhaust
• If possible, eliminate the cause
• Verify proper operation of the deconcentration equipment and the complete immersion of the vaporizer
9.1.2 Corrective measures may be taken simultaneously and immediately after activation of an alarm
• - switching of the filters, if applicable
• - quick draining of liquid oxygen
- if necessary, increase as much as possible the turbine flow rate or use the LIN assist system if provided,
so as to maintain the level of the vaporizer.
9.1.3 Actions to be taken if 2nd Step thresholds are exceeded

Exceeding a 2nd Step thresholds means that something highly abnormal is occurring. Immediate attention is
required. The plant will have to be shutdown if the 2nd threshold is exceeded.
If the situation cannot be corrected the unit should be shut down, all liquids inside the columns should be drained
and complete defrosting of the unit should be undertaken
Note : For N2O, NO, NOx and CO2, operation above the 2nd Step threshold may be allowed for very short period.
Permanent or frequent operation above those thresholds is not acceptable. In such cases the plant should be
shutdown and defrosted.
9.2 Analysis during cold stand by – Short duration ( less than 48 hours)
During standby, the cryogenic liquid begins to evaporate slowly, due to heat leaks from various sources. The longer
the duration of the standby, the more hydrocarbons concentrate in the liquid.
For this reason it is important to continue monitoring the analyses of hydrocarbons (if analyzers are included in the
design) in liquid oxygen. If an alarm threshold 2nd Step, as defined in volume B of this operating manual, is reached,
all liquids must be drained and the unit defrosted.
10 OXYGEN PURITY
It is assumed that a very high purity of oxygen is an aggravating factor in the propagation of the combustion of
aluminum. Therefore, due to the possible presence of hydrocarbons in the liquid oxygen of the vaporizer, the oxygen
purity of this liquid oxygen is taken into account in the design. During operation, the maximum allowable oxygen
content must not be exceeded.
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• Oxygen purity analysis with high purity alarm (if process used allows to reach high oxygen purity).

• Periodical verification of the proper operation of the corresponding loop and calibration of the analyzer.
• Compliance with the design operating conditions.
11 DEAD ENDS
If dead ended line happens to be fed with oxygen enriched liquid (rich liquid, liquid oxygen) a partial vaporization of
this liquid takes place permanently due to the heat entrance. This vaporization leads to:
An increase of the oxygen content of the liquid
An increase of the concentration of the contaminants contained in the liquid filling the line
If the phenomenon is allowed to go on for extended periods of time, this may lead to spontaneous ignition of the
contaminants, inducing damages to surrounding equipment.
When it is located outside the cold box, the freezing of the dead end is a clear indication that liquid is possibly
getting into it and that potential hazard exists. When the freezing is observed, and as already explained, a leak must
be suspected first and corrected. If there is no leak, the presence of the cold point must be investigated.

• for defrosting inlet and outlet, the connection on the line is made at the upper part of the pipe section and
the initial routing of the defrosting line follows an upward slope aimed at creating a gas plug preventing
liquid to enter the line.
• Automatic drain or operating instructions to drain liquid from the liquid oxygen pumps left in cold stand-by
( on line with suction valves opened)

• Observation of dead ends, and detection of possible freezing of dead ends, should be included to the
operating procedures.
• Compliance with operating instruction related to the periodical drain of dead end of LOX pumps in stand-
by.
12 GASEOUS OXYGEN PIPING AND COMPRESSORS

Many engineering materials which are considered "non flammable" may burn fiercely in oxygen enriched
atmosphere. Even metallic material used for the manufacture of equipment such as piping, vessel or machines can
burn in presence of oxygen-enriched gas. Therefore, specific design rules apply for gaseous oxygen piping and
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stringent operating procedure must be set in order to maintain an adequate safety level of the gaseous oxygen
systems.
A fire resulting of the presence of oxygen enriched general lead to burning the material containing the fluid such as
piping or vessel. An oxygen fire is always accompanied by violent projections of incandescent splinters of molten
metal. Serious consequences with regards to casualties and damages to the facility can result of such an incident.
Metallic and non metallic materials used in over oxygen enriched atmosphere are selected for design pressure and
flow. It is therefore recommended to keep the operating condition in the oxygen lines, vessels and equipment at the
design values.
Furthermore oil, grease, hydrocarbons, cloth, wood, paint, and dust among others can react violently with oxygen.
Therefore any maintenance on an oxygen system should be performed with taking a particular care to avoid any
pollution of the equipments with any contaminant. The cleanliness of any oxygen system should be systematically
and exhaustively checked before assembly and start up.

• Choice of architecture and material according to design operating conditions: oxygen content, pressure
and flow
• Selection of materials and equipments compliant for oxygen use in the design conditions
• Installation of protective barriers

• Ensure that cleanliness of all parts in contact with oxygen is ensured after maintenance
• Ensure that any material or equipment replaced during the plant lifetime is compliant for oxygen used in
the design condition
• Operating procedure to be worked out to make sure that during start up of oxygen systems, the
pressurization of oxygen lines is performed at slow speed to limit the increase of temperature due to
adiabatic compression.
• Access inside protective barriers during to be forbidden during the operation of the system
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13 STORAGE TANKS
13.1 Arrangement
13.2 Potential Hazards

The major hazard that is considered is a liquid spillage and its associated oxygen-deficient cloud resulting from
the vaporization of a fraction of the liquid. The extent of a spillage depends on the breached size; a liquid outlet line
rupture is less critical than a large rupture of the inner tank located at the shell bottom.
The identified main causes of the inner tank rupture are the following:
• Overpressure due to the flash of the warmer liquid entering into the inner tank which exceeds the vent and
safety relief valves capacity.
• Overpressure due to overfilling
• Vacuum
• Liquid line rupture may result of various causes, typically external aggression (chock with a truck…)
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- Two rupture disc against overpressure located at the top of the tank.
- A set of pressure safety valves against overpressure and vacuum located at the top of the tank. A
mechanical interlock system ensures that at least 200% of the required capacity through the set is kept in
any circumstance.
- A vent valve controlled by the pressure inside the inner tank
- Pressure control loops to ensure the control of the pressure in the inner tank, to activate an alarm in case of
too low pressure and to isolated the inner tank in case of very high pressure
- A dedicated control loop to prevent the overfilling by detecting a level at the top of the inner tank and
temperature measurement on the line to the overfilling safety valve to detect the presence of liquid.
- A pressure safety valve to release the liquid potentially resulting of an inner tank overfilling
- A pressure control system to set the proper pressure in the tank inter space
- Periodical maintenance of pressure safety devices

- Periodical verification of the proper operation of the corresponding loop and interlocks and calibration of the
flow transmitters.
- Frequent verification of the proper operation of the purge gas of the inter space (flow and pressure).
E-TPL-10-10-4, Rev. C
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PROCESS SAFETY
14 VAPORIZATION SYSTEM
14.1 Arrangement
14.2 Analysis of the hazards

Back up systems installed to provide a high reliability of gaseous products supply ensure the vaporization of
the cryogenic liquid by a heat exchange with air. Since the some piping and equipment cannot withstand cold
temperatures, the verification of the completed vaporization of the liquid and the temperature verification at the outlet
of vaporizers are essential.
That is why the temperature of process fluid at the outlet of the vaporizers is verified by 2 temperature
sensors. A 1 out of two interlock ensure that the automatic on off valves located at the vaporizers inlet will close in
case a low temperature is detected.

- Temperature probes with a one out of two interlocks to close the automatic valve at the outlet of the
vaporization pool.
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Page 24 of 24

PROCESS SAFETY

- Periodical verification of the proper operation of the corresponding loop and interlock.
15 IMPORTANT ELEMENT FOR SAFETY

Changes of the operating conditions can induce an upset of the plant or parts of the plant. In particular
circumstances, the upset might lead to reach hazardous situations with potentially serious consequences for
personnel safety.
The prevention of such events in ensured by the “Important Elements for Safety”. The list of these elements is
included to the volume B of this operating manual.
Since these elements are essential for the general safety of the plant, a special care should be dedicated to the
periodical verification of their proper operation.
E-TPL-10-10-4, Rev. C
REFINERIA TALARA
NIS-Z-001 57506-60-01-PR-019A023
Air Liquide
Operating Manual - Environment
06/08/2019 00
Document N°.
57506-60-01-PR-019A023
OPERATING MANUAL
Rev 0
Page 1 of 14
OPERATING MANUAL - VOLUME A – SECTION A-02 SAFETY/ENVIRONMENT
ENVIRONMENTAL IMPACTS OF AIR SEPARATION UNITS
COVER PAGE


Table of Revisions
Section Description
DISCLAIMER
Air Liquide does not hold itself out as recommending the use of the information contained herein or reliance thereon in any way
without its prior approval and Air Liquide does not give any warranties on the information contained in this document and
assumes no liability or responsibility in connection with the information or suggestions herein contained. Moreover, it should not
be assumed that every acceptable local grade, test or safety procedure or method, precaution, equipment or device is contained
within, or that abnormal or unusual circumstances may not warrant or suggest further requirements or additional procedure.
Users of this document must ensure that they have the latest edition. Non-current versions of the document must not be used.
This document should not be confused with regulations, insurance requirements and codes.
Air Liquide makes no representations or warranties as to the completeness of this document and DISCLAIMS ALL
WARRANTIES, EXPRESS OR IMPLIED INCLUDING, BUT NOT LIMITED TO, THE WARRANTY OF MERCHANTABILITY AND
THE WARRANTY OF FITNESS FOR A PARTICULAR USE OR PURPOSE.
E-TPL-10-10-5 – rev A
Document N°.
FORM Rev …
Page 2 of 14
1 INTRODUCTION
This document details the environmental impacts of Air Separation Units (ASU) and gives guidelines on
practices that can reduce or eliminate the impacts on the environment.
2 SCOPE AND PURPOSE
2.1 Scope
The document concentrates on the environmental impacts of cryogenic Air Separation Units. This document
does not give specific advice on health and safety issues, which must be taken into account before undertaking
any activity. On these issues the relevant documents, and or national legislation should consulted for advice.
2.2 Purpose
This document is intended to serve as a guide for ASU owners to assist in putting in place a formal
environmental management system that can be certified by an accredited 3rd party verifier. It also aims to
provide a guide for operating managers for identifying and reducing the environmental impacts of these
operations.
3 DEFINITIONS
3.1 Environmental Aspect

These are elements of an organization’s activities, products or services that can interact with the environment.
For example use of energy or transportation of products.
3.2 Environmental Impact

Any change to the environment, whether adverse or beneficial, wholly or partially resulting from an
organization’s activities, products or services. For example: the contamination of water with hazardous
substances or the reduction of air emissions.
4 AIR SEPARATION PLANT
4.1 General Environmental Aspects and Impacts

This document covers the environmental impact of air separation units. It includes legislation for the gas
industry and operational good environmental practices. It does not include local environmental regulation and
rules.
Document N°.
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4.2 Introduction
4.2.1 Production methods

Industrial Gas is generally produced as close as technically and economically possible to the customer. This
helps to minimize the impacts of transportation.
Gas (in liquid or gaseous form) can be transported by pipeline, road, rail or sea. Pipeline transportation from on
or off site gas generators avoid many of the environmental impacts, though the pipeline occupies land
resources and there are compression losses.
The advent of small non-cryogenic gas generators has lead to an increase in the gas generated on the
customer site. This avoids the environmental impacts of transporting the gas in liquid form and re-vaporizing it.
4.2.2 Design, Planning and Control

The basic philosophy is the minimization of wastes of any kind and their safe and clean disposal. By considering
the potential wastes which a new process could generate or when engineering a plant, future problems can be
avoided. This WASTE ANALYSIS is a crucial element of Environmental Impact Assessment that is strongly
recommended before any decision of industrial investment.
Eliminating or minimizing waste generated in air separation plant is the first rule to follow; for this purpose it is
needed to stress the importance of minimization during both stages of plant engineering and of plant operation.
4.2.3 Environmental Impact of an ASU

These units have a minimal direct impact on the environment because of the inherent nature of the processes
used in on-site air separation plants.
One important aspect is the reduction of the environmental load when replacing a non-gas process with a
process using gases. There are a very high number of successful gas applications giving the customer an
improved economical result and at the same time decreased emissions, increased recycling of material,
reduced consumption of energy or water, and other environmental benefits.
The production of Atmospheric gases from ASUs uses the Cryogenic air separation technology.
The cryogenic on-site air separation process has the following characteristics :
• Use air as a feedstock
• It is physical process - no chemical reactions are involved.
• Compressors and/or blowers are used to drive the separation and provide products at pressure.
• The products are consistently high quality and contain no unwanted contaminants
• Only materials originally present in the air end up the waste gas streams.
Cryogenic air separation is the most used and the oldest technology, and this document therefore concentrates
on the impacts of cryogenic air separation. Appendix 1 shows a process mapping of the wastes and emissions
and Appendix 2 describes the Good Environmental Management Practices for an ASU.
4.3 Main Environmental Impacts of the process
4.3.1 Principal impacts

The principal wastes, either by amount or by potential consequences on the environment, are:
• Use of water and energy in the compression
• Use of Oil
• Use of PCB (polychlorinated biphenyl) or other equivalent substances
Document N°.
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• Emissions of Volatile Organic Compounds (VOC): HCFC, CFC, chlorinated solvents during
maintenance or accidentally form the chillers.
• Discharges of Contaminated water
4.3.2 Air Intake
4.3.2.1 Air Emissions

The only air emissions result from any of the on-site air separation processes are air gases and impurities in the
air returned back to the air. In some instances a small amount of fuel, normally natural gas, is used in cryogenic
plants to provide heat for regenerating pre-purifiers.
Very low-levels of air emissions result.
However accidental spills and releases of hazardous products may need to be reported to the authorities,
depending on the National regulations.
4.3.2.2 Air filters

Air filters are likely to be contaminated by air borne pollutants. Used filters should be disposed on authorized
facilities.
4.3.3 Compression
4.3.3.1 Energy
Cryogenic Air Separation is an energy intensive process, to typically produce one cubic meter of nitrogen or
oxygen in a cryogenic air separation unit requires approx. 1 kWh/m3 while in a non-cryogenic on-site unit it
requires approx. 0.5 kWh/m3. Most of this energy is used in the compressor to compress the incoming gas
stream. This high energy use results in an indirect environmental impact from the power production plants.
Competitive pressures and environmental concerns have resulted in a continuous improvement in the energy
efficiency of air separation plants through process innovation, equipment design, maintenance and efficient
operating practices.
In addition increasing integration with the energy systems of the customer, and improvements in power plant
performance have considerably reduced this indirect impact.
4.3.3.2 Noise
The main sources of out-door noise at a gas production site are:
• Compressors and other process equipment at the air separation unit.
• Stationary or mobile pumps on tank trailers for the liquid gases
• Venting of tanks or trailers
• Noise is generated not only by compressors but also by gas venting and even by piping that contains
fast moving gases.
In order to manage the noise within the plant, it is highly recommended to start with making an inventory of the
sound levels at the different operations and in different areas including the site boundaries. Noise can be
considered as an environmental nuisance and can often be reduced by applying simple techniques (silencer or
screen for instance).
To reduce the noise at the ASU the following should be considered:
• When purchasing or designing machinery and equipment, the sound levels shall be considered. The
additional cost of choosing equipment with a comparable low sound level is low at this stage. To
afterwards reduce the sound emission is much more expensive. Please also be aware of the
Document N°.
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Machinery Directive where the basic safety and health requirements are established including sound
levels.
• Drive the vehicles and operate equipment to minimize the sound generation.
• The plant lay-out should be established considering the possibility to minimize the sound generation
and the sound level at the site boundary, especially towards sensitive areas.
4.3.3.3 Oil
There are different points of discharge:
• Oil from the compressors due to: leaks vapour emission, cleaning
• Oil from hydraulic systems
• Oil from transformers
Improvement in design and maintenance of the compressors can reduce these waste sources. The
recommendations for the control and disposal are the following:
• On no account should oil be allowed to enter the drainage system from normal operations. If some oil
is mixed with water (cleaning or rain water for instance) separate the oil from the water before
disposing of the water to the drainage system (see water treatment paragraph 4.3.4.1),
• Install a bund (or pit) at each compressor or transformer installation to collect the oil from leaks and
purges,
• Do not mix different types of oil waste, keep them by type, and label appropriately,
• Return the collected waste-oil to the supplier or to a specialized company, for treatment or recycling,
• Prevent inhalation of oil vapours by the operators. Generally vapour emission is low due to proper
cyclone and/or electrostatic demisters. In some cases vapour emission can be avoided by cooling.
4.3.4 Cooling
4.3.4.1 Cooling Water

Specific attention shall be given to the water discharge network, and associated liquid effluents.
For example :
• Cleaning water (detergent, oil)
• Cooling water and cooling tower blow-down
• Condensates
• Rain water
• Domestic water
• Water treatment chemicals and sludges from cooling tower or oily water separator
All the wastewater streams shall be clearly identified.
Condensed water from air is usually acidic and also may contain metals leaching from piping and solder.
Recycled cooling water usually contains chemical treatment products used as biocides and to control corrosion.
These includes chromates, phosphonates, polyacrylates, zinc, etc... Some of these chemicals are strictly
regulated, because of their bio-toxicity. They may enter the drainage system when the cooling circuit is purged.
Cleaning water may contain solid particles and dust.
The recommendations are the following:
• Use water treatment chemicals that do not harm the environment e.g. those that do not contain
chromates or mercury.
Document N°.
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• Use the minimum quantity of treatment chemicals necessary to achieve adequate system protection
and to make sure that the quality of the discharge complies with local and national regulation limit
values.
A special permit from the authorities is normally needed to regulate such discharges and this permit may cover:
• pH of discharge
• Concentration of chromate and chromite
Hence water may need to be neutralised before discharge and discharges of chromate and solids and oil should
be removed from water before discharging it into the sewage system. Decanting and filtration may be used to
improve the water quality before discharge.
4.3.5 Refrigeration Unit
4.3.5.1 Volatile organic compounds (VOC)

CFC, HCFC and chlorinated solvents are used as cooling liquids and as solvents. These products are volatile
compounds and without proper control part of them may disappear as emissions to the atmosphere.
Some halocarbons have ecological consequences, such as destroying the ozone layer. Some of them will be
banned from the market, according to the Montreal protocol and EU regulations, and the suppliers will propose
in some cases less hazardous substitutes.
The recommendations are the following:
• Identify all the points on the refrigeration units where leaks can occur ; check there is no leak or
eliminate it in case of one ; install hermetically sealed units or use refrigerants whith a lower ozone
depleting potential
• Collect and label all waste and used liquid solvent and return to the supplier for recycling or reuse
• Consider recovering solvent and refrigerant for recycling
• Avoid excess use of solvent, and review working practices and workmanship habits where solvent is
used.
4.3.6 Maintenance
4.3.6.1 Regular Maintenance.

Regular maintenance is vital to keep the plant running as efficiently as possible. The change out of
consumables and servicing of equipment does generate some wastes, which are detailed below.
4.3.6.2 Consumables.
The storage of consumables should be reviewed to minimize the quantity of substances, spare parts, etc. used
and stored at the site. It is recommended to:
• Have Material Safety Data Sheets available of all chemical substances at the site and ensure that
storage areas and vessels are properly labelled.
• Storage of large volumes of oil, organic solvents or other hazardous substances should have a
secondary containment.
• Absorption material should be available to clean spill on the floor
• Include environmental events such as major leakage of oil in the emergency plan.
4.3.6.3 Polychlorinated biphenyls (PCB)

PCBs are toxic and carcinogenic substances, and their use has been phased out in accordance with prevailing
legislation.
Document N°.
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If transformers and capacitors with PCB (or equivalent substances) are used, they should be labelled
accordingly. Disposal of this product and any material that is contaminated by PCB (for example rags,
absorbent material and so on) should be controlled by national or local regulations.
PCB or PCB contaminated materials have to be collected into sealed suitable containers labelled and then
recovered and treated by certified waste disposal companies.
4.3.6.4 Catalysts
If catalysts are used, they usually contain Biotoxic metals and must be either recycled by returning to the
supplier or disposed of by certified waste disposal companies.
4.3.6.5 Batteries and electrical cells

Most batteries and electrical cells contain hazardous compounds. According to the kind of chemicals and
composition, they must be:
• Returned to supplier for recycling
• Disposed of by certified waste disposal companies
4.3.6.6 Metal waste

Biotoxic metal waste (for example mercury, cadmium, lead and their compounds) are strictly regulated and
have to be disposed of by certified waste disposal companies.
Scrapped metals should be segregated into ferrous and non-ferrous and recycled.
4.3.6.7 Insulation material

Do not remove, unless strictly necessary.
Non-hazardous recovered insulation material shall be returned to the supplier or disposed of by certified waste
disposal companies.
In the disposal of rockwool the possibility of this exhibiting natural radioactivity should be taken into account.
Care should be taken when undertaking maintenance activities so that there is no release of perlite due to
pressure changes in the cold box.
4.3.6.8 Silica Gel / Alumina Gel / Molecular Sieve

Used gel or molecular sieve should be checked for oil or other contamination.
Uncontaminated absorbent can be disposed of as non hazardous waste. Consideration should be given to
return it to the supplier.
4.3.7 Storage
4.3.7.1 Waste Storage

All waste which will be recovered, recycled or treated by a specialized company, or which will be disposed of at
authorized facilities shall be stored and transported by authorized transporters in suitable containers clearly
labelled to identify the composition of the waste.
Liquid waste storage facilities should be bunded to a capacity capable of safely containing at least the contents
of the largest single container.
Different kind of waste must not be mixed but must be separated in different containers according to their type
and the treatment they will receive.
Document N°.
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The storage itself must be organized in such a way that there is no risk of mixing the containers (separations in
specific area, marking, records etc).
4.3.7.2 Storage Tanks.

The storage tanks entail of course also a risk of contamination of soil and water if the tank starts to leak. But
the control of tank leakage is not complicated.
Even a dripping valve could easily contaminate several cubic meters of soil. Spill plates should be used.
The big storage tanks are frequently used for fuel while the smaller ones could contain oil, antifreeze and other
substances. The importance of avoiding spill and label the tanks are similar independent of the size.
4.3.7.3 All tanks.

When filling a tank the operator must attend the filling at all times. By installing overfill alarms, the risk of major
spill could be further reduced. Minor spill could occur when filling or emptying the tank and proper precautions
such as using spill plates should be taken to avoid any environmental damage caused by this
4.3.8 Visual
Consideration should be given to the visual appearance of the plant in relation to its location and the « green
space » inside the plant. This could be covered by National or local planning conditions.
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Appendix 1: ASU Environmental Impacts- Emissions or Wastes
Air Separation Units (ASU) produce mainly oxygen and nitrogen as well as rare gases as argon, xenon… in
liquefied or/and gaseous state.
The ambient air is the raw material for the fabrication process. This air must be as clean as possible. The output
products are the produced fluids (O2, N2, Ar, Xe…).
This production process has a low impact on the environment, because of the raw material used (Air) and
because of the small amount of chemicals used within the main process.
Therefore is it is still possible to characterize the impact of an ASU on the environment as describe where
under:
The principal wastes, either by amount or by potential consequences on the environment are:
• Use of water and energy in the compression
• Use of oil
• Use of PCB ( PolyChlorinated Biphenyl) or other equivalent substances
• Emissions of volatile organic compounds (VOC): HCFC, CFC, chlorinated solvents during
maintenance or accidentally from the chillers
• Discharges of contaminated water.
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APPENDIX 2 : GOOD ENVIRONMENTAL MANAGEMENT PRACTICES FOR AIR SEPARATION UNITS
Source Environemental Potential Impact(s) Good Environmental Management Practices

Aspect
Cold box insulation Rock wool, perlite, Waste Disposal Check for ice spots
vermiculite
Energy efficiency Replace insulation on shut down
Reuse perlite and vermiculite as a soil conditioner, where allowed.
Recycle, where possible.
Dispose of as solid waste through an approved disposal contractor.
Compressors and Lubricating oil Soil Minimize leaks through preventive maintenance
vacuum pumps
Surface Water Where present, keep foundation curbing and drains free of debris for effective
drainage to oil/water separator.
Waste Disposal
Use absorbents to minimize oil seepage off of foundations that are not tied to an
Groundwater
oil/water separator.
Where practical, install roof over compressors to prevent contaminated storm
water.
Recycle used oil, and where possible, saturated absorbents through an approved
oil recycler.
Do not mix solvents or other chemicals with used oil.
Used oil contaminated with freons or solvents requires special disposal.
Return empty drums to original supplier or recycle through an approved drum
reconditioner, where practical.
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Source Environmental Aspect Potential Impact(s) Good Environmental Management Practices

Compressor - Low pH (acidic), copper, Surface Water Do not discharge onto the ground.
condensate nickel, lead
Groundwater Discharge through a permitted outfall or sewer connection.
Reuse as makeup to cooling tower, where feasible.
Treat any excessive levels of metals.
Neutralize low pH before discharging.
Compressor - vents Lubricating oil mists Air Install oil demisters to collect oil mist emissions.
Soil Recycle the collected oil through an approved oil recycler.
Surface water
Cooler system - Acids, metals, solids, Surface Water Dispose of spent chemical cleaning solutions through an approved disposal
chemical wash chelants contractor
Waste Disposal
Cooling systems – Ethylene glycol, Soil Minimize leaks through preventive maintenance.
closed loop
propylene glycol, and Surface Water Maintain proper level of corrosion inhibitors to extend life of solutions.
similar heat exchange
Waste Disposal Recycle glycols via approved recycler.
fluids
Groundwater Dispose of spent solutions through an approved disposal contractor.
Cooling tower - Biocides, acids, Surface water Discharge through a permitted outfall or sewer connection.
blowdown corrosion inhibitors
Natural Resource Avoid use of chromate-based or zinc-based corrosion inhibitors.
Avoid excessive chemical feed through tight control of water chemistry.
Run cooling tower at optimum concentration cycles to minimize chemical loss,
wastewater discharges, and makeup water consumption.
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Purchase water treatment chemicals in bulk or returnable containers instead of

drums, where practical.
Return empty drums to original supplier or recycle through an approved drum
reconditioner, where practical.
Use of existing supplier of chemicals and obtain any necessary permit modifications
before switching chemicals.
Cooling tower - mists Legionella risk Legionella Planned maintenance and disinfect ion of cooling systemsRegular testing of
systems
Cooling tower - Solids Surface water Treat if required before discharge through a permitted outfall or sewer connection.
sidestream filter
backwash
Cooling tower - sludge Solids, heavy metals Waste Disposal Test for presence of heavy metals to determine if a hazardous waste.
(chromium, copper,
Dispose of through an approved disposal contractor.
zinc)
Electricity Indirect Energy use Design, purchase and maintain equipment to operate efficiently and minimize
energy use.
Air
Conduct energy audits to identify potential opportunities to improve energy
Water
efficiency.
Solid waste
Train employees to conserve energy.
Radioactive materials Waste Disposal Return radioactive cells to manufacturer.
Do not throw in normal (waste) trash.
Report all pending transfers of radioactive materials to and from the site to
applicable regulatory agencies.
Document N°.
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Perform wipe tests for leaks, where required.

Maintain all warning labels on analyzers.
Obtain appropriate regulatory approvals to own and use radioactive materials.
Pre-purification units Silica gel, molecular Waste Disposal If feasible, recycle, reuse or regenerate molecular sieves.
sieve, alumina,
Dispose of as solid waste through an approved disposal contractor.
activated charcoal
Product Storage and Nitrogen, oxygen, Minimize venting of cryogenic gases
Transfer helium, argon
Product venting, Noise Community Design and install, compressors, expanders and other equipment in accordance
Compressors, traffic….. with local noise requirements.
Use appropriate noise-attenuation measures as required (sound insulation, noise
curtains, buildings, walls).
Select sites with adequate land and distance to buffer noise.
Site equipment in a location that will minimize the noise impact to neighbours.
Minimize night time noise-generating activities.
Used filters Filters with dust Waste disposal Change out filters as part of planned maintenance to maintain efficiency
deposits
Test for presence of radioactivity, if warranted, or other dust contaminants to
determine if a hazardous waste, where appropriate
Carbon molecular sieve, Carbon, alumina Waste Disposal Plan ahead to make arrangements for disposal. Adequate lead time is needed.
ceramic molecular sieve
If the customer is responsible for disposal, follow customers procedures.
Document N°.
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and alumina, silica gel

Equipment and parts Spent solvents and Soil Purchase parts pre cleaned
detergents
Surface Water Minimize solvent/chemical purchases. Don’t buy more than needed.
Groundwater Keep containers and parts cleaners closed when not in use
Use drip pans to collect solvents.
Collect spent solvents for recycling through an approved recycler.
Do not pour solvents down any drains or on the ground.
Do not mix spent solvents with used oil or other chemicals.
Report and clean up any spills immediately.
Use biodegradable detergents whenever possible.
Determine if spent detergents can be discharged to sanitary sewer.
REFINERIA TALARA
NIS-Z-001 57506-60-01-PR-019B011
Air Liquide
Operating Manual - Table of Contents
06/08/2019 00
Document N°
57506-60-01-PR-019B011
OPERATING MANUAL
Rev 0
Page 1 of 6
OPERATING MANUAL - TABLE OF CONTENTS
COVER PAGE

0 06/08/2019 M.ATAM RFR – Complete, ready for review

Project Name APSA L4 – TALARA NIS
Table of Revisions
Section Description
Initial Issue

E-TPL-10-10-1 – rev A
Document N°
57506-60-01-PR-019B011
OPERATING MANUAL
Rev 0
Page 2 of 6
TABLE OF CONTENTS
TABLE OF CONTENTS 2
AIR LIQUIDE DISCLAIMER 3
1 INTRODUCTION 4
2 AIR LIQUIDE PROPERTY 4
3 FIELD OF APPLICATION 4
E-TPL-10-10-1 – rev A
Document N°
57506-60-01-PR-019B011
OPERATING MANUAL
Rev 0
Page 3 of 6
AIR LIQUIDE DISCLAIMER
The operating manual was written in English, for any translation of this document, the English version should be the
reference document.
The information contained in this document has been prepared for use for an Air Separation Unit designed by Air
Liquide Engineering (“Air Liquide”) and is based on technical information and experience currently available to Air
Liquide as of the original issue date of this manual. Air Liquide believes that the information contained in this document
is true and correct and that the document suitably addresses the matter to witch it relates. Air Liquide makes no
guarantee to third parties of the performance and assumes no liability or responsibility in connection with the
information or recommendations contained in the operating manual. Moreover, it should not be assumed that
recognized practice, test or safety procedure or method, precaution, equipment or device is contained within, or that
abnormal or unusual circumstances may not warrant or suggest further requirements or additional procedure.
This operating manual is intended to facilitate familiarisation with the ASU and its application for the intended purpose
as specified in the contract. Use for the intended purpose shall also include compliance with the specified operating
data indicated in the operating instructions (data sheets), as well as the inspection and overhaul conditions given in this
operating manual or in the relevant equipment operating manual.
Air Liquide makes no representations or warranties as to the completeness of this document and EXPRESSLY
DISCLAIMS ALL WARRANTIES INCLUDING BUT NOT LIMITED TO, THE WARRANTY OF THE
MERCHANTABILITY AND THE WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE OTHER THAN THE
INTENTED PURPOSE AS SPECIFIED IN THE CONTRAT.
Air Liquide makes no representation or warranty with respect to the accuracy of the information or with respect to the
suitability of the use of such information outside Air Liquide, nor does Air Liquide assume responsibility for any injury or
damage which may result, directly or indirectly, from the use of such information.
E-TPL-10-10-1 – rev A
Document N°
57506-60-01-PR-019B011
OPERATING MANUAL
Rev 0
Page 4 of 6
1 INTRODUCTION
Air Liquide advises you to read completely these instructions.

This Operating manual is written for personnel operating the Air Liquide ASU for PetroPeru at Talara in Peru, Project
Number C57506 and Project Name TALARA NIS.
The purpose of this document is to give a consistent overview of the ASU in order to facilitate the understanding and
the communication between all specialists. The operating instructions must be read and applied by all individuals
responsible for operating the ASU, even if you are fully familiar with the principles of operation and safe practices for
this equipment before taking up their duties. Only personnel who have received appropriate training or familiarization
are allowed to operate the ASU
This manual includes descriptions, instructions and guidelines for commissioning, start-up, operation and shutdown of
the ASU. However, regarding commissioning, start-up, operation and shutdown of equipment, reference should be
made to the relevant description and instructions from the equipment supplier. These instructions are not intended to
cover all details or variations in equipment, or to provide for every contingency connected with the installation,
replacement and maintenance of the ASU. If more information is desired, if any instruction is unclear, or if problems
arise which are not covered herein, contact your Air Liquide representative for clarification.
This document is issued at different revision and users are cautioned to obtain the latest edition.
2 AIR LIQUIDE PROPERTY
This document is the property of:

AIR LIQUIDE GLOBAL E&C SOLUTIONS FRANCE S.A.
75 Quai d’Orsay 75007 Paris (France)
This document contains proprietary information which is the exclusive property of Air Liquide. It must not be
reproduced, copied, lent or otherwise disposed of, directly or indirectly, nor used for any purpose other than assessing
its merits without the written consent of Air Liquide.
3 FIELD OF APPLICATION
This operating manual contains important information on how to operate the ASU properly and safely. However, this
manual is no substitute for on-the job training for operating personnel when the ASU is running. If required Air Liquide
can provide all necessary training for this purpose on a contractual basis.
E-TPL-10-10-1 – rev A
Document N°
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OPERATING MANUAL
Rev 0
Page 5 of 6
Prior to start-up, it is recommended that all the components of the equipment supplied be inspected and adjusted, to
prevent any incident that may occur due to casual erection methods, or result from exposure to bad weather. Read and
fully understand the safety precautions listed in this manual and equipment documentation supplied, before attempting
operation or maintenance.
Proper and safe operation and maintenance of the ASU is subject to an adequate level of qualification and experience
of the personnel in charge.
AIR LIQUIDE shall not assume liability and responsibility as a result of:
Operating errors, unsuitable treatment of the Unit, negligence, omissions, mishandling and misunderstanding by
operating personnel.
Integration of ASU within downstream or upstream processes which could induce abnormal transitory phases.
Operating conditions not in compliance with the conditions of design defined in the contract and which could
affect or damage:
Proper and safe operation of the plant
Personnel safety
Equipment protection
Environmental preservation
Use of this manual for equipment not mentioned in this manual.
No modification shall be made to the plant, equipment, control systems, process descriptions and operating procedures
without authorization from Air Liquide Engineering. In the event of unauthorized modification, Air Liquide Engineering
disclaims all liability as to the consequences to the unit or any personal injury.
In few chapters certain process values are included for the purpose of making explanation clearer. All the operating
values indicated in the operating manual, are preliminary and are likely to be adjusted as of the reception of the final
manual (Rev n°2). In case of not reception of the final manual six months after the end of the starting period, the “as
started manual” (Rev n° 1) will be taken as official reference.
This manual shall be supplemented by the manual supplied by each equipment supplier. In case of discrepancy
between Air Liquide manual and an equipment operating manual, the operating manual for the relevant equipment shall
prevail.
The ASU shall only be operated within the operating data specified in the contract.
The operating instructions shall be supplemented by existing laws, operating and environmental permit, norms, rules
and regulations.
This manual must be available on the site at all times.
E-TPL-10-10-1 – rev A
Document N°
57506-60-01-PR-019B011
OPERATING MANUAL
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TABLE OF CONTENTS
Section Title Revision

B-00 Foreword & Table of Contents 0
B-01 Plant Narrative 0
B-02 Safety/Environment 0
B-03 Plant Start Up 0
B-04 Normal operation 0
B-05 Shutdown and Failures 0
B-06 Maintenance Operations 0
B-07 Deriming Procedure 0
B-08 List of equipment 0
B-09 Performance 0
B-10 PID 0
E-TPL-10-10-1 – rev A
REFINERIA TALARA
NIS-Z-001 57506-60-01-PR-019B031
Air Liquide
Operating Manual - Plant process narrative
06/08/2019 00
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OPERATING MANUAL - VOLUME B - SECTION B-03 – PLANT PROCESS NARRATIVE
COVER PAGE

0 06/08/2019 M. ATAM C. BECKER RFR – Complete, ready for review

Table of Revisions
Rev Section Prepared by Description
DISCLAIMER
The information contained in this document has been prepared by L’Air Liquide S.A. and/or its controlled subsidiaries (“Air Liquide”), exclusively for their use, and is Air Liquide
property. Air Liquide believes the information is current and accurate, but circumstances may warrant additional requirements or procedures. This document is subject to
periodic review and users are cautioned to obtain the latest edition.
Air Liquide makes no representations or warranties to third parties as to the quality, accuracy or completeness of information contained in this document and EXPRESSLY
DISCLAIMS ALL WARRANTIES, INCLUDING, BUT NOT LIMITED TO, THE WARRANTY OF MERCHANTABILITY AND THE WARRANTY OF FITNESS FOR A PARTICULAR
PURPOSE.
Unauthorized use of this document by any third Party, including Air Liquide contractors and subcontractors, shall be at such Party’s own risk, and Air Liquide assumes no liability
in connection with information contained herein. Air Liquide disclaims any liability for any damage suffered by any company or person as a result of or in connection with the use,
application or implementation of the information contained herein or any part thereof. The benefit of this disclaimer shall inure to Air Liquide and its affiliates.

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TABLE OF CONTENTS
1. GENERAL INFORMATION .................................................................................................... 3

1.1. Presentation of the APSA L unit ............................................................................. 3
1.2. Standard conditions of use ...................................................................................... 3
1.3. Special conditions of use ......................................................................................... 3
2. PRESENTATION OF THE PROCESS ........................................................................................ 4
2.1. Generalities ............................................................................................................... 4
2.2. Air Compression ....................................................................................................... 4
2.3. Purification unit ......................................................................................................... 4
2.4. Cold box .................................................................................................................... 4
3. DESCRIPTION OF THE EQUIPMENT ...................................................................................... 8
3.1. Air compressor.......................................................................................................... 8
3.2. Warm skid ................................................................................................................. 8
3.2.1. Front end air purification ........................................................................................ 8
3.3. Cold box Unit ...........................................................................................................16
3.3.1. Vaporizer’s level transmitters LT614 & LT601, Valve LV614...........................17
3.3.2. Column’s level transmitter LT602 .......................................................................18
3.3.3. Hydrocarbon deconcentration valve KV603 ......................................................19
3.3.4. Purge valves KV623 / KV633 ..............................................................................19
3.3.5. Flow control valves-FV615A, FV615B................................................................19
3.3.6. Manual valves .......................................................................................................19
3.3.7. Pressure relief valves ...........................................................................................19
3.3.8 The controller cabinet (Y60) .................................................................................20
3.4. Turbine Expander ET01 ..........................................................................................20
3.4.1. Turbine by-pass pressure control valve PV640.................................................21
3.4.2. Manual valves .......................................................................................................21
3.5. Liquid Nitrogen Storage And Back-up Vaporization ............................................22
3.5.1. Storage Pressure Control Valve .........................................................................22
3.5.2. Storage Inlet & Outlet Control Valve HV813A/B ...............................................22
3.5.3. Atmospheric Vaporizers Automatic Valve PV971A/B .......................................22
3.5.5. Pressure relief valves ...........................................................................................22
4. PRINCIPLE OF THE PRODUCTION CONTROL SYSTEM ..........................................................23
4.1. Air Flow Control .......................................................................................................23
4.2. Nitrogen flow control ...............................................................................................24
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1. GENERAL INFORMATION
1.1. Presentation of the APSA L unit
The unit consists of the following main skids:
♦ The compressor (C01), which supplies the plant with air at the required pressure.
♦ The warm skid (purification vessels R01&R02, valves), in which the air is treated so as to
eliminate any traces of moisture, carbon dioxide, and hydrocarbons. It also contains the counting
equipment and an electrical cabinet.
♦ The cold box (K01 & E02 & E01) in which the nitrogen is separated from oxygen by means of a
cryogenic distillation process.
♦ The turbine expander (ET01) in which a process fluid “vaporized rich liquid” is expanded to
produce cold energy which compensate cold losses of the system.
Note:
An external liquid nitrogen (LIN) storage (separated from the cold box) may be used to start up
the air distillation process.
This storage also ensures the emergency nitrogen supply system (back-up) in case of shut
down of the APSA unit and N2 purity should be compliant with the customer purity gas contract.
The LIN storage is not included in AL E&C CSP scope of supply.
1.2. Standard conditions of use
♦ The flow rates are expressed in Sm3/h (i.e. gas at 0°C, 0 % humidity and 1013 mbar)
♦ If not specified, The reference atmospheric conditions are :

Air temperature: 20°C
Air pressure: 1013 mbar
Relative humidity: 70 %
When atmospheric conditions are different, the flow rates are different from those mentioned in the
AL E&C CSP Offer. For a temperature exceeding 20°C, the correction factor can be estimated to
0.3% per degree above 20°C, in the effect of reducing the flow rate. Corrections must be applied
too in order to take into account the atmospheric pressure and hygrometry.
♦ Purity of the liquid nitrogen for liquid assist must be as good as the purity desired for use.
1.3. Special conditions of use
In the event the customer site conditions are above the standard conditions, it will be necessary to
carry out a special study of the plant, in order for the latter to function correctly. The performance levels
will then be redefined as a function of these special conditions.
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2. PRESENTATION OF THE PROCESS

2.1. Generalities
The APSA L unit uses atmospheric air as raw material to produce:

♦ Gaseous nitrogen (GAN) at very high purity (below 10 ppm of oxygen content)
♦ Liquid nitrogen (LIN) with the same purity as GAN
♦ And rich O2 residual gas (waste) as a co-production gas, not used.
The process used in the APSA L units is based on a cryogenic distillation process (temperature around
-180°C) based on air fractional distillation to separate nitrogen from oxygen of the liquefied air.
2.2. Air Compression
The air is compressed at around 10.8 kg/cm2.a, by an oil free compressor. It is a centrifugal
compressor.
After the compression and the final cooling, the compressed air is around 32oC. The final cooler is
integrated in the compressor. The condensates (mostly water) at each stage of the compressor are
evacuated by automatic drains.
Then the air goes to the front end purification unit (adsorber’s vessels R01/R02).
2.3. Purification unit
The air purification system consists of the following equipment:
• The vessels R01/R02 called adsorbers,

• ON/OFF or control valves,
• Check valves,
• An electrical heater E08
• A derime heater E81
Each adsorber is filled with two beds of specific materials called adsorbents: alumina and molecular
sieve. Alumina material is destined to trap the molecules of water vapour. Molecular Sieve material is
destined to trap the molecules of CO2 and some hydrocarbons CnHm and nitrous oxides.
This phenomenon is called adsorption process.
Inside the vessels, a dust filter of 40 µm is installed, preventing the balls of adsorbents to go
downstream in the process pipes.
2.4. Cold box
After the purification of the air, it enters the cold box to achieve the nitrogen separation by the
distillation process:
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- first, air is cooled down to its dew point in a brazed aluminum plate exchanger E01, which
heats up counter-flow the nitrogen and the waste gas coming out of the distillation
column K01.
- then, air at its dew point is injected into the medium pressure (MP) distillation column K01
which produces :
o nitrogen at the top part of the MP distillation column,
o and oxygen enriched liquid called “rich liquid” in the bottom part of the MP
distillation column.
Rich liquid is collected at the bottom of the medium pressure (MP) distillation column K01 and is
transferred to the vaporizer-condenser E02 through the level control valve LV614 which maintains
the liquid level above the top of the condenser.
E02 is a bath type heat exchanger. It allows the complete condensation of the gaseous nitrogen
(GAN) coming from the top of the column K01 which exchange with rich liquid, then vaporized.
The gaseous nitrogen (GAN) production supplied to the customer is controlled through the production
control valve FV615A.
When the oxygen content in the gaseous nitrogen produced is higher than the set point value, the
valve FV615A closes automatically in order to isolate the APSA L unit from the customer network,
while another valve FV615B blows off the GAN production.
FV615B is used in particular when the customer GAN consumption is lower.
The liquid nitrogen (LIN) production sent to the liquid nitrogen storage tank is controlled through
the level control valve LV602.
LIC602 is also used to control the liquid level in the bottom of the MP distillation column K01.
A pressure control valve PV640 is installed on the waste gas line (vaporized rich liquid vented to
the atmosphere), by-pass of the turbine expander, to control the pressure at the inlet of the turbine
expander ET01 and to stabilize the pressure in the condenser E02.
The APSA L units are automatically operated by means of a programmable logic controller (PLC).
In the case of shutdown for a mechanical fault, the unit automatically adopts a safe position:
o closing of nitrogen valves
o shut down of the compressor
o the nitrogen back-up device is set in operation to supply the customer
Below, the diagram of a standard APSA L unit shows the following parts:
♦ The compression
♦ The purification system (refrigeration dryer, adsorber’s vessels). Usually, counting and
electrical equipment are arranged in the warm valves skid. This is called the Warm Skid.
♦ The cryogenic components (exchanger E01, column K01, vaporizer E02, turbine expander
ET01) are arranged in the Cold box, with an effective thermal insulation.
♦ The liquid nitrogen is stored in a separate liquid storage.
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APSA L PROCESS FLOW DIAGRAM
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APSA L COLUMN PRINCIPLE
WASTE
LV614
RICH LIQUID
BATH E02
RICH LIQUID BATH
LIN
GAN RICH LIQUID
TRANSFER
K01
Air
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3. DESCRIPTION OF THE EQUIPMENT

The following list of devices does not substitute to the equipment in for the P&I diagrams of the relevant unit. In
case of conflict, the latter only is valid.
Some devices which can be installed on the generator are not described below. Conversely, other devices
described below may not be installed.
3.1. Air compressor
Refer to the manufacturer’s operating manual.
3.2. Warm skid
It consists of the vessels, and a self-supporting metal frame containing the valves and the electrical and the
analysis equipment. The dryer is delivered loose.
3.2.1. Front end air purification

The air purification system is dedicated to the removal of the various air contaminants that may cause trouble
to the APSA L unit operations.
♦ It removes water and CO2, which solidify at low temperature and that could clog cold box equipment
♦ It is designed also to remove some hydrocarbons for safety reasons. Their concentration in the
vaporizer can create a potential explosive area in contact with the rich liquid.
The front end air purification unit consists of the following equipment:
♦ the vessels R01/R02 (drawing next page),
♦ the On/Off pneumatic valves KV210, KV220, KV216, KV226, KV215, KV225
♦ a control valve KV230
♦ the check valves CVWO09A, CVWO09B, CVWO09C, CVWO09D,
♦ the electrical heater E08
♦ the electrical heater E81
♦ The adsorbers R01/R02
Each adsorber is filled with three horizontal beds of adsorbents: ceramic balls, alumina and molecular Sieve:
♦ Alumina is dedicated to the removal of molecules of water vapor

♦ Molecular Sieve is dedicated to the removal of CO2 and some hydrocarbons CnHm.
♦ Ceramic Balls
Both adsorbent are solid materials in the form of porous particles of 2~5 mm diameter which attracts and traps
the molecules: this is the adsorption process.
Adsorption is a reversible process which allows the adsorbed molecules to leave the pores of the adsorbent as
the pressure decreases or the temperature increases.
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In each adsorber, a 40 micron filter is installed to retain the dust particles that may be produced by attrition of
the adsorbents.
The sketch next page represents the common design of APSA L vessels.
The valves KV215, KV225, KV216, KV226,KV210, KV220
Valves KV210/KV220 : air inlet valves

Valves KV215/KV225 : waste blow off valves during the depressurization of the vessels
Valves KV216/KV226 : waste blow off valves during the regeneration sequence
Valve KV230 : air pressurization valve
The check valves CVWO09A, CVWO09B, CVWO09C, CVWO09D,
CVWO09C: air outlet for vessel R01.

Opened when R01 is in service position. Closed when R01 is in regeneration position.
CVWO09D : air outlet for vessel R02

Opened when R02 is in service position. Closed when R02 is in regeneration position.
CVWO09A : waste inlet for vessel R01

Closed when R01 is in service position. Opened when R01 is in regeneration position.
CVWO09B : waste inlet for vessel R02

Closed when R02 is in service position. Opened when R02 is in regeneration position
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♦ The electrical heater E08
It enables to warm-up the waste gas (vaporized rich liquid) to regenerate the vessel which is in
regeneration position.
The temperature of the waste TI233 at the outlet of the heater is controlled by a temperature controller
TC.
The heater is fitted with a temperature switch TSHH238 A/B which detects a high temperature on the
electrical resistance: this switch cuts off the power supply on the heater when the temperature of the
resistance becomes too high (around 700°C) (e.g. in case of non sufficient gas flow through the
heater).
♦ The pressure gauges PIT222 / PIT212
These instruments enable to monitor the pressure in the vessels R01 (PIT212) and R02 (PIT222). Low
tresholds PDSL202A/B enable to detect the good operation of the pressurization and depressurization
sequences.
♦ The temperature monitoring
On the blow off pipeline, during the depressurization sequence, the TI213 on R01 vessel and the 2-
TI223 on R02 vessel enable to monitor the good operation of the regeneration process. Low and high
temperature detection would lead to a default in the purification sequence.
Sketch on next page represents all these elements:
♦ The derime heater E08
It enables to warm up the Air Gas (AG) coming from the R01/R02 bottles for deriming purposes.
The heater is fitted with a temperature switch TSHH093 which detects a high temperature on the
electrical resistance: this switch cuts off the power supply on the heater when the temperature of the
resistance becomes too high (e.g. in case of non sufficient gas flow through the heater).
PDIT095 is included as well in order to ensure that there is enough flow passes inside the heater –
helps us to avoid damage-. There is a trip on PDALL095 when there is not enough flow thourough the
heater.
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Heater
Air to E01
Vaporized RL E12
E08
CVWO09A CVWO09B
PIT PIT
212 CVWO09C CVWO09D 222
KV230
R01 R02
Molecular Sieve
Vesselin Vesselin
regeneration service
position Alumina position
Vent Blow Off
KV215 KV225
KV216 KV226
KV210 KV220
Air
APSAL Front End Air Purification System

(with R01 in regeneration step)
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♦ Operation description of the regeneration sequence
The compressed air goes through the vessels R01 or R02 so that the residual humidity, the CO2 and
the hydrocarbons are removed from the air. These vessels work in cycle: during 150 min, one adsorbs
pollutants of the air while the other is regenerated. At the end of this time, there is an inversion: the
vessel previously in regeneration is now in adsorption mode and the other is regenerated.
Through the vessel in regeneration passes the waste gas (vaporized rich liquid), heated at a
temperature controlled by the electrical heater E08. The waste gas pressure is between 0~100 mbar
g). The regeneration sequence is the following:
♦ Depressurization: The bottle is slowly depressurized, near atmospheric pressure, in opposite

direction to the adsorption flow.
♦ Heating phase : of about 30 min with waste gas inlet temperature at about 150°C to maintain a
waste gas outlet temperature above 0°C (desorption of water is an endothermic phenomenon).
♦ Cooling phase: of about 90 min with waste gas coming from the warm end of the main exchanger
E01. Its temperature is ambient.
A peak temperature should occur at the end of the cooling phase which indicates that heating phase
was sufficient.
♦ Pressurization phase: to prepare for the adsorption sequence, the vessel has to be pressurized
before admitting the compressed air. The adsorber gets pressurized with purified air through
balancing line with KV230.
The usual temperature profile for a good purification process is the following:
Inlet and Outlet temperature

T (°C) (regeneration)
160 160
140 140
120 Inlet 120
100 100
80 80
⑥
60 60
⑤ dTPeak ⑦ ⑧
40 40
① dT Ref
④
20 ② Outlet 20
③
0 0
Heating Cooling
Safety
Depressurization Pressurization
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The On/Off valves KV210, KV220, KV215, KV225, KV216 and KV226 and the check valves CVWO09C,
CVWO09D, CVWO09A, CVWO09B, allow the switch positions of the two adsorbers:
♦ in Service position : air goes through the vessel
♦ in Regeneration position: waste gas (vaporized rich liquid) goes through the vessel.
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C: Closed
O: Open
Note: in addition to this normal regeneration, an exceptional regeneration at 290°C is to be regularly

performed to allow the complete elimination of the traces of moisture and the traces of hydrocarbons
which have been trapped in the molecular sieve (see maintenance instructions). This exceptional
regeneration makes it possible to guarantee optimal adsorption efficiency.
3.2.2.1. Vaporized rich liquid pressure control valve PV261
This valve is located on the waste gas pipe at the outlet of the main exchanger E01. It enables to
control the waste gas pressure at the outlet of the turbine.
This valve also ensures that:

♦ enough residual gas is going through the heater E08 for the regeneration of the adsorption
vessels
♦ the turbine discharge pressure is stable
PX PIC
261 261
PT
261
Silencer
E01 PV_261
Atm
R01 R02
3.2.2.2. By-pass air control valve HV240
This valve is located on the dry air pipe upstream E01 and recycles the dry air back to the front end
purification unit during the transitory modes (exceptional regeneration, start-up…).
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3.2.2.3. Pressure transmitter PT202 and temperature transmitter TE203
These transmitters monitor the pressure (PI202) and the temperature (TI203) of the air at the outlet of
the compressor.
A high switch pressure PSH prevents from an overpressure coming from the compressor and a high
switch of temperature TSHH prevents from entering the purification at a too high temperature.
3.2.2.4. The electrical cabinet (Y20)
It usually contains the following equipment:

♦ a lockable load break switch, located on the front panel,
♦ a 400/230 V transformer for the 230 V distribution circuit
♦ circuit-breakers and fuses for equipment protection
♦ selector switches and push buttons located on the front panel
For this project Y20 will be divided into several pieces including electrical panel, PLC panel and
junction boxes.
3.2.2.5. The controller cabinet (Y60)
This cabinet may be equipped with one force ventilated enclosure with an electrical heater and an
electrical fan.
♦ a programmable logic controller (PLC)
♦ input / output cards for all instruments installed in the warm skid
♦ the 230V AC - 24V DC transformers/rectifiers
For this project Y60 will be divided into several pieces including electrical panel and junction
boxes.
3.2.2.6. Analysis cabinets (Y22)
This cabinet is fitted with one force ventilated enclosure with an electrical heater and an electrical fan.
Y22 contains all the analyzers essential to the production of the unit as:
• CO2 ANALYSER
• O2 Purity ANALYSER
3.3. Cold box Unit
Refer to the P&I diagrams of the relevant APSAL unit.
According to the APSA-L design, the cold box includes:
♦ the distillation column K01 where the nitrogen/oxygen separation takes place,
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♦ the main exchanger E01 which serves for cooling down the air to its dew point temperature
while at the same time heating up the nitrogen and the waste coming out of the column by
counter flow,
♦ the vaporizer-condenser E02, which enables the gaseous nitrogen of the column to be
condensed,
♦ The turbine expander ET01 in which the waste gas is expanded to produce enough cold to
compensate cold losses of the global system.
The whole is contained in an envelope and the void space inside the envelope is filled with perlite,
providing thus an effective thermal insulation.
The equipment described below is part of the APSA L cold box.
3.3.1. Vaporizer’s level transmitters LT614 & LT601, Valve LV614

LT614 and LT601 measure the rich liquid level in the vaporizer bath type E02. LT601 measures the
level on the total height of the vaporizer and LT614 measures from 70% to the top of the vaporizer.
LT614 also controls the rich liquid level in the vaporizer with the opening of the rich liquid valve LV614
so as to maintain the level for a total immersion of the body of the exchanger E02. LV614 valve
enables to raise the rich liquid from the sump of the column up to the vaporizer E02.
Acting principle of vaporizer’s level regulation:
If the level monitored on LT614 decreases, the controller LIC614 operates the valve LV614 in order to
increase its opening and inversely...
600
Waste
LIC LT 600
614 614 LV
614
GAN
350 50
LIN
1000 600 600
Dry Air
1000
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3.3.2. Column’s level transmitter LT602

LT602 measures the rich liquid level at the bottom of the column K01.
In the gas running mode of the plant, its function is to keep a sufficient cold production. Thus the
controller LIC602 will act on the turbine nozzles to adjust the cold production.
If the level LI602 rises, the valve FY 608 closes.
FV
HV
ET01
ET01
608
K01
LT
602
LIC
602A
In the liquid run of the plant, the controller LIC602 controls the columns’ level. The output of this
controller is acting on the liquid production valve LV602.
K01
LT LIC
602 LIN STORAGE
602B
LV_602B
If the level LT602 rises, the opening of the LV602 is increased too.
The LIN production acts on the inlet guide vanes via the controller HS602:
• When the LIN production is switched off, a ramp down is applied on the controller (the
percentage is adjusted during the start up)
• When the LIN production is switched on, a ramp up 0-100% is applied on the controller
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3.3.3. Hydrocarbon deconcentration valve KV603

For safety reasons and correct operation of the condenser, the level of RL must be maintained so that the
condenser E02 is immersed at 100%. It is controlled by LIC614, acting on valve LV614. Furthermore, a small flow of
RL is withdrawn from the bottom of the vaporizer by a cyclic purge (through KV603, ON/OFF pneumatic valve) in
order to avoid hydrocarbons concentration in the vaporizer. A minimum purge of 0.2 % of the incoming air flow is
required. To achieve the desired flow rate, it is periodically (every 1 hour) opened for a fixed calculated duration.
Before and after the purge, the level LT601 is recorded. If the difference level is greater or equal to a minimum
value of 5%, a valid purge is added to the event counter FXI603. If this counter value decreased less than 22 on a
sliding period of 24 hours, the alarm FXAL603 appears.
The operator can manually purge by opening the KV603 to try to increase the counter FXI603 value.
If the counter value decreased less than 20 on a sliding period of 24 hours continuously for 24 hours, the unit is
automatically tripped by FXALL603.
For the safety of the plant, the good operation of this valve is crucial.
3.3.4. Purge valves KV623 / KV633

KV623 purge valve enables to drain the rich liquid at the bottom of the distillation column K01 when the
rich liquid level is too high, or for a maintenance operation.
KV633 purge valve enables to drain the liquid nitrogen if the LIN purity does not meet the customer
requirement, or for a maintenance operation.
3.3.5. Flow control valves-FV615A, FV615B
FV615A valve enables the control of GAN flow rate sent to customer network which is collected at the
top of the distillation column K01.
FV615B valve enables the vent of GAN to the atmosphere if the GAN specifications don’t meet the
requirements: high purity, high pressure… or if the customer’s consumption decreases.
3.3.6. Manual valves

♦ the drain valve at the bottom of the column VLR05,
♦ the drain valve of the vaporizer E02 VLR04,
♦ the deriming valves of the vaporizer VE02 and VAD02A
♦ the waste oxygen valve on the cryogenic drain pipes VCVWO10, equipped with a non-return
check valve
3.3.7. Pressure relief valves

♦ PSV105: at the outlet of the compressor. This is a flow safety valve. It protects the warm skid
and the cold box from overpressure coming from the compressor.
♦ PSV257: on the waste residual pipe to warm skid silencer. This is a flow safety valve. It
protects the electrical heater E08, the main exchanger E01 and the turbine ET01. Its sizing is
based on two main scenarios: valve HV240 blocked open or PV261 blocked closed. This safety
valve has to evacuate the maximum total flow of these scenarios.
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♦ PSV610: on the waste gas line coming out of the vaporizer E02. These are flow safety valves
protecting the vaporizer E02 from overpressure. The overpressure can come from the
uncontrolled total opening of the valve LV614. If the maximum flow in this case is lower than
the nominal vaporization rate, the latter will be taken into account for the sizing of the PSV.
♦ PSV615: on GAN line before the tie-in with client, this valve is used to protect the unit from
overpressure that can come from client network
♦ TSV620: on the air line from E01 to K01. This is a flow safety valve and protects the column
during start-up in case of LIN assist mode.
♦ TSV630: on the LIN from K01 to V50. from low pressure column storage tank inlet valves
HV613A/B. This is a pressure safety valve protecting the lines from overpressure by cold liquid
vaporization inside the line.
♦ PSV054: on the instrument air circuit. This is a flow safety valve protecting the valves on the
instrument air circuit from an overpressure coming either from the purification unit or from the
liquid nitrogen storage, which could occur with the rupture of the pressure controllers PCV050
or PCV053.
3.3.8 The controller cabinet (Y60) –This cabinet is replaced by several junction boxes-
This cabinet is fitted with one force ventilated enclosure with an electrical heater and an electrical
fan.

♦ selector switches and push buttons located on the front panel
For example:
♦ Input / output cards for instruments installed in the cold box (level transmitters : LT601, LT602
and LT614, temperature transmitters : TE608, TE615, TE625, pressure transmitters : PT615,
flow transmitters FT615and FT630.
3.4. Turbine Expander ET01
The turbine expands the waste gas coming from the top of the vaporizer E02 to compensate cold
losses of the cold box system.
The waste gas coming from E02 at medium pressure and low temperature, is first sent to main heat
exchanger E01 to be warmed up at around –140°C, so as to enter the turbine at a proper temperature.
The expansion of the gas in the turbine produces cold: the waste gas is then at low pressure and cold
temperature –180°C. It then goes at the cold end of the main heat exchanger E01. Exiting E01, it is
sent to front end purification unit to regenerate adsorbent beds.
The turbine expander section includes the following equipment:

♦ Turbine ET01
♦ Temperature probe : TE608
♦ On / Off isolation valve KV651
♦ Pressure transmitter : PT640
♦ Oil circuit
♦ Oil brake valve
Document N°.
57506-60-01-PR-019B031
FORM
Rev 0
Page 21 of 24
♦ Oil / Water exchanger

♦ Instrument air connections
♦ Deriming pipes
3.4.1. Turbine by-pass pressure control valve PV640

This valve is located on the by-pass of the turbine expander ET01. It maintains the pressure in the
vaporizer-condenser E02 stable in order to keep the column’s pressure stable. It also ensures a
pressure drop constant in the turbine.
PIC
640
PV_640
PT
E02 640
ET01
ET01 E01
3.4.2. Manual valves

♦ The drain valve located on the waste gas line upstream the filter to allow dismantling
operations of the filter,
♦ The oil brake valve located on the oil circuit line upstream the turbine to adjust manually the
cold production capabilities of the turbine expander when switching from LIN to a GAN run.
Document N°.
57506-60-01-PR-019B031
FORM
Rev 0
Page 22 of 24
3.5. Liquid Nitrogen Storage And Back-up Vaporization
It consists of the following equipment:
♦ LIN storage tank V50 and LIN PBUC V50E

♦ LIN vaporizer E51.1/2/3/4
♦ Control valves
The equipment described below is part of the APSA L LIN back-up system.
3.5.1. Storage Pressure Control Valve

To maintain pressure, the valve PV821A on the Pressure Built-Up Coil (PBUC) will be opened by the
thresholds on pressure PI821A. A small amount of liquid is then vaporized in the PBUC and injected at
the top of the tank to increase the pressure.
To fill the tank, the pressure must be lower than the generator. To decrease the pressure, the vent
valve PV821B is opened by the controller PIC821B. During filling, the liquid arrives at the top of the
storage (gaseous phase) which increases tank pressure. When the pressure is low enough the valve
PV821C is open in order to ensure the filling of the tank.
3.5.2. Storage Inlet & Outlet Control Valve HV813A/B

The storage tank V50 operate in two modes, BACK UP and FILLING IN. For each model, the inlet and
outlet valves HV813A, HV813B work in sequence. We can not fill the storage with HV813A and at the
same time continue to vaporize the liquid inside the storage. However it is possible to vaporize while
filling with a truck. In order to fill the storage V50 with HV813A from the column, the pressure shall be
lower than the pressure of the column K01.
Before sending the liquid nitrogen to storage, the line shall be purged via HV813B.
3.5.3. Atmospheric Vaporizers Automatic Valve PV971A/B

Depending on the demand from the client the control valves PV971A/B will have the information from
PY971B and will switch to valve PV971B for the biggest flow and to PV971A for the nominal flow.
In case of the temperature detected by TIC974A the valves PV971A/B will be proportionally closed or
opened in order avoid temperature <0°C. If one of TI974A/B is lower than 0°C, the system will trip.
The vaporization will start automatically upon detection of low pressure PAL971 on client side and only
operators can stop it manually.
HV985A – HV985C – HV985B: In case of a detection from PDAL672, the back-up nitrogen will be
used for seal gas. The valves HV985A/B will open and HV985C will close. It will start automatically the
vaporization, however the vaporization can only by stopped manually.
3.5.5. Pressure relief valves

♦ PSV821: On the line of the outlet of the PBUC, ensures the protection of the storage tank from
overpressure of PBUC.
Document N°.
57506-60-01-PR-019B031
FORM
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Page 23 of 24
♦ PSV0-86513AA/AB/BA/BB: on the inlet line to storage tank after inlet valves HV0-86513A/B.
These are pressure safety valves protecting H0-8601A/B from over pressure.
♦ PSV810A/B: on top of storage tank. There are pressure safety valves protecting V50 from over
pressure.
♦ TSV821A/B/C: on top of storage tank. There are thermal safety valves protecting LIN lines
from over pressure.
♦ PSV0-86542A/B: from storage tank to LIN vaporizer, protecting piping from overpressure.
♦ TSV970: from storage to LIN vaporizer after inlet valve KV0-86553A/B, protecting LIN
vaporizer H0-8607A/B/C/D/E/F/G/H from overpressure
♦ PSV974: at outlet of LIN vaporizer H0-8607A/B/C/D/E/F/G/H, protecting from overpressure to

downstream.
♦ PSV984: at GAN tie-in to seal gas line, protecting seal gas line and equipments from
overpressure.
4. PRINCIPLE OF THE PRODUCTION CONTROL SYSTEM

Refer to the process control strategy document, delivered with your specific plant.
4.1. Air Flow Control
APSA L units have been designed to automatically adjust the consumption to the GAN customer
demand.
The compressor IGV controls the air flow for the inlet of the cold box depending on the nitrogen
requirement. Its set point (calculated by FIC630) is a function of the required GAN production and of
the extraction ratio adjusted during start up.
FX F IC SP
630 630 615
R 01 R 02 G A N SE T
FT TE
630 630 P O IN T
CC0011
A IR T O
FV _630 CO LD BO X
PT
202
Note: FV630 is optional, usually air flow control is directly done by:
- adjusting the IGV of the compressor (in case of centrifugal compressor)
- controlling the opening of blow-off value (PV202) in case of volumetric compressor.
Document N°.
57506-60-01-PR-019B031
FORM
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Page 24 of 24
4.2. Nitrogen flow control
GAN production is modulated by two valves in case of a change in the customer’s consumption.
♦ The valve FV615A limits the GAN production to the network to the requested GAN flow
required by the customer in the limit available by the cold box.
♦ The valve FV615B vents the GAN in case of lower consumption of the customer, so as to
maintain a GAN flow constant at the outlet of the cold box. If the nitrogen consumption
becomes less than that the minimum specified value, the pressure in the network rises up to
the set point and the valve FV615B opens so as to vent part of the GAN production to the
atmosphere.
FIC
615B
FX vent
615 FIC FV615B
615A
PT FT TE
615 615 615
GAN E01 GAN network

FV615A
K01
REFINERIA TALARA
NIS-Z-001 57506-60-01-PR-019B041
Air Liquide
Operating Manual - Important safety elements
13/08/2019 00
Doc No.
57506-60-01-PR-019B041
OPERATING MANUAL
Rev 0
Page 1 of 4
VOLUME B - SECTION B- 04 - SAFETY/ENVIRONMENT -

IMPORTANT SAFETY ELEMENTS
COVER PAGE

0 13/08/2019 M.ATAM RFR – Complete, ready for review

Table of Revisions
Section Description
W-FRM-15-0-14, Rev. A
Doc No.
57506-60-01-PR-019B041
OPERATING MANUAL
Rev 0
Page 2 of 4

TABLE OF CONTENTS
1 INTRODUCTION 3
2 LIMITATIONS 3
3 PROJECT EIS LIST 4
4 MINIMUM SAFETY AND RELIABILITY REQUIREMENTS 4
W-FRM-15-0-14, Rev. A
Doc No.
57506-60-01-PR-019B041
OPERATING MANUAL
Rev 0
Page 3 of 4

1 INTRODUCTION
The purpose of this document is to provide the list of Element Important for Safety (EIS) considered as being specific
for the project.
This list applies to equipment and facilities that are in the Air Liquide engineering entity’s scope.
This document shall be attached to each PID revision.
2 LIMITATIONS
Since the proper operating condition of these elements must be periodically checked, minimum frequencies for
maintenance or verification of proper operation are given in the chart.
This section has been developed taking into account the operating and design experience of Air Liquide at the time
of issuance of this document.
The section does not intend to provide any recommendation on the organization and adequate resources that is to be
set in order to ensure the general and day-to-day safety of personnel and equipment.
This list applies to equipment and facilities that are in Air Liquide engineering entity’s scope. Therefore, other
elements that may be of utmost importance to insure the safety of equipment and personnel and that are not in Air
Liquide engineering entity’s scope are not included in this list.
The setting and the functioning of the safety instrumented functions (system that acts as a safety barrier and
composed of detection elements, processing system and final control elements) established after the first plant start-
up should not be modified without the agreement of the Air Liquide engineering entity.
Standard operating procedures that are considered as EIS should be developed under the authority of the operations
team manager, and should be included in the plant operations procedures files.
W-FRM-15-0-14, Rev. A
Doc No.
57506-60-01-PR-019B041
OPERATING MANUAL
Rev 0
Page 4 of 4

3 PROJECT EIS LIST

FOR EIS SET POINTS AND DELAY REFER TO DCS DATA LIST AND CAUSE AND EFFECT
Refer to EIS List 57506-60-01-HS-009010
4 MINIMUM SAFETY AND RELIABILITY REQUIREMENTS

Refer to EIS List 57506-60-01-HS-009010
W-FRM-15-0-14, Rev. A
TALARA NIS
57506-60-01-HS-009010
PROJECT LIST OF ELEMENTS IMPORTANT FOR
Rev. 0
SAFETY (EIS) Page 1 of 17
TABLE OF CONTENTS
1 INTRODUCTION ........................................................................................................... 2
2 DOCUMENT DISTRIBUTION........................................................................................ 2
3 LIMITATIONS ............................................................................................................... 2
4 DEFINITIONS................................................................................................................ 3
5 PROJECT EIS LIST ...................................................................................................... 4
6 MINIMUM SAFETY AND RELIABILITY REQUIREMENTS..........................................17

PROJECT APPROVALS
0 (FI) 25/03/2019 C.BARIL A. VILLERMET First Issue (FI) according to master

P&IDs revision 0 and ARA rev.0
Table of Revisions
Section Description
All Text in red on “HOLD”
Derived from G-FRM-15-0-4, Rev. 0, issued 26-Mar-13 (replaces W-FRM-15-0-14)

TALARA NIS
57506-60-01-HS-009010
Rev. 0
1 INTRODUCTION
The purpose of this document is to provide the list of Element Important for Safety (EIS) considered as
being specific for the project.
This list applies to equipment and facilities that are in the Air Liquide Global E&C Solutions entity’s
scope.
This document shall be attached to each PID revision.
SPL and SA specification sheets are provided in annex of this document.
2 DOCUMENT DISTRIBUTION
When completed, this form is to be transmitted to the following personnel.
Table 1
Project Manager: M. PAILLET
Project Engineers: M. ATAM
Systems Specialist: E. RODRIGUES
Instrumentation Specialist: M. LAURENT
Process Control Specialist: C. BECKER
Industrial Risk Management Representative: C. BARIL
Installation Specialist: C. JACQUELIN
Site Construction Manager: TBC
Site Commissioning Manager: TBC
3 LIMITATIONS
Since the proper operating condition of these elements must be periodically checked, minimum
frequencies for maintenance or verification of proper operation are given in the chart.
This section has been developed taking into account the operating and design experience of Air
Liquide at the time of issuance of this document.
The section does not intend to provide any recommendation on the organization and adequate
resources that is to be set in order to ensure the general and day-to-day safety of personnel and
equipment.
This list applies to equipment and facilities that are in Air Liquide Global E&C Solutions entity’s scope.
Therefore, other elements that may be of utmost importance to insure the safety of equipment and

TALARA NIS
57506-60-01-HS-009010
Rev. 0
personnel and that are not in Air Liquide Global E&C Solutions entity’s scope are not included in this
list.
The setting and the functioning of the safety instrumented functions (system that acts as a safety
barrier and composed of detection elements, processing system and final control elements)
established after the first plant start-up should not be modified without the agreement of the Air Liquide
Global E&C Solutions entity.
Standard operating procedures that are considered as EIS should be developed under the authority of
the operations team manager, and should be included in the plant operations procedures files.
4 DEFINITIONS
The following definitions are issued from GD-SR-COM-008.
SPL Safety Protection Loop: A SPL is a protection loop that is declared as EIS. A SPL is
made of sensor(s), logic solver(s), final element(s) and connector elements linking
them together to mitigate the frequency/consequences of a risk
DSLS Dedicated Safety Logic Solver: DSLS is a Logic Solver which is dedicated to the
treatment of safety loops. It can be Safe Guard System (SGS) or Relays or
Pneumatic systems
BPCS Basic Process Control System
DCS Distributed Control System: DCS is a type of Programmable Electronic Logic Solver
which is typically used as BPCS for the control of plants
SA Safety Alarm: An alarm that is declared EIS. For example, the high hydrocarbon
content alarm on ASU main vaporizer is a SA. SA = AAHH (or AALL) that is to say
the second threshold
PRF Probability Reduction Factor: It is also known in the industry as Target Risk
Reduction Factor (TRF or RRF). The PRF of a Safety Protection Loop is the ratio of
the probability of occurrence of the feared event (i.e. abnormal situation(s) related to
personnel safety) in absence of the Safety Protection Loop and its probability of
occurrence in presence of the Safety Protection Loop (typical values between 10 and
10000).
PRF is assumed to be equal to one over the Probability of Failure on Demand (PFD)
of the Safety Protection Loop
SIL Safety Integrity Level: Cf GD-SR-COM-008 for correspondence between SIL, PRF
and PFD

TALARA NIS
57506-60-01-HS-009010
PROJECT LIST OF ELEMENTS IMPORTANT FOR SAFETY (EIS) Rev. 0
Page 4 of 17
5 PROJECT EIS LIST

For set points and delays, refer to SPL and SA specification sheets.
Table 2: Project EIS list

SPL Installa-
Main Feared
EIS Description of
Associated
Equipment
tion
No. EIS
EIS: Description, Complete TAG of check or test

Event
D B Required Doc Ref Test Period verified Tested

All Elements and Redundancy Level S P SA PID No. performed on
PRF (5) (1) (3) (4)
(2) L C site if
S S Date/Visa Date/Visa applicable
4 years
Loss of Pressure safety valves at C01 main
MAIN AIR maximum or
containment air compressor discharge: 60-01-PR-
COMPRESSOR - - - N/A - according to
due to 014010
C01 _PSV105 (set@ 12.23 kg/cm²g) applicable
overpressure
regulation
Procedure for safe work in confined
spaces:
AIR Intrusive
PURIFICATION _Monitoring of atmospheric conditions
maintenance in GT-PR-
UNIT - - - N/A - -
air purification _Rescue team HSE-010
R01/R02 vessel
_Purging / venting / inerting
_Personal oxygen detector
ELECTRICAL 4 years
Loss of Pressure safety valve on waste
REACTIVATION maximum or
containment oxygen line upstream E08 electrical 60-01-PR-
HEATER - - - N/A - according to
due to reactivation heater: 014031
applicable
E08 overpressure _PSV257 (set@ 6.11 kg/cm²g) regulation

TALARA NIS
57506-60-01-HS-009010
Page 5 of 17
SPL Installa-
Main Feared
EIS Description of
Associated
Equipment
tion
No. EIS

Event

PRF (5) (1) (3) (4)
(2) L C site if
Temperature measurement on
Direct relay
ELECTRICAL Loss of electrical reactivation heater (thermal
REACTIVATION containment protection): 60-01-PR- All loop: 4
HEATER - - N/A -
due to over- _TE238A/B 014031 years max
E08 temperature _TSHH238A/B with alarm and
shutdown by direct relay
MAIN HEAT 4 years

EXCHANGER Loss of
Pressure safety valve downstream maximum or
E01 containment 60-01-PR-
GAN production valve FV615A: - - - N/A - according to
due to 014060
GAN _PSV615 (set@ 10.5 kg/cm²g) applicable
overpressure
PRODUCTION regulation
LIN 4 years
VAPORIZERS Loss of Pressure safety valve downstream
maximum or
E01 containment LIN vaporizers (GAN back-up 60-01-PR-
- - - N/A - according to
due to production): 014166
GAN applicable
overpressure _PSV974 (set@ 10.5 kg/cm²g)
PRODUCTION regulation
Cold box design:

Cold box _use of resilient material for elements
collapse and processing at cryogenic temperature
massive perlite _pipes mainly welded, flanges and
COLD BOX spillage couplings wrapped up in rock wool for - - - N/A - - -
resulting from diffusion of an eventual leak)
structural
_cold vents not oriented towards
weakness
structures (design and ready for start-
up reviews)

TALARA NIS
57506-60-01-HS-009010
Page 6 of 17
SPL Installa-
Main Feared
EIS Description of
Associated
Equipment
tion
No. EIS

Event

PRF (5) (1) (3) (4)
(2) L C site if
Cold box
collapse and Only
Periodic rounding with check of Weekly
massive perlite applicable
instrument air cold box blowing flow & 60-01-PR- recommended
COLD BOX spillage - - - N/A - by
pressure: 014070 operational
resulting from 1 month max
_FI617 team
structural
weakness
Cold box Periodic site
collapse and rounds for the
massive perlite purpose to
Weighed disc installed on top of cold verify the proper
COLD BOX spillage - - - N/A - - operation of
box structure
resulting from weighed disc on
structural cold box
weakness structure
Cold box
collapse and Calculation and construction of cold
massive perlite box as per aseismic regulations
COLD BOX spillage (Peruvian E.030 National Code - - - N/A - - -
resulting from “Earthquake-resistant Design”: zone 4
structural location; Zone factor Z=0.45)
weakness
Pipe rupture
due to cold Check valve on air discharge lines
MAIN HEAT embrittlement from driers R01/R02: 60-01-PR- GD-SR-
EXCHANGER in case of air - - - N/A 5 years max
_CVWO09C 014030 COM-003
E01 back flow from
the cold end of _CVWO09D
the exchanger

TALARA NIS
57506-60-01-HS-009010
Page 7 of 17
SPL Installa-
Main Feared
EIS Description of
Associated
Equipment
tion
No. EIS

Event

PRF (5) (1) (3) (4)
(2) L C site if
Pipe rupture at
warm end of _By design, main air compressor
MAIN HEAT heat exchanger compensates the loss of air flow, then
EXCHANGER resulting from a low IA pressure (PAL050), then unit - - - N/A - - -
E01 cryogenic trips due to valves discordance or
embrittlement PSLL670 (turbine seal gas)
on air inlet line
Temperature measurement on GAN
line at warm end:
Pipe rupture at
_TE615 GD-SR-
warm end of 3 to 10
MAIN HEAT _TAL615 COM-003
heat exchanger 60-01-PR- All loop : 4
EXCHANGER _TSLL615 - x - (as per
resulting from 014060 GD-SR years max
E01 _Automatic Cold Box trip in particular GDSR)
an improper COM-008
closing of FV615A by solenoid
heating of GAN
deactivation (and FV615B to S02
silencer): IN5.1
Pipe rupture at
warm end of
MAIN HEAT GAN Line at exchanger E01 warm end
heat exchanger 60-01-PR- GD-SR-
EXCHANGER in resilient material at least up to valve - - - N/A -
resulting from 014060 COM-003
E01 FV615A and on the S02 silencer line
an improper
heating of GAN
Pipe rupture at Temperature measurement on WO

warm end of line at E01 warm end: GD-SR-
MAIN HEAT 3 to 10
heat exchanger _TE/TT625 60-01-PR- COM-003 All loop : 4
EXCHANGER _TAL625 - x - (as per
resulting from 014060 GD-SR years max
E01 _TSLL625 GDSR)
an improper COM-008
heating of WO _Automatic plant shutdown: IN5.1

TALARA NIS
57506-60-01-HS-009010
Page 8 of 17
SPL Installa-
Main Feared
EIS Description of
Associated
Equipment
tion
No. EIS

Event

PRF (5) (1) (3) (4)
(2) L C site if
4 years
Loss of
Pressure Safety Valve at K01 column maximum or
MP COLUMN containment 60-01-PR-
outlet (WO line): - - - N/A - according to
K01 due to 014060
_PSV610 (set@ 6.11 kg/cm²g) applicable
overpressure
regulation
Explosion of the
main vaporizer CO2 analysis in the vaporizer sump: Analyser
resulting from _AE684 60-01-PR- calibration as
ignition of _AIT242 014030 per vendor's
MAIN GD-SR-
accumulated _AAH242 - - x N/A manual
VAPORIZER E02 60-01-PR- ASU-001
contaminants & _AAHH242
014070 All loop: 4
propagation to _Operating procedure to be applied if
years max
aluminum of AAHH threshold is exceeded
vaporizer
Explosion of the Analyzer
main vaporizer CH4 Total analyser in the vaporizer calibration /
resulting from sump: verification:
ignition of _AIT684 refer to
MAIN 60-01-PR- GD-SR-
accumulated _AAH684A - - x N/A Operating
VAPORIZER E02 014070 ASU-001
contaminants & _AAHH684A Manual
propagation to _Operating procedure to be applied if Alarm: 4
aluminum of AAHH threshold is exceeded years max
vaporizer

TALARA NIS
57506-60-01-HS-009010
Page 9 of 17
SPL Installa-
Main Feared
EIS Description of
Associated
Equipment
tion
No. EIS

Event

PRF (5) (1) (3) (4)
(2) L C site if
Explosion of the
main vaporizer CnHm (except CH4) analyser in the Analyser
resulting from vaporizer sump: GD-SR- calibration as
ignition of _AIT684 ASU-001 per vendor's
MAIN 60-01-PR-
accumulated _AAH684B - - x N/A manual
VAPORIZER E02 014070 GD-SR
contaminants & _AAHH684B
propagation to COM-008 Alarm: 4
_Operating procedure to be applied if years max
aluminum of
AAHH threshold is exceeded
vaporizer
Explosion of the
main vaporizer
MAIN resulting from
VAPORIZER concentration of _Instruction for purge after 48h - - - N/A - - -
E02 contaminants shutdown of the unit.
inside
passages
Explosion of the
main vaporizer
MAIN resulting from
VAPORIZER concentration of _Visual inspection of Front End - - - N/A - - -
E02 contaminants Purification dust filter
inside
passages
Explosion of the
main vaporizer
MAIN resulting from
VAPORIZER Operating 4 years
concentration of _Periodical deriming and wash test - - - N/A - manual maximum
E02 contaminants
inside
passages

TALARA NIS
57506-60-01-HS-009010
Page 10 of 17
SPL Installa-
Main Feared
EIS Description of
Associated
Equipment
tion
No. EIS

Event

PRF (5) (1) (3) (4)
(2) L C site if
LOX purge flow rate measurement

(0.,2% of air flow rate):
Explosion of the _FX603
main vaporizer GD-SR-
_FAL603
resulting from ASU-001
MAIN _FSLL603 60-01-PR- All loop : 4
concentration of - x - <10
VAPORIZER E02 014070 GT-PR years max
contaminants _Automatic cold box shut down when
inside IN5.1 is activated on FSLL, in ASU-002
passages particular stop the feed air within a
delay in case of purge failure.
Instruction to maintain 100%

immersed level and dual level
Explosion of the measurement:
main vaporizer _LIT601 / LIT614 GD-SR-
MAIN resulting from _LAL601 / LAL614 60-01-PR- ASU-001 All loop : 4
- x - <10
VAPORIZER E02 concentration of _LSLL601 / LSLL614 014070 GT-PR years max
contaminants _ Dual level measurement with
inside ASU-002
automatic cold box shut down when
passages IN5.1 is activated on LSLL, in
particular stop the feed air and close
the main outlet streams.

TALARA NIS
57506-60-01-HS-009010
Page 11 of 17
SPL Installa-
Main Feared
EIS Description of
Associated
Equipment
tion
No. EIS

Event

PRF (5) (1) (3) (4)
(2) L C site if
Seal gas pressure on WO turbine

ET01:
Explosion of the
main vaporizer _PIT670 60-01-PR-
resulting from _PY670 014070
MAIN GD-SR- All loop: 4
concentration of - x - < 10
VAPORIZER E02 _PSLL670 C57506- ASU-001 years max
contaminants
inside _ When PSLL is activated: WO 003-651200
passages turbine shut down (by closing of
KV651 turbine inlet valve by solenoid
deactivation) and oil pump shut down
AIR Explosion of the Analyser
CO2 analysis at purification unit outlet:
PURIFICATION main vaporizer calibration as
_AIT242
UNIT resulting from per vendor's
_AAH242 60-01-PR- GD-SR-
R01 & R02 concentration of - x - manual
_AAHH242 014030 ASU-001
contaminants
MAIN _Automatic purification shutdown All loop: 4
inside
VAPORIZER E02 when IN4.1 is activated on AAHH years max
passages
Micro explosion
MP COLUMN in purge system _Purge system design as per AL
K01 resulting from standard with valves (automatic or - - - N/A - - -
MAIN CnHm manual) protected by gas plug /
VAPORIZER E02 hydrocarbons insulation
concentration
NITROGEN STORAGE AREA
Huge release of
LIN VACUUM nitrogen in the Retention pit or spillage area
INSULATED atmosphere (pebbles, gravel or concrete) GD-SR-
NA - -
STORAGE TANK resulting from ASU-002
V50 (266m3) the rupture of Absence of sewers near spillage area
the vessel

TALARA NIS
57506-60-01-HS-009010
Page 12 of 17
SPL Installa-
Main Feared
EIS Description of
Associated
Equipment
tion
No. EIS

Event

PRF (5) (1) (3) (4)
(2) L C site if
Storage emergency stop buttons:

_HS821A/B
Huge release of _Interlock with action to activate the
LIN VACUUM nitrogen in the safe isolation of the storage tank 60-01-PR-
INSULATED atmosphere 014106 GD-SR-
through shutdown of all relays and - x - N/A 1 year max
STORAGE TANK resulting from solenoids associated with the tank:: 60-01-PR- ASU-009
3
V50 (266m ) the rupture of _Closing of liquid production lines by 014107
the vessel HV813A, and truck to tank valve
PV821C when HS is activated when
HS is activated: IN61
Huge release of Calculation and construction of V50
LIN VACUUM nitrogen in the storage tank anchors as per aseismic
INSULATED atmosphere regulations
- - - NA - - -
STORAGE TANK resulting from (Peruvian E.030 National Code
V50 (266m3) the rupture of “Earthquake-resistant Design”: zone 4
the vessel location; Zone factor Z=0.45)
Combination of pressure safety valve
(PSV) AND Rupture disc on the same
Huge release of line:
4 years
LIN VACUUM nitrogen in the _PSV810A (1x100%) (set@ 12.23
maximum or
INSULATED atmosphere kg/cm²g) and Rupture Disc DR3A 60-01-PR-
- - - N/A - according to
STORAGE TANK resulting from (1x100%) 014107
applicable
V50 (266m3) the rupture of _PSV810B (1x100%) (set@ 12.23
regulation
the vessel kg/cm²g) and Rupture Disc DR3B
(1x100%)

TALARA NIS
57506-60-01-HS-009010
Page 13 of 17
SPL Installa-
Main Feared
EIS Description of
Associated
Equipment
tion
No. EIS

Event

PRF (5) (1) (3) (4)
(2) L C site if
Tank overfilling measurement:

Huge release of _LIT822 on tank
LIN VACUUM nitrogen in the 60-11-PR-
_LAH822 014106
INSULATED atmosphere _LSHH822 with closing all liquid feed GD-SR- All loop: 4
- x - < 10
STORAGE TANK resulting from lines: Closing of liquid production lines 60-11-PR- ASU-009 years max
V50 (266m3) the rupture of by HV813A, and truck to tank valve 014107
the vessel PV821C when LSHH is activated:
IN61.1
Resilient material (line at E51.1/2/3/4
warm end in stainless steel at least up
Pipe rupture at to 10m downstream connection, till
warm end of TP04) and temperature measurement
LIN VACUUM vaporizer at warm end:
3 to 10
INSULATED resulting from _TE974 A / B 60-11-PR- GD-SR- All loop: 4
- x - (as per
STORAGE TANK an improper _TAL974 A / B 014166 COM-003 years max
V50 (266m3) heating of _TY974 (1oo2) GDSR)
cryogenic LIN _TSLL974
to be vaporized _Automatic closing of nitrogen
vaporizers inlet valves PV971A/B
when TSLL is reached: IN65.1
OTHERS
Valves isolating _3 way valve (on V50) upstream
safety valves pressure safety valves to be made
V50 STORAGE - - - NA - - -
and/or rupture impossible to isolate both safety
discs valves simultaneously
Reinforced / bolted box on MAC MV
MAC MV MOTOR Fire motor with vent for surge capacitor in - - - N/A - - -
order to release the overpressure

TALARA NIS
57506-60-01-HS-009010
Page 14 of 17
SPL Installa-
Main Feared
EIS Description of
Associated
Equipment
tion
No. EIS

Event

PRF (5) (1) (3) (4)
(2) L C site if
Valves and actuators are designed for

INSTRUMENT Loss of fail safe position
- - - N/A - - -
AIR SYSTEM instrument gas PSVs are designed to protect the
plant
Back flow of
nitrogen in
intrument air
Check valve on instrument air line to
INSTRUMENT network and 60-01-PR- GD-SR-
ET01 seal gas: - - - N/A 5 years max
GAS nitrogen leak 014200 COM-003
without _CIA01C
operators being
informed
_Physical separation of air and
INSTRUMENT 60-11-PR-
Loss of inerting nitrogen networks with double block - - - N/A - -
GAS HV985A/B and bleed HV985C 014166
CRYOGENIC
LIQUID PURGE Design of vaporizer stack with free
SYSTEM Rapid Phase
water drainage at the bottom of the 60-11-PR-
Transition in - - - N/A - -
LIQUID stack via small hole/purge line routed 014200
stones pit
DISPOSAL to a spillage area
VAPORIZER E80
Pressure vessels inspection

GENERAL - - - - N/A - - -
procedure & plan
Qualification, working permit and lock-

GENERAL - out and tag out procedure for - - - N/A - - -
intervention on electric devices

TALARA NIS
57506-60-01-HS-009010
Page 15 of 17
SPL Installa-
Main Feared
EIS Description of
Associated
Equipment
tion
No. EIS

Event

PRF (5) (1) (3) (4)
(2) L C site if
Emergency response plan:

_Alarm(s), plant shutdown and
personnel evacuation procedures for
GENERAL - each potential risk from neighbouring - - - N/A - - -
site (personnel training and drills)
_Procedure to shutdown and secure
the unit in case of natural disaster
Communication management system

GENERAL - - - - N/A - - -
with neighbouring sites
Traffic plan and limited speed

GENERAL - Safety distance between designated - - - N/A - - -
parking lot and process
Oxygen
Instructions to wear individual oxygen GT-PR-
GENERAL enrichment or - - - N/A - -
monitor HSE-008
deficiency
_Waste Oxygen / Nitrogen exhausts
sent to safe location (hazard zones
assessed by dispersion study)
Gaseous GD-SR-
GENERAL _Gaseous vents design: sufficient - - - N/A - -
venting COM-011
outlet velocity / height / safe location /
vertical direction; not oriented towards
structures
Gaseous
GENERAL WO vent pipe made of stainless steel - - - N/A - - -
venting

TALARA NIS
57506-60-01-HS-009010
Page 16 of 17
SPL Installa-
Main Feared
EIS Description of
Associated
Equipment
tion
No. EIS

Event

PRF (5) (1) (3) (4)
(2) L C site if
Oxygen Sewers distant from liquid spillage

GENERAL - - - N/A - - -
deficiency area
NOTES:
(1) For SPL, testing means full functionality check.
(2) For information, the default minimum safety and reliability requirements to be taken into account in the equipment specifications are given in Section 6.
(3) Installation means proper installation completed. This verification must be performed by the construction manager or construction manager’s delegate and
documented by visa.
(4) When testing is not applicable (e.g. when EIS is a procedure, a wall, etc.), “NA” is to be put instead of the date. The completion of the functionality must be
performed by the commissioning manager or his delegate and documented by visa.
(5) Doc Ref column is to be deleted before EIS list transmission to third party customer.

TALARA NIS
57506-60-01-HS-009010
Rev. 0
6 MINIMUM SAFETY AND RELIABILITY REQUIREMENTS
Table 3
Lambda PFD
MTBF (hours) test frequency = 1 year
MEAN TIME BETWEEN FAILURES
(nb of failure per hour)
PROBABILITY OF FAILURE ON
FAILURE RATE
DEMAND
Instruments
Sensors
Pressure / Level sensor 787 402 1,27E-06 5,56E-03
Temperature sensor 1 886 792 5,30E-07 2,32E-03
Flow sensor 500 000 2,00E-06 8,76E-03
Others
Analyzer 17 544 5,70E-05 2,50E-01
Fire and Gas detector 207 900 4,81E-06 2,11E-02
Treatment
Control System
BPCS / DCS No safety requirement - Design to be in compliance with E-EP-8-7-100
Safeguarding System
SGS - SIL 3 capable - (PLCAK 6) Not applicable Not applicable (!3)'(
Safety Relay Not applicable Not applicable 1,34E-03
Actuators
Pressure relief device
Conventional PSV (Clean service) Not applicable Not applicable 8,59E-04
Piloted PSV (Clean service) Not applicable Not applicable 1,78E-03
Valves
Ball valve * 62 775 1,59E-05 3,93E-02
Gate valve * 96 432 1,04E-05 3,32E-02
Butterfly valve * 26 903 3,72E-05 6,33E-02
Globe valve * 122 249 8,18E-06 1,93E-02
* Values includes solenoid + actuator + valve body

REFINERIA TALARA
NIS-Z-001 57506-60-01-PR-019B051
Air Liquide
Operating Manual - Start up procedure
06/08/2019 00
Document N°
57506 -60-01-PR-019B051
OPERATING MANUAL
Rev 0
Page 1 of 11
OPERATING MANUAL - B-05 – PLANT START-UP
COVER PAGE

0 24/07/2019 P.BARELLE First Issue (all Highlighting part should be
check and adjust during start up)
Project Number C.57506

Table of Revisions
DISCLAIMER
The information contained in this document has been prepared by L’Air Liquide S.A. and/or its controlled subsidiaries (“Air Liquide”), exclusively for their use, and is Air Liquide property. Air
Liquide believes the information is current and accurate, but circumstances may warrant additional requirements or procedures. This document is subject to periodic review and users are
cautioned to obtain the latest edition.
Air Liquide makes no representations or warranties to third parties as to the quality, accuracy or completeness of information contained in this document and EXPRESSLY DISCLAIMS ALL
WARRANTIES, INCLUDING, BUT NOT LIMITED TO, THE WARRANTY OF MERCHANTABILITY AND THE WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE.
Unauthorized use of this document by any third Party, including Air Liquide contractors and subcontractors, shall be at such Party’s own risk, and Air Liquide assumes no liability in connection
with information contained herein. Air Liquide disclaims any liability for any damage suffered by any company or person as a result of or in connection with the use, application or
implementation of the information contained herein or any part thereof. The benefit of this disclaimer shall inure to Air Liquide and its affiliates.

Document N°
57506 -60-01-PR-019B051
OPERATING MANUAL
Rev 0
Page 2 of 11
TABLE OF CONTENTS
1. UTILITIES 3
1.1. Electricity 3
1.2. Instrument Air 3
1.3. Cooling Water 3
1.4. Cold Box and cryodrain vessel E80 ventilation 3
2. START UP 4
2.1. Conditions 4
2.2. Start Up Sequence 4
2.2.1. Dryer 5
2.2.2. Air Compression 5
2.2.3. Air Purification Unit 6
2.2.4. Cold Box 6
2.2.5. Turbine 8
3. PRODUCTION 10
3.1. GAN Production 10
3.1.1. Warning 10
3.1.2. GAN Production 10
3.2 LIN PRODUCTION 10
Document N°
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OPERATING MANUAL
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Page 3 of 11
1. UTILITIES
re to start the unit, all utilities have been checked and adjusted.
1.1. Electricity
SGW-2-SE1-01 MV, SWG-0-SE1-02 MCC, UPSP-0-SE1-S1 UPS panel, SGW-0-SE1-01 and 02 LV service,
and EDP-0-SE1-01 Emergency Panel are energized.
- Medium voltage (MCC substation)
- Low voltage (400V & 230V)
- UPS (230V Uninterrupted Power Supply)
Check that batteries of the UPS system are operational

Check that the electrical protections (fuses, breakers, protection of PLCs) are operational, and set at the
nominal value, adequate to protect personnel and materials, this for all voltages and supplies.
Check that control circuits are fed by the UPS circuit to be protected against micro cut-offs.
Check that all electrical cabinet are closed in order to protect personnel.
1.2. Instrument Air

In normal operation the instrument air is taken by the unit after the front end purification unit (FEP), it is
therefore water and CO2 free. During the first steps of start up, instrument air has to be supplied from
the customer source.
Check that the instrument air for start up is available and that the instrument air manifold is pressurized with
PIT050 indicating about 5.81 Kg/cm2 g.
Check the proper position of the manual valves on the air network: and-PCV050 is set at 5.81 Kg/cm2 g.
Later on when the MAC will be started and one vessel of the FEP is pressurized, the instrument air will switch
automatically to the air out of FEP (Interlock IO4). PCV for normal operation (PCV053) should be set
at a higher pressure than PCV for back up supply. Recommended value is 6,11Kg/cm2 g.
1.3. Cooling Water

Prior the start up of the unit, the cooling water circuit must be operational.
- Ensure that all water instruments are properly calibrated and readings are OK
- Ensure that all manual and/or automatic valves are open or closed depending on their use. Especially at least
isolation valves to C01and ET01 coolers are open to enable a water circulation.
1.4. Cold Box and cryodrain vessel E80 ventilation

Prior the start of the cold box cool-down and the distillation process following points must be ensured.
Document N°
57506 -60-01-PR-019B051
OPERATING MANUAL
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Page 4 of 11
● Cold box is vented with nitrogen

Cold box should be ventilated with nitrogen once it has been filled with perlite and before to start the cool-
down. This will prevent ambient air ingress. First it prevents the perlite from getting wet (heavier and
lower insulation quality). Then the water and CO2 contained in the air will turn to ice when in contact
with the cold lines. This creates mechanical stress and reduces the quality of the thermal insulation.
Ensure PCV617 is set at 1,1 Kg/cm2 g and turn open manual valve VIA04A to see some flow on the
rotameter FG617.
● E80 is vented with warm IA (either air or Nitrogen)

E80 has to be lined up before cold box cool-down starts and when cryogenic liquid can be purged. VIA08A
should be cracked open to ensure a minimal air flow to the vessel; there is no orifice to control the IA
flow so valve opening should be adjusted on site.
2. START UP
2.1. Conditions
- Before to start the unit, all utilities have been checked and adjusted.
- Reset all trips on the unit (I-60). If some alarms can’t be reset find and eliminate the cause.
- Check that the following valves are closed:
Gas and liquid production valves FV615A, FV615B,LV602
Circulation from column K01 to E02 : LIC614, HCV604
Purges lines VLR05, KV623, VLR04, KV603 ,KV633.
Turbine Quick shut off valve KV651
- Air Purification Unit valves are properly aligned and the air purification bottle in service is the one that has
been reactivated last time the unit was stopped.
- Set PIC640 in automatic mode with set point = 3.4 Km/cm2 g., and PIC261 in automatic with set point =
0,170 Km/cm2 g.
- Switch “On” the “Ready to start Request” in the turbine screen. It will start the lube oil system - at first the
heater that will warm up the oil at around 15°C and after start the oil pump.
The turbine oil pump must be started 30 minutes before to start it.
2.2. Start Up Sequence
- Turbine line up
- Air compressor C01 start up / load
- Pressurization
- Air Purification Unit (R01/R02/E08) start up
- Start flow on MP column
- Start up turbine
Document N°
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OPERATING MANUAL
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- Create flow on condenser

- Distillation and Purity
- Start Production
2.2.1. Dryer
Check before to start that:
- Refrigeration compressor heating is on (preheat for at least 6 hours)
- Lube oil system is ready.
- The cooling water system is ready.
- The dryer displays “no alarms”.
Start-up:
- Start the dryer compressor and ensure that it is running correctly (the feedback for running can need 3 minutes
to appear on the PLC).
The dryer must be started 5 minutes before to start the air compressor in order to establish the correct pressure and the
correct temperature of the refrigerant.
It is designed for continuous operation and can remain switched on during periods of no load. (see operating
instruction of the refrigeration unit)
2.2.2. Air Compression

Check before start up that:
- The MCC station is ready
- All emergency stops are released
- All faults and shut-down are reset
- The lubrification system is ready (auxiliary pump running, oil temperature and level are correct)
- The water cooling system is ready (inlet/outlet valves open)
- The inlet guide valve is closed
- The anti-surge valve is fully opened
- The compressor displays “ready to start” and “unload” position
arning: Before the start of the compressor, ensure that the air purification bottle in service is the bottle which has been reactivated
last time the unit was stopped.
Start up:
emote start-up:
t the compressor discharge pressure set point at 9.78 Kg/cm2 g and set the compressor in remote mode. (see operating instruction
for the compressor). The switches on the HMI panels are on the remote position.
t the output of-FIC_630 at 30% and in manual mode. Start the compressor from the HMI. An automatic sequence will start and
load the compressor within 90 seconds. Check that the pressure increase correctly.
Document N°
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OPERATING MANUAL
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Local start-up
Refer to manufacturer manual
2.2.3. Air Purification Unit

Caution:
fer to the document given by the Air Liquide start-up supervisor « instrumentation list & alarms » to check all the controllers
parameters and all alarms set point of the unit.
Check before start up:

- Instrument air is available and supplied to the automatic valves.
- All emergency stop are released.
- Check that the automatic valves are open or closed according to the air purification step active.
- Check that the MCC station is ready for the electrical heater E08.
- The silencer is open to allow water draining during regeneration phase.
- Check that the PIC261 is in auto mode with the correct set point (0,170 Kg/cm2 g).
- The sample point for CO2 analysis is open (AIT242) and the analyzer is working.
REFER TO DOCUMENTATION SUPPLIED (CONTROLLERS SETTINGS)
Start up:
- The pressure in the adsorber should slowly rise to its nominal (9,78 Km/cm2 g) following the start of the
compressor.
- Until the cold box is fully started the regeneration flow will be provided with dry air thanks to HV240 (about
55% open to get regeneration nominal flow).
- When the regeneration pressure is correct, the adsorbers properly aligned, put the sequence in AUTO mode.
The regeneration step will start following this sequence:
Isolation, blowing/depressurization, heating, cooling, parallel
- Check the pressure reached at the end of depressurization step is lower than 0,300 Kg/cm2 .
- Check the two vessels reach the same pressure at the end of pressurization step.
- During heating or cooling steps, make sure the flow of regeneration is sufficient. If necessary, adjust the valve
HV240 opening to achieve the nominal value of the regeneration flow (see. PDIT234 and PIT261).
- It is recommended to monitor the temperature trends of the regenerated vessel and to adjust the temperature
to ensure optimum regeneration of the adsorbents (heat peak must appear).
2.2.4. Cold Box

Check before start:
- Instrument air is available and supplied to the automatic valves
- All emergency stop are released
Document N°
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- The cold box has been dried and dew point measured at different sampling points is below -70°C. If necessary,
deriming procedure can be used for the cold box drying.
- Check that turbine oil pump is ON
- Check that the valve at the turbine suction is closed (KV651)
- Check that the following valves are closed (FV615A, FV615B, LV614, LV602, VLR04, VLR05)
- Open partially incondensable valve HCV604 (~50%)
- Check that PIC640 is in auto mode with the correct set point (~3.25 – 3.35 Kg/cm2 g)
- Check that VIA04A is open for the cold box ventilation
Start-up when the plant is warm:

- The MP column is already pressurizing.
Because the plant is warm, the nominal air flow cannot enter in the cold box. When the temperature will decrease, the air
flow will increase.
- Open manually vent valve FV615B (about 25%) to reach about 60% of the nominal MP nitrogen production
flow. When flow is stable turn the controller to “Auto” and “Remote”.
- Open fully the level control valve LV614 and the manual drain valve VLR04 in order to get the maximum
flow to the condenser and to the turbine. Open VLR05 slightly. Once there is a flow to the waste line open
manual valve VCVW010A to blow cryodrain lines.
Ensure the PIC640 controls the pressure in E02 and PIC261 controls the pressure of the waste gas.
- When the air flow reaches the target set point (to make 60% of the nominal nitrogen production flow) switch
FIC630 controller to “Auto” and “Remote” if the compressor is in remote control mode.
- Check the turbine is in proper conditions to start according to the manufacturer’s instructions (seal gas
available, oil pump, bearing temperature >30°C…)
- Give the order to start the turbine and open IGV’s actuator HV608 (about 20%) to leave the critical zone with
a rotation speed higher than 5000 rpm.
- Gently lift the PIC640 to ~4 Km/cm2 g .
- Gradually load the turbine to the rated speed.
Be careful to outlet temperature, it will drop fast and can reach the alarm.
The drop temperature should be not more than -1°C by minute. The cooling down should be homogenous. All the part of
the column should be cold at the same speed to avoid thermal stress. Monitor the TI615 and adjust the flow of
valves FV615B, LV614.
- When approaching liquefying temperature close completely the manual drain valves VLR04 and VLR05.
- Liquid will start building up. When it reaches 40% in the condenser throttle the rich liquid valve LV614 to
30-50% to limit the gas flowing through this valve. When the condenser level is about 50 % the distillation
will start (pressure fluctuation will be noticed when condenser starts working).
- When the condenser is fully submerged LIC614 at 100% gradually reduces the pressure PIC640 to the rated
3.35 Kg/cm2 g.
Document N°
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OPERATING MANUAL
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- Slowly get all the installation parameters to nominal and switch controllers to automatic mode:
o Close the cold box by-pass HV240 and get regeneration from the waste gas.
o When the inlet flow will meet the requested air flow, put the FIC630 in “Auto” and put the
FV615B at the nominal set point.
o Put the PIC615 in Auto mode with the production set point and the PIC640 in Cascade mode in
order to take the output of the PIC615 as set point value.
Start-up when the plant is cold:

The main advantage of a cold start is the presence of liquid in the condenser and column, so there is no time lost to build
liquid and the condenser starts working immediately.
- For a cold start, use the automatic start.
- Ensure that the levels of liquid in the bottom of the column (LI602) and in the condenser (LI614) are not in
high alarm. If necessary, drain some liquid with the drain valves KV623 and/or KV603.
- Get the regeneration flow directly from the cold box, the flow to the condenser will vaporize the condenser
liquid and create flow through the PV640 in Auto set point at around 2 Kg/cm2. The PIC261 must also be in
Auto with regeneration pressure set point.
- The compressor level control valve LV614 should stay in “Auto” in order to maintain the level in the
condenser.
- Set in “Auto” and “Remote” the nitrogen flow control valves FV615B with a set point about 60% of the
nominal nitrogen production flow.
- Start the turbine and open IGV FV608 higher than critical speed 5000 RPM and load it in function of the
liquid production.
- When the flow will meet the requested air flow, put the FIC630 in “Auto” and “Remote” if the compressor is
in remote control mode.
- Once the nitrogen purity is satisfactory, slowly increase the set point of nitrogen flow to its nominal value.
2.2.5. Turbine
Check before start:
- The turbine has been derimed and dried prior to start up. The deriming line is closed.
- Cooling water: isolation valves are open on the supply and return lines.
- Seal gas is available and flowing through the turbine’s bearings.
Set point of seal gas (PDIT670 about 0,500 Kg/cm2) and flow about 15 Nm3/h.
- The oil circuit is running. Lube oil pump should run for at least 30 min prior to start the expander so as to
warm-up bearings.
Document N°
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- Check the bearing temperature is above min operating temperature (30°C), if not run the oil pump until the
temperature is reached.
- Check that the following valves are closed: Quick shut off valve KV651 and inlet guide vane FV608.
- No interlocks and alarms are active: the level in vaporizer E02 is not in high alarm and “Turbine trip” has
been reset.
Turbine start-up when the plant is warm:

- The level control valve LV614 is fully open, the PIC640 regulates with an opening about 80%.
- When the “Ready to start” is “On”, start the turbine by opening the KV651. The turbine will start to turn at
low speed. Start to open the Inlet Guide Vane FV608 so that the turbine speed be over 5000 rpm within 2
minutes.
- Increase the speed of the turbine but maintain the condenser pressure because the cold box is not cold.
- When the temperature will start to decrease, the flow to the turbine will increase and PV640 will close to
maintain the pressure in the condenser. It’s possible then to open a little bit more the inlet guide vane of the
turbine. The turbine should be loaded to produce enough cold to cool down the cold box at a pace not greater
than 1°C by minute.
Turbine start-up when the plant is in cold:

- The level control valve LV614 is in “Auto” mode in order to maintain the level in the condenser E02.
- The flow valve FV615B (MP Nitrogen vent) is in Auto mode with 60% of the nominal flow.
- The PIC640 regulates the condenser pressure.
- Switch on the “Ready to start Request” in the turbine screen. It will start the lube oil pump and the heater if
they were “Off”.
- Start the turbine by opening the KV651. The turbine will start to turn at low speed. Start to open the Inlet
Guide Vane. By this moment, the turbine speed must be over 5000 rpm within 2 minutes.
- During the start-up of the turbine, the level in the vaporizer will start to increase and then to decrease according
to the pressure fluctuation until the PIC640 stabilizes the pressure.
- Check that the temperature at the outlet of the turbine doesn’t decrease too much and doesn’t reach the low
alarm temperature.
- Load the turbine in function of your liquid production needs.
- In GAN mode the turbine can be regulated with the LIC602A in order to minimize the production of liquid,
and purge only during the deconcentration of condenser.
Document N°
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3. PRODUCTION
3.1. GAN Production
3.1.1. Warning
The Air Purification Unit removed some Dust, Water, Carbon Dioxide and some Hydrocarbon. To ensure that
they are correctly removed, check that the Carbon Dioxide analyze is under 1 ppm and that the heat peak are
correctly reached. If not, stop the plant and perform an exceptional regeneration of the adsorbers (290°C)
An automatic valve with a sequencer drains the correct amount of liquid each hour at least (0.2% of the inlet air
flow) when the “GAN PRODUCTION” is “ON”. In order to start the nitrogen production faster and to avoid to
drain the liquid before reaching a correct level in the E02 vaporizer, when the “GAN PRODUCTION” is “OFF”
the automatic drain is manual and must be strictly performed by the operator as soon as the level is reached. Ensure
that the correct amount of liquid is drained according to the CnHm concentration in the E02 vaporizer.
3.1.2. GAN Production

The main conditions to reach and maintain the GAN production are:
o A correct ratio between air flow and nitrogen flow
o A correct liquid production by the turbine ET01 to maintain the level in the condenser.
All the flow and pressure are stable to avoid perturbation.

After the start-up of the Cold box and the turbine, when the purity is correct, start to increase the nitrogen
production flow by increasing the set point in the production parameters screen. When the nitrogen flow is at the
nominal value and the purity is stable and correct, set the “GAN PRODUCTION” at “ON” in order to supply the
nitrogen to the network. The flow and the pressure controller go automatically in “Auto” and “Remote” mode
By a discrepancy of set-point between FIC_615A and FIC_615B, the priority is given to the FV_615A to open and supply
the network.
The incondensable gas valve HCV_604 must be open at 100% during operation of the plant. The purpose of this
valve is to remove the incondensable gas that cannot be liquefied due to their low temperature of liquefaction.
They can stop the liquid flow in the condenser E02.
Ensure that there is always enough nitrogen flow, otherwise the condenser will be to rich in N2 and the temperature will
decrease too much and stop the correct distillation. If the temperature is too low, the vaporizer-condenser will not
be able to liquefy enough nitrogen for the reflux due to a too low delta T.
3.2 LIN PRODUCTION

In case of LIN production requirement, the cold production shall be maximized in order to produce as much LIN as possible.
The operator shall adjust, through the PLC, HV608 in order to maximize gas expansion. The expansion turbine
by-pass valve (PV 640) will adjust automatically. Optimal cold production is obtained when PV640 is nearly
closed (limitation may be given as well by speed and/or oil brake maximum temperature).
Document N°
57506 -60-01-PR-019B051
OPERATING MANUAL
Rev 0
Page 11 of 11
The LIN is extracted at the top of the column, through the valve LV602. This valve is controlled by LIC602B which
regulates the level at the bottom of the column. When the LIN production is not activated, this valve is forced
closed by the PLC; and the column’s level is regulated by LIC602A (as described in the previous paragraph).
When LIN is extracted from the column, the operator has to reduce the GAN production in order to maintain the purity, by
acting on FIC615A (and possibly FIC615B) set-point.
Start-up:
- Check LIN storage and LIN line
- Put LIN mode, KV633 will open automatically for 30 sec
- LIC 614 will be in manual mode during the purge
- Open the FV608 at 75%
- Open the brake valve for to stabilize the speed of the turbine
- Open LV602 at 15 % and purge of storage
- Check the column level is stable
- Put LV602 in auto mode.
REFINERIA TALARA
NIS-Z-001 57506-60-01-PR-019B071
Air Liquide
Operating Manual - procedure to stop the plant
13/08/2019 00

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REFINERIA TALARA
NIS-Z-001 57506-60-01-PR-019B081
Air Liquide

Operating Manual-Detailed Exceptional regeneration procedure
Operating Manual - Maintenance Operations
13/08/2019 00
Document N°
57506-60-01-PR-019B081
OPERATING MANUAL
Rev 0
Page 1 of 12
OPERATING MANUAL - B-07 – MAINTENANCE OPERATIONS
COVER PAGE

0 13/08/2019 M. ATAM RFR – Complete, ready for review

Project Name APSAL – TALARA NIS
Table of Revisions
DISCLAIMER
The information contained in this document has been prepared by L’Air Liquide S.A. and/or its controlled subsidiaries (“Air Liquide”), exclusively for their
use, and is Air Liquide property. Air Liquide believes the information is current and accurate, but circumstances may warrant additional requirements or
procedures. This document is subject to periodic review and users are cautioned to obtain the latest edition.
Air Liquide makes no representations or warranties to third parties as to the quality, accuracy or completeness of information contained in this document
and EXPRESSLY DISCLAIMS ALL WARRANTIES, INCLUDING, BUT NOT LIMITED TO, THE WARRANTY OF MERCHANTABILITY AND THE
WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE.
Unauthorized use of this document by any third Party, including Air Liquide contractors and subcontractors, shall be at such Party’s own risk, and Air
Liquide assumes no liability in connection with information contained herein. Air Liquide disclaims any liability for any damage suffered by any company
or person as a result of or in connection with the use, application or implementation of the information contained herein or any part thereof. The benefit
of this disclaimer shall inure to Air Liquide and its affiliates.
This document should not be confused with federal, state, provincial, or municipal specifications or regulations, insurance requirements or national safety
codes.

Paper copies of this document are considered to be “uncontrolled” and users should always check for the most recent
revision.
Document N°
57506-60-01-PR-019B081
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TABLE OF CONTENTS
Table of Contents
Table of Contents ..................................................................................................................................................................... 2
1. DERIMING.......................................................................................................................................................................... 3
2. DRYING ............................................................................................................................................................................... 3
2.1 Purpose ..................................................................................................................................................................... 3
2.2 Drying procedure.................................................................................................................................................. 3
2.3 Basic Principles...................................................................................................................................................... 3
3. EXCEPTIONAL REGENERATION .............................................................................................................................. 4
3.1 Purpose of the exceptional regeneration .................................................................................................... 4
3.2 Process description ............................................................................................................................................ 6
3.3 Preliminary conditions required for an exceptional regeneration ................................................ 6
3.4 Start up the exceptional regeneration cycle........................................................................................... 6
3.5 End of the exceptional regeneration cycle.............................................................................................. 7
4. ADSORBENTS ................................................................................................................................................................... 9
4.1 Safety datasheets................................................................................................................................................ 9
4.2 Specifications of the alumina ......................................................................................................................... 9
4.3 Specifications of the molecular sieve ........................................................................................................ 9
4.4 Special precautions ............................................................................................................................................ 9
4.5 Procedure .............................................................................................................................................................. 10
5. ANALYZERS .................................................................................................................................................................... 10
5.1 Production analyzer AIT618 (OXYMAT 64) ....................................................................................... 10
5.2 CO2 analyzer AIT242 (ULTRAMAT 6) .................................................................................................. 11
6. COMPRESSOR................................................................................................................................................................. 11
6.1 Maintenance of the machine........................................................................................................................ 11
7. AUTOMATIC VALVES AND INSTRUMENTATION ........................................................................................... 11
8. TURBINE .......................................................................................................................................................................... 12
Document N°
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1. DERIMING
Deriming is a very important maintenance operation that aims at removing water and CO2 which
may progressively accumulate into the cold box during the continuous normal operation of the
unit and can lead to explosion hazard.
Air Liquide recommends to perform a deriming of the plant (after exceptional regeneration)
every three years but this duration shall be reviewed and reduced if any of the following
abnormalities have occurred:
Repeated CO2 breakthroughs or limited continuous CO2 breakthrough leading to presence of
CO2 in the bath approaching to its solubility limit.
Abnormal hydrocarbon content in the air downstream of the adsorbers, leading to presence of
hydrocarbons in the bath up to abnormal levels.
Abnormal pressure drops in cryogenic equipments (i.e. exchangers, columns, LOX filters…)
Change of the environmental conditions to others than the plant design.
Numerous unplanned plant shut-down"
Refer to Deriming procedure 57506-60-01-PR-019B082.
2. DRYING
Before the unit’s first start up, it is necessary to remove all construction waste as (dusts, welding
and water etc…). This operation is called drying.
2.1 Purpose
All equipment inside the cold box will be at a very low temperature and it is extremely important
for its operation that there remains no water inside the cold box. Any water (generally
accumulated in the low points of the piping system) will turn into ice at low temperature. This
entails a risk of clogging drains, measuring pulse tap points, etc..., bursting pipes or jamming
moving components (valve stems).
The purpose of drying is to remove any water which might be found inside the components and
piping of the cold box. Such water might come from hydraulic testing or condensation of humid
air due to variations in atmospheric temperature.
2.2 Drying procedure

Deriming procedure can be applied to dry the cold box (phases 1 and 2). Yet there is no need to
start deriming heater E81 for the drying.
2.3 Basic Principles

The lowest the pressure and the warmer the temperature in the system, the more efficient the
drying.
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● Care is to be taken to open all outlets: drains, analysis cocks, vents or special
defrosting outlets (DA).
Also disconnect the transmitter pulse tap points in the cold box to eliminate any trace of
moisture in instruments.
● Always start by opening outlets (valves, pulse lines, flanges) on a circuit to be dried.
● Open the inlet valve last.
● Always be careful to avoid overpressure in the various circuits.
The testing of the dryness of the gas leaving circuits can be performed at the various outlets
using a DRAEGER or SHAW type apparatus. A circuit is to be considered as dry when the dew
point is between – 50°C and – 70°C.
3. EXCEPTIONAL REGENERATION
3.1 Purpose of the exceptional regeneration

The aim of this process is to eliminate the residual moisture and hydrocarbons contained in the
molecular sieve (a highly water-greedy product) in order to enhance ths adsorption efficiency:
the higher is the actual adsorption capacity of the Molecular Sieve, the lower its residual water
content is.
The exceptional regeneration must be carried out after the bottles have been normally
regenerated.
The exceptional regeneration will be done at reduced flow (5 to 10 % of the air flow), in a single
cycle, at about 250°C to 300°C (according to the specification of the adsorber) for a period of
time defined further down without exceeding the saturation of the bottle in service.
It is essential that the exceptional regeneration be carried out in a single cycle as the
temperature variations between the grates must be limited (this leads to a rather long procedure)
as well as the frequency of these cycles.
If the special regeneration is not carried out, the main exchanger (E01), the column and the vaporizer
E02 could become clogged by CO2 deposits, leading to a
breakdown in the installation and presenting a serious risk of
explosion due to the hydrocarbons.
Consequently, this specific process must be carried out :
Document N°
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During the first start-up of the plant,

- After any replacement of the adsorbent materials : Alumina, Molecular Sieve.
- After a long period of shut-down : storage position of the APSA L unit longer than
one year.
- At any time, in case of unexpected adsorbents’ contamination by moisture.
Note: Observe carefully the temperature gradients after resuming the regeneration following an
accidental interruption of the cycle.
It is important that the heating and the cooling be done in such a way that the difference in
temperature between the inner and the outer flow do not exceed 150°C when heating and
cooling (to limit the stress on the pipe)
The adjustment can be done, for instance, by changing on the number of resistances in service
or by increasing gradually the air flow in the case the heater has been made of expanded metal.
CAUTION indications of CO2 contents and CnHm on analyzer and chromatograph will provide
information according the time to realize the regeneration.
How to estimate the total duration:
= Total air available for exceptional regeneration
= Time available for exceptional regeneration
How to estimate the air flow:
= Flowrate for exceptional regeneration
It is possible to stay during the (Time available for exceptional regeneration) in adsorption on the same
vessel if only the (Flowrate for exceptional regeneration) is used.
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3.2 Process description

The exceptional regeneration is performed at a reduced flow rate (around 10% of the nominal
air flow) at the temperature of 250°C to 300°C (TI203) for a defined duration.
For this operation, wear gloves suitable for high temperatures. Some pipes will be very hot, in fact, and
one should avoid touching them or leaving equipment liable to
burn on them.
The regeneration gas flow will be dry air collected after passing through the air purification unit.
For the exceptional regeneration of a vessel, only a small part of air flow compressor is used because
the other vessel needs to stay in adsorption for a long time (about 24 hours)
The gas flow rate will be controlled by means of the adjustment valve HV240 in order to obtain
the correct temperature TI233 at the outlet of the electric heater E08.
3.3 Preliminary conditions required for an exceptional regeneration

Ensure that the electrical heater E08 is operational.
Ensure that the cold box section of the APSA L unit is depressurized
Check that turbine section is closed ( HV651 and PV640A are closed)
Check that cold box section is isolated : LV614, LV602, KV603, KV623, KV633 and
FV615A/B are closed
Set the air purification unit in manual mode and check the positioning of the valves KV210,
KV220, KV215, KV216, KV225, KV226 and PV261: valves closed
3.4 Start up the exceptional regeneration cycle

Close HV240
Close PV261
Start the air compressor: complete air flow to atmosphere through compressor blow-off valve
Open HV240 to about 15%
Start exceptional regeneration sequence
Observe increasing TI 233
Depending of the size of the adsorber, the stress is not always important, it’s not necessary to
make the step at 150°C, when you have a small adsorber.
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Manage HV240 in order to stabilize TI 233 at 290°C

Observe TI 213 or TI 223 (adsorber outlet temperature). Depending of molecular sieve and
alumina saturation, this adsorber outlet temperature take time to increase because desorption
is endothermic phenomena.
Wait for stabilization TI213 or TI223 at relative high level (180°C – 200°C) and maintain this
level during 12H00.
3.5 End of the exceptional regeneration cycle
The end of the exceptional regeneration cycle automatically occurs when the cooling timer of
the adsorber R02 is completely elapsed.
Then:
Close the manual valves HV240
Check that the depressurization valve KV215 and KV225 are closed
Press the STOP push button.
Note: At the end of the exceptional regeneration cycle, the valve KV215 and KV225 shall be
closed, and the pressure in the adsorbers R01/R02 will increase up to compressed air pressure.
Note: In certain special cases, it is possible to start up the exceptional regeneration cycle from
the adsorber R02: for that, set the R01/R02 selection switch onto R02 position.
➢ Control of the rise of the temperature TI233 at the beginning of the heating step :
Recommendations :
o Do not raise the temperature TI233 too fast
In such a case, the gas flow through the heater is too low: check if valve HV240 is not tight
closed.
Consequence: risk of damaging the electric resistance(s) of the heater by overheating.
o Inversely, do not raise the temperature TI233 too slowly

In such a case, the gas flow through the heater is too high: check if valve HV240 is not wide
opened.
Consequence #1: efficiency of the regeneration is reduced since the time to rise the temperature
is part of the whole heating time.
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Consequence #2: you may not reach the right temperature value 245°C since the flow through
the heater is too high.
o Average duration:
The duration to reach the value of the intermediate temperature set point (145°C at the end of
phase 1) approximately ranges between 30mn and 50mn.
The duration to reach the value of the final temperature set point (290°C at the end of phase 2)
approximately ranges between 30mn and 50mn.
The temperature TI233 should be maintained at 290°C for about 20 hours per each adsorber.
After the cooling timer is elapsed for the first adsorber R01 (or R02), switch into the second one:
from R01 into R02 (or from R02 into R01).
Note: During the exceptional regeneration cycle, it is essential to monitor, the temperature TI23 and the
heating/cooling timers for each adsorber R01 and R02.
Take care that the valve HV240 is opened prior to start the exceptional regeneration.
If not, you will have irreversible damage on the electric heater E08: destruction of the electric
resistance due to the lack of gas flow through the heater.
AT
E0 M
8 PV
261
From
Exchangers
TI Instrument
Air
63 Deriming
HV
0 Air
240
To
R0 R0 Exchangers
1 2
AT
M KV
215
TI AT
21 M
3
AI
R C01
Inlet
Water
Outlet
Water
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4. ADSORBENTS
The adsorbents contained in the R01/R02 adsorbers shall be changed in the event of contamination of the alumina
or the molecular sieve, or after poor operation of the adsorbers despite the exceptional regeneration
operations.
It is necessary to check that adsorbers are correctly filled before the first start up and periodically during the
first year of use, in order to refill them up if this is necessary.
Note: Poor filling of the adsorbers will cause abrasion of the adsorbents. Adsorbent dust may be prejudicial to the
proper operation of the adsorbers.
4.1 Safety datasheets

For this maintenance operation, refer to the safety information note n° NS B0101 (“MULTIPLE FATALITIES - TOXIC
GAS RELEASED FROM MOLECULAR SIEVES AFTER CONTACT WITH WATER IN REFINERY
COMPLEX”, available on Alexandria database) and to the security datasheet of the molecular
sieve given in the complete constructor files.
4.2 Specifications of the alumina

Reference: ACTIVATED ALUMINA 2-5 GRADE BAA
Quality: balls 2 to 5 mm in size
Description: alumina, 3 H2O hydrate
Nominal density: 770 kg/m3
4.3 Specifications of the molecular sieve

Reference: MOLECULAR SIEVE TYPE 13X 180 / 2
Nominal density: 685 kg/m3*
4.4 Special precautions

Do not wet the adsorbents. The drums shall be opened only at the last moment, just before pouring the adsorbents
into the vessels.
Check the appearance of the adsorbents: no mud caused by entry of water into the drums, or too much powder
caused by abrasion. In the latter case, screen the adsorbents.
Avoid excessive rolling of the drums, placing them so as to prevent abrasion of the adsorbents.
Use gloves, goggles and a dust-proof mask since the alumina and the molecular sieve are irritants.
For the precautions in use, see the safety data sheets of the materials used.
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4.5 Procedure
The filling consists in emptying the drums of adsorbents, one after the other, into the vessels, after having, if
necessary, strained them in order to remove the dust and broken pieces of adsorbents.
Before dealing with the vessels, make sure they are totally depressurized.
Remove the filling holes.

Fill the vessels first with the alumina, according to the height mentioned in the table in the equipment
description chapter.
Then complete totally the vessels with the molecular sieve (volumes indicated in the equipment description
chapter).
An exceptional regeneration must be carried out after a change of the

adsorbents.
5. ANALYZERS
5.1Production analyzer AIT618 (OXYMAT 64)

Before carrying out maintenance operations or verifications on the analyzer, close the isolation valve
VAP618A.
Refer to the operating manual of analyzer.

Range: 0-20 ppm oxygen content in Nitrogen.
In addition to the calibration procedure described in the operating manual of the analyzer manufacturer, it is essential
to make a periodical check on the correct operation of the analyzer (recommended period =
monthly, calibration every 4 months).
For the calibration, an O2 + N2 calibration gas will be injected into the analyzer, the O2 content of which will be slightly
more than the activation threshold ASHH 618.
Equipment required:
- 1 calibration gas cylinder with 1 - 3 ppm O2 in N2 N60
- 1 pressure reducing valve
(Equipment provided solely for the calibrations)
Normal calibration (monthly) refer to manufacturer recommendations

- Span gas cylinder: 18 ppm O2 in N2
- Zero gas cylinder: 100% N2 Purity 5.0 (>99.999%) O2
<2ppm
This operation enables the following potential problems to be detected:

- Increase in the response time
- Possible drift
Note: After performing the calibration, don’t forget to switch the analyzer back to normal operating
mode.
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5.2 CO2 analyzer AIT242 (ULTRAMAT 6)

Refer to the operating manual of analyzer.
Range: 0-20 ppm CO2 content.
The calibration of the equipment must be conducted according to the analyzer supplier recommendation.
Normal calibration (monthly)

- Span gas cylinder: 18 ppm CO2 in N2
- Zero gas cylinder: 100% N2 Purity 5.0 (>99.999%)
The life of the cell is indicated by a statistical system internal to the analyzer itself. The recommended
replacement parts are given in the manufacturer's instruction manual.
6. COMPRESSOR
6.1 Maintenance of the machine
ALL NECESSARY SAFETY PROCEDURE SHALL BE APPLIED
The procedures for the maintenance operations on the compressor are described in the manufacturer's manual.
Refer to the operating manual of compressor.
Before any maintenance work on the compressor, disconnect the main circuit breaker.
7. AUTOMATIC VALVES AND INSTRUMENTATION

Pneumatic valves
Refer to the manufacturer's manual.
Before any maintenance involving the pneumatic valves, the instrument air source should be disconnected.
Hydrocarbon drain valve KV633 (or rich liquid drain valve)

Regarding the importance of the drain valve KV633 for the safety of the installation (risks of explosion in
case of defective drain); it is recommended to check this valve every 720 hours of
operation.
It is also recommended that their systematic replacement be carried out after about 10 000 hours of operation of the
equipment.
Always check, each time the appliance is moved on the installation site, that this valve is operating correctly.
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8. TURBINE
Refer to the manufacturer's manual.
REFINERIA TALARA
NIS-Z-001 57506-60-01-PR-019A031
Air Liquide
NIS-K-001 The compressors - Operating Manual
06/08/2019 00
Document N°.
57506-60-01-PR-019A031
OPERATING MANUAL
Rev 0
Page 1 of 9
OPERATING MANUAL - VOLUME A - SECTION A- 03 THEORETICAL ELEMENTS – NIS-K-

001 COMPRESSORS
COVER PAGE


Table of Revisions
Section Description

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001 COMPRESSORS
TABLE OF CONTENTS
1 SCOPE OF APPLICATION 3
2 INTRODUCTION 3
3 COMPRESSION PARAMETERS 3
4 THE VOLUMETRIC COMPRESSORS 5
5 DYNAMIC COMPRESSORS 8
6 COMPRESSORS RANGE OF USE 9
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001 COMPRESSORS
1 SCOPE OF APPLICATION
This document provides the general principles about compressor’s operation.
2 INTRODUCTION
The role of compressor in the ASU process is to provide gas flow under a certain pressure.
There are two great families of compressors:
• Volumetric compressors:
Pressure is obtained by admitting successive volumes of gas in a closed room and driving back them using a
variable component.
• Dynamic compressors:
Kinetic energy is convert in potential energy. The speed of air is transform to provide pressure.
Fig 1
COMPRESSORS
VOLUMETRIC CONTINUOUS FLOW
RECIPROCATING ROTARY DYNAMIC EJECTOR
3 ROTATE
WITH WITH LIQUID PERIFERIC
PISTON RING WITH
CENTRIFUGAL AXIAL
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001 COMPRESSORS
COMPRESSION PARAMETERS
P 1 T1 P2 > P 1
T2 > T 1
V1 V2 < V 1
COMPRESSION RATIO
Absolute pressure of discharge
Compression ratio = ≤3
Absolute pressure of admission
Note: In case of gas heat is too significant, it would cause ignition of oil and deterioration of machine elements.
MULTISTAGE COMPRESSION
The multiplication of compression stages, increase the compression ration.
1 2 3 4
R1 R2 R3 R4
P 4 ,T
P 0, T P 1, T P 2, T P 3, T
Note:
• The compression ratio realized in each cylinder is only a fraction of the total compression ratio. Thus,
temperature rises reached by gas are low, which lead to lubrication and a better mechanical operation.
The intercoolers extract heat produced at each stage, which would not be possible by the only use of a
water cylinder.
• Multistage compression, by lowering temperature of gas between stages, makes possible to approach
isothermal compression: it results a significant power saving.
For compressor with piston:
• Effort on the stem of piston and connecting rod assembly depend on the difference of pressures acting on
the two faces of the piston, which is weak in case of multistage compression.
• The compression ratios are "weak". So, the primary cylinder and consequently the followings received a
real flow more significant than if the compression ratio was total.
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001 COMPRESSORS
ENERGY OF COMPRESSION
Power necessary for a stage of compression is expressed as follows:
K P2
P [kW] = x Q x T x Log
efficiency P1
K = constant T = Admission temperature of the stage
Q = gas output aspired (Nm3/H) P1 = pressure (abs) of admission of the stage
P2 = pressure (abs) of admission of the stage
A simplified formula can be remembered:
P = 0.11xQxlog(P2/P1) : This formula is valid in the following conditions :
• Suction Temperature : 25 °C
• Relative humidity : 75 %
• Ti = 25 °C
• Isothermal efficiency : 66 %
Power consumption increases with gas flow and compression ratio.
However, this power depends on admission temperature for the considered stage: which highlights the importance of
intercoolers efficiency.
4 THE VOLUMETRIC COMPRESSORS

Their principle is the reduction of volume to involve increase in pressure.
volumetric compressors
ROTARY RECIPROCATING
Rotary compressor with root

Operation :
Two thrusters of lobed form turn in a way synchronized inside a cylinder thanks to a set of
gears.
The gas is not compressed by the machine, but by action of gas present in the collector of
repression.
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001 COMPRESSORS
Used as primary vacuum pump, it provides a vacuum interesting for significant volumes not-lubricated
Characteristics :
• 2 or 3 stages on compression can be assembled
• Flow can go up to 60000 m3/h:
• Air is not contaminated by oil.
• Supports important variations of its compression ratio without affecting its efficiency
Compressor with screw
Operation:
They are composed of two rotors comprising of the male and female helicoid grooves which gear one on the other, in
a cylindrical casing.
1- Aspiration of a quantity of air, defined by volume between the screws
2- Reduction of air in this volume
3- Repression of this air.
Characteristics:
• For oil lubrication: flow can go up to 10000
m3/h
• For water or dry air lubrication: flow can go up
to 30000 m3/h.
• Several stages can be assembled
Rotary compressor with pallets

Operation:
Longitudinal fins slide radially in a rotor whose axis is eccentric from the cylinder.
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001 COMPRESSORS
(Fig1) A radial paddle wheel is motionless in a partially filled up cylindrical body of liquid.
(Fig2) At a sufficient speed, due to the centrifugal force liquid forms a concentric ring with the pump housing.
(Fig3) The volume of the cells delimited by the blades and the liquid ring do not vary.
However, if the wheel is offset compared to the pump housing, this volume varies:
• It grows regularly and it is in depression in the straight lines part of the figure.
• It decrease regularly and it is in pressure in the left part.
(Fig4) Side faces of the pump housing being provided with openings in the shape of crescent the volume of gas is
aspired thanks to the increase in the cells, and is driven back reciprocally thanks to their reduction.
Characteristics:
• Flow can go up to 6000 m3/h
Alternate compressor with piston
Operation:
A piston carrying out a back and forth pass inside a cylinder.
Admission In phase of admission, the induction valve opens and the piston moves, enlarging
the volume of compression room.
Compression
In phase of compression, the valves are closed and the piston moves
reducing the volume of compression room.
In phase of exhaust, the exhaust valve

opens, the piston completes to move, reducing the volume of compression room.
Exhaust
Relaxation
In phase of relaxation of died volume, the valves are closed and the piston
moves increasing the volume of room compression
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001 COMPRESSORS
5 DYNAMIC COMPRESSORS
By opposite to volumetric compressors, dynamic compressors transform an increase speed of a gas (kinetic energy)
in increasing pressure.
Axial Compressors
Dynamic compressors Centrifugal Compressors
Axial /Radial Compressors
Thereafter we will develop only axial compressors and centrifugal ones, the axial-radial compressors consisting of
assembly in series of several axial stages centrifugal wheels.
Note :
When high pressure is required for a very high flow rate ( > 250 000 Nm3/h ), axial and centrifugal technologies are
combined:
• First stages are axial to accept the total flow rate
• Air is admitted in centrifugal stages, when the flow has been reduced enough to be compressed.
Axial compressor
stator bladings rotor bladings

aubage aubage
Operation :
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001 COMPRESSORS
In axial compressor, gas circulates in a way parallel with the rotor axis. Can treat significant flows.
The axial compressors consist of a cylindrical or slightly conical rotor on which is assembled a certain number of
lines bladings decreasing height as one advances in compression. The rotor lines of bladings turn between the stator
lines of bladings which rectify gas flow tangentially.
Dynamic centrifugal compressor
Operation:
The centrifugal compressors are made up with a shaft on which centrifugal wheels are assembled.
• After its passage in a wheel, gas pass in a diffuser.
• An element of the stator transforms its speed in pressure.
• Gas can enter the following wheels
Characteristics:
• They are machines offering the highest compression ratios. It is possible to obtain discharge pressures
about 50bar in the case of oxygen or inert gases and 100bar for air.
• The volume throughputs treated are significant.
• The isothermal efficiency obtained by these compressors is very satisfactory.
6 COMPRESSORS RANGE OF USE
1000
Pressure (bar g)
Reciprocating compressors
100
Centrifugal &
10
Screw compressor axial compressor
1
Liquid ring Roots compressor
compressor
-0,8
-
100 500 1000 10000 100000 Flow m3/h
E-FRM-10-10-6 – rev A
REFINERIA TALARA
NIS-Z-001 57506-60-01-PR-019A051
Air Liquide
NIS-K-001 The compressor - Operating Manual - Preventive machine maintenance

Operating Manual - Preventive maintenance for machine, cold box, electric equipments
06/08/2019 00
Document N°.
57506-60-01-PR-019A051
FORM
Rev 0
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OPERATING MANUAL - VOLUME A - SECTION A-05 MAINTENANCE – PREVENTIVE

MAINTENANCE FOR MACHINES & COLD BOX & ELECTRIC EQUIPMENT
COVER PAGE

0 06/08/2019 M.ATAM M. PAILLET RFR – Complete, ready for review

Table of Revisions
Section Description

Paper copies of this document are considered to be “uncontrolled” and users should always
check for the most recent revision.
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1 INTRODUCTION 3
2 SCOPE OF APPLICATION 4
3 THE COMPRESSORS 5
4 THE CRYOGENIC PUMPS NOT APPLICABLE 6
5 THE EXPANDER/ GENERATOR/ BOOSTER TURBINES 7
6 THE AIR PURIFICATION UNIT 8
7 COLD BOX 8
8 THE HIGH VOLTAGE MOTORS AND GENERATORS 9
9 THE MOTORS AND GENERATORS LOW VOLTAGE 10
10 THE HEATERS 10
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1 INTRODUCTION
The aim of this part is to give a maximum of basic preventive maintenance rules on an ASU plant because:
It is very important to limit the potential risks of accidents
A stop of any plant is expensive for many evident reasons
1.1. WARNING
1.2. COMMENTS CONCERNING THE SAFETY OF THE PROCESS OF THE UNITS
The maintenance operations concerning the filtration process, the adsorbent regeneration operations, and the
deriming operations, are particularly important from the point of view of safety regarding the process of the units.
These operations are necessary to avoid an excessive hydrocarbon concentration in the rich liquid bath of the
exchanger (vaporizer/condenser), and/or to prevent such a concentration due to a “dry vaporization”.
They are therefore necessary to guarantee the reliability of the installations, because the presence of high
hydrocarbons concentration can be the cause of serious cases of explosion.
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Thus, special care should be taken to ensure that the hydrocarbon deconcentration drain valve(s) operate(s)
correctly, and that the total immersion of the exchanger is achieved by monitoring the level on the liquid bath
(using level gauge valve).
2 SCOPE OF APPLICATION
This document is a synthesis of the preventive operations of maintenance.

Air Liquide advises you to take the recommendations below in consideration and, to refer to the suppliers
manuals for information concerning your equipment.
2.1 TYPICAL MAINTENANCE PROCEDURE

SPECIMEN ORGANIZATION OF THE MAINTENANCE PROCEDURES:
It is recommended that the user draws up for each unit a time-table of the maintenance operations, taking
into account the size of the unit, its special equipment, the local regulations and the site characteristics.
On the following tables:

S: means at the start up
D: means once a day
W: means once a week,
M: means once a month
4M: means once 4 months
6M: means every 6 months
Y: means once a year
3Y: means once 3 years
5Y: means once 5 years
See tables on next pages.
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3 THE COMPRESSORS
CONTROLS S D W M Y
READING OUT OF PROCESS DATA P.T.Q X
READING OUT OF VIBRATIONS DATA (1) X X
READING OUT OF MECHANICAL DATA BEARING, OIL T° X X
DELTA P INLET OF COMPRESSOR X X
READING OUT OF COOLING DATA INLET OUTLET WATER X
ABSENCE OF OIL LEAK X X
ABSENCE OF WATER LEAK X X
CONDENSED FLOW OUTLET ON AUTOMATIC WATER TRAP X X
DELTA P INLET AIR FILTER X
ABSENCE OF AIR AT THE TOP OF THE COOLERS, WATER
X
SIDE
OIL LEVEL X X
REAL CLOSING OF THE ANTI SURGE VALVE OR VENT
X
VALVE X
ABSENCE OF ABNORMAL NOISE X
ABSENCE OF ABNORMAL VIBRATIONS (PIPING, DAMPING
X
DRUM...) (2) X
PRESENCE OF COOLING WATER ON COOLERS X X
ABSENCE OF GAS IN THE OUTLET COOLING WATER
X
(SIGHT GLASS) X
ABSENCE OF LEAK ON THE DISCHARGE SAFETY VALVE X
AREA CLEAN AROUND THE COMPRESSOR X
CHANGE OIL AND OIL FILTER X
GENERAL MAINTENANCE OF COMPRESSOR X
REMOVE AND INSPECT AIR FILTER. CLEAN OR REPAIR OF
4M
NECESSARY
CHECK AUTOMATIC DRAIN WORK PROPERLY X
CHECK OIL STRAINER, CLEAN IF NECESSARY X
HAVE INLET GUIDE VANES, BLOW OFF VALVE AND CHECK
X X
VALVE
(1) ONLY ON CENTRIFUGAL COMPRESSORS
(2) ONLY ON RECIPROCATING COMPRESSORS
S: Once per shift – D: Daily – W: Weekly – M – Monthly – 6M: Every 6 months– Y: Yearly
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4 THE CRYOGENIC PUMPS NOT APPLICABLE
CONTROLS S D W M 6M Y
CHECK THE ABSENCE OF COLD GAS LEAK OR LIQUID AT THE X

SHAFT SEAL AND THE SEAL GAS VENT
CHECK THE PRESSURE OF THE SEAL GAS X
CHECK THE ABSENCE OF ABNORMAL VIBRATIONS X

(WITH EARS …)
CHECK THE ABSENCE OF COLD SPOT(S) ON THE CASING X
CHECK THE SUCTION FILTER, CLEAN THE FILTER X
CHECK THE SAFETY VALVES AND ALL THE INSTRUMENTS AS REQUIRED
GREASE THE CRANK DRIVE BEARINGS AS REQUIRED
TIGTHEN THE COUPLING COLD END/CRANK DRIVE X
CHANGE THE GUIDING SLEEVES AND THE BELLEVILLE X

WASHERS IN THE COLD END
COMPLETE MAINTENANCE OF THE COLD END AND THE X
CRANK DRIVE
CHECK THE ABSCENCE OF ESCAPE OR PURGING ON THE X
VENTINGS AROUND THE BOX
REGREASE THE BEARINGS AS REQUIRED
CHECK THE COUPLING BETWEEN ENGINE AND PUMP X
CHECK THE ALIGMENT OF ENGINE X

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5 THE EXPANDER/ GENERATOR/ BOOSTER TURBINES
CONTROLS S D W M Y
READING OUT OF VIBRATIONS DATA X X
READING OUT OF MECHANICAL DATA BEARING, OIL T°... X X
READING OUT OF COOLING WATER DATA, INLET OUTLET
X
WATER
PRESSURE OF SEAL GAS X X
ABSENCE OF OIL LEAK X X
ABSENCE OF WATER LEAK X X
ABSENCE OF COLD GAS LEAK ON THE CARTRIDGE X X
ABSENCE OF AIR AT THE TOP OF EACH COOLER, WATER
X
SIDE
OIL LEVEL X
DELTA P INLET FILTER X
REAL CLOSING OF THE ANTI-SURGE VALVE (1) X X
AREA CLEAN AROUND THE TURBINE X
CHANGE OIL AND OIL FILTER CARTRIDGE X
AFTER START UP, CHECK THAT PROCESS INLET FILTER IS
X
NOT CLOGGED
REPLACE LUBE OIL FILTER CARTRIDGES (INCLUDING
X
SEAL GAS FILTER CARTRIDGES)
CHECK OIL TANK CLEANINGNESS X X
REPLACE BEARINGS, LABYRINTHS, O-RINGS. REPLACE
3Y
OIL PUMP BEARINGS, SEAL AND GASKETS.
INSPECT EXPANDER WHEEL 3Y
REPLACE BRAKE WHEEL 5Y
(1) ONLY ON BOOSTER TURBINE
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6 THE AIR PURIFICATION UNIT

CONTROLS S D W M Y
READING OUT OF PROCESS DATA P.T.Q, DELTA P. X
CHECK THE ABSENCE OF GAS OUTLET OF
X
AUTOMATIC WATER TRAP
CHECK THE ABSENCE OF GAS LEAK ON VALVES X X
CHECK THE ABSENCE OF GAS LEAK ON
X
INSTRUMENTATION
THE REAL CLOSING OF VALVES ON DCS X X
CALIBRATION OF CO2 ANALYSE AT THE END OF THE
X 6M
CYCLE
HEAT PROFILE AFTER EACH REGENERATION X
CHECK THE ABSENCE OF AIR LEAK X
CHECK THE ABSENCE OF ABNORMAL NOISE X
AREA CLEAN AROUND THE DRYING UNIT X
DUST IN ADSORPTION VESSEL X X
CHECK
CONDENSATE STEAM X
FOR REGENERATION LEVEL
STEAM HEATER:
CHECK pH STEAM X
FOR ELECTRIC HEATER, CHECK SKIN TEMPERTURE
X X
OF SHEATH
FOR FLAMME HEATER, CHECK SKIN TEMPERTURE
X
OF TUBE
7 COLD BOX
CONTROLS S D W M Y
ABSENCE OF LEAK ON VALVES GLAND PACKING X
ABSENCE OF LEAK ON INSTRUMENTATION X
ABSENCE OF ICE ON THE COLD BOX CASING X
AREA CLEAN AROUND THE COLD BOX X
CHECK INSTRUMENT AIR CIRCUIT X X X
CHECK RICH LIQUID DRAIN VALVE KV603 X X X
CHECK TIGHTNESS OF THE VALVE 4M X
CHECK TIGHNESS OF THE GAS AND LIQUID PIPES 4M X
PERFORM LEVEL GAUGE TEST X 4M X
CHECK CALIBRATION OF THE CONTROL VALVES X 4M X
CHECK CALIBRATION OF THE LEVEL TRANSMITTERS 4M X
PERFORM THE DERIMING OF THE COLD BOX EVERY 3 YEARS
CHANGE WEARING PARTS OF THE REGULATION VALVES
5Y
(FV/LV/PV) BY THE SUPPLIERS KIT
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8 THE HIGH VOLTAGE MOTORS AND GENERATORS

CONTROLS S D W M Y
READING OUT OF DATA U.I.P... EACH PHASE X
READING OUT OF MOTOR TEMPERATURES (WINDINGS,
X X
AIR, BEARINGS)
ABSENCE OF OIL LEAK ON BEARINGS X X
BEARINGS OIL LEVEL X
BEARINGS OIL PRESSURE AND FLOW X X
FREE COOLING OF THE MOTOR (1) X
PRESENCE OF COOLING WATER FLOW (2) X
ABSENCE OF WATER LEAK ON THE COOLER (2) X
CHECK THE ROTATION OF THE RINGS OF LUBRICATION
X X
OF THE STAGES
CHECK THE OPERATION OF THE RINGS (4) 6M
CHECK THE CIRCULATION CURENT (3) 6M
VISUAL EXAM OF THE START UP FERMENT (4) X 6M
THERMOGRAPHIC EXAM X
(1) ONLY ON MOTORS COOLED BY AIR
(2) ONLY ON MOTORS COOLED BY WATER
(3) ONLY ON MOTORS WITH MAIN CURENT > 1 A
(4) ONLY ON MOTORS WITH RINGS
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9 THE MOTORS AND GENERATORS LOW VOLTAGE

CONTROLS S D W M Y
READING OUT OF DATA U.I.P... EACH PHASE X X
READING OUT OF MOTOR TEMPERATURES (WINDINGS,
X
AIR, BEARINGS)
ABSENCE OF OIL LEAK ON BEARINGS X
BEARINGS OIL LEVEL X
BEARINGS OIL PRESSURE AND FLOW X
FREE COOLING OF THE MOTOR (1) X
PRESENCE OF COOLING WATER FLOW (2) X
ABSENCE OF WATER LEAK ON THE COOLER (2) X
MESURE OF THE ISOLATION RESISTANCE X X
FOLLOW THE SUPPLIERS RECOMMENDATIONS
CONCERNING THE LUBRIFICATION, THE GREASING AND X
MAINTENANCE
(1) ONLY ON MOTORS COOLED BY AIR
(2) ONLY ON MOTORS COOLED BY WATER
10 THE HEATERS
CONTROLS S D W M Y
READING OUT OF DATA U.I.P. EACH PHASE (1) X X
AREA CLEAN AROUND THE HEATER X
(1) DURING HEATING PHASE
E-TPL-10-10-12 – rev A
REFINERIA TALARA
NIS-Z-001 57506-60-01-PR-019A032
Air Liquide
Operating Manual - The Adsorbers
06/08/2019 00
Document N°.
57506-60-01-019A032
OPERATING MANUAL
Rev 0
Page 1 of 10
OPERATING MANUAL - VOLUME A - SECTION A- 03 THEORITICAL ELEMENTS -

ADSORBERS
COVER PAGE


Table of Revisions
Section Description

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ADSORBERS
TABLE OF CONTENTS
1 INTRODUCTION 3
2 PRINCIPLE 5
3 CYCLE DESCRIPTION 6
4 THE USUAL PROBLEMS 10
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ADSORBERS
1 INTRODUCTION
A system of purification is necessary to ensure the continuous operation of an installation. If one does not envisage
any system of elimination of the water vapor and gas CO2, the passages of the air in the exchanger will be gradually
stopped by ice and dry ice. In addition, it will be also necessary to eliminate as much as possible hydrocarbons
present (acetylene, methane, ethane, etc.) because they could concentrate in the columns and cause with the
oxygen of the explosions.
EXCHANGER
O2 N2
PURIFICATION
COMPRESSION
DISTILLATION
A
AIR Main
vaporizer
COLD BOX
NON-CRYOGENIQUE AREA CRYOGENIQUE AREA
The solution use to purify the air after the compressor and before the exchanger by Air Liquid today is the adsorption
(different from absorption).
Adsorption == fixing of a gas or a liquid on surface by a solid (adsorbent)
Absorption == fixing of a gas or a liquid in volume (like a sponge).
All the solid have a more or less high capacity adsorbing, following their nature, their surface quality (porosity), and
the nature of adsorbed gas
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ADSORBERS
Characteristics of the gas in dry air
BOILING VAPORIZ. CONCEN- TRIPLE POINT CRITICAL POINT VOLUMIC WEIGHT MOLE-
POINT at HEAT TRATION TEMP. PRESSURE TEMP. PRESSURE GAS LIQUID CULAR
1 ATM at 1 ATM IN AIR 0° C eb point WEIGHT
1 atm 1 atm
°C Kcal/Kg %, ppm vol C mm/Hg C atm/abs Kg/Nm3 Kg/l g.
OXYGEN - 183 50,9 20,95 - 218,8 12 - 118,8 49,7 1,43 1,14 32

NITROGEN - 195,8 47,6 78,08 - 210 94,6 - 147,1 33,5 1,25 0,81 28
ARGON - 185,9 38,9 0,93 - 189,4 512,2 - 122,5 4,8 1,73 1,4 40
KRYPTON - 153,2 25,8 1.1 ppm - 158,2 550 - 63,8 54,2 3,74 2,16 83,7
XENON - 108,1 23 0.09 ppm - 111,8 612 16,6 58,2 5,9 3,06 131,3
HELIUM - 268,9 5,7 5 ppm / / - 268 2,3 0,18 0,13 4
NEON - 246,1 20,8 18 ppm - 248,6 325 - 228,8 26,9 0,9 1,2 20,2
CO2 / / 330 ppm - 56,6 5.1 atm 31,3 72,9 1,98 1,18 44
AIR - 191,5 49,1 / / / - 140,7 37,2 1,29 1 (28.9)
T1 The phenomenon of adsorption will be

Quantity on supported by:
impurity
adsorbed
- a low temperature
- a raised pressure
T2 > T1 - a low speed of gas in the bottle
Adsorption is a phenomenon of surface, thus it

will be reversible.
So, Air Liquid currently applies adsorption
Partial technology using two bottles that are operated
pressure in turns, i.e. while one bottle is in operation, the
other bottle is regenerated.
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ADSORBERS
2 PRINCIPLE
Adsorption require an attraction between the molecules of impurities and adsorbent surfaces. They are weak forces
of attraction (dipolar) known as forces of VAN DER WAALS. Moreover, it is necessary that the diameter of the
adsorbed impurities is lower than that of the pores of the adsorbent, which plays the role of trap.
The current technology uses beds to remove water and
carbon dioxide. Water is removed on the first bed, i.e. molecular
the alumina bed (Al2O3), while the carbon dioxide is Alumina sieve
adsorbed on the molecular sieve (13X).
It is necessary to remove water before air reaches the
mole sieve, because water on the molecular sieve would
extremely decrease the adsorption capacity of CO2 on
the molecular sieve. Depending on the type of the
molecular sieve, also some secondary impurities are
stopped, e.g. nitrous oxide, hydrocarbons, etc which
cause security problems due to their low volatility in
liquid oxygen and in turn cause explosions.
After the nominal adsorption time the adsorbents are
more or less saturated and further operation would Residual
cause a break through of either water on the molecular AIR
sieve or carbon dioxide on the molecular sieve. Nitrogen
Consequently, the adsorption bottles are regenerated, i.e. dry gas (usually waste nitrogen) is passed at low pressure
and high temperature through the bottles, causing water and carbon dioxide to desorb. Because of limitations due to
the attrition velocity and also due to the fact that the mole sieve is sensitive to water, the bottles must be
regenerated in opposite direction to the adsorption.
There is also the exceptional regeneration which is characterized by a much higher temperature (290°C) and longer
reactivation time than in regular regeneration. It is carried out in the following circumstances:
• each time the adsorbents are replaced
• at the start up of the plant – after filling
• if a water break through on the molecular sieve is suspected (usually, the bottles have a bad
performance)
As the gas is purified in the adsorbent bed, a “face of adsorption” evolves in the same direction as purified gas.
When this face reaches the end of the bottle, this one is saturated and the phase of adsorption must be stopped.
One thus carries out the regeneration of the bottle in opposite direction with the use of a gas already purified which
will ensure the desorption of the components previously purified during the phase of adsorption.
This dry gas thus takes care out of water and CO2 as the adsorbent regenerates itself. In case of accident
operational, one can carry out an exceptional regeneration at high temperature.
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ADSORBERS
3 CYCLE DESCRIPTION
1. High Pressure Isolation 2. Depressurization
Isolation of the bottle in adsorption For the same reasons as described above (water on
mole sieve, attrition) the bottle is slowly depressurized in
opposite direction to the adsorption flow.
heater heater
Epurated air Toward Epurated air toward
Impur N2 OFF cold box Impur N2 OFF Cold box
V6 V5 V6 V5
V4 V3 V4 V3
V11 PSL V11
R01 R02 R01 R02

Hp isolation In service in in service
depressurization
venting venting
V10 V9 V10 V9
V8 V7 V8 V7
V2 V1 V2 V1
Air Air
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ADSORBERS
3. Blow-off 4. Heating
A large amount of water already leaves the bottle The waste nitrogen is heated and routed to the bottle to
be regenerated
heater heater
FSL Epurated air toward
Epurated air toward
Impur N2 OFF Cold box Impur N2 ON Cold box
V6 V5 V6 V5
V4 V3 V4 V3
V11 V11
R01 R02 R01 R02

In blow-off in service In heating in service
venting venting
V10 V9 V10 V9
V8 V7 V8 V7
V2 V1 V2 V1
Air Air
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ADSORBERS
5. Cooling 6. Low Pressure Isolation

The heater is turned off and the waste nitrogen is sent Isolation of the bottle regenerate
via a by-pass (not always the case!) directly to the top of
the bottle. Regeneration parameters (heating time,
cooling time and flow rate) should usually be adjusted in
such a way that a small heat peak (20-30°C) can be
observed at the end of the cycle.
heater heater
Epurated air toward Epurated air toward
Impur N2 OFF Impur N2 OFF Cold box
Cold box
V6 V5 V6 V5
V4 V3 V4 V3
V11 V11
R01 R02 R01 R02

in in service In LP in service
cooling isolation
TSH venting venting
V10 V9 V10 V9
V8 V7 V8 V7
V2 V1 V2 V1
Air Air
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ADSORBERS
7. Pressurization 8. Parallel
The bottle being turned into adsorption is pressurized The purpose of this step is to reduce the temperature of
with purified air from the outlet of the other bottle. During the purified gas entering the exchangers:
the pressurization phase nitrogen is adsorbed and
During the previous pressurization step gas (nitrogen) is
therefore heat is released. This effect becomes more
adsorbed. Since adsorption is an exothermal phenomena
important as the adsorption pressure increases(SIGMA
(heat is released when molecules are adsorbed) the gas
H). In order to prevent considerable temperature
as well as the adsorbents are heated during this step. In
fluctuations in the cold part, the bottle being switched to
order to avoid operating the “hot” directly after
adsorption is operated in parallel with second bottle.
pressurization, the bottles are operated in parallel (each
at 50% flow rate)
heater heater
Epurated air toward Epurated air toward
Impur N2 OFF Cold box
Impur N2 OFF Cold box
V6 V5 V6 V5
V4 V3 V4 V3
PDSL
V11 V11
R01 R02 R01 R02

in in service in service in service
pressurization
venting venting
V10 V9 V10 V9
V8 V7 V8 V7
V2 V1 V2 V1
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ADSORBERS
In order to be able to carry out all the stages necessary to the complete cycle of each bottle, adsorption then
regeneration, it is imperative to have two absorbers. So one bottle is in regeneration while the other is in adsorption,
and conversely without interrupt the alimentation of limps cold in air.
The adjustments
The best thing would be to have the longest possible cycle in order to limit the loss of heat and mechanical
tiredness, and have pressurization and depressurization times as short as possible to reduce the idle times.
4 THE USUAL PROBLEMS

• Problems with the valves (jammed, leaking, etc.)
• Pressure switches not properly adjusted causing the cycle to stop during pressurization or
depressurization,
• Leak on the steam heater resulting in a regeneration with moist gas (control by analysis of the quantity of
water)
• Excessive heating and cooling times (insufficient flow of regeneration gas)
• Regeneration temperature too low (excessive flow of regeneration gas)
• Pressure drop larger on one bottle than the other, causing pressure variations in the cold box during the
cycle and, consequently, difficulties in adjusting the unit
• Phenomenon of attrition: i.e. abrasion of the adsorbent grains by the gas, resulting in the formation of
dust (the depressurization or pressurization is too fast or the flow rate is generally too high).
• Regeneration parameters not optimized:
- Heating time too long or regeneration flow to high: Enormous heat break through at the end of the
cycle – heat loss >>> expensive. Solution: Slightly decrease the ratio of “heating / cooling time”
- Heating time to short or cooling time too long or regeneration flow too low: increase the ratio
“heating / cooling time”
- Summer and winter conditions vary depending on the location of the plant. Consequently, the
optimum regeneration parameters in summer vary from those in winter.
• Bad performance of the adsorption unit: A water break through on the molecular sieve causes an
enormous reduction of the adsorption capacity.
- Short term solution: reduce adsorption time,
- Long term solution: exceptional regeneration.
• Temperature alarms are not set correctly: Higher temperatures cause larger amounts of water brought
into the adsorber. Solutions:
- Respect temperature limits: TSH: +2°C, TSHH +4°C
- Decrease flow rate, and adsorption time
- Increase cooling water rate
• …..
E-TPL-10-10-7 – rev A
REFINERIA TALARA
NIS-Z-001 57506-60-01-PR-019A035
Air Liquide
Operating Manual - The Distillation Columns
06/08/2019 00
Document N°.
57506-60-01-019A035
OPERATING MANUAL
Rev 0
Page 1 of 13
OPERATING MANUAL - VOLUME A - SECTION A- 03 THEORITICAL ELEMENTS – THE

DISTILLATION COLUMNS
COVER PAGE


Table of Revisions
Section Description

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INTRODUCTION 5
1. THE PRINCIPLE OF DISTILLATION 5
1.1 Theoretical Trays 5
1.2 Structured Packing 6
2. THE DISTILLATION COLUMN 7
2.1 The main vaporizer 9
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10
2.2 Importance of the backward flow 11
3. FLOODING OF THE DISTILLATION COLUMN 12
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3.1 General 12
3.2 Flooding 13
3.3 Flooding Detection 13
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INTRODUCTION
The principle of distillation is to separate a mixture in its various components more or less volatile, i.e. which do not
vaporize at the same temperature (with pressure given).
1. THE PRINCIPLE OF DISTILLATION
1.1 Theoretical Trays
The separation of gases by distillation is done by means of a set of distillation trays whose purpose is to achieve a
transfer of heat and material between an ascending vapor and a descending liquid.
The liquid coming from a tray has the same composition as the liquid on the tray.
The ascending vapor Vo enters the tray through perforations and comes into contact with the liquid descending from
the upper tray L2.
During this exchange, part of the vapor Vo condenses, part of the liquid on the tray vaporizes, with a resulting
ascending vapor V1 which is in equilibrium with the liquid on the tray thus with L1, this vapor being richer in light
elements than L1.
When the tray is in continuous operation the material balance must be even, this being achieved for a known flow
and composition of liquid L2.
Vapor V2
liquid L2
Vapor V1
Ponctual contact
Liquid/Vapor liquid L1
vapor V0
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1.2 Structured Packing
Structured Packing is an internal device of distillation columns, facilitating a close contact of liquid with vapor. This
type of packing is made of corrugated metal sheet, criss-crossing one another
The use of this technology for cryogenic separation has been successfully developed and industrially validated by Air
Liquide at the beginning of the 1980s.
The technological advantages, as compared to trays, are:

their low pressure drop and consequently significant energy savings
their greater « flexibility » (good performance over wider range of liquid and vapor flow)
their lower « inertia » (less liquid inventory), permitting quick change of operating modes.
Recently a new generation of Air Liquide improved structured packing has been issued and validated allowing a
significant reduction of column sizesdiameter.
The limit of structured packing operation is flooding. It appears when the gas or liquid flow rates become too high.
Physically, it corresponds to a carry-over of the downward liquid film by the gas stream flowing in the opposite
direction. In the vicinity of flooding, pressure drop increases dramatically with the slightest increase in vapor load.
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2. THE DISTILLATION COLUMN
A column consists of a stack of structured packing elements through which passes a flow of ascending gas, and a
descending liquid. In other words, the heavy products are condensed and the light ones are vaporized.
For a mixture O2 + N 2
Condenser
Most volatile product
(O2+N2) Structured
Packing
Less volatile product
Heater
Depending on what we have to treat (liquid or gas) there are two possibilities:
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The only use of the heater
Residual ( O2 + N2)
Vapor
(O2+N2)
Liquid
We obtain at the bottom of the column , liquid

oxygen (its purity depends on the number of
structured packing elements and on the reflux
ratio) and at the head, the residual: vapor of
oxygen and nitrogen
Less volatile product (O2)

liqui Liquid
Heater
The only use of the condenser
Condenser
Most volatile product (N2)

Vapor
This arrangement is the one which is used on

the Nitrogen generation package, we obtain at
the top of the column a vapor made up of
nitrogen (of which the purity depends among
other things of the number of structured
packing elements and on the reflux ratio), and
at the bottom, a liquid residual containing N2
(O2+N2) andO2 (it is the Rich Liquid)
Vapor Residual ( O2+N2)
Liquid
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2.1 The main vaporizer
The idea enabling the combined operation of the two columns described above, is the condensation of nitrogen gas
with the vaporization of liquid oxygen in the main vaporizer E01
It is located between the column K01 and

the vaporizer E02. It is a bath exchanger
of counter-current type.
Rich Liquid is in the bath, passages are
opened. The liquid enters at the bottom of
the exchanger and is driven by the
thermosiphon effect. It is the formation of
the gas bubbles by vaporization which
generate this effect.
Venting of
incondensable
gas RL: Liquid rich in Oxygen
RL exit
GAN: Gas Nitrogen
LIN: Liquid Nitrogen
K01 Column
Colonne MP
For Nitrogen generator, the upper part of the distillation column is not used since only GAN production is required.
Therefore, the vaporizer bath is not LOX but Rich Liquid and Waste is Vaporized Rich Liquid with about 35% of
oxygen.
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2.2 Importance of the backward flow

It is the ratio:
Liquid flow
L
V Vapor flow
Vapor Liquid
When L/V increases in a section of a column, it involves:

- at the top of the section a reduction in concentration of the least volatile elements
- at the bottom of this section an increase of content in least volatile element.
The result is reversed if L/V decreases.
In Column:
Gas air enter at the bottom, thus the vapor composition arriving in bottom of the column is fixed.
A L/V growing will decrease O2 content at head, thus improve the purity of the product.
Therefore a reduction of L/V will reduce the purity of the product.
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3. FLOODING OF THE DISTILLATION COLUMN
3.1 General
Distillation packing consists of perforated steel strips that are repeatedly folded. This orientation enhances
liquid-vapor contact and improves distillation recovery. The vapor rises through the open channels of the packing. In
trayed columns, the liquid flows across the trays and only contacts the vapor while it is on. In packed columns, the
liquid flows down the packing as a thin film and contacts the vapor throughout the entire column.
NITROGEN
Continuous
VAPOUR RICHER AND RICHER IN NITROGEN
Continuous
LIQUID RICHER AND RICHER IN OXYGEN
liquid
liquid––gas
gas
CONTACT
contact
LIQUID-VAPOURCONTACT
contact
LIQUID-VAPOUR
Packing
OXYGEN
This figure illustrates this concept.
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3.2 Flooding
Although trays are susceptible to the various operational problems, packing only experiences problems with
flooding. For packed columns, flooding occurs when the flow rate of liquid entering the packed section exceeds the
flow rate falling to the sump.
Two variables, unusually high-pressure drop across the packing and/or a decrease in product recovery,
indicate flooding. It appears when the gas and/or liquid volume flow rates become too high, due to high molar flow
rate or low pressure in the column. Also high level in the sump can have consequences similar to flooding due to
liquid carry over.
Physically, it corresponds to a carry-over of the down-ward liquid film by the gas stream flowing in the
opposite direction. In the vicinity of flooding, pressure drop increases dramatically with the slightest increase in vapor
load. A reduction in the vapor and liquid flow-rates or an increase in operating pressure can correct minor flooding
within a distillation column. However, significant flooding problems usually require a complete stopping and restarting
of the column.
3.3 Flooding Detection

Physically, flooding on the column will increase the delta pressure from the bottom to the top of the packed
column. The flooding will affect the distillation inside the column. On Nitrogen generator unit, in case of flooding, the
Oxygen content in GAN production increase, the unit will close the production valve and go in venting sequence as
long as purity is not recovered. After one hour, if the correct purity is not recovered, the unit will trip.
E-TPL-10-10-10 – rev A
REFINERIA TALARA
NIS-Z-001 57506-60-01-PR-019A033
Air Liquide
Operating Manual - The Exchangers
06/08/2019 00
Document N°.
57506-60-01-PR-019A033
OPERATING MANUAL
Rev 0
Page 1 of 12
OPERATING MANUAL - THEORITICAL ELEMENTS – EXCHANGERS
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Table of Revisions
Section Description
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TABLE OF CONTENTS
INTRODUCTION 3
1 THEORY OF THE EXCHANGERS. 3
2 MODES OF HEAT TRANSFER 4
2.1 Transfer of heat by convection 4
2.2 Transfer of heat by conduction 6
2.3 Transfer of heat by radiation 6
2.4 Real transfer in an exchanger 6
3. TECHNOLOGY OF THE EXCHANGERS 7
The Main Exchanger 8
3 EXCHANGE DIAGRAM 9
3.1 Principle 9
4.1 The real diagram ( with vaporization and condensation ) 10
3.2 Influence of flow 11
3.3 Influence of KS 11
3.4 Influence of temperature 11
3.5 Influence of pressure fluctuations 11
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INTRODUCTION
The exchangers ensure the heat transfer in various points of the process.
In fact, to be able to obtain the conditions necessary to the distillation of the air, it is necessary to cool the air to reach
its dew point at the entry of column MP.
To obtain this result, a production of cold, allowing a progressive lowering of the temperature of the air up to the level
wished for the implementation of the process of distillation, is necessary. Once the thermodynamic balance of the
installation obtained, the entering air will be cooled with counter-current of the gas products outgoing of the columns
MP and LP which will be heated: one carries out a heat transfer thus.
1 THEORY OF THE EXCHANGERS.

There are 3 principal types of exchangers:
• Exchangers counter current: used for the main exchangers and main vaporizer.
Fig 1
Nitrogen cold
-5°C -100°C
Nitrogen hot 0°C -95°C
-5°C -100°C Nitrogen cold
• Exchangers Co-current:
Fig 2
insulator
Nitrogen cold -100°C -50°C
Nitrogen hot 0°C -50°C
Nitrogen cold
-100°C -50°C
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• Exchangers with cross currents: used for subcoolers of liquids.

Fig 3
2 MODES OF HEAT TRANSFER
2.1 Transfer of heat by convection

Fig4
Paroi à la température T2
Gaz à la température T1
The molecules of gas come to strike the wall of the tube and during the shock, they tend to equalize their
temperature with that of the tube. It is the exchange by convection (the convection is the movement taken by a gas
under the effect of a variation in temperature).
The quantity of heat exchanged in the section of the tube is a function :
• - variation in T2 - T1
• heat-transferring surface of the section of the tube
• nature of the fluid
• conditions of flow.
The conditions of flow:
In the definition of an exchanger, it is taken account of the type of flow of the fluids. Thus two types of flow are noted.
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Laminar flow: (Re < 3000)

The flow of the fluid is carried out by parallel slip of the
layers of molecules the ones on the others without
exchange (weak transfer of heat by convection)
Fig 5
Turbulent flow: (Re > 3000)
The molecules are shock themselves, thus exchanging

their heat (strong transfer of heat by convection).
Fig 6
The type of flow depends on :

• nature of gas, its density (ρ)
• pressure (P [bar.abs])
• temperature (T [K] )
• surface quality of the walls of the exchanger
• dimension of the conduits (D [m])
• and especially its speed (V [m/s])
• viscosity (μ [Ns/m2])
Re is called REYNOLDS number
ρDV
Re =
µ
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2.2 Transfer of heat by conduction
The bodies have more or less facility to transfer heat by

equalization from their temperature in all points, it is the T2
phenomenon of conduction.
The transfer will depend on:
• the nature of the thermal driver: conductibility
• the thickness of the wall: E T1
• the variation in temperature enters the wall: T2 - T1
E
Fig 7
2.3 Transfer of heat by radiation

Transfer of heat per radiation It also depends on the brightness and the color of the body. It is the emission of heat of
a body which is all the more large as its temperature is high. It can be done in the vacuum.
2.4 Real transfer in an exchanger

Température
Laminar flow
Turbulent flow
Turbulent flow
Laminar flow
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3. TECHNOLOGY OF THE EXCHANGERS
Plates fin exchangers
They consist of aluminum plates brazed together, so

as to form a superposition of passages.
The main advantage of this technology is to provide

an exchange surface much more significant to equal
exchange volume, compared to technology with tubes
Detailed view
Barre
Side
separation
Tôle de latérale
bar
sheet
séparation
Fin d’échange
Onde
Barre
Side
latérale
bar Débit
Fluid fluide
flow
separation sheet
Tôle de séparation
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The Main Exchanger
10 - end plate 14 - side bar

11 - separating plate 15 – end bar
Hot fluid 12 - transfer fin
Cold fluid
13 - distribution fin
The main vaporizer
LP column
It is a main piece of cryogenic process of

separation.
It ensures the operation of distillation by

providing the liquid backward flow at the
head of MP column and the gas
vaporization out of tank of the LP column.
Venting of
It establish also the pressure map by link
incondensable LP column and MP column
gas
LOX exit
As the principal exchanger, the main
vaporizer is a plate-fin exchanger.
MP Column
Colonne MP
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3 EXCHANGE DIAGRAM
3.1 Principle
The cooling fluid is called calorigene since it provides the calories
The heated fluid is called refrigerating since it provides the negative kilocalories.
∆T1
Heat exchange[kcal/h]
∆T2 Temperature (°C)
The quantity of heat ∆H transferred from the hot fluid to the cold fluid will be calculated as below:
∆H = U.A. ∆Taverage
Where:
∆T1 − ∆T2
∆TMOYEN = Variation in
∆T temperature to the
ln 1
∆T2 hot end
Variation in
temperature to the
cold end
• UA is the performance of the exchanger, its capacity of exchange.
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4.1 The real diagram ( with vaporization and condensation )
ΔH
100% gas
Cooling
Liquefaction
knee
Liquefaction & vaporization
Vaporization
knee
100% liquid Sub-cooling
Dew point
Temperature sensors permanently control the liquefaction and the vaporization knees to ensure that the variation of
temperature is right.
The variation in temperature to the hot end of the exchanger, is representative of the cooling energy (cold) which is
not recovered by the fluids to cool.
This variation will be a function:
• material constituting the exchanger
• condition of flow
• characteristic of liquids
It is significant to supervise this variation, because it represents a loss of cold which will have to be compensated by
refrigeration
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3.2 Influence of flow

∆T1 ∆T2
Hot Fluid
flow
Cold Fluid
flow
3.3 Influence of KS
When KS increases:
• exchanged heat increases
• the variations between heat and cold ends decrease.
3.4 Influence of temperature

∆T1 ∆T2
Hot Fluid
temperature
Cold Fluid
temperature
3.5 Influence of pressure fluctuations

Fatigue (Thermal or Pressure): This failure mode relates to a mechanical rupture by fatigue due to
temperature or pressure cycling. Pressure variations in product supply pressure may lead to thermal
variations and thermal cycling and fatigue in the heat exchanger.
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“BAHX’s in this service can be exposed to fatigue by pressure and/or temperature cycling.
Pressure cycles occur on each start up and shutdown and they might occur if the operating conditions are
significantly changed. Temperature cycles occur on start up and shutdown.
Because boiling fluids tend to have a relatively small change in temperature, there can be relatively
large differences in temperature between the process streams in the area of the BAHX where oxygen is
boiled. The location of the boiling zone moves as the operating conditions change (pressure or flow rate).
Depending on the BAHX design, these flow changes can cause temperature cycles.
In order to ensure that the operation of the exchanger is not subject to thermal fatigue, any exchanger battery
where dry vaporization occurs shall be equipped with at least two temperature measurement devices installed
so as to frame the end of the vaporization zone(s) and to monitor any potential cycling due to instabilities in
operation (e.g.; product pressure fluctuations, instabilities in flow, etc.). The temperature sensors shall be
placed in the bars of adjacent passages on one core of the exchanger battery. The positioning and elevation of
the thermocouples shall be made taking into account the expected position of vaporization front(s) and
manufacturing constraints. A brazed aluminum exchanger specialist understanding both the mechanical and
process aspects shall validate the positioning of the thermocouples.
During the start up of the unit, the start up engineer will collect the temperature trends (temperature
fluctuation, its rate of change and amplitude) and send them to the process department for analyses.
Note: this requirement does not apply to exchangers where vaporization does not occur, occurs at
pressures at or above 1.5 x the stream critical pressure or to bath-type or film-type vaporizers.
In order to ensure the operation of the exchanger is not subject to pressure cycling
fatigue due to any fluctuations in the product gas, the above aspects shall remind the
plant operator that the exchanger operating pressure shall not be set to directly follow
any downstream pressure fluctuations from the end user or product network.
E-FRM-10-10-8 – rev A
REFINERIA TALARA
NIS-Z-001 57506-60-01-PR-019A034
Air Liquide
Operating Manual - Cold Production
06/08/2019 00
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OPERATING MANUAL - VOLUME A - SECTION A- 03 THEORITICAL ELEMENTS – COLD

PRODUCTION
COVER PAGE


Table of Revisions
Section Description

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PRODUCTION
TABLE OF CONTENTS
INTRODUCTION 3
1 PRODUCTION OF COLD 5
2 COLD PRODUCTION IN APSA PLANTS 5
2.1 APSA L 6
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PRODUCTION
INTRODUCTION
The refrigerating assessment
Entries of heat = Losses of heat = Entries

Losses of of refrigeration
refrigeration Cold
box
Free expansion of air Radiations (imperfect insulation)
Expansion "with external work" (turbine) Principal exchanger’s warm end

variation of temperature
External liquid assist
Liquid productions
The losses of refrigeration do not have all the same weight following the capacity of Plant, but also according to the
point of operation, i.e. the form in which are produced oxygen, nitrogen or argon: gas or liquid. A production of liquid
is a significant extraction of refrigeration
Small unit Big unit
Gas Liquid Gas Liquid
insulation 70% 7% 20% 1%
Temperature difference at 30% 2% 80% 3%
warm end
Liquid production 0% 91% 0% 96%
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PRODUCTION
Radiations
Variation of
temperature
∆Τ
LOX
LIN
LAR
Note :
In the case of Plants with internal compression, the gas production is ensured by a vaporization of liquid tapped
since the columns. The compensation will be done naturally by giving to the column, the air condensed by
vaporization.
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PRODUCTION
1 PRODUCTION OF COLD
Production of cold is necessary to compensate the refrigerating losses during:
• Initial setting in cold:
During the starting of the installation in a "warm" state (the elements of the installation are at the ambient
temperature), to cool it until a temperature where the liquefaction of the air starts. Obtaining these low temperatures
is necessary to obtain liquid in the columns and to thus start distillation.
• Stable operation of the installation:
The refrigerating production will be necessary to balance the refrigerating assessment, i.e. to compensate for the
losses of cold, which are as follows:
- Losses by variation in temperature to the warm end of the exchangers, which represents an
incomplete "recovery" of the cold of the products leaving the columns
- Losses due to the imperfections of the insulation
- Losses of with the production of liquids: the cold which should have been provided to produce them
is not recovered to cool the air in the exchangers.
An excellent indicator of the result of this assessment is the main vaporizer level. If it decreases or increases -> cold
production is not stable.
If, even by not tapping liquid oxygen, this level cannot be maintained, that means that the refrigerating assessment
"does not buckle" i.e. we lost too much cold compared to what we bring.
2 COLD PRODUCTION IN APSA PLANTS

APSA plants are mainly design for gas production. Nevertheless, a small amount of liquid can be produced if the
plant has been design for.
APSA plants are design for internal compression, it means, GAN is delivered at the required pressure at the Cold
box outlet. Thereby, the use of external machine that can lead to safety issues is avoided.
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PRODUCTION
2.1 APSA L
Air is separated into pure nitrogen and waste gas by simple rectification at cryogenic temperature.
The compressed and purified air is cooled down, near its dew point, in the heat exchanger (E01), against
cold pure nitrogen and waste gas.
The air is injected at the bottom of the column (K01). The air is separated into pure nitrogen at the
top, and oxygen rich liquid at the bottom.
The oxygen rich liquid is expanded and sent to the main vaporizer (E02).
There, it is vaporized against a fraction of the pure gaseous nitrogen coming from the top of the column
(K01). This condensed nitrogen is used as reflux for the column.
After vaporization, the oxygen rich gas is sent to the main heat exchanger (E01), partly warmed up
and then sent to the expansion turbine in order to provide the required refrigeration to the plant. After
expansion the waste gas is heated up in the heat exchanger (E01).
The pure gaseous nitrogen is withdrawn from the top of the column (K01), heated up in heat
exchanger (E01) and then available to be connected to Customer network.
The pure liquid nitrogen is withdrawn from the top of the column (K01) and is made available at a connection on the
cold box to be connected to liquid nitrogen storage.
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PROYECTO DE MODERNIZACIÓN REFINERÍA TALARA PROYECTO: TAL

UNIDADES AUXILIARES Y TRABAJOS COMPLEMENTARIOS

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MANUAL DE OPERACIÓN Y MANTENIMIENTO

HOJA DE CONTROL DE REVISIONES

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6.1. INTRODUCCIÓN ................................................................................................ 140

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13. DIAGRAMAS..................................................................................................... 274

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 REPRESENTANTE DEL EMPLEADOR (PMC): Se refiere al PMC o a la persona nombrada

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Unidades Auxiliares y Trabajos Complementarios, CONSORCIO COBRA SCL UA&TC

1.3. DOCUMENTOS DE REFERENCIA

MANUAL DE OPERACIÓN Y MANTENIMIENTO

N° DOCUMENTO: TAL-NIS-PRO-MAN-0001 REV. 01 FECHA: 22/11/2019

 D.S. 051-1993-EM Decreto Supremo N°051-1993-EM –

MANUAL DE OPERACIÓN Y MANTENIMIENTO

N° DOCUMENTO: TAL-NIS-PRO-MAN-0001 REV. 01 FECHA: 22/11/2019

 TAL-NIS-PRO-HMB-0001 Balances de Materia y Energía Rev. 02[19]

MANUAL DE OPERACIÓN Y MANTENIMIENTO

N° DOCUMENTO: TAL-NIS-PRO-MAN-0001 REV. 01 FECHA: 22/11/2019

Tabla 1 - Unidades de Medida

MANUAL DE OPERACIÓN Y MANTENIMIENTO

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2.2. ALIMENTACION A LA UNIDAD Y CARACTERIZACION DE MATERIAS PRIMAS

2.3. CAPACIDAD DE LA UNIDAD

Tabla 2 - Consumo de nitrógeno en Unidades de proceso. Ver referencia [13]

MANUAL DE OPERACIÓN Y MANTENIMIENTO

N° DOCUMENTO: TAL-NIS-PRO-MAN-0001 REV. 01 FECHA: 22/11/2019

Consumo de Nitrógeno (Sm3/h)

MANUAL DE OPERACIÓN Y MANTENIMIENTO

N° DOCUMENTO: TAL-NIS-PRO-MAN-0001 REV. 01 FECHA: 22/11/2019

Consumo de Nitrógeno (Sm3/h)

MANUAL DE OPERACIÓN Y MANTENIMIENTO

N° DOCUMENTO: TAL-NIS-PRO-MAN-0001 REV. 01 FECHA: 22/11/2019

El consumo de nitrógeno para las unidades de servicios industriales y los tanques de

Tabla 3 - Consumo de nitrógeno en unidades de servicios industriales y almacenamiento [13]

MANUAL DE OPERACIÓN Y MANTENIMIENTO

N° DOCUMENTO: TAL-NIS-PRO-MAN-0001 REV. 01 FECHA: 22/11/2019

Consumo de Nitrógeno (Sm3/h)

MANUAL DE OPERACIÓN Y MANTENIMIENTO

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Capacidad de almacenamiento de nitrógeno líquido

MANUAL DE OPERACIÓN Y MANTENIMIENTO

N° DOCUMENTO: TAL-NIS-PRO-MAN-0001 REV. 01 FECHA: 22/11/2019

Tabla 4. Volumen de Nitrógeno líquido requerido

Volumen de Nitrógeno (m3)

Capacidad de Vaporización de Nitrógeno

MANUAL DE OPERACIÓN Y MANTENIMIENTO

N° DOCUMENTO: TAL-NIS-PRO-MAN-0001 REV. 01 FECHA: 22/11/2019