Ufficio Emittente:

ErreDue N10DT2432 1
N° Doc Rev.: Issue Office:
UP
s.r.l. Titolo:
GENERATORI DI IDROGENO OSSIGENO AZOTO
Title:
GENERAL BOOK
Comm. Cliente N° Del: Comm. Interna N° Del:
176/08 _______ 800176 05/05/2008
Client Job N° Dated: Internal Job N° Dated:
Riferimenti :
Reference’s Cliente / Client
DVEL DENIZCILIK Mehmet Afkan Sok. No: 9 - 11 Ko uyolu,
: Kad köy / STANBUL
Impianto / Plant N2 GENERATION PLANT – NB95
Fornitura / Supply IMP-GN1200M

NITROGEN GENERATION PLANT

MANUAL

2 31/08/09 Rev. sh.30 <2> S.A M. M

1 09/09/08 Rev. added N2 Mode S.A M. M

0 13/06/2008 EMISSION S. A M. M

Rev Date Description Emission Approval

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N° Doc Rev.: Issue Office:
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s.r.l. Titolo:
GENERATORI DI IDROGENO OSSIGENO AZOTO
Title:
GENERAL BOOK
Comm. Cliente N° Del: Comm. Interna N° Del:
176/08 _______ 800176 05/05/2008
Client Job N° Dated: Internal Job N° Dated:
Riferimenti :
Reference’s Cliente / Client
DVEL DENIZCILIK Mehmet Afkan Sok. No: 9 - 11 Ko uyolu,
: Kad köy / STANBUL
Impianto / Plant N2 GENERATION PLANT – NB95
Fornitura / Supply IMP-GN1200M

Don’t work on this device before all the staff concerned has read and well understood the
instructions reported in this manual.
If you require some explanations, please don't hesitate to contact ‘ERREDUE’.

When operating on this device, it is absolutely necessary that the staff works observing the
safety regulations and all the provisions and rules are concerning the work safety.

WARNING AS REGARDS SAFETY OF PEOPLE AND THINGS.

Pay special attention to the words marked with the following symbols

DANGER:

Nitrogen is a non-toxic gas; however, if stored in too high concentrations, it can cause
breathing risks.

The produced nitrogen rapidly disperses in the atmosphere, be however careful no to

directly inhale it since it can be very dangerous.
The premises should always have small air openings for the highest safety.
Before to enter in the nitrogen generator room assure that the air oxygen content must
be at least 21%.

It informs that the non-observance of the provisions

involves a very serious risk to people and/or things

ONLY SKILLED PEOPLE AND WORKERS THAT WELL KNOW HOW THIS DEVICE WORKS
ARE AUTHORIZED TO ITS USE AND MAINTENANCE.

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N° Doc Rev.: Issue Office:
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s.r.l. Titolo:
GENERATORI DI IDROGENO OSSIGENO AZOTO
Title:
GENERAL BOOK
Comm. Cliente N° Del: Comm. Interna N° Del:
176/08 _______ 800176 05/05/2008
Client Job N° Dated: Internal Job N° Dated:
Riferimenti :
Reference’s Cliente / Client
DVEL DENIZCILIK Mehmet Afkan Sok. No: 9 - 11 Ko uyolu,
: Kad köy / STANBUL
Impianto / Plant N2 GENERATION PLANT – NB95
Fornitura / Supply IMP-GN1200M

1 GENERAL DESCRIPTION 5

1.1 MAIN DATA 5

1.2 MAIN COMPONENTS 5
1.2.1 NITROGEN GENERATOR 5
1.2.2 AIR COMPRESSORS 5
1.2.3 AIR DRIERS 5
1.2.4 AIR VESSEL 5
1.2.5 PROCESS TANK 6
1.2.6 REMOTE CONTROL PANEL (CCR.2) 6
1.2.7 WHEEL HOUSE PANEL (BP.3) 6
1.2.8 DECK EQUIPMENT / DOUBLE BLOCK AND VENT 6

2 TECHNICAL DESCRIPTION 7

2.1 INTRODUCTION 7
2.2 NITROGEN GENERATION - BASIC PRINCIPLE OF PSA 7

3 PROCESS DESCRIPTION 8

4 OPERATIVE INSTRUCTIONS 10

4.1 INSTALLATION 10
4.2 NITROGEN SKID 10
4.2.1 ERECTION 10
4.3 COMPRESSORS 11
4.3.1 ERECTION 11
4.4 DRYERS 11
4.4.1 ERECTION 12
4.5 INTERCONNETTING PIPING 12

5 START- UP 13

5.1 CHECK FIRST STARTER 13

5.2 NEXT STARTER 13

6 OPERATOR PANEL FUNCTION DESCRIPTION 14

6.1 UCP.1 / CCR.2 : OPERATOR TOUCH SCREEN PANEL 14

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s.r.l. Titolo:
GENERATORI DI IDROGENO OSSIGENO AZOTO
Title:
GENERAL BOOK
Comm. Cliente N° Del: Comm. Interna N° Del:
176/08 _______ 800176 05/05/2008
Client Job N° Dated: Internal Job N° Dated:
Riferimenti :
Reference’s Cliente / Client
DVEL DENIZCILIK Mehmet Afkan Sok. No: 9 - 11 Ko uyolu,
: Kad köy / STANBUL
Impianto / Plant N2 GENERATION PLANT – NB95
Fornitura / Supply IMP-GN1200M
6.2 PRESSING THE TOUCH KEY START (7) 15
6.3 PRESSING THE TOUCH KEY STOP (4) 15
6.4 ALL THE OTHER FUNCTION FROM OPERATOR PANEL : 16
6.5 NORMAL OPERATIONS OF START – STOP - EMG 24

7 MAINTENANCE 25

7.1 ROUTINE ORDINARY MAINTENANCE 25

7.2 PERIODICAL MAINTENANCE 26
7.2.1 REPLACEMENT OF AIR INLET FILTERS 26
7.2.2 CONTROL AND CALIBRATION OF OXYGEN ANALYSER 29
7.2.3 TOWERS COAL CHECK 30

8 SPARE PARTS 30

8.1 SPARE PARTS FOR ROUTINE MAINTENANCE 30

8.2 ADVISE SPARE PARTS 30

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N° Doc Rev.: Issue Office:
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s.r.l. Titolo:
GENERATORI DI IDROGENO OSSIGENO AZOTO
Title:
GENERAL BOOK
Comm. Cliente N° Del: Comm. Interna N° Del:
176/08 _______ 800176 05/05/2008
Client Job N° Dated: Internal Job N° Dated:
Riferimenti :
Reference’s Cliente / Client
DVEL DENIZCILIK Mehmet Afkan Sok. No: 9 - 11 Ko uyolu,
: Kad köy / STANBUL
Impianto / Plant N2 GENERATION PLANT – NB95
Fornitura / Supply IMP-GN1200M

GENERAL DESCRIPTION

1.1 MAIN DATA

Hull name : NB95
Customer : DVEL DENIZCILIK
Equipment : SAFE AREA
Plant Capacity : 1250Sm3/h@95% N2
Construction year : 2008
System Built in conformity with : SOLAS-IMO
Classification Society : (B.V.)

1.2 MAIN COMPONENTS

1.2.1 NITROGEN GENERATOR

Consisting of 3 unit for indoor location:

N°1 Skid mounted a Double Bank of Columns consisting of:
N°2 banks of Carbon Molecular Sieve (CMS)
N°1 Control Cabinet consisting of:
N°1 Control Panel
N°1 Oxygen Analyser
N°1 Kit of Instrumentation and control valves
N°1 Filter group consisting of:
N°3 Filters with automatic drains.

1.2.2 AIR COMPRESSORS

Consisting of 2 similar units in parallel, for indoor location:

Screw type Compressor Unit
Fresh Water Cooling System

1.2.3 AIR DRIERS

Consisting of 2 similar units in parallel, for indoor location:

Refrigerant 404a
Automatic drain

1.2.4 AIR VESSEL

Consisting of a tank, for indoor location:

Volume 3750Lt
Vertical erection

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s.r.l. Titolo:
GENERATORI DI IDROGENO OSSIGENO AZOTO
Title:
GENERAL BOOK
Comm. Cliente N° Del: Comm. Interna N° Del:
176/08 _______ 800176 05/05/2008
Client Job N° Dated: Internal Job N° Dated:
Riferimenti :
Reference’s Cliente / Client
DVEL DENIZCILIK Mehmet Afkan Sok. No: 9 - 11 Ko uyolu,
: Kad köy / STANBUL
Impianto / Plant N2 GENERATION PLANT – NB95
Fornitura / Supply IMP-GN1200M

1.2.5 PROCESS TANK

Consisting of a tank, for indoor location:

Volume 3750Lt
Vertical erection

1.2.6 REMOTE CONTROL PANEL (CCR.2)

- Located in Cargo Control Room

- It allows the surveillance of the nitrogen purity and pressure, beyond
acoustic and visual signalling of alarms .

1.2.7 WHEEL HOUSE PANEL (BP.3)

- Located in W.H. (Bridge panel)

- It allows the surveillance of the nitrogen purity and pressure, beyond
acoustic and visual signalling of alarms .

1.2.8 DECK EQUIPMENT / DOUBLE BLOCK AND VENT

Valve for isolation between Safe and Hazardous area (located on Deck)
N°1 Automatic Block valve (XV42) located in safe area (PSA location)
N°2 Automatic Block valves located in Hazard area (XV43 - XV44)
N°1 Automatically Vent valve located in Hazard area (XV45)
N°1 manual Control valve (FCV41)
N°1 On-Way valve (VU41) (Supplied by client)
Over equipment group assures the isolation between safe and hazardous area in
phase of shut down; in this case the Vent valve assures to discharge to
atmosphere residual of Hydrocarbon gases come back from tank.

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s.r.l. Titolo:
GENERATORI DI IDROGENO OSSIGENO AZOTO
Title:
GENERAL BOOK
Comm. Cliente N° Del: Comm. Interna N° Del:
176/08 _______ 800176 05/05/2008
Client Job N° Dated: Internal Job N° Dated:
Riferimenti :
Reference’s Cliente / Client
DVEL DENIZCILIK Mehmet Afkan Sok. No: 9 - 11 Ko uyolu,
: Kad köy / STANBUL
Impianto / Plant N2 GENERATION PLANT – NB95
Fornitura / Supply IMP-GN1200M

2 TECHNICAL DESCRIPTION

2.1 Introduction
This Nitrogen Generator is a device for production nitrogen from filtration of continuous
compressed air through a molecular sieve.
The Generator can directly produce nitrogen under pressure up to 7 –10 bars
(according to the supply compressed air) and with programmable level of purity.
Complete equipment allows constantly checking the flow and purity of the produced
nitrogen, thus assuring the on-line inlet of Nitrogen with established values.
The generator is however a very easy device, it is automatically controlled by a PLC
and it consists of highly reliable electro-pneumatic components, thus requiring the
minimum necessary maintenance for a long life

2.2 Nitrogen generation - Basic principle of PSA

The device is an on-site nitrogen generator carried out on the principle of molecular
adsorption of special carbons contained in a ' tower filter' that can hold the oxygen of
the air, which they are in contact with.
The tower is crossed by an air flow, so as to collect only outlet nitrogen, while the part
of molecular oxygen contained in the air remains ‘trapped’ in the carbons that should
be 'regenerated' before their complete saturation.

For ‘regenerating’ the carbons, that is releasing the oxygen hold by them, so as to re-
use them as adsorbents, it is necessary to use two different towers (or benches of
towers) containing the carbons. In this way they can alternatively work in ‘adsorption’
and ‘regeneration’, thus assuring a continuity of the outlet nitrogen flow at the
required purity.

A suitable cycle of commutations of the air flows carried out with electro-pneumatic
valves, pressure and flow regulators, and other pneumatic components allows
optimizing the process until a constant nitrogen production is obtained having suitable
purity and pressures for the required use.
This process of cyclical pressurization and discharge of the towers is called PSA
principle (Pressure Swing Adsorption)

The shown process is automatically controlled by a P.L.C electronic control with main
and remote operator panel that also reads the inserted instrumentations, like pressure,
capacity and oxygen analyzer transmitter, to assures the purity degree established for
the produced nitrogen.

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N° Doc Rev.: Issue Office:
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s.r.l. Titolo:
GENERATORI DI IDROGENO OSSIGENO AZOTO
Title:
GENERAL BOOK
Comm. Cliente N° Del: Comm. Interna N° Del:
176/08 _______ 800176 05/05/2008
Client Job N° Dated: Internal Job N° Dated:
Riferimenti :
Reference’s Cliente / Client
DVEL DENIZCILIK Mehmet Afkan Sok. No: 9 - 11 Ko uyolu,
: Kad köy / STANBUL
Impianto / Plant N2 GENERATION PLANT – NB95
Fornitura / Supply IMP-GN1200M

3 PROCESS DESCRIPTION

With reference to:

- N10EL7239 ( INTERCONNETTING BLOCK DIAGRAM)
- N10FN2420 ( P&I )
Two equal compressor (FAC-1) and (FAC-2) are installed for the compressed air
production. The compressors are cools with fresh water and supplies of automatic
condense drainage. Each one compressor is followed from a compressed air dryer (DE-1)
and (DE-2) supplied of automatic condense drainage. The commandos of Start and Stop
are present on the compressor units, and are remoted to the panels of control UCP-1 (of
the nitrogen generator) and CCR.2 on the Cargo Control Room.
The compressed air crosses a group of filtration constituted from three filters F1-F2-F3,
the first two (of the coalescence type) supplies of automatic condense drainage and
pressure differential indicator (PDI03) and (PDI04). The F3 filter to absorption (active
coal) does not preview the automatic condenses drainage
The compressed air therefore filtered, feeds an air tank (TK1), that has the function of air
accumulate and supplied of automatic condenses drainage), then a Nitrogen Production
Unit to flange (TP9) and through the regulator of flow (FCV21) and automatic valves
(XV21) and (XV23) alternatively load of towers (Tower A and Tower B).
During the phase of cargo of the bench A, the bench B is in drainage to the vent
(regeneration) for means of automatic valve (XV24) and the flow regulator (FCV22);
instead in the successive cycle it will be in cargo the bench B and will be in drainage the
bench A for means of automatic valve (XV22) and the same flow regulator (FCV22).

The selected bench of towers to the cargo, distributes nitrogen (flange TP2) towards the
Process Tank (TK2), through unidirectional valves (VU01) or (VU02) and the flow
regulator (FCV23).
A small nitrogen flow through calibrated hole (FO21), from above feeds the bench of
towers in drainage to the vent, helping therefore the regeneration process (expulsion of
the oxygen caught in the tower).
The nitrogen in outlet from the Process Tank (TK2), through flange (TP3) passes in the
flow meter (FT21), the control valve (FCV27) and one of the two lines selected of nitrogen
outlet:
- (XV25) and (VM29) in the event of nitrogen cargo to the Tanks Cargo
- (XV28) and (VM28) in the event of nitrogen cargo for purging line

The purity of nitrogen in arrival from the Process Tank, comes analyzed with instrument
(AIT21) and if the purity is inferior to demanded value (95% or 98%), the nitrogen flow

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GENERATORI DI IDROGENO OSSIGENO AZOTO
Title:
GENERAL BOOK
Comm. Cliente N° Del: Comm. Interna N° Del:
176/08 _______ 800176 05/05/2008
Client Job N° Dated: Internal Job N° Dated:
Riferimenti :
Reference’s Cliente / Client
DVEL DENIZCILIK Mehmet Afkan Sok. No: 9 - 11 Ko uyolu,
: Kad köy / STANBUL
Impianto / Plant N2 GENERATION PLANT – NB95
Fornitura / Supply IMP-GN1200M

no-spec comes convoyed to the vent for means of automatic valve (XV26), while the
valves of line (XV25) will remain closed.
When the nitrogen catches up the demanded purity happens the commutation online
automatically.

The nitrogen is enabled by (XV25) towards the Tank Cargo and the flow is controlled for
means valve (FCV27) for the nominal value.

When the pressure in the Tank, checked with a pressure transmitter on the bridge (PT41),
begins to increase, the control begins to close the valve (FCV27), reducing the distribution
flow and avoiding to exceed the established set of pressure.
If instead the demand for nitrogen it increases, the pressure will begin to come down and
the control begins to open valve FCV, increasing the distribution flow and ring-establish
the pressure set.
Therefore through the control of the FCV it is possible to maintain the demanded pressure
constant.
The FCV takes part in the event in closing also of high, too much advanced consumption
to the nominal capacity of the system checked through Flow-Meter (FIT 21), so as to
prevent the distribution of a nitrogen no.spec.
In the inert gas supply main (process line) are installed the double block and bleed valves
(XV42, XV43, XV44, XV45) and the PLC check permanently the status (open/close) as
described on the “Alarm List” (doc. N. N10DC7241).

NOTE:

All operative functionally of this system are according to the Bureau Veritas
rules “Pt.D, Ch.7, Sec.6 – par. 5 & Pt.D, Ch.8, Sec.9 – par. 2.5 Inert Gas
System”

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N° Doc Rev.: Issue Office:
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s.r.l. Titolo:
GENERATORI DI IDROGENO OSSIGENO AZOTO
Title:
GENERAL BOOK
Comm. Cliente N° Del: Comm. Interna N° Del:
176/08 _______ 800176 05/05/2008
Client Job N° Dated: Internal Job N° Dated:
Riferimenti :
Reference’s Cliente / Client
DVEL DENIZCILIK Mehmet Afkan Sok. No: 9 - 11 Ko uyolu,
: Kad köy / STANBUL
Impianto / Plant N2 GENERATION PLANT – NB95
Fornitura / Supply IMP-GN1200M

4 OPERATIVE INSTRUCTIONS

4.1 INSTALLATION
Necessary instructions to the installation and putting in service for the production of
demanded nitrogen.
Pay attention to use means of raising and movement adapted to cargos declares to
you for every device.
Pay attention the raising points indicated on the devices.

ATTENTION : The nitrogen is an inert gas and can harmful if be breathed to high
concentrations.
All nitrogen vent-lines must be convoyed to the atmosphere in safe area.

4.2 NITROGEN SKID

The installation consists in the positioning and implantation of the skid to the
foundation, for means of bolts and therefore the connection of piping and electrical
cables like from supplied outlines drawing.
The connection of vent-lines TP6 (Vent for no-spec) and TP7 (Vent for Oxygen
enriched gas) must be used minimum section area to guarantee a max back
pressure of 0.005 barg. ( not dependent from lenght of the line itself).
The vent-lines must discharge in safe area on the open deck far from zone stay.
It’s possible to apply a anti-noise filter on the end of vent-line.
Vent-line for no.spec and Vent line for Oxygen enriched gas may be connected to a
common line, always holding account of one back pressure max 0,005 barg.
To hold clearance area around to the Skid in manner to have an adequate and sure
access for the maintenance.
Provide an independent mechanical extraction ventilation and low oxygen alarm
are to be fitted.
Provide portable instrument for measuring oxygen & flammable vapour
concentration in the generator room (for presence of oxygen content) and in the
cargo tanks (for presence of oxygen or flammable vapour content).

4.2.1 ERECTION

To install the Nitrogen Skid like described.

To complete the piping between the several devices (Compressor-Dryer-Vessel-
Nitrogen skid-Deck valves)
To make the electrical connections toward all the instruments in field and to test
them.
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s.r.l. Titolo:
GENERATORI DI IDROGENO OSSIGENO AZOTO
Title:
GENERAL BOOK
Comm. Cliente N° Del: Comm. Interna N° Del:
176/08 _______ 800176 05/05/2008
Client Job N° Dated: Internal Job N° Dated:
Riferimenti :
Reference’s Cliente / Client
DVEL DENIZCILIK Mehmet Afkan Sok. No: 9 - 11 Ko uyolu,
: Kad köy / STANBUL
Impianto / Plant N2 GENERATION PLANT – NB95
Fornitura / Supply IMP-GN1200M

To make the electrical power supply connections and to test them.

4.3 COMPRESSORS

To hold clearance area around to the Skid in manner to have an adequate and sure
access for the maintenance.
Install in the engine room preferably.
Verified if the ventilation in the room is sufficient for a normal cooling of
compressors.
Provide a drainage for removal of condenses (water more oil).
To check the Pressure and Capacity of fresh water cooling and the correct grade of
filtration.
To install a Shut-off valve on water cooling feeding line
For other details of installation and starter to make reference to ‘HANDBOOK’
supplied with the compressor

ATTENTION: The local of installation of the compressors and dryer must have one
temperature comprised between 0°C and 45°C

4.3.1 ERECTION

Install the Compressors as described .

Connect with flexible hoses to the cooling water
Connect with flexible hoses the compressed air outlet
Connect the remote signals towards Nitrogen Skid and test them.
Connect the cables of electrical power supply and test them.

ATTENTION:
- Pay particular attention at correct connection to protection heart.
- All electrical connection must be made from qualified personnel in according to IEC
standards and local rules.
- Make sure for a correct operating voltage (maximum variation +/- 10%).

4.4 DRYERS

To hold clearance area around to the Skid in manner to have an adequate and sure
access for the maintenance.
Verified if the ventilation in the room is sufficient for a normal cooling of dryers.
Provide a drainage for removal of condenses (water more oil).
For other details of installation and starter to make reference to ‘HANDBOOK’ supplied
with the dryers

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Title:
GENERAL BOOK
Comm. Cliente N° Del: Comm. Interna N° Del:
176/08 _______ 800176 05/05/2008
Client Job N° Dated: Internal Job N° Dated:
Riferimenti :
Reference’s Cliente / Client
DVEL DENIZCILIK Mehmet Afkan Sok. No: 9 - 11 Ko uyolu,
: Kad köy / STANBUL
Impianto / Plant N2 GENERATION PLANT – NB95
Fornitura / Supply IMP-GN1200M

ATTENTION: The local of installation of the compressors and dryer must have one
temperature comprised between 0°C and 45°C

4.4.1 ERECTION

Install the Dryers as described .

Connect the line of inlet and outlet compressed air
Connect the remote signals towards Nitrogen Skid and test them.
Connect the cables of electrical power supply and test them.

ATTENTION:
- Pay paticular attention at correct connection to protection heart.
- All electrical connection must be made from qualified personnel in according to IEC
standards and local rules.
- Make sure for a correct operating voltage (maximum variation +/- 10%).

4.5 INTERCONNETTING PIPING

Yard must supply to the pipages of connection between the main units:
o Piping of connection between Compressor and relative Dryer
o Piping of connection between Dryer and filter group.
o Piping of connection between filter group and air compressed tank
o Piping of connection between air compressed tank and Nitrogen generator.
o Piping of connection between Nitrogen generator N2 95% e and cargo tanks.
o Assembly of the Deck valves and branch of sampling towards the instruments
panel on the deck.
o Piping of connection between Nitrogen generator N2 98% and buffer tank

ATTENTION:
- Pay particular attention to cleaning and washing of the lines in order protect valves
and applied instrumentation

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s.r.l. Titolo:
GENERATORI DI IDROGENO OSSIGENO AZOTO
Title:
GENERAL BOOK
Comm. Cliente N° Del: Comm. Interna N° Del:
176/08 _______ 800176 05/05/2008
Client Job N° Dated: Internal Job N° Dated:
Riferimenti :
Reference’s Cliente / Client
DVEL DENIZCILIK Mehmet Afkan Sok. No: 9 - 11 Ko uyolu,
: Kad köy / STANBUL
Impianto / Plant N2 GENERATION PLANT – NB95
Fornitura / Supply IMP-GN1200M

5 START- UP
5.1 CHECK FIRST STARTER

- Before starting the system it is necessary to supply to some controls and set :

o Check for electric connection.

o Control the correct position of all manual valves.
o Control the SET of the operation parameters demands.
o Control the SET of alarms.
o Select the function mode required (IG or N2).
o Control the calibration of the instrument analyzer O2%.

To proceed with the indicated operating sequence to the successive point.

5.2 NEXT STARTER

- The starters can be made independently from HMI Panel on main unit UCP.1 or on
remote Panel CCR.2 place in Cargo Control Room.
- Any signalling of alarms together indication of Pressure to deck and the Purity
Nitrogen are visualized also on Panel BP.3 place on the Bridge.
- Before other operation it’s necessary to supply every unit (Compressor, Dryers, N2
generator), by relative Electrical Switchboard (customer supply).
- Press the key “START” on the touch screen panel on the N2 Generator or on CCR.2
panel and follow the procedure described on par. 6.2.

ATTENTION:
- DRYES will be start operating on Push-buttons of START directly on the relative main
local panels.
- Every other operation will be carried out operating indifferently on panels UCP.1 and
CCR.2.

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N° Doc Rev.: Issue Office:
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s.r.l. Titolo:
GENERATORI DI IDROGENO OSSIGENO AZOTO
Title:
GENERAL BOOK
Comm. Cliente N° Del: Comm. Interna N° Del:
176/08 _______ 800176 05/05/2008
Client Job N° Dated: Internal Job N° Dated:
Riferimenti :
Reference’s Cliente / Client
DVEL DENIZCILIK Mehmet Afkan Sok. No: 9 - 11 Ko uyolu,
: Kad köy / STANBUL
Impianto / Plant N2 GENERATION PLANT – NB95
Fornitura / Supply IMP-GN1200M

6 OPERATOR PANEL FUNCTION DESCRIPTION

6.1 UCP.1 / CCR.2 : OPERATOR TOUCH SCREEN PANEL

MAIN PAGE

2 5
1 4
3 6

9 16

10 15
11 12 14
13
POS.1 Touch Key silent - alarm horn
POS.2 Show the percentage of residual O2 in produced nitrogen
POS.3 Show the N2 Pressure to Deck (in IG mode) or Buffer tank (in N2 mode)
POS.4 Touch Key function of Stop
POS.5 Touch Key function of Reset
POS.6 Touch Key selection Mode (IG 95% or N2 98% @7bar)
POS.7 Touch Key function of Start
POS.8 Touch Key access to manual command of set e test
POS.9 Show % O2 of selected mode
POS.10 Touch Key access of pages of e graphic visualization
POS.11 Touch Key access to pages of parameters setting
POS.12 Touch Key access alarms knowledge
POS.13 Show the state of system
POS.14 Touch Key access to the variable values list (running values)
POS.15 Touch Key access to the history alarms list
POS.16 Show enable to Local or Remote command (CCR PANEL)

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Client Job N° Dated: Internal Job N° Dated:
Riferimenti :
Reference’s Cliente / Client
DVEL DENIZCILIK Mehmet Afkan Sok. No: 9 - 11 Ko uyolu,
: Kad köy / STANBUL
Impianto / Plant N2 GENERATION PLANT – NB95
Fornitura / Supply IMP-GN1200M

EXAMPLE: In the condition indicated in figure the system Is electrically fed, in

absence of alarms and ready to the starter.

6.2 PRESSING THE TOUCH KEY START (7)

An automatic procedure of starter has beginning, that it previews

- The start of the two compressors if enabled and the waiting for the
conditions of minimal air pressure (demanded t to enable the N2 unit
generator).
- Countdown of a time of initialization of the instrument analyzer of O2
- Vent of produced nitrogen no-spec, until the attainment of the purity of the
set up.
The upon steps are shown in the restricted area to the state of the system (13)
In absence of alarms, after a set time, in the field of state (13) the following
messages will appear sequential :
- Waiting for Power
- Compressor 1 Turning ON
- Compressor 2 Turning ON
- System initializing
- Discharge N2 no-spec
- ……and then write “DELIVERY IG 95%” or “DELIVERY N2 98%” and will be
visualizes the values of Purity O2 and Nitrogen pressure in the areas (2) and (3)
respectively.

6.3 PRESSING THE TOUCH KEY STOP (4)

A second window is opened with demand for :

- STOP N2 Generator, that it previews the single stop of the nitrogen generator,
leaving the feeding of the compressed air
- AIR COMP.1 DISENABLE or/and AIR COMP.2 DISENABLE, that it previews the stop
of one or/and both compressors. (The stop of both compressors is possible only

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GENERATORI DI IDROGENO OSSIGENO AZOTO
Title:
GENERAL BOOK
Comm. Cliente N° Del: Comm. Interna N° Del:
176/08 _______ 800176 05/05/2008
Client Job N° Dated: Internal Job N° Dated:
Riferimenti :
Reference’s Cliente / Client
DVEL DENIZCILIK Mehmet Afkan Sok. No: 9 - 11 Ko uyolu,
: Kad köy / STANBUL
Impianto / Plant N2 GENERATION PLANT – NB95
Fornitura / Supply IMP-GN1200M

after the Stop of N2 generator).

6.4 ALL THE OTHER FUNCTION FROM OPERATOR PANEL :

Access to manual functions

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GENERAL BOOK
Comm. Cliente N° Del: Comm. Interna N° Del:
176/08 _______ 800176 05/05/2008
Client Job N° Dated: Internal Job N° Dated:
Riferimenti :
Reference’s Cliente / Client
DVEL DENIZCILIK Mehmet Afkan Sok. No: 9 - 11 Ko uyolu,
: Kad köy / STANBUL
Impianto / Plant N2 GENERATION PLANT – NB95
Fornitura / Supply IMP-GN1200M

Next page

Next page SETTING DATE & HOUR

Test enable only in state of Stop N2 generator.

Nitrogen Generator Test Valves

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Comm. Cliente N° Del: Comm. Interna N° Del:
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Client Job N° Dated: Internal Job N° Dated:
Riferimenti :
Reference’s Cliente / Client
DVEL DENIZCILIK Mehmet Afkan Sok. No: 9 - 11 Ko uyolu,
: Kad köy / STANBUL
Impianto / Plant N2 GENERATION PLANT – NB95
Fornitura / Supply IMP-GN1200M

Deck Line Test Valves

Next page

Pressing on the valve symbols is possible to force manually the commutation:

Black Symbol = Valve Close
White Symbol = Valve Open

Pressing theTouch key is

possible enable the remote
commands from CCR – B.P.
See Pos.16 on main page
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GENERAL BOOK
Comm. Cliente N° Del: Comm. Interna N° Del:
176/08 _______ 800176 05/05/2008
Client Job N° Dated: Internal Job N° Dated:
Riferimenti :
Reference’s Cliente / Client
DVEL DENIZCILIK Mehmet Afkan Sok. No: 9 - 11 Ko uyolu,
: Kad köy / STANBUL
Impianto / Plant N2 GENERATION PLANT – NB95
Fornitura / Supply IMP-GN1200M

Calibration
Analyzer O2

Operation/Test enable only in state of Stop N2 generator.

To apply a reference gas, with know residual O2 to the point of calibration and
therefore to proceed like indicated
Note: The Reference value indicated of default is relative to air(20.9-21%):
the value can be modified pressing it and operating with the key board as
usually.

Access to visualization of the analogic parameters and setting.

ACCESS TO PAGES OF
ONLY VISUALIZATIONS

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GENERAL BOOK
Comm. Cliente N° Del: Comm. Interna N° Del:
176/08 _______ 800176 05/05/2008
Client Job N° Dated: Internal Job N° Dated:
Riferimenti :
Reference’s Cliente / Client
DVEL DENIZCILIK Mehmet Afkan Sok. No: 9 - 11 Ko uyolu,
: Kad köy / STANBUL
Impianto / Plant N2 GENERATION PLANT – NB95
Fornitura / Supply IMP-GN1200M

Pressing the Touch Key and insert the password for access to the next pages of
parameters.

Pressing on the area of the value to modified it’s opened automatically a

window with a digital keyboard for write the new setting .

FIRST PAGE

Note:
- Showed value are Default setting.
- IG mode accept only vales 95%

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Client Job N° Dated: Internal Job N° Dated:
Riferimenti :
Reference’s Cliente / Client
DVEL DENIZCILIK Mehmet Afkan Sok. No: 9 - 11 Ko uyolu,
: Kad köy / STANBUL
Impianto / Plant N2 GENERATION PLANT – NB95
Fornitura / Supply IMP-GN1200M

NEXT PAGE

Access to visualization of the analogic parameters and setting

HISTORY ALARM

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Client Job N° Dated: Internal Job N° Dated:
Riferimenti :
Reference’s Cliente / Client
DVEL DENIZCILIK Mehmet Afkan Sok. No: 9 - 11 Ko uyolu,
: Kad köy / STANBUL
Impianto / Plant N2 GENERATION PLANT – NB95
Fornitura / Supply IMP-GN1200M

PARAMETER ANALOG LIST

ALARM LIST

FIRST PAGE

NEXT PAGE

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Title:
GENERAL BOOK
Comm. Cliente N° Del: Comm. Interna N° Del:
176/08 _______ 800176 05/05/2008
Client Job N° Dated: Internal Job N° Dated:
Riferimenti :
Reference’s Cliente / Client
DVEL DENIZCILIK Mehmet Afkan Sok. No: 9 - 11 Ko uyolu,
: Kad köy / STANBUL
Impianto / Plant N2 GENERATION PLANT – NB95
Fornitura / Supply IMP-GN1200M

Pages to visualize of the principal parameters of the process.

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Title:
GENERAL BOOK
Comm. Cliente N° Del: Comm. Interna N° Del:
176/08 _______ 800176 05/05/2008
Client Job N° Dated: Internal Job N° Dated:
Riferimenti :
Reference’s Cliente / Client
DVEL DENIZCILIK Mehmet Afkan Sok. No: 9 - 11 Ko uyolu,
: Kad köy / STANBUL
Impianto / Plant N2 GENERATION PLANT – NB95
Fornitura / Supply IMP-GN1200M

ALARMS LIST:
When the panel show the message “Alarm present” or “Shutdown Alarm

present” is possible to visulize the text alarm message pressing the key .

History Alarm
Text Message
Code
1 Insufficient air pressure
2 High air temperature
3 Insufficient cooling water pressure
4 Insufficient instrument air pressure
5 Automatic discharge air filters SC1 SC2 fault
6 Emergency button pressed
7 Feed air compressor 1 fault
8 Feed air compressor 2 fault
9 PT02 fault (Cooling water pressure transducer)
10 PT21 fault (Air inlet pressure transducer)
11 PT23 fault (Air instrument pressure transducer)
12 PT41 fault (Cargo tanks pressure transducer)
13 PT42 Fault (Cargo tanks pressure transducer)
14 TT21 fault (Air inlet temperature transducer)
15 DBB failure
16 Discharge N2 no spec
18 High Inlet Air Pressure
Shutdown cargo pumps
Dryer 1 Faulty
Dryer 2 faulty
Power failure
Air inlet filters engaged
Power supply recorder absent
Dryer 1 switched OFF
Dryer 2 switched OFF
FT21 fault (Flow transmitter)
AT21 fault (Oxygen Analyser)
PT30 fault (Nitrogen Outlet pressure transducer)

NOTES:
For alarm press to ”‘reset key” to reset.
For shutdown alarm, press “reset key” for more then 5 second for erase the
message.
For more detail of the alarm function refer to the “TEST ALARM LIST” doc.
N. N10DC7241.

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Comm. Cliente N° Del: Comm. Interna N° Del:
176/08 _______ 800176 05/05/2008
Client Job N° Dated: Internal Job N° Dated:
Riferimenti :
Reference’s Cliente / Client
DVEL DENIZCILIK Mehmet Afkan Sok. No: 9 - 11 Ko uyolu,
: Kad köy / STANBUL
Impianto / Plant N2 GENERATION PLANT – NB95
Fornitura / Supply IMP-GN1200M

6.5 NORMAL OPERATIONS OF START – STOP - EMG

START PROCEDURE
- To control that the electrical power is inserted to the compressors, the dryers and
the nitrogen generator leave in stand-by the compressors and the nitrogen generator.
- To start the dryers by relative local “start key”.
- Check the control panel for absence of alarm messages.
- Select the function mode required (IG or N2)
- Press the touch- key start (for one second)

NOTE: The demanded time can vary to second of the operating conditions.

STOP PROCEDURE
- Press the touch-key stop
- Stop therefore the nitrogen generator pressing the relative key stop.
- Stop the compressors pressing the relative key-stop
- Switch off the electrical power of the compressors, the dryers and the nitrogen
generator.

NOTE: If the system must be stopped for a short time (smaller of an hour) it advises
to only act on the push-button of Stop of the nitrogen generator and to leave the
Compressors and the Dryers in Stand-by.

Function STOP acts on the block of the automatic valves of escape of the nitrogen
generator XV25 - XV28 and Vent XV26 and on the group `Double Block & Bleed' XV42-
XV43-XV44-XV45 of isolation of the Cargo tanks

EMERGENCY

MANUAL EMERGENCY PROCEDURE

- Press one of the fungus push-buttons present on the devices and operating panels
(main and remote).

Function EMG acts on the same automatic valves of isolation like the STOP, but they
come de-energized with the cut of the feeding tension.
Moreover the emergency function acts also on the Compressor

The Fungus of emergency has a bi-stable function, therefore it must be restored

manually after every intervention.

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Comm. Cliente N° Del: Comm. Interna N° Del:
176/08 _______ 800176 05/05/2008
Client Job N° Dated: Internal Job N° Dated:
Riferimenti :
Reference’s Cliente / Client
DVEL DENIZCILIK Mehmet Afkan Sok. No: 9 - 11 Ko uyolu,
: Kad köy / STANBUL
Impianto / Plant N2 GENERATION PLANT – NB95
Fornitura / Supply IMP-GN1200M

7 MAINTENANCE

7.1 ROUTINE ORDINARY MAINTENANCE

WARNING DANGER!

Maintenance requires highest care, observance of all work safety procedures and use of
individual protection clothing.
Maintenance should be performed only by skilled staff.

IN GENERAL,
Before performing anyone of the below listed maintenance operations, the
following should be done:
1. shut down the power supply.
2. depressurize the hydraulic circuits (checking on the safety internal
manometer).
3. wear individual protection clothing.

CIRCUIT DEPRESSURIZATION
Before every operation of maintenance, control or verification that it demands
the opening of hydraulic circuits is necessary to verify of the happened one '
depressurization' controlling that all the inner pressure gauges indicate value
ZERO.

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Title:
GENERAL BOOK
Comm. Cliente N° Del: Comm. Interna N° Del:
176/08 _______ 800176 05/05/2008
Client Job N° Dated: Internal Job N° Dated:
Riferimenti :
Reference’s Cliente / Client
DVEL DENIZCILIK Mehmet Afkan Sok. No: 9 - 11 Ko uyolu,
: Kad köy / STANBUL
Impianto / Plant N2 GENERATION PLANT – NB95
Fornitura / Supply IMP-GN1200M

7.2 PERIODICAL MAINTENANCE

The generator doesn't use any consumable materials, therefore its maintenance is
reduced to a few easy operations.

To always verify effective operating conditions in order to determine maintenance

interval.
To always use original spare parts making reference.

7.2.1 REPLACEMENT OF AIR INLET FILTERS

WARNING!
RISK FROM TANK OR PIPING IN PRESSURE
DEPRESSURIZATION BEFORE EVERY OPERATION

This is the only really important operation to be carried out within suitable times and
manner, in order to assure a long life to the same generator.

The oil is particularly harmful for the tower carbons and also small quantities
contained in the inlet air can cause irreversible damages that require the complete
replacement of the same carbons through expensive operations of extraordinary
maintenance.

The filter set is formed of three filters in series with different degrees. They can
protect the sieve even by temporary air supply with insufficient quality.

F1-first filter : coalescence of 0.1 mg/mc oil

F2-second filter : coalescence of 0.01 mg/mc oil
F3-third filter : activated carbons 0.003 mg/mc oil

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GENERAL BOOK
Comm. Cliente N° Del: Comm. Interna N° Del:
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Client Job N° Dated: Internal Job N° Dated:
Riferimenti :
Reference’s Cliente / Client
DVEL DENIZCILIK Mehmet Afkan Sok. No: 9 - 11 Ko uyolu,
: Kad köy / STANBUL
Impianto / Plant N2 GENERATION PLANT – NB95
Fornitura / Supply IMP-GN1200M

FILTER – F1
FILTER – F3

FILTER – F2

The first and second filters should be replaced according every 2000 working
hours or before if the differential manometer show a 400mbar.
The third filter should be replaced every 4000 working hours.

The first two filters automatically drain the condensate. The drainage should be piped
inside an external tank for the disposal according to the rules in force.

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Client Job N° Dated: Internal Job N° Dated:
Riferimenti :
Reference’s Cliente / Client
DVEL DENIZCILIK Mehmet Afkan Sok. No: 9 - 11 Ko uyolu,
: Kad köy / STANBUL
Impianto / Plant N2 GENERATION PLANT – NB95
Fornitura / Supply IMP-GN1200M

7.2.2 CONTROL AND CALIBRATION OF OXYGEN ANALYSER

The oxygen analyzer should be periodically calibrated: about every 6 months or even
before if doubts on the quality of the produced nitrogen arise.

O2 ANALYSER – AT21

For the operative instruction about the control and calibration operate on the 3-way
valve VICA open the inlet calibration pure nitrogen way and then refer to Drager
Polytron 7000 Analyser manual.
The oxygen sensor must be substitute about every 18 months.

MANUAL VALVE – VI31

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Riferimenti :
Reference’s Cliente / Client
DVEL DENIZCILIK Mehmet Afkan Sok. No: 9 - 11 Ko uyolu,
: Kad köy / STANBUL
Impianto / Plant N2 GENERATION PLANT – NB95
Fornitura / Supply IMP-GN1200M

7.2.3 TOWERS COAL CHECK <2>

Is suggested to check the towers coal level every 8000 working hours or before if the
performance are not respected and if necessary added the coal to restore the level.
The coal level must be over the horizontal welding internal of the tank.
To check the coal remove the elbow disassembling the “flange 1” and “flange 2” on
each towers.

FLANGE 2

ELBOW

FLANGE 1

8 SPARE PARTS
8.1 SPARE PARTS FOR ROUTINE MAINTENANCE

POS. DESCRIPTION ERREDUE CODE Q.TY

1 Coalescent Cartridge of 0,1 mg/mc oil- AIR FILTER (F2) FCF120 1
2 Coalescent Cartridge of 0,01 mg/mc oil - AIR FILTER (F3) FCF121 1
3 Activated Carbon Cartridge 0,003 mg/mc oil - AIR FILTER (F4) FCF122 1
4 Draeger O2 Sensor 6809630 0÷25% ANZ034 1
5 Towers Coal CHI060 100KG

8.2 ADVISE SPARE PARTS

Use original spare parts and however always verify the compliance with all the required
specifications.

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Riferimenti :
Reference’s Cliente / Client
DVEL DENIZCILIK Mehmet Afkan Sok. No: 9 - 11 Ko uyolu,
: Kad köy / STANBUL
Impianto / Plant N2 GENERATION PLANT – NB95
Fornitura / Supply IMP-GN1200M

Electrical Panel spare parts:

POS. DESCRIPTION ERREDUE CODE Q.TY
1 PLC ABB KT97 EOPLC002 1
2 Digital Expansion ABB DC91 EOPLC004 1
3 Analog Expansion EOPLC014 1
4 Fuse 6A 2
5 Fuse 4A 2
6 Relè 24Vdc 2
7 Lamp 2
8 Power Supply ELVAR425 1

Components and Instruments spare parts:

POS. DESCRIPTION ERREDUE CODE Q.TY

1 Analyser ANZ031 1
2 Flow-Transmitter PSE028 1
3 Pressure Transmitter PSE030 1
4 Proportional Valve Positioner VSF015+VPN057+VPR099 1
5 Pressure Transmitter Atex PSE029 1
6 Pilot Valve E3V008 1
7 Butterfly Pneumatic Valve DN80 VSF015 1
8 Butterfly Pneumatic Valve DN50 VSF016 1
9 Actuator VPN045+VPN58 1
10 Pilot Valve E2V038 1
11 Valve Position Indicator VPN047 1
12 Valve Position Indicator ATEX VPN055 1
13 Butterfly Pneumatic Valve DN150 ATEX VSF019 1
14 Actuator ATEX VPN046 1
15

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