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KDO-100 型
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空气分离设备使用说明书
This drawing is the proprietory of HZJH GROUP CO., LTD., CHINA,

OPERATION MANUAL FOR

本图纸为杭州锦华气体设备有限公司财产，未经本公司许可不得转给第三者或复制。

MODEL KDO-100AIR SEPERATION PLANT

杭 州 锦 华 气 体 设 备 有 限 公 司
HANGZHOU JINHUA AIR SEPARATION EQUIPMENT
CO., LTD., CHINA
2019-08
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KZO-100 Air Separation Equipment User Manual

INDEX
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This drawing is the proprietory of HZJH CO., LTD., CHINA,

Chapter1. General information of KDO-100 AIR SEPARATION PLANT............3

Chapter2. Explanation on main components inside rectifying column system 6

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Chapter3. Operation of air separation plant..................................................8

Chapter4. Maintenance in use.....................................................................17

Chapter5. Analysis........................................................................................21

Chapter6. Supplementary provisions...........................................................23

资 料 来 源 编 制
FROM COMPILED
校 对
CHK’D
标准化
STD’D
审 定
FINAL’D
标记 处数 更改文件号 签 字 日期 提出部门 批 准
MARK NOS. REV.NO. SIGNED DATE PROPOSED APP’D
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KZO-100 Air Separation Equipment User Manual

Chapter1. General information of KDO-100 AIR SEPARATION PLANT

1.1 Operating principle
KDO-100 air separation plant is a set of equipment to get high pressure oxygen with
the inner compressing process of liquid oxygen pump. This is a new type of low pressure
process with turbine expander.
After heat changing process between purified inlet gas and the return gas in the main
heat exchanger, the purified inlet air is cooled to saturated air with some liquefied. Then
the inlet air goes to lower column for rectifying. The rectifying process is to get pure
oxygen and nitrogen by several times of evaporation and condensation in the rectifying
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column. The lower column is to get liquid air and nitrogen gas; the main condenser
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evaporator is to vaporize the liquid oxygen to gas oxygen and is to liquefy the nitrogen
gas from lower column to liquid nitrogen; the upper column is to get product liquid
oxygen, product gaseous oxygen and product nitrogen gas.
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1.2 Main technical data

1.2.1 Model: KDO-100
1.2.2 Process air capacity: 1500Nm3/h
1.2.3 Product capacity: 100±5Nm3/h; purity≥99.6%
1.2.4 Process air pressure:
Start up period: ≤1MPa
Normal operation period: 0.95~1MPa
1.2.5 Output pressure:
Oxygen: 15MPa
1.2.6 Power consumption:
Oxygen: ~0.8 KW∙h/m3 O2
1.2.7 Cooling water consumption: 25 ton/h
1.2.8 Heat end temperature difference of heat exchanger: ~2℃
1.2.9 Working period: ~12 months
1.2.10 Start up time: 15 hours (after expander’ start up)
Note: The process air capacity is 1300Nm 3/h under condition that air compressor inlet air
temperature is 20℃ and 101.325KPa. Meanwhile, the oxygen product capacity is in
proportion to the process air capacity. Thus, if inlet air temperature increases or inlet air
pressure decreases; the process air capacity shall decrease, and oxygen product capacity
shall decrease accordingly.
1.3 Components of this plant
This plant is composed of air compressor, refrigeration unit, purifier, electric heater,
expansion turbine, rectifying column, liquid oxygen pump, liquid nitrogen pump,
instrument control equipments, as well as flow meters etc..
Only the equipment structure, operation and maintenance explanation of rectifying
columns are stated here. While for other equipments, please follow their own
explanations.
1.4 Process description of air separation plant
This plant adopts normal temperature molecular sieve and low pressure back flow
expander process. The character of the process is advanced technology, low power
consumption and reliable operation.
The feed air is suctioned from the atmosphere. After removed dust by the air compressor.
The last stage of air cooling unit and air pre-cooling unit cool the gas to around 5℃. After
removed water from the water separator process, the gas is sent to the air purification
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KZO-100 Air Separation Equipment User Manual

system to clean out the moisture, CO2, acetylene and other hydrocarbon.
The purified air goes into the heat exchanger in the rectifying column. It makes heat
exchanging process with return oxygen and water nitrogen. Then goes to the lower
column, and make the first separation in the lower column. Liquid air will be suctioned to
the mid section of upper column from the bottom of lower column.
The nitrogen get from the upper section of lower column gets condensed by condenser. A
part of the liquid nitrogen goes to the lower column as a return liquid; another part of
liquid nitrogen goes the upper column as return liquid after the sub-cooler and throttle.
Then draws out some liquid nitrogen after the throttle valve, and then pressed by the liquid
nitrogen pump. After that, it is sent to the liquid nitrogen heat exchanger to warm up to
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normal temperature for filling the gaseous nitrogen tub.

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Some purified liquid oxygen is got from the bottom section of conedenser-evaporator.
The liquid oxygen from the bottom goes to the liquid oxygen pump. After that, it is sent to
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the liquid oxygen heat exchanger to warm up to normal temperature for filling the gaseous
oxygen tub. The nitrogen from the top section of upper column will pass through the sub-
cooler and the main heat exchanger to get to come temperature, and then to the turbine
expander. After that , it returns to the bottom of the main heat exchanger to normal
temperature. Some goes to the purification unit as a regeneration gas ; some goes to the
went.
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KZO-100 Air Separation Equipment User Manual

Chapter2. Explanation on main components inside rectifying column system

The rectifying column system is composed of upper column, lower column, main
condenser evaporator, main heat exchanger, LN2-LAir subcooler, cylindrical shell,
instrument panel, valves and supports etc. Please see the explanation of each component
as following:
2.1 Upper column
The structure of upper column plate is convection sieve plate with merit of high
efficiency. These column plates are fixed on the cylindrical shell with rings; the middle
part of column plates are fixed and supported by specially made bolts. There are many
evenly distributed small holes on the column plates through which cryogenic gas flows
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upwards and cryogenic liquid flows downwards and further flows to the next column plate
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through overflow chute.

Upper column are all aluminum structure; there is a fixed distance between every two
column plates. On the top of upper column there is equipped with a liquid-gas separator;
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and at the bottom of which connects with main condenser evaporator

2.2 Main condenser evaporator
It is a plate fin type heat exchanger equipped between upper column and lower column
whose function is to condense the middle pressure nitrogen gas in the lower column and
evaporate the lower pressure liquid oxygen in the upper column. As the temperature of
liquid oxygen is lower than that of nitrogen gas; usually this temperature difference is
1.5℃. Then the heat exchange is formed due to this temperature difference.
2.3 Main heat exchanger
Main heat exchanger is a plate type heat exchanger. Process air is sent to main heat
exchanger where it is cooled to about -120℃. One part of air is extracted and sent to
expansion turbine to refrigerate; the other part is being further cooled to -165℃ and
partial liquefied, then it is throttled after V1 and goes to lower column; finally it is being
reheated in the main heat exchanger to normal temperature and being sent out of cold
box in the form of waste nitrogen and product gas.
2.4 Liquid air subcooler
This heat exchanger is using to subcool the liquid air and liquid nitrogen before they are
being throttled, so as to reduce the rate of gasification during throttling and to improve
the rectification of upper column. It is plate fin type heat exchanger.
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KZO-100 Air Separation Equipment User Manual

Chapter3. Operation of air separation plant

2.1 Preparation before starting the machine.
2.1.1 Before starting the machine, we should heat and blow off the rectifying column
completely according to the heat and blow off process. And make preparation of the
regenerated purifier. All the machinery should be prepared well according to the
operation specification.
2.1.2 The following work should be finished before starting the rectifying column:
2.1.2.1 Check whether all the joints have been tighten well, and whether all the gas tightness of
the connecting pipes is good or not.
2.1.2.2 Check completely about the sensitivity of the suction & discharge valve of the expander.
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And give power to the rotational speed meter and the instrument meters of the rectifying
column.
2.1.2.3 Check the level meter, flow meter pipe and signal cable are assembled rightly. And
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adjust the pressure meters and thermal meters to reach the specification.
2.1.2.4 Open the following valves: liquid air throttling valveV01, LOX discharging valve V304,
helium and neon blow off valve V306, heat exchanger blow off valve V301, all the
analyzing valves, upper and lower valves of the level meter, pressure gauge valve,
oxygen& nitrogen outlet valve and vent valve, fraction outlet valve.
2.1.2.5 Close the following valves: V04& V05 inlet valves of the expander, all the heating valve,
oxygen& nitrogen product discharge valves.
2.1.2.6 Prepare the nitrogen & oxygen analyzing instruments and pipes. Assemble the thermal
meters on the high pressure inlet pipe, oxygen outlet pipe, nitrogen outlet pipe and the
fraction outlet.
2.1.2.7 Check carefully whether the inlet and outlet valve is sensitive or not. Connect electricity
to the tachometer and the instrument units of rectifying column.
2.2 Start the liquefaction and the adjustment.
When the preparation work is finished, do the work according to the following process:
2.2.1 Start the air compressor. When it is running in the normal state, close all blowing off
valves of every stage cooler and start the pre-cooling unit. Open the inlet valve of purifier
and the air inlet valve of cold box to lead the air into the heat exchanger. When the seal
pressure reach 0.1MPa, and the bearing pressure is above 0.5MPa, open the inlet valve of
the expander slowly to make the air goes into the expander (operate according to the
expander manual). While the pressure reach 0.95MPa and in a stead state, start the other
expander and adjust the speed to its rated rotational speed gradually and then keep it.
2.2.2 Keep the pressure steadily at the 0.95MPa to let more air goes into the expander to get
refrigeration. Open the V01 valves in a proper position to keep the lower column pressure
at 0.9MPa. ( The valves are open very little and then gradually to a large extent when the
temperature decreased)
2.2.3 If the air is redundant, open the V1002 valve and then close the vent valve V1001
gradually in accord with the temperature decrease inside the column.
2.2.4 The rotational speed of the expander should keep at the manufacture’s rated rotational
speed. And the final outlet temperature of the expander should keep between -180 ～ -
188℃
2.2.5 When the outlet temperature of the expander reach -150℃, with the temperature
decrease, close the front vent valve of the purifier, all the air goes into the column. When
the state last for a while, the pressure before expanding will decrease, so the V01 valve
should be open at a certain extent to keep the pressure stable before expansion.
Counting from the start of expander, after running for about 4 hours, the temperature of
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KZO-100 Air Separation Equipment User Manual

T1 will below ~ -166℃ and the liquid air will appear. At this moment, something should
be noted specially during the operation:
2.2.5.1 Keep the T1 temperature at about -166℃, and then maintain it.
2.2.5.2 Keep the air pressure to accelerate the liquid accumulation inside the column.
2.2.5.3 Increase the upper column pressure to be good for the liquid accumulation.
2.2.5.4 Keep the condition stable inside the column.
2.2.5.5 Increase the working pressure of the expander to make full use of the refrigeration
efficiency of the expander.
2.2.6 When the liquid air appeared for 3 or 4 hours, the liquid oxygen will appeared in the
condenser and evaporator. And when the liquid oxygen last for 2 ～3 hours and the liquid
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level of the liquid oxygen arrives at ～ 60 cm, close the V01 valves slowly to adjust the
liquid air and liquid oxygen purity. At this moment, some liquid oxygen should be
discharged. And then check whether there are floating matters on the liquid oxygen level.
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If so, discharge the liquid oxygen a little bit more.

When at the start, the valves can be closed a little quickly. When above 1 revolution open
extent, close the valve 15° every time. When below the 1 revolution, 5 ～ 10° very time.
And the later adjustment should be done more carefully. It should be closed by 5°, 10°
every time. And the time interval should be 5 ～ 7 minutes. Analyze the LOX purity 3
minutes after the adjustment of the valves.
Maintain the pressure as 0.92MPa in the air pipe, and keep the change of the liquid level
of liquid oxygen. Maintain the pressure in the upper column at 0.25MPa .If the liquid
oxygen level keeps rising, the operator may open a little bit of the V03 valve. After cooled
around 20 minutes,the liquid oxygen pump can be start up.Simultaneously open some of
the V1215 valve to let the air go into the liquid oxygen gasifier heat exchanger. Adjust
the rotate speed of the liquid oxygen pump according to the liquid oxygen level (to adjust
the production of oxygen product ). In the same time, adjust the V1215 valve to avoid the
frost or condensing water at the outlet pipe of oxygen products. If the production is too
much and the user does not need too much production, the operator may decrease the
pressure at the outlet of compressor to adjust the production quantity.
Now, we should analyze the liquid air purity. If the purity does not reach the specification,
use the V01 to adjust. If the liquid level below 11cm, close the V01 valve a little, and its
open extent should be controlled at the 11cm-17cm of liquid air level.
2.2.7 When closing down the V01 valves to adjust the upper column purity, we also should
adjust the inlet valve of expander and V04( V05) valve according to the working condition
of the LOX level. And the adjusting speed should depend on the increase and decrease
condition of the LOX level. When the level increasing, we should close down the expander
inlet valve a little and open V04( V05) valve a little bit more. Otherwise, the reaction
should be opposite. The point of adjustment is to maintain the the liquid level of LOX.
2.2.8
When the purity of oxygen has reach the using demands, open the product discharge
valve and increase the production capacity under the premise of ensuring the product
purity. Correspondingly, close nitrogen outlet valve to a certain extent and open the valve
of V08 to a great extent (Increase withdrawal amount of the waste nitrogen) to keep the
low pressure for the purpose of improving oxygen purity. At this moment, we should pay
attention to the stability of the oxygen purity and LOX level. If the LOX level is decreasing,
we should close down the LOX discharge valve to find the balance point to make the
equipment stale wholly.

2.3 Operation in the normal running

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KZO-100 Air Separation Equipment User Manual

2.3.1 The index when the rectifying column works normally

2.3.1.1 Pressure
Air pressure after exchanger: ~0.90MPa

Upper column pressure: 0. 235~0. 25 MPa

2.3.1.2 Temperature:
The outlet average temperature difference between the air of heat exchanger and the
flow back gas like oxygen, nitrogen, and fraction is： ~2℃~3℃.
The inlet temperature of expander T2(T3): ~—163℃
The outlet temperature of expander T4(T5): ~-185℃
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The outlet temperature of air out of heat exchanger T1: ~-166℃

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2.3.1.3 Liquid level:

LOX liquid level: 60～80cm
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2.3.1.4 Purity:
Liquid oxygen purity (AE-1): 99.6%O2
2.3.1.5 Valve opening angle:
V08 valve (liquid pump inlet valve): proper angle
V-01 valve( liquid air throttling valve):
60°~100°(according to the actual operation)
2.3.1.6 Flow
Oxygen flow: ~60m3/h

During the adjustment operation, analyze the purity of liquid air, LIN, oxygen and
nitrogen every half an hour. When the state is stable, analyze every one hour and make a
record. Open the V-304 every two hours to blow off the helium and neon gas to delete
the accumulation of the helium and neon gas.
2.3.2 Adjustment during the running
Every adjustment should be done very carefully and cautiously so as not to break the
normal index of the rectifying column.
2.3.2.1 The V03 valves are the valves which the air has to pass through when going into the
expander. Its main function is to control the gas flow into the expander. Open a little bit
more when the liquid air level decreases, otherwise close a little more.
2.3.2.2 Use the liquid air throttling valve (V01) to control the liquid air level, open the V01 wider,
the level will decrease, close the V01 more, the level will increase.
2.3.2.3 At every working group ( 8 hours), the V01 valve should be rotated rapidly one time, and
then reset to prevent the frost of valve port.
2.4 Stop at the running
2.4.1 Normal stop
2.4.1.1 Open the V01 valve to make the liquid air to go to the upper column immediately. But
please make sure the upper column pressure should not above 0. 35MPa.
2.4.1.2 Open the oxygen vent valve and close the oxygen discharge valve.
2.4.1.3 Open the blow off valve of water separator of purifier. Close the inlet valve V0 4, V05 of
expander, and then close the outlet valve of the expander, keep the bearing gas for 20
minutes. After ensuring stopping the expander, close the power supply of the expander
and the bearing gas suction valve.
2.4.1.4 Stop the pre-cooling unit and heater of purifier.
2.4.1.5 Stop the air compressor. During all the process, the air compressor should not be over
pressure.
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KZO-100 Air Separation Equipment User Manual

2.4.2 Temporary stop

When the machine is in trouble or it does not need the oxygen and nitrogen for a while,
but the ASP will start in a few hours. The operation is noted as the following: (for the sake
of safety, the operator should be on duty near the cold box to observe the condition
change inside the column.
2.4.2.1 Open the oxygen vent valves, close the oxygen discharge valve.
2.4.2.2 Close the V01 valve to maintain the medium pressure.
2.4.2.3 Close the V04(V05)valves, stop the pre-cooling unit and the heater.
2.4.2.4 Close the air inlet valve V101, and then open the purifier oil and water separator blow off
valves.
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2.4.2.5 Inform the air compressor operator to stop the compressor normally.
2.4.2.6 To send the oxygen in advance, close the oxygen vent valve and fraction discharge valve
and turn up the nitrogen vent valve.
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2.4.3 Emergency stop

2.4.3.1 Close the V04 valve or V05 valve rapidly, and cut off the power source of expander. Stop
the pre-cooling unit and purifier heater.
2.4.3.2 Operate according to the temporary stop step 2 or 4.
2.4.3.3 Open the nitrogen vent valve and close the oxygen discharge valve.
2.5 Restart operation after emergency stop
2.5.1 Start the air compressor, and close the oil and water separating blow off valve of purifier
system
2.5.2 Lead the gas into the purifier. While the pressure increases to 0.8-0.9MPa, turn up the
inlet general valve to let the air goes into the heating exchanger (other valves the same),
open the air throttling valve V101 slowly to make the air flowing in the column. And then
start the expander and open the V04 or V05 to adjust the valve to its normal condition.
2.5.3 Adjust the opening angle of liquid air throttling valve according to the time interval of
stop.
2.5.4 According the liquid level of LOX and the T3 temperature to adjust the opening angle of
the V03 valve to make the LOX level reach the demanding height. And analyze the
oxygen purity at the same time to make it meet the demands of specification and then
start to send the oxygen, liquid oxygen.
After ensuring the pressure, level, temperature, and the purity in the normal state, we
should reduce the restore time and send the product as soon as possible.
2.6 Heating and blow off of rectifying column.
2.6.1 If the following situation exits, the rectifying column must be heated and blown off:
2.6.1.1 The front and back pressure difference of heat exchanger is more than 0.1MPa and the
heating end temperature difference increases.
2.6.1.2 The upper and lower tower plate is blocked by the CO2 and water, which makes the
purity or production of oxygen and nitrogen decrease.
2.6.1.3 The new equipment is assembled, but before the start.
2.6.1.4 Restart after a long time stop.
2.6.1.5 The rectifying column has just been cleaned or repaired.
2.6.1.6 Hydrosol appears in the rectifying column, and the liquid air or oxygen can not be
adjusted.
2.6.2 The step of heating and blowing off work is as following:
2.6.2.1 Drain out the liquid in the rectifying column.
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KZO-100 Air Separation Equipment User Manual

2.6.2.2 Disassemble the thermal meter, level meter, flow meter and all the pressure meters
except the low pressure meter of oxygen and fraction outlet.
2.6.2.3 Close the air inlet valve V101, V1215, oxygen delivering valve. Open completely all the
valve and oxygen, nitrogen vent valves in the rectifying column, open completely V201,
V202, V203,V204heating valves of rectifying column.
2.6.2.4 Detach the rotator of the expander.
2.6.2.5 Start the air compressor and maintain its pressure.
2.6.2.6 Open the heating general inlet valve V1213 slowly to let the dry air go into the rectifying
column to blow off for half an hour to 1 hour. And then it is allowed to connect the power
supply of electric heater. We should pay attention often to measuring the gas
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temperature heated, and make it maintain between 5～10℃.

2.6.2.7 During the heating, we should adjust every outlet temperature time and time. And turn
down the high temperature outlet and turn up the low temperature outlet. And pay
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attention to the upper column pressure to make it no bigger than the normal working
pressure at any time. When all discharge temperature in summer is higher than the room
temperature at 10-15℃, and in winter higher than the room temperature for 8℃, we can
cut the heater power. And wait until the heater temperature decrease to room
temperature, the heating process is finished.( During the first big heating of the new
equipment, the time can be prolong for a little.)
2.6.2.8 After heating, close the V04, V05 valve, close the heating valve of rectifying column,
assemble pressure meter of the heat exchanger in the lower column. Open the valve
V301~V306, to blow off the heat exchanger and lower column until there is not impurity
in the gas and the hand feels good when touching the gas. Use the V0 1 to blow off the
upper column and open the oxygen and nitrogen discharge vent valve.
2.6.2.9 After blowing, close the general air inlet valve of rectifying columnV101, open the vent
valve v1001. if the ASP will not start at once, inform the air compressor operator to stop
the air compressor. If the ASP will start at once, the air compressor can not be stop.
2.6.2.10 Something need special attention during the heating: ( mentioned above except)
 The air compressor should blow off the water and supplying cooling water in time like
its normal running. The action of turning down the cooling water to increase the
heating gas temperature is not permitted.
 The heating of rectifying column need dry gas, so the purifier should be switched
over in time and regenerated in time at the same time. The other purifier should be
prepared for the start of ASP.
 During the heating, check all the liquid level, joint of pressure meter and the blow off
valve of analyzer is ventilated.
 When blowing off the throttling valve, the body should avoid facing the valve port, to
prevent the mechanical impurity.
2.7 The cleaning of the rectifying column.
2.7.1 Water cleaning
When the rectifying column is contaminated by lubrication oil or other impurity or the
capability of rectifying column is deteriorating after using a long time, it means all pipes
and tower plate small hole is blocked and needs the cleaning. When cleaning, the hot
temperature is between 60-80ºC, the water should be clean and not oil and deposit
impurity mixed. When purging water into the rectifying column system, it is better to use
the customized box, and use the low pressure nitrogen or air to push the water into the
rectifying column.
The following steps can be changed properly according to the actual situation;
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KZO-100 Air Separation Equipment User Manual

2.7.1.1 Clean the heat exchanger

Close the air throttling valve and inlet valve V04,V05 of expander, the hot water goes in
through the air blow off valve (V302,V303) until the water goes out through the high
pressure air suction valve. The time maintain for 1-1.5 hours every time. And repeat for
three times until the water goes outside is clean.
2.7.1.2 The cleaning of rectifying column
Close all the throttling valve (V01) and the V06, V07 valve. The hot water goes in through
the valve V301 of lower column until the water go out. Keep it for one hour, and repeat it
three times.
2.7.1.3 The cleaning of upper rectifying column
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The hot water go in through the analyzing valve AE-02 until the water go out from the
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LOX discharge valve V304 of condensed evaporator bottom. Keep the cleaning time for
one hour and repeat for three times.
To make the rectifying column plate a little more clean, we can blow 0.01-0.015MPa
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nitrogen from the lower column. The water go in from the condense evaporator level
indicator, and go out from the nitrogen outlet of upper column. The water draining can be
through all valves of the lower part of rectifying column. But it must use the rubber tube
to lead the water out to avoid contaminate the machine.
After water washing, use the compressed air to blow for 1-1.5hours. And the pressure
should not be bigger than working pressure of the column. If we use the dichloroethane
to clean after water washing, the blowing time should be prolonged for 2-2.5 hours.
2.7.2 Dosing cleaning method
We usually use the dichloroethane, trichloro acetylene, carbon tetrachloride to clean. And
carbon tetrachloride is the most common dose. It can clean the oil mixed into the
rectifying column. If we find there is oil, clean it at once. Normally, clean one time after
five years usage. And the clean method is the same as the water cleaning. But special
safety attention should be paid as the following:
2.7.2.1 If we use the dichloroethane to clean, we should use the water to clean first (the method
is the same as water washing), and use the 90%-95% nitrogen to blow for 10-15 minutes.
2.7.2.2 Only the low pressure nitrogen are allowed to push the dosage into the column.
2.7.2.3 During the whole process of using the dosage, we should be high sensitive, when
meeting the dense gas smell, wear the gas mask at once.
2.7.2.4 After cleaning with the dosage, use the clean water to wash again until there is no
dosage smell in the water.
2.7.2.5 At last, use the hot air to blow, and the blow time should not less than 8 hours.
2.7.2.6 As the dichloroethane is inflammable, we must use the hot nitrogen to blow off during the
blow off operation.
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Chapter4. Maintenance in use

4.1 Regular inspection and maintenance of machines and equipments.
The following items should be noticed except check and maintenance of specification:
4.1.1 Air compressor
4.1.1.1 Checking each moving part of air compressor after working one year.
a. Cleaning cylinder jacket for one time.
b. Adjusting gaps of piston end surface.
4.1.1.2 Checking pressure manometer each year.
4.1.1.3 Checking safety valve after one year adjusting.
unauthorized disclosure to any third party or duplication is not permitted.

4.1.1.4 Making pressure test for cylinder every three years.

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4.1.1.5 Uninstalling and cleaning the valves of 1st stage every periodic stop.
4.1.1.6 Cleaning air filter according to resistance.
4.1.2 Air pipeline system of producing oxygen and nitrogen
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4.1.2.1 Blowing off for air system should be:

a. After installation and re-installation of machines.
b. After total maintenance and middle maintenance of air pipeline system.
c. After air separation 10-12 months.
4.1.2.2 Total pressure test for air system after working 3 years.
4.1.3 Rectifying column
4.1.3.1 Calibrating safety valve and then sealing with lead seal every 1-2 periods.
4.1.3.2 Cleaning the column with hot water and medicament every 1-5 years.
4.1.3.3 Making sealing test with work pressure (test order should be high-middle-low pressure)
after working one year.
4.1.4 Expander
Checking the situation of gap bridge pipe thermal insulation layer between expander and
air separation column every year.
4.1.5 Purifier
4.1.5.1 Checking adsorbent every one year, sieving or exchanging should be done if
pulverization and oil-sucking happened.
4.1.5.2 Making water pressure test every 3 years, and its relative deformation should be less
than 5%.
4.1.6 Oxygen filling station (supplied by user)
4.1.6.1 Checking safety valve every half a year.
4.1.6.2 Checking pressure manometer every half a year.
4.1.6.3 Making water pressure test every working 1.5-2 years.
4.1.7 Air pre-cooler
Make seal test by work pressure every one year.
4.1.8 Electrical heater
4.1.8.1 Checking circuit insulation every half a year.
4.1.8.2 Checking resistance wire every year.
4.2 Sealing and unsealing of air separation devices
4.2.1 Sealing:
4.2.1.1 Machines and equipments should be cleaned before oil-sealing.
4.2.1.2 Place for putting machines and equipments should be tidy, dry and ventilation, indoor
temperature should be 15-30℃, and relative humidity should be less than 70%.
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KZO-100 Air Separation Equipment User Manual

4.2.1.3 Oil for sealing should be test, acid value and moisture should be less than standard.
4.2.1.4 Acid value of impregnated wax paper for package machine parts or spare parts should be
assayed and can achieve specific requirements.
4.2.1.5 Oil-sealing period of each machine normally is 3 months, sealing again if extending.
Note: For oil-sealing for moving parts see attached manual.
4.2.2 Unsealing:
4.2.2.1 After cleaning with petrol, coating with lubricant, especially noting oil orifice is clear.
4.2.2.2 Cleaning each instrument and then installing.
4.2.2.3 Supplying enough oil for oil-using system.
unauthorized disclosure to any third party or duplication is not permitted.

4.2.2.4 Installing valves of air compressor, blowing off and making sealing test for all the
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pipelines of the system.

Note: For other unsealing requirements see attached maintenance manual.
4.3 Safety technique
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Air separation work under deep low temperature, producing course is doing under
pressure and hypothermia, accidents will happen if not pay attention to safety, therefore
operators should take care:
4.3.1 People who work in air separation plant should obey operating rules.
4.3.2 Workers who know less about air separation shouldn’t operate individually and managing
devices.
4.3.3 Workers should wear mask and protective spectacles when they assemble and
disassemble insulation (magnesium carbonate and perlite).
4.3.4 Vessels that work under pressure should do water pressure test regularly.
4.3.5 Plant around should be clean, it is forbidden to smoke; moreover, there must be no oil on
the earth especially one meter away around rectifying column.
4.3.6 It is forbidden to screw flange and nut.
4.3.7 It is forbidden to block the door during work time.
4.3.8 Fire-protection tools should keep well and be put proper places. All the people should
learn fire security measures.
4.3.9 It is forbidden to repair and weld during the plant working. These works should be done
after the system stop.
4.3.10 It is forbidden to do welding (acetylene welding) 20 meters away around air separation
devices and machine room.
4.3.11 Any machine part and tool touched with oxygen must be kept away from oil. Tools for
expander and rectifying column should not be confounding.
4.3.12 Lubricant oil is not test shouldn’t be used.
4.3.13 Each pressure manometer should be kept well and have lead seal.
4.3.14 Moving parts shouldn’t be repaired or adjusted during working; the plant should be
stopped if these works are necessary.
4.3.15 Rubber gloves should be taken when using knife switch, it is forbidden to put things on
the switch.
4.3.16 Rectifying column should be blown off with heating before starting and after stopping.
4.3.17 Rectifying column should be blown off with heating before repairing.
4.3.18 Each throttle valve of rectifying column should be opened and closed slowly.
4.3.19 If pressure in rectifying column goes low suddenly, decreasing pressure at once, stopping
air compressor and finding the reason.
4.3.20 Belt roller of expander should be installed with safety cover.
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KZO-100 Air Separation Equipment User Manual

4.3.21 It is forbidden to put liquid air and liquid oxygen randomly on the earth and touch oil
when putting off liquid from rectifying column.
4.3.22 Carbon tetrachloride extinguisher and sand bucket should be kept in the oxygen plant.
4.3.23 It is forbidden to adjust nut by circling in order to make safety valve have no leakage.
4.3.24 It is forbidden to strike the frozen expander for material will become friable under
hypothermia.
4.3.25 Only oxygen cylinder can be used for filling oxygen. Outdated cylinder should take
pressure test before filling, cylinder without certificate should be cleaned and then take
pressure test.
4.3.26 It is forbidden to blow or suck by mouth when oxygen valve blocks; it is necessary to turn
unauthorized disclosure to any third party or duplication is not permitted.
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off the valve slowly and clear it by thin iron wire.

4.3.27 It is forbidden to do cleaning work besides moving parts or around.
4.3.28 It is necessary to notice content of acetylene always in condenser, taking off acetylene
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regularly to keep devices away from explosion because of excess acetylene.

4.3.29 The followings should be noticed if accidents happened:
4.3.29.1 The biggest danger is combustion and explosion in producing devices, so firstly keeping
calm.
4.3.29.2 Naked fire shouldn’t be lead to oxygen compression workshop.
4.3.29.3 Operators should close main valve, cut off the power supply and rush accidental area
when accident happens. It is forbidden to open oxygen valve of filling oxygen if there is
combustion. Keep oxygen cylinders away from the fire immediately.

Chapter5. Analysis
In the analyzer a chemical reaction is carried out between oxygen and the copper wire rings
put in the solution of ammonium chloride and ammonium hydroxide. The chemical reaction is
shown as follows:
2Cu+ O2 →2CuO
CuO + 2NH4CI + H2O→2NH4OH +CuCI2
CuCI2 + 2NH4OH →Cu (OH)2+ 2NH4CI
Cu(OH)2 + 4NH4OH →Cu(NH3)4(OH)2+4H2O
Reaction principle:
The reaction of fresh copper and oxygen produces copper oxide that comes into contact with
the solution. As a result, copper oxide is soluble in the solution. The result of the chemical reaction
is that oxygen is absorbed totally till the solution becomes saturated with deposition. The unit of
oxygen content obtained in the chemical analysis is the percentage by volume.
5.1 Preparations prior to analysis:
5.1.1 Take a piece of copper wire of Φ 1mm, which is coiled as a spring with a
diameter of 5 mm. The length to be cut is 10 mm. Put these coils into the gas absorber
which is sealed by a rubber plug (8).
5.1.2 Conciliate solution. Put ammonium chloride of 750g into the distilled
water of 1 liter. At this moment, there is a small amount of deposited solid ammonium
chloride in the solution. Then add the solution of 1 liter containing 18 〜 25% ammonium
hydroxide into the solution containing ammonium chloride.
5.1.3 Put the solution into the gas absorber with the liquid level 1〜2cm
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KZO-100 Air Separation Equipment User Manual

upperer than the gas absorber (up to the red line). The remaining solution shall be put into a
glass bottle with a plug. And place it in a cool position.
5.1.4 The lifting cup is connected with the graduated tube by the rubber hoses
of (2) and (7). The graduated tube and the gas absorber are shown in Fig.10.
5.1.5 The lifting cup is full of clean water (distilled water or cooled boiling
water).
5.1.6 Let the graduated tube be connected with atmosphere. Then hold the
lifting cup up to squeeze air out of the graduated tube.
5.1.7 Make the graduated tube be connected with the gas absorber. Then put
the lifting cup down in order to suck out air from the gas absorber. The operation will not
stop until liquid flows into the gradurated tube. Again squeeze air out of the graduated tube
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to atmosphere and close the three-way valve at last.

5.2 Analyzing operation
5.2.1 Put the connecting rubber hose onto the analyzing valve and purge the
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hose carefully to make it clean. Afterwards make the valve slightly open so that trace of gas
will blow out.
5.2.2 Let the other end of the connecting hose be connected with the
graduated tube. At the same time open the three-way valve and put down the lifting cup in
a gradual way. Make the gas to be analyzed flow into the graduated tube , forcing the liquid
in the tube into the lifting cup. Close the three-way valve as soon as the liquid level falls
down to the zero, and make the level in the lifting cup equal to the level in the graduated
tube. After calibration of the zero, take off the rubber hose.
5.2.3 Turn round the three-way valve to let the graduated tube be connected
with the gas absorber. Then hold up the lifting cup so that the gas in the graduated tube
can be totally pressed into the gas absorber. As a result, close the three-way valve.
5.2.4 Agitate the gas absorber for 1〜2 minutes, and observe the condition of
oxygen absorption. If the bubbles do not become smaller, it shows that oxygen in the gas
has been absorbed thoroughly..
5.2.5 Reconnect the graduated tube with the gas absorber, and put the lifting
cup down in order to let the residual gas be sucked into the graduated tube (till there is
liquid flowing out). Then close the three-way valve.
5.2.6 Hold up the lifting cup to let the liquid level in the cup equal to the liquid
level in the graduated tube. At this time the reading of the graduated tube indicates the
percentage of oxygen content, i.e. the purity of the gas analyzed.
5.2.7 As the newly compounded solution absorbs the gas very slowly with very
low absorbability, it is necessary to use the solution to do analysis for 2 〜 3 times without
considering the analyzing results when adding newly compounded solution into it.
5.2.8 When the solution used for analyzing is used for 5〜6 times, a kind of
deposition with a blue-yellow color appears on the wall of the apparatus. At the same time
the absorption capacity decreases. Now it is required to pour out the solution and copper
coils and clean the apparatus thoroughly. Finally put new solution into the apparatus.
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KZO-100 Air Separation Equipment User Manual

Chapter6. Supplementary provisions

6.1 Oxygen plant workshop design and equipment installation
6.1.1 Workshop design shall confirm to following conditions:
6.1.1.1 Circumstance dry, good ventilation.
6.1.1.2 Distance between workshop and residential district shall not be less than 50m.
6.1.1.3 Distance between workshop and acetylene generating station or other hydrocarbon
generating station shall not be less than 50m.
6.1.1.4 Workshop is composed of main machine room, oxygen filling station, oxygen/ nitrogen
storage tanks and warehouse etc. Normally, the distance between main machine room
and oxygen filling station shall not be less than 20m; the distance between oxygen filling
unauthorized disclosure to any third party or duplication is not permitted.
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station and warehouse shall not be less than 50m. Main machine room and oxygen filling
station shall be connected with each other by means of electric bell and traffic lights.
6.1.1.5 If the main machine room and oxygen filling station have to be built together due to site-
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specific constraints, there must be equipped with a reliable protection wall between
them.
6.1.1.6 High pressure oxygen pipe connecting with oxygen filling station should be buried in pipe
trench at a height under winter frozen layer. If located outdoors, it must be rust
prevention treated. There are air compressor, oxygen compressor, expansion turbine,
rectifying column and electric heater etc. located inside main machine room. The
distance between air compressor and oxygen compressor shall not be less than 5m.
Electricity supply shall be able to satisfy the power consumption of all machines and
lamps inside the whole plant.
6.1.2 Attentions during equipments’ installation:
6.1.2.1 Foundation shall comply with the foundation drawings supplied by the equipment
suppliers; it is prohibited to reduce the foundation area arbitrarily.
6.1.2.2 The soil should endure a minimum 6ton/m2 pressure; the user should consider the actual
foundation depth according to actual soil condition.
6.1.2.3 Foundation watering period shall be decided by the circumstance temperature but no less
than 5~7 days.
6.1.2.4 It is better that all pipelines inside workshop be buried in purpose made trenches.
6.1.2.5 Oil stain is forbidden on grouting are before cement grouting.
6.1.2.6 The leveling of air compressor, oxygen compressor and expansion turbine can be
implemented on the plane of crankcase. The verticality of rectifying column shall be
strictly controlled during installation; it can be controlled by using vertical plumb to hang
on two extrusive ears on the left side surface of column
6.1.2.7 The verticality of purifier shall be controlled during installation.
6.1.2.8 There must be an inclination angle on the ground of pipe trench so as to drain out waste
water easily. Meanwhile, the ground shall be at a suitable high level so that the rain water
shall not be filled into trench.
6.1.2.9 All pipelines shall be painted with their regulated paint color.
High pressure air red
Low pressure air light grey
Oxygen gas sky blue
nitrogen gas light yellow
oil, water blow off pipe: black
Water pipe: dark green
Heating pipe: heatproof aluminum paint
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KZO-100 Air Separation Equipment User Manual

Inside trenches, pipes cannot contact with each other directly. Try to prevent pipeline
crossover; if it is inevitable, the water pipe shall be at the bottom, air pipe in middle and
oxygen pipe above all pipes.
6.1.2.10 Before installation, all pipes of air separation plant shall be internal derusting treated and
be blew down by high pressure air. Elbow pipes made by means of sands inserting
method shall be acid etching treated so as to get rid of oxide skin and sands; then it shall
be tested by water with pressure of 1.5 time its working pressure. The testing method of
high pressure oxygen pipes is the same as aforesaid, there shall not leave metal
particles, and stones etc. Therefore, the pipe end shall be covered by fabric or wooden
plug before installation.
unauthorized disclosure to any third party or duplication is not permitted.

6.1.2.11 All horizontal pipelines shall keep horizontal during installation and shall be fixed with
This drawing is the proprietory of HZJH GROUP CO., LTD., CHINA,

anchor ear in case of vibration. The gas pipe from rectifying column to oxygen filling
station shall be degreasing treated and checked in case of inside block. After assembly,
pipes shall be blew down carefully. It is recommended to use hammer to knock the pipes
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during blowing so as to get rid of water and rust.

6.1.2.12 Flange connection of all pipes shall not be leaky. Using dry air with working pressure to
check the gas tightness; check with soap water.
The pressure drop in one hour shall not be bigger than 5% of test pressure.
6.1.2.13 The connecting pipe between expansion turbine and rectifying column is the better the
shorter; it shall be heat insulation treated with magnesium carbonate or perlite. Before
insulation material’s filling, a cold pressured test shall be implemented; that is under
condition of 0.45MPa pressure and the minimum temperature, check tightness of all
connections. If any leakage is found, heat the pipe to normal temperature and fasten the
flange bolts. It is permitted to use a strengthener on the wrench to fasten flange bolts.
6.1.2.14 Please consider convenience of installation, manipulation and maintenance when locate
machines.
6.1.2.15 Workshop shall have good ventilation window and inside of which shall equip fire
prevention devices.
6.1.2.16 During the lifting up of rectifying column, please take care of the steel wire rope bundle
area. Insert thick wood block between steel wire rope and rectifying column.
6.1.2.17 After the installation of rectifying column is finished, open the top cover of it and check
whether perlite drops; if so, please fully fill in time.
6.2 Instruction on use of pressure difference flowmeter
6.2.1 Basic principle:
fluid filling inside pipelines, passing through throttling devices inside pipeline, shall form
local contraction which shall increase the flow speed and decrease the static pressure.
Thus a pressure drop (pressure difference) is formed before and after the throttling
device.
The bigger the flow rate of fluid is; this pressure drop before and after the throttling
device is bigger. Therefore, we can measure flow rate by means of measuring pressure
difference. This method is on basis of law of conservation of energy and law of flow
continuity.
The pressure difference is not only determined by flow rate, but also some other factors.
Such as: when the type of throttling devices or physical property (Specific Gravity,
viscosity etc.) of fluid inside pipelines change, under same flow rate, the pressure
difference are different.
6.2.2 Calculation of flow rate:
This pressure difference flowmeter is used to measure the flowrate of oxygen gas,
nitrogen gas and fraction of KZO-100air separation plant. The opening diameter of
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KZO-100 Air Separation Equipment User Manual

oxygen orifice is Ø28.6mm; that of nitrogen orifice is Ø58.58mm; that of fraction orifice is
Ø16mm. According to de condition of measured gas, the flow rate can be calculated by
using the following formula:
Q = 3600CF m3/hr
in which:
Q: volume flowrate per hour (m3/hr)
F: opening sectional area of orifice (m2)
C = a·√2gh/r (m/s)
in which:
C: flow speed of measured gas passing through opening (m/sec)
a: gas flow rate coefficient, relates with gas viscosity (a1), pipe roughness (a2), orifice lip
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unsharpness (a3) etc.

a = aucx. a1. a2. a3
aucx: original flow rate coefficient of standard orifice, can be checked according to
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M=F0/F value.
F0: opening sectional area (m2)
F: pipe internal sectional area (m2)
As for oxygen a = 0.624
nitrogen a = 0.621
fraction a = 0.625
g: acceleration of gravity which is 9.80 (m/s 2)
h: pressure difference before and after the orifice, mmH
r: specific gravity of gas (kg/m2)
6.3 Calculate output capacity by means of charting:
6.3.1 Relationship between nitrogen gas output, fraction output (Q) and pressure difference
flow rate (△h) is as Charting 14.
6.3.2 Relationship between oxygen gas output (Q) and pressure difference flow rate (△h) is as
Charting 15.
6.4 Installation of pressure difference flowmeter:
6.4.1 Installation of throttling device inside pipes shall confirm: the axes of orifice opening and
that of pipeline shall be the same; and the axes of pipeline shall be vertical with the end
face of orifice.
6.4.2 No matter where the throttling device is, it can be only installed in the straight pipelines.
Make sure there are at least 1 m straight pipe before and after the orifice, but this
straight pipe before orifice shall be longer than that after.
6.4.3 Make clear the direction of throttling device during installation; do not install in the
contrary way. The side marked in“+” shall be in front.
6.4.4 There shall not appear any extrude (extruded gasket, crude welding seam and
thermometer bushing etc.) 2 times the pipe diameter distance before and after the
orifice.
6.4.5 The thermometer installed before orifice shall keep a distance from orifice no less than
0.5m.
6.4.6 Before the installation of orifice, please clean the oil dirt on the surface. Make sure to
keep the sharp edges of orifice; do not use emery cloth or file to further process.
 本图纸为杭州锦华气体设备有限公司财产，未经本公司许可不得转给第三者或复制。
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unauthorized disclosure to any third party or duplication is not permitted. KZO-100 Air Separation Equipment User Manual
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