Design, Fabrication, Supply, Installation and Commissioning of Nitrogen Generator. · 2016-09-19 · Design, Fabrication, Supply, Installation and Commissioning of Nitrogen Generator.

Design, Fabrication, Supply, Installation and Commissioning of Nitrogen Generator.

I. INTRODUCTION

The work involves the Supply, Installation and Commissioning of a Nitrogen Generator along with storage and its associated subsystems which

are required to supply nitrogen gas of purity 99.999% with impurity levels H2O 2ppm & O2 2 ppm. The required flow rate is 15 Nm3/hr (minimum) at a minimum pressure of 10 Bar at the final Nitrogen delivery point.

II. EQUIPMENT DESCRIPTION

The nitrogen generator shall include the following subsystems, however, based on the design requirement the supplier may add/omit sub-systems if required:

1. Screw type Air Compressor 2. Air Receiver 3. Multistage Oil Filters in Air-line 4. Air Dryer unit 5. Nitrogen PSA Unit 6. Nitrogen Surge Vessel 7. Copper De-Oxo Unit 8. Nitrogen Dryer Unit 9. Low Pressure Nitrogen Tank (to be provided only if required as per design) 10. Nitrogen Booster of 50 Bar pressure 11. High Pressure Nitrogen Tank 12. Pressure Regulator After Tank

13. Program Logic Controller 14. Electrical Panel

15. Percent Oxygen Analyzer 16. PPM Oxygen Analyzer 17. Digital Dew Point Meter

18. Cooling Tower (to be provided if required as per design)

III. DETAILED EQUIPMENT DESCRIPTION

1.0 Screw Air Compressor

A suitable compact Oil Free Screw type Air Compressor conforming to ISO-8753 Class1-quality Air of repute make with limited vibration and sound (having suitable vibration isolating mounts to absorb suitable high-frequency vibrations) shall be supplied.

The compressor system should incorporate after cooler and instrumentation.

The compressor should be compatible with the PSA generator described in 5.0.

1.1 Make : Atlas Copco/Elgi/Kaeser/Chicago Pneumatic/ Ingersoll Rand/Bosch

1.2 Type : Oil Free Screw type Air Compressor conforming to ISO-8753 Class1-quality Air)

1.3 Air Capacity : The compressor ratings shall be suited for 15 Nm3/hr Nitrogen generator.

1.4 Delivery Pressure : The vendor may clearly indicate the delivery pressure of the compressor

1.5 Climate : Sea Environment

1.6 Drive : Electrically driven

2.0 Air Receiver

A suitable air receiver shall be provided for cooling the air

2.1 Material of Construction : Carbon Steel

2.2 Code of construction : Design Construction & Testing as per ASME Boiler & Pressure Vessel Code Section VIII, Div.1

2.3 Test Pressure : The vendor may clearly indicate the test pressure (minimum 1.5 times operating pressure)

3.0 Oil Filters in Air Line

Suitable Multistage Oil filters shall be provided to make the Air Oil free

3.1 Number of Filters : 3 No.s minimum in series

3.3 Air Capacity : The Air Capacity of the oil filters in the air line shall be suited for 15 Nm3/hr Nitrogen generator. The vendor may clearly indicate the air capacity.

3.5 Make : Omega/Wilkerson/Speedaire/Masterpneumatic/Exair

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4.0 Air Dryer Unit

The filtered air may contain water vapour and should be purified further by an Air Dryer.

4.1 Air Flow Capacity : The air flow capacity of the air dryer unit shall be suited for 15 Nm3/hr Nitrogen generator. The vendor may clearly indicate the air flow capacity.

4.2 Make : Friulair/Kaeser/Ingersoll Rand/SMC Pneumatics


5.0 Nitrogen PSA Unit

Nitrogen PSA unit should produce Nitrogen gas with suitable pressure by the pressure swing adsorption technique.

Nitrogen PSA unit should have two adsorbers filled with suitable “carbon molecular sieves” and interlinked by valves required for different functions of the PSA System.

Dry nitrogen gas should be generated by the processes of adsorption, desorption (by depressurization) and re-pressurization.

5.1 Nitrogen Generation Capacity

: To be designed considering a final delivery of 15Nm3/hr (Excluding the gas required for copper catalyst regeneration)

Sufficient amount of excess Nitrogen capacity to be considered for catalyst regeneration in the Copper De-oxo unit as elaborated in 7.0

5.2 Number of PSA towers : 2 Nos. (1 in operation mode & another in regeneration mode)


5.4 Type of Vessel : Vertical Vessel (preferable)

5.5 PSA Valve operation : PLC controlled

5.6 Operating pressure : 7 bar g

5.7 Nitrogen Purity : 99.99% (minimum)

5.8 Make of carbon molecular sieves

: CarboTech, Germany/Kuraray Chemical Co, Japan/Japan Enviro Chemicals

5.9 Type of valves : Pneumatic valves (Rotex/SMC Pneumatics/Schrader Duncan)

6.0 Nitrogen Surge Vessel

A suitable Nitrogen Surge Vessel shall be provided with appropriate pressure rating and safety relief valves.

The capacity and the pressure rating of the surge tank should be designed for the continuous operation of the copper de-oxo unit as elaborated in 7.0.

6.1 Type of vessel : Cylindrical Vertical Tank (preferably)




6.5 Safety Valves : A pressure relief valve assembly should be provided to relieve the pressure in case of pressure build up (beyond the design pressure) inside the chamber.

6.6 Pressure Measurement : Bourdon type dial gauge (Dwyer/Waaree/Swagelok/Wika/Kenny/Pfeiffer/Leybold/Edwards) of suitable range should be provided for the Nitrogen Surge Vessel.

7.0 Copper De-oxo unit

Nitrogen PSA unit has to be coupled with Cu-Deoxo Catalyst Unit.

The Cu-Deoxo Catalyst Unit should produce nitrogen gas of purity 99.999% and the impurity levels shall be H2O 2

ppm, O2 2 ppm.

7.1 Number of catalyst towers

: 2 Nos

7.2 Type of catalyst : Copper catalyst

7.3 Outlet Oxygen content in Nitrogen

: 2ppm

7.4 Temperature Display : A suitable digital temperature display may be provided

7.5 Material of construction

: Carbon Steel


7.7 Switching Cycle of vessels

: To be cyclically controlled by PLC


7.9 Nitrogen flow : Rotameters (Flowstar/Linde/Swagelok)

7.10 Outlet gas flow : To be designed considering a final delivery of 15Nm3/hr (Excluding the gas required for copper catalyst regeneration)

Sufficient amount of excess Nitrogen capacity to be considered for catalyst regeneration in the Copper De-oxo unit.

7.11 Hydrogen flow meter : A suitable hydrogen flow regulator and tubings shall be provided for connection of hydrogen cylinders to the copper de-oxo unit

The flow rate of hydrogen shall not exceed 0.3 Nm3/hr

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The regulator should be designed for gaseous hydrogen media and suitable for fitting Hydrogen cylinders with valves as per IS: 3224.

8.0 Nitrogen Dryer Unit

Suitable dryer units shall be provided to remove the moisture content in the nitrogen. Moisture in final gas should not exceed 2ppm

The dryer unit should be suitably linked to the PLC, so that the moisture in final gas should be 2ppm before delivery to the final unit.

9.0 Low Pressure Nitrogen Tank (if required as per design)

A Low Pressure Nitrogen Tank of suitable geometrical volume may be provided with appropriate pressure rating, safety relief valves and suitable ports for cleaning

The Nitrogen in the Low Pressure Nitrogen Tank shall have to be boosted to 50 bar pressure using a Nitrogen booster as explained in 10.0.

Low Pressure Nitrogen Tank shall have to be sized suitably and shall have to be linked to the PLC so as to ensure the operation of the nitrogen booster without any manual intervention.

Suitable anti-corrosion coatings may be provided on the inner surface of the Low Pressure Nitrogen Tank

9.1 Type of vessel : Cylindrical Vertical Tank preferable

9.2 Code of construction : ASME Section VIII, Div.1

9.3 Material of Construction

: Carbon Steel


9.5 Safety Valves : Suitable pressure relief valve assembly should be provided to relieve the pressure in case of pressure build up (beyond the design pressure) inside the chamber.

9.6 Pressure Measurement

: Bourdon type dial gauge of suitable range should be provided for the Low Pressure Nitrogen Tank. (Dwyer/Waaree/Swagelok/Wika/Kenny/Pfeiffer/Leybold/Edwards)

10.0 Nitrogen Booster Compressor.

Nitrogen Booster Compressor shall have to be sized and linked to the PLC so as to ensure the plant operation without any manual intervention.

10.1 Make : Sauer-Germany/Bauer-USA/Hycomp-USA/Atlas Copco USA/Rix Industries/PDC Machines/Howden

10.2 Suction Pressure

: 2-7 bar g

10.3 Discharge Pressure

: 50-bar g

10.4 Type of compressor

: Reciprocating type, air cooled compressor


11.0 High Pressure Nitrogen Tank

A suitable High Pressure Nitrogen Storage tank (geometrical volume 2m3) may also be provided with appropriate pressure rating, safety relief valves and suitable ports for cleaning

The tank shall be buffed from inside and powder coated in blue colour from outside.

Suitable anti-corrosion coatings may be provided on the inner surface of the High Pressure Nitrogen Tank

The tank shall be Designed Constructed & Tested as per ASME Boiler & Pressure Vessel Code Section VIII, Div.1

This would be installed outside the building on a concrete platform. Suitable supporting structure if any shall be provided by the vendor. (foundation shall be the responsibility of VSSC as per the details provided by the party)

11.1 Type of vessel : Cylindrical Vertical Tank (preferable)

11.2 Volumetric capacity

: 2m3 to store gas at 50 bar


: Carbon Steel

11.4 Operating pressure

: 50 bar g


11.6 Clearance : To be obtained from CCOE by the vendor

11.7 Safety Valves : Suitable pressure relief valve assembly should be provided to relieve the pressure in case of pressure build up (beyond the design pressure) inside the chamber. There should be two safety relief valves to protect the high pressure nitrogen tank from over pressure as per ASME Boiler and Pressure Vessel Code Section VIII, Div 1.


: Bourdon type dial gauge of suitable range should be provided for the High Pressure Nitrogen Tank. (Dwyer/Waaree/Swagelok/Wika/Kenny/Pfeiffer/Leybold/Edwards)

11.9 Ports : Suitable standard ISO ports should be provided for hydraulic pressure testing (both inlet & outlet) and for cleaning

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12.0 Pressure Regulator After High Pressure Nitrogen Storage

A suitable nitrogen flow regulator shall be provided after the high pressure nitrogen tank to provide nitrogen flow with constant 10 bar (minimum) Pressure required for our application.

This outlet of this regulator will be connected to the user end points.

12.1 Type : Dome loaded pressure regulator with flanged end connections

12.2 Material of construction

: Regulator Body-SS BS EN 1088 1.4401 Trim – PCTFE Elastomers - Nitrile

12.3 Make : Swagelok/Concoa/Tesscom/Norgen/Shavo

12.4 Size : Sizing of the regulator shall be conducted by the party using the inputs provided below and the same shall be submitted along with the flow characteristic curves to VSSC for approval, before integration to the plant.

12.5 Inlet Pressure : 50 bar g (maximum)

12.6 Outlet relieved Pressure

: 10-bar g constant

12.7 Maximum Flow rate

: 15 Nm3/hr

12.8 End connections : Flanged (ANSI)

13.0 Program Logic Controller

The system shall have a PLC based control system to automatically carry out the sequence of operations, give feedback and control system parameters on real time basis.

The PLC shall have add-on input/output modules supplemented by various additional drives and interfaces to accept inputs from sensors and provide appropriate signals to ensure a continuous supply of 99.999% pure Nitrogen with impurity levels O2 ≤ 2ppm, H2O ≤ 2ppm at the outlet of the system.

13.1 Make : Siemens/Schneider/Mistubishi

14.0 Electrical Panel

A suitable electrical panel of repute make may be provided. The electrical panel may have a mimic diagram of operations with appropriate status indications.

14.1 Make of Switchgear : Siemens/L&T/Legrand

15.0 Online Percent Oxygen Analyzer with digital display

15.1 Make : Teledyne Instruments/Michell Instruments/Systech Illinois

15.2 Measurement Range : 0-10% Oxygen

15.3 Type of sensor : Electrochemical

15.4 Accuracy : ±1.0 % of the measured value.

15.5 Calibration : NPL/NIIST Traceable Calibration Certificate for Sensor to be provided

16.0 Online PPM Oxygen Analyzer with digital display

16.1 Make : Teledyne Instruments USA/Michell Instruments UK/Systech Illinois

16.2 Measurement Range : 0-10 ppm oxygen




17.0 Online Digital Dew Point Meter

17.1 Make : GE-USA/Michell Instruments UK/Elco USA/Phymetric

17.2 Range : Dew Point Measurement upto (-)80°C

17.3 Accuracy : ± 2°C Dew point

17.4 Repeatability : ± 0.3°C Dew point

17.5 Resolution : 0.1 °C Dew point or 0.1 ppm

17.6 Calibration : Auto-calibration, NPL/NIIST Traceable Calibration Certificate for Sensor to be provided

18.0 Cooling Water System (to be provided if required as per design)

Cooling tower of suitable capacity with integral water tank should be provided along with the nitrogen generator. (NOTE: Cooling Tower should be procured from M/S. GEM / PAHARPUR/MIHIR).

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19.0 CONDITIONS TO BE NOTED

19.1 The party shall Design, Fabricate, Supply, Install and Commission the Nitrogen Generator at VSSC, Trivandrum. During installation & commissioning at VSSC, the party has to bear all the costs related to their personnel. The transportation, unloading and installation at site are the responsibilities of the supplier and the Nitrogen Generator should be commissioned on turnkey basis.

19.2 A detailed point wise technical compliance statement (format given below) should be enclosed along with the offer. Deviations if any from the tender specifications should be clearly highlighted The offer will not be accepted in the absence of a detailed point wise technical compliance statement.

19.3 On receipt of the enquiry, the party may submit the Technical Bid [along with the P& I diagram of the system and bill of materials (BOM) complete with all details].

19.4 The vendor should have built similar Copper Deoxo type Nitrogen Plants in Nitrogen capacities above 10 Nm3/hr and the list of supplies with supporting documents (Purchase Order) may also be provided.

19.5 The vendor should be ISO 9001 Certified Company & should attach ISO Certificate.

19.6 All CCOE clearance/license/certifications pertaining to the “Nitrogen Generator and its associated subsystems” where ever applicable should be obtained by the party on behalf of VSSC

19.7 All the pressure vessels shall be designed constructed & tested as per ASME Boiler & Pressure Vessel Code Section VIII, Div.1. The interconnected piping’s shall be pressure tested for minimum 1.5 times operating pressure.

19.8 The following utility shall be the SCOPE OF VSSC:

Additional City water connection if required (details to be provided by the party)

Power Supply (details to be provided by the party)

Necessary space (details to be provided by the party)

All Civil works including Foundation for 15 NM3/hr Nitrogen Generator (details to be provided by the party)

Fencing if required

Crane/Fork lift facility for Erection of 15 NM3/hr Nitrogen Generator(details to be provided by the party)

20.0 SUBMISSION OF TECHNICAL BID & PRICE BID

20.1 Bids shall be submitted in two parts namely: 1. Technical bid 2. Price bid

Both the bids have to be submitted in hardcopy, in separate sealed covers within the stipulated time limit.

The bids received in one cover for both Technical and the Price bid will not be considered.

The vendor may submit a “BLANK PRICE BID” along with the technical bid in the format given in 20.2

The price bid shall be opened only if the technical bid is found suitable.

A list of spares/consumables required for 2 years, for the smooth functioning of the nitrogen generator may be quoted as optional

20.2 The Price bid shall be prepared under the following headings:

Sl.No Specification Cost (Rs)

1 Nitrogen generator with all associated sub-systems

2 Packing & Forwarding charges

3 Installation & Commissioning charges

4 AMC charges for 3 years beyond the 2 year warranty period

5 Total

21.0 WARRANTY

21.1 The Nitrogen Generator should be guaranteed for trouble free service for a period of two years from the date of installation and commissioning at our site. Any extended warranty for bought out items should be passed on to VSSC.

21.2 The party should carry out maintenance free of cost during the guarantee period. Any part/device requiring replacement during maintenance and not covered under guarantee should be replaced by procurement after obtaining permission from VSSC and payment for the same shall be effected on the basis of actual invoice.

22.0 GENERAL

22.1 On receipt of the purchase order, the party has to submit the “layout of the equipment/P & I diagram/drawings of the system & list of bought out items” complete with relevant details for approval by VSSC.

22.2 The supplier shall initiate fabrication activities only after getting the drawing approval from VSSC.

22.3 The instruments used for the Nitrogen Generator should be individually calibrated to relevant standards and individual calibration certificate should be given. After the installation, system level calibration also should be carried out at the site by the authorized agency.

22.4 Supplier should offer the above Nitrogen Generator for inspection by the VSSC personnel at their works before dispatch, for which intimation should be given well in advance for deputing VSSC engineers to the party’s site.

22.5 The party has to submit the list of bought-out-items indicating their specification, make and Indian source & calibration certificates at the time of PDI.

22.6 All the calibration certificates of the components, material test certificates and the conformance to the Quality Assurance Plan will be verified.

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22.7 All components susceptible for corrosion should be painted with anti-corrosive paint.

22.8 A training should be imparted to our engineers which include operation, installation, calibration and maintenance and usage of control system. Training of VSSC engineers should be given free of cost.

22.9 Any Software developed for this application will be a property of VSSC and it should be supplied to VSSC in installable CD media in duplicate. Provision should be there to upload/download/install the software at site with connectivity to PC if required.

22.10 Any application software used in the system should be supplied to VSSC in original along with the software license, if any.

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FINAL CHECK-LIST FOR SUBMISSION OF TECHNICAL BID & PRICE BID YES/NO

1. Bids shall be submitted in two parts namely: 1. Technical bid 2. Price bid

2. Technical Bid should compulsorily comprise of the following documents:

i. A detailed point wise “Technical Specification” ii. A detailed point wise technical compliance statement in the format given

should be enclosed along with the offer. Deviations if any from the tender specifications should be clearly highlighted (The offer will not be accepted in the absence of a detailed point wise technical compliance statement.)

iii. Technical Bid should include the P& I diagram of the system and bill of materials (BOM) complete with all details.

iv. The vendor should be ISO 9001 Certified Company & should attach ISO Certificate.

v. CCOE clearance/license/certifications pertaining to the “Nitrogen Generator and its associated subsystems” where ever applicable should be clearly mentioned and obtained by the party on behalf of VSSC. This shall be clearly mentioned in the Technical Bid.

vi. All the pressure vessels shall be designed constructed & tested as per ASME Boiler & Pressure Vessel Code Section VIII, Div.1. The interconnected piping’s shall be pressure tested for minimum 1.5 times operating pressure. This shall be clearly mentioned in the Technical Bid.

3. The following utility shall be the SCOPE OF VSSC, however details are to be provided by the party in the technical bid:

A. Additional City water connection if required (details to be provided by the party)

B. Power Supply (details to be provided by the party) C. Necessary space (details to be provided by the party) D. All Civil works including Foundation for 15 NM3/hr Nitrogen Generator

(details to be provided by the party) E. Fencing if required F. Crane/Fork lift facility and tools for Erection of 15 NM3/hr Nitrogen

Generator(details to be provided by the party)

3.

4. Both the bids have to be submitted in hardcopy, in separate sealed covers within the stipulated time limit.

5. The bids received in one cover for both Technical and the Price bid will not be considered.

6. The vendor may submit a “BLANK PRICE BID” along with the technical bid in the following format

Sl.No Specification Cost (Rs)

1 Nitrogen generator with all associated sub-systems

2 Packing & Forwarding charges

3 Installation & Commissioning charges

4 AMC charges for 3 years beyond the 2 year warranty period

5 Total

7. The price bid shall be opened only if the technical bid is found suitable.

8. A list of spares/consumables required for 2 years, for the smooth functioning of the nitrogen generator may be quoted as optional

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Compliance Matrix for Specifications

1.0 Screw Air Compressor Complied (Yes/No)

Remarks

A suitable compact Oil Free Screw type Air Compressor conforming to ISO-8753 Class1-quality Air of repute make with limited vibration and sound (having suitable vibration isolating mounts to absorb suitable high-frequency vibrations) shall be supplied.

The compressor system should incorporate after cooler and instrumentation.

The compressor should be compatible with the PSA generator described in 5.0.

1.1 Make : Atlas Copco/Elgi/Kaeser/Chicago Pneumatic/ Ingersoll Rand/Bosch

1.2 Type : Oil Free Screw type Air Compressor conforming to ISO-8753 Class1-quality Air)

1.3 Air Capacity : The compressor ratings shall be suited for 15 Nm3/hr Nitrogen generator.

1.4 Delivery Pressure

: The vendor may clearly indicate the delivery pressure of the compressor

1.5 Climate : Sea Environment


2.0 Air Receiver Complied (Yes/No)

Remarks

A suitable air receiver shall be provided for cooling the air


: Carbon Steel



3.0 Oil Filters in Air Line Complied (Yes/No)

Remarks

Suitable Multistage Oil filters shall be provided to make the Air Oil free

3.1 Number of Filters

: 3 No.s minimum in series

3.3 Air Capacity

: The Air Capacity of the oil filters in the air line shall be suited for 15 Nm3/hr Nitrogen generator. The vendor may clearly indicate the air capacity.

3.5 Make : Omega/Wilkerson/Speedaire/Masterpneumatic/Exair

4.0 Air Dryer Unit Complied (Yes/No)

Remarks

The filtered air may contain water vapour and should be purified further by an Air Dryer.

4.1 Air Flow Capacity

The air flow capacity of the air dryer unit shall be suited for 15 Nm3/hr Nitrogen generator. The vendor may clearly indicate the air flow capacity.

4.2 Make : Friulair/Kaeser/Ingersoll Rand/SMC Pneumatics

4.3 Test Pressure

: The vendor may clearly indicate the test pressure (minimum 1.5 times operating pressure)

5.0 Nitrogen PSA Unit Complied (Yes/No)

Remarks

Nitrogen PSA unit should produce Nitrogen gas with suitable pressure by the pressure swing adsorption technique.

Nitrogen PSA unit should have two adsorbers filled with suitable “carbon molecular sieves” and interlinked by valves required for different functions of the PSA System.

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Dry nitrogen gas should be generated by the processes of adsorption, desorption (by depressurization) and re-pressurization.

5.1 Nitrogen Generation Capacity

: To be designed considering a final delivery of 15Nm3/hr (Excluding the gas required for copper catalyst regeneration)

Sufficient amount of excess Nitrogen capacity to be considered for catalyst regeneration in the Copper De-oxo unit as elaborated in 7.0

5.2 Number of PSA towers

: 2 Nos. (1 in operation mode & another in regeneration mode)


: Carbon Steel

5.4 Type of Vessel : Vertical Vessel (preferable)

5.5 PSA Valve operation

: PLC controlled

5.6 Operating pressure : 7 bar g

5.7 Nitrogen Purity : 99.99% (minimum)

5.8 Make of carbon molecular sieves

: CarboTech, Germany/Kuraray Chemical Co, Japan/Japan Enviro Chemicals


6.0 Nitrogen Surge Vessel Complied (Yes/No)

Remarks

A suitable Nitrogen Surge Vessel shall be provided with appropriate pressure rating and safety relief valves.

The capacity and the pressure rating of the surge tank should be designed for the continuous operation of the copper de-oxo unit as elaborated in 7.0.


6.2 Code of construction

: Design Construction & Testing as per ASME Boiler & Pressure Vessel Code Section VIII, Div.1


: Carbon Steel


6.5 Safety Valves : A pressure relief valve assembly should be provided to relieve the pressure in case of pressure build up (beyond the design pressure) inside the chamber.


: Bourdon type dial gauge (Dwyer/Waaree/Swagelok/Wika/Kenny/Pfeiffer/Leybold/Edwards) of suitable range should be provided for the Nitrogen Surge Vessel.

7.0 Copper De-oxo unit Complied (Yes/No)

Remarks

Nitrogen PSA unit has to be coupled with Cu-Deoxo Catalyst Unit.

The Cu-Deoxo Catalyst Unit should produce nitrogen gas of purity 99.999%

and the impurity levels shall be H2O 2 ppm, O2 2 ppm.

7.1 Number of catalyst towers : 2 Nos

7.2 Type of catalyst : Copper catalyst

7.3 Outlet Oxygen content in Nitrogen

: 2ppm

7.4 Temperature Display : A suitable digital temperature display may be provided

7.5 Material of construction : Carbon Steel


7.7 Switching Cycle of vessels : To be cyclically controlled by PLC


7.9 Nitrogen flow : Rotameters (Flowstar/Linde/Swagelok)

7.10 Outlet gas flow : To be designed considering a final delivery of 15NM3/hr (Excluding the gas

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required for copper catalyst regeneration)

Sufficient amount of excess Nitrogen capacity to be considered for catalyst regeneration in the Copper De-oxo unit.

7.11 Hydrogen flow meter : A suitable hydrogen flow regulator and tubings shall be provided for connection of hydrogen cylinders to the copper de-oxo unit

The flow rate of hydrogen shall not exceed 0.3 Nm3/h

The regulator should be designed for gaseous hydrogen media and suitable for fitting Hydrogen cylinders with valves as per IS: 3224.

8.0 Nitrogen Dryer Unit Complied (Yes/No)

Remarks

Suitable dryer units shall be provided to remove the moisture content in the nitrogen. Moisture in final gas should not exceed 2ppm

The dryer unit should be suitably linked to the PLC, so that the moisture in final

gas should be 2ppm before delivery to the final unit.

9.0 Low Pressure Nitrogen Tank (if required as per design) Complied (Yes/No)

Remarks

A Low Pressure Nitrogen Tank of suitable geometrical volume may be provided with appropriate pressure rating, safety relief valves and suitable ports for cleaning

The Nitrogen in the Low Pressure Nitrogen Tank shall have to be boosted to 50 bar pressure using a Nitrogen booster as explained in 10.0.

Low Pressure Nitrogen Tank shall have to be sized suitably and shall have to be linked to the PLC so as to ensure the operation of the nitrogen booster without any manual intervention.

Suitable anti-corrosion coatings may be provided on the inner surface of the Low Pressure Nitrogen Tank

9.1 Type of vessel : Cylindrical Vertical Tank preferable

9.2 Code of construction

: ASME Section VIII, Div.1


: Carbon Steel


9.5 Safety Valves : Suitable pressure relief valve assembly should be provided to relieve the pressure in case of pressure build up (beyond the design pressure) inside the chamber.


: Bourdon type dial gauge of suitable range should be provided for the Low Pressure Nitrogen Tank. (Dwyer/Waaree/Swagelok/Wika/Kenny/Pfeiffer/Leybold/Edwards)

10.0 Nitrogen Booster Compressor.

Complied (Yes/No)

Remarks

Nitrogen Booster Compressor shall have to be sized and linked to the PLC so as to ensure the plan operation without any manual intervention.

10.1 Make : Sauer-Germany/Bauer-USA/Hycomp-USA/Atlas Copco USA/Rix Industries/PDC Machines/Howden

10.2 Suction Pressure : 2-7 bar g

10.3 Discharge Pressure

: 50-bar g

10.4 Type of compressor

: Reciprocating type, air cooled compressor


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11.0 High Pressure Nitrogen Tank Complied (Yes/No)

Remarks

A suitable High Pressure Nitrogen Storage tank (geometrical volume 2m3) may also be provided with appropriate pressure rating, safety relief valves and suitable ports for cleaning

The tank shall be buffed from inside and powder coated in blue colour from outside.

Suitable anti-corrosion coatings may be provided on the inner surface of the High Pressure Nitrogen Tank

The tank shall be Designed Constructed & Tested as per ASME Boiler & Pressure Vessel Code Section VIII, Div.1

This would be installed outside the building on a concrete platform. Suitable supporting structure if any shall be provided by the vendor. (foundation shall be the responsibility of VSSC as per details given by the party)


11.2 Volumetric capacity

: 2m3 to store gas at 50 bar


: Carbon Steel

11.4 Operating pressure

: 50 bar g


11.6 Clearance : To be obtained from CCOE by the vendor

11.7 Safety Valves : Suitable pressure relief valve assembly should be provided to relieve the pressure in case of pressure build up (beyond the design pressure) inside the chamber. There should be two safety relief valves to protect the high pressure nitrogen tank from over pressure as per ASME Boiler and Pressure Vessel Code Section VIII, Div 1.


: Bourdon type dial gauge of suitable range should be provided for the High Pressure Nitrogen Tank. (Dwyer/Waaree/Swagelok/Wika/Kenny/Pfeiffer/Leybold/Edwards)

11.9 Ports : Suitable standard ISO ports should be provided for hydraulic pressure testing (both inlet & outlet) and for cleaning

12.0 Pressure Regulator After High Pressure Nitrogen Storage Complied (Yes/No)

Remarks

A suitable nitrogen flow regulator shall be provided after the high pressure nitrogen tank to provide nitrogen flow with constant 10 bar (minimum) Pressure required for our application.

This outlet of this regulator will be connected to the user end points.

12.1 Type : Dome loaded pressure regulator with flanged end connections

12.2 Material of construction : Regulator Body-SS BS EN 1088 1.4401 Trim – PCTFE Elastomers - Nitrile

12.3 Make : Swagelok/Concoa/Tesscom/Norgen/Shavo

12.4 Size : Sizing of the regulator shall be conducted by the party using the inputs provided below and the same shall be submitted along with the characteristics to VSSC for approval, before integration to the plant.

12.5 Inlet Pressure : 50 bar g (maximum)

12.6 Outlet relieved Pressure : 10-bar g constant

12.7 Maximum Flow rate : 15 Nm3/hr

12.8 End connections : Flanged (ANSI)

13.0 Program Logic Controller Complied (Yes/No)

Remarks

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The system shall have a PLC based control system to automatically carry out the sequence of operations, give feedback and control system parameters on real time basis.

The PLC shall have add-on input/output modules supplemented by various additional drives and interfaces to accept inputs from sensors and provide appropriate signals to ensure a continuous supply of 99.999% pure Nitrogen with impurity levels O2 ≤ 2ppm, H2O ≤ 2ppm at the outlet of the system.

13.1 Make : Siemens/Schneider/Mistubishi

14.0 Electrical Panel Complied (Yes/No)

Remarks

A suitable electrical panel of repute make may be provided. The electrical panel may have a mimic diagram of operations with appropriate status indications.

14.1 Make of Switchgear : Siemens/L&T/Legrand

15.0 Online Percent Oxygen Analyzer with digital display Complied (Yes/No)

Remarks

15.1 Make : Teledyne Instruments/Michell Instruments/Systech Illinois

15.2 Measurement Range : 0-10% Oxygen




16.0 Online PPM Oxygen Analyzer with digital display Complied (Yes/No)

Remarks

16.1 Make : Teledyne Instruments USA/Michell Instruments UK/Systech Illinois

16.2 Measurement Range : 0-10 ppm oxygen




17.0 Online Digital Dew Point Meter Complied (Yes/No)

Remarks

17.1 Make : GE-USA/Michell Instruments UK/Elco USA/Phymetric

17.2 Range : Dew Point Measurement upto (-)80°C

17.3 Accuracy : ± 2°C Dew point

17.4 Repeatability : ± 0.3°C Dew point

17.5 Resolution : 0.1 °C Dew point or 0.1 ppm

17.6 Calibration : Auto-calibration, NPL/NIIST Traceable Calibration Certificate for Sensor to be provided

18.0 Cooling Water System (to be provided if required as per design) Complied (Yes/No) Remarks

Cooling tower of suitable capacity with integral water tank should be provided along with the nitrogen generator. (NOTE: Cooling Tower should be procured from M/S. GEM / PAHARPUR/MIHIR).

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Design, Fabrication, Supply, Installation and Commissioning of Nitrogen Generator. · 2016-09-19 · Design, Fabrication, Supply, Installation and Commissioning of Nitrogen Generator.

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