Industrial and Medical Cryogenic Oxygen Nitrogen Production 27.42TPD KDON-1140Y Air Separation Plant by Piston Compressor Air Separation

BASIS OF DESIGN

2.1.  AMBIENT CONDITIONS        (To be provided by Buyer in detail)

Ambient  pressure          100 KPa.A

Ambient  temperature  35 ℃

Relative humidity  80% 

Altitude       612m

EXTREME TEMPERATURE

Max temperature     50 ℃

Min temperature      -4 ℃

EXTREME RELATIVE HUMIDITY

Max RH in Month Mean 100%

Min RH in Month Mean  30%

Note:

Plant shall be capable of operating at the “Max. and Min.” operation conditions.

Design and Guarantee shall be based on Ambient Condition.

All equipment to be installed outdoor should be designed for a higher protection degree for outdoor service.

 Raw air conditions:

Mechanical impurities      ≤100 mg/m3

CO2 ≤500 PPm

C2H­2      ≤0.3 PPm

CnHm     ≤20 PPm

Others     As per normal conditions

SEISMIC INTENSITY:

Earthquake shall be considered for 8 degrees

POWER CONDITIONS:

Medium voltage power    4600V

Low voltage power  380 V

 Frequency      60Hz

COOLING WATER CONDITIONS

Normal industrial water

Cooling water inlet temperature       30°C

Cooling water outlet temperature     50°C

Cooling water inlet pressure     4.5 bara

Cooling water outlet pressure   2.5 bara

Flow Rate 200 T/h

INSTRUMENT GASES FOR START UP (SUPPLIED BY USER)

Capacity 150 Nm3/h

Pressure 6.5 Bara

Dew point        -40 °C

Inquire    Oil and dust free

CODES, STANDARDS AND REGULATIONS

Pressure Vessels

Pressure vessels shall be designed, manufactured, tested and inspected according to ASME standards.

Piping

All piping works shall comply with ASME standard;

Flange ANSI/ASME standard. ASTM material.

Machinery

Design, manufacture, testing and inspection of machinery shall be according to manufacturer's standard and to the standards of the country of origin considering Seller’s specific Standards.

Electrical Equipment

Electrical equipment and material shall be in accordance with the relevant IEC and ISO standards or electrical standards used in China where applicable. In addition to the above, the referenced manufacturer’s standards shall also apply. 

Area classification with regard to explosion proof design: non-hazardous.

Instrumentation

Design of plant instrumentation shall be in accordance with Seller's Standards. Symbols and identifications of instrumentation in P&I Diagram shall be in general in accordance with ISA-Standard. The numbering system will follow Seller’s standards.

Area classification with regard to explosion proof design: non-hazardous.

Piping & Steel Structure

The design and fabrication of piping and steel structure will follow GB standards.  

Safety & Environmental Protection

Plant design will be in accordance with relevant GB standards and regulations.

Note: all equipments are according to international standards and suitable for heavy duty use.

EMISSIONS

Basis of acoustic plant design is to meet a sound noise level of 85dB(A) at a distance of 1m from each individual, accessible equipment placed outside the machine house. Equipment inside the machine house (in Buyer’s scope) will have no special noise protection since the machine house itself will be designed as noise adsorbing shell.

The acoustic design applies to normal operation of equipment, rather than

start-up, shut-down and other abnormal or transient operation conditions as well as emergency situation.

Generally no other emissions harmful to the environment have been foreseen.

3.      PLANT PERFORMANCE

3.1   PERFORMANCE AND UTILITIE REQUIREMENT

Performance Specification      

Production                   

Liquid oxygen Nm3/h      800 

Pressure            

Liquid oxygen bar.A        2      

Purity                

Oxygen    O2 Min    99.5%     

Plant Utilities Required       

Installed powerKW  1569

Shaft power     KW  1241

Specific power         Kwh/Nm3        1.55

Cooling water  T/H  165 

Notes:

Liquid flow, pressure and purity are to be measured at the product valve; liquid flow is measured in stationary tanks by means of liquid level, but the vapor losses in pipes and tanks shall be taken into account.

Power consumption is related to user terminals. Losses from user terminals to measuring points in cables and switchgears are not included.

The quantity of output are under the standard condition, which is the volume flow under 0°C,101.325kPa

The specific power is counted by LOX out of Cold Box only. And the power excludes the power consumption for cooling water system etc.

3.2   PERFORMANCE GUARANTEES

3.2.1 Products

Product Flow

Seller guarantees the total gaseous oxygen product flow as specified in Section 3.1 under the condition of Section 2”Basis of Design”.

                  Product Purity

Seller guarantees the purity for gaseous as specified in Section 3.1 under the condition of Section 2”Basis of Design”.

         Product Pressure

Seller guarantees the pressure for gaseous as specified in Section 3.1 under the condition of Section 2”Basis of Design”.

3.3        PERFORMANCE TEST

         General

The plant performance test shall verify the performance guarantees as stipulated in Section 3.2 above.

The performance test shall be conducted in accordance with the stipulations of the Contract and with the procedures set forth hereinafter. If necessary, adaptations of the procedures can be agreed upon by Buyer's and Seller's site representatives.

During the performance test the plant shall be operated by Buyer’s operating personnel but under supervision of Seller' expert.

After Seller's announcement of the performance test Buyer has to ensure within one week that the following prerequisites are fulfilled:

Availability / supply of all required utilities as specified in Chapter 1.2.3.

possibility for a plant shutdown before starting the performance test, if required by Seller's personnel

By mutually agreement, Buyer and Seller shall decide which operating values shall be recorded and in an interview of how much time.

The guaranteed operating case, Section 3.1 shall be manually adjusted as exactly as possible according to the instructions of Seller's personnel. After steady operating conditions are achieved the performance test shall be conducted for the duration of 48 hours of operation. The average results (mean measured values) from a period of 24 hours of operation are the basis for the comparison between the guaranteed and the achieved figures, under consideration of the corresponding measuring tolerances.

Should a termination ahead of schedule become necessary for any reasons, for which Seller is not responsible, the period of the test run until the termination shall upon Seller’s and Buyer’s common selection – be the basis for the validation, provided the duration of operation was at least 24 hours.

During the performance test the relevant operating values shall be read from the existing measuring devices and analyzers and shall be recorded. All records shall be signed by both parties and shall be accessible to both parties.

If the existing conditions are deviating from the conditions specified in Section 2, Basis of Design, conversions, corrections respectively, have to be made. These shall be made by Seller in accordance with the relevant valid Chinese regulations and shall be handed over and explained to Buyer.

Measuring Methods and Tolerances

For verification of the guaranteed plant performance, the measuring methods and tolerances as specified below:

For guarantee measurements the installed measuring devices shall be used under consideration of the manufacturer’s tolerances.

The following measuring methods shall be used:

Gas flows:                 as read with flow measuring element

Purity:              as read in the automatic online analyzer *)

Pressure:          as read with pressure transmitter

Power:              as read in the kWh – meters plus ±4 tolerance

         Detailed product analyzing (other than O2 traces), if required, shall be carried out by Buyer e.g. by means of laboratory analysis of product samples.

4.      PROCESS DESCRIPTION

SCOPE OF SUPPLY

Engineering design

Complete design and engineering, on all levels, of the entire plant.

Process Engineering

Complete process engineering of the entire plant. The process engineering will include, but not limited to the following:

Detailed calculations on line-sizing

Specifications for automatic control valves

Detailed calculations on orifice diameters for safety valves

Calculations on required heat surface of heat exchangers

Pressure drop calculations

Line list (process level)

The process engineering efforts will result in (not limited):

Process Flow Diagram (PFD)

Piping and Instrumentation Diagram (P&ID)

Line sizing calculations per line and resulting pressure drops

HAZOP Study and Reports        As an option

A HAZOP study will be executed during the execution of the project, China;

Those to be executed at “design” stage include:

Process Flow Diagram,

P&ID,

Initial Plant-lay-out

The session will cover as minimum;

Review and update setting PID, PFD and equipments

Tackle all parts of the plant in detail

Tackle any parts, modifications and extensions of the plant

Basic Civil Engineering

Complete arrangement of the concrete slab on which the equipment will be placed.

Including but not limited to:

Foundation drawing indicating equipment weights and heights

Dedicated civil engineering office to make the detailed civil drawings

Detailed indication of the location of all anchor-bolts to be poured in the slab

Design of earthing network to be poured in the concrete slab

Detailed indication of 'poured-in' cable channels

The civil package submitted will allow for the (local) civil engineering company to finalize the civil drawings in accordance with the local constitution of the soil.

Mechanical Engineering

Entire mechanical engineering, not limited to:

General Arrangement drawing (GA)

Plot plan

Side views

Piping arrangement plan

Piping isometrics

Detailed drawings of all supporting

Line list (mechanical)

Electrical Engineering

Complete electrical package

Schematic Wiring Diagram (SWD)

Cable list

Safety shut-down system (hard wired)

Lay-out of cable trays an conduits

Instrumentation

Specification of all instrumentation (auto-valves, transmitters, PT's, LT's, PT-100's, etc.)

Hook-up diagrams

Instrumentation cabling list

BASIC SCOPE OF SUPPLY

Note: The datasheet for all equipment listed hereinafter are only for reference. Detail data shall be provided in the later detailed design stage after the contract effected.

Self-clean air filter                            2 sets

Model      ZKG-100

Type Auto-clean

Effective range 2100Nm3/h (Max. 6000 Nm3/h)

Filter Efficiency       99.9%  1μm

Filter resistance       150~600 pa

  Supplier      A.H. or equal

Specification:

A differential pressure transmitter measures the pressure losses before and after the filter.

PLC auto control, back-flush at an adjustable interval.

Filter cartridge is made of high quality fiber material 

SMC or Equal solenoid valve

Air compressor                                2 sets

Type Centrifugal, Multi-stage, Skid

Operating capacity   2100 Nm3/h

Inlet pressure   98Kpa(A)

Inlet temperature     32 °C

Discharge pressure  11 bara

Discharge temperature     ≤40 °C

Reference motor power    310 KW

Reference shaft power      275 kW

Reference cooling water 25 t/h

Electricity situation  4600 V/60Hz

Manufacture:   Ingersoll Rand or Equal

Refrigeration unit                         2 sets (1W+1S)

Style Skid model

Mode       SAYL-4200/10W

Air treated        4200 Nm3/h

Air Inlet pressure     11 bar.A

Air Inlet temperature        ≤45 ℃

Air Outlet temperature     8 ℃

Motor power    25 KW

Electrical voltage     380V

Cooling water  23 t/h

Frequency       60Hz

Specification:

A modular refrigeration unit comprises one compressor, one filter, one condenser, one expansion valve and one evaporator.

Semi-closure screw refrigerating compressor;

HH / LL pressure , over heat self-protection functions;

Evaporator with high efficiency overlap type heat exchanger.

Schneider PLC controller

  Supplier      Shanli(Linde qualified ) or Equal

Pre-Purifier                               1 set

 Model    HXK-4200/11

Air treated        4200 Nm3/h

Working pressure     11 bara

Inlet Air temperature        16 °C

Outlet air temperature      23 °C

Regeneration temperature 170 °C

Purified air  content        CO2 ≤1 ppm

         Dew point of H2O   ≤ -65 °C

Working period       4 h  auto-switch

Electrical voltage    380 V

Power  of electrical heater      65 Kw

Frequency       60 Hz

  Supplier      WINTEK

Specification:

The whole system will include two vertical absorber vessels, one vertical electric heater, nitrogen vent silencer, after-filter, a compact set of interconnecting piping, fittings and valves.

Normal temperature 13X APG molecule sieve and active aluminum as absorbent, which was evenly scattered on the two floors inside the vessel;

Instrumentation works such as meters, transmitters, gauges, etc included.

High quality NELES-JAMESBURY Butterfly valves.

Recycle Booster Compressor                               1 set

Suction volume        4800 Nm3/h

Inlet pressure   1.05 bar.A

Inlet temperature     43℃

Discharge pressure  10.8 bar.A

Discharge temperature     ≤45 ℃

Power of motor 580 Kw

Shaft power     525 Kw

Electricity condition 4600V/60Hz

Cooling water

consumption   48 t/h

Manufacture    Ingersoll Rand or equal

Specification:

The compressor will include inter and after-coolers, interconnecting piping, inlet guide vanes, blow off silencer, lube oil system, gear box and coupling.

Equipped Local control panel including the surge protection, discharge pressure set-points, vibration- and temperature alarms etc.

Microprocessor controller, LCD monitor;

70%~105% operating adjust range

Skid model, non-foundation requirement

Cold Box System                                1 set

Model      FLOLN-800

LOX capacity  800Nm3/h

Purity

LOX purity      99.5%

Pressure

               LOX Pressure      2.0 bara

              Supplier        WINTEK

Specification:

The whole cold box include HP column, LP column, boiler, main heat exchanger, sub-cooler etc;

Aluminum columns and piping inside the cold box;

Aluminum plate/fin design for main heat exchanger, boiler and sub-cooler;

All piping and electrical wiring within the cold box package is completed prior to delivery.

High quality Wuxi KOSO cryogenic valves.

Low Temperature Refrigeration Unit        1 set

Type Skid

Mode       SAYL-5900/10W

Air treated I      5900 Nm3/h

Air Inlet pressure     11 bar.A

Air Inlet temperature        248k

Air Outlet temperature     235k

Motor power    50 KW

Electrical voltage     380V

Cooling water  18 t/h

Frequency       60Hz

Specification:

A packaged refrigeration unit utilizing R404A refrigerant. The package will include a compressor, motor, and a shell and tube water cooled condenser.

Semi-close screw refrigerating compressor equipped;

High, low pressure and over heat self-protection functions;

The cold production is adjusted by heat off shoot valve, which can prevent the water in the compressed gas ice up.

Evaporator uses high efficiency overlap style heat exchanger.

Schneider PLC controller

  Supplier      Shanli(Linde qualified  ) or Equal

Booster Turbine Expander              1 set          

Expander suction volume 4800Nm3/h

Expander Inlet pressure         14 bar

Expander Outlet pressure      1.25 bar

Expander inlet temperature      151K

Adiabatic efficiency 81%

Booster suction volume   4800Nm3/h

Booster Inlet pressure            10.7 bar

Booster Outlet pressure         14.4 bar

Booster inlet temperature 313K

Adiabatic efficiency 76%

Specification:

The system will includes oil supply system, expander inlet filter etc.

Use purified air expansion, oil lubricate

  Supplier      Ruite. CHINA

Fan- break Turbine expander 1 set

Expander suction volume 2900Nm3/h

Expander Inlet pressure         10.6 bar

Expander Outlet pressure      5.8 bar

Expander inlet temperature      118K

Adiabatic efficiency 81%

Specification:

The system will includes oil supply system, expander inlet filter etc.

Use purified air expansion, oil lubricate

  Supplier      Xida (Linde qualified) CHINA

ISO LOX storage tank              2 sets

Valid capacity          50 m3

Operation pressure   13barG

Design temperature -196 ℃

Insulation method    Perlite

Media      LOX/ LIN

Main Material Inner vessel     Stainless Steel

         Outer vessel     Carbon steel

Supplier   Wintek or Equal

Transfer LOX pump         2 sets

Capacity 800 Nm3/h

Discharge pressure 30 barG

Design temperature -196 ℃

Motor Power    - KW

Supplier   Cryomec or Equal

LOX Road tanker Charging Pump            2 sets

Capacity 20 m3/h

Discharge pressure 20 barG

Design temperature -196 ℃

Motor Power    - KW

Supplier   Cryomec or Equal

GOX Filling Pump            1 set

Capacity 300 Nm3/h

Discharge pressure 200 barG

Design temperature -196 ℃

Motor Power    - KW

Supplier   Cryomec or Equal

GOX Filling Vaporizer             1 set

Flow rate         300 Nm3/h

Design pressure       200 barG

Filling manifold                                            1 set

Mode       GC20

Filling head      2X10

Pressure   200bar

Control System

The control system will include all valves, instrumentation, analyzers, relief devices, flow elements and PLC equipment to effectively monitor and control the production process.  The main control station will be located in a central control room cabinet.  A single operator interface station with a PC and printer is included. Only European vendors will be used for the plant control system.

The control system is a SIEMENS PLC S/7-400.

Programming : Step-7 V5-3

Visualization: WINCC V. 6.0.

Operating software PC :  Windows XP- professional

1x operator control screen :      21" LCD (Dell)

1x UPS :  6kVA/ 0.5 hour

Note: the PLC configuration list hereinbefore only for reference, the final configuration will be based on the final design and contract.

Analyzer

(Note: The analyzers listed hereinafter are only for reference, the final analyzers shall as per the final design and the contact)

No.   Meters     Analysis spot Range      The Min. capacity    Brand

1       Products

Oxygen(1 set)  Product oxygen pipe 98~100%        0.05%      SERVOMEX or Equal

2       CO2 content after purifier(1 set)       After purification system          0~20PPmCO2 0.2PPm   

Electric Control System          

The electrical system consists of: e.1) Medium Voltage System, e.2) 380V system, e.3) remaining systems.

e.1. High Voltage System

HV Switch Gear

Oil immersed transformer, 13.8kV±2x2.5 / 4.16kV, 2000kVA, 6%, ONAN

e.2. Medium Voltage System

MV incoming unit

MV bus VT unit

MV motor feeder for Main air compressor

Main motor for  Main air compressor

e.3. 380V System

All required 380V MCC (Motor Control Center)  for main motors, aux. oil pumps, demister fans, regeneration heater, etc.

e.4. Remaining Electrical

Further the electrical system includes:

220V system for PC/PLC, printers, etc.

Either 24VDC, 110VAC/220VAC system for solenoids controls

 Cooling water system

Water cooling tower

Water pumps and motors

Motors’ controllers

Piping system and cable system to connect related components inside the Battery Limit.

Note:

For all civil construction for cooling water system and water soften system, the buyer will do it by themselves. The Supplier will provide necessary civil drawings.

 Piping system and cable system materials inside the battery limit

Piping system to connect all components (includes valves);

For outlet the products gaseous extend one meter inside the B.L.,;

Piping system and valves for cooling water system inside the B.L.

The Cables to connect all the electrical equipments inside the B.L. (excluding the cable outlet from HV/MV transformer inlet to the MV electrical panel, and from MV/LV transformer inlet to the LV electrical panels);

Pipes and cables assistant support materials like angle iron etc.;

Installation materials for instrument control system;

Painting and insulation for all components and pipes.

Carbon pipes using between the equipments, After cold box will using S.S. Pipes.

Supervision of erecting, commission and start up (Optional) 

Supervision of erection of components supplied by supplier;

Field pressure testing supervision;

Loop checking/valve stroking/etc.

All main components supplied by supplier commission;

Cooling water system commission;

Analyzers commission;

Cold box thaw;

Cold box cool down;

Performance testing.

Note:

For erecting supervision, the supplier will only provide on site engineers to do supervision for all components erecting on site, but will not attend the erecting job themselves.

All erecting jobs will be done by the buyer or the erecting team hired by the buyer.

All equipments and special tools like welding machines etc will be prepared by the buyers.

The supplier will provide a detail list for all equipments and tools may used for erecting to the buyer.

For special labors like welding labors etc that needed in erecting, the supplier will also provide a detail list to the buyer for reference.

For round flight tickets, transportation, lodging, food and necessary medical for on site engineers will be provided by the buyer.

Note: “Optional” means this service is not included in the basic scope of supply but only a choice for the customer.

 Painting

Rotating machinery and cold box, storage tanks will be supplied with the final painting, other process equipments and piping etc. will supplied with primary coat, the finish painting and touch up will be done by buyer or installation company. Painting material shall be supplied and purchased in local market by Buyer because the sea shipment policy.

 Shipping and Transport

Seller will provide shipping and transportation of the equipment to China FOB Port in accordance with generally accepted industry practice and all applicable codes and standards.

5.3   BATTERY LIMITS

Basis for equipment arrangement is the attached Plant Layout

The main connection points for the Plant are defined as follows:

Air

Process air                         at inlet flange air filter

Products

LOX at outlet flange of LOX production line of CBX

Utilities

Electricity                  at receiving end terminals of LV switchgear

Cooling water/makeup water   connection points to plant system

Earthing           connected to interconnection points of earthing system

Instrument Air connection points to plant system

Emissions

Liquid drains   outlet of ejector

Deriming vents outlet of deriming lines

Gaseous blow-off     outlet of silencer

Waste nitrogen outlet of silencer

Safety blow-off        outlet safety valves  

Q1: How about the quality of your products?

A: Our machines are manufactured strictly according to national and international standards, and we take a test on each equipment before delivery. You can also use Trade Assurance by Alibaba for product quality protection, on-time shipment protection and payment protection.

Q2: How about the price?

A: We are manufactory, and we can give you lower price than those trade companies. Besides, customers from Alibaba can geta discount.

Q3: Do you provide after-sale service?A: Yes. The warranty peniod of our machines is one year, and we have a professional after-sale service team to promptly and thoroughly solve your problems.