CTO BEST PRACTICES Draft

Author: S.R.Pandian Supersedes Doc Date:

INERTING OF BASKET
Release Date: 25.09.08
CENTRIFUGES
Released By : Guideline No – CTO ENGG BP 001 ISSUE 1
Martin Ghosh

1. Purpose

The purpose of this document is to prevent the fire and explosions in process
centrifuging operations.

2. Scope

This is applicable all the basket type centrifuges used in manufacturing at all the CTO
sites

3. Responsibility

Production Manager / Plant Heads

4. Guidelines

 The centrifuge should be leak free and should be maintained to ensure that there are no
leakages through the lid and body gaskets
 The maximum allowable leak rate is 100 m bar in 60 minutes
 The centrifuge and the connected equipment should be inertised to a sufficient degree
therefore, oxygen is not permeating into the filtration system
 The possibility of air leaking into the centrifuge through feed and vent line should be
prevented by suitable means
 Provide separate inerting lines to the centrifuge bearing housing, basket, feed vessel
and receivers
 Liquid seal with controllable liquid level in filtrate line to be provided
 Filtrate discharge line should be sufficiently sized and sloped that accumulation and
vapor lock in the line is prevented. Discharge line diameter should be minimum 2xD
( D – diameter of feed pipe ). The slope to be min 100 mm in 1 mtr.
 Nitrogen pressure required in side the basket is in the range of 10 to 15 mbar
 Nitrogen pressure required in the bearing housing is in the range of 15 to 20 mbar
 Pressure Relief to avoid excess pressure in the centrifuge to be provided
 Sufficient level of automation to be provided to ensure the following
o Sufficient Nitrogen flow is maintained
o Sufficient Nitrogen pressure is maintained in the system

Page 1 of 5
 CTO BEST PRACTICES Draft
Author: S.R.Pandian Supersedes Doc Date:
INERTING OF BASKET
Release Date: 25.09.08
CENTRIFUGES
Released By : Guideline No – CTO ENGG BP 001 ISSUE 1
Martin Ghosh

5. Interlocks

 Power to the centrifuge should have an interlock with the set point of the nitrogen
inerting pressure in the centrifuge system
 Nitrogen supply should be automatically cut off, on opening of the centrifuge lid
 The centrifuge and the feed valve not to operate if the O2 level in the centrifuge is above
5%

6. Procedure

The following are the established procedure to operate any process centrifuge handling
flammable slurries.

6.1 Pre-flushing

Before starting the filtration operation in the centrifuge, the centrifuge is pre
flushed with N2 until the O2 sensor reads 5%. This is done by selecting the Pre-flush
mode in the PLC. The PID valve for Basket and for bearing housing open fully and
allow more N2 to flow into the system. The following points ensure that the pre-flushing
can be stopped and Blanketing can be selected in the PLC.

1. O2 sensor reads 5% or less.

2. N2 pressure in the basket shows as 10 mbar or more
3. N2 pressure in the bearing housing shows as 15 mbar or more

The PID valves’ opening percentage and the flow rate for pre-flushing are
selected depending upon the size and model of the centrifuge.

6.2 Blanketing

There should be some over pressure maintained in the centrifuge basket and in
the bearing housing of the centrifuge during the operation. Select Blanketing in the PLC
and ensure the following are maintained in the system,

1. O2 sensor read continuously 5% or less.

2. N2 pressure in the basket shows as 10 mbar or more
3. N2 pressure in the bearing housing continuously shows as 15 mbar or more

Page 2 of 5
 CTO BEST PRACTICES Draft
Author: S.R.Pandian Supersedes Doc Date:
INERTING OF BASKET
Release Date: 25.09.08
CENTRIFUGES
Released By : Guideline No – CTO ENGG BP 001 ISSUE 1
Martin Ghosh

The PID valve opening percentage and the flow rate for blanketing are selected
depending upon the size and model of the centrifuge.

This condition can be maintained continuously as long as the centrifuging

operation is on.

6.3 Alarms

There should be provisions in the automate systems to trigger alarms ( audio-

visual ). The following alarms should be provided but not limited to the list given

1. Very Low Nitrogen pressure in the basket ( less than 3 mbar )

2. Very Low Nitrogen Pressure in the Bearing Housing ( 3 mbar )
3. O2 sensor reading high percentage ( above 5% )

Upon activation of an alarm, the following actions must happen automatically,

1. Closing of slurry feed valve

2. Stoppage of centrifuge motor with a time delay which can be set by the
operator
3. More flow of N2 to the system

Remedial actions should be taken as per approved SOP to re establish the

system into operation

7. Oxygen Analyzer

The sensor of the O2 analyzer must be protected against direct contact with
liquid solvents or their mist. Frequent check is essential to purge the sensor of the O2
analyzer with ambient air to ensure that it reads correctly (calibration to 21% Vol.). This
frequency shall be validated on case to case basis. Defective sensor to be replaced and
necessary actions has to be initiated.

It must be ensured that the measured O2 concentration is in fact representative

of the actual concentration in the basket. Large air leakages into the basket may
mislead the measurements and care should be taken by technical means to check such
leakages and arrest them periodically.

Page 3 of 5
 CTO BEST PRACTICES Draft
Author: S.R.Pandian Supersedes Doc Date:
INERTING OF BASKET
Release Date: 25.09.08
CENTRIFUGES
Released By : Guideline No – CTO ENGG BP 001 ISSUE 1
Martin Ghosh

SCHEMATIC DIAGRAM FOR TOP DISCHARGE CENTRIFUGE INERTING

Page 4 of 5
 CTO BEST PRACTICES Draft
Author: S.R.Pandian Supersedes Doc Date:
INERTING OF BASKET
Release Date: 25.09.08
CENTRIFUGES
Released By : Guideline No – CTO ENGG BP 001 ISSUE 1
Martin Ghosh

LEGENDS

CV 1 PID CONTROL VALVE

CV2 ON / OFF CONTROL VALVE
FI FLOW INDICATOR
PS 1 PRESSURE SENSOR / TRANSMITTER

8. Sequence of control valve operation

All the control valves are in closed condition prior to start of the centrifuging operation.
The operator select the pre-flushing mode of inerting cycle in PLC before loading the
centrifuge. Valves CV1 and CV2 open and allow high flow of N2 into the system. The O2
sensor senses the presence of the O2 in the basket continuously and displays the same
in the HMI panel. The PS1 installed on the bearing housing N2 pipe measure the
pressure in the bearing housing and gives signal to close CV2 on the vent line and
ensure that the N2 pressure in the bearing housing is within the specified limit. PLC gives
a “centrifuge ready to load” display once the O2 % and the N2 pressure in the system
reaches with in the specified or “safe to operate” limits of the particular centrifuge. The
operator select the blanketing mode in the PLC now.

In the blanketing mode the PLC set the PID valves’ open position in the
minimum( predetermined % ) level and ensure a minimum flow of N2 is allowed to
maintain the required over pressure in the centrifuge basket and in the bearing housing.
CV2 will on/off depending upon the signal from PS1 to maintain the over pressure in the
system.

If the pressure in the system goes below the LOW LOW set point PS1 activate audio
visual alarm and simultaneously open CV1 to high flow levels to allow more N2 flow into
the system. If the pressure in th system reaches HIGH HIGH then CV2 open and release
pressure to vent and maintain the required pressure in the system.

CV2 installed on both the vent lines will go on and off to maintain the pressure in the
system. They remain close if the pressure in the system is within the specified limit. They
open if the pressure reaches HIGH HIGH set point. They will close once the pressure
drops down to HIGH set point.

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