OPERATION & INSTRUCTIONS

MANUAL
FOR
OXYGEN PLANT
(Capacity - 30 Nm3/Hr, 90-93 % Purity)

CLIENT:

M/s.

SUPPLIED BY:

M/S. AIRRO ENGINEERING CO.

PLOT No. : 476, G. I. D. C. MAJUSAR, SAVLI,
Vadodara – 391 775, Gujarat-India.
Phone No.: 02667 – 290376,
E MAIL: airroenggco@gmail.com
WEBSITE: www.airroengineering.com
 OPERATION MANUAL

NAME OF THE EQUIPMENT PSA OXYGEN GAS PLANT

CAPACITY 30 Nm3/hr. @ 90-93% Purity

Level.
CLIENT NAME

LOCATION

AIRRO JOB NO.

YEAR OF INSTALLATION 2021-22

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 INDEX
SR. NO. CHAPTETR
1. TECHNICAL SPECIFICATIONS

2. DESCRIPTION OF VARIOUS EQUIPMENTS

3. PLC CONFIGURATION

4. NORMAL START UP AND SHUT DOWN

5. IMPORTANT POINTS FOR TROUBLE FREE OPERATION

OF THE UNIT

6. TROUBLE SHOOTING OPERATIONS

7 PERIODIC MAINTENANCE

8. LOG SHEET OF NITROGEN GAS PLANT

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 CHAPTER – I

TECHNICAL SPECIFICATIONS

SR. NO. Parameter Value

1 FLOW RATE  30 Nm3/hr.

2 Composition O2 : 90-93 %( Min.)

Other Gas (Nitrogen): Less
Than 7%( Max. )

Dew Point: (-) 400 C.

3 Pressure in Final 4.5 Kg/Cm2g.
Outlet

4 Service Continuous

5 Gas quality Totally free from oil &

moisture
6 Utility
Requirement
Air Compressor 440 VAC 50 HZ 3 Phase
Power Required
Power Supply of 230 VAC, Single Phase
Ref. Dryer Supply
Power Supply of 230 VAC, Single Phase
Control Panel Supply

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 CHAPTER-II

DESCRIPTION OF VARIOUS EQUIPMENTS

1. AIR COMPRESSOR with Inbuilt REFRIGERATED AIR DRYER:

This is a rotary fluid air cooled stationary screw Air Compressor which compresses
air up to 7.5 kg/cm2g. Though air compressor is cooled but compressed air
temperature varies 15deg-20deg plus ambient,

The free air delivery of the compressor is 270 SCFM at normal working pressure of
7.0 Kg/Cm2g. If working pressure of the compressor exceeds 7.0 Kg/cm2g the
compressor is automatically unloaded by Electrical displayed unit also fitted sov. The
air compressor and Electric motor drive comp. & cap 270 SCFM @ 7.0 bars.
The condensate is extracted via an automatic condensate drain. After this, the
Compressed
Air is re-heated in the air-to-air heat exchanger. Finally, the Purified air leaves the
Dryer in warm and dry state.

 REFRIGERATED AIR DRYER:

The Ref dryer cools the hot, humid air delivered from the compressor in the two stage down 
to a pressure dew point +3 deg. C. in the first stage, the compressed air initially cooled by 
heat exchanger with the cold air existing from the dryer. Further cooling occurs in the 
second stage with the use of evaporating refrigerant. A highly efficient separating system 
connected in series with the second stage purifiers the compressed air by separating the 
condensed and contaminated water droplets formed by the refrigeration process. The 
condensate is extracted via an automatic condensate drain. After this, the compressed air is 
re‐heated in the air‐to‐air heat exchanger. Finally, the purified air leaves the dryer in

For details regarding operation and maintenance of the compressor, please refer
to the attached instruction manual of the compressor.

2. AIR RECEIVER:

The cold compressed air at 270 CFM, 7.5 Kg/cm2g and Temp. At 40°C after drainage
of moisture is taken to an air receiver to feed to the downstream system. This acts as a
temporary storage of air for cyclic consumption in the system. This Wet air receiver
is equipped with pressure gauge, safety valve, Needle Valve, ADT and manual drain
valve.
 The cold compressed air is taken to an impingement baffle type Air receiver. The
moisture laden air hits the baffle plate, moves downwards thereby draining the
moisture by gravity and then moves up with a relatively low velocity.

An automatic drain trap drains off the moisture in pre-set intervals as controlled by an
asynchronous timer.

3. OIL FILTERS:-

Three Stage Oil filters are provided in the series for removing of oil, Dust & water
practical in Compressed air inlet.

 1ST STAGE FILTER :

This is a Pre Filter in Compressed air line provided with filter element of
Borosilicate fiber type filter element. This is required to restrict the flow of
dust/foreign particle and physical water droplets with the compressed air supply.
Filtration level 1.0 micron at 99% efficiency. In this filter lot of moisture get
condensed, therefore manual drain valve are provided at the bottom of pre filter.
Flow direction of air should be outside to inside the filter element.

 2ND STAGE FINE FILTER :

This is important to make the compressed air supply absolutely free from dust
/foreign particle and tiny water droplets. For the purpose Borosilicate Fiber
element is used in fine filter to clean the air up to 0.01 micron level at 99%
efficiency. There is manual draining valve at the bottom to check for any water/oil
accumulation in the unit. It is important to take care the flow direction of the
compressed air line should be inside to outside in the fine filter elements after the
maintenance/check-up or replacing.

 3RD STAGE FILTER :

This is important to make the compressed air supply absolutely free from dust
/foreign particle and tiny water droplets. For the purpose Borosilicate Fiber
element is used in carbon filter to clean the air up to 0.003 micron level at 99%
efficiency. There is manual draining valve at the bottom to check for any water/oil
accumulation in the unit. It is important to take care the flow direction of the
compressed air line should be inside to outside in the fine filter elements after the
maintenance/check-up or replacing.

Note: -Filter Elements should be replaced when the differential pressure

(between Air Receiver & PSA) is high (Pr. Drop Max- 0.5 Kg/cm2G). The Filter
Element should be replaced at an interval of 8000 hour of operation or 1 year
whichever is earlier.
4. PSA UNIT

The dry compressed air is now taken to a twin tower PSA Unit consisting of
Molecular Sieves. Two vessels are filled with special grade of alumina and
Molecular Sieves to adsorb moisture, Nitrogen & CO2 present in air. Each tower
has air inlet valves (VI & V2) bottom and exhaust outlet valves (V3 & V4) at the
bottom. Besides these, a valve V5 is for Pressure equalization at the top. The air
inlet line from air receiver has one (1) No globe valve to control the flow of air so
that the pressure in the adsorbing towers goes to 5.0-6.0 Kg/Cm2g. Separation of
oxygen from air is based on selective absorption of oxygen particles in Molecular
sieves at high pressure. The adsorbed oxygen for sequential operation of valves,
please refer attached drawing -TIMER -PSA (Sequence Chart for PSA Unit), which
is explained as under: At the time when Tower I is in operation valves V-1 (Inlet
valves of Tower –I) V-4 (Exhaust valve of Tower –II) are open. Air enters in
Tower I from V-1, N2 gets adsorbed as the air passes to top of tower and product
O2 comes out from NRV. At end of Cycle, V-1, & V-2 will close (Air inlet valve
Tower –I) and V-3 & V-4 (Exhaust valve of Tower- I) also Closed & V-5
(Equalization t valve) will open. This is the condition when there is NO AIR
INLET, NO Exhaust. This is called PRESSURE EQUALISATION. After
Cycle Change over Cycle, Then V2 (Air Inlet Valve) & V-3 (Exhaust valve of
Tower I) are open. Air will enter Tower II and O2 will start coming out from NRV.
This is called CHANGEOVER.

5. OXYGEN SURGE VESSEL:

Oxygen from PSA Module will have varying purity depending upon the pressure in
the adsorber during the one minute cycle time. This vessel gives product Oxygen at
constant pressure with constant average gas purity. One pressure gauge, one number
safety valve & one No. Manual drain valve are fitted with vessel. For analyzing the
O2 percentage in the gas, one Needle Valve for Sampling is provided over the vessel.

6. SHUTOFF VALVE:

Shutoff valve is a pneumatically operated 2-way valve. Thus when the gas generator
is started the gas initially of low purity will then valve will be closed. The solenoid
valve will get energized after checking the quality of product gas for some time Valve
is on position & gas goes to surge vessel

7. OXYGEN ROTAMETER

This is an Acrylic body Type Oxygen Rota meter fitted at the outlet of the surge
vessel. This constantly indicates the amount of Oxygen being fed to the purification
system. One (1) No globe valve is fitted at the inlet of Rota meter to control the flow
of Raw Oxygen.
8. PERCENTAGE OXYGEN ANALYZER/TRANSMITTER:

To monitor Oxygen content in Oxygen Gas produced from the PSA, an ON LINE
percentage oxygen analyzer is installed. This analyzer is having a resolution of 0.1%.
Sample is fed to the Analyzer from the outlet line of surge vessel. In case of Lower
Oxygen percentage than the set point, the analyzer will generate signal to rise. Visual
alarm and open 3 way vent valve to the atmosphere. This will prevent passage of gas
of high Oxygen content to your system and thus spoilage of product.

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 CHAPTER – III

PLC CONFIGURATION
The lists of inputs / output address are given below.

A-Digital Input:
S. No Input Description ADD
1 Spare All DI - Spare

B-Analog Input Card -1:

S. No Input Description ADD

1 Oxygen % AN 0.0
2 PT -1 Air Receiver Pressure AN 0.1
3 PT -2 O2 Storage Tank Pressure AN 0.2

C-Digital Output:

S. No Input Description ADD

1 Valve (PV1 & PV4) Relay R1 Q-0
2 Valve (PV2 & PV3) Relay R2 Q-1
3 Valve (V5 ) Relay R3 Q-4
4 Shut off Valve Q-7

A) LIST OF TRIPPING INTERLOCKS WITH ALARM:

1. PSA SEQUENCE WILL TRIP ON: (Out –Q-0 to Q4)

 Air Receiver Pr. Low –AN0.1

 O2 Storage Tank Pr. High.- AN-0.2

2. SHUT OFF VALVE ON: (Out –Q-7)

 Oxygen Percentage low –AN0.0

FAULT & STATUS MESSAGES ON COMPONENT HMI SCREEN (GXU

3512 HMI – 7” Display)

FAULT MESSAGES: - (ONLY THE MESSAGE IS TO BE DISPLAYED ON

SCREEN, NOT THE INPUT/OUTPUT OR IT’S CONDITIO
SL MESSAGE INPUT/OUTPUT CONDITION
1 Air Receiver Pr. Low AN0.1 NOT AVAILABLE
2 O2 Tank pr. High AN-0.2 NOT AVAILABLE
3 Oxygen Percentage low AN-0.0 NOT AVAILABLE
 B) Value of Tripping Interlocks:

SL MESSAGE INPUT/OUTPUT CONDITION

Analogue Input Valve
1 AN -0.0 AVAILABLE
Oxygen PERCENTAGE
(Range 0-100%)
Only Alarm Indication 4-20 mA
2 AN -0.1 AVAILABLE
Air Receiver Pr.
(Range -0-16 Kg/cm2 G)
In case Air Receiver Pr. Less then 4.5-5.5
Kg/cm2 G PSA Seq will be trip &
Pressure Increase 4.5 Kg/cm2 G PSA Seq
Start Automatic 4-20 mA
3 AN-0.2 AVAILABLE
O2 Storage Tank Pr.
(Range – 0-16 Kg/cm2 G.
In case O2 Storage Tank Pr. High 4.0. To
4.5 Kg/cm2 G (AS per Customer
Required, PSA Seq will be trip &
Pressure Decrease 0.5-1.0 Kg/cm2 G PSA
Seq Start Automatic 4-20 mA

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 CHAPTER – IV

NORMAL START‐UP AND SHUT‐DOWN

The area near the unit should be kept clean.

1. Check that all electrical are O.K. Power and Control panel is getting power supply.

2. Check the Zeroing of all instruments.

3. Ensure that manual drain valves of all equipment are closed.

4. Switch ‘ON’ the main switch & control supply switch and open water
5. Line valve and ensure that the water pressure is about 1.5 Kg/Cm2g.

6. Start the air compressor and Refrigeration Air Dryer

7. As soon as air receiver pressure reaches 5.5 Kg/Cm2g, the sequence of PSA Starts
automatically.

8. Observe the operation of the Units for some time and see that the PSA module is
working all right. Check that the pressurization and depressurization of towers are
O.K.

9. Check the maximum pressure in the adsorbing towers of PSA unit goes to 6.0
Kg/Cm2g. If required, control that airflow by the globe valve V6 provided just at the
air inlet into the PSA module. Settings should be disturbed only after watching the
result for 15-20 minutes.

10. Check and control the Globe valve V7, to produce the desired Oxygen Flow rate.

11. After the pressure in Oxygen Buffer tank has reached up to 4.0 – 4.5 Kg/Cm2G. open
and set the globe valve in Oxygen line Rotameter for desired oxygen flow
12. (Maximum 30 Nm3/ Hr).

13. Check that the purity of raw oxygen is at-least 90-93. %, i.e. percentage

B) NORMAL SHUT DOWN:

1. De-pressurize system by opening various drain valves. However, if the plant is to

be restarted within 2-3 hours, it is not required.
C) EMERGENCY SHUTDOWN
In case of any emergency:
- Switch-off main MCCB.
- *****************
 CHAPTER – V

IMPORTANT POINTS FOR TROUBLE FREE OPERATION

OF THE UNIT

1. Check and ensure that all valves of PSA module are opening/closing properly and
maximum pressure in both absorbers goes to 5.0 to 6.0 kg/Cm2g. and time sequence is all
right. Check and ensure the changeover of towers and working of valves are proper.

2. A logbook should be maintained in which all operating conditions should be recorded

after regular intervals of 1 hour.

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 CHAPTER – VI

TROUBLE SHOOTING OPERATIONS

This Chapter widely covers the troubles associated with the operation of the Oxygen plant
and the process involved in Oxygen production. The interlock list for the plant should also be
referred as most of the troubles are due to non-fulfillment of interlock conditions. For
component level trouble shooting i.e. trouble shooting of Air Compressor, Analyzers, etc.
separate manuals provided for individual components/equipment shall be referred in detail.

1. TROUBLE SHOOTING OF PSA UNIT.

A. Malfunctioning of PSA Valves.

 Check PLC Signal. Wiring may be loose.

 Check Supply to Coil of Solenoid valve. Field wiring may be loose.
 Check Instrument air pressure and air signal to solenoid valve. Choking may
be there in Instrument air tube.
 Check that the coil of solenoid valve is OK. Coil may be damaged.
 Check that the plunger of solenoid valve is working. Plunger may be chocked due to
dust not allowing the air to pass to the actuator of the valve.
 Check exhaust port of Solenoid valve.
 Check for the operation of Change over Valve. May be Leakage.
B. Towers not pressurizing

 Check if V1 & V2 (Air inlet valves) remained in closed Condition due to conditions
stated above
 Check whether the air inlet valve is open or not.

C. Towers not De-pressurizing

 Check Operation of V3, and V-4 (Individual exhaust valves and Common exhaust
valve)

D. PSA Module working all right but Raw oxygen flow from Buffer Tank
gradually decreases to zero

 Buffer Tank inlet Manual globe valve V-8 is in closed condition.

E. PSA Module seems to work properly but flow from Oxygen Buffer Tank is low
with
LOw Oxygen Percentage.
 Check production valves NRV-1 & NRV-2 of individual towers. One may be in
closed condition due to failure. This will lead to production through one tower only,
no pressure equalization, and no back flow to one tower from Buffer Tank.

F. Buffer Tank pressure too high

 Back flow NRV (Non Return Valve) may be leaking heavily, check & replace
 Very low consumption of Raw Nitrogen from Buffer Tank.
 Pressure indicator not working properly.

G. Functioning of PSA Valves all right but low pressure in Buffer Tank.

 Leakage may be there through pipelines or flanges.

 Pressure gauge may be faulty.
 Check whether PSA valve is opening properly or not.
 Inlet globe valve of Buffer Tank may be chocked.

H. Oxygen Percentage low

 Any of the PSA valves not functioning properly.

 Control of air input or raw nitrogen improper. Check and retune.
 PSA beds may not be sufficiently tight.
 Air compressor after cooler not working efficiently and inlet air temperature is high.
 Check leakages in the Oxygen line and from the top of PSA towers. Since the
rotameter is installed at the outlet of the PSA system, any leakage will add on to the
quantity of the gas flowing out of the system and hence result in running the system
in over capacity.

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 CHAPTER – VII
PERIODIC MAINTENANCE

1 Daily checks
1a Daily checks refer to religiously maintaining an hourly log sheet.
Certain maintenance and check activities can neither be scheduled nor be
anticipated, say failure of a solenoid coil or seat leakage of a changeover valve.
Maintaining a log sheet immediately reflects that there is an abnormality or change in
operating parameter, compared to previous parameters and the required component of the
system can be immediately located and attended by maintenance staff.
Log sheet enables the monitoring of all the components of the plant, may it be
a mechanical, electrical, and instrumentation or process component. To mention a few, log
sheet ascertains the following:
 PSA sequence is working properly.
 Operations of changeover valves of PSA are in order.
 Operation of Oxygen Analyzer are proper.
 System is producing gas as per desired quantity and quality.
1b Check At least once in a shift, operator should witness and record the
drainage from all the manual drain valves should be opened to drain out the moisture.
2 15 days checks, maintenance and replacements
2a Check and stop leakages of instrument air from any SOV or Instrument Air
tubing.
3 Six monthly checks, maintenance and/or replacements
3a Open & clean 3 stage Filter Element to avoid exceed Pressure drop. Filter should be
replaced after 3-4 cleaning.
3b Condition of non-return valves should be assessed by change in operating parameters
across the non-return valve. Any abnormality should be brought into the notice of
maintenance personnel immediately.
Even in case of no abnormality, condition of non-return valves should be checked in every
six months. If required, non-return valves to be replaced.
3C Check all interlocks in the system properly working.
3d Check availability of spare part in stock for smooth functioning of the system
4 Yearly checks (and replacements) :
4a Replacements of following to be carried out strictly on “8000 hours of operation or 1
years whichever is earlier” basis:
 Element of 1st stage Oil Filter
 Element of 2nd stage Oil Filter
 Element of 3rd stage filter
4b Following instruments should be calibrated every 6 Month
 Oxygen Gas Analyzer (percentage Type )
4c Do Testing of all Change Over valves of PSA unit Change Over Valve, if found leakage,
arranged serviced or replaced such valves.
4d Check availability of spare part in stock for smooth functioning of the system.

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LOG SHEET FOR Oxygen PLANT-SHEET-1/1

DATE & SHIFT: INSTRUMENT TIME

LOCATION
AIR COMPRESSOR-1
OUTLET PRESSURE- INTILLISYS
BAR G
OUTLET TEMP. OC INTILLISYS
PSA MODULE-1
AIR RECEIVER. PRESS. - F
KG/CM2G
PSA TOWER-1 PRESS. - F
KG/CM2G
PSA TOWER-2 PRESS. - F
KG/CM2G
SURGE VSL’ PRESS. - F
KG/CM2G
OXYGEN CONTENT- % CTR’ PANEL
O2 Flow F

SIGN OF OPERATOR SIGN OF SHIFT INCHARGE