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    Vol 9.Om.st-mech (n2 Storage&Dist Sys-h2 Plant-standby Eng Gen-hvac Sys-wwt Sys)

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    Vol 9.om - St-Mech (n2 Storage&Dist Sys-H2 Plant-Standby Eng Gen-Hvac Sys-Wwt Sys)

    Uploaded by

    ika yuliyani murtiharjono

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    PT PLN (PERSERO) | CILEGON COMBINED CYCLE POWER PLANT (740MW) CONTRACT NO.:0136.PJ/060/DIR/2004 e OPERATION MANUAL (ST HRSG BOP PART) ® MECHANICAL VOLUME-9 Nu-05036 R-1 CONTRACTOR : MITSUBISHI CORPORATION MITSUBISHI HEAVY INDUSTRIES, LTD. MITSUBISHI ELECTRIC CORPORATION RECORD OF CHANGES DOCUMENT NUMBER: NJ-05036 Revision | Date Title and Brief Description Remarks | Entered No. by — | 2006/02/14! issued Design Manual, Operation Manual & Maintenance Manual for Steam Turbine/HRSG/BOP Part. 1 | 2006/08/11 | Fully revised Steam Turbine JHRSG/BOP -Part including the responses to Customer's comments. oe METS UEISH IMPORTANT INFORMATION © These documents are intended for the use by operating and maintenance personnel and must be accessible to them at all times. © Do not perform any operation or maintenance on this system until you read and understand all instructions in these documents. O You must comply with all applicable laws, codes and local regulation. © Only qualified personnel must work on or around this system after becoming thoroughly familiar with all warnings, safety notices, operating procedures, and maintenance procedures contained herein. © Employers must implement all training and safety requirements mandated by national standards and local governing agencies. © Mitsubishi Heavy Industries, Ltd. (herein after referred to as MHI) cannot anticipate every possible circumstance that might involve a potential hazard. The warnings in these documents and on the equipment are therefore not all inclusive. © Improper operation or maintenance of this system can be dangerous and could result in injury or death. © Ifa procedure, work method or operating technique not specified in this manual is used, you must satisfy yourself that itis safe for you and others. ‘You should also ensure that the system will not be damaged or made unsafe by the method of operation or maintenance procedure you choose. © Itis assumed that this system will be operated and serviced by English speaking personnel. If this is not the case, the customer should add safety, caution, and operating signs in the native language of the operating and maintenance personnel. © Should particular problems arise which are not covered sufficiently for the intended purposes in these documents, you should refer to following: Mitsubishi Heavy Industries, Ltd. ‘Takasago Machinery Works 4-4,Arai-cho, Shinhama 2-chome, Takasago City, Hyogo,Japan 676-8686 © These documents are placed at your disposal for your own use only and may not be copied, nor reproduced in hard copy or any electric medium. The copyright remains with MHI. ‘MHI Propristary information i MITSUBISHI LIMITED WARRANTY The warranty contained in the Contract between the parties is the sole warranty of MHI. Any statements contained herein do not create new warranties or modify the existing warranty. MHI DOES NOT WARRANT AND IS NOT RESPONSIBLE FOR: DAMAGE CAUSED BY FAILURE TO PROVIDE A SUITABLE OPERATING ENVIRONMENT FOR THE SYSTEM; © DAMAGE CAUSED BY FOREIGN OBJECTS, DROPPING, FALL, SPILLED LIQUIDS, OR IMMERSION INLIQUIDS OR GASES; ‘© DAMAGE CAUSED BY A POWER SURGE OR IMPROPER SUPPLIED UTILITY; © DAMAGE CAUSED BY ATTACHMENTS, ALTERATIONS, OR MODIFICATIONS WITHOUT MHI'S WRITTEN APPROVAL; © DAMAGE FROM IMPROPER OPERATION OR MAINTENANCE; © DAMAGE CAUSED BY ANY ABUSE, MISUSE, MISHANDLING, OR MISAPPLICATIONS; © PRODUCTS OR SERVICES OF COMPANY OTHER THAN MHI OR MHI AUTHORIZED COMPANY. © DAMAGE CAUSED BY UNSPECIFIED UTILITY CONDITIONS SUCH AS TEMPERATURE, PRESSURE, FLOW RATE, CONCENTRATION AND QUALITY; © _DAMAGE CAUSED BY ANY BUGS IN THE MEMORY CHIPS OR OPERATING SOFTWARE. OTHER THAN MHI'S SOFTWARE; ‘MH! Propristary Information ii de MUTSUBISH— SAFETY INSTRUCTION General Safety Rules © This system contains hazardous voltage, rotating parts, high pressure, high temperature, chemical and noise. © During operation and maintenance, extreme caution must be exercised for personnel to be in proximity of potentially dangerous mechanical and electrical devices. © Never operate any equipment unless all guards and safety devices are in place and in proper operating conditions. © Keep the area well maintained at all times. © Most accidents involving system operation and maintenance are caused by failure to observe basic safety rules or precautions. © Wear appropriate work clothes, gloves, shoes or boots, hard hats and eye protectors in accordance with customer's Personal Protective Equipment Program. © Incase of an accident while running, shut down the system immediately if required. © MSDS (Material Safety Data Sheets) should be filed for easy access, and safety & handling instruction should be followed. © Operate the system in accordance with customer's Health and Safety programs. © Make reports for any improper operation, misoperation of system, especially safety devices and repair records. Return tools to their proper places after use. ‘Wam others of an intended action that may endanger them. oO ° © Do not remove safety devices. © Do not start the system unless you are sure there is no danger to you and others. ° Do not leave unattended equipment in an unsafe condition. ‘MHI Proprietary Information ili © General Safety Rules (Cont.) of Signal Words} In these documents and on the product, ea DANGER indicates immediate danger and that special precautions are necessary. CAUTION indicates warning against potential hazards or caution against unsafe practices. ‘MH! Proprietary Information iv Short Contents INDONESIA PLN CILEGON C/C OPERATION MANUAL (R-1, ST HRSG BOP PART IMPORTANT INFORMATION i LIMITED WARRANTY SAFETY INSTRUCTIONS iii ‘SECTION 1 SECTION 2 SECTION 3 SECTION 4 GENERAL POWER PLANT MECHANICAL ELECTRICAL Contents VOLUME SECTION DESCRIPTION PAGES. 1 1 GENERAL 44 GENERAL INFORMATION ON OPERATION 11-1 2 2 POWER PLANT 24 OPERATING PROCEDURE 21-1 22 PRINCIPAL OPERATING LIMITS 22-1 23 REQUIRED ACTION AT EMERGENCY 2.3.41 GENERAL 23-1 2.3.2 STEAM TURBINE 23-3 2.3.3 BOTTOMING CYCLE 23-47 24 CONTROL SETTING (INCLUDING ALARM & TRIP SET POINTS) 244 STEAM TURBINE RELATED EQUIPMENT 24-1 2.4.2 BOTTOMING CYCLE 24-3 25 HRSG OPERATION 2.5.1 FUNCTIONAL DESCRIPTION OF CONTROL 25-1 25.2 OPERATION GUIDELINES 2.5.2.1 GUIDELINES FOR HRSG START-UP OPERATION 25-35, 2.5.2.2 PREDICTED START-UP AND SHUT-DOWN 25-37 PERFORMANCE GUIDELINES OF HRSG CONTROL. 26-42 HRSG PREDICTED PERFORMANCE 25-43 GENERAL PRECAUTION 25-44 PRECAUTION DURING OPERATION 25-46 BLOW-OFF PROCEDURE 26-49 PRESERVATION PROCEDURE 25-50 CONTROL SETTING 28-51 (INCLUDING ALARM & TRIP SET POINTS) Contents VOLUME SECTION DESCRIPTION PAGES: 3 3 MECHANICAL 3.4 OIL SYSTEM 3.44 CONTROL AND LUBE OiL SYSTEM 34-1 32 CONDENSATE WATER SYSTEM. 3.2.1 CONDENSATE PUMP 32-4 3.2.2 CONDENSER VACUUM PUMP. 3.2- 39 3.2.3 MAKE UP WATER PUMP 3.2-101 3.3 FEED WATER SYSTEM 3.3.1 HPAP FEED WATER PUMP. 33-1 3.3.2 LP FEED WATER PUMP 3.3-331 4 34 CIRCULATING WATER SYSTEM 3.41 CIRCULATING WATER PUMP 34-1 342 CWP LUBE WATER PUMP 3.4-169 3.43 SEA WATER BOOSTER PUMP 3.4-221 3.4.4 CONDENSER TUBE CLEANING SYSTEM 3.4-289 3.4.5 CONDENSER DEBRIS FILTER 3.4-323 3.46 CWPRIMING PUMP 3.4-547 3.5 ST CLOSED COOLING WATER SYSTEM 3.5.1 ST CLOSED COOLING WATER PUMP 35-1 5 3.6 MAIN CYCLE CHEMICAL INJECTION SYSTEM 3.6-1 37 SAMPLING SYSTEM & CONDENSER TUBE LEAK 37-1 DETECTOR 6 3.8 FUEL GAS TREATMENT PLANT 3.8-1 3.9 HSD FUEL-OIL UNLOADING STATION 3.9-1 3.10 DESALINATION PLANT 3.10-1 7 3.11 DEMINERALIZED WATER SYSTEM 3.14.1 DEMINERALIZED WATER SYSTEM 311-1 3.11.2 DEMINERALIZED WATER TRANSFER PUMP. 3.41-2 3.12 SERVICE WATER SYSTEM 3424 SERVICE WATER PUMP 312-4 3.13 INSTRUMENT AND SERVICE AIR SYSTEM 3.13.1 INSTRUMENT AND SERVICE AIR COMPRESSOR 3.13-4 3.13.2 INSTRUMENT AIR DRYER 3.13-185} 8 3.44 FIRE FIGHTING SYSTEM 314-4 9 3.15 NITROGEN STORAGE AND DISTRIBUTION SYSTEM —3.15- 1 3.16 HYDROGEN PLANT. 3.16-1 3.17 STANDBY DIESEL ENGINE GENERATOR 3.17-1 3.18 HVAC SYSTEM 3.18-1 VOLUME 9(Cont.) 10,14 12 13,14 14 15 16 17 SECTION 3.19 3.20 3.21 3.211 3.21.2 3.21.3, 3.22 3.23 3.23.1 3.23.2 3.24 3.25 3.26 441 444 4.2 4.3 4.3.4 4.3.2 4.3.3 4.34 4.3.5 4.3.6 44 444 442 45 46 47 474 472 DESCRIPTION WASTE WATER TREATMENT SYSTEM AUXILIARY BOILER SCREEN SYSTEM STOP LOG & STORAGE BAR SCREEN & TRAVELING TRASH RAKE Contents PAGES, 3.19 4 3.20- 1 3.21-4 3.21-27 TRAVELING BAND SCREEN & WASH WATER DEVICE = 3.21-105} CHLORINATION SYSTEM CATHODIC PROTECTION SYSTEM 3,22-1 CATHODIC PROTECTION SYSTEM FOR FIELD PIPING 3.23-1 CATHODIC PROTECTION SYSTEM FOR CIRCULATING 3.23-15 WATER SYSTEM POTABLE WATER CHEMICAL INJECTION SYSTEM. HSD FUEL OIL TREATMENT SYSTEM SUMP PUMP: ELECTRICAL GENERATOR GENERATOR AND GENERATOR AUXILIARY (STG) PT & SACUBICLE CONTROL PANEL SYSTEM DESCRIPTION EXCITATION CONTROL PANEL (EXC, AVR} GENERATOR CONTROL PANEL GENERATOR PROTECTION RELAY PANEL ‘TRANSFORMER PROTECTION RELAY PANEL SEAL CIL CONTROL PANEL TRANSFORMER ST GENERATOR TRANSFORMER, LV TRANSFORMER ISOLATED PHASE BUSDUCT NIA 6.3KV MV SWITCHGEAR: MC SET-INSTRUCTIONS FOR USE. LF DRAW-OUT CIRCUIT BREAKERS-INSTRUCTIONS FOR USE 3.244 3.25-1 3.261 44-4 44-3 424 43-1 43-3 43-39 43-137 43-385, 43-937 43-1397 44-1 44-3 44-9 45-1 47-1 47-3 4.7-51 17(cont.) 4.7.3 ATA 475 48 48.1 4.8.2 49 49.1 49.2 4.10 18 4.41 4.12 4.13 4.14 4.15 19 4.16 447 418 20,21,22 4.19 VOLUME SECTION DESCRIPTION MC SET METAL CLAD SWITCHGEAR-CATALOGUE 2003 SEPAM-PROTETION RELAY FOR MC SET METAL CLAD SWITCH GEAR HIGH SPEED BUS TRANSFER RELAY-BECKWITH MODEL M-0272-0236B RELAY 380V LV SWITCHGEAR, BLOKSET-INSTRUCTION MANUAL LV POWER CIRCUIT BREAKERS-MASTERPACT NT AND NW-CATALOGUE 2003 380V MCC BLOCSET-INSTRUCTION MANUAL, LV POWER CIRCUIT BREAKERS-COMPACT NS. CATALOGUE 2002 AC DISTRIBUTION PANEL DC SYSTEM UPS SYSTEM AUXILIARY MOTORS COMMUNICATION SYSTEM CLOCK SYSTEM LIGHTING SYSTEM CLOSED CIRCUIT TV SYSTEM ST DC STARTER PANEL 150 KV SUBSTATION Contents PAGES 4.7.91 47-147 4.7-239 48-4 48-3 4.8-75 49-1 49.3 4.9-75 410-1 4114 412-1 413-1 414-1 415-1 416-1 417-1 418-1 449-1 de MIT SURESH 3 MECHANICAL ‘MEI Proprietary Information 3.15 NITROGEN STORAGE AND DISTRIBUTION SYSTEM KKS NUMBER : 10QJA01SS101 ‘MHI Proprietary information MINIMAX GmbH & Co. KG Region Intemational CC Special Syetoms 1D-25840 Bad Oldesloo [pecumeraron Minimax Operating and Maintenance Instruction Ne-GAS SUPPLY SYSTEM FOR INERTIZATION e i i ! | i I HLL Ce VILLé | Hank) oe) | i: e@ = et Document 1_010366-10 O8M manuel doe Pov. 2 Side tof 9 315-1 MINIMAX GrabH & Co, KO DOCUMENTATION Ee Specat sys ° Desoto Bas Guesoe Table of contents TABLE OF CONTENTS 0 GENERAL 3 Identification 3 Manufacturer - Supplier 3 ‘Technical Support: 3 1. PURPOSE OF DOCUMENT 4 e 2. OPERATING PERSONNEL 4 3, DESCRIPTION OF PLANT AND DESIGNATED USE 5 4, DESIGN AND FUNCTION 5 5. TECHNICAL DATA OF N,-SUPPLY SYSTEM 6 6. INSTALLATION x 7. COMMISSIONING OF THE Nz-GAS SUPPLY SYSTEM 9 ‘Document 1_010866-10 08M marual.doe Rew. 2 Side 2ot 8 315-2 MINDAAX GmbH & Co. KG DOCUMENTATION MmIinimAx saben inert i236 Bad Cidesion General Identification Type of plant: Na-GAS SUPPLY SYSTEM Minimax Job-Nc 1-010366 Customer: MITSUBISHI HEAVY INDUSTRIES, LTD TAKASAGO MACHINERY WORKS. Customer PO No.: A1FP-Cl-9K-7370M02036 Plant: CILEGON PROJECT 740 MW C/C POWER PLANT, INDONESIA Year of construction: 2004 Date of documentation: 26. September 2004 Manufacturer - Supplier Company: Minimax GmbH & Co. KG Department: CC Special Systems, International Village: D-28840 Bad Oidesioe Technical Support: Phone: +49 4531 803-989 Fax: +49 4531 803-120 From our Singapore Branch: 25 International Buisness Park : 03-59/60 German Centre SINGAPORE 609916 Phone: +65 6562 - 8632 Fax: +49 6562 - 8699 Person in charge Mr. Roland Bittner (Project Manager) DID: +65 6562 - 8637 Document 1_010366-10 O&M manual. doc Rev. 2 ‘Side Sof 9 3.15-3 MINIMAX GmbH & Co, KG DOCUMENTATION MinimAx Cees 1, Purpose of Document ‘These Instructions including the enclosed material like = Operation & Maintenance Instructions - Data sheets = Certificates of the used equipment are designed to famillarize the user and operator with the plant and its designated use. \ The instruction manual contains important information on how to operate the plant safely, properly and most efficiently. Observing these instructions helps to avoid danger, to reduce repair costs and downtimes and to increase the reliability and life of the plant. The instruction manual is to be supplemented by the respective national rules and regulations for accident prevention and environmental protection. ‘The used position numbers in this manual refer to the general arrangement drawing and the parts list (1-010366-010). 2. Operating Personnel “These operating instructions must be read and applied by any person in charge of carrying out work with and on the plant. In addition to the operating instructions and to the mandatory rules and, regulations for accident prevention and environmental protection in the country and place of use of the machine/plant, the generally recognized technical rules for safe and proper working must also be observed. © 2004 Minimax GmbH & Co. KG, D-28840 Bad Oldesioe All rights reserved Reprint also in parts are only permitted with the approvel of Minimax GmbH & Co KG Document: _010366-10 O&M manual. doe Rav. Side 4of 9 4 315-4 MINIMAX GmbH & Co. KO Minimax Piatt 1.25040 Bad Oleesioe DOCUMENTATION 3. Description of Plant and designated use The N,« Gas Supply System can be used! for the following purposes: = to render inert areas to protect them against fire or explosion ~ to il Ne-Gas inside of steam pipe or equipment to prevent the condensate water from corroding during long term preservation. Using the plant for purposes other than those mentioned before is considered contrary to its designated use. 4, Design and Function ‘The gas supply ensure gas cylinder bottles stored horizontal in steel racks. The charging of bottles and racks will be done manually by the bottle Isolation valves respectively by the blocking valve to the bottle rack. Each rack can be removed without bottles dismantled from the rack for charging by means of unscrew the union at the ball valve which belongs to the respective bottle rack. The system can be used one or more bottle racks Close the blocking valve which belongs to the bottle rack before unscrew the union Important The cylinder bottles feed all one common manifold, The maximum pressure caused by the bottles amounted 200 bar. This pressure will be reduced by two pressure reducing stations from 200 barg to 5 barg and 6 barg to 1,6 barg. Tha requirement at the terminal point is 200 Nmh at 1,5 barg. The pressure reducing stations and their components are protected with safety valves. For correct operation and adjustment of the pressure reducing stations and its components the individual data sheets of components, which are part of the documentation, have to be read and observed. ‘Document: 1_010486-10 O&M manualdoe Pov. 2 Side Sot 9 3.15-5 Length (per reducing Suciridity Pressure Heduclhg'Station: inlet pressure”. Dee ; pisses oe 9 : ‘Satety valve (downline) 25. Dak lowoff reed Ferminalpoit (tit of Supply Minima) ‘Screw ANS! Flange 2° {BNS@), ocuront: {_010986-10 O&M manual. doe Rev Side Gof 9 3.15-6 DOCUMENTATION MINIMAX GrobH & C0. KG MIinimAx Sep re 10-20040 Bad Olsesioe 6, Installation @ installation has to be carried out by means of the arrangement drawing 1_010366-010. le racks and pressure reducing stations as well as its equipment are fested and and align the bottle racks and the pressure reducing station according to the erent drawing 1_010366-010 in the provided location. Pos. 200, 210, 220 and 280 ha to be installed according to arrangement drawing. For floor fixing of the steel frames lise according to drawing. Ifthe pipe system is connected corect stations are aligned according to the arra the bottle racks as follows: the wedge screw and washer (Pos. 720 and 720) and the bottle racks and pressure reducing igement drawing the cylinder bottles can be lald in Begin with the two bottom distance spacer (Ros. 190) and put them onto the U:Stee! Pay attention that the distance spacer lays setyre completely on the U-steel. ‘The measurements 259 and 392 shall be kept approximately to secure a proper bending radius of the Nz-hoses. Use a hammer if hecessary to correct the measurement by hit the wooden spacer accordingly, 259 | [12 Bottles Storage Rack No.1 12 Bottles Storage Rack No.2 32 Document: 1_010886-10 O&M manual doe Rev.2 Side 7ot 9 315-7 Lay the first three Nz-Gylinder onto the spacer. the arrangement drawing. The axis of the isolation valve.qust be the same as the pipe manifold (2 - DN5O). (See arrangement drawing - Put the middle distance spacer (Pos\{80) onto the bottles beside the clamping screw M20. ‘ill all twelve cylinders are stacked - Install the top sunshade (Pos. 130} and use a second nut M20 (Pos. 740) to fix it for the end side of the 780 and Pos 760) to = Alter laying of all Ne-Cylinder install the two sunshade (Pos. six bottle racks. Use the hexagon screws with nut and washer (I fix the sunshade sheets. + Screw on all hoses onto the Nz-Cylinder isolation valves (W24,92x1/14").and the check valves (3/4") of the manifold ‘Whefi the piping and the bottles with hoses are installed correctly the system is now ready for commissioning. Document: 1_010966-10 O8M marual. doo Rov. 2 Side Bot 8 3.158 ‘MINIMAX GmbH & C0. KG pocumentaTion | FTLIMIMAX Peer tenato (0-75840 Bad Oldasioo 7. Commissioning of the N-Gas Supply System Before carrying out any commissioning, inform the authorities in charge. Check the following points before starting commissioning work 1, Make sure that all piping is connected properly according to the General Arrangement Drawing. 2, Make sure that all hoses are installed property. 3. Make sure that all ball valves are in closed position (Ball Valve: Pos. 420, 490, 440, 450, 460, 470, 480, 490, 500, 510, 520, and 630) Commissioning: ‘Open the Nz-Cylinders by means of the isolation valve. ‘Open the ball valve corresponding to the bottle rack (@.g. Ball Valve Pos. 470 for bottie rack 6) The remain content of a Nz Gylinder bottle can be calculated approximately by means of the prossure gatige 620 and the ambient temperature. For the commissioning ofthe primary and secondary pressure reducing station see the individual data sheets of the pressure reducing valves. For the primary pressure reducing station Data sheet 1_010366 - 200 of U13W6G and For the primary pressure reducing station Data sheet 1_010386 - 300 of K32 The documentation of the involved equipment attached to this documentation has to be observed aiso. Important Document: 1_010966-10 O8M marual doc Rev.2 Side 9of 9 315-9 Intentionally Blank 315-10 Installation, Operation and Maintenance Instructions Pressure Reducing Valve Model: U13 W6G Document; 1_010366-200.doe Rrov.2 Side 1 of 9 70 315-11 Pressure Reducing Valve (PRV) ‘Accurate working gas regulator for constant gas pressure. Even at extreme pressure drops and throughputs. Type + Tectron Model : UIs Wea Manufacturer: MESSER OrderNo, =: 717.06916 Pressure Regulator Valve with Pressure and Leaking Test 1. Technical Specification: Initial Pressure: Py max. 200bar Pressure Output: Py 3 - 20bar (adjustable) Brass ‘Alu- Epoxy ooating EPDM /NBAL Polyarnid from-30°C up to 60°C Ports: Input / Output female thread: @ 1/2” Flow Rate (mh) at Back Pr initial Pressure (bar) a 5 6 8 a2 5 35_|_ 30 = - - : 10 7070 70. 5. = = 15 300400 |4e0_[ 300 | 60 = 20 ‘420_[120_| 420 [420 | 420 [420 ‘30 200~|~200 {200 | 200_|~200__| 200) Up to 200, ‘200 “200 “| 200" [200 | 200 | 200, Tabie 7.7 Flow Rate {In the present application the flow will be 200 m#/h for intial pressure A S0bar. Ifthe supply of nitrogen drop below 30 bar the Indicated vakies in table 1.1 will be resulted according to the adjusted back pressure, Initial pressure 15 bar Back pressure 5 bar (adjusted by the adjusting spindle; see Point 7) Resulting Flow Rate 100(m*/h) 1_910388.200.d00 Fev.2 Side 2019 “ 3.1512 Data sheet DWG.-No. 1_,010366- 200 (mm) Inlet Pressure Outlet Pressure 30 Gag dA ct i 130 Figure 2.1 Adjusting spindle ocurnent: 4,,010366-200.doc Rev. 2. Side 3 of 9 Pp 3.1513 Data sheet eNotes DWG.-No, 1_010366 - 200 GC Special Systeme 1D-29840 Bod Oidesloo 3. Applications For pressure control within the indicated range of capacity. £,g. for oxygen, nitrogen or other gaseous from bottle bundle. itls permitted to use the pressure regulator only for gases which indicated on the pressure regulator. 4, Arrangement Single-stage in direction of gas flow losed design. ‘With central fine fiter and blow off vaive (safety valve). Incase of big inlet pressure fluctuations or litle outlet pressure (back pressure) the subsequent arrangement of a second pressure regulator is suitable, 5, Type of Gas e ‘All gases in gasoous phase which are non-aggressive against the used materials, tke Compressed Alr, Oxygen, Nitrogen, Argon, Hydrogen, Carbon dioxide The use for gases In liquid phase Is not permitted! Working principle ‘The pressure output charge the membrane and result muttipfed with its area to a force. This force Is In balance with the spring force. ‘The stroke of the throttle valve will be changed by ite variations of working pressure. “Thus the opening cross-section will be adjusted to the fluctuated inlet pressure respectively the fluctuated ‘throughput. 7. Blow off valve within the pressure regulator Little leakage losses from the throttle valve in the pressure regutator in case of closed discharge tine will be blown off by the blow off valve mounted in the pressure regulator. This blow off valve does not serve as a safely valve for the components in the downstream pipeline. e A safety valve has to be installed in the downstream pipe work to protected the armatures in case of a fellure of the pressure regulator. 8. Hints for mounting ‘The pressure regulator of this series are for upright installation or for direction of flow from left to right. ‘A blocking gete valve shoul be installed in the upstream pipe work. During the opening ofthis valve the inital pressure manometer should be viewed easily. ‘A blocking gate valve is necessary in the downstream pipe work whan there is no possibilty to close the pipe or when there is a long distance to the discharge point (more than 50 x pipe ciameter). Document: 1_010868-200.doe Rov. 2 Side 4.09 13 3.15-14 UIMAMAX GmbH & Co, KG owa.ners ovoes-200 | PRUATWIITHRIX Ragen tua 23840 Bad Oldesioe 9. Commissioning 9.1 Make sure that all connections are clean and without damages. Its not allowed to take the pressure regulator commissioning in case of pipe damages. 8.2 Close the upstream and the downstream blocking gate valves (see Pos. 480 and 500 in Dwg. 1_010366-010.) The blocking gate valve Pos 490 has to be closed also! 9.3 Screw out the adjusting spindle. See Figure on page 2. ‘Then screw in the adjusting spindle approximately at the hatf spindle aistance, ‘9.4 Open the upstream blocking gale valve (Pos. 480) so less that the initial pressure increase slowly to its highest value and the pressure output at the downstream side about to its half value. After completion of that fil in procedure open the upstream blocking gate vaive (Pos. 480) completely. 9.5 Screw in the adjusting spindie til the requested pressure output is reached. (Open the downstream blocking valve (Pos. 500) slowiy that the subsequent arrangement is filed vwithout heavy vibrations. ‘After thal counter the adjusting spindle with the counter nut Pay attention to the maximum allowable pressure for the subsequent equipments! 10. Hints for Operating and Maintenance ‘The PRV have to be protected always against damages. “The adjustment on the blow off valve should be never adjusted. Pay attention on perfect conditions to gaskets, sealing faces and manometers. In case of technical fault: 0.g. - _ increasing of pressure output at extraction = 0 = leakage against atmosphere - defect manometer or respond of blow off valve. take the PRV out of operation and close the blocking valve (Pes. 480, 490) Document: 1_010966-200.doe Rev. 2 Side 5 of 8 ce 3.15-15 Data sheet tmamax ond Co, a —e— | minimax | Soe zeoc0 Bao Solve 11, Shutting down off pressure regulator Itis sufficient enough to close the blocking valve (Pos. 500) in the down line pipe work ‘at work stoppage for a short time, For long term stoppage the pressure regulator has to be relieved . Close the upstream blocking valve (Pos. 480) 2. Relieve the pressure regulator by discharging the gas Via the consumer line or @ by-pass Il to the atmosphere 3. Screw out the adjusting spindle compietely till the end works Repairs are only special skiled workers in authorised repair shops. nied by using original spare parts. Repairs or alterations without permission from the manuté jppitor will lead in expiry of the ‘warranty likewise the liability of damages caused by these forbidden a ‘The correct function and operation is or ‘The pressure regulator has to be checked and tested completely after repairs. Document: 1_010966-200.doc Rov.2 Side 8 of 9 oe 3.15-16 amas andi 00 ka Dons Bod ere, Installation, Operation and Maintenance Instructions Dome Loaded Pressure Reducing Valve Model: K32 - 2" ‘Document: +_010986-300.doo Rev.2 Side tof 9 “a 3.15-17 MINIMAX GenbH & Co, KG owe.no-s orace-ooo | ATTANMIITIRIX Dome Loaded Pressure Reducing Valve Model: K32 - 2" Manufacturer: GHR FC Order No. :01K32P8SE 1. General Notes + These instructions apply to the K32 series + The pressures supplying and controlled by this Pressure Reducing Valve (PRV; are sufficiently high to endanger human life. + Suitably trained, qualified and authorised personne! must carry out ail installation and maintenance procedures. Unauthorised persons must be prohibited from tempering with, or operating this equipment. ‘+ lis assumed that the system into which this PRV is to be set Is provided with adequate isolation and safety deviess relevant to the media being processed. 2. Typical Applications + Hightlow purge systems + Pressure test rigs + Nitrogen pant e + Breweries + Stee! manufacture and Mining + Many other industrial applications Docurnent: 1_010866-300.doc Rev. 2 Side 20f 9 a 315-18 Data sheet MuniBAAX GmbH & C0. XG Region International co DWG.-No. 1_010366 - 300 ‘Spocia Systems 25640 Bad Oldesiow 3. Description + The PRV is suitable for use in low medium-pressure gas/iquid systems where a reduction of pressure I required. Idea! for high flow and low to medium pressure applications, + Falk-safe to closed position + Hesvy-duty construction + Stable and noiseless dome-loaded prossure regulator used for accurate control of outlet pressure + This valve isnot considered subject o creep or ftgue within ts spected operating nts. ‘+The range of pressure reduction is infinite, and is mede possible by the infinitely variable dome charging pressure, «As standard, a 25.4 mm (1*) diameter, soft trimmed, balanced valve is fitted. + Internal sealing is achieved with ,O* rings. + The Inlo¥Outlet connections are suitable for mounting into pipelines of DNSO. + Its recommended that connecting pipe-work be suitably supported as close as possible to the PRV ‘eonnections, + Lis assumed that a gauge reflecting the outlet pressure is positioned before the outlet isotation valve. + Suitable downstream pressure reliet must be incorporated. + Approximate weight of the equipment is, for all material versions 18.5 Kg, therefore, the equipment may be regarded as portable. Document: 1_010368-300.doc Agee Side 3 of 9 3.15-19 TINAX GmbH & C0. KG Data sheet Region International DWG.-No. 1_010366-300 CC Special Systams 23840 Bad Oldesioa 4, Technical Data ‘Standard Features Materials Specifications "Nodular iron Part ‘Material ‘Specification — emcee Body and : 103 bar (1800p) Dome ——Nodulariron BS 2789 400/18 L20 (069 bar (0-950 psi) ‘Seat ‘Stainless steet BS EN 10088 1.4401 ‘Tri, Seals Rubber 9 bar (100056) Blailoss steal / High ite ES Sonera sere oat Sones Nom. Size 254mm (1°) Orie area At 323 mn (0.50) e 1803 men* (2.33 in®) Kv297 (Gretta) Document: $_010366-200.doo Rev. 2 . Side 40t 8 a 3.15-20 MINIMAX GmbH & Co, KG agjon atin ower cvoces-coo | ATTANUTIFLX (0G Special Sysiems (0-23840 Bed Oldesioe 5. Profile and Dimensions: ‘mim (inches) B: 227 (8.9) C: 267 (10.5) D: 210 (8.26) E: 75 (2.95) A sees c : b i Q a a Senne Figure: 6.1 Ax Screw Plug B= Needle Vatve C= Noodle Vane Document: 1_016996-800.doc fev.2 Side Sot 3.15-21 Data sheet woman x8 DWG.No, 1_010366 - 300 GC Special Systems 1D-29840 Bad Oldesion 6. Function ‘To obiain flow through a K32 PRY, itis necessary to charge its dome with an inert gas (nitrogen or air~ not oxygan). Before the valve of the controller will open, the pressure in the dome must overcome the combined load of the valve spring and the inlet pressure under the valve head, \coment of any installation work, itis Important that source of pressurised media be turned off point at which the PRY willbe installed. Damage may occur to ti if subjected to any impact. This risk increases at lower temperatures. I the. impact it should be returned to the manufacturer for inspection. valves must be actuated slowly to avold the risk of explosion. e n without any effect from shock loads Incurred as a result of ‘use in these areas is at user risk, Atail times, itis essentlal that iso} ‘The valve Is not designed specifically adverse traffic, wind or seismic conditions. + Remove packaging and ensure that there are ne-okviously loose parts or visuel signs of damage. + Check that the information listed on the nameplate confiniisthet the PRV supplied is sultable for the Intended service. + The system into which the PRV is to be set must be clean and free of afiy-sold Inclusion that could be a source of damage to soft-seated components. +. The PRV is set directly into the line using the threaded inlet and outlet connections. + The two ports are diametrically opposite and it is important that the PRV is correctly oriented int ‘work. A flow diraction arrow © is cast on the body. Document: 1_010368-300.doe Rev. 2 Side 6of 8 3.15-22 MINIMAX GmbH & Co. KO: owa-no-t crosee-200 | ANTNNIITNLX Cees Spe 123840 Bad Ordesioe 8. Commissioning (Feeding of the PRV) 18.1 Make sure that all connections are clean and without damages. tis not allowed to take the pressure regulator commissioning In case of pipe damages. 8.2 Make sure that the required pressure supply is available. This Is to assure by means of the upstream pressure gauge (Pos. 630) 8.3 Stacken screw plug A (see Figure 5.1) and needle valve B In order to relieve possible gas pressure In the dome. ‘Check ita flat gasket is inserted and screw needle valve and screw plug tight. 8.4 Open blocking gate vaives in the downstraam and upstream piping carefully. Make sure that the pressure regulator does not have any leakage In Its closed condition (dome without pressure) @ a5 open to nec valve C bya hall revolution. 8.6 Open the needle valve B very carefully. Let gas flow into the dome and read the less pressure on the manometer in the piping. Carry on charging procedure as long as the requested pressure output is reached. After that screw needle valves 8 and C tight. ifthe dome pressure is adjusted to high comply with the following: = Relieve the downstream piping + Slacken screw plug A and needle valve Now the pressure Is able to leak. The pressure manometer has to be observed til the requested pressura ‘output is reached. ff the requested output pressure is reached screw the screw plug A and needle valve B tight. 8.7 Now the dome loaded pressure reducing valve is adjusted and ready for operation. ‘Open blocking valves in the upstream and downstream piping completely. e Note: Do not use Quick Action Gate Valves which feed the PRV within 2 seconds ! Document: 4_010886-900.doc Rev. 2 Side 7 of 9 az 3.15-23 MINIMAX GmbH & Co. KG FRogion Intomatlonal CC Specie! Systems 23940 Bad Oldesioe Data sheet DWG.-No. 1_010366 - 300, ving few moving parts, the K32 will require only periodic Inspection of those items subject to wear, oF oration to, ensure long service and rellabilty. that when servicing or repair becomes necessary the PRV be retumed for factory However, the design of the K32 does enable servicing in the field, with minimal {o satisfy plant operations and minimise down times. In @ clean systom, the K32 will continue deliver trouble free service over long periods of time. Under these conditions, maintenance intervals may be along as 24-38 months. In more arduous conditions or in ‘aggressive media service, the periods may be shorter, 6-12 months, Itis however, important that units in ‘safety rotated applications be Inspected mora frequently. During these preventative maintenance periods, the {following procedure is suggested: 2) Inspect ail ,0" coals for wear, bitleness or other sighg of damage. All those displaying any indication of damage or deterioration should be replaced. However, i\[s recommended that all seats, regardless of any damages should be routinely replaced. b) Remove the valve and seat and inspect closely for wear or damage. Typical signs of damage will be nicks or raleed burns around the seating edge of the seat, or indentations, abrasions and hard particle inclusions in the soft (seating) area of the valve member. Severe weer andlor very apparent nicks, burrs or particle inclusion would indicate that replacement is necessary. Light wear and'ihe presence of a clean, continuos seating ring on both parts would Incloate that they are sultable for re-use, ©) Any components showing signs of corrosion should be inspected for indications of permanent damage (le. pitting etc.) and replaced if any are present. 9.2 Remedial Maintenance * Ifthe 32 is maintained to a planned programme, itis unikely that the need for remediat However, ifthe system becomes contaminated of an operating system problem causes dam: the control elements, the PRV may malfunction. in general its recommended that damaged PRs be retumed to the factory for repair. To faciltate fle repait, and minimise pient downtime, Table 1 I possible faults and probeble causes/solutions. Document: 1_010366-200.doo Rov. 2 Side 8.0f 8 33 315-24, -20040 Bad Olcesioe rable that the PRV be repaired or serviced under workshop conullions, as the opened equipment jected from ingress if dir and other foreign material. Should operational requirements make it service the PRV in the pipeline, then precautions should be taken to avoid contamination of ‘SYMPTOM (CAUSE SOLUTION Rise in outlet pressure | Damaged valve andor soat. Roplace parte). above that set. Dirty valve and/or seat. Clean partis). Damaged valve ‘o" ring. Replace part. Damaged seat ,o* ring. ee Valve spring failure, Replacé Valve jams open. Investigate cat Replace valve ifn Toss of outlet preseure. [Damaged diaphragm. Leaking dome. Tablet Document: 1_010368:-00.doo Rav. 2 Skie 8 ot @ Ve 3.15-25 Intentionally Blank 3.15-26 3.16 HYDROGEN PLANT KKS NUMBER : 10QJHO1SS101 ‘MHI Propriatary information Operation Manual For Hydrogen System 316-4 H4-04003 Intentionally Blank 3.16-2 2.0 SYSTEM OPERATION 24 WARNINGS AND CAUTIONS 24.4 Hydrogen Safety - HYDROGEN IS HIGHLY FLAMMABLE - Hydrogen gas is colorless, odorless, tasteless and lighter than air. Hydrogen, when combined with oxygen gas or air can ignite with explosive violence. The equipment within the hydrogen room has been specially designed to prevent the accumulation of hydrogen with simultaneous Presence of an exposed ignition source. Personnel operating hydrogen equipment should be familiar with the various concepts involved in these protective design features. 2.4.1.4 Protective Features Protective features, which depend on the component, may be one of the following: Natural or forced ventilation systems Enclosing devices which can provide an ignition source under normal operating conditions, such as motor starters, inside explosion-proof enclosures. These enclosures are designed to contain combustion pressures and prevent a flame path to the surrounding environment. Monitoring of the hydrogen area with a combustible gas detector with equipment interlock The use of hermetically sealed switch contacts, indicator lights, etc. to prevent the accumulation of hydrogen around ignition sources. ‘The use of electrical conduit seals at the wall between the hydrogen room and the unclassified electrical room. 24 316-3 H4-04003 2.4.1.2 Wamings Safety features should be maintained and should not be defeated in any way. Ventilation systems should be operational; electrical enclosures should be properly closed and sealed; combustible gas detector should be functional and calibrated. Bypass lines without check valves, excess flow valves or restrictors, should not be installed between a compressed hydrogen source and equipment inside the machine room. The hydrogen afea should be isolated from the electrical room and other potential sources of ignition while hydrogen equipment is operating. ‘Smoking or any type of open flame should be prohibited in the hydrogen room. ‘The user should install appropriate warning signs per local practice. Hydrogen gas lines should be checked for leaks after installation or disassembly for maintenance (see below). The use. of unclassified electrical equipment such as drop lights, instruments or power tools, within the hydrogen area, should be limited to maintenance functions ‘when hydrogen is not being produced or handted. 2.1.1.3 Flame Arresters There are flame arresters installed at the outlet of the Hydrogen Generator hydrogen vent lines. They are designed to keep an outside flame from eniering a tank or other vessel. To insure proper functioning at all time, it is necessary that the flame arresters be given correct maintenance. Dirty inserts will cause excessive pressure drop. The maximum design pressure drop for this model is 72.5 bar. Maximum allowable pressure drop for any installation must be determined by the user, Pressure drop readings should be taken on a regular monthly basis. When the pressure drop is found to have reached the limits of the system, the unit should be removed and cleaned. After removing the arrester from the line, unscrew the body end caps to expose the Inserts. The inserts can be cleaned by submerging the flame arrester body assembly In a nonfilm solvent and back blowing with compressed air. 22 3.16-4 H4-04.003 Compressed air should always be blown from the refractory insert end. Re- install the end caps on the arrester to ensure sealing. When re-installing the flame arrester in the pipe line, make sure that the flow Is in the proper direction, that is, gas should enter the flame arrester through the metallic insert and discharge through the refractory insert. 24.2 Electricat Circuits - ELECTRICAL SHOCK WARNINGS - De-energize electrical equipment before servicing. Operation of electrical equipment with enclosure covers removed or doors open is not recommended. There are several voltages in the hydrogen generator and Instruments. Verify proper wiring before energizing circuits. Use e@ caution during service. 24.3 Gas Systems : - COMPRESSED GAS HAZARD ~ Exercise caution in handling compressed gas bottles (portable hydrogen and nitrogen bottles). Secure bottles to appropriate fixtures and utllize protective caps during transport. Use proper equipment for transport. Verify that lines and vessels have been depressurized before loosening fittings. Following ‘Installation or dis-assembly for maintenance, process gas and vent lines should be gradually pressurized and bubble-checked for leaks, utilizing an inert gas. - STORAGE TEMPERATURE WARNING ~ Care must be exercised in establishing and monitoring the hydrogen storage pressure. {n warm climates, temperature swings can cause storage pressures to exceed relief valve settings. Avoid filling bottles to maximum pressure during cool periods. Monitor storage pressure carefully, especially during very warm periods. The Hydrogen Compressor suction pressure should not exceed 6.9 bar. 23 ates H4-04003 214 245 22 2.2.4 2.2.2 2.23 Several system pressure set points in the control program protect against equipment damage and/or hazardous situations. Follow manual procedures for adjusting system pressure set points. The orientation (flow direction) of check valves should be verified before system operation. Electrolyte - POTASSIUM HYDROXIDE (KOH) IS HIGHLY CORROSIVE- Care should be taken to avoid contact with potassium hydroxide (KOH). Potassium hydroxide is harmful and a severe irritant to the skin and eyes. This material may be encountered in the form of a clear tiquid or a white crystalline powder or solid. If contact does ‘occur, neutralize the KOH with a 3-5% solution of boric acid, wash with mild soap and rinse with potable water. Grounding e. User is responsible for connection of system equipment to the facility ground system and for proper ground protection. . User is responsible for protection against lightning, if necessary. PREREQUISITES Electrical ‘Three-phase 380 VAC available at the power distribution panel. All field connection wiring completed and inspected. Facility ground wiring completed Gas Piping Process gas and. vent piping and pre-pressurization gas lines (hydrogen, ‘oxygen and nitrogen} completely installed and checked. Inert gas pressure testing completed. Cooling Water Supply Facility cooling water pressure available. 2-4 316-8 H4-04003 2.24 23 23.1 23.2 2.3.3 2.3.4 Consumables Potassium hydroxide (KOH) and a bucket & rod for mixing must be available. Potable water is required. Calibration gas must be available for the combustible gas detectors. Nitrogen gas bottle(s) connected to pressure reducing supply manifold. POWER ACTIVATION Verify the following power OFF conditions: + Circuit breakers CB2, CB3, CB8, CB7, CB8 and CB9 are OFF on the Power Distribution Panel (circuit breaker CB1 is ON). * Compressor Safety Switches are OFF. + HM Hydrogen Generator Emergency Switches are OFF. Activate C82 and CB3 one at a time. Check that 380 VAC, 50 Hz, three-phase power is available inside the HM Generator 1 and Generator 2 Power Supplies at the main power contactors, respectively. Activate CB7 and CB8 one at a time, Check that 380 VAC, 50 Hz, three-phase power is available at the input side of Compressor Safety Switches SS-1 and 88-2. Check that the HM Generator touch screens are not activated. Activate CBG. Check that 380 VAC, 60 Hz, single-phase power is available at the input side, and 110 VAC 50 Hz, single-phase power is available at the output side of the transformer, T1, in the Annunciator Panel. The flat panel computer on the Annunciator Pane} should be ON Activate the Compressor Safety Switches and verify the compressor controt circuits are powered. Activate HM Hydrogen Generator Emergency Switches and check the following: . . HM Power Supply main power contactors are activated and the Power Supply control circuits are energized (indicator lights will be energized). 25 3.167 H4-04.003 + HM Hydrogen Generator control circults are energized (touch screens are activated). CAUTION: The touch screen controls the HM Hydrogen Generator. DO NOT touch the touch screen without a thorough understanding of HM Hydrogen Generator operation. 24 PRE-OPERATIONAL CHECKS These steps are taken after installation of equipment is complete and wiring and pressure checks have been made. 241 Building Ventilation system unrestricted and functional, this could be @ simple roof ‘pening Combustible Gas Detectors powered and calibrated Cooling water pressure at supply manifold 24.2 — Electrical 380 VAG, 3-phase at the Power Supply rectifiers and the Compressors. ~ 410 VAG, single-phase on the Annunclator Panel, terminal board 4 (TB4) 24.3 Feedwater Supply Water pressure available at solenoid valve Solenoid controls energized Feedwater tank clean and full Filler installed in supply line Flow to Hydrogen Generators established e 26 316-8 H4-04003 we 244 @ 245 24.6 Hydrogen Generators (refer to Generater Section) Check electrical supply for 380 VAC, 3-phase, 100 amp service Correct phase rotation of KOH pump Check cooling water flow Check pre-pressurization gas supply (4.1 to 6.9 bar) Check demineralized water supply Refer to detailed pre-operational checks found in the Commissioning Procedures Pressure test Pressure Switch Calibration External Module Inspection Module Retorque Electrolyte Fill and/or Check Feedwater Pump Priming Hydrogen Compressors (refer to Compressor Section) Check motor rotation ‘Check oil level Check/adjust drive belt tension Check cooling water supply Power available at contro! panel Pressure switch set-points checked Instruments Individual Manuals coritain instruction on the Annunciator Panel and the individual sensors. Information on start-up, programming, calibration, ete. can be found there, 27 316-9 H4-04.003 25 25.1 25.1.1 25.1.2 START-UP AND NORMAL OPERATION {installation and pre-operational checks completed) Power must be applied to the Annunciator Panel in order to start the equipment. If it is not energized the Generators will be in alarm condition and will not produce hydrogen. Overview of Operation Hydrogen Generators The HM Hydrogen Generators are designed to provide a constant pressure supply of hydrogen according to facility or compressor demand. A pressure transducer reacts to slight pressure changes which occur due fo a change in flow, and, within a few seconds, the PLC control system increases or decreases the gas generation rate. This process is limited by the capacity of each generator which is 5.67 Nm’h. If the demand on one of the generators exceeds 5.67 Nmih, then a pressure regulator (inside the generator gas cabinet) begins to close in order to prevent a loss of pressure within the electrolysis module. Anytime that the demand downstream of the Hydrogen Generators is less than generaior idle operation (approximately 17% of generator. output capacity), the Generators will go into an idle condition in . which hydrogen will be vented to the atmosphere through a back pressure regulator.. When pressures drop, indicating a downstream demand, this regulator will close and hydrogen will be defivered seamlessly. ‘The hydrogen delivery pressure at the generators will be nominally 6.9 bar and no less than 6.2:bar, The pressure at the inlet to the Compressors will be very close to generator pressure. There Is a three-way valve at the outlet of each generator, allowing the hydrogen gas to flow to either Compressor 1, Compressor 2, or to be shut-off, These vaives will allow flexibility in the system for maintenance or trouble- shooting. Hydrogen Compressors The Hydrogen Compressors are positive displacement machines for which the throughput is a linear function of suction pressure. Suction pressure is adjusted with a forward pressure regulator on each compressor panel. The Compressors are wired at the factory for automatic cycling based on storage pressure, once the START button is pushed. 28 316-10 H4-04003 The compressor control circuit consists of normal cycling and safety pressure ‘switches wired in series with the motor starter. The fault condition switches are: ‘Switch Set Point First stage leak detection 1.03 bar Second stage leak detection 1.03 bar Low suction pressure 1.03 bar High discharge pressure 154 bar The normal cyole-on and cyole-off switch settings were set by the factory to 122 bar and 150 bar, respectively. They can be changed by the end-user if desired, The cycle-on point depends on what the end-user considers to be a depletion pressure. The cycle-off point depends on the desired bottle fill pressure and may be influenced by ambient temperature. Care must be used to avoid filling the storage cylinders to capacity when ambient temperatures are cooler than maximum expected temperatures, Maximum pressure is determined by the relief valve setting of the storage system manifolds which is 170 bar. The Compressor high pressure safety pressure switch should be set below this point (factory sot at 162 bar) since Itis desirable to shut down before lifting a relief valve. Finally, the normal cycle-off ‘switch is set below the safety pressure switch, or at the desired tank fill pressure (factory set at 150 bar). The pressure of hydrogen delivered to the facility Is set with the two forward pressure regulators on the High Pressure Control Panel. This is discussed in the Operating Situations section. 25.1.3 Storage System The end-user can use as many of the hydrogen cylinders as desired by closing off some of the individual isolation valves. When the Compressors have filled the on-line cylinders to their cycle-off pressure value, then the Compressors will shutdown until, the facility has used enough hydrogen to decrease the pressure to the cycle-on value of the Compressors. ‘The following section should be read in its entirety before operating the hydrogen equipment, 29 316-11 H4-04003 2.5.2 Operating Situations The flow of hydrogen to the facility from either the Hydrogen Generators or the storage area Is controlled at the Gas Control Panel. This panel contains two forward pressure regulators which, in conjunction with the compressor suction pressure regulators and pressure switches, automatically direct hydrogen according to facility demand and storage conditions. This section provides a discussion of the various operating possibilities and limitations of this gas control system. There are several possible operating situations which depend on facility demand, storage conditions, generator status and compressor status. Each Situation is illustrated on the following figures (1 through 5) which show a diagram of the pertinent regulators and valves. Generally, it is desirable to run the generators and compressors during periods when facility demand is low, in order to maintain full storage capacity. When facility demand is normal, the Compressor(s) should be taken off-line to allow the Generator(s) to meet facility demand direclly and to avoid unnecessary alarms (compressor jow suction pressure). In this mode, the leak make-up of the electric generator is entirely and directly produced by the Hydrogen Generators. Compressors need only be run after the electric generator has been shutdown. Therefore necessitating a refiling of the storage vessels. If demand exceeds hydrogen generator(s) output, additional gas will flow automatically from the storage system. This occurs because of the setting of the High Pressure Control Panel forward pressure regulators. The génerator- to-acility regulator, is set to open when the facility pressure falls below 6.9 bar and will adjust to varying facility demand, When demand begins to exceed the generator(s) maximum output, a regulator in the generator will begin to close to maintain process pressure. This results in a drop in the Gas Control Panel pressure, The second forward pressure regulator (storage-to-facily,) is set to maintain flow at a slightly lower delivery pressure, hence it responds when the facility is demanding more than the maximum output flow of the Generators. This regulator is a high Row design. Most of the gas in very high demand Periods flows through this regulator. ‘The operator(s) should review figures 1 through 5 and be sure that each operating situation Is understood, before placing the system in automatic operation, 210 3.16-12 H4-04003 ste Prat Pa FROM conpacsscR cues AREA ceneearan SUCTION PRESSURE YeLve seGuLatae ccRTERNAL TY COMPRESSOR el venyoatgs wer @ dt th FACILITY PRESSURE FACILITY PRESSURE REGULATOR REGULATOR y cCENERATIRY ¢STORAGED 0 Facltity conpeessoe OFF INDICATES HYDROGEN FLOW FACILITY DEMAND: <5. 67 Nan Let ses Fah Cee FIGURE 1 244 3.16-13 H4-04003 pt COMPRESSOR IN ros cowpressoe cece sroRast cenzzaror | sucTeane pRessuRe vaLve mee RrGuate eure Ta CbPRESSOR | He Fly FACILITY PRESSURE FACILITY PRESSURE Balatce ReauLerae cGencRarOR) STORAGE ta Faciulty commresso arr INDieATes HYDREGEN FLOM FACILITY Devan. Low Ok HGH FuRW FAGLLETY SUPPLIED FROM SVERAGE ONLY. FIGURE 2 212 3.16-14 H4-04003 x @ ‘COMPRESSOR TN Feo COMPRESSOR CHECK ‘sraRaGe GENERATOR ‘SUCTION PRESSURE YeLve ante ReGuaroe INTERNAL TO COPPRESSOR) e #2 fe rune Faw TF ReaD crens uF NALNTATNS. PRESSURE heaps 63 BAR 10 62 man FOCILLTY PRESSURE FACLLITY PRESSURE, REGULATAR REGULATOR ) «GENERATOR STORAGE? 10 Factliry cowRrssoR. OFF 7 1 FACILETY DEMAND NORWAL To HIGH FLOW INDICATES HYDROGEN FO FACILITY SUPPLIED BY GENERATOR UNLESS OR UNTIL DEHAND EGE Gr tere! TFG STORAGE Rech ator BEGES i ante FIGURE 3 2413 3.16-15 H4-04003 —~ nt @- 9 COMPRESSOR I FRoM coMPeEssoR cuca stogace GenEeATOR suction pRessuse Save meee ecu aioe crnzeeuat TO COMPRESSOR) ste @ Bho FACILITY PRESSURE FaCtLLTy PRESSURE REBLLATES Reguunece CGERATIR

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