ak-P-Mc 2000 (En)

Part: Operating manual
Operating manual Section: 1

for File: 1
Oxygen-VPSA-Plant Doc. no.: &AK-P-MC 2000 (EN)
Proj. no.: 2210 CCP8
Code: Lubumbashi STL
Page 1 of 6 page(s)
Company : Société pour le traitement du

Terril de Lubumbashi (STL)
Contract No. :
Date : February 10th, 2012
Plant : Oxygen-VPSA-Plant
1,050 Nm³/h [273K / 1,013 mbar(a)]
93 Vol% O2, 5.5 bar(a)
corresponding to 977Nm³/h(@100% O2)
Contractor : LINDE GmbH

Linde Engineering Division
Dr.-Carl-von-Linde-Strasse 6-14
82049 Pullach (near Munich)
Germany
Phone : +49 89 7445-0

Fax : +49 89 7445-4931
E-mail : info@linde.com
Internet : www.linde.com
Project number : 2210 CCP8

Job code : Lubumbashi STL
Year of construction : 2022
01 IFC 18-Jul-2022 Szyrkowiec / ADPA Valenta / ADDA Wildgruber / ADPA First Issue for start up
Issue State Date Prepared Checked Approved Remarks
The reproduction, distribution and utilization of this document as well as the communication of its contents to others without explicit
authorization is prohibited. Offenders will be held liable for the payment of damages. All rights reserved in the event of the grant of a patent,
utility model or design.
Proj. no.: 2210 CCP8 Doc. no.: &AK-P-MC 2000 (EN) Issue: 01 Page 2 of 6
PREAMBLE
The following operating manual is based on the long-standing theoretical research and
practical experience of Linde AG Engineering Division (LINDE) and its experts. Its purpose is,
together with training carried out by LINDE personnel, to provide information to the personnel
operating the unit designed by LINDE with respect to the correct operation of the unit, the
hazards associated with the operation of the unit and the prevention of dangerous situations.
This operating manual has been prepared with due care and diligence, using presently
available information and experience, and based on the assumption that the unit will be
operated exclusively by well-trained and responsible qualified personnel.
This operating manual alone, however, cannot contain an exhaustive description in respect of
operation of the unit and all possibly required safety precautions. LINDE will be available for
technical advice in case of queries or doubts regarding operation of the unit and its safety
precautions during training carried out by LINDE and thereafter. Additional technical assistance
and advice by LINDE experts at unit site will be available at reasonable notice and at
commercial terms and conditions.
LINDE recommends that the owner/operator of the unit trains his operating personnel
according to this operating manual and have his personnel confirm that the information and
safety precautions received have been understood and will be adhered to.
The responsibility of the owner/operator for operation and safety of the unit will not be affected
by this operating manual or by the training by LINDE experts.
The owner/operator of the unit must always comply with all applicable and valid legal, public
regulations, recommendations and guidelines and/or those of professional associations or
worker's compensation insurance (environmental protection, prevention of accidents and/or
safety provisions for workers, etc.).
LINDE may supplement this operating manual with improvements during start-up and normal
operation of this unit and/or update the same based on subsequent experience or development
of the state of the art.
WARNING
The unit must be operated within the operating conditions specified in the contract and the
engineering documents. If the unit is operated outside specified operating conditions, such as,
but not limited to, different feed, different or higher impurities, increased throughput, increased
pressures, higher or lower temperatures, more frequent or wider variations in pressure or
temperatures, etc., this may adversely affect safety and reliability of the unit or cause personal
injuries or damage to equipment, adjacent property or the environment.
When operated at the edge of the design envelope additional care needs to be taken,
especially in terms of controller stability APC fluctuations, machine loads and control, cooling
water system conditions and utility supply in general. This includes but is not limited to
awareness of resonance phenomena.
TABLE OF CONTENTS
The complete manual consists of following parts
Operating Manual : Part O

Technical Data Book : Part T
Mechanical Data Report : Part M
O OPERATING MANUAL ............................................................................ 1
1 SAFETY INSTRUCTIONS........................................................................ 1
1.1 Introduction ................................................................................................................. 2
1.2 Dangers ........................................................................................................................ 3
1.2.1 Fire hazards of oxygen and oxygen enriched atmospheres ............................. 3
1.2.2 Oxygen deficiency ............................................................................................ 7
1.2.3 Impurities .......................................................................................................... 7
1.2.4 Noise ................................................................................................................ 8
1.2.5 Brittle fracture ................................................................................................... 8
1.3 Protective measures ................................................................................................... 9
1.3.1 Clothing ............................................................................................................ 9
1.3.2 Design of buildings ......................................................................................... 10
1.3.3 Protective measures against fire hazards ....................................................... 11
1.3.4 Fire protection equipment ............................................................................... 11
1.3.5 Repair and maintenance works ...................................................................... 12
1.3.6 General safety precautions ............................................................................. 12
1.3.7 Materials used in oxygen plants...................................................................... 13
1.3.8 Confined spaces ............................................................................................. 13
1.3.9 Cleanliness and inspection ............................................................................. 15
1.3.10 Noise protection .............................................................................................. 18
1.3.11 Safety devices against excess pressure ......................................................... 18
1.3.12 Start of the VPSA............................................................................................ 19
1.4 Safety signs acc. European Directive 92/58/EC (extract) ....................................... 20
1.4.1 Prohibition safety signs ................................................................................... 20
1.4.2 Mandatory safety signs ................................................................................... 20
1.4.3 Hazard safety signs ........................................................................................ 20
1.4.4 Safety signs .................................................................................................... 21
1.4.5 Fire equipment signs ...................................................................................... 22
Attachment: Safety data sheets................................................................................... 23
2 DESCRIPTION OF THE VPSA-PLANT ................................................... 1

2.1 Design purpose ........................................................................................................... 1
2.2 General ......................................................................................................................... 1
2.3 Principle description ................................................................................................... 2
2.4 Process description .................................................................................................... 2
2.5 Impact of process parameters on the plant capacity ............................................... 6

2.6 Basis of design and performance data...................................................................... 7
2.6.1 Standards ......................................................................................................... 7
2.6.2 Design conditions ............................................................................................. 7
2.6.3 VPSA performance ........................................................................................... 8
2.6.4 Utilities .............................................................................................................. 8
3 VPSA SEQUENCE................................................................................... 1
3.1 VPSA flow sheet .......................................................................................................... 2
3.2 Steps of the sequence ................................................................................................ 3
3.3 Description of steps .................................................................................................... 4
3.4 Step diagram.............................................................................................................. 11
3.5 VPSA sequence cycle at full load ............................................................................ 12
3.6 VPSA sequence cycle at partial load ....................................................................... 13
3.7 Typical pressure cycle adsorber/buffer vessel ....................................................... 14
3.7.1 Full Load ......................................................................................................... 14
3.7.2 Partial Load .................................................................................................... 14
4 OPERATING MODE ................................................................................ 1

4.1 Description of the operating modes .......................................................................... 1
4.1.1 Operating mode 'STOP' .................................................................................... 1
4.1.2 Operating mode 'START' .................................................................................. 2
4.1.3 Operating mode 'OFF SPEC' ............................................................................ 3
4.1.4 Operating mode 'INCREASE FLOW' ................................................................ 3
4.1.5 Operating mode 'ON SPEC' ............................................................................. 4
4.1.6 Operating mode 'REDUCE FLOW' ................................................................... 4
4.1.7 Operating mode 'ERROR STOP' ...................................................................... 5
4.1.8 Operating mode 'STOP CYCLE' ....................................................................... 5
4.1.9 Operating mode 'HAND' ................................................................................... 6
4.2 Flow chart of operating modes .................................................................................. 8
5 CONTROL OF THE VPSA-PLANT .......................................................... 1

5.1 Introduction ................................................................................................................. 1
5.1.1 Starting up the PLC control system .................................................................. 2
5.1.2 Operating modes of the CPU ............................................................................ 4
5.1.3 Start of the VisualiZation System ...................................................................... 5
5.2 Operating of the VPSA-Plant ...................................................................................... 5
5.3 Function of the illuminated push buttons ................................................................. 6
5.4 How to use the Operator Workstation ....................................................................... 8
5.4.1 General ............................................................................................................. 8
5.4.2 Structure of the visualization pictures ............................................................... 9
5.4.3 Main picture .................................................................................................... 14
5.4.4 Process units .................................................................................................. 16

5.4.5 Permission, Protection and Interlocking .......................................................... 18
5.4.6 Operating the plant through the “Plant Management”-Menu........................... 20
5.5 Start and stop of the VPSA-plant ............................................................................. 21
5.5.1 Preparations before start ................................................................................ 21
5.5.2 Preparation of the oxygen compressors ......................................................... 22
5.5.3 Start of the VPSA-Plant .................................................................................. 23
5.5.4 Start and stop of the oxygen compressors ..................................................... 24
5.5.5 Stop of the VPSA-Plant .................................................................................. 26
5.5.6 Start of the VPSA-Plant after ERROR STOP ................................................. 26
5.6 Operating the plant in ‘HAND’ mode........................................................................ 27
5.6.1 Preparations before start ................................................................................ 27
5.6.2 Test run of feed air blower and vacuum pump ................................................ 29
5.6.3 Test run of oxygen compressor ...................................................................... 31
5.6.4 Test of valve sequence ................................................................................... 33
5.6.5 Test of individual valves .................................................................................. 34
5.6.6 Test of motors and heaters ............................................................................. 36
6 DISPLAY AND CHANGING OF PARAMETERS ..................................... 1

6.1 General ......................................................................................................................... 1
6.1.1 Faceplate window for process values ............................................................... 3
6.1.2 Faceplate window for controllers ...................................................................... 4
6.1.3 Faceplate window for motors and heaters ........................................................ 6
6.1.4 Faceplate window for maintenance counter ..................................................... 7
6.1.5 Faceplate window for valves ............................................................................. 8
6.1.6 Detail window for operating limits ................................................................... 10
6.2 Password protection and log in procedure............................................................. 17
6.2.1 Log in / log out procedure ............................................................................... 17
6.3 Parameter list............................................................................................................. 18
Attachment: &AK J-LA 2001 Alarm and Setpoint List ................................................ 47
7 ALARMS AND TROUBLESHOOTING PROCEDURES .......................... 1

7.1 Display of alarms ......................................................................................................... 1
7.2 Alarm messages and troubleshooting procedures .................................................. 4
List of SHUT DOWN Alarm Messages .......................................................................... 6
Code Table for Troubleshooting .................................................................................. 16
7.3 Important operations for troubleshooting............................................................... 27
7.3.1 Troubleshooting for purity alarm ..................................................................... 27
7.3.2 Replacing butterfly valves ............................................................................... 30
7.3.3 Manual pressure equalization ......................................................................... 31
7.3.4 Manual depressurization ................................................................................. 36
7.3.5 Leakage test of valves and piping................................................................... 37
7.3.6 Checking limit switches ................................................................................... 38
7.3.7 Checking valve positioners ............................................................................. 39
7.3.8 Troubleshooting of valves ............................................................................... 41
7.3.9 Checking pressure transmitters ...................................................................... 45

7.3.10 Changing PLC backup battery ........................................................................ 45
7.3.11 Replacing the power supply module ............................................................... 47
7.3.12 Replacing CPU / Communication modules ..................................................... 49
7.3.13 Changing I/O modules .................................................................................... 49
7.3.14 Configuring analogue input modules in the PLC ............................................. 51
7.4 Communication with LINDE ..................................................................................... 52
7.5 Service and repair assistance .................................................................................. 52
8 CONTROL VISITS AND MAINTENANCE ................................................ 1

8.1 General ......................................................................................................................... 1
8.2 Control visits ............................................................................................................... 2
8.2.1 Feed air blower / vacuum pump........................................................................ 2
8.2.2 Oxygen compressor.......................................................................................... 3
8.2.3 Adsorber station................................................................................................ 4
8.2.4 Butterfly valves ................................................................................................. 4
8.2.5 Product purity analyzer (Servomex).................................................................. 5
8.2.6 Instrumentation ................................................................................................. 8
8.2.7 Instrument air system ....................................................................................... 8
8.2.8 Cooling water system ....................................................................................... 8
8.3 Maintenance................................................................................................................. 9
8.3.1 Feed air blower / vacuum pump........................................................................ 9
8.3.2 Oxygen compressor.......................................................................................... 9
8.3.3 VPSA-unit ....................................................................................................... 10
8.3.4 Checking adsorbent level / INTEGRITY ......................................................... 10
8.3.5 Butterfly valves ............................................................................................... 12
9 CONTROL LOOPS AND CALCULATIONS ............................................. 1

9.1 Pressure-flow-controller ............................................................................................. 1
9.1.1 Pressure controller PIC-1521 ........................................................................... 2
9.1.2 Flow controller FIC-1545 .................................................................................. 2
9.1.3 Combination of both controllers ........................................................................ 2
9.1.4 Calculating the setpoint for the flow-controller .................................................. 3
9.2 Partial load of the VPSA-Plant.................................................................................... 5
9.3 Blow-off controller FICC1545 ..................................................................................... 6
9.4 Switching time of valves ............................................................................................. 7
9.5 Temperature controller ............................................................................................... 8
9.5.1 Process air temperature controller TIC-1121 .................................................... 8
9.5.2 Cooling water temperature controller ................................................................ 9
9.6 Control of environment ............................................................................................. 10
9.6.1 General operation ........................................................................................... 10
for File: 1
Oxygen-VPSA-Plant Doc. no.: &AK-P-MC 2001 (EN)
Safety Instructions Proj. no.: 2210 CCP8
Page 1 of 23 page(s)
O OPERATING MANUAL
1 SAFETY INSTRUCTIONS
PREFACE
The following instructions are complementary to all official regulations and such
regulations as may have been issued by the trade associations and insurance
companies.
This chapter addresses safety issues in the location, installation, operation and
maintenance of Vacuum Pressure Swing Adsorption (VPSA) plants for the generation
of oxygen out of ambient air. Oxygen generators that utilize pressure swing adsorption
technology have some degree of potential hazards which must be recognized and
addressed. Common hazards associated with these generators are the asphyxiant
properties of oxygen-deficient atmospheres, and the ability of oxygen-enriched
atmospheres to accelerate combustion. Further hazards include noise, electricity,
rotating equipment and gases under pressure.
The personnel employed in this plant (either permanently or temporarily) must be

thoroughly familiar with the respective safety regulations and rules for the prevention
of accidents. A safety induction shall be done before assignment and afterwards not
less than once per year (or in accordance with the requirements of local regulations).
The training must include detailed information about possible dangers for personnel
and environment as well as the required protection measures and guidelines to avoid
such risks. It shall also contain behavioral rules in event of danger and first aid
measures.
The minimum information that is required is shown in IGC Document 23/18 "Safety
training of employees" (www.eiga.org).
Safety training of all personnel shall be thoroughly documented and confirmed by the
participants. All persons participating in such a safety training shall confirm by their
signature, that they have been instructed accordingly and fully familiarized themselves
with the instructions for the prevention of accidents and with the safety devices.
It is presupposed that only well trained and authorized operating personnel will run the
plant.
Modifications on the plant or on individual equipment, e.g. during maintenance and

repair work, must be thoroughly evaluated regarding their consequences to safety,
health and environmental issues. This also applies for changing the composition of
feedstocks or utilities, so that they will differ from the process data sheets, which are
the basis of the safety concept of the plant.
A permit to work system (example see IGC Document 40/17 "Work permit systems")
shall be established for all non-routine work, e.g. flushing and purging with temporary
connections, maintenance and repair work. Temporary connections such as hoses etc.
must be removed prior to equipment being put (back) into service.
LINDE is not liable for any unauthorized changes carried out without LINDE's written
approval. Refer also to 'Preamble' and 'Warning' note at the beginning of this manual.
For machines (e.g. blowers, compressors and pumps) as well as for packaged units
such as instrument air compressors or cooling water systems refer to the additional
safety instructions provided in the manuals of the respective machinery or package
supplier.
1.1 INTRODUCTION
The following chapters emphasize on hazards which are specific for the technology of
oxygen recovery by means of pressure swing adsorption technology.
Only limited coverage will be given to hazards of specific plant components such as
valves, pumps or compressors, as those items are widely used in other industrial
applications and safe practices in design, installation and use have already been
established elsewhere. For detailed safety instructions of such plant components,
please refer to the respective manufacturer's manual (see Technical Data Books of
this manual).
Coverage is also not extended to supplemental equipment such as liquid back-up

systems and product transmission piping outside the plant's boundaries, unless such
equipment does belong to the original scope of LINDE's supply. For safety instructions
on such equipment refer to the manuals of each individual supplier.
The most severe hazards in an oxygen plant are fire, explosion or unintended release
of gases. Therefore, the tightness of all parts of the plant is the fundamental
requirement for the construction and operation of such a plant.
The tightness of the plant will be jeopardized, if material is being over-stressed by

prohibited operation (e.g. beyond the process parameters) or poor maintenance or
repair work, respectively.
Material will be over-stressed, when it is exposed to conditions which it is not designed

for (e.g. pressure, temperature, composition, mass flow).
Process parameters like pressure, temperature, flow rate and

consistency of chemical components must be kept within their
specified limits. The relevant process parameters (e. g.
pressure, temperature, flow, composition) can be found on this
manual. They normally differ from the mechanical design
conditions.
A plant operation beyond the specified ranges is not covered
by the safety design and can lead to extremely hazardous
situations. Deviations from normal operating conditions must
be strictly observed and the reason for these changes shall be
found out and eliminated as fast as possible.
An increase of the plant load exceeding the specified limits may
result in not permitted overload of equipment.
Local safety rules and regulations for the prevention of accidents must be observed
during operation of air separation plants. This applies equally to storage, transport and
subsequent treatment of the products generated from any of such plants.
International standards, rules and guidelines for safety, health and environment,
especially covering equipment used for generation or handling of oxygen (e.g. issued
by EIGA, CGA or other associations) must be observed as well.
1.2 DANGERS
The following details are intended to provide a general view of possible dangers that
may arise in operating air separation plants or in handling the products of such plants.
Recommendations are also made for minimizing such dangers.
However, it cannot be claimed that these details and recommendations are fully
comprehensive. It is imperative that one should observe and follow international as
well as all the local safety instructions valid for each specific plant.
1.2.1 FIRE HAZARDS OF OXYGEN AND OXYGEN ENRICHED ATMOSPHERES
Oxygen in the sense of this chapter not only includes pure oxygen but also any mixture
of oxygen/air containing more than 21% of oxygen.
Oxygen is essential to life and although oxygen itself will not ignite and is neither a fuel
nor inflammable, it supports and accelerates combustion (strong oxidizer).
Gaseous oxygen (GOX)

Gaseous oxygen is slightly denser than air. It is a colorless, odorless and tasteless gas
and therefore the presence of oxygen enriched atmosphere cannot be detected by
normal human senses. Gaseous oxygen also does not give any physiological effects
which could alert personnel to the presence of oxygen enrichment.
Liquid oxygen (LOX)

Liquid oxygen is slightly denser than water. It is a light blue, odorless, transparent liquid
with a temperature of -183°C at ambient pressure. Due to this low temperature, any
kind of contact with liquid oxygen (but also with the oxygen vapor rising from it) will
cause severe frostbite.
The uncontrolled release of liquid oxygen leads to the formation of a large cloud of
gaseous oxygen as every liter of liquid oxygen will generate a cloud of approx. 850
liters of gaseous oxygen. Due to its low temperature, this cloud will not mix well with
the surrounding air (three times heavier than air). The cold gas lowers the air
temperature causing mist to form. A mist-free zone is formed close to the discharge
point. The air in this area will have been completely replaced by the discharged oxygen
(100% oxygen atmosphere).
As any kind of oxygen – whether resulting from a release of liquid or gaseous oxygen –
is heavier than air, it will accumulate in lower areas such as pits, trenches or
underground rooms, resulting in oxygen enriched atmosphere.
The normal concentration of oxygen in ambient air is approximately 21% by volume.

Any oxygen concentration higher than 23.5% creates a significantly greater fire hazard
than normal air.
Most materials burn fiercely in oxygen, the reaction may even be explosive. The risk
of fire increases with:
- Rising concentration of oxygen
- Rising temperature and
- Rising pressure of oxygen and mixtures of oxygen
For any kind of fire or explosion to occur, three conditions must be present, symbolized
by the 'triangle of fire':
With the elimination of one of those three conditions a fire cannot occur.
As the presence of oxygen itself cannot be eliminated inside this plant, the main focus
must be to eliminate
- fuel (i.e. the combustible material)
- heat (i.e. the source of ignition) and additionally
- avoiding unintended release of oxygen from the plant itself
Very detailed coverage about this subject can be found in IGC Document
04/18 'Fire hazards of oxygen and oxygen enriched atmospheres' (www.eiga.org).
This document not only includes description of the dangers connected with oxygen,
but also contains useful material for safety trainings and exemplary cases of accidents
that happened in connection with oxygen.
Combustible materials
In principle, almost any organic or metallic material will burn in fiercely in oxygen.
Rising pressure will increase most oxygen hazards, as

- it lowers the ignition temperature (of non-metallic materials)
- it lowers the minimum energy required for ignition
- lower content of oxygen is sufficient to sustain combustion
- combustion rate increases
Therefore, any pressurized oxygen system must only be constructed using materials
which have been approved for the relevant operating conditions (pressure,
temperature, oxygen concentration).
Oil and grease are extremely hazardous in presence of oxygen, as they can ignite very
easily and burn with explosive violence. In oxygen plants ignitions of oil and grease
often cause a chain reaction which results in metal burning or melting. A jet of flame
and a widening spray of molten metal are projected away from the equipment under
fire and may be accompanied by a release of high-pressure oxygen. The consequence
will be a fierce and rapidly spreading fire in any adjacent combustible material.
One of the most common combustible materials affecting personal safety is clothing.
All clothing material will burn fiercely in oxygen. The same applies to plastics and
elastomers. Enrichment of oxygen will also occur in clothing, if the person is exposed
to an elevated concentration of oxygen for a certain period of time. Once ignited by
even a relatively weak ignition source such as a spark or a cigarette, clothing may burst
into flames and burn rapidly.
Ignition sources
Ignition sources may be
- adiabatic compression
sufficient heat is generated when a gas is rapidly compressed from low to high
pressure (direct ignition of non-metals)
- mechanical friction
heat generated by rubbing between two or more parts
- mechanical impact
single or repeated impact with sufficient energy to ignite material
- particle impact
small particles striking a material with sufficient velocity to ignite the particle
and/or the material itself (direct ignition of metals)
- flow friction
high flow of oxygen leaking across a polymer in a way to create enough heat
- contaminant promotion
heat from ignition/combustion of a more flammable material such as
contaminants inside the system igniting less flammable materials such as
metals
- electrical arcing, electrostatic discharge
Release of oxygen
Reasons for oxygen enrichment may be
- leaking connections on flanges, fittings etc.
- breakage of system under oxygen pressure
(by accident, vibration etc.)
- desorption, when cold adsorbent material heats up
(e.g. molecular sieve, silica gel etc.)
- oxygen vents
Another frequent reason for serious accidents is the use of oxygen for applications for
which it was not intended to such as
- driving pneumatic tools
- pressurizing and purging systems
- cooling or refreshing the air in confined spaces
- cleaning of workplaces, machinery and clothing
1.2.2 OXYGEN DEFICIENCY
As oxygen is essential to life, lack of oxygen will also create a significant safety hazard.
The normal concentration of oxygen is approximately 21% by volume (see chapter

1.2.1), the normal concentration of nitrogen approximately 78% by volume.
Any oxygen concentration less than 19.5% constitutes a hazardous working

environment, resulting in a decreased ability to perform tasks, lack of coordination etc.
With decreasing content of oxygen any individual breathing this atmosphere will
become mentally incapable of diagnosing the situation.
Exposure to an atmosphere containing 12% oxygen or less will bring about

unconsciousness without warning so quickly, that individuals cannot help or protect
themselves.
Since vacuum pressure swing adsorption plants are generating oxygen out of ambient
air, the residual gas from such plants will contain a significantly higher level of nitrogen
than ambient air.
Nitrogen is a colorless, odorless and tasteless gas and therefore the presence of
oxygen deficient atmosphere cannot be detected by normal human senses. Nitrogen
is a simple asphyxiant and, if present in sufficient quantity, can reduce oxygen in the
local atmosphere and may cause death by suffocation.
Nitrogen enriched areas may appear inside closed buildings, around waste gas vents,
or in lower areas such as pits, trenches or underground rooms.
1.2.3 IMPURITIES
Insufficient cleaning and drying inside plant components will create a hazardous
condition:
- particles may cause serious damage to machines
- moisture may damage the performance of a VPSA plant irreversibly
- contamination in the system may result in severe fires in presence of oxygen
(see chapter 1.2.1).
The most frequent reason for a fire in oxygen plants are impurities which remained
inside the system after maintenance works!
Combustibles in a pipeline under oxygen service may be ignited, under certain flow
conditions, by impingement of particles on the metal surface. This applies to both loose
and easily removable particles such as rust, slag etc.
1.2.4 NOISE
The noise produced by compressors, vacuum pumps and by high gas velocities
through piping and valves creates a hazard to the hearing system of any person, who
must enter and remain inside the plant for a short time on a regular basis.
Since the effect of excessive noise is cumulative (it may take 10 years of regular
exposure to excessive noise before the effect becomes large enough to get serious),
the individual will not be aware about the dangers of excessive noise levels. Damage
to the hearing mechanism inside the ear is never reversible.
The effect of noise to the human ear measured over a time of 8 hours is called
‘assessment level’. Starting at a sound pressure level of 85 dB(A), a daily exposition
of 8 hours may cause irreversible hearing damages. With increasing sound pressure
level, the daily exposition time to cause a possible hearing damage decreases
dramatically:
exposition time sound pressure level exposition time sound pressure level
8 hours 85 dB(A) 15 minutes 100 dB(A)
4 hours 88 dB(A) 7‘ 30“ 103 dB(A)
2 hours 91 dB(A) 3‘ 45“ 106 dB(A)
1 hours 94 dB(A) 1‘ 52“ 109 dB(A)
30 minutes 97 dB(A) 0‘ 56“ 112 dB(A)
The expected average sound pressure level inside the machine house is
approximately 110 - 120 dB (A). Hence the danger of irreversible damage to the human
ears is already present with a daily exposition time of less than two minutes!
1.2.5 BRITTLE FRACTURE
The risk of brittle fracture is given, if equipment is operated below its minimum design
temperature and sufficient stress is present, e.g. caused by internal pressure or
thermal stress.
Brittle fracture may happen, if liquefied or low temperature gas is fed into plant
components, which are not designed for low temperature conditions (e.g. vessels or
piping made of carbon steel).
1.3 PROTECTIVE MEASURES
The following protective measures are recommendations to avoid the previously

named dangers. However, these advices and recommendations cannot be fully
comprehensive. Local safety rules and regulations for the prevention of accidents must
be followed.
International standards, rules and guidelines for safety, health and environment,
especially covering equipment used for generation or handling of oxygen (e.g. issued
by EIGA / CGA or other associations) must be observed as well.
Inside of air separation plants and all plants, where the product gases of such air
separation plants will be stored, transported or further processed, the following
protective measures are strictly recommended.
1.3.1 CLOTHING
The use of proper personal protective clothing such as overall, safety shoes, gloves,
hard hat and similar is a mandatory requirement. The extent and type of work wear to
be used should follow the local conventions of the plant site.
Fire-resistant or flame-retardant clothing can help to reduce the fire hazards when
working with oxygen, but prevention of the fire hazard shall be the primary objective,
since most of the materials used may burn in presence of higher concentrations of
oxygen anyway. Furthermore, the effectiveness of the fabric treatment can wear off
after washing.
The advantage of fire-resistant or flame-retardant clothing is the fact that those would
be self-extinguishing once removed to a normal air atmosphere.
In general, synthetic materials are preferable to cotton from a flammability point of view,
however they tend to melt and cause serious burns due to the adhesion of the molten
material to the skin.
The danger of oxygen enrichment in clothing will always be present, regardless of the
type of clothing used. Therefore, any kind of work wear should always be free from oil
and grease. Even fatty cosmetics may constitute a source of danger.
Persons who have been exposed to an oxygen enriched atmosphere shall not smoke
or go near open flames, hot spots or sparks until their clothes have properly ventilated
in normal atmosphere. A ventilation period of at least 15 minutes with movement of
arms and legs and with coats unbuttoned is recommended.
Special attention shall be given to accidental sources of ignition. To prevent unintended

sparking, shoes studded with iron nails or having other iron or steel parts must not be
worn. No means of ignition shall be carried. Electrostatic charging shall be eliminated
by using clothes and shoes made of suitable materials.
1.3.2 DESIGN OF BUILDINGS
Facilities where oxygen is produced must have ceilings, walls and floors made of
non-combustible building materials.
Areas where oxygen is produced, compressed or where liquid oxygen is evaporated

must be separated from adjacent rooms, which are endangered for fire or explosion,
to an extent that no enrichment of oxygen can appear in these rooms.
Buildings in air separation plants and their auxiliaries must be equipped with sufficient
ventilation systems to avoid enrichment of oxygen in the air. Depending on
requirements, fans or blowers may be necessary. Sufficient ventilation must be
provided. Natural ventilation may be sufficient if the ventilation openings are big
enough, are located diagonally opposite each other and free circulation of air without
blind spots is possible.
If natural ventilation is not possible, a fan unit with a capacity of at least 6-8 air changes
per hour shall be installed. Provisions must also be made for the ventilation of cellars,
pits and channels, since the danger of increased concentrations of leaking gas is
particularly high in such locations.
Areas where oxygen enrichment may appear (e.g. vent lines and blow-offs) must be
marked accordingly and increased precautions shall be taken. All vents should be
piped to a safe area to prevent oxygen enrichments hazard.
A sufficient number of emergency exits must be provided and clearly marked.
In areas where oxygen is produced and inside the protective barriers of oxygen
compressors the storage of combustible materials is prohibited and self-igniting
materials must not be present. An exception to this rule is only given for those
lubricants and raw materials that are necessary for the operation of the plant.
Areas with a risk of release of large quantities of gas (especially around the liquid
oxygen backup tank) must not have any basement openings within a radius of 5
meters, all drain inlets must be provided with a liquid seal.
Paving in the storage area of liquid oxygen systems including the unloading areas for
trucks or similar must be of non-flammable material (e.g. concrete, cobblestone).
1.3.3 PROTECTIVE MEASURES AGAINST FIRE HAZARDS
Special care must be taken against oxygen-enriched atmosphere. It is not allowed to

stay or work in areas with increased concentration of oxygen or in areas where
increased concentration of oxygen may appear.
Any kind of hot work involving open flames, such as welding, soldering, grinding etc.
is strictly forbidden inside the plant area. However, if such work is required, steps must
be taken to avoid enrichment of oxygen in the work area before starting such work.
During execution, it must be assured that no enrichment of oxygen in the working area
will appear.
A written work permit from the plant operator is required for hot work. The plant
operator shall define the necessary protective measures in his permission, e.g.
depressurizing of the equipment, blanking and purging of pipelines, personal safety
precautions during work like gas monitoring, cleaning procedures, inspection of
cleanliness etc. Works shall only be carried out under observation of a responsible
supervisor.
1.3.4 FIRE PROTECTION EQUIPMENT
It must be clearly indicated, that smoking and the use of open fire are forbidden inside
air separation plants and inside all oxygen endangered areas.
This applies to all areas where oxygen is produced, compressed, filled or liquid oxygen
will be evaporated, as well as to outside areas where enrichment of oxygen possible.
This rule shall be clearly indicated, unless there is a similar restriction given for the
whole factory premises.
Depending on the size of the plant, sufficient fire fighting equipment must be provided
and kept ready for use. The primary fire protection for oxygen plants is a sufficient
water supply. Other suitable media could be dry chemical (powder) or carbon dioxide.
Automatic fire extinguisher systems - for instance with CO2 - that may cause danger to
any personnel employed, must be equipped with self acting warning devices.
Portable fire extinguishers should be strategically located throughout the plant and
must be accessible fast and easily. All places where fire extinguishers are located must
be clearly and permanently marked, as long as they are neither operated automatically
nor centrally.
The use of powder extinguishers, suitable for class A, B, C and D according to

DIN-EN 2 as well as CO2-extinguishers, specifically for electrical equipment is
recommended.
A sufficient number of employees must be trained in operation of fire extinguishing

devices.
All installations must be kept in good condition at any time. Alarm devices shall be
inspected in regular intervals. The plant operator must make sure, that all fire
extinguishers are checked for proper function by an expert on a regular basis (at least
every 2 years or in accordance with local regulations). Record shall be kept about these
inspections.
Suitable equipment must exist for extinguishing burning clothes. For this purpose, the
use of emergency showers is recommended. Emergency showers must be designed
to open completely with just a single grasp. Fire blankets are not suitable for this
purpose. In case of emergency, the fire may as well be choked by rolling the person
on the floor. Running away of people with burning clothes under panic must be
prevented.
1.3.5 REPAIR AND MAINTENANCE WORKS
Only qualified and reliable persons shall be allowed to maintain plant equipment.
Construction personnel shall be familiarized with plant safety regulations and made
aware of all potential hazards.
All work in the plant shall be controlled by means of a work permit system and
lock-out/tag-out procedure that will promote critical analysis of the safety aspects and
hazard potential of the job as it applies to all personnel.
Consideration shall be given to the following hazards:

- Oxygen-enriched or oxygen-deficient atmospheres
- Working at heights
(if works must be performed significantly above grade)
- Working in confined spaces
- Trapped or elevated pressure
Following precautionary measures shall be taken before starting work:

- Depressurizing of vessels and/or piping
- Isolating pipelines and/or vessels with blind flanges
- Purging with dry and oil free air followed by monitoring of atmosphere
Greases and lubricants, which get in contact with oxygen, may only be used if
- those are absolutely necessary for proper function and
- if they have been tested by an authorized inspection authority and found
suitable for the intended use considering the relevant operating pressures and
temperatures; any kind of lubricant contained in spray cans with inflammable
gases are generally considered not suitable
1.3.6 GENERAL SAFETY PRECAUTIONS
Machines and other equipment must be separated from power supply before starting
of work. Suitable measures must be taken against unauthorized re-powering (lock-
out).
The term ‘power supply’ does not exclusively refer to all kinds of electrical power, but
also includes isolation from any other mechanical driving force such as pressurized
vessels, instrument air system or similar. For any kind of work involving valves, the
instrument air supply must be disconnected and de-pressurized, to avoid unintended
switching of valves.
Precautions shall be taken to ensure that equipment cannot be started without the
knowledge of personnel in the area around the equipment.
These measures not only apply to working at machinery itself, but also any kind of
work involving valves or the piping system.
1.3.7 MATERIALS USED IN OXYGEN PLANTS
Components must never be replaced by substitute or 'equal grade' material. Any

material in contact with oxygen must only be used, if it has been tested successfully
by an authorized institution for compatibility with oxygen considering the relevant
pressure and temperature conditions.
Preference shall be given to original manufacturer spare parts and original gasket
materials.
In case new materials should be used, the respective supplier shall give proof for its
compatibility with oxygen by showing certificate of an authorized institution.
1.3.8 CONFINED SPACES
Special consideration must be given to work inside of vessels and other confined
spaces, like storage tanks, pipes, pits etc. This is even more important in air separation
plants, due to the additional danger of enrichment of dangerous gases (see sections
"Fire hazards of oxygen and oxygen enriched atmospheres" and "Oxygen deficiency").
Strict precautions shall be taken before entering any confined spaces with potentially
oxygen-enriched or oxygen-deficient atmospheres, such as vessels, storage tanks,
ducts or other closed or poorly ventilated areas, as serious injuries or fatalities can
occur.
Atmosphere within all such confined spaces must be checked and unprotected
personnel prohibited from entering an atmosphere that does not fall within the range
of 19.5% to 23.5% oxygen.
A written work permit from the plant operator is required before starting of works in
confined spaces. The permit shall define the necessary protective measures such as
blanking and purging, monitoring of atmosphere in the working area etc. These works
must only be carried out under survey of a responsible supervisor. The work may only
be started, if the authorized supervisor has verified that all written safety measures
have been followed.
Before working in vessels or confined spaces it must be assured, that the work space
is effectively disconnected from all sources which may change the normal ratio of
nitrogen and oxygen. This can be done by taking out intermediate pieces of piping or
by using tight closing and clearly visible blind discs. Sizes and materials shall match
the expected pressures and temperatures as well as other stresses applicable.
Before entering vessels or pipes, these areas must be purged sufficiently with air. The
concentration of oxygen shall be closely monitored. During the entire work, sufficient
ventilation of air (preferably forced ventilation) must be kept and the atmosphere inside
these areas must be checked frequently. Special consideration shall be given to
enrichment of oxygen or nitrogen as well other gases, steams or dusts (for instance
cleaning agents, swarf a. s. o.). The use of self-contained breathing apparatus or direct
air supply is an option that may be considered, but it will not eliminate the risk of other
hazardous conditions, like evaporation of cleaning agents, which may create a
significant fire hazard. Sufficient ventilation of these areas will still be necessary.
Personnel working in confined spaces shall use the attendant system for protected
entry, i.e. a safety guard outside of the vessel will stay in permanent contact with
people inside the vessel, either by visual sight, voice communication or a rope
connection.
Working with electrical equipment inside of vessels or piping will require safety
measures against electrical dangers such as protective insulation or low voltage tools.
Before starting of fire works inflammable materials must be removed and suitable fire
extinguishing devices must be kept in reach. The use of pressurized gas bottles inside
of confined spaces is not allowed. Burners and hoses must be removed from confined
spaces during any interruption of work. Welding works inside these areas will require
removal of evolving gases and fumes. Electric arc welding is only allowed using
protective isolation or low voltage equipment.
For work on molecular sieve adsorbers:

Avoid contact between molecular sieve material and moist parts of the body, especially
mouth and eyes. Clothes must cover the body entirely. Eye protection and protection
against dust are required for work.
1.3.9 CLEANLINESS AND INSPECTION
Recognition of oxygen's reactivity has led to stringent requirements regarding

cleanliness of equipment in oxygen service.
Attention for best cleanliness shall be paid during all steps of repair and maintenance.
This is required for all parts of the plant getting in contact with oxygen, like piping,
instruments and machinery, but also for any kind of tools, which are used to work on
such parts.
Start Verify Assemble Maintain

clean clean clean clean
Many parts of the plant may not see oxygen enriched media during normal operation.
However, they may be exposed to oxygen during process upsets, startup or shutdown.
Hence it is a common practice to observe strict cleanliness also for these parts.
Due to the high fire hazard all parts of the plant getting in contact with oxygen must be
'Cleaned for oxygen service', as far as technically possible. This means they must
not have any visible traces of
- organic material such as oil, grease, paint etc.
- cleaning agents, detergents
- rust and loose scale, weld splatters, dust, fibers or other foreign material
- moisture, liquids
- accumulation (i.e. a local concentration) of particles of any size is not
acceptable
There are several factors to be considered in choosing the most appropriate cleaning
process. It depends on the type of contamination (particle, organic, film and/or fluid),
size and accessibility of the parts in the cleaning process, environmental, health and
safety aspects, the compatibility of the cleaning agent with the construction materials
and on economic aspects as well.
Cleaning in a workshop and cleaning at site may require different cleaning procedures.
Equipment with complex geometry (e.g. valves or machinery) shall be disassembled
for cleaning as far as the construction permits, as non-volatile cleaning agents may
remain trapped and react with oxygen, may destroy non-metallic components in an
assembly or cause corrosion of metallic surfaces.
For these reasons, preference shall always be given to cleaning in the workshop prior
to final assembly and maintaining the cleanliness level during all subsequent steps of
assembly and operation.
Information for suitable cleaning agents and procedures can be given by the supplier
of the respective component.
Typical cleaning methods for cleaning of components in oxygen service include:

- Mechanical cleaning
- Chemical cleaning
- Detergent cleaning
- Hot water / steam cleaning
- Emulsion cleaning
- Solvent cleaning
A detailed survey of the different cleaning methods, their advantages/disadvantages

and the relevant safety precautions can be found in IGC Document 33/18 'Cleaning of
equipment for oxygen service' (www.eiga.org).
Before application of any kind of cleaning agent, local safety regulations concerning
the acceptance of usage and the use of adequate personal safety equipment has to
be reviewed. This applies especially for cleaning agents containing volatile
substances. Special consideration must be given to comply with the occupational
exposure limits.
Before re-assembly all impurities, residues of cleaning agents and possible emulsified
contaminants must be removed as far as technically possible from the cleaned parts.
This applies particularly to cleaning processes where the cleaning agent itself can
create a fire hazard with oxygen (e.g. solvents) or may negatively affect certain
components such as sealing systems. Drying of cleaned equipment might be required
to prevent corrosion and to speed up the total cleaning process.
The cleanliness of the equipment shall be verified by the responsible supervisor prior
to re-assembly. Acceptance criteria must be defined in accordance with the equipment
manufacturer's quality control procedures and depend strongly on the pressure range.
Based on these considerations, limits will be defined for:
- Oil, grease and detergents
- Other foreign matter like particles, dust, liquids etc.
Various methods exist for determining the cleanliness of the cleaned parts. It is
necessary that the selected method complements the cleaning method and shows
whether the acceptance criteria are achieved.
Recommended test methods to determine cleanliness are
• Visual examination under bright white light (daylight or artificial light), using a
magnifying glass, wherever required:
impurities and particles must not be visible
• Visual examination with ultraviolet light:

strong fluorescence may not be visible
ATTENTION: Oil and grease from herbal, animal or synthetic origin do not
fluorescence like hydrocarbons from mineral origin. The fluorescence of
mineral oils is different as well.
• Wiping test by using a white, lint-free cloth or filter paper:

After forceful wiping the cloth or paper will be tested by each of the previously
mentioned methods
• Solvent flushing test in laboratory:

Applicable also for inaccessible surfaces polluted with oil or grease. Special
agreements are required. Fresh, applicable solvents shall be used in a well-
known amount. The parts to be cleaned will be dipped into a bath or surfaces
of bigger parts will be purged with the solvent. The solvent will be drained and
by evaporation of the probe the solved amount of oil grease will be detected.
Further inspection methods can be found in IGC Document 33/18 'Cleaning of

equipment for oxygen service' (www.eiga.org).
Equipment shall be clearly marked as 'Cleaned for oxygen service' after successful
inspection.
However:
- Inspection is usually the last line of defense in assuring
cleanliness
- If contamination is observed, previous process has failed and
components need to be re-cleaned
- Non-observance of contamination is no guarantee that parts are
clean
Inspection must rely on a qualified cleaning process
The cleanliness of each part shall be preserved during storage, intermediate transport,
shipment and installation up to the time of start-up. Impurities shall be avoided by
taking suitable measures.
Touching of clean parts with oil contaminated cloth or greasy fingers is strictly
prohibited. Clothing must be absolutely free of oil and grease.
Protection against contamination can be provided by various means, such as packing

in clean plastic bags with desiccant agents, blinding of openings, pressurizing with dry
and oil free air or nitrogen etc.
The preservation shall not be removed until the equipment is ready to be installed.
Prior to installation, the cleanliness shall be verified again to ensure that the required
standard has been maintained and that the equipment is suitable for oxygen service.
- Ensure initial cleanliness of components

(e.g. incoming inspection)
- Ensure clean environment and procedures
- Minimize time of exposure (keep parts packed until use)
- Inspect components again prior to assembly
- Ensure clean assembly
- Minimize quantity of compatible lubricants
1.3.10 NOISE PROTECTION
The expected average sound pressure level around the machinery is approximately
110 dB (A). The area shall be designated and signed as restricted area. Any kind of
entry to the plant in operation shall be restricted to the absolute minimum, like regular
inspections and check visits.
The wearing of suitable hearing protection is mandatory for all areas where noise
exceeds the legal levels. This applies equally to temporarily employed personnel and
for daily inspection walks of the shift personnel.
All hearing protection shall conform to the requirements of recognized standards, such
as EN 352-1 for ear-muffs.
Due to the high sound pressure level wadding or earplugs are not suitable for personal
protection. The choice of the hearing protection (e.g. earmuff, helmet-mounted
earmuffs…) should be determined by taking into consideration both separately and in
combination
− frequency of use
− noise level
− duration of exposure
− ambient noise level
− frequency spectrum of the noise
− additional equipment required for work activity
(e.g. helmet, goggles...)
1.3.11 SAFETY DEVICES AGAINST EXCESS PRESSURE
All vessels and piping under pressure and any equipment, where pressure can build
up, must be provided with safety devices against excess pressure. All devices against
excess pressure must be held in good and workable condition. The set pressure of
safety valves shall be tested regularly and adjusted if required.
Safety devices against excessive pressure are not provided for the adsorber vessels
and the oxygen product buffer, since the upstream air compressor is the only source
of air supply and is protected against excess pressure with a suitable device.
1.3.12 START OF THE VPSA
The VPSA-plant must be protected against entry and presence of unauthorized

persons at any time. Before start of the plant, operators must verify that no person is
inside the plant area.
Since the plant is designed for remote operation and the operator typically has no
visual contact to the plant area during start, optical and acoustical warning devices
(flashing alarm horn) are provided to indicate an upcoming start. Signs that warn of the
potential of automatic start of the plant must be clearly posted around the equipment.
At the sound of the horn all persons inside the plant must evacuate the plant area
immediately. The proper function of the warning device shall be checked periodically
by the plant operator.
Prior to restart of the plant after shutdown, especially following any kind of maintenance
works, the plant operator must make sure that the plant is in safe condition.
It must be verified that all safety measures have been taken (cleanliness, fire
protection…), that all flange connections are closed tight, all blind discs, shut-offs or
other devices have been removed or opened. The correct installation of guards for
couplings, covers for electrical terminals etc. must be checked.
1.4 SAFETY SIGNS ACC. EUROPEAN DIRECTIVE 92/58/EC (EXTRACT)
1.4.1 PROHIBITION SAFETY SIGNS
No smoking or naked flames
No access for unauthorized persons
Do not switch
1.4.2 MANDATORY SAFETY SIGNS
Use ear protectors
Safety helmets must be worn
1.4.3 HAZARD SAFETY SIGNS
Oxidizing agent
Electrical danger
Hot surface
Danger of automatic start
Gas cylinder
Danger overhead crane
1.4.4 SAFETY SIGNS
First aid
Emergency shower
Escape route
Emergency exit
1.4.5 FIRE EQUIPMENT SIGNS
Fire extinguisher
Fire fighting device (general)
Fire hose
Fire alarm
ATTACHMENT: SAFETY DATA SHEETS
Adsorbent material (TYPES: LMS K300, LMS CL8, LMS CL5 )
SAFETY DATA SHEET
(according to Regulation (EC) No 1907/2006)
Trade Name: Linde Adsorbent - LMS Document No: &AA Q-QS 1005 (EN)
Product No: LMS 200, LMS 215, LMS 216, LMS 400, LMS 750, LMS 920, LMS 920N, LMS Issue: 26.0
930, LMS 930N, LMS 935, LMS 935N, LMS 1020, LMS 1030, LMS 1035, LMS Date: 2023-08-21
1040, LMS 920S, LMS 930S, LMS 935S, LMS C200F, LMS CCL5, LMS CL2, LMS Print Date: 2023-08-21
CL5, LMS CL8, LMS CL0, LMS G50, LMS G100, LMS G122, LMS G144, LMS
Page: 1 of 10
G200B, LMS G200C, LMS G200D, LMS G215B, LMS K225, LMS K300, LMS
K303, LMS K300T, LMS K330T, LMS K335T, LMS K1825, LMS K2550, LMS
K2535, LMS K5012, LMS K5012L, LMS K5025, LMS K5025L, LMS KL5, LMS
KL8, LMS L1-17, LMS X2015, LMS X2021, LMS X5015, LMS X5021, LMS
XEP20, LMS XSP20, LMS 1120, LMS 1130, LMS 1135, LMS 1140, LMS CL305,
LMS CL308, LMS CL315, LMS CL725, LMS CL735, LMS CL755, LMS CL201, LMS
CL202, LMS CL105, LMS CL108, LMS CL535, LMS CL555, LMS CL733, LMS
C812K, LMS K304, LMS CL515, LMS K304, LMS K700, LMS K700T, LMS C814,
LMS C812K, LMS CL105, LMS CL108, LMS CP520, LMS CP530, LMS CP540,
LMS CP620, LMS CP630, LMS CP640, LMS A303C, LMS A304C
1. IDENTIFICATION OF THE SUBSTANCE/PREPARATION AND OF THE COMPANY/UNDERTAKING
1.1 Identification of the substance or preparation

LINDE ADSORBENT – LMS
1.2 Use of the substance / preparation

Identified uses: Adsorbents
1.3 Company/undertaking identification

Supplier: (Downstream user)
Linde GmbH, OS Engineering
Dr.-Carl-von-Linde-Str. 6-14
82049 Pullach Emergency Assistance - 24 hour Emergency
GERMANY Telephone Number: +49-89-7445-2112
Tel: +49-89-7445-0
Fax: +49-89-7445-4908
2. HAZARDS IDENTIFICATION
2.1 Hazards description

2.1.1 Label elements
Regulation (EC) No 1272/2008 [CLP]: The product does not require a hazard warning label in accordance
with GHS criteria.
Directive 67/548/EEC or 1999/45/EC: The product does not require a hazard warning label in accordance
with EC Directives.
2.1.2 Classification of the substance or mixture

Regulation (EC) No 1272/2008 [CLP]: Not hazardous.
Directive 67/548/EEC or 1999/45/EC: Not hazardous.
2.1.3 General information

When first wetted, the product can heat up to the boiling point of water. Flood with water to cool material.
Repeated or prolonged exposure may irritate eyes, skin and respiratory system. Repeated and prolonged
inhalation of crystalline silica in the form of quartz from occupational sources may cause cancer.
Refer to protection notice ISO 16016.

Form: &AX-Q-PP 1050.460.011 (EN) / draft 0.1 dated 29.09.2010
SAFETY DATA SHEET
Page: 2 of 10
3. COMPOSITION/INFORMATION ON INGREDIENTS
3.1 Preparation/mixture related information

Description: CAS No EINECS No Conc. REACH No
Zeolite 1318-02-1 215-283-8 >99% 01-2119429034-49-XXXX
(aluminosilicate)
Water 7732-18-5 231-791-2 <1%
Quartz 14808-60-7 238-878-4 < 1% 02-2119513676-36-0000
4. FIRST AID MEASURES

General information: The product has a drying effect and may therefore cause irritation.
In case of inhalation: Remove to victim to fresh air. If symptoms persist, call a physician.
In case of skin contact: Wash off with soap and plenty of water. If skin irritation persists, call a physician
In case of eye contact: Flush immediately with plenty of water for at least 15 minutes. If eye irritation
persists, consult a physician.
In case of ingestion: Immediately give large volume of water to drink. If symptoms persist, call a
physician.
Information to physician
Treatment: This product is a desiccant and generates heat as it adsorbs water. Symptomatic
treatment is advised. The used product can contain material of a hazardous nature.
Identify that material and treat symptomatically.
5. FIRE FIGHTING MEASURES
Suitable extinguishing The substance is non-flammable and non-combustible. Fire fighting agents are to be
media: selected to suit the fire in the surrounding area.
Specific hazards: The product itself does not burn. The used product can retain material of a hazardous
nature. Identify that material and inform the fire fighters.
Special protective In the case of breathable dust and/or fumes, use self-contained breathing apparatus
equipment: and dust impervious protective suit.
Further information: The heat development that occurs if the product reacts with fire fighting water can
result in a maximum temperature increase of 60 K and is therefore insignificant in
normal circumstances.

SAFETY DATA SHEET
Page: 3 of 10
6. ACCIDENTAL RELEASE MEASURES
Personal precautions: Avoid dust development if possible and do not inhale any dust that may occur. If dust
develops wear a breathing mask, safety goggles and safety gloves. Avoid lengthy
direct skin contact as a result of the risk of the skin drying out.
Environmental No special environmental precautions required.
precautions:
Methods for cleaning up Sweep, shovel or vacuum spilled product into appropriate containers but do not use a
or taking up: vacuum if material has contacted a hydrocarbon material. Pick-up and arrange
disposal without creating dust. Never use spilled product. Spilled product should be
disposed of in accordance with all applicable government regulations.
Intensive skin contact may cause drying.
Reaction with water results in palpable heat development.
7. HANDLING AND STORAGE
7.1 Handling: Handle and open container with care. Avoid formation of dust particles. Avoid contact
with skin and eyes. Provide an electrical ground connection during loading and
transfer operations to avoid static discharge in an explosive atmosphere and to
prevent persons handling the product from receiving static shocks.
Zeolite depletes oxygen from air and, therefore, dangerously low levels of oxygen
may be encountered. Whenever workers enter a vessel containing zeolite, the
vessel's oxygen content should be determined and work procedures for potentially
low oxygen areas be followed. Appropriate protective equipment should be worn.
Zeolite is non-flammable and not explosive.
7.2 Storage: Store the product in the tightly sealed original containers in a dry room. Do not store
outdoors. If the product has to be stored temporarily outdoors, the original containers
are to be protected from precipitation using suitable materials (watertight tarpaulins,
etc.) . If necessary the product may be decanted into other tightly sealing containers.
The decanting process must be designed to ensure that the product cannot absorb
humidity from the air unnecessarily. The product must be stored such that there is no
possibility of other stored items damaging the packaging.
Storage stability: If stored correctly the product remains fully useable for several years.

SAFETY DATA SHEET
Page: 4 of 10
Further information on -
storage conditions:
8. EXPOSURE CONTROLS / PERSONAL PROTECTION
8.1 Components with occupational exposure limits

There are no special exposure limits for molecular sieves. The general dust limit value is to be kept.
In case no specific national exposure limit is established, the national exposure limit for general
dust applies.
Workplace Exposure Limit:
UK (WEL) Germany (AGW)

Zeolites (1318-02-1) Long term*: 4 mg/m³ Short term*: 6 mg/m³ Long term*: 3 mg/m³
Long term**: 10 mg/m³ Short term**: 20 mg/m³ Long term**: 10 mg/m³
* Alveolar/respirable dust ** total inhalable dust
1 ACGIH has not established specific exposure limits for this material. However, ACGIH has established limits for nuisance dusts which are the least stringent exposure limits applicable to dusts.
The ACGIH TLV/TWA for particulates not otherwise classified is 10 mg/m3 total dust (TD). These limits are stated only to indicate the least stringent airborne dust exposure levels applicable to
nuisance dusts.
Derived No Effect Levels – DNELs:
Zeolites (1318-02-1) General Population Workers

Oral DNEL (long-systemic): 1,25 – 1,5 mg/kg bw/day
Dermal DNEL (long-systemic): 1,25 – 1,5 mg/kg bw/day 2,5 – 3,0 mg/kg bw/day
Inhalativ DNEL (long-local): 3 mg/m³
Predicted No Effect Concentrations - PNECs
Zeolites (1318-02-1)
PNEC aqua (Freschwater) 3,2 mg/l (Daphnia magna)
8.2 Personal protective equipment

SAFETY DATA SHEET
Page: 5 of 10
Respiratory protection: No special breathing apparatus is required if the product is used correctly. If it is
not possible to avoid the formation of fine dust, or in case of insufficient
ventilation, wear suitable respiratory equipment:
- Disposable filtering half mask Class FFP3 (EN149).
- Half mask with a particle filter P3 (EN143).
Hand protection: No special hand protection is required if the product is used correctly. Avoid
unnecessary and lengthy direct skin contact as a result of the risk of the skin drying
out. After completing work, wash hands thoroughly and apply suitable cream.
In case of skin exposure, use protective gloves:
- Type of material: Dustproof (Vinyl-PE-PVC-Nitril-Latex)
- Protection Category: Category 1 (EN420)
- Breakthrough time: N.A.
Eye protection: No special eye protection is required if the product is used correctly. If it is not
possible to avoid the formation of fine dust, tight-fitting goggles must be worn.
Body protection: No special body protection is required if the product is used correctly. If it not
possible, use lightweight protective clothing.
General safety and Handle in accordance with local environmental regulations and good industrial
hygiene measures: hygiene and safety practice. Hands and/or face should be washed before breaks
and at the end of the shift.
Ensure adequate ventilation, especially in confined areas by using local exhaust
ventilation system. In case of exposure to large quantities of wetted product, the
oxygen level should be checked. In conditions with low oxygen a self containing
breathing apparatus should be used.
9. PHYSICAL AND CHEMICAL PROPERTIES
9.1 Appearance
Physical state: Colour: Odour: Odour threshold:
Solid beads or pellets Slight brown or white Odourless N.A.
Value Method Remark

pH (20°C) 8 – 11 With 5g to 100g water -
Melting Point/Range > 1000 °C - -
Boiling Point/Range (°C) Undetermined - -

SAFETY DATA SHEET
Page: 6 of 10
Phase conversion Thermal decomposition at - -

approx. 600°C, resulting in the
formation of aluminium oxide
and silicium dioxide phases
Flash Point (°C) Not applicable - -
Flammability Non- flammable and not fire - -
promoting
Self-igniting Product is not self-igniting - -
Explosive properties Not explosive - -
Vapour Pressure (°C) Not applicable - -
Vapour density Not applicable - -
Relative Density (kg/m³) Not applicable - -
Bulk Density (kg/m³) 600 – 800 kg/m³ - -
Water Solubility (20°C in g/l) Insoluble in water - -
Solubility Insoluble in solvents - -
Viscosity, dynamic (mPa s) Not applicable - -
10. STABILITY AND REACTIVITY
Chemical stability: Stable at normal conditions.

Hazard reactions: No hazardous reaction known.
Conditions to avoid: No condition to avoid known.
Substance to avoid: The product is decomposed by mineral and some organic acids. The aluminium
content may be permanently dissolved in this case, whilst the silicium content may be
precipitated in the form of colloidal and/or crystalline silicic acid. When it reacts with
water the product releases a great deal of heat, but the maximum temperature is
limited to approx. 60 K.
Hazardous No hazardous decomposition products if used as directed. Hydrocarbons and other
decomposition products: materials that contact the product during normal use can be retained on the product.
It is reasonable to expect that decomposition products will come from these retained
materials of use.
11. TOXICOLOGICAL INFORMATION
Acute toxicity: No toxic effect on humans or animals is known.

SAFETY DATA SHEET
Page: 7 of 10
Zeolites (CAS Nr. 1318-02-1)

Effect dose
Species Method Evaluation Remark
(Exposure time)
OECD
LD50 (Oral) Rat > 5110 mg/kg
TG 401 The product has not been
Experimental/ OECD tested. The statement has been
LD50 (Dermal) Rabbit > 2000 mg/kg
calculated data TG 402 derived from the products of a
IUCLID Dataset similar structure or composition
LC0 (Inhalative) Rat > 3350 mg/m³/4h
18-02-2000
Irritating effects: Direct contact with the skin and mucous membranes may cause irritation as a result
of the removal of water.

OECD
Skin irritation Rabbit 0 The product has not been tested. The statement
TG 404
has been derived from the products of a similar
OECD
Eyes irritation Rabbit 0,7 – 1,3 structure or composition.
TG 405
Sensitization: No sensitising effect is known.

Buehler Test The product has not been tested. The statement
No sensitization
sensitization Guinea-pig OECD 406 has been derived from the products of a similar
observed
(Zeolite) structure or composition.
Subchronic toxicity: No negative effects were determined during test for Carcinogenity and
Teratogenecity.

SAFETY DATA SHEET
Page: 8 of 10
Additional toxicological The product is not subject to classification according to the calculation method of the
information: General EU Classification Guideline for Preparations as issued in the last version. When
used and handled according to specifications, the product does not have any harmful
effects to our experience and the information provided to us.
12. ECOLOGICAL INFORMATION

12.1 Ecotoxicity effects: The following information relates to the product as supplied, not contaminated by use.
The product is neutral to the environment in normal conditions. Acidic media may
cause chemical decomposition with the release of soluble aluminium salts and
colloidal silicic acid. As a result of its effect as an ion exchanger, the product may trap
heavy metals.
Effect dose
Toxicity Species Method Evaluation Remark
(Exposure time)
Pimephales EPA 660/3 –
Fish LC50 (96h) > 680 mg/l -
promelas 75/009
OECD
Water Flea EC50 (24h) Daphnia magna 2808 mg/l -
TG 202
Scenedesmus OECD
Algae EC 50 (96h) > 328 mg/l -
subspicatus TG 201
Pseudomonas
Bacteria EC 50 (16h) DIN 38412/8 950 mg/l -
putida
1
Persistence and Do not expect the product to degrade biologically. The only degradation method
2
degradability: known to date is slow hydrolysis, particularly in acidic media.
.
2
1
Bioaccumulative Since the absorption of the products by bio-organisms should not be expected as a
2
potential: result of its granulate form, the accumulation of the product in biota and enrichment
. in the food chain can be almost totally discounted.
3
1
Mobility in soil: As a result of the fact that the product is practically insoluble in water, no mobility of
2 the material in the natural environment should be expected.
.
4

SAFETY DATA SHEET
Page: 9 of 10
1
Other information: Product must not be released into the environment if dangerous substances are
2 adsorbed onto the product.
. Insoluble in aqueous solution, the product can be separated by filtration or
5 sedimentation.
13. DISPOSAL CONSIDERATIONS

13.1 Disposal Place in a landfill in compliance with local, state and Federal regulations.
For European Waste Catalogue, use code 15 02 03 “Absorbent and filter materials,
wiping cloths and protective clothing”. After use of the material as an adsorbent the
composition of the residue of the adsorbed substances provides the basis for the
classification.
13.2 Waste treatment Can be landfilled after chemical and physical treatment, when in compliance with the
methods local regulations. Store containers and offer for recycling of material according to the
local regulations. Contact waste disposal services.
Materials of a hazardous nature that contact the product during normal use may be
retained on this product. The user of the product must identify the hazards associated
with the retained material in order to assess the waste disposal options.
Uncontaminated product must be disposed of at an approved waste disposal site.
13.3 Contaminated Empty completely if possible; recycling is possible depending on material. Rinse with
packaging water and dry after complete mechanical emptying.
14. TRANSPORTATION INFORMATION

Land transport (ADR/RID): Exempt from transport classification and labelling.
Inland waterway transport (ADNR): Exempt from transport classification and labelling.
Sea transport (IMDG-Code/GGVSee): Exempt from transport classification and labelling.
Air transport (ICAO-IATA/DGR): Exempt from transport classification and labelling.
15. REGULATORY INFORMATION

Identification: The product is not a hazardous substance or preparation in the sense of the latest
versions of the Chemicals Law or Hazardous Substances Directive, or pursuant to
Directives 67/548/EC or 1999/45/EC.
Germany: Not potentially water-polluting (substance No. 2653). Calcinated zeolites
are not classed as potentially water-polluting by the Commission for the Assessment
of Potentially Water-Polluting Substances (KBwS).
Symbol: None

SAFETY DATA SHEET
Page: 10 of 10
Relevant R phrases: Not applicable

Relevant S phrases: 29 (Do not empty into Drain)
Labelling acc. to EC The product does not need to be labelled in accordance with EC-
directives: Directives67/548/EC and 1999/45/EC.
Registered in the international inventory lists:

Component EINECS ELINCS NLP TSCA DSL NDSL PICCS
Adsorbent
X - - - - - X
LMS
Legend
EINECS/ ELINCS - European INventory of Existing Commercial chemical Substances / European LIst of Notified Chemical Substances
NLP - European No-Longer Polymer List
TSCA - USA Toxic Substances Control Act Section 8(b) Inventory
DSL/NDSL - Canadian Domestic Substances List/Non-Domestic Substances List
PICCS - Philippines Inventory of Chemicals and Chemical Substances
ENCS - Japan Existing and New Chemical Substances
CHINA - China Inventory of Existing Chemical Substances
AICS – Australian Inventory of Chemical Substances
KECI - Korea Existing Chemical Inventory
16. OTHER INFORMATION

Vertical lines in the left hand margin indicate an amendment from the previous version.
The data contained in this safety data sheet are based on our current knowledge and experience and describe the
product only with regard to safety requirements. The data do not describe the product's properties (product
specification). Neither should any agreed property nor the suitability of the product for any specific purpose be
deduced from the data contained in the safety data sheet. It is the responsibility of the recipient of the product to
ensure any proprietary rights and existing laws and legislation are observed.

for File: 1
Oxygen-VPSA-Plant Doc. no.: &AK P-MC 2002 (EN)
Description of the VPSA-Plant Proj. no.: 2210 CCP8
Page 1 of 9 page(s)
2 DESCRIPTION OF THE VPSA-PLANT

2.1 DESIGN PURPOSE
The LINDE VPSA-plant is designed to separate oxygen from ambient air. Ambient air
is filtered and compressed by a feed air blower unit. The dry process air is then fed
into the adsorber-unit.
The VPSA-plant produces a continuous product gas stream, which is sent to the
company’s gaseous oxygen (GOX) piping system, and a discontinuous residual gas
stream which is sent back into atmosphere through a silencer.
2.2 GENERAL
The most important advantage of the LINDE VPSA-plant is its easy operation. The
VPSA-plant can be started and stopped by simple push button only and will produce
the required capacity and purity within a few minutes.
Automatic load adjustment will allow operating the plant in its best operating point,
even with less demand of oxygen. This is done automatically by the control system
without need for adjustments by an operator.
The VPSA-plant is designed for unattended operation. However, one check visit per
shift is recommended. The VPSA-plant is controlled by means of a programmable logic
controller (PLC).
Its main control features include:

− Automatic operation and control of the entire VPSA-plant
− Monitoring of most process values including safety shut down and
alarm management in case of abnormal plant operation
− Control of all process parameters through a display with the possibility
to change setpoints manually (password protected)
− Fault analysis in case of shutdown
draft IFC 10-Mar-2023 Szyrkowiec / ADPA Valenta / ADDA Wildgruber / ADPA First Issue for start up
Proj. no.: 2210 CCP8 Doc. no.: &AK P-MC 2002 (EN) Issue: draft Page 2 of 9
2.3 PRINCIPLE DESCRIPTION
The LINDE VPSA-plant operates based on the principle of adsorptive air separation.
The use of the adsorption technique in the recovery of gases is based on the ability of
porous materials to adsorb gases at their surfaces. Individual gases are adsorbed to
different extents depending on pressure and temperature of the feed gas and the
selectivity of the adsorbent.
Depending on the gases to be adsorbed, zeolitic molecular sieves, silica oxide,

aluminum oxides or carbon molecular sieves are used as adsorption materials.
Since the adsorbing capacity of the molecular sieves is limited, the air separation by
adsorption is a periodic process, where the adsorption material is recurrently
− loaded with pressurized air, to produce the required product through
air separation by adsorption, and
− regenerated by vacuum, to remove the residual gases from the
adsorbent
During the production of oxygen occurs a cyclic swing between pressure and vacuum
(VPSA → Vacuum-Pressure-Swing-Adsorption). To reduce stress for the adsorbent,
pressure equalization is carried out between each step of production and regeneration.
Each adsorber undergoes a cyclic process, consisting of:

− Adsorption (production of oxygen)
− Desorption (regeneration by evacuation)
− Pressure equalization (de-pressurization or pressure build-up)
2.4 PROCESS DESCRIPTION
Air compression
The feed air blower aspirates the ambient air through a filter unit. Compression is done
using a rotary piston blower (roots-type compressor).
Two double or triple lobe rotary pistons rotate in opposite direction inside a common
housing. By means of a pair of accurately machined timing gears the pistons revolve
with a very small gap neither touching each other nor the casing. As there is no friction
between moving and stationary parts, no internal lubrication is required.
With every revolution of the pistons in the casing a defined volume of gas is fed from
the suction to the discharge side of the blower.
The compression is caused by gas, which flows reverse into the blower as the rotor
turns to open to the discharge side.
The differential pressure created by the blower depends on the resistance of the
downstream system. With rising back pressure, the discharge temperature is rising
(leak flow through the gaps).
The compressed air flows from the feed air blower to the valve skid. Following a pre-
defined sequence, both adsorbers are filled consecutively with air by opening of the
relevant air valve.
During pressure equalization between both adsorbers, the air stream is separated from
the adsorbers. Valve KV-1105 opens and air is flowing in a bypass back to the suction
side of the feed air blower until the pressure equalization is finished.
Adsorber station
The present plant is designed as "2-adsorber-system", i.e. the system consists of two
adsorber vessels. One adsorber is in the step of adsorption while the second one is
regenerated. For pressure equalization both adsorbers will be connected together.
Adsorption
The adsorber which is in adsorption step is fed with compressed process air through
the opened air valve.
Moisture and carbon dioxide are adsorbed in the entrance zone of the adsorbent layer.
The nitrogen molecules are continuously adsorbed through the remaining layer of
adsorbent filling. Following the ability of the adsorbent to bind nitrogen on its surface,
nitrogen passes much slower through the adsorbent layer compared to oxygen.
Inside the adsorbent layer a so-called transient zone is built, where oxygen molecules
are separated from nitrogen molecules. At the discharge side of the adsorber dry
oxygen product flows into the buffer vessel.
Due to the limited capacity of the molecular sieves the transient zone shifts gradually
to the product side. Just before the transient zone reaches the end of the adsorbent
layer and nitrogen will get into the product, the system must be switched to the next
adsorber, to regenerate the loaded adsorber.
Desorption
Simultaneously with the first adsorber being in its adsorption phase, the charged
second adsorber is regenerated by opening of residual gas valve and connecting it to
the vacuum pump.
Humidity, carbon dioxide and nitrogen are drawn out in opposite direction to the
adsorption mode with a vacuum pump. The so-called residual gas is sent back into
atmosphere.
At the end of desorption oxygen will be fed from the product side into the evacuated
adsorber. With this step the partial pressure of the remaining nitrogen in the evacuated
adsorber drops and nitrogen merges easier into the residual gas. This supports the
regeneration of the molecular sieve.
Pressure equalization
Before nitrogen breaks into the product, the air supply from the feed air blower is cut
off and pressure equalization is initiated.
Both adsorbers will be separated from the machinery (feed air blower, vacuum pump)
and connected by opening the pressure equalization valve. Dry gas from the
pressurized adsorber will flow into the evacuated adsorber. Additional pressure build-
up will be done with process air from the feed air blower unit.
Vacuum generation
The vacuum pump is also a rotary piston blower which works based on the roots-type
principle. Its function is identical to the feed air blower.
With every revolution of the pistons in the casing a defined volume of gas is fed from
the suction to the discharge side of the vacuum pump. With elapsing time, less gas
molecules will remain inside the evacuated system; therefore, the suction pressure will
drop.
Just as the feed air blower, the vacuum pump is alternately connected with one of the
two adsorbers by opening of the residual gas valve in the valve skid.
As evacuation and compression happens at the same time, the capacity of both
machines must be roughly equal, since the required pressure inside the first adsorber
and the required vacuum inside the second adsorber must be reached at the same
point during the cycle.
During pressure equalization between both adsorbers the vacuum pump will be
separated from the vessels. The valves KV-1835 and KV-1845 are opened and the
vacuum pump is taking air through silencer N-1850 until the pressure equalization has
finished.
Oxygen supply
The oxygen produced inside the adsorbers flows from the adsorber into the buffer
vessel. During adsorption, the pressure inside the buffer vessel rises to its maximum
value at the end of the adsorption phase. During pressure equalization, the pressure
inside the buffer vessel steadily drops, since no oxygen is produced.
The purity of oxygen during the adsorption step is not entirely constant. Gas samples
taken upstream of the buffer will always have higher fluctuation than samples taken
downstream of the buffer. The buffer vessel therefore not only provides a continuous
flow of oxygen, but also widely eliminates such purity fluctuations.
The oxygen from the buffer vessel is compressed by 3-stage piston compressors to
the required end pressure and fed into the pipe work.
The bypass valve of the oxygen compressor equalizes the pressure fluctuations
coming from the buffer vessel. If required, the bypass valve also limits the amount of
oxygen product fed into the downstream pipeline.
This will be required in case of poor quality caused by a plant fault or in case of
excessive demand for oxygen from the subsequent process.
To achieve a constant purity, it is essential to observe the design limit of the

VPSA-Plant, which is defined by the amount of adsorbent, the adsorption and
desorption pressure, process temperature etc. Excessive oxygen consumption - even
for a short period of time - may cause nitrogen to break through into the product
causing lower purity.
On the other hand, it will also be necessary to discharge a minimum amount of oxygen
from the plant in case of low demand for oxygen. Due to the similar behavior of argon
and oxygen in the adsorption process, low oxygen consumption may cause enrichment
of undesired argon in the product and cause purity to drop as well.
For this reason, an amount corresponding to approximately 30% of the plant’s design
flow must be discharged from the system continuously. In case this amount is not
needed by the subsequent process, the oxygen is discharged to atmosphere through
the blow-off valve PCV-1513, either in part or in total.
2.5 IMPACT OF PROCESS PARAMETERS ON THE PLANT CAPACITY
The capacity of an adsorber filled with adsorbent is defined by the amount of oxygen
product that can be recovered from the feed air at design conditions. The higher the
maximum loading of the adsorber, the higher the performance of the plant will be.
Different gases are adsorbed to a different extent, depending on pressure and

temperature of the feed air as well as the properties of the adsorbent. Primarily the
performance of the plant will depend on the amount and quality of the adsorbent used
and the design parameters of the process.
Subsequently the main process conditions affecting the plant capacity are listed:
Adsorption pressure
The extent to which an adsorber can be loaded increases with increasing adsorption
pressure. Therefore, the adsorber capacity will be higher using a high adsorption
pressure and lower if using a low adsorption pressure.
Desorption pressure
Since a loaded adsorber is regenerated by decreasing the pressure, it is obvious that

best regeneration is achieved at lowest desorption pressure. If the desorption pressure
increases, the residual loading of the adsorbent will also increase. Hence the adsorber
capacity will decrease. Therefore, the adsorber capacity will be higher at low
desorption pressure and lower at high desorption pressure.
Process air temperature
The best loading capacity of the adsorbent is reached in a range between 40°C to 60°C
process air temperature. The extent to which an adsorber can be loaded will decrease
as the feed gas temperature rises above the optimum range and will also decrease, if
the temperature falls below the optimum range.
Since adsorption is accompanied by the release of the adsorption heat, the product
temperature is always slightly higher than the feed gas temperature. It is obvious that
the residual gas temperature is slightly lower than the feed gas temperature. Therefore,
it will become necessary to stop the VPSA-plant in case the feed gas temperature falls
too low to avoid freezing of the adsorbed humidity.
Product purity
The extent to which an adsorber can be loaded increases with increasing nitrogen
content in the oxygen product. Therefore, the adsorber capacity is higher at high
nitrogen content (lower purity) and lower at low nitrogen content (high purity).
2.6 BASIS OF DESIGN AND PERFORMANCE DATA
2.6.1 STANDARDS
Design of the VPSA-plant is based on the following standards:

− LINDE-standards
− UVV safety regulations and other standards explicitly mentioned
− EIGA regulations
− Applicable directives, national regulations and codes.
Design, manufacturing, testing and acceptance of the adsorber vessels and the buffer
vessel are based on the DIN/AD2000/PED Code.
The electrical equipment and instrumentation is designed and fabricated in accordance

with the relevant DIN/IEC-standards.
Machines including instrumentation are designed and fabricated based on

manufacturer standards. Respective CE certificates for machinery equipment and
separately electrical motors will be provided.
2.6.2 DESIGN CONDITIONS
This plant has been designed for the below described operation conditions and has
been tested in its operation range during the commissioning phase.
When operated differently, additional care needs to be taken, especially in terms of

controller stability, machine loads, cooling water system condition. Operation in
mechanical resonance in piping systems, especially in oxygen piping, must be
excluded under all circumstances.
The following conditions are valid for design and for performance guarantees of the
VPSA-Plant. Flow quantities in Nm³/h are measured at 273 K and 1.013 bar abs and
dry basis. Values for pressure are absolute pressure values, unless explicitly
mentioned.
Ambient air / site conditions
Barometric pressure at plant site: 876 mbar
Altitude above sea level: 1,208 m
Ambient air temperatures: min +11 °C
max +32 °C
Relative humidity at 20 °C: 48 %
Earthquake factor: not considered
Area classification: non-hazardous
Wind / snow loads: max. 0,5 kN/m²
Plant design and performance is based on the following conditions

Atmospheric pressure: 876 mbar
Suction temperature of feed air blower: +21 °C
Relative humidity at 20 °C: 48 %
Normal industrial air – free of excessive quantities (contents) of dust, chemicals,

carbon dioxide, hydrocarbons and corrosive elements causing damage to molecular
sieve filling, corrosion or fouling in piping and equipment – shall be used as feed.
2.6.3 VPSA PERFORMANCE
Gaseous oxygen flow (100% O2) 977 Nm³/h [273 K / 1,013 bar(a)]
Gaseous product flow (93% O2) 1,050 Nm³/h [273 K / 1,013 bar(a)]
Oxygen content average 93 %
Product pressure, approx 5.5 bar(a)
2.6.4 UTILITIES
Electrical supply
Nominal voltage for machinery 6,600 / 400 V
Phases 3
Frequency 50 Hz
Max. voltage fluctuation 5 %
Max. frequency fluctuation 2 %
Energy consumption at 100% capacity 548  5% kW
Energy consumption at electrical terminal and normal operation at design conditions

under design capacity for feed air blower, vacuum pump and oxygen compressor
excluding auxiliary equipment.
Instrument air
A separate instrument air unit will be supplied together with the VPSA plant
Pressure 5…7 bar(g)
Temperature ambient
Consumption approx. 35 Nm³/h
Dew point (below min. ambient temperature) -20 °C
Particles max. DIN ISO 8573-1, class 3 1-5 µm (≤1.000 particlesl / m3)
0,5-1 µm (≤90.000 particlesl / m3)
Oil content, max. DIN ISO 8573-1, class 3 1 mg/m3
Cooling water
Cooling water is required for the first filling of a closed loop cooling unit. The following
requirements for the cooling water shall be met:
pH-value 7 – 8.5
Total dissolved solids (TDS) <3.000 mg/l
Total suspended solids (TSS) <10 mg/l
Total hardness 100…900 mg CaCO3/l
Ca-hardness 100…500 mg CaCO3/l
Total alkalinity 100…200 mg CaCO3/l
Total iron and manganese <0.2 mg (Fe+Mn)/l
Chloride <50 mg Cl-/l
Nitrate & Nitrite <10 mg (NO3-+NO2-)/l
Ammonium <5 mg NH4+/l
Sulphate <500 mg SO42-/l
Supply pressure 3…4,5 bar (g)
Supply temperature (min/design/max) 20 / 35 / 47 °C
Temperature rise 10 °C
Consumption approx. 52 Nm³/h
Warm water
Warm water is not required!
for File: 1
VPSA-sequence Proj. no.: 2210 CCP8
3 VPSA SEQUENCE
The LINDE VPSA-process is divided into ten single steps, which are described below.
Due to the cyclic nature of the VPSA-process, the two adsorbers are operating in
corresponding steps. In step no. 1 for instance adsorber A is executing adsorption,
whereas adsorber B is executing desorption. In step no. 6 the situation will be reverse.
The complete step sequence of all those steps is called 'cycle'. Steps 1 to 5 (and
accordingly 6 to 10) are referred to as 'half-cycle'.
All valves are switched automatically by the PLC program following the required
function in each step of the process. Each adsorber is equipped with one air valve, one
product valve and one residual gas valve (waste gas valve). An additional valve is
installed to connect both adsorbers together for pressure equalization.
The designation of tag numbers follows the LINDE-Standard:
KV-25xy
Figure x:
refers to the number of the individual adsorber, e.g.
'1' refers to adsorber A

'2' refers to adsorber B a. s. o.
Valves which cannot be assigned to a special adsorber are tagged with number '0'
Figure y:
refers to the function of each valve, e.g.
'1' feed gas valve (i.e. process air)

'2' product gas valve (i.e. oxygen)
'4' residual gas valve
Following this convention, the product valve of adsorber A will be tagged KV-2512, the
residual gas valve of adsorber B will be tagged KV-2524 a. s. o. The purge- and
pressure equalization valve has the tag number KV-2505.
draft IFC 10-Mar-2023 Szyrkowiec / ADPA Valenta / ADDA Wildgruber / ADPA First Issue for start up
3.1 VPSA FLOW SHEET
O2
Page.: 1
1
Atm.
of
Atm.
PCV-1513
C-1861
Doc. No.:
AB
KV-1835
Atm.
Lubumbashi STL
2nd stage
2210 CCP8
C-1561
PCV-1545
KV-1845
1st stage
Proj. No.:
ID-No.:
Code:
Flow Sheet
D-2532
KV-2524
A-2526B
Approved by Wildgruber / ADPA

Checked by Szyrkowiec / ADPA
Prepared by Valenta / ADDA
KV-2522
KV-2505
KV-2521
KV-2514
KV-2512
A-2526A
Date: 21-Feb-23
KV-1105
KV-2511
Issue: 01
C-1161
Atm.
VP
3.2 STEPS OF THE SEQUENCE
ADSORBER A B
STEP
1 A EV
2a AP EVP
(2b) P EVP
3 waiting waiting
(only in partial load) (only in partial load)
4 E1o R1o
5 E1oEV R1o / (R1u)
6 EV A
7a EVP AP
(7b) EVP P
8 waiting waiting
(only in partial load) (only in partial load)
9 R1o E1o
10 R1o / (R1u) E1oEV
Abbreviations:
A: adsorption
AP: adsorption plus production of purge gas for corresponding adsorber
P: production of purge gas for corresponding adsorber
E1o: de-pressurization by pressure equalization via oxygen side
E1oEV: de-pressurization by pressure equalization in combination with evacuation
by vacuum pump
EV: evacuation
EVP: evacuation and purging with oxygen from corresponding adsorber
R1o: pressure build-up by pressure equalization via oxygen side
(R1u): pressure build-up with air from feed air blower (optional)
3.3 DESCRIPTION OF STEPS
The control of the LINDE-VPSA-Process is done by means of a mainly pressure driven

step sequence, i.e. the PLC will initiate the next step, as soon as a defined pressure
has been reached.
In addition to the pressure conditions a certain interval of time is defined, in which the
length of the step may fluctuate. Few steps are exclusively time controlled.
If the defined pressures are reached outside of the designated time intervals either the
minimum step time will be kept, or the step will be aborted as soon as the maximum
step time is reached. The sequence will then switch to the next step if all other
conditions are fulfilled.
STEP-1
Pressure equalization valve KV-2505 closes at the beginning of this step.
The connection between both adsorbers is cut. Air valve KV-2511 opens on the
adsorber A which is about to produce oxygen (the valve may already be open in case
it was already opened in step 10).
By closing the feed air blower bypass valve KV-1105, compressed air is fed to the
adsorber A. The bypass valve may close with a certain delay to cover seasonal
variations of flow rates on the feed air blower due to different density of air in summer
and winter time.
As soon as the pressure inside the adsorber A exceeds the pressure of the oxygen
buffer vessel, product valve KV-2512 opens and oxygen flows from the adsorber A into
the oxygen buffer vessel.
The corresponding adsorber B remains in evacuation from the previous step. For this
reason, the residual gas valve KV-2524 is open.
If the oxygen producing adsorber A reaches a specified pressure level, the step will be
terminated, and the next step will be initiated. If the required pressure level is reached
before the minimum step time has expired, the step will be extended until the specified
minimum step time is reached. If the adsorber does not reach the specified pressure
level within the defined maximum step time, the step will be terminated, and the next
step will be initiated regardless of the pressure inside the adsorber vessel.
STEP-2a
During this step a part of the oxygen produced inside the adsorber A is fed into the
corresponding adsorber B for purging during the evacuation phase. The pressure
inside the adsorber A increases with a reduced rate.
Purging is done by opening valve KV-2505 partially, so that some oxygen can flow to
the product side of the adsorber B, which remains connected to the vacuum pump for
regeneration. By purging with oxygen, the partial pressure of the nitrogen inside the
evacuated adsorber B will drop, therefore allowing it to pass easier into waste gas.
The pressure inside the evacuated adsorber B should stay constant or increase slightly
during purging. Therefore, the position of valve KV-2505 can be adjusted individually
for both adsorbers.
Remark:
The time for step 2a shall be adjusted in such way, that the maximum step time will
terminate this step before reaching the specified pressure level, otherwise high
fluctuations of purity may appear.
STEP-2b (HEAVY PURGE)
At the beginning of this step air valve KV-2511 and product valve KV-2512 of the
adsorber A, which has produced oxygen before, will be closed. The waste gas valve
KV-2524 of the adsorber A and valve KV-2505 will remain open.
The vacuum pump takes oxygen via valve KV-2505 from the product side of the
pressurized adsorber. The pressure inside this adsorber therefore decreases rapidly.
Contrary to the previous steps this step is only controlled by a fixed time. It can be
disabled by reducing the step time to zero.
Depending on the demand of oxygen, the sequence continues with

− step 3 (partial load operation) or
− step 4 (full load operation).
STEP-3 (PARTIAL LOAD OPERATION)
If the demand for oxygen is lower than the design capacity, the PLC will switch
automatically into partial load operation. During this step, all air valves (KV-25x1) and
all residual gas valves (KV-25x4) will be closed.
The bypass valves of the vacuum pump (KV-1835 / KV-1845) and of the feed air blower
(KV-1105) will be opened. Feed air blower and vacuum pump will be operated in
bypass mode at low energy consumption (idle run).
Oxygen product is taken from the buffer vessel only, subsequently compressed and
supplied into the downstream pipeline system. The PLC calculates the remaining step
time by measuring the amount of oxygen taken from the buffer vessel in relation to the
plant’s design capacity. Low demand of oxygen will therefore result in an extended
cycle time.
In order to maintain a certain minimum pressure level inside the buffer vessel and to
avoid alarm or shutdown of the oxygen compressor due to low suction pressure, the
product valve KV-2512 of the adsorber A which has produced oxygen before, will
remain open for a certain period of time allowing some more oxygen to pass from the
adsorber into the buffer vessel.
As soon as the plant has produced a certain amount of oxygen, which is based on the
design capacity of the plant, the step will be terminated.
Depending on local conditions (costs for electric energy, availability of liquid backup
system) a maximum and minimum time for partial load can be defined.
Defining a minimum step time may be reasonable, if the plant is working close to its
design flow. In such situation, short intervals of partial load (< 1sec) may appear, which
may cause additional stress for valve KV-2505, since it has to close after purging and
to open for pressure equalization again within short time. In this case the partial load
step will only be activated in case the PLC calculates a step time which is longer than
the specified minimum value.
Defining a maximum step time may be reasonable, in case a certain pressure level
inside the buffer vessel shall be kept, or if it is more economic to cover the low demand
for oxygen from a liquid backup system. In this case the step will be terminated, as
soon as the maximum step time has been reached.
STEP-4
As soon as the designed adsorber capacity has been reached, pressure equalization
is initiated.
The adsorber A which has been producing oxygen before is connected with the
regenerated adsorber B by opening of valve KV-2505. Oxygen flows from the adsorber
A with higher pressure to the adsorber B with lower pressure.
During this step both feed air blower and vacuum pump remain in bypass mode. The
bypass valves of the vacuum pump KV-1835 / KV-1845 and of the feed air blower
KV-1105 are open.
In this way the evacuated adsorber B will be prepared for the following adsorption step
by raising its pressure closer to ambient level, whereas the other adsorber A, which is
now fully loaded with nitrogen, is prepared for the following regeneration by lowering
its pressure.
As soon as the evacuated adsorber reaches a certain pressure level during pressure
equalization, the step will be terminated, and the next step starts. In case the required
pressure is reached faster than the minimum step time, pressure equalization will be
continued until the minimum step time is reached. In case the required pressure level
inside the adsorber is not reached within the maximum step time, pressure equalization
will be terminated regardless of the pressure which has been reached, and the next
step will be initiated.
STEP-5
In the second half of the pressure equalization waste gas valve KV-2514 of the
adsorber A, which has been producing oxygen before, will be opened and evacuation
can be started by closing bypass valves KV-1835 / KV-1845 of the vacuum pump.
Similar as for the air blower, the closing of those bypass valves may have a certain
delay to cover the seasonal variation of flow rate on the vacuum pump due to different
density of gas in summer and winter.
As an additional possibility, the air valve KV-2521 of the adsorber B to start production
of oxygen, can be opened to support the pressure build-up with process air. The
remaining vacuum inside the adsorber B will suck air through the open bypass valve
KV-1105 and through the feed air blower at the same time.
The pressure equalization valve KV-2505 remains open until the end of the step is
reached.
STEP-6
Pressure equalization valve KV-2505 closes at the beginning of this step.
The connection between both adsorbers is cut. Air valve KV-2521 opens on the
adsorber B which is about to produce oxygen (the valve may already be open in case
it was already opened in step 5).
By closing the feed air blower bypass valve KV-1105, compressed air is fed to the
adsorber B. The bypass valve KV-1105 may close with a certain delay to cover
seasonal variations of flow rates on the feed air blower due to different density of air in
summer and winter time.
As soon as the pressure inside the adsorber B exceeds the pressure of the oxygen
buffer vessel, product valve KV-2522 opens and oxygen flows from the adsorber B into
the oxygen buffer vessel.
The corresponding adsorber A remains in evacuation from the previous step. For this
reason, the residual gas valve KV-2514 is open.
If the oxygen producing adsorber reaches a specified pressure level, the step will be
terminated, and the next step will be initiated. If the required pressure level is reached
before the minimum step time has expired, the step will be extended until the specified
minimum step time is reached. If the adsorber does not reach the specified pressure
level within the defined maximum step time, the step will be terminated, and the next
step will be initiated regardless of the pressure inside the adsorber vessel.
STEP-7a
During this step a part of the oxygen produced inside the adsorber B is fed into the
corresponding adsorber A for purging during the evacuation phase. The pressure
inside the adsorber B increases with a reduced rate.
Purging is done by opening valve KV-2505 partially, so that some oxygen can flow to
the product side of the corresponding adsorber A, which remains connected to the
vacuum pump for regeneration. By purging with oxygen, the partial pressure of the
nitrogen inside the evacuated adsorber A will drop, therefore allowing it to pass easier
into waste gas.
The pressure inside the evacuated adsorber A should stay constant or increase slightly
during purging. Therefore, the position of valve KV-2505 can be adjusted individually
for both adsorbers.
Remark:
The time for step 7a shall be adjusted in such way, that the maximum step time will
terminate this step before reaching the specified pressure level, otherwise high
fluctuations of purity may appear.
STEP-7b (HEAVY PURGE)
At the beginning of this step air valve KV-2521 and product valve KV-2522 of the
adsorber B, which has produced oxygen before, will be closed. The waste gas valve
KV-2514 of the corresponding adsorber A and valve KV-2505 will remain open.
The vacuum pump takes oxygen via valve KV-2505 from the product side of the
pressurized adsorber B. The pressure inside this adsorber B therefore decreases
rapidly.
Contrary to the previous steps this step is only controlled by a fixed time. It can be
disabled by reducing the step time to zero.
Depending on the demand of oxygen, the sequence continues with

− step 8 (partial load operation) or
− step 9 (full load operation).
STEP-8 (PARTIAL LOAD OPERATION)
If the demand for oxygen is lower than the design capacity, the PLC will switch
automatically into partial load operation. During this step, all air valves (KV-25x1) and
all residual gas valves (KV-25x4) will be closed.
The bypass valves of the vacuum pump (KV-1835 / KV-1845) and of the feed air blower
(KV-1105) will be opened. Feed air blower and vacuum pump will be operated in
bypass mode at low energy consumption (idle run).
Oxygen product is taken from the buffer vessel only, subsequently compressed and
supplied into the downstream pipeline system. The PLC calculates the remaining step
time by measuring the amount of oxygen taken from the buffer vessel in relation to the
plant’s design capacity. Low demand of oxygen will therefore result in an extended
cycle time.
In order to maintain a certain minimum pressure level inside the buffer vessel and to
avoid alarm or shutdown of the oxygen compressor due to low suction pressure, the
product valve KV-2522 of the adsorber B which has produced oxygen before, will
remain open for a certain period of time allowing some more oxygen to pass from the
adsorber B into the buffer vessel.
As soon as the plant has produced a certain amount of oxygen, which is based on the
design capacity of the plant, the step will be terminated.
Depending on local conditions (costs for electric energy, availability of liquid backup
system) a maximum and minimum time for partial load can be defined.
Defining a minimum step time may be reasonable, if the plant is working close to its
design flow. In such situation, short intervals of partial load (< 1sec) may appear, which
may cause additional stress for valve KV-2505, since it has to close after purging and
to open for pressure equalization again within short time. In this case the partial load
step will only be activated in case the PLC calculates a step time which is longer than
the specified minimum value.
Defining a maximum step time may be reasonable, in case a certain pressure level
inside the buffer vessel shall be kept, or if it is more economic to cover the low demand
for oxygen from a liquid backup system. In this case the step will be terminated, as
soon as the maximum step time has been reached.
STEP-9
As soon as the designed adsorber B capacity has been reached, pressure equalization
is initiated.
The adsorber B which has been producing oxygen before is connected with the
regenerated adsorber A by opening of valve KV-2505. Oxygen flows from the adsorber
B with higher pressure to the adsorber A with lower pressure.
During this step both feed air blower and vacuum pump remain in bypass mode. The
bypass valves of the vacuum pump KV-1835 / KV-1845 and of the feed air blower
KV-1105 are open.
In this way the evacuated adsorber A will be prepared for the following adsorption step
by raising its pressure closer to ambient level, whereas the other adsorber B, which is
now fully loaded with nitrogen, is prepared for the following regeneration by lowering
its pressure.
As soon as the evacuated adsorber A reaches a certain pressure level during pressure
equalization, the step will be terminated, and the next step starts. In case the required
pressure is reached faster than the minimum step time, pressure equalization will be
continued until the minimum step time is reached. In case the required pressure level
inside the adsorber is not reached within the maximum step time, pressure equalization
will be terminated regardless of the pressure which has been reached, and the next
step will be initiated.
STEP-10
In the second half of the pressure equalization waste gas valve KV-2524 of the
adsorber B, which has been producing oxygen before, will be opened and evacuation
can be started by closing bypass valves KV-1835 / KV-1845 of the vacuum pump.
Similar as for the air blower, the closing of those bypass valves may have a certain
delay to cover the seasonal variation of flow rate on the vacuum pump due to different
density of gas in summer and winter.
As an additional possibility, the air valve KV-2511 of the adsorber A to start production
of oxygen, can be opened to support the pressure build-up with process air. The
remaining vacuum inside the adsorber A will suck air through the open bypass valve
KV-1105 and through the feed air blower at the same time.
The pressure equalization valve KV-2505 remains open until the end of the step is
reached.
3.4 STEP DIAGRAM
End End
FUNCTION CORRESPONDING STEP continue, Duration
STEP Pressure Pressure
if approx.
ADSOBER A ADSOBER B Ads. A Ads. B
VIA VALVE VIA VALVE [kPa abs] [kPa abs] [kPa abs] [sec]
KV-2511 Ads. A
1 A KV-2512 EV KV-2524 141,5 58,0
> 141,4
10,2
KV-2511 KV-2524 Ads. A

2a AP KV-2512 EVP KV-2505
151,3 56,9
> 158,0
7,8
KV-2524
(2b) P KV-2505 EVP KV-2505
142.9 57.3 --- 1,3
3 Wait --- Wait --- varies varies --- varies

(only partial load) (only partial load)
Ads. B
4 E1o KV-2505 R1o KV-2505 123,8 78.6
> 78,5
3,9
KV-2505 KV-2505
5 E1oEV KV-2514 R1o / (R1u) (KV-2521)
102,8 98,0 --- 2,0
KV-2521 Ads. B
6 EV KV-2514 A KV-2522
58,0 141,8
> 141,7
10,3
KV-2514 KV-2521 Ads. B

7a EVP KV-2505 AP KV-2522
56,3 151,9
> 158,0
7,8
KV-2514
(7b) EVP KV-2505 P KV-2505 56,5 143,8 --- 1,2
8 Wait --- Wait --- varies varies --- varies

(only partial load) (only partial load)
Ads. A
9 R1o KV-2505 E1o KV-2505 78,6 123,4
> 78,5
4,1
KV-2505 KV-2505
10 R1o / (R1u) (KV-2511) E1oEV KV-2524
97,9 102,7 --- 2,0
Note: Values in brackets indicate optional activities
Abbreviations:
A: adsorption
AP: adsorption plus production of purge gas for corresponding adsorber
P: production of purge gas for corresponding adsorber
E1o: de-pressurization by pressure equalization via oxygen side
E1oEV: de-pressurization by pressure equalization in combination with evacuation
by vacuum pump
EV: evacuation
EVP: evacuation and purging with oxygen from corresponding adsorber
R1o: pressure build-up by pressure equalization via oxygen side
(R1u): pressure build-up with air from feed air blower (optional)
3.5
open

feed air blower KV-1105 time delay time delay
(calculated by PLC) (calculated by PLC) close
pressure build up with air pressure build up with air

(if enabled) (if enabled)
open
air KV-2511 pressureads. > pressurebuff er

close
open
O2 KV-2512
close
A-2526A
adsorber
open
residual gas KV-2514
close
pressure 100%
equalization KV-2505
+ purging 0%
pressure build up with air

(if enabled)
open

close
open
VPSA SEQUENCE CYCLE AT FULL LOAD
O2 KV-2522
close
A-2526B
adsorber
open

close
Doc. no.: &AK P-MC 2003 (EN)
open
unload KV-1835
time delay time delay time delay close
(calculated by PLC) (calculated by PLC) (calculated by PLC) open
Issue:
full load KV-1845
vacuum pump
close
1 2a 2b 4 5 6 7a 7b 9 10
draft
Issue: 01 prepared by Wildgruber / ADPA Code: Lubumbashi STL Page: 1

Date: 21-Feb-23 checked by Valenta / ADDA
Step Diagram Proj. No.: 2210 CC8P of 1
(Full Load)
approved by Szyrkowiec / ADPA ID-No.: Doc. No.: &AK-P-CA 2001
Page 12 of 14
3.6
open
air blower KV-1105

close
time delay time delay
(calculated by PLC) (calculated by PLC)
pressure build up with air pressure build up with air

(if enabled) (if enabled)
open
air KV-2511 pressureads. > pressurebuff er P P

close
open
O2 KV-2512
A A
close
A-2526A
adsorber
R R open

T close
T
pressure
I I 100%
equalization KV-2505
+ purging A A 0%
L pressure build up with air L

(if enabled)
open

close
open
O2 KV-2522
L L
close
A-2526B
adsorber
VPSA SEQUENCE CYCLE AT PARTIAL LOAD
O open
O
close
A A
D D open
unload KV-1835
Issue:
time delay time delay time delay close

(calculated by PLC) (calculated by PLC) (calculated by PLC) open
full load KV-1845
vacuum pump
close
draft
1 2a 2b 3 4 5 6 7a 7b 8 9 10
Issue: 01 prepared by Wildgruber / ADPA Code: Lubumbashi STL Page: 1

Date: 21-Feb-23 checked by Valenta / ADDA
Step Diagram Proj. No.: 2210 CCP8 of 1
(Partial Load)
approved by Szyrkowiec / ADPA ID-No.: Doc. No.: &AK-P-CA 2002
Page 13 of 14
3.7 TYPICAL PRESSURE CYCLE ADSORBER/BUFFER VESSEL
3.7.1 FULL LOAD
[kPa a]
150,0
D-2532
A-2526A
100,0
A-2526B
500
50,0
3.7.2 PARTIAL LOAD
[kPa a]
150,0
D-2532
A-2526A
100,0
A-2526B
50,0
500
for File: 1
Operating modes Proj. no.: 2210 CCP8
Page 1 of 8 page(s)
4 OPERATING MODE
The operating mode of the VPSA-plant can be influenced by three different items:
1. PLC control system
2. Operator commands (switches or push buttons)
3. Malfunctions causing stop, shut down or change of flow rate
4.1 DESCRIPTION OF THE OPERATING MODES
Following operating modes are possible:
4.1.1 OPERATING MODE 'STOP'
Activated by:
− Completion of operating mode 'STOP CYCLE'
− Operating mode 'ERROR STOP' after correction of a fault and
pressing "ERROR RESET"
Indication:
− Continuous indication of lamp XL-9321 “VPSA-STOP” (red light)
− The operating mode ‘STOP’ will be indicated in the “Start/Stop/Hand”-
Menu on the left side of the main picture
Action:
The plant is now ready for start. All valves are in closed position. Depending on the
previous situation, the step sequence now is either
− at the beginning of step 1 or 6, if the plant was stopped by a normal
‘STOP CYCLE’ or the program was just loaded into the PLC or
− at any other point within the cycle, in case the plant was stopped by a
shutdown
Proj. no.: 2210 CCP8 Doc. no.: &AK P-MC 2004 (EN) Issue: 01 Page 2 of 8
Regardless of the previous situation, the plant can be started right away, when it is in
'STOP'. On starting up from a normal stop, the usual step cycle will be initiated as soon
as the plant has been started up. On start-up following a shutdown situation, the step
cycle will be continued at exactly the same point, where the shutdown appeared, i.e.
the PLC program will continue with the previously interrupted step until the remaining
step time has expired or the pressure condition is fulfilled and then continue with the
next step.
4.1.2 OPERATING MODE 'START'
Activated by:
− Push button HS-9320 “VPSA-START” in the left front door of the PLC
cabinet or
− Symbol “START” in the “Start/Stop/Hand”-Menu on the left side of the
main picture or
− By remote start command from main control room
Indication:
− Lamp XL-9320 “VPSA-START” (green light) will flash
− The visualization system indicates the individual steps of the start
sequence in the main picture
Action:
Following steps for start sequence will be done automatically by PLC:
− PLC will check for availability of the different utilities (instrument air,
cooling water etc.). If all utilities are available, PLC will initiate
following steps to start the VPSA
− ‘AB/VP-START’
PLC starts feed air blower and vacuum pump in bypass mode
− ‘ADS. START’
PLC starts step sequence of the adsorber station.
Depending on the previous situation, the step sequence will be started
either at the beginning of step 1 or 6 (if the plant was stopped normally
or in case the program was just loaded into the PLC) or exactly at the
same point within the step sequence, where the plant tripped before.
− ‘COMP. START’
PLC subsequently starts oxygen compressor in bypass mode
(provided it has been included by the operator in the automatic start
sequence)
After finishing the 'START', operating mode changes to 'OFF SPEC'.
4.1.3 OPERATING MODE 'OFF SPEC'
Activated by:
− Finishing of operating mode 'START' or
− An average oxygen concentration, which is lower than setpoint
ASALL-1545
Indication:
− Lamp XL-9320 “VPSA in operation” flashes
− The visualization system indicates operating mode ‘OFF SPEC’
Action:
− The supply of oxygen into the pipeline system is blocked by closing
valve XV-1550
− The PLC automatically discharges some oxygen into atmosphere by
opening blow-off valve PCV-1513
− As soon as the average oxygen concentration recovers and exceeds
the setpoint ASH-1545, flow reduction will be stopped.
In case 'OFF SPEC' is occurring during operation of the plant (without a previous start
situation), an alarm for bad purity is generated showing to the operator that the supply
of oxygen will be interrupted now.
4.1.4 OPERATING MODE 'INCREASE FLOW'
Activated by:
− An average oxygen concentration, which is higher than setpoint
ASHH-1545
Indication:
− Lamp XL-9320 “VPSA-START” will show a permanent indication
− The visualization system indicates operating mode 'INCREASE
FLOW'
Action:
− Product supply valve XV-1550 is open to allow oxygen to be delivered
into the downstream pipeline system
− PLC will increase the set point for oxygen delivery of the VPSA plant
stepwise up to the design capacity of the plant. As soon as the design
capacity of the plant has been reached, the operating mode changes
to 'ON SPEC'.
4.1.5 OPERATING MODE 'ON SPEC'
Activated by:
− Design capacity of the plant is reached
Indication:
− Lamp XL-9320 “VPSA-START” will show a permanent indication
− The visualization system indicates operating mode 'ON SPEC'
Action:
− Product supply valve XV-1550 is open. Oxygen is delivered into the
pipeline system with specified quality following the consumer’s
demand up to the design capacity. The PLC automatically controls
oxygen delivery pressure and oxygen flow within the design limits.
− In case of low oxygen demand PLC automatically changes into partial
load mode and opens the blow-off valve PCV-1513 if the demand
drops below 30% of the design capacity.
− If the product demand is higher then the design value of the plant, the
product supply will be limited to the design value by opening
compressor bypass valve PCV-1545. In this case the discharge
pressure will drop.
The PLC will automatically initiate flow reduction in case the average oxygen
concentration drops lower than setpoint ASAL-1545 (operating mode 'REDUCE
FLOW').
4.1.6 OPERATING MODE 'REDUCE FLOW'
Activated by:
− An average oxygen concentration, which is lower than setpoint ASAL-
1545
Indication:
− Lamp XL-9320 “VPSA in operation” will show a permanent indication
− The visualization system indicates operating mode 'REDUCE FLOW'
Action:
− The PLC will automatically decrease the setpoint for oxygen delivery
step by step to improve product quality. If the average product purity
gets higher than setpoint ASH-1545, the PLC will stop reducing the
oxygen flow.
− In case average oxygen concentration improves above setpoint
ASHH-1545, operating mode changes into 'INCREASE FLOW'. If
average oxygen concentration drops lower than setpoint ASALL-1545,
operating mode 'OFF SPEC' will be initiated.
4.1.7 OPERATING MODE 'ERROR STOP'
Activated by:
− Any plant condition, which requires scheduled or immediate plant
shutdown.
Indication:
− Continuous flashing of lamp XL-9313 “General Alarm”. An alarm text
will be indicated at the visualization system showing the reason for the
plant shutdown. As soon as the RESET-button HS-9313 or the
RESET symbol on the visualization system is pushed, flashing
indication changes into permanent indication to show that an alarm is
active.
Action:
− Alarm messages will be transmitted via remote connection to the DCS
to inform the operator about the shut down and its reason.
− As soon as all the problems have been solved and the RESET-button
HS-9313 or the RESET-symbol on the visualization system is pushed,
the operating mode changes into 'STOP'.
4.1.8 OPERATING MODE 'STOP CYCLE'
Activated by:
− Push button HS-9321 “VPSA-STOP” in the front door of the PLC
cabinet or
− Symbol “STOP” in the visualization system or
− By remote stop command from main control room
Indication:
− Permanent indication of lamp XL-9320 “VPSA-START” will be
switched off and lamp XL-9321 “VPSA-STOP” will start flashing
− The visualization system indicates operating mode 'STOP CYCLE'
Action:
Following steps for stop sequence will be done automatically by PLC:
− After finishing the present half cycle the oxygen supply to the pipeline
system is cut off by closing valve XV-1550. Subsequently both oxygen
compressors are switched off.
− An additional half cycle is concluding to fill up the oxygen buffer vessel
without oxygen supply to the pipeline system.
− As soon as pressure equalization between both adsorber vessels has
been finished, feed air blower and vacuum pump will be switched off.
− Product valves KV-2512 / KV-2522 will be opened for a short moment,

allowing oxygen from the buffer vessel will flow back into both
adsorbers until they have reached atmospheric pressure or slight
overpressure. This is done to prevent moisture from entering the
adsorber vessel through leakages if the adsorber should still be
slightly under vacuum.
The bypass valves KV-1105 / KV-1835 / KV-1845 will remain open for a few minutes,
to allow a smooth run down of the machinery. When all machines have stopped, the
valves will be closed to provide maximum security against moist air entering the
system.
The operating mode changes into 'STOP', shown by permanent indication of lamp
“STOP”.
4.1.9 OPERATING MODE 'HAND'
Activated by:
− Symbol “HAND” in the visualization system (password protected)
‘HAND’-mode can only be initiated when the plant is operating mode 'STOP' or
'ERROR STOP'.
Indication:
− All lamps at the PLC cabinet are switched off
− In the upper left corner of the visualization system the operating mode
'HAND' will be shown
Action:
In ‘HAND’-mode following operations can be done:
a) Functional tests of individual machines

In ‘HAND’-mode each machine can be switched on and off for test runs, e.g.
after maintenance. For start and stop the symbols in the detail picture of each
machine are used.
The PLC monitors all process values for the machines and provides the
same safety shut down functions as in automatic mode.
Like in normal operation, starting of machines is only possible, if there are no
active alarms for this unit, which might prevent proper function.
b) Functional test of individual valves

In operating mode 'HAND' each valve can be switched manually, provided
that no machine is running.
To enable this feature, the symbol “VALVE HAND” has to be pushed first in
the “Start/Stop/Hand”-Menu of the visualization system. After that any valve
can be operated using the buttons “OPEN” and “CLOSE” or by entering the
desired percentage of opening (in case of control valves) in the detail picture
for the desired valve.
The PLC monitors the plant and might prevent operation of a valve, if the
differential pressure is too high and damage to the plant might be caused.
c) Functional test of the whole valve sequence

In ‘HAND’-mode the correct function of the whole step sequence can be
tested without starting machinery. Choose “VALVE AUTO” in the Start/Stop-
menu, and then start the whole sequence by pushing "START" or “STOP” in
the submenu of the adsorber station.
Also in this mode the PLC monitors the plant and might prevent the start of
the sequence, if damage to the plant might occur.
‘HAND’-mode shall only be initiated and operated by specially

trained personnel.
Incorrect operation of the plant may cause serious damages.
4.2
RESET

Error
(shut down)
HAND**
AB/VP ERROR
START STOP HAND HAND** Power on / off
START STOP
AUTO
Emergency
shut off
STOP
Stop cycle
finshed
Condition
Air blower & STOP
OEPRATING CYCLE
vacuum pump MODE
running
BUTTON
** = Button at operator panel

STOP
FLOW CHART OF OPERATING MODES
STOP STOP STOP

Last stop situation:
REDUCE
FLOW STOP
STOP ADS.
CYCLE START %O2 %O2
Adsorber
< AALL < AAL

station
running
COMPR. All systems OFF %O2 %O2 ON
START running SPEC < AAL > AAHH SPEC
Last stop situation: Adsorber
station
%O2 Design flow
running
ERROR ADS. > AAHH reached
Issue: 01
STOP START!
INCREASE
FLOW
Issue: 01 Prepared by Valenta / ADDA Code: LUBUMBASHI Page: 1

Date: 14-Jun-22 checked by Windhorst / ADDA
Sequence Diagram Proj. No.: 2210 CCP8 of 1
Page 8 of 8
Operating Modes
approved by Wildgruber / ADPA ID-No.: Doc No.: &AK-A-ZM 2099
for File: 1
Control of the VPSA plant Proj. no.: 2210 CCP8
5 CONTROL OF THE VPSA-PLANT

5.1 INTRODUCTION
All process steps will be controlled by a PLC (programmable logic controller). The PLC
control system is mounted inside the PLC cabinet +P9395, which consists of following
components:
1. Power supply module
2. CPU 410E Process Automation
3. Ethernet link module for communication with the Operator
Workstation of the VPSA-Plant
The individual process units like feed air blower, vacuum pump, valve skid or oxygen
compressors are equipped with single/redundant I/O system and are connected via
single/redundant interface modules to the CPU like the following picture. The PLC
communicates with the I/O system via profinet protocol.
Figure 5-1: General configuration of control system
The operating workstation for visualization of the process and change of parameters
and settings a personal computer with Siemens PCS7 application is used.
The internal memory contains the latest issue of the PLC software with adjustments
for set points and parameters. At the start-up of the PLC system the internal load
memory (persistent) will be copied to the work memory of the CPU. This process of
loading the software and synchronizing the CPU may take 10-20 minutes due to the
internal check-up and linking both CPUs in redundant PLC system. The content of the
work memory will be stored if the CPU is connected to the power supply or sufficient
power is available from the backup batteries, located inside the power supply module.
Note: Batteries must be maintained regularly!

Changing of batteries must be done while PLC is in operation.
Do not unplug PLC components while the PLC unit is under voltage.
ATTENTION: IN CASE SETTINGS ARE CHANGED AFTER THE LOAD

MEMORY WAS WRITTEN, THESE CHANGES ARE ONLY
STORED IN THE INTERNAL WORK MEMORY OF THE CPU AND
NOT ON THE LOAD MEMORY. FOR THIS REASON, ANY
CHANGE OF PARAMETERS SHOULD BE CAREFULLY NOTED
IN THE DAILY PROTOCOL. IN CASE THE INTERNAL MEMORY
GETS LOST, THESE CHANGES HAVE TO BE REDONE.
5.1.1 STARTING UP THE PLC CONTROL SYSTEM
The following information contains only the required minimum. In case further
information is required, please refer to the SIEMENS manual in the technical part of
LINDE’s manuals.
Following switches are located at the power supply module (see Figure 5-2):
1. Standby switch
The standby switch turns off the output voltages by intervening in the
control loop. This switch does not cut off the main power supply.
2. FMR switch (failure message reset)
The FMR switch acknowledges and resets any fault indicator after
correcting the fault.
3. BATT INDIC switch (located under cover)
Defines the number of batteries used for backup of the internal memory
and enables the battery monitoring LEDs.
Figure 5-2: Controls and indicators on power supply module
To start the PLC system, turn on the standby switch at the power supply. The CPU will
automatically switch to RUN mode and transfer the program from the load memory to
the work memory.
ATTENTION: IN CASE SETTINGS ARE CHANGED AFTER THE LOAD MEMORY

WAS WRITTEN, THESE CHANGES ARE ONLY STORED IN THE
INTERNAL WORK MEMORY OF THE CPU AND NOT ON THE
LOAD MEMORY. FOR THIS REASON, ANY CHANGE OF
PARAMETERS SHOULD BE CAREFULLY NOTED IN THE DAILY
PROTOCOL. IN CASE THE INTERNAL MEMORY GETS LOST,
THESE CHANGES HAVE TO BE REDONE.
The CPU is ready for operation, if only the RUN LED at the CPU is lighting. Please
note that the start-up process of the CPU may take 10-20 minutes.
Figure 5-3: Operating elements of the central processing unit (CPU)
5.1.2 OPERATING MODES OF THE CPU
STOP operating mode

− the software is not executed
− the current values for timers, counters, flags and process image I/O
tables are saved as soon as the CPU turns into STOP
− output signals are disabled (signal status “0” or “4mA”)
− all process image I/O tables, timers, non-retentive flags and counters
are set to “zero” during transition from STOP to RUN
RUN operating mode

− the software is processed cyclically
− already started timers continue to run
− signal states from the input modules will be read in and processed
inside the software program
− output modules are addressed by the CPU
START-UP operating mode

− the operating system processes a start-up routine of the software
program and loads all user parameters, e.g. addresses, interface
configurations etc.
− the start-up organization block of the user program is processed
− the input and output modules are disabled during start up
Note: A change of operating mode can be caused only with engineering

rights and respective licenses. To stop the PLC system, turn off the
power via the standby switch at the power supply.
ATTENTION: Any access to and modification of the user program must

exclusively be done by LINDE or persons acting on behalf of
LINDE. Any interference in the software will be recorded and
will cause exclusion of warranty. Any unauthorized interference
can cause severe damage to life and equipment. In case a
modification of the software is required, contact LINDE home
office!
5.1.3 START OF THE VISUALIZATION SYSTEM
There are two options for start of visualization available:

− Within a restart of the computer, the visualization will automatically start
− Manually with the following procedure
1. Open the windows task bar and right click at the icon and choose the
option “Open project”.
2. Open the MCP-File in the folder D:\VPSA\Project Name\Os\wincproj\OS(1).
If the project is opened.
3. Open the windows task bar again, right click at the icon and choose the
option “Activate runtime”.
4. The start-up of the visualization is active and WinCC Runtime application
will open.
5.2 OPERATING OF THE VPSA-PLANT
The VPSA-plant can be operated as follows:

− using the four push buttons located in the left front door of the PLC
cabinet:
VPSA START HS-9320
VPSA STOP HS-9321
ALARM RESET HS-9313
AUTOMATIC ON HS-9314
− using the primary Operator Workstation with the PCS7 visualization
system in the PLC Room
− via communication link from the DCS
For using the PCS7 visualization system, the operator must authorize himself with a
user name and password (refer to chapter 6.2).
5.3 FUNCTION OF THE ILLUMINATED PUSH BUTTONS
Figure 5-4: Push buttons in the front of plc cabinet
Button HS-9320 "VPSA START"

Indicator XL-9320 "PRODUCTION ON"
By pressing this button, the VPSA-unit will be started if the plant is in automatic mode.
Prior to start, warning signals will be sounded in the plant area, indicating the
forthcoming start of the machinery to any person still inside the plant.
At the sound of the warning signal, all work at the plant shall be
interrupted immediately!
DANGER FOR LIFE!
Do not continue work, as long as the plant is not securely
protected against start.
Do also inform contractors about the meaning of this signal!
The PLC initiates an automatic start-up-sequence, in which all components of the

VPSA are started one by one.
During the start-up-sequence the green light is flashing. If sufficient oxygen quality is
reached, the product will be feed into the consumer pipeline automatically. The PLC
will automatically control the amount and quality of the oxygen product up to the
designed capacity of the plant according to the customer’s requirements.
The green light is showing permanent indication, if the specified oxygen quality and
amount is reached.
Button HS-9321 "VPSA STOP"

Indicator XL-9321 "PLANT STOP"
After pressing this button, the VPSA-plant will be stopped. The PLC will initiate an
automatic shut-down sequence for all machinery and equipment. The green light
"START" is turned off and the red signal lamp "PLANT STOP" starts flashing.
After finishing the present half cycle the oxygen supply to the client is cut off by closing
the product valve XV-1550. Then the oxygen compressor will switch off.
An additional half cycle is started without supplying oxygen to the client to fill up the
oxygen buffer vessel. As soon as pressure equalization between both adsorber
vessels has been finished, feed air blower and vacuum pump will be shut off.
Product valves KV-2512 / KV-2522 will be opened for a short moment, allowing oxygen
from the buffer vessel to flow back into both adsorbers until they have reached
atmospheric pressure or slight overpressure. This is done to prevent moisture from
entering the adsorber vessel through leakages if the adsorber is still slightly under
vacuum.
The bypass valves KV-1105 / KV-1835 / KV-1845 will remain open for a few minutes,
to allow a smooth run down of the machinery. When all machines have stopped, the
valves will be closed to provide maximum security against moist air entering the
system.
Once the shut-down-sequence is finished, the red signal lamp will show a permanent
indication.
Button HS-9313 "ALARM RESET"

Indicator XL-9313 "GENERAL ALARM"
When a new alarm is generated by the PLC control system, the lamp starts flashing.
By pushing the button, the alarm can be reset.
In parallel a message will be created on the visualization system showing the reason
for failure. This message is also transmitted via communication link to the DCS system.
When the failure has been fixed, the alarm can be reset by pushing the button.
Button HS-9314 "AUTOMATIC ON"

Indicator XL-9314 "AUTOMATIC MODE"
Operating the plant by using the illuminated push buttons can only be done as long as
the plant is in automatic mode.
Should the plant not be in automatic mode, it can be switched back to automatic mode
by pushing this button. The PLC will bring back the plant to its initial state from which
it can be started. All manipulations done hand mode, like opening of valves, will be
reset.
In automatic mode the blue lamp is showing permanent indication.
Additionally, all sources of power (electric, pneumatic etc.)

must be switched off and secured against unauthorized re-
powering (lock-out / tag out).
DANGER FOR LIFE!
Do not start any kind of work, if the plant is not secured against
start.
5.4 HOW TO USE THE OPERATOR WORKSTATION
5.4.1 GENERAL
The Operator Workstation containing the visualization system is in the PLC Room and
shall be used by authorized and well-trained personnel only.
The Operator Workstations can be operated like a normal personal computer using
mouse and keyboard.
The entire process is visualized in one main picture and various sub-pictures
representing the main process units.
The Operator Workstation displays the plant similar to the P&I diagram. The system
displays all plant data such as pressures, temperatures, run signals of machinery,
position of valves, alarm-, shutdown and operating limits a.s.o.
On each screen, symbols similar to the P&I diagram are displayed to represent
machinery, vessels and valves along with their assigned tag numbers.
A mouse click at those symbols will open a window and reveal more detailed
information such as alarm, shutdown limits and operating data and trends belonging
to the selected instrument tag number or buttons for operation of equipment.
The PLC will only allow reasonable operations, i.e. some function keys may be enabled
or disabled, depending on the operating state of the plant. Different colours are used
to symbolize enabled and disabled function keys.
Active function key, which may be used
Non-active function key, which is locked for operation
Reasons for disabling of a function key by PLC may be:

− The assigned operation is not allowed in the present operating mode
Example: valves cannot be opened or closed manually in automatic
operation, as the process is entirely controlled by PLC
− The assigned operation is not allowed at the present moment
Example: if opening of a valve at high differential pressure may cause
damage, opening will not be allowed by the PLC (shutdown values or
operating limits are exceeded)
− the current user level does not authorize the operator to perform the
desired operation
5.4.2 STRUCTURE OF THE VISUALIZATION PICTURES
For more detailed and complete information regarding icons, symbols and the use of
the visualization system please refer to the PCS7 “Operating Instructions” from
Siemens.
This section describes the main features of the PCS7 system used for the visualization
of the oxygen VPSA unit. The following elements can be found in all pictures of the
visualization system.
IMPORTANT: The following pictures of the visualization system are only

intended for information.
The values for alarm, shutdown and operating limits shown in
these pictures do not correspond to the actual values.
The actual values for this plant can be found in the parameter
list handed over after commissioning.
All visualization pictures are divided into three areas:
The upper part is referred to as “Overview Area” and the bottom part is referred to as
“Button Area”. Overview Area and Button Area are displayed on each visualization
picture (see Figure 5-5). The area between Overview and Button Area is referred to as
“Working Area”. The Working Area shows individual process pictures with faceplates
and operator control windows.
Figure 5-5: Main picture
The Overview Area provides a constant overview of the status of the entire
VPSA-Plant. The Overview Area is used for monitoring the plant and fast detection of
problems in the different process units of the plant. Each process unit of the
VPSA-Plant is represented by its specific button in the Overview Area (see Figure 5-6).
Figure 5-6: Summary of process unit pictures in the overview area
By clicking on the button of a selected process unit, its corresponding picture will be
displayed in the Working Area and the button will be activated (example: clicking on
the button will open the picture for process unit adsorber and the
button will turn into ).
Next to the button of each process unit the indicators for Group Display and the Open
Picture Tree Navigator are shown. The Group Display shows the states of messages
associated with the corresponding main process unit in a graphic form. If there are no
messages, the button is displayed in grey colour.
Figure 5-7: Group display and open picture tree for process unit “Air blower”
Shutdown Violation
The red button at the Group Display shows, that shutdown conditions
are present at this process unit. Clicking on this button will display the
picture of the related process unit, showing the source of the
message.
Warning Violation
The yellow button at the Group Display shows, that warning
conditions are present at this process unit. Clicking on this button will
display the picture of the related process unit, showing the source of
the message.
Tolerance Violation
The blue button at the Group Display shows, that tolerance conditions
are present at this process unit. Clicking on this button will display the
picture of the related process unit, showing the source of the
message.
Malfunction
The black button ‘S’ at the Group Display shows, that instruments with
fail measurement are present at this process unit. Clicking on this
button will display the related process unit, showing the source of the
message.
Maintenance
The black button ‘M’ at the Group Display shows, that maintenance
requests of instruments are present at this process unit. Clicking on
this button will display the related process unit, showing the source of
the message.
Process Message
The turquoise button at the Group Display shows, that an interlock is
bypassed.
Open Picture Tree Navigator

The Open Picture Tree Navigator allows a fast selection of secondary
process pictures of the various process units.
At the upper end of the Overview Area, a message line showing the message with the
highest priority in the plant is displayed (see Figure 5-8). If two messages have the
same priority, the latest one will be displayed.
Figure 5-8: Message line
On both sides of the Message Line buttons for the following functions are displayed:
Extended message line

A click on this icon will open a list of all incoming messages in the
Working Area.
Loop in Alarm
A click on this icon will open a picture containing the source of the
message displayed in the Message Line.
Message acknowledge button

A click on this icon will acknowledge the message currently displayed
in the Message Line.
On the right edge of the Overview Area the following functions are displayed:
Date/Time
The current date and time are displayed.
User
A click on this button provides user logon and logoff for process
control. The name of the currently logged on user is displayed
Screen printout
A click on this button will start a printout of the screen content
In the Button Area two sets of standardized operator buttons are defined for process
control. Button Set #1 appears, when process mode is started. For a detailed
description of all buttons and their functions, please refer to the PCS7 Operating
Instructions.
Subsequently this manual will only list those buttons, which are mainly used to operate
the VPSA-Plant:
Button Set #1:
Button Set #2:
Change the button set

Click this button to switch between the two button sets
Password
Click this button to open the Login Dialog Box
Alarm List
Click this button to open message system with the incoming alarm list
displayed in the work area
Reports
Click this button to open the “Reports” system dialog box that provides
you with an overview of all reports
Trend groups
Click this button to open the process trends of the visualization system
Picture selection via process tag
Click this button to open the “Picture selection via measurement point”
system dialog. This function is used to select a graphic based on the
measurement point name and to display it in the work area
Picture via name
Click this button to open the “picture selection via name” system dialog
box. This function is used to select a graphic based on a name and to
display ist in the work area
Picture left / right
Click this button to display the process picture that is located within the
subarea level to the left/right of the previously displayed process picture
in the work area
Picture above / below
Click this button to change between the next higher / lower level of
visualization pictures
Previous picture
Click this button to display the process picture last displayed in the work
area
Next picture
Click this button to display the process picture selected next in the work
area
Store picture
Click this button to save the currently displayed process picture
enabling you to later display it using the "Output picture" command
Recall picture
Click this button to display the process picture saved with the "Store
picture" function in the work area
Call up screen composition
Click this button to open a screen composition of pictures and windows
that has been previously saved
Bookmark screen composition
Click this button to save the current composition of pictures and
windows on the screen, enabling you to call it up again later
Clear screen composition
Click this button to delete a screen composition of pictures and
windows that has been previously saved
System configuration
Click this button to display the system configuration
Picture information
Click this button to open a dialog box in the work area providing
information on the currently displayed process picture
Acknowledge horn
Click this button to acknowledge a queued signal from a signalling
device, such as a horn. However, the alarm that triggered the horn is
not acknowledged with this function
Acknowledge message
Click this button to acknowledge all the visible messages displayed in
the work area
Change language
Click this button to open a dialog box in the work area in which you can
select the required language for the user interface
PCS 7 Measuring Point Browser
Click this button to open the measuring point browser.
Trend Group
Click this button to display or configure the trend groups in the working
area.
Show/Hide Tag Names
Click this button to show or hide the tag names of process units.
Paint
Click this button to open windows paint.
Windows Access
Click this button to activate the access to windows with windows button.
The windows access will be disabled after log off or user change.
Simatic Manager
Click this button to open the simatic manager.
CMD
Click this button to open the windows command prompt.
Lock messages
Click this button to inhibit messages from any process tags that are
affected by group displays in the process picture
Unlock messages
Click this button to enable messages from any process tags that are
affected by group displays in the process picture
User Authorization
Click this button to open the user administrator dialog box.
Exit Runtime
Click this button to open the “Exit Runtime” dialog box
5.4.3 MAIN PICTURE
The Working Area of the main picture (see Figure 5-9) shows in the middle an isometric
view of the Oxygen-VPSA-Plant, unframed by the windows “Plant Management” and
“Plant Statistic” on the right side.
Figure 5-9: Main picture
The symbols displayed on the left side of the main picture provide access to following
information:
Plant Management
The left section displays the main buttons to

operate the plant through the visualization
system (referres to chapter 5.4.6).
The right section provides a quick overview about

the status of the main process units and the
status of start permission and interlocking.
The symbols displayed on the right and bottom side of the main picture provide the
following information:
Plant Statistic
Displays the most important performance data, such as average product flow, average
product purity, power consumption, operating hours, number of plant starts etc.
Total
shows the total amount of oxygen production,
power consumption and running time of the
VPSA-Plant since its first start-up
Since last start

shows the amount of oxygen production, power
consumption and running time of the VPSA-
Plant since its last start
Electrical Power
displays the instantaneous values of the VPSA-
Plant’s power consumption
Adsorber-Cycle-Performance
shows the average values of product flow,
oxygen purity and electrical power consumption
for the last process cycle.
Trends VPSA-Plant
Flow / Purity / Pressure

Click on this button to open the flow/ purity/
pressure trends
Adsorber-Cycle-Performance
Click on this button to display trends of all
adsorber average values
5.4.4 PROCESS UNITS
There are separate pictures for each process unit, similar to their representation on the
P&I diagram (see Figure 5-10).
Once selected in the Overview Area, the picture of the process unit is displayed in the
Working Area of the Operator Workstation, showing all process parameters and the
status of machinery, valves and motors. The status of machinery, valves, motors and
process parameters are indicated using different colours:
Electric motors and heaters:

█ green: in operation
█ gray: not in operation
█ red: faulty
Valves:
█ gray: closed
█ green: open
█ red: faulty
Process values:
█ green: within normal range
█ yellow: alarm limit exceeded
█ red: shut down limit exceeded
█ black: fail measurement
Figure 5-10: Visualization picture of the process unit “Air blower”
Elements displayed on the process unit pictures:
Process values
Each measurement in the process pictures is symbolized showing its current

measurement value and its tag number according to the P&I Diagram.
A click on the process value symbol will open a window with the faceplate for the
corresponding measurement. The faceplate contains a graphic representation of all
elements of the technical block intended for operator control and monitoring. For
detailed description refer to chapter 6.1.1
Controllers
Controllers will be indicated showing the current setpoint (blue) above of their current
measurement value (green) and the manipulated variable (orange).
A click on the controller symbol will open a window with the faceplate for the
corresponding controller. The faceplate contains a graphic representation of all
elements of the technical block intended for operator control and monitoring. For
detailed description refer to chapter 6.1.2
Valves
A click on a valve symbol will open a window with the faceplate for the corresponding
valve. The faceplate contains a graphic representation of all elements of the technical
block intended for operator control and monitoring. For detailed description refer to
chapter 5.6.5
Motors, heaters, cabinets
A click on a symbol for any electric motor or heater will open a window with the
faceplate of the corresponding motor/heater/cabinet. The faceplate contains a graphic
representation of all elements of the technical block intended for operator control and
monitoring. For detailed description refer to chapter 5.6.2.
Next to the symbols for actuated valves, controllers, electric motors a.s.o. status
symbols are displaying the actual status of the corresponding element:
Internal setpoint
Automatic mode
External setpoint
Manual mode
Bypass mode (only used for bypassed interlocks)
Permission, protection or interlock is active
Simulation mode of device is active
5.4.5 PERMISSION, PROTECTION AND INTERLOCKING
The permission, protection and interlocking view of motors, heaters and valves, as well
as the common plant functions gives information about the start permission and shut
down conditions of each device.
At the main view of motor, heater and valve faceplates

there are extended permission, protection and interlocking
views located.
At the main page, there are the common plant permission

and interlocking blocks located.
The operation and function are identical for all permission, protection and interlocking
views.
(1), (9) Switching between the values 1 to 8 and 9 to 16

(2) Status of the output signal of the interlock block
(3) Exclude input values
(4) "First in" status display
(5) Open faceplate of the output value
(6) Status of the block output
(7) Display the status for further processing
(8) Display of input values with signal status
(9) Switching input values
(10) "Reset" the settings for further processing
(11) Button to switch to another faceplate
(12) Displaying analog input values
(13) Open faceplate of the input value
Figure 5-11: Interlocking faceplate
The symbol below the output signal indication (7) depicts the status for further
processing of input values. For each input value, a symbol in the shape of a rectangular
icon is displayed, which contains a specifically filled colour. The rectangle icon with its
specific colour and description is displayed as follow:
The input value is good
The input value is bad
The input value is bypassed
If a device or the plant tripped, the “First in” indication gives information of the first
coming trip value. In this case there is a purple circle behind the trip value displayed.
This is a useful function to find the problem of the process that produced a trip of the
plant or a device.
For the erection of the plant or test run of machines it is possible to bypass interlock
values. Bypass input values is only possible with the proper password level of Linde
and Supervisor account. If an interlock is bypassed, a process message is
automatically generated by the control system. The message is only cleared when the
bypassed signal is reset.
ATTENTION: A bypassed permission, protection and interlocking

value can damage the plant! Danger for life!
This function should be only used by authorized

people and the approval from Linde! In this case
Linde is not responsible for any kind of damage!
5.4.6 OPERATING THE PLANT THROUGH THE “PLANT MANAGEMENT”-MENU
If the plant is operated through the operating workstation, the plant will be started and
stopped using the “Start / Stop / Hand”-Menu.
Open the Main Picture of the operating workstation by clicking on the selection button
displayed in the Overview Area. The “Start / Stop / Hand”-Menu is displayed
on the left edge of the Main Picture.
The present operating mode of the plant is displayed above

the operation buttons. For the description of the Operating
Modes please refer to chapter 4.
VPSA Automatic Start

A click on these buttons will start and stop the VPSA-Plant.
Note: These buttons will be locked in “HAND”-Mode or in
case of an active failure or restart time.
Hand/Automatic Operation of Plant
These buttons will select between operation modes “HAND”
or “AUTO”.
Hand-/Auto-Operation of Valves
These buttons will select between operation modes
“VALVE HAND” or “VALVE AUTO”
Note: Changing between operating mode “VALVE HAND”
and “VALVE AUTO” is only possible, if the plant is stopped
and the “HAND” operation mode.
5.5 START AND STOP OF THE VPSA-PLANT
5.5.1 PREPARATIONS BEFORE START
Before the VPSA-Plant is started up, it shall be verified, that the plant is ready for
operation. For this reason, an inspection around the plant is recommended.
The following points should be considered:
• Instrumentation
➢ Pressure transmitters: all valves in the tubing must be open
➢ Differential pressure transmitters: all valves to the high and low connect point
of the transmitter must be open, the equalizing valve on the pressure
transmitter must be closed
➢ All instruments must be ready and properly calibrated
➢ Oxygen analyzer must be switched on and the warm-up time must be
finished. The sample point shall be selected to analyze gas taken from the
downstream side of the buffer vessel (sample point AE-1538).
• Instrument air supply:

➢ All block valves for instrument air supply must be open
➢ Pressure regulator PIC-8312 shall be adjusted to 6 bar(g)
➢ Open drain valves of buffer vessels D-8332 to verify, if condensation has
appeared.
Do not start the plant, if water is found at those points, as condensate will
affect proper function of automatic valves in the plant.
• Cooling water supply:

➢ Block valves HV-1501 and HV-1502 must be open
➢ All drain valves must be closed
➢ Piping system and coolers must be vented
• Electrical supply:
➢ The power supply to the PLC cabinet +P9395 must be available
➢ The thermostats for fan control inside the PLC cabinet shall be adjusted to
35°C
➢ The main power switches -Q00, located inside PLC cabinet +P9395 must be
‘ON’ and all automatic fuses must be set to '1'
➢ The standby switches on power supply modules must be set to '1'
➢ The CPU unit must be set to 'RUN'. The green LED indicates that the CPU
unit are ready and operating.
➢ Verify readiness of main power supply (6,6kV & 400V) for machinery and
equipment
• General:
➢ Visible or audible leakage (gas, oil, water, instrument air)?
➢ Unusual observations (burned paint, cracks in plant components or
foundations, abnormal pollution, damage)?
➢ All connections tightened up properly (spot checks)?
AFTER THIS INSPECTION IT SHALL BE CHECKED, IF THERE ARE STILL SOME

ACTIVE ALARMS WHICH MAY PREVENT STARTING UP THE PLANT. IN CASE
OF ACTIVE ALARMS BLOCKING THE START OF THE PLANT, THESE MUST BE
ELIMINATED FIRST (SEE CHAPTER 7).
5.5.2 PREPARATION OF THE OXYGEN COMPRESSORS
The oxygen compressor may require additional measures to be taken prior to start-up.
Start-up and test run on nitrogen is a mandatory requirement on following situations:

− Start-up of a new machine after erection
− Start-up of a machine after a prolonged standstill
− Start-up of a machine after a maintenance of the following type:
- Maintenance that required purging with dry air or nitrogen
- Replacement of bearings
- Replacement of internal parts, internal sealing system etc.
A direct start-up on oxygen is only permissible under following conditions:

− Start-up as a normal procedure after a planned shutdown
− Start-up of an operational stand-by machine previously in oxygen
service
− Start-up after trip or malfunction shown on investigation not to be
dangerous
− Start-up of a machine after maintenance, except the types of
maintenance listed above
5.5.3 START OF THE VPSA-PLANT
As soon as all above mentioned conditions have been fulfilled, the VPSA-Plant can be
started.
Starting of the VPSA-Plant can be done by

− pushing the green button HS-9320 "VPSA START" in the left front
door of the PLC cabinet
− clicking the button “Start” in the “Plant Management”-Menu of the
Operater Workstation
− remote start via communication link from the DCS
Prior to starting machinery, a warning signal is sounded inside each unit, which should
warn all persons about the forthcoming start of the machinery.
DANGER FOR LIFE!
Do not continue work, if the plant is not securely protected
against start.
The PLC will start up the main components of the plant as follows:
− vacuum pump and feed air blower in bypass mode
− valve sequence of the adsorber station including bypass valves of air
blower and vacuum pump
− oxygen compressor
(only if operator has included oxygen compressor in the automatic
start-up sequence, see chapter 5.5.4)
Following a successful start of the oxygen compressors a certain amount of oxygen

will be discharged through blow-off valves PCV-1513. Purity alarms and alarms for
process air temperature will be disabled for approximately 15 minutes. Partial load
operation (step 3 and 8) will also be disabled within the first 5 minutes following a plant
start.
Once the system has reached the specified oxygen purity, the PLC enables oxygen
supply to the piping system and opens product valves XV-1550.
The start-up time after a normal stop takes only a few minutes until the plant delivers
oxygen in the required amount and purity (8-10 minutes).
5.5.4 START AND STOP OF THE OXYGEN COMPRESSORS
The automatic start of the oxygen compressors during start-up of the VPSA-Plant must
be pre-selected by the operator in the detail picture for the parameters of the oxygen
compressor:
− Open the parameters for the process unit oxygen compressor
− Select “Auto-Start Compressor”
This option enables the operator to choose for start of oxygen compressor as per his
convenience and requirement.
If the compressor is not selected for automatic start, operator must start the
compressor manually to initiate delivery of oxygen to the consumers according to the
following procedure using the faceplate for the main compressor motor:
− Open the picture for the process unit oxygen compressor
− Open the motor faceplate, clicking on the symbol of the electric motor
The main view of the faceplate for the motor is now displayed (see Figure 5-12)
(1) Displaying and switching the operating mode
(2) Starting and stopping the motor
(3) Resetting the block
(4) Operator control and display area for interlock function
(5) Display of auxiliary values
(7), (8), (9) and (10) Display area for block states
(11) Automatic preview
(12) Status display of the motor
Figure 5-12: Motor faceplate
In this view the current operation mode and status of the motor are displayed.
Click on the button next to the “Command” field to expand the faceplate.
On the faceplate extension displayed, the operation command can be executed (see
Figure 5-13).
Select command button
.
Confirm the execution of this
command by selecting
.
Figure 5-13: Extension of motor faceplate
The PLC will now start the
oxygen compressor.
The oxygen compressor can be stopped at any time using the faceplate of the main
motor of the compressor. Open the faceplate and the expansion of the faceplate as
described above to stop the compressor.
Select command button

.
command by selecting
Figure 5-14: Extension of motor faceplate .
The PLC will now stop the
oxygen compressor
If no oxygen compressor is in operation, the VPSA-Plant will keep on running for 45

minutes and will be stopped subsequently. An alarm message will be generated on the
operating workstation, indicating that the plant was stopped because no compressor
was running.
In case of a problem at the oxygen compressor, only the compressor will be shut down
by the control system. The VPSA-Plant will keep on running. If the problem can be
fixed within the before mentioned 45 minutes, the oxygen compressor can be restarted
manually according to the procedure described before in this chapter.
In case the problem cannot be fixed within 45 minutes, the VPSA-Plant will be stopped
by the control system. An alarm message will be displayed, indicating that the plant
was stopped because no oxygen compressor was running.
Furthermore, there is an option to select if oxygen streams to the client consumers or

it blow off the oxygen to atmosphere (see Figure 5-15). By clicking on the button
the valve XV1550 will open, and the oxygen will stream to the client
consumers. By clicking on the valve XV1550 will be closed and the
valve PCV1513 and PCV1545 will open. Hence the oxygen is discharged to the
atmosphere or streams through the bypass.
Figure 5-15: Oxygen compressor unit
5.5.5 STOP OF THE VPSA-PLANT
The plant can be stopped at any time by the following three options:
− pushing the button HS-9321 "VPSA STOP" in the left front door of the
PLC cabinet
− clicking the button “Stop” in the “Plant Management”-Menu of the
operating workstation
− remote stop via communication link from the DCS
IMPORTANT: The plant is not stopped right away, since it will be prepared for
the next start.
After finishing the present half cycle, the supply of oxygen into the pipeline system is
interrupted by closing oxygen delivery valve XV-1550 and switching off the oxygen
compressor. One more half cycle is commencing in order to fill up the oxygen buffer
vessel to its maximum pressure, without supplying oxygen to the company’s piping
system.
After finishing pressure equalization between both adsorber vessels, product valves
KV-2512 / KV-2522 will be opened for a short moment. Oxygen from the buffer vessel
will flow backwards into both adsorbers, until the adsorbers have reached atmospheric
pressure or a slight overpressure. This way the filling inside the adsorber vessels is
protected against moist ambient air.
A few minutes after the shutdown, the bypass valves on the machines will be closed
automatically.
The plant can be started again, as soon as the waiting time for the restarting the electric
motors has expired.
5.5.6 START OF THE VPSA-PLANT AFTER ERROR STOP
A restart of the VPSA-Plant after a trip requires

− that all problems, which are causing a shutdown are solved
− that all alarms in the message list are acknowledged by clicking on the
acknowledge icon
− that all alarms are reset by clicking on the reset button
shown in the Main Picture
The procedure to restart the plant after ERROR STOP is similar as mentioned in
chapter 5.5.3.
The control system will continue the step sequence exactly at the same point, where it
had been interrupted before.
If the remaining step time is very short, it may occur in exceptional cases that the plant
will shut down again. If that happens, try another restart.
5.6 OPERATING THE PLANT IN ‘HAND’ MODE
To performing test runs after maintenance works, individual parts can be tested in
HAND mode. In HAND mode only ordinary function tests without load are possible.
HAND mode must only be initiated by trained personnel and is protected with a
password.
The operating instructions of the individual suppliers must be

strictly followed!
In HAND mode the same interlocks will be active as there are in automatic mode, i.e.
neither of the defined limits (levels, pressures, temperatures, valve positions etc.) must
be violated, otherwise the unit cannot be started.
Failures, which may be present on other units however, will not be considered by the
PLC.
In this plant the following units can be started in HAND mode:

− vacuum pump and feed air blower
− oxygen compressor
− valve sequence without oxygen delivery valve XV-1550
− individual valves
− individual motors and heaters
5.6.1 PREPARATIONS BEFORE START
Before start of each unit it shall be verified, that this unit is ready for operation. For this
reason, an inspection around the plant is recommended.
The following points should be considered:
• Instrumentation
➢ Pressure transmitters: all valves in the tubing must be open
➢ Differential pressure transmitters: all valves to the high and low connect point
of the transmitter must be open, the equalizing valve on the pressure
transmitter must be closed
➢ All instruments must be ready and properly calibrated
➢ Oxygen analyzer must be switched on and the warm-up time must be
finished. The sample point shall be selected to analyze gas taken from the
downstream side of the buffer vessel (sample point AE-1538).
• Instrument air supply:

➢ All block valves for instrument air supply must be open
➢ Pressure regulator PIC-8312 shall be adjusted to 6 bar(g)
➢ Open drain valves of buffer vessels D-8332 to verify if condensation has
appeared.
Do not start the plant, if water is found at those points, as condensate will
affect proper function of automatic valves in the plant.
• Cooling water supply:

➢ Block valves HV-1501 and HV-1502 must be open
➢ All drain valves must be closed
➢ Piping system and coolers must be vented
• Electrical supply:
➢ The power supply to the PLC cabinet +P9395 must be available.
➢ The thermostats for fan control inside the PLC cabinet shall be adjusted to
35°C
➢ The main power switches -Q00, located inside PLC cabinet +P9395 must be
all ‘ON’ and all automatic fuses must be set to '1'
➢ The standby switches on power supply modules must be set to '1'
➢ The CPU unit must be set to 'RUN'. The green LED indicates that the CPU
unit are ready and operating.
➢ Verify readiness of main power supply (6,6kV & 400V) for machinery and
equipment
• General:
➢ Visible or audible leakage (gas, oil, water, instrument air)?
➢ Unusual observations (burned paint, cracks in plant components or
foundations, abnormal pollution, damage)?
➢ All connections tightened up properly (spot checks)?
AFTER THIS INSPECTION IT SHALL BE CHECKED, IF THERE ARE STILL SOME

ACTIVE ALARMS WHICH MAY PREVENT STARTING UP THE PLANT. IN CASE
OF ACTIVE ALARMS BLOCKING THE START OF THE PLANT, THESE MUST
ELIMINATED FIRST (SEE CHAPTER 7).
5.6.2 TEST RUN OF FEED AIR BLOWER AND VACUUM PUMP
In HAND mode feed air blower and vacuum pump unit can be tested in bypass mode.
During this test, the machines will be operated in bypass, i.e. valves KV-1105 or
KV-1835 and KV-1845 will be open to limit the differential pressure at the blowers to
the pressure loss of the piping system, strainers and silencers.
For testing the machine in HAND mode proceed as follows:

1. Open the Main Picture on the Operator Workstation
2. Switch the plant to HAND mode in the “Plant Management”-Menu by

selecting the button and check, if automatic operation of valves is
selected
3. Change to the process unit “feed air blower” or “vacuum pump”
4. Click on the symbol of the electric motor to open the faceplate to start the
individual motor.
NOTE
If the motor M1181 or M1881 is switched to manual mode, the
related bypass valve KV-1105 or KV1835/KV1845 will be
opened automatically due to the interlock of the machinery.
The main view of the faceplate for the motor is now displayed.
(4) Operator control and display area for interlock
functions of the block
To switch a motor in manual mode, click on the button next to “Mode” field to
expand the faceplate. On the faceplate extension displayed the operation command
can be executed. This is only possible if the plant mode on ‘Main’ screen is set up to
‘Hand/Manual’.
Select command button .
Confirm the execution of this command

by selecting .
Now the motor is in manual mode
Click on the button next to “Command” field to expand the faceplate.
On the faceplate extension displayed the operation command can be executed.

by selecting .
Figure 5-18: Extension of motor faceplate The PLC will now start the oxygen
compressor.
The bypass valves of feed air blower or vacuum pump unit will be opened. A warning
signal is sounded inside the plant, to warn all persons about the forthcoming start of
the machinery. Shortly afterwards the machine unit will start.
DANGER FOR LIFE!
Do not continue work, if the plant is not securely protected
against start.
To end the test run, re-open the faceplate and the extension of the faceplate as
described above for the start of the machinery unit.

command by selecting .
Figure 5-19: Extension of motor faceplate The PLC will now stop feed air blower
and vacuum pump
After the unit has run down, bypass valves will close automatically. Once the bypass
valves are closed, it is possible to switch back the VPSA-Plant into automatic mode.
5.6.3 TEST RUN OF OXYGEN COMPRESSOR
For testing proper function of the oxygen compressor before start-up or after
maintenance works, a test run with nitrogen must be performed first (see also chapter
5.5.2).
For this purpose, the oxygen compressor will be operated with valve XV-1550 closed
and bypass valve PCV-1545 open. The entire volume of gas is circulating through the
bypass piping for the test run.
Figure 5-20: Oxygen compressor manual start options
Prior to the test, it is required to open the window with parameter settings for the
compressor in order to check, whether the test shall be done with the oxygen buffer
connected or disconnected.
Information: Connecting the buffer vessel provides an additional volume of gas

to the compressor system during test run, thus preventing the
compressor from shutdown during start-up due to low suction
pressure.
Connecting the oxygen buffer vessel is typically required for mid-
size and large-size oxygen plants in connection with an oxygen
compressor with two or more compression stages.
The mode of testing is usually preset during first commissioning of
the plant and does not need to be changed.
First, connect a bundle of nitrogen bottles along with a pressure reducer to the N2 feed
valve HV-1512 to allow nitrogen to be fed into the compressor system. The pressure
reducer shall be sized to lower the pressure of the gas bottles to approximately 0,5
bar(g).
Before starting the test run, the whole compressor system and the oxygen buffer vessel
shall be purged with dry nitrogen several times. To do so open the bypass valve
PCV-1545 and compressor suction valve XV-1530 manually (see chapter 5.6.5).
Open valve HV-1512 slowly now and apply some slight overpressure (approx.
0,4 bar(g)) to the system. Now open blow-off valve PCV-1513 fully to release the
pressure into atmosphere. Close blow-off valve PCV-1513 again and repeat this
procedure several times.
For testing the oxygen compressor with nitrogen proceed as follows:

1. Fill up the entire system including the oxygen buffer vessel with dry nitrogen
(approx. 0,4 bar(g)). To do so open bypass valve PCV-1545 and
compressor suction valve XV-1530 manually (see chapter 5.6.5).
2. Go to the “Plant Management”-Menu of the VPSA-Plant and select
automatic valve mode. The PLC will now close all valves again.
For the following test run at least two persons will be required. While the first person
must start the oxygen compressor, the second shall observe the suction pressure of
the first stage and has to open or to close the nitrogen supply accordingly during the
start of the test run.
Therefore, it is necessary for this person to be aware of the shutdown limits for high
and low suction pressure, to open or close the nitrogen supply early enough to prevent
a shutdown of the compressor.
3. Change to the picture for the oxygen compressor and start the unit as
described in chapter 5.5.4. The auxiliary oil pump for prelubrication will start,
bypass valve PCV-1545 will be opened and subsequently the oxygen
compressor will be started.
4. Observe carefully the suction pressure of the first compressor stage and
add some nitrogen into the system if required.
5. Operate the compressor now with dry nitrogen following the instructions of
the compressor manufacturer to check for correct function. Pay attention for
excessive temperatures and pressures, unusual noise, leakages a.s.o.
Keep a record of all measured values of the compressor during this test run. Operate
the compressor within the entire range between minimum and maximum suction
pressure (refer to the manufacturer manual). Do not finish the test run before pressures
and temperatures have stabilized.
Compare all measured values with values from earlier test runs. In case noticeable
deviations appear, consult the manufacturer prior to operate the compressor with
oxygen.
To finish the test run, re-open the faceplate and the extension of the faceplate and stop
the compressor as described in chapter 5.5.4. The compressor will be stopped
automatically. After the unit has come to a full stop, bypass and vent valves will close
automatically. Only once all valves are closed, the VPSA-Plant can be switched back
into automatic mode.
If the test is successfully completed, ensure that valve HV-1512 is closed tight and
blinded to prepare the compressor for operation with oxygen.
Switch back the plant to automatic mode. The plant is now ready for start.
5.6.4 TEST OF VALVE SEQUENCE
In order to check the correct function of a valve after repair or maintenance, the valve
sequence should be tested before taking the plant back into operation.
In ‘HAND’-Mode individual valves can be switched manually. However, in most cases

it is preferable to start the entire valve sequence for a few minutes. During this test the
PLC evaluates the switch times of the new valve and the valve supervision is adapted
to the new values.
As a condition for this test, the adsorber and oxygen buffer pressures must be
approximately equal to ambient pressure to allow opening of valves. Perform a manual
pressure equalization or de-pressurization if required.
For testing of the valve sequence proceed as follows:
Figure 5-21: Process unit “Adsorber”, showing present step number and remaining time
1. Go to the “Plant Management”-Menu in the Main Picture of the VPSA-Plant

and open the button . Switch the operation mode to valve
sequence simulation and start the plant as a normal start up. The process
simulation will start with switching the valves in the field.
2. To stop the sequence, stop the plant.
3. If the test is completed, go back to the Main Picture. Switch the VPSA-Plant
back into “Plant Operation” Mode. The plant is now ready for operation and
can be started as described in chapter 5.5.
ATTENTION: The valve sequence simulation is only possible, if

there is no pressure inside the adsorber vessels
and the oxygen buffer tank. The product valve
XV-1550 to client oxygen network will not open in
valve sequence simulation.
5.6.5 TEST OF INDIVIDUAL VALVES
To test individual valves in ‘HAND’-mode, please proceed as follows:

1. Go to the “Plant Management”-Menu in the main picture of the Operator
Workstation, switch between Hand-/Auto-Operation of the plant by selecting
the button and subsequently switch between Hand-/Auto-Operation
of valves by selecting the button for a manual operation of valves.
2. Go to the picture of the process unit, which displays the valve that is
supposed to be tested.
The faceplates for manual operation of individual valves slightly differ from each other,
depending whether the valve is an OPEN/CLOSE valve or a control valve.
Test of OPEN/CLOSE valves
Open the faceplate by clicking on the symbol for the OPEN/CLOSE

valve to be operated
The main view of the faceplate for open/close valves is displayed.

(2) Opening and closing the valve
(4) Interlock functions of the block
(12) Status display of the valve
Figure 5-22: Valve faceplate
In this view the current operation mode and status of the valve are displayed.
To switch a valve in manual mode, click on the button next to “Mode” field to
can be executed. This is only possible, if the plant mode on ‘Main’ screen is set up
to ‘Hand/Manual’.

by selecting .
Figure 5-23: Extension of valve faceplate
Now the valve is in manual mode
Click on the button next to the “Command” field to expand the faceplate.

Select command button or

.

Figure 5-24: Extension of valve faceplate by selecting .
The PLC will now open the valve.
Test of control valves
Open the faceplate by clicking on the symbol for the control valve to be
operated
The main view of the faceplate for open/close valves is displayed.

(2) Opening, closing the control valve
(3) Switching the default manipulated variable
(5) Scale range for the manipulated variable
(6) Changing the manipulated variable
(7) Displaying the position feedback
(8) Target manipulated variable
(9) Bar graph for the manipulated variable
(10) Bar graph for position feedback
(11) Display of external manipulated variable
(14) Button for switching to the annother faceplate
(15), (16), (17), (18) Display area for block states
(19) Representation of neutral position
(21) Status display of the control valve
(22) Picture of auxiliary valve
Figure 5-25: Valve faceplate
In this view the actual operation mode and status of the valve are displayed.
Ensure that next to the “Command” field the control mode is selected .
If not, click to the button next to the “Command” field to expand the faceplate
and select the control mode in the extension.
In this view the current operation mode and status of the control valve are displayed.
To switch a control valve in manual mode, click on the button next to “Mode”
field to expand the faceplate. On the faceplate extension displayed the operation
command can be executed. This is only possible, if the plant mode on ‘Main’ screen
is set up to ‘Hand/Manual’.

by selecting .
Now the valve is in manual mode
Select the blank input box in

the dialog box.
Use the keyboard to enter a manual

opening value into the input box.

by selecting .
The valve will now move to the

requested opening position.
5.6.6 TEST OF MOTORS AND HEATERS
To test individual motors or heaters in “HAND”-Mode proceed as follows:

1. Open the Main Picture
2. In the “Plant Management”-Menu switch the VPSA-Plant first to ‘HAND’-Mode by
selecting the button and then to ‘HAND’-Mode by selecting the button
for a manual operation of motors or heaters.
3. Go to the picture of the main process unit, which includes the valve that should be
tested.
Open the faceplate by clicking on the symbol for the motors or

heaters to be operated
The main view of the faceplate for motors is displayed.

(5) Navigation button for switching to the standard
view of any faceplate
To switch a motor in manual mode, click on the button next to “Mode” field to
can be executed. This only possible, if the plant mode on ‘Main’ screen is set up to
‘Hand/Manual’.

Figure 5-29: Extension of motor faceplate by selecting .
Now the motor is in manual mode
Click on the button next to “Command” field to expand the faceplate.

by selecting .
The PLC will now start the respective
motor or heater.
Operating manual Part: Operating manual
for Section: 1
Oxygen-VPSA-Plant File: 1
Display and changing of Doc. no.: &AK P-MC 2006 (EN)
parameters Proj. no.: 2210 CCP8
6 DISPLAY AND CHANGING OF PARAMETERS

6.1 GENERAL
The parameters of the VPSA-Plant are divided into three separate groups:
1. Warning limits
Violation of a warning limit will create a message, signalizing to the operator
that the plant is working in an exceptional state. This warning message is
displayed on the Operator Workstation and is also forwarded via remote
connection to the DCS. Some warnings may trigger automatic actions
defined in the PLC software to prevent shutdown of the plant.
2. Alarm limits
Violation of an alarm limit will trigger an immediate shutdown or regular stop
of the plant to prevent critical operating conditions. An alarm message is
displayed on the Operator Workstation and is also forwarded via remote
connection to the DCS.
3. Operating limits
Operating limits are meant for adjustment of the plant and define the plant
performance.
The parameters of the VPSA-Plant can be accessed in the visualization system

through the following ways:
Each measurement in the process pictures will be symbolized showing
its current value and its tag number according to the P&I Diagram.
Clicking on the measuring point will open a faceplate for the
corresponding measurement. This faceplate contains a graphic
representation of all elements of the technical block intended for
operator control and monitoring. For detailed description refer to
chapter 6.1.1
Each controller in the process pictures will be symbolized showing its

current setpoint next to the measurement value and the controller
output. Clicking on the controller symbol will open a faceplate for the
corresponding controller. This faceplate contains a graphic
operator control and monitoring. For detailed description refer to chapter
6.1.2.
Each motor or heater in the process pictures will be symbolized showing

its current state. Clicking on the symbol will open a faceplate for the
corresponding motor or heater. This faceplate contains a graphic
6.1.3.
Each maintenance counter in the process pictures will be symbolized

showing the current run time since the last maintenance stop. Clicking
on the counter symbol will open a faceplate for the corresponding
maintenance counter. This faceplate contains a graphic representation
of all elements of the technical block intended for operator control and
monitoring. For detailed description refer to chapter 6.1.4.
Each valve in the process pictures will be symbolized showing the

current state. Clicking on the valve symbol will open a faceplate for the
corresponding maintenance counter. This faceplate contains a graphic
6.1.5.
Further settings, adjustments and operating values, which are required

for control of the Oxygen-VPSA-Plant, but cannot be implemented into
the standardized PCS7 faceplates, have been implemented as
secondary process pictures, which are accessible through special
buttons or through the Open Picture Tree Navigator in the Overview
Area. For detailed description refer to chapter 6.1.6
The Operator Control and Display Bar shown at the upper end of each faceplate is
standardized for the PCS7 software. The following figure shows an example of this
Operator Control and Display Bar in a faceplate:
Figure 6-1: Operator Control and Display Bar
Below is a short functional description of the icons and buttons of the Operator Control
and Display Bar for the Oxygen-VPSA-Plant. For additional information refer to the
operating instructions of the SIEMENS PCS7 visualization system.
A click on this icon will open the main window of the faceplate
A click on this icon will open a window with the trend graphic of the
faceplate
A click on this icon will open a window with the setpoint values of
the faceplate
A click on this icon will open a window with the setpoint values and
measuring data of the faceplate
A click on this icon will display additional available buttons of the

faceplate
Icons and buttons displayed in grey are disabled and cannot be

used. The reason may be, that there is either no function for this
icon in the displayed faceplate or that the user level currently
logged in is not allowed to perform this kind of operation
6.1.1 FACEPLATE WINDOW FOR PROCESS VALUES
A click on each process value will open a faceplate for the correspond-
ding measurement. This faceplate contains a graphic representation of
all elements of the technical block intended for operator control and
monitoring
(1) Displaying and switching the operating

mode
(2) High and low scale range
(3) Display of the process value
(4) High and low scale range for the gradient
(5) Display of the gradient
(6) Resetting the peak values of the gradient
(8) Button for switching to the other faceplate
(9) and (10) Display area for block states
(11) Bar graph for the process value
(12) Bar graph for the gradient
(13) Display of the gradient
(14) Display of limits in the bar graph
(15) Limit display
Figure 6-2: Faceplate of analog measurements
The main window of the faceplate for an analogue measurement (see Figure 6-2)
shows the current process value as digital number and in analogue form in a scale bar.
The triangular markers next to the scale bar are representing the setpoints for tolerance
limits (blue), warning limits (yellow) and alarm limits (red). The instrument measuring
range is shown above and below the digital display of the process value.
Clicking on the symbol for the setpoint values ( ) in the Operator Control and Display
bar opens the faceplate to display and access tolerance, warning and alarm limits:
Figure 6-3: Setpoint window of faceplate for analogue measurements
Clicking on one of the setpoint fields (e.g. ) will expand the faceplate. This
function only works, if the operator is logged in with the appropriate user level required
to change the selected setting. In the extension of the faceplate (see Figure 6-4) the
setpoint value can be changed:
Figure 6-4: Extension window of faceplate for analogue measurements
The dialog box shows the upper and lower limit for any possible setpoint modification.
To modify the setpoint, click on the blank box of the setpoint dialog box and type in the
new setting using the keyboard. Confirm the value typed in with the ENTER key on the
keyboard.
Confirm the execution of this modification by selecting . The new setting is

applied, and the dialog box will be closed. It is also possible to use the direct control
function of the faceplate. With a click at a direct control button, the alarm limit will
change directly without confirmation. The percentage value refers to the high scale
value.
6.1.2 FACEPLATE WINDOW FOR CONTROLLERS
A click on each controller symbol will open a window with the faceplate
for the corresponding controller. This faceplate contains a graphic
operator control and monitoring.

(2) Displaying and switching the setpoint
(3) High and low scale range for the process value
(4) Displaying the process value
(5) Displaying and changing the setpoint
(6) High and low scale range for the setpoint
(7) Display of manipulated variable
(8) Display of feedback value
(11) Display area for interlock functions of the block
(12) Navigation button of the "ConPerMon" block
(13) Button for switching to the other faceplate
(14), (15) and (16) Display area for block states
(17) Limit display
(18) Bar graph for the process value
(19) Bar graph for the setpoint
(20) Display of external setpoint
Figure 6-5: Faceplate for controllers (21) Display for the target setpoint of the ramp mode
(22) Limit display for the setpoint
The main window of the faceplate for a controller shows the current operation mode of
the controller (automatic or manual). The setpoint and process values are displayed
as digital numbers and in analogue scale bars. The current output signal of the
controller is indicated as digital number in the field “Manipulated var.”
Clicking on the setpoint field will expand the faceplate. This function only works, if the
operator is logged in with the appropriate user level required to change the selected
setting. In the extension of the faceplate (see Figure 6-6) the controller setpoint can be
changed:
Figure 6-6: Extension window of faceplate for controllers

The dialog box shows the upper and lower limit for a possible setpoint modification. To
modify the setpoint, click on the blank box of the setpoint dialog box and type in the
new setting using the keyboard. Confirm the value typed in with the ENTER key on the
keyboard.
applied, and the dialog box will be closed. With a click at a direct control button, the
alarm limit will change directly without confirmation. The percentage value refers to the
high scale value.
Clicking on the symbol for the controller parameters ( ) in the Operator Control and
Display bar opens the faceplate to define controller parameters:
Figure 6-7: Parameter window of faceplate for controllers
Clicking on one of the allowed parameters (e.g. ) will expand the faceplate. This
to change the selected setting. In the extension of the faceplate the parameters can
be changed such as the setpoint value.
6.1.3 FACEPLATE WINDOW FOR MOTORS AND HEATERS
A click on each motor or heater symbol will open a window with the
faceplate for the corresponding motor or heater. This faceplate
contains a graphic representation of all elements of the technical block
intended for operator control and monitoring.

(5) Navigation button for switching to the standard
view of any faceplate
The main window of the faceplate for motors and heaters (see Figure 6-8) shows the
current state of the motor and heater (ON or OFF). If the device includes permissions,
protection or interlocking, it is possible to open the corresponding interlocking view
(see chapter 5.4.5).
Clicking on the symbol for the motor or heater parameters ( ) in the Operator Control
and Display bar opens the faceplate to define motor or heater monitoring parameters:
Figure 6-9: Monitoring parameters for motors and heaters
The time monitoring for startup, shutdown and during operation of the motor can be
changed as follow
• "Control Start": Monitoring time during startup of the motor (dynamic)

• "Control stop": Monitoring time during shutdown of the motor (dynamic)
• "Status": Monitoring time during permanent operation of the motor (static)
Clicking on the parameter field (e.g. ) will expand the faceplate. This function only
works, if the operator is logged in with the appropriate user level required to change
the selected setting. In the extension of the faceplate (see Figure 6-10) the setpoint
value can be changed:
Figure 6-10: Extension window of faceplate for analog and binary valves
To modify the parameter, click on the day, hour, minutes or second field of the setpoint
dialog box and type in the new setting using the keyboard. Confirm the value typed in
with the ENTER key on the keyboard.

applied and the dialog box will be closed.
6.1.4 FACEPLATE WINDOW FOR MAINTENANCE COUNTER
A click on each maintenance counter symbol will open a window with

the faceplate for the corresponding maintenance counter. This
faceplate contains a graphic representation of all elements of the
technical block intended for operator control and monitoring.

(2) Enabling and disabling the counter
(3) High and low scale range for the count value
(4) Displaying the counts values
(5) Navigation button to switch to other faceplate
(6) Display area for block states
(7) Graphic display of the current count value
(8) Limits
Figure 6-11: Maintenance counter faceplate
The main window of the faceplate for maintenance counters (see Figure 6-11) shows
the current run time of the corresponding device. The run time is displayed in days,
hours and minutes. This faceplate is used to give the operator a hint for the next
maintenance.
Clicking on the limit symbol ( ) in the Operator Control and Display bar opens the
faceplate to display and access warning limits that can be changed:
Figure 6-12: Run time limits of maintenance counter
Clicking on warning setpoint field (e.g. ) will expand the faceplate. This
to change the selected setting. In the extension of the faceplate (see Figure 6-13) the
setpoint value can be changed:
Figure 6-13: Extension window of faceplate for analogue measurements
To modify the setpoint, click on the day, hour or minutes field of the setpoint dialog box
and type in the new setting using the keyboard. Confirm the value typed in with the
ENTER key on the keyboard.

If the run time limit is violated, the operator gets a maintenance message. The counter
can be reseted to zero if the motor is stopped and the maintenance is finished with the
corresponding reset button that is placed next to the counter.
NOTE The warning setpoint must be changed manually by the operator due to
the next maintenance stop regarding the maintenance instruction of the
manufacturer.
6.1.5 FACEPLATE WINDOW FOR VALVES
A click on each valve symbol will open a window with the faceplate for
the corresponding valve. This faceplate contains a graphic
operator control and monitoring.

(2) Opening and closing the valve
(12) Status display of the valve
Figure 6-14: Binary valve faceplate

(2) Opening, closing and stopping the control valve
(3) Switching the default manipulated variable
(5) High and low range for the manipulated variable
(6) Changing the manipulated variable
(7) Displaying of position feedback
(8) Target manipulated variable
(11) Display of external manipulated variable
(12) Interlocking functions of the block
(14) Navigation button for switching to other faceplate
(15), (16), (17), (18) Display area for block states
(19) Representation of neutral position
(21) Status display of the control valve
(22) Picture of auxiliary valve
Figure 6-15: Analog valve faceplate
The main window of the faceplate for binary valves (see Figure 6-14) or analog valves
(see Figure 6-15) shows the current state OPEN, CLOSE or POSTION of the
corresponding valve.
Clicking on the symbol for the valve parameters ( ) in the Operator Control and Display
bar opens the faceplate to define valve monitoring parameters:
Figure 6-16: Monitoring parameters of analog and binary valves
The time monitoring for startup, shutdown and during operation of the motor can be
changed as follow
• "Control": Monitoring time during opening and closing of the valve (dynamic)
• "End position": Monitoring time of the end position of the valve (static)
Clicking on the parameter field (e.g. ) will expand the faceplate. This function only
works, if the operator is logged in with the appropriate user level required to change
the selected setting. In the extension of the faceplate (see Figure 6-17) the setpoint
value can be changed:
Figure 6-17: Extension window of faceplate for analog and binary valves
To modify the parameter, click on the day, hour, minutes or second field of the setpoint
dialog box and type in the new setting using the keyboard. Confirm the value typed in
with the ENTER key on the keyboard.

6.1.6 DETAIL WINDOW FOR OPERATING LIMITS
As not all operating limits, settings, or preselection buttons, required for control of the
Oxygen-VPSA-Plant can be implemented into the standardized PCS7 faceplates,
additional detail pictures have been configurated for such settings.
The detail pictures can be selected via separate buttons, which are implemented in the
different process unit pictures. Clicking on the specific button will open the requested
detail picture.
Figure 6-18: Separate “Parameter”-Button in oxygen compressor unit picture
Operating limits are displayed in a dark grey field. Blue values can be
changed by selecting the value, if the operator is authorized with his
appropriate user level to perform a change of the selected value.
Green values can be only monitored. These values are calculated by
the plc system.
After entering the new value using the keyboard, the new value needs to be confirmed
by pressing ENTER on the keyboard. If the new value is wrong before the value is
confirmed, the change of parameter can be abort by pressing ESC on the keyboard.
The following section describes all additional detail windows of the Oxygen-VPSA-
Plant.

Air blower parameters
Figure 6-19: Detail window for air blower parameters
The detail window Air Blower Parameters shows the actual process values (marked
with a green frame) and operating limits (marked in a blue frame).
Those parameters ensure, that both adsorbers of the Oxygen-VPSA-Plant operate with
the same adsorption pressure, avoiding an imbalance of the system.
After the minimum step time of step no. 1 and 6 the pressure of both adsorbers should
be within the specified pressure range.
Should one of the two adsorbers turn out to be outside this range, the PLC will either
increase or decrease the delay time for closing feed air blower bypass valve KV-1105
at the beginning of step no. 1 or 6. The operating limits define the pressure range and
the parameter to control the delay time.
The process values (marked in a green frame) show the actual pressure, the current
pressure control range, and the current delay time individually for each adsorber.
Vacuum pump parameters
Figure 6-20: Detailed window for vacuum pump parameters
The detail window Vacuum Pump Parameters shows the actual process values
(marked with a green frame) and operating limits (marked in a blue frame).
Those parameters ensure, that both adsorbers of the Oxygen-VPSA-Plant operate with
the same desorption pressure, avoiding an imbalance of the system.
After the minimum step time of step no. 1 and 6 the pressure of both adsorbers should
be within the specified pressure range.
Should one of the two adsorbers turn out to be outside this range, the PLC will either
increase or decrease the delay time for closing vacuum pump bypass valves KV-1835
and KV-1845 at the beginning of step no. 1 or 6. The operating limits define the
pressure range and the parameter to control the delay time.
The process values (marked in a green frame) show the actual pressure and the
current delay time individually for each adsorber.
Adsorber parameters
Figure 6-21: Detailed window for adsorber parameters

The detail picture Adsorber Parameter displays
− the operating limits for the adsorber sequence such as step times,
transition conditions, aperture for pressure equalization valve KV-2505
in the different steps (marked with a red frame)
− the settings for monitoring of the desorption pressures (marked with a
blue frame)
− the settings for purity control (marked with a yellow frame)
-> description see chapter 9.1.4
− the settings for partial load control (marked with an orange frame)
-> see description in chapter 9.2 and
− the permissions for operation of adsorber valves and machinery
bypass valves (marked with a purple frame)
Parameters in the section Step Times define either a range or a fixed time for each
step of the adsorber sequence. Parameters in the section Transition Condition define
certain pressures that shall be reached for the sequence to continue with the next step.
Parameters in the section KV2505 Position define aperture values for valve KV-2505
in the purge steps (2a/2b/7a/7b) and pressure equalizing steps (5/10). Refer to chapter
3 for a detailed description of the adsorption sequence.
The detail picture Analyzer displays the faceplate for the oxygen product analyzer (see
description in chapter 8.2.5)
Figure 6-22: Detail window of adsorber pressure profile
The detail picture Adsorber Pressure Profile shows and monitors the pressure curve
for both adsorbers and the buffer vessel in each step and compares the current curve
with a recorded profile.
If the profile for any of the vessels significantly deviates from the recorded profile, an
alarm message will be created to inform the operator, as this might indicate upcoming
problems (e.g. malfunction of valves).
The button for the detail picture Step Values is implemented in the Adsorber Pressure
Profile picture. By clicking this button, the detail picture Min/Max/Step-End-Values will
be shown (see Figure 6-23).
Figure 6-23: Detail window of adsorber min-max-step-values
The detail picture Min/Max/Step-End-Values displays the current operating data for
− current duration of each step
− adsorber and buffer pressures at the end of each step
− minimum and maximum pressure of adsorbers and buffer vessel
− minimum and maximum suction pressure of vacuum pump
− minimum and maximum discharge pressure of feed air blower
− minimum and maximum oxygen content of the product
Figure 6-24: Detail window of adsorber pressure equalization settings
The detail picture Pressure Equalization displays the opening values for valve KV-2505
in the pressure equalizing steps 4 and 9. Refer to chapter 3 for a detailed description
of the adsorption sequence.
Oxygen compressor
The detail picture Oxygen Compressor Parameter shows pre-defined settings for the
oxygen compressor control.
Figure 6-25: Detailed window for oxygen compressor parameters
The section Automatic start of oxygen compressor defines, whether the oxygen
compressor will be started in “HAND” mode or in “AUTOMATIC” mode.
The section Option for manual start defines, whether the oxygen compressor will be
started in HAND mode with or without the oxygen buffer vessel as an additional storage
volume.
The section PSH1521 – Bypass valve open defines, at which pressure the bypass
valve will be opened to prevent to open the safety valve.
The section PSL1521 – Blow off valve open in case of motor off defines, at which
pressure the blow-off valve PCV-1513 will be opened, if the compressor is not in
operation (prevention of pressure build-up in the system in case of leakage from
downstream system).
The section FSL1545 – Setpoint of blow off valve defines the amount of oxygen to be
sent to atmosphere when there is either no or little consumption of the downstream
system (see chapter 9.3).
The section Product-Flow-Control includes the settings of the product controllers. For
detailed information of the special product control refer to chapter 9.1.
6.2 PASSWORD PROTECTION AND LOG IN PROCEDURE
For access to the visualization system certain user types have been defined:
Operator : access to controller settings and to operate the plant

Engineer : access to warning limits and certain operating limits
During mechanical warranty period, the access to alarm limits and a full access to all
operating limits will be restricted, as changing these settings may affect the integrity
and performance of the plant.
A special password is neither required to check any kind of measuring values like flow,
pressures and temperatures, nor to start and stop the plant nor for acknowledging of
error messages. These activities can be done at any time by the shift personnel,
provided they are familiar with the basic operation of the plant.
Changing of warning/alarm limits or operating limits or switching into HAND mode (see
chapter 4) is only possible if the user is authorized with the proper password level.
Whenever authorization is required, a window will be displayed asking the user to log
in with his assigned password.
Passwords must only be communicated to skilled personnel!
Any unauthorized change of parameters may cause serious

damage to the plant and/or human beings and will cause loss
of warranty claims!
6.2.1 LOG IN / LOG OUT PROCEDURE
The current user that is logged into the system is shown on the right side of the
Overview Area of the visualization system (e.g. ).
A click on this icon will open the Login Dialog Box
Figure 6-26: login/logout window
To log into the system, enter your assigned user account under “Login”, your password
using the keyboard and click OK.
To lock the system against unauthorized interference, click “Logout”. The user will be
logged off from the system automatically after a pre-defined time of inactivity.
6.3 PARAMETER LIST
The following table contains a functional description of all parameters configured in the
software for the VPSA-Plant.
The actual setting of each parameter can be found in document &AK J-LA 2001 Alarm
List, which forms an attachment to this chapter.
IMPORTANT: IN CASE SETTINGS ARE CHANGED AFTER THE LOAD

MEMORY WAS WRITTEN, THESE CHANGES ARE ONLY
STORED IN THE INTERNAL WORK MEMORY OF THE CPU AND
NOT ON THE LOAD MEMORY. FOR THIS REASON, ANY
CHANGE OF PARAMETERS SHOULD BE CAREFULLY NOTED
IN THE DAILY PROTOCOL. IN CASE THE INTERNAL MEMORY
GETS LOST, THESE CHANGES HAVE TO BE REDONE.
ATTENTION: ANY CHANGE OF PARAMETERS WITHOUT EXPLICIT

APPROVAL FROM LINDE MAY CAUSE DAMAGE TO THE PLANT
AND LOSS OF MECHANICAL WARRANTY
Tag no. / Parameter name Description
FEED AIR BLOWER
Motor M1181
Monitoring time for feedback errors or feedback start error after
Control Start (dynamic)
successful operation.
Monitoring time for feedback stop errors after successful
Control Stop (dynamic)
operation.
Status (static) Monitoring time for feedback errors without operation.
Valve parameters KV-1105

Time limit for opening/closing of valve. Plant will shut down, if
Control (dynamic)
valve does not open/close within this time.
Time limit for deviation from open/close position. Plant will shut
End position (static)
down, if valve position deviation is longer than this time.
Valve parameters TCV-1121

Time limit for opening/closing of valve. Plant will not shut down,
Control (dynamic)
if valve does not open/close within this time.
Time limit for deviation from open/close position. Plant will not
shut down, if valve position deviation is longer than this time.
Temperature controller TIC-1121

Setpoint Setpoint for process air temperature to adsorbers.
Gain Gain factor for adjustment of controller behavior.
Integral time Integral time for adjustment of controller behavior.
Derivative time TD Derivative time for adjustment of controller behavior.
PDISH-1106
Indicates high pressure drop at process air filter.
PDAH-1106
Warning will be displayed, if setpoint is exceeded (time delay).
PDISH-1107
Indicates high pressure drop at process air filter.
PDAH-1107
PI-1114
Hysteresis Deviation of setpoints, that must be occurred to delete alarms.
Indicates low pressure at suction side feed air blower.
L warning (PAL-1114)
Warning will be displayed, if pressure drops below this setpoint.
Indicates low pressure at suction side feed air blower.
L alarm (PSALL-1114)
Shutdown will occur, if pressure drops below this setpoint.
PDI-1114
Indicates high differential pressure across feed air blower.
H alarm (PDSAHH-1114)
Shutdown will occur, if setpoint is exceeded.
Indicates high differential pressure across feed air blower.
H warning (PDAH-1114)
Warning will be displayed, if setpoint is exceeded.
PI-1115
Indicates high pressure at discharge side feed air blower.
H alarm (PSAHH-1115)
Indicates high pressure at discharge side feed air blower.
H warning (PAH-1115)
Indicates low pressure at discharge side feed air blower.
Indicates low pressure at discharge side feed air blower.
MSH-1121
Indicates high moisture in process air after process air cooler.
MSAH-1121
Shutdown will occur, if moisture exceeds this setpoint.
PDSH-1148
Indicates high differential pressure at oil filter feed air blower.
PDAH-1148
PSL-1149
Indicates low oil pressure at feed air blower.
PSAL-1149 Shutdown will occur, if pressure drops below this setpoint.
Alarm will be activated shortly after start of feed air blower.
LSL-1138
Indicates low oil level at feed air blower.
LAL-1138
Warning will be displayed, if level drops below this setpoint
TI-1114
Indicates high temperature at suction side of feed air blower.
H alarm (TSAHH-1114)
Shutdown will occur, if temperature drops below this setpoint
Indicates high temperature at suction side of feed air blower.
H warning (TAH-1114)
Indicates low temperature at suction side of feed air blower.
L warning (TAL-1114) Warning will be displayed, if temperature drops below this
setpoint.
Indicates low temperature at suction side of feed air blower.
L alarm (TSALL-1114)
Shutdown will occur, if temperature drops below this setpoint.
TDI-1114
Indicates high differential temperature across feed air blower.
H alarm (TDSAHH-1114) Shutdown will occur, if differential temperature exceeds this
setpoint
Indicates high differential temperature across feed air blower.
H warning (TDAH-1114) Warning will be displayed, if differential temperature exceeds
this setpoint
TI-1115
Indicates high temperature at discharge side feed air blower.
Shutdown will occur, if temperature exceeds this setpoint
Indicates high temperature at discharge side feed air blower.
Warning will be displayed, if temperature exceeds this setpoint
TI-1121
Indicates high temperature after process air cooler.
Plant will be stopped, if temperature exceeds this setpoint
Indicates high temperature after process air cooler.
Indicates low temperature after process air cooler.
setpoint
Indicates low temperature after process air cooler.

Plant will be stopped, if temperature drops below this setpoint
TI-1181-1
Indicates high temperature at winding U of electric motor.
H alarm (TSAHH-1181-1)
H warning (TAH-1181-1)
TI-1181-3
Indicates high temperature at winding V of electric motor.
TI-1181-5
Indicates high temperature at winding W of electric motor.
TI-1181-7
Indicates high temperature at drive-end bearing (vacuum pump
H alarm (TSAHH-1181-7) side) of electric motor. Shutdown will occur, if temperature
exceeds this setpoint
H warning (TAH-1181-7) side) of electric motor. Warning will be displayed, if temperature
TI-1181-8
Indicates high temperature at non-drive-end bearing (air blower
VI-1131
Indicates high vibration at drive-end side of air blower.
H alarm (VSAHH-1131)
Shutdown will occur, if vibration exceeds this setpoint
Indicates high vibration at drive-end side of air blower.
H warning (VAH-1131)
Warning will be displayed, if vibration exceeds this setpoint
VI-1132
Indicates high vibration at non-drive-end side of air blower.
Indicates high vibration at non-drive-end side of air blower.
Warning will be displayed, if vibration exceeds this setpoint
Air Blower Parameters

Delay for closing bypass valve KV-1105 will be increased, if this
Increase Delay-Time Limit pressure is exceeded in the adsorber at the end of step 1 /
step 6
Delay for closing bypass valve KV-1105 will be decreased, if
Decrease Delay-Time Limit pressure in the adsorber drops below this value at the end of
step 1 / step 6
Max. Delay-Time Maximum delay time for closing of bypass valve KV-1105
Min. Delay-Time Minimum delay time for closing of bypass valve KV-1105
Delay-Interval Idle time between two steps of increasing or decreasing of delay
Delay-Step Increment for increasing or decreasing of delay time
Maximum delay time; bypass valve KV-1105 will be closed
Max. Delay-Time
regardless to the pressure if this time is reached
Max. Pressure Offset If the pressure limit of both adsorbers remains within the range
defined by Increase / Decrease Delay-Time parameters, this
range will be shifted to higher / lower pressure values to avoid
Min. Pressure Offset imbalance between the two adsorbers
Offset Interval Idle time between two steps of increasing or decreasing offset
Offset Step Increment for increasing or decreasing of offset
Overlap between opening of air blower bypass valve KV-1105
Valve Synchronization
and closing of process air valves KV-2511/KV-2521
ADSORBER UNIT

Control (dynamic) valve does not open/close within this time and pressure
deviation in adsorbers is active.
End position (static) down, if valve position deviation is longer than this time and
pressure deviation in adsorbers is active.






PI-2511
Indicates high pressure in adsorber A.
Shutdown will occur, if setpoint is exceeded
Indicates high pressure in adsorber A.
Warning will be displayed, if setpoint is exceeded
Indicates low pressure in adsorber A.
Indicates low pressure in adsorber A.
PI-2521
Indicates high pressure in adsorber B.
Indicates high pressure in adsorber B.
Indicates low pressure in adsorber B.
Indicates low pressure in adsorber B.
PI-2531
Indicates low pressure in oxygen buffer vessel.
Indicates low pressure in oxygen buffer vessel.
PDI-2515
Indicates high differential pressure in adsorber A (top).
Indicates high differential pressure in adsorber A (top).
PDI-2516
Indicates high differential pressure in adsorber A (bottom).
Indicates high differential pressure in adsorber A (bottom).
PDI-2525
Indicates high differential pressure in adsorber B (top).
Indicates high differential pressure in adsorber B (top).
PDI-2526
Indicates high differential pressure in adsorber B (bottom).
Indicates high differential pressure in adsorber B (bottom).
Oxygen Analyzer
FISL-1502
Indicates low sample gas flow through analyzer system.
FSAL-1502
Plant will be stopped if flow drops below this setpoint.
PISL-1545L
Indicates low pressure in the gas bottle for LOW CAL.
PAL-1545L Automatic calibration will be de-activated, if pressure drops
below this setpoint (time delay).
PISL-1545H
Indicates low pressure in the gas bottle for HIGH CAL.
PAL-1545H Automatic calibration will be de-activated, if pressure drops
below this setpoint (time delay).
Adsorber Parameters
Step Times
Step 1 Time interval for step 1.
Step 2a Time interval for step 2a.
Step 2b Time for step 2b.
Step 5 Time for step 5.
Step 7a Time interval for step 7a.
Step 7a Time for step 7b.
Step 10 Time for step 10.
Transition Condition
Step 1 will be terminated, if this pressure is reached in adsorber
Stop Step 1
A-2526A (or VP suction pressure is reached).
Step 2a will be terminated, if this pressure is reached in
Stop Step 2a
adsorber A-2526A.
Stop Step 4
A-2526B.
Stop Step 6
A-2526B (or VP suction pressure is reached).
Step 7a will be terminated, if this pressure is reached in
Stop Step 7a
adsorber A-2526B.
Stop Step 9
A-2526A.
Step 2a/7a will be terminated, if pressure of buffer vessel
Stop Step 2a/7a
exceeds this limit.
Step 1/6 will be terminated, if suction pressure of vacuum pump
Stop Step 1/6
downstream filter drops below this limit.
KV-2505 Position
Purge-Pos. Step 2a Position of KV-2505 during Step 2a.
Purge-Pos. Step 2b Position of KV-2505 during Step 2b.
PE-Pos. Step 5 Position of KV-2505 during Step 5.
Purge-Pos. Step 7a Position of KV-2505 during Step 7a.
Purge-Pos. Step 7b Position of KV-2505 during Step 7b.
PE-Pos. Step 10 Position of KV-2505 during Step 10.
Purity Control
Design Flow Maximum flow limit of the VPSA-Plant.
If the average product purity exceeds this limit, the setpoint for
ASAHH1545 O2-Purity OK
the flow controller will be increased stepwise.
If the average product purity exceeds this limit, the stepwise
ASAH1545 Flow-Reduction Stop
reduction of the setpoint for the flow controller will be stopped.
If the average product purity drops below this limit, the stepwise
ASAL1545 Flow-Reduction Start
reduction of the setpoint for the flow controller will be started.
If the average product purity drops below this limit, delivery
ASALL1545 Delivery Valve Close
valves XV-1550 will be closed to interrupt delivery of oxygen.
Flow-Increasing Step / Interval Increment & interval for increasing of flow limit.
Flow-Decreasing Step / Interval Increment & interval for decreasing of flow limit.
Minimum Flow Minimum limit for flow setpoint.
Partial Load Control

Partial Load Stop related to If oxygen flow drops below this limit, allowance for partial load
Design Flow operation will be given, if average oxygen purity is OK.
Minimum Partial Load Time Minimum step time required for partial load operation.
Partial load time will be increased, if average product purity
ASH1545-PL Increase PL-Time
exceeds this value.
Partial load time will be decreased, if average oxygen purity
ASL1545-PL Decrease PL-Time
drops below this value.
Partial load step will be terminated, if pressure of oxygen buffer
PSL2531-PL Stop Partial Load
drops below this limit.
Time ratio for the partial load step, in which oxygen shall be
Partial Load just by buffer vessel supplied only from the buffer vessel (i.e. product valves will
remain closed).
PL-Increasing Step / Interval Increment & interval for increasing of step time for partial load.
PL-Decreasing Step / Interval Increment & interval for decreasing of step time for partial load.
Minimum Partial Load Flow in Flow limit for partial load operation; below this flow of oxygen
case of bad Purity partial load will be initiated, even if purity should be low.
Pressure Limits
Close VP-Bypass
Limit for closing vacuum pump bypass valves during production
cycle. If pressure in adsorber A drops below this value, permis-
PSHHH2511
sion to close vacuum pump bypass valves will be given and
evacuation of adsorber A can be started.
Limit for closing vacuum pump bypass valves during production
cycle. If pressure in adsorber B drops below this value, permis-
PSHHH2521
sion to close vacuum pump bypass valves will be given and
evacuation of adsorber B can be started.
Close AB-Bypass
Limit for closing air blower bypass valve during production cycle.
If pressure inside adsorber A exceeds this limit, permission to
PSHH2511
close air blower bypass valve will be given and adsorption in
adsorber A can be started.
Limit for closing air blower bypass valve during production cycle.
If pressure inside adsorber B exceeds this limit, permission to
PSHH2521
close air blower bypass valve will be given and adsorption in
adsorber B can be started.
Open-Permission Air-Valves (…1)
Limit for permission to open air valve KV-2511. If pressure in
PSH2511 adsorber A exceeds this limit, permission to open air valve
KV-2511 will be given.
Limit for permission to open air valve KV-2521. If pressure in
PSH2521 adsorber B exceeds this limit, permission to open air valve
KV-2521 will be given.
Close KV-1835 (Big VP-Bypass)
Limit for closing vacuum pump bypass valve KV-1835 during
production cycle. If suction pressure of vacuum pump drops
PSH1812
below this value, permission to close KV-1835 is given and
evacuation of adsorber can be started.
OPEN-Permission Vacuum-Valves (…4)
Limit for permission to open waste gas valve KV-2514. If
PDSL2511A differential pressure exceeds this limit, permission to open
waste gas valve on adsorber A will be given.
Limit for permission to open waste gas valve KV-2524. If
PDSL2521A differential pressure exceeds this limit, permission to open
waste gas valve on adsorber B will be given.
Open KV1845 (Small VP-Bypass)
Full load bypass valve KV-1845 will be opened, if suction
PSL1812
pressure upstream strainer drops below this value.
Full load bypass valve KV-1845 will be opened, if suction
PSL1814
pressure downstream inlet strainer drops below this value.
OPEN-Permission Oxygen-Valves (…2)
Limit for permission to open product valve KV-2512. If
differential pressure exceeds this value, permission to open
PDSL2511B product valve on adsorber A will be given (pressure in adsorber
must be higher than pressure inside buffer vessel to prevent
backflow of oxygen).
Limit for permission to open product valve KV-2522. If
differential pressure exceeds this value, permission to open
PDSL2521B product valve on adsorber B will be given (pressure in adsorber
must be higher than pressure inside buffer vessel to prevent
backflow of oxygen).
Vacuum Protection after Stop
In case pressure inside oxygen buffer vessel drops below this
PSH2531 limit during shutdown, oxygen valves KV2512/22 will be closed
to prevent excessive vacuum.
In case pressure inside adsorber vessels exceed this limit
PSL2511 / PSL2521 during shutdown, oxygen valves KV2512/22 will be closed to
prevent excessive vacuum in buffer.
Vacuum not reached Adsorber A/B

Indicates insufficient desorption pressure of adsorber A.
PSAH-2511 Shutdown will occur, if this pressure is not reached during
evacuation
Indicates insufficient desorption pressure of adsorber A.
PSAHH-2511 Warning will be displayed, if this pressure is not reached during
evacuation
Indicates insufficient desorption pressure of adsorber B.
PSAH-2521 Shutdown will occur, if this pressure is not reached during
evacuation
Indicates insufficient desorption pressure of adsorber B.
PSAHH-2521 Warning will be displayed, if this pressure is not reached during
evacuation
Vacuum Pump – Unload Limits
Indicates low pressure at suction side of vacuum pump
PAL-1812UL downstream strainer during bypass operation.
Warning will be displayed, if pressure drops below this setpoint
PSALL-1812UL downstream strainer during bypass operation.
Shutdown will occur, if pressure drops below this setpoint
Pressure Equalization Settings

Step 4 Register 1 Position of KV-2505 during Step 4, 1st time interval.
Step 4 Register 2 Position of KV-2505 during Step 4, 2nd time interval.
Step 4 Register 3 Position of KV-2505 during Step 4, 3rd time interval.
Step 4 Register 4 Position of KV-2505 during Step 4, 4th time interval.
Step-Time 4 Duration of each time interval in step 4.
Step 9 Register 1 Position of KV-2505 during Step 9, 1st time interval.
Step 9 Register 2 Position of KV-2505 during Step 9, 2nd time interval.
Step 9 Register 3 Position of KV-2505 during Step 9, 3rd time interval.
Step-Time 9 Duration of each time interval in Step 9.
Pressure Equalization with Air in If this option is activated, pressure equalization in step 5/10 will
Step 5 and 10 be additionally supported with air from the feed air blower.
VACUUM PUMP
Motor M1881
operation.

Control (dynamic)
valve does not open/close within this.

Control (dynamic)
PI-1812
L warning (PAL-1812) upstream strainer.
L alarm (PSALL-1812) upstream strainer.
PDI-1812
Indicates high differential pressure across strainer of vacuum
pump. Shutdown will occur, if setpoint is exceeded.
Indicates high differential pressure across strainer of vacuum
pump. Warning will be displayed, if setpoint is exceeded.
PI-1814
L warning (PAL-1814) downstream strainer.
L alarm (PSALL-1814) downstream strainer.
PDI-1814
Indicates high differential pressure across vacuum pump.
Indicates high differential pressure across vacuum pump.
PI-1815
Indicates high pressure at discharge side vacuum pump.
Indicates high pressure at discharge side vacuum pump.
PDSH-1848
Indicates high differential pressure at oil filter vacuum pump.
PDAH-1848
PSL-1849
Indicates low oil pressure at vacuum pump.
PSL-1849
LSL-1838
Indicates low oil level at vacuum pump.
LAL-1838
Warning will be displayed, if level drops below this setpoint.
TI-1814
Indicates high temperature at suction side vacuum pump.
Shutdown will occur, if temperature exceeds this setpoint.
Indicates high temperature at suction side vacuum pump.
Warning will be displayed, if temperature exceeds this setpoint.
Indicates low temperature at suction side vacuum pump.
setpoint.
Indicates low temperature at suction side vacuum pump.
Shutdown will occur, if temperature drops below this setpoint.
TDI-1814
Indicates high differential temperature across vacuum pump.
H alarm (TDSAHH-1814) Shutdown will occur, if differential temperature exceeds this
setpoint.
Indicates high differential temperature across vacuum pump.
H warning (TDAH-1814) Warning will be displayed, if differential temperature exceeds
this setpoint.
TI-1815
Indicates high temperature at discharge side vacuum pump.
Indicates high temperature at discharge side vacuum pump.
TI-1881-1
TI-1881-3
TI-1881-5
TI-1881-7
exceeds this setpoint.
TI-1881-8
VI-1831
Indicates high vibration at drive-end side of vacuum pump.
Shutdown will occur, if vibration exceeds this setpoint.
Indicates high vibration at drive-end side of vacuum pump.
Warning will be displayed, if vibration exceeds this setpoint.
VI-1832
Indicates high vibration at non-drive-end side of vacuum pump.
Shutdown will occur, if vibration exceeds this setpoint.
Indicates high vibration at non-drive-end side of vacuum pump.
Warning will be displayed, if vibration exceeds this setpoint.
Vacuum Pump Parameters

Delay for closing bypass valves KV-1835/KV-1845 will be
Increase Delay-Time increased, if pressure drops below this value during evacuation
of the adsorber in step 1 / step 6.
Delay for closing bypass valves KV-1835/KV-1845 will be
Decrease Delay-Time decreased, if this pressure is not reached during evacuation of
the adsorber in step 1 / step 6.
Maximum delay time for closing of bypass valves KV-1835 /
Max. Delay-Time
KV-1845.
Minimum delay time for closing of bypass valves KV-1835 /
Min. Delay-Time
KV-1845.
Idle time between two steps of increasing or decreasing of
Delay-Interval
delay.
Delay-Step Increment for increasing or decreasing of delay time.
Option to choose average pressure of both adsorbers for
Activate averaging determination of delay time of bypass valves KV-1835 /
KV-1845 instead of individual pressures.
Increment for increasing of delay time, in case suction pressure
Delay-Step by Pressure Low
of vacuum pump drops too far during evacuation.
Overlap between opening of vacuum pump bypass valves
Valve Synchronization KV-1835/KV-1845 and closing of waste gas valves
KV-2514/KV-2524.
OXYGEN COMPRESSOR
Motor M1581
operation.
Valve parameters XV-1530

Control (dynamic)
Valve parameters XV-1550

Control (dynamic)
Valve parameters PCV-1513

Control (dynamic)
Valve parameters PCV-1545

Control (dynamic)
Pressure controller PIC-1521

Setpoint for discharge pressure of oxygen product. The setpoint
Setpoint can be changed in the detail parameter window of oxygen
compressor.
Gain factor for adjustment of controller behavior. The gain of the
Gain controller can be changed in the detail parameter window of
oxygen compressor.
Integral time for adjustment of controller behavior. The integral
Integral time time of the controller can be changed in the detail parameter
window of oxygen compressor.
Derivative time for adjustment of controller behavior. The
Derivative time TD derivative time of the controller can be changed in the detail
parameter window of oxygen compressor.
Flow controller FIC-1545

Gain factor for adjustment of controller behavior. The gain of the
Gain controller can be changed in the detail parameter window of
oxygen compressor.
Integral time for adjustment of controller behavior. The integral
Integral time time of the controller can be changed in the detail parameter
window of oxygen compressor.
Derivative time for adjustment of controller behavior. The
Derivative time TD derivative time of the controller can be changed in the detail
parameter window of oxygen compressor.
Blow off controller FICC-1545

Max-Value Defines the maximal value of the blow off valve.
Min-Value Defines the minimal value of the blow off valve.
Gradient Defines the gain of the two-point controller.
Hysterese Defines the hysteresis of two-point controller.
PDI-1512
Indicates high differential pressure at suction filter oxygen
compressor. Shutdown will occur, if setpoint is exceeded.
compressor. Warning will be displayed, if setpoint is exceeded.
PDISH-1513
PDAH-1513
compressor. Warning will be displayed, if setpoint is exceeded.
PI-1514
Indicates high pressure at suction side oxygen compressor.
Indicates high pressure at suction side oxygen compressor.
Indicates low pressure at suction side oxygen compressor.
Indicates low pressure at suction side oxygen compressor.
PI-1521
Indicates high discharge pressure oxygen compressor.
Indicates high discharge pressure oxygen compressor.
PISL-1566
Indicates low oil pressure at oxygen compressor.
PSAL-1566
TI-1514
Indicates high temperature at suction side oxygen compressor
H alarm (TSAHH-1514) 1st stage. Shutdown will occur, if temperature exceeds this
setpoint
H warning (TAH-1514) 1st stage. Warning will be displayed, if temperature exceeds this
setpoint
TI-1515
Indicates high temperature at discharge side oxygen
H alarm (TSAHH-1515) compressor 1st stage. Shutdown will occur, if temperature
H warning (TAH-1515) compressor 1st stage. Warning will be displayed, if temperature
TI-1524
H alarm (TSAHH-1524) 2nd stage. Shutdown will occur, if temperature exceeds this
setpoint
H warning (TAH-1524) 2nd stage. Warning will be displayed, if temperature exceeds this
setpoint
TI-1525
H alarm (TSAHH-1525) compressor 2nd stage. Shutdown will occur, if temperature
H warning (TAH-1525) compressor 2nd stage. Warning will be displayed, if temperature
TI-1521
Indicates high discharge temperature at oxygen compressor.
Indicates high discharge temperature at oxygen compressor.
TI-1518
Indicates high stuffing box temperature at oxygen compressor
H alarm (TSAHH-1518) 1st stage. Shutdown will occur, if temperature exceeds this
setpoint
H warning (TAH-1518) 1st stage. Warning will be displayed, if temperature exceeds this
setpoint
TI-1528
H alarm (TSAHH-1528) 2nd stage. Shutdown will occur, if temperature exceeds this
setpoint
H warning (TAH-1528) 2nd stage. Warning will be displayed, if temperature exceeds this
setpoint
TI-1566
Indicates high oil temperature at oxygen compressor.
Indicates high oil temperature at oxygen compressor.
Indicates low oil temperature at oxygen compressor.
L warning (TSAL-1566) Warning will be displayed, if temperature drops below this
setpoint and start of compressor will be blocked
TI-1581-1
TI-1581-3
TI-1581-5
TI-1581-7
Indicates high temperature at drive-end bearing of electric
motor. Shutdown will occur, if temperature exceeds this setpoint
Indicates high temperature at drive-end bearing of electric
H warning (TAH-1581-7) motor. Warning will be displayed, if temperature exceeds this
setpoint
TI-1581-8
Indicates high temperature at non-drive-end bearing of electric
motor. Shutdown will occur, if temperature exceeds this setpoint
Indicates high temperature at non-drive-end bearing of electric
H warning (TAH-1581-8) motor. Warning will be displayed, if temperature exceeds this
setpoint
FSL-1572
Indicates low cooling water flow at oxygen compresor.
FAL-1572
Warning will be displayed, if flow drops below this limit
LSL-1561
Indicates low oil level at oxygen compresor. Shutdown of oil
LAL-1561
heater, if oil level drops below this setpoint.
TSH-1564
Indicates high oil temperature at oxygen compresor. Shutdown
TAH-1564
of oil heater, if oil temperature exceeds this setpoint.
VSH-1561
Indicates high vibration at oxygen compressor.
VSAH-1561
Compressor Parameters
Defines whether the oxygen compressor will be started
Automatic start of oxygen
automatically after automatic plant start or must be started
compressor
manually by the operator.
Defines whether oxygen compressor will be started in manual
Option for manual start mode with shut-off valve XV-1530 open or closed for stable
operation.
If the discharge pressure exceeds this setpoint, the bypass
PSH1521 – Bypass valve open
valve will open to prevent the triggering of the safety valve.
When compressor is stopped, blow-off valve PCV-1513 will be
PSL1521 – Blow off valve open
opened to release pressure if pressure PI-1521 exceeds this
in case of motor off
setpoint
FSL1545 – Setpoint of blow off Setpoint of blow off controller FICC-1545. Defines the minimal
valve flow through the blow off valve.
Settings Pressure Control

Normal: General pressure setpoint of oxygen product
Setpoint
Reduced: Reduced pressure setpoint in case of IDLE mode
The prefilter of pressure setpoint smooths the measured value
Prefilter (PT1)
with a PT1 function. The function can be enabled or disabled.
General PID controller of pressure control mode with the
Control Parameter (PID) possibility of adjustment for Gain, Integral Time and Derivative
Time of PIC-1521.
The disturbance compensation in pressure control mode
Disturbance compensation (DT1) smooths the discharge pressure due to the changing of suction
pressure. The function can be enabled or disabled.
Settings Flow Control

The prefilter of flow setpoint smooths the measured value with a
Prefilter (PT1)
PT1 function. The function can be enabled or disabled.
General PID controller of flow control mode with the possibility
Control Parameter (PID) of adjustment for Gain, Integral Time and Derivative Time of
FIC-1545.
The disturbance compensation in flow control mode smooths
Disturbance compensation (DT1) the flow due to the changing of product flow. The function can
be enabled or disabled.
INSTRUMENT AIR SYSTEM
Instrument air compressor C8361A

Control Monitoring time for feedback errors after operation.
Instrument air compressor C8361B

PI-8303
Indicates high pressure for instrument air supply.
Plant will be stopped, if setpoint is exceeded.
Indicates high pressure for instrument air supply.
H tolerance (PAH-8303)
Indicates low pressure for instrument air supply.
L tolerance (PAL-8303)
L warning (PSALL-8303)
Plant will be stopped, if pressure drops below this setpoint
L alarm (PSALLL-8303)
AI-8326
Indicates high dewpoint of instrument air.
H warning (AAH-8326)
Warning will be displayed, if dewpoint exceeds this setpoint.
COOLING WATER SYSTEM
Cooling water pump M8481A

Cooling water pump M8481B

PI-8413
Indicates high pressure of cooling water system.
Warning will be displayed if setpoint is exceeded.
Indicates low pressure of cooling water system.
Warning will be displayed if pressure drops below this setpoint
Indicates low pressure of cooling water system.
Oil pumps will stop if pressure drops below this setpoint
TI-8401
Indicates high temperature of cooling water.
Indicates low temperature of cooling water.
L warning (TAL-8401) Warning will be displayed if temperature drops below this
setpoint
ENVIRONMENT
AT-1598
Indicates high oxygen concentration inside machine hall at
H alarm (ASAHH-1598) compressor area.
Shutdown will occur if this setpoint is exceeded.
Indicates high oxygen concentration inside machine hall at
H warning (AAH-1598) compressor area.
Indicates low oxygen concentration inside machine hall at
compressor area.
L warning (AAL-1598)
Warning will be displayed, if oxygen concentration drops below
this setpoint
Indicates low oxygen concentration inside machine hall at
compressor area.
L alarm (ASALL-1598)
Shutdown will occur, if oxygen concentration drops below this
setpoint
Activate or deactivate the oxygen concentration detector due to
Activate / Deactivate
maintenance work.
AT-2598
Indicates high oxygen concentration inside machine hall.
H alarm (ASAHH-2598)
Shutdown will occur if this setpoint is exceeded.
Indicates high oxygen concentration inside machine hall.
H warning (AAH-2598)
Indicates low oxygen concentration inside valve machine hall.
L warning (AAL-2598) Warning will be displayed, if oxygen concentration drops below
this setpoint
Indicates low oxygen concentration inside machine hall.
L alarm (ASALL-2598) Shutdown will occur, if oxygen concentration drops below this
setpoint
Activate or deactivate the oxygen concentration detector due to
Activate / Deactivate
maintenance work.
HS-9304
Indicates fire or smoke in machine hall from external signal.
HS-9304 Shutdown will occur, if fire/smoke is detected.
Signal must be supplied by client.
Activate or deactivate the external fire/smoke signal, due to
Active HS-9304
maintenance work.
TI-1101
Indicates high temperature inside machine hall. Warning will be
displayed, if temperature exceeds this setpoint.
Indicates low temperature inside machine hall. Warning will be
L warning (TAL-1101)
displayed, if temperature drops below this setpoint.
ATTACHMENT: &AK J-LA 2001 ALARM AND SETPOINT LIST
for Section: 1
Alarms and troubleshooting Doc. no.: &AK P-MC 2007 (EN)
procedures Proj. no.: 2210 CCP8
7 ALARMS AND TROUBLESHOOTING PROCEDURES

7.1 DISPLAY OF ALARMS
This section describes the main features of the PCS7 visualization system, used to
display alarm messages of the Oxygen-VPSA-Plant. For more detailed information
please refer to the documentation of the SIEMENS PCS7 visualization software.
In case an abnormal situation is detected by the control system, an alarm message will
be generated containing following information:
Date Time Source Event Status
23/03/17 08:40:27.502 PI2521 Vacuum Adsorber B not reached, L-Alarm and Shut-Down ! C
Figure 7-1: Alarm message
Date: Date of event coming in, going out or being acknowledged

Time: Whenever the message status changes, the associated time (time
stamp of the state change) is displayed
Source: Technological assignment of the message source
Event: Message type with instrument tag number according to the P&I
diagram
Status: Message status:
C = event coming in
QS = event acknowledged by operator
G = event going out and reset by operator
As soon as a new alarm appears, it will be displayed in the list of incoming messages
and the corresponding button of the Group Display in the Overview Area starts blinking
until the message is acknowledged by the operator. Once a message is acknowledged
by the operator, it disappears from the “Incoming List”, but remains present in the
“History List” and it also remains in the “List of pending messages” until the problem
has been solved and the event has been reset by the operator.
The alarm message line in the Overview Area shows the unacknowledged message
with the highest priority. If more than one message has the same priority level, the one
that came in last is displayed.
Note: After shutdown, the plant can only be restarted once all failures have
been remedied. When the problem has been solved, the button
in the main process picture must be clicked.
This icon for “Alarm logging” is displayed on each picture in the

Overview Area and in the Button Area.
A click on this icon in the Overview Area opens a Message Window
overlaying the Working Area, which shows all incoming messages not
yet acknowledged (see Figure 7-2).
A click on this icon in the Button Area (Button Set #1) opens the
incoming alarm list in the Working Area. Together with this list a new
button set with specific buttons for the message system will be
displayed in the Button Area (see Figure 7-3).
This icon is displayed in the Button Area specific for the Message
System (alarm logging).
A click on this icon opens a list of pending alarm messages (both
acknowledged and unacknowledged) in the Working Area.
This icon is displayed in the Button Area specific for the Message
System (alarm logging).
A click on this icon opens a history of all messages in the Working
Area.
Figure 7-2: Message Window showing incoming messages
Figure 7-3: Message system (alarm logging) - incoming message list with specific button set
Warning limits
Alarms are meant for signalizing an exceptional state. If an exceptional condition is
detected, an alarm message will be indicated via a flashing button in the group display
at the Overview Area. A click on the flashing button opens the process picture with the
source of the alarm in the Working Area. The corresponding process value is displayed
in the process picture with a yellow-colored background and marked with a “W” in a
yellow colored background.
(e.g. )
Alarm / Shutdown limits

Shutdowns are meant to prevent critical conditions for the plant. Whenever such a
condition occurs, the plant will be stopped. An alarm message will be indicated via a
flashing button in the group display at the Overview Area. A click on the flashing button
opens the process picture with the source of the shutdown in the Working Area. The
corresponding process value is displayed in the process picture with a red colored
background and marked with a “A” in a red colored background.
(e.g. )
Failmeasurement
Whenever a fail measurement of an important process value is detected, the plant will
be stopped. An alarm message will be indicated via a flashing button in the group
display at the Overview Area. A click on the flashing button opens the process picture
with the source of the fail measurement in the Working Area. The corresponding
process value is displayed in the process picture with a purple-colored background and
marked with a “S” in a purple-colored background.
(e.g. )
7.2 ALARM MESSAGES AND TROUBLESHOOTING PROCEDURES
In case of a warning or an alarm is violated, the operating workstation will display an

alarm message showing the reason for the warning or alarm (see also 7.1).
The subsequent table 'List of Alarm Messages' lists alarm messages from the process
and their matching code numbers, which can be used as a rough guideline for
troubleshooting of a shut down.
The meaning of each code number is explained in the table 'Codes for
Troubleshooting', which will give a systematic guideline to determine the reason for
each alarm or shutdown as well as a procedure for its remedy.
A daily operation logbook (see chapter 8.1) may be helpful to evaluate, if process
parameters have changed recently. With the data from the daily operation logbook and
a record of process parameters, any deviation from the current operating state can be
checked. Thus, the process of troubleshooting will be significantly easier.
IMPORTANT: ONLY PROCESS ALARMS ARE INCLUDED IN THE LIST OF

ALARM MESSAGES. THERE CAN BE OTHER MESSAGES FROM
THE PCS 7 APPLICATION SYSTEM. FOR FURTHER
INFORMATION ABOUT THE MEANING AND TROUBLESHOOTING
OF THESE MESSAGES REFER TO THE SIEMENS MANUALS.
EXAMPLE FOR TROUBLESHOOTING:
Assumed, the following message is displayed on the operator workstation:
Date Time Source Event Status

29/10/19 08:40:27.502 PT-2521/PI-2521 PI-2521 - Pressure adsorber B, High alarm vacuum not reached - Shut down ! C
The following table 'List of Alarm Messages' lists (in alphabetical order) all possible
sources of alarm messages along with their assigned events.
The 'List of Alarm Messages' provides the following codes for source ‘PI2521’ and
event ‘Vacuum Adsorber B not reached, L-Alarm and Shut-Down’:
Source Event Code
PT-2521/PI-2521 PI-2521 - Pressure adsorber B, High alarm vacuum not reached - Shut down 16/17/18/2
The last column provides four codes for this event, intended to serve as a guided
troubleshooting procedure. These codes and their meaning can be found in the table
'Codes for Troubleshooting':
Code Possible Cause Remedy

No.
2 Check, if
- the signal of the transmitter is correct (apply - calibrate transmitter
test pressure)
- transmitter is working correctly - refer to mfr. manual / replace transmitter, if
required
- transmitter tubing is blocked or leaking - clean / fasten tubing
- manual valves in the tubing have been - open manual valves
opened
16 Check, if one of the valves KV-1105,
KV-2511/22, KV-2512/22, KV-2514/24, KV-
2505
- is not working properly - see code no. 9, 11, 12
- is leaking - refer to mfr. documentation
17 Check, if one of the bypass valves
KV-1835/45
- is not working properly - see code no. 11
18 Check, if
- all connections in the waste gas piping are - tighten up loose pipe connections
tightened up properly
- adsorbers are closed tight - tighten up loose flange connections
LIST OF SHUT DOWN ALARM MESSAGES

Source Event Code
GENERAL ALARM MESSAGES
EmergencyControl/Event XA-9310 - Unit emergency stop is active - Shut-down 47
EmergencyControl/Event XA-1510 - Oxygen compressor emergency stop is active - Shut down 47
EmergencyControl/Event XA-9311 - External emergency stop is active - Shut down 47
Electrical/Event5 +P9487 - Main switch is opened - Shut down 112

Electrical/Event5 +P9487 - Feed-in undervoltage - Shut down 112
Electrical/Event5 +P9487 - Earth fault of control power 112
Electrical/Event5 +P9487 - Surge protection is tripped - Shut down 112
Electrical/Event6 +P9488 - Main switch is opened - Shut down 112

Electrical/Event6 +P9488 - Feed undervoltage - Shut down 112
Electrical/Event6 +P9488 - SF6-Alarm 112
AirBlower/Event KV-1105 - Open bypass valve due to differential pressure 106
Adsorber/Event PI-2511 - Pressure deviation in adsorber A by process 27/74

Adsorber/Event PI-2521 - Pressure deviation in adsorber B by process 27/74
Adsorber/Event PI-2531 - Pressure deviation in buffer by process 27/74
Adsorber/Event Adsorber Interlock / Permission bypassed 114
VacuumPump/Event KV-1835/KV-1845 - Open bypass valve due to differential pressure 106
OxygenCompressor/Event No compressor running - Plant stop 46

OxygenCompressor/Event Oxygen disabled by process or manual 115
OxygenCompressor/Event Flow reduction due to bad product purity 27/28/51
Analyse/Event AT-1545 - Analyser error due to maximum calibration time 52

Analyse/Event AT-1545 - Analyser maintenance request 88
Analyse/Event AT-1545 - Analyser common fault 7
Analyse/Event AT-1545 – Analyser is deactivated 82
MAIN
JT-9486/JI-9486 JI-9486 - Power meter, External error has occurred 1/48
AIR BLOWER
K-1161/KI-1161 KI-1161 - Maintenance counter, High warning 116
KV-1105/KV-1105 KV-1105 - Bypass valve, Feedback error - Shut down 5

KV-1105/KV-1105 KV-1105 - Bypass valve, External error has occurred - Shut down 1
KV-1105/KV-1105 KV-1105 - Bypass valve, Maintenance required 11
M1181/M1181 M1181 - Air blower, Motor feedback error - Shut down 113
M1181/M1181 M1181 - Air blower, Motor protection triggered - Shut down 50
M1181/M1181 M1181 - Air blower, External error has occurred - Shut down 1
M1181/M1181 M1181 - Air blower, Interlock / Permission bypassed 114
M1181/M1181 M1181 - Air blower, Soft start error - Shut down 111

Source Event Code
MSH-1121/MSAH-1121 MSAH-1121 - Humidity downstream cooler, High alarm - Shut down 60
MSH-1121/MSAH-1121 MSAH-1121 - Humidity downstream cooler, External error has occurred - Shut down 1
PD-1114/PDI-1114 PDI-1114 - Difference pressure air blower, High alarm - Shut down 21/55/71
PD-1114/PDI-1114 PDI-1114 - Difference pressure air blower, High warning 21/55/71
PDSH-1106/PDAH-1106 PDAH-1106 - Difference pressure air filter S1146, High warning 19

PDSH-1106/PDAH-1106 PDAH-1106 - Difference pressure air filter S1146, External error has occurred 1
PDSH-1107/PDAH-1107 PDAH-1107 - Difference pressure air filter S1147, High warning 19

PDSH-1107/PDAH-1107 PDAH-1107 - Difference pressure air filter S1147, External error has occurred 1
PT-1114/PI-1114 PI-1114 - Suction pressure air blower, Low warning 2/19/20/21

PT-1114/PI-1114 PI-1114 - Suction pressure air blower, Low alarm – Shut down 2/19/20/21
PT-1114/PI-1114 PI-1114 - Suction pressure air blower, External error has occurred - Shut down 1/2
PT-1115/PI-1115 PI-1115 - Outlet pressure air blower, High alarm - Shut down 2/71/77
PT-1115/PI-1115 PI-1115 - Outlet pressure air blower, High warning 2/71/77
PT-1115/PI-1115 PI-1115 - Outlet pressure air blower, Low warning 2/75/76
PT-1115/PI-1115 PI-1115 - Outlet pressure air blower, Low alarm - Shut down 2/75/76
PT-1115/PI-1115 PI-1115 - Outlet pressure air blower, External error has occurred - Shut down 1/2
TCV-1121/TCV-1121 TCV-1121 - Cooling water control valve, Feedback error 5

TCV-1121/TCV-1121 TCV-1121 - Cooling water control valve, External error has occurred 9
TCV-1121/TCV-1121 TCV-1121 - Cooling water control valve, Maintenance required 12
TD-1114/TDI-1114 TDI-1114 - Difference temperature air blower, High alarm - Shut down 25/26
TD-1114/TDI-1114 TDI-1114 - Difference temperature air blower, High warning 25/26
TE-1114/TI-1114 TI-1114 - Suction temperature air blower, High alarm - Shut down 3/39
TE-1114/TI-1114 TI-1114 - Suction temperature air blower, High warning 3/39
TE-1114/TI-1114 TI-1114 - Suction temperature air blower, Low warning 3/40
TE-1114/TI-1114 TI-1114 - Suction temperature air blower, Low alarm - Shut down 3/40
TE-1114/TI-1114 TI-1114 - Suction temperature air blower, External error has occurred - Shut down 1/3
TE-1115/TI-1115 TI-1115 - Outlet temperature air blower, High alarm - Shut down 3/39/25
TE-1115/TI-1115 TI-1115 - Outlet temperature air blower, High warning 3/39/25
TE-1115/TI-1115 TI-1115 - Outlet temperature air blower, External error has occurred - Shut down 1/3
TE-1121/TI-1121 TI-1121 - Temperature downstream air cooler, High alarm - Shut down 3/65/66
TE-1121/TI-1121 TI-1121 - Temperature downstream air cooler, High warning 3/65/66
TE-1121/TI-1121 TI-1121 - Temperature downstream air cooler, Low warning 3/40/66
TE-1121/TI-1121 TI-1121 - Temperature downstream air cooler, Low alarm - Shut down 3/40/66
TE-1121/TI-1121 TI-1121 - Temperature downstream air cooler, External error has occurred - Shut down 1/3
TE-1181-1/TI-1181-1 TI-1181-1 - Temperature motor winding 'U’, High alarm - Shut down 3/57
TE-1181-1/TI-1181-1 TI-1181-1 - Temperature motor winding 'U’, High warning 3/57
TE-1181-1/TI-1181-1 TI-1181-1 - Temperature motor winding 'U’, External error has occurred - Shut down 1/3
TE-1181-3/TI-1181-3 TI-1181-3 - Temperature motor winding 'V’, High alarm - Shut down 3/57
TE-1181-3/TI-1181-3 TI-1181-3 - Temperature motor winding 'V’, High warning 3/57
TE-1181-3/TI-1181-3 TI-1181-3 - Temperature motor winding 'V’, External error has occurred - Shut down 1/3

Source Event Code
TE-1181-5/TI-1181-5 TI-1181-5 - Temperature motor winding 'W’, High alarm - Shut down 3/57
TE-1181-5/TI-1181-5 TI-1181-5 - Temperature motor winding 'W’, High warning 3/57
TE-1181-5/TI-1181-5 TI-1181-5 - Temperature motor winding 'W’, External error has occurred - Shut down 1/3
TE-1181-7/TI-1181-7 TI-1181-7 - Bearing temperature DE, High alarm - Shut down 3/100/101
TE-1181-7/TI-1181-7 TI-1181-7 - Bearing temperature DE, High warning 3/100/101
TE-1181-7/TI-1181-7 TI-1181-7 - Bearing temperature DE, External error has occurred - Shut down 1/3
TE-1181-8/TI-1181-8 TI-1181-8 - Bearing temperature NDE, High alarm - Shut down 3/100/101
TE-1181-8/TI-1181-8 TI-1181-8 - Bearing temperature NDE, High warning 3/100/101
TE-1181-8/TI-1181-8 TI-1181-8 - Bearing temperature NDE, External error has occurred - Shut down 1/3
VT-1131/VI-1131 VI-1131 - Vibration air blower DE, High alarm - Shut down 69/100/101
VT-1131/VI-1131 VI-1131 - Vibration air blower DE, High warning 69/100/101
VT-1131/VI-1131 VI-1131 - Vibration air blower DE, External error has occurred - Shut down 1
VT-1132/VI-1132 VI-1132 - Vibration air blower NDE, High alarm - Shut down 69/100/101
VT-1132/VI-1132 VI-1132 - Vibration air blower NDE, High warning 69/100/101
VT-1132/VI-1132 VI-1132 - Vibration air blower NDE, External error has occurred - Shut down 1
LSL-1138/LAL-1138 LAL-1138 - Oil level air blower, Low warning 70

LSL-1138/LAL-1138 LAL-1138 - Oil level air blower, External error has occurred 1
PDSH-1148/PDAH-1148 PDAH-1148 - Difference pressure oil filter air blower, High warning 24
PDSH-1148/PDAH-1148 PDAH-1148 - Difference pressure oil filter air blower, External error has occurred 1
PSL-1149/PSAL-1149 PSAL-1149 - Oil pressure air blower, Low alarm - Shut down 24/38/68/80
PSL-1149/PSAL-1149 PSAL-1149 - Oil pressure air blower, External error has occurred - Shut down 1
ADSORBER
AT-1545/AI-1545 AI-1545 - Oxygen product content, External error has occurred - Shut down 1/7/6
FT-1545/FI-1545 FI-1545 - Flow upstream compressor, External error has occurred - Shut down 1/8
KV-2505/KV-2505 KV-2505 - Pressure equalisation valve, Feedback error - Shut down 5

KV-2505/KV-2505 KV-2505 - Pressure equalisation valve, External error has occurred - Shut down 9
KV-2505/KV-2505 KV-2505 - Pressure equalisation valve, Maintenance required 12
KV-2511/KV-2511 KV-2511 - Adsorber A air valve, Feedback error - Shut down 5

KV-2511/KV-2511 KV-2511 - Adsorber A air valve, External error has occurred - Shut down 1
KV-2511/KV-2511 KV-2511 - Adsorber A air valve, Maintenance required 11
KV-2512/KV-2512 KV-2512 - Adsorber A product valve, Feedback error - Shut down 5

KV-2512/KV-2512 KV-2512 - Adsorber A product valve, External error has occurred - Shut down 1
KV-2512/KV-2512 KV-2512 - Adsorber A product valve, Maintenance required 11
KV-2514/KV-2514 KV-2514 - Adsorber A waste gas valve, Feedback error - Shut down 5
KV-2514/KV-2514 KV-2514 - Adsorber A waste gas valve, External error has occurred - Shut down 1
KV-2514/KV-2514 KV-2514 - Adsorber A waste gas valve, Maintenance required 11
KV-2521/KV-2521 KV-2521 - Adsorber B air valve, Feedback error - Shut down 5

Source Event Code
KV-2521/KV-2521 KV-2521 - Adsorber B air valve, External error has occurred - Shut down 1
KV-2521/KV-2521 KV-2521 - Adsorber B air valve, Maintenance required 11
KV-2522/KV-2522 KV-2522 - Adsorber B product valve, Feedback error - Shut down 5

KV-2522/KV-2522 KV-2522 - Adsorber B product valve, External error has occurred - Shut down 1
KV-2522/KV-2522 KV-2522 - Adsorber B product valve, Maintenance required 11
KV-2524/KV-2524 KV-2524 - Adsorber B waste gas valve, Feedback error - Shut down 5
KV-2524/KV-2524 KV-2524 - Adsorber B waste gas valve, External error has occurred - Shut down 1
KV-2524/KV-2524 KV-2524 - Adsorber B waste gas valve, Maintenance required 11
PDT-2515/PDI-2515 PDI-2515 - Difference pressure adsorber A - TOP, High alarm - Shut down 37/75/2/5
PDT-2515/PDI-2515 PDI-2515 - Difference pressure adsorber A - TOP, High warning 37/75/2/5
PDT-2515/PDI-2515 PDI-2515 - Difference pressure adsorber A - TOP, External error has occurred - Shut down 1/2
PDT-2516/PDI-2516 PDI-2516 - Difference pressure adsorber A - BOTTOM, High alarm - Shut down 37/75/2/5
PDT-2516/PDI-2516 PDI-2516 - Difference pressure adsorber A - BOTTOM, High warning 37/75/2/5
PDI-2516 - Difference pressure adsorber A - BOTTOM, External error has occurred - Shut
PDT-2516/PDI-2516 1/2
down
PDT-2525/PDI-2525 PDI-2525 - Difference pressure adsorber B - TOP, High alarm - Shut down 37/75/2/5
PDT-2525/PDI-2525 PDI-2525 - Difference pressure adsorber B - TOP, High warning 37/75/2/5
PDT-2525/PDI-2525 PDI-2525 - Difference pressure adsorber B - TOP, External error has occurred - Shut down 1/2
PDT-2526/PDI-2526 PDI-2526 - Difference pressure adsorber B - BOTTOM, High alarm - Shut down 37/75/2/5
PDT-2526/PDI-2526 PDI-2526 - Difference pressure adsorber B - BOTTOM, High warning 37/75/2/5
PDI-2526 - Difference pressure adsorber B - BOTTOM, External error has occurred - Shut
PDT-2526/PDI-2526 1/2
down
PT-2511/PI-2511 PI-2511 - Pressure adsorber A, High alarm - Shut down 2/67

PT-2511/PI-2511 PI-2511 - Pressure adsorber A, High warning 2/67
PT-2511/PI-2511 PI-2511 - Pressure adsorber A, Low warning 2/74
PT-2511/PI-2511 PI-2511 - Pressure adsorber A, Low alarm - Shut down 2/74
PT-2511/PI-2511 PI-2511 - Pressure adsorber A, External error has occurred - Shut down 1/2
PT-2511/PI-2511 PI-2511 - Pressure adsorber A, High alarm vacuum not reached - Shut down 2/16/17/18
PT-2511/PI-2511 PI-2511 - Pressure adsorber A, High warning vacuum not reached 2/16/17/18
PT-2521/PI-2521 PI-2521 - Pressure adsorber B, High alarm - Shut down 2/67

PT-2521/PI-2521 PI-2521 - Pressure adsorber B, High warning 2/67
PT-2521/PI-2521 PI-2521 - Pressure adsorber B, Low warning 2/74
PT-2521/PI-2521 PI-2521 - Pressure adsorber B, Low alarm - Shut down 2/74
PT-2521/PI-2521 PI-2521 - Pressure adsorber B, External error has occurred - Shut down 1/2
PT-2521/PI-2521 PI-2521 - Pressure adsorber B, High alarm vacuum not reached - Shut down 2/16/17/18
PT-2521/PI-2521 PI-2521 - Pressure adsorber B, High warning vacuum not reached 2/16/17/18
PT-2531/PI-2531 PI-2531 - Pressure buffer vessel, Low warning 2/49

PT-2531/PI-2531 PI-2531 - Pressure buffer vessel, Low alarm - Shut down 2/49
PT-2531/PI-2531 PI-2531 - Pressure buffer vessel, External error has occurred - Shut down 1/2
TE-1545/TI-1545 TI-1545 - Temperature downstream buffer, External error has occurred - Shut down 1/3
TE-2512/TI-2512 TI-2512 - Bed temperature adsorber A, External error has occurred 1/3

Source Event Code
TE-2522/TI-2522 TI-2522 - Bed temperature adsorber B, External error has occurred 1/3
FSL-1502/FSAL-1502 FSAL-1502 – Gas flow, Low alarm - Plant stop 51

FSL-1502/FSAL-1502 FSAL-1502 – Gas flow, External error has occurred - Plant stop 1
PSL-1545H/PAL-1545H PAL-1545H - Zero gas cylinder empty, Low warning 72

PSL-1545H/PAL-1545H PAL-1545H - Zero gas cylinder empty, External error has occurred 1
PSL-1545L/PAL-1545L PAL-1545L - Range Gas cylinder empty, Low warning 72

PSL-1545L/PAL-1545L PAL-1545L - Range Gas cylinder empty, External error has occurred 1
VACUUM PUMP
KV-1835/KV-1835 KV-1835 - Unload valve big, Feedback error - Shut down 5
KV-1835/KV-1835 KV-1835 - Unload valve big, External error has occurred - Shut down 1
KV-1835/KV-1835 KV-1835 - Unload valve big, Maintenance required 11
KV-1845/KV-1845 KV-1845 - Unload valve small, Feedback error - Shut down 5

KV-1845/KV-1845 KV-1845 - Unload valve small, External error has occurred - Shut down 1
KV-1845/KV-1845 KV-1845 - Unload valve small, Maintenance required 11
KV-1845/KV-1845 KV-1845 - Unload valve small, Open due to pressure condition 85/81
PD-1812/PDI-1812 PDI-1812 - Difference pressure suction filter, High alarm - Shut down 21/86
PD-1812/PDI-1812 PDI-1812 - Difference pressure suction filter, High warning 21/86
PD-1814/PDI-1814 PDI-1814 - Difference pressure vacuum pump, High alarm - Shut down 21/56
PD-1814/PDI-1814 PDI-1814 - Difference pressure vacuum pump, High warning 21/56
PT-1812/PI-1812 PI-1812 - Suction pressure upstream filter, Low warning 2/54

PT-1812/PI-1812 PI-1812 - Suction pressure upstream filter, Low alarm - Shut down 2/54
PT-1812/PI-1812 PI-1812 - Suction pressure upstream filter, External error has occurred - Shut down 1/2
PT-1812/PI-1812 PI-1812 - Suction pressure upstream filter, Low warning unload 2/20/21
PT-1812/PI-1812 PI-1812 - Suction pressure upstream filter, Low alarm unload - Shut down 2/20/21
PT-1814/PI-1814 PI-1814 - Suction pressure vacuum pump, Low warning 2/21/54

PT-1814/PI-1814 PI-1814 - Suction pressure vacuum pump, Low alarm - Shut down 2/21/54
PT-1814/PI-1814 PI-1814 - Suction pressure vacuum pump, External error has occurred - Shut down 1/2
PT-1815/PI-1815 PI-1815 - Outlet pressure vacuum pump, High alarm - Shut down 2/20
PT-1815/PI-1815 PI-1815 - Outlet pressure vacuum pump, High warning 2/20
PT-1815/PI-1815 PI-1815 - Outlet pressure vacuum pump, External error has occurred - Shut down 1/2
TD-1814/TDI-1814 TDI-1814 - Difference temperature vacuum pump, High alarm - Shut down 25/26
TD-1814/TDI-1814 TDI-1814 - Difference temperature vacuum pump, High warning 25/26
TE-1814/TI-1814 TI-1814 - Suction temperature vacuum pump, High alarm - Shut down 3/65/66/39
TE-1814/TI-1814 TI-1814 - Suction temperature vacuum pump, High warning 3/65/66/39
TE-1814/TI-1814 TI-1814 - Suction temperature vacuum pump, Low warning 3/40/66/39
TE-1814/TI-1814 TI-1814 - Suction temperature vacuum pump, Low alarm - Shut down 3/40/66/39
TE-1814/TI-1814 TI-1814 - Suction temperature vacuum pump, External error has occurred - Shut down 1/3
TE-1815/TI-1815 TI-1815 - Outlet temperature vacuum pump, High alarm - Shut down 3/66/39/25
TE-1815/TI-1815 TI-1815 - Outlet temperature vacuum pump, High warning 3/66/39/25

Source Event Code
TE-1815/TI-1815 TI-1815 - Outlet temperature vacuum pump, External error has occurred - Shut down 1/3
VT-1831/VI-1831 VI-1831 - Vibration vacuum pump DE, High alarm - Shut down 69/100/101
VT-1831/VI-1831 VI-1831 - Vibration vacuum pump DE, High warning 69/100/101
VT-1831/VI-1831 VI-1831 - Vibration vacuum pump DE, External error has occurred - Shut down 1
VT-1832/VI-1832 VI-1832 - Vibration vacuum pump NDE, High alarm - Shut down 69/100/101
VT-1832/VI-1832 VI-1832 - Vibration vacuum pump NDE, High warning 69/100/101
VT-1832/VI-1832 VI-1832 - Vibration vacuum pump NDE, External error has occurred - Shut down 1
LSL-1838/LAL-1838 LAL-1838 - Oil level vacuum pump, Low warning 70

LSL-1838/LAL-1838 LAL-1838 - Oil level vacuum pump, External error has occurred 1
PDSH-1848/PDAH-1848 PDAH-1848 - Difference pressure oil filter vacuum pump, High warning 24
PDSH-1848/PDAH-1848 PDAH-1848 - Difference pressure oil filter vacuum pump, External error has occurred 1
PSL-1849/PSAL-1849 PSAL-1849 - Oil pressure vacuum pump, Low alarm - Shut down 24/38/68/80
PSL-1849/PSAL-1849 PSAL-1849 - Oil pressure vacuum pump, External error has occurred - Shut down 1
OXYGEN COMPRESSOR
K-1561/KI-1561 KI-1561 - Maintenance counter, High warning 116
M1581/M1581 M1581 - Oxygen compressor, Motor feedback error - Shut down 113
M1581/M1581 M1581 - Oxygen compressor, Motor protection triggered - Shut down 50
M1581/M1581 M1581 - Oxygen compressor, External error has occurred - Shut down 1
M1581/M1581 M1581 - Oxygen compressor, Interlock / Permission bypassed 114
M1581/M1581 M1581 - Oxygen compressor, Soft start error - Shut down 111
PCV-1513/PCV-1513 PCV-1513 - Unload control valve, Feedback error 5

PCV-1513/PCV-1513 PCV-1513 - Unload control valve, External error has occurred 9
PCV-1513/PCV-1513 PCV-1513 - Unload control valve, Maintenance required 12
PCV-1545/PCV-1545 PCV-1545 - Bypass control valve, Feedback error 5

PCV-1545/PCV-1545 PCV-1545 - Bypass control valve, External error has occurred 9
PCV-1545/PCV-1545 PCV-1545 - Bypass control valve, Maintenance required 12
PD-1512/PDI-1512 PDI-1512 - Difference pressure suction side, High alarm - Shut down 99/19
PD-1512/PDI-1512 PDI-1512 - Difference pressure suction side, High warning 99/19
PDSH-1513/PDAH-1513 PDAH-1513 - Difference pressure suction filter, High warning 2/19

PDSH-1513/PDAH-1513 PDAH-1513 - Difference pressure suction filter, External error has occurred 1/2
PT-1514/PI-1514 PI-1514 - Suction pressure oxygen compressor, High alarm - Shut down 2/92
PT-1514/PI-1514 PI-1514 - Suction pressure oxygen compressor, High warning 2/92
PT-1514/PI-1514 PI-1514 - Suction pressure oxygen compressor, Low warning 2/16/19/21
PT-1514/PI-1514 PI-1514 - Suction pressure oxygen compressor, Low alarm - Shut down 2/16/19/21
PT-1514/PI-1514 PI-1514 - Suction pressure oxygen compressor, External error has occurred - Shut down 1/2
PT-1521/PI-1521 PI-1535 - Pressure stage 2, High alarm - Shut down 2/14/15/23/92

PT-1521/PI-1521 PI-1535 - Pressure stage 2, High warning 2/14/15/23/92

Source Event Code
PT-1521/PI-1521 PI-1535 – Pressure stage 2, External error has occurred - Shut down 1/2
TE-1514/TI-1514 TI-1514 - Temperature upstream stage 1, High alarm - Shut down 3/65/62
TE-1514/TI-1514 TI-1514 - Temperature upstream stage 1, High warning 3/65/62
TE-1514/TI-1514 TI-1514 - Temperature upstream stage 1, External error has occurred - Shut down 1/3
TE-1515/TI-1515 TI-1515 - Temperature downstream stage 1, High alarm - Shut down 3/13/31/62
TE-1515/TI-1515 TI-1515 - Temperature downstream stage 1, High warning 3/13/31/62
TE-1515/TI-1515 TI-1515 - Temperature downstream stage 1, External error has occurred - Shut down 1/3
TE-1518/TI-1518 TI-1507 - Temperature stuffing box cylinder 1, High alarm - Shut down 3/34
TE-1518/TI-1518 TI-1507 - Temperature stuffing box cylinder 1, High warning 3/34
TE-1518/TI-1518 TI-1507 - Temperature stuffing box cylinder 1, External error has occurred - Shut down 1/3
TE-1521/TI-1521 TI-1521 - Temperature compressor outlet, High alarm - Shut down 3/13/62
TE-1521/TI-1521 TI-1521 - Temperature compressor outlet, High warning 3/13/62
TE-1521/TI-1521 TI-1521 - Temperature compressor outlet, External error has occurred - Shut down 1/3
TE-1524/TI-1524 TI-1524 - Temperature upstream stage 2, High alarm - Shut down 3/13/62
TE-1524/TI-1524 TI-1524 - Temperature upstream stage 2, High warning 3/13/62
TE-1524/TI-1524 TI-1524 - Temperature upstream stage 2, External error has occurred - Shut down 1/3
TE-1525/TI-1525 TI-1525 - Temperature downstream stage 2, High alarm - Shut down 3/13/31/62
TE-1525/TI-1525 TI-1525 - Temperature downstream stage 2, High warning 3/13/31/62
TE-1525/TI-1525 TI-1525 - Temperature downstream stage 2, External error has occurred - Shut down 1/3
TE-1528/TI-1528 TI-1528 - Temperature stuffing box cylinder 2, High alarm - Shut down 3/34
TE-1528/TI-1528 TI-1528 - Temperature stuffing box cylinder 2, High warning 3/34
TE-1528/TI-1528 TI-1528 - Temperature stuffing box cylinder 2, External error has occurred - Shut down 1/3
TE-1581-1/TI-1581-1 TI-1581-1 - Temperature motor winding 'U', High alarm - Shut down 3/57
TE-1581-1/TI-1581-1 TI-1581-1 - Temperature motor winding 'U', High warning 3/57
TE-1581-1/TI-1581-1 TI-1581-1 - Temperature motor winding 'U', External error has occurred - Shut down 1/3
TE-1581-3/TI-1581-3 TI-1581-3 - Temperature motor winding 'V', High alarm - Shut down 3/57
TE-1581-3/TI-1581-3 TI-1581-3 - Temperature motor winding 'V', High warning 3/57
TE-1581-3/TI-1581-3 TI-1581-3 - Temperature motor winding 'V', External error has occurred - Shut down 1/3
TE-1581-5/TI-1581-5 TI-1581-5 - Temperature motor winding 'W', High alarm - Shut down 3/57
TE-1581-5/TI-1581-5 TI-1581-5 - Temperature motor winding 'W', High warning 3/57
TE-1581-5/TI-1581-5 TI-1581-5 - Temperature motor winding 'W', External error has occurred - Shut down 1/3
TE-1581-7/TI-1581-7 TI-1581-7 - Bearing temperature DE, High alarm - Shut down 3/100/101
TE-1581-7/TI-1581-7 TI-1581-7 - Bearing temperature DE, High warning 3/100/101
TE-1581-7/TI-1581-7 TI-1581-7 - Bearing temperature DE, External error has occurred - Shut down 1/3
TE-1581-8/TI-1581-8 TI-1581-8 - Bearing temperature NDE, High alarm - Shut down 3/100/101
TE-1581-8/TI-1581-8 TI-1581-8 - Bearing temperature NDE, High warning 3/100/101
TE-1581-8/TI-1581-8 TI-1581-8 - Bearing temperature NDE, External error has occurred - Shut down 1/3
VSH-1561/VSAH-1561 VSAH-1561 - Vibration oxygen compressor, High alarm - Shut down 69/100/101
VSH-1561/VSAH-1561 VSAH-1561 - Vibration oxygen compressor, External error has occurred - Shut down 1

Source Event Code
XV-1530/XV-1530 XV-1530 - Suction valve, Feedback error - Shut down 5

XV-1530/XV-1530 XV-1530 - Suction valve, External error has occurred - Shut down 1
XV-1530/XV-1530 XV-1530 - Suction valve, Maintenance required 11
XV-1550/XV-1550 XV-1550 - Discharge valve, Feedback error - Shut down 5

XV-1550/XV-1550 XV-1550 - Discharge valve, External error has occurred - Shut down 1
XV-1550/XV-1550 XV-1550 - Discharge valve, Maintenance required 11
E1564/E1564 E1564 - Oil heater oxygen compressor, Heater feedback error 113
E1564/E1564 E1564 - Oil heater oxygen compressor, Heater protection triggered 50
E1564/E1564 E1564 - Oil heater oxygen compressor, External error has occurred 1
E1564/E1564 E1564 - Oil heater oxygen compressor, Interlock / Permission bypassed 114
LSL-1561/LAL-1561 LAL-1561 - Oil level oxygen compressor, Low warning 80/78

LSL-1561/LAL-1561 LAL-1561 - Oil level oxygen compressor, External error has occurred 1
PISL-1566/PSAL-1566 PSAL-1566 - Oil pressure low, Low alarm - Shut down 2/80/68
PISL-1566/PSAL-1566 PSAL-1566 - Oil pressure low, External error has occurred - Shut down 1/2
TE-1566/TI-1566 TI-1566 - Oil temperature oxygen compressor, High alarm - Shut down 3/13/62
TE-1566/TI-1566 TI-1566 - Oil temperature oxygen compressor, High warning 3/13/62
TE-1566/TI-1566 TI-1566 - Oil temperature oxygen compressor, Low warning 3/61
TE-1566/TI-1566 TI-1566 - Oil temperature oxygen compressor, External error has occurred - Shut down 1/3
TSH-1564/TAH-1564 TAH-1564 - Oil temperature heater oxygen compressor, High warning 62/13
TSH-1564/TAH-1564 TAH-1564 - Oil temperature heater oxygen compressor, External error has occurred 1
INSTRUMENT AIR
InstrumentAir/Event Instrument Air System A is switched off 123
InstrumentAir/Event Instrument Air System B is switched off 123
InstrumentAir/Event A8326A - I-Air dryer - Alarm 50/122
InstrumentAir/Event A8326B - I-Air dryer - Alarm 50/122
AT-8326/AI-8326 AI-8326 - Dewpoint instrument air, High warning 124

AT-8326/AI-8326 AI-8326 - Dewpoint instrument air, Low warning 124
AT-8326/AI-8326 AI-8326 - Dewpoint instrument air, External error has occurred 1/2
C8361A/C8361A C8361A - Instrument air compressor, Common alarm 50/122

C8361A/C8361A C8361A - Instrument air compressor, External error has occurred 1
C8361A/C8361A C8361A - Instrument air compressor, Interlock / Permission bypassed 114
C8361B/C8361B C8361B - Instrument air compressor, Common alarm 50/122

C8361B/C8361B C8361B - Instrument air compressor, External error has occurred 1
C8361B/C8361B C8361B - Instrument air compressor, Interlock / Permission bypassed 114
PT-8303/PI-8303 PI-8303 - Pressure instrument air, High warning - Plant stop 2/43
PT-8303/PI-8303 PI-8303 - Pressure instrument air, High tolerance 2/42/22
PT-8303/PI-8303 PI-8303 - Pressure instrument air, Low tolerance 2/42/22
PT-8303/PI-8303 PI-8303 - Pressure instrument air, Low warning - Plant stop 2/42/22
PT-8303/PI-8303 PI-8303 - Pressure instrument air, Low alarm - Shut down 2/42/22
PT-8303/PI-8303 PI-8303 - Pressure instrument air, External error has occurred - Shut down 1/2

Source Event Code
COOLING WATER
CoolingWater/Event M8481 - Cooling water pump, Redundancy fault 50, 62
FSL-1572/FAL-1572 FAL-1572 - Flow cooling water oxygen compressor, Low warning 62

FSL-1572/FAL-1572 FAL-1572 - Flow cooling water oxygen compressor, External error has occurred 1
M8481A/M8481A M8481A - Cooling water pump A, Motor feedback error 113

M8481A/M8481A M8481A - Cooling water pump A, Motor protection triggered 50
M8481A/M8481A M8481A - Cooling water pump A, External error has occurred 1
M8481A/M8481A M8481A - Cooling water pump A, Interlock / Permission bypassed 114
M8481B/M8481B M8481B - Cooling water pump B, Motor feedback error 113

M8481B/M8481B M8481B - Cooling water pump B, Motor protection triggered 50
M8481B/M8481B M8481B - Cooling water pump B, External error has occurred 1
M8481B/M8481B M8481B - Cooling water pump B, Interlock / Permission bypassed 114
M8483A/M8483A M8483A - Cooling fan A, Motor feedback error 113

M8483A/M8483A M8483A - Cooling fan A, Motor protection triggered 50
M8483A/M8483A M8483A - Cooling fan A, External error has occurred 1
M8483A/M8483A M8483A - Cooling fan A, Interlock / Permission bypassed 114
M8483B/M8483B M8483B - Cooling fan B, Motor feedback error 113

M8483B/M8483B M8483B - Cooling fan B, Motor protection triggered 50
M8483B/M8483B M8483B - Cooling fan B, External error has occurred 1
M8483B/M8483B M8483B - Cooling fan B, Interlock / Permission bypassed 114
M8483C/M8483C M8483C - Cooling fan C, Motor feedback error 113

M8483C/M8483C M8483C - Cooling fan C, Motor protection triggered 50
M8483C/M8483C M8483C - Cooling fan C, External error has occurred 1
M8483C/M8483C M8483C - Cooling fan C, Interlock / Permission bypassed 114
M8483D/M8483D M8483D - Cooling fan D, Motor feedback error 113

M8483D/M8483D M8483D - Cooling fan D, Motor protection triggered 50
M8483D/M8483D M8483D - Cooling fan D, External error has occurred 1
M8483D/M8483D M8483D - Cooling fan D, Interlock / Permission bypassed 114
M8483E/M8483E M8483E - Cooling fan E, Motor feedback error 113

M8483E/M8483E M8483E - Cooling fan E, Motor protection triggered 50
M8483E/M8483E M8483E - Cooling fan E, External error has occurred 1
M8483E/M8483E M8483E - Cooling fan E, Interlock / Permission bypassed 114
PT-8413/PI-8413 PI-8413 - Pressure Cooling water, High warning 62/73

PT-8413/PI-8413 PI-8413 - Pressure Cooling water, Low warning 62/73
PT-8413/PI-8413 PI-8413 - Pressure Cooling water, Low alarm 62/73
PT-8413/PI-8413 PI-8413 - Pressure Cooling water, External error has occurred 1/2
TCV-8401/TCV-8401 TCV-8401 - Cooling water control valve, Feedback error 5

TCV-8401/TCV-8401 TCV-8401 - Cooling water control valve, External error has occurred 9
TCV-8401/TCV-8401 TCV-8401 - Cooling water control valve, Maintenance required 12
TE-8401/TI-8401 TI-8401 - Temperature cooling water (upstream), High warning limit violated 13/62/73

Source Event Code
TE-8401/TI-8401 TI-8401 - Temperature cooling water (upstream), Low warning limit violated 13/62/73
TE-8401/TI-8401 TI-8401 - Temperature cooling water (upstream), External error has occurred 1/3
ENVIRONMENT
AT-1598/AI-1598 AI-1598 - Oxygen content ambient air, High alarm - Shut down 42/58/39
AT-1598/AI-1598 AI-1598 - Oxygen content ambient air, High warning 42/58/39
AT-1598/AI-1598 AI-1598 - Oxygen content ambient air, Low warning 42/58/39
AT-1598/AI-1598 AI-1598 - Oxygen content ambient air, Low alarm - Shut down 42/58/39
AT-1598/AI-1598 AI-1598 - Oxygen content ambient air, External error has occurred - Shut down 1
AT-1598/AI-1598 AI-1598 - Oxygen content ambient air, Disabled 79
AT-2598/AI-2598 AI-2598 - Oxygen content ambient air, High alarm - Shut down 42/58/39
AT-2598/AI-2598 AI-2598 - Oxygen content ambient air, High warning 42/58/39
AT-2598/AI-2598 AI-2598 - Oxygen content ambient air, Low warning 42/58/39
AT-2598/AI-2598 AI-2598 - Oxygen content ambient air, Low alarm - Shut down 42/58/39
AT-2598/AI-2598 AI-2598 - Oxygen content ambient air, External error has occurred - Shut down 1
AT-2598/AI-2598 AI-2598 - Oxygen content ambient air, Disabled 79
HS-9304/HS-9304 HS-9304 - Signal from external "Smoke/Fire detection", High Alarm - Shut down 83
HS-9304 - Signal from external "Smoke/Fire detection", External error has occurred - Shut
HS-9304/HS-9304 1
down
HS-9304/HS-9304 HS-9304 - Signal from external "Smoke/Fire detection", Disabled 84
TE-1101/TI-1101 TI-1101 - Temperature machine hall, External error has occurred 1/3
TE-1102/TI-1102 TI-1102 - Ambient temperature (outdoor), External error has occurred 1/3
CODE TABLE FOR TROUBLESHOOTING

No.
1 Check electrical connection between field
instrument and the I/O-card in the PLC / remote IO
for
- broken wires - install new cable
- short circuit - check cable
- inverse polarity - invert polarity
- loose terminals - fasten terminals
- availability of power supply on I/O-card or the - switch on power supply / check fuses
instrument
2 Check, if
- the signal of the transmitter is correct (apply test - calibrate transmitter
pressure)
- transmitter is working correctly - refer to mfr. documentation / replace transmitter,
if required
- transmitter tubing is blocked or leaking - clean / fasten tubing
- manual valves in the tubing have been opened - open manual valves
3 Check, if
- signal of RTD is correct - refer to mfr. documentation / change RTD, if
required
- the calculated temperature is correct - refer to mfr. documentation / change RTD, if
required
4 Check, if
- setpoint is adjusted correctly - adjust setpoint
- switch is working correctly - replace switch, if required
- electrical connection between switch and I/O - see code no. 1
Card in the PLC is OK
5 Check, if
- pilot valve / limit switches / positioners are - replace pilot valve / limit switches / positioner if
working correctly required
- power supply is available - switch on power supply / check fuses
- electrical connection between pilot valve / limit - see code no. 14
switches / positioner and the I/O-card in the PLC
is OK
6 Check, if
- analyzer is working correctly - refer to mfr. documentation
- sample gas pressure is adjusted correctly - adjust sample gas pressure / flow
- calibration of the analyzer is OK - calibrate analyzer
7 Check, if
- analyzer is connected to power supply - switch on power supply / check fuses
- analyzer is still heating up - wait until heat-up time has expired
- error message is displayed on the analyzer - refer to mfr. documentation
panel
8 Check, if
- flow measurement is working correctly - refer to mfr. documentation / calibrate
transmitter
- pressure measurement is working correctly - refer to mfr. documentation / calibrate transmitter
- temperature measurement is working correctly - refer to mfr. documentation
- design capacity of the VPSA is exceeded - check, if flow limitation is working correctly and
adjust, if required

No.
9 Check electrical connection between output-card
in the PLC and the positioner for
- broken wires - install new cable
- short circuit - check cable
- inverse polarity - invert polarity
- loose terminals - fasten terminals
- availability of power supply on I/O-card or the - switch on power supply / check fuses
positioner
Check, if
- position feedback-sensor is working correctly - refer to mfr. documentation
and if power supply for the positioner is available
10 Check, if
- pilot valve is working correctly - repair / replace pilot valve
- solenoid on the pilot valve is working correctly - repair / replace solenoid
- power supply is available for the solenoid - switch on power supply / check fuses
- manual override on the pilot valve has been - switch manual override to ’0’
activated (only for pilot valves equipped with
manual override)
- throttles on pilot valve have been closed - adjust throttles
11 Check, if
- valve shows irregular switching times - compare switching times with identical valves
- loose connections between valve body / - tighten up loose connections
actuator, actuator / pilot valve or actuator / limit
switch box can be found
- instrument air supply to actuator / pilot valve is - tighten / replace / clean instrument air tubing
loose, damaged or tubing is dirty
- throttles on the pilot valve have been closed - open throttles
- silencers in the openings of the pilot valve are - clean / replace silencers
blocked with dirt
- bearings or sealings inside the valve body or - maintain valve / actuator, refer to mfr.
inside the actuator have excessive wear documentation
12 Check, if
- valve shows irregular switching times - compare switching times with identical valves
- loose connections between valve body / actuator - tighten up loose connections
or actuator / positioner can be found
- instrument air supply to actuator / positioner is - tighten / replace / clean instrument air tubing
loose, damaged or tubing is dirty
- silencers in the openings of the positioner are - clean / replace silencers
blocked with dirt
- bearings or sealings inside the valve body or - maintain valve / actuator, refer to manufacturer
inside the actuator show signs of excessive wear manual
13 Check, if
- cooling water temperatures are within specified - provide cooling water as per technical
range specification
- cooling system is clean (deposits, fouling…) - clean cooling system and provide cooling water
in accordance with the project specification
- safety valves are adjusted correctly - adjust safety valve
14 Check, if
- setpoint for pressure controller PIC-1535 is - adjust pressure setpoint
correct
- parameters for controller are chosen correctly - adjust controller settings
(stable behaviour)
15 Check if bypass valve of the oxygen compressor See code no. 9, 12
is working properly

No.
16 Check, if one of the valves KV-1105,
KV-2511/22, KV-2512/22, KV-2514/24, KV-2505
- is not working properly - see code no. 9, 11, 12
17 Check, if one of the bypass valves KV-1835/45
- is not working properly - see code no. 11
18 Check, if
- all connections in the waste gas piping are - tighten up loose pipe connections
tightened up properly
- adsorbers are closed tight - tighten up loose flange connections
19 Check filter for cleanliness Clean / replace filter elements
20 Check piping / silencers for blockage Remove blockage in the piping / silencer
21 Check strainer for cleanliness Clean / replace strainer
22 Check, if
- instrument air supply is working - start-up instrument air supply
- differential pressure at the filter/dryer is too high - maintain instrument air system
- pressure reducer in the instrument air system is - adjust pressure reducer
adjusted correctly
- manual valves in the instrument system are open - open valves
- instrument air piping is damaged or leaking - replace / tighten up piping
- safety valve of the instrument air system is - replace safety valve / close manual lifting device
closing tight
23 Check, if
- safety valves in downstream piping are adjusted - adjust set pressure of safety valve
correctly
- manual / automatic valves in downstream piping - open valves
are closed
24 Oil filter is blocked Change over to standby filter and clean/replace
clogged filter element
25 Check, if
- pressure ratio between suction & discharge side - remove blockage
has increased (e.g. due to clogged filter /
strainer)
- temperature range of suction & discharge side - compare with design values / previous records
are within specified range
- clearances between impellers / casing have - contact manufacturer
increased (volumetric efficiency decreases with
increasing of gaps, since more compressed air
is flowing back to the suction side)
26 Temperature difference between casing and Contact manufacturer
impellers is too high (start-up at low ambient
temperature)
27 Check adsorber pressures for irregularities Refer to section 7.3.1
28 Low demand for oxygen will cause enrichment of
argon in the oxygen product. Check, if
- at least 25% of oxygen are discharged from the - increase demand for oxygen
plant OR
- valve VPV-1513 is opened wide enough to
discharge 25% of the design flow
- settings for the blow-off controller FICC-1545 are - adjust settings
correct
- partial load steps 3 and 8 are active - check settings for partial load operation and
adjust, if required

No.
29 The required pressure for opening of valve
KV-2511 at adsorber A after pressure equalization
is not reached. Check, if
- the time interval for pressure equalization in step - increase maximum cycle time in step no. 9
no. 9 has been chosen big enough
- pressure equalizing valve KV-2505 works - see code no. 12, 9
properly
Manual pressure equalization may be required
before restarting the plant
30 The required pressure for opening of valve
KV-2521 at adsorber B after pressure equalization
is not reached. Check, if
- the time interval for pressure equalization in step - increase maximum cycle time in step no. 4
no. 4 has been chosen big enough
- pressure equalizing valve KV-2505 works - see code no. 12, 9
properly
31 Check, if
- compressor valves are closing tight - repair / replace valves
- compressor valves are broken - replace valves
NOTE: Leakage on compressor valves will
cause elevated temperature due to gas
cycling back and forth
32 Differential pressure for opening of valve KV-2514
at adsorber A is too big. Check, if
- transmitters PT-2511 and PT-1812 are working - see code no. 2
properly
- valves KV-2514 and KV-1835 are working - see code no. 11, 5
properly
33 Differential pressure for opening of valve KV-2524
at adsorber B is too big. Check, if
- transmitters PT-2521 and PT-1812 are working - see code no. 2
properly
- valves KV-2524 and KV-1835 are working - see code no. 11, 5
properly
34 Check, if
- stuffing box is leaking - replace stuffing box wearing parts
35 Check pressure transmitters PT-2511 and See code no. 2
PT-2531
36 Check pressure transmitters PT-2521 and See code no. 2
PT-2531
37 Check, if
- stroke limitation of valve KV2505 is adjusted - adjust stroke limitation
correctly
38 Check, if
- tubing of pressure switch is blocked - clean tubing
- setpoint is adjusted correctly - adjust setpoint
- pressure switch is working properly - refer to manufacturer documentation

No.
39 Check, if
- ventilation system is working properly - start-up ventilation system
- filters of the ventilation system are clogged - clean filter elements
40 Check, if
- all doors are closed - close doors
- heating system is working properly - start-up heating system
41 Check, if
- stroke limitation of valve KV-2505 is adjusted - adjust stroke limitation
correctly
- positioner is calibrated properly - calibrate positioner
For calibration of positioner stroke limitation
must be fully released and re-adjusted
following successful calibration (see chapter
7.3.7)
42 Check, if all flange connections are closed tight Tighten up loose flange connections
43 Instrument air pressure is adjusted too high. High Adjust pressure of instrument air system to
pressure might cause damage to positioners / pilot approx. 6 bar(g)
valves
44 Power supply to the control board has failed. PLC Check electric power supply
is in UPS operation
45 UPS is operating in bypass mode Switch UPS over to normal operation to make sure
that power supply to the PLC is kept alive in case
of power failure
46 Plant was stopped, since no oxygen compressor Start up plant and make sure that oxygen
was operating for the last 45 minutes. compressor is working
During operation of the plant at least part of the
oxygen has to be discharged to prevent
enrichment of argon.
47 Emergency-off button was pressed Check directly on site for the reason
Emergency-off buttons will lock in the pushed
position and must be manually pulled out to
restart the plant
48 Check, if
- power transducer is working properly - refer to mfr. documentation / replace power
transducer, if required
- configuration of power transducer is correct - refer to mfr. documentation
49 Check, if product valves KV-2512/22 are
- not working properly - see code no. 11
- leaking - refer to mfr. documentation
50 Check, if
- external power supply is available - re-establish power supply
- surge protectors are intact - replace surge protectors
- main circuit breaker is on - close main circuit breaker
- control voltage is available - turn on control voltage
- power dips (undervoltage) can be observed - provide stable power supply
(especially during start of large drives)
51 Check, if
- analyzer tubing is blocked (sample and vent - clean / replace tubing
tubing)
- manual valves in the tubing are closed - open manual valves
- leakages in the analyzer system are present - tighten up leakages

No.
52 Check, if
- parameters for calibration have been configured - adjust parameters
correctly in the analyzer
- calibration gases have been chosen correctly - change calibration gases / enter correct values
and if the correct composition has been entered for composition of calibration gases
into the analyzer panel
- automatic calibration unit is working properly - refer to mfr. documentation
53 Problem in communication to the DCS. Check, if
- communication got lost - restart communication processor
- communication processor is working properly - replace communication processor
- signal cable to DCS is interrupted - replace cable
54 Check, if
- switching times of the valves KV-2514/24 are OK - compare switching times with similar valves
- silencers / throttles in the vent openings of the - clean / replace
pilot valves are dirty
- pilot valves are working properly - replace pilot valves
- short spikes can be found in the pressure curves - overlap between closing of waste gas valves KV-
during changeover into bypass operation 2514/24 and bypass valve KV-1835 is too short;
increase overlap time
- time interval for delay of bypass valve KV-1835 - increase maximum time limit for delaying closure
has been chosen big enough of bypass valve KV-1835, to limit the vacuum
reached
- limit for opening of full-load bypass valve - adjust limit value
KV-1845 has been adjusted properly
55 Check, if transmitters PT-1114 and PT-1115 are See code no. 2
working properly
working properly
57 Check, if
- motor or ducts for air cooling are blocked with dirt - clean
- motor fan is blocked or damaged - remove blockage / replace fan
58 Check, if
- measuring value of the gas detector is correct Refer to mfr. documentation / calibrate / replace
measuring cell
Note: Measuring cells of the gas detectors have
a limited life span and must be replaced
regularly
59 Operation of valve XV-1550 is disabled by PLC See code no. 13
due to high discharge temperature of oxygen
compressor (protection against increased fire
hazard in connection with high temperature
oxygen). Investigate reason for increased
discharge temperature!
60 Check, if
- process air cooler is leaking - repair cooler
- sensor is working properly - refer to mfr. documentation
Do not operate the plant before cooler has
been repaired. Risk of irreversible damage to
the adsorbent material!
61 Check, if
- electric oil heater is operating - switch on

No.
62 Check, if
- pressure at cooling water pump outlet ist wrong - adjust outlet pressure with manual valves, if
adjusted required
- cooling water supply is working properly - start-up cooling water supply
- cooler is supplied with water - check flow at local indication and open manual
valves if required
- coolers are clogged/scaled - clean coolers
- air is trapped inside cooling water system - vent air from the system or replace automatic
vent valves
Note:
Cooling water must be available to start the plant
(see also section 5.6.1)
63 Check, if the required differential pressure Check plant for leakages
between adsorber A and oxygen buffer vessel is
reached during step 1
64 Check, if the required differential pressure Check plant for leakages
between adsorber B and oxygen buffer vessel is
reached during step 6
65 Check, if
- process air cooler is working properly - check cooling water flow, cooling water
temperature
- air is trapped inside cooling water system - vent air from the system or replace automatic
vent valves
- process air cooler is clogged/scaled - clean cooler elements
66 Check, if
- temperature controller TIC-1121 is adjusted - change settings
properly
- control valve TCV-1121 is working properly - refer to mfr. documentation
67 Check, if safety devices are adjusted properly Adjust safety valve, refer to mfr. documentation
68 Check, if
- lubrication system is working properly - refer to mfr. documentation
- oil level is sufficient - fill up oil
- pressure reducer for the oil pressure is adjusted - adjust settings, refer to mfr. documentation
properly
69 Check, if
- vibration sensors are working properly - refer to mfr. documentation
- vibration sensors are mounted properly - tighten up loose connections
- all bolts on the blower / in the piping system are - tighten up loose connections
tight
- fixing of the machine on the base frame / inside - tighten up loose connections
the container is tight
- couplings between motor and blower are aligned - refer to mfr. documentation
properly
Inititate spectrum analysis to investigate for
possible bearing damages
70 Check, if
- oil level is correct - refer to mfr. documentation
- oil level switch is working properly - refer to mfr. documentation
- vent openings on the blower or in the oil system - clean
are blocked
- leakages can be found on the blower or in the oil - tighten up leakages, refer to mfr. documentation
system

No.
71 Check, if
- short spikes can be found in the pressure curves - overlap between closing of air valves KV-2511 /
during changeover into bypass operation KV-2521 and opening of bypass valve KV-1105
is too short; increase overlap time
- valves are working properly - refer to mfr. documentation
- time interval for closing of bypass valve KV-1105 - increase maximum delay time for delay of
has been chosen big enough closing of bypass valve KV-1105
72 Calibration gas bottle is empty Order new calibration gas. Calibration of analyzer
will be blocked until new bottle is installed to
prevent faulty calibration
73 Check if
- temperature controller TIC8401 is adjusted - adjust settings, if reqired
properly
- control valve TCV8401 is working properly - refer to manufacturer manual
- cooling air fans at coolers E8483A-E are working - repair air cooling fans, if required (refer to
properly manufacturer manual)
- the proper air flow at coolers E8483A-E is - clean cooler, if required (refer to manufacturer
affected by dirt manual)
74 Pressure profile of the adsorption process is not
within the expected range, Check, if
- mechanical problems on certain butterfly valves - replace valve
may be present
- leakages on the adsorber unit can be found - tighten up loose connections
- time interval in steps 1/6, 3/8 (only for partial - adjust settings
load) and 4/9 of the step cycle have been chosen
big enough
- settings for delay of closing bypass valves on - adjust settings
feed air blower and vacuum pump have been
adjusted properly
- in case of purity fluctuations appearing as well: - adjust settings
time interval and transition condition in steps
2a/7a have been adjusted properly
- limiting factors for machinery performance can - check machinery according to mfr.
be found (clogged filters, increased clearances documentation
etc.)
Get in contact with LINDE for proper
optimization of the process
75 Check, if
- setpoint PSH-2511 for opening air valve - adjust setpoint
KV-2511 after pressure equalization is adjusted
correctly
- pressure transmitter PT-2511 is working - see code no. 2
properly
76 Check, if
- setpoint PSH-2521 for opening air valve - adjust setpoint
KV-2521 after pressure equalization is adjusted
correctly
- pressure transmitter PT-2521 is working - see code no. 2
properly
77 Check, if pressure transmitters PT-2511 / PT-2521 - see code no. 2
are working properly
78 Check, if
- oil level switch is adjusted properly - refer to mfr. documentation
- oil level switch is working properly - refer to mfr. documentation

No.
79 Shut down of VPSA due to high/low oxygen Sensor must be replaced as soon as possible, and
content in the ambient air was temporarily monitoring function must be enabled
disabled by an operator due to sensor failure or
maintenance
80 Check, if
- oil level is sufficient - fill up oil to the required level, refer to mfr.
documentation
- leakages in the oil system can be found - tighten up leakages
- main/auxiliary oil pump are working properly - refer to mfr. documentation / replace pump
81 Check, if
- bypass valve KV-1845 is working properly - refer to mfr. documentation
- setpoints for opening KV-1845 are adjusted - adjust setpoints
correctly
82 VPSA-Plant is temporarily operated without Activate analyzer as soon as possible, to provide
monitoring oxygen purity (e.g. due to technical sufficient oxygen purity
problems on the analyzer)
83 Automatic fire detection system has detected fire Call local fire department and check proper
in the plant; plant was switched off for safety function of fire detectors
reasons
84 Safety shutdown of the VPSA-Plant in case of fire In case of fire plant will not be stopped; activate
alarm has been temporarily disabled (e.g. for fire monitoring as soon as possible
maintenance)
85 Unusual process condition has required opening In case this alarm appears frequently, malfunction
of full load bypass valve KV-1845 in the step cycle of the plant (bad purity) may result due to
imbalance.
Check pressure profiles for irregularities and get in
contact with LINDE.
working properly
87 Spare
88 Technical problem at analyzer unit Refer to mfr. manual
89 Spare
90 General alarm UPS power supply Refer to mfr. manual
91 Low battery UPS power supply Charge / replace battery pack of UPS power
supply to ensure backup power for PLC in case of
power failure
92 Check no-return valve PV-1514 for proper function Replace non-return valve PV-1514
/ leakage from downstream system
93 Check, if gas side of coolers is blocked Clean cooler and evaluate source of clogging
94 Spare
95 Spare
96 Spare
97 Spare
98 Check, if
- setting of thermostats inside PLC cabinet is - adjust thermostat
correct
- electrical circuit for power supply and control of - repair electrical system
cabinet fans is OK
working properly
100 Check, if unit is operated outside of contractual Make sure, that blowers are operated only within
conditions (temperatures, pressures, speed) acceptable limits

No.
101 Possible bearing damage Check, if vibration levels are normal and consult
manufacturer.
Major damage is possible, if equipment is
operated under this condition!
102 Spare
103 Spare
104 Spare
105 Spare
106 Bypass valve was opened automatically due to Check valves KV-2511/21 or KV-2514/24 for
differential pressure of the machine. In this case, leakages.
the machine can be turn slowly. The start of the
unit is not possible to prevent damages during
start-up.
107 Start of plant is blocked with key switch HS-9315 Investigate, why key switch HS-9315 has been put
to ‘blocked’ position (e.g. due to ongoing activities
in the plant).
Plant must not be started as long as personnel is
still working at the plant.
DANGER FOR LIFE!
108 Spare
109 Spare
110 Electrical fault Check, if all MCBs are in position ‘I’

111 Failure of unit during soft start Starting time exceeds the maximum permissible
limit. Check the soft start unit in the electrical
cabinet for alarm messages.
NOTE: It is necessary to reset the alarms at the
electrical equipment before a restart is possible.
112 Failure of electrical switchgear. Check, if
- external power supply is available - re-establish power supply
- surge protectors are intact - replace surge protectors
- main circuit breaker is on - close main circuit breaker
- control voltage is available - turn on control voltage
- power dips (undervoltage) can be observed - provide stable power supply
(especially during start of large drives)
113 Failure of unit during start-up or operation Starting time exceeds the maximum permissible
(mechanical or electrical reasons) limit. Check entire unit for mechanical or electrical
reasons, which may cause increased starting time
(e.g. low voltage, increased friction etc)
NOTE: After start command, PLC expects to
receive a ‘RUN’ status signal from
switchgear within a certain time, thus
indicating successful start-up.
If this signal is not received, PLC
generates ‘Feedback-Error’ message
114 Bypassed permit, interlock or protection. Activated the bypassed signal as soon as possible
in the related device or unit.
Major damage is possible if equipment is
115 Check, if
- off spec mode is reached - check product purity, see code no. 27, 28, 51
- oxygen was disabled by operator - activate oxygen in the compressor view

No.
116 Maintenance time of the unit is exceeded. Maintenance is required. Refer to mfr.
documentation for detailed information.
NOTE: Time limit for next maintenance indication
can be set up in the limit view of the counter
faceplate. The run time and the alarm
message can be only reset during stopped
plant.
Major damage is possible, if maintenance is
not carried out in certain time.
117 Spare
118 Spare
119 Outdoor temperature is in critical range Check climate conditions and install further
cooling or heating system
120 There is too much vacuum in machine building.
Check, if
- ventilation system is working properly - start-up ventilation system
- openings in building walls are blocked - open doors and flaps in building wall or install
additional ventilation flaps to get more air inside
the building
Major damage is possible, if equipment is
121 Check if
- Condensate drain filled with water - release water out of condensate drain by
opening condensate drain valve manually
122 Check if
- Instrument air compressor is working properly - Restart instrument air compressor/air dryer
- Refer to manufacturer documentation
123 Instrument air system was manually switched off Switch on instrument air system
by operator If instrument air compressor is switched off,
instrument air will only be supplied from
instrument air buffer until it is empty.
124 Dew point of instrument air is not in specified - Check condition of supplied instrument air
range - Check if instrument air is in specified range
125 Spare
126 Spare
127 Spare
7.3 IMPORTANT OPERATIONS FOR TROUBLESHOOTING
7.3.1 TROUBLESHOOTING FOR PURITY ALARM
One of the most frequent problems in a VPSA-plant is purity alarm, since most
mechanical problems will start with an imbalance of the VPSA-process and therefore
causing irregularities of purity or a decrease of average purity before they become
obvious as a mechanical problem.
Good performance of a two bed VPSA will always go hand in hand with a balanced
pressure profile on both adsorber vessels. Irregularities in the maximum or minimum
pressure will always result in a situation that one of the adsorbers will produce more
oxygen than the other one. Therefore, the adsorbent layer of one adsorber will get
overloaded with nitrogen whereas the other adsorbent layer will not use its capacity
adequately.
In general, the PLC software is programmed in a way to balance both adsorbers

automatically. However, it is advisable to check the settings regularly by comparing the
pressure curves of both adsorbers and other values.
To review the pressures of both adsorbers proceed as follows:

1. In the Overview Area select the process unit picture “Adsorber”
2. In the “Adsorber” picture select the button to open the picture

“Adsorber Unit - Pressure Profile”.
3. Select the button in the upper left corner to open the picture
“Step Values” to review the valued pressure profile of the adsorber unit
The following table will be displayed:
Figure 7-4: Minimum / maximum pressures and pressures at the end of each step
Values will be continuously updated and refreshed after each complete cycle.
Following points should be reviewed (see also Figure 7-5):

1. compare pressures at the end of corresponding steps of both adsorbers
example:
adsorber A at the end of step 1 against adsorber B at the end of step 6
adsorber A at the end of step 2a against adsorber B at the end of step 7a
and so on
2. compare step time of corresponding steps
example:
time of step 1 against time of step 6
time of step 2a against time of step 7a
and so on
3. compare maximum and minimum pressures of both adsorbers
2 3
1
Figure 7-5: Reviewing pressure profiles
Please note that due to the response time of the PLC pressures and times will never
be perfectly equal, but pressures should always be in the range of ± 500 Pa (=5 mbar),
times in the range of ± 0.2 seconds.
Some additional information about the performance of the plant can be found in looking
at the delay times of the bypass valves KV-1105 and KV-1835/KV-1845.
The PLC automatically calculates a delay time for closing of the bypass valves to reach
the required maximum and minimum pressures in both adsorbers.
To review those values, proceed as follows:

1. In the Overview Area select the process unit picture of feed air blower
or vacuum pump .
2. Select the button in the process unit picture to review the

settings for the automatic delay of the bypass valves
Depending on which type of machine was chosen, either one of the following pictures
will be displayed:
Figure 7-6: Delay function of bypass valve feed air blower (top) and vacuum pump (bottom)
The upper section shows the actual pressures and delay times individually for each
adsorber. Delay times of feed air blower and vacuum pump may be different, but on
each unit the delay time of each adsorber should be roughly equal.
A severe imbalance would be indicated by a significant difference in the pressure limits

reached in connection with a delay time of several seconds on one adsorber, and no
delay on the corresponding adsorber.
Please note, that delay times will always be varying with seasonal changes.
Having collected all the above-mentioned information, the operator will get an
indication on what to check to find out the reason for poor performance of his plant.
Differences in the pressure profiles may indicate valve problems on the adsorber unit
(e.g. corresponding valves switching with different speed), changes in the adsorption
or desorption pressure may indicate mechanical problems with machinery (leakages,
problems with bypass valves) a.s.o.
Further information can be collected looking at the maximum and minimum

concentration of oxygen during each cycle. The PLC registers the maximum and
minimum purity in each cycle of production (see Figure 7-4). The oxygen buffer vessel
usually equalizes purity fluctuations coming from the process almost completely. For
this reason, the sample point of oxygen can be swapped to measure oxygen
concentration upstream of the buffer vessel (refer to chapter 8.2.5) to get a better
impression of which adsorber is producing better quality.
Consideration must be given to the response time of the oxygen analyzer. The
response time is based on the measuring principle of the analyzer but is also influenced
by the length of the sample tubing to the analyzer. Therefore, the response time will
be different, depending if the sample is taken upstream or downstream of the buffer
vessel.
Response time may be up to 30 seconds and must be evaluated individually for each
installation.
The maximum and minimum peaks of the oxygen concentration should (same as the
pressures) be almost equal for both adsorbers.
If further investigation is required to determine the source of bad quality product the
response time of the analyzer installation must be taken into consideration, since a
negative peak on the analyzer does usually not mean that it is caused by the adsorber
which is currently in production.
7.3.2 REPLACING BUTTERFLY VALVES
Since a shutdown will usually happen at any point during the step cycle, some parts of
the plant will be under pressure while other parts will be under vacuum.
If opening of the process system is required (e.g. for replacing butterfly valves), a
manual pressure equalization or de-pressurization of the VPSA-plant has to be made.
Proceed as follows:
1. Wait until the plant has stopped and all valves are closed
Wait until all bypass valves of machines have been closed
by the PLC as well!
(approx. 2 minutes after stop of plant)
2. Initiate a manual pressure equalization / de-pressurization

(refer to chapter 7.3.3 and 7.3.4)
3. Close the instrument air supply and release the pressure
4. Replace valves and tighten all flange connection carefully considering the
required torque
Make sure that all flanges are tightened properly after
maintenance!
Leakage will affect the performance and the safety of the
VPSA-Unit!
For assembly and disassembly of valves the rules and
instructions of the manufacturer must be followed.
If a valve cannot be replaced right away, open pipelines must be closed with caps or
blind flanges, otherwise moist ambient air and dirt may affect the adsorbent filling,
machinery and piping.
During any kind of work inside the piping system or on valves

absolute cleanliness is mandatory!
Loose parts, forgotten tools or particles may cause severe
damage up to total loss of assets!
Oil, grease or parts polluted with oil and grease inside the
piping can cause heavy combustion in connection with
oxygen!
Humidity inside the piping system can irreversibly damage the
adsorbent filling!
Following assembly, the correct function of the step sequence should be tested (refer
to chapter 5.6 ‘Operating the plant in ‘HAND’ mode’).
Right after restart a leakage test must be performed (refer to chapter 7.3.5).
7.3.3 MANUAL PRESSURE EQUALIZATION
Since a shutdown will usually happen at any point during the step cycle, some parts of
the plant will be under pressure while other parts will be under vacuum.
Under certain circumstances it may be necessary, to build up pressure, e.g. in case a

valve needs to be replaced, in order to disassemble parts without danger.
In case manual pressure-equalization must be made, the pressure should be

preferably taken from the oxygen side, to make sure that the adsorbent filling is not
loaded with moist ambient air more than required.
Therefore, the remaining volume of oxygen inside the buffer vessel and inside the
pressurized adsorber should be taken preferably for re-pressurizing the adsorber
which is under vacuum.
To initiate manual pressure build-up please proceed as follows:

1. Go to the “Plant Management”-Menu in the main picture of the Operating
the button
2. Switch between Hand-/Auto-Operation of valves by selecting the button

for a manual operation of valves
3. Change to the faceplate for manual operation of valve KV-2505.
4. Open the valve to an extent of 50% (select “Manipulated var.” to extend the
faceplate, select the blank input box , enter ‘50’ and confirm
execution of this command with OK)
KV2512 KV2522
KV2505
O2
A2526A A2526B D2532
KV2511 KV2514 KV2521 KV2514
KV 1105
Atm.
residual gas
C1161
Figure 7-7: manual pressure equalization between both adsorbers
Valve KV-2505 will be opened now and the pressure between both adsorbers will be
equalized. Close the valve as soon as the pressures are equal. Enter “0” under section
“Manipulated var.” and confirm with “Enter”.
If the pressure inside adsorbers is still below atmospheric pressure, the vessels have
to be pressurized with oxygen from the buffer vessel by opening of product valves
KV-2512 and KV-2522.
Proceed as follows:
1. Check, which adsorber is in vacuum
2. In case adsorber A-2526A is under vacuum valve KV-2512 must be opened,
in case adsorber A-2526B is under vacuum, open valve KV-2522.
3. Open the product valve by pressing “Open” in the extension of the faceplate
4. Close the valve using the “Close” button as soon as the adsorber has
reached atmospheric pressure (watch the pressure indication on the panel)
5. Repeat this procedure for the second other adsorber, if required.
KV2512 KV2522
KV2505
O2
A2526A A2526B D2532
KV2511 KV2514 KV2521 KV2524
KV 1105
Atm.
residual gas
C1161
Figure 7-8: manual pressure build-up from buffer
If the volume contained inside the oxygen buffer vessel is not sufficient to build up
pressure inside the adsorber, the PLC will automatically close the product valve to
avoid low pressure in the buffer vessel (vacuum protection).
In case one adsorber is still in vacuum, ambient air must be used for the remaining
pressure build-up. For this purpose, bypass valve KV-1105 of the feed air blower and
air valves KV-2511/ KV-2521 must be switched.
Moist ambient air may only be used for pressure build-up, if no more oxygen is
available in the system.
In case moist ambient air is used, it must only be fed to the adsorber using the air/waste
gas side of the adsorber, never through the oxygen side.
Proceed as follows:
1. Enter the menu for valve KV-1105
2. Open the valve (press “Open” in the extension of the faceplate)
3. Check, which adsorber is under vacuum
4. In case adsorber A-2526A is under vacuum, valve KV-2511 must be
opened, in case adsorber A-2526B is under vacuum, open valve KV-2521
5. Open the air valve by pressing “Open” in the extension of the faceplate
6. Close the valve using the “Close” button as soon as the adsorber has
reached atmospheric pressure (watch the pressure indication on the panel)
7. Repeat this procedure for the second adsorber, if required
KV2512 KV2522
KV2505
O2
A2526A A2526B D2532
KV2511 KV2514 KV2521 KV2524
KV 1105
Atm.
residual gas
C1161
Figure 7-9: manual pressure build-up through air
Opening of air valves KV-2511 and KV-2521 is only possible, if the differential pressure
over the valve is lower than a certain limit (i.e. if the adsorber is not too deep under
vacuum).
Otherwise, the molecular sieve might be damaged, since the flow velocities of the gas
passing through such big size valves will be too high.
If one of the adsorbers is too deep under vacuum and opening of the air valve is not
permitted by the PLC, ambient air has to be taken through the first adsorber to reach
the second adsorber from the oxygen side.
The amount of gas taken into the evacuated adsorber can be limited using the
positioner of valve KV-2505.
Due to the smaller size of valve KV-2505, there is also no restriction with regard to
pressure to open the valve.
Proceed as follows:
2. Open the valve (press “Open” in the extension of the faceplate)
3. Open the air valve of the adsorber, which is currently not under vacuum
5. Open valve KV-2505 to an extent of 50% (select “Manipulated var.” to
extend the faceplate, select the blank input box , enter ‘50’ and
confirm execution of this command with OK)
Ambient air is now taken into the evacuated adsorber, passing the air valve and the
adsorbent layer of the corresponding adsorber. This way the air will be dried before it
enters the adsorber from the oxygen side.
As the pressure rises in the evacuated adsorber, the pressure equalization valve
KV-2505 may be opened completely to speed up the process.
Wait until the pressure build-up has finished and close all valves.
KV2512 KV2522
KV2505
O2
A2526A A2526B D2532
KV2511 KV2514 KV2521 KV2524
KV 1105
Atm.
residual gas
C1161
Figure 7-10: manual pressure build-up through the corresponding adsorber
In very rare occasions it may happen after a malfunction or a faulty manual operation,
that
a) both adsorbers are under full vacuum
b) the available amount of oxygen in the buffer vessel is not sufficient for
pressure build-up and
c) opening of the air valves is not permitted
In such exceptional cases manual valves can be used for building up pressure in
emergency situations.
1. Remove blind flanges on both manual valves HV-2510 and HV-2520
2. Open the manual valves slowly
Due to the small cross section, pressure can be raised up to the point, when the
opening of the air valves is enabled by the PLC. Now the pressure build-up can be
completed using one of the above-mentioned methods.
Close the valves again and cover the openings assembling the blind flanges so that
intentional opening during operation may not cause moist air to enter the adsorber
vessel.
KV2512 KV2522
KV2505
O2
A2526A A2526B D2532
HV2510 HV2520
KV2511 KV2514 KV2521 KV2524
KV 1105
Atm.
residual gas
C1161
Figure 7-11: manual pressure build-up using valves HV2510/HV2520
7.3.4 MANUAL DEPRESSURIZATION
In case vessels must be opened, valves must be replaced, or pipe spools must be
removed, the whole system has to be de-pressurized first, venting all the gas through
the buffer vessel and the oxygen blow-off silencer to atmosphere.
It is strictly forbidden to simply release the gas into the machinery hall or other confined
spaces. Extreme risk of fire due to the high content of oxygen!
To de-pressurize the system proceed as follows:

1. Go to the “Start/Stop/Hand”-Menu in the main picture of the Operating
the button
3. Change into the picture for manual operation of valve PCV-1545 and open
the valve completely
4. Change into the picture for manual operation of the blow-off valve
PCV-1513 and open it to an extent of 50%
5. Now change into the picture manual operation of valve XV-1530 and open
the valve
All the gas inside the oxygen buffer is now released to atmosphere through the bypass
piping of the oxygen compressor and the oxygen blow-off silencer. When all the gas
inside the buffer has been released, the gas from the adsorber vessel has to be
released as well through the buffer into atmosphere.
1. Change into the picture for manual operation of oxygen valve KV-2512
2. Open the valve by pressing the “Open” button
3. Repeat the last two steps for oxygen product valve KV-2522
The remaining pressure inside the system is now released into atmosphere.
Atm.
KV2521 KV2522
KV2505
PCV1545
PV1513
XV1530
O2
A2526A A2526B D2532

C1561
KV2511 KV2514 KV2521 KV2524
Air Residual gas
Figure 7-12: manual de-pressurization through buffer vessel and bypass of the O2-compressor
7.3.5 LEAKAGE TEST OF VALVES AND PIPING
Tightness of valves and piping is extremely important in order to ensure the

performance of the VPSA. In case of leakage in piping, especially if leakage occurs on
the oxygen side, small amounts of atmospheric air will get into the adsorber during
each cycle of evacuation. The moisture contained in atmospheric air can irreversibly
damage the performance of the VPSA.
Therefore, it is required to check tightness of valves and piping, especially if valves or

piping have been disassembled.
To check tightness, proceed as follows:

1. Start up the VPSA-plant. Push the emergency-off button after 3 to 5 cycles,
when the pressure inside adsorber A has reached its highest level.
2. Wet all flange connections using foam-frothing agent. Do not forget to check
manhole flanges, instrument tubing and shafts of all valves (manual or
automatic).
3. In case bubbles will be visible, tighten up the connections.
Leakages to atmosphere are not acceptable!
4. When all connections are closed tight, observe the pressure inside the
vessel. The pressure inside the vessel should not drop more than 2,5 kPa
per 30 minutes. If higher pressure loss is observed, try to locate the point of
leakage by listening on different points on the pipes where gas might be
leaking through the butterfly valves.
5. Start up the VPSA-plant again and repeat procedure for adsorber B.
Another option for locating leakages is to mask all flange connections using adhesive
tape. In case of leakage the tape will inflate (during phases of overpressure inside of
pipe) or deflate (during phases of vacuum inside the pipe).
This way a leakage test can be made without stopping the plant. Using this method,
only leakages to the outside can be found, but not leakages through the butterfly
valves.
7.3.6 CHECKING LIMIT SWITCHES
All open/close valves in the VPSA are equipped with limit switches which will indicate
the valve position and provide a possibility to measure the switching time (see chapter
9.4).
Proximity sensors (limit switches), actuating elements and the connecting shaft are
completely prefabricated and wired in a black plastic housing (limit switch box). The
limit switch box is connected through a NAMUR-bridge to the shaft of each actuator.
There are two proximity switches for each valve: one indicating the CLOSED-position,
the other one indicating the OPEN-position.
The position of the valve will be transferred over the connecting shaft to the actuating
element. The actuating element will either cause a signal from the OPEN- or from the
CLOSE-sensor to the PLC, depending on the position of the valve.
To verify proper function, proceed as follows:

1. Close the valve. The actuating element should now be close to the sensor
for CLOSED-position without touching it. The yellow LED on the proximity
switch for CLOSED-position should be lit.
2. Check the connection to the PLC. The corresponding LED on the front side
of the digital input module of the PLC should be lit, as long as the actuating
element is close to the proximity sensor. Make sure there is no excessive
wear or tolerance in moving elements or sensor position to have a stable
feedback signal. For the correct input address of the CLOSED-sensor refer
to the I/O-list or the wiring diagrams.
3. Open the valve. The actuating element should now be close to the sensor
for OPEN-position without touching it. The yellow LED on the proximity
switch for OPEN-position should be lit.
4. Check the connection to the PLC. The corresponding LED on the front side
of the binary input module of the PLC should be lit, as long as the actuating
element is close to the proximity sensor. Make sure there is no excessive
wear or tolerance in moving elements or sensor position to have a stable
feedback signal. For the correct input address of the OPEN-sensor refer to
the I/O-list or the wiring diagrams.
Make sure that all screws at the limit switch box as well as its connection to the actuator
are tightly fastened.
Whenever replacing a limit switch box, make sure, that the position of the actuating
element is properly adjusted and its angular adjustment corresponds to the adjustment
of all other sensors, otherwise problems in timing of valves might be the consequence.
7.3.7 CHECKING VALVE POSITIONERS
Following valves are assembled with a positioner:

- TCV-1121 Control valve for air temperature (feed air blower unit)
- PCV-1513 Blow-off valves O2-compression
- PCV-1545 Overall bypass valves oxygen compressor
- KV-2505 Pressure equalization valve (adsorber unit)
- TCV-8401 Cooler bypass valve (cooling water pump skid)
To check the correct adjustment of the valve positioners, proceed as follows:

1. Switch off the VPSA-plant and wait until the plant has stopped and all valves
are closed. Wait until the PLC has also closed the bypass valves of
machinery (approximately 1-2 minutes after machinery has been stopped).
2. Change into the start/stop menu of the visualization system
3. Go to the “Plant Management”-Menu in the main picture of the Operating
the button
5. Change into the picture for manual operation of the valve to be checked
6. Open the valve completely (enter “100” and confirm with OK)
7. Check the position of the valve. The valve must be fully open now. The
feedback signal must be at 100%
8. Open the valve to an extent of 50% (enter “50” and confirm with OK)
9. Check the position of the valve. The valve must be half open now. The
feedback signal must be at 50%
10. Close the valve completely (enter “0” and confirm with OK)
11. Check the position of the valve. The valve must be closed now. The
feedback signal must be at zero
12. If necessary, adjust zero and span or initiate an automatic calibration
sequence (refer to manufacturer manual)
Positioner of valve KV-2505 must only be checked or

calibrated, when both adsorbers are under atmospheric
pressure.
Danger of fluidization of the adsorbent layer (bedlifting)!
IMPORTANT: Remark on valve KV-2505:

Pressure equalization valve KV-2505 is equipped with a
mechanical stroke limitation, which restricts the maximum
opening of the valve.
This stroke limitation is intended to prevent a full opening of the
valve at maximum differential pressure, as such action might
cause fluidization of the adsorbent layer (bedlifting).
For calibration of the positioner, the mechanical stroke limitation
must be temporarily removed.
Before unfastening of the stroke limitation and calibrating the positioner, the
adjustment of the stroke limitation must be recorded, e.g. by measuring the distance L
between the shaft of the stroke limiter and the cover of the actuator (refer to Figure
7-13).
Caution:
Do not open the lock screw (288) while
the actuator is pressurized!
Numbering of locking parts:
283 Hexagon lock nut

284 Hexagon socket screw
287 Cap cover
288 Hexagon lock screw
289 Pin fastener (pin & wire)
Figure 7-13: Adjustment L of the stroke limitation
Before starting the automatic calibration sequence, disconnect the instrument air
supply to the valve. Then remove the cap cover (287), open the lock nut (283) of the
hexagon lock screw (288) and turn the hexagon lock screw completely back to allow a
full opening of the butterfly valve during calibration.
Once the automatic calibration sequence is completed and the valve has been closed,
the hexagon lock screw (288) must be re-adjusted according to the distance L that was
previously measured. Following the adjustment, the lock nut (283) must be re-
tightened properly to prevent unintentional shifting during operation. After that install
the cap cover and open slowly the instrument air supply to the valve.
7.3.8 TROUBLESHOOTING OF VALVES
The plant performance can be affected by the wear of valves. The status for
maintenance can be measured with the switchwing time and switching cycles. The
switching behavior of every open/close valve can be displayed in the extended valve
maintenance view in the “Plant Management” menu of the main window.
The valve maintenenace view can be divided into two main areas:
The left / right part is referred to as “Overview Area” and the middle part is referred to
as “Detail Area”. The overview area displays all binary and analog valves of the VPSA
plant. The detail area displays information about the switching behavior of the
corresponding valves. Due to the second detail area valves can be easily compared.

Troubleshooting of open/close valves
The picture shows the detail maintenance view of an open/close valve.
T1
T2
T3
T4
The BLUE AREA shows the current values of switching time. The area is divided into
sections and shows the following values:
• Opening time delay (T1) • Closing time delay (T3)

• Opening switch time (T2) • Closing switch time (T4)
• Total opening time • Total closing time
For detailed information of these values, refer to chapter 9.4.
The RED AREA provides information about the extreme values of switching time. It is
possible to set up limit values for each switching time. If a limit is violated, the related
extreme value is displayed in red/white color. Extreme values can be reset with the
button “Reset extreme values”. The displayed alarm message can be reset with the
“Error Reset VPSA” on the main window.
The GREEN AREA provides information about filtered switching time with low pass
filter. If the filter constant in the BLACK AREA is set to ‘0’, there is no low pass filtering.
A constant ‘1 … x’ describes the number of valve cycles to reach the current value. It
is possible to set up limit values for each filtered switching time. If a limit is violated,
the related filtered value is displayed in red/white color. The displayed alarm message
can be reset with the “Error Reset VPSA” on the main window.
Alarms for exceeded switching times can be disabled in the ORANGE AREA. Linde
recommends to enable alarm for the total opening and total closing time. These values
should be always less than the maximum switching time refer to the attached Alarm
List (&AK J-LA 2001) in chapter 1.
The PURPLE AREA provides information about the number of switching cycles. It is
possible to set up a limit value for the maximum number of switching cycles. If the limit
is violated, the number of switching cycles is displayed in red/white color. The number
can be reset with the button “Reset counter”. The displayed alarm message can be
reset with “Error Reset VPSA” on the main window.
The manufacturer gives information about the maximum number of switching cycles to
perform a predictive maintenance of the related valve.
The total swichting times are stored in the archive of the PCS 7 system and can be
displayed within the GREEN AREA.
The maintenance alarm setpoints should be always less than

the maximum allowed limit.
Troubleshooting of analog valves
The picture shows the detail maintenance view of an analog valve.
The BLUE AREA shows the current deviation time of the valve after a change of the
valve setpoint.
The RED AREA provides information about the extreme values of deviation time. It is
possible to set up a limit for the extreme deviation time. If the limit is violated, the
extreme value is displayed in red/white color. The extreme value can be reset with the
button “Reset values”. The displayed alarm message can be reset with the “Error Reset
VPSA” on the main window.
Alarm for exceeded deviation time can be disabled in the ORANGE AREA. Linde
recommends to enable the alarm. This value should be always less than the maximum
deviation time refer to the attached Alarm List (&AK J-LA 2001) in chapter 1.
The PURPLE AREA provides information about the total moved path of the valve. It is
possible to set up a limit value for the total moved path. If the limit is violated, the total
moved path is displayed in red/white color. The number can be reset with the button
“Reset counter”. The displayed alarm message can be reset with “Error Reset VPSA”
on the main window.
The moved path is stored in the archive of the PCS 7 system and can be displayed
within the GREEN AREA.
The maintenance alarm setpoints should be always less than

the maximum allowed limit.
7.3.9 CHECKING PRESSURE TRANSMITTERS
Since many actions inside the process are controlled by pressure, it is important that
all transmitters are working properly. For this reason transmitter readings should be
verified annually.
Verification of transmitters can only be done, when the plant is stopped.
A manual pump with calibrated gauges is required for checking pressure transmitters.
Apply a certain pressure to the transmitter and compare the reading of the calibrated
pressure gauge with the reading on the visualization system.
For calibrating the transmitter, please follow the instruction of the manufacturer.
High accuracy calibration devices are often not available on site. Therefore, it is
recommended to keep one transmitter for each measuring range on stock. In case of
problems, the damaged transmitter can be replaced, and the faulty one can be sent for
recalibration.
7.3.10 CHANGING PLC BACKUP BATTERY
For permanent storage of settings and parameters in the internal memory of the PLC
(RAM), it is required to replace the backup battery regularly.
In case the electric power supply fails when the backup batteries are empty, the
program in the internal memory (RAM) will get lost and on return of power the CPU will
load the program from the internal flash memory. All settings, limits, counters etc.,
which have been changed after the flash memory was written, will be overwritten.
Therefore, it is recommended to keep a written record of all set points that have been
changed after commissioning of the plant. Counters for operating hours or oxygen
amount should be recorded as well.
The PLC will automatically display an error message in case the backup batteries are
low and need to be changed. The power supply to the CPU must not be switched off,
when the batteries are changed.
For change of battery proceed as follows:

1. Remove the cover from the battery compartment on the power supply
module. The module can be found on the left side of the CPU.
2. Pull out the batteries from the compartment using the plastic ties
(see Figure 7-14)
Figure 7-14: Removal of batteries from battery compartment

3. Insert new batteries into the battery compartment of the power supply
module. Verify correct polarity.
4. Check the position of the BATT INDIC-switch.
one battery is used: -> ‘1BATT’
two batteries are used: -> ‘2BATT’
5. Push the FMR-button to reset failure messages
6. Reinstall the cover of the battery compartment
The PLC system uses lithium batteries (lithium/ thionylclorid). This type of battery can
develop a passive layer in case of extended storage. This may cause an error message
after inserting new batteries when switching on the power supply module.
The power supply module has the ability to remove the passive layer by applying a
defined load to the battery.
This procedure may take a few minutes. As soon as the passive layer is removed, and
the battery has reached its nominal voltage, the error message can be acknowledged
using the FMR button.
Since the storage time is usually unknown, we recommend using following procedure:
1. Insert the batteries into the battery compartment
2. A possible battery error should be acknowledged using the FMR-button
3. If the battery error can not be acknowledged, try again after a few minutes
4. If it is still not possible to acknowledge the battery error, remove the batteries
and make a short circuit for 1 to max. 3 seconds.
5. Insert the batteries and try again to acknowledge with button FMR
6. In case the battery error is gone, the batteries are okay now
7. In case the battery error cannot be acknowledged, the batteries are empty
7.3.11 REPLACING THE POWER SUPPLY MODULE
In case power supply module needs to be replaced, proceed as follows:

1. Switch off the power supply to the module which needs to be replaced
2. Set the standby switch of the power supply module to (0V output voltage)
3. Set the line disconnector to OFF
4. Remove the cover:
5. Remove the backup battery/batteries (if applicable)

6. Disconnect the power supply connector from the power supply module:
7. Loosen the mounting screws of the module:
Anzugsmoment
0,8 bis 1,1 Nm
8. Swing out the module and unhook it:

(2)
(1)
To install a new power supply module, please proceed as follows:

9. Make sure, that the voltage selector switch on the new power supply module
is in the correct position
10. Attach the new module of the same type and swing it downwards
11. Fasten the mounting screws
12. Check that the power supply to the module is switched off and the standby
switch on the module is set to
13. Plug in the power supply connector at the power supply module.
14. Insert the backup battery/batteries (if applicable) and close the cover
15. Turn on the power supply to the module
16. Set the standby switch of the power supply module to “I”
INFORMATION: The CPU should start up now, load the software program.
This process may take 10-20 minutes.
Please note that all settings that are changed during after the
internal flash memory was written must be changed again.
7.3.12 REPLACING CPU / COMMUNICATION MODULES
In case CPU or communication modules need to be replaced, proceed as follows:

1. Set the standby switch of the power supply module to (0V output voltage)
2. Remove the cover of the CPU / communication module
3. Disconnect the network cable (Profibus DP/Modbus/Ethernet)
4. Loosen the mounting screws of the module
5. Swing out the module and unhook it
To install a new CPU / communication module, please proceed as follows:

6. Attach the new module of the same type and swing it downwards
7. Fasten the mounting screws
8. Re-connect all network cables (Profibus DP/Modbus/Ethernet)
9. Set the standby switch of the power supply module to “I”
10. Set the CPU mode switch to RUN
11. Close the cover
INFORMATION: There is no program in the CPU. It requires a new download of

the software. For the change of CPU Linde will give you
assistant and can send you a new CPU with the latest issue of
the PLC program.
7.3.13 CHANGING I/O MODULES
For changing of input or output modules proceed as follows:

1. Stop the VPSA-Plant
2. Set the standby switches on both power supply modules to (0V output
voltage)
3. Switch off the load voltage to the relevant input / output module
4. Open the front cover of the relevant input / output module

5. Remove the fixing screw from the middle of the front connector
6. Pull the front connector out, holding it at the grips
7. Unfasten the module fixing screws

8. Swing out the module and unhook it
To install a new input or output modules, please proceed as follows:

9. Attach the new module of the same type on the rack and swing it downwards
10. Tighten the mounting screws to fix the module on the mounting rack
11. Re-insert the front connector and fasten it by tightening the fixing screw
12. Close the front cover
13. Set the standby switch of both power supply modules back to “I”
INFORMATION: The PLC should start up in RUN mode.

This process may take 10-20 minutes.
NOTE: Use only identical module types for replacement. Always plug
new modules in same place as the old ones.
Analogue and digital modules have different coloured coding
keys at the front connector. Make sure that the correct coding
key is placed.
Before plugging analogue input modules, make sure that

configuration for measuring ranges matches to the old values.
7.3.14 CONFIGURING ANALOGUE INPUT MODULES IN THE PLC
Analogue input modules in the PLC must be configured before mounting. The
measuring range is determined by modules, which are plugged into one side of the
card. These modules can be plugged in four different positions for different
instruments. Make sure that the configuration of the measuring range modules is
transferred correctly to the new input module.
Figure 7-15: levering a measuring range module out of an analogue input module
In case configuration is incorrect, the analogue input module
can be destroyed.
The assignment for different types of measurement and
measuring range can be found in the description of the
corresponding analogue module.
The assignment for different types of measurement and
measuring range is also printed on each analogue module.
7.4 COMMUNICATION WITH LINDE
Detailed information is required for LINDE to be able to provide proper assistance and
support in case of troubleshooting.
The following information is necessary:

- Information about the plant (LINDE project number and job code)
- Detailed description of the problem and its impact on the VPSA-process
- Records of the daily log book with readings of the pressure cycle of the
adsorber vessels, the oxygen buffer vessel, flow, purity, pressure and
temperature of the process air
- Records of the maintenance log book
- List of alarm messages, if any
- Name, function/position of the person in charge along with telephone/fax
number and e-mail address in case further information is needed for evaluating
the problem
7.5 SERVICE AND REPAIR ASSISTANCE
LINDE offers to send out specialists for support / supervision of maintenance and repair
on VPSA-plants based on a service-agreement.
For detailed information please contact:
LINDE GmbH
Linde Engineering
Dept. ADPA
Dr.-Carl-von-Linde-Str. 6-14
82049 Pullach near Munich
Germany
Tel. No.: +49-89-7445-0

e-Mail: aftersales.psa.airgases@procorr.linde.com
spareparts-psa@procorr.linde.com
Always contact LINDE before returning equipment for service or repair. Information will
be given, which will help LINDE to provide a more effective service. If mechanical
warranty has expired, a purchase order will be required for initiating service and/or
repair.
In case equipment is returned to LINDE, following form must be filled describing the
problem. Without the information contained in this sheet, an effective response is not
possible.
REQUEST FOR INSPECTION / REPAIR
CLIENT: ____________________ UNIT: ___________________________________
ORIGINAL PURCHASE ORDER NO.: ______________________________________
LINDE JOB NO.: _______________________________________________________
NAME: ______________________ TEL. NO.: ________________________________
DATE: _______________________________________________________________
ITEM: ________________________________________________________________
TAG NO.: _____________________________________________________________
FAULT DESCRIPTION:__________________________________________________
__________________________________________________
__________________________________________________
__________________________________________________
__________________________________________________
__________________________________________________
__________________________________________________
__________________________________________________
__________________________________________________
__________________________________________________
__________________________________________________
__________________________________________________
__________________________________________________
__________________________________________________
for Section: 1
Control visits and Doc. no.: &AK P-MC 2008 (EN)
maintenance Proj. no.: 2210 CCP8
8 CONTROL VISITS AND MAINTENANCE

8.1 GENERAL
It is recommended to keep:
a) a daily operation logbook and
b) a maintenance logbook.
All important measurements, alarms, events and works on the plant should be
recorded in those two logbooks.
It is recommended to have a control visit in each shift. During this control visit, a record
of
- temperatures
- pressures
- product flow
- analyses (oxygen purity)
shall be made. Due to the cyclic nature of the VPSA-process it is recommended to
record minimum as well as maximum values in the logbook. In case the plant is
provided with a SCADA system, data can also be taken from the SCADA.
During his check visit the operator shall watch out for correct oil level of the machinery,
leakage of oil or other fluids, unusual noises, burnt paint etc.
The plant site has to be kept clean at any time. Litter, combustible materials, oil and
grease must be removed immediately from the plant. The safety instructions of chapter
1 “Safety instructions” must be strictly followed.
Local laws and regulations must be followed additionally.
8.2 CONTROL VISITS
For the operation of machinery, the manuals of each manufacturer must be followed.
Subsequently only the most significant information is given.
8.2.1 FEED AIR BLOWER / VACUUM PUMP
The following values must be recorded daily:

- Suction temperature AB / VP
- Suction pressure AB / VP
- Discharge temperature AB / VP
- Discharge pressure AB / VP (alternatively: differential pressure)
- Temperatures of motor windings
- Bearing temperatures for motor and blower
- Power consumption motor
- Vibrations AB / VP
- Differential pressure suction strainer VP
During his daily control visits, the operator should check and record following values:
- Pressure drop of the suction filter AB
- Oil level AB / VP
- Oil pressure AB / VP
- Operating hours AB / VP
Pay attention for all unusual incidents like discoloration of paint, strange noises,
vibrations, unusual odours, oil-leakages a.s.o.
All records should be evaluated regularly and compared with previous records to detect
possible problems in time. Pay attention to both, sudden changes and long-term trends
that may indicate an upcoming problem.
Forward your observations to LINDE and/or the manufacturer of machinery.
Bearing vibrations should be recorded on a regular basis and archived. If abnormal

trends are detected, a frequency analysis of the vibrations should be performed
immediately.
8.2.2 OXYGEN COMPRESSOR
The following values have to be recorded during operation:

- Differential pressure suction filter
- Suction temperature
- Suction pressure
- Discharge temperature after each compression stage / after each cooler
- Discharge pressure after each compression stage / after each cooler
- Oil pressure
- Temperatures of motor windings
- Temperatures of motor bearings
- Power consumption motor
- Vibration compressor
During his daily control visits, the operator should check and record following values:
- Oil level
- Cooling water temperatures
- Operating hours
Pay attention for all unusual incidents like discoloration of paint, strange noises,
vibrations, unusual odours, oil-leakages a.s.o.
All records should be evaluated regularly and compared with previous records to detect
possible problems in time. Pay attention to both, sudden changes and long-term trends
that may indicate an upcoming problem.
Forward your observations to LINDE and/or the manufacturer of machinery.
Bearing vibrations should be recorded on a regular basis and archived. If abnormal

trends are detected, a frequency analysis of the vibrations should be performed
immediately.
8.2.3 ADSORBER STATION
The following parameters of the adsorber station are to be recorded in the logbook:
- Maximum and minimum pressure of both adsorbers
- Maximum and minimum pressure of the buffer vessel
- Product purity
- Product flow
Most likely malfunctions of the VPSA-Unit are connected with a decrease of the product
purity. Some possible reasons may be:
- Exceeding of the maximum allowable product flow
- Unequal pressure profile between both adsorbers
(adsorption- or desorption pressures not reached, pressure profile not equal
etc.)
- Process air temperature too high / too low
- Valve failures like leakages, poor accuracy on control valves, extended open or
close times, wrong overlap times etc.
- Damage of the molecular sieves caused by humidity
Following items should be checked when doing a regular evaluation of records:

- equal pressure profiles of both adsorbers
- equal adsorption- and desorption pressures at both adsorbers
- Identical times for opening and closing on all valves of the same size
8.2.4 BUTTERFLY VALVES
Along with machinery the butterfly valves are those components on the VPSA-Unit
enduring most of the stress.
Within the daily control visits the following values should be checked:
- Unusual noises during switching
- Extended time for opening or closing or jerky operation
- For control valves: poor accuracy in moving to the desired position
Leakages may occur on the process side (internally over the disc sealing element and
also externally through the shaft seals) as well as inside of the valve actuator.
Leakages on the process side may result in reduced plant performance and may also
create a potential safety hazard (e.g. if leakage occurs on oxygen valves at the shaft
seals). Leakages inside of the valve actuator can reduce accuracy in moving to the
required position (for control valves) and/or increased instrument air consumption (for
control and binary valves).
Since leakages can hardly be heard during operation, due to the short cycle times and
the high noise level inside the plant, it is recommended to check the butterfly valves
during shutdown of the plant.
Leakages on the process side cause slow pressure equalization between the
adsorbers. Leakages inside the valve actuator will cause audible noise from one of the
vent openings on the pilot valve. In case of control valves, it has to be considered, that
all positioners have a certain consumption of instrument air, which also causes audible
sound.
8.2.5 PRODUCT PURITY ANALYZER (SERVOMEX)
The product purity analyzer is used to control the VPSA-unit and must be calibrated
once per week to ensure sufficient product purity.
In this plant the product purity analyzer is equipped with an automatic calibration unit,
i.e. calibration will be executed automatically without influence from the operator. The
operating personnel must only provide correct amount and quality of calibration gases.
NOTE: Use only calibration gases with certified composition.

Make sure that the correct concentrations are transferred from
the certificate and programmed into the analyzer to avoid false
measurement (especially after changing gas bottles).
The composition of calibration gases may alter during storage.
Use always new calibration gases and observe the information
given on the certificate about the maximum date of use.
The following calibration gases are recommended (for measurements in the range
between 80 and 100% oxygen):
a) HIGH CAL gas: oxygen 5.6 (purity O2 = 99,9996%),

10 litre steel bottle,
filling pressure 200 bar, charge 2 m³
b) LOW CAL gas: oxygen content appr. 85%,

10 litre steel bottle,
filling pressure 200 bar, charge 2 m³
The automatic calibration is started by command from the PLC and will only be
triggered if enough calibration gas is available (signalized by a pressure switch on the
pressure reducer station of each calibration gas bottle). If the pressure inside the bottle
is too low an error message is shown on the visualization system and calibration will
not be started.
Note: To enable a change of calibration gases without problem, the alarms

for HIGH CAL gas and LOW CAL gas are delayed for 15 minutes.
Another option is to start the cycle through in internal clock timer of the analyzer. In
this case enough pressure of the calibration gas bottles must be verified by the
operator before start of calibration, otherwise this might result in a faulty calibration.
Therefore, it is recommended to disable the internal timer of the analyzer unit.
The time for executing automatic calibration can be adjusted at the visualization
system. The automatic calibration sequence can also be triggered manually from the
visualization system.
Following settings should be checked at the analyzer cabinet before starting the VPSA-
Plant. For complete parameter list of the analyzer see instruction manual in the
Technical Part.
- Check, that the target values for oxygen content of HIGH CAL and LOW CAL
calibration gases are correctly programmed into the analyzer menu (Menu:
Setup -> AutoVal -> O2 -> Target-> Low Target or High Target)
- Check, that automatic calibration/validation via binary input is selected (Menu:
Setup -> Switch Inputs -> AutoVal)
- Check, that both, low and high point calibration will be performed (Menu: Setup
-> AutoVal -> Control -> Low&High)
- Check, that analyzer is set for calibration (Menu: Setup -> AutoVal -> Mode ->
Calibrate)
Note: If this parameter is set to Validate, analyzer will not calibrate, but only
verify the accuracy of measurement
- Make sure, that the correct sequence for automatic calibration cycle is
programmed:
1. LOW CAL gas: 5 min
2. HIGH CAL gas: 5 min
3. Flushing with sample gas: 5 min
- Check, that HIGH CAL gas bottle and its certificate are available. The valve of
the bottle should be open, and the pressure reducer should be adjusted to
0,3 kPa(g).
- Check, that LOW CAL gas bottle and its certificate are available. The valve of
the bottle should be open, and the pressure reducer should be adjusted to
0,3 kPa(g).
- Pressure controller PCV-1501 in the analyzer panel should be adjusted to a
pressure of 20 kPa(g)
- The flow through the gas analyzer should be between 100…250 cm³/min
(adjustable with needle valve on flow switch FISL-1502)
To display the detail window for the oxygen product analyzer (see Figure 8-1), select
the oxygen analyzer using the Open Picture Tree Navigator next to the Group
Display for process unit “Adsorber” . Following picture will
be shown:
Figure 8-1: Detail window analyzer
The function of the buttons and switches in this picture is as follows:

Click the button to start the calibration manually
• Check box for activation of automatic cyclic calibration
• Drop-down-menu for selection of the automatic calibration day
• Click button to adjust time of automatic calibration
Defines, whether purity control e.g. oxygen alarm is activated or

deactivated. In case of upstream measurement, the oxygen alarm
should be deactivated to ensure that the production is not
interrupted.
Defines, whether the sample gas for analysis is taken upstream of
buffer vessel D-2531 or downstream of the oxygen compressors.
The green displayed button represents the currently active
selection. Additionally, an open sample gas valve will be displayed.
The closed sample gas valve will be shown in grey color.
NOTE: During normal operation of the VPSA-Plant, the sample
gas is always taken from the sample point downstream
of the oxygen compressors. Selection of the upstream
sample point will result in higher purity fluctuations and
may cause a misinterpretation of the plant’s
performance. To use the upstream measurement for
troubleshooting, the oxygen alarm should be deactivated
to ensure that purity plant control is stopped.
For maintenance and trouble-shooting procedures for the analyzer please refer to the
manufacturer manual in the Technical Data Book.
8.2.6 INSTRUMENTATION
Instrumentation of the VPSA-Plant demands very few regular checks and controls.
However, it is advisable to check for accuracy of measurement and for tightness of
tubing during annual maintenance.
To check or even replace instruments during operation of the plant is not possible
except for some minor important instruments, since most instruments are triggering
alarm and shutdown functions in the PLC. Disconnecting those instruments while the
plant is in operation would result in an immediate shutdown of the plant since the PLC
will detect failmeasurement.
8.2.7 INSTRUMENT AIR SYSTEM
The plant must only be operated with instrument air in compliance with the data
specified in chapter 2.6.4.
Operation with instrument air outside the specified conditions will result in reduced
performance of butterfly valves (excessive wear, malfunctions etc.).
If any kind of dirt or condensate is found inside the system, the reason for the
contamination shall be investigated immediately.
For maintenance of instrument air system, the instructions and maintenance periods
of the manufacturer must be followed.
8.2.8 COOLING WATER SYSTEM
The cooling water system shall be inspected on a regular basis for excessive corrosion,
deposits, fouling etc.
The plant must only be operated with cooling water in compliance with the data
specified in chapter 2.6.4.
The cooling water circuit shall be regularly vented to make sure that no air is trapped
inside the system since this may cause corrosion.
Special consideration shall be given to the proper function of moisture detector

MSH-1121, as it detects possible carry-over of water to process air due to corrosion or
internal leakage.
Contamination of process air with water will irreversibly

reduce the production capacity of the VPSA-Plant, as water
will de-activate the adsorbent material permantenly.
8.3 MAINTENANCE
8.3.1 FEED AIR BLOWER / VACUUM PUMP
For maintenance of feed air blower and vacuum pump the instructions and
maintenance periods of the manufacturer must be strictly followed.
Cleanliness inside pipes is essential for avoiding damage on machinery. The clearance
between rotors and the blower casing of roots type blowers is very small, therefore
even small particles could cause heavy damage up to complete destruction of the unit.
Special attention has to be paid on cleanliness following every routine maintenance,
especially when piping has been removed.
Machinery has to be kept free of oil and grease on all parts that will be in direct contact
with process media. For lubrication of machinery only lubricants which have been
approved by the manufacturer must be used. For further details refer to the
manufacturer’s manual.
8.3.2 OXYGEN COMPRESSOR
For maintenance of oxygen compressor, the instructions of the manufacturer must be

strictly followed.
Only original spare parts or parts which have been released by the compressor
manufacturer must be used for replacement. All parts in contact with oxygen must be
tested and approved for use in oxygen service. Parts must only be assembled, if they
have been cleaned "free of oil and grease for oxygen service".
Cleanliness inside pipes is essential to avoid damage on machinery and to avoid fire
hazards in connection with oxygen. Special attention has to be paid on cleanliness
following every routine maintenance, especially when piping has been removed.
A start-up on dry clean air or nitrogen is required on following occasions:

- Start-up of a new compressor after erection
- Start-up of a compressor after a prolonged standstill
- Start-up of a compressor after maintenance of the following type
• Maintenance that required purging with dry air or nitrogen
• Replacement of bearings
• Replacement of impellers, internal sealing system etc.
The compressor may only be started up under oxygen again following a successful
test run with dry clean air or nitrogen.
Pay attention to absolute cleanliness during maintenance

works on oxygen compressor!
The most frequent reason for fires on oxygen compressors is
pollutions of oil, grease or other impurities due to
maintenance work!
It is strongly recommended to use only trained service
engineers from the compressor manufacturer for
maintenance.
8.3.3 VPSA-UNIT
Preventative maintenance of equipment which is outside of process piping, like

positioners, valve position sensors and transmitters can only be done if the complete
VPSA-Plant is switched off.
For replacing valves, checking adsorbent level or replacing diaphragms the VPSA
must be shut off and depressurized (see chapter 7.3.4 “Manual depressurization”).
8.3.4 CHECKING ADSORBENT LEVEL / INTEGRITY
The level and integrity of adsorbent filling inside the adsorbers should be checked in
regular intervals. The adsorbent material inside the vessels must be securely fixed
during operation.
The adsorbent material is fixed using an inert layer of ceramic balls. The level of the
filling can be checked through a sight glass on top of each adsorber.
After refilling of an adsorber vessel the adsorbent level may drop slightly within a few
operating hours due to settlement. This settlement will get less after some time.
However, it is recommended to check the filling level regularly, e.g. during annual
maintenance. If there is no evidence of significant settlement, the inspection interval
can be extended.
Due to the high affinity of the adsorbent to humidity, the adsorber must not be opened
during rainfall or showers. Even in case of increased humidity like haze or fog the
adsorber must not be opened. Supervision by LINDE is highly recommended.
Before opening of the adsorber vessels following points have to be checked:

• The necessary safety equipment has to be available
• For lifting and setting up of the manhole flange proper tools and lifting devices
must be available.
• Vessels must be de-pressurized before opening
• During all steps of work it has to be made sure, that no humidity will get into the
adsorbers. Therefore opening must only be done on dry weather conditions. To
protect the molecular sieve, nitrogen must be available for purging.
• New gaskets must be available for closing of the manhole flange
Check and refill of adsorbent must be done through the manhole flange on top of the
adsorber vessel. Before loosening the manhole flange, the oxygen line must be
disconnected.
All works on an open adsorber must be done as quickly as possible, to avoid excessive
contact between the molecular sieve and moist ambient air. If necessary, the filling has
to be protected with dry nitrogen (Pay attention for nitrogen enrichment!).
During interruptions of work the adsorber has to be closed. In case of sudden rainfall,
the work has to be interrupted immediately and the manhole flange must be closed.
Before closing of the adsorber vessels following points have to be checked:

• Flange faces on the adsorber and on the manhole cover must be clean and
unscathed. If necessary, the flange faces must be cleaned or reworked.
• New gaskets must be used for closing the adsorber and connecting pipework.
• For closing of the vessel, the specified screws, bolts, nuts and gaskets may
used only
• Tightening of the bolts has to be done crosswise and in several steps. The valid
torques for the flange connection must be followed.
All connections must be tested for leakages after tightening. If the plant is started up,
the check for tightness has to be done during the first number of cycles. For this check
it is important to know whether the adsorber is under pressure or under vacuum (see
chapter 7.3.5 ‘Leakage test of valves and piping’).
Make sure that all flange connections are tight after

maintenance.
Leakages will affect the performance of the VPSA-Plant and
your personal safety!
If the vessel is under pressure, the leak test can be done using soapy water. For leak
test under pressure and vacuum it is advisable to close the gap between manhole
flange and manhole cover with adhesive tape. In case of leakage the tape will inflate
(during phases of overpressure inside of pipe) or deflate (during phases of vacuum
inside the pipe). In case there are some doubts about tightness, the plant must be shut
down using the emergency stop button when the pressure is at its highest level. The
tightness can be checked when the plant is stopped using one of the procedures
mentioned above.
8.3.5 BUTTERFLY VALVES
For maintenance of butterfly valves, the instructions and maintenance periods of the
manufacturer have to be followed.
To achieve high availability of the VPSA it is recommended to keep one complete valve
on stock for each nominal diameter, plus all ancillary equipment like limit switches,
positioners and solenoid valves. In event of failure the faulty valve can be changed
completely, and the plant can be restarted within shortest time.
The defective valve can be repaired later.
Tightness of butterfly valves and actuators shall be checked on a regular basis, e.g.
during annual maintenance. For testing of valves refer to chapter 7.3.5 “Leakage test
of valves and piping“. For checking actuators, it is recommended to measure the
instrument air leakage between both chambers of the drive (at closed position).
Detailed information on permissible leakage rates can be found in the manufacturer’s
manual.
for File: 1
Control loops and calculations Proj. no.: 2210 CCP8
9 CONTROL LOOPS AND CALCULATIONS

The following chapter contains a description of the most important control loops and
calculations of a VPSA-plant.
9.1 PRESSURE-FLOW-CONTROLLER
The most important control loop of the VPSA-plant is the pressure-flow-controller.
In any VPSA-process there is a close relation between the amount of oxygen produced
by the plant and the purity which can be achieved using this process (see chapter 2
“Description of the VPSA-Plant”). The higher the amount of oxygen product, the lower
the product purity will be, since the ability of the molecular sieve to absorb gas is
limited.
In theory, it would be possible to increase efficiency of the process, if the delta pressure
between adsorption and desorption could be increased. In the practical plant this
option is limited by the capacity of the machinery used.
Therefore, the maximum flow of oxygen must be limited to avoid a drop of the required
oxygen purity.
Limiting the amount of oxygen is also required, if oxygen purity drops due to
malfunctions in the process, even if the maximum amount of oxygen has not yet been
exceeded.
Reducing the flow of oxygen will usually lead to an increase of purity, without further
actions required by the operator.
In practice this is done using the bypass valve on the oxygen compressor. The more
this bypass valve is opened, the more oxygen will be flowing in the bypass piping and
the less oxygen product is taken from the adsorber unit and delivered to the
downstream pipeline.
The opening of the bypass valve also determines the discharge pressure of the oxygen
product. The further the bypass valve is closed, the higher the oxygen product pressure
will be and vice versa. Therefore, two values will influence the pressure-flow-controller:
9.1.1 PRESSURE CONTROLLER PIC-1521
The discharge pressure of the oxygen compressor is measured using a pressure

transmitter (PT-1521). If the measured pressure X is below the setpoint W, the
controller will continue closing the bypass valve, until the setpoint for the pressure has
been reached. If the measured pressure is higher than the setpoint, the controller will
open the bypass valve further.
9.1.2 FLOW CONTROLLER FIC-1545
The control of the oxygen flow is based on the amount of gas measured in Nm³/h. The
flow is measured using an orifice plate. As gas flows through an orifice plate, a
differential pressure can be measured between the upstream and the downstream side
of the orifice plate. This differential pressure is proportional to the amount of gas
passing through. Since the volume of gas is depending on its pressure and
temperature, the measured differential pressure must be compensated using the
actual values for pressure and temperature measured at the orifice plate at any time.
The conversion into Nm³/h is done with the following formula:
𝑁𝑚3 𝑇𝑜𝑟𝑖𝑓 [deg 𝐶] + 273.15 𝐾 𝑃𝐼2531 [𝑏𝑎𝑟 𝑎𝑏𝑠]

𝐹𝐼1545 [ ] = 𝐹𝑀𝑒𝑎𝑠 × √ ×
ℎ 𝑇𝐼1545 [deg 𝐶] + 273.15 𝐾 𝑃𝑜𝑟𝑖𝑓 [𝑏𝑎𝑟 𝑎𝑏𝑠]
FMeas : Measured flow on the orifice, uncompensated

Torif : Design temperature of the orifice
Porif : Design pressure of the orifice
TI-1545 : Measured gas temperature at the orifice
PI-2531 : Measured gas pressure at the orifice
If the measured flow X is below the setpoint W, the controller will continue closing the
bypass valve, until the setpoint for the flow has been reached. If the measured flow is
too high, the controller will open the bypass valve further, to avoid an excessive amount
of oxygen.
9.1.3 COMBINATION OF BOTH CONTROLLERS
As long as the amount of oxygen is lower or equal to the setpoint W of the flow
controller, the command to the bypass valve (control value Y) is only determined by
the pressure controller PIC-1521, i.e. the plant will be pressure controlled.
If the measured flow of oxygen exceeds the setpoint W of the flow controller, the flow
controller FIC-1545 will take over control of the bypass on the oxygen compressor and
determine the command Y give to the bypass valve.
In the picture of the pressure-flow-controller an arrow symbolizes the control over the
bypass valve. The arrow will always indicate, which controller is active (see Figure
9-1).
Figure 9-1: Pressure-flow-controller (pressure control active)
9.1.4 CALCULATING THE SETPOINT FOR THE FLOW-CONTROLLER
Contrary to the setpoint of the pressure controller, the setpoint W for the flow controller
cannot be influenced by the operator. The setpoint is automatically calculated by the
PLC, depending on the operating mode of the plant (see chapter 4).
The calculation of the flow setpoint is based on a variety of parameters, mainly

depending on the average purity of oxygen (see Figure 9-2). These parameters can
be found in the section 'Purity Control' in the detail picture of the adsorber station.
Figure 9-2: Purity control: parameters for calculating the setpoint for the flow controller (example)
The meaning of the individual parameters is shown in Figure 9-3. As soon as the
average purity drops below limit value ASAL (time T1) during operation, the setpoint
for the flow controller will be reduced (flow reduction).
The setpoint for the maximum amount of oxygen, which in this example is given with
1098.0 Nm³/h, will be reduced using the parameters defined under ‘Flow-Decreasing
Step / Interval’. In this example, flow will be reduced by 2% (in relation to the design
flow of 1098.0 Nm³/h) every 100 seconds. The reduction of the setpoint will be
continued down to the minimum flow, which is given in this example with 50 % (in
relation to the design flow of 1098.0 Nm³/h).
If the average oxygen purity drops below limit ASALL (time T2), product valve XV-1550
will be closed, to avoid the delivery of low-quality oxygen to the downstream process
(which may cause problems).
As soon as the average oxygen purity rises again due to the decreased amount of
oxygen delivered to the consumer and exceeds the limit ASALL (time T3), the product
valve will be opened again. However, flow reduction will be continued.
As soon as the average oxygen purity exceeds the limit ASAH (time T4), flow reduction
will be stopped and the setpoint for the flow controller will be frozen at its present level.
When the average oxygen purity has recovered better than limit ASAHH (time T5), the
setpoint for the flow controller will be raised again step by step until the maximum flow
(plant design flow) has been reached again. The setpoint will be raised using the
parameters defined under ‘Flow-Increasing Step / Interval’. In this example, flow will
be increased by 1% (in relation to the design flow of 1098.0 Nm³/h) every 300 seconds.
Raising the oxygen flow shall always be done more carefully than reducing the flow to
prevent any imbalance in the system.
average
product
purity [%]
ASHH
ASH
ASAL
ASALL
set point flow
controller
[Nm³/h]
1098
2%
1076
1054
100s 1032
1010
1% 0988
0966
600s 0944
0922
T1 T2 T3 T4 T5
Time
Figure 9-3: Flow chart for reduction / increase of flow rate (example)
9.2 PARTIAL LOAD OF THE VPSA-PLANT
Based on the amount of zeolite contained in each adsorber, a certain amount of oxygen
can be taken from the VPSA in each cycle.
Example:
Design flow of the VPSA 1098 Nm³/h
Number of adsorbers 2
Cycle time 60 seconds
Adsorber cycle time 30 seconds
Using these figures, each cycle of the VPSA-plant will produce 18 Nm³ of oxygen at
full load operation. Since the plant consists of two adsorbers, it is obvious that each
adsorber will produce 9 Nm³ of oxygen.
If the present demand for oxygen is lower than the design value, each adsorber would
produce less then 9 Nm³ per cycle. First the oxygen purity will rise, since the flow of
oxygen is lower than in full load operation (refer to chapter 2.5 “Impact of process
parameters on the plant capacity”). The amount of process air and the energy
consumption will remain unchanged. Therefore, the efficiency of the plant drops and
the specific energy consumption (power consumption related to the amount of oxygen
product) will rise.
If the adsorber is operated at low load for an extended period, the oxygen purity will
drop, due to the increasing content of argon in the oxygen product. This is caused by
the similar physical behaviour of oxygen and argon in the adsorption process.
To prevent a drop of oxygen purity during partial load operation, provisions must be
made that both adsorbers will produce the same amount of oxygen per cycle than
under full load conditions, i.e. 9 Nm³ in our example.
This can be done by extending the total cycle time of the VPSA-plant, e.g. by
introducing a waiting step (step 3 / 8, see chapter 3). The PLC counts the actual
amount of oxygen produced by each adsorber. The summary will be reset every time
another adsorber is starting its production step (i.e. reaching step 1 or step 6).
The PLC calculates the time for the waiting step 3/step 8 as follows
Partial load operation will be started, if

a) the actual demand for oxygen is lower than the specified limit for starting
partial load operation
b) the average oxygen purity is better than ASH-1545 and
c) the waiting step time (see above) is more than the specified minimum partial
load time
NOTE: The partial load step will be interrupted if the pressure inside the buffer
vessel will drop below a certain limit. A reason for such behaviour
might be a sudden rise of the demand for oxygen.
Nevertheless, the oxygen purity in partial load operation would still slightly rise since
the uncertainty of the flow measurement in partial load operation is higher than under
full load.
To optimize energy savings, the product purity will be taken into consideration as an
additional factor for calculating the length of the partial load step.
The parameters for this control can be found in the section 'Partial Load Control' in the
detail picture of the adsorber station.
Figure 9-4: Partial load control: parameters for partial load operation
If the average product purity exceeds ASH1545-PL-limit (see Figure 9-4), the partial
load step will be extended additionally. If the average product purity drops below the
ASL1545-PL-limit, the step time for partial load will be reduced.
Like operation in full load, the setpoint for the flow controller will also be reduced in
partial load operation in case of bad purity. For this reduction different parameters can
be defined compared to full load operation (see Figure 9-4).
9.3 BLOW-OFF CONTROLLER FICC1545
Reduction of oxygen delivery is only practical if the demand for oxygen is not less than
approximately 30% of the design flow. Below this value the danger of poor oxygen
purity rises significantly, due to the increasing inaccuracy of the flow measurement,
which prevents an exact calculation of the time for the partial load step. Therefore, the
setpoint FSL-1545 of the blow-off controller FICC1545 should be set to approximately
30% of the design flow.
As soon as the demand for oxygen drops beyond setpoint FSL-1545, blow-off
controller FICC1545 opens the blow-off valve PCV-1513 to atmosphere. The controller
will now make sure, that at least this amount of oxygen is taken from the plant, either
to the consumer or vented to atmosphere.
Figure 9-5: Blow-off controller
The blow-off controller acts as a so-called ‘dead band controller’, i.e. if the measured
flow is close to the setpoint FSL-1545, the controller will not be active. If the measured
flow deviates significantly from setpoint FSL-1545, the controller will be activated. The
controller opens or closes the blow-off valve with the speed defined under ‘Gradient’
in the faceplate of the blow off controller FICC-1545 (see Figure 9-6).
Figure 9-6: Gain of FICC-1545
9.4 SWITCHING TIME OF VALVES
All valves equipped with a feedback signal to the PLC will be monitored for proper
function by measuring the switching time.
For binary valves four switching times will be measured (T1-T4, see Figure 9-7)
OPEN
90° 90°
80° T1: Opening time delay

70° T2: Opening switch time
60° T3: Closing time delay
50°
T4: Closing switch time
40°
30°
20°
10° CLOSE
0° 0°
T1 T2 T3 T4
t (sec)
0 1 2 3 4
24 VDC
Signal to
pilot valve
0
Figure 9-7: Switching cycle of a butterfly valve
The PLC calculates predicted values for the next operations of each valve, based on
the previous times for opening and closing (model time). On each operation of the
valve, the PLC measures the actual switching times and compares the measured
values with the limit values for opening and closing.
For control valves the required times for opening and closing are registered and
compared with limit values for opening and closing. Additional information about
correct operation of control valves is the accuracy of each valve to reach the requested
position. To monitor this accuracy a hysteresis is defined, i.e. an acceptable deviation
between the command from the PLC and the actual position that has been reached. If
the valve fails to reach the requested position within the range of hysteresis, this will
indicate a failure to the PLC.
If the values for valve operation are outside of the acceptable tolerance, an alarm will
be shown on the visualization system. On certain critical valves (e.g. bypass valves of
machinery) the plant will be shut down immediately.
On less critical valves (e.g. oxygen product valves or pressure equalization valve), the
plant will only be shut down, if the pressure of the adsorber vessels or the buffer vessel
is outside of the expected range.
9.5 TEMPERATURE CONTROLLER
9.5.1 PROCESS AIR TEMPERATURE CONTROLLER TIC-1121
The adsorber inlet temperature is kept on a constant level using process air cooler
E-1121. The amount of cooling is regulated with a PID-controller (see Figure 9-8).
Figure 9-8: Temperature controller TIC-1121
The PLC monitors the process air temperature going into the adsorber vessels
(TI-1121). If the measured value is higher than setpoint, the PLC will send more water
through the cooler E-1121 by opening the control valve TCV-1121 towards the cooler.
If the measured value is lower than the setpoint, the control valve will open the bypass
around the cooler E-1121 a little bit more, and air is fed to the adsorbers with less
cooling.
9.5.2 COOLING WATER TEMPERATURE CONTROLLER
The cooling water supply temperature is kept on a constant level using the five cooling
water cooler E8483A-E. The amount of cooling is regulated with the PID-controller TIC-
8401. The PLC monitors the cooling water supply temperature (TI-8401).
TIC-8401 Control by cooler bypass valve
If the measured value of TI-8401 is higher than the setpoint, the PLC will send more
water through the coolers E-8483A-E by closing the cooler bypass valve TCV-8401. If
the measured value is lower than the setpoint, cooler bypass valve will open the bypass
around the coolers E-8483A-E a little bit more, and less cooling water is supplied for
less cooling.
Controlling of cooling fans E-8483A-E
The fan configuration picture can be reached by selecting the button on

the process picture of the cooling water system .
The configuration picture is shown in Figure 9-9.
Figure 9-9: Fan configuration window
If automatic control is activated, the number of active fans is controlled by cooling water
temperature TI-8401 related to the start and stop limits. If temperature TI-8401 is
exceeding the first start limit, the fan with the highest priority will start. Next fan will
start if second start limit is reached, a.s.o.
If automatic control is not active, all fans will be switched on at the same time
independent from priority and start limits.
If automatic priority selection is activated, priorities of the fans are depending on their
runtime. The fan with the lowest runtime gets the highest priority. If automatic priority
selection is not activated, priorities can be changed by operator input. In this case the
runtime will not be recognized for changing priorities.
The runtime counter of each fan can be set to zero by pressing the “Reset” button, if
fan is not in run mode.
9.6 CONTROL OF ENVIRONMENT
During operation of the Oxygen-VPSA-Plant, sufficient ventilation must be ensured in

all areas, where enrichment or deficiency of oxygen in the ambient air may possibly
occur (see also chapter 1).
The ventilation system must be installed and controlled by the client and is not part of
the VPSA plant. The client has the responsibility for enough ventilation of the machine
building.
Figure 9-10: Environment window

9.6.1 GENERAL OPERATION
The building is equipped with monitoring of oxygen content and the possibility to
connect an external fire detection signal.
• HS-9304 Smoke/Fire detector (external)

• AI-XX98 Oxygen content of ambient air
For maintenance of these systems, the alarm and shut down can be deactivated with
an appropriated user level. An alarm will be displayed if an alarm is deactivated or
bypassed.
For testing of bypassed fire detection sensors, the current state of the input is displayed
Status of sensor is good
Status of sensor is bad
For testing of deactivated monitoring of oxygen content, the measured value is

displayed.
Measured value with deactivated alarms

and shut down
NOTE The client is responsible for installation of fire detection

system. Linde only supports a digital input for a client fire
detection system. This signal is only used to stop the VPSA
plant.

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Part: Operating manual

Operating manual Section: 1

Company : Société pour le traitement du

Contractor : LINDE GmbH

Phone : +49 89 7445-0

Project number : 2210 CCP8

Issue State Date Prepared Checked Approved Remarks

The complete manual consists of following parts

Operating Manual : Part O

O OPERATING MANUAL ............................................................................ 1

2 DESCRIPTION OF THE VPSA-PLANT ................................................... 1

2.5 Impact of process parameters on the plant capacity ............................................... 6

4 OPERATING MODE ................................................................................ 1

5 CONTROL OF THE VPSA-PLANT .......................................................... 1

5.4.4 Process units .................................................................................................. 16

6 DISPLAY AND CHANGING OF PARAMETERS ..................................... 1

7 ALARMS AND TROUBLESHOOTING PROCEDURES .......................... 1

7.3.9 Checking pressure transmitters ...................................................................... 45

8 CONTROL VISITS AND MAINTENANCE ................................................ 1

9 CONTROL LOOPS AND CALCULATIONS ............................................. 1

The personnel employed in this plant (either permanently or temporarily) must be

Issue State Date Prepared Checked Approved Remarks

Modifications on the plant or on individual equipment, e.g. during maintenance and

Coverage is also not extended to supplemental equipment such as liquid back-up

The tightness of the plant will be jeopardized, if material is being over-stressed by

Material will be over-stressed, when it is exposed to conditions which it is not designed

Process parameters like pressure, temperature, flow rate and

1.2.1 FIRE HAZARDS OF OXYGEN AND OXYGEN ENRICHED ATMOSPHERES

Gaseous oxygen (GOX)

Liquid oxygen (LOX)

The normal concentration of oxygen in ambient air is approximately 21% by volume.

Rising pressure will increase most oxygen hazards, as

1.2.2 OXYGEN DEFICIENCY

The normal concentration of oxygen is approximately 21% by volume (see chapter

Any oxygen concentration less than 19.5% constitutes a hazardous working

Exposure to an atmosphere containing 12% oxygen or less will bring about

1.2.5 BRITTLE FRACTURE

1.3 PROTECTIVE MEASURES

The following protective measures are recommendations to avoid the previously

Special attention shall be given to accidental sources of ignition. To prevent unintended

1.3.2 DESIGN OF BUILDINGS

Areas where oxygen is produced, compressed or where liquid oxygen is evaporated

A sufficient number of emergency exits must be provided and clearly marked.

1.3.3 PROTECTIVE MEASURES AGAINST FIRE HAZARDS

Special care must be taken against oxygen-enriched atmosphere. It is not allowed to

1.3.4 FIRE PROTECTION EQUIPMENT

The use of powder extinguishers, suitable for class A, B, C and D according to

A sufficient number of employees must be trained in operation of fire extinguishing

1.3.5 REPAIR AND MAINTENANCE WORKS

Consideration shall be given to the following hazards:

Following precautionary measures shall be taken before starting work:

1.3.6 GENERAL SAFETY PRECAUTIONS

1.3.7 MATERIALS USED IN OXYGEN PLANTS

Components must never be replaced by substitute or 'equal grade' material. Any

1.3.8 CONFINED SPACES

For work on molecular sieve adsorbers:

1.3.9 CLEANLINESS AND INSPECTION

Recognition of oxygen's reactivity has led to stringent requirements regarding

Start Verify Assemble Maintain

Typical cleaning methods for cleaning of components in oxygen service include:

A detailed survey of the different cleaning methods, their advantages/disadvantages

Recommended test methods to determine cleanliness are

• Visual examination with ultraviolet light: