sop for Operation of Nitrogen and Oxygen
1.0 OBJECTIVE:
1.1 To lay down the Procedure for the Operation of Nitrogen and oxygen Plant.
2.0 SCOPE:
2.1 This Standard Operating Procedure shall be applicable for Operation of Nitrogen and Oxygen Plant
3.0 RESPONSIBILITY:
3.1 Operator/Technician-Engineering
4.0 ACCOUNTABILITY:
4.1 Head Engineering Department shall be responsible for compliance of SOP.
5.0 PROCEDURE:
5.1 PRIMARY CHECKS:
5.1.1 The area near the unit should be kept clean.
5.1.2 Check that all electrical system is ok.
5.1.3 Check Control panel is getting power supply.
5.1.4 Ensure that drain valves of all equipment’s are closed.
5.2 OPERATING PROCEDURE:
5.2.1 Switch ON the main switch.
5.2.2 Turn ON the compressor and air dryer, and allow the air receiver to pressurize. Let the compressor keep
running and observe that the compressor shifts to unloaded operation.
5.2.3 Now adjust the pressure regulator placed before the inlet ball valve to required set pressure.
5.2.4 Air received in air receiver tank after filtration and pressure should be up to 5 to 7 kg/cm².
5.2.5 Air transfer into Air Separation tank A and B. A tank supply for Nitrogen Operation and B tank supply for Operation Oxygen.
5.3 OPERATING PROCEDURE FOR NITROGEN
5.2.6 Switch on Control Panel by selector switch and touch on Nitrogen icon then touch the Run icon
on display screen Open air inlet valve for Operating Nitrogen.
5.2.7 Compression, drying and filtering air transfer into Air receiver tank to PSA Modules.
5.2.8 Observe the operation of the unit for some time and see that the PSA module is working properly.
When one PSA Tower Cycle Pressurized then second PSA Tower depressurized.
5.2.9 Our PSA units have two cylinders filled with Carbon Molecular Sieve. (CMS). Compressed and
purified air flows through the cylinder; the CMS bed adsorbs oxygen, while nitrogen passes through to
the nitrogen accumulation tank. The adsorption process is interrupted before the CMS becomes saturated
with nitrogen by diverting the input air to the second cylinder, which at this point starts producing nitrogen
during this step of the cycle, the second cylinder is cleaned.
5.2.10 Check the minimum pressure in the PSA Cylinder should be 5 to 7 kg/cm².Control that air flow by
the valve provided just at the air inlet into the PSA module Setting should be disturbed only after watching the result for 5-10 minutes.
5.2.11 The pressure between the two cylinders is equalized.
5.2.12 The CMS of the first cylinder (now saturated with oxygen) is regenerated by reducing pressure in the
cylinder below that of the adsorption step. The adsorbed oxygen is released and vented into atmosphere. After
this step it is again ready for another cycle.
5.2.13 Adsorption and desorption steps are repeated in the CMS tanks at equal time intervals A constant
flow of nitrogen is stored to nitrogen surge tank and pressure has reached up to 5.5 kg/cm2,
5.2.14 At Complete Operation adsorption process Check the oxygen content in Oxygen Analyzer on control panel.
5.2.15 Check the flow rate of nitrogen via flow meter.
5.2.16 Pure nitrogen goes to Surge tank to Nitrogen Storage Tank.
5.2.17 Open Out let Valve now the plant is ready for normal operation.
5.3 OPERATING PROCEDURE FOR OXYGEN
5.3.1 Switch on Control Panel by selector switch and touch on Oxygen icon then touch the Run icon on
display screen Open air inlet valve for Operating Oxygen.
5.3.2 Compression, drying and filtering air transfer into Air receiver tank to PSA Modules.
5.3.3 Observe the operation of the unit for some time and see that the PSA module is working properly. When one
PSA Tower Cycle Pressurized then second PSA Tower depressurized.
5.3.4 Our PSA units have two cylinders filled with Carbon Molecular Sieve. (CMS). Compressed and purified
air flows through the cylinder; the CMS bed adsorbs oxygen, while nitrogen passes through to the
nitrogen accumulation tank. The adsorption process is interrupted before the CMS becomes saturated
with nitrogen by diverting the input air to the second cylinder, which at this point starts producing nitrogen
during this step of the cycle, the second cylinder is cleaned.
5.3.5 Check the minimum pressure in the PSA Cylinder should be 5 to 7 kg/cm².Control that air flow by the
valve provided just at the air inlet into the PSA module Setting should be disturbed only after watching the result for 5-10 minutes.
5.3.6 The pressure between the two cylinders is equalized.
5.3.7 The CMS of the first cylinder (now saturated with oxygen) is regenerated by reducing pressure in
the cylinder below that of the adsorption step. The adsorbed oxygen is released and vented into atmosphere.
After this step it is again ready for another cycle.
5.3.8 Adsorption and desorption steps are repeated in the CMS tanks at equal time intervals A constant flow
of nitrogen is stored to nitrogen surge tank and pressure has reached up to 5.5 kg/cm2,
5.3.9 At Complete Operation adsorption process Check the oxygen content in Oxygen Analyzer on control panel.
5.3.10 Check the flow rate of nitrogen via flow meter.
5.3.11 Pure nitrogen goes to Surge tank to Nitrogen Storage Tank.
5.3.12 Open Out let Valve now the plant is ready for normal operation.
5.4 SHUT DOWN PROCEDURE FOR NITROGEN:
5.4.1 Touch on the Stop Icon on display screen at control panel and Switch off the control panel by Selector Switch.
5.4.2 Turn off the compressor & air dryer.
5.4.3 Switch ON the main switch.
5.4.4 Stop the air inlet supply valve and out let supply valve.
5.4.5 Maintain Log sheet as per Annexure-I.
5.5 SHUT DOWN PROCEDURE FOR OXYGEN:
5.5.1 Press the Stop Icon on display screen at control panel and Switch off the control panel Selector Switch.
5.5.2 Turn off the compressor & air dryer.
5.5.3 Switch ON the main switch.
5.5.4 Stop the air inlet supply valve and out let supply valve.
5.5.5 Maintain Log sheet as per Annexure-II
6.0 ABBREVIATIONS:
SOP | Standard Operating Procedure |
QA | Quality Assurance |
No. | Number |
Pvt. | Private |
No. | Number |
Ltd. | Limited |
EN | Engineering |
nm³/hr | Normal Meter Cubed per Hour |
kg/cm² | Kilo Per Square Centi meter |
7.0 ATTACHMENTS (ANNEXES) :
Annexure-I: Log Book of Operation Nitrogen Plant
Annexure-II: Log Book of Operation Oxygen Plant
8.0 REFERENCES:
In-House
9.0 REVISION HISTORY:
Change Control No | Description | New Change | Effective Date | Name |
New SOP | Not Applicable |
Annexure-I:
NITROGEN PLANT LOG BOOK
DATE
|
START TIME
|
STOP TIME
|
AIR INLET PRESSURE kg/cm² | PRESSURE OF P.S.A TOWER kg/cm² | PRESSURE OF SURGE TANK kg/cm² | FLOW OF N2 nm3/hr | NITROGEN % | DONE BY | CHECKED BY | REMARK |
Annexure-II
OXYGEN PLANT LOG BOOK
DATE
|
START TIME
|
STOP TIME
|
AIR INLET PRESSURE kg/cm² | PRESSURE OF P.S.A TOWER kg/cm² | PRESSURE OF SURGE TANK kg/cm² | FLOW OF O2 nm3/hr | OXYGEN % | DONE BY | CHECKED BY | REMARK |
sop for Execution of Preventive Maintenance
Preparation of Sodium Hydroxide Solution
sop for water cooled chiller operation
cleaning and preventive maintenance of LAF and RLAF
sop for replacement of water system filters
cleaning and preventive maintenance of insectocutor
sop for operation of preventive maintenance
sop for material receiving and consumption record
sop for Preventive maintenance of bottle washing machine
sop for Replacement of Battery of Electronic Devices
sop for Preparation of R.O. Antiscalant Solution
Preventive Maintenance of Rapid Cooling Steam Sterilizer
Preventive Maintenance of Rapid cooling steam Generator
sop for Preventive Maintenance of Dust Collector
sop for Replacement of HVAC filters
SOP for Battery Backup in Mobile Laminar Air Flow Trolley
sop for Replacement of Tube lights
sop for Replacement of UV light of purified water plant
sop for Cleaning of soft water storage tank and RO feed tank
sop for Preparation of Sodium hydroxide Solution
sop for Operation and regeneration of softener plant
Procedure Of Issuance Of material from Engineering Store
sop for Preventive Maintenance of Filter Press
sop for Preventive Maintenance of Sugar Transfer System
sop for Preventive Maintenance of Shrink Sleeve Machine
sop for Preventive Maintenance of ROPP Cap Elevator
sop for Preventive Maintenance of Liquid Transfer Pumps
sop for Preventive Maintenance of Liquid Tanks
Preventive Maintenance of Strip De-Foiling Machine
sop for Preventive Maintenance of Colloidal Mill
sop for Preventive Maintenance of Packing Collator Belt
sop for Checking light intensity
sop for Operation of Fire- Extinguisher
sop for Passivation of WFI Distribution Loop
sop for Analysis of Effluent Treatment Plant Water
sop for Methodology to Dispose ETP Sludge
sop for Action Plan In Case Of Electrical Power Failure
sop for Colour Coding of Piping and Accessories of Utilities
sop for Disposal of Engineering Waste
Filter Cleaning of HVAC System RLAF & LAF
Procedure for Calibration of Magnehelic Gauge
Procedure for Calibration of Vacuum Gauge
Procedure for Calibration of Pressure Gauge
sop for Procedure for Calibration of Temperature Controller
sop for Preventive Maintenance of Infrared Dryer Umbrella Type
sop for Preventive Maintenance of Battery stacker
sop for Preventive Maintenance of Lift
sop for Preventive Maintenance of Vacuum Cleaner
sop for Preventive Maintenance of laminar air flow unit
sop for Preventive Maintenance of Lozenges Manufacturing Line
sop for Preventive Maintenance of Garment Washing Machine
sop for Preventive Maintenance of Multi Column Distillation Plant
sop for Preventive Maintenance of Steam Sterilizer Autoclave
sop for Preventive Maintenance of Pure steam Generator
sop for Preventive maintenance of Depyrogenating Tunnel
sop for Preventive Maintenance of vial sealing machine
sop for preventive maintenance of Powder Filling and Rubber Stoppering machine
sop for Preventive Maintenance of Vial Washing Machine
sop for Preventive Maintenance of Inspection Table
sop for Preventive Maintenance of Hi-Cart
sop for Preventive Maintenance of Turn table
sop for Preventive Maintenance of sticker labeling machine
sop for Preventive Maintenance of Liquid Filling and Sealing Machine
sop for Preventive Maintenance of Linear Bottle Washing Machine
sop for Preventive Maintenance of De-Foiling Machine
sop for Preventive Maintenance of Strip Packing Machine
sop for Preventive Maintenance of Blister Packing Machine
sop for Preventive Maintenance of Capsule Polishing and Sorting Machine
sop for Preventive Maintenance of Capsule Filling Machine
sop for Preventive maintenance of Auto Coater
sop for Preventive Maintenance of Compression Machine
sop for preventive maintenance of packing conveyor belt
sop for Preventive Maintenance of Sifter Cum Multi mill
sop for Preventive Maintenance of Rapid Mixer Granulator
sop for Preventive Maintenance Of Fluid Bed Dryer
sop for Preventive Maintenance of Octagonal Blender
sop for Preventive Maintenance of Lifting and Positioning Device
sop for Preventive Maintenance of Paste Preparation vessel
sop for preventive maintenance of Vibro-Sifter
sop for preventive maintenance of air curtain
sop for preventive maintenance of air handling units
Preventive Maintenance of Diesel Generator
sop for Preventive Maintenance of cooling towers
sop for Preventive Maintenance of Boiler
sop for Preventive Maintenance of Air Compressor
sop for Preventive Maintenance of Chilling Plant
sop for Preventive Maintenance of Transformers
sop for Preventive maintenance of Purified Water System
sop for Break Down maintenance of Machine and Work Requisition
sop for Operation of Dust Extraction System
sop for Operation Of Effluent Treatment Plant
sop for Operation Of Diesel Generator
sop for Operation of Multi Column Distillation Plant
sop for Operation of Pure Steam Generator
sop for Operation of Air Handling Unit
sop for Operation of Cooling Tower
sop for Operation of Air Compressor
sop for Operation of Water Chilling Plant
sop for Cleaning of Pure Steam Generator
Cleaning of Over Head Water Tanks HDPE
sop for Cleaning of Water tanks
sop for Sanitization of multi column plant
sop for Sanitization of Ultrafiltration System
Sop for Chemical Sanitization of Reverse Osmosis
Sop for Sanitization of Hot Sanitization & Electro Deionization unit
sop for Sanitization of Purified Water Loop
sop for preparation of sodium meta bisulphate solution
sop for Testing of Hardness of Soft Water
sop for Operation & back wash of multi grade filter
sop for testing of chlorine contents in water