nitrogen expansion systems PURITY 99% N2 VM VP ...keeps the pressure on!

Transcription

1 nitrogen expansion systems PURITY 99% N2 VM VP...keeps the pressure on!

2 SOTEX nitrogen expansion systems A short introduction We at SOTEX are experts in the area of nitrogen generators, expansion systems and compressed air systems. The nitrogen produced by our nitrogen generators may be used for all kinds of purposes, such as for tank blanketing or in production processes. Furthermore, SOTEX is a representative of manufacturer FLAMCO. Thanks to this collaboration, we are able to offer a wide range of solutions for any situation and anywhere in the world! A third major activity of our dynamic company is supplying complete compressed air systems. As of 2002, SOTEX has been active in the international horticultural sector and in regional heating projects. We are also extremely successful in counselling and in supplying small-scale and large-scale projects in the industrial and utility sectors and geothermal projects. SOTEX delivers its products through the heating installer. We provide consultancy agencies with the latest information, if desired accompanied by clear and simple explanations. SOTEX has its own service and maintenance department, which is available 24/7 for any malfunctions and/or technical support. We are also a VCA* certified company. Safe and responsible use! With a SOTEX nitrogen expansion system, you are always assured of pure nitrogen for use in a vertical heat storage tank, for example. A smart and user-friendly control system regulates the pressure balance of the nitrogen cushion in the heat storage tank, and monitors the water content. In this way you can rely on optimal safety and protection of the tank and heating system. Nitrogen purity The air around us consists of approximately 78% nitrogen and 21% oxygen. Compressed air is no different. Furthermore, compressed air contains a certain quantity of moisture and, when using oil-lubricated compressors, also a certain quantity of oil vapour. After removal of oxygen, moisture and oil vapour from the air, only nitrogen remains. SOTEX uses two highly reliable and proven techniques to remove oxygen from compressed air; Type VM; gas separation membrane (1.8 / 2.6 / 4.6 Nm3 per hour). Type VP; PSA* system (1.5 / 3.0 / 4.0 / 6.0 / 8.0 / 12.0 / 17.0 / 22.0 / 33.0 Nm3 per hour). * pressure swing adsorption All SOTEX nitrogen expansion systems are factory set to a purity of 99%. In other words, this means a residual oxygen concentration of 1%. Extensive testing has demonstrated that this is the best nitrogen purity to protect a steel heat storage tank against internal corrosion in the long-term. Using a higher residual percentage will result in lower investment in the short term. However, the negative effects of internal corrosion will be much larger (and thus an undesirable investment) in the long-term. 99 % PURE NITROGEN How it works The air pressure on the SOTEX Nitromat nitrogen generator should always be at least 6 bar. If this is not the case, the Nitromat nitrogen generator will not start. The SOTEX nitrogen expansion systems - types VM and VP - can only be applied to the vertical buffer tanks. For special applications (e.g. horizontal buffer tank or geothermal projects) SOTEX offers identical nitrogen expansion systems. However, these types (HM and HP) operate at a higher pressure (approx. 1 bar). The system ensures a nitrogen cushion at the top of the vertical buffer tank. The desired pressure is set at 15 mbar. It is necessary to provide the buffer tank with a nitrogen blanket (purity 99% N2) to prevent the water from absorbing oxygen. In addition, the system prevents damage due to corrosion of the internal parts of the steel tank. When the water level in the tank increases, the pressure of the nitrogen cushion will also increase. This is measured using the pressure sensor supplied, which is attached to the top of the buffer tank. As soon as the pressure reaches 20 mbar, the mechanical relief valve (part of the mechanical vacuum/overpressure control valve) will open to vent nitrogen. When the water level in the tank decreases, the pressure of the nitrogen cushion will decrease. As soon as it is 5mbar below the set desired pressure, the nitrogen supply valve (solenoid valve 1/2 in the Nitromat nitrogen generator) will open to allow for the flow of nitrogen from the nitrogen storage vessel to the buffer tank. Upon reaching the desired value, this valve will close again. With regard to the pressure control and the measurement of the expansion space, there are two conditions under which the installation generates alarms by means of signals; e.g. low water pre-alarm, low water alarm, under-pressure alarm and over-pressure alarm. For more information, please refer to the instruction manual. The fully automatic and well-considered control method of the SOTEX control panel with SIEMENS PLC guarantees the safety of the vertical buffer tank. Scope of delivery The complete SOTEX nitrogen expansion system complies with the European Pressure Equipment Directives ( marking) and is also available in accordance with the (CU TR) or ASME / CSA / UL regulations. The delivery consists of the following components: Nitrogen generator types Nitromat VM en VP; professionally assembled in a high-quality stainless steel frame: central SIEMENS PLC control unit with multi-colour LCD display air dryer VM VM-L VP-L cyclone filter with automatic condensate drain VP compressed air filters with float drain VM VP compressed air filters automatic condensate drain VM-L VP-L activated carbon absorber VM VM-L VP-L nitrogen membrane VM VM-L PSA barrels and 24 Volt valve set VP VP-L nitrogen supply valve (solenoid valve) pressure switch nitrogen production pressure switch minimum compressed air pressure oil/water separator Screw compressors on compressed air receivers; including automatic condensate drain and electric connection cable. Nitrogen storage tank; complete with required accessories, including pressure gauge and spring-loaded safety valve. Fittings and accessories; pressure sensor mbar, for mounting on top of vertical heat storage tank content sensor mbar, for mounting at the side of vertical heat storage tank plastic protective caps for the sensors ball valve 2 for emergency relief, including pipe nipple 300 mm. - 2 vacuum/over-pressure control valve* PN10 including DN50 relief valve * flange diameter depending on tank capacity Compact & modern design Plug & Play installation Incl. nitrogen storage tank Long-Life packages Advanced Siemens PLC Including screw compressor Ultimate clean air Extremely reliable Purity 99% N2 Long lifespan Sophisticated technology Very user friendly with oil/water separator 2 3

3 SOTEX nitrogen expansion systems Two techniques SOTEX uses two highly reliable and proven techniques to separate oxygen from compressed air. The VM systems use a gas separation membrane and the VP systems use a PSA technique: The gas separation membrane contains hollow fibres. The separation of the oxygen and nitrogen molecules is based on the difference in diffusion rate. Oxygen diffuses faster through the fibre walls than nitrogen. The nitrogen molecule is larger than the oxygen molecule. By pressing the compressed air through thousands of fibres, the oxygen exits the fibre walls while the nitrogen remains. If designed properly and maintained according to the guidelines, membrane nitrogen generators are extremely reliable. Due to the absence of valves or other moving components, it is a very reliable system. The main condition is that the supplied compressed air is treated according to the specifications. The PSA nitrogen generator also produces nitrogen from the surrounding air. Two barrels with high-quality Carbon Moluculair Sieve (CMS) act as a molecular sieve, which are able to absorb oxygen molecules for a certain period. Once fully saturated, diverter valves ensure an automatic switch to the next barrel. The saturated barrel is prepared for the next cycle by removing the pressure from the barrel, during which the absorbed oxygen molecules are blown out at the same time. The main condition is that the supplied compressed air is treated according to the specifications. Nitrogen storage tank The pure nitrogen is stored in the nitrogen storage tank. This is done under a pressure of 5 to 8 bar. At requested times, the nitrogen is transported from this tank to the heat storage tank (by means of the nitrogen supply valve) up to the set desired pressure of 15 mbar. This pressure reduction and temperature increase of about 25 C to 90 C results in a substantial increase in volume. The volume of the nitrogen storage tank is an important part of the design of the installation, because it determines the rotation time of the screw compressor. After all, screw compressors are designed for long-term use and should reach a desired temperature to prevent condensation problems in oil and in the screw block. SOTEX delivers standard vertical vessels made of coated steel with the system. These vessels comply with the pressure equipment directive 2014/68/EU, which is suitable for most projects. For projects in North America, SOTEX delivers the nitrogen storage vessels built in accordance with the ASME guidelines (excluding a conformity stamp) and, for projects in Russia, Belarus and Kazakhstan, with mark (CU TR certification). Compressed air It is necessary to provide the SOTEX Nitromat nitrogen generator with the right amount of compressed air, a complementary delivered compressor and the required compressed air treatment. As previously mentioned, SOTEX delivers a screw compressor on compressed air receiver with the system. SOTEX systems includes a Atlas Copco or a Nu Air screw compressor. These comply with the pressure equipment directive PED 2014/68/EU and the (CU TR) regulations (Russia, Belarus and Kazakhstan). The Atlas Copco screw compressors are also used in North American projects where the ASME, UL and CSA guidelines apply. It is necessary to select a screw compressor with a working pressure of 10 bar. Furthermore, the capacity of the screw compressor must be attuned to the required use of the nitrogen generator. All screw compressors must be extremely reliable and silent, and must have a long life cycle (insofar as they are correctly and responsibly used and maintained). For more information about usage and maintenance, please refer to the comprehensive manuals that are available separately. Every SOTEX Nitromat nitrogen generator is provided standard with a sophisticated compressed air treatment that consists of a combination of compressed air dryer/cyclone filter and compressed air filters, specifically designed for all types. The compressed air treatment is absolutely necessary to guarantee a long life cycle of the gas separation membrane / PSA and consequently achieve high purity nitrogen. These compressed air filters should be maintained regularly. SOTEX also offers an optional Long Life package for every nitrogen generator. This includes a more comprehensive compressed air treatment, guaranteeing an even longer life cycle. For more information about usage and maintenance, please refer to the comprehensive manuals that are available separately. 4 5

4 SOTEX nitrogen expansion systems SOTEX provides every nitrogen expansion system with a matching vacuum/overpressure control valve. This is an additional safety device that protects the precious vertical heat storage tank against undesired underpressure or overpressure situations The mechanical nitrogen relief valve is part of the vacuum/ over-pressure control valve. By opening at 20 mbar, this valve controls the working pressure. Optionally, the vacuum/ over-pressure control valve can be equipped with a customised protective cover, which can be easily mounted on top of the control valve. This cover protects the control valve against sun and wind. Environment In order to produce the nitrogen, compressed air treated by the compressed air filters is used. These filters are included in every SOTEX Nitromat nitrogen generator. After all, the compressed air must be clean and dry for the benefit of the nitrogen-producing system. The residual product of this filtering is mainly condensed water, which also contains dust and oil particles and is therefore harmful to the environment. However, SOTEX has always been mindful of the environment. Therefore, this condensate is drained using an oil/water separator (always included with the nitrogen expansion system). In this separator, the oil is absorbed by the presence of activated carbon. This activated carbon must be replaced periodically. Consequently, the water that is drained remains clean and can be drained into the sewage system. Optional The basis of the SOTEX nitrogen expansion system is formed by the types VM and VP. These can be optionally expanded with the following: SOTEX package (VM-L and VP-L) This option is a significant upgrade of the compressed air treatment of the SOTEX Nitromat nitrogen generator, which significantly improves the reliability and longevity of the generator. If the SOTEX Nitromat nitrogen generator is equipped with the Long-Life package, this is indicated by the type designation: VM-L and VP-L. With the VM-L type, two compressed air filters are equipped with an electronic condensate drain and the activated carbon absorber is increased. With the VP-L type, the compressed air cyclone filter is replaced with a refrigerant dryer and the two compressed air filters are both equipped with an electronic condensate drain. The system also includes an activated carbon absorber. SOTEX Protective Cover' for vacuum- / over-pressure control valves This is a customised protective cover that can be placed over the vacuum / over-pressure control valve. The SOTEX plastisol protective cover reduces the risk of freezing. However, it by no means guarantees 100% frost-free condition and therefore, SOTEX provides no guarantee. However, it is an important tool. SOTEX Usually, the SOTEX nitrogen expansion system only controls a single vertical heat storage tank. If there are two vertical heat storage tanks, you may decide to have two separate nitrogen expansion systems. However, SOTEX can provide a better solution: type DUO. This is a single nitrogen expansion system suitable for controlling both vertical heat storage tanks. The SOTEX control panel with SIEMENS PLC is equipped with two separate multi-colour displays and the SOTEX Nitromat nitrogen generator has two nitrogen supply valves. By opting for the DUO type, the costs of use are much lower than when installing two separate systems. The DUO SOTEX Nitromat nitrogen generators can be recognised by the type designation: VM-D and VP-D. SOTEX Nitrogen purity measurement' If desired, the SOTEX Nitromat nitrogen generator can be equipped with a sensor incorporated into the control panel, which continuously monitors the quality of the nitrogen from the nitrogen storage tank. The measured purity is shown as a percentage on the display of the control panel. SOTEX Potential water loss If ordered, the SOTEX control panel can be expanded with an additional module and an extra sensor 0-1 bar. The additional sensor should be mounted at the bottom of the side wall of the vertical heat storage tank. On the basis of physical water filling (pressure/weight), you can set a desired deviation upon which an alarm will ring. This will be generated by means of a potentialfree contact. SOTEX 'TMB-DUO basic' When coupling the vertical heat storage tanks in a parallel manner, a problem that has emerged is the excess of mass in one tank and a lack of mass in the other. The Law of Communicating Vessels applied insufficiently (passive return-pipeline) due to height differences of the tanks and/or a too long connecting pipeline. Mass differences caused by the transfer of heat from one buffer tank to another are a thing of the past when using the SOTEX TMB-DUO. The Sotex TMB-DUO basic is an inventive monitoring system, which ensures that the correct mass is maintained in vertical heat storage tanks. Using sensors and an intelligent control unit, we provide voltage-free contacts (max. 10 Amp.) with which the rotation speed of the return pump can be controlled after receiving an enable signal. This is a separate control unit and will be delivered as such. SOTEX 'Tracing' When a project is realized in a location with extreme cold winters we advise to protect the sensors and vacuum-/overpressure regulating valve against frost using a heat tracing system. We deliver a complete DIY package or a pre-mounted version, both with a clear installation manual. Quality and reliability The SOTEX nitrogen expansion system is characterised by quality and reliability. All systems undergo an extensive final test before delivery; the compressor is extensively tested on achievement of capacity and final pressure. The capacity of the nitrogen generation is set and inspected with a digital flow meter. Naturally, the nitrogen purity is adjusted and measured using a calibrated residual oxygen meter. Nevertheless, a failure or malfunction may always occur. If this is the case, it is important that you can rely on high-quality service. SOTEX believes service and availability are paramount. Our 24-hour service is always ready to assist you. Failures or defects are quickly and professionally resolved by our own technicians. This also means at night, on weekends and during holidays! For us merely a matter of course, and for you very important and pleasant! SOTEX provides service and maintenance for nitrogen generators, expansion breakers, compressors and compressed air system. SOTEX, as well as its service technicians, are VCA-certified*. (i.a. certified to work safely) SOTEX calamity valve 2" is included with every nitrogen expansion system. Mounted on the top of the vertical heat storage tank, this manual cock will be rarely used. However, in case of an unexpected malfunction, then you can set the pressure control to zero using the controls and easily open the cock. The vertical heat storage tank is atmospheric after opening the cock until you close the cock after the malfunction has been resolved. 6 7

5 VM series SOTEX nitrogen expansion systems TYPE NITROGEN GENERATOR SUPPLY VOLTAGE FREQUENCY CAPACITY MAX. FUSE SIZES PERNTAGE O² REQUIRED AIR WEIGHT Volt Hz Nm3/hr. Amp mm % m3/hr. kg VM-1.8 Standard version. VM-1.8 VMNitromat VM-1.8L Nitromat VM-1.8 Nitromat VM-1.8L Nitromat VM-1.8D Nitromat VM-1.8DL UL/CSA / / 1, The compressed air filters of the SOTEX VM and VP series nitrogen generators are very effective and reliable. The drainage of the condensation is regulated by an internal mechanical float switch. VM-1.8L Version with package. NITROGEN GENERATOR Nitromat VM-1.8D Nitromat VM-1.8DL Nitromat VM-2.6 Nitromat VM-2.6L Nitromat VM-2.6D Nitromat VM-2.6DL Nitromat VM-4.6 Nitromat VM-4.6L Nitromat VM-4.6 Nitromat VM-4.6L Nitromat VM-4.6D Nitromat VM-4.6DL Nitromat VM-4.6D Nitromat VM-4.6DL / / / LL / UL/CSA / / / / / LL 2,6 4, x 750 x SOTEX also offers an optional Long-Life package. The compressed air filters of the SOTEX VM-L and VP-L series nitrogen generators are even more effective and reliable as condensation drainage is then regulated by an electronic condensate drain. The Long-Life package improves operational reliability. Every SOTEX nitrogen expansion system comes with a clear installation and user manual. This manual - available in multiple languages - is located in the control panel and provides the engineer and/or user with stepby-step instructions. The explanations are supported by clear drawings and examples in colour. The SOTEX Nitromat nitrogen generators are characterised by a high reliability thanks to the use of the finest materials, such as high-quality pressure switches. Every SOTEX Nitromat nitrogen generator is equipped with an oil/water separator. In this separator the oil is absorbed by the presence of activated carbon. Consequently, the water that is drained remains clean and can be drained into the sewage system. This makes the system environment-friendly. 8 9

6 VP series SOTEX nitrogen expansion systems Two highly reliable pressure sensors are provided for measurements on the exterior of the vertical heat storage tanks. The sensor that measures the volume is placed on the side wall of the tank and the sensor that measures the pressure of the nitrogen cushion is placed on top of the tank. For more information, please peruse the installation and user instructions. The sensors include a removable PVC cover, as shown in the pictures below. TYPE NITROGEN GENERATOR SUPPLY VOLTAGE FREQUENCY CAPACITY MAX. FUSE SIZE PERNTAGE O² REQUIRED AIR SUPPLY Volt Hz Nm3/hr Amp mm % m3/uur kg VP VP-1.5L / 168 VPNitromat Nitromat VP Nitromat VP-1.5L / ,5 Nitromat VP-1.5D / 140 Nitromat VP-1.5DL / 177 Nitromat VP-1.5D / 140 Nitromat VP-1.5DL / / LL 177 Nitromat VP Nitromat VP-3.0L / 185 Nitromat VP Nitromat VP-3.0L / ,0 Nitromat VP-3.0D / 155 Nitromat VP-3.0DL / 192 Nitromat VP-3.0D / 155 Nitromat VP-3.0DL / / LL 192 WEIGHT VP-8.0 Standard version. NITROGEN GENERATOR Nitromat VP Nitromat VP-4.0L / Nitromat VP Nitromat VP-4.0L / ,0 Nitromat VP-4.0D / 1 Nitromat VP-4.0DL / 197 Nitromat VP-4.0D / 1 Nitromat VP-4.0DL / / LL 197 Nitromat VP-6.0 Nitromat VP-6.0L / ,0 Nitromat VP-6.0D / 163 Nitromat VP-6.0DL / 199 Nitromat VP Nitromat VP-8.0L 233 Nitromat VP Nitromat VP-8.0L / ,0 Nitromat VP-8.0D 203 Nitromat VP-8.0DL / 240 Nitromat VP-8.0D / 203 Nitromat VP-8.0DL / / LL x x

7 VP series SOTEX nitrogen expansion systems The refrigerant dryers that SOTEX uses in its systems are very robust and reliable. They are standard included in all VM models and optionally available through the Long-Life package in the VP series. By cooling the compressed air to a dew point of 3 C, the refrigerant dryer withdraws condensate from the compressed air. The built-in automatic electronic condensate drain takes care of draining the condensate to the oil/water separator. The refrigerant dryers are equipped with their own displays and failure systems that are connected to the SOTEX PLC display and can be read on it. This pressure switch protects the nitrogen generator from undesired low pressure. Below it is a connection point for clean and dry compressed. After concurring with SOTEX, it can be used for external, small compressed air consumers. VP-8.0L Version with package. The control panel of the SOTEX Nitromat nitrogen generator is equipped with a SIEMENS S7 PLC and a multi-colour LCD display. In the event of a failure, the display will turn red and display the malfunction. NITROGEN GENERATOR TYPE NITROGEN GENERATOR SUPPLY VOLTAGE FREQUENCY CAPACITY VP-12.0 VPNitromat Nitromat VP-12.0L Nitromat VP-12.0 Nitromat VP-12.0L Nitromat VP-12.0D Nitromat VP-12.0DL Nitromat VP-12.0D Nitromat VP-12.0DL Nitromat VP-17.0 Nitromat VP-17.0L Nitromat VP-17.0 Nitromat VP-17.0L Nitromat VP-17.0D Nitromat VP-17.0DL Nitromat VP-17.0D Nitromat VP-17.0DL Nitromat VP-22.0 Nitromat VP-22.0L Nitromat VP-22.0 Nitromat VP-22.0L Nitromat VP-22.0D Nitromat VP-22.0DL Nitromat VP-22.0D Nitromat VP-22.0DL Nitromat VP-33.0 Nitromat VP-33.0L Nitromat VP-33.0D Nitromat VP-33.0DL UL/CSA / / / / / LL / / / / / / LL UL/CSA / / / / / LL / MAX. FUSE SIZES PERNTAGE O² REQUIRED AIR WEIGHT Volt Hz Nm3/hr. Amp mm % m3/hr. kg 12,0 17,0 22,0 33, x x x x x x x x

8 SOTEX nitrogen expansion systems The production of compressed air creates condensation. Most of the condensate is collected in the compressed air tank, which is located under the screw compressor. Normally, you should regularly and manually empty the tank using the drain. However, the compressors provided by SOTEX are userfriendly and thus equipped with a fully automatic electronic drain, which drains the condensate to the oil/water separator. For the purpose of routine maintenance, SOTEX delivers carefully selected maintenance packages with original parts. WEIGHT CON- TENT SUPPLY VOLTAGE CAPACITY (FAD) SIZE ENGI- NE kg liter Volt m3/uur mm kw , x 510 x , ,1 3, ,1 4, x ,0 5, Hz,0 7, x 700 x ,0 11, ,0 15, ,0 15, x 700 x ,0 2, x Hz 28,0 4, ,0 5, , x 0 x x 0 x , ,1 3, ,1 4, x ,0 5, Hz 50,4 7, ,9 7, , ,8 15 PED 2014/68/EU / CU-TR Lloyds / ASME PED 2014/68/EU / CU-TR Standard choice. For Mexico, Canada / U.S.A. Standard choice. TYPE ROTARY SCREW COMPRESSOR NU AIR Mercury Mech type Nitro incl NU AIR Mercury Mech NU AIR Mercury Mech NU AIR Mercury Tronic NU AIR Sirio NU AIR Sirio NU AIR Sirio NU AIR Sirio ATLAS COPCO GX2P-10 EP ATLAS COPCO GX4P-10 EP ATLAS COPCO GX5P-10 EP ATLAS COPCO GX2-10 EP ATLAS COPCO GX3-10 EP ATLAS COPCO GX4-10 EP ATLAS COPCO GX5-10 EP ATLAS COPCO GX7-10 EP ATLAS COPCO G7-10 EL ATLAS COPCO G11-10 EL ATLAS COPCO G15-10 EL 10 BAR COMPRESSOR SBV NITROGEN STORAGE TANK TYPE TANK / REIVER CONTENT MAX. PRES. SIZES WEIGHT liter bar mm kg SBV Ø 0 x ,0 SBV Ø 790 x SBV Ø 790 x SBV Ø x SBV Ø x SBV Ø x ,5 SBV Ø x SBV Ø x SBV Ø x SBV Ø x SBV ASME 500 Ø 0 x ,0 SBV ASME 900 Ø 790 x SBV ASME Ø 790 x SBV ASME Ø x SBV ASME Ø x SBV ASME Ø x ,5 SBV ASME Ø x SBV11-00 ASME Ø x SBV ASME Ø x SBV ASME Ø x SBV Ø 0 x ,0 SBV Ø 790 x SBV Ø 790 x SBV Ø x SBV Ø x SBV Ø x ,5 SBV Ø x SBV Ø x SBV Ø x SBV Ø x PED 98/4040 PED 2014/68/EU ASME excl. stamp CU TR certifcate () Default choice; European label. Delivery includes Connection set. Receivers for projects in Canada and U.S.A. Delivery includes Connection set. Receivers for projects in Russia, Belarus and Kazakhstan. Delivery includes Connection set. Every package is provided with clear maintenance instructions. For more information, please contact our support department. Every nitrogen storage tank is accompanied by the related accessories, such as a manometer, valves and pressure relief valve

9 SOTEX B.V. Coenecoop PH Waddinxveen The Netherlands Models and specifications listed in this catalog are subject to change without notice. Copyright SOTEX B.V photos & design by Arjen - V2.0