CGA-P-8-2005.pdf
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1、 CGA P-82005 SAFE PRACTICES GUIDE FOR CRYOGENIC AIR SEPARATION PLANTS FOURTH EDITION COMPRESSED GAS ASSOCIATION, INC. 4221 Walney Road, 5th Floor Chantilly, VA 20151 Phone: 703-788-2700 Fax: 703-961-1831 E-mail: CGA P-82005 COMPRESSED GAS ASSOCIATION, INC. PAGE ii PLEASE NOTE: The information conta
2、ined in this document was obtained from sources believed to be reliable and is based on technical information and experience currently available from members of the Compressed Gas Association, Inc. and others. However, the Association or its members, jointly or severally, make no guarantee of the re
3、sults and assume no liability or responsibility in connection with the information or suggestions herein contained. Moreover, it should not be assumed that every acceptable commodity grade, test or safety procedure or method, precaution, equipment or device is contained within, or that abnormal or u
4、nusual circumstances may not warrant or suggest further requirements or additional procedure. This document is subject to periodic review, and users are cautioned to obtain the latest edition. The Association invites comments and suggestions for consideration. In connection with such review, any suc
5、h comments or suggestions will be fully reviewed by the Association after giving the party, upon request, a reasonable opportunity to be heard. Proposed changes may be submitted via the Internet at our web site, . This document should not be confused with Federal, state, provincial, or municipal spe
6、cifications or regulations; insurance requirements; or national safety codes. While the Association recommends reference to or use of this document by government agencies and others, this document is purely voluntary and not binding. A listing of all publications, audiovisual programs, safety and te
7、chnical bulletins, and safety posters is available via the Internet at our website at . For more information contact CGA at Phone: 703-788-2700, ext. 799. E-mail: . Docket 07-36 Atmospheric Gases and Equipment Committee NOTEDue to the extensive changes in and reorganization of this document, technic
8、al changes from the previous edition are not identified. FOURTH EDITION: 2005 REAFFIRMED: 1994, 2002 THIRD EDITION: 1989 2005 BY THE COMPRESSED GAS ASSOCIATION, INC. ALL RIGHTS RESERVED. 4221 WALNEY ROAD, 5TH FLOOR, CHANTILLY, VA 20151. Printed in U.S.A. -,-,- CGA P-82005 COMPRESSED GAS ASSOCIATION,
9、 INC. PAGE iii Contents Page 1 Introduction.1 2 Scope .1 3 Typical ASU features1 4 Definitions.2 5 Health hazards.7 5.1 Cryogenic liquids.8 5.2 Gas products.8 5.3 Asphyxiation8 5.4 Oxygen hazards 9 5.5 Protective clothing.10 6 General plant considerations10 6.1 Site selection.10 6.2 Safety factors i
10、n plant layouts10 6.3 Materials of construction10 6.4 Insulationother than coldbox11 6.5 Cleaning 12 6.6 Electrical requirements12 6.7 Noise .12 7 Intake air quality.12 7.1 Contaminants 12 7.2 Reactive contaminants that concentrate in oxygen.14 7.3 Reactive contaminants that concentrate in nitrogen1
11、4 7.4 Plugging components15 7.5 Haze and smoke from fires15 7.6 Contaminant sources.15 7.7 Identification of contaminants16 7.8 Location of air intake .16 7.9 Monitoring intake air16 8 Compressors16 8.1 Axial compressors.16 8.2 Centrifugal compressors17 8.3 Other dynamic compressor considerations.17
12、 8.4 Reciprocating compressors.18 8.5 Diaphragm compressors .20 8.6 Rotary positive displacement compressors.20 8.7 Refrigerant gas compressors 20 8.8 Screw compressors.20 8.9 Lubrication systems.20 8.10 Coolers and separators.22 8.11 Suction filters or screens.22 8.12 Special considerations for oxy
13、gen service 22 8.13 Operating and maintenance procedures.23 9 Air contaminant removal.23 9.1 Removal methods23 9.2 Contaminant removal stages.24 9.3 PPU operation.25 9.4 REVEX operation 28 9.5 Supplemental mechanical chillers.30 9.6 Caustic scrubbers31 -,-,- CGA P-82005 COMPRESSED GAS ASSOCIATION, I
14、NC. PAGE iv 10 Expanders 31 10.1 Loss of loading and overspeed31 10.2 Oil contamination of the process.32 10.3 Abnormally low temperatures33 10.4 Solids in gas stream33 10.5 Loss of lubrication33 10.6 Abnormal bearing temperature34 10.7 Abnormal vibration.34 10.8 Abnormal speed 34 10.9 Fouling of ex
15、pander with ice or carbon dioxide.34 10.10 Startup and shutdown .35 10.11 Operating and maintenance procedures.35 11 Cryogenic pumps .35 11.1 General35 11.2 Types of pumps.35 11.3 Materials of construction36 11.4 General pump system design36 11.5 Special considerations for oxygen service 37 11.6 Pum
16、p motor.37 11.7 Pump operation.37 11.8 Operating and maintenance procedures.38 12 Coldbox38 12.1 Foundations.38 12.2 Casings38 12.3 Insulation.39 12.4 Internal supports39 12.5 Coldbox and duct purging39 12.6 Process leaks39 12.7 Removing particulate material.40 12.8 Cryogenic adsorbers .40 12.9 Liqu
17、id levels.41 12.10 Monitoring contaminants .42 12.11 Argon separation and purification42 12.12 Noncondensable purge .43 12.13 Coldbox cleaning.44 12.14 Safe holding time for LOX .44 12.15 Liquefaction of air in the main heat exchanger44 12.16 Process upsets44 13 Control systems45 13.1 Instrumented s
18、ystems functions45 13.2 Critical safety systems.46 13.3 Operational safety systems.46 13.4 Routine plant operation .47 13.5 Unattended or partially attended operation .47 13.6 Remote operation47 13.7 Additional considerations for computer-based control systems 48 13.8 Additional considerations for f
19、ailsafe systems.48 13.9 Regulatory considerations.48 14 Product handling equipment.48 14.1 Liquid storage49 14.2 High pressure gas storage vessels .49 14.3 Liquid vaporizers .50 -,-,- CGA P-82005 COMPRESSED GAS ASSOCIATION, INC. PAGE v 15 Plant piping.50 15.1 General design considerations for plant
20、piping .50 15.2 General design considerations for check valves.50 15.3 Oxygen piping hazards50 15.4 Pressure relief devices51 15.5 Cryogenic piping52 15.6 Dead legs 52 15.7 Carbon steel piping .52 15.8 Venting 52 15.9 Product delivery.53 16 Shutdown procedures 53 16.1 Coldbox shutdown.53 16.2 Liquid
21、 and gas disposal.54 16.3 Plant derime 54 17 Repair and inspection.55 17.1 General maintenance considerations55 17.2 Supervisory control55 17.3 Special construction and repair considerations.55 17.4 Coldbox hazards55 17.5 Hazards of working in oxygen-enriched or oxygen-deficient atmospheres.56 17.6
22、Cleaning 56 18 Operations and training56 18.1 Operating procedures56 18.2 Emergency procedures .56 18.3 Management of change.57 19 References.57 Tables Table 1Effects at various oxygen breathing levels 9 Table 2Plugging, reactive, and corrosive contaminants in air .13 Table 3Typical default air qual
23、ity design basis13 Table 4Typical removal in PPU process25 Table 5Typical removal in REVEX process.28 Table 6Cryogenic adsorber names .40 Figure Figure 1Representative air separation plant flow diagram2 -,-,- CGA P-82005 COMPRESSED GAS ASSOCIATION, INC. PAGE 1 1 Introduction This publication provide
24、s guidance on the safe operation of cryogenic air separation plants. It is based on the experience of CGA member companies that operate cryogenic air separation units (ASUs). Industrial cryogenic air separation has some potential hazards that must be recognized and addressed. The hazards include ele
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