Incident Report Flyers

IR-M0116PI02
On the 28th of January, around 0200 HRS, new N2 unit, M-4203, malfunctioned which
led to the presence of 9.0 % Oxygen in the N2 Header which supplies EDC/VCM.

IR-M0216N04
On the 03rd of February 2016, around 0200 HRS at UTY/CCPP, it was reported that
AI-4201, the purity analyzer of the old N2 Unit, M-4202, malfunctioned.

Incident Investigation
N2 Unit Operation
EPCL uses two Nitrogen generation units, the Old N2 Unit, M-4202 and the new N2
Unit, M-4203, for nitrogen extraction from air via Pressure Swing Adsorption (PSA).

The PSA Nitrogen Unit consists of the following components: Air Compressor, Mist
Eliminator, Carbon Filter, Air Buffer Tank, two Adsorption Towers, Nitrogen Buffer
Vessel, After Filter and Nitrogen Storage Tank, VE-7404, of a total capacity of 100
m3. The process is distributed over Feed Air Compression, Feed Air Pretreatment,
Adsorption and Desorption. Atmospheric air is compressed by the Air Compressor
and is fed through the Mist Eliminator to remove any moisture and entrained oil.
The air is then passed through the Carbon Filter to remove oil vapours prior to
entering the Air Buffer Vessel. The treated air enters one of the Adsorption Towers
where it comes into contact with the Carbon Molecular Sieve (CMS). Oxygen is
removed at the CMS and purified nitrogen passes to product delivery operation
through the Nitrogen Buffer Vessel.

PSA uses the fact that under high pressure, gases tend to be attracted to solid
surfaces, or adsorbed. The higher the pressure, the more gas is adsorbed; when the
pressure is reduced, the gas is released, or desorbed.
So when air is fed under pressure into a vessel containing an adsorbent bed of CMS
that attracts oxygen more strongly than it does nitrogen, the oxygen stays in the
bed, and the gas coming out of the vessel is enriched in nitrogen.
When the bed reaches the end of its capacity to adsorb oxygen, it is regenerated by
reducing the pressure, thereby releasing the adsorbed oxygen. The N2 Unit uses
two adsorbent vessels because it allows near continuous production of the target
gas. This results in significant energy savings, and is therefore a common industrial
practice. Finally after passing through the After Filter, it is stored in Nitrogen Storage
Tank, VE-7404.
Nitrogen produced at the N2 unit is consumed at the following units/operating-posts
at EDC/VCM: Crude EDC Tanks, VCM Pyrolysis Furnaces, Stripper Vacuum Pump,
Chiller Condenser, Chlorine Header, Ethylene Header, Chlorine and Ethylene
Analyzers etc.
Nitrogen purity analyzer, AI-4203, is used to monitor the purity of the nitrogen
generated at the new N2 Unit, M-4203 while nitrogen purity analyzer, AI-4201, is
used to monitor the purity of the nitrogen generated at the old N2 Unit, M-4202.

New N2 Unit, M-4203, Malfunction

On the 28th of January 2016, around 0200 HRS, 9.0 % O2 was reported in the N2
header which is used to supply the nitrogen demand at EDC/VCM. The N2 header in
question is supplied from the HP N2 header at the Nitrogen Generation Unit at
UTY/CCPP.
AI-4203 was registering a purity of 99.2 % in the field while tests done at the Lab
showed 96.85 % purity.

The following comprehensive checks were carried out by the relevant interfaces to
diagnose, troubleshoot and address the failure at the new N2 Unit, M-4203. A
summary of the actions taken and their findings is presented below:

AI-4203 was inspected. The analyzer and its sensing line were found choked
with carbon dust and cleaned. AI-4203s calibration was checked and found
okay as verified by the span (99.9 % N2 Concentration) and zero (78 % N2
Concentration).
Although the analyzer was found okay, to rule out any other possibilities, a
new purity analyzer was issued and installed. However, the nitrogen purity
issue still could not be resolved
Function testing was performed on the XVs next. One XV was found stuck on
account of a damaged O-ring. The O-ring had been worn out due to carbon
media carry-over as evidenced by the presence of carbon around it. The XV
was therefore replaced. However, the nitrogen purity issue continued to
persist.
The regeneration line was inspected. Its filter was found filled with carbon
dust and was therefore cleaned.
Uneven pressure drop was observed at the regeneration line as indicated by
its regulator PG. The PG would indicate maximum pressure drop during one
regeneration cycle while it would indicate little to no pressure drop during the
other cycle. Further investigation showed that one of the NRVs was damaged.
Because of the damaged NRV, proper purging would not happen during one
regeneration cycle and the purity of Nitrogen would end up being disturbed.
The NRV was checked and replaced by Maintenance. The NRVs have been
highlighted in the figure above. Nitrogen purity issue was finally resolved
after replacement of the damaged NRV.
The filters were inspected and found okay as per feedback by Process and
Maintenance. However, this raises concern because dust carry-over still
continues to persist despite the fact that the filters were found healthy. The
dust carry-over in the piping, equipment and downstream circuit issue still
has not been concluded so the adequacy of the filters needs to be checked
and the dust carry-over issue needs to be further investigated, evaluated and
resolved.

AI-4201 Malfunction at Old N2 Unit, M-4202:

On the 03rd of February 2016, around 0200 HRS at UTY/CCPP, it was reported that
AI-4201, the purity analyzer of the old N2 Unit, M-4202, malfunctioned.
The following checks were taken and the following observations were made while
addressing the failure of AI-4201:

The purity analyzer sensor was inspected. It was found choked with carbon.
The analyzer was therefore cleaned via back-purging and recalibrated. It
must be noted that the same issue was also reported a day back and similar
choking was observed and duly rectified.
The main outlet regulator was also found choked with carbon. It was cleaned.
However, desired nitrogen purity was still not achieved.
So the regeneration line was inspected and found filled with carbon. It was
cleaned and desired purity levels were finally achieved.

Conclusion:
Nitrogen purity issue occurred due to the NRV sticking on account of carbon dust
carry-over. Because of the damaged/stuck NRV, proper purging would not happen
during one regeneration cycle and the purity of nitrogen would end up being
disturbed. The NRV was replaced which resolved the purity issue. However, the dust
carry-over issue still has not been concluded.

Recommendations:
Risk
Level

1.
2.

3.
4.

5.
6.
7.

8.

9.

10.
11.

Checking and replacement of damaged NRVs at the

regeneration line of New N2 Unit, M-4203.
Checking and cleaning of XVs at both N2 Units. Replacement of
stuck XV at New N2 Unit due to damaged O-ring due to carbon
dust carry-over.
Cleaning of choked analyzer sensing lines at Old N2 Unit, M4202 and New N2 Unit, M-4203.
PM frequency of purity analyzers, AI-4201 and AI-4203, and their
sampling tubes/sensing lines to be increased from 1 month to
one week for the timing being for one months time.
Replacement of the remaining XVs of the N2 units with butterfly
type XVs for reliability enhancement.
Institution of a PM plan for regular NRV inspection of Old N2
Unit, M-4202 and New N2 Unit, M-4203.
Analyzer sensing line tapping to be provided from the top of the
line to limit carbon media carry-over into the analyzer sensing
lines.
Installation of filter regulators at the sensing line of the purity
analyzers, AI-4201 and AI-4203, to avoid carbon media carryover into the analyzers.
Inspection of the mesh assembly in the adsorption towers and
filters to investigate and address media carry-over issue at both
the N2 units.
The filters need to be inspected for proper seating/sealing and
their adequacy needs to be verified.
Devise routine PM/inspection regime of the Adsorption Towers,
the Buffer Tanks, pre-filters and main filters of both the N2 units.

Name:
Date:
Name:
Date:

Section Head

Signed:

Department Manager

Signed:

Responsibility

Completion
Date

III

MUS

Done.

III

MM

Done.

III

MM

Done.

III

MM

III

MM

III

SK

III

MSA/SRA

III

MM

III

SK/SRA

III

MUS/SRA

III

SK/SRA

30-9-16