System_and_Supply_Specification__High-Pressure_High-Purity_Nitrogen_Generator.pdf

Portable Special-Purpose High-Purity (<50 ppm) Nitrogen

Generation System

Document ID: PSNS-SPEC-N2-4500

Facility: Puget Sound Naval Shipyard & Intermediate Maintenance Facility (PSNS &

IMF)

Classification: Technical Acquisition Specification

1. System Overview and Purpose

This documents the minimum mandatory performance, design, automation, layout, and safety requirements for a turn-key, portable, combined containerized high-purity nitrogen generation with a high-pressure booster gas compression and storage

The system shall be deployed in a heavy industrial maritime environment to supply high-pressure, generated gaseous nitrogen w/inert gas components to exterior storage banks. The system accepts shipyard-provided compressed Grade D breathing air or operates autonomously via self-supplied feed air, separating nitrogen to high purity (< 50 ppm O2), and boosts the output using a high-pack booster compressor directly to a delivery pressure of 4,500 psig.

All generation, compression, automated manifolding, controls, and maintenance storage should preferably be fully contained within a single ISO 668 Type 1C (20-

ft) intermodal container, while the high-pressure bottle bank/s can be standalone but included with the system.

2. Gas Supply and Purity Requirements

2.1 Gas Quality Specifications

The generated gas supply shall meet or exceed all requirements for Type 1, Grade

A Gaseous Nitrogen per Federal Specification CID A-A-59155, with a mandatory enhanced oxygen limitation:

• Oxygen (O2) Content: < 50 ppm by volume (≥ 99.995% Nitrogen/Argon, Grade A enhanced).

• Moisture Content: Maximum 0.02 mg/L (equivalent to 26.3 ppm water vapor by volume, dew point −63.5∘F/−53∘C or drier).

• Particulate Cleanliness: Free of particles > 50 microns; final supply filtration assured by an inline 10-micron or finer filter.

• Hydrocarbon (Gas) Content: < 50 ppm as Methane by volume.

• Oil Content: 100% oil-free gas delivery.

• Odor: None detectable.

• Argon, Neon, and Helium: Trace quantities permissible per CID A-A-59155.

2.2 Qualification Testing and Pre-Delivery Certification

1. NRTL Certification: The complete integrated assembly shall demonstrate full required operation and pass an OSHA-accredited Nationally Recognized Testing

Laboratory (NRTL) field evaluation and inspection prior to delivery.

2. Purity Verification: Prior to shipment, gas purity shall be verified by an accredited independent testing laboratory using samples collected directly from the system’s sample port in accordance with Section 4.5 of CID A-A-59155 and

CGA G-10.1 test procedures.

3. Capacity, Delivery, and Operating Profiles

3.1 Performance Ratings

• Nominal Storage Pressure: 4,500 psig (±50 psig).

• Nominal Delivery Pressure: 350 psig (±15 psig).

• Continuous Delivery Flow Rate: 100 SCFM at or above minimum required pressure.

• Mass Flow Rate: Equivalent to 7.81lbs/min (100 SCFM × 0.07807 lb/ft3 at standard conditions).

• Draw Cycle Capacity: Capable of sustaining 100 SCFM continuous flow for minimum 40-minute operational draws (4,000 SCF per cycle).

• Operational Frequency: Minimum 3 draws per 8-hour shift (≥ 9 draws per 24-hour continuous operating cycle).

• Supply Storage Capacity: minimum 24 hours of supply storage capacity.

(~36000 SCF) in commercially standard high pressure bottle bank racks.

• Supply Temperature: Delivered gas shall be within 15∘F to 20∘F of ambient temperature.

3.2 Dual-Mode Feed Air Architecture

The system shall incorporate dual intake capabilities with seamless switching:

3. Mode 1 (Primary Shipyard Supply): Direct tie-in to shipyard-provided Grade D breathing air supply (90-125 psig) standard pneumatic connection.

4. Mode 2 (Self-Supplied Feed): Onboard feed air compressor train complete with moisture separation, and filtration to provide required feed air when exterior compressed air is unavailable.

3.3 High-Pack Booster Compression Train

• Manufacturer: The high-pressure booster compressor shall match the make and model of command high-PAC fleet.

• Compressor Pressure Capability: > 4,500 psig.

• Auxiliaries: Complete with interstage cooling, gas conditioning/filtration, control and monitoring tied into the system PLC.

4. Fully Automated Supply Manifold Architecture

The system shall feature a fully automated, stainless steel, high-pressure distribution manifold accessible via an exterior lockable, weatherproof interface recessed panel. The manifold shall be physically divided into three distinct operational ports:

Supply Manifold ⟶ {

𝐒𝐭𝐨𝐫𝐚𝐠𝐞 𝐁𝐚𝐧𝐤 (𝐀𝐮𝐭𝐨𝐦𝐚𝐭𝐞𝐝 𝐇𝐏 𝐅𝐢𝐥𝐥 𝐏𝐨𝐫𝐭)

𝐒𝐭𝐨𝐫𝐚𝐠𝐞 𝐁𝐚𝐧𝐤/𝐬 (𝐀𝐮𝐭𝐨𝐦𝐚𝐭𝐞𝐝 𝐇𝐏 𝐅𝐢𝐥𝐥 𝐏𝐨𝐫𝐭)

𝐀𝐜𝐜𝐞𝐬𝐬𝐚𝐛𝐥𝐞 𝐒𝐚𝐦𝐩𝐥𝐞 𝐏𝐨𝐫𝐭 (𝐌𝐚𝐧𝐮𝐚𝐥 𝐆𝐫𝐚𝐛 & 𝐀𝐧𝐚𝐥𝐲𝐭𝐢𝐜𝐚𝐥 𝐏𝐨𝐫𝐭)

4.1 Automated Bank 1 and Bank 2 Connections

5. Valving and Automation: Each bank discharge line (bank/s) shall be equipped with an automated, fail-closed, high-pressure isolation and control valve

(pneumatic or electro-hydraulic actuator rated for ≥ 6,000 psig).

6. Automated Bank Filling Sequence:

• The PLC shall support fully automated sequencing to fill banks sequentially or operator pre-selection or autonomous bank priority routines.

• Filling shall automatically initiate once gas purity is verified and pressure conditions are validated.

• Filling shall automatically terminate and isolate the respective bank when the target cutoff pressure (4,500 psig) is reached.

7. Automated Isolation:

• In the event of an off-spec gas condition, process fault, emergency stop, or high-pressure setpoint breach, the automated bank valves shall immediately isolate within < 1 second to protect external bottle banks from contamination or backflow. An Isolation event type and exact condition need to be clearly displayed on operator HMI.

• Redundant inline reverse-flow check valves rated for full system pressure shall prevent back-pressurization into the generator or booster stages.

8. Automated Pressure and Purity Monitoring:

• The control system shall continuously monitor, display on the HMI, and log the real-time supply and bank/s pressure and purity of supply during all phases of operations.

9. Automated Manifold Purge Circuit:

• The manifold assembly shall include an automated or operator controlled, PLC-operated high-pressure purge and vent circuit.

• Upon system startup, bank transition, or off-spec detection, the system shall be able to automatically execute an engineered purge routine, safely venting contaminated or off-spec gas through engineered vent (preventing oxygen depletion limits) until supply specification requirement is detected.

• Automated line depressurization/venting shall be provided to safely bleed manifold pressure between supply storage bank/s.

4.2 Dedicated Sample Port

10. Design and Safety: A dedicated, permanently plumbed sample port shall be provided downstream supply isolation point.

11. Pressure Regulation: Equipped with a precision high-pressure reduction regulator and metering valve to safely deliver low-pressure gas streams

(15-30 psig) to portable gas analytical instruments or sample collection cylinders.

12. Overpressure Protection: The sample circuit shall include an independent

ASME-coded thermal and overpressure relief valve to protect testing personnel and connected analytical equipment.

5. Gas Quality Monitoring, Control, and Automated Logging

5.1 Continuous In-Line Gas Quality Monitoring

13. The system shall continuously monitor and control for gas quality in real time prior to permitting gas delivery into the manifold.

14. Monitored parameters shall include residual oxygen concentration (ppm O2), moisture/dew point, discharge pressure, and discharge temperature.

15. The monitoring instruments shall provide continuous real-time digital feedback directly to the system PLC and operator HMI display.

5.2 Automated Gas Quality Control and Interlock

16. Strict Quality Interlock: The system shall automatically inhibit and prevent charging of bank/s, or any exterior storage bank unless all delivered gas strictly meets or exceeds the required purity standards (< 50 ppm O2 and ≤ 0.02 mg/L moisture).

17. Automated Off-Spec Diversion and Purge: If measured gas quality deviates outside acceptable limits during operation, the control system shall instantly:

• Close the automated bank/s isolation valves to prevent off-spec gas entry.

• Direct the generator and booster output to an automated atmospheric purge bypass valve.

• Issue an alarm on the operator HMI and log the non-conformance event.

• Resume bank charging only after gas quality has autonomously returned to verified compliant parameters for a minimum consecutive stabilization period.

5.3 Automated Bank Charge and Quality Transaction Logging

The system shall feature an automated, non-resettable, tamper-evident digital logging system that records and archives every bank charge event. Each log entry shall record:

• Target Destination: Identification of the specific bank charged (Bank 1, Bank 2, etc. or Alternate Manifold Circuit).

• Timestamps: Exact date, charge initiation time, charge completion time, and total cycle duration.

• Pressure Profile: Initial bank pressure, peak fill pressure, and final stabilized pressure (4,500 psig).

• Gas Purity Record: Continuous average and peak oxygen concentration

(ppm O2), moisture level, and delivery temperature throughout the fill duration.

• Delivered Volume: Calculated standard cubic feet (SCFM) or total mass delivered per charge cycle.

• Event Outcome: Fill status (Successful Complete, User Aborted, or Quality

Interlock Abort, etc.).

• Data Export: All logged charge records shall be retrievable directly via the HMI display and exportable via a secure USB interface or standard Ethernet/SCADA network connection.

6. Equipment Layout and Enclosure Requirements

6.1 Single 20-Foot ISO Container Enclosure

• Container Standard: The entire system—including feed air supply components, nitrogen generation train, high pressure booster compressor, automated manifold, electrical distribution, control console, and maintenance and material locker should be completely housed within a single ISO 668 Type 1C (20-ft) heavy-duty intermodal shipping container.

• Structural Handling: Full container transport, structural corner castings, ISO twist-lock compatibility, forklift pockets, and certified top-crane lifting spreader capacities shall remain 100% intact per CSC and ISO specifications.

• Marine Environmental Hardening: Enclosure and exterior components shall be fully weather-sealed, insulated, and salt-air corrosion resistant, rated for continuous operation in coastal marine shipyard environments with 100% relative humidity (non-condensing) and temperatures ranging from

10∘F to 105∘F (−12∘C to 41∘C).

6.2 Integrated Onboard Maintenance Locker

The container interior shall incorporate a heavy-duty, permanently installed, latchable industrial maintenance and consumable storage locker with the following provisions:

• Capacity and Construction: all-steel industrial construction with internal shelving and secure latching to prevent transit movement.

• Pre-Stocked Maintenance Materials: The locker shall be delivered 100% fully stocked with all required maintenance materials, replacement consumables, and specialized tools necessary to perform all preventative and intermediate routine maintenance tasks across the entire system between vendor-required service cycles.

7. Controls, Electrical, and Autonomous Operation

7.1 Master PLC and HMI Architecture

• Controller: Industrial Programmable Logic Controller (PLC) programmed in an open, non-proprietary, standard IEC 61131-3 environment. Proprietary “black-box code” is not authorized.

• HMI Display: Minimum 12-inch daylight-readable, glove-compatible industrial touchscreen displaying real-time system P&ID schematic, pressure levels

(booster, bank/s, manifold, etc.), oxygen concentration, flow rates, operating temperatures, active alarms, and maintenance interval counters.

• Autonomous Run Capabilities: The system shall operate fully autonomously without requiring an on-site operator for up to 7 consecutive days of continuous operation, with the exception of startup, scheduled sampling, or manual shutdown.

7.2 Safety Interlocks and Autonomous Shutdown Conditions

The system control logic shall automatically execute immediate fail-safe shutdown and operator notification under the following conditions:

• Excess Discharge Flow: > 200 SCFM output flow detected.

• Low Gas Purity: Delivered gas fails to meet purity thresholds (> 50 ppm O2 or excessive moisture).

• High Atmospheric Oxygen in Enclosure: Interior oxygen levels exceed

> 23.0%.

• Low Atmospheric Oxygen in Enclosure: Interior oxygen levels fall below

< 19.5%.

• Compressor Faults: High interstage temperature/pressure, low oil pressure, or motor overload.

7.3 Electrical Utilities

• Service Rating: The complete containerized system shall operate from a single shipyard utility connection: 480 VAC (±10%), 3-phase, 60 Hz, 200 A maximum service.

• Electrical Safety: All control panels, motor starters, and wiring shall comply with NFPA 70 (NEC), NFPA 79, and NEMA 4X (exterior) / NEMA 12 (interior) standards.

8. Life Safety, Environmental, and Shipyard Compliance

8.1 Atmospheric Oxygen Monitoring and Life Safety Alarms

The container interior shall be continuously monitored by an independent dual-level ambient oxygen monitoring system equipped with audible sirens (110-120 dB) and high-intensity visual strobes:

• High Oxygen Event (> 23.0% O2): Initiates automated ventilation exhaust, visual/audible alarms, and annunciates:

"HIGH OXYGEN - SECURE ALL HOT WORK WITHIN 35 FT"

• Low Oxygen / Asphyxiation Event (< 19.5% O2): Initiates automated forced-air purge ventilation, visual/audible alarms, and annunciates:

"EVACUATE - LOW OXYGEN"

8.2 Acoustic Limits

• Exterior noise level shall not exceed 84 dBA measured immediately outside the closed container doors during full-load generation and compression.

• System vent and purge exhaust shall not exceed 104 dBA at maximum discharge, equipped with certified industrial silencers.

8.3 Restricted Paint Colors (PSNS Shipyard Rule)

In strict accordance with shipyard safety and radiological/hazmat protocols, the exterior and structural surfaces shall NOT utilize the following restricted shipyard colors:

𝐑𝐞𝐬𝐭𝐫𝐢𝐜𝐭𝐞𝐝 𝐂𝐨𝐥𝐨𝐫𝐬: 𝐌𝐚𝐠𝐞𝐧𝐭𝐚, 𝐘𝐞𝐥𝐥𝐨𝐰, 𝐑𝐞𝐝, 𝐚𝐧𝐝 𝐁𝐥𝐮𝐞

9. Deliverables, Site Support, and Warranty

18. On-Site Commissioning: Vendor shall include on-site turnkey delivery:

electrical/pneumatic hook-up oversight, functional commissioning, and formal operational verification at PSNS.

19. Technical Documentation: Vendor shall supply three (3) complete sets of comprehensive Operation and Maintenance (O&M) manuals, as-built electrical/P&ID schematics, structural lifting diagram (including exterior permanent lifting diagram), and a fully itemized Bill of Materials (BOM) detailing commercial part numbers, descriptions, and procurement sources for all active production/COTS components.

20. Consumable Spares & Locker Provisioning: In container maintenance locker with maintenance consumables: filters, lubricants, and spare consumable parts, etc.

> 23 . 0 % O 2

110 - 120 dB

200 A

60 Hz

± 10 %

480 VAC

< 19 . 5 %

> 23 . 0 %

> 50 ppm O 2

> 200 SCFM

− 12 ∘ C to 41 ∘ C

10 ∘ F to 105 ∘ F

100 %

SCFM

ppm O 2

4 , 500 psig

≤ 0 . 02 mg/L

< 50 ppm O 2 ppm O 2

15 - 30 psig

< 1 second

≥ 6 , 000 psig

Supply Manifold ⟶ { 𝐒 𝐭 𝐨 𝐫 𝐚 𝐠 𝐞 𝐁 𝐚 𝐧 𝐤 ( 𝐀 𝐮 𝐭 𝐨 𝐦 𝐚 𝐭 𝐞 𝐝 𝐇 𝐏 𝐅 𝐢 𝐥 𝐥 𝐏 𝐨 𝐫 𝐭 ) 𝐒 𝐭 𝐨 𝐫 𝐚 𝐠 𝐞 𝐁 𝐚 𝐧 𝐤 / 𝐬 ( 𝐀 𝐮 𝐭 𝐨 𝐦 𝐚 𝐭 𝐞 𝐝 𝐇 𝐏 𝐅 𝐢 𝐥 𝐥 𝐏 𝐨 𝐫 𝐭 ) 𝐀 𝐜 𝐜 𝐞 𝐬 𝐬 𝐚 𝐛 𝐥 𝐞 𝐒 𝐚 𝐦 𝐩 𝐥 𝐞 𝐏 𝐨 𝐫 𝐭 ( 𝐌 𝐚 𝐧 𝐮 𝐚 𝐥 𝐆 𝐫 𝐚 𝐛 & 𝐀 𝐧 𝐚 𝐥 𝐲 𝐭 𝐢 𝐜 𝐚 𝐥 𝐏 𝐨 𝐫 𝐭 )

> 4 , 500 psig

90 - 125 psig

15 ∘ F to 20 ∘ F

≥ 9 draws

4 , 000 SCF

40 -minute

100 SCFM

100 SCFM × 0 . 07807 lb/ft 3

7 . 81 lbs/min

100 SCFM

± 15 psig

± 50 psig

< 50 ppm

10 -micron

> 50 microns

− 63 . 5 ∘ F / − 53 ∘ C

26 . 3 ppm

0 . 02 mg/L

≥ 99 . 995 %

< 50 ppm

O 2

< 50 ppm O 2

𝐑 𝐞 𝐬 𝐭 𝐫 𝐢 𝐜 𝐭 𝐞 𝐝 𝐂 𝐨 𝐥 𝐨 𝐫 𝐬 : 𝐌 𝐚 𝐠 𝐞 𝐧 𝐭 𝐚 , 𝐘 𝐞 𝐥 𝐥 𝐨 𝐰 , 𝐑 𝐞 𝐝 , 𝐚 𝐧 𝐝 𝐁 𝐥 𝐮 𝐞

104 dBA

84 dBA

< 19 . 5 % O 2