O2 N2 SITE
Gas Systems
NM Portable Nitrogen Generator
Owner’s Manual
Manufactured by:
On Site Gas Systems, Inc.
35 Budney Road, Budney Industrial Park, Newington, CT 06111 USA
Telephone: +1-860-667-8888 / Fax: +1-860-667-2222
E-mail: info@onsitegas.com - Web site: www.onsitegas.com
PROPRIETARY NOTICE: All information herein is the property of On Site Gas Systems and must be
kept confidential and not be disclosed without On Site ’s agreement nor used, in whole or in part, in
manufacturing or selling gas separation equipment without the express written permission of On
Site. On Site authorizes the necessary and reasonable use of this document, and information herein,
solely for the evaluation, installation, operation, and maintenance of On Site ’s Nitrogen Generators.
No other use is authorized.
System Specifications
Make
Model
Output flow
Output pressure
Output pipe size
Compressor
Sullair
1450HH
1450 CFM
200psi
3"
Nitrogen Generator
Inlet
Compressed air
Inlet pipe size
2"
Filtration
Water trap, Coalescing, Particulate with auto drains
Membranes
8
Output
Nitrogen
Output flow
600 CFM
Output purity
96%
Output pipe size
2"
Make
Model
Output pressure
Booster
Hurricane
6T-276-43B-1200
1200psi
2
Table of Contents
1 INTRODUCTION ........................................................................................ 4
1.1
1.2
1.3
1.4
1.5
Company Presentation ............................................................................ 4
Safety Information ................................................................................... 4
Limits of Liability ...................................................................................... 6
Warranty .................................................................................................. 6
Service Return Policy .............................................................................. 7
2 SITE AND UTILITY REQUIREMENTS ................................................... 8
2.1
2.2
2.3
2.4
Air Supply ................................................................................................ 8
Altitude Adjustment.................................................................................. 8
Electrical Supply ...................................................................................... 8
Exhaust ................................................................................................... 8
3 SYSTEM OVERVIEW ................................................................................ 9
3.1
3.2
3.3
3.4
3.5
3.6
Control Sub System................................................................................. 9
Feed Air Sub System............................................................................. 10
Nitrogen Generator ................................................................................ 11
Membrane Sub System ......................................................................... 13
Nitrogen Output Sub System ................................................................. 14
Nitrogen Booster Sub System ............................................................... 15
4 PRINCIPLES OF OPERATION................................................................ 16
5 GENERATOR OPERATION .................................................................... 17
5.1
5.2
5.3
5.4
5.5
5.6
5.7
5.8
Pre-start Valve Positions ....................................................................... 17
Electrical Power ..................................................................................... 17
Purity Control Mode ............................................................................... 17
Feed Air Compressor ............................................................................ 17
Booster Compressor.............................................................................. 18
Nitrogen Generator Flow Control Valve Bypass Procedure ................... 18
System Shutdown.................................................................................. 19
Depressurize System ............................................................................ 19
6 MAINTENANCE....................................................................................... 20
6.1 Nitrogen Generator Preventive Maintenance (PM) ................................ 20
6.2 Hurricane Booster Preventive Maintenance (PM).................................. 22
6.3 Sullair Compressor Preventive Maintenance (PM) ................................ 25
7 TROUBLE SHOOTING ............................................................................ 31
3
1
INTRODUCTION
Congratulations on your purchase of an On Site Gas Systems, Inc. portable
membrane Nitrogen Generator. This turnkey machine provides a cost-effective
means for on-site generation of nitrogen. The Nitrogen Generator is based on the
latest membrane technology and utilizes specialized polymer fibers to separate the
nitrogen from the other gases contained in the air. The Nitrogen Generator uses
membrane modules to separate compressed air into a high-pressure nitrogen
product stream and low-pressure oxygen enriched waste stream. Particulate,
coalescing and carbon filters are included to remove impurities from the feed air.
Each Nitrogen Generator comes pre-tested and tuned to meet the customer
specified nitrogen flow rate and purity.
Since the system contains very few moving parts, maintenance and repairs are
minimal. Maintenance is simple yet necessary. Air compressor and filter
maintenance procedures are especially important and should be followed carefully.
If the recommended maintenance procedures are followed, your nitrogen generator
will provide you with many years of reliable service.
1.1
Company Presentation
On Site Gas Systems is an established world leader in the design and supply of
systems for generation of oxygen and nitrogen. We have been manufacturing
oxygen and nitrogen generators since 1987. Information about our products
and our company can be found at our web site: www.onsitegas.com
On Site Gas Systems activities frequently include full responsibility for
conceptual and detail engineering design, procurement, fabrication, supply and
installation of packages for various industries worldwide.
1.2
Safety Information
The following section outlines the basic safety considerations regarding use of
your Nitrogen Generator. Please refer to the technical references for additional
information.
Read carefully and act accordingly before installing, operating or
repairing the unit.
· The operator must employ safe working practices and rules
when operating the nitrogen generator.
4
· The owner is responsible for maintaining the unit in a safe
operating condition.
· Always use approved parts when performing maintenance and
repairs. Make sure that replacement parts meet or exceed the
pressure requirements.
· Only authorized, trained and competent individuals must perform
installation, operation, maintenance and repairs.
· Completely depressurize the generator and lines prior to
performing any mechanical work, including changing the filters.
The nitrogen must be vented to the outside or to a large, wellventilated room to avoid suffocation due to lack of oxygen.
· Personal Protective Equipment should be worn at all times when
in the proximity of or on the portable N2 system.
WARNING
Pressurized gases are contained within the generator, the air
compressor, the N2 booster compressor and all piping. Highpressure gases are dangerous and may cause injury or death if
handled or used inappropriately. Be certain all pressurized gas is
released before performing any maintenance.
· Never allow high-pressure gas to exhaust from an unsecured
hose. An unsecured hose may exhibit a whipping action, which
can cause serious injury. If a hose should burst during use,
immediately close all isolation valves.
· Never disable or bypass any safety relief valves on the air
compressor, N2 generator or booster compressor
· Always make certain that the nitrogen generator disconnect
switch is in the “off” position and unplugged prior to performing
any electrical work.
NOTE
If any statement or specification within this booklet, especially with
regard to safety, does not agree with legislation or standard
industry practices, the more demanding shall apply.
5
1.3
Limits of Liability
Buyer's exclusive remedy for all claims shall be for damages, and seller's total
liability for any and all losses and damages arising out of any cause whatsoever
including, without limitation, defects in or defective performance of the system,
(whether such claim be based in contract, negligence, strictly liability, other tort
or otherwise) shall in no event exceed the purchase price of the system in
respect of which such cause arises or, at seller's option, the repair or
replacement of such; and in no event shall seller be liable for incidental,
consequential or punitive damages resulting from any such cause.
Seller shall not be liable for, and Buyer assumes all liability for, the suitability
and the results of using Nitrogen by itself or in any manufacturing or other
industrial process or procedure, all personal injury and property damages
connected with the possession, operation, maintenance, other use or resale of
the System. Transportation charges for the return of the System shall not be
paid unless authorized in advance by Seller.
NOTE
Any modifications made by the customer without the consent of
On Site Gas Systems will negatively affect the product purity and
output specifications, and subsequently void the warranty.
1.4
Warranty
The Nitrogen Generator, excluding air supply system, is warranted against
defects in materials and workmanship, under normal use within the purity and
flow parameters quoted on the P.O. and operation, as applicable on the
warranty listed below. All compressors and boosters are covered by the
original equipment manufacturer's warranty.
The On Site Gas Systems Warranty includes the following:
Free repair or replacement of component parts where defects occur within the
first twelve (12) months of operation or twelve (12) months from the date of
invoice which ever comes first applies.
These warranties shall be null, void, inoperative, and not binding upon On Site
Gas Systems, Inc. if a defect or malfunction occurs in the product or any part
thereof from any feed air malfunction, or improper filter element
maintenance, or repair, attempted repair, adjustment or servicing by anyone
other than an authorized representative of On Site Gas Systems, or external
causes. Said warranty shall extend and apply to the Nitrogen Generator only
while said system is owned and used exclusively by the original purchaser.
6
NOTE
THERE ARE NO EXPRESS WARRANTIES BY ON SITE GAS
SYSTEMS INC, OTHER THAN THOSE SPECIFIED HERE. NO
WARRANTY OF TITLE AS PROVIDED IN THE UNIFORM
COMMERCIAL CODE SHALL BE IMPLIED OR OTHERWISE
CREATED UNDER THE UNIFORM COMMERCIAL CODE,
INCLUDING BUT NOT LIMITED TO WARRANTY OF
MERCHANTABILITY AND WARRANTY OF FITNESS FOR A
PARTICULAR PURPOSE.
1.5
Service Return Policy
If it is necessary to return a system for service, follow the procedure given
below. This procedure must be followed when returning a system for service.
If the system cannot be repaired at the site, then the owner must obtain a
written Return Material Authorization (RMA) number, which references the
model and serial number, from On Site Gas Systems Inc. No items will be
accepted for service or credit unless prior written authorization has been issued
by On Site Gas Systems Inc.
7
2
SITE AND UTILITY REQUIREMENTS
The following requirements must be met to enable the nitrogen generator to
perform at its rated capacity. Deviation from these requirements may result in
poor performance, injury to persons or machinery, and voiding of warranty.
Select a suitable flat, stable area for deployment, adequate space must be
provided around the portable N2 system for access and routine maintenance.
2.1
Air Supply
Air supplied to the N2 generator must be between 50F/10C and 130F/38C,
with a water dew point of 40F/5C or below. Air at temperatures higher or lower
than this may cause damage not covered by warranty. Likewise, moisture content
higher than that specified may damage the membranes and void the warranty.
The performance of the membrane Nitrogen Generator is based on a specific
operating pressure. [see specifications on pg 2] Operation at higher or lower
pressure will result in a nitrogen production above or below design; and pressures
higher than the design pressure will damage the N2 system and may void the
warranty. Air consumption for each Nitrogen Generator depends on nitrogen
product purity and flow rate. Please consult On Site Gas Systems for details.
2.2
Altitude Adjustment
Add 1% to the feed air requirement per every 300 feet above sea level
2.3
Electrical Supply
If the optional electrical generation equipment is incorporated within the system, it
will be sized to fit the needs of the system. If an electrical generator is not
provided with the system then it will be necessary to provide an appropriate power
source.
2.4
Exhaust
The exhaust piping from the nitrogen generator is vented outside the container.
Piping used should be the same size as the exhaust piping supplied with the
generator.
The exhaust for the compressor, the booster, and the electrical generator (If
supplied) is generated by internal combustion diesel engines.
8
3
SYSTEM OVERVIEW
This section describes the function of each control on the System
Control Panel. The location and purpose of all instrumentation is also
listed. A programmable logic controller (PLC) is located inside the
control box, which controls your On Site Nitrogen Generator. (Do not
attempt to alter the set points or the PLC program; any changes made
will alter the performance specifications, and void the warranty.)
3.1 Control Sub System
-Reference Appendix A for process flow of the following components-
3.1.1
Control Box
Controls for the nitrogen generation system are located inside the
Control Box that is mounted under the bed of the trailer on the drivers
side. Controls for supporting equipment, such as the compressor and
booster, are not included in this section. Please consult the original
manufacturer’s instructions for further information.
3.1.2
Main Power Switch
This switch supplies power to the System Control Panel. The Operator
Interface Terminal (OIT) Display will be lit when the switch is “ON”. The
“Main Power” switch is located on the control panel inside the control
box mounted under the trailer bed.
3.1.3
Heater Power Switch (Optional)
This switch supplies power to the Air In Heater Relay. The Heater
Power Light will be lit when the switch is “ON”. The “Heater Power”
switch is located on the control panel inside the control box mounted
under the trailer bed.
The “Heater Power” switch allows the operator to disconnect power to
the Air In Heater Relay. The system will continue to operate without the
air being heated. This may result in a reduction in the purity.
3.1.4
Heater Power Light (Optional)
The green indicator is lit when the “Heater Power” switch is “ON”.
3.1.5
Emergency Stop - Compressor
The emergency stop for the compressor is located in the control box and
will shut the feed air compressor off. Some compressor models may
have an emergency stop switch at the compressor control panel.
Because it is a latching switch, the feed air compressor cannot be
restarted until the engaged switch position is pulled and returned to the
run position. Operation of the remaining system will not be interrupted.
9
3.1.6
Emergency Stop - Booster
The emergency stop for the booster is located in the control box and will
shut the nitrogen booster off. Some booster models may have an
emergency stop switch at the booster control panel.
Because it is a latching switch, the booster cannot be restarted until the
engaged switch position is pulled and returned to the run position.
Operation of the remaining system will not be interrupted.
3.1.7
Programmed Logic Controller
A Programmed Logic Controller (PLC) controls the nitrogen generator.
The program allows for the optimum settings and is set at the factory.
(Do not attempt to alter the PLC program; any changes made will alter
the performance specifications, and void the warranty.)
3.1.8
Operator Interface Terminal
The OIT is a central location that allows the operator to monitor the
nitrogen generation system. It allows the operator to monitor all process
parameters, view all alarms, troubleshoot the source of the alarm, and
shut the system down if necessary.
3.2 Feed Air Sub System
3.2.1
Feed Air Compressor
The rotary screw air compressor is equipped with an instrument panel
that includes mechanical gauges, diagnostic shut down indicators,
circuit breakers and an engine monitoring system. The two stage air
filters will require regular maintenance as listed in the maintenance
section of this manual and described in detail in the mfg manual.
The feed air compressor supplies the nitrogen system with pressurized
air. It must be started and stopped at the feed air compressor control
panel on the compressor. An emergency stop button is sometimes
located on the compressor and always on the system control panel in
the control box mounted under the trailer.
3.2.2
After-Cooled Feed Air Input Valve (CV100a) (Optional)
The after cooled feed air valve controls the input air that has been
cooled internally prior to exiting the compressor, to the nitrogen
generator. After-cooled feed air will be at a lower temperature and
contain less moisture than the standard feed air.
3.2.3
Standard Feed Air Input Valve (CV100b)
The standard feed air valve, (the handle may have been removed to
insure that the appropriate output air is used), controls the input air.
This air has not been conditioned prior to exiting the compressor.
Standard air will be at a higher temperature than the after-cooled feed
10
air. This valve should remain closed at all times if after-cooled air is
available and should be after cooled to remove humidity.
3.3 Nitrogen Generator
The nitrogen generator first filters the feed air to remove condensate and
particulates. The air is then heated before flowing through the membranes.
The Nitrogen product that flows from the membrane outlet is controlled to
maintain flow and purity.
3.3.1
Feed Air Manifold Drains (CV201&205)
The feed air manifold drain will dispose of any water that has
accumulated in the manifold. These drains are directed through the
floor of the container and the trailer deck.
3.3.2
Pressure Relief Valves (PRV121 & PRV122)
These pressure relief valves are set at 200 psi.
3.3.3
Pre Filter Air Isolation Valve (CV101)
The pre filter isolation valve will stop the flow of input air to the filters. It
will isolate air from the filter sequence when used in unison with the post
filter air input valve (CV 105).
3.3.4
Pre Filter Pressure Transducer (PT110)
The pre filter pressure transducer is monitoring the pressure prior to the
filter sequence. A 4-20 mA signal is sent to the PLC and the signal will
be converted and can be viewed on the OIT
3.3.5
Pre Filter Pressure Indicator (PI112)
The pre filter pressure indicator is displaying the pressure prior to the
filter sequence.
3.3.6
Water Separator Filter (F102)
The water separator filter is the first in a series of filters. This filter will
capture any water droplets and automatically drain this water below the
trailer deck.
3.3.7
Coalescing Filter (F103)
The coalescing filter will coalesce any remaining condensate and drain
this below the trailer deck.
3.3.8
Carbon Filter (F104)
The filter is equipped with a 1-micron filter element to capture particles
greater that 1 micro in size. Any collected condensate will be drained
below the trailer deck.
11
3.3.9
Filter Auto Drains (CV202-204)
The filter auto drains will dispose of any water that has been removed
by the three-filter sequence. These drains are directed through the floor
of the container and the trailer deck.
3.3.10 Post Filter Pressure Transducer (PT111)
The post filter pressure transducer is monitoring the pressure after the
filter sequence. A 4-20 mA signal is sent to the PLC, the signal is
converted, and can be viewed on the OIT.
3.3.11 Post Filter Pressure Indicator (PI113)
The post filter pressure indicator is displaying the pressure after the filter
sequence.
3.3.12 Post Filter Air Isolation Valve (CV105)
The post filter air isolation valve will stop the flow of the filtered input air.
3.3.13 Pre Heater Temperature Transducer (TT113)
The pre heater temperature transducer is monitoring the temperature
before the circulation heater. A 4-20 mA signal is sent to the PLC and
the signal will be converted and can be viewed on the OIT. Pre Heater
Temperature Indicator (TI114)
The pre heater temperature indicator is displaying the temperature
before the circulation heater.
3.3.14 Heater (H107) (Optional)
The circulation heater will heat the input air before entering the nitrogen
membrane. When there is no available airflow through the heater, it
should be turned off. The heater is equipped with a thermostatic
temperature control and shut off.
3.3.15 Post Heater Temperature Transducer (TT115) (Optional)
The post heater temperature transducer is monitoring the temperature
before the circulation heater. A 4-20 mA signal is sent to the PLC and
the signal will be converted and can be viewed on the OIT.
3.3.16 Post Heater Temperature Indicator (TI117) (Optional)
The post heater temperature indicator is displaying the temperature
after the circulation heater.
12
3.4 Membrane Sub System
3.4.1
Membrane Air Inlet Isolation Valves (CV121,122,123…)
This series of valves control the air inlet to each individual membrane.
Closing the valve will stop all airflow through the associated membrane.
3.4.2
Membrane (MEM1, MEM2, MEM3…)
Compressed air enters the lower end of the permeable membrane. The
membrane is comprised of many hollow fibers. The nitrogen in the air
travels the length of the fibers and exits at the top of the membrane. The
oxygen in the air passes through the sidewall of the fibers and exits the
side of the membrane.
3.4.3
Membrane N2 Outlet Check Valves (CHV311,312,313…)
The membrane nitrogen outlet check valve will allow the nitrogen
product to exit the top of the membrane and prohibit any reverse flow
through the membrane
3.4.4
Membrane N2 Outlet Isolation Valves CV321,322,323…)
This series of valves control the nitrogen outlet from each individual
membrane. Closing the valve will stop all nitrogen flow out of the
associated membrane.
Insure that the membrane nitrogen inlet
isolation valve is closed first before closing the membrane nitrogen
outlet isolation valve.
3.4.5
N2 Manifold Drain Valve (CV210)
The nitrogen manifold drain valve will dispose of any water that has
accumulated in the manifold. This drain is directed out the sidewall of
the container and should be manually opened at regular intervals as
described in the maintenance section of this manual.
If any
condensation is observed flowing from this drain, notify ON Site Gas
Systems immediately.
3.4.6
Product Sample Valves (CV400a,b,c…)
This valve provides a means of sampling the purity of each individual
membrane.
13
3.5 Nitrogen Output Sub System
3.5.1
Nitrogen Product Pressure Transducer (PT331)
The nitrogen product pressure transducer is monitoring the pressure of
the nitrogen product outlet manifold. A 4-20 mA signal is sent to the
PLC and the signal will be converted and can be viewed on the OIT.
3.5.2
Nitrogen Product Pressure Indicator (PI306)
The nitrogen product pressure indicator is displaying the pressure of the
nitrogen product outlet manifold.
3.5.3
Oxygen Sensor (OS307)
The oxygen analyzer receives a small sample flow from the nitrogen
output manifold to continuously monitor the product nitrogen purity. The
oxygen analyzer display is located on the front of the signal wire panel
and at the OIT.
3.5.4
Oxygen Sensor Pressure Regulator (PCV308)
The oxygen sensor pressure regulator limits the pressure to the sensor
element.
3.5.5
Oxygen Sensor Pressure Indicator (PI309)
The oxygen sensor pressure indicator displays the pressure to the
sensor element.
3.5.6
Nitrogen Product Control Valve (CV320)
The nitrogen product control valve is controlled through the control
panel. It manages the flow of nitrogen from the nitrogen generator. The
output flow is directly related to the purity of the nitrogen and the output
flow of the booster.
3.5.7
Nitrogen Control Isolation Valves (CV 321-2)
The nitrogen flow control isolation valves allow the nitrogen flow and
pressure to be removed from the nitrogen product flow control valve.
Closing these valves will force the control of the nitrogen product
through the Nitrogen product manual flow control valve.
3.5.8
Nitrogen Product Manual Control Valve (HO323)
The nitrogen product manual control valve provides manual flow control
as an alternative to the PLC controlled nitrogen product flow control
valve. The nitrogen product manual control valve should be closed
during normal operation. Follow the nitrogen product flow control valve
bypass procedure to change flow control from the PLC controlled
nitrogen product flow control valve to the manual flow control valve.
(Generator Operation - Section 5.7)
14
3.5.9
Nitrogen Product Bypass Valve (CV325)
The nitrogen product bypass valve opens the nitrogen product line to
the atmosphere.
3.5.10 Nitrogen Product Bypass Muffler (M326)
The nitrogen product bypass muffler will reduce the noise level of the
exiting air.
3.6 Nitrogen Booster Sub System
The Nitrogen Booster will boost the nitrogen from the nitrogen generator
to a specified Pressure.(See specifications on pg…). The flow can be
monitored and controlled at the control panel. Detailed procedures for
this booster can be found in the manufacturer’s manual.
3.6.1
Nitrogen Product Shutoff Valve (CV 330)
The nitrogen product flow shutoff valve is the main shut off valve for the
low-pressure nitrogen product. Closing this valve will stop inlet flow to
the booster.
3.6.2
Main Discharge Valve (CV 340)
The main discharge valve is the main shut off valve for the highpressure nitrogen product. Closing this valve will stop outlet flow from
the booster.
3.6.3
High Pressure N2 Outlet Pressure Transducer (PT332)
The high-pressure nitrogen outlet pressure transducer is monitoring the
pressure of the nitrogen product after the booster and before the flow
meter just before it exits the system. A 4-20 mA signal is sent to the
PLC and the signal will be converted and can be viewed on the OIT.
3.6.4
High Pressure Nitrogen Outlet Flow Meter (FM335)
The high-pressure outlet flow meter is a volumetric measuring turbine
type. The nitrogen engages the flow sensor that results in the
generation of an electrical signal. The 4-20 mA signal is sent back to
the PLC.
3.6.5
High Pressure Relief Valve (PRV323)
This pressure relief valve is rated for the specific customer application.
15
4
PRINCIPLES OF OPERATION
The On Site Nitrogen Generator uses state-of-the-art technology to provide the
end user with a reliable source of nitrogen. An overview of the operation of the
generator is given below.
The Nitrogen Generator is a membrane technology based system. The Nitrogen
Generator consists of membrane modules, valve assemblies, air filters, inlet air
heater, and is controlled by an Operator Interface Control. Dry, (less than a dew
point of 40º F), compressed air (78% nitrogen, 21% oxygen, <1% argon), at the
specified pressure and normally 68°F/20°C is passed through the air filters, which
remove particles and oil vapor, and then through the inlet air heater, which heats
the air to the final optimum temperature of 100° F/ 38 °C. It is important to maintain
the inlet air at the correct pressure; otherwise generator performance may deviate
from design. Clean, dry, warm air is directed to the membrane inlet manifold where
the air stream is evenly distributed across the seven membrane modules. The
makeup of the membrane module fibers allows for the permeation of the oxygen
molecules back to the atmosphere, where it exits via the permeate vent as an
oxygen enriched gas. The nitrogen molecules are forced through the membrane
module fibers and are collected in the nitrogen discharge manifold.
The N2 purity is controlled by the speed in which the air flow is allowed to pass
across the membrane module fibers; the faster the air is allowed to pass, the less
exposure the O2 molecules have within the fiber assembly to permeate through the
fibers and exit to the atmosphere. The slower the air is allowed to pass over the
membrane modules the longer exposure the O2 molecules have to permeate out of
the membrane fibers and exit to the atmosphere. More O2 molecules equal less N2
purity
The N2 generator system is designed based upon customer purity and flow
requirements and the N2 purity is controlled by a flow control valve, which in effect
backpressures the nitrogen generator system and controls the speed of the air
across the membrane fibers.
Dry nitrogen product stream, with the specified purity content, exits the N2
generator. Nitrogen purity is checked using an oxygen analyzer. Table 2 below
graphically describes the N2 generators process.
16
5
GENERATOR OPERATION
This section describes the procedure for starting, running, and stopping the
nitrogen generator. The operator should notify personnel in the area that the
generator will be started and make sure the start-up will not interfere with any
other operations. Personal Protection Equipment should be used according to
site requirements.
5.1
Pre-start Valve Positions
Close the Feed Air Input Valves. (CV100b)
Open the Pre and Post Filter Air Isolation Valves. (CV101 and CV105)
Open the Membrane Air Inlet and N2 Outlet Valves. (CV121-7 and CV321-7)
Open the Nitrogen Product Bypass Valve approx. ½ open. (CV325)
Close the Nitrogen Product Shutoff Valve. (CV330)
Remove oxygen enriched purge cap.
5.2
Electrical Power
Confirm that the electrical cord from the N2 generator to the electrical generator
or an appropriate power source is securely connected.
If provided, start the electrical generator as per the manufacturer’s instructions
or insure that the power source is turned on.
Main power switch on Control Panel to “on” position
5.3
Purity Control Mode
On the Control Panel Display, insure that the unit is in the Purity Control mode.
[N2 System / PID / (enter password) / “Switch Mode” / Main Menu]
5.4
Feed Air Compressor
Start feed air compressor as per manufacturer’s instructions
When feed air compressor is “loaded” slowly open CV100b feed air input valve
When feed air compressor pressure (PI-110 or PT-110, PT305 @ Air
Compressor screen on the OIT) is stabilized; if provided turn inlet air heater to
“on” at Control Panel.
5.5
Booster Compressor
Monitor OS-307 until it displays 95% (or the desired purity)
Monitor TI-116 in the nitrogen generator or TT-115 on the Control Panel
Display until they stabilize at approx. 100°F.
[N2 System]
Close N2 generator vent bypass (CV- 325)
Slowly open nitrogen product valve (CV -330)
Open the main discharge valve CV340
Start the booster engine as per manufacturers’ instructions
On Control Panel Display, change from O2 purity control to flow control
[N2 System / PID / (enter password) / “Switch Mode” / Main Menu]
5.6
Nitrogen Generator Flow Control Valve Bypass Procedure
Partially open the Nitrogen Product Manual Control Valve (HO 323)
Slowly close Nitrogen Product Control Isolation Valve (CV321)
Close Nitrogen Product Control Isolation Valve (CV322)
Monitor OS307 and adjust HO323 to maintain the desired purity.
18
5.7
System Shutdown
If the system includes an internal heater: Turn heater control to “off” at the
Control Panel; wait approx. 5 minutes till proceeding to next step.
Open Nitrogen Product Bypass Valve approx. 25%. (CV325)
Slowly close Main Discharge Valve (CV340)
Close the Nitrogen Product Shutoff Valve. (CV330)
Shut down Booster Compressor as per manufacturer’s instructions.
Turn off Feed Air Compressor as per manufacturer’s instructions
Close Feed Air Input Valve (CV100a)
Close Pre-Filter Air Isolation Valve (CV-101)
Turn power to “off” at Control Panel Display.
Shut down Electric Generator as per manufacturer’s instructions.
NOTE
The generator will remain pressurized after shut down. Before
performing any maintenance or opening any piping systems,
always depressurize the system. Failure to do so may result
in injuries.
5.8
Depressurize System
Follow this procedure to depressurize the generator before addressing any
maintenance on the equipment.
Close Pre-Filter Air Isolation Valve. (CV-101)
Open Nitrogen Product Bypass Valve (CV 325)
Open the Nitrogen Flow Control Isolation Valves (CV321-2)
Confirm zero pressure reading at PI- 115 and PI- 306
19
6
MAINTENANCE
On Site Gas Systems Generators will provide many years of trouble-free
operation if the recommended maintenance is performed thoroughly and
regularly. In addition to the procedures given below, the customer must also
perform all maintenance recommended by the manufacturers of the component
items employed in the On Site Gas Systems Generators. Note that where any
component manufacturer specifications are different from those of On Site Gas
Systems, the more demanding schedule should be utilized.
WARNING
Read and follow all safety procedures given below and in
Section 1.2, Safety Information.
6.1
Nitrogen Generator Preventive Maintenance (PM)
The nitrogen generator is a rugged unit and requires only minimal maintenance.
Failure to follow the maintenance schedule may result in damage to the unit
and void the warranty. (Table 4 summarizes the Generator PM Schedule)
(Table 6 log can be used)
Hour meter can be found on the OIT Configuration screen.
Daily:
Check for air and product leaks and repair if necessary.
Visually check control panel.
Record nitrogen concentration and flow rate, operating or ambient
temperature, feed air pressure and product pressure.
Record inlet and outlet temperature upstream and downstream from the
heater.
Verify that the automatic filter drain is working properly.
Every 150 Hours:
Clean filter bowls.
Calibrate oxygen analyzer per the manufacturer’s instructions.
Every 500 Hours:
Change coalescing filter element.
Operate safety valves.
Operate manual valves.
Annually:
Replace O2 analyzer sensor for proper operation per the manufacturer’s
instructions.
20
GENERAL PREVENTIVE MAINTENANCE
SCHEDULE
Daily
Check for fluid or air/N2 leaks
X
Visually check Control Panel
X
Weekly
Verify Automatic Filter Drains Work
X
Manually operate condensate and filter drains
X
Monthly
Clean Filter Bowls
X
Calibrate Analyzer*
X
Quarterly
Change Particulate and Coalescing Filter Elements
x
Operate Safety Valves
X
Operate Manual Valves
X
Change Oxygen sensor*
6 Months
Annually
X
X
* Per manufacturers instructions
21
6.2
Hurricane Booster Preventive Maintenance (PM)
If operating in extreme environmental conditions (very hot, cold, dusty, or wet),
these time periods should be reduced accordingly.
Hour meter can be found on the OIT Configuration screen.
Hourly:
Drain inlet scrubber tank and interstage separator tanks (or as needed).
Daily:
Walk around inspection
Check pumper oil level (adjust if necessary)
Check engine oil level (adjust if necessary)
Check coolant system level (adjust if necessary)
Check air filter restriction indicator (adjust or replace if necessary)
Check gauges/lights (adjust or replace if necessary)
Check shutdown switches (adjust or replace if necessary)
Every 150 Hours:
Check fan belts (adjust or replace if necessary)
Check hoses and clamps ((air, oil, coolant) adjust or replace if
necessary)
Check coolers and radiator (adjust or replace if necessary)
Automatic shutdown system (test)
Check fasteners (adjust or replace if necessary)
Every 250 Hours:
Lubricate and Replace pumper oil and filter change
Every 500 Hours:
Check coolers and radiator (Clean Exterior)
Drive Engine
Refer to engine manual for all engine related service, adjustments, and
specifications.
Pumper Oil Level
Maintain between full and add
Pumper Crankcase Lubrication Oil
Lubricant viscosity chart for outside ambient temperatures
22
Oil Viscosity
SAE 0W-20
SAE 0W-30
SAE 0W-40
SAE 5W-30
SAE 5W-40
SAE 10W-30
SAE 15W-40
Ambient F
Minimum
Maximum
-40
-40
-40
-22
-22
-4
5
50
86
104
86
104
104
122
Refer to the Hurricane Booster Manual to select the appropriate oil viscosity based
upon maximum expected operating temperature
To determine if the oil in the crankcase will flow in cold weather, remove the oil
dipstick before starting. If the oil will flow off the dipstick, the oil is fluid enough to
circulate properly.
Select oil with API CH-4 (preferred) or API CG-4 (preferred) or API CF-4 certification.
Synthetic base stock oils are acceptable for use.
Recommended Crankcase Oils
Mobil Delvac 1300 Super 15W-40
Mobil Delvac 1300 Super 10W-30
Mobil Delvac 1300 1 Synthetic 5W-40
Radiator
The engine cooling system if filled at the factory with a 50/50 mixture of
distilled water and ethylene glycol. This is a permanent type antifreeze,
which contains rust inhibitors and provides protection to –35F. It is
recommended that the radiator be cleaned by directing compressed air
opposite fan flow direction which contains a non-flammable safety
solvent through the core of the cooler fins. Vent system when filling,
including pumper block and compressor valve-cooling fittings.
Coolers
The compressor suction, interstage, and discharge air-cools by means
of fin and tube type coolers, located at the pumper end of the booster.
The air flowing internally through the tube section is cooled by the air
stream passing through the fin section from the fan. When grease, oil
and dirt accumulate on the exterior surfaces of the coolers their
efficiency is impaired. It is recommended that the coolers be cleaned
by directing compressed air opposite fan flow direction which contains a
non-flammable safety solvent through the core of the cooler fins.
Batteries
Keep battery post to cable connections clean, tight and lightly coated
with corrosion preventative. The electrolyte level in each cell should
cover the tips of the plates. If necessary, top-off with distilled water.
23
Suction Scrubber Tank
Drain hourly as needed.
Caution – Drain suction scrubber tank more often as needed when
operating during high humidity.
Danger – Failure to drain suction scrubber tank may result in
compressor valve damage or hydraulic lock.
Air Cleaner
The drive engine is equipped with air filter restriction indicator. If the
indicator shows red the element should be replaced. The air cleaner
housing and piping should be inspected for leakage paths or inlet
obstructions.
Compressor Valve Inspection:
Remove suction piping from booster head.
Pressurize discharge manifold from 80 psig -100 psig.
Check all areas for O-ring leaks. Air leaking into the suction port of the
head is most likely a damaged inner O-ring on valve adapter plate or
head. It could also be a worn/broken compressor valve or damaged
internal compressor valve O-ring.
Use a straight bladed screwdriver to push the intake plate of the
compressor valve down. This may require a slight bump from the heel
of your hand. A burping sound and a short rush of air is normal. A very
slight leak indicated by a quiet hissing sound is okay. Continue
bumping the intake plate around the compressor valve to clean out any
oil and/or debris.
A continued rush and loud hissing of air while holding the intake plate
open is most likely a worn/broken discharge side compressor valve. It
could also be a damaged internal compressor valve O-ring.
BOOSTER PREVENTIVE MAINTENANCE SCHEDULE OVERVIEW
Hourly
Drain Inlet Scrubber/Interstage tanks
Daily
150 Hrs
250 Hrs
500 Hrs
X
Walk Around Inspection
X
Check Pumper Oil Level
X
Check Engine Oil Level
X
Check Coolant System Level
X
Check Air Filter Restriction
X
Check Gauges/Lights
X
Check Shutdown Switches
X
Check Fan Belts
X
Check Hoses and Clamps
X
Automatic Shutdown System
X
Check Fasteners
X
Lubricate and Replace Pumper Oil
X
Check Coolers and Radiator
X
24
6.3
Sullair Compressor Preventive Maintenance (PM)
A good maintenance program is the key to long compressor life.
Below is a program that when adhered to, should keep the
compressor in top operating condition.
WARNING
DO NOT remove caps, plugs and/or other components when
compressor is running and pressurized.
Stop compressor and relieve all internal pressure before doing
so
Daily Operation:
Prior to starting the compressor, it is necessary to check the fluid
level in the receiving tank. Should the level be low, simply add the
necessary amount.
NOTE
The radiator and engine cooling system must be drained and
flushed every two (2) years. Replace the coolant with a solution
of 50% ethylene glycol and 50% water or as required for your
geographic region. DO NOT use a leak sealing type of
antifreeze. Should a 100% water solution be used, a nonchromate rust inhibitor must be added.
After a routine start has been made, observe the instrument panel
gauges and be sure they monitor the correct readings for their
particular phase of operation. After the compressor has warmed up,
it is recommended that a general check on the overall compressor
and instrument panel be made to assure that the compressor is
running properly. Also check the air filter restrictions. Should they
indicate restriction, replace the elements immediately.
After initial 50 hours of operation:
Clean the return line orifice and strainer.
Change the compressor fluid filter.
Check Engine Operator’s Manual for required service.
Every 100 Hours:
Check the battery level and fill with water if necessary.
Check Engine Operator’s Manual for required service.
Every 250 Hours:
Check fan belt tension and adjust if needed.
Clean the radiator and cooler exterior. Depending on how
contaminated the atmosphere may be, more frequent cleaning may
25
be necessary. To clean between fluid cooler and radiator, the three
bolts securing the top of the fluid cooler to the top-mounting bracket
should be removed, allowing the fluid cooler to swing down on its
lower hinge.
Check Engine Operator’s Manual for required service.
Every 1000 Hours:
Clean the return line orifice and strainer.
Compressor Fluid Change Procedure
Turn on the compressor for 5 to 10 minutes to warm the fluid. Shut
the compressor off and relieve all internal pressure before
proceeding. Drain the fluid by removing the plug at the bottom of the
receiver tank. Change the compressor fluid and replace the fluid filter
element.
Main Fluid Filter Servicing
The main fluid filters are located in the coolant line between the
receiver tank and the compressor unit. The main filter elements are
replaceable. For installation of the filter elements, follow the
procedure explained below:
The compressor MUST be shut off and the system pressure MUST
be relieved.
Position a suitable container beneath the elements to catch fluid
drainage.
Remove elements using a suitable tool.
Rotate each element counterclockwise to remove.
Remove element and discard. These elements are not cleanable.
Make certain that the mounting surfaces of the filter heads are clean.
Apply a light film of clean fluid to each element gasket surface.
Center the new elements on filter housing heads and tighten until the
gaskets make contact with the filter housing. After gaskets make
contact, tighten ½ to 2/3 of a turn.
Run compressor and check for leaks.
Air Filter Maintenance
Air filter maintenance should be performed when indicated on the
instrument panel. The air filters are equipped with a primary element
and secondary element each.
NOTE
DO NOT strike elements against any hard surface to dislodge
dust. This will damage the sealing surfaces and possibly
rupture the elements.
26
The secondary element must be replaced after every third primary
element change. DO NOT reconnect the secondary element once it
is removed.
Element Removal
Clean the exterior of the air filter housing.
Remove the cover/element assembly by loosening the wing nut
securing the cover/element assembly.
Remove the cover/element assembly from the housing by unscrewing
the wing nut.
Clean the interior of the housing by using a damp cloth. DO NOT
blow out dirt with compressed air as this may introduce dust
downstream of the filter.
When it becomes necessary to remove the secondary element, pull
the element out of the housing.
Install the new secondary element over the rod.
With the secondary element in place, replace the primary element.
Element Inspection
Place a bright light inside the element to inspect for damage or leak
holes. Concentrated light will shine through the element and disclose
any holes.
Inspect all gaskets and gasket contact surfaces of the housing.
Should faulty gaskets be evident, correct the condition immediately.
If the clean element is to be stored for later use, it must be stored in a
clean container.
After the element has been installed, inspect and tighten all air inlet
connections prior to resuming operation.
Primary Element Replacement
Place the element in position over the secondary element.
Install the cover with the clean-out facing down. Clamp in place using
all latches located on the canister.
Separator Element Replacement
When fluid carry-over is evident after the fluid return-line strainer and
orifice, as well as the blow down valve diaphragm, have been
inspected and found to be in satisfactory condition, or if the separator
restriction gauge reads in excess of 10 psig (0.7 bar), separator
element replacement is necessary. Follow the procedure explained
below:
Remove all piping connected to the receiver tank cover to allow
removal (return line, service line, etc.).
Remove the fluid return line from the fitting in the cover. The
secondary element must be replaced after every third primary
27
element change. DO NOT reconnect the secondary element once it
is removed.
Clean the exterior of the air filter housing.
Remove the cover/element assembly by loosening the wing nut
securing the cover/element assembly.
Remove the cover/element assembly from the housing by unscrewing
the wing nut.
Clean the interior of the housing by using a damp cloth. DO NOT
blow out dirt with compressed air as this may introduce dust
downstream of the filter.
When it becomes necessary to remove the secondary element, pull
the element out of the housing.
Install the new secondary element over the rod.
With the secondary element in place, replace the primary element.
Place a bright light inside the element to inspect for damage or leak
holes. Concentrated light will shine through the element and disclose
any holes.
Inspect all gaskets and gasket contact surfaces of the housing.
Should faulty gaskets be evident, correct the condition immediately.
If the clean element is to be stored for later use, it must be stored in a
clean container.
After the element has been installed, inspect and tighten all air inlet
connections prior to resuming operation.
Place the element in position over the secondary element.
Install the cover with the clean-out facing down. Clamp in place using
all latches located on the canister.
When fluid carry-over is evident after the fluid return-line strainer and
orifice, as well as the blow down valve diaphragm, have been
inspected and found to be in satisfactory condition, or if the separator
restriction gauge reads in excess of 10 psig (0.7 bar), separator
element replacement is necessary. Follow the procedure explained
below:
Remove all piping connected to the receiver tank cover to allow
removal (return line, service line, etc.).
Remove
Remove the twelve (12) 5/8 x 2.25 in cap screws and lock washers
and lift the cover from the receiver tank with the minimum
pressure/check valve in place.
Remove the separator element.
Scrap the old gasket material fro the cover and the flange on the
receiver tank. Be sure to keep all scrapings from falling inside the
tank.
Install the gaskets.
28
Make sure grounding staples are attached to the separator gasket.
DO NOT REMOVE STAPLES.
Replace the receiver tank cover. Install the twelve (12) 5/8 x 2.25 in
cap screws and lock washers in finger-tight, then gradually tighten in
a crisscross pattern in 4 to 5 steps. Always tighten the cap screws
alternately at opposite ends of the cover. Never tighten cap screws
adjacent to each other. Torque cap screws to 112 to 127 ft-lb (151 to
172 N-m).
Reconnect all piping. The fluid return line should extend to the
bottom of the separator element or no more than 1/16 in (1.6 mm) up
from the bottom. This will assure the proper fluid return flow.
Clean the fluid return line strainer and clear the orifice prior to
restarting the compressor.
Control System Adjustment
Start the machine and let it warm-up. Place pressure selector switch
in the “HIGH” position. Check for leaks around connection.
Open service valve slightly. Slowly close the service valve, watching
the pressure gauge to ensure the unload pressure does not exceed
170 psig. If it does, the control regulator setscrew must be backed
out until the compressor will unload. With service valve closed, adjust
the control regulator for a 60-psig setting. With service valve still
closed, adjust the high-pressure regulator to maintain a discharge
pressure of 160 psig. Check the idle speed setting and adjust the
threaded rod in the speed control cylinder to maintain 1400 RPM.
Open the service valve to load the compressor to maintain 150-psig
discharge pressure. Check to see that the engine throttle lever is
against the high-speed stop screw. If it is not, the control regulator
setting may have to be raised. Set full load operating speed to 1800
RPM by adjusting the high-speed stop screw.
Switch to “LO” position. Close the service valve and set the lowpressure control regulator to maintain 115-psig discharge pressure.
Open the service valve to maintain 100 psig and check for 1800-RPM
full-load speed. If lower speed is observed, raise the setting of the
low-pressure control regulator until speed is achieved.
COMPRESSOR PREVENTIVE MAINTENANCE SCHEDULE OVERVIEW
50 Hrs
Clean Return Line Orifice and Strainer
X
Change Compressor Fluid Filter
X
Check Engine Operator’s Manual
X
100 Hrs
Check Battery Level
X
Check Engine Operator’s Manual
X
250 Hrs
Check Fan Belt Tension
X
Clean Radiator and Cooler Exterior
X
Check Engine Operator’s Manual
Clean Return Line Orifice and Strainer
1000 Hrs
X
29
X
SYSTEM PREVENTIVE MAINTENANCE SCHEDULE
Table 4 – PM Schedule Overview
Hourly
Drain Inlet Scrubber/Interstage tanks
Daily
50 Hrs
100 Hrs
250 Hrs
500 Hrs
1000 Hrs
Annually
X
Walk Around Inspection
X
Check Pumper Oil Level
X
Check Engine Oil Level
X
Check Coolant System Level
X
Check Air Filter Restriction
X
Check Gauges/Lights
X
Check Shutdown Switches
X
Check for Leaks
X
Visually check Control Panel
X
Record Flow/ Pressure/ Purity
X
Record Temperature
X
Verify Automatic Filter Drain
X
Clean Return Line Orifice and Strainer
X
Change Compressor Fluid Filter
X
Check Engine Operator’s Manual
X
Check Battery Level
X
Check Engine Operator’s Manual
X
Clean Filter Bowls
X
Calibrate Oxygen Analyzer*
X
Check Fan Belts
X
Check Hoses and Clamps
X
Automatic Shutdown System
X
Check Fasteners
X
Check Fan Belt Tension
X
Clean Radiator and Cooler Exterior
X
Check Engine Operator’s Manual
X
Lubricate and Replace Pumper Oil
X
Change Coalescing Filter Element
X
Operate Safety Valves
X
Operate Manual Valves
X
Inspect Valve, Repair Kit as needed
X
Check Coolers and Radiator
X
Clean Return Line Orifice and Strainer
X
Replace O2 Analyzer*
X
* Per manufacturers instructions
30
7
TROUBLE SHOOTING
This section enables the operator to determine the cause of operation problems
and suggests remedies for the problems. If there are several likely causes,
investigate the simpler solutions first. Regardless of the type of malfunction, a
person who is thoroughly familiar with the system performs the troubleshooting
best. See table 5 for trouble shooting details. If further assistance is required,
contact On Site Gas Systems Inc.
Symptom
Low N2 flow
Low product
purity
Trouble Shooting - Table 5
Probable Cause
Corrective Action
Low O2 purity set point in control
Increase O2 set point
logic
High DP across filters (>10 psi)
Replace filter elements
Check feed air compressor for
Insufficient feed air supply
any alarm conditions; correct as
per vendor operating manual
Inlet air temperature low
Check heater function
Confirm all individual module
Some membrane modules
inlet and discharge valves are
isolated
open as per original setup
Check temperature at TI-115
Inlet air temperature low
(approx. 100° F); check heater
operation
Check FM-335 set point; design
Excess N2 draw
max parameter is 400 scfm
Product flow too high
Decrease product flow @FM 335
O2 analyzer malfunction
Check operation and calibration
Check feed air compressor
operation; check DP across inlet
filters
Feed air pressure too low
Filter drain
remains open
Filter drain does
not open
Oil or water in N2 System
(see section 5.5.5)
Contact On Site Gas Systems
Drain valve dirty
Clean valve
Drain valve plugged
Clean valve
Tubing plugged or pinched
Replace tubing
IF NONE OF THESE CORRECTIVE ACTIONS RESOLVE THE PROBLEM,
CALL ON SITE GAS SYSTEMS – TECHNICAL SUPPORT- AT 860-667-8888
31
Appendix A
Nitrogen Generator Data
Log
Table 6
Model:_____________________
Serial Number:_____________
Date Received______________
Date
Input PSI@ Regulator
Peak PSI on Gauges
N2 Tank PSI
O2 Purity (Analyzer)
Analyzer
Calibration
Date
Appendix B
System P&ID
3