Service, Maintenance &
Troubleshooting
Presented by:
Peter Knotko
Service Engineer
Oxymat-Slovakia, s.r.o.
Worldwide Manufacturer of PSA Generators
Preventive maintenance
Monitoring the operation of the
unit and Preventive Maintenance
(PM) on a regular basis is the best
way how to ensure a long life for
your PSA Generator.
How often?
Daily
Weekly
Biannualy
Annualy
Every 5 years
And what is necessary to service ?
• Air compressor – all PM according to
manufacturer’s manual
• Filter elements – coal tower incl.
• Dryer – according to manufacturer’s
manual
• Drain system - Oxymat manual
• PSA generator - Oxymat manual
• High pressure equipment as RIX,
Haug or Bauer compressor –
according to manufacturer’s manual
Complete line
Daily maintenance
Daily inspection consist of:
• Every day simply observe the
operation of the unit
• Check
purity
and
product
consumption
• Verify what is the dew point of
feed air or displayed temperature
on the refrigeration dryer
• Make sure that the drain system is
functioning properly – press test
button
!!! Plugging off
the drain systems will cause water/oil
carry-over into the adsorbent vessels, and
will cause severe damage to the adsorbent
which is not covered under the
manufacturer's warranty
Weekly maintenance
Weekly inspection consist of:
Do observe your Air Supply
system basis
• Check operation conditions of
the air compressor (oil level, oil
temperature, noise etc...)
• Check filters – clogging /
diferential pressure indicators
must not be in red arrea at any
time of operation
Air compressor flow diagram
Weekly maintenance
plus:
• Air compressor – cleaning
procedure of oil after-cooler
+ oil level check
Clean procedure
• With an air jet (max. 2 bar / 30 psig)
blowing from inside towards outside blow
out the dust
• Repeat this operation blowing in the
opposite way
• Air Dryer – cleaning
procedure of cooler
• PSA control cabinet –
cleaning procedure of dust
filter
!!! Be careful not to damage the
aluminium fins of the cooling
package.
Biannualy maintenance
The biannualy inspection of the
PSA unit consists of:
1.
Service of air compressor
according to supplier manual
(filters and oil replacement, etc...)
2.
Service
of
air
dryer
according to supplier manual
(drain and strainer cleaning, etc...)
3.
Replace pre-filter element
1μm
and
micro-filter
element 0,01μm
Annual maintenance
The Annual PM of the unit
consist from the points of
biannualy PM, plus:
1.
Coal-Tower PM: Replacement
of coal, oil indicator and microfilter element is recommended
2. Air Tank PM:
• Inspection of drain system
• Each non-return valve has to be
cleaned and checked for damage
(replace if needed)
• Axial drain valve has to be cleaned
and properly re-greased
3. Inline filter for gas analyzer:
. Replacement of inline filter
Oil indicator and
micro- filter
Coal tower
Non-return
valve
Air tank
Axial drain
valve
Annual maintenance
3. PM of PSA generator :
• all system has to be inspected for
function, damage, leakage (solenoid
valve block, hose/pipe connection,
safety valves, etc...)
• process VIP valves has to be cleaned
and properly re-greased (for O2
application oxygen grease has to be
used)
• strainer and main regulator has to
be cleaned
• gas analyzer has to be checked with
calibration gas and calibrated if
needed
4. PM of receiver tank:
• active-carbon and bacterial/sterile
filter elements has to be replaced
Omal axial VIP valve
Omed upgrade filters placed
behind the receiver tank
Annual maintenance :
How to lubricate process valves
Every 2 years maintenance :
Recommended replacement of all process valves.
Every 2 years maintenance :
Top brass filters and O-rings for each column.
Every 3 years maintenance :
Recommended replacement parts :
HDMI valve block.
O2 Analyzer.
Inlet pressure regulator.
OXY Z - zirconia cell
OXY F - fuel cell
OXY FS - fuel cell (ppm)
OXY P - paramagnetic
Example when regular or proper
maintenance is not performed!
PSA generator types :
5 years maintenance – every 40 000 wh
PM of PSA generator every
5 years consist of:
• Molecular sieve replacement
is recommended
• Top brass filter replacement
• Vessel inspection
!!! Be carefull not to damage
the bottom stainless steel
filters during moleculare
sieve replacement
Top brass filter
Bottom stainless steel filter
Replacement of filter elements
Poor quality of compressed air could affect
the operation of your PSA generator.
The filter element(s) supplied with each
unit have been selected by manufacturer
based upon the units feed air requirements.
Replacement of filter element step by step:
• Close the air inlet for filter.
• Carefully remove 4/6 mm tube below
filter.
• Remove filter element by
counterclockwise turn.
• Remove one-way valve from old element
and mount it to the new one.
• Install new element with one-way valve.
• Plug-in the 4/6mm tube to filter element.
• Perform leak test.
filter
period [y]
period [h]
1μm
1/2 year
4,000
0.01μm
1/2 year
4,000
active carbon
1 year
8,000
bacterial/sterile
1 year
8,000
Replacement of active coal in coal tower:
• Once per year (recommended)
• Otherwise: when oil indicator gets red
Safety valves
Visual inspect safety relief valves
and other safety devices for dirt or
damage.
If there is debris in the valve seat,
scavenge the valve as follows:
1.
Pressurize vessel and loosen
the top screw one turn. This
should remove debris from
the valve.
2.
Retighten the top screw
Pressure vessel maintenance
•
External and internal inspection
of vessels and other pressurized
equipment must be carried out
according to local regulations.
• When your Oxymat or Nitromat
Generator is installed and
operated according to the
prescribed conditions, it is not
needed to do internal inspection
of generator vessels on regular
basis
•
If molecular sieve is replaced inspect
vessels for corrosion or other damage
(replace if needed)
•
Refer to molecular sieve material
safety data sheet for handling and
safety instructions of sieve.
•
Receiver vessel should be inspected
internally every 4 years or according to
local regulations.
Leak test procedure
1. Safely shut down the application /
consumption
2. Let the plant run in auto mode,
until generator will automatically
stop by pressure.
3. Close the feed air supply.
4. If fitted with purity monitoring
probe close of the pressure
reduction valve on probe inlet.
• After an hour read and note the pressure
P2 in oxygen receiver, column 1, column 2
and feed air tank.
• Then determine an eventually pressure
drop as the difference between P1 and P2
for each component.
• The Leak Test is OK, if the pressure drop
after one hour is less than 0.1 bar.
5. Read and note the pressure P1 in
oxygen receiver, column 1, column
2, coal tower and feed air tank.
• If a leak is detected, a suitable device must
be used to locate the leaking component
(leak tester in spray or soap water)
6. Let the plant stand still (rest) and
isolated in pressurized condition
for an hour.
• If closed, reset the pressure reduction valve
on probe inlet
Required tools
Safety warning:
Always wear personal protection
equipment for ears, hands, eyes etc...
Installation:
• Plastic tubes 4/6/8 mm
• spare valves, regulator
• pliers, screwdriver, spanner, etc.
• Connecting fittings for tubes
• reductions
• spare indicators
• PC with installed software
• Design Review Certificate
For valve lubrication:
• Paint brush
• Grease (for O2 application oxygen grease
has to be used-Kluebertemp YV 9392),N2 application –SuperLube.
• 2 spanners (according to size of the
valve).
• spare valve
For filter element replacement:
• spanner of proper size
• belt pliers
• PTFE tape
• filter element
Vessel inspection:
• spanner of proper size
• battery light
Troubleshooting
Most common operation failure is
insufficient product purity due to:
1.
Generator is overflowed !
2.
Low quality of feed air !
3.
Valve block error !
4.
Process valve error !
5.
Gas analyzer error or
misreading !
Solution:
1. Check system for leaks ,fastenings and
product consumption.
2.
Check filters, drain system, air
compressor temperature, dryer
temperature, ambient air temperature.
3.
Check air signals from solenoid valve
block to process valves (replace if
needed).
4.
Re-grease or replace valve if needed.
5.
Calibration or replacement if needed.
6.
Otherwise contact OXYMAT A/S.
• Service check list
• recommended to use on
daily(weekly,anually) basis to
avoid failure
and prevent possible
breakdown.
Oxymat A/S
Fasanvej 18-20
DK-3200 Helsinge
Denmark
Questions…
www.oxymat.com