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GSE NPM06P User Manual

Module nitrogen generator
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Module Nitrogen Generator
- User Manual -

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Summary of Contents for GSE NPM06P

  • Page 1 Module Nitrogen Generator - User Manual -...
  • Page 2 CATALOG １．Technical Parameters 1.1 Design Parameters 1.2 Capability Parameters 1.3 Utilities ２. Safety 2.1 Application 2.2 Preventing Accident 2.3 Danger Source ３. Function and System Structure 3.1 Using CMS to separate air 3.2 Pressure Swing Adsorption 3.3 Process flow 3.4 Air compressor and purification system 3.5 Air Separation 3.6 Nitrogen Storage and Supply ４.
  • Page 3 TECHNICAL PARAMETERS 1. Technical Parameters 1.1 Design Parameters Requirement of Compressed Air ： ≥2225CFH（63Nm Compressed Air Flow: /h） ≥101.5PSI（ 0.7MPa ） Compressed Air Pressure : Compressed Air Dew Point: 35.6~50℉（ 2℃-10℃ ） 1.2 Capability Parameters The Request of Nitrogen ： Flow 370.8CFH(10.5 Nm ≥99.99%（anaerobic）...
  • Page 4 2.1 Application PSA nitrogen generator system is designed with flow and purity described in chapter 1.2. However, without the permission of GSE. may not be changed as follows： · Setup changing goes beyond the limitation stated in part 1.2 · Changing Hardware setup in system If the above situations happen, the quality-guarantee is invalid.
  • Page 5 SAFETY Compressor, dryer and PSA System may run automatically under the mode of automatic manipulation. Therefore, before maintenance, the whole system and all parts of system must be shut down. Fire！ Waste gas generated by the system contains nearly 35% highly concentrated oxygen, it is easy to cause fire.
  • Page 6 FUNCTION AND SYSTEM STRUCTURE 3. Function and System Structure Nitrogen will be generated by separating Oxygen from air through Pressure Swing Adsorption technology. 3.1 Using CMS to separate air CMS (Activated Carbon Molecular Sieve) is a specially treated material. It is used to separate air.
  • Page 7 FUNCTION AND SYSTEM STRUCTURE Compressed air goes into one adsorption tank and flows from the bottom to the top of the tank. C o n t r o l C o n t r o l S y s t e m S y s t e m P V 1 0 8 P V 1 0 8...
  • Page 8 FUNCTION AND SYSTEM STRUCTURE ★ The lower air flow rate and longer adsorption time will result in lower nitrogen concentration. When adsorption of adsorbent reaches to saturation, it needs regeneration. The regeneration is caused by decompression. Due to the features of gas adsorption, it provides de-adsorption under low pressure.
  • Page 9 FUNCTION AND SYSTEM STRUCTURE 0.01μm (Remnant oil less than , which meets the demand of PSA system. Under rated running conditions, the 1 grade filter can normally work continuously for more than 4000 hours. After activate carbon tank, the compressed air will reach the required specifications: ·...
  • Page 10 FUNCTION AND SYSTEM STRUCTURE 3-1 Periodic Procedures Status Valve Opening Description and PV101、PV102、PV106、 Adsorption and separation in A and Adsorption in A PV108、PV105 regeneration in B regeneration in B Pressure balance in A and PV102、PV103、 Pressure balance of these two towers, PV106、PV107 adsorption and preparation for regeneration Regeneration in A...

  • Page 11: Installation

    INSTALLATION 4.1 Installation Requirement 1）Clean and dry compressed air 2) 120V/60Hz power 4.2 Normal installation way The nitrogen generator should be laid on the tidy and horizontal ground. A place with good ventilation is needed. If it is placed in a sealed area, air with over-oxygen and unqualified nitrogen should be emitted outdoors with pipes.

  • Page 12: Operation

    OPERATION 5．Operation 5.1 Control system SIEMENS CPUSR30 Type PLC is applied to this control system. 8 pneumatic valves will be controlled by the PLC. Oxygen analyzer detects oxygen concentration and when the concentration exceeds the setting value, the PLC will alarm to call attention to the manipulators to open the unqualified gas outlet valve and close the nitrogen outlet valve to prevent unqualified nitrogen going to the next system.
  • Page 13 OPERATION Drawing 5-1 Control panel display 1. HMI （A1） Display all the valve working condition as well as the adsorption time. Press“Start”--N Generator start to work. Press“Stop”--N Generator stop work. Press“Setup”--Parameter setting. Oxygen Content: ppm of oxygen content in N...
  • Page 14 Flow Rate: Flow rate of N State of Generator: Green,PLC work,N Generator work;Red ,PLC stop work,N Generator stop work; Setup LOGON : admin password:68213687 2.Pressure gauge(P1、P2、P3、P4): P1-P4 show the Pressure of Air Inlet; adsorber tower A; adsorber tower B and nitrogen tank 5.3 Oxygen analyzer The remnant oxygen content is detected by the oxygen analyzer continuously...
  • Page 15 Caution:There are three minutes for oxygen analyzer preheat from the Power ON. During this period, it is forbidden to start the nitrogen generator,otherwise the valve will act abnormally. 5.4 Start-Up: 1) Start the air compressor and make it meet the requirements of this machine (required conditions).
  • Page 16 OPERATION 2) Turn on the switch of nitrogen generator and oxygen analyzer on the control panel. Then set the allowed max value on the oxygen analyzer. Whether they two adsorption towers work normally are judged by the pressure switch between the two towers. During normal working, the pressure of the adsorption tower should be almost the same as the compressed air (perhaps lea than 7PSI (0.05MPa) ) while the regeneration pressure is 0.
  • Page 17 5.5 Shut Down: (A) Press “STOP” (B) close nitrogen product outlet valve and sampling valve. (C) Inlet valve of compressed air shall be closed. (D) Switch of nitrogen machine shall be turned off.

  • Page 18: Possible Malfunctions And Troubleshooting

    POSSIBLE MALFUNCTIONS AND TROUBLESHOOTING 6.1 Daily Maintenance and inspection Inspection Inspection method Rated value Period Filter Check whether there is effluent Discharge Daily from the discharge outlet Clean of the build-in Take the valve apart and clean in Every discharge valve neutral solution week The compressed air buffer tank...
  • Page 19 Check the sampling flow and The gas can be felt Oxygen pressure, if needed, adjust them. by hands Daily analyzer Check the flow meter and adjust it if needed. The flow should not be Flow meter Daily larger than the rated flow Pressure gauge Check whether they work normally Daily...
  • Page 20 POSSIBLE MALFUNCTIONS AND TROUBLESHOOTING 6.2 Possible Malfunctions and Troubleshooting Appearance Possible reasons Treatment Nitrogen flow too Check the nitrogen flow Analyzer alarm high Set value not correct Check the set value Check whether the PLC output light is on, if not, the PLC should be changed to a new one PLC problem Make sure the gas source pressure larger than...
  • Page 21 If there is no the above appearance, Check the The solenoid valve corresponding solenoid valves and check coil is burnt whether the wiring is fixed or not. If the coil is burnt, change the solenoid valve. There is a lot of The activate carbon black dust from or molecular sieves is...
  • Page 22 6.3 List of spare parts S.N. Name Number Replacement Remark cycle Air Filter element 180238 Half a year F104 Filter element 180213 a year F105 Silencer 180004 a year SL101/102 Pressure reducing 180679 2 years V103 filter Solenoid valve 181421 5 years 2-way Pneumatic...
  • Page 23 APPENDIX 7. Appendix 7.1 Flow Diagram 7.2 Electrical Diagram...