GENERON HPLC Membrane Nitrogen System

Operating and Maintenance Manual

SECTION 1
INTRODUCTION / WARRANTY POLICY

1.1

SCOPE
This manual describes the general operating and maintenance instructions for a
GENERON* HPLC Membrane Nitrogen System as designed by Generon IGS.. The
purpose of this manual is to enable a trained operator to start-up, shutdowns, make minor
process adjustments, and maintain a unit, which has been set-up initially by a trained
Generon IGS. Service representative. This manual is not intended to instruct the user on
how to perform detailed modifications or major set-up changes to the HPLC membrane
system.
Customers may direct specific questions related to the maintenance and operation of the
GENERON HPLC Membrane System to the Generon IGS. Customer Service Department
at 713-937-5200.

1.2

CONFIDENTIALITY
This document contains confidential or proprietary information of Generon IGS.. Neither
the document nor the information herein is to be reproduced, distributed, used or disclosed,
either in whole or in part, except as specifically authorized by Generon IGS..

1.3

Membrane Protection
The membrane modules should never reach freezing temperatures. Keep the modules
between 40F (4.4C) and 122F (50C). Exposure to temperatures outside the specified
range could lead to membrane damage and performance reduction.

* GENERON is a trademark of Generon IGS., Inc.


GENERON HPLC Membrane Nitrogen System
Operating and Maintenance Manual

SECTION 2
SAFETY

2.1

SAFETY
The GENERON HPLC Membrane System is capable of producing nitrogen with purities
ranging between 95% to 99.9%. The nitrogen produced by the GENERON HPLC
Membrane System is a colorless, odorless, chemically inert gas defined as a simple
asphyxiant. There are no definite warning signs for exposure to nitrogen. Nitrogen is nontoxic, however, the liberation of large amounts of nitrogen will displace the oxygen needed
to support life.
2.1.1

Nitrogen Gas

The GENERON HPLC Membrane System is designed to separate nitrogen

from compressed air. The concentrations of oxygen contained in the nitrogen
product stream of any GENERON HPLC Membrane System will not support human
life. If released in an unventilated area, nitrogen will displace oxygen and cause
asphyxiation and/or injury. A Material Safety Data Sheets (MSDS) for this system
are located at the end of this section.
A general indication of the symptoms and effects experienced when
exposed to various levels of oxygen deficient atmospheres is given below.
Oxygen Content
Symptoms and Effects
(% by volume) (Atmospheric Pressure)
15-19%
Decreased ability to work
strenuously. May impair coordination and may induce early
symptoms in persons with coronary, pulmonary, or
circulatory problems.
12-14%
Respiration increases with
exertion, increase of pulse rate, impaired coordination,
perception and judgment affected.
10-12%
Respiration further increases
in rate and depth, poor judgment, blueness of lips.
8-10%
Mental
failure,
fainting,
unconsciousness, ashen face, blueness of lips, nausea, and
vomiting.
6-8%
8 minutes exposure, fatal; 6
minutes exposure, 50% fatal; 4-5 minutes exposure,
recovery with treatment.
4-6%
Coma
in
convulsions, respiration ceases; death.

40

seconds,


GENERON HPLC Membrane Nitrogen System
Operating and Maintenance Manual

2.1.1

Nitrogen Gas (continued)

Avoid confined spaces until oxygen adequacy (20.9%) has been proven by
analysis or other positive means, or until breathing air has been provided by air
pack, air hose or other trusted sources. Confined areas/spaces include the
following:
1.
Pits, deep depressions, wells.
2.
Above ground confined spaces - refrigerators, furnace
boxes, combustion chambers, silos, food storage barns and the like.
3.
Tanks - portable, storage and mixing
4.
Gas generators, gas tanks, gas holders and receivers
Do not allow the product nitrogen to be vented other than through proper
piping. Warning signs should be posted in any area and/or confined space which
may be a potential nitrogen deficient area. Appropriate warning signs are available
from the GENERON IGS. Service Department.
2.1.2

Enriched Oxygen

The enriched oxygen vent gas (permeate) consists of 30-45% oxygen as

compared to normal levels which are 20.9% oxygen. While oxygen will not burn,
oxygen concentrations above 28% can support combustion of other materials much
more readily than air. It is imperative that the enriched oxygen vent gas be
discharged only in well-ventilated and safe areas. If the GENERON HPLC
Membrane System is located in an air tight or poorly ventilated room, the vent gas
should be piped outdoors for release.
2.1.3

Pressurized Equipment

The GENERON HPLC Membrane System is operated under pressure.

Therefore, a hazardous work program should be followed when working around or
servicing this equipment.
The PVC permeate vent line must never be pressurized. This line should always
be allowed to flow un-restricted to atmosphere in a safe area.
The GENERON HPLC Membrane System should not be subjected to
excessive external forces or impact. Excessive force or impact applied to a
pressurized line may result in the sudden release of pressurized air and possibly
inflict injury to nearby personnel.
ALWAYS ISOLATE THE AREA TO BE SERVICED. DEPRESSURIZE ALL
LINES AND VESSELS BEFORE DISCONNECTING LINES OR DISASSEMBLY
OF THE GENERON HPLC Membrane System. Associated air and nitrogen supply
lines should be shut off and locked out.
Leak checks should be performed on all piping components to ensure no
compressed air or product nitrogen is allowed to escape. When performing leak
checks, use an accepted leak detection solution.


GENERON HPLC Membrane Nitrogen System
Operating and Maintenance Manual

2.1.4

Electrical Equipment
Use normal commercial safety practices while performing maintenance or
troubleshooting.
Personnel unfamiliar with the electrical equipment supplied with the GENERON
HPLC Membrane System should not attempt to service this equipment. The
electrical currents supplied to the various electrical components on the GENERON
HPLC Membrane System are at levels high enough to cause severe injury and/or
death.
When installing a GENERON HPLC Membrane System, ensure that all
applicable earth grounds are installed as required by the National Electric
Code and/or local requirements. Refer to the appropriate manufacturer's manuals
for correct grounding procedures for each piece of electrical equipment.
2.1.5

Material Safety Data Sheet (MSDS)

The Material Safety Data Sheets (MSDS) included in this section are
provided to inform the customer of the nature of the bulk substances contained in or
produced by the GENERON HPLC Membrane System. It is the responsibility of the
customer to provide access to this information for personnel working around the
equipment as appropriate. The MSDS sheets included in this section are for
Nitrogen gas and Activated Carbon.


GENERON HPLC Membrane Nitrogen System
Operating and Maintenance Manual

SECTION 3
ENVIRONMENTAL

3.1

CONDENSATE DRAIN LINES

Several components on the GENERON HPLC Membrane System are equipped with
condensate drain lines. Refer to the GENERON HPLC Membrane System Piping and
Instrument Diagram (P&ID) located in Section 10 of this manual for the specific equipment
and location of the drain lines. These drain lines collect oily condensate removed from the
compressed air supplied to the GENERON HPLC Membrane system. It is the customer's
responsibility to ensure that the oily condensate released from these drain lines is disposed
of in accordance with local statutes.
Waste oil collected during compressor oil changes and oil soaked filter elements removed
from the coalescing and particulate filters are considered hazardous waste. It is the
customer's responsibility to ensure that all waste oil and oil soaked filter elements are
disposed of in accordance with governing statutes.
Oil spills or leaks from the compressor must be properly cleaned up. Commercial
absorbent materials are available for this purpose. Use only absorbent material that has
been approved by a responsible governing agency. In some cases, disposal of
contaminated soil may be necessary.


GENERON HPLC Membrane Nitrogen System
Operating and Maintenance Manual

SECTION 4
PROCESS DESCRIPTION

4.1

GENERAL
The GENERON HPLC Membrane System is equipped with modules in which the nitrogen
separation takes place. The modules are filled with a cylindrical bundle of hollow fiber
membranes made of a polymer-based material. Each bundle contains several million
fibers, each about the size of a human hair. Compressed air enters the end of the fibers
and flows inside the fibers through the membrane bundle to the opposite end.
Gas separation takes place as the pressurized air contacts the membranes. "Fast" gases
such as oxygen, carbon dioxide, and water vapor quickly permeate through the fiber walls
and exit at atmospheric pressure through the vent port on the side of the module case.
Nitrogen, a slower gas, does not permeate through the fiber as quickly under flowing
conditions. It flows down bore of the fibers and exits at the product manifold on the end of
the module case. This enriched nitrogen stream exits the case at 2-10 psi (0.13-0.7 bar(g))
lower than the pressure at which air enters the case.

4.2

MODULE OPERATING PROPERTIES

Membrane performance is generally described by the terms productivity (flow) and
recovery (efficiency). This performance is a function of the product purity, operating
temperature, and operating pressure.
In general, productivity increases with an increase in pressure and temperature (at constant
purity).
Recovery, on the other hand, increases slightly with pressure, but decreases as
temperature rises (at constant purity).
Both recovery and productivity increase as the oxygen concentration (product impurity)
increases (at constant pressure and temperature).

.
The HPLC system operates most effectively at 135-188 psig 80o-110oF (9-13 bar(g), 27o43oC).


GENERON HP Series Membrane Nitrogen System
Operating and Maintenance Manual

Section 5
Equipment Description
5.1

General
For explanation purposes, the GENERON HP Nitrogen Generator has been broken down
into four standard subsystems. These subsystems are: Feed Air, Air Pretreatment, Product
Gas Separation, and Control System. The descriptions included in this section are
designed to provide the operator with a basic understanding of
the function of the
components used on the generator.
The Process and Instrumentation Diagram (P&ID) located in Section 10 of this manual
reflects these components and process system supplied to the customer.

5.2

Feed Air Subsystem

The feed air source for the Generator may consist of a dedicated air compressor or
customer-supplied compressed air from a plant or instrument air system.
A dedicated
compressor, if supplied by Generon IGS, is usually a lubricated rotary screw compressor
sized to produce the required air flow rate at operating pressures with a minimal horsepower
requirement. The air compressors are typically equipped with the
following features:
modulating controls, auto restart from Standby state, high dust filters,
and outdoor/freeze
protection (if required), and are filled with synthetic lubricant. Refer to the compressor
manual itself for a description of the actual compressor.
Customer provided air sources of lower feed pressures will result in correspondingly lower
nitrogen production (see Section 4.2). The customer should ensure, however, that the feed
pressure of the air source remains stable and consistent to meet the intended membrane
system design performance.

5.3

Air Pretreatment Subsystem

The Air Pretreatment subsystem contains equipment required to properly condition
the
process or feed air supplied to the membrane modules. It is recommended that a means
for removing bulk water be used prior to the skids feed air inlet. On-skid equipment
includes: moisture separator (MS-10), coarse coalescing filter (F-11), fine coalescing filter
(F-12), process heater (EH-14), carbon filter (F-16), particulate filter (F-18), and feed valve
(FSV-19-1). Refer to the P&ID located in Section 10 for specific equipment supplied.
Proper operation and maintenance of this filtrati on system will prevent oil (liquid or vapor)
condensate, airborne particles and pipe scale from
contaminating and/or clogging the
membrane fiber openings.


GENERON HP Series Membrane Nitrogen System
Operating and Maintenance Manual

5.3.1

Off-Skid Means To Remove Bulk Water

An air receiver or moisture separator prior to the skid inlet is recommended to collect
and remove the bulk of the oily condensate. The equipment should be equipped
with a condensate drain line.

5.3.2

Moisture Separator
The first on-skid air conditioning component is a moisture separator (MS-10). The
primary function of the moisture separator is to further remove large quantities of oily
water condensate from the feed air supply. The moisture separator is equipped with
an automatic electrical drain trap which will notify the generators control system if a
drain failure occurs.

5.3.3

Coalescing Filters
Coarse and fine coalescing filters F-11 and F-12, which
utilize a 1.0-micron and
0.01-micron filter element respectively, are designed to remove virtually the entire
remaining oil aerosol still present in the feed air despite the moisture separator.
Regular replacement of the filter elements is essential for proper filter operation.
Refer to section VI for further information. The coalescing filters are also tied into
the condensate drain line through automatic mechanical drain traps.

5.3.4

Process Heater
The process heater (EH-14) changes the state of the incoming air from saturated to
sub saturated by maintaining a constant temperature increase between 6 and 12C.
EH-14 is an electric air circulation heater that optimizes the membrane
module
performance by ensuring that the feed air stream is
heated and maintained at a
constant temperature of 45oC.

5.3.5

Carbon Filter
The carbon filter (F-16) consists of a carbon steel pipe assembly or locally-coded
vessel containing a specially packed activated carbon. The activated carbon pellets
used in the carbon filter absorb heavy hydrocarbon vapors that may be entrained in
the feed air supply. Refer to Section 8 (Maintenance and Trouble Shooting) for
further information regarding the maintenance intervals for replacing the activated
carbon.


GENERON HP Series Membrane Nitrogen System
Operating and Maintenance Manual

5.3.6

Particulate Filter
The particulate filter (F-18), which utilizes a 0.01 micron filter element, is intended to
remove all remaining airborne particulate matter (rust, carbon dust, etc.) remaining
in the feed air supply. The particulate filter is typically identical to the fine coalescing
filter, although the primary reason for this filter is solid particle removal. Note: to
optimize its operation as a particulate filter, this filter is installed backwards (reverse
of the normal flow indicated on the filter housing).

5.3.7

Feed Valve
The feed valve (FSV-19-1), which is controlled by the PLC, provides on/off control of
the feed air supplied to the membrane module(s). The feed valve is classified as a
fail-close valve which enables the GENERON HP Nitrogen Generator to isolate the
feed air supply in the event of an instrument air supply failure or loss of power.

5.4

Product Gas Separation Subsystem

The Product Gas Separation subsystem contains the membrane
modules and the
components necessary for the proper operation and control of the GENERON HP Nitrogen
Generator. The Process and Instrumentation Diagram (P&ID) located in Section 10 of this
manual reflects the components and flow system specifically provided to the customer.
5.4.1

Membrane Modules
Each membrane module case (MM-19) is filled with a cylindrical bundle of hollow
fiber membranes, made of a polymer-based material.

5.4.2

Flow Control Valve

The flow control valve (FCV-23-1) is used to control the nitrogen purity. The Flow
Control Valve receives its control signal (4-20 mA) from the PLC, using a PID control
loop to maintain the preset purity. The positioner (FY-23-1), located at the control
valve, converts this signal from the PLC into a valve opening as required.
The flow control valve is classified as a fail-close type valve. When the control
signal from the PLC is 4 mA or less, the control valve will be fully closed.


GENERON HP Series Membrane Nitrogen System
Operating and Maintenance Manual

5.4.3

Purity Assurance Valves

The GENERON HP Nitrogen Generator is equipped
with two purity assurance
valves (FSV-24-1A&B). The valve FSV-24-1A allows on-spec product gas to flow into the
customer's pipeline if the purity is in the allowed range, see the logic description in
section 10. The valve FSV-24-1 B will vent off-spec product gas with too high or too
low oxygen impurity. The off-spec gas vented from the product vent valve contains
high purity nitrogen which can be hazardous to personnel safety. This gas shall be
vented in accordance with good safety practices and local guidelines.

5.4.4

Permeate Gas
The permeate gas is the waste gas stream from the nitrogen separation process.
The permeate gas typically contains 30-45% oxygen and should be piped outdoors
to a safe area. Refer to Section 2.1.2 for proper handling of the waste gas.
It is critical that downstream permeate piping contain no valves or blockages
that
may result in a backpressure being placed on the modules. Any backpressure on
the modules via the permeate line will result in a decrease in nitrogen production
(keep the piping diameter relatively large).

5.5

Control System
The control system on the GENERON HP Nitrogen Generator consists of a PLC-Based
Control System, Oxygen Analyzer, Pressure Switch (off-skid), Panel Lamps and Switches,
Operator Interface Terminal, and Heater Control Panel.
5.5.1

PLC-Based Control System

The Programmable Logic Controller (PLC), located in the HP Control Panel is preprogrammed with the appropriate program for the individual system. It consists of
an assembly of modular components which is responsible for:
a)

Taking input signals from front panel buttons and switches and displaying
status information.

b)

All switching valve sequencing timers and counters. The PLC will energize
and de-energize piloting solenoids, as appropriate.


GENERON HP Series Membrane Nitrogen System
Operating and Maintenance Manual

5.5.1

PLC-Based Control System (continued)

c)

Monitoring of the oxygen content of the product gas to ensure on-spec

purity. If the O 2 analyzer indicates a high O 2 level during normal operations,
the PLC will vent the off-spec product gas and ultimately
shut down the
GENERON HP Nitrogen Generator.

d)

Monitoring the off-skid pressure transmitter (PT-27-1) to either initiate a

startup from the Standby State or go into Standby from the Running State.

e)

Monitoring of the electronic drain (LSH-10-1) and the optional differential

pressure indicating transmitter (PDIS-18-1). An alarm signal from either will
alarm and then shut down the system to prevent the compromising of
filtration.

f)

Control of nitrogen purity by continually adjusting the flow control valve to

maintain nitrogen purity under changing ambient and operating conditions.

g)

Monitoring and controlling of the heaters. Alarm and shutdowns will occur
for exceeding high temperature limits. Monitoring the flow transmitter (FS19-1) to transmitter the heater off in case there is no flow of air.

For specific instructions on programming the HP control

system, consult the
Generon IGS Service Center. In general, most control system programming
changes are nothing more than changing setpoints in the PLC memory.
5.5.2

Oxygen Analyzer
The oxygen analyzer (AIT-20-1) located in the GENERON HP control cabinet
continuously monitors nitrogen product gas for oxygen content. During operation,
sample gas from the product header flows
through the analyzer cell which
generates a signal proportional to oxygen concentration. The product sample purity
is monitored by the PLC, which adjusts the flow control valve (FCV-23-1), via
the
positioner (FY-23-1), to maintain nitrogen purity.

5.5.3

Nitrogen Receiver Pressure Transmitter

The system makes use of a 4-20mA signal from a remote pressure transmitter (PT26-1) to sense customer product demand.

5.5.4

PLC Control Panel CC-2

The lamps and switches located on exterior of the PLC Control Panel are described
below. The Programmable Logic Controller is located within the panel and
functionally tied into the Operator Interface Terminal on the enclosures door.


GENERON HP Series Membrane Nitrogen System
Operating and Maintenance Manual

5.5.4.1

Power Switch
When the On-Off Power switch is in the ON position and the power to the
control panel is energized, the Power ON button will illuminate. The Power
switch controls power supplied to the rest of the HP Panel. This button must
be in its ON position for any operation, programming, or calibration to occur.

5.5.4.2

Alarm Lamp
An illuminated Alarm lamp indicates that the system has entered a general
Alarm State. Various conditions can trip this alarm: filter drain malfunction,
filter differential pressure limit exceeded, off-spec product, and heater over
temperature. If the cause for alarm is not cleared within the individually set
amounts of time (5 seconds to 90 minutes) the system
will enter the
Shutdown state.

5.5.4.3

Shutdown Lamp
An illuminated Shutdown lamp indicates that
the system has entered a
Shutdown state. If an alarm persists for longer than its shutdown timer, the
system will enter a shutdown state.

5.5.4.4

Auto-Stop-Manual Switch
A three position switch that allows the user to run the system automatically
or manually. The Stop function is described in greater detail
throughout
section 7.

5.5.4.5

Emergency Stop Switch

In case of a need for an emergency shutdown, this button is pushed to
immediately shutdown the system. It is pulled to start the system again.

5.5.4.6

Operator Interface Terminal

The Operator Interface Terminal (OIT) built into the control panel front allows
the user to easily interface with the PLC.
The OIT provides the user with
menu-oriented functions to view operating, configuration, and programming
data. The selection keypad enables movement through the
menus and
changing of system set point values. If the HP
Nitrogen Generator is
designed to operate in 2 different modes, the current mode can be chosen
via the OIT.

5.5.5

Heater Control Panel CC-1(*)


GENERON HP Series Membrane Nitrogen System
Operating and Maintenance Manual

The electrical supply for the HP nitrogen generator is fed to the Heater Control
Panel. The disconnect switch on the enclosure door acts as the disconnect switch
for the skid. The heater circuit, individually
fused and controlled, is inside the
enclosure along with the 24VDC power supply for the PLC Control Panel. A step
down transformer may be included in some systems.
Taking in 4-20mA signals from the PLC control panel, the solid state power controls
provide the power to the heater.
The PLC monitors the sheath/element temperature and shutdown the heater if the
dial set limit is reached.
Descriptions of the switches and lamps located on the heater panels door follow.
5.5.5.1

Power Switch
The power switch will illuminate when the power to the heater panel is on.

* For cabinet systems, the heater controls are located in the PLC control panel.


GENERON HPLC Membrane Nitrogen System
Operating and Maintenance Manual

SECTION 6
OPERATION OVERVIEW
6.1

GENERAL
The GENERON HPLC Membrane System has been designed to run unattended except for
periodic operational and calibration checks.
This section describes the various operating modes, machine states, and alarm functions of
the HPLC control system, as well as the physical maintenance requirements with which the
on-site operator should be familiar.

6.2

CONTROL MODES
The GENERON HPL C Membrane System allows a choice of control modes: Manual
Control and Puri ty Control. The mode chosen determines how constantly purity will be
maintained over transitions of air supply, product demand, and ambient conditions.
6.2.1

Manual Control

In the Manual control mode the Product FCV Opening is controlled with respect to
the value (0-100%) entered on the Analog Setup Screen. Beca use of e ver
changing airflow this method should not be used. This is mainly for convenience of
troubleshooting the valve or stroking the valve to check movement.
6.2.

Auto Control

Auto Control uses t he O2 Analyzer to maintain the desired purity. The O2 purity
setpoint is entered on the Panelview Analog Setup screen and the PLC maintains
this setpoint reacting to flow, temperature and pressure changes.

6.3

MACHINE STATES
The Generon HPLC Membrane System operates in one of six machine states. Of these six
states, four are considered Normal and two are considered Abnormal.
6.3.1

Normal States

The four Normal states in which the GENERON HPLC Membrane System operates
are STANDBY, STARTUP, MANUAL, VENT and AUTO CONTROL. When the
GENERON HPLC Membrane System is operating in one of the Normal states, it is
operating correctly and within the parameters set up by the startup engineer.


GENERON HPLC Membrane Nitrogen System
Operating and Maintenance Manual

6.3.1.1 Standby State

The Standby State is the non-producing state that is available during
automatic or manual operation when the pressure reaches the maximum
N2 setting. The indications of this state are:
6.3.1.2 Startup State
The Startup state is a transitional state that must precede the
Running state. The Startup state is entered when the GENERON HPLC
Membrane System energized for the first time and is designed to allow the
O2 analyzers time to warm up.
Startup cannot be obtained until startup timer is finished.
An alarm will energize if time has not expired.
Startup time remaining can be found on the Main Menu.
The duration of the Startup state is a 60 second timer that energizes when
the PLC is first energized.
6.3.1.3 Manual State
In the Manual control mode the Product FCV Opening is controlled
with respect to the value (0-100%) entered on t he Analog Setup Screen.
Because of e ver changing airflow this method should not be used. This is
mainly for convenience of troubleshooting the valve or stroking the valve to
check movement.
Indications of this state are:
Switch is in MANUAL position
6.3.1.4 Auto Control State
The Auto Control State is nearly the same as the Running state,
except that the O2 setpoint controls the valve to maintain an oxygen
concentration.
Indications of this state are:
Switch is in AUTO position
6.3.1.5 Vent State
The Vent State is active when the system is first started up until O2
purity been reached or has been above shutdown setpoint for over allotted
time.
Indications of this state are:
Vent valve is open and Product valve is closed. Alarm is active


GENERON HPLC Membrane Nitrogen System
Operating and Maintenance Manual

6.3.2

Abnormal States

As the title suggests, when in one of the two following states, the GENERON HPLC
Membrane System is not operating within the prescribed parameters as set up b y
the startup engineer.
6.3.2.1 Alarm State
6.3.2.2 Shutdown State
If a shutdown has occurred, the alarm must be corrected and the system
must be put into STOP, then restarted.
6.4

ALARM LOGIC
SYSTEM HAS BEEN FORCED TO VENT Force vent F10 on the Flow Screen
has been activated, this is a reminder alarm
NO FLOW DETECTED FOR RUN The system has been started but flow switch
FSL-8870A has not detected flow for 60 seconds.
AT- is offline The O2 analyzer has faulted. The fault must be corrected and
the AUTO/STOP switch must be p laced in ST OP before the system can b e
restarted
SHUTDOWN- High Heater Temp shutdown >392 F (200 C) The heater element
is above 200C or the safety contactor has tripped or there is a Shorted SCR
Condition and caused a shutdown. The problem must be resolved and the
AUTO/STOP/MANUAL switch must be placed in STOP before the system can be
restarted.
VENTING TO LONG, SHUTDOWN The system has been venting longer that the
allotted time set on the Analog Setup Screen. The AUTO/STOP/MANUAL switch
must be placed in STOP before the system can be restarted.
RUN NOT ALLOWED BEFORE O2 WARMUP When the system is first powered
up, a 60 second timer allows the O2 analyzer to warm-up. If a system start is
requested before the timer is finished, this alarm energizes to remind the operator
to wait. The time remaining can be found on the Main Menu Screen.
WARNING- Air to Modules Temp High > 140 F (60 C) Hea ted air to the modules
is at or above 140F.
SHUTDOWN-Air to Modules High > 150 F (65 C) Heated air to the module is at or
above 150F and has shutdown the generator. The air must fall below 140F and the
AUTO/STOP/MANUAL switch must be placed in STOP before the system can be
restarted


GENERON HPLC Membrane Nitrogen System
Operating and Maintenance Manual

O2 OFF SPEC,SYSTEM TO VENT The O2 content has fallen above or below the
High/Low O2 set point and is venting to atmosphere.
HEATER NOT HEATING AIR TRAIN After 15 minutes the hea ter (H-5270) has
not heated the air up at least 5.5 degrees, check heater
WARNING- Heater Outlet Temp High > 138 F (59 C) Heater Outlet temperature is
hot.
WARNING- Incoming Air is Low < 45 F (2 C) Incoming temperature is cold.
SHUTDOWN - Heater Trouble There is problem with heater or heater contactor.
Shutdown will occur after 30 minutes.
57'- is offline lost signal of 57', check electrical wiring and device.
57' is offline lost signal of 57', check electrical wiring and device.
57'is offline lost signal of 57', check electrical wiring and device.
57'LVRIIOLQHORVWVLJQDORI57'FKHFNHOHFWULFDOZLULQJDQGGHYLFH
AT-20-1 is offline lost signal of AT, check electrical wiring and device.
FT-22-1 is offline lost signal of FT-22-1, check electrical wiring and device.

6.5

OPERATIONAL MAINTENANCE
The Generon HPLC Membrane System is d esigned to run u nattended and requires only
minor attention to assure proper operation.
6.5.1

HPLC Membrane System Operational Maintenance

A listing of operational checks is given in Ta ble 6.5. Some critical activities are
detailed below. For further information on these and other items please contact the
Generon IGS. Service Department.
6.5.1.1 Particulate and Coalescing Filter Differential Pressure
Most particulate and coalescing filters can tolerate very high differential
pressures.
In fac t, manufacturers typically do no t require element
replacement until the steady state differential exceeds 9 psi (0.6 bar(g)).


GENERON HPLC Membrane Nitrogen System
Operating and Maintenance Manual

The membrane module performance is a function of the feed air pressure and, as a result, will
decline with increased differential pressure.
Filt
er Differential Pressure
In order to optimize the membrane module performance, the pressure
differential across the coalescing filters should be checked on a quarterly
basis checking the filters pressure differential gauge. Th e filter elements
should be changed out when the differential pressure (at steady state)
across each filter is in the 5-8 psig (0.3-0.5 bar(g)) range unless the
membrane module performance dictates otherwise.
A minimum change out rate of six months is usually appropriate depending
on the feed air quality.
6.5.1.2 Carbon Vessel
The activated carbon used in the Carbon Vessel must be rep laced on a
regular basis. Minimum change out rate for the carbon is every 4000 hours
or 18 mo nths, which ever comes first. Refer to the Refill Procedure for
Carbon Bed in the back of this section.
6.5.1.3 Oxygen Analyzer Calibration
The Oxygen analyzer's fuel cell sensor used in the GENERON HPLC
control has a service life of approximately one year. Du ring that time, the
calibration may drift slightly, and should be checked weekly. See Section-9
and the manufacturers documentation in Section-10 for information of
calibration and service of this critical instrument.


GENERON HPLC Membrane Nitrogen System
Operating and Maintenance Manual

SECTION 7
OPERATIONAL MAINTENANCE
7.1

GENERAL
The following procedure should be used to bring the GENERON HPLC Membrane System
on-line after a prolonged shutdown or major maintenance. Ensure that all piping
connections are properly fitted and electrical
connections are secure before initiating
startup.

7.2

POWER UP
Switch the Main Power Panel (heater panel) disconnect switch to the "ON" position.
Turn on the HPLC Control panel by turning the Power switch on. The HPLC Control panel
will activate the timer for the warm up period for the Oxygen analyzer.

7.3

PRESSURIZATION/INSTRUMENT SETUP
Pressurize the HPLC Membrane System
Start the feed air compressor per the manufacturer's instructions.
7.3.1 Instrument Setup
The following equipment settings need to be established when starting up the unit.
Some must be done prior to start-up, others can only be done when the system is
operating.
7.3.2 Instrument Air (H.P.I.A.)
Set the instrument air regulator (PRV- 19-1) to 5.9-Bar 85-psi. This can be done
prior to startup, when the skid is pressurized.
7.3.3

Product Gas Sample

Once there is pressure in the nitrogen product pipeline
set the sample regulator
(PRV-20-1) to 0.35-bar (5-psi). Adjust the sample flow rate, using flow indicator
fi-20-1inside the panel, to 1.0 SCFH.

7.4 Start HPLC Membrane System

Turn the AUTO/STOP/MANUAL switch to AU TO. The GENERON HPLC Membrane System will
initiate a Startup state. During the start-up state, which lasts 60 seconds the PLC will direct the feed
valve XCV-080102 to open. Initially the product flow will be directed though the Fail-Open off-spec
line.
Flow Meter (FT-22-1) will enable power to the process heater contactor when the inlet air flow is
high enough for heater control. If the air inlet valve is not open, FSV-19-1 , the flow meter will


GENERON HPLC Membrane Nitrogen System
Operating and Maintenance Manual

not detect flow and heater contactor will not allow power to be the process heater (due to no air
flow).
The GENERON HPLC Membrane System will continue to vent product gas until the startup timer
times out. When the startup timer times out, the GENERON HPLC Membrane System will switch to
purity control or manual control depending on the Control mode used and the customers' product
nitrogen demand.
7.5 Begin Production
Once the purity valve (FCV-23-1) is controlling O2 purity level and product pipeline O 2 level falls
within the preset vent limits, the PLC will automatically direct the off-spec/product valve ( FSV-24-1A
) to change to the product line and thus placing the GENERON HPLC Membrane System
On-Line.
7.6 Changing the Setpoints
The Operator Interface Terminal in the GENERON HPLC Panel allows an operator to change
setpoints. Most of these will be set by the factory, but some will occasionally need to be set by the
user. This is only the case when the unit is to operate differently from its original set up
at
commissioning.
After power is applied to the PLC, there is a programmable warm-up period. At the end of that
period, use the F keys to navigate to all screens.
Purity Setpoint can be changed from .01 to 10%.
7.7 Shutdown
This section is intended to instruct an operator on procedures for shutting down the GENERON
HPLC Membrane System as well as afford a means to identify a non-operator initiated shutdown.
7.7.1 Controlled Shutdown
MANUAL SHUTDOWN - To turn the GENERON HPLC Membrane System off:
* Turn the AUTO/STOP/MANUAL switch to Stop.
* Isolate the GENERON HPLC Membrane System from the feed air source
* If there is a dedicated compressor, shut it down per manufacturer's recommendations
* It is generally advisable to close the final product valve (if applicable) to keep the product
receiver (if supplied) at pressure.
7.7.2 Uncontrolled Shutdowns
SAFETY ALARM SHUTDOWN
Any time there has been a non-user system shutdown, the problem must be fixed and the
auto/off/manual switch must me moved to off before the system can be re-started.
LOSS OF UTILITIES


GENERON HPLC Membrane Nitrogen System
Operating and Maintenance Manual

Power Outages (Blackouts and/or Brownouts): When power is interrupted to the HPLC
control panel, all devices will go to their fail position. The feed valve will block the feed air
supply. To restart, follow the steps outlined in Section 7.
Instrument Air Loss: When instrument air is lost completely, the feed valves on the
GENERON HPLC Membrane System will switch to its fail closed position thus blocking the
incoming feed air supply. If this continues for several minutes, a low pressure shutdown will
occur.
If instrument air pressure drops, but is not lost completely, the valves will operate sluggishly,
not seal properly, etc. A high oxygen vent may eventually occur.


GENERON HPLC Membrane Nitrogen System
Operating and Maintenance Manual

SECTION 8
MAINTENANCE AND TROUBLE SHOOTING
8.1

General Maintenance
A properly functioning filtration system is of premiere importance to this membrane system.
Drains must be checked daily. Filters should be opened up and inspected quarterly.
Closely observe the differential pressure gauges (a drop from the previous days reading
could indicate a torn/damaged element).

Table 8.1 - Operational Maintenance

Check Drain Trap Operation
Log Process Operating Parameters
Verify Calibration of Oxygen Analyzer
Inspect Filter Elements
Test Alarm/Shutdown Features
Replace Activated Carbon in F-16-1
Inspect & Clean Instrumentation, Pneu. & Elect.
Replace FIL-11-1, FIL-12-1 FIL-18-1,
(2)
Leak Test Piping Joints
Inspect and clean F-18-1
Replace PLC battery (3)

Daily
(1)
X
X

Notes:
(1)
Refer to Section 8.2.
(2)
More frequent attention may be required.
(3)
There is a low battery indicator on the PLC.

BiWeekly

Quarterly

SemiAnnually

X
X
X
X
X
X

Other

4 yr.


GENERON HPLC Membrane Nitrogen System
Operating and Maintenance Manual

8.2

Daily Maintenance
Each day the operator should record the systems operational parameters on copies made
from Table 8.2A (Nitrogen Unit Daily Check List/Log) located in the back of this section.
The procedure below outlines a step by step process for completing this log. This
procedure should be performed at a set time under the same conditions each day after the
unit has been running for at least one hour.
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.

8.3

Record O2 reading from the OIT.

Record air pressure at PI-10-1and module inlet pressure at PI- 19-2. If either
pressure is fluctuating it can have an effect on O2 purity.
Record differential temperature for EH-14 from OIT (RTD-14-1, RTD-14-2).
Record module inlet temperature from OIT (RTD-19-1).
Record run hours and shutdown hours from the OIT.
Verify the setpoints for high pressure instrument air PI-19-1 (set at 85PSIG).
Verify the setpoint for O2 sample regulator PI-20-1. (set at 5PSIG).
Verify the setpoint for O2 sample flow FI-20-1 (2 SCFH).
Manually drain the moisture separator T-10-1 into a cup.
Some moisture is
expected. If there is too much drainage refer to trouble-shooting Section 8.3.
Manually drain both coalescing filters F-11-1, F-12-1, F-18-1 into a
cup. Some oily condensate is expected. If there is too much drainage refer to
trouble-shooting Section 8.3. Water at this point would be a problem.
Manually drain the carbon filter F -16 and the particulate filter F -18 into a
cup. Any liquid drainage here is a serious matter, refer to trouble-shooting Section
8.3.
Observe the differential pressure on the coalescing and
particulate filters PDI-11-1
, PDI-12-1 and PDI-18-1. If filter differential pressure is near
9 PSIG
refer to Section 8.3.

Trouble-shooting
Refer to this section for identifying causes of problem indicators, alarms, and shutdowns.
Begin at the indication of the problem and work back (upstream)
problem.
Too much liquid water/oil from
separator drain

Incorrect

to find the source of the

Ensure drain line is not blocked.

Incorrect function of off-skid Moisture
Separator (from compressor), it is not
removing the bulk of water.
function of the automatic drain.


GENERON HPLC Membrane Nitrogen System
Operating and Maintenance Manual

8.3

Trouble-shooting (continued)
Too much liquid water/oil from
filter drains
moisture
Air
Liquid water/oil present at drain
of carbon and particulate filters

Ensure drain line is not blocked.

Incorrect function of the automatic drains or
separator.
supply too hot.
Upstream moisture removal is not working
properly.
Air supply too hot or EH-14 error.

Air temperature too high or low

Compressed
O2 content drifting
HE-0801
Inlet
Not enough nitrogen

Heater setpoints are incorrect.

air too hot.
Changing pressure in air supply.
not properly operating.
air extremely hot.
O2 content too high. System Is venting.

System

in Standby State.

System

is air starved, compressor problem.


GENERON HPLC Membrane Nitrogen System
Operating and Maintenance Manual

SECTION 8
SHUTDOWNS
This section is intended to instruct an operator on procedures for shutting down the GENERON
HPLC Membrane System as well as afford a means to identify a non-operator initiated shutdown.
8.1

CONTROLLED SHUTDOWN
8.1.1

Manual Shutdown
To turn the GENERON HPLC Membrane System off:
.

Turn the AUTO/STOP/MANUAL switch to Stop.

Isolate the GENERON HPLC Membrane System from the feed air source

If there is a dedicated compressor, shut it down per manufacturer's

recommendations

It is generally advisable to close the final product

product receiver (if supplied) at pressure.
8.2

valve (if applicable) to keep the

UNCONTROLLED SHUTDOWNS
8.2.1

Safety Alarm Shutdown

Any time there has been a non-user system shutdown, the problem must be fixed
and the auto/off/manual switch must me moved to off before the system can be restarted.

8.2.2

Loss of Utilities
Power Outages (Blackouts and/or Brownouts):
When power is interrupted to the HPLC control panel, all devices will go to their fail
position. The feed valve, FSV-19-1 will block the feed air supply. To restart, follow
the steps outlined in Section 7.
Instrument Air Loss:
When instrument air is lost completely, the feed valves on the GENERON HPLC
Membrane System will switch to its fail closed position thus blocking the incoming
feed air supply. If this continues for several minutes, a low pressure shutdown will
occur.
If instrument air pressure drops, but is not lost completely, the valves will operate
sluggishly, not seal properly, etc. A high oxygen vent may eventually occur.


GENERON HPLC Membrane Nitrogen System
Operating and Maintenance Manual

SECTION 9
OXYGEN ANALYZER CALIBRATION AND MAINTENANCE
9.1

General
The GENERON nit rogen generator is provided with a Fujikura o xygen
percent analyzer transmitter, which is an i ntegral part of the purity control system. The
analyzer has been calibrated and tested by the factory prior to s hipment. Although the
analyzer should not require any additional calibration, a certified oxygen content span gas
should be used to verify the calibration once every month.
On the bottom side of the control panel is a Span / Sample selection valve and a fitting for
span gas input. The pressure of the span gas needs to be regulated to 1.5-bar. The span
gas used to check (verify) the analyzer should have an oxygen content around the contract
purity. The nominal acceptable variation between oxygen span gas c ontent and the
analyzer reading is +/- 0.20 (% O2).
Calibration procedures are found on the following pages in this section. It is useful and
important to log the analyzer verifications and calibrations.