PSA pressure swing adsorption nitrogen generator operation and matters needing attention

1. Installation requirements
1.1 A large enough site should be selected according to the actual size of the equipment. It is best to keep the distance from the surrounding environment at least 1 meter to facilitate operation and maintenance.
1.2 The installation site must have good ventilation and less dust.
1.3 Cannot be installed in a corrosive environment.
1.4 The muffler (exhaust gas outlet of the PSA nitrogen generator) can be installed indoors or outdoors. When the air compressor and the nitrogen generator are in the same room, the muffler should be installed outdoors to avoid affecting the nitrogen production.
1.5 The nitrogen generator should be placed in a poorly ventilated place, and the muffler should be installed outdoors.
1.6 If the muffler is installed outdoors, the muffler installed outdoors should be equipped with rain-proof facilities, and pay attention to its placement height not higher than the exhaust gas outlet, otherwise the pipeline sewage will not be discharged and the sewage will easily be poured back.
1.7 Precautions for power supply installation: 1.7.1 The power supply should be configured according to the calibrated voltage (V), current (A), and number of phases;
1.7.2 The grid voltage should be within the range of AC ±10%;
1.7.3 In order to ensure safety, safe voltage electrical components, etc. must be effectively grounded;
1.7.4 The installation of electrical equipment must be carried out in accordance with relevant national regulations and requirements.
2. Operation (see the schematic diagram of the control cabinet panel)
2.1 Preparation before operation
2.1.1 Check that the sampling gas control valve of the nitrogen analyzer should be closed.
2.1.2 Please read the relevant instructions carefully before use (instructions for air compressors, high-efficiency degreasers, refrigeration dryers, precision filters, nitrogen generators, flow meters, and nitrogen analyzers) to pay attention to correct use.
2.2 Several related valve adjustments (the valve has been adjusted before leaving the factory)
2.2.1 The take-off pressure of the safety valve is adjusted to 1.05 times of the maximum inlet pressure.
2.3 Driving
2.3.1 Before driving, check the oil level of the air compressor.
2.3.2 Start the air compressor, and when the air pressure rises to the set pressure, the compressor automatically discharges the load.
2.3.3 Switch on the power supply of the refrigeration dryer, press the start button of the refrigeration dryer, the refrigeration dryer starts, wait for the refrigeration dryer to run for 5-10 minutes, slowly open the ball valve on the air compressor, and wait for the pressure to balance , Fully open this valve, and then adjust the shut-off valve in front of the nitrogen generator (adjusted at the initial start-up), and the dry compressed air is ready to pass into the nitrogen generator.
2.3.4 Adjust the inlet pressure of the control gas of the pneumatic valve on the nitrogen generator to 0.55 Mpa. If it is too small, the valve may not work.
2.3.5 Press the start button of the nitrogen generator to start the nitrogen generator.
2.3.6 After the pressure of the nitrogen buffer tank is balanced, open the venting device to vent. Then adjust the shut-off valve behind the nitrogen generator (adjusted at the first startup), and then slightly open the sampling gas control valve of the nitrogen analyzer. If the nitrogen analyzer on the control cabinet panel shows that the nitrogen purity has been reached, the regulating valve will set the nitrogen pressure When it reaches 0.6Mpa, then adjust the valve to make the flow meter reading meet the requirements; finally, fully open the valve, and at this time qualified nitrogen is sent to the gas point.
2.4 Monitoring and recording during operation
2.4.1 During the operation of a complete set of equipment, it is important to check the operation of each equipment regularly. Such as whether the air compressor is in working condition, whether the switching valve of the nitrogen generator is operating normally, and the operating status of each control instrument meter.
2.4.2 Make operation records (record once every 8 hours)
The records include: time, room temperature, compressed air inlet pressure and inlet temperature, the outlet pressure of the high-efficiency degreaser, the low pressure of the refrigerant of the cold dryer, the adsorption pressure of the nitrogen generator, the nitrogen pressure, the nitrogen purity, and the nitrogen flow.
2.5 parking
2.5.1 Close the upper valve of the vent system;
2.5.2 Press the stop button of the nitrogen generator to turn off the nitrogen generator;
2.5.3 Press the stop button of the dryer to turn off the dryer;
2.5.4 Close the ball valve on the air compressor;
2.5.5 Open all sewage outlets to discharge sewage, especially in winter, all the water in the equipment must be drained;
2.5.6 If the shutdown is for a long time, close the sampling gas control valve of the nitrogen analyzer
2.5.7 If it is shut down for a long time, cut off the power supply of all equipment;
Three, maintenance and maintenance
3.1 Daily maintenance of equipment
The maintenance of equipment in the nitrogen generation system mainly includes the maintenance of air compressors, refrigeration dryers, filters, and nitrogen generators. The daily maintenance of air compressors is mainly to check whether the drain outlet of the air compressor tank of the air compressor is blocked and dissipates heat. Check whether the holes are obstructed; the radiator of the refrigeration dryer should be cleaned frequently; the drain outlet of the filter should be checked frequently for blockage; the exhaust port of the muffler of the nitrogen generator should be checked frequently to see if it is unblocked. The appearance of all equipment should be kept clean and clean, and often wiped with a damp cloth or neutral soapy water.
3.2 Maintenance of air compressor
3.2.1 Please keep the machine clean.
3.2.2 The drain valve of the gas storage tank is opened once a day to drain oil and water. In places with heavy humidity, please open it every four hours.
3.2.3 Please check the lubricating oil surface once a day to ensure the lubrication between the air compressors.
3.2.4 The air filter should be cleaned or replaced in about 150 days (the filter element is a consumable). However, it may be increased or decreased depending on the environment.
3.2.5 Check the tightness of the belt and the screws of each part once a month.
3.2.6 Please change the lubricating oil after the first 100 hours of operation, and then change the oil once every 1000 hours (the oil should be changed every 500 hours if the environment is poor).
Notice! : When replacing the new oil, the crankcase must be cleaned, and the new oil can be injected after cleaning.
3.2.7 Please take out the air valve and clean it after 1000 hours (or half a year).
3.2.8 Clean each part of the machine once a year.
3.3 Maintenance of high-efficiency degreaser
3.3.1 Manual blowdown ball valve, under normal circumstances, discharge once every 8 hours;
3.3.2 The electronic drainer automatically drains, and only needs to check for blockage every 8 hours;
3.3.3 The filter element in the high-efficiency degreaser should be replaced every 6000 hours;
3.4 Maintenance of precision filter
3.4.1 Manual blowdown ball valve, under normal circumstances, discharge once every 8 hours;
3.4.2 The electronic drainer automatically drains, and only needs to check for blockage every 8 hours;
3.4.3 The filter element in the precision filter is replaced every 8000 hours or so;
3.5 Maintenance of refrigeration dryer
3.5.1 Manual blowdown ball valve, under normal circumstances, discharge once every 8 hours;
3.5.2 The electronic drainer automatically drains, and only needs to check for blockage every 8 hours;
3.5.3 The fins on the air condenser are purged once a week. If there is less dust in the environment, the purging time can be extended.
3.6 Maintenance of the nitrogen generator
3.6.1 Maintenance of pneumatic valve
3.6.1.1 This equipment adopts imported pneumatic valve, and its actuator is pneumatic piston brake to control the opening of the valve. Under good working conditions, maintenance is basically unnecessary;
3.6.2 Maintenance of the adsorption tower group
3.6.2.1 The adsorption tower group is a key component of the machine, and its maintenance directly affects the service life of the equipment; the alarm indicator of the adsorption tower should be checked when the equipment is running, and carbon molecular sieve should be added in time if there is an alarm.
3.6.3 The oxygen electrode on the nitrogen analyzer should be replaced every 6 months.
3.7 Maintenance of electrical system
3.7.1 Regularly check whether there is any disconnection or loose support of each terminal. If there is, it should be reconnected or tightened in time, but it must be carried out in a power failure state.
3.7.2 The dust in the electrical box must be cleaned frequently (be careful to cut off the power first) and check whether the plugs on the rear panel are in good condition, otherwise, repair them in time.
Four, matters needing attention
4.1 The equipment should be reliably grounded;
4.2 When servicing the equipment, before disconnecting the connecting pipeline or opening the adsorption tower, the pressure in the inner container of all pipelines should be exhausted, otherwise it will cause serious injury or death; the connecting gasket should use high-density cardboard to prevent nitrogen Of leaks;
4.3 Nitrogen is a colorless, odorless, non-toxic, oxygen-free gas, and it is easy to cause suffocation when inhaled directly by the human body. When discharging nitrogen, it must be far away from the mouth and nose of the person and directly discharged into the atmosphere;
Five, faults and troubleshooting
Fault name
Cause Analysis
Troubleshooting method
Low work pressure
1. Insufficient air supply to the system
2. Leakage of pipelines and valves
3. The air supply valve is not opened or not fully opened
1. Configure the air compressor as required
2. Replace pipelines and valves
3. Open the air supply valve
Low nitrogen purity
1. Debugging is not in place
2. Molecular sieve is contaminated
3. Excessive blowback
1. Debug according to the debugging method
2. Replace the molecular sieve
3. Reduce back blow
Vent the exhaust volume is large
1. The pneumatic valve gasket is damaged and leaking
2. Solenoid valve failure
1. Replace the gasket
2. Replace the solenoid valve