Core PSA Medical Oxygen Generator

Oxygen generator, based on pressure swing adsorption technology, for producing oxygen at
point of use with purity up to 95%. built according to proven design standards and is suitable for
indoor use in a normal industrial environment. The design, materials and workmanship ensure
of the best available quality and performance.
The Oxygen Generator makes use of Pressure Swing Adsorption (PSA) technology to produce
oxygen by passing pre-treated compressed air through a vessel containing a zeolite adsorbent
(molecular sieves - MS). The PSA process is inherently a batch process, as the adsorbent bed
requires periodic desorption. In order to secure steady flow, the PSA Oxygen Generator
systems contain two adsorbent vessels to provide operational continuity. One vessel is active
while the other one is inactive. At the end of each cycle they switch roles.

The active vessel is pressurized, and pre-treated compressed air enters the active vessel and
follows up through the MS. Nitrogen molecules are being adsorbed while the oxygen molecules
pass through.

When the adsorbing vessel approaches saturation, the regenerated vessel is partly re-
pressurized with the compressed air from the adsorbing vessel. This is called the equalization
step, and is intended to reduce compressed air consumption.
When pressure from the saturated vessel is released, the regeneration process starts. At the
same time the regenerated vessel is further pressurized up to working pressure with the
compressed air from the inlet. The cycle starts over again.

Scope of Supply of PSA Generator:

Air Circuit
 An inlet pressure regulator to set the inlet pressure to a maximum of 7 bar.
 2 Pneumatic actuated inlet valves to guide the air to one of the adsorber vessels.
 2 Pneumatic actuated exhaust valves, one for each adsorber vessel, to release the
pressure in the vessel and start the regeneration sequence. The exhaust valves
alternate every half cycle.
 An air silencer is connected to the exhaust valves, and reduces the noise level during
exhaust / regeneration
 A Pneumatic actuated equalization valve to bring both adsorber vessels to the same
pressure
 2 Adsorber vessels, filled with Zeolite Molecular Sieves (ZMS), to adsorb the nitrogen
molecules from the inlet air, while oxygen molecules can pass.

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  A pressure relief valve on each adsorber vessel

Oxygen Circuit

 A Pneumatic actuated equalization valve to bring both adsorber vessels to the same
pressure
 A purge nozzle that allows a small portion of oxygen flow into the depressurized vessel
for regeneration purposes
 2 Non-return valves at the outlet of each tower to avoid back flow from the outlet of the
generator
 A oxygen feedback line from the oxygen storage vessel to the oxygen sensor of the
generator.
Gauges and instrumentation

 Pressure gauge on each adsorber vessel

 Oxygen storage vessel pressure transmitter
 Oxygen purity sensor in nitrogen storage vessel

Controller :
Controller should be Available in different languages, and graphical high definition color display
with pictograms and LED indicators for key events is easy to use. The keyboard should be
durable to resist tough treatment in demanding environments.

The generator should be of

 Continuous availability. (24 hours a day, 7 days a week)

 Risk of production stoppage due to gas running out is eliminated.
 Oxygen purity levels according to your need: from 90% to 95%

PSA type Oxygen Generation plant to produce equivalent of 60 Cubic Meter capacity per hour
medical grade oxygen at 93% +/- 3% purity hospital. Service Provider will also ensure adequate
supply of Oxygen by expanding/installing parallel plant of the required capacity in case the
demand increases in future. The plant should be able to deliver medical grade oxygen with the
following standard:
- Oxygen : 95% +/-3%
- CO : < 5 pm
-

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 - CO2 : < 300 ppm
- SO2 : 0 ppm
- NOx : 0 ppm

Air compressor
Compressed air system comprising of screw air compressor, air cooled with PLC based
control panel driven directly by permanent magnet variable speed motor. The compressor
should be capable of delivering air as required for PSA, pressure swing adsorption
generator. The compressor shall have to be with all standard accessories compatible with
oxygen generator. The flow capacity of the compressor and delivery pressure shall be as
specified by Core PSA Medical Oxygen Generator service provider.

The compressor shall be driven by a Variable Speed Drive as standard, a compact motor
with an iPM (interior Permanent Magnet) technology. The motor shall be equipped with this
technology VSD to reduce energy consumption by 50% on average, with uptimes assured
even in the harshest operational conditions. The IP protection of the motor shall be
Pressure-tight IP66 motor Best efficiency: IE 4

Compressor screw element shall be directly connected in Vertical set-up Oil-cooled drive train
(one oil circuit for motor, element, bearings).

Condensate Prevention Cycle (CPC)

Designed for extreme low load applications

Delayed Stop: Runs at minimum speed until minimum working temperature of 65°C is
reached (recirculates the produced air)

Eliminates risk of water condensation in the oil

The compressor shall be designed in-house and designed to operate in 46°C/115°F ambient
conditions that includes an integrated dryer.

Oil Separation :
Shall be of high efficiency 2-step air-oil-separator system for reduced oil consumption ensures
low maintenance costs and a good oil separation result in between two service intervals.

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The oil filter cleans the oil continuously from particles bigger than 25 micron with 99% efficiency
in order to protect the lubrication quality and health of the rotating components.

Controller :
The regulating system includes the module to regulate, control and monitor compressor
operation. The graphic control module display and monitor the following:
1. Compressor Status Indication
 Voltage on
 Automatic operation
 Service timer
 Compressor speed
2. Temperature, numerical readouts
 Element outlet
 Ambient air temperature on FF units
3. Pressure, numerical readouts
 Delivery air
4. Compressor Control
 Start / Stop
 Reset / Test
5. Hour meters
 Total running hours
 Total loading hours (in different speed zones)
6. Timers
 Programming compressor time-based start/stop commands
7. Service requirement indications
 Air filter
8. Compressor safety - warning indications
 High element outlet temperature.
 Electronic drain operation
 Sensor error
 High dew point
 Cooling water inlet temp (for water cooled versions)
 Cooling water outlet temp (for water cooled versions)
 Pressure drop over PD/DD filters (optionally)
9. Compressor safety - shutdown indications
 High element outlet temperature.
 Drive motor/fan motor overload
 Emergency stop
10. Digital output relays for remote monitoring (voltage free)
 Automatic operation / Manual operation
 General warning
 General shutdown

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In Brief:
The compressor shall be constructed with the following major components:
 State of the art compression element
 The patented, oil cooled, IP66 (NEMA4X) motor exceeds all IEEE and NEMA Premium
efficiency standards
 Display graphic controller
 High efficiency aftercooler
 Innovative cooling fan
 Moisture separator
 Inlet air filter
 Full Feature includes an integrated refrigerated air dryer using environmentally friendly
R410a refrigerant.

Air receiver
The Air Receiver Tank shall be of capacity as specified by Core PSA Medical Oxygen Generator
service provider. The design pressure shall be based on compressor discharge pressure. The vessel
shall be designed and manufactured as per ASME Section VIII Div 1 or Equivalent. The Service
provider shall maintain design calculations. A corrosion allowance of 3 mm shall be considered. The
receiver vessel shall be provided with a pressure gauge, safety valve and auto drain valve. Vertical
floor mounted design equipped with pressure gauge, safety release valve, manual and automatic,
zero-loss drain valve (float-type are not acceptable). The receiver assembly shall be fitted with a
pressure safety valve capable of passing the maximum flow output of the compressor at 10% receiver
overpressure.
The air receiver tank shall be galvanized to protect the vessel material and secure highest quality
standards and shall be in vertical (LV). Volume of receiver shall be 3000 liter.

Oxygen Receiver :
The oxygen receiver tank shall be of capacity as specified by Core PSA Medical Oxygen Generator
service provider. Nominal operating pressure shall be based on maximum rated pressure for tank,
both to be clearly indicated. The vessel shall be designed and manufactured as per ASME Section
VIII Div 1 Or Equivalent. The Service provider shall maintain design calculations. A corrosion
allowance of 1.6 mm shall be considered. The receiver vessel shall be provided with a pressure
gauge, safety pressure release valve and auto drain valve. Vertical floor mounted design equipped
with pressure gauge, safety release valves.
Size of vessel shall be not less than 1500 liter.

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Filtration system for compressed air:
The feed air quality to the oxygen concentrator should be confirming to ISO8573 class4 and should
have a filtration grade of 0.01 Micron. Coal tower The coal tower shall be provided at upstream of
Medical Oxygen PSA generator to arrest any accidental carryover of oil or oil vapour in air being fed
to PSA generator.

Filters shall be designed for maximum contaminant removal and minimal pressure drop, filters offer
significant energy savings in the compressed air system as well as minimizing the problems that
result from poor air quality.
Filters should be comply with ISO 12500-1:2007 and ISO 8573-2:2007 standards.

Filters Standard scope of supply

 Head
 Bowl
 Filter element(s)
 Differential pressure gauge
 Automatic drain
 Manual drain

Oxygen Compressor
The High Pressure Oxygen Compressor shall be designed to provide a maximum discharge pressure
of 3000 PSIG /207 BARG for oxygen. The High Pressure Oxygen Compressor will fill up to (100)
3000 PSI Oxygen Cylinders in a 24-hour period. High pressure compressor shall be made as a 4-
stage compressor that uses four oil-free, single-acting cylinders on a “V” type crosshead designed
crankcase. Heat exchangers, crankcase, and compression cylinders are air cooled, and the crankcase
is pressure, splash-lubricated with an automotive grade oil. The 3rd and 4th stage pistons shall be
free-floating in order to allow for easy piston and ring change-out without cylinder or piston rod
removal.

General Feature:
Designed and made in the USA or Europe
oil-free design
oxygen cleaned for oxygen service
safety relief valves
high pressure safety shut down
heavy duty
continuous duty cycle
low rpm for long service life

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Oxygen Filling Ramp
The oxygen manifold shall be of size 4+4 jumbo cylinders. Manifold shall consist of two high
pressure header bar assemblies to facilitate connection of primary and secondary cylinder supplies.
Each header bar shall be provided with required numbers of cylinder pigtail connections to suit
cylinder valves as per IS 3224 incorporating a check valve at the header connection. The high-
pressure header bar shall be designed in such a manner that it can be extended to facilitate additional
cylinder connections. Each header bar assembly shall be provided with a high-pressure shut-off
valve.
The manifold should be so designed that it shall suit easy cylinder changing and positioning.
The cylinder should be placed with the help of cylinder brackets and fixing chains which should be
zinc plated.
The manifold should be suitable to withstand a pressure of 140-150 Kg/cm2. The manifold should be
tested (hydraulically) at 3500 psig pressure.
The Oxygen Manifold System shall be compatible to allow integration with the medical Oxygen
Generation Plant.

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Our Requirements
Description Detail Qty.
OGP Pressure Swing Adsorption Hospital Use 1 unit
Oxygen Generator Variable speed
working press. : 10 bar(e)
oxygen flow purity 95% :60 m3/h
oxygen inlet pressure : 6-9.75 bar
oxygen outlet pressure : 4.5-7.75 bar
average air inlet flow : 216 Nm3/h
oxygen outlet quality : class 1-2-1
vertical aIR receiver Max. working Medical Use, 1 unit
pressure : 11 bar Galvanized with all
Capacity : 3000 liter accessories
Application : Medical
Coalescent Air filter - 16 bar(e) max Air flow 310 l/sec 1 unit
model : G 1 1/2
air flow :310 l/s
High efficiency coalescing Air filer - 16 Air flow 310 l/sec 1 unit
bar(e) max (G 1 1/2)
Active carbon tower bar(e) max 16 bar Air flow 310 l/sec 1 unit
(G1 1/2)
Air flow : 310 l/s
Air compressor oil injected rotary screw Approx Power 75 1 unit
Air cooled variable speed air compressor kW
Supply voltage : 400V/ 50/3
Free air delivery : 250 – 300 l/s
Max. working pressure : 12.5 bar(e)
Integrated air dryer : Yes
vertical Oxygen receiver Max. working Medical Use, 1 unit
pressure : 11 bar Galvanized with all
Capacity : 1500 liter accessories
Application : Medical
Oxygen compressor Gas type : oxygen 1 unit
Flow rate : 32-60.0 Nm3 / HR Variable speed
Air cooled
Oil free produced oxygen
Max. bar : 207 barg

Note : all material should be of USA or European Made.

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