GENERON O&M Manual
GENERON O&M Manual
Package
Owner / Operator
Manual
GENERON
16250 Tomball Parkway
Houston, Texas 77086
Phone: 713-937-5200
Fax: 713-937-5250
www.generon.com
ALL SYSTEMS MADE IN USA
Version 1.0
Table of Contents
1 GENERAL SAFETY WARNINGS ......................................................................................................................................... 1
1.1 Confidentiality ......................................................................................................................................................... 2
2 INTRODUCTION ............................................................................................................................................................... 3
2.1 Proper Use of Nitrogen Generation package.......................................................................................................... 3
3 INSTALLATION ................................................................................................................................................................. 6
3.1 Receiving & Inspecting Equipment ......................................................................................................................... 6
3.2 Site & Utility Requirements .................................................................................................................................... 6
4 PROCESS DESCRIPTION ................................................................................................................................................... 7
4.1 General.................................................................................................................................................................... 7
4.2 Module Operating Properties ................................................................................................................................. 7
5 EQUIPMENT DESCRIPTION.............................................................................................................................................. 8
5.1 Nitrogen Generation Package (Membrane)............................................................................................................ 8
6 CONTROL SYSTEM ......................................................................................................................................................... 10
6.1 CC-2 Control panel ................................................................................................................................................ 10
7 MAINTENANCE .............................................................................................................................................................. 21
7.1 Nitrogen Generation Package ............................................................................................................................... 21
7.2 Valves .................................................................................................................................................................... 22
7.3 Instrumentation .................................................................................................................................................... 22
8 TROUBLESHOOTING ...................................................................................................................................................... 23
8.1 Filters..................................................................................................................................................................... 23
8.2 Instrumentation / Transmitters ............................................................................................................................ 23
8.3 Drain...................................................................................................................................................................... 23
8.4 Operation Cycle Problems .................................................................................................................................... 23
List of Tables
Table 1 Oxygen Deficient Atmosphere Symptoms ................................................................................................................. 3
Table 2 Maintenance Schedule ............................................................................................................................................. 21
Table 3 Analyzer Span Gas Requirements .......................................................................................................................... 222
D_0101 P&ID
G_0101 GAD
E_0101 On-Skid Interconnection Diagram
E_0102 In-Cabinet Interconnection Diagram
E_0121 CC-2 Control Back Pan Layout & BOM
E_0122 CC-2 Control Back Pan Wiring Diagram
E_0123 CC-2 Control Back Pan I/O Diagram
E_0124 CC-2 Control Back Pan Schematic Diagram
PLEASE READ MANUAL CAREFULLY AND FOLLOW ALL PROCEDURES BEFORE INSTALLING,
OPERATING OR REPAIRING THE UNIT.
WARNING:
Pressurized gases are contained within the generator, receiver and product tanks. High pressure
gases are dangerous and may cause injury or death if handled or used inappropriately. Never point
the compressed air, nitrogen, or condensate drain outlet towards anyone.
The GENERON® IGS Nitrogen Generation System is capable of producing nitrogen with purities ranging 95% to
99.9%. The nitrogen produced by the GENERON® IGS Generation 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 non-toxic; however, the liberation of large amounts of nitrogen will displace the oxygen needed to
support life.
Ensure connections are depressurized prior to performing maintenance, including changing the filters.
Only use GENERON® IGS approved replacement parts when performing maintenance and repairs. Make sure
that replacement parts meet or exceed the pressure requirements. The owner is responsible for maintaining
the unit in a safe operating condition.
Installation, operation, maintenance and repair must be performed only by authorized, trained, and competent
individuals. The operator must employ safe working precautions and rules when operating or working with
mechanical and electrical pieces of equipment.
Never allow high pressure gas to exhaust from an unsecured hose which may exhibit a whipping action that can
cause serious injury. If a hose should burst during use, immediately close all isolation valves.
Never disable or bypass any safety relief valve.
Always make certain that the electrical system is “locked-out” and that the voltage is disconnected and the unit
is without power prior to performing any electrical work on routine maintenance.
GENERON® IGS Systems are equipped with condensate drain lines. These drain lines could collect oily condensate,
if any, removed from the compressed air supplied to the systems. It is 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.
15-19% Decreased ability to work strenuously. May impair coordination and may
induce early symptoms in persons with coronary, pulmonary, or
circulatory problems.
6-8% 8 minutes exposure, fatal; 6 minutes exposure, 50% fatal; 4-5 minutes
exposure, recovery with treatment.
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.
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) could consist 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® IGS Nitrogen Generation package 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® IGS package is operated under pressure. Therefore, a hazardous work program should be
followed when working around or servicing this equipment.
The permeate vent line must never be pressurized. This line should always be allowed to flow un-restricted to
the atmosphere for discharge in a safe area.
The GENERON® IGS package 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 BEFORE DISASSEMBLY OF GENERON® IGS Nitrogen Generation package. 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.
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® IGS packages should not
attempt to service this equipment. The electrical currents supplied to the various electrical components on the
GENERON® IGS package are at levels high enough to cause severe injury and/or death.
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.
Purity is varied by controlling the flow rate through the modules. Slow/low flow yields high purity, while
fast/high flow yields a lower purity.
MAIN MENU
All Screens link to the Main Menu. From this menu you may go to any screen in the system. Date and time is
found on this screen. Use the touch screen to navigate to any screen for the following options:
• PS 27-1: Pressure switch status on Nitrogen receiver tank STANDBY OFF/STANDBY ON.
• SV 24-1: Automated valves positions Vent/Product.
• SV 24-1: Automated valves positions Inlet.
• Sys. Status: System Status Stop/Run/Standby.
• %O2: Oxygen analyzer reading
• % Open: Purity valve open % (0-100%)
• RTD 19-1: Post heater feed Temperature indicator
• RTD 14-1: Pre heater feed Temperature indicator
• Use Main/Next to navigate to next screen or back to main menu screen.
SET UP 1
• High O2 SP: High oxygen impurity set points are entered into the PLC via the HMI for HIGH OXYGEN
ALARM/SHUTDOWN LEVEL. If oxygen concentration of the product gas exceeds these set points, the
product gas will be vented by off-spec automated valve to prevent the contamination of the customer's
process with off-spec nitrogen. This venting will continue until purity is re-established or changed by
user.
• Low O2 SP: High oxygen impurity set points are entered into the PLC via the HMI for LOW OXYGEN
ALARM/SHUTDOWN LEVEL.
• Use Back/Main/Next to navigate to previous screen, back to main menu screen or proceed to next
screen.
• Use Back/Main/Next to navigate to previous screen, back to main menu screen or proceed to next
screen.
• This is the PID setup screen for purity control Valve. These settings should only be changed by qualified
personnel.
• Offline: to go offline for HMI settings. The Offline screens are password protected and are for factory
setup usage.
• Use Main/Next to navigate to next screen or back to main menu screen.
• Use Active Alrm/Main to navigate to Active Alarm list screen or back to main menu screen
Note:
(1) More frequent attention may be required (depending on inlet air quality).
7.1.1 Daily Maintenance
Each day, it is recommended that the operator record the system’s operational parameters on copies of the
Nitrogen Unit Daily Check List / Log located in Appendix C. It is recommended that the readings be performed
at a set time under the same conditions each day after the unit has been running for at least one hour. Retain
these records for as long as possible. These records will aid service technicians in diagnosing and
troubleshooting the system.
7.2 Valves
The valves on the package are rated for millions of cycles. However, the air automated valves on the package
can wear out over time due to high frequency cycling and contamination. This may result in lower performance
of the system.
Repair kits are available to replace worn valve seals. Changing of these seals can be accomplished by a trained
service technician.
7.3 Instrumentation
Please refer to the manufacture’s literature for recommended maintenance for specific items.
7.3.1 Oxygen Analyzer
Please refer to the manufacturer’s literature for recommended maintenance. The Oxygen Analyzer should be
periodically calibrated (at least bi-annually) with a certified span gas to ensure proper nitrogen purity reading.
If deviations are detected contact GENERON® IGS service for support. Please refer to Appendix C for a sample
calibration log.
Please see table 3 for calibration gas compositions for these analyzers.
8.3 Drain
If there is not any liquid water/oil from drain, check to ensure that the drain line is not blocked by opening the
bypass line. If there is water draining from the bypass line, remove the drain, disassemble and clean port. If
water is still not draining, open the filter and verify the outlet is not plugged from inside the vessel.
Notes:
GENERON recommend changing carbon filter element every 2000 hr or 4months, whichever occurs
first.
GENERON recommend changing filter elements every 4000 hrs or six months, whichever occurs first.
Check all pressure regulators and gauges every week.
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SECTION 3: Composition/information on ingredients
3.2. Mixtures
The components are not hazardous or are below required disclosure limits.
List of abbreviations and symbols that may be used above
CLP: Regulation No. 1272/2008.
DSD: Directive 67/548/EEC.
M: M-factor
vPvB: very persistent and very bioaccumulative substance.
PBT: persistent, bioaccumulative and toxic substance.
#: This substance has been assigned Community workplace exposure limit(s).
Large Spills: Wet down with water and dike for later disposal. Shovel the material into waste
container. Avoid the generation of dusts during clean-up. Following product recovery, flush area
with water.
Small Spills: Sweep up or vacuum up spillage and collect in suitable container for disposal.
6.4. Reference to other For personal protection, see section 8. For waste disposal, see section 13 of the SDS.
sections
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Germany. DFG MAK List (advisory OELs). Commission for the Investigation of Health Hazards of Chemical Compounds
in the Work Area (DFG)
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Slovakia. OELs. Decree of the government of the Slovak Republic concerning protection of health in work with chemical
agents
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Hygiene measures Always observe good personal hygiene measures, such as washing after handling the material
and before eating, drinking, and/or smoking. Routinely wash work clothing and protective
equipment to remove contaminants.
Environmental exposure Environmental manager must be informed of all major releases.
controls
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Symptoms Dusts may irritate the respiratory tract, skin and eyes. Coughing.
11.1. Information on toxicological effects
Acute toxicity No data available.
Skin corrosion/irritation Due to partial or complete lack of data the classification is not possible.
Serious eye damage/eye Due to partial or complete lack of data the classification is not possible.
irritation
Respiratory sensitisation Due to partial or complete lack of data the classification is not possible.
Skin sensitisation Due to partial or complete lack of data the classification is not possible.
Germ cell mutagenicity Due to partial or complete lack of data the classification is not possible.
Carcinogenicity Due to partial or complete lack of data the classification is not possible.
Reproductive toxicity Due to partial or complete lack of data the classification is not possible.
Specific target organ toxicity - Due to partial or complete lack of data the classification is not possible.
single exposure
Specific target organ toxicity - Due to partial or complete lack of data the classification is not possible.
repeated exposure
Aspiration hazard Due to partial or complete lack of data the classification is not possible.
Mixture versus substance No information available.
information
Other information Not available.
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IMDG
Not regulated as dangerous goods.
14.7. Transport in bulk Not applicable.
according to Annex II of
MARPOL 73/78 and the IBC
Code
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Full text of any statements or None.
R-phrases and H-statements
under Sections 2 to 15
Training information Follow training instructions when handling this material.
Disclaimer The information in the sheet was written based on the best knowledge and experience currently
available. The information contained in this document is intended merely as a guide to the
appropriate handling of the supplied material by a properly trained person. The information may
have been gathered from a number of sources, including third parties. While the information is
believed to be accurate as of the date this document was compiled, no warranty or representation,
express or implied, with respect to the information is being made. It is the recipient’s responsibility
to ensure the safe handling of the material and to ensure its suitability for the recipient’s intended
use. Hollingsworth & Vose Company, and its affiliates, accepts no liability for any loss or damage
that may occur from the use of this information.
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16250 Tomball Parkway
Houston, Texas 77086
(T): 713-937-5200
(F): 713-937-5250
Page 1 of 4
16250 Tomball Parkway
Houston, Texas 77086
(T): 713-937-5200
(F): 713-937-5250
Page 2 of 4
GENERON 16250 Tomball Parkway
Houston, Texas 77086
INNOVA!l\IE GASSi'SY!'l.\S (T): 713-937-5200
(F): 713-937-5250
Protect cylinders from physical damage. Store in cool, dry, well-ventilated area away from
heavily trafficked areas and emergency exits. Do not allow the temperature where cylinders are
stored to exceed 130° F (54° C). Cylinders should be stored upright and firmly secured to
prevent falling or being knocked over. Full and empty cylinders should be segregated. Use a
"first in-first out" inventory system to prevent full cylinders being store for excessive periods of
time.
Other: N/A
Protective Gloves: Any material.
Eye Protection: Safety Goggles or glasses.
Other Protective Equipment: Safety Shoes.
Physical State; Gas, Appearance; Clear, Color; Colorless, Odor; Odorless, Taste; Tasteless
Boiling Point; -321F (-196C) Freezing Point; -346 F ( -210 C)
Page 3 of 4
GENERON 16250 Tomball Parkway
Houston, Texas 77086
IN!>IOVAJIVE GAS (T): 713-937-5200
(F): 713-937-5250
.•
Page 4 of 4
Appendix E.
Membrane Module Warranty Policy
Generon IGS warrants that, at the time of shipment, the membrane module hereinafter referred to as
"Module", will conform to all applicable laws, rules, regulations, specifications then in effect and meet or
exceed the minimum performance criteria as outlined in the scope of supply.
Subject to the Original Equipment Manufacturers (hereinafter referred to as "OEM"), or end user's
compliance with the provisions below, the Generon IGS warranty is for a period of eighteen (18) months
from date of shipment or twelve (12) months from module installation, whichever comes first. The
warranty shall include all module models manufactured by Generon IGS.
4) Test bore side at up to 135 psig and compare with initial QC data
1. All parts and labor required to repair the malfunctioning component(s), which is removable and
returnable to Generon IGS.
A. Generon IGS shall determine what is removable and returnable. The end user shall be
responsible for submitting all warranty claims in writing to Generon IGS with date of installation,
verified by shipping and/or installation documentation, and removing and shipping the
component(s). If date of installation is not provided, the warranty period will be twelve (12)
months from date of shipment.
B. Upon receipt of a Purchase Order from the end user, Generon IGS will ship the replacement part
(s) to be installed by the end user. Generon IGS will issue a "Return Merchandise Authorization
Number" (RMA) to be used by the end user, for returning the component(s) to Generon IGS. After
the items(s) has been returned, Generon IGS will determine if the item(s) are covered under
warranty. Generon IGS will notify the end user in writing of this determination within 60 days of
item(s) receipt. If it is determined that item(s) are not covered under warranty, an invoice will be
issued for all replacement parts based on list price plus a 20% handling fee. The 20% handling fee
will also be invoiced in the case where no replacement parts are shipped.
2. Service work performed onsite, at the end user's request, must have a Purchase Order. If it
is determined that failure was caused by end user misuse or neglect, the cost will be
billable as follows: See attached Service Price Schedule below.
WARRANTY LIMITATIONS/EXCLUSIONS: The Limited warranties contained in the above paragraphs are
Generon IGS's sole warranties with respect to the systems and are expressly in lieu of and preclude any
warranty of fitness for a particular purpose and other express or implied representations and
warranties.
LIMITATION OF REMEDY: In the event of a covered defect, Generon IGS will repair or replace the non-
conforming part(s) of the System. The remedies provided herein are expressly agreed to be exclusive.
IN NO EVENT SHALL GENERON IGS BE LIABLE
FOR ANY INCIDENTAL OR CONSEQUENTIAL DAMAGES. The foregoing limitations apply whether the
claim against Generon IGS is based upon breach of warranty expressed or implied, strict liability in
tort, negligence or any other cause of action.
FORCE MAJEURE/ALLOCATION: In the event of war, fire, flood, strike, labor dispute, breakage of
equipment, accident riot, action of governmental authority and laws, rules, ordinances and regulations
including, but not limited to, those dealing with pollution, health, ecology or environmental matters, acts
of God, or contingencies beyond the reasonable control of Generon IGS, materially interfering with the
production, supply, transportation or consumption practice of Generon IGS at the time respecting the
goods covered by this warranty, or in the event of inability to obtain on reasonable terms any raw
materials due to force majeure as defined herein or due to exceptionally high demand by its customers
allocate its supply of such goods or raw materials among the various uses therefore in any manner which
is fair and reasonable; provided, however, that (i) Generon IGS shall have no obligation to obtain goods
or raw materials from a third party in order to supply Generon IGS's excused contractual shortfall, and
(ii) any goods or raw materials obtained by Generon IGS from a third party solely for Generon IGS
internal use are not subject to allocation.
Schedules
Generon IGS requires a Purchase Order or Advance Payment, for service and
expenses prior to the scheduling of a Field Service Technician’s departure. Generon
will provide an estimate of cost for the customer with an estimated number of days
and expected travel related expenses. If an extended amount of time is requested
while the technician is on site a Revised Purchase Order or Additional Payment
must be received by Generon before any adjustments are made to the technician’s
schedule.
Training
Technical, start-up, and maintenance training is available if requested by the
customer and will be charged to the Customer at the current daily service rate, plus
travel and living expenses