Operation Manual INMATEC Nitrogen Generators Model range IMT-MN INMATEC GaseTechnologie GmbH & Co. KG Gewerbestrasse 72 82211 Herrsching / Germany Phone +49 . 8152 . 9097-0 Fax +49 . 8152 . 9097-10 Email info@inmatec.de Serial No.: 16.063/1001The World of Gas fisEZ Table of contents 4 Description of functions 4.4. The Principle 1.2. The Process 1.3. Influence of the settings 4.3.1 Influence of flow rate 5 4 Fehler! Textmarke nicht definiert. Fehler! Textmarke nicht definiert. Fehler! Textmarke nicht definiert. 4.3.2. Influence of temperature 5 1.3.3 Influence of membrane pressure (inner parts of hollow fibre) 6 1.3.4 Influence of outer pressure of the hollow fibre 6 2. Safety instructions 6 2.4 Legend of safety symbols as shown Fehler! Textmarke nicht definiert. 2.2 Due diligence of the Operator Fehler! Textmarke nicht definiert. 2.5. Exclusion of Llabiitty Fehler! Textmarke nicht definiert. 2.4. Safety regulations 8 2.4.1 Oxygen content limits Fehler! Textmarke nicht definiert. 2.5 Special risks Fehler! Textmarke nicht definiert. 3 Operating Data Fehler! Textmarke nicht definiert. 5.1 Specification of compressed air 12 3.2 Ambient conditions Fehler! Textmarke nicht definiert. 3.3. Electrical Data 12 3.4 Technical dimensions and connections 3 3.5. Noise level 3 4 Technical Data of model range MN 8 4.4 Capacity 8 4.2. Correction factor for variation from nominal pressure 8 4.3 Calculation of compressed air supply* B 5 _EC-Deciaration of Conformity, Annex II A of EC-Machinery Directive (98/37/EC) Fehler! Textmarke nicht definiert. 6 Selection of compressor 45 6.1. Genereal information Fehler! Textmarke nicht definiert. 7 Transport and installation 45 7.4. Condition of delivery Fehler! Textmarke nicht definiert. 7.2. Installation Fehler! Textmarke nicht definiert. 7.3. Installation location Fehler! Textmarke nicht definiert. 8 Operation of Nitrogen generator 16 Seite 2 von 31 INMATEC GaseTechnologle GmbH & Co. KG, Gewerbestr. 72, 82241 Herrsching 2. A Fon +49(018152 9097-0, Fax +4910)8152 9097-10, Email info@inmatec.deThe World of Gas 8.1. General instructions for operation 8.2 Checklist before commissioning 8.3. Starting up 8.4 Shutdown 9 Maintenance 9.1 General information 9.2 Maintenance instruction 9.3 Return of generator for maintenance 9.4 Maintenance-Documentation 40 Fault clearance 11 Wear parts 12 Spare parts 13 Drawings 43.1 Installation plan 13.2 Connecting diagram 43.3. R&l Scheme MN 1150 F 13.4 R&l Scheme MN 1250 F 18.5 R&l Scheme MN1350F = 414 Product Warranty Fehler! Textmarke nicht definiert, 16 Fehler! Textmarke nicht definiert. Fehler! Textmarke nicht definiert. Fehler! Textmarke nicht definiert. Fehler! Textmarke nicht definiert. Fehler! Textmarke nicht definiert. 21 Fehlerl Textmarke nicht definiert. Fehler! Textmarke nicht definiert, Fehler! Textmarke nicht definiert, Fehler! Textmarke nicht definiert. Fehler! Textmarke nicht definiert. 25 Fehler! Textmarke nicht definiert. ar 28 29 Fehler! Textmarke nicht definiert. Seite 3 von 34 INMATEC GaseTechnologie GmbH & Cn. KG, Gewerbestr. 72, 82241 Horrsching 2. A Fon +49(018152 9097-0, Fax +491018152 9097-10, Email Info@inmatec.deThe World of Gas MAY 41 Description of functions 4.1 The Principle INMATEC Nitrogen generators produce nitrogen by using the ambient alr. The ambi- ent air is composed of nitrogen (78, 1%), oxygen (20,9%), argon as well as traces of ‘some other rare gases. The system is suitable to eliminate oxygen and some other constituents from the ambient air. ‘The functioning principle of the generators is based on the process of gas separation. Thereby the nitrogen is separated from the other constituents of the ambient alr by use of Membrane modules. These modules are composed of bundles of hollow fibres (see illustration 1) inside which the effective separation (segmentation) is effected. ilustration 4: membrane ‘As part of the process the treated compressed alr is guided through the inner parts of the fibres (see illustration 2). Oxygen and traces of nitrogen permeate through the fibre wall and are discharged from the system under atmospheric pressure. At the outlet of the modules thé nitrogen, i.e. air being separated from oxygen, is supplied in concentrated form for further application. eT Nitrogen © ‘© @ Nitrogen e ° @=0, =N Illustration 2: principle of gas separation Seite 4 von 34 INMATEC GaseTechnologle GmbH & Cn. KG, Gewerbestr. 72, 82244 Herrsching 2. A. Fon +49(018152 9097-0, Fax +49108152 9097-10, Email Info@inmatec.deThe World of Gas MA 4.2 The Process For the installation of a complete, operative system you need a compressed air supply network or a dedicated compressed air system of the required capacity. ‘The INMATEC nitrogen generator shall be connected to the supply line of appropriately treated compressed air. The ambient air is compressed, cleansed as well as dehumidified and then conducted through the INMATEC nitrogen generator. Hereby the air flow enriched with ‘oxygen is collected under atmospheric pressure and subsequently blown out into the ambient air. ‘The compressed air flow enriched with nitrogen is supplied as result of the separation process at the outlet of the plant for further application, ‘The measuring of composition of the produced gas is effected by gauging the residual oxygen content in volume percentage. The content of nitrogen Is. calculated by subtracting the measured residual oxygen content from 100 %. It should also be considered that this data value is designated as nitrogen content ‘and quoted in %, but is in fact the content of inert gas, because this flow is com- Posed nat only of nitrogen, but also of slightest traces of other rare gases, even if they are present in lowest concentration only. ‘As an option the system may be completed by further components, such as hourmeter, gas analysis, heater, pressure booster, or else be designed In ATEX layout. 1.3. influence of settinas - The performance characteristics of INMATEC Nitrogen generators depend on the pre- sct operation parameters. In the following part the influence of the most important process parameters shall be explained 1.5.1 Influence of flow rate The oxygen content depends on the fiow rate of compressed air. This means, if the flow rate of compressed air is changed, the oxygen content will also change. When the flow rate of compressed air is decreasing, the retention time of the air Inside the system is longer, and as a result the oxygen content shall fall The nitrogen purity may be adjusted by use of a calibration valve. For this purpose suitable measuring instruments are reauired. 1.3.2 Influence of temperature The optimum operation range of the INMATEC Nitrogen generator Is at a temperature of approx. + 20 °C up to + 25°C. At increasing temperature there will occur a slight decline of the selectivity of the system, resulting in a higher consumption of compressed air. It is therefore recommended to set up the plant inside a room for which no overly rise of temperature may be expected. In case this should not be possible, we recommend the installation of a pre-cooler. Seite 5 von 31 IWMATEC GaseTechnologie GmbH & Co. KG, Cewerestr. 72, 82211 Herrsching 2. A. Fon 4491018152 9097-0, Fax +-4910)8152 9097-10, Email info@inmatec.ceThe World of Gas 1.3.3 Influence of membrane pressure (inner parts of hollow fibre) At increasing membrane inlet pressure the capacity of the plant shall also be built-up. 1.3.4 Influence of hollow fibre membrane outer pressure Pressure outside of the hollow fibre membrane must be at atmospheric pressure; at higher pressure a dramatic loss of capacity and selectivity of the plant has to be assumed. The plant's construction is designed in such a way that no pressure build-up is effected. With regard to this parameter it is essential that the installation instructions are followed precisely. 2 Safety Instructions 2.4 Legent I wn In the Operation Manual at hand the following safety symbols are used. These symbols, are intended to call the reader's attention to the wording of the safety instruction next to it. damage to persons or considerable material damage are designated by use of the illustrated pictograph und the word “Danger” (‘Gefahr") Specific information resp. commands and interdictions to prevent A underneath. Gefanr Specific information resp. commands and interdictions relative to loss prevention are designated by use of the Illustrated pictograph and the word “Attention” ("Achtung") underneath Achtung [= ___ Specific statements relative to Information which contributes to the : better understanding of the system are designated by use of the 1 illustrated pictograph und the word “Indication” (“Hinweis”) undemeath. Hinweis to electrical voltages inside the system, are designated by use of the illustrated pictograph und the word “Electrical” ("Elektrisch”) Specific staternents about information presenting indications relative A undemeath, Elektrisch The respective symbol used cannot substitute for the wording of the safety instructions. ‘Therefore, always read the entire wording of the safety instructions! Seite 6 von 34 INMATEC GaseTechnologie GmbH &. Co. KC, Gewerbostr. 72, 82241 Herrsching 2. A Fon +49(018152 9097-0, Fax +4910)8152 9097-10, Email info@Inmatec.deEN IMA The World of Gas TEC 2.2 Due Diligence of the Operator ‘The INMATEC Nitrogen generators have been designed and manufactured in careful compliance with applicable harmonised norms as well as further technical specifications. Therefore they are In accordance to the latest state-of-the-art technology and ensure the maximum possible level of safety. However, this safety may only be achieved in practice, if all relevant necessary measures are taken. It fs part of the due diligence of the operator of the nitrogen generator and of its users to plan these measures accordingly and to supervise their implementation. The operator must especially ensure that: + the nitrogen generators will only be operated in compliance to thelr intended use * the nitrogen generators will only be operated in a faultiess and well functioning state and that especially the safety devices will regularly be monitored with regard to their full Functionality * the necessary personal protective equipment will be made available for and be used by the operation, maintenance and repair staff, = the operation manual will always be avaliable in legible and complete condition at operation site of the nitrogen generators, * only sufficiently qualified and authorized personnel operate, maintain and repair the nitrogen generators. + the authorized personnel will Be regularly trained in labour safety and environmental protection and that they are familiar with the operation manual and especially the safety instructions included therein. * all safety instructions, warning notices and symbols attached to the nitrogen generators shall not be removed and are kept in legible condition. 2.3. Exclusion of Liability We explicitly call attention to the fact that INMATEC is not liable for any damage resulting from incorrect or negligent operation ar maintenance resp. servicing, INMATEC Is not liable for any specific indirect, accidental or consequential damage resulting from the utilisation or any malfunction of the plant. This is applicable in particular for abnormal utilisation as well as undue modifications of the nitrogen generators that may impair their safety, In any such case the product warranty and any liability shall be null and void. Seite 7 von 34 INMATEC GaseTechnologie GmbH & Co. KG, Gewerestr 72, 82211 Herrsching 2. A. Fon +49(018152 9097-0, Fax +49(018152 9097-10, Email Info@inmatec.ceThe World of Gas 2.4 Safety Reauiations ‘Achtung Hinweis y Achtung Elektrisch Achtung i) The INMATEC Nitrogen generators produce air enriched with nitrogen and also oxygen. Air enriched with nitrogen may lead to danger of asphyxiation. By contrast, air enriched with oxygen may cause increased fire hazards, For the reasons mentioned before, sufficient ventilation of the plant installation room needs to be provided for. ‘The necessary ventilation capacity depends on the capacity of the plant, and the size of the room where the plant is located. Moreover the legal regulations applicable at installation site are valid, (Please inquire with the local competent authorities). Make sure that the INMATEC Nitrogen generator is always connected to the electrical power line and that the power switch is activated, If the INMATEC Nitrogen generator is operated without being connected to the electrical power line and without being activated, this may result in ir- Teparable damage to the membranes. Make sure that the separation and removal of condensate from the com- prossad air is always in correct function. Damage to the membranes caused by a poor condensate separation is not covered by the manufacturer's warranty. Maintenance and/or servicing may only be undertaken by authorised technicians of INMATEC. Before undertaking maintenance or servicing, prior consultation with the authorised superior/operational manager Is mandatory. The installation and maintenance of the plant may only be carried out by experts, who are trained and qualified by INMATEC, ‘The INMATEC Nitrogen generators are put under pressure during ‘operation. The pressure build-up may continue, even after compressed air supply has been powered down. Therefore It is to be ensured that the system is completely depressurised. before any maintenance ar servicing is undertaken, Dangerous electric voltages may remain active on certain components even after switching off any electric current and disconnecting the generator from the electric power line. The plant must always be disconnected from the electric power line before any maintenance or servicing is undertaken. ‘The INMATEC Nitrogen generators use electric components which are not explosion-proof as a standard. Therefore it Is not permitted, to install the generators inside locations where explosion- or fire hazard materials are handled, Seite 8 von 34 INMATEC CaseTechnologie GmbH & Co. KC, Gewerbestr, 72, 82211 Herrsching 0. A Fon +49(018152 9097-0, Fax +4910)8152 9097-10, Email Info@inmatec.deThe World of Gas rN MA, TEC Achtung Gefahr Hinweis Hinweis With a view to guarantee safe operation of the plant, the installation Foor temperature must be kept between + 2°C and max. + 40°C. The maximum inlet pressure must not exceed 43 bar. The INMATEC Nitrogen generators are designed to produce nitrogen enriched air from compressed air. It has to be observed that the correct nitrogen concentration required for the respective application is effectively adjusted. It is not permitted to feed the generator with other gases than air resp. air with poor oxygen content. For the trouble-free and safe utilisation of the nitrogen generator checks and maintenance in regular intervals are required. (See Maintenance Instructions in the following part of Operation Manual). Installation of peripheral equipment, piping and buffer tank is effected in compliance to the generally acknowledged provisions and standards of engineering, In case the residual oxygen content of the produced gas should be critical under safety considerations or with regard to your application. ‘the manufacturer formally recommends to install the optional automatic oxygen monitoring unit. ‘The INMATEC Nitrogen generator is to be operated by trained staff only. The operational safety of personnel is under the full responsibility of the operator of the nitrogen generators. ‘The operator is aware of the risk associated with the operation of the nitrogen generators, as well as the accompanying processes. The operator is responsible for training anu operational safety of personnel. Seite 9 von 34 INMATEC GaseTechnologie GmbH & Co. KG, Gewerbestr. 72, 82211 Herrsching a. A. Fon 4.49(018152 9097-0, Fax +49(0)8152 9097-10, Email info@inmatec.deBIZ The World of Gas =i im cl | i 2.4.1 Oxygen content limits Declining capability to work intensely, May impair on coordination. 15 = 19% Heightening of respiration, along with strain, heightening of pulse 12-14% _ | beat, impair on coordination, receptiveness and discernment are affected - ‘Respiration increases further In frequency and deepness, debilitated 10-12% | discemment, blue colouration of lips 8—10% _ | Mental blackout, fainting, unconsciousness, ashen face, blue colouration of lips, nausea and vomiting, Impact of 8 minutes: fatal Impact of 6 minutes: deadly peril Impact of 4-5 minutes: recovery under therapy Coma within 40 seconds; convulsions, ending respiration or death. 8-9% 4-6% Hinweis Values oxygen content related to percent by volume at atmospheric pressure. Nitrogen may lead to asphyxiation. Before entering a closed or Poorly ventilated location inside which a nitrogen generator or other transmission equipment resp. piping are installed, all well-established safety procedures and practices are to comply with. If product gas cantaining 5 % or less oxygen is not correctly handled, It will lead to asphyxiation. Product gas should not be vented or be deflected by other means, except by use of the normal piping. Adequate information signs should be fixed inside tne area of the nitrogen plant as a warning of this danger. The air flow enriched with nitrogen does not support any life activity, for this reason it must be used and handled accordingly. Seite 10 von 34 INMATEC CascTechnologie Gmbi| & Co, KO, Gewerbestr. 72, 82211 Herrsching a. A Fon +491018152 9097-0, Fax +49(018152 9097-10, Email info@inmatec.desiz The World of Gas sj ial ih 25 Shecial Risks Risk of injury The INMATEC Nitrogen generators are manufactured compliant to the latest state-of-the-art technology and the well-established safety-related regulations, However, during their operation risks may emerge as threat to life or physical Condition of the operator or a third party, resp. in regard to damage of the plant or other material assets. When inappropriately used, the following injuries amongst others may occur: « tilting danger of the plant during inappropriate in-house transport or installation. * Injuries caused by being squashed-in during servicing * electroshock by touching electric components of the INMATEC Nitrogen generator, In case the electric connection has not been performed correctly, the connecting cable is damaged, or by contact with other electric lines, Seite 44 von 34 IWMATEC GascTechnologie GmbiI'& Co, KO, Gewervestr. 72, 82211 Henischiny 2, A. Fon +4910)8152 9087-0, Fax +4910)8152 9097-10, Email Info@inmatec.deZ hi IMA The World of Gas TEC 3 Operating Data 5.4 ‘ion of. mre ir Max. working pressure | 13 bar Temperature range +10°C up to +40°C Alr quality Acc. to ISO 8573.1; Class 1 dirt and oil, Class 4 water Compr.air temperature | < 10 °C over room temperature Size of particles* <0,01n Relative humidity* < 100 % (no liquid water ) Residual oil content” < 0,01 mg/m? Pressure dew point < +3 * Operating data marked with (*) are depending upon the quality of filters. The filters need to be examined as instructed and be replaced according to maintenance plan instructions (minimum once per year). 3.2 A nditions 7 Temperature range* +2°C up to +40°C (frost free) The air sucked in by the compressor must be according Air quality to normal ambient air, and must be clean and free from any vapour of organic substances or other contaminations. Ambient pressure Atmospheric * At increasing temperature there will be higher consumption of compressed air. Asa result the capacity will decline. In case the rise of room temperature over more than + 25 °C may routinely be expected, installation of a pre-cooler for compressed air Is recommended. 3.3 Eb Ds Mains connection * 230V/50 Hz (Safety plug) *Ontional: differering valtage on request Selte 12 von 31 INMATEC GaseTechnologie GmbH & Co. KG, Gowerbestr. 72, 82211 Herrsching a. A. Fon 4491018152 9097-0, Fax +49(018152 9097-10, Email info@inmatec.ceMA The World of Gas TEC 3.4 Technical dimensions and connections Dim. H x Wx D (mm) 2000 x 800 x 650 Net weight (ka) 480 - 250 (according to actual layout) Inlet compr.air 4" (compressed air) Condensate drain 1/2" 3.5 Nose level Noise level less than 45 dB(A) 4 — Technical Data MN model range 4.1 Capacity Nmé/h Nitrogen content (4) 995 | 99 98 97 96 95 IMT-MN 1150 F 7,0 11,0 19,0 26,0 33,0) 40,0 IMT ~ MN 1250 F 14,0 22,0 38,0 52,0 66,0 80,0) IMT ~ MN 1350 F 24,0| 33,0) 57,0] 78,0] 99,0] +1200 IMT = MN 1450 F 2,0} 44,0] 76,0) 104.0] 132,0] 160.0 4.2 Correction factor at variation from nominal pressure Pressure ( bar} 5 6 7 a 9 10 11 42 Correction factor 0,65 |0,85] 4,0 | 1,2 44 | 1,6 18 | 2,0 Multiplication of nitrogen capacity under below listed air factor 43 mre ir + Nitrogen content 99,5 | 99 98 97 96 95 Air factor 85 60 43 35 5,0 2.6 “Tolerance = 10% Seite 13 von 34 INMATEC GaseTechnologie GmbH & Co. KC, Goworbestr. 72, 82241 Herrsching a, A. Fon +491016152 9097-0, Fax +49(018152 9097-10, Email info@inmatec.deZ S > The World of Gas Fi] [el li EC-Declaration of Conformity, Annex il A of EC-Machinery Directive (98/37/EC) The Manufacturer: INMATEC GaseTechnologie GmbH & Co. KG Gewerbestrasse 72 D-82211 Herrsching / Germany declares herewith that the plant Plant 4: designated alongside, subject to Model: IMT-MN 4350 ‘appropriate and professional Serial-Number: 16.063/1001 ‘connection of power and supply units, {compliant to desian data) and ‘observance of all required safety ( € devices, fulfils the safety- and health requisitions of the following EC Directives: Article 8.2.a of EC-Directive 98/37/CE of before mentioned Directive of the European Council on the approximation of the laws of the Member States relating to machinery, The machinery plant is simiarly in conformity to Directives (if applicable hereunto) 87/404/EC (Simple Pressure Vessels), 89/336/EC (Electromagnetic Compatibility), 97/23/EC (Pressure Equipment), 75/23/EC (Low Voltage). 87/404/EC Simple Pressure Vessels 97/23/EC (Pressure Fquipment) 89/336/EC Electromagnetic Compatibility 73/23/EC (Low Voltage) Applied national standards and technical specifications: uw: BOV AT Principles of Prevention BGV AZ Electric Machines and Equipment Constructional modifications of the plant, having implications on the technical data Mentioned in this present operation manual and its intended use, and consequently alter the plant significantly, invalidate this Declaration of Conformity ! Herrsching/Germany, 23.04.2007 Guido Kuschmierz ~ Managing Director Seite 14 von 34 INMATEC GaseTechnologie Gmbl! & Co. KG, Gewerbestr. 72, 82211 Herrsching a. A Fon +49(018152 9097-0, Fax +49(018152 9097-10, Email info@inmatec.ceny IMA The World of Gas TEC 72 73 Selection of compressor General information Supply of compressed air to the nitrogen-generator may either be effected by the on-site existing compressed air distribution system, or by means of a dedicated com- pressor, each providing the required capacity. The INMATEC Nitrogen generator will be connected to the supply of preprocessed compressed air. = In case the supply is intended to be effected by existing on-site compressed air distribution system, it is recommended to examine the sufficient capacity of the system. = In case the supply is Intended by dedicated air compressor, the following instruc- tions have to be followed: ‘the manufacturer of the nitrogen-generator does not specify a certain compressor brand. However, the optimum performance and a long lasting service life of your nitrogen-generator may only be achieved by the use of premium modern oil lubri- caled or oll-free alr compressors, resp. alr conditioning systems, Transport and Installation Condition of delivery In order to carry out correctly the assembly of the INMATEC Nitrogen generators the enclosed operation manual is needed. The nitrogen product tank (if included in the scope of delivery) shall be delivered as separate unit. Setting-up of the plant has to be effected at its designated site. If after unpacking and check of the plant any damage is detected. this incident has to he declared to the forwarder Immediately. ‘The manufacturer is not liable for any damage which happened during transport. Immediately after receipt of the INMATEC Nitrogen generator the i] lant needs to be checked carefully for any damage. The indication of any damage, outside or inside the plant, is to be documented in writing on the delivery note and has to be notified immediately Hiqwe's to the forwarder, as welll as to INMATEC. Installation Before installation of the INMATEC Nitrogen generator It Is essential to check the designated site for available space, as well as for compressed air and electric power supply, and also for appropriate ventilation of the room. Transport of the generator has always to be carried out by use of appropriate equipment, such as forklift truck. lation Sit The generator is to be set-up inside an efficiently ventilated room which is kept In the range of more than + 2 °C and below + 40°C. Operation of the generator under temperatures of less than + 2 °C or more than + 40 °C will cause damages which are not covered by the manufacturer's warranty. Seite 15 von 34 INMATEC CaseTechnologie GmbH & Co. KG, Gewerbestr, 72, 82211 Herrsching a, A Fon +49(018152 9097-0, Fax +-4910)8152 9097-710, Email info@inmatec.ceThe World of Gas MA 82 Operation of the Nitrogen generator General instructi In order to prevent perilous injuries or plant damage during commissioning of the INMATEC Nitrogen generators the following points need obligatory to be observed: » the nitrogen generators may only be operated in accordance to their intended application, + before activating the nitrogen generators require information about the correct attitude in case of incidents. * commissioning of the nitrogen generators may only be carried out by qualified personnel and in compliance to relevant safety instructions, + before activating the first start-up check thoroughly, if all tools and foreign parts have been cleared from the nitrogen generator. * activate all safety devices before commissioning. Checklist before Commissioning * Check all supply and discharge lines of the unit to be open and in proper condition. = Check all connections to be performed appropriately. * Always make sure before building connections that inlet- and outlet tubes are free from dust, particles, liquid droplets and fat. * Connect compressed air supply to Inlet Air. * If existing, connect N2-product tank or your N2-system to N2-output (N? product) * The air enriched with oxygen may be dissipated to the ambient alr. Upon request, this oxygen enriched air flow may be deflected to the outside by use of a hose or Lube with Inner diameter of min, 1° and length oF max. 5 meters. Inside of this vent line any valves or other flow obstructions are not permitted. = Connect the system to the power supply. Seite 46 von 34 INMATEC GaseTechnologie GmbH & Co. KG, Gewerbestr. 72, 82211 Herrsching a. A. Fon +4910)8152 9097-0, Fax +49(008152 9097-10, Email info@inmatec.ceThe World of Gas Ma Illustration 3: Control panet = Open slowly the supply of compressed air. (open external valve) = Check the entire plant for leakages. Although all INMATEC Nitrogen generators have Individually undergone factory inspection and were checked for leakages, It may Not be excluded that leakiness was subsequently caused during transport. * The switch must be set to the required start-up pressure and the required cut-out Pressure. (See separate Operation Manual Burkert). Illustration 4; Pressure sensor with switching relay Achtung These settings are already effected at the factory. The procedure as described before explains the situation if operating conditions inside your plant installation have been modified. For example: cut-out ressure 6 bar, range scale to be set to 6. Start-up pressure 5 bar, differential scale to be set to 1 -> 6-1 = 5. ‘The plant stall now produce nitrogen within the settings of pressure range. Seite 47 von 34 IWMATEC GaseTechnologle GmbH 8 Co. KC, Gewerbestr. 72, 82211 Herrsching 2. A. Fon +49(018152 9097-0, Fax +4910)8152 9097-10, Email info@inmatec.ceThe World of Gas 8.4 Shutdown * If nitrogen production is suspended temporamlly, please cut compressed air supply to the nitrogen generator, = As soon as compressed air supply to the nitrogen generator Is opened again, production may resume. * If nitrogen production is discontinued for a longer period, e.g. over night, it is recommended to cut compressed alr supply and to power-off the plant. = After disconnecting compressed air supply, please wait a few minutes until the system is depressurised, Check it on the inlet pressure gauge, At the output side pressure may still be remaining according to actual operating conditions. Check it on the nitrogen outlet Pressure Gauge = N2 PRESSSURE OUT, Achtung Seite 48 von 34 INMATEC GaseTechnologie GmbH & Co. KG, Gewerbestr. 72, 82211 Herrsching 2. A Fon +4910)8152 9097-0, Fax +49(018152 9097-10, Email Info@inmatec.deThe World of Gas 9 94 92 Maintenance General information In order to prevent damage to the plant or perilous injuries during maintenance of the nitrogen generators, the following points are obligatory to be observed: = All job steps for maintenance of the generators must imperatively be done in the specified order. = Secure a wide area around the plant to carry out maintenance work. = Switch off all the voltage sources and secure Lhe voltage sources against unintentional switch-on. = Switch the pressure units to depressurised mode. = Use only operating materials as specified. = Use only INMATEC-spare parts which are itemised in our spare parts list. = All maintenance operations are to be documented according to the following maintenance plan. ‘Maintenance instructions In order to ensure correct operation, it is necessary that maintenance for the INMATEC Nitrogen generator Is carried out in accordance to maintenance plan resp. maintenace instructions of the manufacturer. Hinwels Seite 19 von 31 INMATEC GaseTechnologie GmbH & Co. KG, Gowcrbestr. 72, 82214 Herrsching 2. A Fon +49(018152 9097-0, Fax +-49(0)8152 9037-70, Emall info@inmatec.deZz S| >| The World of Gas El The following routine checks need to be effected reaularly on the INMATEC Nitrogen generator: Daily Check of drains Monthly, Check of Analyser unit (if existent) Yearly = Visual inspection of the entire plant - Inspection of gas connections for tightness = Inspection of Oxygen outlets for flow through - Inspection of pneumatic switching- and control elements - Inspection of entire electrical equipment for functioning - Inspection of clectrical connections and fixing of all lines - Replacement of industry filter elements - Inspection of floater drainage for functioning - Inspection of condensate drain for tightness - Replacement of kits for check valves - Setting of inlet pressure control - Inspection and setting of gas adjusting valves - Inspection and setting of pressure transducer for solenoid valves - Measuring of inlet and outlet pressure of the plant - Replacement of gas analyser sensor ~ Calibration of air intake~ anu nitrogen flow on Une Gas Analyser unit - Inspection and Calibration of N2-purity - Calibration and setting of N2-supply flow - Functions test of Nitrogen generator ( Achtung Before replacement of filter element please make sure that: a) compressed air supply Is disconnected b) Nitrogen generator Is depressurised, check pressure reading ©) the filler Jackets are depressurised @) the actual settings of the Nitrogen generator are still compliant to the settings made upon installation and commissioning, Seite 20 von 34 INMATEC CaseTechnologie GmbH & Co. KG, Gewerhestr 72, 89211 Herrsching aA Fon +49(0\8152 9097-0, Fax +49(0)8152 9097-10, Email Info@inmatec.deZ S| >| The World of Gas (lel 9.3 Return of the Generator for Maintenance Prior to return of generator it is necessary to make an appointment with INMATEC. When contacting INMATEC to agree an appointment the following Information should be at hand: = Model designation of generator = Serial No. of generator » Date of Invoice {In order to ensure safe transportation, an appropriate packing is to be provided. INMATEC does not assume liability for damages caused to the generator or its com- ponents resulting from Inadequate packing. Selte 24 von 34 INMATEC GaseTachnoingle GmbH & Co.KG, Gewerbestr. 72, 82211 Herrsching a. A Fon +49(08152 9097-0, Fax +4910)8152 9097-10, Email info@inmatec.deiN IMA The World of Gas TEC 9.4 Maintenace Documentation Date Operation Operating hours Technician Seite 22 von 34 INMATEC GaseTechnologie GmbH & Co. KG, Gewerbestr. 72, 82211 Herrsching a. A Fon +49(018152 9097-0, Fax +49(0)8152 9097-70, Email info@inmatec.deThe World of Gas aSz 10 Fault Clearance ‘The generator supplies little or no nitrogen at all Check air supply coming from compressor. Room temperature is too high. Temperature of compressed air Is too low. Filters are polluted. Permeate outlet is blocked. Flow rate valve is shut. Inlet ball valve is shut. Check for leakages in the condults. ‘Supply line (N2) Is blocked. Nitrogen concentration Is wrong, Check air supply coming from compressor. Room temperature is too high. Filters are polluted. Permeate outlet is blocked. Leakages on piping connections, Membrane pressure Is too low Check alr supply coming from compressor. Room temperature is too high. ‘Temperature of compressed air is too high. Check functions of after-cooler. Filters are polluted. Check for leakages in the conduits. Seite 23 von 34 INMATEC GaseTechnologie GmbH & Co. KG, Gewerbestr, 72, 822414 Horrsching a. A. Fon +49(018152 9097-0, Fax +49(0)8152 9097-10, Email info@inmatec deThe World of Gas elsiz i "1 12 Wear Parts Plant Filterel lement Type tem No. IMT-MN 14150 F to 1450 F [Pre filter IMT-EFV ....50 - Fine filter IMT-EFF ...50 Activated carbon filter _[IMT-EFA 50 Filterset (3 pleces) IMT-EFS ....50 Equipment Type item No. __| Gas analysis sensor IMT-ESO 1010 Spare Parts Unit No. TAG No. Designation —_[__Spare part 4 00 IMT 36 FF 004 Filter E 2 00 IMT 36 AA014 Check valve E 2 00 IMT 56 AA 012 Check valve E 2 00 IMT 36 AAD13 Check valve E 2 (00 IMT 36 AA 014 Check valve E 2 00 IMT 36 AAO15 Check valve | E - 2 (00 IMT 36 AA 016 Check valve E 5 00 IMT36DR001 | Pressure control valve E 5 00 IMT36DR002__ | Pressure control valve E 5 00 IMT 36 DR 003 Pressure control valve E 6 00 IMT 36 AA 004 Membrane E 6 00 IMT 36 AA 002 Membrane E 6 (00 IMT 36 AA 003, Membrane E 7 00 IMT 361004 Adjusting valve E 7 00 IMT 36 JV 002 Adjusting valve E OO-MT 36 JV 003 Adjusting valve E 00 IMT 56 DM 001 Flowmeter E Selte 24 von 34 INMATEC GassTechnologie GmbH & Co. KG, Cewerbestr. 72, 822414 Ilerrsching a. A. Fon +49(018152 9097-0, Fax +49(0)8152 9097-10, Emall info@inmatec.deThe World of Gas 13 Drawings 13.1 Installation plan (possible diaararn) ~ Seite 25 von 34 INMATEC GascTechnotogle GmbH & Co. KG, Gewerbestr. 72, 82211 Herrsching a. A. Fon +49(018152 9097-0, Fax +4910)8152 9097-10, Emall Info@inmatec.deZz IMA The World of Gas sears] TEC) 13.2 Connecting diagram L I Zz a + Anzeige Drucklufteingang ‘Analyse (optional) Pressure Gauge Air In Analysis (optional) Anzeige Stickstoffausgang Pressure Gauge Nitrogen Out 0 8} | 2 | ial 1 ale el 5 c| al 3} * a 4 oA 300 610 - |D| a [WF [mamta “arco LU eT These ute eae raters LF [ren iid | terse 15 | [stata | —vatessere [one afer ie | S| Arve [sot econ cine Sit i eonates baie] Schrank / Housing MT Stand INMATEC ial flees —| me fom Sar aa Seite 26 von 31 INMATEC GaseTechniologié GmbH & Co. KG, Gewerbestr. 72, 822111 Herrsching a. A. Fon 449(018152 9097-0, Fax +49(018152 9097-10, Email info@inmatec.deThe World of Gas 13.3 R&l diagram MN 1450 F Seite 27 von 34 INMATEC GaseTechnologic GmbH & Co. KG, Gewerbestr. 72, 82211 Herrsching a. A. Fon +49108152 9097-0, Fax +-4910)8152 9097-10, Email info@inmatec.deThe World of Gas MAY Seite 28 von 34 INMATEC CaseTechnologia GmbH & Co. KG, Cewerbestr. 72, 82244 Herrsching 3. A Fon +49(0187152 9097-0, Fax +491018152 3097-70, Email Info@inmatec.ceThe World of Gas leslz Seite 29 von 34 INMATEC GaseTechnologie GmbH & Cu. KG, Gewerbestr, 72, 82211 Herrsching 2. A Fon +491016152 9097-0, Fax +49(0)8152 9097-10, Email info@inmatec. deZ| Ss > The World of Gas = rl io i 14 Product Warranty ‘The INMATEC Warranty Is valid with regard to manufacture and use of faultless com- ponents for all nitrogen generators during a period of 12 months. The warranty period is set to start from the date of invoice to purchaser. The warranty performance is deemed to be provided under the precondition of normal utilisation. For this purpose it is assumed that nitrogen generators are operated in one dally shift, or resp. 2.000 operating hours yearly. ability of INMATEC in fine with this warranty Is limited to repair (all components and labour expense without charging, however filter elements are excluded hereof, or refund of the purchasing price of such plant. Each generator for which warranty claim is submitted, shall be returned to INMATEC by purchaser under freight prepaid upon request by INMATEC, with evidence of the purchasing date. Any re- placement part shall be warranted as stated above for the unexpired portion of the original one-year warranty. This warranty is not valid for the generator or parts of It, in case a failure or ‘malfunction was caused by incorrect utilisation (the assessment of which is exclusively established by INMATEC) in particular by: = defective air supply (compressed air must be provided at temperature of less than 40 °C before being fed into the generator); a higher feeding temperature will cause damages which are not covered by the INMATEC manufacturer's product warranty. - * inappropriate mairterrance of filter elements (the fliter elements are to be replaced depending on the number of operating hours, at a minimum once per year. In case the replacement of filter elements on schedule is omitted, the claim for INMATEC product warranty expires. » extraneous cause (in order to prevent damages, the system Is to be set-up inside a closed, efficiently ventilated room at temperature between + 2°C and + 40°C.) In case of different ambient conditions, the claim for INMATEC product warranty expires. The warranty is invalid (null and void), in case the generator was subject to repair or modification outside of the INMATEC factory premises, without the formal and written authorisation of INMATEC. The before mentioned warranty is valid in lieu of any other warranty, expressed or implied, in fact or in law, including and without limitation the warranty of merchantability or the warranty of fitness for a particular purpose. It is expressly agreed that the purchaser's sole and exclusive remedy for defect in Parts is limited to enforcement of INMATEC’s obligation as set forth above. INMATEC shall not be liable to the purchaser or others for loss of use of the equipment or for other special, indirect, incidental or consequential damages. Seite 30von 34 INMATEC GaseTechnologie GmbH & Co. KG. Gewerbestr. 72, 82211 Herrsching a. A. Fon +49(0\8152 9097-0, Fax +491018452 9097-10, Emall info@inmatec. deThe World of Gas \rrespective to anything to the contrary herein, during the warranty period as specified above, INMATEC will return generators after repair under freight Prepald. After expiration of the warranty period, payment of freight costs both ways is at purchaser's charge. The specified warranty shall extend and apply to the generator only while the unit is owned and exclusively operated by the original purchaser, ‘status UY/2Uvb ~ errors ana omenissons excepted Seite 31 von 34 INMATEC GaccTechnologie GmbH & Co. KG, Cewerbestr. 72, 82211 Herrsching a. A, Fon +49(018152 9097-0, Fax +4910)8152 9097-10, Email info@inmatec.de