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GENERON NPU Membrane Nitrogen System

Operating and Maintenance Manual OCT. 2007
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Section Inserts
(this page does not go into the manual)

Section Material

1 Generon Warranty Policy

Generon Module Warranty

2 nitrogen MSDS
activated carbon MSDS

3 Figure 3.1A
Figure 3.1B

4 Figure 4.2.A
Figure 4.2.B

6 table 6.6
Refill Procedure for Carbon Bed

9 chart 9-2
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SECTION 1

INTRODUCTION

1.1 SCOPE

This manual describes the general operating and maintenance instructions for a
GENERON* NPU 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 NPU membrane system.

Customers may direct specific questions related to the maintenance and operation of the
GENERON NPU Membrane System to the Generon IGS. Customer Service Department at
713-937-5200 or 800-871-0310.

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 40°F (4.4°C) and 150°F (65.6°C). Exposure to temperatures outside the specified
range could lead to membrane damage and performance reduction.

The system is equipped with a space heater, which is able to keep the temperature inside
the container at any time above 50°F. The space heater has a thermostat, which shall be
set to 50°F.

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

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SECTION 2

SAFETY

The GENERON NPU Membrane System is capable of producing nitrogen with purities ranging from
95% to 99.9%. The nitrogen produced by the GENERON NPU Membrane System is colorless,
odorless; chemically inert gases defined as a simple asphyxiate. 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.

2.1 Nitrogen Gas

The GENERON NPU Membrane System is designed to separate nitrogen from

compressed air. The concentrations of oxygen contained in the nitrogen product stream of
any GENERON NPU 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 Sheet (MSDS) for nitrogen gas is 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 40 seconds, convulsions, respiration ceases; death.

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2.1 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.

2.2 Oxygen Enriched Permeate Gas

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 NPU Membrane System is located in an air tight or poorly
ventilated room, the vent gas should be piped outdoors for release.

2.3 Pressurized Equipment

The GENERON NPU 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 NPU 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
NPU 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.
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2.4 Electrical Equipment

Use normal commercial safety practices while performing maintenance or troubleshooting.

Personnel unfamiliar with the electrical equipment supplied with the GENERON NPU
Membrane System should not attempt to service this equipment. The electrical currents
supplied to the various electrical components on the GENERON NPU Membrane System
are at levels high enough to cause severe injury and/or death.

When installing a GENERON NPU 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
NPU 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.
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SECTION 3

ENVIRONMENTAL

3.1 CONDENSATE DRAIN LINES

Several components on the GENERON NPU Membrane System are equipped with
condensate drain lines. Refer to the GENERON NPU 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 NPU 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. Anticipated quantities and oil concentrations of
condensate can be calculated utilizing Figures 3.1.A and 3.1.B.

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.
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SECTION 4

PROCESS DESCRIPTION

4.1 GENERAL

The GENERON NPU 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).

Figures 4.2a and 4.2b graphically represent the above relationships.

The NPU system operates most effectively at 335 psig 80o-110oF (23 bar(g), 27o- 43oC).
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SECTION 5

EQUIPMENT DESCRIPTION

5.1 GENERAL

For explanation purposes, the GENERON NPU Membrane System has been broken down
into four standard subsystems. These subsystems include the Feed Air subsystem, the Air
Pretreatment subsystem, the Product Gas Separation subsystem, and the HPLC 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 GENERON NPU
Membrane System.

The Process and Instrument 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 GENERON NPU Membrane System 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.

Customers 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. Typical equipment includes an air
receiver, moisture separator and air dryer to dry the air prior to the container feed air inlet.
Within the container are a demister vessel (T-10), coarse coalescing filter (F-11), fine
coalescing filter (F-12), carbon filter (F-16) and a particulate filter (F-18). Refer to the
Process and Instrument Diagram (P&ID) located in Section 10 for specific equipment
supplied.

Proper operation and maintenance of this filtration system will prevent oily condensate,
airborne particles and pipe scale from contaminating and/or clogging the membrane fiber
openings.
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5.3.1 Demister Vessel

The demister vessel (T-10) is a coded pressure vessel with a design pressure of
375 psig (25.9 bar(g)). An internal demister pad conditions the air before leaving the
vessel. The primary function of the demister vessel is to remove large quantities of
oily water condensate from the feed air supply.

The demister vessel is equipped with a drain line and all components necessary to
continuously drain the collected condensate.

5.3.2 Coalescing Filters

Coarse and fine coalescing filters (F-11 & F-12), which utilize a 1.0-micron and 0.01-
micron filter element respectively, are designed to remove virtually all of the
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 6 for further information.

The coalescing filters are each also equipped with a condensate drain line.
Equipment on the drain line for the coalescing filters includes a block valve and an
electronic drain trap.

5.3.3 Process Heater – Electric Heater

The process heater (EH-14) is an electric air circulation heater which optimizes the
membrane module performance by ensuring that the feed air stream is heated and
maintained at a constant temperature ranging between 86 oF and 113 oF (30oC and
45oC). In case of a higher inlet temperature than 113 oF (45oC), the heater will
increase the temperature further to superheat the feed air before entering the
membrane modules. The process heater receives its controlled power from the main
power panel mounted in the GENERON NPU.

5.3.4 Process Heater – Heat Exchanger

The process heater (HE-14) is an heat exchanger which optimizes the membrane
module performance by ensuring that the feed air stream is heated and maintained
at a constant temperature ranging between 77 oF and 113 oF (25oC and 45oC).

5.3.5 Carbon Filter

The carbon filter (F-16) consists of a carbon steel ASME or locally coded vessel
containing a specially packed activated carbon bed. The activated carbon pellets
used in the carbon filter adsorb heavy hydrocarbon vapors that may be entrained in
the feed air supply. Refer to Section 6 for further information regarding the
maintenance intervals for replacing the activated carbon pellets.

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
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in the feed air supply. The particulate filter is typically identical to the coalescing
filter, although the primary reason for this filter is solid particle removal.

The drain line used on the particulate filter contains a block valve for manual venting
to ensure that no liquid is present at this point.

5.3.7 Feed Valve

Feed valve FSV-19-1, which is controlled by the PLC, provides on/off control of the
feed air supplied to the membrane modules. The feed valve is classified as a "fail
close" valve that enables the GENERON NPU Membrane System to isolate the
membrane modules from the feed air stream in case of a shutdown condition.

5.3.8 Air Bypass Valve

Air bypass valve FSV-19-2, which is controlled by the PLC, provides control of the
air bypass of the membrane modules. The air bypass valve is classified as a "fail
close" valve.

5.4 AIR SEPARATION SUBSYSTEM

The Product Gas separation subsystem contains the membrane modules and the
components necessary for the proper operation and control of the GENERON NPU
Membrane System. 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

The GENERON Membrane modules are encased in coded cylindrical pressure

vessels with semi-elliptical removable ends. Each membrane module case is filled
with a cylindrical bundle of hollow fiber membranes, made of a polymer-based
material.

Refer to Section 10 for information on the module cases used on the GENERON
NPU Membrane System.

5.4.2 N2 Purity Control Valve, FCV-23-1

The N2 Purity Control valve is used to control the N2 Purity from the membrane
modules. An electro-pneumatic positioner FY-23-1 located on the valve receives the
control signal from the PLC. The PLC System uses a PID control loop to maintain
purity at the preset set point. The O2 analyzer AT-20-1 monitors the actual O2
content downstream of the membrane modules and transmits the information to the
PLC.

The N2 control valve is classified as a Fail-Close type valve. When the control
signal from the PLC is less than 4 mA, the control valve will be fully closed.
Increasing flow corresponds to decreasing the purity; and reducing the flow will
correspond to increasing the N2 purity.
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5.4.3 Purity Assurance Valves

The GENERON NPU Membrane System is equipped with purity assurance valves
(FSV-24-1A & FSV-24-1B). When actuated the product valve FSV-24-1A allows on-
spec product gas to flow into the customer's pipeline. The product valve FSV-24-1A
fails to the closed position and the product vent valve FSV-24-1B fails to the open
position, when product gas contains too high or too low oxygen impurity, or the
system shuts down. The off-spec gas vented from the product vent valve FSV-24-
1B is Oxygen deficient and can be hazardous to personnel safety. This gas shall be
vented outdoors.

5.4.4 Backflow/Over pressurization Check Valve

The backflow/over pressurization check valve CV-25-1 is located downstream of the

purity assurance product valve and the air bypass valve to prevent backflow of
product gas when pressure on the customer's side exceeds the GENERON NPU
Membrane System product pressure. As a further safety measure, the customer
shall ensure that his downstream processes cannot overpressure the nitrogen
receiver (if supplied) and/or the GENERON NPU Membrane System.

5.4.5 Permeate Gas Subsystem

The permeate gas is the waste gas stream from the nitrogen separation process.
Running the module in parallel, 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. THEREFORE,
ALWAYS OPEN THE DOOR COVERING THE PERMEATE PIPING BEFORE
STARTING THE GENERON NPU MEMBRANE SYSTEM. Backpressure on the
modules via the permeate line will result in a decrease in nitrogen production.

5.5 CONTROL SYSTEM

The control system on the GENERON NPU Membrane System consists of a PLC-based
control system, oxygen analyzer, pressure transmitters, front panel pushbuttons and
operator interface terminal, purity assurance system and purity control system.

5.5.1 PLC-Based Control System

The Programmable Logic Controller (PLC), located in the NPU Control Panel is pre-
programmed 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 on front panel indicators as well as remote status
indicators.
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b) All switching valve sequencing timers and counters. The PLC will energize
and de-energize piloting solenoids, as appropriate.

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

purity. If the O2 analyzer indicates a high O2 level during normal operations,
the PLC will vent the off-spec product gas and ultimately shut down the
GENERON NPU Membrane system.

d) Control of nitrogen purity by continually adjusting the module outlet pressure

setpoint to maintain nitrogen purity under changing ambient and operating
conditions.

For specific instructions on programming the NPU control system, consult the
Generon IGS Service Center. In general, though, control system programming
changes are nothing more than changing the set points in the PLC memory.

5.5.2 Oxygen Analyzer

The oxygen analyzer located in the GENERON NPU control cabinet continuously
monitors nitrogen product gas for oxygen content. During operation, sample gas
from the product header flows through the analyzer cell and generates a signal
proportional to oxygen concentration. The product sample purity is monitored by the
PLC, which adjusts the module outlet pressure setpoint to control nitrogen purity.

5.5.3 Front Panel Pushbuttons and Operator Interface Terminal

The front panel consists of Lighted Pushbuttons and an Operator Interface Terminal.

5.5.3.1 Lighted Pushbuttons & Switches

There are two lighted pushbuttons on the panel, ALARM & SHUTDOWN.
Two switches are POWER ON/OFF & AUTO/STOP/MANUAL

5.5.3.1.1 ALARM (Yellow lamp)

The Alarm Light flashes any time an alarm is present.

Clearing the alarm via the Panelview will not stop the flashing
of the light, only correcting the alarm condition will turn it
OFF.

5.5.3.1.2 SHUTDOWN (Red lamp)

When the SHUTDOWN light is ON the system is stopped

and is ready to run.

5.5.3.1.3 AUTO

Placing the AUTO/STOP/MANUAL switch in AUTO will allow

the N2 Generator to run using the O2 Analyzers for purity
control.
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5.5.3.1.4 MANUAL

Placing the AUTO/STOP/MANUAL switch in MANUAL will

allow the N2 Generator to run with all the same functionality
as AUTO, but the O2 analyzers will not control the Purity
Valve. The valve can now be opened and closed via the
Panelview on the Analog Setup Screen, (0-100%).

5.5.4.1.5 STOP
Placing the AUTO/STOP/MANUAL switch in STOP will stop
the flow of air into the modules and shut off the heater.

5.5.3.2 Operator Interface Terminal (OIT)

There is an operator terminal built into the control panel front that allows the user to
easily interface with the PLC System within the panel. The OIT has several screens
that provide the user with menu-oriented functions to view operating, configuration,
and programming data. The terminal also has an Alarm Banner that can clear the
alarm from the Panelview screen only.

MAIN MENU
All Screens link to the Main Menu. From this menu
you may go to any screen in the system. To navigate
to any screen, push the corresponding “F” key. On all
other screens the “F1” key will take you back to the
MAIN MENU. O2 analyzer warm-up time as well as
current time and date can be found here also.

FLOW SCREEN (F1)

The Flow screen is an overview of the N2 Generator.
This is an information screen only. The following
information can be found here.
1) FT-15-1 Incoming air flow in SCFM and Pressure
2) RTD 14-1, 14-2 & 14-3 Air temperature in, heated
air temperature & heater element temperature.
3) T-10,F-11 and F12 Drain Conditions
4) FSV 19-1A, FSV-19-1B Module inlet valve
position/Air bypass
5) RTD 19-1 Air temperature before modules
6) O2 Control Set point and actual O2 reading used
for control.
7) Purity Control Valve FY-23-1 % open.
8) RTD 22-1 N2 Temperature
9) PT 22-1 N2 Pressure after modules
10) FT 22-1 N2 Flow SCFM
11) Force Air Option “F9”
12) Force Vent Option “F10”
13) Product, Vent or Air Bypass indication is shown
by the green flow indication through the system.
14) System in Warm-up Mode indication
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SETUP SCREEN ANALOG (F2)

The Analog Setup Screen is a User Input Screen.
The following can be configured from this screen..
1) O2 setpoint for Auto control. “F2” (.5 to 15%)
2) EH-14 heater setpoint. “F3 (80 to 135 deg F)
3) FCV-23-1 Manual Valve Control “F4” (0 – 100%)
4) High O2 Shutdown (Vent) % “F5” (4 – 25%) This
is the maximum allowed O2 content before the
user wants the system to vent off high O2.
5) Low O2 Shutdown (Vent) % “F6” (0 – 5%) This is
the minimum allowed O2 content before the user
wants the system to vent off high O2
6) O2 Vent Time in Seconds “F7” (0 – 32767). This
is the maximum allowed time in Seconds that the
O2 Content can be above/below the preceding
high/low O2 content setpoint before system vents
to atmosphere.

SETUP SCREEN Heater PID Loop (F3)

This is the PID setup screen for EH-14 heater. These
setting should only be changed by qualified personal
1) Gain Kc, Reset Ti, Rate Td and Loop Update
values “F2” “F3” “F4” & “F5”

SETUP SCREEN FY-23-1 (F4)

This is the PID setup screen for The N2 Control
Valve. These setting should only be changed by
qualified personal
1) Gain Kc, Reset Ti, Rate Td and Loop Update
values “F2” “F3” “F4” & “F5”

RUN Data (F5)

Two sets of Days, Hours, Minutes and flow totals that
the system has run. First set is a grand total and
cannot be reset. The second set is re-settable “F10”
and the reset data is stored in the flow history screen.

FLOW HISTORY (F6)

The last five reset flows and run times are stored
here, the X on the right shows the last stored data. If
the stored total flows number is two large the
multiplier will go from 1 to 10 to 100 and the total flow
will have to be multiplied be this number. After 5
stored sets of data is reached, the 1st set is written
over and from top to bottom.

ALARM LIST (F7)

List of Active and Inactive Alarms

SYSTEM SETUP (F8)

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Password protected screens used to change ranges,

actions of Analog & Digital inputs/outputs, drain
timers and warm up timers and settings. These
settings should only be changed by qualified
personal, personal and property damage can occur if
settings are incorrect. The password as it left
Generon is 5214
START FAN (F10)
Toggle “F10” to turn fan on and off.

5.5.4 Purity Assurance System

High oxygen impurity set points are entered into the PLC via the OIT Menu. The
menu items for HIGH OXYGEN ALARM/SHUTDOWN LEVEL are under the Analog
Setup Screen. If oxygen concentration of the product gas exceeds these set points,
the product gas will be vented by FSV-24-1B to prevent the contamination of the
customer's process with off-spec nitrogen. This venting will continue until purity is
re-establishment, change by user or the Vent Shutdown Time “F7” from the Analog
Setup Screen times out.

5.5.5 Purity Control System

The Purity Control Valve position is controlled by the PLC to control a level of
expectable purity.
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SECTION 6

OPERATION OVERVIEW

6.1 GENERAL

The GENERON NPU 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 PRESSURE CONTROL MODES

The GENERON NPU Membrane System allows a choice of product pressure control
modes: Manual Control and Purity 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 PCV Opening is controlled with respect to
the value (0-100%) entered on the Analog Setup Screen. Because of ever
changing airflow this method should not be used. This is mainly for convenience of
troubleshooting the valve or stroking the valve to check movement.

6.2.2 Auto Control

Auto Control uses the 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 NPU Membrane System operates in one of six machine states. Of these
six states, five are considered Normal and one is considered Abnormal.

6.3.1 Normal States

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

6.3.1.1 Startup State

The Startup state is a transitional state that must precede the Running state.
The Startup state is entered when the GENERON NPU Membrane System
energized for the first time and is designed to allow the O2 analyzers time to
warm up.
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Auto and Manual can not 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 determined by the Startup Timer (60
seconds)

6.3.1.2 Warm up State

When the system is started from a cold state the system will be sent to vent
and the heater will fire to a hotter than normal set point in order to warm the
system up quickly. All these settings are settable in the Generon setup
screen.

6.3.1.3 Manual State

In the Manual control mode the Product PCV Opening is controlled with
respect to the value (0-100%) entered on the Analog Setup Screen.
Because of ever 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 set point 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 for 10 minutes or
when O2 purity has been above shutdown setpoint for over allotted time.

Indications of this state are:

Vent valve is open and Product valve is closed.

6.3.2 Abnormal State

As the title suggests, when in the abnormal state, the GENERON NPU Membrane
System is not operating within the prescribed parameters as set up by the startup
engineer.
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6.3.2.1 O2 Alarm State

The GENERON NPU Membrane System can enter this state from the
Running or Purity Control states when the oxygen level is above the High
Alarm/Shutdown level.

The purpose of this state is to notify an operator that a problem exists, while
allowing a set period of time to correct an off-spec condition without shutting
down. In this state:

“High O2 Alarm” energizes.

Alarm lamp flashing.
Product goes to Vent

Once this state is entered, an internal software timer is activated. If the

Oxygen Alarm has not corrected before the timer times out, the unit will go to
the Vent state. If the oxygen does come back within spec, the machine will
return to the Running (or Purity Control) state from where it came. An alarm
message will appear in the OIT display, however, indicating that this Alarm
Condition has existed (see Section 6.4).

If a heater alarm has occurred, the alarm must be corrected, and the system
must be put into STOP, then restarted.

6.4 ALARM LOGIC

Alarms can be acknowledged using the F2 key. This will clear the alarm from the screen but
will not stop the Alarm Light from flashing. If the alarm condition clears, the Alarm Light will
stop flashing on it's own. The ALARM HISTORY SCREEN will keep a history of the last 50
alarms. If a shutdown alarm occurs, the system AUTO/STOP/Manual switch must be place
in the STOP position and the alarm condition cleared before the system can be re-started.

6.4.1 System Alarms

E-STOP ACTIVE
Sytem emergency stop is pushed

WARNING-AFTER HEATER TEMP. HIGH > 176 (80 C)

Temperature at heater outlet is high

AIR BYPASS ACTIVE

The air bypass option has been selected on the flow screen and air is being
forced around the modules.

Module Inlet Temp. Low < 35 F (2 C) Alarm

Temperature at modules inlet is low
Modules Low Temp. < 35 F (2 C) SHUTDOWN
Temperature at modules inlet is low more than 3 minutes and need to shutdown to
protect membranes.
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SYSTEM HAS BEEN FORCED TO VENT

Any time the system is forced to vent from the FLOW SCREEN "F10", this
alarm will energize to remind the user of this condition

NO FLOW DETECTED FOR RUN

System Run has been requested and no flow has been detected at FT-15-1
after 60 seconds. Check for proper flow and transmitter failure, the heater
will not operate without a proven flow.

AT-20-1 IS OFFLINE
The Oxygen Analyzer has dropped below 3.0 mA and has failed. Check for
analyzer failure, the system will become unstable and may be place into
manual to continue operation if necessary. The high/low O2 limit setting may
have to be adjusted if running the system is needed while the problem is
solved.

HEATER NOT HEATING AIR

After 15 minutes air is not being heated, check for heater problems.

RUN NOT ALLOWED BEFORE O2 WARM-UP

The Generator has been place in AUTO or MANUAL before the O2 analyzer
has warmed up. The system will not start until warm up has finished. Time
remaining can be found on the MAIN MENU SCREEN.

DT IN USE
Incoming air temperature (RTD 14-1) is within 7 degrees F of the heater set
point. Heater set point is being raised automatically to adjust for the hotter
incoming air.

WARNING- AIR TO MODULES IS HIGH >140F

Heated air to modules is greater than 140 degrees F

O2 OFF-SPEC, SYSTEM TO VENT

The O2 content has gone above the High / Low set point set on the
ANALOG SETUP SCREEN for the allotted allowed time.

DIGITAL FORCE ACTIVE

A Digital Input or Output has been forced.

System High Temperature HEATER SHUTDOWN >150F

The air temperature into the modules has gone above 150F and has shut
down the heater. When the air cools below 140F heating will resume.

HEATER TRIP
If electrical heater is used, the heater contactor has tripped and shutdown
the heater, check heating circuit for heater problems

INPUT FORCED OPEN AND CLOSED ERROR

A digital input has been forced both on and off on the password protected
setup screen. The input will be forced off at this condition.
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OUTPUT FORCED OPEN AND CLOSED ERROR

A digital output has been forced both on and off on the password protected
setup screen. The output will be forced off at this condition.

HEATER TROUBLE, HEATER SHUTDOWN

The heater contactor has tripped and shutdown the heater, check the
heating circuit for heater problems.

LSH 11-1 Fault

Level switch for the drain has a fault, check water level.

LSH 11-1 Fault SHUTDOWN

Level switch for the drain has a fault for 30 minutes and need to shutdown to
protect membranes.

LSH 12-1 Fault

Level switch for the drain has a fault, check water level.

LSH 12-1 Fault SHUTDOWN

Level switch for the drain has a fault for 30 minutes and need to shutdown to
protect membranes.

LSH 10-1 Fault

Level switch for the drain has a fault, check water level.

LSH 10-1 Fault SHUTDOWN

Level switch for the drain has a fault for 30 minutes and need to shutdown to
protect membranes.

SYSTEM STARTUP WARM-UP ACTIVE

System is in warm-up mode. This is active when system is first start-up to
maintain temperature at setpoint.

Heater Over Temp > 392F SHUTDOWN

Heater temperature is too hot.

6.5 OPERATIONAL MAINTENANCE

The GENERON NPU Membrane System is designed to run unattended and requires only
minor attention to assure proper operation.

6.5.1 NPU Membrane System Operational Maintenance

A listing of operational checks is given in Table 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

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Most particulate and coalescing filters can tolerate very high differential
pressures. In fact, manufacturers typically do not require element
replacement until the steady state differential exceeds 9 psi (0.6 bar(g)).

The membrane module performance is a function of the feed air pressure

and, as a result, will decline with increased differential pressure.

Coalescing Filter Differential Pressure

In order to optimize the membrane module performance, the pressure
differential across the coalescing filters should be checked on a quarterly
basis using a portable pressure differential gauge. Refer to manufacturer's
manual for instructions on how to install the portable pressure differential
gauge. The 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.

Particulate Filter Differential Pressure

The NPU control panel is equipped with a 0-15 psi differential pressure
indicator. PDI-18-1 is used to monitor the differential pressure across the
particulate filter. The particulate filter DP should be checked on a periodic
basis in order to determine when to change the filter elements.

The filter elements should be changed when the differential pressure(at

steady state) is in the 5-8 psid (0.3-0.5 bar(g)) range.

6.5.1.2 Carbon Filter

The activated carbon used in the Carbon Filter must be replaced on a

regular basis. Minimum change out rate for the carbon is every 4400 hours
or 12 months, 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 NPU control
have a service life of approximately one year. During that time, the
calibration may drift slightly, and should be checked monthly. See Section-9
and the Fujikora documentation in Section-10 for information of calibration
and service of this critical instrument.
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SECTION 7

STARTUP PROCEDURE

7.1 GENERAL

The following procedure should be used to bring the GENERON NPU 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 CC-1 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

7.3.1 Pressurize the NPU Membrane System

Start the compressor per the manufacturer's instructions.

7.3.2 Instrument Setup

The following equipment settings need to be established when starting up the unit.
Some must be done prior to startup, others can only be done when the system is
operating.

7.3.2.1 Instrument Air (H.P.I.A.)

Set the instrument air regulators (PRV-19-1 & PRV-19-2) to 6-Bar 87-psi.
This can be done prior to startup, when the skid is pressurized.

7.3.2.2 Product Gas Sample

Once there is pressure in the nitrogen product pipeline, also set the sample
regulator inside the CC-2 control panel (PRV-20-2) to 0.35-bar 5-psi. Adjust
the sample flow rate, using flow indicator FI-20-1 inside the panel, to 0.5 to
1.0 scfh.

7.4 START NPU MEMBRANE SYSTEM

Before turning the AUTO/STOP/MANUAL switch to AUTO, select the heater output signal to
either “Electrical” or “Heat Exchange” mode. This can be achieved by toggling “F9” on Main
screen of HMI. Read the instruction on the screen carefully to insure right selection. The
selection will only active before system starts. While system running, the selected mode will
not be active and the selection will stay remain the same.
Turn the AUTO/STOP/MANUAL switch to AUTO. The GENERON NPU Membrane System
will initiate a Startup state. During the Startup state, which lasts for 10 minutes until the
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temperature requirements are satisfied, the PLC will direct the N2 to vent off spec valve
FSV-24-1B. Once the temperature requirements are reached, the product valve FSV-24-1A
switches and directs the N2 to product.

Once there is pressure in the nitrogen product pipeline, set the sample PRV-20-1 to 0.35-
bar. Adjust the sample flow bleed off (flow indicator FI 20-1 in CC-2) to 1 SCFH (this value
may need revision to optimize for the on-site configuration).

Flow transmitter FT-15-1 will enable power to the process heater contactor when the inlet
air flow is high enough for heater control.

The GENERON NPU Membrane System will continue to vent product gas until the startup
timer times out. When the startup timer times out, the GENERON NPU Membrane System
will switch to purity control or manual control depending on the Control mode used and the
customers' product nitrogen demand.

Once the system has been pressurized, ensure that the drains are all operating properly.

7.5 BEGIN PRODUCTION

Once the product pipeline O2 level falls within the preset vent limits, the PLC will
automatically direct the purity assurance valve FCV-23-1 to Open, thus placing the
GENERON NPU Membrane System On-Line.

7.6 CHANGING THE NPU SETPOINTS

7.6.1 General Notes

The Operator Interface Terminal in the GENERON NPU Panel allows an operator to
change set points. The factory will set most of these, 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.

7.6.2 Menus and Sub-menus

The software leads the operator through the programming procedure using menus
and sub-menus. The documents titled “Ladder Logic / Operator Interface Menu
Screens” in Section 10 shows the flow of these screens as they appear to the user.

7.6.3 Programming Procedure

The following procedure is used for all programming of the NPU Controller:

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.

7.6.4 Screens

See section 5.5.4.2 for detailed description of each screen.

7.7 CHANGING PURITY SETPOINT

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Purity Setpoint can be changed from .01 to 7%. Running Oxygen set points between 0.6
and 0.1 may require a change from series module configuration to parallel.
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SECTION 8

SHUTDOWNS

This section is intended to instruct an operator on procedures for shutting down the GENERON
NPU 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 NPU Membrane System off:

. Turn the AUTO/STOP/MANUAL switch to Stop.

. Isolate the GENERON NPU 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.

8.2 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/STOP/MANUAL switch must me moved to STOP before the system
can be re-started.

8.2.2 Loss of Utilities

Power Outages (Blackouts and/or Brownouts):

When power is interrupted to the NPU 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 NPU
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.
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SECTION 9

OXYGEN ANALYZER CALIBRATION AND MAINTENANCE

9.1 General

The GENERON nitrogen generator is provided with two Fujikora FCX-MVL-AC oxygen
percent analyzer transmitter, which is an integral part of the purity control system: One (1)
process nitrogen gas analyzer AT-20-1 and one (1) room oxygen analyzer AT-1-1. The
analyzers have been calibrated and tested by the factory prior to shipment. Although the
analyzers should not require any additional calibration, a certified oxygen content span gas
should be used to verify the calibration once every month.

Inside the control panel is a Span / Sample selection valve for AT-20-1. The pressure of the
span gas needs to be regulated with PRV-20-2 to 5 PSI (0.35 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 content and the analyzer reading is
+/- 0.20 (% O2).

The room analyzer AT-1-1 is also mounted inside the control cabinet CC-2 and detects low
oxygen concentrations inside the membrane system container. Therefore the analyzer is
mounted through the bottom of Control Panel CC-2 and the sensor is exposed to the
atmospheric air inside the container.

Calibration procedures are found on the following pages in this section. It is useful and
important to log the analyzer verifications and calibrations.