NGN-50 NITROGEN GENERATOR

Be Familiar with the operation manual before operation

Operation Manual

Shanghai Research Institute of Chemical Industry

SHANGHAI CHINA
 上 海 化 工 研 究 院
Shanghai Research Institute of Chemical Industry

Index
**********

1、Summary

2、Main Technical Parameter

3、Basic Operating Principle

4、Process Flow

5、Blow off Device

6、Installation Requirement

7、Operation

8、Maintenance

9、Attention

10、Appendix : Wiring Diagram

11、The fault phenomenon, reason analysis, treatment method

Shanghai Research Institute of Chemical Industry

 上 海 化 工 研 究 院
Shanghai Research Institute of Chemical Industry

1. Summary
NGN-50 Nitrogen generator, which adopts carbon molecular sieve as adsorbent,
is able to generate Nitrogen in the condition of atmospheric temperature and low
voltage by taking advantage of PSA (pressure swing adsorption) principle and lend a
simply creditable economic method to industries to produce Nitrogen.

2. Principal Technology Parameter

Technical parameter Technical parameter
3
Nitrogen output Nm /h 100（effective air consumption ≥5.5Nm3/min）
Purity of Nitrogen) % 95 (adjustable)
Air pressure of Nitrogen MPa ≥0.45 (adjustable)
Dew point of Nitrogen ℃ -45
Power source V/Hz W 220/50 500
Working pressure MPa 0.65～0.70
Required quality of Temperature of inlet air ℃ ≤45
Source of inlet air Oil content of inlet air ppm ≤0.03
(Must be clean air without corrosive agent)
Ambient temperature ℃ <36

3. Basic Operating Principle

Oxygen and Nitrogen separate inside the adsorption tank through PSA (pressure
swing adsorption). Enriched Nitrogen flow to the downstream as the product gas.
Diffusion rate of Oxygen is obviously faster than the rate of Nitrogen due to the
aerodynamics effect. So Nitrogen would be enriched in the gas phase before the
absorbing is in balance.
Two adsorption tanks are adopted in the generator to produce high quality
Nitrogen continuously by the alternative switch from absorption to regeneration.

Shanghai Research Institute of Chemical Industry

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Shanghai Research Institute of Chemical Industry

4. Process Flow (Figure 1)

The generator adopts twin-tower flow: air is compressed; purifying air will be
suctioned to the adsorptive separation system to separate Nitrogen from air. The
adsorptive separation system is made up of two adsorption tanks which are filled by
carbon molecular sieve, a set of valves and a controller. Valves that are normally
closed are opened by electromagnetic valves which are controlled by the controller.
When adsorption tank is working, air source enters from the opened valve under the
tank and flows from the opened valve to the top of the tank. The waste gas which is
produced in regeneration tower will flows out from the bottom of the tank. There are
a set of valves in the middle of each tank to balance the pressure. Nitrogen will flows
from upside valve to nitrogen tank and then to the end user. See also figure 1.
Adsorption procedure。
Application program of absorber is referred to inferior table.
Setup Adsorption Tank A Adsorption Tank B
1 Adsorption Discharge
2 Adsorption Purge
3 Press Equal. Pressurize
4 Discharge Adsorption
5 Purge Adsorption
6 Pressurize Press Equal.

Shanghai Research Institute of Chemical Industry

 上 海 化 工 研 究 院
Shanghai Research Institute of Chemical Industry

PI PI
102 103
KV5 KV6

KV7
SV102
PI
104

L-1 TV1 QL-1 FI

101

SV101
PI
101 P

S-01

KV3 KV4
Nitrogen
analyzer
KV8
AI

KV1 KV2
Silencer
消音器

Air filter Freezing type air drier Oil Remover Air buffer tank Nitrogen generator Nitrogen buffer tank Nitrogen filter
过滤器 冷冻式干燥机 除 油 器 空气缓冲罐 制氮机组 氮气缓冲罐 氮气过滤器

PI PI
102′ 103′
L-1 TV1 QL-1 KV5′ KV6′

KV7′

L-1 TV1 QL-1

KV3′ KV4′

KV8′

KV1′ KV2′
Silencer
消音器

Nitrogen generator
制氮机组

Figure 1 Flow diagram of NGN-50 Nitrogen Generator

Shanghai Research Institute of Chemical Industry

 上 海 化 工 研 究 院
Shanghai Research Institute of Chemical Industry

5. Blow off device

While the purity of the outlet nitrogen could not reach the quality requirement,
it is allowed to blow it off by blowing off. (See figure 2)

A u to
B lo w o f f

N it r o g e n to t h e s c e n e

FI
101

S -0 1
N it r o g e n

N it r o g e n
a n a ly s e r

AI

Figure 2 Sketch map of blow off device

Auto blow off (Option)
Adjust the nitrogen gas pressure with regulator as shown in the figure. There is
a micro-content nitrogen analyzer in parallel connection with solenoid valve. In case
the nitrogen purity doesn’t reach the set value, this instrument will send signals to
solenoid valve to open it and blow off the gas by valve 1.

Manual blow off

Adjust the nitrogen gas pressure with regulator as shown in the figure. There is
a micro-content nitrogen analyzer in parallel connection with solenoid valve. In case
the unit is started up or the nitrogen purity doesn’t reach the set value, manual open

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Shanghai Research Institute of Chemical Industry

valve 1 and close valve 2; if the purity is OK, manual open valve 2 and close valve 1,
the nitrogen then is sent to downstream;

6. Requirement of Installing
6.1 The device must be installed where ventilate well and is scarce of dust. Positive
ventilating is better in order to avoid the accident such as asphyxiation arise because
of deficiency of oxygen as a result of Nitrogen dispersion.
6.2 The distance to ambience should reach 1 m convenient to operate and tending.
6.3 Device cannot be installed in the caustic environment.
6.4 Notice of electric source installation
6.4.1 Electric source should be arranged according to set prescriptive voltage(V),
current(A) and number of phases.
6.4.2 Fluctuation of rating power network voltage should be in 10% of the ranges.
6.4.3 Electric appliance components should be earth effectively in order to ensure
safety.
6.4.4 The installation of electric appliance must according to the national relative
decree and requirement.
6.5 The venting porthole should be put outdoors high altitude, never vent indoors.
6.6 The venting porthole which settled outdoors should be protected by flashing.
6.7 When Nitrogen need to be transported far (can’t reach 100 m), diameter of duct
should be considered and abating the number of elbow for fear bigger loss of
pressure and flow.

Shanghai Research Institute of Chemical Industry

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Shanghai Research Institute of Chemical Industry

7. Operation
7.1 Preparation of Operation (See Process Flow Figure,typically)
Read the relative handbooks carefully before using, notice use correctly.
7.2 Starting
7.2.1 Open the suction inlet valve of material air. After the air pressure reach
0.7MPa, startup Nitrogen generator, then device is in the operation state.
7.2.2 Start freezing dryer.
7.2.3 Adjust the triple pieces to 0.5MPa, press nitrogen generator to open, and then
the nitrogen machine is running.
7.2.4 When the nitrogen pressure of Nitrogen buffer tank reaches 0.5Mpa, prepare
to operate to supply gas if the purity which is indicated by the Nitrogen analyzer on
the faceplate is up to the mustard.
7.2.5 To supply the gas, adjust the Nitrogen’s pressure to 0.45Mpa (adjustable), and
then open the valve 3 slowly. Pay attention to the flow meter and pressure upkeep.
7.3 Monitoring and recording during the running period
7.3.1 During the running period, operational equipment should be regular checked,
such as: the pressure of adsorption tank and the Nitrogen purity.
7.3.2 Pay attention to whether the Nitrogen purity indicated by the Nitrogen
analyzer is up to the requirement.
7.3.3 Record the operation carefully (check whether the instrument readings are
normal every half an hour)
The recording shall include time, ambient temperature, inlet/outlet/nitrogen
pressure, nitrogen flow and purity.
7.3.4 Pay attention to draining: use manual drain 2 or 3 times per shift.
7.3.5 Release the dirt accumulated in the active carbon filter periodically.
7.4 Shut off
7.4.1 Close the outlet valve of Nitrogen generator to stop supplying nitrogen.
7.4.2 Close the inlet valve of absorber
7.4.3 Press the stop button on the controller and the system will be stopped；
7.4.4 Close all inlet valves of any instrument;
7.4.5 Cut off power
7.4.7 Open all drain valves. Close them after finished blowing down.
7.4.8 Close and stand by

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Shanghai Research Institute of Chemical Industry

C LIE N T:
P O W E R G E NERATI ON
N O R TH W ES T P O W E R G E N E R AT ION C OM PAN Y LIM ITED , BAN G LAD ESH
E P C C O N TR ACTOR:
C H IN A N A TIO N AL M A C H IN ER Y IM POR T & EXPOR T C OR POR ATION

S U B C O N TRA CTOR :
SH A N G H AI PO W E R EQ U IPM EN T R E SEAR C H IN S TITU TE

Figure 3 Floor plan of Nitrogen generator

Shanghai Research Institute of Chemical Industry

 上 海 化 工 研 究 院
Shanghai Research Institute of Chemical Industry

8. Maintenance and servicing

8.1 The filters should be maintained routinely according to the specification.
8.2 Check and service the valves of Nitrogen generator periodic (such as pneumatic
cut off valve, magnet valve, back valve, gate valve, etc) and inner equilibrium
compressing apparatus. Wearing parts and sealing should be replaced when they are
damaged.
8.3 The controller, electrical apparatus, Nitrogen analyzer and oxygen electrode
should be often checked whether they run well. If not, the abnormal part must be
repaired or replaced in time.
8.4 Periodic verify the gauges and instruments (such as flow meter).
8.5 Mind you to supply the molecular sieve. While having to supply the molecular
sieve, the air in the container should be emptied, then open the blind flange on the top
of adsorption tower (Attention: The Spring Will Jump Out!) to supply the molecular
sieve.
8.6 After the Nitrogen generator is powered off, must close the inlet and outlet valves
of generator and keep certain Nitrogen in the absorber because the effect of molecular
sieve would reduced if the sieve was in air for a long time.
8.7 Nitrogen analyzer is shown in the relative chapters of “Nitrogen analyzer ”.
8.8 Corresponding measure should be adopted to assure the control gas is clean which
will enter the magnet valve, or apt to break down.
8.9 Servicing of wiring of absorber magnet valve and PLC controller see “10
appendix: schematic diagram of wire splice of PLC controller”.
8.10 Switch valve
Double cylinder switching is adopted in the generator to accomplish circulation
of adsorbent absorption and regeneration. Switch valve is used so frequently that it is
the most important component. Consequently it should be taken good care routine
service.
There are 10 pneumatic angle seat valves in the Nitrogen generator which had
been debugged before they left factory. In general, there should be no problem about
machine parts. The inlet air pressures of the gas that control the valves are all 0. 5MPa,
or there would be operational failure if the pressure is less. Additionally, if there is
still some failure, the control system should be checked firstly, such as whether power
source, magnet valve or controller is well running.
If there is failure about valve, it is most possible that the obturator is damaged.
Just replace the part according to the diagram. There are spare parts in company with
the machine.
Suggestion: Valves should be opened to clean the operative parts, replace the obturator.

Shanghai Research Institute of Chemical Industry

 上 海 化 工 研 究 院
Shanghai Research Institute of Chemical Industry

9. Notice
9.1 Person will asphyxiate because of lacking of Oxygen when the content of
Nitrogen in the air is too high. The volume concentration of Oxygen in the working
place should reach 19% at minimum.
9.2 To avoid increasing the concentration of Nitrogen in the workshop, it is forbidden
that blow off Nitrogen indoors. Oxygen aspirator should be worn while working in the
place where is rich of Nitrogen.
9.3 Air replacement must be done when person has to enter the large-scale equipment that is full of
Nitrogen or container duct to examine and repair. Working in the environment above-mentioned is
permitted only when the oxygen content up to grade.
9.4 The stabilizations of the pressure and flow of the air are required. When inlet air
pressure is lower than the rated operating pressure (See 2. principal technical
parameter), effective air consumption should be increased.
9.5 The air displacement of the selected air compressor must to be 1.05~1.1 times of
the effective air consumption.
9.6 Before equipment repaired, electric current must be cut off and the pressure of
relative duct and container must be decreased to zero.
9.7 When starting or halting, pressure should be increased or decreased slowly
because exceeding instant pressure difference will influence the long-term running of
the equipment.
9.8 The related pressure vessels should all be examined periodic according to the
relative nation stipulation.

Figure 4 Control panel of Nitrogen generator

Shanghai Research Institute of Chemical Industry

 上 海 化 工 研 究 院
Shanghai Research Institute of Chemical Industry

10. Schematic diagram of wire splice of PLC control

Shanghai Research Institute of Chemical Industry

 上 海 化 工 研 究 院
Shanghai Research Institute of Chemical Industry

11. The fault phenomenon, reason analysis, treatment method

Fault phenomenon Reason analysis Treatment method

Low working pressure
Procedure error
The product gas purity decline
Pressure display
The power indicator light does not shine
Power indicator light system does not work
Pipeline leakage
Low output pressure of air compressor
Nitrogen supply capacity is too large
An electrical fault
Solenoid valve failure
Pipeline leakage
Valve leakage
Oxygen electrode fault
Solenoid valve failure
Nitrogen production is too big
Damaged pressure gauge conduit
Damaged pressure gauge
Power is not connected
Line loss
Break inside
Lamp failure
Repair the pipeline
Adjust the output pressure of air compressor
Adjust the quantity of gas supply
Check the electrical part
Maintain the electromagnetic valve
Repair the pipeline
Replace with the valve pad
Calibrate or replace with the oxygen electrode
Replace with electromagnetic valve
Adjust the gas production
Replace with pressure gauge conduit
Replace with pressure gauge
Check power supply
Check circuit
Check circuit
Replace with lamp

Shanghai Research Institute of Chemical Industry