3.1 Generon Manual

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GENERON HPLC Membrane Nitrogen SystemOperating and Maintenance Manual

SECTION 1

INTRODUCTION / WARRANTY POLICY

1.1 SCOPE

This manual describes the general operating and maintenance instructions for aGENERON* HPLC Membrane Nitrogen System as designed by Generon IGS.. Thepurpose of this manual is to enable a trained operator to start-up, shutdowns, make minorprocess adjustments, and maintain a unit, which has been set-up initially by a trainedGeneron IGS. Service representative. This manual is not intended to instruct the user onhow to perform detailed modifications or major set-up changes to the HPLC membranesystem.

Customers may direct specific questions related to the maintenance and operation of the

GENERON HPLC Membrane System to the Generon IGS. Customer Service Departmentat 713-937-5200.

1.2 CONFIDENTIALITY

This document contains confidential or proprietary information of Generon IGS.. Neitherthe 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 40F (4.4

C) and 122

F (50

C). Exposure to temperatures outside the specified

range could lead to membrane damage and performance reduction.

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


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SECTION 2

SAFETY

2.1 SAFETY

The GENERON HPLC Membrane System is capable of producing nitrogen with puritiesranging between 95% to 99.9%. The nitrogen produced by the GENERON HPLCMembrane System is a colorless, odorless, chemically inert gas defined as a simpleasphyxiant. 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 neededto support life.

2.1.1 Nitrogen Gas

The GENERON HPLC Membrane System is designed to separate nitrogenfrom compressed air. The concentrations of oxygen contained in the nitrogenproduct stream of any GENERON HPLC Membrane System will not support humanlife. If released in an unventilated area, nitrogen will displace oxygen and causeasphyxiation and/or injury. A Material Safety Data Sheets (MSDS) for this systemare located at the end of this section.

A general indication of the symptoms and effects experienced whenexposed to various levels of oxygen deficient atmospheres is given below.

Oxygen Content Symptoms and Effects(% by volume) (Atmospheric Pressure)

15-19% Decreased ability to workstrenuously. May impair coordination and may induce earlysymptoms in persons with coronary, pulmonary, orcirculatory problems.

12-14% Respiration increases withexertion, increase of pulse rate, impaired coordination,perception and judgment affected.

10-12% Respiration further increasesin rate and depth, poor judgment, blueness of lips.

8-10% Mental failure, fainting,unconsciousness, ashen face, blueness of lips, nausea, andvomiting.

6-8% 8 minutes exposure, fatal; 6minutes exposure, 50% fatal; 4-5 minutes exposure,recovery with treatment.

4-6% Coma in 40 seconds,convulsions, respiration ceases; death.


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2.1.1 Nitrogen Gas (continued)

Avoid confined spaces until oxygen adequacy (20.9%) has been proven byanalysis or other positive means, or until breathing air has been provided by air

pack, air hose or other trusted sources. Confined areas/spaces include thefollowing:

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 mixing4. Gas generators, gas tanks, gas holders and receivers

Do not allow the product nitrogen to be vented other than through properpiping. Warning signs should be posted in any area and/or confined space whichmay be a potential nitrogen deficient area. Appropriate warning signs are available

from the GENERON IGS. Service Department.

2.1.2 Enriched Oxygen

The enriched oxygen vent gas (permeate) consists of 30-45% oxygen ascompared to normal levels which are 20.9% oxygen. While oxygen will not burn,oxygen concentrations above 28% can support combustion of other materials muchmore readily than air. It is imperative that the enriched oxygen vent gas bedischarged only in well-ventilated and safe areas. If the GENERON HPLCMembrane System is located in an air tight or poorly ventilated room, the vent gasshould be piped outdoors for release.

2.1.3 Pressurized Equipment

The GENERON HPLC Membrane System is operated under pressure.Therefore, a hazardous work program should be followed when working around orservicing this equipment.

The PVC permeate vent line must never be pressurized. This line should alwaysbe allowed to flow un-restricted to atmosphere in a safe area.

The GENERON HPLC Membrane System should not be subjected toexcessive external forces or impact. Excessive force or impact applied to apressurized 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 ALLLINES AND VESSELS BEFORE DISCONNECTING LINES OR DISASSEMBLYOF THE GENERON HPLC Membrane System. Associated air and nitrogen supplylines should be shut off and locked out.

Leak checks should be performed on all piping components to ensure nocompressed air or product nitrogen is allowed to escape. When performing leakchecks, use an accepted leak detection solution.


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2.1.4 Electrical Equipment

Use normal commercial safety practices while performing maintenance ortroubleshooting.

Personnel unfamiliar with the electrical equipment supplied with the GENERONHPLC Membrane System should not attempt to service this equipment. Theelectrical currents supplied to the various electrical components on the GENERONHPLC Membrane System are at levels high enough to cause severe injury and/ordeath.

When installing a GENERON HPLC Membrane System, ensure that allapplicable earth grounds are installed as required by the National ElectricCode and/or local requirements. Refer to the appropriate manufacturer's manualsfor 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 areprovided to inform the customer of the nature of the bulk substances contained in orproduced by the GENERON HPLC Membrane System. It is the responsibility of thecustomer to provide access to this information for personnel working around theequipment as appropriate. The MSDS sheets included in this section are forNitrogen gas and Activated Carbon.


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SECTION 3

ENVIRONMENTAL

3.1 CONDENSATE DRAIN LINES

Several components on the GENERON HPLC Membrane System are equipped withcondensate drain lines. Refer to the GENERON HPLC Membrane System Piping andInstrument Diagram (P&ID) located in Section 10 of this manual for the specific equipmentand location of the drain lines. These drain lines collect oily condensate removed from thecompressed air supplied to the GENERON HPLC Membrane system. It is the customer'sresponsibility to ensure that the oily condensate released from these drain lines is disposedof in accordance with local statutes.

Waste oil collected during compressor oil changes and oil soaked filter elements removed

from the coalescing and particulate filters are considered hazardous waste. It is thecustomer's responsibility to ensure that all waste oil and oil soaked filter elements aredisposed of in accordance with governing statutes.

Oil spills or leaks from the compressor must be properly cleaned up. Commercialabsorbent materials are available for this purpose. Use only absorbent material that hasbeen approved by a responsible governing agency. In some cases, disposal ofcontaminated soil may be necessary.


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SECTION 4

PROCESS DESCRIPTION

4.1 GENERAL

The GENERON HPLC Membrane System is equipped with modules in which the nitrogenseparation takes place. The modules are filled with a cylindrical bundle of hollow fibermembranes made of a polymer-based material. Each bundle contains several millionfibers, each about the size of a human hair. Compressed air enters the end of the fibersand flows inside the fibers through the membrane bundle to the opposite end.

Gas separation takes place as the pressurized air contacts the membranes. "Fast" gasessuch as oxygen, carbon dioxide, and water vapor quickly permeate through the fiber wallsand 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 flowingconditions. It flows down bore of the fibers and exits at the product manifold on the end ofthe 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) andrecovery (efficiency). This performance is a function of the product purity, operatingtemperature, and operating pressure.

In general, productivity increases with an increase in pressure and temperature (at constantpurity).

Recovery, on the other hand, increases slightly with pressure, but decreases astemperature rises (at constant purity).

Both recovery and productivity increase as the oxygen concentration (product impurity)increases (at constant pressure and temperature).

.

The HPLC system operates most effectively at 135-188 psig 80o-110oF (9-13 bar(g), 27o- 43oC).


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GENERON HP Series Membrane Nitrogen System

Operating and Maintenance Manual

Section 5

Equipment Description

5.1 General

For explanation purposes, the GENERON HP Nitrogen Generator has been broken downinto four standard subsystems. These subsystems are: Feed Air, Air Pretreatment, ProductGas Separation, and Control System. The descriptions included in this section aredesigned to provide the operator with a basic understanding of the function of thecomponents used on the generator.

The Process and Instrumentation Diagram (P&ID) located in Section 10 of this manualreflects these components and process system supplied to the customer.

5.2 Feed Air Subsystem

The feed air source for the Generator may consist of a dedicated air compressor orcustomer-supplied compressed air from a plant or instrument air system. A dedicatedcompressor, if supplied by Generon IGS, is usually a lubricated rotary screw compressorsized to produce the required air flow rate at operating pressures with a minimal horsepowerrequirement. The air compressors are typically equipped with the following features:modulating controls, auto restart from Standby state, high dust filters, and outdoor/freezeprotection (if required), and are filled with synthetic lubricant. Refer to the compressormanual itself for a description of the actual compressor.

Customer provided air sources of lower feed pressures will result in correspondingly lowernitrogen production (see Section 4.2). The customer should ensure, however, that the feedpressure of the air source remains stable and consistent to meet the intended membranesystem design performance.

5.3 Air Pretreatment Subsystem

The Air Pretreatment subsystem contains equipment required to properly condition theprocess or feed air supplied to the membrane modules. It is recommended that a meansfor removing bulk water be used prior to the skids feed air inlet. On-skid equipmentincludes: moisture separator (MS-10), coarse coalescing filter (F-11), fine coalescing filter(F-12), process heater (EH-14), carbon filter (F-16), particulate filter (F-18), and feed valve(FSV-19-1). Refer to the P&ID located in Section 10 for specific equipment supplied.

Proper operation and maintenance of this filtrati on system will prevent oil (liquid or vapor)condensate, airborne particles and pipe scale from contaminating and/or clogging themembrane fiber openings.


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5.3.1 Off-Skid Means To Remove Bulk Water

An air receiver or moisture separator prior to the skid inlet is recommended to collectand remove the bulk of the oily condensate. The equipment should be equipped

with a condensate drain line.

5.3.2 Moisture Separator

The first on-skid air conditioning component is a moisture separator (MS-10). Theprimary function of the moisture separator is to further remove large quantities of oilywater condensate from the feed air supply. The moisture separator is equipped withan automatic electrical drain trap which will notify the generators control system if adrain failure occurs.

5.3.3 Coalescing Filters

Coarse and fine coalescing filters F-11 and F-12, which utilize a 1.0-micron and0.01-micron filter element respectively, are designed to remove virtually the entireremaining 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 VI for further information. The coalescing filters are also tied intothe condensate drain line through automatic mechanical drain traps.

5.3.4 Process Heater

The process heater (EH-14) changes the state of the incoming air from saturated tosub saturated by maintaining a constant temperature increase between 6 and 12C.EH-14 is an electric air circulation heater that optimizes the membrane moduleperformance by ensuring that the feed air stream is heated and maintained at aconstant temperature of 45oC.

5.3.5 Carbon Filter

The carbon filter (F-16) consists of a carbon steel pipe assembly or locally-codedvessel containing a specially packed activated carbon. The activated carbon pelletsused in the carbon filter absorb heavy hydrocarbon vapors that may be entrained inthe feed air supply. Refer to Section 8 (Maintenance and Trouble Shooting) forfurther information regarding the maintenance intervals for replacing the activatedcarbon.


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5.3.6 Particulate Filter

The particulate filter (F-18), which utilizes a 0.01 micron filter element, is intended toremove all remaining airborne particulate matter (rust, carbon dust, etc.) remaining

in the feed air supply. The particulate filter is typically identical to the fine coalescingfilter, although the primary reason for this filter is solid particle removal. Note: tooptimize its operation as a particulate filter, this filter is installed backwards (reverseof the normal flow indicated on the filter housing).

5.3.7 Feed Valve

The feed valve (FSV-19-1), which is controlled by the PLC, provides on/off control ofthe feed air supplied to the membrane module(s). The feed valve is classified as afail-close valve which enables the GENERON HP Nitrogen Generator to isolate thefeed air supply in the event of an instrument air supply failure or loss of power.

5.4 Product Gas Separation Subsystem

The Product Gas Separation subsystem contains the membrane modules and thecomponents necessary for the proper operation and control of the GENERON HP NitrogenGenerator. The Process and Instrumentation Diagram (P&ID) located in Section 10 of thismanual reflects the components and flow system specifically provided to the customer.

5.4.1 Membrane Modules

Each membrane module case (MM-19) is filled with a cylindrical bundle of hollowfiber membranes, made of a polymer-based material.

5.4.2 Flow Control Valve

The flow control valve (FCV-23-1) is used to control the nitrogen purity. The FlowControl Valve receives its control signal (4-20 mA) from the PLC, using a PID controlloop to maintain the preset purity. The positioner (FY-23-1), located at the controlvalve, converts this signal from the PLC into a valve opening as required.

The flow control valve is classified as a fail-close type valve. When the controlsignal from the PLC is 4 mA or less, the control valve will be fully closed.


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5.4.3 Purity Assurance Valves

The GENERON HP Nitrogen Generator is equipped with two purity assurancevalves (FSV-24-1A&B). The valve FSV-24-1A allows on-spec product gas to flow into the

customer's pipeline if the purity is in the allowed range, see the logic description insection 10. The valve FSV-24-1B will vent off-spec product gas with too high or toolow oxygen impurity. The off-spec gas vented from the product vent valve containshigh purity nitrogen which can be hazardous to personnel safety. This gas shall bevented in accordance with good safety practices and local guidelines.

5.4.4 Permeate Gas

The permeate gas is the waste gas stream from the nitrogen separation process.The permeate gas typically contains 30-45% oxygen and should be piped outdoorsto 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 thatmay result in a backpressure being placed on the modules. Any backpressure onthe modules via the permeate line will result in a decrease in nitrogen production(keep the piping diameter relatively large).

5.5 Control System

The control system on the GENERON HP Nitrogen Generator consists of a PLC-BasedControl System, Oxygen Analyzer, Pressure Switch (off-skid), Panel Lamps and Switches,Operator Interface Terminal, and Heater Control Panel.

5.5.1 PLC-Based Control System

The Programmable Logic Controller (PLC), located in the HP Control Panel is pre-programmed with the appropriate program for the individual system. It consists ofan assembly of modular components which is responsible for:

a) Taking input signals from front panel buttons and switches and displayingstatus information.

b) All switching valve sequencing timers and counters. The PLC will energizeand de-energize piloting solenoids, as appropriate.


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5.5.1 PLC-Based Control System (continued)

c) Monitoring of the oxygen content of the product gas to ensure on-specpurity. If the O2analyzer indicates a high O 2level during normal operations,

the PLC will vent the off-spec product gas and ultimately shut down theGENERON HP Nitrogen Generator.

d) Monitoring the off-skid pressure transmitter (PT-27-1) to either initiate astartup from the Standby State or go into Standby from the Running State.

e) Monitoring of the electronic drain (LSH-10-1) and the optional differentialpressure indicating transmitter (PDIS-18-1). An alarm signal from either willalarm and then shut down the system to prevent the compromising offiltration.

f) Control of nitrogen purity by continually adjusting the flow control valve tomaintain nitrogen purity under changing ambient and operating conditions.

g) Monitoring and controlling of the heaters. Alarm and shutdowns will occurfor exceeding high temperature limits. Monitoring the flow transmitter (FS-19-1) to transmitter the heater off in case there is no flow of air.

For specific instructions on programming the HP control system, consult theGeneron IGS Service Center. In general, most control system programmingchanges are nothing more than changing setpoints in the PLC memory.

5.5.2 Oxygen Analyzer

The oxygen analyzer (AIT-20-1) located in the GENERON HP control cabinetcontinuously monitors nitrogen product gas for oxygen content. During operation,sample gas from the product header flows through the analyzer cell whichgenerates a signal proportional to oxygen concentration. The product sample purityis monitored by the PLC, which adjusts the flow control valve (FCV-23-1), via thepositioner (FY-23-1), to maintain nitrogen purity.

5.5.3 Nitrogen Receiver Pressure Transmitter

The system makes use of a 4-20mA signal from a remote pressure transmitter (PT-26-1) to sense customer product demand.

5.5.4 PLC Control Panel CC-2

The lamps and switches located on exterior of the PLC Control Panel are describedbelow. The Programmable Logic Controller is located within the panel andfunctionally tied into the Operator Interface Terminal on the enclosures door.


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5.5.4.1 Power Switch

When the On-Off Power switch is in the ON position and the power to thecontrol panel is energized, the Power ON button will illuminate. The Power

switch controls power supplied to the rest of the HP Panel. This button mustbe in its ON position for any operation, programming, or calibration to occur.

5.5.4.2 Alarm Lamp

An illuminated Alarm lamp indicates that the system has entered a generalAlarm State. Various conditions can trip this alarm: filter drain malfunction,filter differential pressure limit exceeded, off-spec product, and heater overtemperature. If the cause for alarm is not cleared within the individually setamounts of time (5 seconds to 90 minutes) the system will enter theShutdown state.

5.5.4.3 Shutdown Lamp

An illuminated Shutdown lamp indicates that the system has entered aShutdown state. If an alarm persists for longer than its shutdown timer, thesystem will enter a shutdown state.

5.5.4.4 Auto-Stop-Manual Switch

A three position switch that allows the user to run the system automaticallyor manually. The Stop function is described in greater detail throughoutsection 7.

5.5.4.5 Emergency Stop Switch

In case of a need for an emergency shutdown, this button is pushed toimmediately shutdown the system. It is pulled to start the system again.

5.5.4.6 Operator Interface Terminal

The Operator Interface Terminal (OIT) built into the control panel front allowsthe user to easily interface with the PLC. The OIT provides the user withmenu-oriented functions to view operating, configuration, and programmingdata. The selection keypad enables movement through the menus andchanging of system set point values. If the HP Nitrogen Generator isdesigned to operate in 2 different modes, the current mode can be chosen

via the OIT.

5.5.5 Heater Control Panel CC-1(*)


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The electrical supply for the HP nitrogen generator is fed to the Heater ControlPanel. The disconnect switch on the enclosure door acts as the disconnect switchfor the skid. The heater circuit, individually fused and controlled, is inside the

enclosure along with the 24VDC power supply for the PLC Control Panel. A stepdown transformer may be included in some systems.

Taking in 4-20mA signals from the PLC control panel, the solid state power controlsprovide the power to the heater.

The PLC monitors the sheath/element temperature and shutdown the heater if thedial set limit is reached.

Descriptions of the switches and lamps located on the heater panels door follow.

5.5.5.1 Power Switch

The power switch will illuminate when the power to the heater panel is on.

* For cabinet systems, the heater controls are located in the PLC control panel.


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SECTION 6

OPERATION OVERVIEW

6.1 GENERAL

The GENERON HPLC Membrane System has been designed to run unattended except forperiodic operational and calibration checks.

This section describes the various operating modes, machine states, and alarm functions ofthe HPLC control system, as well as the physical maintenance requirements with which theon-site operator should be familiar.

6.2 CONTROL MODES

The GENERON HPL C Membrane System allows a choice of control modes: ManualControl and Puri ty Control. The mode chosen determines how constantly purity will bemaintained over transitions of air supply, product demand, and ambient conditions.

6.2.1 Manual Control

In the Manual control mode the Product FCV Opening is controlled with respect tothe value (0-100%) entered on the Analog Setup Screen. Beca use of e verchanging airflow this method should not be used. This is mainly for convenience oftroubleshooting the valve or stroking the valve to check movement.

6.2. Auto Control

Auto Control uses the O2 Analyzer to maintain the desired purity. The O2 puritysetpoint is entered on the Panelview Analog Setup screen and the PLC maintainsthis setpoint reacting to flow, temperature and pressure changes.

6.3 MACHINE STATES

The Generon HPLC Membrane System operates in one of six machine states. Of these sixstates, four are considered Normal and two are considered Abnormal.

6.3.1 Normal States

The four Normal states in which the GENERON HPLC Membrane System operatesare STANDBY, STARTUP, MANUAL, VENT and AUTO CONTROL. When theGENERON HPLC Membrane System is operating in one of the Normal states, it isoperating correctly and within the parameters set up by the startup engineer.


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6.3.1.1 Standby State

The Standby State is the non-producing state that is available duringautomatic or manual operation when the pressure reaches the maximum

N2 setting. The indications of this state are:

6.3.1.2 Startup State

The Startup state is a transitional state that must precede theRunning state. The Startup state is entered when the GENERON HPLCMembrane System energized for the first time and is designed to allow theO2 analyzers time to warm up.

Startup cannot 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 a 60 second timer that energizes whenthe PLC is first energized.

6.3.1.3 Manual State

In the Manual control mode the Product FCV Opening is controlledwith respect to the value (0-100%) entered on t he Analog Setup Screen.Because of ever changing airflow this method should not be used. This ismainly for convenience of troubleshooting the valve or stroking the valve tocheck 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 setpoint controls the valve to maintain an oxygenconcentration.


Switch is in AUTO position

6.3.1.5 Vent State

The Vent State is active when the system is first started up until O2purity been reached or has been above shutdown setpoint for over allottedtime.


Vent valve is open and Product valve is closed. Alarm is active


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6.3.2 Abnormal States

As the title suggests, when in one of the two following states, the GENERON HPLCMembrane System is not operating within the prescribed parameters as set up b ythe startup engineer.

6.3.2.1 Alarm State

6.3.2.2 Shutdown State

If a shutdown has occurred, the alarm must be corrected and the system

must be put into STOP, then restarted.

6.4 ALARM LOGIC

SYSTEM HAS BEEN FORCED TO VENT Force vent F10 on the Flow Screenhas been activated, this is a reminder alarm

NO FLOW DETECTED FOR RUN The system has been started but flow switchFSL-8870A has not detected flow for 60 seconds.

AT- is offline The O2 analyzer has faulted. The fault must be corrected andthe AUTO/STOP switch must be p laced in ST OP before the system can b e

restarted

SHUTDOWN- High Heater Temp shutdown >392 F (200 C) The heater elementis above 200C or the safety contactor has tripped or there is a Shorted SCRCondition and caused a shutdown. The problem must be resolved and theAUTO/STOP/MANUAL switch must be placed in STOP before the system can berestarted.

VENTING TO LONG, SHUTDOWN The system has been venting longer that theallotted time set on the Analog Setup Screen. The AUTO/STOP/MANUAL switchmust be placed in STOP before the system can be restarted.

RUN NOT ALLOWED BEFORE O2 WARMUP When the system is first poweredup, a 60 second timer allows the O2 analyzer to warm-up. If a system start isrequested before the timer is finished, this alarm energizes to remind the operatorto wait. The time remaining can be found on the Main Menu Screen.

WARNING- Air to Modules Temp High > 140 F (60 C) Heated air to the modulesis at or above 140F.

SHUTDOWN-Air to Modules High > 150 F (65 C) Heated air to the module is at orabove 150F and has shutdown the generator. The air must fall below 140F and theAUTO/STOP/MANUAL switch must be placed in STOP before the system can berestarted


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O2 OFF SPEC,SYSTEM TO VENT The O2 content has fallen above or below theHigh/Low O2 set point and is venting to atmosphere.

HEATER NOT HEATING AIR TRAIN After 15 minutes the hea ter (H-5270) hasnot heated the air up at least 5.5 degrees, check heater

WARNING- Heater Outlet Temp High > 138 F (59 C) Heater Outlet temperature ishot.

WARNING- Incoming Air is Low < 45 F (2 C) Incoming temperature is cold.

SHUTDOWN - Heater Trouble There is problem with heater or heater contactor.Shutdown will occur after 30 minutes.

-is offline lost signal of , check electrical wiring and device.

is offline lost signal of , check electrical wiring and device.

is offline lost signal of , check electrical wiring and device.

AT-20-1 is offline lost signal of AT, check electrical wiring and device.

FT-22-1 is offline lost signal of FT-22-1, check electrical wiring and device.

6.5 OPERATIONAL MAINTENANCE

The Generon HPLC Membrane System is designed to run unattended and requires onlyminor attention to assure proper operation.

6.5.1 HPLC 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 theGeneron IGS. Service Department.

6.5.1.1 Particulate and Coalescing Filter Differential Pressure

Most particulate and coalescing filters can tolerate very high differentialpressures. In fac t, manufacturers typically do no t require elementreplacement until the steady state differential exceeds 9 psi (0.6 bar(g)).


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The membrane module performance is a function of the feed air pressure and, as a result, willdecline with increased differential pressure.

Filt er Differential PressureIn order to optimize the membrane module performance, the pressuredifferential across the coalescing filters should be checked on a quarterlybasis checking the filters pressure differential gauge. Th e filter elementsshould 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 themembrane module performance dictates otherwise.

A minimum change out rate of six months is usually appropriate dependingon the feed air quality.

6.5.1.2 Carbon Vessel

The activated carbon used in the Carbon Vessel must be rep laced on aregular basis. Minimum change out rate for the carbon is every 4000 hoursor 18 mo nths, which ever comes first. Refer to the Refill Procedure forCarbon 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 HPLCcontrol has a service life of approximately one year. During that time, the

calibration may drift slightly, and should be checked weekly. See Section-9and the manufacturers documentation in Section-10 for information ofcalibration and service of this critical instrument.


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GENERON HPLC Membrane Nitrogen System


SECTION 7

OPERATIONAL MAINTENANCE

7.1 GENERAL

The following procedure should be used to bring the GENERON HPLC Membrane Systemon-line after a prolonged shutdown or major maintenance. Ensure that all pipingconnections are properly fitted and electrical connections are secure before initiatingstartup.

7.2 POWER UP

Switch the Main Power Panel (heater panel) 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

Pressurize the HPLC Membrane System

Start the feed air compressor per the manufacturer's instructions.

7.3.1 Instrument Setup

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

operating.

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

Set the instrument air regulator (PRV- 19-1) to 5.9-Bar 85-psi. This can be doneprior to startup, when the skid is pressurized.

7.3.3 Product Gas Sample

Once there is pressure in the nitrogen product pipeline set the sample regulator(PRV-20-1) to 0.35-bar (5-psi). Adjust the sample flow rate, using flow indicatorfi-20-1inside the panel, to 1.0 SCFH.

7.4 Start HPLC Membrane System

Turn the AUTO/STOP/MANUAL switch to AU TO. The GENERON HPLC Membrane System willinitiate a Startup state. During the start-up state, which lasts 60 seconds the PLC will direct the feedvalve XCV-080102 to open. Initially the product flow will be directed though the Fail-Open off-specline.

Flow Meter (FT-22-1) will enable power to the process heater contactor when the inlet air flow ishigh enough for heater control. If the air inlet valve is not open, FSV-19-1 , the flow meter will


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not detect flow and heater contactor will not allow power to be the process heater (due to no airflow).

The GENERON HPLC Membrane System will continue to vent product gas until the startup timer

times out. When the startup timer times out, the GENERON HPLC Membrane System will switch topurity control or manual control depending on the Control mode used and the customers' productnitrogen demand.

7.5 Begin Production

Once the purity valve (FCV-23-1) is controlling O2 purity level and product pipeline O 2level fallswithin the preset vent limits, the PLC will automatically direct the off-spec/product valve ( FSV-24-1A) to change to the product line and thus placing the GENERON HPLC Membrane SystemOn-Line.

7.6 Changing the Setpoints

The Operator Interface Terminal in the GENERON HPLC Panel allows an operator to changesetpoints. Most of these will be set by the factory, but some will occasionally need to be set by theuser. This is only the case when the unit is to operate differently from its original set up atcommissioning.

After power is applied to the PLC, there is a programmable warm-up period. At the end of thatperiod, use the F keys to navigate to all screens.

Purity Setpoint can be changed from .01 to 10%.

7.7 Shutdown

This section is intended to instruct an operator on procedures for shutting down the GENERONHPLC Membrane System as well as afford a means to identify a non-operator initiated shutdown.

7.7.1 Controlled Shutdown

MANUAL SHUTDOWN - To turn the GENERON HPLC Membrane System off:* Turn the AUTO/STOP/MANUAL switch to Stop.* Isolate the GENERON HPLC 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 productreceiver (if supplied) at pressure.

7.7.2 Uncontrolled Shutdowns

SAFETY ALARM SHUTDOWN

Any time there has been a non-user system shutdown, the problem must be fixed and theauto/off/manual switch must me moved to off before the system can be re-started.

LOSS OF UTILITIES


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Power Outages (Blackouts and/or Brownouts): When power is interrupted to the HPLCcontrol panel, all devices will go to their fail position. The feed valve will block the feed airsupply. To restart, follow the steps outlined in Section 7.

Instrument Air Loss: When instrument air is lost completely, the feed valves on theGENERON HPLC Membrane System will switch to its fail closed position thus blocking theincoming feed air supply. If this continues for several minutes, a low pressure shutdown willoccur.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 8

MAINTENANCE AND TROUBLE SHOOTING

8.1 General Maintenance

A properly functioning filtration system is of premiere importance to this membrane system.Drains must be checked daily. Filters should be opened up and inspected quarterly.Closely observe the differential pressure gauges (a drop from the previous days readingcould indicate a torn/damaged element).

Table 8.1 - Operational MaintenanceDaily

(1)Bi-

WeeklyQuarterly Semi-

AnnuallyOther

Check Drain Trap Operation X

Log Process Operating Parameters X

Verify Calibration of Oxygen Analyzer X

Inspect Filter Elements X

Test Alarm/Shutdown Features X

Replace Activated Carbon in F-16-1 X

Inspect & Clean Instrumentation, Pneu. & Elect. X

Replace FIL-11-1, FIL-12-1 FIL-18-1,(2)

X

Leak Test Piping Joints X

Inspect and clean F-18-1 X

Replace PLC battery (3) 4 yr.

Notes:(1) Refer to Section 8.2.(2) More frequent attention may be required.(3) There is a low battery indicator on the PLC.


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8.2 Daily Maintenance

Each day the operator should record the systems operational parameters on copies madefrom Table 8.2A (Nitrogen Unit Daily Check List/Log) located in the back of this section.

The procedure below outlines a step by step process for completing this log. Thisprocedure should be performed at a set time under the same conditions each day after theunit has been running for at least one hour.

1. Record O2 reading from the OIT.2. Record air pressure at PI-10-1and module inlet pressure at PI-19-2. If either

pressure is fluctuating it can have an effect on O2 purity.3. Record differential temperature for EH-14 from OIT (RTD-14-1, RTD-14-2).4. Record module inlet temperature from OIT (RTD-19-1).5. Record run hours and shutdown hours from the OIT.6. Verify the setpoints for high pressure instrument air PI-19-1 (set at 85PSIG).

7. Verify the setpoint for O2 sample regulator PI-20-1. (set at 5PSIG).8. Verify the setpoint for O2 sample flow FI-20-1 (2 SCFH).9. Manually drain the moisture separator T-10-1 into a cup. Some moisture is

expected. If there is too much drainage refer to trouble-shooting Section 8.3.10. Manually drain both coalescing filters F-11-1, F-12-1, F-18-1 into a

cup. Some oily condensate is expected. If there is too much drainage refer totrouble-shooting Section 8.3. Water at this point would be a problem.

11. Manually drain the carbon filter F -16 and the particulate filter F -18 into acup. Any liquid drainage here is a serious matter, refer to trouble-shooting Section8.3.

12. Observe the differential pressure on the coalescing and particulate filters PDI-11-1, PDI-12-1 and PDI-18-1. If filter differential pressure is near 9 PSIG

refer to Section 8.3.

8.3 Trouble-shooting

Refer to this section for identifying causes of problem indicators, alarms, and shutdowns.

Begin at the indication of the problem and work back (upstream) to find the source of theproblem.

Too much liquid water/oil from Ensure drain line is not blocked.separator drain

Incorrect function of off-skid MoistureSeparator (from compressor), it is notremoving the bulk of water.

Incorrect function of the automatic drain.


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8.3 Trouble-shooting (continued)

Too much liquid water/oil from Ensure drain line is not blocked.filter drains

Incorrect function of the automatic drains ormoisture separator.

Air supply too hot.

Liquid water/oil present at drain Upstream moisture removal is not workingof carbon and particulate filters properly.

Air supply too hot or EH-14 error.

Air temperature too high or low Heater setpoints are incorrect.

Compressed air too hot.

O2 content drifting Changing pressure in air supply.

HE-0801 not properly operating.

Inlet air extremely hot.

Not enough nitrogen O2 content too high. System Is venting.

System in Standby State.

System is air starved, compressor problem.


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SECTION 8SHUTDOWNS

This section is intended to instruct an operator on procedures for shutting down the GENERON

HPLC 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 HPLC Membrane System off:

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

. Isolate the GENERON HPLC Membrane System from the feed air source

. If there is a dedicated compressor, shut it down per manufacturer'srecommendations

It is generally advisable to close the final product valve (if applicable) to keep theproduct receiver (if supplied) at pressure.

8.2 UNCONTROLLED SHUTDOWNS

8.2.1 Safety Alarm ShutdownAny time there has been a non-user system shutdown, the problem must be fixedand the auto/off/manual switch must me moved to off 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 HPLC control panel, all devices will go to their failposition. The feed valve, FSV-19-1 will block the feed air supply. To restart, followthe steps outlined in Section 7.

Instrument Air Loss:When instrument air is lost completely, the feed valves on the GENERON HPLCMembrane System will switch to its fail closed position thus blocking the incomingfeed air supply. If this continues for several minutes, a low pressure shutdown willoccur.

If instrument air pressure drops, but is not lost completely, the valves will operatesluggishly, 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 nit rogen generator is provided with a Fujikura o xygenpercent analyzer transmitter, which is an i ntegral part of the purity control system. Theanalyzer has been calibrated and tested by the factory prior to s hipment. Although theanalyzer should not require any additional calibration, a certified oxygen content span gasshould be used to verify the calibration once every month.

On the bottom side of the control panel is a Span / Sample selection valve and a fitting forspan gas input. The pressure of the span gas needs to be regulated to 1.5-bar. The spangas used to check (verify) the analyzer should have an oxygen content around the contractpurity. The nominal acceptable variation between oxygen span gas c ontent and the

analyzer reading is +/- 0.20 (% O2).

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

Documents

3.1 Generon Manual