Service, Maintenance & Troubleshooting Worldwide
Manufacturer of PSA Generators Presented by: Peter Knotko Service
Engineer Oxymat-Slovakia, s.r.o.
Slide 2
Preventive maintenance Monitoring the operation of the unit and
Preventive Maintenance (PM) on a regular basis is the best way how
to ensure a long life for your PSA Generator. How often? Daily
Weekly Biannualy Annualy Every 5 years And what is necessary to
service ? Air compressor all PM according to manufacturers manual
Filter elements coal tower incl. Dryer according to manufacturers
manual Drain system - Oxymat manual PSA generator - Oxymat manual
High pressure equipment as RIX, Haug or Bauer compressor according
to manufacturers manual
Slide 3
Complete line
Slide 4
Daily maintenance Daily inspection consist of: Every day simply
observe the operation of the unit Check purity and product
consumption Verify what is the dew point of feed air or displayed
temperature on the refrigeration dryer Make sure that the drain
system is functioning properly press test button !!! Plugging off
the drain systems will cause water/oil carry-over into the
adsorbent vessels, and will cause severe damage to the adsorbent
which is not covered under the manufacturer's warranty
Slide 5
Weekly maintenance Weekly inspection consist of: Do observe
your Air Supply system basis Check operation conditions of the air
compressor (oil level, oil temperature, noise etc...) Check filters
clogging / diferential pressure indicators must not be in red arrea
at any time of operation Air compressor flow diagram
Slide 6
Weekly maintenance plus: Air compressor cleaning procedure of
oil after-cooler + oil level check Air Dryer cleaning procedure of
cooler PSA control cabinet cleaning procedure of dust filter Clean
procedure With an air jet (max. 2 bar / 30 psig) blowing from
inside towards outside blow out the dust Repeat this operation
blowing in the opposite way !!! Be careful not to damage the
aluminium fins of the cooling package.
Slide 7
Biannualy maintenance The biannualy inspection of the PSA unit
consists of: 1.Service of air compressor according to supplier
manual (filters and oil replacement, etc...) 2.Service of air dryer
according to supplier manual (drain and strainer cleaning, etc...)
3.Replace pre-filter element 1 m and micro-filter element 0,01
m
Slide 8
Slide 9
Annual maintenance The Annual PM of the unit consist from the
points of biannualy PM, plus: 1.Coal-Tower PM: Replacement of coal,
oil indicator and micro- filter element is recommended 2.Air Tank
PM: Inspection of drain system Each non-return valve has to be
cleaned and checked for damage (replace if needed) Axial drain
valve has to be cleaned and properly re-greased 3. Inline filter
for gas analyzer:. Replacement of inline filter Coal tower Axial
drain valve Oil indicator and micro- filter Non-return valve Air
tank
Slide 10
Annual maintenance 3. PM of PSA generator : all system has to
be inspected for function, damage, leakage (solenoid valve block,
hose/pipe connection, safety valves, etc...) process VIP valves has
to be cleaned and properly re-greased (for O 2 application oxygen
grease has to be used) strainer and main regulator has to be
cleaned gas analyzer has to be checked with calibration gas and
calibrated if needed 4. PM of receiver tank: active-carbon and
bacterial/sterile filter elements has to be replaced Omed upgrade
filters placed behind the receiver tank Omal axial VIP valve
Slide 11
Annual maintenance : How to lubricate process valves
Slide 12
Every 2 years maintenance : Recommended replacement of all
process valves.
Slide 13
Every 2 years maintenance : Top brass filters and O-rings for
each column.
Slide 14
Every 3 years maintenance : Recommended replacement parts :
HDMI valve block. Inlet pressure regulator. O2 Analyzer. OXY Z -
zirconia cell OXY F - fuel cell OXY FS - fuel cell (ppm) OXY P -
paramagnetic
Slide 15
Example when regular or proper maintenance is not
performed!
Slide 16
PSA generator types :
Slide 17
5 years maintenance every 40 000 wh PM of PSA generator every 5
years consist of: Molecular sieve replacement is recommended Top
brass filter replacement Vessel inspection !!! Be carefull not to
damage the bottom stainless steel filters during moleculare sieve
replacement Top brass filter Bottom stainless steel filter
Slide 18
Replacement of filter elements Poor quality of compressed air
could affect the operation of your PSA generator. The filter
element(s) supplied with each unit have been selected by
manufacturer based upon the units feed air requirements.
Replacement of filter element step by step: Close the air inlet for
filter. Carefully remove 4/6 mm tube below filter. Remove filter
element by counterclockwise turn. Remove one-way valve from old
element and mount it to the new one. Install new element with
one-way valve. Plug-in the 4/6mm tube to filter element. Perform
leak test. filterperiod [y]period [h] 1m1/2 year4,000 0.01m1/2
year4,000 active carbon1 year8,000 bacterial/sterile1 year8,000
Replacement of active coal in coal tower: Once per year
(recommended) Otherwise: when oil indicator gets red
Slide 19
Safety valves Visual inspect safety relief valves and other
safety devices for dirt or damage. If there is debris in the valve
seat, scavenge the valve as follows: 1.Pressurize vessel and loosen
the top screw one turn. This should remove debris from the valve.
2.Retighten the top screw
Slide 20
Pressure vessel maintenance External and internal inspection of
vessels and other pressurized equipment must be carried out
according to local regulations. When your Oxymat or Nitromat
Generator is installed and operated according to the prescribed
conditions, it is not needed to do internal inspection of generator
vessels on regular basis If molecular sieve is replaced inspect
vessels for corrosion or other damage (replace if needed) Refer to
molecular sieve material safety data sheet for handling and safety
instructions of sieve. Receiver vessel should be inspected
internally every 4 years or according to local regulations.
Slide 21
Leak test procedure 1.Safely shut down the application /
consumption 2.Let the plant run in auto mode, until generator will
automatically stop by pressure. 3.Close the feed air supply. 4.If
fitted with purity monitoring probe close of the pressure reduction
valve on probe inlet. 5.Read and note the pressure P1 in oxygen
receiver, column 1, column 2, coal tower and feed air tank. 6.Let
the plant stand still (rest) and isolated in pressurized condition
for an hour. After an hour read and note the pressure P2 in oxygen
receiver, column 1, column 2 and feed air tank. Then determine an
eventually pressure drop as the difference between P1 and P2 for
each component. The Leak Test is OK, if the pressure drop after one
hour is less than 0.1 bar. If a leak is detected, a suitable device
must be used to locate the leaking component (leak tester in spray
or soap water) If closed, reset the pressure reduction valve on
probe inlet
Slide 22
Required tools Safety warning: Always wear personal protection
equipment for ears, hands, eyes etc... Installation: Plastic tubes
4/6/8 mm spare valves, regulator pliers, screwdriver, spanner, etc.
Connecting fittings for tubes reductions spare indicators PC with
installed software Design Review Certificate For valve lubrication:
Paint brush Grease (for O 2 application oxygen grease has to be
used-Kluebertemp YV 93- 92),N 2 application SuperLube. 2 spanners
(according to size of the valve). spare valve For filter element
replacement: spanner of proper size belt pliers PTFE tape filter
element Vessel inspection: spanner of proper size battery
light
Slide 23
Troubleshooting Most common operation failure is insufficient
product purity due to: 1.Generator is overflowed ! 2.Low quality of
feed air ! 3.Valve block error ! 4.Process valve error ! 5.Gas
analyzer error or misreading ! Solution: 1.Check system for
leaks,fastenings and product consumption. 2.Check filters, drain
system, air compressor temperature, dryer temperature, ambient air
temperature. 3.Check air signals from solenoid valve block to
process valves (replace if needed). 4.Re-grease or replace valve if
needed. 5.Calibration or replacement if needed. 6.Otherwise contact
OXYMAT A/S.
Slide 24
Service check list recommended to use on daily(weekly,anually)
basis to avoid failure and prevent possible breakdown.