Mastering Nitrogen Generation: PGEN-50 Startup Guide

Table of Contents

1. Introduction
2. Verifying Inlet and Outlet Valves
3. Programming the Digital Pressure Switch
4. Testing the Production of the Nitrogen Generator
5. Adjusting the Flow Control Valve
6. Checking the Nitrogen Purity
7. Calibrating the Nitrogen Analyzer
8. Taking Readings from the Nitrogen Generator
9. Checking for Leaks
10. Conclusion

Article

Introduction

Welcome to this guide on commissioning a nitrogen generation system. In this article, we will walk you through the steps to ensure a successful installation and operation of a nitrogen generator. Proper commissioning is essential to maximize the performance and efficiency of the system. We will cover key aspects such as verifying valve positions, programming the pressure switch, testing production, checking purity, and more. Let's dive in!

1. Verifying Inlet and Outlet Valves

Before powering on the nitrogen generator, it is crucial to ensure that both the inlet and outlet valves are in the open position. These valves control the flow of nitrogen through the system. To verify their positions, visually inspect them and ensure they are parallel to the piping. Once confirmed, you can proceed to turn on the nitrogen generator.

2. Programming the Digital Pressure Switch

The digital pressure switch plays a vital role in maintaining desired pressure levels in the nitrogen generator. Before programming, let's understand the numbers displayed on the pressure switch. The prominent number indicates the live pressure in the supply line. The next two numbers are the setpoint (SP) and reset point (RP). SP represents the cutout pressure, while RP is the cut-in pressure for the generator.

To program the pressure switch, press and hold the right button. This will take you to the set SP1 screen. However, instead of starting with SP1, set RP1 first by using the right button to toggle down. To change the setpoint, press the center button, and adjust it to your desired value. Repeat the process for SP1. Once both values are set, lock them in by pressing the center button. Return to the previous screen by pressing the left button. You can go back to the home screen by either waiting for the time delay or simultaneously pressing the left and right buttons.

3. Testing the Production of the Nitrogen Generator

To ensure the nitrogen generator produces enough nitrogen as specified, we need to test its production. Behind the flow meter, there is a ball valve that controls the nitrogen flow. Open this valve and observe the nitrogen coming out. Once the valve is open, close the outlet valve to direct the nitrogen flow through the meter. Depending on the specific model, the target nitrogen production may vary. Referencing the QuickStart guide provided with the nitrogen generator will help ensure the desired flow rate. Adjust the flow control valve if necessary to achieve the intended production level.

4. Adjusting the Flow Control Valve

The flow control valve, also known as a needle valve, regulates the flow of nitrogen in the generator. Increasing the flow will result in higher nitrogen production, but it may lower the nitrogen purity. The key is to strike a balance. Consult the QuickStart guide to determine the optimal nitrogen flow rate for your generator. To adjust the flow, loosen the knob on the flow control valve. Increase or decrease the flow until you reach the desired level. Once set, tighten the knob to maintain the selected flow.

5. Checking the Nitrogen Purity

After allowing the system to run for five to ten minutes to stabilize, it is essential to check the nitrogen purity. This step ensures that the nitrogen generated meets the required specifications. To measure the nitrogen purity, you need to attach a nitrogen analyzer to the sampling port of the generator. However, before taking readings, it is crucial to calibrate the analyzer. Remove the adapter fitting from the back of the unit, expose it to fresh air, and press and hold the right button to initiate the calibration process. Once calibrated, reattach the fitting and use the analyzer to measure the nitrogen purity.

To obtain accurate readings, there must be pressure on the supply line. Open the flow meter valve slightly until the pressure reaches around 20 to 25 pounds. This will enable the nitrogen to flow to the analyzer, allowing you to obtain the nitrogen reading. The target nitrogen purity is generally 98 percent. If the reading falls below the desired level, fine adjustments can be made using the flow control knob. Aim for a nitrogen purity of 98 percent or higher for optimal results.

6. Calibrating the Nitrogen Analyzer

To ensure accurate measurements, regular calibration of the nitrogen analyzer is essential. Calibration ensures that the analyzer accurately reflects the atmospheric concentration of nitrogen. To calibrate the analyzer, remove the adapter fitting at the back of the unit, expose it to fresh air, and press and hold the right button. The screen will display "Kal" to indicate the calibration mode. Introduce fresh air into the analyzer, and it will automatically recalibrate itself to atmospheric concentration. Once calibration is complete, reattach the adapter fitting, and the analyzer will be ready for use.

7. Taking Readings from the Nitrogen Generator

To obtain nitrogen readings from the generator, it is crucial to have pressure in the supply line. Without pressure, there will be no nitrogen flow to the analyzer, resulting in inaccurate readings. To address this, slightly open the flow meter valve to achieve 20 to 25 pounds of pressure in the supply line. Once the pressure is stable, take nitrogen readings using the analyzer. The target nitrogen purity should be 98 percent. If adjustments are required, refer to the flow control knob to fine-tune the nitrogen flow.

8. Checking for Leaks

While the nitrogen generator is checked for leaks before shipment, it is always advisable to perform a double-check upon installation. Inspect all connections inside the generator to ensure there are no leaks. Any leaks can compromise the performance and efficiency of the system. Once you are confident that there are no leaks, you can proceed to put the generator back into production.

9. Conclusion

Commissioning a nitrogen generation system is a critical step in ensuring its optimal performance. By following the steps outlined in this guide, you can verify valve positions, program the pressure switch, test production and purity, calibrate the analyzer, and check for leaks. These steps will help you set up a reliable and efficient nitrogen generator that meets your specific needs. Should you have any further questions or require assistance, please don't hesitate to contact us at [phone number] or visit us online at [website]. Thank you for choosing Engineered Corrosion Solutions.

Highlights

• A comprehensive guide on commissioning a nitrogen generation system
• Step-by-step instructions for verifying valve positions and programming the pressure switch
• Testing nitrogen production and adjusting the flow control valve for optimal performance
• Checking the nitrogen purity using a calibrated analyzer
• Double-checking for any leaks to ensure system integrity
• Ensuring a reliable and efficient nitrogen generator for your specific requirements

FAQs

Q: Why is commissioning a nitrogen generation system important? A: Commissioning ensures that the system is properly installed and functioning optimally, maximizing performance and efficiency.

Q: What are the key steps in commissioning a nitrogen generator? A: The key steps include verifying valve positions, programming the pressure switch, testing production and purity, calibrating the analyzer, and checking for leaks.

Q: What should I do if the nitrogen purity is below the desired level? A: If nitrogen purity falls below the desired level, adjustments can be made using the flow control knob to fine-tune the nitrogen flow.

Q: Can the nitrogen generator be put back into production after commissioning? A: Yes, once all steps, including checking for leaks, have been completed successfully, the nitrogen generator can be put back into production.

Q: What should I do if I have further questions or need assistance? A: If you have any further questions or require assistance, you can contact us at [phone number] or visit our website for more information.