Installation, Operation & Maintenance Manual
7-2716 SCFH 90-200 PSIG
Installation, Operation & Maintenance Manual This manual contains important safety information and should be made available to all personnel who operate and/or maintain this product. Carefully read this manual before attempting to operate or perform maintenance on this equipment.
Manual No. 65086-1A June 2005 Edition
Table of Contents Section I - General Information Safety Alert Symbols .......................................................................................................... Introduction ........................................................................................................................ Spare Parts Ordering Information ...................................................................................... Servicing Information ......................................................................................................... Limited Warranty ................................................................................................................
1 2 2 2 3
Section II - Description System Description ............................................................................................................. 4 Nitrogen System Description ............................................................................................. 4
Section III - Safety Safety ................................................................................................................................. Breathing ............................................................................................................................ Effects & Symptoms of Decreased oxygen Levels ............................................................. Combustion ........................................................................................................................ Pressure .............................................................................................................................. Electrical ............................................................................................................................. Environmental.....................................................................................................................
6 6 6 7 7 7 7
Section IV - Installation Installation Instructions ....................................................................................................... Location & Setting of Unit .................................................................................................. Inlet Air Quality .................................................................................................................. Condensate Drain Connections ......................................................................................... Nitrogen Piping Connections ............................................................................................. Compressed Air Inlet Connection ...................................................................................... Pre-start Inspection............................................................................................................. Initial Start-up & Adjustment .............................................................................................. Nitrogen Purity Sampling Setup .........................................................................................
8 8 8 8 8 8 9 9 9
Section V - Operating Instructions General Operation ........................................................................................................... Operation of the Unit ....................................................................................................... Analyzer Operation .......................................................................................................... Auto Start/Stop Pilot Valve Operation ............................................................................. Pilot Valve Adjustment Procedure .................................................................................... Flow & Purity Controller Operation ..................................................................................
10 10 10 11 11 12
Section VI - Servicing Routine Maintenance ....................................................................................................... Isolate Unit ....................................................................................................................... Change Filter Elements ~ Premium Filtration – Annually ................................................. Change Carbon ................................................................................................................ Change Filter Elements ~ Standard Filtration – Annually ................................................ Maintenance Schedule .....................................................................................................
13 13 13 14 14 15
Section VII - Spare Parts List Spare Parts Lists................................................................................................................ 16 Quincy Compressor-DEFENDER™
Section I - General Information Safety Alert Symbols
IMPORTANT! Throughout this manual we have identified key hazards. The following symbols identify the level of hazard seriousness:
CAUTION!
DANGER! This symbol identifies immediate hazards which will result in severe personal injury, death or substantial property damage.
WARNING! This symbol identifies hazards or unsafe practices which could result in personal injury, death or substantial property damage.
Identifies hazards or unsafe practices which could result in minor personal injury or property damage.
NOTICE! Identifies important installation, operation or maintenance information which is not hazard related.
Quincy Compressor-DEFENDER™
1
Section I - General Information
NOTICE! Every effort has been taken to ensure complete and correct instructions have been included in this manual, however, possible product updates and changes may have occurred since this printing. Quincy Compressor reserves the right to change specifications without incurring any obligation for equipment previously or subsequently sold. Not responsible for typographical errors.
Introduction This manual describes the installation, operating, and maintenance instructions for the Quincy DEFENDER™ Series nitrogen generator. Please read and be familiar with this manual before attempting to operate the unit. Although this unit is very simple to operate, the user will be working with highpressure gas that must be handled with caution.
2
DANGER! Compressed gas, if handled improperly, can result in serious or fatal injury.
Spare Parts Ordering Information Quincy Compressor maintains replacement parts for all Quincy compressor products. A repair parts list for the Quincy DEFENDER™ can be found in the back of this manual. Order parts from your Authorized Quincy distributor. Use only genuine Quincy replacement parts. Failure to do so may void warranty.
Servicing Information For questions not addressed in this manual concerning the operation, maintenance or repair of the DEFENDER™, please contact your local Quincy Distributor.
Quincy Compressor-DEFENDER™
Section I - General Information
LIMITED WARRANTY
Warranties and Limitation of Liability Quincy Compressor (“the Company”) warrants that it will, at it sole discretion, repair or replace products and/or parts of products sold that have defects in material or workmanship provided: (a) Customer notifies the Company of any claim of defect in material or workmanship within fourteen (14) months from date of shipment from the Company’s factory or twelve (12) months from the date of initial operation of product or installation of a part, whichever occurs first; (b) Customer returns the products or parts with Company authorization, within fifteen (15) days after such authorization, with transportation charges prepaid and shipped pursuant to the Company’s directions; (c) The products or parts are found to be defective because they do not substantially fulfill performance requirements set forth in the Company literature and are manufactured in accordance with the Company’s specifications or government specification when applicable.
This warranty does not extend to products or parts which: (a) have been subject to misuse, neglect, accident, or have been repaired or altered by, or at the direction of the Customer without the Company’s written authorization, or (b) have not been maintained or installed by Customer pursuant to the Company’s guidelines. The Company shall not be liable for any expense, liability or loss incurred by Customer nor for any special, consequential, liquidated or other damage or penalty suffered by Customer or anyone else with respect to any product or part. The foregoing is in lieu of all other warranties and the Company makes no other warranty, expressed or implied, including warranties of merchantability or of fitness for use which extend beyond the above warranty.
Quincy Compressor-DEFENDER™
3
Section II - Description System Description The DEFENDER™ Series utilizes a hollow fiber semi-permeable membrane for the separation of nitrogen and other gases from a compressed air stream.
N2 VENT
O2 CO2 H2O AIR
The membranes divide the air into two streams; one is essentially nitrogen along with argon and traces of other inert gasses. The other stream is oxygen plus carbon dioxide, hydrogen and other trace gases. While fast gases such as oxygen, carbon dioxide and water vapor quickly permeate the membrane surface, most of the nitrogen flows inside the membrane fiber as a separate product stream. Millions of fibers, about the size of a human hair, can be packed into a single module. This provides a very large membrane surface area that efficiently produces large quantities of nitrogen.
AIR
N2
This system is designed to deliver nitrogen plus other inert gases at specified concentration. Because water vapor is being permeated out of the gas stream, the resulting atmospheric dew point is -85°F (65°C) or below.
The system is designed to operate with feed air from a plant compressed air system that has been dried to at least +40°F (4°C) pressure dew point. The membrane modules are protected from hydrocarbons by a highly efficient, six-step filtration system. This system consists of a combination of particulate, coalescing filters and carbon adsorption. The result is air purity with a heavy hydrocarbon carryover at or below 2 parts per billion.
Nitrogen System Description Inside the DEFENDER™ nitrogen generator, the compressed air first comes into contact with the membrane pre-filtration system. On Standard and Premium Filtration Packages, this consists of a coalescing filter (#1) followed by an additional high efficiency coalescing filter (#2). On Standard Filtration Packages, the final pre-filter is a high efficiency absorbing filter (#3) which removes vapors and aerosols. On Premium Filtration Packages, the second coalescing filter is followed by an oversized carbon bed that eliminates any vapor or aerosol that may have been left and a final dust filter (#4), installed after the carbon bed, removes any charcoal dust before the air reaches the membrane bundles.
4
These filters are sized for low system pressure drop (
Installation, Operation & Maintenance Manual This manual contains important safety information and should be made available to all personnel who operate and/or maintain this product. Carefully read this manual before attempting to operate or perform maintenance on this equipment.
Manual No. 65086-1A June 2005 Edition
Table of Contents Section I - General Information Safety Alert Symbols .......................................................................................................... Introduction ........................................................................................................................ Spare Parts Ordering Information ...................................................................................... Servicing Information ......................................................................................................... Limited Warranty ................................................................................................................
1 2 2 2 3
Section II - Description System Description ............................................................................................................. 4 Nitrogen System Description ............................................................................................. 4
Section III - Safety Safety ................................................................................................................................. Breathing ............................................................................................................................ Effects & Symptoms of Decreased oxygen Levels ............................................................. Combustion ........................................................................................................................ Pressure .............................................................................................................................. Electrical ............................................................................................................................. Environmental.....................................................................................................................
6 6 6 7 7 7 7
Section IV - Installation Installation Instructions ....................................................................................................... Location & Setting of Unit .................................................................................................. Inlet Air Quality .................................................................................................................. Condensate Drain Connections ......................................................................................... Nitrogen Piping Connections ............................................................................................. Compressed Air Inlet Connection ...................................................................................... Pre-start Inspection............................................................................................................. Initial Start-up & Adjustment .............................................................................................. Nitrogen Purity Sampling Setup .........................................................................................
8 8 8 8 8 8 9 9 9
Section V - Operating Instructions General Operation ........................................................................................................... Operation of the Unit ....................................................................................................... Analyzer Operation .......................................................................................................... Auto Start/Stop Pilot Valve Operation ............................................................................. Pilot Valve Adjustment Procedure .................................................................................... Flow & Purity Controller Operation ..................................................................................
10 10 10 11 11 12
Section VI - Servicing Routine Maintenance ....................................................................................................... Isolate Unit ....................................................................................................................... Change Filter Elements ~ Premium Filtration – Annually ................................................. Change Carbon ................................................................................................................ Change Filter Elements ~ Standard Filtration – Annually ................................................ Maintenance Schedule .....................................................................................................
13 13 13 14 14 15
Section VII - Spare Parts List Spare Parts Lists................................................................................................................ 16 Quincy Compressor-DEFENDER™
Section I - General Information Safety Alert Symbols
IMPORTANT! Throughout this manual we have identified key hazards. The following symbols identify the level of hazard seriousness:
CAUTION!
DANGER! This symbol identifies immediate hazards which will result in severe personal injury, death or substantial property damage.
WARNING! This symbol identifies hazards or unsafe practices which could result in personal injury, death or substantial property damage.
Identifies hazards or unsafe practices which could result in minor personal injury or property damage.
NOTICE! Identifies important installation, operation or maintenance information which is not hazard related.
Quincy Compressor-DEFENDER™
1
Section I - General Information
NOTICE! Every effort has been taken to ensure complete and correct instructions have been included in this manual, however, possible product updates and changes may have occurred since this printing. Quincy Compressor reserves the right to change specifications without incurring any obligation for equipment previously or subsequently sold. Not responsible for typographical errors.
Introduction This manual describes the installation, operating, and maintenance instructions for the Quincy DEFENDER™ Series nitrogen generator. Please read and be familiar with this manual before attempting to operate the unit. Although this unit is very simple to operate, the user will be working with highpressure gas that must be handled with caution.
2
DANGER! Compressed gas, if handled improperly, can result in serious or fatal injury.
Spare Parts Ordering Information Quincy Compressor maintains replacement parts for all Quincy compressor products. A repair parts list for the Quincy DEFENDER™ can be found in the back of this manual. Order parts from your Authorized Quincy distributor. Use only genuine Quincy replacement parts. Failure to do so may void warranty.
Servicing Information For questions not addressed in this manual concerning the operation, maintenance or repair of the DEFENDER™, please contact your local Quincy Distributor.
Quincy Compressor-DEFENDER™
Section I - General Information
LIMITED WARRANTY
Warranties and Limitation of Liability Quincy Compressor (“the Company”) warrants that it will, at it sole discretion, repair or replace products and/or parts of products sold that have defects in material or workmanship provided: (a) Customer notifies the Company of any claim of defect in material or workmanship within fourteen (14) months from date of shipment from the Company’s factory or twelve (12) months from the date of initial operation of product or installation of a part, whichever occurs first; (b) Customer returns the products or parts with Company authorization, within fifteen (15) days after such authorization, with transportation charges prepaid and shipped pursuant to the Company’s directions; (c) The products or parts are found to be defective because they do not substantially fulfill performance requirements set forth in the Company literature and are manufactured in accordance with the Company’s specifications or government specification when applicable.
This warranty does not extend to products or parts which: (a) have been subject to misuse, neglect, accident, or have been repaired or altered by, or at the direction of the Customer without the Company’s written authorization, or (b) have not been maintained or installed by Customer pursuant to the Company’s guidelines. The Company shall not be liable for any expense, liability or loss incurred by Customer nor for any special, consequential, liquidated or other damage or penalty suffered by Customer or anyone else with respect to any product or part. The foregoing is in lieu of all other warranties and the Company makes no other warranty, expressed or implied, including warranties of merchantability or of fitness for use which extend beyond the above warranty.
Quincy Compressor-DEFENDER™
3
Section II - Description System Description The DEFENDER™ Series utilizes a hollow fiber semi-permeable membrane for the separation of nitrogen and other gases from a compressed air stream.
N2 VENT
O2 CO2 H2O AIR
The membranes divide the air into two streams; one is essentially nitrogen along with argon and traces of other inert gasses. The other stream is oxygen plus carbon dioxide, hydrogen and other trace gases. While fast gases such as oxygen, carbon dioxide and water vapor quickly permeate the membrane surface, most of the nitrogen flows inside the membrane fiber as a separate product stream. Millions of fibers, about the size of a human hair, can be packed into a single module. This provides a very large membrane surface area that efficiently produces large quantities of nitrogen.
AIR
N2
This system is designed to deliver nitrogen plus other inert gases at specified concentration. Because water vapor is being permeated out of the gas stream, the resulting atmospheric dew point is -85°F (65°C) or below.
The system is designed to operate with feed air from a plant compressed air system that has been dried to at least +40°F (4°C) pressure dew point. The membrane modules are protected from hydrocarbons by a highly efficient, six-step filtration system. This system consists of a combination of particulate, coalescing filters and carbon adsorption. The result is air purity with a heavy hydrocarbon carryover at or below 2 parts per billion.
Nitrogen System Description Inside the DEFENDER™ nitrogen generator, the compressed air first comes into contact with the membrane pre-filtration system. On Standard and Premium Filtration Packages, this consists of a coalescing filter (#1) followed by an additional high efficiency coalescing filter (#2). On Standard Filtration Packages, the final pre-filter is a high efficiency absorbing filter (#3) which removes vapors and aerosols. On Premium Filtration Packages, the second coalescing filter is followed by an oversized carbon bed that eliminates any vapor or aerosol that may have been left and a final dust filter (#4), installed after the carbon bed, removes any charcoal dust before the air reaches the membrane bundles.
4
These filters are sized for low system pressure drop (
