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Service, Maintenance & Troubleshooting Worldwide Manufacturer of PSA Generators Presented by: Peter Knotko Service Engineer Oxymat-Slovakia, s.r.o.

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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

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Complete line

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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

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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

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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.

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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

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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

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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

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Annual maintenance : How to lubricate process valves

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Every 2 years maintenance : Recommended replacement of all process valves.

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Every 2 years maintenance : Top brass filters and O-rings for each column.

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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

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Example when regular or proper maintenance is not performed!

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PSA generator types :

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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

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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

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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

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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.

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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

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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

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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.

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Service check list recommended to use on daily(weekly,anually) basis to avoid failure and prevent possible breakdown.

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www.oxymat.com Questions Oxymat A/S Fasanvej 18-20 DK-3200 Helsinge Denmark