Instruction

1 General information

Commissioning instruction NGP+

Applicable to : NGP8+ to NGP100+

Safety Instructions : General

Special Tools : n/a

Consumables : n/a

Printed Matter Number : 2946 2002 00

2 Document overview

This document describes the following:

1 General information ........................................................................................................................................................... 1

2 Document overview ........................................................................................................................................................... 1

3 Document Information and History .................................................................................................................................... 1

4 Safety first ......................................................................................................................................................................... 2

5 Safety Precautions ............................................................................................................................................................ 3

6 Installation ......................................................................................................................................................................... 4

7 Installation requirements ................................................................................................................................................... 5

8 Nitrogen generator connections ........................................................................................................................................ 6

9 Voltage selection ............................................................................................................................................................... 7

10 Flow calculation ................................................................................................................................................................. 8

10.1 Correction factors ....................................................................................................................................................... 8

10.2 Example ..................................................................................................................................................................... 8
11 Start-up procedure ............................................................................................................................................................ 9

12 Commissioning sheet ...................................................................................................................................................... 16

3 Document Information and History

Edition Date Description Author

00 14/03/2016 First Edition Hannes Vertommen

01 15/09/2016 Info on purity set point, flow calculation and voltage added Hannes Vertommen
02 22/02/2017 Info for gen2 (step 11) added and info for FF compressors Hannes Vertommen

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4 Safety first

Identify the hazard Evaluate the risk

Take action Start work safely

KNOW THE SAFETY KNOW THE SAFETY

RULES OF YOUR INSTRUCTIONS OF
CUSTOMER YOUR MACHINE

LOCK OUT / TAG OUT

PERSONAL PROTECTION KEEPS YOU SAFE TAKE AWAY THE RISKS

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5 Safety Precautions

Please follow strictly all the safety precautions as per mentioned in the instruction book and as per local regulation as
applicable.

Nitrogen generators produce high purity nitrogen with oxygen enriched waste air.

The standard oxygen concentration in the air around us is equal to 20,9 %, increased or decreased oxygen concentrations
pose specific risk as indicated in the below table:

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6 Installation

The installation must be done with the following components, in the following order:

1 Compressor with integrated refrigerant dryer

2 UD+ filter

3 QDT filter

4 PDp filter inlet

5 Air receiver

6 Nitrogen generator

7 Nitrogen buffer vessel

8 PDp filter outlet (in line C ‘from N2 buffer’)

9 Needle valve

1 2 3 4 5 6 7

A
E

B
C

A D

1 2 3 4 5 7 8 6 9

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7 Installation requirements

Proper ventilation of the generator room is required. If natural ventilation is not sufficient, at least 4 air changes/hour are
required.
Natural ventilation can be sufficient if:

 Ventilation openings have an area bigger than

1/100 of the room’s floor area

 Ventilation openings are placed diagonally

opposite each other and aren’t blocked

A room oxygen level detection with an audible/visual alarm is advisable. When working in rooms where the oxygen content
can rise to a dangerous level, a continuous measurement system is necessary.
Alarm levels should be set below 19.5% and above 22.5%.
Put the measuring equipment in the working area and near to the worker. Personal oxygen alarms are always advised when
working around oxygen generators.

If exposed to an oxygen enriched atmosphere, make sure to ventilate your clothing for at least 15 minutes in normal
atmosphere. Do not come near open flames or do not smoke.

The generator is delivered with label 1622 5408 03. This green label can be used to stick on the Nitrogen vessel to
differentiate with the compressed air vessel.

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8 Nitrogen generator connections

The following connections are present on the Nitrogen generator:

Following sizes of filters, vessels and piping need to be respected:

NGP+ # 8 – 12 15 – 20 25 – 35 40 – 50 60 – 70 85 100

UD+ filter 2

QDT filter 3
To be verified with NGP 8-100+ product sizing calculator
PDp filter in 4

PDp filter out 8

Air and Nitrogen buffer vessel 5&7 150 L 280 L 500 L 1000 L 1000 L 1500 L 2000 L

N2 outlet pipe diameter E 1/2” 1/2” 3/4” 1” 1” 1” 1”

Air piping diameter A&B 1/2” 3/4” 1” 1” 1 1/4” 1 1/2” 1 1/2”

Connection to and from

C&D 1/2” 3/4” 1” 1” 1 1/4” 1 1/2” 1 1/2”
N2 buffer vessel

Exhaust connection <3m 1x DN70 1x DN70 1x DN70 1x DN70 2x DN70 2x DN70 2x DN70

Exhaust connection >3m 1x DN100 1x DN100 1x DN100 1x DN100 2x DN100 2x DN100 2x DN100

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9 Voltage selection

The generator is designed to work on 115V/60Hz and 230V/50Hz. Ex-factory, the generator is wired to operate at 230V.

If the generator needs to work at 115V, the wiring of the transformer inside the cubicle needs to be changed.

Transformer

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10 Flow calculation

Based on inlet air pressure and temperature, the performance of the CMS adsorbant inside the generator will change.
Increased temperatures will result in reduced capacity, increased pressure in improved capacity.

In order to have the generator running in optimal conditions, we need to make sure that the customer doesn’t consume more
nitrogen from the nitrogen receiver than what the generator is capable to deliver. This can be achieved by limiting the flow
after the nitrogen receiver by means of a needle valve.

To regulate this consumption, the maximum capacity of the generator needs to be known, this can be calculated with the
AML data and correction factors.

Note: refer to the business portal for the latest AML data

10.1 Correction factors

P
4 4.5 5 5.5 6 6.5 7 7.5 8 8.5 9 9.5 10 10.5 11 11.5 12 12.5 13
[BAR]

% 0,56 0,63 0,71 0,77 0,85 0,93 1 1,07 1,13 1,19 1,25 1,3 1,35 1,4 1,45 1,5 1,54 1,58 1,61

PPM 0,52 0,6 0,67 0,75 0,83 0,91 1 1,04 1,09 1,11 1,13 1,15 1,16 1,17 1,18 1,2 1,21 1,23 1,25

T
5 10 15 20 25 30 35 40 45 50 55 60
[°C]

% 1 1 1 1 0,98 0,95 0,92 0,88 0,83 0,78 0,72 0,66

PPM 1,02 1,02 1 1 0,96 0,93 0,88 0,83 0,78 0,72 0,67 0,62

10.2 Example
NGP35+ | Purity 99.5% | Working pressure: 11.5 bar | Inlet air temperature 40°C

In this case the generator is capable of delivering 50.37m³/h so we need to make sure this is the maximum flow that can be
consumed by the customer by limiting the flow with a needle valve.

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11 Start-up procedure

# Action Information

1 Make sure that all the ball valves Closed

between the generator and the
nitrogen buffer vessel are
opened.

The ball valve after the

compressor must be closed.

The outlet consumption valve

Closed
must be closed.

2 The following ball valves in the

generator must be closed:
 BA03
 BA04
 BA05 (if option outlet
PDP is not selected) BA04 – Nitrogen sample
ball valve to Oxygen
 BA07 sensor

BA07 – Nitrogen sample

ball valve

BA05 – optional outlet

PDP sensor ball valve

BA03 – inlet air flushing

ball valve

BA04 detail:

BA04 – Nitrogen sample

ball valve to Oxygen
sensor

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 3 The following ball valves in the
generator must be opened:
 BA01
 BA02
 BA05 (if option outlet BA01 and BA02
PDP is selected)
 BA06
BA05 – optional outlet
PDP sensor ball valve

BA06 – Nitrogen purity

ball valve

BA01 and BA02 detail:

BA02 – PDP ball valve

BA01 – Pilot air ball

valve (to pneumatic
solenoids)

4 Disable energy efficient mode

for the refrigerant dryer (ID or
FD).

NOTE: This mode can cause an

increase of outlet dew point and a
shutdown of the generator.

5 In case of a stand-alone
refrigerant dryer: switch on the
dryer 10 minutes in advance in
order to cool down the dryer.

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 6 Start the compressor.

In case of an integrated
refrigerant dryer, start the
compressor with the outlet ball
valve closed for 10minutes so
the dryer has time to cool down.

7 Slowly open the valve after the Closed

compressor for max 25%. The
inlet vessel will gradually fill with
dry, compressed air.
For machines with integrated
dryer this is extremely
important. If the valve is
opened above 25% at initial
¼ Open
start, the dryer will not be
capable of providing a good
dew point.

8 Enter the requested nitrogen

purity in the controller:

Menu/Settings/Generator/
Regulation/Purity

The generator will use this

setting to calculate what the
generator capacity is.

Based on purity set point, inlet

pressure and inlet temperature,
the generator will display how
much nitrogen flow he can
deliver at the current conditions.
The generator itself is not
capable of regulating the
purity.
Based on the flow provided to
the generator or by the pressure
difference between air and
nitrogen vessel pressure, the
purity will be influenced.
High flow through the CMS
adsorbent results in low purity.
Low flow through the CMS
results in high purity.

NOTE:
There will be a warning when purity
drops below purity set point and
above minimum purity.
During flushing, the generator keeps
on running but the vessel is flushed
over a nozzle until the purity is again
above minimum purity setting.

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 9 Enter the minimum required
nitrogen purity in controller:

Menu/Settings/Generator
/Regulation/Minimum Purity

The controller will use this

setting to flush the nitrogen
buffer vessel to the minimum
purity by opening valve 11.

NOTE: During flushing, the

consumer valve V10 is closed and
no nitrogen is available at the outlet.

V11 – Low purity

exhaust valve

V10 – Consumer valve

10 Make sure the pilot air pressure

regulator PR03 is set to a
pressure of 6 bar(g) or 85 psi(g).
PR03 – Pressure
regulator pilot air

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 11 Check the inlet dew point on the
controller display. If this value
exceeds 5°C, the air receiver
needs to be flushed until a value
below 5°C is reached.

To flush the air receiver, make

sure the refrigerant dryer is
switched on. Continue by slowly
opening the inlet air flushing ball
valve BA03. Have the ball valve
opened so that the compressor
runs at a low speed and the
refrigerant dryer can lower the
PDP.

Close BA03 when the PDP is

lower than 5°C.
BA03 – inlet flushing
ball valve

NOTE: The PDP sensor can require

up to 10 minutes to indicate the
correct value.

11 On software generation 2
bis (NGP+ from API205450,
produced since 10/2016),
manual ball valve BA03 is
replaced with solenoid valve
Y14.

This solenoid will automatically

open when the inlet dew point is
too high, flushing the wet air
through the silencer.
When the dew point is back ok,
the valve will close.

Y14 – inlet flushing ball

valve

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 12 Start the generator.

During start-up, the nitrogen

buffer vessel is filled through
OR04 – Filling orifice
restricted orifice OR04 until the
pressure difference between the
air tank and nitrogen buffer
vessel is less than 0.5 bar.

During flushing, the nitrogen

buffer vessel is flushed through
orifice OR06 by opening V11,
until the purity in the vessel is
equal to the min. purity setting.
Flushing can take up to 2 hours
for %-generators and up to 6 OR06 – low purity
hours for ppm-generators. exhaust nozzle

After flushing, the generator is

ready for nitrogen production.
V11 – Low purity
exhaust valve

13 Regulate the outlet nitrogen

pressure with pressure regulator
PR01 to the requested nitrogen
pressure.

PR01 – N2 pressure
regulator

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 14 Make sure the outlet flow
(measured by FT01) does not
exceed the nominal flow of the
nitrogen generator.

If the purity drops below the

minimum purity setting, the
outlet flow is cut off to enable
FT01 – N2 flow meter
flushing of the nitrogen vessel
(by opening V11).

The flow can be regulated with

the needle valve (component 9):

See chapter Flow calculation for

the nominal flow of the
generator.

Based on the purity set point,

measured inlet pressure and
temperature, the generator will
display the current capacity in
the screen capacity control.
(Menu – settings – generator –
capacity control)
The flow consumption may not
exceed the generator capacity
value.

15 Verify time and date in the

Settings menu:

Menu/Settings/General/Time
Format dd/mm/yy and hh:mm:ss

16 Set the flow alarm warning 10%

above the nominal flow of the
generator, calculated in chapter
Flow calculation.
Menu – Warnings - Flow

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 17 Perform a complete leak test of
the installation. The smallest
leak in the nitrogen installation
can cause the generator to
malfunction.
 Check both the generator and the piping network for leaks.
 Fill the nitrogen buffer tank to the nominal working pressure.
 Stop the generator and wait for one hour while monitoring the pressure in the
adsorbent with the nitrogen outlet valve (downstream N2 buffer vessel) closed.
 If a pressure drop of more than 100 mbar shows after one hour, leaks are
present and have to be fixed before taking the generator in operation.

18 Set the generator in automatic

operation mode. This enables
Standby and Capacity control
modes.

In Standby mode, towers A and

B are pressure less. The
generator will start producing
nitrogen flow consumption from
the nitrogen receiver is detected.

12 Commissioning sheet

To write down all parameters and during during the commissioning, excel sheet 246 2003 00 can be used.

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