Nitrogen Generator Maintenance & Troubleshooting Guide

A nitrogen generator will last for years without any problems, but only if it is well cared for. This is the hard way for many factories. The product quality of a packaging company can suddenly deteriorate, but a problem can be identified: the nitrogen purity has decreased, and the reason for this can be simply a filter change that is not done. Sometimes, the little maintenance work that is done makes all the difference. When, what, and how to determine the early warning signs can save time, money, and unplanned shutdowns. Here's an introductory guide to help you keep your Nitrogen generator working as it should, and help you with some of the most common problems.

Daily Inspection and Maintenance Item List for Nitrogen Generators

The daily checks are not too time consuming, but rather can help prevent the majority of the issues that can cause a system to be turned off. Check the pressure of the air compressor and the nitrogen generator first. When the numbers are lower or greater than usual, it's frequently the initial indication that something is amiss. One day a small food packaging plant operator noticed a slight pressure drop while performing a routine inspection. It was a loose connection that could have resulted in a full stop later on in the day.Drain any collected water from air filters and air tanks. Moisture is a major enemy of a Nitrogen machine . Water accumulation can cause damages to the internal parts and decrease the efficiency. This step is even more critical in humid conditions and in such instances should be repeated more than once daily.Hear the machine while it is operating. Any unusual noises, such as hissing, knocking or irregular cycling, indicate the presence of leaks or issues with the valves. Many technicians use sound as an early warning system because it can alert them to problems prior to the alarms.Additionally look for air leaks around pipes and fittings. A soap water test can be used to detect small leaks. A small leak can add up, and over time reduce system performance.Lastly, check the running times and alarms (if there are any). A log of the simplest type helps to notice trends and change. These are simple daily operations, but they can be the key to a stable and reliable Industrial nitrogen generator .

Maintenance Points of Compressed Air Pre-Treatment System

The compressed air pre-treatment system does much of the work in advance of air entering the nitrogen generator. Without proper maintenance of this component, the entire system will suffer. This is often not where many nitrogen problems begin, but rather in a nitrogen generator.Begin with the air filters. These purify the compressed air from dust, oil and other particles. Measure the pressure loss across each filter. If the drop is greater than usual, it means the filter is probably clogged and needs to be cleaned or replaced. A blocked filter in one workshop was unnoticed for weeks until a member of the workshop's users discovered the issue. The generator continued to operate, but the purity gradually decreased, resulting in an impact on production.Then, pay keen attention to the air dryer. It is either refrigerated or desiccant and its function is to deplete moisture. When the dryer is not working correctly, water will pass through the dryer and also ruin the carbon molecular sieves within the generator. Monitor the dew point reading on a daily basis. Decreasing air temperature will not be an indication that the dryer needs attention, but increasing dew point will. Also, check if the automatic drainage is functioning. When it gets stuck water will accumulate rapidly.If your system is oil lubricated, check the oil separator. Oil carryover may cover the inside surfaces and lower the adsorption efficiency. Inspect for oil contamination in downstream lines and change out separator elements if required.Check all points in the system where the drains can be opened. Manual and automatic drains should be releasing the water properly. While blocked drains are a simple job, they could be a cause for greater problems with moisture if neglected.Lastly, inspect the pipeline for leaks, rust or loose parts while you are walking along it. The principles of a dependable supply of nitrogen are clean, dry and stable air. Daily maintenance of the pre-treatment system can prevent larger and more costly problems in the future.

Causes and Solutions for Nitrogen Purity Reduction

A reduction in the purity of nitrogen typically doesn't occur at once. In many instances, the change is slow and gradual, and not noticed initially. One food packaging line ran for days with one or two points lower than the standard in purity, only realizing when the product shelf life began to decrease. Moisture can be a common problem. Water vapour flows through the air dryer, which will impact the carbon molecular sieves if the air dryer isn't working properly. This decreases their capacity to pump oxygen out of the body and to remove nitrogen. Look for a dew point increase or drains that are constantly damp as indications of a dryer issue, and repair or replace any damaged components immediately.The other is that of ageing or contaminated carbon molecular sieves. These materials become less effective with time particularly if oil or water have been introduced. If the purity continues to decline despite efforts to address air quality problems, it might be time to replace the sieves. This is normal and as a result of long term use.Purity is also decreased by air leaks. The adsorption towers are disturbed by the introduction of external air. A small leak can make a big difference. Test for leaks and seal any leaks as soon as possible.Inspect valves and control systems as well. When valves are not switching between towers the adsorption process is unstable. This may result in separation incomplete and reduced purity. Check for irregular switching noises or for delayed cycles.

Replacement Cycle and Precautions for Carbon Molecular Sieves

If nitrogen purity begins to decline, or the level is known to drop over time, after checking all filters, dryers and valves, one of the largest indicators is that the issue lies with the replacement. A chemical plant used to be making adjustments to its settings for weeks and a chemical engineer thought it was a control problem. The final issue turned out to be the ageing molecular sieves which lost their performance.Increased air use for the same amount of nitrogen is another indicator of trouble. If the system begins to use more energy or more compressed air to achieve the same output then the sieves may be losing capacity.Cleanliness is of utmost importance during replacement of carbon molecular sieves. Inside the tower, any dust, oil or moisture will reduce the life of the new material. The inside of the adsorption vessel must be cleaned and completely dried out prior to filling. Any trace of oil residual can have an immediate impact on performance.