Holtec NitroBreezeTM Series

”HNBS”- PSA NITROGEN GENERATOR

Operating and Maintenance Manual

Rev. No.: 9
28 July 2020

By
Holtec Gas Systems, LLC
979 Portwest Dr. Suite 101, Saint Charles, MO 63303, USA
Phone: 1-636-757-3920
Web site: www.holtecllc.com E-mail: [email protected]

PROPRIETARY NOTICE: All information herein is the property of Holtec Gas Systems, LLC (Holtec), and
must be kept confidential and not be disclosed without Holtec’s agreement nor used, in whole or in part, in
manufacturing or selling gas separation equipment without the express written permission of Holtec. Holtec
authorizes the necessary and reasonable use of this document, and information herein, solely for the
evaluation, installation, operation, and maintenance of Holtec’s nitrogen generation systems. No other use is
authorized.
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Table of Contents
1 Safety Precautions and Operating Limits ................................................... 3
2 Introduction ................................................................................................ 4
3 Technical Specification .............................................................................. 5
3.1 Process Description / Operation Sequence................................................ 5
3.2 PSA HMI Operation .................................................................................... 6
3.3 System Performance& Physical Characteristics ...................................... 15
3.4 Connections and recommended air and nitrogen receiver sizes .............. 16
3.5 Other Utility Consumption ........................................................................ 17
4 Installation, Piping and Tie-in Points ........................................................ 17
4.1 Lifting and Installation .............................................................................. 17
4.2 Piping and Tie-in Points ........................................................................... 18
5 Start-up Procedure ................................................................................... 19
5.1 Initial Start-up ........................................................................................... 19
5.2 Normal Start-up ........................................................................................ 21
5.3 Continuous automatic operation............................................................... 21
5.4 Turndown operation (EnergyAssistant) .................................................... 22
6 Shutdown ................................................................................................. 22
6.1 Manual shutdown ..................................................................................... 22
6.2 Long term shutdown ................................................................................. 22
7 Inspection and Maintenance .................................................................... 23
7.1 Operation, Inspection and Maintenance Check List ................................. 23
7.2 Instrument Air Filter Replacement ............................................................ 23
7.3 Oxygen Analyzer ...................................................................................... 24
7.4 Switching Valve or Solenoid Replacement ............................................... 24
7.5 Lubrication Recommendations ................................................................. 25
7.6 Special Tools............................................................................................ 25
7.7 Clearances ............................................................................................... 25
8 Troubleshooting ....................................................................................... 25
9 Warranty................................................................................................... 26
10 Drawings and Manufacturers’ Catalogues ............................................... 27
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1 Safety Precautions and Operating Limits

Caution: Nitrogen is an inert gas that can and will cause asphyxiation or
oxygen deprivation if leaking into an enclosed area. It is therefore important
to check nitrogen tanks and piping for leaks and always vent nitrogen outside
the building or to a well-ventilated area.

The waste air stream from the nitrogen generator is enriched in oxygen
content (average is typically 25 - 35%). Local fire-code may require that this
gas be piped outside the building. Check with local authorities to find out if
this is required, particularly if the ventilation is insufficient. It is not harmful to
breathe oxygen-enriched air.

IMPORTANT: Do not install any valves or restrictions in the vent / waste-

gas line since the waste-gas line must remain at atmospheric pressure
at all times for the system to function properly.

The nitrogen generator will start and stop automatically when turned to “Auto”,
and run continuously when turned to “Manual”.

The nitrogen generator has to be connected to a grounded outlet rated for min
2 amps and max 10 amps. Before opening the control panel or doing any
electrical/wiring work, always disconnect the power supply with facility breaker
or disconnect switch. The power on/off switch located on the right side of the
nitrogen generator control panel removes power to everything inside except
the incoming terminal blocks and power switch terminals.

The nitrogen generator adsorber vessels are each equipped with a Safety
Relief Valve set to 165 psig / 11.3 barg (setpoint may vary on custom orders).
This valve is sized to protect the system from over pressurization due to
external fire. Note that the MAWP of the absorbers may be higher than this.
Considerations for sizing the relief valve were derived from the American
Petroleum Institute (API) standards. The Owner/user is responsible to ensure
that the upstream air source (compressor) has a relief device and/or other
means to ensure pressure of air feeding the nitrogen generator can never
exceed 165 psig.

Always depressurize lines and components before performing maintenance

or repair work that require opening to the atmosphere.

WARNING: If maintenance will be performed on switching valves, or

any items connected to the adsorber vessels, open the manual ball
valves (V-113 & V-114) in the bottom pipe sections (gases will desorb
from the Carbon Molecular Sieve for many hours, so even if the adsorber
pressure has been brought to zero once, the pressure will build up again
by itself if the ball valves and vent valves are closed, which could lead
to dangerous situations). Isolate air and nitrogen lines and depressurize
as needed.
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The nitrogen generator is designed to produce Nitrogen using dry, particle

and oil free compressed air. See section 3.4 for specification.

Limitations:

 Operating a Holtec nitrogen generator without using an operating and

effective upstream dryer, to achieve a dew point of max 38 °F / 3 °C,
will invalidate any warranty given for this equipment.
 Failure to use proper filtration and replace filter cartridges in the
compressed air filters, on an annual basis as a minimum, will invalidate
any guarantees given for this equipment.
 Failure to ensure that the compressed air being fed to the nitrogen
generator remains oil free (<0.003 ppm oil) before the activated carbon
filter will invalidate any guarantees given for this equipment.
 Restriction orifices RO-101, 105, & 106 have been installed at the
factory to limit maximum flow for the protection of the adsorber beds.
Removal or tampering with these orifices without factory authorization
may result in rapid equalization or pressurization and excessive
velocities across the adsorber beds, causing the Carbon Molecular
Sieve pellets to turn into dust. This mode of operation can result in
catastrophic failure and invalidates any warranties given for this
equipment.
 Failure to comply with the recommended procedures set out in this
manual and attached Manufacturers’ Catalogues invalidates any
warranty or performance guarantee given for this equipment.

This manual is designed to be read in conjunction with the P&ID and

manufacturers’ catalogues included in Section 10.

2 Introduction

The Holtec HNBS is a skid-mounted Pressure Swing Adsorption (PSA) type

Nitrogen Generation System. The Generator includes adsorber vessels filled
with Carbon Molecular Sieve (CMS), switching valves, manual valves,
instrumentation, oxygen analyzer with sampling system, and automated PLC
and HMI control system with digital display and alarms.

The supplied equipment and controls are suitable for indoors operation in a
non-hazardous environment. A heated control panel can be offered as an
option for operation in below freezing conditions under a roof.

Scheduled maintenance requirements are minimal, limited to replacing the air

supply and nitrogen product filters (optional/by others) once every 6 – 12
months. Your nitrogen generator will provide you with many years of reliable
service as long as the compressed feed air quality remains as specified in this
manual.
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3 Technical Specification
3.1 Process Description / Operation Sequence

The Nitrogen Generator is comprised of two adsorber vessels filled

with CMS, together with a valve & piping assembly. Dry, clean, pre-
filtered, oil-free, compressed air (78% nitrogen, 21% oxygen, <1%
argon) is supplied to one of the adsorber beds where oxygen and
water vapor is adsorbed faster than nitrogen into the pore structure of
the CMS, thus increasing the nitrogen concentration of the product gas
stream exiting the bed. This product flows out of the top of the
adsorber bed, through a flow control valve before entering a nitrogen
receiver.

A small portion of the intermediate product is directed through an

Typical PSA Diagram interconnecting line containing a restriction orifice and flows back
through the other adsorber sieve bed and out through the exhaust line
at atmospheric pressure. This action purges the CMS of oxygen, and
prepares the bed for the next cycle. One adsorber bed is operated for a set
time period (in the range of one to two minutes) before the next cycle starts.
The beds switch roles; the first bed is de-pressurized and purged while the
second bed produces nitrogen product. The active bed will remain on-line
until just prior to becoming saturated with oxygen. When the cycle is
completed, the PLC controller will switch the valves in the system to
depressurize and exhaust the saturated bed, and pressurize the fresh
adsorber bed. This allows a continuous flow of nitrogen gas from the unit for
as long as the unit is in operation.

Oxygen enriched waste gas is piped to atmosphere through a silencer.

The dry nitrogen product stream, with the specified max O2 content (see
section 3.4), monitored continuously by an oxygen analyzer, enters a
downstream product receiver tank before it is filtered (optional) and supplied
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to the consumer. Note that the nitrogen generator can be operated at lower
flow rates to produce nitrogen with higher purity.

The nitrogen generator includes a pressure transducer that will turn the
nitrogen generator to standby mode if nitrogen usage falls. The pressure
settings for standby/restart are programmable from the HMI display. The
system will automatically start again when the pressure drops to the restart
set point.

3.2 PSA HMI Operation

The HMI provides the means of control and informational feedback to and
from the internal PLC that operates the PSA. On power up, the screen
defaults to the Home Screen. There are screens which are Operator
accessible and additional screens which are Engineering accessible which
can be accessed only after a correct password is entered.
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Home Screen (Operator accessible):

O2 Purity (% or PPM) – shows the amount of Oxygen in the product

Nitrogen.
N2 Pressure (psig) – shows the product Nitrogen pressure.
N2 HI Press. (psig) – Only displayed when booster skid connected. Displays
Nitrogen pressure in the high-pressure tank on the skid.
The circular valve indicators appear when the system is in Run status and
turn red independently when the corresponding valve is Open.
The boxed number between vessels indicates current time in seconds for
production cycles.
System Status indicator (“Stopped” above) – shows the current system
status, either: “Stopped”, “Running”, “Stopping”, “Standby” or “Venting”.
F1 Run – Press to Start the process of Nitrogen generation and sequence to
a run cycle.
F2 Stop – Press to Stop the system. System waits until the process reaches
end of sequence and then stops the run cycle.
F3 Vent – Press to open the vessel exhaust valves. Note that the system
has to be in a "stopped" sate for vent operation. (Will not activate in
"stopping" state.). Be sure to deactivate as soon as finished!
F4 Reset – Press to Reset the nitrogen generation process and stop all
sequences.
Menu – Press to change to the Menu screen.
Automatic – Press to toggle between Manual and Automatic operation. Box
text will indicate which operation mode it is currently in.
Trend – Press to change to the Trend graphing screen.
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Local – Only displayed when remote connections are set up. Prevents
system from starting remotely if in local mode.
TD OFF – Only displayed on systems with EnergyAssistant set up. Turns the
feature on and off.
Filter Maintenance Required – Appears when filters need to be inspected
or changed. Press to go to the Filter Maintenance screen.

Menu Screen (Operator accessible):

Setpoints – Press to go to the Setpoints screen.

Filter Maintenance – Press to change to the Filter Maintenance screen.
GotoConfig – Visible only with correct password entered. Press to exit the
application and go to the terminal configuration mode screen. To return to the
application, Run the appropriate file, typically PV800_PSA_HMI.
Timers – Visible only with correct password entered. Press to change to the
Timers screen.
Password Login – Touch the adjacent blue box to enter password to gain
access to the Timer Setpoints screen and GotoConfig. Initial value for
Password is: 1234
Log Out – Press to log out and block access to Timers screen.
Change Password – Visible only with correct password entered. Touch the
adjacent blue box to enter a new user password.
Runtime Hours – Indicates the number of hours the system has operated.
Home – Press to return to the Home screen.
Previous – Press to return to the previous screen.
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Setpoints Screen (Operator accessible):

Each individual setpoint can be accessed and changed by touching the

adjacent blue box showing the current value.

High Oxygen – Indicates the setpoint for alarm condition.

Standby Pressure – Indicates the setpoint for initiating Standby.
Reset Pressure – Indicates the setpoint for the pressure to drop below to exit
Standby.
High Reset Pressure – Only displayed when booster is connected. Indicates
the setpoint for the pressure to drop below in the high-pressure tank to exit
Standby.
Flow Factor – Only present on generators with Energy Assistant. Indicates
the amount of turndown for the system when turndown is enabled (Further
Explaination in turndown operation section)
Home – Press to return to the Home screen.
Menu – Press to return to the Menu screen.
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Trend Screen (Operator accessible):

Depending on which ‘button’ is pressed, the Trend Graph can display the
Purity, Nitrogen Pressure, or Flow on the vertical axis with time along the
horizontal axis.

Purity* - shows the amount of oxygen in the nitrogen gas.

Pressure – Press to change to the Pressure trend screen.
Flow – Press to change to the Flow trend screen.
Home – Press to return to the Home screen.

* The purity for the gas in the receiver as it is being produced depending on
setting of the sample source valve.

The vertical axis high and low limit values can be changed on each of the
screens by pressing the appropriate blue ‘buttons’ and inputting the desired
values.
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Timers Screen (Engineering accessible):

Each individual timer can be accessed and changed by touching the adjacent
blue box showing the current value. Consult factory before adjusting values.

Home – Press to return to the Home screen.

Menu – Press to return to the Menu screen.
Factory Defaults – Press to change to the Timer Default reset screen.
Update Defaults – Press to insert current settings in the Factory Defaults
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Timer Reset Screen (Engineering accessible):

Timer Default Settings Reset red box – Press to reset all timer values to
factory default values. Note that the offset left and right values will not be
reset.

Home – Press to return to the Home screen.

Previous – Press to return to the Timer Setup screen.

Timer Default Update (Engineering accessible):

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Filter Maintenance Screen (Operator accessible):

Carbon Bed Operation Hours – Indicates the number of hours of runtime

since reset of the last change of carbon.
Air Filter Operation Hours – Indicates the number of hours of runtime since
reset of the last change of air filter elements.
Hours since last checked – Indicates the number of hours of runtime since
reset of checking the air filters for element replacement needs.
Goto Reset Screen – Press to change to the Filter Reset screen.
Home – Press to return to the Home screen.
Menu – Press to return to the Menu screen.
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Filter Reset Screen (Operator accessible):

Carbon Bed Operation Hours – Indicates the number of hours of runtime

since reset of the last change of carbon. Press adjacent Reset button when
carbon is changed to reset time to zero.
Air Filter Operation Hours – Indicates the number of hours of runtime since
reset of the last change of air filter elements. Press adjacent Reset button
when filter elements are changed to reset time to zero.
Hours since last checked – Indicates the number of hours of runtime since
reset of checking the air filters for replacement needs. Press adjacent Reset
button when air filters are inspected to reset time to zero.
Order replacement carbon if not on hand – Appears when carbon bed
operation hours gets to 7000 hrs. Touch notification after verifying carbon is
on hand or ordered and hours exceeds 7000 hrs to acknowledge and clear
warning.
Order replacement filter elements if not on hand – Appears when air filter
operation hours gets to 7000 hrs. Touch notification after verifying filter
elements are on hand or ordered and hours exceeds 7000 hrs to
acknowledge and clear warning.
Home – Press to return to the Home screen.
Previous – Press to return to the Filter Maintenance screen.
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3.3 System Performance& Physical Characteristics

Model
95% 96% 97% 98% 99% 99.5% 99.9% 99.99% 99.999%
Number
HNBS-25 14.6 12.1 10.4 9.1 7.3 6.1 4.8 2.9 1.9
HNBS-35 19.1 15.8 13.6 11.9 9.5 7.9 6.3 3.9 2.4
HNBS-45 25.3 20.9 18.1 15.7 12.6 10.5 8.3 5.1 3.2
HNBS-55 31.5 26.0 22.5 19.5 15.7 13.0 10.3 6.4 4.0
HNBS-70 38.3 31.5 27.3 23.7 19.1 15.8 12.5 7.7 4.9
HNBS-80 46.1 38.0 32.9 28.6 23.0 19.1 15.1 9.3 5.9
HNBS-100 54.6 45.0 38.9 33.9 27.2 22.6 17.9 11.0 6.9
HNBS-115 63.6 52.4 45.4 39.4 31.7 26.3 20.8 12.8 8.1
HNBS-130 -- 59.9 51.8 45.0 36.2 30.0 23.8 14.6 9.2
Air Factor 1.83 1.91 2.00 2.13 2.36 2.59 3.11 4.12 5.49

Performance and air factor listed above is for ambient temperature 70°F and inlet pressure 110
psig. Please contact Holtec for performance at other conditions. Air factor listed may vary by ±5%.
(Flow listed in SCFM)

Model
95% 96% 97% 98% 99% 99.5% 99.9% 99.99% 99.999%
Number
HNBS-25 11.9 10.3 9.3 8.2 6.6 5.4 4.3 2.6 1.5
HNBS-35 15.6 13.5 12.1 10.7 8.6 7.1 5.6 3.4 2.0
HNBS-45 20.6 17.9 16.0 14.2 11.4 9.4 7.4 4.4 2.7
HNBS-55 25.7 22.2 20.0 17.7 14.2 11.7 9.2 5.5 3.3
HNBS-70 31.1 27.0 24.2 21.5 17.3 14.2 11.1 6.7 4.0
HNBS-80 37.6 32.5 29.2 25.9 20.8 17.1 13.4 8.1 4.8
HNBS-100 44.4 38.5 34.6 30.6 24.6 20.2 15.9 9.6 5.7
HNBS-115 51.8 44.9 40.3 35.7 28.7 23.6 18.5 11.2 6.7
HNBS-130 -- 51.2 46.0 40.8 32.8 26.9 21.1 12.7 7.6
Air Factor 2.00 2.09 2.19 2.34 2.59 2.85 3.44 4.71 6.46

Performance and air factor listed above is for ambient temperature 95°F and inlet pressure 110
psig. Please consult Holtec for performance at other conditions. Air factor listed may vary by
±5%.(Flow listed in SCFM)
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3.4 Connections and recommended air and nitrogen receiver sizes

Air Tie- Nitrogen

Model Number in* Tie-in*
(inches) (inches)
HNBS-25 ½” ½”
HNBS-35 ¾” ½”
HNBS-45 ¾” ½”
HNBS-55 ¾” ½”
HNBS-70 1” ¾”
HNBS-80 1” ¾”
HNBS-100 1” ¾”
HNBS-115 1” ¾”
HNBS-130 1” ¾”

* Notes: Filters and dryer are always installed upstream of the air receiver.
Filter sizes, air and nitrogen lines may have to be larger than the tie-in
connections depending on flow, pipe lengths and configurations.

Recommended Air Receiver Sizes, in gallons*

Nominal Model
# 95% 96% 97% 98% 99% 99.5% 99.9% 99.99% 99.999%
HNBS-25 60 60 60 60 60 60 60 30 30
HNBS-35 80 80 60 60 60 60 60 60 60
HNBS-45 120 120 80 80 80 80 60 60 60
HNBS-55 120 120 120 120 80 80 80 80 80
HNBS-70 200 200 120 120 120 120 120 80 80
HNBS-80 200 200 200 200 120 120 120 120 120
HNBS-100 200 200 200 200 200 200 200 120 120
HNBS-115 240 240 200 200 200 200 200 200 200
HNBS-130 -- 240 240 200 200 200 200 200 200

Recommended Nitrogen Receiver Sizes, in gallons*

Nominal Model
# 95% 96% 97% 98% 99% 99.5% 99.9% 99.99% 99.999%
HNBS-25 120 120 120 80 80 60 60 60 30
HNBS-35 200 200 120 120 120 80 80 60 30
HNBS-45 240 200 200 200 120 120 120 60 60
HNBS-55 400 240 200 200 200 120 120 120 60
HNBS-70 400 400 240 240 200 200 200 120 60
HNBS-80 400 400 400 400 240 200 200 120 80
HNBS-100 500 400 400 400 400 240 200 120 120
HNBS-115 660 500 400 400 400 240 240 200 120
HNBS-130 -- 500 500 400 400 400 240 200 120
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*NOTE: Recommended receiver sizes are provisional and based on worst

case scenario. In many cases, depending on application conditions,
smaller receivers may be suitable. Contact Holtec for further advice.

3.5 Other Utility Consumption

Electric power:

N2 Generator ....... <0.12 kW, 120 - 240 V / 1ph / 50/60 Hz

4 Installation, Piping and Tie-in Points

4.1 Lifting and Installation

1. Put the skid gently down in the desired location on a concrete pad. It may
be moved with a pallet jack or forklift using the forklift pockets. The system
is top-heavy, use extreme caution when using this method. Always
ensure the forks are fully through the back end of skid. Do not transport
over uneven or slippery surfaces.

2. Anchor holes are provided in the skid base at the corners. Anchor skid
base as required (anchors supplied by others).

3. Connect the feed air supply line with dry, oil free air (max 38 °F / 3 °C dew
point and <0.003 ppm oil before activated carbon bed) to tie-in T-101 for
the nitrogen generation system. Make sure the line has been blown out
prior to making the connection to make sure no dirt or foreign material is
introduced to the nitrogen generator.

4. Connect the nitrogen distribution line to skid outlet tie-in T-102.

5. Install the power supply conduit and wiring (power supply will accept 110-
240 VAC, 1–ph, 50/60 Hz). Connect the L1 and N wires to the matching
terminal blocks and connect ground wire to a ground terminal block. See
Nitrogen Generator Wiring Diagrams for details.

6. All equipment and piping have been hydro-tested / pneumatically leak

tested if required by code and do not require further hydro-testing.
Additional testing for the piping system is not recommended, due to the
difficulty to remove all the water. Caution: Do not hydro-test adsorber
vessels (B-101/102) or filter housings as this will damage the Carbon
Molecular Sieve and filter media inside the filter housings.

7. Install nitrogen sample line, (shipped loose). Line should be run from V-
116 located on the side of the control panel to downstream of the nitrogen
receiver tank.
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Note: Confirm proper pipe class and material of construction for all lines
and that the nitrogen distribution line is protected against pressurization
above 165 psig. All facility piping must be properly supported to avoid
application of excessive forces or moments to the nitrogen generator
piping.
8. Check all instrument and piping connections for leaks with a soap solution
after the system has been started up. Repair detected leaks, if any.

4.2 Piping and Tie-in Points

All internal interconnecting piping and wiring are included inside of Nitrogen
System battery limits. The termination points will be as follows: (See data
sheet or General Arrangement Drawing for connection sizes)
a) Compressed air supply to PSA Inlet: T-101
b) Nitrogen Generator Product Outlet: T-102
c) Vent Gas: T-103
 For HNBS-25 through -55, the Vent Gas exhausts to atmosphere
through a silencer. The silencer elements should be replaced
annually or as needed, to avoid excessive backpressure.
 For HNBS-70 through -130, there is a 2.5” MNPT Vent Gas
connection. The O2-rich vent gas can be left un-piped in many
facilities, especially large ones, depending on specific facility
requirements. Otherwise, it can be piped out of building, but
pressure drop must be minimized. Note: Pipe size must not be
reduced, blocked, or be of excessive length or nitrogen
generator function will be impaired. Standard HNBS models are
not intended for outdoor operation.
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5 Start-up Procedure
5.1 Initial Start-up

The nitrogen generator has been functionally tested and leak tested prior to
delivery. Flow control valves have been adjusted close to their final positions,
and PLC timers have been pre-set. Fine-tuning to reach specified nitrogen
flow and purity at other conditions will be done in the field.

The nitrogen generator should be operated for minimum 1 hour after the
system has first been started and the resulting product nitrogen vented
continuously at or near the exit of any new pipes that have been installed
close to point of use. Caution: Ensure adequate ventilation and O2 level
in room, or pipe N2 out with temporary hose. The purpose is to remove
oxygen from the nitrogen receiver tank and downstream lines before nitrogen
is supplied to the end use points. We do not recommend making any
adjustments until the system has been operated for at least one hour since
this may result in improper flow and pressure settings. Higher purity (lower
O2) applications need to be operated longer than lower purity applications.

It is important to check the nitrogen purity with the oxygen analyzer (AIT-301)
when adjusting nitrogen production flow control valve FCV-102.

After the nitrogen generator has been tuned in as described below, it is

sufficient to follow the instructions given in section 5.2 for consecutive start-
ups. Should the nitrogen generator have to be tuned in again for any reason,
the initial start-up procedure for the system is as follows:

1. Leak test, and make the nitrogen distribution system ready to receive
nitrogen and open isolation valves between the nitrogen generator and
the nitrogen receiver. All nitrogen outlet valves downstream of the
nitrogen receiver tank should be closed.

2. Turn the nitrogen generator main Power switch to “On”.

3. Verify that clean, oil-free, dry (dew point <38 °F) is available upstream of
tie-in T101.

4. Open the main inlet air isolation valve V-100. Verify that process air
pressure is per process specifications.

5. Open nitrogen receiver tank inlet and outlet isolation valve V-110.

6. Set nitrogen generator instrument air regulator PCV-104 to about 90 psig.

7. Turn the lever for sample gas selector valve V-109 towards RUN (nitrogen
product sample). Verify that V-116 and any other sample isolation valves
are open. Note: The purity of the nitrogen from the individual adsorber
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vessels will fluctuate during the production cycle. The purity will be close
to constant downstream of the nitrogen receiver.

8. Start the nitrogen generator by pushing the “Start” button on the HMI. To
stop the system, push the “Stop” button on the HMI. The nitrogen
generator will complete the cycle before stopping.

9. The nitrogen generator will run continuously if in “Manual” mode. In “Auto”

mode the generator will cycle between operating and standby should the
nitrogen demand be less than the nitrogen generator capacity.
Manual/Auto mode is selected on the HMI.

10. It will take several minutes from when the nitrogen generator is started
until the nitrogen receiver tank has been pressurized (see data sheet for
recommended nitrogen pressure). The oxygen content will be higher than
design when the system is first started. Open a valve close to the main
nitrogen point of use to purge the nitrogen distribution system of oxygen
during this initial run period of 1 hour or more, or until the oxygen level is
within the specifications. (A nitrogen receiver drain valve can be cracked
open if the purpose is only to purge the nitrogen receiver). Warning:
Make sure there is very good ventilation in the area where the
nitrogen is vented to avoid asphyxiation, or direct the vent to the
open atmosphere using a temporary hose line.

11. Signal from pressure transducer PT-301 controls the automatic nitrogen
generator operation. Adjust standby pressure set point in the PLC/HMI, if
required. Typical setpoint is 5 – 10 psig below the air pressure. A slightly
lower set pressure may be considered if the nitrogen generator never
switches to “Standby” mode.

12. Slightly open a drain valve or product isolation valve to purge out oxygen
in the downstream piping and/or nitrogen receiver.

13. If the concentration of oxygen indicated on AIT-301 is higher than design

after the nitrogen receiver tank and piping have been purged for oxygen,
gradually reduce the setting (clockwise adjustment) of valve FCV-102,
using the Allen wrench provided, (a small adjustment every 5 minutes)
until the design oxygen concentration is achieved. Actual nitrogen
concentration is indicated on AIT-301. If the concentration of oxygen is
lower than design, gradually increase the setting (counter-clockwise
adjustment) of valve FCV-102 valve until the design oxygen concentration
is achieved. (In summary, decreasing the opening (CW) of the valve
will reduce the nitrogen production rate and reduce the oxygen
content. Opening (CCW) the valve will increase nitrogen production
and the oxygen content).

Note: It is important to keep the nitrogen receiver pressurized at normal

operating pressure to achieve optimum performance. The nitrogen
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receiver is a process tank not designed to cover large surges in the

nitrogen consumption. Additional tanks may be required to cover peak
consumptions. Consult Holtec for recommendations.

14. Adjust sample pressure control valve PCV-103 if the flow shown on FI-
301 has changed from the target value of 1.2 scfh.

15. Restriction orifices RO-105, 106, have been installed at the factory to limit
maximum flow. Some units may use flow control valves in lieu of orifices
in these equalization lines, in which case they must not be adjusted
without factory authorization, to avoid invalidation of any warranty and
performance guarantee. NOTE: In the case of systems with flow
control valves for equalization, equalization time must be a minimum
of 3.5 seconds.

5.2 Normal Start-up

Assuming that main power switch is turned “ON” and the tasks described in
section 6.1 have been performed, normal start-up procedure is as follows:

1. Verify that clean, dry, oil-free feed air is available and the pressure dew
point is below 38 °F/ 3 °C.

2. Slowly open all air supply isolation valves upstream of the nitrogen
generator tie-in T101.

3. Open the system main inlet air isolation valves (V-100).

4. Start the nitrogen generator by pushing the “Start” icon on the LCD HMI.

5. It takes 3 to 4 minutes for the PSA to start producing nitrogen and feeding
it into the nitrogen receiver.

6. Verify that nitrogen isolation valve V-110; downstream of the nitrogen

generator tie-in T102 is open.

5.3 Continuous automatic operation

Once the nitrogen generator has been started as described above, the
nitrogen generator will successively run and then switch to standby mode as
the pressure in the nitrogen receiver tank falls below and rises above set point
pressure in response to variations in nitrogen consumption.
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5.4 Turndown operation (EnergyAssistant)

The nitrogen generator produces nitrogen on demand based on automatic

on/off control. It is possible to reduce the opening of nitrogen flow control
valve FCV-102 to produce less nitrogen of better purity. Using an Allen
wrench, turn clockwise to reduce flow. See Section 5.1 paragraph 13 for
additional instructions.

Holtec EnergyAssistant, when purchased and enabled on the HMI home

screen, automatically adjusts the cycle time to match demand. If Turndown
is enabled and oxygen level remains high, the Flow Factor on the Setpoints
screen should be decreased. If the oxygen level is always well under required
levels, then it can be increased (example 10% step) to maximize
performance.

6 Shutdown

6.1 Manual shutdown

The normal shutdown procedure is as follows:

1. Push the “Stop” icon on the LCD HMI. The unit will cycle to stop.

6.2 Long term shutdown

If the system will be shut down for an extended period of time, stop the system
as described in section 6.1 and:

1. Turn the nitrogen generator main power switch to “Off”.

2. Close feed air isolation valve (V-100).

3. Close nitrogen product isolation valve (V-110).

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7 Inspection and Maintenance

This section covers the general maintenance procedure for the PSA Nitrogen
Generator and the upstream air purification system (optional or by others).
Please refer to Manufacturer Catalogues in section 10 for further details.

7.1 Operation, Inspection and Maintenance Check List

Daily Weekly Monthly 3 6 - 12

Months Months
Visually check the overall system X
operation. Make adjustments if required.
Check nitrogen purity X
Check nitrogen sample flow X
Check operating pressure X
Check dryer dew point temp. below 38°F / X
3 ºC
Check oxygen analyzer span(AIT-01) X
Check pressure transducer setting/standby X
operation (PT-301)
Check for air and nitrogen leaks X
Replace filters and activated carbon Xa
Replace switching valve muffler element X

a. Activated carbon should be replaced once every 12 months as a minimum. Filter

cartridges should be replaced once every 12 months as a minimum or when the
pressure differential indicator gets into the red zone.

Pressure safety (relief) valves (PSVs) are sized for fire-case protection of vessels. If the
plant has a maintenance schedule for PSVs, these can be included in that schedule.

7.2 Instrument Air Filter Replacement

The instrument air filter (F-106) element needs to be replaced at least every 12
months. The filter is located under the control panel skirt directly behind the
instrument air pressure gauge (PI-104).
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7.3 Oxygen Analyzer

The zirconium oxygen analyzer does not require calibration. Calibration can
only be done by Holtec. The sensor must be returned to Holtec for calibration.
A replacement transmitter can be sent out and partially credited upon the
return of the old sensor.

The oxygen analyzer’s span can be verified by using calibrated gas for PPM
analyzer, and air for percent analyzers. Allow the oxygen analyzer to warm
up for minimum 1 hour before checking span.

1. Obtain a bottle of nitrogen mixed with appropriate PPM O2. Connect the
regulated calibration gas pressure (max 125 psig) to sample gas.

2. Turn the lever for sample gas selector valve V-109towards CAL =
Calibration gas source. Wait until reading is stable (~ 1 hour for PPM
ranges).

3. Adjust sample flow control valve PCV-103 if necessary until the sample
flow as indicated on flow indicator FI-101 is about 1.2 scfh.

4. Turn the lever for sample gas selector valve V-109 towards RUN =
nitrogen product sample.

If a galvanic type sensor is provided, It must be periodically calibrated. It is

spanned using compressed air. For calibration instructions see analyzer
manual in section 10.3.

The oxygen analyzer “Hi” Alarm can be set to desired value. The value is set
by programming the set points using the HMI touch-screen.

1. Touch MENU on the HMI.

2. Touch SETPOINTS and the return symbol.

3. Touch HIGH O2 SETPOINT and enter the desired set point.

4. After both the HIGH and LOW values are set, touch the home icon to
return to the main screen.

7.4 Switching Valve or Solenoid Replacement

If any of the switching valves or solenoid valves have to be replaced, it is

important to connect the various fittings and tubes to the appropriate valve
ports, and the wires to the appropriate terminals. See the wiring diagram and
Piping & Instrument Diagram in section 10 for details.
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7.5 Lubrication Recommendations

The Nitrogen Generators do not require lubrication.

7.6 Special Tools

The Nitrogen Generator does not require any special tools for operation and
maintenance. Except for the following: Allen wrench for adjusting FCV-102
and Wago terminal block insertion tool, located in envelope inside control
panel.

7.7 Clearances
A minimum of 3 ft./ 0.9 meters clearance should be kept around the nitrogen
generator for proper access to maintenance and operation.

8 Troubleshooting
This section covers general trouble shooting for the PSA Nitrogen Generator.
Please refer to Manufacturers’ Catalogues in section 10 for further details.

Nitrogen Generator runs continuously

Probable Cause Suggested remedy

Leaks in air or nitrogen lines Check and repair leaks
The nitrogen consumption is too high Reduce nitrogen consumption.
Feed air supply pressure too low Increase supply pressure or replace air filter
elements.
The nitrogen production is set too Adjust control valve FCV-102 to increase the
low product flow. This adjustment must only be done
by an experienced operator and close attention
must be paid to the oxygen content in the
product nitrogen.
Nitrogen transducerPT-301 set too Reduce pressure set point or replace pressure
high or defective transducer.
One or more of the switching valves Check operation or consult Holtec.
(XV-100 – 108) or solenoid valves
(SOV-100 – 108) are malfunctioning.

Nitrogen Generator is not running

Probable Cause Suggested remedy

Main power switch is turned “Off” Turn switch to “On”
System is not in Run mode Push “Start” icon on HMI
Feed air supply closed Open all feed air isolation valves including V-103
System is in “Standby” mode Start using nitrogen. Open all manual valves
downstream of the nitrogen generator
The switching valves (XV-100 – Check valve operation.
08) are not opening.
Fuse blown Check and replace fuse. See wiring diagram for
proper fuse rating.
PLC controller is not working See PLC manual section 10 for suggestions.
External circuit breaker tripped Reset circuit breaker
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Nitrogen product flow below design

Probable Cause Suggested remedy

Leaks in air or nitrogen lines Check and repair leaks.
Feed air supply pressure too low Increase supply pressure psig or replace air filter
elements
The oxygen content in the product Adjust control valve FCV-102 to increase the
nitrogen is below specification product flow until the nitrogen purity increases to
specification
One or more of the switching Check operation or Consult Holtec.
valves (XV-100 – 08) or solenoid
valves) are malfunctioning.
Carbon Molecular Sieve Contact Holtec.
contaminated with oil or water.

Too high oxygen content in the Nitrogen product

Probable Cause Suggested remedy

Leaks in air or nitrogen lines Check and repair leaks
Feed air supply pressure too low Increase supply pressure or replace air filter
elements.
The nitrogen consumption is set Reduce nitrogen consumption.
too high
The nitrogen production is set too Adjust valve FCV-102 to decrease the product flow
high until the nitrogen purity is at specification.
One or more of the switching Check and replace.
valves (XV-100 – 108) or solenoid
valves are malfunctioning.
Carbon Molecular Sieve Contact Holtec
contaminated with oil or water.

Filter drains not working properly

Probable Cause Suggested remedy

Auto drains (by others) stuck in Check and clean drain mechanism
open or closed position

9 Warranty

See section 10.

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10 Drawings and Manufacturers’ Catalogues

1. Drawings & pictures:

- General Arrangement
- Piping & Instrument Diagram
- Wiring Diagrams, Nitrogen Generator

2. Material Safety Data Sheets:

- Nitrogen MSDS
- CMS MSDS

3. Analyzer:
- Galvanic Oxygen analyzer, AIT-301 (If applicable)

4. Warranty:
- Holtec’s standard warranty

5. Additional Equipment (If applicable)

- Compressor
- Dryer
- Filters