Onsite PSA N2 Generator Safety and Daily Operational Guidelines

Safety Guidelines

General Safety Measures

Authorized Access Only:

• Only trained and authorized personnel may operate, service, or maintain the PSA nitrogen generator.
• Unauthorized access to the equipment is prohibited.

Personal Protective Equipment (PPE):

• Always wear appropriate PPE, including safety glasses, gloves, and steel-toe boots.
• Use hearing protection in high-noise environments

Site and Environment:

• Ensure the generator area is well-ventilated to prevent oxygen displacement.
• Maintain a clean, debris-free workspace to avoid tripping hazards and ensure proper airflow.
• Check that all warning labels and safety instructions are clearly visible and legible.

Emergency Preparedness:

• Know the location of fire extinguishers, eyewash stations, and emergency stop buttons.
• Familiarize yourself with site-specific emergency evacuation plans and shutdown procedures.

Daily Safety Checks

• Inspect for Leaks: Perform a visual inspection to check for gas leaks, wear, or damage to piping, hoses, or fittings.
• Check Pressure and Purity: Verify system pressure, nitrogen purity, and flow rate against expected values.
• Monitor Ambient Conditions: Ensure the area is within the temperature and humidity range specified by the manufacturer.
• Power Supply: Inspect cables and electrical connections for damage or loose fittings.

Day-to-Day Operational Guidelines Daily Startup Procedure

Pre-Startup Inspection:

• Check that all valves are in their proper positions.
• Ensure filters are clean and installed correctly.
• Confirm that the air compressor supplying the generator is operational and within its specified parameters.

System Initialization:

• Follow the manufacturer's startup procedure step by step.
• Gradually open isolation valves to prevent pressure surges.
• Monitor the initial startup for any unusual sounds, vibrations, or pressure irregularities.

System Monitoring:

• Continuously monitor the system dashboard or indicators for key metrics:
  • Nitrogen purity (%).
  • Pressure levels (PSI/bar).
  • Flow rate (SCFM or other unit).
• Log these parameters for tracking and troubleshooting.

Daily Operational Best Practices

Performance Monitoring:

• Check nitrogen purity levels at regular intervals to ensure consistent output quality.
• Verify that system pressure remains within safe operating limits.
• Observe flow rates to match the demand requirements of your process.

System Cooling and Ventilation:

• Ensure that the generator's cooling system (if applicable) is functioning correctly.
• Verify that the ventilation system is unobstructed and effectively dissipates heat.

Preventative Measures:

• Do not exceed the generator's rated capacity for prolonged periods.
• Avoid unauthorized adjustments to system controls or settings.

Environmental Monitoring:

• Use oxygen detectors in enclosed areas to ensure safe breathing conditions.
• Avoid using the generator near flammable or corrosive substances.

Daily Shutdown Procedure

System Shutdown:

• Follow the manufacturer’s recommended shutdown procedure.
• Depressurize the system by slowly closing the isolation valves.
• Turn off the power supply to the generator.

Post-Shutdown Inspection:

• Inspect for leaks or abnormalities that may have occurred during operation.
• Check oil levels and coolant levels (if applicable) in associated compressors.

Documentation:

• Record system performance metrics and note any irregularities in a maintenance log.
• Report unusual issues to the site supervisor immediately.

Maintenance and Servicing

Routine Maintenance (Daily/Weekly):

• Filter Inspection: Check and replace air intake and coalescing filters if they show signs of clogging or wear.
• Visual Inspection: Inspect all connections, hoses, and valves for signs of wear, corrosion, or damage.
• Drain Maintenance: If applicable, ensure condensate drains are functioning correctly and are not clogged.

Periodic Maintenance (Monthly/Quarterly):

• System Calibration: Test purity analyzers and recalibrate if necessary to ensure accuracy.
• Adsorbent Maintenance: Replace the molecular sieve or adsorbent material as specified in the maintenance schedule.
• Pressure Relief Devices: Test and verify the functionality of pressure relief valves to ensure safety.

Incident Response

Gas Leaks:

• Evacuate the area immediately if a leak is suspected.
• Use gas detectors to confirm the presence of nitrogen or air leaks.
• Notify site safety personnel and follow emergency response procedures.

System Failures:

• Shut down the system if alarms indicate critical issues.
• Do not attempt repairs without proper authorization and training.

Emergency Shutdown:

• Activate the emergency stop button if required to protect personnel or equipment.

Documentation and Reporting

Daily Logs:

• Maintain a log of daily performance metrics, including purity, pressure, and flow rates.
• Record any maintenance performed or irregularities observed.

Incident Reports:

• Document all incidents, including gas leaks, system alarms, or operator errors.
• Submit reports to supervisors for review and corrective action.

Important: Always refer to the manufacturer's manual for specific instructions and site-specific safety protocols. Consistent adherence to these safety and operational guidelines will ensure optimal performance and the safety of personnel.