HPCF Series — Safety Guidelines – South-Tek Systems

Applies to: HPCF Series — 1, 2, 4, and 6 K-cylinder/day configurations

Does NOT apply to: HPCF-SFI — see HPCF-SFI Safety Guidelines

This article outlines the safety requirements for installation, operation, and maintenance of the HPCF Series nitrogen generator. All personnel involved in any aspect of this system must read and understand these guidelines before working with the equipment. For safety requirements specific to supporting equipment — air compressors, refrigerant dryers, receivers — refer to those manufacturers' documentation.

🛑 Pressurized Gas Hazard: Pressurized gases are contained within the generator, PSA adsorption beds, nitrogen storage tank, and all interconnecting piping. Pressurized gases are dangerous and may cause serious injury or death if handled or used incorrectly. Never work on any part of the pressurized system without first fully depressurizing the affected section and confirming all gauges read 0 PSIG.

General Safety Practices

Read this article and the full HPCF O&M manual before installing, operating, or performing any maintenance on the system.
Use the nitrogen generator only for its intended purpose. Do not tamper with, experiment on, or attempt to exceed the equipment's technical specifications.
Only authorized, trained, and competent personnel are permitted to perform installation, operation, maintenance, and repair. Work performed by unqualified personnel voids the warranty.
The equipment owner is responsible for maintaining the unit in safe operating condition at all times.
Always use South-Tek-specified replacement parts. Replacement parts must meet or exceed the original components' specifications.
Follow all applicable OSHA regulations and local health and safety codes throughout installation, operation, and maintenance.
Contact South-Tek Systems for any problem that cannot be resolved using the O&M manual or this knowledge base.

Nitrogen — Asphyxiation Hazard

Nitrogen is an odorless, colorless, non-poisonous inert gas. However, in high concentrations, it displaces oxygen in the air and can cause rapid asphyxiation without warning. There is no detectable odor or visible sign that nitrogen concentration is dangerous.

🛑 Asphyxiation Risk: Never operate the HPCF Series generator in a sealed or poorly ventilated space. Nitrogen accumulation can occur rapidly and without warning. If dizziness, headache, or lightheadedness occurs in the vicinity of the equipment, immediately evacuate the area, move to fresh air, and ventilate the space before re-entering.

Install and operate the generator only in a well-ventilated room that is not sealed from normal air circulation and air changes.
Never directly inhale nitrogen gas from any port, vent, or cylinder connection on the system.
Do not discharge storage cylinders or vent nitrogen into an enclosed area.
If a nitrogen leak is suspected, evacuate the area immediately, ventilate, and correct the leak before resuming operation.

Exhaust Gas and Room Ventilation

The PSA process exhausts oxygen-enriched waste gas during normal operation. This exhaust typically contains between 20.9% and 40% O2 (balance nitrogen) — a higher oxygen concentration than normal air. While not immediately hazardous at these levels, oxygen-enriched atmospheres significantly increase the risk of fire and combustion. The exhaust volume is substantial: it is approximately equal to the pressurized bed volume at 50% of the incoming air pressure, exhausted every minute.

Route all PSA exhaust gas to the outside or to a large, well-ventilated room. Do not allow exhaust to accumulate in enclosed spaces.
Keep all ignition sources, open flames, and combustible materials well clear of exhaust outlets.
Size exhaust piping to maintain backpressure below 0.5 PSIG at the generator exhaust port — see the Site & Utility Requirements article for exhaust piping rules.
Ensure the exhaust outlet is never positioned where it can re-enter a building through air intakes, doors, or windows.

Pressurized System Safety

Completely isolate all incoming and outgoing pressures and fully depressurize the affected section before performing any mechanical work, including routine filter changes. Confirm all gauges read 0 PSIG before opening any connection.
Never allow pressurized gas to exhaust from an unsecured hose. An unsecured hose under pressure can whip violently and cause serious injury or death.
If a hose bursts during operation, close all isolation valves immediately if it is safe to do so, then power down the unit.
Never disable, bypass, or tamper with any safety relief valve. All relief valves on this system are ASME-approved and are the last line of protection against over-pressurization.
Do not exceed the rated operating pressure for any component in the system, including cylinders, hoses, valves, and fittings.
All high-pressure equipment — cylinders, CGA valves, and high-pressure hoses — must be rated for the system's cut-off pressure. Visually inspect all high-pressure hoses and connections before each use.
Store and secure all high-pressure cylinders upright at all times. Never overfill cylinders beyond their rated pressure.

⚠ System Remains Pressurized After Shutdown: The generator and all associated piping remain under pressure after the unit is stopped. Never assume a stopped system is depressurized. Always verify all pressure gauges read 0 PSIG before opening any component.

Electrical Safety

Always disconnect the generator from all electrical supply power before performing any electrical work on the unit or on any connected equipment.
All electrical connections must be made by a qualified electrician in compliance with all applicable local and site codes.
Verify that the available supply voltage and frequency match the unit nameplate before connecting power.
Do not reroute, tap into, or replace any electrical component or wiring with non-manufacturer-specified parts.
Do not operate the system in the presence of liquids or in wet environments unless the unit was specifically designed with appropriate ingress protection.

⚠ Lockout / Tagout: Apply lockout/tagout procedures to the main electrical disconnect and all pneumatic isolation points before beginning any maintenance or repair. Verify zero energy state (electrical and pneumatic) before starting work.

Personal Protective Equipment (PPE)

Situation	Required PPE
Cabinet door open while generator is running	Safety glasses
Generator operating (any proximity)	Hearing protection (system noise level up to 90 dBA)
Any maintenance or service task	Safety glasses, appropriate gloves; additional PPE per site safety requirements
Working with high-pressure cylinders or connections	Safety glasses, gloves; ensure face is never in line with cylinder valve or CGA fitting during connection or disconnection

Safety Relief Valves

Safety relief valves are installed throughout the system — on both PSA adsorption beds, on the nitrogen storage tank, and on the booster output. All relief valves are ASME-approved. They must never be blocked, bypassed, capped, or tampered with in any way.

Inspect relief valves periodically for corrosion, debris buildup, or mechanical damage.
If a relief valve activates during normal operation, stop the generator immediately and contact South-Tek Systems — a relief valve lifting under normal conditions indicates an over-pressurization fault that must be diagnosed before restarting.
Follow all local and site codes for safe venting of relief valve discharge. Relief valve outlets must be routed to a safe discharge location and must never be directed toward personnel.
PSA adsorption beds greater than 4 inches in diameter are ASME-certified pressure vessels. Contact South-Tek Systems if ASME certification documentation is required.

Emergency Procedures

Emergency Situation	Immediate Action
Hose burst or sudden pressurized gas release	Close all isolation valves immediately if safe to do so; power down the generator at the main disconnect; evacuate the area; do not re-enter until the system is confirmed depressurized
Suspected nitrogen leak / person feels dizzy or lightheaded	Evacuate immediately; move to fresh air; ventilate the space before re-entering; locate and correct the leak before restarting
Electrical fault or fire	Disconnect power at the main electrical disconnect; use appropriate fire suppression for electrical fires; evacuate and contact emergency services
Any unsafe condition not covered above	Stop the generator at the main power switch; evacuate if necessary; contact South-Tek Systems at (910) 415-1880 before restarting

Contact South-Tek Systems

Phone: (910) 415-1880

Email / Ticket: support@southteksystems911.zendesk.com