Possible minor issues with nitrogen generators at the current stage and their solutions.

PSA (Pressure Swing Adsorption) nitrogen generator, as a commonly used nitrogen production device, uses pressure fluctuations and specific adsorption materials to separate oxygen from the air and obtain pure nitrogen. However, during long-term operation, PSA nitrogen generators may encounter various problems that can interfere with the stable operation of the equipment and the quality of nitrogen gas. The following is a comprehensive summary and in-depth analysis of common faults in PSA nitrogen generators:

 
 
1、 Incomplete exhaust and abnormal pressure
1. One way valve leakage
Fault manifestation: High pressure gas reflux was observed, resulting in a decrease in nitrogen purity and an abnormal increase in tower pressure.
Root cause of the malfunction: The problem stems from the weakened sealing effect of the one-way valve.
                                              
Solution: Check the one-way valve and its sealing ring to determine the degree of wear, and replace damaged parts in a timely manner to ensure that the one-way flow of gas is not affected.
                                              
2. The blowback valve is too open
Fault manifestation: Incomplete exhaust was observed, resulting in a decrease in the purity of nitrogen gas.
 
Cause of malfunction: The opening of the blowback valve exceeds the normal range.
Solution: Adjust the opening of the blowback valve to an appropriate level to ensure the effectiveness of the exhaust, and regularly check the wear condition of the blowback valve to replace any worn or damaged components in a timely manner.
 
3. Pressure sensor malfunction
 
Fault manifestation: The pressure reading on the equipment deviates or cannot display the pressure value at all.
Root cause of malfunction: The pressure sensor is damaged or malfunctioning.
Solution: Check the pressure sensor and replace it when a fault is found to ensure the accuracy of pressure readings.
 
 
4. Pipeline blockage or leakage
Fault manifestation: Unstable system pressure and reduced nitrogen quality.
Root cause of malfunction: Accumulation of impurities in the pipeline causing blockage, or leakage of gas in the pipeline.
Solution: Remove blockages in the pipeline, use leak detectors or soapy water methods to detect and repair leaks, and ensure unobstructed gas flow.
 
 
2、 Long term alarm for purity failure
1. Adsorption pressure fluctuation
Fault manifestation: There is a significant change in the purity of the produced nitrogen gas.
Root cause of malfunction: The pressure during the adsorption process exceeds the normal range, or the pressure is unstable.
 
Solution: Adjust the intake pressure to a suitable level, usually maintained at 0.6~0.8MPa; Install an air storage tank at the intake to stabilize the gas supply pressure.
 
2. Poor quality of gas source
Fault manifestation: The purity of nitrogen has decreased
 
Root cause of malfunction: High moisture or oil content in the gas supply source.
Solution: Check the operation status and filter element status of the refrigerated dryer, and replace the filter element on schedule; If necessary, add an oil-water separator to ensure the dryness and cleanliness of the gas source.
 
3. The adsorbent loses its effectiveness
Fault manifestation: The purity of nitrogen continues to decrease.
 
Root cause of malfunction: The adsorbent is poisoned, powdered, or loses its effectiveness.
Solution: Regularly replace the adsorbent to maintain its adsorption effect; At the same time, pay attention to the protection and maintenance of adsorbents to prevent them from being contaminated or damaged.
 
3、 Equipment automatic shutdown issue
 
1. Power system malfunction
Fault manifestation: The device suddenly shuts down and the power indicator light does not light up.
Root cause of malfunction: Fuse blown or power interface and socket without power supply.
Solution: Check if the fuse is intact. If it has blown, it needs to be replaced; Confirm whether the power interface and socket are powered on. If they are not powered on, the power circuit needs to be checked.
 
 
2. PLC system malfunction
Fault manifestation: The device automatically shuts down and the display shows an alarm.
Root cause of malfunction: PLC program error or physical hardware malfunction.
Solution: Determine if there is a problem with the PLC based on the alarm code on the display. If necessary, contact professional maintenance personnel to inspect, repair, or replace the PLC.
 
 
4、 Operation control fault handling
1. Control system malfunction
Fault manifestation: The device has difficulty starting or abnormal operation.
Root cause of malfunction: Internal program errors or hardware failures in the control system.
 
Solution: Check and replace the controller as necessary to ensure its normal operation.
 

Root cause of the fault: Loose or damaged equipment components.
Measures: Check and repair equipment components to ensure stable operation; tighten loose parts and replace damaged parts.
 
3. No display on the screen
Fault performance: After the device is turned on, the screen shows no response.
Root cause of the fault: Power issues, loose circuit connections, or damage to the screen itself.
Measures: Check if the power supply is normal; confirm if the circuit connections are secure; if the screen is damaged, it needs to be replaced with a new one.
 
Overall, PSA pressure swing adsorption nitrogen generators may encounter various faults during operation. To ensure the continuous stable operation of the equipment and the quality of nitrogen production, operators need to regularly perform maintenance and upkeep on the equipment, promptly identify and resolve potential faults. In addition, operators should have a deep understanding of the structure and working mechanism of the equipment and master the skills to identify and handle common faults so that they can quickly take effective measures in response to any issues that arise.