Air System
Air System
Air System
1.
General
A compressed air system may consist essentially of one or more compressors with a power source,
control system, intake air filter, aftercooler and separator, air receiver, air dryer, and inter
connecting piping, plus a distribution system to carry the air to points of application.
Atmospheric Air is sucked by air Compressor which basically contains water vapor & dust.
Besides, in lubricated type Air Compressors, oil is present in the air compression chamber, traces
of which are present, in compressed air in Liquid / Vapor form, which condenses into a heavy
gummy oil varnish.
Condensed moisture together with dust and oil in compressed air leads to emulsion formation
causing following troubles:
Formation of rust & scale, clogging orifices, resulting in malfunctioning of tools, controls
& instruments.
By corrosion of air or gas the instruments can give false reading disrupting product quality.
Rust & scale contaminates products when compressed air is used in mixing and processing.
The object of installing a compressed air system shall be to provide air to the various points of
application in sufficient quantity and quality and with adequate pressure for efficient operation of
air tools or other pneumatic devices.
The total air requirement is the sum of the plant air and instrument air inclusive of contingency for
each category.
1.1
Plant Air
The plant air requirements should not be designed for coincident operation. Optimum
schedule for overhaul, regeneration, decoking, etc. shall be considered when arriving at the
total capacity of the complex.
Plant air consumption is intermittent and difficult to estimate at early project stages.
For initial estimate add 130-170 Sm3/h to compressor capacity.
2.
3.
The humidity shall be measured with a water-content analyzer of the lithium chloride type (or
equivalent), with a local indication and with a high-humidity alarm on the main panel.
Safety/relief valves shall be provided when required by statutory regulations and/or by the relation
between maximum compressor discharge pressure and the maximum allowable working pressure
of vessels and piping.
4.
Air Compressors
To ensure maximum reliability of the instrument air supply, at least two compressors shall be
installed. Each compressor shall be arranged for normal operation and for stand-by, and shall be
capable of supplying the designed quantity of instrument air, plus the required quantity of plant
air, and, if applicable, the required quantity of regeneration air.
Where it is essential to have stand-by also if one of the two compressors is not operational, e.g.
because of repairs or maintenance, the installation of a third compressor shall be considered.
The installation of more than two compressors may also be considered for other reasons, e.g.
where the fluctuations in air consumption are greater than the range ability of one compressor, or
where purchasing and maintaining a number of compressors each with relatively low capacity is
more attractive than a (small) number of compressors each with relatively large capacity.
In any case, the total capacity of the compressors driven by the most reliable utility shall be
sufficient to supply the design quantity of instrument air.
Note:
In addition to the above compressors for normal plant operation, an independent
emergency air compressor may be required.
4.1
4.2
Oil free rotary screw and lobe-type compressors are available, having a design that does not
require lubrication in the compression chamber for sealing and lubrication.
Centrifugal air compressors are inherently nonlubricated due to their configuration.
Generally, nonlubricated compressors have a higher initial cost due to the special design
and materials.
Nonlubricated reciprocating air compressors also tend to have higher operating costs due
to higher maintenance cost associated with shorter valve and ring life.
4.3
Compressor selection
Compressor selection shall be as per CHAGALESH Standard, "Process Design of
Compressors".
4.4
Compressor Specification
The compressor shall be of the dry type cylinder and shall supply oil-free air, and be
complete with non-return valves, intercoolers, after coolers, condensate draining facilities,
etc.
The compressors and their drives shall satisfy the requirements for running equipment as
specified by the user.
Electric motors shall be suitable for installation in a non-hazardous area.
4.5
Compressor Controls
Each compressor shall have facilities for manual and automatic starting in the case of
failure of the other compressor(s).
The automatic starting system shall be so arranged that stopping of a compressor is only
possible by manual control.
Automatic starting of the stand-by compressor(s) shall be as quick as possible; in addition
to an initiator on the piping downstream of the air drier. Initiators shall be provided at each
compressor discharge upstream of the non-return valve and/or on the compressor oil
system. Starting of each stand-by compressor shall be indicated by an alarm on the main
panel.
The electric motor(s) shall have local start /stop controls and be protected against
repetitive starting. Electric controls supplied as integral parts of the compressor, as for oil
filter, oil pump, oil heater, shall be interlocked with the start/stop controls and shall be
located in a weatherproof housing on, or close to, the compressor.
4.6
Compressor Piping
The inlet of the compressors shall be so located that the instrument air is free from toxic,
P1 P2
C P0
(1-1)
time
hr
P1
kPa (ga)
P2
final pressure
kPa (ga)
P0
atmospheric pressure
kPa (abs)
air requirement
Sm3/hr
receiver capacity
m3
This equation assumes that the temperature of the receiver is constant at standard atmospheric
temperature and that P0 is standard atmospheric pressure. It also assumes that no air is supplied to
the receiver during the time interval. If air is being supplied steadily to the receiver at a rate of S
cubic meters of free air per hour, then C in the equation should be replaced by C minus S.
The buffer vessel shall be sized to maintain the air supply between the moments of compressor
failure caused by mechanical failure of one compressor or failure of one utility supply for the
compressor(s) normally in operation, and the moment that the stand-by compressor(s) is or are
operating.
The period between these moments shall be taken as the time required for starting the stand-by
compressor(s) manually if automatic starting is unsuccessful, and shall be determined by plant
operations in connection with mechanical engineering and utility engineering, but shall be at least
(15) minutes.
During this period, the instrument air pressure shall not drop below the minimum value required for
proper operation of the instruments (especially control valves) and other services depending on
instrument air. This minimum pressure can usually be taken as (3.0 barg), but may be higher for
some special cases.
Note:
The sizing of the air receiver shall be based on the design quantity of instrument air
consumption for the period required to bring the emergency compressor into service.
The minimum of 15 min. should be selected if not time period specified for this purpose.
The capacity should also be sufficient for condensate collection and removal [1].
Alternatively, consideration may be given to bottled high-pressure air or nitrogen as emergency
supply for such equipment.
The sizing of the buffer vessel shall be based on the design quantity of instrument air, plus the plant
air consumption until the safeguarding device closes.
The buffer vessel shall have automatic draining facilities. The wall thickness shall have a 3 mm
corrosion allowance, and the lower part of the vessel shall be provided internally with a protective
coating.
The vessel shall be installed between the compressors and the drier. Where limited space makes it
impossible to install the buffer vessel in this place, part of the required buffer volume may be
located downstream of the drier, provided the buffer vessel between compressor and drier remains
of sufficient size for condensate separation.
6.
Air Drier
This equipment will dry compressed air having 100% relative humidity to the stipulated dew point,
and shall be durable for continuous operation under the specified pressure, humidity and flow rate.
The design dew point for instrument air shall be more than 10C below the lowest recorded outside
temperature under the line pressure. The design dew point for plant air shall be of lowest ambient
recorded outside temperature under the line pressure.
Compressed air may be dried by [2]:
1) Absorption;
2) Adsorption;
3) Compression;
4) Cooling;
5) Combination of compression and cooling.
The air drier shall normally be of the twin-vessel adsorption type with regeneration. Switching of the
vessels shall be either manual or automatic.
The air drier shall have a sight glass for indication of outlet air humidity.
The selected methods of drying, regeneration and switching are usually specified by the user; where
this has not been done the contractor shall submit a proposal for approval by the user.
6.1 The Desiccant
The desiccant shall normally be activated alumina or silica gel or molecular sieve in beaded
form. When silica-gel is used, a bottom layer (approx. 10%) of activated alumina shall be
provided to achieve a better resistance to entrained water. The quantity of desiccant shall be
such that adequate drying capacity is still available after the desiccant activity has deteriorated.
The continuous operating time of one desiccant drum shall not be less than 8 hours under the
specified conditions. However, based on ultimate life and other parameters, the operating time
shall be optimized.
The dryer has two desiccant drums, regeneration equipment, instrumentation, piping and
other accessories. While one desiccant drum is being operated, the other drum will be
automatically regenerated.
When using an electric heater for regeneration integrated into the desiccant drum, this heater
shall be capable of being maintained without affecting dryer operation.
6.2 Regeneration
The regeneration for heater type drier shall be at elevated temperature either at atmospheric
pressure or at operating pressure.
Regeneration for heatless air drier shall be at ambient temperature and atmospheric pressure.
The heat required for regeneration shall be supplied by electric heaters or steam heaters.
Notes:
1) When selecting electric heaters, it should be realized that these are large consumers of electric
energy (approximately 30 kW for a drier of 0.5 m3/s capacity at 15C and 1.013 bar abs.), and this
power must be available from emergency generators during prolonged power failures, e.g. for
more than 1 hour.
2) Heatless regeneration is preferable (See fig. 3).
Steam heaters shall be of good mechanical construction to avoid leakage into the desiccant
vessel.
For regeneration of heater type drier at atmospheric pressure the water vapor is removed by
means of air which can either be taken from the outlet of the drier (2-3 wt %) or be provided by
a separate blower; see fig. 4.
Where separate blower is used, the heater shall be external to the vessel; otherwise each vessel
may be internally heated.
Where internal electric heaters are applied, these should preferably be removable during
operation of the drier.
Where regeneration at atmospheric pressure is used, the vessel shall be depressurized slowly to
prevent blowing out and/or fragmentation of the desiccant and to reduce exhaust noise.
After the desiccant has been regenerated, the vessel shall be pressurized slowly before switchover.
For regeneration of heater type drier at operating pressure, the regeneration air is taken
upstream of a restriction in the drier inlet piping, heated by an electric or steam heater, passed
through the desiccant to be regenerated, cooled and (after separation of condensed water)
returned to the drier inlet piping downstream of the restriction (see fig. 5).
Fig. 5) Typical Drier With Regeneration At Elevated Temperature And Operating Pressure
Cooler and water separator shall be adequately sized. Quantity control for the regeneration air
shall be by means of a local flow indicating controller with low-flow interlock on the heater
and a pneumatically operated control valve with mechanical limit stop.
After the desiccant has been regenerated, it shall be cooled by a flow of cold air (For heater
type only).
For regeneration of heatless type drier, the water vapor is removed by means of air which shall
be taken from the outlet of drier (15-20 wt% as purge air to desorb the desiccant and carry the
moisture to atmosphere).
6.3 Filters
An air prefilter with a drain trap shall be installed at the entrance of the desiccant drum.
An air after-filter with a drain valve shall be installed at the exit of the dryer system.
For the desiccant type dryer, the filter mesh shall be less than 3 micrometers (microns).
Measures shall be provided so that the flow of air will not stop even in the case of
replacement or cleaning of the filter elements.
All filters shall be in duplicate and have isolating valves.
7 Calculation
7.1 Compressor capacity
The air compressor capacity is summation of plant air+wet air for instrument air.
10 percent over design shall be added to compressor capacity for air leakage of the
compressed air system.
7.1.1
Plant air
Please refer to item 1.1
7.1.2
Instrument air
The required instrument air shall be determined by instrument Department.
Process department also can estimate the required instrument air by considering
table 1.
The consumption thus obtained above shall be multiplied by 1.3 to account for
uncertainties in the data used for the estimate and for the installation of additional
instruments during the first years of plant operation.
For regeneration of air drier, especially for heatless type as the required quantity is
about 20% of drier outlet.
The wet air required for dryer to add to compressor capacity is obtained from the
following procedure:
Relative Humidity (RH)
40
52.6
Qdry air
918
Sm /hr
2.02
Psia
PH2o
0.808
Psia
RH *VH2o
Vdry air
13.892
14.7-PH2o
Qwet air
971.4
Psia
3
Sm /hr
Determine vapor pressure water at max. ambient temperature from steam table or software.
time
15
min.
P1
900
kPa (ga)
P2
final pressure
600
kPa (ga)
P0
atmospheric pressure
100
kPa (abs)
air requirement
50
Sm3/hr
receiver capacity
receiver diameter
4.17
m3
1210
mm
3630
mm
T=V
P1 P2
C P0
Use hold up time (T) based on design criteria, else assume 15 minutes.
Consider Initial receiver pressure based on design criteria (max. compressor discharge
press.), else assume 9 barg.
L/D=3
REV.
PREP'D
CHK'D
APPR'D
DATE
INSTRUMENT AIR
COMPRESSOR
PROCESS DATA SHEET
CHAGALESH
CONSULTING
ENGINEERS
ORIG.
ITEM NO.:
NO.REQUIRED :
PROJECT NO.:
SITE:
UNIT:
TYPE OF MACHINE:
ROTARY
NONLUB.RECIP
CENTRIFUGAL
LUBRICATED RECIP
TYPE OF DRIVER:
OPERATING:
SPARE:
OPERATING:
SPARE:
OPERATING CASE
CONDITIONS
GAS HANDLED
AIR
3
CAPACITY (1)
SM /HR
o
HUMIDITY
3
M /HR
MASS FLOW
KG / HR
o
SUCTION TEMPERATURE
MAX.SUCTION PRESS.
BARA
SUCTION PRESSURE
BARA
BARA
DISCHARGE PRESSURE
BARA
DIFFERENTIAL PRESSURE
BAR
COMPRESSION RATIO
(2)
(2)
MOLECULAR WEIGHT
TURN DOWN RATIO
START-UP GAS
GHP
KW
SITE DATA
DESCRIPTION
UNIT
ALTITUDE
CONDITION
REMARK
BAROMETER
BARA
O
MIN./MAX/AMB. TEMPERATURE
WINTERIZATION REQUIRED
TROPICALIZATION REQUIRED
UNUSUAL CONDITION:
DUST
FUME
OTHERS:
NOTES :
o
PROJECT:
PAGE:
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DISTRIBUTION TO:
1.PROCESS DEPT.
2.MECHANICAL DEPT.
DOC. NO. :
INSTRUMENT AIR
COMPRESSOR
PROCESS DATA SHEET
CHAGALESH
CONSULTING
ENGINEERS
REV.
PREP'D
CHK'D
APPR'D
DATE
ORIG.
ITEM NO.:
NO.REQUIRED :
PROJECT NO.:
SITE:
UNIT:
PROJECT:
PAGE:
OWNER:
OF:
DISTRIBUTION TO:
1.PROCESS DEPT.
2.MECHANICAL DEPT.
DOC. NO. :
REV.
PREP'D
INSTRUMENT
AIR DRYER
PROCESS DATA SHEET
CHAGALESH
CONSULTING
ENGINEERS
ORIG.
CHK'D
APPR'D
DATE
ITEM NO.:
SERVICE:
NO. REQ'D :
PROJECT NO.:
SITE:
DESCRIPTION
UNIT
UNIT:
OPERATING CONDITION
REMARKS
OPERATING CONDITION
REMARKS
SM 3/HR
CAPACITY
BARG
BARG
BAR
BARG
O
DESIGN TEMPERATURE
%
O
MM
SITE CONDITION
UNIT
ELEVATION
NOTE :
PROJECT :
PAGE:
OWNER :
DOC NO.:
OF:
DISTRIBUTION TO:
1.PROCESS DEPT.
2.CIVIL
MECHANICAL
DEPT. DEPT.
REV.
PREP'D
INSTRUMENT
AIR DRYER
PROCESS DATA SHEET
CHAGALESH
CONSULTING
ENGINEERS
ORIG.
CHK'D
APPR'D
DATE
ITEM NO.:
SERVICE:
NO. REQ'D :
PROJECT NO.:
SITE:
UNIT:
PROJECT :
PAGE:
OWNER :
DOC NO.:
OF:
DISTRIBUTION TO:
1.PROCESS DEPT.
2.CIVIL
MECHANICAL
DEPT. DEPT.
8 References:
1.
IPS-E-IN-200
2.
IPS-E-PR-905
3.
IPS-E-PR-905
4.
5.