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Home > Confirm Best Practices for Compressed Air in Refineries

Confirm Best Practices for Compressed Air in

Refineries

Within a refinery, four main utilities are considered essential to operations: electricity,
natural gas, water and compressed air.

Within a refinery, four main utilities are considered essential to operations: electricity,
natural gas, water and compressed air. If a refinery were to lose access to any of these
utilities, it would be forced to shut down. Therefore, understanding the characteristics of
each utility—including compressed air—and the equipment that is reliant upon them is
crucial.

Compressed air is an important element for many processes within the petrochemical and
oil refining industries. First, compressed air acts as a medium for the transfer of energy,
which is critical to power equipment such as drills, jack hammers and air-powered tools,
among others. Compressed air is also used elsewhere in refineries to move material such
as paint, oils, cylinders for industrial and automation, and brakes on large equipment.

Compressed air is also utilized in a refinery for breathing gas when operations face
confined space requirements. Additionally, it controls precise measurements and
calibration in the production of gases and liquids during operation of specific machinery
and instrumentation.

For more than 140 yr, compressed air has been a critical tool used to help drive the
industry. Due to its nature, compressed air is a stable process for process equipment
needed for drilling, pneumatic tools, power machinery and generators that produce light
without combustible fuels. Types of compressors found in refinery and petrochemical
facilities include:

• Compound compressors
• Rotary screw compressors
• Rotary vane compressors
• Scroll compressors
• Turbo compressors
• Reciprocating compressors
• Centrifugal compressors

Refineries most commonly use electrically-driven reciprocating, rotary screw and

centrifugal compressors based on the specific application for which they are being utilized.
These compressors are then classified by the amount of pressure they produce:

• Low-pressure compressors produce 150 psi or less

• Medium-pressure compressors produce 151 psi–1,000 psi
• High-pressure compressors produce more than 1,000 psi

COMPRESSOR TYPES

Reciprocating Compressors

These compressors are generally used for smaller applications within the refinery. Several
types of reciprocating compressors exist:

• Single-stage, < 5 hp range

• Two-stage, 5 hp–30 hp
• More stages are added to increase hp range

A piston-stroke type air compressor pumps air into a tank to a required psi, distributes the
air as required and maintains the maximum psi within the tank. These positive
displacement compressors force air into a chamber that decreases by the demand of
compressed air.

Rotary Screw
Compressors

These compressors (FIG.

1) use positive
displacement
compression by matching
two helical screws that
guide air into a chamber
when turned, decreasing
the volume as the screw
turns. Alternatively, rotary
vane compressors use a
slotted rotor with varied
blade placement to guide
air into a chamber and
compress the air. This
results in fixed air at high pressure.

Centrifugal Compressors

Centrifugal compressors are most commonly used in very large applications within
refineries. Rotating components impart kinetic energy to the air, which is eventually
converted into pressure energy. A centrifugal force is generated by the impeller to capture
and then pressurize the air.

Two types of centrifugal compressors are used in a refinery environment: oil-lubed

compressors, which are very common, and oil-free compressors, which are louder and
more expensive. Oil-free compressors come in different forms: oil-free centrifugal
compressors, oil-free screw compressors and oil-free tooth compressors.

When an application calls for 100% oil-free air, an oil-free centrifugal compressor is
appropriate. Due to the ultra-high-speed electric motors used to drive impellers, it contains
a compact compressor without a gearbox and associated oil-lubrication system, making it
oil-free. These types of compressors are an optimal solution for an engineered skid
combined with dryers, controls and receivers. If the priority is superior reliability and
efficiency, often due to very harsh conditions, oil-free screw compressors are ideal.
Furthermore, these compressors can be engineered with a fire-proof canopy and
additional controls on an engineered skid.

When the efficiency in energy consumption is important, oil-free tooth compressors are
often selected. This compressor utilizes a symmetrical, dynamically-balanced rotor that
facilitates efficient and oil-free compression.

Finally, low-pressure blowers and compressors are generally used for applications that
require low-pressure air. This can be in the form of aeration, pneumatic conveying and
sulfur recovery, among others.

Temperature

The heat that is generated from compressing the air, air-water or oil (as required for rotary
type compressors) is used to cool the compressors. When the air is compressed, it
contains more water vapor than high-pressure air can hold. This relative humidity
(dewpoint) plays a large role in the quality of the compressed air. When air is compressed
at temperatures above its dewpoint, it becomes saturated with moisture. When the
temperature of the compressed air is below the dewpoint, condensation will occur.

Coalescing should be done at the lowest possible temperature to preclude moisture

precipitation. At low temperatures, compressor oil varnish accumulation and large
accumulations of dirty finger prints on the coalesce elements can all cause high differential
pressure and lead to lower coalescing efficiency and, eventually, premature element
failure.

Compressed Air Filters

Compressed air filters are an important element in a refinery. These compressed air filters
come in various forms, including coalescing, water separator, vapor removal and
particulate removal.

A combination of particulate (FIG. 2), coalescing and

sub-micron post-filters protect equipment and
instrumentation by removing oil, water and
particulate that can adversely affect the refineries
process. In areas where very delicate instruments
are in service, an adsorbent filter is recommended.

Water separators remove bulk liquid at any point in a

compressed air system. They provide protection to
the pre-filtration train prior to membranes and
desiccant dryers. Additionally, water separators
remove liquid from compressor intercoolers and
aftercoolers, and provide liquid separations within
refrigeration dryers.

Vapor removal compressed air filters are useful for

odor removal, breathing air, high-purity gases and
hydrocarbon vapor removal.

Compressed air filters should always be placed downstream of the receiver. If no

aftercooler is in use or the aftercooler is inefficient, a coalescing filter should be installed
as close to the point of use as possible. Air saturated with water vapor leaves a
compressor at 240°F–400°F (116°C–204°C). Without an aftercooler, the air cools close to
ambient in the distribution lines, and water condenses throughout the air distribution line.
Two-thirds of the total water content of the air will be condensed when it has cooled to
100°F (38°C). A filter located just before the main airline will branch into smaller
distribution lines and remove most of the water load from the system.

Many refineries use compressed air filters that have polycarbonate bowls. These are
suitable for use in normal industrial environments but should not be used in areas where
they could be subjected to direct sunlight, an impact blow or temperatures outside the
rated range. Also, they should not be exposed to chlorinated hydrocarbons, ketones,
esters and certain alcohols, nor used in air systems where compressors are lubricated
with fluids such as phosphate ester and diester types.

In all applications where a polycarbonate bowl is in use, a properly fitted metal guard
should be attached to the bowl to protect against any issue resulting in a rupture. Metal
bowls are useful where ambient and/or media conditions are incompatible with
polycarbonate bowls. Metal bowls can resist the effects of most solvents but should not be
subjected to salt laden atmospheres nor used where strong acids or bases are present.

All safety precautions must be followed when working with and sizing compressed air
filters, as safety is paramount to an efficient process. A responsible person must be
available to supervise the regular inspection and maintenance of compressed air filters.
For extensive amounts of filters within the refinery, some form of written system of
planned maintenance should be used, and records of tests, repairs and modifications
should be kept. In addition to any maintenance required by governmental requirements,
daily, weekly, monthly, quarterly and by-yearly procedures should be implemented.

• Daily—The procedure should include daily checks of the compressed air filters for
leaks and repairs that must be carried out, as necessary. At the end of each day,
any accumulation of water should be drained from the drain ports. The drain valves
should be inspected to make sure they are not choked with sediment. Those
responsible for compressed air quality should be notified if the water contains
hydrocarbons that do not drain to a controlled environmental sump.
• Weekly—At the end of each week, airline lubricators should be filled, as needed,
with the correct grade of oil and checked to ensure they are providing adequate but
not excessive lubrication. Compressed air filters should be checked; those that are
clogged or causing unacceptable flow restrictions (dp) should be replaced.
• Monthly—All connections should be inspected for signs of cracking or deterioration
and be replaced, as necessary. Every 3 mos, the valves and leaks should be
replaced. New vessels may be required, and filter cartridges may require
replacement.
• Twice per year—The coalescers, pre-filters and final filters should be replaced, and
the air supply must be checked so it operates freely.

Before any pressurized components are dismantled, they should be effectively isolated
from all pressure sources and completely vented to atmosphere. Manufacturers or local
suppliers typically supply clear instructions on how to service compressed air filters.

Compressor Oil Filters

Another critical piece to keeping a compressor running efficiently is the use of oil, which is
primarily used to cool anything mechanical within the compressor. This oil will have a
specific ISO code that is used to identify the machine’s capabilities according to the
manufacturer. This code is important, as it points to the cleanliness level standard.
Attention to this detail is gaining wide acceptance in the industry. The struggle comes in
maintaining the code due to the amount of particulate in the atmosphere. While in the
compressor, this particulate can be difficult to maintain. Leakage seals are utilized.
However, in doing so, the potential of particulate in the water from the seals breaking
down increases.

If ISO codes with compressors dictate that particles within the oil must be less than a
specific number of microns, proper filtration must be implemented. One method is to
properly filter the oil as it goes into the compressor. In this scenario, the oil sits in a pump
as it is being circulated through the compressor. These filters can either be paper or
synthetic.
The second option is to install a filter that not only handles the problem with particulates
but is also designed to properly filter out water. In these situations, a kidney loop system
can be installed on the compressor’s oil reservoir. These filters are known as oil
conditioners.

As the compressor ages and begins to leak, humidity can become an issue, caused by
factors that include the type of tank and where it is located. Many of these tanks are
submerged underground. In a dry area, fewer problems arise. Humidity breaks down the
oil, diminishing its quality. If it is protecting equipment and keeping heat dissipated, the
present water can turn into steam. This can affect the metals it is supposed to be
protecting. Hot water can crack a bearing. To avoid these kinds of issues, this oil should
be checked daily.

Static can also be an issue with oil filters. Often, static can occur in the oil, causing the
filters to break down quickly. Fortunately, available filters are designed specifically to
handle static.

Maintenance

Servicing a main compressor requires a planned shutdown in a refinery. However, as

these shutdowns can sometimes take years to be scheduled, some temporary
workarounds can be performed. Rental equipment can be used to address any water
issues a plant may be experiencing with a compressor. In these situations, oil can be
recirculated until it reaches an acceptable cleanliness level and then maintained until the
next planned outage.

Planning for routine maintenance during a planned outage is critical to avoid complete
failures in refineries. Those failures come with a significant cost. Emergency, unplanned
shutdowns can often cost a refinery up to five times as much in repairs than during a
planned outage.

Article featured in Hydrocarbon Processing Magazine

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