Pete a SYSTEMS i Introduction to design, operation and maintenance Edited by ck Broughton 4. COMPRESSED AIR 41 retmooecrion Compresied ais saplied on industries for to mai wes — plat a for encase wa crument a er cently Bot of ee ates ge prsorzed ai typically 67 bar: Plant sir doesnt always need be died, tute aba fitered prevent des contaminating lo wig trent Airs ed to prevent coesation and water gathering in te tribution sytem and the contol mechanisms. Of for convenience, plant at and ‘strament a (neh stale eae hare he secret 421 REQUIREMENTS Pact is nora we for purging equipment contig inet gs oslo ‘eaty for maintenance. except where contamination with water and iis 2 [role I ao sed for diving tons ring atenance a Some in| ‘Process units ach a dom filing pps and aga. Becae this wie Imermitet, sevice sation ae oie provided 0 ste which canbe wed 19 ‘connect ito daring maintenance werk. These ols and wers ae at ambient temperatures and have shor resdence time forthe ait — that thea pases ‘trough very guy: for example, i devs on pnp. Therefore there it lie oppor for condensing wate 1 collect. Consequently the plat ix ‘normally fered, compeesied about 6-7 ba , cooked an wae condersed ‘mabea exchanger The bl of be wae femoved ina downteae separator andthe ars pase ino a service bender with bf tank a between 10 [rove wars wh sme capac Wo meet peak derarh, Therfore the a 9 {he rom dt di ati atropine with water, Deiat plautoo sit ‘ystems ae fen supplied wid ai frm oi ited compere, which {ncers tht hs ar ay cota trce of. Inver cold cimnes (for example, Ria, Cando Als) la at may requ dying. ers centr ean rw athe whe ed ce pie elas can be tought in. Ths compe «mob compres et (conker nd tert pus means of comeing tl bos.consumption design values for pneumati plants Planta, tntrument al, Nate Neh _ iene wit opiates) 1500 00 Cane 450 0 yerogen la reforming oid ey Spr lane v0 Boke 0 Water samen plant » Nivoge lat yoni uit) © (OW sytem coe et with sootgtome) 6 tment amen plant ry Aides Gorrepenerstion 5-15 toby oes) ‘pentagon (teas etry “The consamer for pint and oo! sr vary considerably andthe tre sould be stadiedceeuly to ascertain thei loads (average, peak) and heir Aturation before sizing. Table 4.1 provides some typical valves. It would be normal to ad a margin for contingency and Ture growth of the stem of ‘piel 50%, TYPICAL TOOL AIRUSERS [Note tha these are peak Fgues and tat average luds ae often 10-38% of thes valves Air boists0.5-50tomnes: 10-200! Drs na barmer: 12-80 Nm (Grinders 3-8" 20-85" renee 30-50Nm'm Blow guns 20a Send ast unis: 70-118 Nel Mos compressed air systems operate a7 br This means that the discharge resne of te sr comprenorhesto be about br gto scout fre preset Tose receiver drier, piping and controls 422 ARRANGEMENT fan appeciabe tae load ofr for smal ve i required, and he meas 8 rele source ofa is ecomiendd hata separ system i povided for Pla air The proposed sytem shauldconsist of wo ses of ites. compresors, ‘cooks and Water knock-out post ensure that good relat is provided. Valvng soul be incladed tallow easy maintenance of ach compresor ‘The contol system is aranged to ensue thatone machine is conte orn, idune seconds backup tors presre above the selected miimam, ‘Many installations ned oaly small wont of constant lant o tol sir ow, Whee the plantar low snot rl othe operation oy one plant compressor needs o be installed to give adequate eit In extreme «eases, no plot air ompressr may be needed becase te demand for scat iteey smaller iticimermient Thchoul adi desig whichncorportes 1 plata daw from th isrument compressor sytem. When te plant sirisasie raw, anupsteam pressure console shouldbe installed inthe plant tire to prevent encessve wage of plat ai starving the nsirument aye, “The rewire controler closes if too much ais ein deine from he nt inet ir system. ‘When designing an ar suply system care should he aka to ascenain the base and peak loads for plant and lstrament at to determine whichis ‘ominant Uta the instrument sit the dominant wer and the system is ‘evdoped around tha 43° INSTRUMENT AIRSYSTEMS 431 REQUIREMENTS ‘Thesirsytem should be capable of sopping instrament air, nd psi plant sir, consumers the peak smulaneows demand ate “Te instrument sr should alway edit dew pint tha will not «cause condnstion a he lowest ste smicatenperatse. Ir isften suggest 40°C at atmospheric pressure witb on UK ses. However. tines thisredaces the eit of he varios vendor’ rier packages. Therefore, for‘mos temperate climates sch a incon and southern Europe, a design deo point of 1°C below the minimum ambient emperature is suficiet. “The instrument sir sould be fe from soi, ol otous gases and any comosive material Theol content shouldbe ss than. n/N? wit atl ies es than 3 um. “Te presue ofthe instrament ai system shouldbe nthe region of7 ‘ar gandcersinly not less thin tar 16 ensure hat instruments and valves operate propery ‘Some proces user can draw a fom the instumea ar sytem. They may not have the ruiements for dew point and cleslins of contol systems butte wil probably ned posve protection measores to prevent backow of proces Mui ino te assem, These wes ncade * ili abies ystems servers for proces aid handing aches. ‘These systems should be supplied via separate header protected with 1 nontum valve as # minimim, and consideration given to an upstream rcsneconrler which loses on si ile nsring that the piety ofthe {instrument system at demand is maintained. There shuld ten ether connec- tio between the plant and instrument air stems. “Te quantity of msrumentaircan be assed based on the umber of enrol lope and whether the syem i preumaiclly conte or electronic cally controlled with paewmatic actos. Oler plans with aly poeumaic systems were generally sized onthe basis of about 3 Naa per lop and the tuition of growth design margin of 30-50%, Table 4.1 on page 40 gives tome typical consumption figure, Modern plans tendo be electronically controll with only the act tos using instrument ai Therefor, the las ofa confined the actuator itself n such eases he consumption i assumed tobe about I-15 Nn per loop and the capaciy ofthe instument af system is calulted from an assessment of lof the loops andthe adton of design or growth margin of 30-508, 432. ARRANGEMENT OF UNFTS “The instrumental sysem normaly comprises filet, compression, oo. ater, knock-out, eying, blferng of dry ar and daribtion to pant wer Standby equipment is highly recommended to ensure pt reliability. Figure 44.1 on pages 44-45 shows a ypc rangement with two compressors, Nor ‘mally wo 100% aircompressr, cooler separators, ries an buertanks re ‘nsallod For ager nits 3 50S machines maybe specified. Where possible ‘separate sours of energy shouldbe supplied foreach diver. This can be ‘ete motors supplied fom separate feeders an electric rive pus diesel ora Similarly relable configuation. The system shouldbe o configured as 10 nsure automatic staring ofthe sand by machine Asuming an arangement ‘vith wo 100% ty compresses is nse, the conta sytem shoul be set (ovals sugested in Table 2. Ture types of air compressors are possible, with the following approximate ranges of capaci : (1) reciprocating — upto 2500 Nah (2) serew —500-10,000 Neh: (G) centrifugal —600-50.000 Nh, ‘Tere are benefits of greater reliahilty with screw and centfugl units, However itis fiat to imagine instrament i systems alin fr the largest capacities inthe cena ange. The compressors shoul be specified ail free and purchased as packages including inlet tes, slencers, ves, Coolers, water tps, lube and seal systems, cantly and indication eqipen. Alteaiely, small ol ube sere compressors of capacity 50 Newruprards tne vsed with ol removal ystems. "The contol ofthe compressors shoud be automatic, sing the di- ‘charge presse, For example tthe pres ries above the required level recprcating compressors shuld ‘unoal! — that i he ileouet valves ‘howld open 10 that there ipo load on the mator and hence low power ‘consumption. Analarm should sound onthe stating of the stand-by compresae tonform the operator of potential problems with he duty machine ‘TABLE 2 Control etings fora twin air eompresso system Premere bare“The screw comprestor has god tumdown capabilities to abou 105, wits catia wll only tr down to 70% with power savings a constant Glscharge presure, Carey, centtugal machines do have Toudhnload facies sto scowireciprocatng machines. These fc have 10 be ‘ome in mind when selecting a compressor. ‘Teil ofthe compressors must be lcaed in a non hazardous aes so thar he nsrumest aire from bse of hydrocarbon ga “The tom fhe rin shod be oat a easnaedtnce ay 441061) above ground lve andthe inet opening shoud be Fed with a wie meth cage of adequate sie oprevent ey of objets which cel damage the ‘ompreso,Aocations whet rene ikl to acer provision sould be tmade to prevest ce formation onthe ire mesh The compres inlet piping requires 4 doe fer To redsce the load on the air dir, te ai from the ‘compresors should te cooled 1 a tenpentre no more thin 10°C above he ‘cooling men int, Care must be taken with vendor standard packages 10 ‘creuetha therequred outlet specfetion i flied "A war eparaor should be salled downstream of the afercoole of ‘each iecompresso and provided with shighlevl alam and anautomatc dain trap. The sir leving the separator shoul no be more then S% oer the strated ‘open under all operating contin Tn yer cold linates, due tothe compressor seal compton, the inlet, sirmay have tte eatedto maintain miimam temperature of-5°C at below this tempera the stl can permanent deform. Specification ofthe in ‘mum ambien temperatre mist be made and dscseed wit the compresoe ‘enor to ovensme problems beloe Focureen [Atleast wo dete! sets of air dierse normaly installed, ee pair on dty andthe other ton stacy. The chargeover between theses is manual. is radent to change sts very few week sing each set in tum ‘The a drier must educe the dew point of the ir—under operating temperature nd pressure at a maximom overstuation of $% doe to mist. ‘aryorer om the separator — 1 a least IOC below the lowest ambien temperature. ‘The a eis normally atwn-vesel orton ip, with regener. stion at levaed temperature (hemul swing), ra heals drier (ressure ‘wing, Sometines very smal packages based on reigeraionae used. Ther- ‘mal swing canbe a either atmoeperc pressure or at opeating pressure ‘Switching of te vessels is automa ‘Standud packages ike the oe in Figure 4.2 ae often selected. The L nts pn cat nw 42. Typ drier wit eles regeneration at mone eurelesican is usualy activa slminn or sca gel ead. When sili ge s ‘sed, a boom lye of approximately 10% of activated alumina can be po- ‘ied oacieve atte resstance earalred wae Ther ate ree mebods ofepeneato: + selevatd temperature and atmorperic ese (ermal swing with press # meleated temperature ad operaing pres (hema swing Without ress resin) * satmonpteripesue (esr wing eens. Het for regeneration, ifmqured.n supp ec hesters or Seam beaters extemal tothe drying ‘esl: Inihe cascf very mall nts hese can beside the ves Fee regeneration atmosherie pressure and levied temperature, ‘vate vapours emoved by means fa when usally taken Tom Be tet ofthe drier, using bout MEof he compresor out ‘Abeatls deer, cperaingat ambient temperature, vlleed 10-15% pr a oregonian "Where regeneration a imoapheri pressr is apd, the vessel i depress sow to prevent blowing out nor fagmentton ofthe desic- at After the desiccant has een reper the vesel is pessrize lowly tee switchover Siow veating and pressing reduce ne and damage 0 Ferregenertion atoperating pressure the fw conte of regeneration sir is by lal flow coool, with low-flow ito onthe hese and 3 eat opented con valve with atcha lini top. ‘Ax adequate numler of temperate sensi devices shoul be io sted in appropriae posts — er examps. int. owet ai bed —in order tormontor ihe regeneration ye ‘Aer the esicanthas ben regenerated at elevate temperature its ‘The err proved wit valves the veel inlet and oats for sitchin he vss rom he drying othe regeneration Sige and Vc versa. These valves may te pl bl pe, of eer une way o single fet Wi peuatic peaion which einelacke via sn atomatic ool pie. The ‘ye tine forte dies wil vary sonsidenbly depending onthe ype. Foe eats or press swing dies, «10 mines i pel cyte tne, For ‘hema swing diem 4-8 house mere oa. Preis hulle povided o prevent us particles fom sling on ‘he desicea. Afi stouldalvays be nstalledo preven deca pa ticks frm entering tear suply pring Because of te adoro hes gener ding te dying yee he ‘outt temperature ofthe dir may ise, sometimes sigh as 50 or OC the tir des not col dowa 640°C maxinum afer leaving the Ble ese, Meroe shuld be iste, 435° BUFTER VESSELS (One ce more turer vests re sully stalled downstream of he a rs to «+ bufer volume inthe vent of compressor file damper wen compessarsare on led/unlon con: 1 system sug capac. ‘The tsfer velista maintain th isupy between he tan ‘of comprestot false and the instant atthe standby compressor stato ‘operas The rerio been hese eves soul be taken a the ime reseed forstating estan by compressor marly etomatc staingisonsses- fa Tas period shouldbe agree plat operatons and engincerag and eof at leat minses dation; 10-15 minus is reuetly eed ‘The design possre tld be abe or test off or surge cn ‘utp: a the mcumulaed pres. Ar vale alwys equ, se for theficase The design tempentre shel be ieitble forthe hiph epee tp pent owsren of compen aercooh. “The ome the ber vss can becalcltl fom he flowing: £ a time hour sone = Lor bers na reset nepest ones contr ting for duty machine Py = final ressore bar g(siggest 42 bar > Cole tow eNOManos ewes Typicaarangmentt ne heer runs 4436 INSTRUMENT HEADER ARRANGEMENT sowing are ui stations wit plat a daw fom the se header is ‘some ta hs pln afore use oly. The prs crop ny arto the header sytem shouldnt be mor thanaboutO1 tO frm the uff tant oe ose. 4A. OPERATIONAL ANDMAINTENANCE ASPECTS (Oferaoal ard maintenance spec of instrument ai sjsems we ratvely sthightrward and depend raotacnre’ reemmendaa fr con resorsand ders. Parca oie wach inca the fllowing: 1 pul ispection (ay well) of les dovnsteum of te compres I iltubricted maces ae wed fr plat ar systems then more fequent inspection and rind of fers ecmmended to ayo ui of i ech cul be potently hazardous 1 regu inspection of coaionf dees (anally + taal inspection of cangever valves es « regule moatly montving of dew pon of ar — usualy taken fom te er tanks 1 gute blowing Grou of ke pine et somal wed check fo ny uik-up wate, (Clean, -re air tems have few poten za. The main oe is when using incest ded eaipmen: proper goggles and gloves motte worn 0 prevent injury Compress irs nd th bur vasel mst al have over Prosi eliefinstalle conn proper safety of these rection mst be we sucesso " ‘outorcned sytemssboud regulary loan downtocheck foray uid poo whic oul ead exploias ndlor res de to vetting. 46 TeruTRE ane slowly being phased ot lecrni cml syste the nen in ew innate Distt orl stems (DCS) fear greyed spend of respense tthe operuoy, bt the use of DCS an conputer coal ‘ysems scent mesn a sume wil eps ont wil meey be ec in ie Rather thar go e expensive mura valves mat pla tarator retain ira the safer oie fore t0 operte contol aves bt we tlestoipeimaiconeren to ctnect up to mort responsive DCS. ‘The equipment wed 59 compre, dry and ier at fn bey 0 otal beng aires and impoved