Compressed Air System For Chemical and Industrial Plants

TCE CONSULTING ENGINEERS LIMITED SECTION: TITLE
TCE.M1-ME-640-007 SHEET i OF iii

BASIC STUDY GUIDE FOR
COMPRESSED AIR SYSTEM FOR
CHEMICAL AND INDUSTRIAL PLANTS

FLOPPY NO. : TCE.00000-ME-FP-130

FILE NAME : M1ME007R1.DOC
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DATE 99.08.23 01.08.13
TCE FORM NO. 020R2

TCE CONSULTING ENGINEERS LIMITED SECTION: CONTENTS
TCE.M1-ME-640-007 SHEET ii OF iii
CONTENTS
SL. NO. TITLE SH. NO.
1.0 SCOPE 1
2.0 INPUT DATA 1
3.0 SYSTEM DESIGN 2
4.0 AIR RECEIVERS 10
5.0 MATERIALS AND CODES OF CONSTRUCTION 10
6.0 AIR DRYING PLANT 11
7.0 EQUIPMENT AND MOTOR LIST 13
8.0 SPACE REQUIREMENT 13
9.0 COST ESTIMATES 13
10.0 RECOMMENDATION 13
APPENDICES
1. GUIDELINES FOR USING COMMON OR SEPARATE 14

COMPRESSORS FOR SERVICE AND INSTRUMENT AIR
2. COMPARISION OF RECIPROCATING, CENTRIFUGAL 15

AND SCREW TYPE COMPRESSORS
3. CAPITAL AND TOTAL COST 17
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TCE CONSULTING ENGINEERS LIMITED SECTION:
TCE.M1-ME-640-007 SHEET iii OF iii
REVISION STATUS
REV. NO. DATE DESCRIPTION
R0 99.08.23 ---------
R1 01.08.13 Generally revised.
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TCE CONSULTING ENGINEERS LIMITED SECTION: WRITE-UP
TCE.M1-ME-640-007 SHEET 1 OF 18
1.0 SCOPE
This guide covers guidelines for carrying out a basic study for compressed air system for
chemical and industrial plants. For format, structure and other guidelines for preparation
of basic study refer TCE.M9-PCS-25. The objective of the basic study is to identify a
cost effective and appropriate compressed air system to generate required quality and
quantity of compressed air. Also covered are guidelines for selection of various
equipment like compressors, inter-coolers, after-coolers, oil-coolers, air receivers and
air drying plant etc. The basic study shall form the basis for procurement and detailed
engineering of the compressed air system.
2.0 INPUT DATA
2.1 Quantity, quality and pressure requirements for service air. Service air means wet air as
coming out from the after-cooler or from the compressor, if there is no after-cooler. In
addition to moisture, it may also contain small quantity of oil. Refer TCE.M6-ME-640-
011 “Design Guide for Compressed Air System” for estimation of service air
requirement. For neutralizing pits of effluent treatment plants also, service air may be
required.
2.2 Quantity, quality and pressure requirements for instrument air and process air.
Instrument air is dry and oil-free air with a dew point as (-) 400C at atmospheric
pressure. Temperature of instrument air is generally 40 °C. Process air is dry and oil-
free air used for pneumatic conveying, agitation in agitated vessels, reaction vessels, air
scouring of pressure sand filters etc. However air required for scouring of pressure sand
filters need not be dry air. Refer TCE.M6-ME-640-011 “Design Guide for
Compressed Air System” for estimation of instrument air requirement. Requirement of
process air shall be derived from other basic studies.
2.3 Maximum ambient temperature, maximum relative humidity and height above Mean Sea
Level (MSL) of the site.
2.4 Details of cooling water system like quality of water, minimum and maximum pressure at
inlet to compressed air system, allowable pressure drop, maximum inlet temperature
and allowable temperature rise.
2.5 Electrical power supply voltage levels
2.6 Details of existing compressed air system, in case of expansion project.
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3.0 SYSTEM DESIGN
3.1 COMPRESSORS
3.1.1 Design Calculations
Based on input data, following design calculations shall be carried out:
(a) Capacity and discharge pressure of compressors
(b) Conversion of capacity in NM³/Hr to volume in M³/Hr at site conditions i.e.

Free Air Delivery (FAD)
(c) Drive motor ratings
Refer TCE.M6-ME-640-011 “Design Guide for Compressed Air System” for norms
and guidelines for carrying out these calculations.
3.1.2 Common versus Separate Compressors
For service air lubricated reciprocating, centrifugal or screw type of compressors are
required. For instrument air and process air non-lubricated reciprocating, centrifugal or
screw type compressors are required. Hence, if only service air or only instrument air
and process air is required, suitable type from reciprocating, centrifugal and screw
compressors shall be selected based on availability, equipment cost, foundation cost,
power consumption, space availability, operation and maintenance aspects. However, if
service air and instrument and process air both are required, guidelines given below may
be followed and economic analysis for various alternatives may be carried out before
making a decision. In following paras words “instrument air” shall mean “instrument air
+ process air”
(a) If pressure requirements for service air and instrument air are equal or nearly
equal and total requirement is less than or equal to 500 NM³/Hr, common non-
lubricated compressors for both the services may be considered.
(b) If pressure requirements for both the services are equal or nearly equal and total
requirement is more than 500 NM³/Hr, separate compressors may be
considered if instrument air requirement is upto 30 % of the total requirement.
Common non-lubricated compressors may be considered if instrument air
requirement is more than 30 % of the total requirement.
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(c) If pressure differential for service air and instrument air is large and total
requirement is less than or equal to 500 NM³/Hr, common compressor with
pressure reducing station may be considered.
(d) If pressure differential for the two (2) services is large and total requirement is
more than 500 NM³/Hr, separate compressors for each service may be
considered.
Appendix 1 gives these guidelines in a tabular form.
3.1.3 Types of Compressors
Generally reciprocating, centrifugal and screw compressors are used to meet the
compressed air requirements. Following guidelines may be considered for selection of
type of compressors :
(a) Reciprocating compressors are available in both lubricated and non-lubricated

types. Generally, horizontal or vertical or horizontal balanced opposed type
models are used. The capacity range is upto 10,000 NM3/Hr and can develop
pressure upto 500 Kg/cm2 (g).
(i) Vertical compressors are available and shall be used upto 500
NM3/Hr with discharge pressure of 10 Kg/cm2 (g).
(ii) Horizontal compressors are used for higher capacities. Considering

economics of foundation, horizontal balanced opposed compressors
shall be used.
(b) Centrifugal compressors shall be used for 5,000 NM3/Hr and higher capacity
requirements, though these are available in the range of 1,500 NM3/Hr to
42,000 NM3/Hr and can develop pressure upto 85 Kg/cm2 (g).
(c) Screw compressors shall be used for requirements upto 5,000 NM3/Hr
capacities and pressure of 50 Kg/cm2 (g). However, only lubricated type is
indigenously available. These are compact units and selection shall be on case to
case basis. Foundation requirements, space requirements are low.
(d) In case of expansion projects, existing compressed air system may be

augmented by adding similar compressors as existing ones so to have similarity,
less spares inventory, etc.
Comparison of various types of compressors is given in appendix 2.
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3.1.4 Number of Compressors
(a) In case of reciprocating compressors at least one standby compressor shall be

provided. Standby is generally of 100 % capacity. For example, if 1000
NM3/Hr is the requirement two (2) compressors each of 1000 NM3/Hr shall be
provided. However considering specific requirement like cost, necessity of
simultaneous consumption etc. one (1) 50 % standby also may be considered,
i.e. three (3) compressors each of 500 NM3/Hr shall be provided to cater 1000
NM3/Hr of air requirement.
(b) In case of centrifugal compressors and screw compressors standby

compressors may not be provided. Provision of standby compressor shall result
in non-economical alternative, as compared to reciprocating compressors.
However, if these compressors are selected due to various other reasons or
advantages, it is suggested to provide one (1) 50 % or one (1) 33 % standby
compressor.
(c) Based on capacity and discharge pressure, motor rating of compressor shall be
calculated as per TCE.M6-ME-640-011 “Design Guide for Compressed Air
System”. In case motor rating is above 175 kW and power supply is available
only at 415 V, re-selection of compressor capacity may be necessary. This
aspect shall be decided in consultation with project electrical engineer.
3.2 INTER-COOLERS, AFTER-COOLERS AND OIL-COOLERS
3.2.1 Inter-coolers are provided between two (2) stages of a multi-stage compressor. These
inter-coolers cool the compressed air coming out from one stage thus reducing inlet
temperature of air being compressed in the next stage. As a result, power consumption
is reduced.
3.2.2 After-coolers are provided after the last stage of the compressor. This is to bring down
the temperature of air coming out from the last stage of the compressor to the required
value, so as to make it suitable for operating various valves, instruments and actuators.
3.2.3 Inter-coolers and after-coolers are normally water cooled. These are normally shell and
tube type heat exchangers with counter-current flow. These shall be designed and
fabricated as per ASME and TEMA.
3.2.4 Cooling Water Requirement
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(a) Cooling water is required for jacket cooling of compressor, inter-coolers and
after-cooler, etc. Quantity of cooling water may be estimated based on
following guidelines and shall be checked later with bidder’s and vendor’s data.
(b) Cooling water quantity may be found out by equating heat lost by compressed
air to heat gained by cooling water.
(c) Heat lost by compressed air shall consist of (i) Heat lost by dry air and (ii) Heat
lost by water vapour.
(i) Heat lost by dry air = m × Cp × Dt
Where,
m = Mass of dry air in Kg/Hr,
Cp = Specific heat of air at constant pressure ≅0.245 Kcal/Kg- °C
Dt = Temperature difference between inlet to cooler and outlet from
cooler in °C
(ii) Heat lost by vapour = Sensible heat + Latent heat
Sensible heat = mass of vapour in Kg/Hr × specific heat of vapour (≅0.45

Kcal/Kg-°C) × temperature difference between inlet to
cooler and outlet from cooler in °C
Latent heat = mass of condensate in Kg/Hr × latent heat of condensation (=

542 kcal/Kg)
(d) Mass of dry air shall be found out by formula PV = nRT
Where,
P = Pressure of dry air at inlet in Kg/M2
V = Volume of air (FAD) at the inlet in M3/Hr
R = Gas constant for air = 29.27 Kg-M/Kg- °K
T = Temperature of air at the inlet in °K
n = mass of air in Kg/Hr
A typical example is given below :

Compressor capacity = V = 1000 M3/Hr
Temperature at Inter-cooler inlet = 162 °C
Temperature at Inter-cooler outlet = 40 °C
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Air at Inlet of First Stage Air at Outlet of Inter-

Cylinder Cooler
Pressure P1 = 1.012 Kg/cm2 P2 = 2.89 Kg/cm2
Temperature T1 = 48 + 273 = 321 °K T2 = 40 + 273 = 313 °K
Relative Humidity RH1 = 81 % RH2 = 100 %
Saturated Vapour Pv1 = 0.1139 Kg/cm2 Pv2 = 0.0753 Kg/cm2
Pressure *
Specific Humidity ** 0.0624 0.0166

* From Table 2 of Chapter 6
** From Equation 21 of Chapter 6
1993 ASHRAE HANDBOOK FUNDAMENTALS
Cooling Water Inlet temperature (32 0C)
Wet Air at 435 0 K

(Dry Air + Water Vapour)
SECOND
FIRST STAGE INTER- AFTER-
STAGE
CYLINDER COOLER COOLER
CYLINDER
Cooling Water Outlet temperature (37 0C)
P1 = 1.012 Kg/cm2 P2 = 2.89 Kg/cm2

AIR LINE T1 = 321 0K T2 = 313 0K
V1 = 1000 M3/Hr (FAD) RH2 = 100 %
WATER LINE RH1 = 81 %
FIGURE 1
∴P = [1.012 – (0.81 × 0.1139)] × 104 Kg/M2
= 9197.41 Kg/M2
PV 9197 .41 × 1000
∴ Weight of dry air (n) = =
RT 29.27 × 321
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= 978.9 Kg/Hr
Heat Loads
(i) Heat lost by dry air = 978.9 × 0.245 × (162-40)

= 29259.28 Kcal/Hr
(ii) Heat lost by water vapour
Sensible heat = 978.9 × 0.0624 × 0.45 × (162-40)

= 3353.47 Kcal/Hr
Latent heat = 978.9 × (0.0624-0.0166) × 542

= 24299.80 Kcal/Hr
Total heat lost = 29259.28 + 3353.47 + 24299.80 = 56912.55 Kcal/Hr
(e) Heat gained by cooling water = Q = m × Cp × Dt
Where,
Q = Heat gained by cooling water in Kcal/Hr
m = Cooling water flow rate in Kg/Hr,
Cp = Specific heat of water (1.00 Kcal/Kg- °C)
Dt = Temperature rise in °C
Considering maximum temperature rise as 5 °C
56912.55
m= = 11,382.5 Kg/Hr = 11.38 M3/Hr
1× 5
≅ 11.4 M3/Hr
Generally, compressor jacket cooling is in series with inter-cooler as indicated in figure

1. Considering temperature rise in jacket, quantity of cooling water passing through
inter-cooler shall be increased by about twenty-five (25) percent, e.g. in above example
11.4 × 0.25 = 2.850 M3/Hr shall be added to 11.4 M3/Hr. Hence total quantity for
inter-cooler with jacket cooling shall be 11.4 + 2.85 = 14.25 M3/Hr.
Cooling water quantity for after-cooler shall be calculated on similar lines as given for
inter-cooler. However no additional requirement for jacket cooling is to be considered
in this case.
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(f) Another method of finding cooling water quantity is given below :
(i) Find out Motor rating (HP) of the compressor as per design guide
TCE.M6-ME-640-011.
(ii) Assuming isothermal compression,

HP × 4500
Heat generated = Kcal / Min
427
(iii) Consider temperature rise of cooling water as 5 °C
HP × 4500 60
Quantity of cooling water in M3/Hr = ×
427 × 5 1000
= 0.126 × HP
(g) After finding out cooling water quantity by two methods given above, higher of
the values shall be considered.
3.2.5 Oil-cooler (if provided) shall be designed and fabricated similar to inter-cooler and
after-cooler.
3.3 CAPACITY CONTROL
Capacity control means adjustment of the quantity of air supplied by the compressor to
suit the fluctuating demands. Methods as described in following paragraphs are used
for capacity control of compressors.
3.3.1 By Speed Variation
The amount of air delivered is controlled by varying the speed. This can be used
effectively if compressor is driven by a steam engine or steam turbine or diesel engine or
DC shunt motor.
3.3.2 At Constant Speed
(a) Automatic start-stop - This method is advantageous in cases where an AC

electric motor is used and when there are sudden large demands for
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compressed air followed by periods of very small consumption or no

consumption at all.
(b) Load-unload of suction valve - This method is advantageous if demands keep

on fluctuating i.e. large demands are followed by small consumption for a short
period and demand is increased again.
(c) Throttling the suction line - In this method, the amount of air delivered by the
compressor can be controlled by throttling the suction line and thus reducing the
amount of free air delivered.
(d) By-passing air from delivery to suction line - The air is by-passed from delivery
to suction line by means of a by-pass valve.
(e) Increasing clearance volume - The clearance volume is created by using a

clearance pocket.
(f) Variable filling using a by-pass valve – In case of screw compressors, a by-pass
valve located at the top of the casing at some point along the length of casing, is
opened. This allows some of the induced air to be displaced back to suction.
Depending upon the pressure ratio for which the machine is designed, the
quantity of air thus delivered can be reduced. Similar variation is achieved by
slide valve operation. In this method the slide valve moves parallel to the rotor
axis and changes the area of operation at the bottom of the rotor casing. This
lengthens or shortens the region of compression gap of the rotor and returns the
air to the suction side before the compression has taken place.
(g) Movable inlet guide vanes - The movable inlet guide vane adds pre-whirl to the
air stream entering the impeller, which in turn, reduces the axial component of
the absolute velocity. The vanes are located directly in the flow path
immediately in front of the impeller. The vanes are operated manually or by and
automatic control through linkages.
(h) Combination of above methods
3.3.3 Methods employed for capacity control of various types of compressors are given
below:
(a) For reciprocating compressor
(i) By speed variation,

(ii) Automatic start-stop, load-unload,
(iii) By-passing gas from delivery to suction line.
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(iv) Increasing clearance volume and

(v) Combination of (ii), (iii) and (iv)
(b) For centrifugal compressor

(ii) Movable inlet guide vane
(c) For screw compressor

(ii) Automatic start-stop, load-unload,
(iii) Throttling the suction line,
(iv) Variable filling using a by-pass valve and
(v) Combination of (ii) and (iii)
4.0 AIR RECIEVERS
4.1 Air receivers help to dampen the pulsations created in case of reciprocating
compressors and screw compressors and help to condense and trap the moisture in the
compressed air, and also to let oil and other impurities settle down before air is
conveyed to users. Air receivers also supply compressed air during starting of stand-by
compressor.
4.2 The capacity of air receiver shall be calculated by three (3) methods as given in
TCE.M6-ME-640-011 “Design Guide for Compressed Air System”.
5.0 MATERIALS AND CODES OF CONSTRUCTION
5.1 Materials and codes of construction for various compressor components shall be as per
applicable code i.e. API 617, 618,619 or 672.
5.2 Materials of construction for inter-cooler, after-cooler and oil-cooler, considering fresh
water as cooling medium, shall be generally as follows:
(a) Shell - Carbon steel as per SA 106 GR B or IS 2002

(b) Tubes - Copper or Admirality brass as per BS EN 1057 except for eddy
current test
(c) Tube sheets - Carbon steel as per SA 105 or IS 2002 or brass or SS 316
(d) Tube support plate - IS 2002
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Specific material shall be selected based on case to case basis depending on application
e.g. if sea water is used as cooling media, material of contact parts may be titanium or
monel or carbon steel with rubber lining etc.
5.3 Materials of construction for air receiver shall be generally carbon steel as per IS 2002
or IS 2062. Air receiver shall be coated internally with black bituminous paint. Code of
construction shall normally be IS 2825.
5.4 Material of inter-connecting piping for compressed air and cooling water shall generally
be grade CA and grade GA as per TCE.M6-ME-590-428 “Guide for the Selection of
Piping Materials for Utilities”. If project specific piping material specifications have been
prepared for these services, same shall be followed.
6.0 AIR DRYING PLANT
Instrument air and process air have to be oil free and moisture free. Dry air with (−)
400C atmospheric dew point is required for the instruments etc. Non-lubricated type
compressors are used to get oil free air. However, to get moisture free air, air drying
plant has to be used. Following types of air drying plants are available:
(a) Desiccant type
(b) Refrigerated type
6.1 DESICCANT TYPE AIR DRYING PLANTS
In this type of air drying plants, a desiccant that has affinity for water vapours, is used.
Alumina, molecular sieves and silica gel are commonly used desiccants. Water vapour
molecules are removed by means of adsorption. The plant consists of two (2) desiccant
chambers complete with interconnecting piping, change-over valves, heaters, etc.
Operation of the plant is fully automatic.
Desiccant is loaded in desiccant chambers and wet compressed air is directed to flow
through one of them. Water vapour from the air is adsorbed on surface of the desiccant
granules. Eventually, when the desiccant reaches its moisture adsorption capacity,
change-over valves are operated such that wet compressed air flows through the
second chamber. One with the saturated desiccant is regenerated and restored to the
original water adsorption capacity by various methods. While one of the chambers
undergoes ‘regeneration’ other one undergoes ‘adsorption’. Hence dry air is available
at the outlet of the plant without interruption. Depending on method of regeneration,
desiccant type air drying plants are classified further as :
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(a) Blower Reactivated Type
In this type, external blower and heater are used. Hot air from this external
source is used for regeneration of desiccant. These are not preferred as more
mechanical equipment are involved and more power is consumed.
(b) No Purge Loss - Split Flow Type
In this type, a part of wet air is diverted for regeneration, using distributor. This
air passes through a heater, gets heated, passes through the chamber under
regeneration. Thus water vapour adsorbed during previous cycle is carried
away by hot air. This air is then passed from a cooler and moisture separator
and the excess moisture is removed. This wet air again joins back the main
stream through distributor.
This is the most commonly used type and is suitable for almost all capacities.
However, considering requirements, it is suggested that one unit of maximum
5,000 NM3/Hr shall be used. If requirements are higher, more units shall be
used.
(c) Heatless Type
In this type, a small amount (approximately 10 to 15 %) of dry compressed air

is passed through the chamber under regeneration to take away the moisture.
This air is then purged out. As there is loss of compressed air, these are used
for small capacity plants (say upto 2,500 NM3/Hr). However, decision shall be
taken on case to case basis.
(d) Heat of Compression Type
In this type, after-cooler is not provided. Hot air as coming out of compressor is
used to regenerate the desiccant. This type of air drying plant requires insulation
of interconnected piping, air receiver etc.
Additional cooler is also required as explained below :
In order to regenerate desiccant, heating cycle is followed by cooling cycle.
Since after-cooler is not available for this type of drying plant, additional cooler
will be required to cool the air coming out of compressor during cooling cycle.
Passing of air through the cooler is achieved by means of change-over valves.
These can be used for almost all applications similar to ‘No purge loss split flow
type’. Installation cost is higher but the same is generally recovered well within
one (1) year of operation, as there is considerable power saving.
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6.2 REFRIGERATED TYPE AIR DRYING PLANT
In this type of air drying plants, the wet compressed air is cooled down to the required
dew point temperature through mechanical cooling. The water vapour is condensed and
the condensate is separated and discharged. The plant consists of air circuit and
refrigeration circuit. These can be used only if pressure dew point requirement is
approximately (+) 2 0C. In these types of units, refrigerant is used to condense moisture
contained in compressed air.
If compressed air is required at a dew point of (-) 40 0C atmospheric pressure,

adsorption type air drying plants are used. If compressed air is required with a pressure
dew point of (+) 2 0C, refrigerated type of air drying plant may also be used.
7.0 EQUIPMENT AND MOTOR LIST
An appendix covering all equipment like compressor, inter-coolers, after-coolers, oil-

coolers, air receiver, air drying plant, heaters, blowers, etc. with equipment tag
numbers/name/title/designation, major design parameters, materials of construction and
estimated motor ratings shall be furnished. Cooling water requirement for compressors,
coolers and air drying plants, etc. shall also be included.
8.0 SPACE REQUIREMENT
Space requirements for compressed air system and air drying plant may be included by
way of a sketch. Clear heights below chain pulley block or hoists monorails, or cranes
with lifting requirements shall be included. Overall dimensions of compressors, motors,
air drying plants etc. may be obtained from vendor’s catalogues and shall be rechecked
later with bidder’s and vendor’s data.
9.0 COST ESTIMATES
If included in TCE scope of work, cost estimates for various alternatives considered
shall be furnished. Refer TCE.M6-ME-640-011 “Design Guide for Compressed Air
System” for capitalisation factor, evaluation of differential cost of energy consumption
etc. Typical format for capital and total cost is given in appendix 3.
10.0 RECOMMENDATION
Recommendation summarizing the following shall be included in this paragraph :
(a) Salient features of the recommended compressed air system

(b) Number of compressors with capacities and discharge pressures
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(c) Number of inter-coolers, after-coolers, oil-coolers etc.

(d) Number of air receivers with capacities
(e) Method of capacity control
(f) Number and type of air drying plants with capacities
(g) Requirements of power, cooling water and space
(h) Cost estimate for the recommended system
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TCE CONSULTING ENGINEERS LIMITED SECTION: APPENDIX
APPENDIX 1
GUIDELINES FOR USING COMMON OR SEPARATE COMPRESSORS FOR

SERVICE AND INSTRUMENT AIR
PRESSURE TOTAL AIR IA REQUIREMENT AS GUIDELINES

REQUIREMENT REQUIREMENT % OF TOTAL
REQUIREMENT
UPTO 30 % COMMON
UPTO
500 NM³/Hr
EQUAL ABOVE 30 % COMMON
OR
NEARLY
EQUAL UPTO 30 % SEPARATE
ABOVE
500 NM³/Hr
ABOVE 30 % COMMON
COMMON
UPTO 30 % WITH
UPTO PRS
500 NM³/Hr COMMON
LARGE ABOVE 30 % WITH
DIFFERENCE PRS
(MORE THAN
30 %) UPTO 30 % SEPARATE
ABOVE
500 NM³/Hr
ABOVE 30 % SEPARATE
IA : INSTRUMENT AIR
PRS : PRESSURE REDUCING STATION
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APPENDIX 2
COMPARISON OF RECIPROCATING, CENTRIFUGAL AND SCREW TYPE

COMPRESSORS
SL. RECIPROCATING CENTRIFUGAL SCREW

NO.
1. Available as lubricated By nature of design it is 100 Available as lubricated in
or oil-free % oil-free. India. However, imported
oil-free screws are also
available.
2. It is constant volume It is a constant pressure It is also a constant volume
machine suitable for high machine suitable for high machine. However,
pressure application upto capacity applications upto pressure is limited to 50
2 3
500 Kg/cm (g) and 42,000 NM /Hr and Kg/cm2(g) and capacity
capacity 10,000 pressure upto 85 upto 5,000 NM3/Hr.
NM3/Hr. Kg/cm2(g).
3 An expensive foundation Only static weight bearing Only static weight bearing
is required for static and foundation is necessary. foundation is necessary.
dynamic loads generated Dynamic load is low. Dynamic load is low.
during operation.
4. For capacities above Unit is compact. Unit is compact.
3
1700 NM /Hr, the size
of unit is very large using
valuable space.
5. Compressor is noisy. Compressor is less noisy. Compressor is noisy.
6. The discharge air has Being a dynamic Being a positive
pulsations necessitating compressor, there are no displacement machine it has
pulsation dampener i.e. pulsations at all. some pulsations.
air receiver.
7. Lowest full load power About 3% to 5% higher full About 10% to12% higher
consumption load power consumption as full load power consumption
compared to reciprocating as compared to
compressor reciprocating compressor
8. Lowest no load power No load power Highest no load power
consumption consumption is slightly consumption
higher than that of
reciprocating compressor.
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APPENDIX 2 (CONTD.)
SL. RECIPROCATING CENTRIFUGAL SCREW

NO.
9. High maintenance cost Low maintenance cost, Maintenance cost of
since the moving parts are lubricated compressor is
not in contact with the static minimum. However, for dry
parts screw, maintenance cost is
high.
10. High inventory of spare Bare minimum inventory of Less spare parts are
parts is necessary. spare parts is necessary necessary compared to
reciprocating compressor.
11. Continuous operation is Continuous duty without Availability for continuous
not available because of shutdown is possible. duty is much better than
frequent maintenance that of reciprocating
shutdowns. compressor because of
rotary action and less
moving parts.
12. Operators are familiar Skilled, trained operators Operators are not as
with the equipment. are required to run the familiar with the equipment
machine properly. specially for dry screw
machines.
13. Moving parts are Moving parts are minimum. Less moving parts as
maximum. compared to reciprocating
compressors.
14. Initial cost is minimum. Initial cost is high. Lubricated compressor
cost is comparable with
reciprocating, but dry
screw is costlier.
ISSUE
R1
TCE FORM NO. 120 R1

APPENDIX 3
CAPITAL AND TOTAL COST
A. CAPITAL COST
SL. ITEM QUANTITY UNIT COST IN TOTAL COST REMARKS

NO. LAKHS (Rs) IN LAKHS (Rs)
RC CC SC RC CC SC RC CC SC
1.0 Cost of
compressor
2.0 Cost of electric
motor or drive
unit
3.0 Inter-cooler
4.0 After-cooler
5.0 Oil-cooler
6.0 Air Receiver
7.0 Air Drying Plant
8.0 Piping and valves
within battery
limits of
compressor room
9.0 Control panel
10.0 Instrumentation
11.0 Spares
13.0 Erection, testing
and
commissioning
14.0 Total cost
CC : Centrifugal Compressor
RC : Reciprocating Compressor
SC : Screw Compressor
ISSUE
R1
TCE FORM NO. 120 R1

APPENDIX 3 (CONTD.)
B. TOTAL COST
SL. DESCRIPTION COST IN LAKHS REMARKS

NO. (Rs)
RC CC SC
1.0 Total capital cost including
erection, testing and
commissioning (14.0 of A)
2.0 Cost of foundations
3.0 Capitalised differential cost of

energy consumption
4.0 Capitalised cost of spares
5.0 Total cost (1.0 to 4.0)
ISSUE
R1
TCE FORM NO. 120 R1

ISSUE
R1
TCE FORM NO. 120 R1

Compressed Air System For Chemical and Industrial Plants

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TCE CONSULTING ENGINEERS LIMITED SECTION: TITLE

TCE.M1-ME-640-007 SHEET i OF iii

BASIC STUDY GUIDE FOR

FLOPPY NO. : TCE.00000-ME-FP-130

INITIALS SIGN. INITIALS SIGN. INITIALS SIGN. INITIALS SIGN.

PPD.BY PCS Sd/- PCS

CHD.BY GDN Sd/- GDN R1

DATE 99.08.23 01.08.13

TCE FORM NO. 020R2

SL. NO. TITLE SH. NO.

2.0 INPUT DATA 1

3.0 SYSTEM DESIGN 2

4.0 AIR RECEIVERS 10

5.0 MATERIALS AND CODES OF CONSTRUCTION 10

6.0 AIR DRYING PLANT 11

7.0 EQUIPMENT AND MOTOR LIST 13

8.0 SPACE REQUIREMENT 13

9.0 COST ESTIMATES 13

1. GUIDELINES FOR USING COMMON OR SEPARATE 14

2. COMPARISION OF RECIPROCATING, CENTRIFUGAL 15

3. CAPITAL AND TOTAL COST 17

TCE FORM NO. 120 R1

REV. NO. DATE DESCRIPTION

R1 01.08.13 Generally revised.

TCE FORM NO. 120 R1

2.0 INPUT DATA

2.5 Electrical power supply voltage levels

2.6 Details of existing compressed air system, in case of expansion project.

TCE FORM NO. 120 R1

3.0 SYSTEM DESIGN

3.1.1 Design Calculations

Based on input data, following design calculations shall be carried out:

(a) Capacity and discharge pressure of compressors

(b) Conversion of capacity in NM³/Hr to volume in M³/Hr at site conditions i.e.

(c) Drive motor ratings

3.1.2 Common versus Separate Compressors

TCE FORM NO. 120 R1

3.1.3 Types of Compressors

(a) Reciprocating compressors are available in both lubricated and non-lubricated

(ii) Horizontal compressors are used for higher capacities. Considering

(d) In case of expansion projects, existing compressed air system may be

Comparison of various types of compressors is given in appendix 2.

TCE FORM NO. 120 R1

3.1.4 Number of Compressors

(a) In case of reciprocating compressors at least one standby compressor shall be

(b) In case of centrifugal compressors and screw compressors standby

3.2 INTER-COOLERS, AFTER-COOLERS AND OIL-COOLERS

3.2.4 Cooling Water Requirement

TCE FORM NO. 120 R1

(i) Heat lost by dry air = m × Cp × Dt

(ii) Heat lost by vapour = Sensible heat + Latent heat

Sensible heat = mass of vapour in Kg/Hr × specific heat of vapour (≅0.45

Latent heat = mass of condensate in Kg/Hr × latent heat of condensation (=

(d) Mass of dry air shall be found out by formula PV = nRT

A typical example is given below :

TCE FORM NO. 120 R1

Air at Inlet of First Stage Air at Outlet of Inter-

Specific Humidity ** 0.0624 0.0166

Cooling Water Inlet temperature (32 0C)

Wet Air at 435 0 K

Cooling Water Outlet temperature (37 0C)

P1 = 1.012 Kg/cm2 P2 = 2.89 Kg/cm2

∴P = [1.012 – (0.81 × 0.1139)] × 104 Kg/M2