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INSTRUMENT AIR COMPRESSORS PTP 4.1
(Introduction and Operation)

COURSE CONTENT
Page No.

1. INTRODUCTION 03

2. TYPES OF COMPRESSORS 07

3. COMPRESSOR OPERATION 10

4. AIR DRYERS 13

5. OPERATION CHECKLIST 16

6. SAFETY 17

7. TERMS & DEFINITIONS 18

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1. Introduction
All stations in P.D.O. will be equipped with a Plant Operating Manual (POM). The
first step in all POM's for startup is "Utilities start-up".
When the competent electrical personnel restore the electrical power supply, the first
step to start the station is starting the ‘instrument air system’.

The Instrument Air compressors are started.

Only after establishing the availability of air system, the plant can be started. The
inlet ESD's, isolation ESD's and the various control valves will have to be fully
operable to bring a stations on line. Therefore it is essential to make sure that air
compressor is running with proper back up and the instrument air header pressure is
maintained at the specified value. (6.9 Bar).

We know that most of the final control elements operate using pneumatic force,
usually termed as "instrument air". Devices that can move its designed parts using air
pressure are called actuators.

Actuators operate emergency shut down valves, fluid flow control valves, and similar
equipment. The design of equipment will vary according to its application. In
requirement of pressure to operate them also are not unique. We have many devices
requiring different pressure in the PDO field.

The highest pressure to operate an actuator in our P.D.O. facilities is not more than
690 kPa or 6.9 Bar. The locations of actuators are scattered around the operating area
of station. In order to bring the air pressure to the actuator, proper piping is done to
the actuator from a main air "header" or pipeline. The pressure is regulated to the
required value of the actuator using a regulator for each actuator or device.

For constant regulation of pressure, the pipeline " header" must be supplied with a
pressure higher than the required value. The highest value being
690 kPa, the header is pressurized to a higher value than 6.9 Bar.
Therefor the header is connected to a continuous supply source of higher pressure.

CAUTION: Instrument air “low low” pressure shuts down the plant.
In P.D.O., this source of air supply is the instrument air compressor skid.

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PDO Skids
A skid containing two or three air compressors is the source of pressure supply in
most of the stations in PDO.
Air compressor skids in stations includes a main compressor and a standby
compressor at least. Larger stations may have three compressors; one main, one stand
by and one taking the load fluctuations. The compressor draws atmospheric air and
compresses it to a sufficiently higher pressure than the highest pressure required in
that station. Most of our stations maintain an air pressure of 8 Bar.
The compressor discharge is sent to a receiver, generally called " air receiver", (a
vessel) with considerable capacity to store the pressurized air.
This vessel absorbs the pressure fluctuations in the compressor discharge when the
compressor gets loaded and unloaded. Then the air from receiver is sent to a drier
where moisture in the air is removed and clean dried air is supplied to the header.
The pressure in the header is maintained some where near 8 Bar and this is done using
a pressure dependant loading and unloading control of the compressor. A pressure
sensing device at the inlet of air receiver controls the load / unload logic
" Loading " means allowing the compressor to compress the air and pressurize the
vessel. " unloading " is like bypassing the compressor. The compressor is not
stopped, but runs without compressing air, namely “without load".
In order to perform capacity control (in the case of more than one compressor)
different set points are given to each compressor for loading and unloading.
The discharge pressure is continuously measured and when it falls below a set point,
usually, 7.5 Bar, the compressor inlet will be opened allowing air to enter compressor
and the compressor is "loaded".
The pressure in receiver increases, and the pressure in header too increases. When the
pressure in the header crosses the high set point, the in let to compressor is closed, and
compressor stops pressurizing the vessel.
The air pressure in receiver is drawn by the user, pressure drops and when it falls
below the low set point, compressor gets loaded.
This cycle continues to maintain header pressure. The air form receiver is sent to the
drier system to take all moisture content in the air. The drier is using a drying agent
for drying. This drying media (silica gel/alumina) has to be regenerated - remove all
moisture it has absorbed - at an interval not more than 10 minutes.
Therefore two dryers are used.
When one is drying, the other will be regenerating and will change over automatically
at a timer setting which we can set according to our station requirement.

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STANDARDS

As per international standards, the instrument air system shall supply air of
the following specifications.

Pressure: Shall be not less than 690kPa (ISA)

DewPoint: Pressure dewpoint as measured at the drier out let shall be

at least 10°C below the minimum temperature to which
any part of the air system is exposed.

Filter : Maximum particle size allowable in the air system is

5 microns.

Lubricant: Where lubrication oil is used in air compressors, the header

air shall contain traces of lubricant less than " one ppm.v/v."

Receiver: Shall be provided with a relief valve and an auto drain. (ISA).

Important: The air intake shall be free of engine exhaust, dust,

rust particles, chemical particles and corrosive or hazardous
gases.

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‘IAC’ in P.D.O.

Generally “Atlas Copco” screw type air compressors are used in P.D.O. facilities.
There are "two compressor" skids and "three compressor" skids.

In either case a pressure not less than 690kpa will be maintained in the header. The
header is routed through the plant near the clusters containing equipment that operate
with air.
A branch header is taken from main header for each cluster.

From the branch headers, separate lines are derived for each instrument that need
instrument air.
This air supply shall pass through a filter regulator. This regulator maintains the
required pressure to the device requirement.

The filter regulator will have a drain valve to flush the filter whenever required.

690 KPa INSTRUMENT - AIR HEADER.

AIR DRYER / FILTER UNIT

COMP.1

To ESD Valves
COMP.2

To other Instruments
To Process Instruments

PRESSURE REGULATOR
Control Valves

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2. Types of Compressors

Compressors draw air from atmosphere and pressurize it by adding energy to it. There
are different methods of adding energy (compression).
Based on the methods of compression, compressors can be segregated into two
categories:

1.POSITIVE DISPLACEMENT &

2.DYNAMIC IMPULSE (TURBO)

Positive displacement compressors can then be branched off in to further categories.

ROTATING
· Blowers with intermeshing lobes.
· Blowers with eccentric rotors, or with sliding vanes in round casing.
· Screw compressors (The one used in PDO for air compressors)

ALTERNATING
· Reciprocating compressors

Dynamic Impulse (Turbo compressors) act by subjecting the compression medium

to a combination of pressure and linear velocity in the rotating impellers and then
transferring the velocity into pressure in the fixed casing that surrounds the impeller.
According to the type of path that the compressed medium takes through the impellers
designates the type of compressor.
· Centrifugal compressors
· Axial compressors
· Mixed flow compressors

This package is dealing with Screw Compressors.

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Screw Compressors

SCREW COMPRESSOR CASING HOUSES

TWO SCREW TYPE ROTORS, MOUNTED
ON BEARINGS.THE MALE ROTOR IS
DRIVEN BY THE FEMALE ROTOR, WHICH
IS DRIVEN BY THE ELECTRIC MOTOR
THROUGH GEAR.
THE MALE ROTR HAS LOBES AND
FEMALE ROTOR HAS FLUTES.
THE AIR (ENTERING THE SPACE
BETWEEN ROTORS) IS CARRIED
FORWARD AND COMPRESSED WHEN
FLUTES
THE ROTORS REVOLVE. INJECTED OIL
MIXING WITH AIR LUBRICATES THE
LOBES ROTORS AND SEALS BETWEEN ROTOR
TIP AND CASING.

The Atlas Copco manual in the station will contain details like;
Data sheet containing: Hazardous area classification, Motor type, model, Compressor type, model,
lubrication, Coupling details, Max. discharge pressure, Cooler details.
Control details, Power consumption, Panel details, Painting requirements. Etc.

Refer station manual for exact model and data you are working with.

Important:

Many different models of Atlas Copco air compressors are used in PDO production
stations.
One or two compressors from other manufacturers also may be found in PDO
facility.
This package refers to Atlas Copco alone.

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 Atlas Copco Gt
SIGNAL TO LOGIC (load/unload) P Gp
S
AV
Air after cooler.

Signal from
load / unload
system SV MT
VI

AF
Oil scavenging line. VP
UA*
Dm

AIR
OS RECIEVER
AND
UV*
DRIER
CA SYSTEM
AR
E FN
MOTOR CO Gl

TO HEADER
V CV DP
S
OF

Air comp. discharge

Gt

AF Air Filter. Gp Pressure Gauge

AR Air / Oil Separator Gt Temperature Gauge
AV Air Outlet valve MT Moisture Trap
CA Air Cooler OF Oil Filter
CO Oil Cooler OS Oil Separator Element
CV Check Valve PS Pressure Control Switch
Dm Drain Valve SV Safety Relief Valve
DP Drain Plug UA Un-Loader Assembly
E Compressor Element UV Un-Loading Valve
FN Cooling Fan VP Minimum Pressure Valve
Gl Oil level Indicator VS Oil Stop Valve
VI Vacuum Indicator

* Air to load system is shown

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3. Compressor Operation

AIR / OIL SYSTEM

Air is drawn in to the compressor element through filter (AF) and unloader assembly
(UA). The air is then compressed in the inter-lobe spaces of the rotors, where oil is
injected via the oil stop valve (VS) to absorb the compression heat of the air and to
lubricate and seal the rotors. At the discharge port the air/oil mixture flows through
check valve (CV) into the air/oil separator (AR) Here most of the oil is centrifuged
out of the air and drips down in to the bottom of the receiver. The air then flows
through the oil separator element (OS) which retains the remaining oil. The oil
collecting in the bottom of separator (OS) returns to the compressor via scavenge line.

LUBRICATION SYSTEM

Oil present in the bottom of the separator (AR) is forced into the pipe-work system
owing to the minimum 4 Bar pressurization. The oil flows into the bottom of the
cooler (CO) and passes through to the top during which, the temperature is lowered
owing to the air flow absorbing the heat as it passes through the fins. The oil is then
directed through a filter (OF), before finally reaching the oil stop valve. In the
unloaded position the pressure of the oil pushing against the piston inside the valve
causes the valve to make contact with the seat allowing no oil to pass through to the
compressor. When the compressor is loaded, a small port behind the piston is
pressurized from air that is tapped off from the discharge side of the compressor prior
to the check valve (CV), causing the piston to lift the valve off the seat allowing oil to
enter the compressor.

AIR SYSTEM (UNLOADED)

Air enters the top of the compressor via the air filter (AF), a vacuum indicator (V1) is
present in the intake housing to show when the filter requires changing. Because the
compressor is in an unloaded condition air cannot pass into the compressor owing to
the unloading valve (UV) piston being in the closed position. To keep the compressor
rotors lubricated a small air supply is delivered to the compressor via the vent valve
(VV) by-passing the unloader valve and air intake.

LOADED

Air once again enters the top of the compressor via the air filter and passes through
the opened unloader valve (UV) into the compressor casing. As the air passes along
the rotors it is compressed increasing the pressure, until it is discharged through the
exhaust port. Check valve (CV) is opened, owing to the pressure overcoming the
spring tension and the air/oil mixture passes into the receiver. Inside the receiver the
air is directed into an oil separator element (OS), as it's name implies the oil is
separated from the air and drops to the bottom of the receiver allowing the hot dry air
to exit the top of the receiver via the minimum pressure valve (VP). The air then
passes through a cooler reducing the temperature and past a moisture trap (MT) which
removes any excess moisture in the air before leaving the system

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LOADING / UNLOADING

Loading:

Compressor runs with air inlet valve open so that air is allowed into
compressor and is compressed. Pressure increases and air is discharged to
header.

Unloading:

Compressor runs idle, with air inlet valve closed. There is no air to be
compressed and pressure is not increasing further.

The system controls the air delivery in relation to the air consumption and maintains
the net pressure within the selected upper and lower limits of the working pressure
(unloading and loading pressure settings).

The pressure sensing at inlet pipe of receiver controls the loading / unloading cycle.

When the net pressure reaches the unloading pressure, the contact of air pressure
switch opens, actuating the solenoid valve. This signals the air inlet valve to close.
The air delivery is stopped, the compressor runs unloaded, waiting for demand.

When the net pressure decreases to the loading pressure, the contacts on air pressure
switch closes, so that the solenoid valve is actuated. Then the air inlet is opened to
allow air to compressor. Compressor is now loaded.

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Downstream Compressors

Air Receivers

The compressed air from compressor discharge is sent to the vessel “receiver”.
This vessel is having sufficiently large volume to store the pressurized air.
Loading and unloading of the compressors maintain receiver pressure. The pressure
fluctuations due to this will not be transmitted to header because the volume of
receiver absorbs them.
The receiver is provided with a relief valve set @ ≈10 Bar, a pressure gauge, moisture
drain trap and a drain.

Where the discharge header of compressors enter the vessel, on the pipe; a pressure
sensing device is mounted to send pressure signals to the control logic that controls
loading and unloading.

Air filter.

Air from receiver goes through a filter assembly.

Filter assembly comprises of two filter elements mounted in parallel, and can be put
in line or isolated one by one. This is to allow changing the element.
A differential pressure (across the filter) indication is installed to know when the
element gets clogged.

Another filter assembly is provided after the dryer too, to make sure any dryer
desiccant particles do not travel to air header.

Air Dryer.

Air then passes through drier.

The drier works on the principle “adsorption and desorption”.
Principle of operation and control is explained later in this package’

Air after dryer is sent to instrument air header.

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4. Air Dryers

The principle of the adsorption dryer (Regeneration by Air) is based on the physical
property of the desiccant to adsorb water vapor.

Absorption:
Absorption and adsorption sounds similar but are different process terms.
Absorption means to include or incorporate integrally some thing else, as part of
itself.
In process terminology, absorption occurs when the smallest sample (molecule) of
any one substance behaves like a sponge to water.

Adsorption is to hold (molecules of gas or liquid) to its surface allowing the forming
of a thin film (layer) on the surface. In our application, water vapor is held to the
surface of the alumina while wet air flows through alumina granules in the drier.
Regeneration:
In our context, removing the water vapor attached to alumina by the high velocity
flow of dry air in opposite direction.

The dryer consists of two drying towers, one of which is in drying service whilst the
other is under regeneration treatment.
During drying, air passes through the desiccant (activated alumina) and goes to the
outlet.
In regeneration, bulk airflow is stopped and a small quantity of air (purge air) is
allowed to flow through the desiccant in the opposite direction to vent. This stream of
air takes away the moisture from the adsorber regenerating it for use again. In some
units purge air is through a fixed orifice and in others a regulator is provided.
A valve system (V₁ to V₄) automatically reverses the flow when the two towers have
to change function, (drying / regeneration) in the drying system.
In this way the drying process is made continual.
Before the drying capacity of the desiccant is fully used in the tower while in drying
service, it is put to regeneration.

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Dryer Schematic

DRY AIR OUT

PURGE AIR

PG1 PG2
PG1- PG2 -Adsorber’s pressure.

Air Filter Purge air control

PURGE
SIGNAL FROM TIMER
CONTROL
SOLINOIDS

Exhaust
Adsorber I (drying) Silencer Adsorber II (regenerating)

E E -Exhaust to atmosphere

V3 V4
V1-V4 -Changeover valves.

V1 V2

WET AIR IN

DRYER
COLOUMNS AIR
RECIEVER
VESSAL

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Drier Functioning

A timer mounted in the instrument panel controls the drier change over.
The timer output electrical signal operates a solenoid and the air signal to valves V1
& V3 is removed.
V1 opens allowing air to drier adsorber -1. V3 closes the vent line to exhaust.
At the same time a second solenoid is energized to allow air supply to V2 & V4. V2
closes the inlet to adsorber II.
V4 opens and vent the air pressure in adsorber-II.
Discharge air at the top of adsorber 1 pass through an orifice, a throttle valve and a
second orifice to purge the adsorber II.
The throttle valve and orifice together controls the purge airflow.
The pressure gauges will show the drier pressure and we can know which one is in
line. The drier which is regenerating will be vented and carry less pressure.
Now drier number 1 (Adsorber I) is in drying mode and the other is in vent mode or
regeneration time.
The timer is set at few minutes (5-8) will change over the signal to solenoids.
First,
Air from V2 & V4 is removed, V2 opens and V4 closes thereby bringing drier-II back
in drying mode.
Then air is fed to V1 & V3. V1 closes the inlet and V3 vent the air in adsorber I.
Now drier I is in regeneration mode.
The cycle continues by changing over the dryers.

This is because the desiccant (activated alumina) after absorbing moisture for some
time gets saturated with moisture. Desiccant can be made usable again to absorb
moisture, by blowing hot air over the desiccant. This process is regeneration.

Regeneration is done automatically.

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5. Operation Checklists

The operations people ensure that the instrument air supply is uninterrupted and
adequate. In order to do this routine monitoring is implemented. Daily checks,
logging of parameter data are integral part of plant operation.

CHECKS.

1. Checks and make sure duty/standby selection.

2. Checks the air pressure trend.
3. Checks for any abnormal sound in compressor skid.
4. Checks oil level in air / oil separator.
5. Checks all condensate traps, drains.(assess oil carryover)
6. Checks pressure drop across filters.
7. Checks the dryer changeover cycle is normal.
8. Checks the loading/unloading is proper.
9. Checks the vacuum indicator on compressor air intake filter is OK.
10. Checks for any leak on airlines on skid and afterwards in plant.
11. Checks the gas compressor air intake air blast cleaner is normal.

DATA LOGGING

1. Discharge temperature.
2. Air receiver pressure.
3. Pre dryer filter ∆p.
4. After filter ∆p.
5. Oil separator level.
6. After cooler air temperature.
7. Purge air flow
8. Run hours.
9. Compressor load in ampere.
10. Ambient temperature.

Those parameters not included in DCS history log are entered in log sheet and is
archived. This is useful for MMS (maintenance management system). RCM
recommends maintenance plan. Standby change over according to each station plan.

The pressure plot / trend is a very helpful record that tells you performance of compressors,
Loading system and dryer. Often plant air leaks and air system performance can be assessed from
Air pressure plot.

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6. Safety

All personnel operating or maintaining compressor units must observe all the standard
safety procedures and precautions as designated by P.D.O.

The following list is a guideline when working on any type of compressor.

· Never use compressed air in direct contact with skin or clothes for cleaning
purposes.

· Never operate a machine beyond all rated limits (Pressure, Temperature, Speed).

· Always use the correct designated lubricants inside the compressor. Failure to
comply may result in an explosion or fire due to the high temperatures and
pressures inside the casing.

· Suitably trained personnel who are aware of the potential hazards faced when
performing maintenance on compressors shall only carry out maintenance work.

· If the machine has overheated and shut down, never remove any inspection covers
or plugs until unit has completely cooled down. This is to avoid the possibility of
spontaneous combustion taking place when the hot oil vapor is mixed with air.

· All maintenance operations other than general visual checks must only be
undertaken when the machine is at a standstill.

· Always follow the correct isolation procedures both Electrical/mechanical.

Isolation certificates and boards must always be displayed before the
commencement of work.

· Before dismantling any pressurized component, operator shall ensure the unit and
systems has been fully de-pressurized and ensure all discharge valves have been
blinded.

· All maintenance repairs and adjustments should be thoroughly documented to

ensure any reoccurring faults or breakdowns can be assessed, with a view to the
safe running operation of the compressor.

· All exposed components and pipe work should be kept clean and covered to
prevent contamination from dust/sand etc.

· Never operate the compressor with any of the safety devices or protection systems
overridden. The only exception to this is for troubleshooting purposes when a
fully competent technician is in attendance to the machine at all times during
operation.

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7. Terms & Definitions

Listed are some of the definitions of some of the terms that are used in connection
with compression / compressors

BASE PLATE is a metal structure on which the compressor is mounted and possibly
the driver (motor).

CASING is the pressure containing stationary element that encloses the rotor and
associated internal parts. It usually includes integral inlet and discharge connections
(nozzles). Casing supports and a means of lifting are provided

DYNAMIC COMPRESSOR is any rotary continuous flow unit in which the

mechanical action of rotating vanes or impellers imparts velocity and pressure to the
flowing medium. The term blower has been used for dynamic units in the lower
pressure range, but nowadays all dynamic units are known generally as compressors,
whether centrifugal or axial.

SEALS are devices used between rotating and stationary parts to minimize gas
leakage between areas of unequal pressure.

SHAFT is that part of the rotating element on which the rotating parts are mounted
and through which rotation from the prime mover is transmitted.

SHAFT BEARINGS are lubricated stationary parts that support and hold in position
the compressor shaft.

SHAFT SLEEVES are parts that may be used to position the impeller on the shaft
and to protect the shaft.

ABSOLUTE PRESSURE is the pressure with reference to vacuum and is the

arithmetic sum of gauge and atmospheric pressures.

ABSOLUTE TEMPERATURE is the temperature of a body referred to the absolute

zero. On the Fahrenheit scale this is minus 459.67 f, on the Celsius scale it is minus
273.15.c Engineering values of minus 460 f and minus 273 c are used from now on.

DISCHARGE PRESSURE is the total gas pressure (static plus velocity) at the
discharge flange of the compressor.
Note: - Pressure may be expressed as gauge or absolute pressures.
kPa.(g). plus atmospheric pressure equals kPa. (a).

DISCHARGE TEMPERATURE is the temperature existing at the discharge flange

of the compressor.

GAUGE PRESSURE is pressure as determined by most instruments and gauges.

HEAT is energy transferred because of a temperature difference.

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HUMIDITY, in normal usage, has to do with moisture (water vapor) in the
atmosphere. There are two engineering terms involved.

INERT GAS, to a chemist, is one that does not enter into known chemical
combination, either with itself or another element. There are four known gases of this
type: helium; neon; argon; and krypton. To the engineer, however, the term usually
means a gas that does not supply any of the needs of combustion say, Nitrogen.

NORMAL AIR is the term used for average atmospheric air at sea level in a
temperature zone where it contains some moisture.

PRESSURE is force per unit area.

A PROCESS occurs whenever the system undergoes either a change in state or an

energy transfer at a steady state (See State).

SPECIFIC GRAVITY is the ratio of the density of a given gas to the density of dry
air, both measured at the same specified conditions of temperature and pressure.

TEMPERATURE is the property of a substance that gauges the potential or driving

force for the flow of heat.

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