COMPRESSED AIR SYSTEM DESCRIPTION 压缩空气

OWNER
OWNER’S ENGINEER
SubC Power Facility
EPC CONTRACTOR
DESIGNER
PROJECT
AL DUR II IWPP
2 13/02/2020 UPDATED AS PER HAYA COMMENTS KDS DLA ELB
1 09/12/2019 UPDATED AS PER HAYA COMMENTS IFA DLA ELB
0 28/05/2019 UPDATED AS PER S3 COMMENTS IFA DLA ELB
A 25/04/2019 First issue IFA DLA ELB
REV DATE DESCRIPTION DONE CHECKED APPROVED
FOR INFORMATION DOCUMENT OWNER EPC CONT. SIGNATURE DATE

STATUS
FOR APPROVAL
VALID FOR PURCHASE
FOR CONSTRUCTION
AS BUILT
DOCUMENT NUMBER DOCUMENT NAME
AD2-C1-00-QFB-PSD-IDM-00623 COMPRESSED AIR SYSTEM DESCRIPTION

PROJECT DOCUMENT OWNER
AL DUR II IWPP
OWNER EPC CONTRACTOR DOCUMENT NUMBER DATE
AD2-C1-00-QFB-PSD-IDM-00623 13/02/2020
DOCUMENT NAME PAGE
COMPRESSED AIR SYSTEM 2 / 20

DESCRIPTION Rev.: 2
CONTENTS:
1. AIM ............................................................................................................................... 3
2. GENERAL DESCRIPTION ........................................................................................... 4
2.1. MAIN FUNCTIONS ........................................................................................... 4
2.2. DESCRIPTION.................................................................................................. 6
2.3. MAIN EQUIPMENT ........................................................................................... 9
3. INTERFACES..............................................................................................................11
3.1. GENERAL ........................................................................................................11
3.2. SUPPORT SYSTEMS ......................................................................................11
3.3. DEPENDENT SYSTEMS .................................................................................11
4. OPERATION CONCEPT .............................................................................................12
4.1. NORMAL OPERATION ....................................................................................12
4.2. START-UP .......................................................................................................12
4.3. SHUTDOWN ....................................................................................................13
5. INSTRUMENTATION AND CONTROL .......................................................................14
5.1. INSTRUMENTATION .......................................................................................14
5.2. CONTROL .......................................................................................................14
6. REFERENCE DOCUMENTS .......................................................................................19
7. ANNEXES ...................................................................................................................20
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DESCRIPTION Rev.: 2
1. AIM
The aim of this document is to provide a description of the compressed air system for
Al Dur II IWPP project, to be erected by SEPCOIII for Haya Power & Desalination
Company B.S.C. in Bahrein.
This document defines the purpose, characteristics, control and protection philosophy
for the above-mentioned system.
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DESCRIPTION Rev.: 2
2. GENERAL DESCRIPTION
2.1. MAIN FUNCTIONS
The main function of compressed air system is to produce, store and distribute service
and instrument air to the plant consumers.
The instrument air will be used for the actuation of pneumatic operated valves or when
any equipment demands it.
The instrument air consumers are listed below:
o BOP control and on-off valves (compressed air system)
o Gas metering facilities (outside power plant)
o Gas expanders
o Gas regulating and metering station
o BOP control and on-off valves (water systems)
o Water treatment plant
o BOP control and on-off valves (CCW system)
o BOP control and on-off valves (fuel gas conditioning system

11/12/21/22)
o Fuel gas conditioning air buffer tank 11/12/21/22
o CEMS (bypass stack and HRSG stack 11/12/21/22)
o BOP control and on-off valves (GT air preheater GT 11/12/21/22)
o BOP control and on-off valves (HRSG blowdown Cooling System

Block 10/20)
o HRSG 11/12/21/22
o BOP control and on-off valves (feedwater pumps 11/12/21/22)
o HP steam bypass valves 11/12/21/22
o GT 11/12/21/22 generator H2 skid

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DESCRIPTION Rev.: 2
o GT 11/12/21/22 pulse air
o GT 11/12/21/22 other air consumers
o GT 11/12/21/22 IPB pressurization system
o H2 generators
o BOP control and on-off valves (condensate system Block 10/20)
o BOP control and on-off valves (steam system 11/12/21/22 & Block
10/20)
o ST 10/20 auxiliary systems air consumers
o ST 10/20 generator H2 skid
o ST 10/20 IPB pressurization system
The service air will be used for plant cleaning/maintenance purposes and will be
routed to the following areas:
o Firefighting pump building
o Black start & emergency diesel generators area
o Gas expander area
o Gas regulating and metering station area
o Water pumps area
o Water treatment plant area
o CCWS pump and heat exchanger area
o Circulating water pumps area
o Warehouse/workshop building
o Gas turbine 11/12/21/22 areas
o Air preheater gas turbine 11/12/21/22 areas
o HRSG 11/12/21/22 areas

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DESCRIPTION Rev.: 2
o Feedwater water pumps 11/12/21/22 areas
o Steam turbine building, ST 10 area
o Steam turbine building, ST 20 area
2.2. DESCRIPTION
2.2.1. General
The compressed air system includes following major equipment, to produce, store
and supply the compressed air to the plant systems as mentioned above (see chapter
2.1).
o 3x50% Air Compressor.
o 2x100% Coalescing Filtering Skids.
o 2 Air Receiver Tanks.
o 2x100% Air Dryer (heatless regeneration type) for instrument air, with pre-
filters and after filters.
o Service air distribution network.
o Instrument air distribution network.
All the main equipment of this system (compressors, filters, dryers and receivers) are
located in the south-west area of the power plant. From here the service air and
instrument air distribution network fed the different areas of the plant.
Instrument air shall be dry and oil free over the full range of ambient conditions.
Heatless desiccant type air dryers shall be provided. The instrument air and service
air distribution are independently, however as they are connected, an actuated
isolation valve (00QBE10AA201) is provided in the service air distribution to close in
case of low pressure in the instrument air system. This is done to give priority to the
instrument air system.
AL DUR II IWPP
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DESCRIPTION Rev.: 2
The distribution of instrument air will be done in ring configuration.
2.2.2. Air Compressor
The compressed air system includes 3x50% heavy duty compressors, air cooled, oil
free, driven by an electric motor. During normal operation, up to two compressors will
be on duty and the other one will be in stand-by mode. Compressors will start and
shut down according to the pressure of the compressed air network and the two air
receivers (service and instrument) will act as buffer vessels to avoid excessive start-
stop cycles and to provide more stable pressure.
The main characteristics of the air compressors are:
o Total air capacity : 1012 Nm3/h
o Discharge pressure : 9,2 – 10 barg
(*) Nm3 are defined as ideal gas at 0ºC and 1 atm
2.2.3. Filtering skid
The filtering skid consists of 2x100% coalescing filters. The purpose of these filters is
to remove any liquids and solids that could be present after the air compressor
discharge.
The main characteristics of the filtering skid are:
o Solid Particles: Class 3, maximum particle 5 microns, maximum solid content 5

mg/m3
2.2.4. Dryer Skid
The dryer skid consists of 2x100% pre-filter, 2x100% twin-tower heatless

regeneration air dryers and 2x100% after-filter. The purpose of these trains is to filter
and to dry the air to reach the required air quality by the consumers.
AL DUR II IWPP
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DESCRIPTION Rev.: 2
The first stage of the air treatment is made by a 2x100% configuration coalescing pre-
filter. After the pre-filter, 2x100% heatless adsorption dryers composed of two towers
that will reduce the moisture content to the required level. In case that during the
operation the air dew point is not reaching the expected quality, it takes place an
automatic tower changeover. This automatic changeover from operation dryer tower
to standby tower is made by means of an analyzer located downstream the dryer
station. A dry air stream is recirculated to the saturated tower for regeneration. The
last stage of the air treatment train has a particulate type 2x100% configuration after-
filter.
The main characteristics of the dryer skid are:
o Dryer Type : Twin-tower heatless regeneration air dryer
o Air dew point at outlet : -40ºC @ 1,013 bara
o Solid Particles : Class 3, maximum particle 5 microns, maximum solid

content 5 mg/m3
2.2.5. Air Receiver
The outlet of the filtering skid is connected to a common header that conveys the
compressed air to the first air receiver. From this receiver, service air is distributed
and also dryers are fed. After the dryers, the second air receiver is installed, just
before the distribution of instrument air.
The air receivers have capacity to minimize the number of load-unload cycles of the
compressors as they act as a buffer volume of the system. They also provide some
minutes of autonomy to allow plant shutdown (when compressors are not available)
or to support operation during the transient in case of compressor trip and start-up of
standby compressor.
The main characteristics of these air receivers are:
o Total air capacity : 15 m3

AL DUR II IWPP
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DESCRIPTION Rev.: 2
o Operating pressure : 9,2 – 10 barg
For the details of the air receivers, please refer to vendor documentation.
• AD2-C3-00-AXE-MDW-CON-03001 Tank Dimensions
2.3. MAIN EQUIPMENT
In this section most relevant equipment and components of the system are highlighted
2.3.1. Air compressors
KKS: 00SCA11/12/13AN001
Type of equipment: oil free screw compressors
Maintenance: yes, as per compressor maintenance schedule
Control function: yes, compressors start and load-unload to maintain compressed air
system pressure
Reference drawings:
• AD2-C3-00-AXE-PDW-CON-00501 PID for Air Compressor System
• AD2-C3-00-AXE-MDW-CON-03004 GA Drawing for Air Compressor System
• AD2-C3-00-AXE-MDW-CON-03000 Compressor Dimensions
2.3.2. Filtering skid
KKS: 00SCA21/22AT001
Type of equipment: liquid and solid particle filter
Maintenance: yes, cleaning and/or change of filtering media based on pressure drop
on the filter
Control function: N/A

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DESCRIPTION Rev.: 2
Reference drawings:
• AD2-C3-00-AXE-MDW-CON-03003 Filter Dimensions
2.3.3. Dryer skid
KKS: 00SCA41/42AT001 (pre-filters), 00SCA51/52AT001 (dryers),

00SCA61/62AT001 (after-filters)
Type of equipment: basket filter
Maintenance: yes, cleaning and/or change of filtering media based on pressure drop
on the pre and after filters
Reference drawings:
• AD2-C3-00-AXE-MDW-CON-03002 Dryer Dimensions
2.3.4. Air receivers
KKS: 00SCA30BB001 / 00QFB20BB001
Type of equipment: pressure vessel
Maintenance: if needed, during outage of the power plant
Reference drawings:
• AD2-C3-00-AXE-MDW-CON-03001 Tank Dimensions

AL DUR II IWPP
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DESCRIPTION Rev.: 2
3. INTERFACES
3.1. GENERAL
The interfaces of the compressed air system with other systems or related equipment
are described below. The interfaces are classified according to those that are
necessary for the operation of the system (support systems) or according to those
that are provided by the system and are necessary to allow other systems to carry out
their functions (dependent systems).
3.2. SUPPORT SYSTEMS
Electrical Systems:
o Low voltage system. For operation of air compressors and dryers.
Control Systems:
o Distributed control system (DCS)
3.3. DEPENDENT SYSTEMS
Mechanical systems:
o All systems that requires compressed air, typically pneumatic valves but also GT
pulse air cleaning system, gas expanders, etc...
AL DUR II IWPP
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DESCRIPTION Rev.: 2
4. OPERATION CONCEPT
4.1. NORMAL OPERATION
Instrument air is required in multiple systems along the power plant, therefore this is
considered a critical system and must be always in operation.
It is expected that compressed air system will operate continuously with one or two
compressors running (configuration is 3x50%). In case air demand/consumption is
low, one compressor will operate loading and unloading to maintain the pressure in
the system, however if high demand consumers operate simultaneously (for example
GT air intake pulse cleaning systems) it is possible that a 2nd compressors will be
required to start to operate. Third compressor is not expected to be required.
In normal operation the status of the main equipment and components will be as
follows:
• One air compressor will be running continuously, and the other 2 compressors
will be in standby.
• One filter of the filtering skid will be operating and the other will be isolated (as
spare)
• One air dryer (together with one pre-filter and one after-filter) will be operating
and the other will be isolated (as spare).
• On-off valve for supply of service air will be open (as long as air in the
instrument air distribution is within normal range).
4.2. START-UP
For the start up of this system, the following conditions are required:
• Electrical and control systems are operating/available
• System is properly drained from all low points

AL DUR II IWPP
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DESCRIPTION Rev.: 2
Start up of this system is done automatically and is summarized in the following

events:
• One (or two) compressor is started (by the local controller)
• One dryer is started (by the local controller)
• Actuated valves (control and on-off) are put in auto to operate as per logics
defined
4.3. SHUTDOWN
The shutdown of this system should be done only after all systems are shutdown as
this system provides instrument air through all the plant.
The shutdown of the system is done automatically and is summarized in the following
events:
• All running compressor are stopped (by the local controller)
• Running dryer is stopped (by the local controller)
• Control and on-off valves are positioned in initial/default position

AL DUR II IWPP
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DESCRIPTION Rev.: 2
5. INSTRUMENTATION AND CONTROL
5.1. INSTRUMENTATION
Instruments are represented on the following piping and instrumentation diagram:
• AD2-C1-00-QFB-PDW-IDM-00621 P&ID Compressed Air System
5.2. CONTROL
In this section, descriptive narrative is provided for the control and protection of the
system. For details on the logics of this system, please refer to the following
document:
• AD2-C1-00-QFB-IDW-IDM-06752 Compressed Air System. Logic diagrams
This system is in close relation with the Compressed air package PLC, therefore
some signals are exchanged between this PLC and the DCS in order to operate in a
coordinated way. Details of this exchange are included in the logic diagram document
mentioned above.
The table below summarizes the actuators of this system:
KKS Service Type Notes

00SCA11AN001 Air Compressor 1 Package plant
00SCA51AT001 Air Dryer 1 Package plant
00SCA52AT001 Air Dryer 2 Package plant
On-off pneumatic
00QEB10AA201 Service air supply valve
valve
Notes:
The filters downstream the compressors have no active components and therefore they are
not considered an actuator of the system
For the settings applicable to this system, refer to the annex 1.

AL DUR II IWPP
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DESCRIPTION Rev.: 2
5.2.1. Compressed Air Functional Group (00SCA10EE100)
Compressed Air system functional group is in charge of managing the start/stop

sequence of the Air compressor station at the initial stage.
There are no actuators / drives included in this functional group as the system control
will be done from its own PCS.
Compressed Air Functional Group receives the orders from the Automatic Plant
Sequencer.
The below table summarized the logic for the Compressed Air System Functional
Group:
00SCA10EE100 Compressed Air system Functional Group
Manual Reject N/A

Auto permitted Always permitted
On permitted Always permitted
Off permitted Always permitted
Auto Selection Compress Air Functional Group ON Command from
Automatic Plant Sequencer (00SCA10EE100:XA61; as
pulse)
Auto On command Compress Air Functional Group ON Command from
Automatic Plant Sequencer (00SCA10EE100:XA61 as
pulse) (for certain time delay)
Auto Off command N/A
Force On N/A
Force Off N/A
No Discrepancy Compressor System in remote (00SCA10GH001:XA57)
AND
Air Dryer System in remote (00QFB10GH001:XA57)
5.2.2. Air Compressors
Air compressors with 3x50% configuration are provided. The Air Compressor is a
package plant with its own controller. Between Air compressor local controller and
AL DUR II IWPP
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DESCRIPTION Rev.: 2
DCS there is basic signal exchange to allow coordinated operation. The Air
Compressors are required to operate based on the pressure at the service air tank.
Normally, one single compressor will run based on the pressure of the air network.
In case pressure reduces below the load setting of the running compressor because
there is a high demand, a 2nd compressor will start and load to support the increased
demand of the network.
If the pressure recovers and reaches a high pressure setting, 2nd compressor will
unload to return to operation with one single compressor. 3rd compressor will be in
standby mode to start in case there is a problem with one of the two other
compressors.
The package controller is also in charge of avoiding unequal wear of the three
compressors. This is done automatically, by controlling how many hours is running
each compressor to regularly change the operating compressor.
The below table summarizes the logic for the Air Compressor System:
00SCA10GH001 Compressed Air system
Start command [Air Group ON Command (00SCA10EE100:XA91)

OR
Compress Air System start command
(00SCA10EE100:XL91)]
AND
Compress Air System Ready to Start
(00SCA10GH001:XB84)
Stop command Air Group OFF Command (00SCA10EE100:XA92)
OR
Compress Air System stop Command
(00SCA10EE100:XL92)
5.2.3. Air Dryers
Air dryers with 2x100% configuration are provided. The Air dryers is a package plant
with its own controller. Each dryer includes 2 towers with desiccant and operation
between these 2 towers is automatically controlled by the dryer’s controller based on
dew point analyzer. Regeneration of saturated tower is controlled automatically by the
dryer’s controller. Changeover between air dryers is not automatic as this is only
required during maintenance of a dryer package.
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DESCRIPTION Rev.: 2
The below table summarizes the logic for the Air Drier System:
00QFB10GH001 Air Dryer System
Start command [Air Group ON Command (00SCA10EE100:XA91)

OR
Air Dryer System start command
(00QFB10GH001:XL91)]
AND
Air Dryer System Ready to Start (00QFB10GH001:XB84)
Stop command Air Group OFF Command (00SCA10EE100:XA92)
OR
Air Dryer System stop Command
(00QFB10GH001:XL92)
5.2.4. Service air supply valve 00QEB10AA201
This valve is in charge of closing the supply of service air in case of low pressure in
the instrument air system. The idea of this valve is to stop the supply of service air in
order to give priority to the consumers of instrument air as this is related to plant
operation and therefore it is considered more critical.
Once the valve is closed, it must be re-open manually by the operator once the
problem of low pressure has been solved.
The below table summarizes the logic for the Service Air Distribution ON-OFF Valve:
00QEB10AA201 Service Air Distribution ON-OFF Valve
Manual Reject N/A

Auto permitted Always permitted
On permitted Always permitted
Off permitted Always permitted
Auto Selection Auto Sel. Order from Air Group (00SCA10EE100:XA69)
Auto Open command Instrument Air Discharge Pressure NOT Low
(00QFB20CP901:XH52)
AND
Air Group ON Command (00SCA10EE100:XA91)
Auto Close command Instrument Air Discharge Pressure Low
(00QFB20CP901:XH52)
OR
Air Group OFF Command (00SCA10EE100:XA92 )
AL DUR II IWPP
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DESCRIPTION Rev.: 2
00QEB10AA201 Service Air Distribution ON-OFF Valve
Force Open N/A

Force Close Instrument Air Discharge Pressure Low Low
(00QFB20CP901:XH54)
Override Close N/A
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DESCRIPTION Rev.: 2
6. REFERENCE DOCUMENTS
Main system documents

AD2-C1-00-QFB-PDW-IDM-00621 P&ID Compressed Air System
AD2-C1-00-QFB-PCR-IDM-00622 Compressed Air System. Calculation Note
Control documents
AD2-C1-00-QFB-IDW-IDM-06752 Compressed Air System Logic Diagrams
AD2-C1-00-YDS-IDW-IDM-06740 Logic Control Diagrams Symbology
AD2-C1-00-YYD-ILS-IDM-06130 Alarms and Set Points List
Other related P&IDs
N/A
Compressed air main equipment documentation
AD2-C3-00-AXE-PDW-CON-00501 PID for Air Compressor System
AD2-C3-00-AXE-MDW-CON-03004 GA Drawing for Air Compressor System
AD2-C3-00-AXE-MDW-CON-03000 Compressor Dimensions
AD2-C3-00-AXE-MDW-CON-03001 Tank Dimensions
AD2-C3-00-AXE-MDW-CON-03002 Dryer Dimensions
AD2-C3-00-AXE-MDW-CON-03003 Filter Dimensions
AL DUR II IWPP
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DESCRIPTION Rev.: 2
7. ANNEXES
• Annex 1: Compressed air system settings
• Annex 2: Compressed air Functional Diagram

COMPRESSED AIR SYSTEM DESCRIPTION 压缩空气

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OWNER

SubC Power Facility

FOR INFORMATION DOCUMENT OWNER EPC CONT. SIGNATURE DATE

DOCUMENT NUMBER DOCUMENT NAME

AD2-C1-00-QFB-PSD-IDM-00623 COMPRESSED AIR SYSTEM DESCRIPTION

COMPRESSED AIR SYSTEM 2 / 20

COMPRESSED AIR SYSTEM 3 / 20

COMPRESSED AIR SYSTEM 4 / 20

2.1. MAIN FUNCTIONS

The instrument air consumers are listed below:

o BOP control and on-off valves (compressed air system)

o Gas metering facilities (outside power plant)

o Gas regulating and metering station

o BOP control and on-off valves (water systems)

o Water treatment plant

o BOP control and on-off valves (CCW system)

o BOP control and on-off valves (fuel gas conditioning system

o Fuel gas conditioning air buffer tank 11/12/21/22

o CEMS (bypass stack and HRSG stack 11/12/21/22)

o BOP control and on-off valves (GT air preheater GT 11/12/21/22)

o BOP control and on-off valves (HRSG blowdown Cooling System

o BOP control and on-off valves (feedwater pumps 11/12/21/22)

o HP steam bypass valves 11/12/21/22

o GT 11/12/21/22 generator H2 skid

COMPRESSED AIR SYSTEM 5 / 20

o GT 11/12/21/22 pulse air

o GT 11/12/21/22 other air consumers

o GT 11/12/21/22 IPB pressurization system

o BOP control and on-off valves (condensate system Block 10/20)

o ST 10/20 auxiliary systems air consumers

o ST 10/20 generator H2 skid

o ST 10/20 IPB pressurization system

o Firefighting pump building

o Black start & emergency diesel generators area

o Gas expander area

o Gas regulating and metering station area

o Water pumps area

o Water treatment plant area

o CCWS pump and heat exchanger area

o Circulating water pumps area

o Gas turbine 11/12/21/22 areas

o Air preheater gas turbine 11/12/21/22 areas

o HRSG 11/12/21/22 areas

COMPRESSED AIR SYSTEM 6 / 20

o Feedwater water pumps 11/12/21/22 areas

o Steam turbine building, ST 10 area

o Steam turbine building, ST 20 area

o 3x50% Air Compressor.

o 2x100% Coalescing Filtering Skids.

o 2 Air Receiver Tanks.

o Service air distribution network.

o Instrument air distribution network.

COMPRESSED AIR SYSTEM 7 / 20

The distribution of instrument air will be done in ring configuration.

2.2.2. Air Compressor

The main characteristics of the air compressors are:

o Total air capacity : 1012 Nm3/h

o Discharge pressure : 9,2 – 10 barg

(*) Nm3 are defined as ideal gas at 0ºC and 1 atm

2.2.3. Filtering skid

The main characteristics of the filtering skid are:

o Solid Particles: Class 3, maximum particle 5 microns, maximum solid content 5

2.2.4. Dryer Skid