Compressed Air

1.1 Training Aim

The aim of this module is to provide you with the necessary information and knowledge required to understand compressed air systems and their control. The specific knowledge gained from studying the principles and applications involved can then be used toward developing an overall understanding of the interaction of compressed air with other Utility, Process and Safety Systems. This in turn will lead towards safe, efficient and economic operation of Plant and Equipment.

1.2 Training Objectives

n completion of the compressed air module, participants will be able to!

Understand the different systems of "nstrument, Plant and #lack Start $ir. #e able to describe the operation of air compressors and associated systems. Understand the need to dry compressed air and the equipment required to do so. #e aware of the distribution systems for both Plant and "nstrument air. E%plain the control systems for air compressors and air supply systems.

2 GENERAL DESCRIPTION
$ &ompressed $ir System is designed and installed to supply air at the correct pressure and quality for all plant and instrument users on worksites and "nstallations.

$ typical &ompressed $ir System is composed of three primary sub'systems! "nstrument $ir System Plant $ir System #lack Start $ir System. The Instrument Air/ Plant Air System supplies plant air and instrument air to all users, including drilling, from a single integrated utility system. n offshore installations the Black Start Air System supplies compressed air to start the diesel engines on the essential generators and the fire water pump generators when the normal plant air supply is not available, such as following a complete power outage.

3 ASIS O! DESIGN
Instrument / Plant Air &ompressed air systems will vary between "nstallations, therefore a typical system and its operating parameters are described. The system is designed to supply dry, oil free compressed air from a sufficient number of compressors to ensure that all air requirements are met. There will be sufficient e%cess design capacity to allow a compressor or compressors to be taken off'line for maintenance.

&lick here for larger view. (our )).)* compressors or three +,* compressors could achieve such a requirement. "n a three'compressor system, one compressor will act as lead and run continuously, the second will act as a lag compressor providing a topping up capability, while the third remains on automatic standby. The compressor selection system is such that if either the lead or lag compressor should fail, the standby compressor starts automatically and is loaded onto the system on falling air pressure. $ny combination of the three air compressors can be selected for lead-lag-standby duties from the control panel. To prevent unnecessary stopping and starting of the duty air compressor, each air compressor is equipped with an .unloading system. which, when the compressed air system pressure is within its required limits, will unload the running compressor by recirculating the compressor discharge to the compressor suction. The compressor will reload when the compressed air system pressure falls to a preset level.

3 ASIS O! DESIGN ... CONTIN"ED

Black Start Air n an offshore installation the so'called #lack Start $ir System provides an emergency supply of starting air for the diesel engines that drive the fire pumps and the essential power generators.

&lick here for larger view. This system is independent of all platform utility systems. The supply is provided by two /,,* diesel engine driven units operated with one as the duty unit and the second as a spare. Types of Air Compressors The two main types of air compressors utilised for air supply are the 0eciprocating &ompressor and the 0otary Screw &ompressor. 0eciprocating &ompressors have a high operating efficiency, especially at the higher pressure ranges.

1owever they have a number of disadvantages! They cannot handle slugs of free water. 2ibration and piping resonance occurs due to inertia forces of the moving parts. "n lubricated systems, oil removal systems are required to prevent oil carryover affecting the dryers and distribution systems. 3on lubricated systems provide oil free air, but more maintenance is required for the moving parts of the compressor. The reciprocating action generates a pulsating discharge flow which requires air bottles and pulsation dampers to prevent damage to downstream equipment.

# DETAILED S$STE% DESCRIPTION

Air Compressors Skids $ typical "nstrument or Plant $ir compressor package consists of an inlet filter, three compressor stages, intercoolers, aftercooler, lube oil system, an air-oil separator and associated control panel.

&lick here for a larger view. Throughput is controlled by an automatically operated inlet valve, which controls the airflow into the first stage. $n unloading valve dumps e%cess air from the third stage discharge. &ompressed air leaves the package at a discharge pressure of appro%imately 4.)+ barg 5/)+.+6 psig7 and with a temperature of )+8& 54+8(7, 9oining the air from the other packages 5#, & and :7 in a common header.

Air Compressor The unit comprises a three stage centrifugal compressor with the stages being independent single stage units driven through two shafts, one for the first stage and a common shaft for the second and third stages.

&lick here for larger view. The rotation is provided by a single driving gear wheel powered by a +,, 1P electric motor. 2ibration probes are installed in the compressor gear case to monitor high and low speed pinion vibration. These provide alarm and trip signals displayed on the local air compressor panel and remotely in the control room.

$ir discharged from the first stage is cooled in an intercooler before entering the second stage suction. The intercooler is a shell and tube e%changer with service water flowing through the tubes and air in the shell. Similarly, air discharged from the second stage is cooled in an intercooler before flowing to the third and final stage. The use of inter stage cooling avoids high temperatures within the compressor and improves compressor efficiency. ;oisture condensing in these coolers continuously discharges to the drains through drain valves. $ir from the final stage is fed to an aftercooler for final cooling to leave the package at around )+8& 54+8(7. The aftercooler is also a shell and tube e%changer with service water flowing through the tubes and air in the shell.

Lubrication System The lubrication system supplies oil to the compressor bearings and gears and the lube oil is stored in a reservoir which is located in the compressor package base plate.

The reservoir is equipped with a heater to maintain the temperature of the oil at )<8& 5/,,.=8(7 when the machine is not running. Typical instrumentation

would include temperature and level indication, temperature and level alarms and temperature and level trip functions. The lubrication system has two positive displacement rotary pumps, each being capable of supplying oil at a flow rate and pressure in e%cess of that required for normal operation of the compressor. These pumps provide a constant flow of oil to the compressor bearings and gears. n startup the au%iliary pump provides lubrication to the compressor, during normal operation the main oil pump 5driven by the gear shaft from the compressor7 maintains lubrication of the compressor.

DETAILED S$STE% DESCRIPTION ...CONTIN"ED

A Typical Local Control Panel $ microprocessor provides the start up, operating mode and shutdown logic as well as monitoring the operating parameters of the compressor to initiate alarms or shutdown if the parameters e%ceed set limits. $ common unit alarm will also be initiated in the &ontrol 0oom.

Drying Chambers

(rom the prefilters the air is directed into the chamber selected for drying duty via a three'way valve and flows downward through the desiccant bed of the drying chamber. The moisture entrained in the air stream is attracted to and adsorbed on the surface of the activated desiccant.

$s stated the adsorption is an e%othermic process, which contributes heat for regeneration . The dry air then leaves the drying chamber through a three' way valve and flows on to afterfilters. >hile one chamber is in the drying cycle the second chamber can be in either of the following conditions dependent upon the position of the adsorbed moisture front as determined by a probe-sensor mounted half way down the chamber.

Afterfilters &ompressed air flows from the dryer?s outlet valve, through a header which splits to feed the two afterfilters operating in parallel. Each afterfilter has four filter cartridges, through which the dry air flows to leave the filter from the top no@@le.

The purpose of the filter elements is to remove desiccant dust carried over from the dryers, and are capable of removing 4<* of particles down to + micron. :ifferential pressure across the filters is monitored and indicated.

Compressed Air

ecei!er

:ry air flows from the dryer package to the &ompressed $ir 0eceiver before entering the "nstrument - Plant $ir :istribution 3etwork. Typically the receiver is capable of supplying air to instruments for /+ minutes from the shutdown of plant air at 6.) barg 5/,+.< psig7 to a plant shutdown at =.< barg 5A4.A psig7. The vessel is protected from over'pressure by one of a pair of relief valves set at /B., barg 5/6= psig7

&lick here for larger view.

Instrument Air Distribution :ry air leaving the compressed air receiver for use by process and utilities instrumentation, flows through a pressure reduction valve. This reduction valve reduces the air pressure to appro%imately 6.,, barg 5/,/.+ psig7 before it is routed to all areas through the distribution headers.

&lick here for larger view. The headers are protected from over'pressure by one of a pair of relief valves set at <.+ barg 5/B).B psig7 downstream of the control valve. $ pressure transmitter provides high and low pressure alarms in the control room, set at <., barg 5//A psig7 and +.+ barg 564.6+psig7 respectively. :ownstream of this transmitter there are a further two transmitters, providing low pressure trip when both switches are activated, to initiate a full plant shutdown at =.< barg 5A4.A psig7

Plant Air Distribution $ir for use as plant air is supplied through a pressure reduction valve where the pressure is reduced to appro%imately <.+ barg 5/B, psig7. Typically the controller provides a high and low'pressure alarm set at 4., barg 5/),.+ psig7 and <.Bbarg 5//<.4 psig7 respectively. "f the pressure at the receiver falls to 6.) barg 5/,+.< psig7, the process logic will close a control valve on the plant air supply to conserve air for instrument supplies.

&lick here for larger view. Black Start Air System The #lack Start $ir System is normally a trolley mounted portable system which provides air for the start systems on the essential generators and the fire pump generators in the absence of the main plant air supply.

&lick here for larger view. The compressors are two stage reciprocating units with intercooler and aftercooler. The air passes through an air liquid separator before flowing into the manifold and on to the start air systems. Each compressor is driven by a single cylinder diesel engine started by hand crank.

Compressed Air System "tilities The following utility systems are required to support an air compressor system. Cooling #ater is required for each air compressor skid. &ooling water-service water is used by the finned tube interstage coolers, the aftercooler, the lube oil cooler and must be established before attempting to start the &ompressed $ir System. $lectric po#er must be available to each air compressor skid and each set of air dryers. Electric power is supplied to the main motor, the lube oil heater, and the au%iliary lube oil pump.

Instrument air is necessary for the initial startup of the compressors and must also be supplied to the control panel and the control valves to enable the compressor to develop pressure. $dditionally, purge air should be applied to the compressor seals to prevent oil carryover to the dryers. $ nitrogen bottle supply can be used for start up in the absence of instrument air.

& INITIAL START'"P

System relief valves should be lined up for operation and machinery guards should be in place to prevent possible in9ury to personnel. The following steps are a typical start'up procedure for a compressor package! /. &arry out pre'start checks and reset all alarms and trips B. Ensure valve positions are as detailed in the Start'up 2alve &heckCist. Ensure compressor controls are on .$uto. and setpoints correctly entered. ). Ensure cooling water supply is established. Start the compressor and monitor initial loading and all local operating conditions when on full load.

( AIR CO%PRESSOR CONTROL S$STE% ELE%ENTS

The "nstrument air supply is a critical utility and must be maintained at the correct pressure to avoid restrictions on the use of instrument air or even a total platform shutdown. The &ontrol System on a typical air compressor unit is designed to! Monitor the operating parameters Provide alarm and trip indications Sequence the start up and shut down of the unit Govern the different modes of operation Communicate with the control network Regulate inlet, unloading and optional interstage temperature control valves.

) S*mmar+
Dou have now finished the training section of this module on &ompressed $ir. "n it you have learned about the two main systems that comprise compressed air namely! Instrument ir and Plant ir. Dou have e%amined the ma9or items of plant required such as compressors, drying chambers, filters and distribution networks. Dou should now understand the design and layout of a typical air compressor system and the main associated utilities required such as lubrication, filtration and drying. Dou have also learned about the interaction of the systems and indeed the dependancy of process plant on compressed air in order to safely manage and control the various parameters. (inally, we hope that you have en9oyed this module and in order to finish it you are required to complete a set of questions that are designed to assess and underpin the knowledge you have gained.