Air System Design

NORTHERN AREA
GOSP OUTSIDE OPERATOR

Trainee Handbook
Module 2.1
Identify the GOSP Air and Nitrogen Systems
Training & Development

September 2012
Copyright Saudi Aramco, 2012.
All rights reserved. No portion of this book may be reproduced, by any process
or technique, without the express written consent of Saudi Aramco.
TABLE OF CONTENTS
Unit 2: Identify GOSP Utilities Operations
Module 2.1
Identify the GOSP Air and Nitrogen Systems
TRAINEE HANDBOOK
Information Sheets................................................................1
Exercise A........................................................................27
Exercise B.........................................................................39
Plant Visit
Exercise C.........................................................................40
Glossary.................................................................................43
September 2012
INFORMATION SHEET
Enabling Objectives
Terminal Objective
2.1.1
Unaided, the trainee
Unaided, the trainee will correctly state the will correctly identify the
function of a GOSP air system and identify the GOSP air and nitrogen
major equipment and controls. systems.
2.1.2
Unaided, the trainee will correctly state the
function of a GOSP nitrogen system and identify
the major equipment and controls.
INTRODUCTION
In part I of this module, you will learn the GOSP
air system. In part II, you will learn about the GOSP
nitrogen system.
A utility system provides a service to other plant

areas on a GOSP. However, the services provided at
one GOSP may not be the same at another. Some
of these services may have interrelationships with
other plant areas. In this module, you will learn
which systems are utility systems and their purpose.
You will also learn some of the relationships
between the utility systems.
Some GOSPs have a separate utility plant and some

have the utility system plants spread around the
GOSP.
On most offshore GOSPs, the utilities are on the

auxiliary platforms. On some offshore GOSPs, some
utilities are on the accommodation and production
platforms.
Module 2.1 September 2012 1

INFORMATION SHEET
PART I OBJECTIVE 2.1.1
State the Function of a GOSP Air System and Identify the

Major Equipment and Controls
INTRODUCTION
Air systems play important roles in GOSPs. In this
part of the module, you will learn about the:
o function of a GOSP air system
o air system major equipment
o system controls
AIR SYSTEM FUNCTION

The function of an air system in GOSPs is to
provide compressed air for the operation of
pneumatic equipmentprocess control valves and
instrumentation. Compressed air is also used in
plant operations. Each GOSP has one or more air
systems. The number of air systems depends on the
processes and equipment in the GOSP. Figure 1
shows a typical air system.
UTILITY AIR
INTAKE
FILTER INSTRUMENT AIR
COMPRESSOR RECEIVER PREFILTER DRYER AFTERFILTER
DISTRIBUTOR
HEADER
Figure 1
Overview of an Air System
Figure 1 shows that compressed air from the

Figure 1 receiver separates into:
Northern Area GOSP Outside Operator
Module 2.1
o utility air
o instrument air
2 September 2012 Northern Area GOSP Outside Operator

INFORMATION SHEET
Utility Air
GOSPs use utility air for certain process equipment
operations. Utility air coming from the receiver is
sent directly into the utility air header (see figure
1), which then supplies the GOSP utility stations.
Instrument Air
GOSPs use instrument air to operate instruments
and the emergency shutdown (ESD) valves that Loss of instrument air, will
close during emergencies. Instrument air must not cause a complete shutdown
of the GOSP.
have water or other impurities that might damage
valves and instruments. Water and other impurities
can corrode tanks and air lines. All these can cause
process problems in the GOSP.
As shown in figure 1, from the receiver, the

compressed air to be used as instrument air goes
to a prefilter before going into a dryer and
afterfilter. Then it is distributed to the instrument
air header. The prefilter and afterfilter remove
impurities. The dryer removes water.
AIR SYSTEM MAJOR EQUIPMENT

A GOSP air system consists of the following
equipment: Refer to HO 2.1-1 and HO
2.1-2 as you read about
equipment.
o air compressor
o air receiver
o moisture separator (in some air systems)
o prefilters
o air dryers
o afterfilters

INFORMATION SHEET
Air Compressor
The function of the air compressor is to supply
compressed air. The compressor takes air from the
atmosphere through filters that are made of
disposable paper and compresses the air to
approximately 110 psig. The filters remove dust
and sand in the air.
Large GOSPs normally use centrifugal compressors

to supply instrument and utility air. Large GOSPs
also use reciprocating compressors for backup.
However, some small offshore GOSPs use
reciprocating compressors to supply compressed air.
Figure 2 shows reciprocating compressors and
figure 3 shows a centrifugal compressor.
Figure 2
Reciprocating Compressors
Figure 2
Module 2.1

INFORMATION SHEET
Figure 3
Centrifugal
Figure 3 Compressor
Figure 4 shows the air flow from a two-stage
Module 2.1
compressor, through a cooler, to the air receiver.
TO AIR
COOLER RECEIVER
INLET
FILTERS
INTEGRAL
OIL PUMP MOTOR
COMPRESSOR COMPRESSOR
FIRST STAGE SECOND STAGE
Figure 4
Air Flow5Through a Compressor
Figure
Module 2.1

INFORMATION SHEET
Most air systems use two compressors. However,

only one compressor is running. The running
compressor is called the lead compressor. The other
compressor is called the standby or lag compressor.
Air Receiver
The air receiver (see figure 5) is normally a
vertically mounted drum. It receives compressed air
from the compressor. The air receiver stores
compressed air during normal operations until it is
needed. The air receiver also acts as a surge vessel
to reduce the effects of sudden load changes on
the compressor
Air enters the air receiver from the compressor. As

the air cools in the air receiver, water vapor
condenses. The water drains through an automatic
drain pot in the bottom of the receiver, to the
gravity sewer. If for some reason, the automatic
drain does not operate correctly, a high-level
switch will alarm in the control panel. A bypass
valve around the automatic drain lets you check if
the automatic drain is operating correctly.
The air receiver sends some air to the utility air

header and some toward the instrument air
header. Instrument air must be clean, cool, and dry
before it entered the instrument air header for
distribution. Instrument air goes into a prefilter (or
a moisture separator).

INFORMATION SHEET
Figure 5 shows and air receiver in a plant and

figure 6 shows the flow through the air receiver.
On figure 6, you can see the lines from the two
compressors and the auxiliary air inlet. The figure
also shows (at top) the lines to the utility air
system and air that goes through prefilters for use
as instrument air. At the bottom is the drain for
water.
PZVs
AUXILIARY TO PLANT
AIR INLET UTILITY
AIR SYSTEM
Figure 5
Air Receiver
Figure 5
TO Northern Area GOSP Outside Operator
PREFILTER Module 2.1
AIR
RECEIVER
FROM
COMPRESSOR
A
FROM
COMPRESSOR
B
AUTO
DRAIN
GS
Figure 6
Flow
FigureThrough
6 an Air Receiver
Module 2.1

INFORMATION SHEET
Moisture Separator
Some GOSP air systems also have moisture
separators. (This equipment is not shown in figure
1.) The moisture separator removes water droplets
from the air that is discharged from the compressor.
Figure 7 shows an air system with a moisture
separator between the aftercooler and the prefilters.
PRE-FILTER
C/W MOISTURE
SEPARATOR
AIR FROM TO AIR

COMPRESSOR DRYERS
AFTER
COOLER
AUTO PRE-FILTER
DRAIN
Figure 7
Air System with Moisture Separator
Figure 7
Northern Area GOSP Outside Operator In many separators, compressed air flows into the
Module 2.1 DEFLECTOR
PLATE
moisture separator from the compressor after-
cooler and goes over a deflector plate in the
AIR DEMISTER
INLET PAD separator inlet. The deflector plate is a flat metal
section that redirects and slows down the flow of
the air and helps to remove drops of water. Figure
8 shows the deflector plate at the air inlet, air
outlet with demister pad, and the water outlet
LG
with automatic drain pot, which drains to the
gravity sewer.
WATER
OUTLET
AUTOMATIC
DRAIN POT
TO
GRAVITY Figure 8
SEWER Moisture Separator

Figure 8
Module 2.1
INFORMATION SHEET
On some systems, the separator is a cyclone

moisture separator connected to the compressor
after-cooler. As air flows around the circular vessel,
centrifugal force throws the water droplets out of
the air. The droplets coalesce on the side of the
separator and run down to the bottom of the
vessel. An automatic drain pot is on the water
outlet, like the one on the air receiver. Figure 9
shows a cyclone moisture separator in operation.
Prefilters
The two prefilters are vertically mounted drums
that contain coalescing-type filter elements. The
function of the filters is to remove any water
remaining in the air before the air flows to the
Figure 9
dryer. One is online, and the other is on standby. Cyclone 9Moister Separator
Figure
An alarm will sound to indicate that the filter is Northern Area GOSP Outside Operator
blocking and the filter element needs to be Module 2.1
FILTER
replaced. Figure 10 points out the filter element, ELEMENT
the air inlet and outlet, the water outlet, the AIR
INLET
automatic drain, and the piping to the sewer.
PDI
AIR
OUTLET
WATER
OUTLET
AUTOMATIC
DRAIN
TO
GRAVITY
SEWER
Figure 10
Prefilter
Figure 10
Module 2.1
September 2012 9
Module 2.1
INFORMATION SHEET
Figure 11 shows the location of the prefilters in

the air system and the air flow through the
prefilters. You can see the air from the compressor
to the three-way valve, the prefilters, another
three-way valve, and then onward to the dryer.
MECHANICAL
PRE-FILTER LINKAGE
THREE-WAY THREE-WAY
VALVE VALVE
PRE-FILTER
FROM AIR BYPASS TO AIR

COMPRESSOR VALVE DRYERS
Figure 11
Air Flow Through Prefilters
Figure 11
Northern
Also note Area GOSP
the OutsideofOperator
position the bypass valve in figure
Module 2.1
11. You can bypass the prefilters by using a line
that is controlled by a manually operated bypass
valve, which normally is closed. If both filters are
out of service, you open the bypass valve so air
continues to flow to the instrument air system.
After it passes through the prefilters, the air flows
to the instrument air dry dryer(s).

INFORMATION SHEET
Air Dryers
The air coming from the pre filter is still warm,
and it contains moisture. The air cools and loses
pressure as it passes through the instrument air
lines and instruments. If permitted to go forward
untreated, the compressed air would reach its dew
point. To prevent this, the air passes through a
special drying tower. Figure 12 shows the air dryers
in operation in a plant and points to the prefilter
at lower right side of the picture.
AIR-DRYERS
PRE-FILTER
Figure 12
Figure 12 and Prefilter
Air Dryers
Module 2.1 are two vertical vessels (desiccant towers)
Air dryers
that are packed with desiccant (an activated
alumina) that remove remaining moisture in the
compressed air. The dryers dry the air to a low
dew point of about -40F. Drying the air keeps
moisture from forming in the instrument lines and
instruments.

INFORMATION SHEET
The dryer has a desiccant bed made of balls of

PZV activated alumina that rest on a support grid. As
AIR INLET
/ OUTLET air flows through the desiccant bed, the alumina
absorbs the water. The bed is reactivated by
MOISTURE
ANALYZER
directing a slipstream purge of dried air in the
ACTIVATED AE reverse direction through the off-line dryer. The
ALUMINA
BALLS
bypass valve on a dryer is normally closed.
PI
Figure 13 shows the air inlet and outlets, a

SUPPORT
GRID pressure indicator and pressure safety valve (PZV)
to control high pressure, the activated alumina
balls, moisture analyzer, and the support grid.
AIR INLET
/ OUTLET One dryer is online while the other reactivates.
The dryers are switched over periodically every five
Figure 13 minutes. A computerized changeover system
Figure 13 Interior View
Air Dryers
Northern Area GOSP Outside Operator controls the timing sequence. Figure 14 shows
Module 2.1
details of the air dryer
TO INSTRUMENT changeover system. You can
1 AIR SYSTEM A - ON-LINE
B - REACTIVATING see the air coming from the
prefilters, the invent and vent
valves, the two dryers (one
10% AIR FLOW
online and one offline), the
PZV PZV PZVs and the air flow to the
instrument air system.
PI PI
A B
TO
ATMOSPHERE
INLET INLET
VENT VALVE VALVE VALVE VENT VALVE
C D E F
AIR FROM
AIR DRYER
CHANGEOVER PRE-FILTERS
SYSTEM
Figure 14
Air Dryer Changeover
12 14
Figure September 2012 Northern Area GOSP Outside Operator
Module 2.1
INFORMATION SHEET
Afterfilters
The prefilters and afterfilters are almost identical
in their operation. Afterfilters are small, vertically-
mounted drums that contain particulate filters.
Afterfilters remove desiccant and any fine particles
carried over from the dryer. Each afterfilter
contains a replaceable filter element. Normally, one
is online, and the other is on standby.
Figure 15 shows the afterfilters in a plant. Figure

16 shows the air inlet and air outlet (and the
sensing device that monitors the air and triggers
an alarm to indicate a filter is blocking and needs
replacement).
Note: Usually the afterfilter has no automatic drain as the

air is dry. However, it has a differential pressure switch if
the afterfilter is blocked.
PZVs
AIR OUTLET
AIR
INLET
Psid
AFTER FILTERS
Figure 16
Figure 16
Afterfilters
Figure 15 Northern Area GOSP Outside Operator
Afterfilters in Plant Module 2.1
Figure 15
Module 2.1

INFORMATION SHEET
SYSTEM CONTROLS
The air system controls ensure a constant supply of
compressed air is supplied at the correct pressure.
System controls also protect the compressors from
damage from heat or insufficient lubrication. The
variables controlled in the air system are:
o air pressure
o utility air limiting
o automatic compressor changeover (lead/lag)
o dryer changeover
Air Pressure
The air pressure is the primary requirement in the
instrument/utility air system. Air pressure is
controlled by the load/unload control loop. In
addition, pressure relief valves (PZVs) protect the
system from damage from high pressures. Pressure
sensors monitor the instrument air distribution
header for low pressure. You will now learn about:
o reciprocating compressor load/unload
o centrifugal compressor load/unload
o high-pressure relief
o low-pressure protection
Reciprocating Compressor Load/Unload

Each GOSPs has a load/unload system that controls
the supply of air to the air receiver. The load/
unload control loop keeps air pressure in the air
receiver within the normal operating range. This
control loop causes the compressor to unload, or
to stop compressing, when pressure in the air
receiver reaches the desire operating pressure.

INFORMATION SHEET
Figure 17 shows the air pressure control for a

reciprocating air compressor. You can follow the
flow from the air inlet on the left, to the
compressor and the unloading valve, to the cooling
water in the aftercooler, and on to the air receiver.
AIR
RECEIVER
COOLING
WATER
AIR
INLET PS
AFTERCOOLER
ZV UNLOADING
VALVE
COMPRESSOR
Figure 17
Figure 17 Compressor Air Pressure Control
Reciprocating
Module 2.1
On reciprocating compressors, unloading is
controlled by a spring-loaded, pneumatically
operated unloading device. When the pressure in
the air receiver reaches unload (or high) pressure
setting, a pressure switch at the air receiver signals
the unloading valve to hold the compressor inlet
(suction) valve open. No air is compressed as long
as this valve is open.
A typical air system will have a load pressure-

switch setting of 110 psig and an unload pressure-
switch setting of 125 psig. The unloader at the

INFORMATION SHEET
compressor holds the suction valve open until the

pressure in the air receiver drops below the load
low-pressure setting (110 psig). When this valve is
open, any air drawn into the compressor cylinders
is pushed back out through the inlet port rather
than being compressed.
When the pressure in the receiver drops below the

low-pressure setting, the loader allows the suction
valve on the compressor to operate normally so
that air can be compressed. The compressor will
then operate until air pressure in the air receiver
again reaches the unload-pressure or high-pressure
switch setting (125 psig).
The unloaders can be adjusted to unload at

different pressures. A hand-operated unloading
screw allows the compressor to load manually.
Figure 18 shows the inside of the unloader device.
PRESSURE- DIAPHRAGM
REGULATING
SCREW
LOCK
NUT
VALVE
AIR FROM
RECEIVER
INLET
VALVE
HAND-OPERATED MOVABLE FORK FOR

UNLOADING SCREW OPENING INLET VALVE
Figure 18
Cutaway View of the Unloader Device
Figure 18
Module 2.1
INFORMATION SHEET
On the left side of figure 18, you see the air from
the receiver and the valve, the lock nut under the
pressure-regulating screw, and the hand-operated
unload screw. On the right side of figure 18, you
see the inlet valve and its movable fork for
opening inlet valve, and the diaphragm.
Loading and unloading are done automatically. The

time lapse between loading periods can tell the
operator when there is a leak in the air system.
When air loading periods become more frequent,
the operator will check if air is leaking from the
system or perhaps a drain or vent is open, or a
combination of the three. At some GOSPs a record
of loading and unloading times is kept for each
compressor.
Centrifugal Compressor Load/Unload

A centrifugal compressor controls high pressure in
the instrument air header in a slightly different The centrifugal air compressor
does not need a PZV protection
way. When header pressure increases, and demand on the interstage. The
reduces, flow through the compressor also reduces. reciprocating air compressor
needs this protection.
When this happens, the compressor approaches its
surge point. This makes the compressor surge
control computer start to close the inlet pressure
control valve (PCV). If the compressor continues to
approach its surge point, the unloading PCV starts
to open and direct the compressor discharge air EXHAUST
SURGE
flow to the atmosphere. A check valve keeps the CONTROL
instrument air from flowing back from the receiver UNLOADING
PCV
when the unloading valve is open. AIR
IN
Figure 19 shows the components and flow in a

COMPRESSOR
centrifugal air compressor load/unload. It shows air INLET
PCV
going into the surge control, the inlet PCV, the
flow to the compressor and out of the compressor,
the unloading PCV, and the direction to the
Figure 19
Figure 19
exhaust. Centrifugal Air Compressor Load/Unload
Module 2.1
INFORMATION SHEET
High-Pressure Relief
The air system normally operates automatically.
However, pressure relief valves (PZVs) protect the
air system from excessive pressures, if any part of
the automatic control system fails. PZVs are located
on each compressor and on the air receiver, dryers,
and air surge drums.
The pressure relief valves add protection to the

discharge of each compressor stage. Figure 20
shows a two-stage compressor. The PZV on the
first-stage discharge line opens to the atmosphere
if the pressure reaches 55 psig. The PZV on the
second-stage discharge is set to open at 140 psig.
In this example, a pressure indicator is also on the
second-stage suction.
PI 0 - 160 PSIG
FROM
INTER-COOLER
TO
INTER-COOLER
SET AT TO
55 PSIG AFTER-COOLER
SET AT
PZV PZV
PZV
ATM. 140 PSIG
ATM.
L.O. L.O.
INLET
FILTERS
1ST 2ND INTEGRAL

STAGE STAGE OIL MOTOR
PUMP
Figure 20
Centrifugal Air Compressor Load/Unload
Figure 20
Module 2.1

INFORMATION SHEET
Low-Pressure Protection
GOSPs must control for low pressure for reasons of
safety and operations. The minimum air pressure
required to operate the ESD valves and process
instrumentation is 65 psig. If the air pressure in
the air system drops below 65 psig, the ESD system
will be activated and the whole GOSP will be shut
down. Figure 21 shows the flow of air from the air
compressor skid to the instrument air distribution
header, with all pressure sensors (PS) connected to
the ESD set at 65 psig.
COMPRESSED TO INSTRUMENT
AIR AIR DISTRIBUTION
HEADER
SET AT SET AT
65 PSIG PS PS PS 65 PSIG
SET
AT 65
PSIG
ESD
SYSTEM
Figure 21
Figure 21 Protection
Low-Pressure
Module
The 2.1 low-pressure sensors (set at 65 psig)
three
monitor the pressure in the instrument-air
distribution header. Two of the sensors must be
activated before the ESD system will operate. This
prevents one faulty sensor from shutting down the
GOSP.
Two methods prevent an ESD in a GOSP from low

instrument air header pressure. In the first method,
a low header-pressure set point starts the standby
compressor. The second method is isolating the
utility air from the instrument air.

INFORMATION SHEET
Utility Air Limiting

You previously learned that utility air provides
power to certain process equipment operations.
Limiting utility air pressure will cause fewer and
less significant problems than limiting instrument
air. Utility air is important, but not more important
than instrument air. If the instrument air fails, the
whole GOSP must be shut down. So, if the
pressure from the compressors starts to fall, it is
more important to maintain the instrument air
supply than the utility air.
Figure 22 shows the air going from air receiver to

utility air and instrument air. You can see the PCV
on the utility piping going to utility air header.
The drawing also shows the air dryers before the
instrument air receiver, the pressure controller (PC)
and its connection with the utility air PCV and its
connection with the pressure transmitter (PT) in
the instrument air line. The pressure control valve
is set at 85 psig, with the low-pressure alarm set at
75 psig.
UTILITY
AIR
PCV
FROM AIR SET AT 85 PSIG

PC
RECEIVER LOW ALARM AT 75 PSIG
PT
- AIR
PRE-FILTER INSTRUMENT
- DRYERS AIR
- AFTERFILTER
Figure 22
Utility Air Limiting
Figure 22
Module
20 2.1September 2012 Northern Area GOSP Outside Operator
INFORMATION SHEET
The instrument air PT senses the pressure in the

instrument air line and sends a signal to the PC. If
the instrument air pressure falls to 75 psig, the
controller closes the PCV on the utility air line.
In some systems, a self-regulated PCV controls the

pressure in the utility air header.
Automatic Compressor Changeover

(Lead/Lag)
The compressors may be started and run manually
or automatically. Some compressors have an
automatic changeover and shutdown system to
take over if problems occur. Figure 23 is a drawing
of the compressor changeover and shutdown
system between the lead and lag compressors.
Figure 23 also shows the connections for lube oil
pressure, air compressor head temperatures, and
air temperature.
LEAD COMPRESSOR LAG COMPRESSOR
COMPRESSOR
CHANGEOVER AND
SHUTDOWN SYSTEM
AIR TEMPERATURE COMPRESSOR

HEAD TEMPERATURE
LUBE OIL PRESSURE
Figure 23
Compressor Changeover and Shutdown System
Figure 23
Northern
Module 2.1 Area GOSP Outside Operator September 2012 21
Module 2.1
INFORMATION SHEET
The automatic changeover control system switches

from the lead to the lag compressor when it
detects:
o high discharge air temperature
o high compressor cylinder head temperature
o low compressor lube oil pressure
Also, the lag compressor will automatically start if

the pressure in the instrument air receiver falls to
the preset low pressure. It assists the lead
compressor in bringing the receiver pressure back
to normal.
Dryer Changeover
The dryer changeover involves changing the
direction of air flow from the operating dryer to
the standby dryer.
The dried air flows out from the top of the dryer
through a check valve to the afterfilters. Some of
the air passes through a restricted orifice (RO) and
flows downward through the offline dryer. This
downward air flow dries the desiccant in the off-
line dryer. This is called reactivating. The purged
air leaves the bottom of the dryer through a
control valve and passes through a silencer. The air
is then vented to the atmosphere.
After five minutes, the timer changeover

pressurizes the standby dryer. These operate four
control valves that change the direction of the air
flow from the operating dryer to the standby
dryer. The standby (reactivated) dryer then comes

INFORMATION SHEET
online while the desiccant in the other dryer is

being reactivated. The control sequence is shown
in the drawing in figures 24 through 27.
TO INSTRUMENT
1 AIR SYSTEM A - ON-LINE
B - REACTIVATING
10% AIR FLOW
PZV PZV
PI PI
A B
TO
ATMOSPHERE
INLET INLET
C D E F
AIR FROM
AIR DRYER
SYSTEM
Figure 24
Air Dryer Controls (#1)
Figure 24
Northern
Look at Area GOSP
figure 24.Outside
Dryer Operator
A is online, while dryer B
Module 2.1 When monitoring the dryer
is reactivating. Air flows into dryer A through the purge sequence, it is important
inlet valve D. The dry air leaves the top of dryer A. to not have high back
pressure on the tower that is
Most of it passes the instrument air system. But a being reactivated. Otherwise,
small amount (typically less than 10%) flows into complete reactivation will not
take place.
the top of dryer B, and down through dryer Bs
desiccant bed. It reactivates the alumina in the
desiccant bed. The reactivation air from dryer B is
vented to the atmosphere vent valve F.

INFORMATION SHEET
Now look at figure 25. The

TO INSTRUMENT
2 A - ON-LINE
AIR SYSTEM changeover system controller
B - PRESSURIZING
closes vent valve F. This shuts
off the reactivation flow, and
dryer B pressurizes.
10% AIR FLOW
PZV PZV
PI PI
A B
TO
ATMOSPHERE
INLET INLET
C D E F
AIR FROM
AIR DRYER
SYSTEM Figure 25
Next, look at figure 26. When TO INSTRUMENT

Figure 25 3 A - REACTIVATING
AIR SYSTEM
dryer BArea
Northern is fully
GOSP pressurized,
Outside Operator B - ON-LINE
Module 2.1
the controller opens inlet
valve E, closes inlet valve D,
and opens vent valve C. The 10% AIR FLOW
air-drying flow is now PZV PZV
through dryer B. Because

PI PI
dryer A is now depressurized A B
to atmosphere, the
reactivation flow will start
through dryer A. TO
ATMOSPHERE
INLET INLET
C D E F
AIR FROM
AIR DRYER
Figure 26 SYSTEM
Figure 26
INFORMATION SHEET
Look now at figure 27. The changeover system

controller closes vent valve C. Dryer A pressurizes.
The drying and reactivation sequence repeats.
TO INSTRUMENT
4 AIR SYSTEM A - PRESSURIZING
B - ON-LINE
10% AIR FLOW
PZV PZV
PI PI
A B
TO
ATMOSPHERE
INLET INLET
C D E F
AIR FROM
AIR DRYER
SYSTEM
Figure 27
Figure 27
Module 2.1

INFORMATION SHEET
SUMMARY
As an outside operator, you will be directly
involved in the instrument and utility air systems.
You will monitor the compressor to make sure it is
operating correctly. You will make sure the air
dryers are recycling correctly and they provide
clean, dry air. Regular checks of the whole system
will be part of your duties on every shift.
In this part, you followed the process flows

through the air system. You learned the air that
leaves the air receiver is separated into instrument
air and utility air. You also learned the major
equipment in an air system and controls in the
instrument air system. You will use what you have
learned to help you operate the air system safely
and efficiently.
After you do the exercise, you will learn about the

GOSP nitrogen system.

INFORMATION SHEET
EXERCISE A
B
Directions: Use figures 28 through 31 to complete this
exercise. C
A
D
1. Name the components of the moisture
separator that are labeled A through G in
figure 28. Write the names in the spaces next
to their letters.
a.
F
b.
E
c.
G
d.
e.
Figure
Figure2828
f.
Module 2.1
g.
2. Name the components of the filter that are

B
labeled A through E in figure 29. Write the
names in the spaces next to their letters.
A
a.
b.
c. D
d. C
e.
Figure 29
Figure 29
Module 2.1 Northern Area September 27
2012 Operator
GOSP Outside
Module 2.1
INFORMATION SHEET
3. Name the components of the dryer that are

A labeled A through E in figure 30. Write the
names in the spaces next to their letters.
E
a.
B
b.
c.
C
d.
e.
D
4. Explain the operation of the system shown in

Figure 30
Figure 30
figure 31. Write the explanation in the lines
Northern Area GOSP Outside Operator below.
Module 2.1
COMPRESSED TO INSTRUMENT
AIR AIR DISTRIBUTION
HEADER
SET AT SET AT
65 PSIG PS PS PS 65 PSIG
SET
AT 65
PSIG
ESD
SYSTEM
Figure 31
Figure 31
Module 2.1

INFORMATION SHEET
PART II OBJECTIVE 2.1.2
State the Function of a GOSP Nitrogen System and Identify

the Major Equipment and Controls
INTRODUCTION
This part of the module teaches you about the:
o function of a GOSP nitrogen system and the

uses of nitrogen
o nitrogen generation equipment
o nitrogen storage equipment
o nitrogen distribution and controls
GOSP NITROGEN SYSTEM FUNCTION AND

USES OF NITROGEN
The function of the nitrogen system in a GOSP is
to produce nitrogen, store the nitrogen, and
distribute the nitrogen to users.
GOSPs have several uses of nitrogen. Operators use

nitrogen as a pressure nitrogen blanket of inert
gas on top of hydrocarbon products in storage
vessels. They also use nitrogen to purge equipment
and piping of oxygen. Nitrogen is used to purge
vessels and other equipment of hydrocarbon and
toxic gases. In some plants, nitrogen is used in gas
compressor mechanical seals instead of seal oil.
Some equipment and piping is pressure-tested with
nitrogen.

INFORMATION SHEET
NITROGEN GENERATION EQUIPMENT

The function of the nitrogen generation in a GOSP
nitrogen system is to produce 99% pure nitrogen.
The nitrogen generation system uses instrument air
to generate nitrogen.
Figure 32 shows the equipment used in nitrogen

generation. As you can see, one system is online
and one is on standby. The equipment used for
nitrogen generation consists of:
o feed air filters
o heater
o membrane separators
o oxygen analyzer
o nitrogen receiver (drum)
o outlet filters
o distribution header
FEED
AIR
FILTER MEMBRANE
SEPARATOR OXYGEN
HEATER ANALYZER OUTLET FILTER
110 F D-317A
STANDBY
INSTRUMENT DISTRIBUTION
AIR N2 HEADER
RECEIVER
ONLINE
110 F D-317B
HEATER OXYGEN OUTLET FILTER
MEMBRANE ANALYZER
FEED SEPARATOR
AIR
FILTER
Figure 32
Figure
Nitrogen32
Generation Equipment
Module 2.1

INFORMATION SHEET
Feed Air Filters

Instrument air is already clean and dry. For this
Refer to figure 32 as you
reason only one set of filters is in line to the read about each piece of
membrane separators. The filters are particulate/ equipment.
coalesce type filters. These are filters that remove
very small particles and also cause small liquid
droplets to join and form bigger drops. This makes
the drops easier to filter out. The filters have a
differential pressure sensor. A high differential
pressure across the sensor means the filter is dirty.
Heater
The filtered air then passes through an electric
heater. The heater maintains the feed air
temperature at the optimum temperature for the
maximum production of nitrogen. The efficiency of
the membrane separator depends on both the
pressure and temperature of the feed air. Feed
pressure is preset. The feed air temperature is read
at a temperature indicator.
Membrane Separator
The atmosphere is 78% nitrogen, 21% oxygen, and O2
N2 N2
1% trace gases. In nitrogen generation, the
membrane modules separate nitrogen from the
compressed instrument air coming from the filter.
This feed air is compressed, dried, heated, and
filtered. The separation equipment must have pure
air to produce good quality nitrogen.
OXYGEN
The air-separation modules are made up of FIBER

MEMBRANE
permaeable membranes, in the form of hollow fiber SURFACE
tubes. Each membrane module has a bundle of

many very small fiber tubes. The bundles pack into
a case. Figure 33 shows a drawing of a part of the
COMPRESSED AIR
nitrogen collecting membrane, with feed air going
Figure 33
in and separated nitrogen and oxygen going out. Nitrogen
Figure 33Collecting Membrane
Module 2.1 Module 2.1 September 2012 31
INFORMATION SHEET
At both ends of the module, the ends of the fibers

pass through an epoxy sheet. The epoxy sheet
forms a barrier between each fiber and the space
around it. When pressurized and heated, feed air
passes over the tubes. The oxygen permeates the
membrane easily. The nitrogen in the feed air
cannot easily permeate the membrane. These two
conditions make the air outside the tubes rich in
nitrogen. The air inside the tubes is rich in oxygen.
Membrane performance depends on feed air
pressure and temperature, and membrane
condition.
The product is 99% nitrogen gas. The waste is

oxygen. The oxygen is vented to the atmosphere.
Before it goes to the atmosphere, it passes through
a restriction orifice. The orifice keeps the required
back pressure on the system.
Oxygen Analyzer
Oxygen content in the nitrogen affects its purity.
The oxygen analyzer monitors a sample from the
nitrogen membrane outlet. If the oxygen content
in the sample stream goes above 5%, the analyzer
activates an alarm. The analyzer also activates a
relay. The relay opens a valve at the membrane
outlet. The valve vents the nitrogen product to the
atmosphere.

INFORMATION SHEET
Nitrogen Receiver (Drum)

The nitrogen flows from the membrane separators
to a nitrogen drum. The drum acts as a surge
supply to feed the distribution system if the
demand varies from the GOSP. A pressure control
valve (PCV) regulates the nitrogen pressure.
The nitrogen drum has a level gauge, a pressure

indicator, and a relief system. It also has a bottom
drain. You can drain any liquid in the drum to the
gravity sewer drain.
Outlet Filters
Outlet filters are on the line between the nitrogen
drum and the nitrogen distribution header. One
filter is in service and the other is on standby. A
pressure differential switch measures the
differential across the filters. When the online filter
reaches the high differential pressure setpoint, it
means the filter is dirty and blocking up. You
switch filters when this happens.
Distribution Header
The nitrogen flows from the outlet filter to the
distribution header. The distribution header is
controlled by PCVs. You will find the distribution
headers are different on each GOSP.

INFORMATION SHEET
NITROGEN STORAGE EQUIPMENT

Many GOSPs use liquid nitrogen storage tanks to
As you read this section, refer
to HO 2.1-3. It shows the contain nitrogen for plant nitrogen requirements.
nitrogen storage at Tanijib. An advantage of this method over nitrogen
generation is that the GOSP can store larger
volumes of gas as a liquid under pressure. Figure
34 shows the major equipment in a nitrogen
storage system.
NITROGEN NITROGEN
STORAGE STORAGE
TANK TANK
VACUUM
PUMPS FILL LINE FILL LINE
N2 N2
VAPORIZER NITROGEN VAPORIZER
SUPPLY
VAPORIZER
BOIL OFF
HEATER
TO GOSP DISTRIBUTION
Figure 34
Nitrogen Storage
Figure 34
The nitrogen
Module 2.1 storage system holds liquid nitrogen
in bulk. The liquid nitrogen storage system also
vaporizes the liquid nitrogen. The vaporized
nitrogen is distributed through the nitrogen header
to equipment that uses nitrogen gas. The
equipment used in nitrogen storage system are:
o liquid nitrogen storage tanks
o nitrogen supply vaporizer
o nitrogen distribution headers

INFORMATION SHEET
Liquid Nitrogen Storage Tanks

Each liquid nitrogen storage tank (see figure 35)
has an inner pressurized vessel and an outer shell.
The space between the shell and the inner tank
contains insulation. Nitrogen is stored in the inner
tank as a liquid. Because nitrogen is normally a gas
at atmospheric pressure, the contents of the inner
tank must be kept under pressure to prevent liquid
boiling off as gas. Pressure is maintained on the
liquid contents by boiling off a portion of the
liquids and returning the gas to the tank.
Nitrogen storage tanks come with:
o pressure-building system
o boil-off heater
Figure 35
Figure
Nitrogen35Storage Tank
o vacuum insulation Northern Area GOSP Outside Operator
Module 2.1
Pressure-Building System
Both nitrogen storage tanks have a pressure-
building system. Each system has a PCV and a
vaporizer. If the tank pressure falls too lower than
the set pressure, a controller opens. The controller
admits liquid nitrogen to the vaporizer. The
vaporizer changes the liquid into gas. The nitrogen
gas has a higher pressure than the liquid. The gas
returns to the tank. The gas increases the tank
pressure to the normal pressure.
Boil-Off Heater
The boil-off heater keeps the storage tanks from
over-pressurizing. If the storage tank pressure goes
too high, a pressure regulator valve opens.
Nitrogen vapor flows to the header for distribution

INFORMATION SHEET
to the GOSP. This removes some of the nitrogen

pressure. Headers also have on them safety
devicesPZVs and PZEs (bursting disks) that break
if the excess gas over-pressurizes the system.
Vacuum Insulation
Vacuum insulation in the storage tanks keeps the
liquid nitrogen in the tanks cold. As you have
learned, if nitrogen is not kept cold, it boils off
and vaporizes. When the liquid nitrogen boils off,
the pressure in the tank increases and nitrogen
vapor will be lost to the relief system that goes to
the atmosphere. A space between the inner
nitrogen storage tank and the tank shell is a
vacuum. The vacuum space is filled with granular
insulating material called perlite that helps insulate
the nitrogen. Vacuum pumps maintain the vacuum
insulation.
Nitrogen Supply Vaporizer

The nitrogen supply vaporizer changes liquid
nitrogen from nitrogen storage tanks to nitrogen
gas. The gas supplies the nitrogen supply
headers. The vaporizer (see figure 36) is between
the storage tanks and the
nitrogen supply headers
distribution line. The
nitrogen supply vaporizer
consists of three fin-fan type
VAPORIZER exchangers. Ambient air is
PCV
forced by the fin-fans over
DISTRIBUTION
LINE the coils. This heats up and
vaporizes the liquid nitrogen.
The fans operate whenever
the inlet temperature falls
below a set point.
Figure 36
Vaporizer
Figure 36PCV and Distribution Line
Module 2.1
INFORMATION SHEET
Nitrogen Distribution Headers

Distribution
The nitrogen supply headers distribute the
nitrogen, which is used in most plant areas.
Distribution of supplies goes to the GOSP, utilities,
and compression plants. Takeoffs on the headers
supply nitrogen directing to where we need it in
the plant. One example is the utility stations. You
can use hose connections to move the nitrogen
from utility stations to many different locations.
Controls
The pressure control in the nitrogen header makes
sure enough pressure is in the header to supply
nitrogen users. A PCV maintains the nitrogen
header pressure at 125 psig. This regulates the
nitrogen flow through the nitrogen supply
vaporizer. A temperature switch located before the
nitrogen supply header PCV senses any low
temperature and closes the PCV. This protects the
header pipe metal from the extreme cold
temperature for which it is not designed.
SUMMARY
You now know about a GOSP air system and GOSP
nitrogen system. In part I, you learned the function
of major equipment and components of the air
system and how the system provides utility and
instrument air. You also learned the components
and controls in the instrument air system. You will
use this knowledge to help you operate the air
system safely and efficiently when you work in the
plant as an outside operator.

INFORMATION SHEET
In part II, you learned about the function of the

nitrogen system and uses for nitrogen. You also
learned about the equipment used in nitrogen
generation and storage. And you learned about
nitrogen distribution and controls. You now know
nitrogen is vital to operation of a GOSP. As an
outside operator, you will monitor nitrogen
generation and storage equipment to help ensure
the plant always has enough nitrogen to meet the
plant needs. Now do the exercise.
In the next module, you will learn the function

and operation of a chemical storage system and a
chemical injection system.

INFORMATION SHEET
EXERCISE B
Directions: Identify the numbered components in figure 37
by writing the component number in the diagram next to
the name of each component in the list below.
7 7
3 3
Figure 37
Figure 37
1.
Module 2.1
nitrogen supply vaporizer 5. distribution header
2. boil-off heater 6. N2 storage tanks
3. fill line 7. vacuum pumps
4. pressure-building system

INFORMATION SHEET
PLANT VISIT
PLANT VISIT EXERCISE C

Directions: Your instructor will arrange to take the class
on a plant visit to see the air and nitrogen systems in
operation. He will ask members of the class to identify
major equipment of both systems and state its function,
based on your knowledge gained in the module. Follow
all safety rules and be prepared to answer the following
questions.
This module explains two different systems in the utility

plant. Part 1 explains air systems and part 2 explains
nitrogen systems. Therefore, the questions in this exercise
are divided into two parts: the air system in part 1 and
the nitrogen system in part 2.
QUESTIONS
Part 1
1. What supplies compressed air to plant utilities

and instruments?
2. In which plant do you usually find the air

compressors?
3. What is the function of the air intake filters?
4. Why is the instrument air filtered and dried?
5. What is the function of the air receiver?
6. What removes the water vapor condensate

from the air receiver?
7. What is the difference between prefilter and

afterfilter?
8. What does the air dryer contain?

INFORMATION SHEET
PLANT VISIT
9. What are the types of compressors used for

air compression?
10. What monitors the pressure in the instrument-

air distribution header and how do they
work?
Part 2
11. How is nitrogen used in the GOSPs?
12. What are the sources of nitrogen in utilities

plants?
13. What are the 7 major components of nitrogen

generation system?
14. What is one advantage of nitrogen storage

over nitrogen generation?
15. What are the 3 major components of nitrogen

storage system?

GLOSSARY
Activate Drop/Droplet
To start up or make active. Small unit of a liquid that is still heavy
enough to fall as a sphere, like a
Alumina raindrop. A droplet is a very small drop.
Any of several forms of aluminum
oxide, consisting of two parts of Inert
aluminum and three of oxygen. Without chemical reaction. Forms few
or no chemical compounds.
Bulk
A very large size, mass, quantity, or Lead/Lag
volume. For example, you can buy food In front of or ahead of. Lag means to
by single item, such as 5 kilo of rice, or follow or be behind the lead. The one
in bulk (many kilos). in a group who goes first leads the way.
Followers lag behind. For example,
Cyclone moister separator a lead compressor is the one that is
A circular vessel that uses centrifugal operating. To lead means to go first or
force to push the water droplets out show the way to accomplish a goal. (Do
of the air. The droplets coalesce on the not confuse this meaning of lead with
side of the separator and run down to name of the metal of the same spelling
the bottom of the vessel to a drain. and pronunciation. A type of heavy
metal is the element lead.)
Deflector plate
A flat metal section mounted over a Load/Unload
vessel inlet. Redirects and slows down To do work. For example, a compressor
the flow of gas and liquid into a vessel. load when it is compressing air.
Unloading a compressor stops it
Desiccant working.
A drying agent. A substance that
attracts and absorbs moisture. Membrane
A thin, soft sheet or layer.
Dew point
Air temperature and pressure at which Nitrogen blanket
a gas condenses to a liquid. A nitrogen layer in the upper part of
a vessel. The blanket keeps a positive
pressure on the tank.

GLOSSARY
Perlite
Granular insulating material that helps
insulate the nitrogen.
Permeable
Having pores or openings that liquids or
gases can pass through.
Pneumatic
Air operated, as in air-operated
instruments.
Reactivate (Regenerate)
Reactivate is to make active again.
Regenerate is to restore or return
something to a previous condition.
For example, you reactive a piece of
equipment by turning it on when it is
turned off. You regenerate a desiccant
by removing the water from the
desiccant so it can absorb more water.
Standby
One that is held in reserve, ready
for use. Also: a system where a fixed
quantity of liquid or gas circulates
continuously.
Surge (to)
To rise and fall continuously.
Tube/tubes
A pipe, usually of small diameter, and
normally made of plastic or light metal.

HANDOUT
803-0-3A 803-K-7A/9A 803-0-42A/43A 803-0-445/45A 803-U-7A/9 803-0-429/432 803-0-448/458 803-K-78/88

INSTRUMENT AIR RECEIVER INSTRUMENT AIR DRYERS AIR DRYER PRE-FILTERS AIR DRYER AFTER FILTERS DRYER PACKAGE AIR DRYER PRE-FILTERS AIR DRYER AIR DRYER
PSIG
CAPACITY: 100 SCFV
CAPACITY: 100 SCFV
2-1A-151-203
PP-15154
COMPRESSED
011 AIR FROM AIR
COMPRESSOR 8-10 1-1A-150-201
PP-18164
PI SET@ PI SET@ TO PLANT AIR
2-1A-152-203 PI PCV SET@ 015
PP-15154 PSIG PSIG DISTRIBUTION
2104 2904 PSIG 2104
COMPRESSED 2904
012 AIR FROM AIR ST LSTE ST LSTE
NOTE 1 CONTRACTOR
COMPRESSOR 8-10 CONTRACTOR NOTE 1
AUXILIARY
VENDOR 803-U-7A 2 VENDOR
803-U-7B
UV FT
AIR INLET
2 2-1A-154-203 0114 2701 MOISTURE
UV 1 UV
LOCATE 0708 0708
A GRADE
2-1A-155-203
ZV 1/2 FT ZV 1/2 FT
0114 1714 2704 1714
SET@
2-1A-157-203
SET@
2-1A-161-203
PI PSIG FT AIR SET@
PSIG AOV AOV PI PSIG
1704 1714 100 PI 1704 1714 8927
PI LL SET@
FROM AIR RECEIVER 0113 2429 PSIG
HIGH HIGH PRESSURE 1 1-1A-150-201
PP-138164 SET@ PP-18164
TO ATM @ TO ATM @ TO ATM @ SET@ TO LOADER/
011 ALARM TO COMPRESSOR TO ATM @
SAFE LOCATION PSIG SAFE LOCATION SAFE LOCATION PSIG
LO 012
C-1A CONTROL PANEL SAFE LOCATION PS UNLOADER SV
PS
HH PI PS 2429 PI PS PI PIT
PI 0112
FROM AIR RECEIVER 0112 0113 0112 8928 8927 1 1-1A-151-201
2905 0113 100
HIGH HIGH PRESSURE SET@ SET@ SET@ SET@ PP-18164
PP-138164 TEST LO TO LOADER/
PSIG PSIG PSIG PSIG
ALARM TO COMPRESSOR PI PI PI PI ORIFICE UNLOADER SV 011
012 C-1A CONTROL PANEL LO LO 0111 2429 LO LO
HH 0111 PZV PZV PZV PZV 0111 2
FROM AIR RECEIVER PS 0113 0114 2429 0114 1-1A-151-201
LOW PRESSURE ALARM SET @ 2905 + PP-18164
PP-138164
& AUTO START SYSTEM
PSIG
-
2 803-K-7A 803-K-8A 2 2
803-K-1B 803-K-3B 2 TO INSTRUMENT
015
AIR DISTRIBUTION
011 TO COMPRESSOR X-1A
AUTO START 2 PS PS PS SET@
150-RF A B C PSIG
FROM AIR RECEIVER 8929 8929 8929
LOW PRESSURE ALARM LL LL LL
& AUTO START SYSTEM PS
PP-138164 TIMER TIMER
SET @ 2905
012 TO COMPRESSOR IT LL
X-1A AUTO START PSIG C
2905
PI LL
FROM AIR RECEIVER 2905 B
HIGH LIQUID LEVEL ALARM 2 2 2 2 LL XI
PP-138164 PURGE TO PURGE TO DISCREPANCY
TO COMPRESSOR A
011 X-1A CONTROL PANEL ATM & ATM &
SAFE SAFE LL
ZV ZV ZV ZV ZV ZV SEA
LOCATION LOCATION
FROM AIR RECEIVER 0101 0102 0103 0101 0102 0103 TO CENTRAL
HIGH LIQUID LEVEL ALARM S S S S S S S S
GOSP
PP-138164 2 OUT OF
TO COMPRESSOR LCV MOV LCV LL SHUTDOWN
012 X-1A CONTROL PANEL MOV 1 VOTING
2 0101 0103 0101 0103
102 102 P P P P PI
SET @ SET @
0340 LL
150 PSIG 150 PSIG
2-1A-155-203
1-1/2 P P 1-1/2 1-1/2 P P 1-1/2

TO ATM PZV PZV TO ATM FC FC FC FC
@ SAFE 5101 5102 @ SAFE
LOCATION LOCATION
2 2 AOV
AOV AOV AOV
ZV S S 0402 0402 0402
0402
100 300 8954
ZV S
2-1A-156-203
ELECTRICAL 8954 S ELECTRICAL

1 1 FAILURE FAILURE
CLOSE CLOSE
LCV LCV
2 LO 2 LC 8954
2 8954
2 158 - RF
2 2
LO 803-0-42A LC
803-0-42B
LC
1 2 2 2
803-D-34 PI
Pd3
2
Pd3
LO 1901
EXTERNALLY 100 PRE-FILTERS PI PRE-FILTERS
PI P4 P4 2
COATED RF V 2 2 2 PI
1901 1901 1901
1 1901 0340
Pd3 Pd3
NOTE 2 NOTE 2
LO PC PC
0340 0340
803-0-43A 803-0-43B
FG 2 FC FG 2 2
LC LS FC
1901 1901 1901 1901 1901
1901
AFTER
AFTER
FILTERS
24 LA FILTERS
1/2 2 1/2 1/2 2 2
1
2 1901
LO
AUTO AUTO 803-0-44A E3-0-45A AUTO AUTO
803-0-44B 803-0-45B
DRAIN DRAIN DRAIN DRAIN
NOTE 1 NOTE 1
NOTE 1 NOTE 1
2-5R-544-101 MINIMUM 1X2 3
LO 1A10
203 NPT
AUTO
DRAIN 2-5R-545-203
NPT
NOTE 1 PI
0340
1A10 GS
GS
203 190 AF
GS
Handout 2.1-1
Northern
NorthernArea GOSPGOSP
Area OutsideOutside
Operator Operator September 2012 Handout 2.1-1
Module 2.1
HANDOUT
SERVICE AIR G77-E-020/022 G77-E-021/023

4-a-7-IAIA TO INTERCOOLERS AFTERCOOLERS
DISTRIBUTION
SET AT 4 DWG. XA-J62995,SH2 G77-D-024 G77-E-030/031
517 kP00 PCV IAIA
4x2 P1 0-1600kPoo AIR RECEIVER JACKET WATER COOLERS
(175 PSIG) 143 IDIA
229 (0-250 PSIG)
2 2
4x2 MALFUNCTION TO AIR DRYERS
4 XL XA XL
TO ATM. 190 16 139
TO ATM. 2
RUN/ RUN/
IDIA 1x2 1x2 STOP STOP
4x2 IAIA
BY VENDOR
SET AT PZV PZV
1834kP00 726 1 1 727
(150 PSIG) LO LO SET AT PRE- 2 2
1834kP00 PRE-
(150 PSIG) FILTER FILTER
2 8
HANDHOLE 2
G77-D-024 1/2 1/2 1/2 1/2 2
TRM 1A-37-IAIA
0-1600kPog LC VL
PI (0-250 PSIG) 3/4 1 x 3/4
2 251
LO 732
8
2 HAND 2 2
UNLOAD HOLE G77-0-118/119
LEAD H
PS PS LOAD LAG
COMPR. 728 730 LL-SET
SET AT PS 0-680kPog
792kPog 729 (180 PSIG) 1/2 1/2
(115 PSIG) LOAD L-SET 1/2
0-120kPog
LEAD (105 PSIG)
3/4 COMPR.
PI
733
0-1600kPog
(0-230 PSIG)
INSTRUMENT AIR
PACKAGE
CONTROL PANEL
M-SET @ 65 oC 1149 oF)

TS COOLING WATER LC VL
378 SURGE TANK 250
G77-E-021/020/030
2 SEP/ 2 2 AC
TRAP
C 1/2 3 3
IC
1/2 SEP/
TRAP
JW 1/2 C
G77-D-148 1/2 0-300 o C
2
HAND HS 0-120 o C G77-D-117 (0-600 oF)
OFF
AUTO (0-250 oF) TI TI
3 0-120 o C 363 3
M TI (0-250 oF) 364
362
RUN/ XL DEL OUT
STOP 3 2
1-1/2x 2 ATM DEL IN 0-608kPog ATM

(0-90 PSIG) 1 x 2
PI
SET @ 721
PZV 413.4 kPog PZV
1-1/2 1 725
723 (60 PSIG)
AIR SET @
INTAKE 3/4 1034kPog
LO LO
6x 3 6 (150 PSIG)
FIRST RUN/STOP PULSATION
STAGE
SECOND BOTTLE 3
HS XL STAGE
PS
0-300 o C TI HAND 736 SET @
LOW OIL 68kPog
(0-600o F) 365 OFF M PRESSURE (9-16 PSIG)
AUTO G77-KM-00
RTD RTD RTD RTD RTD RTD 0-150kPog
TE TE TE TE TE TE PI
(0-60 PSIG)
295 296 297 298 293 294 737
G77-K-001
1-SR-212-IAIL
0-200 oC H
(0-400 o F) TI TI H TI H TI H TE H TI H
o 0-200 oC o
295 296 297 298 0-200 oC 293 294 0-200 oC
(0-400 F) (0-400 o F) (0-400 F)
0-200 oC 0-200 oC BOTH ALARMS
TO OPEN DRAIN o o
HEADER (0-400 F) (0-400 F) SET @ 165 o C (329 oF)
DWG. XA-J62992.SH.2 BOTH ALARMS SET @ 165 o C (329 o F)
Northern Area GOSP Outside Operator September 2012 Handout 2.1-2

Handout 2.1-2
PERLITE FILLED
VACUUM
SPACE
LEVEL
INDICATOR
DP

JACKET
TANK TANK OUTER COIL FOR
PRESSURE BUILD
INNER
TANK GAS HEATER COIL
PZE
MAIN VAPORIZER COIL
PRESSURE BUILD COIL

VACUUM
TO N2 HEADER
PUMP FILL CONNECTION
CONNECTION WATER FILLED
NITROGEN VAPORIZER
LEVEL TEST
COCK
PCV
September 2012
PZE PZV
PCV
STEAM INJECTION
WATER
TO R.O. OVERFLOW
ATMOSPHERE PCV
AMBIENT
AIR
VAPORIZER STEAM
TCV
TANAJIB NITROGEN STORAGE

HANDOUT
Handout 2.1-3
Handout 2.1-3
Module 2.1

Air System Design

Uploaded by

Document Information

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Air System Design

Uploaded by

Copyright:

Available Formats

NORTHERN AREA

GOSP OUTSIDE OPERATOR

Training & Development

Unit 2: Identify GOSP Utilities Operations

A utility system provides a service to other plant

Some GOSPs have a separate utility plant and some

On most offshore GOSPs, the utilities are on the

Module 2.1 September 2012 1

PART I OBJECTIVE 2.1.1

State the Function of a GOSP Air System and Identify the

o function of a GOSP air system

o air system major equipment

AIR SYSTEM FUNCTION

Figure 1 shows that compressed air from the

2 September 2012 Northern Area GOSP Outside Operator

As shown in figure 1, from the receiver, the

AIR SYSTEM MAJOR EQUIPMENT

o moisture separator (in some air systems)

Module 2.1 September 2012 3

Large GOSPs normally use centrifugal compressors

4 September 2012 Northern Area GOSP Outside Operator

Module 2.1 September 2012 5

Most air systems use two compressors. However,

Air enters the air receiver from the compressor. As

The air receiver sends some air to the utility air

6 September 2012 Northern Area GOSP Outside Operator

Figure 5 shows and air receiver in a plant and

Module 2.1 September 2012 7

AIR FROM TO AIR

8 September 2012 Northern Area GOSP Outside Operator

On some systems, the separator is a cyclone

Figure 11 shows the location of the prefilters in

FROM AIR BYPASS TO AIR

10 September 2012 Northern Area GOSP Outside Operator

Module 2.1 September 2012 11

The dryer has a desiccant bed made of balls of

Figure 13 shows the air inlet and outlets, a

Figure 15 shows the afterfilters in a plant. Figure

Note: Usually the afterfilter has no automatic drain as the

Module 2.1 September 2012 13

o utility air limiting

o automatic compressor changeover (lead/lag)

o reciprocating compressor load/unload

o centrifugal compressor load/unload

Reciprocating Compressor Load/Unload

14 September 2012 Northern Area GOSP Outside Operator

Figure 17 shows the air pressure control for a

A typical air system will have a load pressure-

Module 2.1 September 2012 15

compressor holds the suction valve open until the

When the pressure in the receiver drops below the

The unloaders can be adjusted to unload at

HAND-OPERATED MOVABLE FORK FOR

Loading and unloading are done automatically. The

Centrifugal Compressor Load/Unload

Figure 19 shows the components and flow in a

The pressure relief valves add protection to the

1ST 2ND INTEGRAL

18 September 2012 Northern Area GOSP Outside Operator

Two methods prevent an ESD in a GOSP from low

Module 2.1 September 2012 19

Utility Air Limiting

Figure 22 shows the air going from air receiver to

FROM AIR SET AT 85 PSIG